Pulsafeeder PULSAR 25HJ

Questions and Answers

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courtney71Aug 18, 2025
Why Pulsafeeder PULSAR 25HJ does not start?
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  Wanda DillonAug 18, 2025
  If your Pulsafeeder Water Pump doesn't start, it could be due to several reasons. The coupling might be disconnected, so ensure it is properly connected. There might be an issue with the power source, so check that. A blown fuse or circuit breaker could also be the cause; replace them, addressing any overload. Look for any broken wires and repair them. Verify that the pump is wired correctly by checking the wiring diagram. Finally, check for any blockages in the pipe or line and open the valves.
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Willie MillerAug 20, 2025
What to do if Pulsafeeder PULSAR 25HJ Water Pump has no delivery?
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  awellsAug 20, 2025
  If your Pulsafeeder Water Pump isn't delivering, there are several potential causes. First, ensure the motor is running by checking the power source and wiring diagram. Verify that the supply tank isn't empty and fill it if needed. Check for clogged lines and clean and flush them. Make sure all line valves are open. Inspect the ball check valves for solids holding them open and clean them. Address vapor lock or cavitation by increasing suction pressure. If the prime is lost, reprime the pump and check for leaks. Clean the strainer, replacing the screen if necessary. For an under-primed hydraulic system, refer to Repriming the Pump.
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Charles WyattAug 23, 2025
What to do if Pulsafeeder Water Pump delivery is low?
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  vincentbrockAug 23, 2025
  If your Pulsafeeder Water Pump's delivery is low, several factors could be responsible. Check if the motor speed is too low by examining the voltages, frequency, wiring, and terminal connections, and comparing them to the specifications on the nameplate. Also, inspect the check valves for wear or dirt; clean them, and replace them if damaged. Other potential issues include a hydraulic bypass valve operating each stroke, a calibration system error, product viscosity being too high, product cavitating, a worn or damaged piston seal, or a leaking process pressure relief valve.
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webbmalikAug 26, 2025
Why is Pulsafeeder PULSAR 25HJ motor overheating?
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  Crystal FlowersAug 26, 2025
  If your Pulsafeeder Water Pump motor is overheating, it could be due to a few reasons. The pump might be overloaded, so check the operating conditions against the pump design. There could be high or low voltage, so check the power source. Also, a loose wire could be the culprit, so trace and correct it.
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delgadosamanthaAug 27, 2025
What causes noisy gearing or knocking in Pulsafeeder PULSAR 25HJ Water Pump?
- E
  Erika GutierrezAug 27, 2025
  Noisy gearing or knocking in your Pulsafeeder Water Pump can stem from several causes. The discharge pressure might be too high, so reduce it. It could also be water hammer, in which case you should install a PULSAtrol. If the hydraulic bypass valve is set too high, readjust it. Note that nondestructive knocking is characteristic of lost motion pumps when the stroke length is at a partial setting.
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Jon KingAug 30, 2025
Why does Pulsafeeder PULSAR 25HJ Water Pump delivery gradually drop?
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  lozanojuanAug 30, 2025
  If the delivery of your Pulsafeeder Water Pump is gradually dropping, it could be due to several reasons. Check valve leakage could be a cause; clean the valves, and replace them if damaged. There might be a leak in the suction line, so locate and correct it. A fouled strainer could also be the problem, so clean or replace the screen. A change in the product could affect delivery, so check the viscosity. Bypass leakage or a worn piston seal can also cause this issue. Lastly, ensure the supply tank vent isn't plugged.
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James BrownSep 1, 2025
Why is Pulsafeeder PULSAR 25HJ piping noisy?
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  Jessica RamosSep 1, 2025
  Noisy piping in your Pulsafeeder Water Pump system can be caused by several factors. If the pipe size is too small, increase the size of the piping and install a PULSAtrol. If pipe runs are too long, install a PULSAtrol in line. Should surge chambers be flooded, replace the contents with air or inert gas; if a PULSAtrol is installed, replace the diaphragm and recharge. If no surge chambers are used, install a PULSAtrol.
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Isaiah HayesSep 3, 2025
What causes erratic delivery in Pulsafeeder PULSAR 25HJ?
- B
  brownemilySep 3, 2025
  Erratic delivery in your Pulsafeeder Water Pump can be attributed to several factors. There might be a leak in the suction line, so locate and correct it. Product cavitation could also be the cause, so increase suction pressure. Entrapped air or gas in the product might be the issue. Erratic motor speed could also lead to this problem, so check the voltage and frequency. Lastly, fouled check valves can cause erratic delivery, so clean or replace them if necessary.
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tamaradavisSep 5, 2025
Why is Pulsafeeder Water Pump delivery higher than rated?
- J
  joelcraneSep 6, 2025
  If your Pulsafeeder Water Pump's delivery is higher than rated, it could be due to a few reasons. The suction pressure might be higher than the discharge pressure, so install a backpressure valve. If a back pressure valve is set too low, increase the setting. A leaking back pressure valve could also be the cause, so repair, clean, or replace it. Lastly, a calibration error could lead to higher delivery, so review the calculations.
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Christopher GarciaSep 8, 2025
What to do if Pulsafeeder PULSAR 25HJ Water Pump loses hydraulic oil?
- X
  xosborneSep 8, 2025
  If your Pulsafeeder Water Pump is losing hydraulic oil, several issues could be the cause. A ruptured diaphragm could be leaking, so replace it. A leaky seal could also be the source, so replace it as well. Check for cover gasket leaks and replace or retighten them. If the pump head gasket leaks, replace it and tighten the pump head bolts, applying sealing compound. Also, if the pump head is overfilled, remove the excess oil.

