how to fix lmi and roytronic metering pumps
DESCRIPTION
How to fix LMI and Roytronic Metering Pumps. Problems, Causes and Solutions -- Step-By-Step with Photos.TRANSCRIPT
Troubleshooting LMI Troubleshooting LMI andand LMI LMI RoytronicRoytronic®® Pumps Pumps
LMILMI RoytronicRoytronic®®LMI
IntroductionIntroduction
Problems
Causes
Solutions
Helping your customers when their pump stops working.
Troubleshooting OverviewTroubleshooting Overview
These five problems will be addressed:These five problems will be addressed:
I.I. Pump will not prime or loses primePump will not prime or loses prime
II.II. Leakage at tubing or fittingLeakage at tubing or fitting
III.III. Low output Low output – – fails to pump against pressurefails to pump against pressure
IV.IV. Excessive pump outputExcessive pump output
V.V. Failure to runFailure to run
Protective Clothing and Protective Clothing and Eye ProtectionEye Protection
Wear protective clothing and Wear protective clothing and eye protectioneye protection
Check MSDS sheet for other Check MSDS sheet for other precautionsprecautions
I.I. Pump Will Not Prime or Pump Will Not Prime or Loses PrimeLoses Prime
Possible CausePossible Cause
Output dials not set Output dials not set properlyproperly
SolutionSolution
Always prime pump Always prime pump with speed at 80% with speed at 80% and stroke at 100%and stroke at 100%
STROKE LENGTH KNOB
SPEED KNOB
I. Pump Will Not Prime or Loses I. Pump Will Not Prime or Loses PrimePrime
Possible CausePossible Cause
Foot valve not in vertical position on bottom of tank
SolutionSolution
Foot valve must be Foot valve must be verticalvertical
Foot valveFilterscreen
Ceramic
weight
I.I. Pump Will Not Prime Pump Will Not Prime or Loses Primeor Loses Prime
Possible CausePossible CausePump suction lift tooPump suction lift too
highhigh
SolutionSolution
Keep Suction
Lift< 5 FT
I. Pump Will Not PrimeI. Pump Will Not Primeor Loses Primeor Loses Prime
Possible CausePossible Cause
Pump suction lift too high
SolutionSolution Pumps with high
viscosity liquid-handling assemblies require flooded suction
Possible CausePossible Cause Suction tubing is
curved or coiled in tank
SolutionSolutionSuction tubing must be
vertical
I.I. Pump Will Not PrimePump Will Not Primeor Loses Primeor Loses Prime
Parts Item # 32293
Possible CausePossible Cause Air trapped in suction
tubing
SolutionSolution Suction tubing should
be as vertical as possible. Avoid false flooded suction!
I.I. Pump Will Not Prime Pump Will Not Prime or Loses Primeor Loses Prime
I.I. Pump Will Not Prime Pump Will Not Prime or Loses Primeor Loses Prime
Possible CausePossible CauseSolution container Solution container
ran dryran dry
SolutionSolutionRefill container with Refill container with
solution and reprimesolution and reprime
I.I. Pump Will Not PrimePump Will Not Prime or Loses Prime or Loses Prime
Possible CausePossible Cause
Air leak on suction side
SolutionSolutionCheck for pinholes
and/or cracks
Replace if necessary
AutoPrime AutoPrime ValveValve
I.I. Pump Will Not Prime Pump Will Not Prime or Loses Primeor Loses Prime
For use with sodium hypochlorite and hydrogen peroxide applications
Automatic re-prime
Retrofit existing pumps
LMI Roytronic: Liquid EndsLMI Roytronic: Liquid Ends
Mach AutoPrime HeadMolded FastPrime Head Mach FastPrime Head
7X8 NI7X8 SI8XX SI
9XX SI 9XX HI
I.I. Pump Will Not Prime or Loses Prime Pump Will Not Prime or Loses Prime
LMI RoytronicLMI Roytronic®® AutoPrime HeadAutoPrime Head
Features:
Improved compact design
Addition of second ball in the
de-gassing valve prevents back-flow
4FV can be added for yet more features
Machined Acrylic and PVC Head Only (No molded version)
One-Way Degassing
Valve
Suction Check Valve
Spring-LoadedDischarge Check Valve
IIII.. Leakage at Tubing or FittingLeakage at Tubing or Fitting
Possible CausePossible Cause
Worn tubing endsSolutionSolution
Cut about 1 inch (25mm) off end of tubing and reinstall
II. Leakage at Tubing or FittingII. Leakage at Tubing or Fitting
Possible CausePossible Cause Loose or cracked Loose or cracked
fittingfitting
SolutionSolutionReplace the fitting if crackedReplace the fitting if cracked
Carefully - tightenCarefully - tighten
Once fitting comes into contact Once fitting comes into contact with seal ring, tighten an with seal ring, tighten an additional 1/8 or 1/4 turnadditional 1/8 or 1/4 turn
All LMI pumps have straight screw machine All LMI pumps have straight screw machine threads on the head and fittings and are sealed threads on the head and fittings and are sealed by the seal rings or O-rings. by the seal rings or O-rings.
