3. Connect the fill tube, supplied with the replacement diaphragm, to the fill valve tubing
connection. Any short length of the appropriately sized tubing may be used for this purpose.
4. Open the fill valve.
5. Place the fill tube into a container of the barrier fluid being used.
6. Apply vacuum, the fluid should rise into the fill tube and enter the system.
7. Observe the fluid at the exit (vacuum pump) side. When clear, air free fluid is observed,
close the fill valve, while maintaining the vacuum on the system to begin the process of
drawing out excess fluid.
If you a re-using a previous diaphragm, it will take time for the silicone fluid to migrate
through the system, be patient!
8. Release the vacuum and remove both the fill tube and the vacuum pump from the fittings.
9. Empty the fill tube of fluid, and place it on the fitting near the switch, extending upwards,
open to the atmosphere.
10. Ensure that the eccentric box of the pump has been filled to the appropriate level with the
correct (normally Pulsalube 7H
™
) hydraulic fluid.
11. Adjust the pump to the zero stroke (0%) position.
12. If the pump is not already hydraulically primed, remove the PTP valve from the top of the
pump head. Using a plastic funnel or similar, slowly pour hydraulic fluid into the pump head
cavity until full.
13. Inspect the PTP valve to ensure the sealing o-ring is still in position and re-install the valve.
14. Adjust the pump to full (100%) stroke.
15. In order to fully balance and evacuate the leak detection system, the pump must now run at
normal discharge pressure for a period of one hour. This ensures that excess barrier fluid is
fully evacuated from the system.
16. Supply either process fluid, or test fluid (i.e. water) to the suction fitting and ensure that the
discharge system is configured for safe operation. The pump can be started with minimal
discharge pressure and then slowly brought up to full pressure, if the system allows for this.
17. Apply power and start the pump. Hold down the PTP valve momentarily and observe the
middle port under the diagnostic cover. If no fluid is coming from this port, stop the pump
and return to step 11. If fluid is present, continue to step 18.
18. Slowly increase the discharge pressure to full operating pressure and continue to run the
pump for a period of one hour.
19. During this time, excess barrier fluid will be displaced from the system into the short length
of tubing attached to the exit port, balancing the system for proper operation. A small pen
mark on the tube can assist in observing this process visually.
20. After the one-hour startup period, remove the tubing and connection from the housing body
and reinstall the pressure gage. Remove the fitting from the fill port and replace with the
supplied pipe plug.
21. Reconnect the alarm switch to the external system if necessary.
22. The pump and pressure leak-detection system are now properly prepared and ready for
normal service. During normal operation, the gauge should indicate 0 (zero) pressure.
Under certain circumstances, the system may not completely evacuate excess barrier
fluid during the procedure as outlined above. In these cases, after several days run time,
a small amount of pressure may build in the system. If this occurs, simply loosen the
pressure gauge from the switch housing and relieve a small amount of barrier fluid,
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