Pulsafeeder PULSAR 25HJ Specifications

General

Model	PULSAR 25HJ
Type	Diaphragm Metering Pump
Power Supply	115/230V AC, 50/60Hz
Inlet/Outlet Size	1/2" NPT
Materials	316 Stainless Steel, PVC, PTFE
Pressure	Up to 20 bar (290 psi)
Max Temperature	60°C (140°F)

Summary

PULSAR FACTORY SERVICE POLICY

TRADEMARKS

SAFETY CONSIDERATIONS

CONVENTIONS

REVISION HISTORY

INTRODUCTION

GENERAL DESCRIPTION

Provides a general overview of the PULSAR metering pumps and their basic function.

PRINCIPLES OF OPERATION

OVERALL OPERATION

Details the overall working principle of the pump, including suction and discharge strokes.

COMPONENT LOCATION AND OPERATION

Identifies and describes the key components of the PULSAR pump assembly.

PULSAlarm LEAK DETECTION

Details the PULSAlarm leak detection system option for pumps.

Pump Head;Piston assembly

Explains the pump head/piston assembly and its hydraulic system components.

Control Assembly

Describes the control assembly for adjusting pump stroke length and motor speed.

Gear Ratio Assembly

Explains how the drive motor and gears convert rotary motion to reciprocating motion.

EQUIPMENT INSPECTION

STORAGE INSTRUCTIONS

Guidelines for short-term (up to 12 months) and long-term storage, including oil fill and periodic operation.

INSTALLATION

LOCATION

Guidelines for selecting an appropriate installation site, considering environmental factors and maintenance access.

PIPING SYSTEM

Details the components and considerations for designing the suction and discharge piping for the pump.

SUCTION PRESSURE REQUIREMENTS

Specifies the necessary suction pressure conditions for optimal pump performance and to prevent cavitation.

DISCHARGE PRESSURE REQUIREMENTS

Defines the requirements for discharge pressure to ensure proper pump operation and prevent flow-through.

AUTOMATIC CONTROL (DLC, DLCM OR MPC)

Information on optional electronic controllers for automatic stroke length and motor speed adjustment.

PULSALARM LEAK DETECTION ELECTRICAL CONNECTIONS

Details electrical connections for the PULSAlarm leak detection system's pressure switch.

EQUIPMENT SETUP

LUBRICATION

Details the types of oils used, their capacities, and procedures for filling the gearbox and eccentric housing.

Hydraulic Oil Fill

Provides instructions on how to fill the hydraulic oil reservoir in the eccentric box.

PULSAlarm LEAK DETECTION

Refers to Appendix I for specific startup instructions for pumps equipped with this option.

DRIVE MOTOR INSTALLATION

Instructions for installing the drive motor onto the pump assembly.

STARTUP PROCEDURE

OUTPUT ADJUSTMENT

Instructions on how to adjust the pump's output stroke length using the hand-wheel.

Suction System

Emphasizes ensuring clear and unrestricted flow in the suction system before operation.

Priming the Pump head (Hydraulic System)

Procedures for priming the pump's hydraulic system, including purging air.