DO NOT use TeflonDO NOT use Teflon®® tape or pipe dope to seal tape or pipe dope to seal threads. Teflonthreads. Teflon®® tape may only be used on tape may only be used on the ½the ½"" NPT thread side of the Injection Check NPT thread side of the Injection Check Valve as well as stainless steel liquid end Valve as well as stainless steel liquid end connections.connections.
All fittings should be -tightened. An additional All fittings should be -tightened. An additional 1/8-1/4 turn may be necessary to provide a leak-1/8-1/4 turn may be necessary to provide a leak-proof seal. proof seal.
IIII.. Leakage at Tubing or FittingLeakage at Tubing or Fitting
Possible CausePossible Cause
Worn seal ringsWorn seal ringsSolutionSolution
Replace seal rings and ballsReplace seal rings and balls
Purchase Spare Parts SP-XX or
RPM PRO PAC™ kit
II. Leakage at Tubing or FittingII. Leakage at Tubing or Fitting
Compression washers are Compression washers are located in fittings and located in fittings and function valves function valves
If necessary, remove the If necessary, remove the washer washer
Push washer into fitting Push washer into fitting
by to avoid by to avoid damagedamage
How to: Replace a Compression Washer
II. Leakage at Tubing or II. Leakage at Tubing or FittingFitting
BOTTOM
TOP
Directionof Flow
CORRECT
INCORRECT
SmoothsideBall seat
side
TOP
BOTTOM
How to:How to: Correctly Install Cartridge Valves
II. Leakage at Tubing or FittingII. Leakage at Tubing or Fitting
Install new cartridge valves or Install new cartridge valves or check valve balls and seal check valve balls and seal rings in pump headrings in pump head
O-ringO-ring
How to:How to: Replace Suction and Discharge Cartridge Valves (Check Valve)
Directionof
Flow
Configuration 2
FOOTVALVEFOR LARGER
PUMPS (WITHOUT CARTRIDGE)
Configuration 1
FOOTVALVEFOR SMALLER
PUMPS(WITH CARTRIDGE)
CARTRIDGEVALVE SHOWN
DIS-ASSEMBLED {{ SEAL RING
BALL
Foot Valves come in TWO basic configurations
II. Leakage at Tubing or FittingII. Leakage at Tubing or Fitting
Place O-ring on Place O-ring on cartridge valvecartridge valve
Position Position ball seat sideball seat side of cartridge valve of cartridge valve toward floortoward floor
II. Leakage at TubingII. Leakage at Tubing or Fittingor Fitting
CARTRIDGEVALVE
O-RING
How to: Install new cartridge valve and O-ring
(Floor)
(Ceiling)(Ceiling)
Position Position ball seat ball seat side this side this surface surface down.down.