Priming the Reagent Head (Product System)

Steps for priming the pump's reagent head and suction line for product delivery.

Calibration

Guidance on calibrating the pump to ensure accurate stroke length settings for required flow rates.

CHECKING THE DIAGNOSTIC WINDOW

Explains how to interpret the diagnostic window for normal and abnormal operating conditions.

MAINTENANCE

Oil Changes

Details recommended intervals and procedures for changing gear oil and hydraulic oil based on service conditions.

Hydraulic Oil Change

Provides the step-by-step procedure for changing the hydraulic oil in the eccentric box.

WET END REMOVAL, INSPECTION, AND REINSTALLATION

Covers the process of removing, inspecting, and reinstalling pump components like the diaphragm.

Standard Diaphragm Replacement

Detailed procedure for replacing the diaphragm in the standard pump head assembly.

Re-Priming the Pump head

Step-by-step guide for re-priming the hydraulic system of the pump head after maintenance.

CHECK VALVES

General Description

Describes the basic function and components of the check valves.

Removal, Inspection, and Reinstallation

Provides detailed steps for removing, inspecting, and reinstalling the check valve assemblies.

HYDRAULIC PERFORMANCE VALVE (HPV)

General Description

Explains the role of the HPV in maintaining proper hydraulic oil volume and pump protection.

Check Valve Screen - Removal and Cleaning

Step-by-step instructions for removing and cleaning the screen within the HPV check valve.

HPV Removal and Replacement - A & B Pump head Style

Procedure for removing and replacing the HPV in A & B pump head configurations.

HPV Removal and Replacement - C & D Pump head Style

Procedure for removing and replacing the HPV in C & D pump head configurations.

HYDRAULIC BYPASS VALVE (HBV)

PTP (PUSH TO PURGE; AUTOMATIC BLEED VALVE)

General Description

Explains the automatic air purging function of the PTP valve.

Removal, Cleaning, & Reinstallation

Step-by-step instructions for removing, cleaning, and reinstalling the PTP valve.

PISTON SEAL

General Description

Describes the construction and mounting of piston seals.

Removal

Procedures for removing piston seals from different pump head sizes.

Reinstallation

Steps for reinstalling piston seals, including lubrication and priming.

OIL SEALS

General Description

Lists the locations of the motor adapter, gearbox, and eccentric box oil seals.

Removal and Replacement

Step-by-step instructions for removing and replacing the motor adapter oil seal.

Gearbox Oil Seal Removal and Replacement

Procedure for removing and replacing the oil seal in the gearbox.

Eccentric Box Seal Removal and Replacement

Procedure for removing and replacing the oil seal in the eccentric box.

COVER ASSEMBLY

Removal & Reinstallation

Steps for removing and reinstalling the pump cover assembly, maintaining calibration.

PUMP MOTOR

REMOVAL & REINSTALLATION

Detailed steps for disconnecting, removing, and reinstalling the pump motor.

REPLACEMENT PARTS

PULSAR KOPKIT PROGRAM

Explains the PULSAR KOPkit program for preventative maintenance parts.

ORDERING KOPKITS OR PARTS

Specifies required information when ordering replacement parts or KOPkits.

TROUBLESHOOTING CHART

Start-up & Delivery Problems

Addresses pump not starting, no/low/dropping delivery, and erratic flow issues.

Hydraulic & Operational Issues

Covers hydraulic oil loss, air bleeding, noise, motor overheating, and piping noise.

PULSAlarm Leak Detection Issues

Diagnoses false alarms and failures to alarm for the PULSAlarm leak detection system.

DIAGNOSIS OF DIAPHRAGM FAILURE

APPENDIX I PULSALARM LEAK DETECTION SYSTEM

PULSALARM LEAK DETECTION REAGENT HEAD ASSEMBLY

Describes the components of the PULSAlarm leak detection reagent head assembly.

PULSAlarm Leak Detection Diaphragm

Explains the construction and function of the PULSAlarm leak detection diaphragm.

LEAK DETECTION OPTION - SETUP FOR PRESSURE

Details the factory setup for the pressure leak detection system and required setup after maintenance.

PRESSURE SYSTEM SET-UP AND PRIMING

Steps for re-priming the pressurized leak detection system after it has been opened.

PULSALARM LEAK DETECTION DIAPHRAGM MAINTENANCE

Covers maintenance procedures for the PULSAlarm leak detection diaphragm, including removal.