- tighten
SPRING
BALL
PTFE SEAT
O-RING
Install New Injection Check Valve Components
II. Leakage at Tubing or FittingII. Leakage at Tubing or FittingFlapperFlapperValveValve
- tighten
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
Possible CausePossible Cause System pressure System pressure
exceeds pump’s exceeds pump’s maximum pressuremaximum pressure
SolutionSolution Do not exceed Do not exceed
maximum on Pump maximum on Pump Data PlateData Plate
Replace worn Replace worn
parts every parts every
6-12 months6-12 months
carries parts carries parts and kitsand kits
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
Possible CausePossible CauseWorn seal ringsWorn seal rings
SolutionSolution Replace worn seal rings or
cartridge valves
Purchase
Spare Parts SP-XX
or
RPM PRO PAC™ kit
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
PossiblePossible CauseCausePPressure control setting ressure control setting is incorrectis incorrect
SolutionSolutionChange pressure settingChange pressure setting
9 Series Pump
Note: Pressure level ranges from 0 – 5
Press the Mode Key and Up Key simultaneously and hold for 2 seconds
Alter the pressure using Up and Down Keys
P5
Pressure level
control
Mode Key
Up Key
Down Key
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
Possible CausePossible CausePressure control setting Pressure control setting is incorrectis incorrect
SolutionSolutionChange pressure settingChange pressure setting
Adjust with screw driver
B/C & 7 Series Pump
PossiblePossible CauseCause
Ruptured Liquifram™Ruptured Liquifram™
(diaphragm)(diaphragm)
SolutionSolution
Replace Liquifram™ Replace Liquifram™ (diaphragm)(diaphragm)
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
Replacing the Liquifram™Replacing the Liquifram™
TURN THE PUMP OFF!TURN THE PUMP OFF!Twisting the pressure relief Twisting the pressure relief
knob (black) 1/4 turnknob (black) 1/4 turn
will de-pressurize the linewill de-pressurize the line
Step 1: De-pressurize the Liquid End
III. Low Output/Fails to Pump Against Pressure
Replacing the Liquifram™Replacing the Liquifram™
Turn the coupling nut Turn the coupling nut
and remove the tubing from and remove the tubing from
the fitting by pulling upthe fitting by pulling up..
Step 2: Remove the Discharge Tubing
III. Low Output/Fails to Pump Against Pressure
Turn the coupling nutTurn the coupling nut
to remove and pull the tubing to remove and pull the tubing out of the valve out of the valve
Step 3: Remove the Return Line Tubing
Replacing the Liquifram™Replacing the Liquifram™
III. Low Output/Fails to Pump Against Pressure
Turn the 4-FVTurn the 4-FV
to removeto remove
Replacing the Liquifram™Replacing the Liquifram™
Step 4: Remove the 4-FV
III. Low Output/Fails to Pump Against Pressure
Remove the suction tubing by Remove the suction tubing by unscrewing itunscrewing it
Remove the cartridge valve or Remove the cartridge valve or check valve ball and seal check valve ball and seal ring from the pump headring from the pump head
Step 5: Remove the suction fitting
Replacing the Liquifram™Replacing the Liquifram™
III. Low Output/Fails to Pump Against Pressure
Remove the four screws Remove the four screws that mount the pump that mount the pump headhead
Step 6: Remove the pump head
Replacing the Liquifram™Replacing the Liquifram™
III. Low Output/Fails to Pump Against Pressure
Remove the pump Remove the pump LiquiframLiquifram™™ by turning it by turning it
Replacing the Liquifram™Replacing the Liquifram™
Step 7: Remove the pump Liquifram™Liquifram™
III. Low Output/Fails to Pump Against Pressure
Discard the LiquiframDiscard the Liquifram™™ and inspect the backing and inspect the backing disk for damagedisk for damage
Step 8: Remove the Liquifram™Liquifram™ and the backing disk
Replacing the Liquifram™Replacing the Liquifram™
Liquifram™Liquifram™
Backing disk
III. Low Output/Fails to Pump Against Pressure
Remove used shaft sealRemove used shaft seal
Step 9: Remove the shaft sealRemove the shaft seal
Replacing the Liquifram™Replacing the Liquifram™
III. Low Output/Fails to Pump Against Pressure
Push the seal in place by Push the seal in place by using a large hollow pen using a large hollow pen cap or wrench socket cap or wrench socket large enough to clear large enough to clear the Liquiframthe Liquifram™™ shaft shaft
Step 10: Install the new shaft
Replacing the Liquifram™Replacing the Liquifram™ III. Low Output/Fails to Pump Against Pressure
Replacing the Liquifram™Replacing the Liquifram™
Step 10 (cont.)
III. Low Output/Fails to Pump Against Pressure
Replacing the Liquifram™Replacing the Liquifram™
Step 10 (cont.)Before starting the pump, match the pump series with
the stroke knob setting on this chart.
III. Low Output/Fails to Pump Against Pressure
LiquiframLiquifram™ ™ Stroke Setting ChartStroke Setting Chart Pump SeriesPump Series Stroke Knob SettingStroke Knob Setting
All A, B, J and P SeriesAll A, B, J and P Series
C10, C11, C12, C70, C71, C72, C76, C10, C11, C12, C70, C71, C72, C76, C90, C91, C92, E70, E71, E72C90, C91, C92, E70, E71, E72
90%90%
C78C78 50%50%
C13, C14, C73, C74, C77, C93, C94, C13, C14, C73, C74, C77, C93, C94, E73, E74E73, E74 70%70%
Turn both the disk and Turn both the disk and new Liquiframnew Liquifram™™
moving the Liquiframmoving the Liquifram™™ until its center is flush until its center is flush with the outside housingwith the outside housing
Step 11: Install the disk and new Liquifram™
Replacing the Liquifram™Replacing the Liquifram™
III. Low Output/Fails to Pump Against Pressure
Replacing the Liquifram™Replacing the Liquifram™ III. Low Output/Fails to Pump Against Pressure
Lightly re-install the four Lightly re-install the four mounting screws and mounting screws and then tighten gradually in then tighten gradually in a crisscross pattern a crisscross pattern until tightuntil tight
Step 12: Re-install the Pump Head
Replacing the Liquifram™Replacing the Liquifram™
You’re done replacing the Liquifram™ . . .
III. Low Output/Fails to Pump Against Pressure
Install the 4-FV and Install the 4-FV and the suction valvethe suction valve
Re-connect the Re-connect the tubing on suction tubing on suction and discharge and discharge sidessides
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
PossiblePossible CauseCause
Incorrect stroke lengthIncorrect stroke length
SolutionSolution
Check zero or re-zero pumpCheck zero or re-zero pump
With pump runningWith pump running, turn stroke knob, turn stroke knob
toward zero or end of black or red band toward zero or end of black or red band on dialon dial
The pump should operate quietly The pump should operate quietly without clicking at the zero position; if without clicking at the zero position; if not, the pump zero must be reset. not, the pump zero must be reset.
Remove stroke knob by grasping the knob firmly and pulling it toward you
Pry off the yellow cap
Place the knob on a flat surface
Using needle-nose pliers, squeeze the inner section together while lifting the outer section up
Push the inner section back onto the “D”-shaped stroke
HOW TO: Re-Zero Type I Pump -- Push-On KnobHOW TO: Re-Zero Type I Pump -- Push-On Knob
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
HOW TO: Re-Zero Type I Pump -- Push-On Knob (Cont.)HOW TO: Re-Zero Type I Pump -- Push-On Knob (Cont.)
With the pump running, zero the pump as before
Push down on the outer section (a snap sound indicates parts are locked together)
Replace the yellow cap over the outer section of the knob, aligning the tabs on the cap with the slots inside the knob
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
How to: Re-Zero Type II Pump -- Collet KnobHow to: Re-Zero Type II Pump -- Collet Knob
1. Remove the Yellow Cap2. Hold knob with soft jaw pliers3. Loosen but do not remove the 5/16” (8mm) collet nut to
disconnect the knob4. Pull the knob toward you to remove5. With the pump running, zero the pump as before6. Position the knob at zero, or the end of the low range
band, and tighten the 5/16” (8mm) collet nut7. Replace the yellow cap
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
Stroke Adjustment for the Roytronic® pump
1. Install a new Stroke Shaft. There might be resistance as the O-ring slides into the control panel. To get the STROKE SHAFT completely forward, turn the Stroke Shaft by using the Stroke Knob until there is no diaphragm movement. It may be necessary to turn on the pump in order to get the SHAFT forward.