Leak Detection Diaphragm Removal

Step-by-step procedure for removing the leak detection diaphragm assembly.

Inspection

Guidance on inspecting the diaphragm assembly for damage or deformation.

Leak Detection Diaphragm Reinstallation

Instructions for reinstalling the leak detection diaphragm assembly and related components.

Leak Detection system conversion

Information on converting older vacuum leak detection systems to the new pressure system.

APPENDIX II PIPING CALCULATIONS

SUCTION HEAD REQUIREMENTS

Details Net Positive Suction Head (NPSHR) requirements for PULSAR pumps to prevent cavitation.

SYSTEM BACK PRESSURE

Explains system back pressure requirements and the use of backpressure valves.

NOMENCLATURE

Defines the variables and symbols used in piping calculation equations.

APPENDIX III OIL SPECIFICATIONS

PULSAlube # 7 H

Details the physical and chemical specifications for PULSAlube 7H hydraulic oil.

PULSAlube # 8 G

Details the physical and chemical specifications for PULSAlube 8G gear oil.

APPENDIX IV BOLT TORQUE REQUIREMENTS

Metal Construction

Torque values for pumps with metal heads.

Plastic Construction

Torque values for pumps with plastic heads.

APPENDIX V PULSAFEEDER ACCESSORIES

PULSATROL INSTALLATION, OPERATION, & REMOVAL INSTRUCTIONS

Guide for installing, operating, and removing the PULSATROL accessory.

BACK PRESSURE VALVE

PRESSURE RELIEF VALVE

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Pulsafeeder PULSAR 25HJ - User Manual

Table of Contents

Questions and Answers

Pulsafeeder PULSAR 25HJ Specifications

Summary

PULSAR FACTORY SERVICE POLICY

TRADEMARKS

SAFETY CONSIDERATIONS

CONVENTIONS

REVISION HISTORY

INTRODUCTION

GENERAL DESCRIPTION

PRINCIPLES OF OPERATION

OVERALL OPERATION

COMPONENT LOCATION AND OPERATION

PULSAlarm LEAK DETECTION

Pump Head;Piston assembly

Control Assembly

Gear Ratio Assembly

EQUIPMENT INSPECTION

STORAGE INSTRUCTIONS

INSTALLATION

LOCATION

PIPING SYSTEM

SUCTION PRESSURE REQUIREMENTS

DISCHARGE PRESSURE REQUIREMENTS

AUTOMATIC CONTROL (DLC, DLCM OR MPC)

PULSALARM LEAK DETECTION ELECTRICAL CONNECTIONS

EQUIPMENT SETUP

LUBRICATION

Hydraulic Oil Fill

PULSAlarm LEAK DETECTION

DRIVE MOTOR INSTALLATION

STARTUP PROCEDURE

OUTPUT ADJUSTMENT

Suction System

Priming the Pump head (Hydraulic System)

Priming the Reagent Head (Product System)

Calibration

CHECKING THE DIAGNOSTIC WINDOW

MAINTENANCE

Oil Changes

Hydraulic Oil Change

WET END REMOVAL, INSPECTION, AND REINSTALLATION

Standard Diaphragm Replacement

Re-Priming the Pump head

CHECK VALVES

General Description

Removal, Inspection, and Reinstallation

HYDRAULIC PERFORMANCE VALVE (HPV)

General Description

Check Valve Screen - Removal and Cleaning

HPV Removal and Replacement - A & B Pump head Style

HPV Removal and Replacement - C & D Pump head Style

HYDRAULIC BYPASS VALVE (HBV)

PTP (PUSH TO PURGE; AUTOMATIC BLEED VALVE)

General Description

Removal, Cleaning, & Reinstallation

PISTON SEAL

General Description

Removal

Reinstallation

OIL SEALS

General Description

Removal and Replacement

Gearbox Oil Seal Removal and Replacement

Eccentric Box Seal Removal and Replacement

COVER ASSEMBLY

Removal & Reinstallation

PUMP MOTOR

REMOVAL & REINSTALLATION

REPLACEMENT PARTS

PULSAR KOPKIT PROGRAM

ORDERING KOPKITS OR PARTS

TROUBLESHOOTING CHART

Start-up & Delivery Problems

Hydraulic & Operational Issues

PULSAlarm Leak Detection Issues

DIAGNOSIS OF DIAPHRAGM FAILURE

APPENDIX I PULSALARM LEAK DETECTION SYSTEM