2. Once the Stroke Shaft is completely forward, reset the stroke length by pressing in the Stroke Knob so that the Stroke Knob Pointer indicates 0 (zero)
3. Install the Stroke Knob Screw using a Phillips
4. Insert the Stroke Knob Pointer into the Stroke Knob
RoytronicRoytronic®®RoytronicRoytronic®®
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
TO AVOID PUMP DAMAGE be sure the Stroke Shaft is contacting the plunger before turning on pump
Possible Cause Tubing run on discharge Tubing run on discharge
may be too long.may be too long.
SolutionReduce tubing run lengthReduce tubing run length
Shorten tube length for Shorten tube length for higher viscosity fluidshigher viscosity fluids
Increase tube diameter to Increase tube diameter to permit longer run permit longer run lengthlength
Consult Consult for more informationfor more information
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
Possible CauseClogged Foot Valve Clogged Foot Valve strainerstrainer
SolutionRemove the Remove the
Foot Valve Foot Valve Strainer and Strainer and clean it. clean it.
Replace if Replace if cracked or cracked or damageddamaged
Foot Valve Strainer
III. Low Output/Fails to Pump Against PressureIII. Low Output/Fails to Pump Against Pressure
IV.IV. Excessive Pump Output Excessive Pump Output
Possible Cause
Siphoning (pumping Siphoning (pumping downhill without a downhill without a multi-function valve)multi-function valve)
Solution
Move injection point to a pressurized location or install an LMI 4-FV when applicable
IV.IV. Excessive Pump OutputExcessive Pump Output
Possible Cause
Little or no pressure at injection point
Solution If pressure at
injection point is less than 25 PSI (1.7 Bar) install an LMI multi-function valve when applicable
IV.IV. Excessive Pump Output Excessive Pump Output
Remove the yellow screw cap on the top of the pump head and screw in the valve so that it contacts the O ring. An additional 1/8 -1/4 turn may be necessary to prevent leakage
1/4" O.D. tubing connects to the side of the valve and acts as a return line to the solution tank. To ensure priming, this tubing must NOT be submerged in the solution.
Secure return line to ensure pumped solution returns to supply tank
Multi-Function (4-FV) Valve Tubing Connection
IV.IV. Excessive Pump Output Excessive Pump Output
Improves diaphragm sealing
Double ball design
RoytronicRoytronic®®RoytronicRoytronic®®
Encapsulated Encapsulated HardwareHardware
Ergonomic Ergonomic KnobsKnobs
FEATUREFEATURE
RICHRICH
FEATUREFEATURE
RICHRICH
Mates onto discharge
check valve giving
customer control of rotational alignment
IV.IV. Excessive Pump Output Excessive Pump Output
NEW TUBING CONNECTIONS
RoytronicRoytronic®®RoytronicRoytronic®®
IV.IV. Excessive Pump Output Excessive Pump Output
DO NOT OVER TIGHTEN
STEP 1 Thread the 4FV fitting
onto the head
STEP 2.
Insert ¼" tubing through Bleed Nut
DO NOT SUBMERGE TUBING IN SOLUTION
Assemble 4FV Fitting and Coupling Nut with appropriate cartridges into the discharge
port of the pump. Use 13/16” or 20mm socket wrench to tighten to 50 inch-pounds.
STEP 3.
- tighten
Bleed Nut
NOTE
RoytronicRoytronic®®RoytronicRoytronic®®
O-Ring
O-Ring
IV.IV. Excessive Pump OutputExcessive Pump Output
Possible Cause
Excessive strokes Excessive strokes per minuteper minute
Solution
ConsultConsult
PULSER may need PULSER may need replacementreplacement
V. Failure to RunV. Failure to Run
Possible CausesEPU (Electronic EPU (Electronic
Processing Unit) Processing Unit) or or
PULSER failurePULSER failure
Solution
DO NOT VOID YOUR DO NOT VOID YOUR WARRANTY WARRANTY
by attempting to repair your by attempting to repair your EPU or PULSER EPU or PULSER
yourselfyourself
Contact Contact
Authorized Warranty Authorized Warranty Service CenterService Center
TROUBLESHOOTINGTROUBLESHOOTINGLMI and ROYTRONICLMI and ROYTRONIC
®® PUMPS PUMPS