Nova-Tech LMI Roytronic Series A Metering Pump User Manual

Instruction Manual

®

[e-mail]
www.novatech-usa.com
Tel: [phone] Fax: [phone]
Tel: [phone] Fax: [phone]

Series A

Electronic Metering Pumps

For le reference, please record the following data:

Model No: _____________________________________

Serial No: _____________________________________

Installation Date: ________________________________

Installation Location: _____________________________

When ordering replacement parts for your LMI Metering Pump
or Accessory, please include complete Model Number and
Serial Number of your unit.

Carefully read and understand all precautions before

installing or servicing any metering pump.

201 Ivyland Rd.

Ivyland, PA 18974
TEL: [phone]
FAX: [phone]

www.lmipumps.com

Lit# 2002.A 2/2010

Liquid End

Control Code

Speed (stroking frequency) fixed and stroke length manually
adjustable

Speed (stroking frequency) and stroke length manually
adjustable

External control capability through pulse input and low level float
switch plus manual control adjustments of control code 0

External control capability through pulse input and low
level float switch plus manual control adjustments of control
code 1

External control capability through 4-20 mA input and
low level float switch plus manual control adjustments of
control code 1

See Most Recent Price List for Flow and Pressure Ratings

1 – 110-120V US Plug
2 – 220-240V US Plug
3 – 220-240V DIN Plug
4 – 220-240V Israel Plug
5 – 220-240V UK Plug
6 – 220-240V Aust/NZ Plug
7 – 220-240V Swiss Plug
8 – 110-120V No Plug
9 – 220-240V Indian Plug

7 – Molded Head, Single Ball Check Valves
8 – Molded Head, Double Ball Check Valves
9 – Machined Head, Double Ball Check Valves

1 – 0.2 in

2

2 – 0.4 in

2

3 – 0.8 in

2

4 – 1.6 in

2

See Most Recent Price List for Material Options

S – FastPrime™Head + 4FV
N – FastPrime

™

Head

H – AutoPrime

™

Head + 4FV

A – AutoPrime

™

Head

I – Inch Tubing

M – Metric Tubing

P – 1⁄2” NPT - 1⁄2” BSP Pipe

U – Black, UV Resistant Tubing

Model A 7 5 1 - 8 2 8 S I

Model Code Configuration

Series A

Drive

Not all configurations are available. Please see your local

distributor or price list for available options.

(SS Head only)

®

Contents

1.0 Precautions ................................................................ 4

2.0 Introduction ................................................................. 6

2.1 Specications ........................................................ 6

2

.2 Unpacking Check List ................................................. 7

3

.0 Installation.................................................................. 8

3

.1 Pump Location and Installation........................................... 8

3.2 Pump Mounting....................................................... 8

3

.2.1 Flooded Suction ...................................................... 8

3

.2.2 Suction Lift - Wall Bracket Mount ..........................................9

3

.2.3 Suction Lift - Tank Mount.................................................9

3

.2.4 Suction Lift - Shelf Mount ................................................9

3

.3 Tubing Connections....................................................10

3

.4 Four-Function Valves (4-FV) .............................................11

3

.5 Four-Function Valve Installation...........................................12

3

.6 FastPrime™ .........................................................12

3

.7 AutoPrime™ .........................................................13

3

.8 Foot Valve/Suction Tubing Installation......................................14

3

.9 Injection Check Valve and Discharge Tubing Installation .......................15

4

.0 Operation ..................................................................16

4.

1 Output Adjustment Controls .............................................16

4.

2 Start-up and Adjustment ................................................17

4.2.1 Start-Up/Priming for FastPrime™ Heads ....................................17

4.

2.2 Start-Up/Priming for Pump Supplied with 4-FV...............................18

4.

2.3 Start-Up/Priming Without 4-FV ...........................................18

4.

3 Output Adjustment ....................................................18

4.

3.1 Total Pump Output ....................................................19

4.

3.2 Calibration in Internal Mode .............................................19

4.

3.3 Calibration in External Mode.............................................20

4.

4 Methods of Externally Triggering or Pacing A3, A7, and A8 Pumps................21

4.4.1 Control Modes........................................................22

4.4.1.1 Local Mode ..........................................................22

4.4.1.2 Remote Mode (for A3, and A7) ...........................................22

4.4.1.3 Remote Mode (for A8)..................................................22

4.4.1.4 Calibrating the Analog Input Settings (for A8) ................................23

5.

0 Spare Parts Replacement and Routine Maintenance.................................24

5.

1 Depressurizing the Discharge Line (for Pumps Equipped with a 4-FV Only) ........24

5.

2 Depressurizing The Discharge Line (for Single Ball FastPrime™ Heads Only) .......24

5.

3 Liquifram™ (Diaphragm) Replacement .....................................25

5.

4 Cartridge Valve and O-Ring Replacement ..................................26

5.

5 Injection Check Valve Parts Replacement...................................27

5.

6 FastPrime™ Valve O-Ring Replacement ....................................28

5.7

Stroke Length Setting ..................................................30

5.8

A Drive Parts List .....................................................31

5.9

EPU Wiring Diagram ...................................................32

5.10

Liquid End Parts List ...................................................32

6

.0 Troubleshooting..............................................................37

3

PRECAUTIONS

1.0 PRECAUTIONS

The following precautions should be taken when working with LMI metering pumps.
Please read this section carefully prior to installation.

Protective Clothing

ALWAYS wear protective clothing, face shield, safety glasses and gloves when working
on or near your metering pump. Additional precautions should be taken depending on
the solution being pumped. Refer to MSDS precautions from your solution supplier.

Water Pre-Prime

All LMI pumps are pre-primed with water when shipped from the factory. If your solu­tion is not compatible with water, disassemble the Pump Head Assembly. Thoroughly
dry the pump head, valves, seal rings, balls and Liquifram
head assembly tightening screws in a crisscross pattern. Rell the pump head with the
solution to be pumped before priming the pump. (This will aid in priming.)

Liquid Compatibility

CAUTION: The evaluation performed by UL was tested with water only. LMI pumps
are tested by NSF for use on muriatic acid and sodium hypochlorite. Determine if the
materials of construction included in the liquid handling portion of your pump are ad­equate for the solution (chemical) to be pumped. Always refer to the solution supplier
and the LMI Chemical Resistance Chart for compatibility of your specic LMI metering
pump. Contact your local LMI distributor for further information.

™

(diaphragm). Reassemble

Tubing Connections

Inlet and outlet tubing or pipe sizes must not be reduced. Outlet tubing size must not be
increased. Make certain that all tubing is SECURELY ATTACHED to ttings prior to
start-up (see Section 3.3, Tubing Connections). ALWAYS use LMI supplied tubing with
your pump, as the tubing is specically designed for use with the pump ttings. It is rec­ommended that all tubing be shielded and secure to prevent possible injury in case of
rupture or accidental damage. If tubing is exposed to sunlight, black UV resistant tubing
should be installed. Check tubing frequently for cracks and replace as necessary.

Vinyl Tubing

Your carton may contain a roll of clear vinyl tubing; this is only for connection to the
return line of the FastPrime

Fittings and Machine Threads

All ttings should be hand-tightened. An additional 1/8 - 1/4 turn after the tting is snug
may be necessary to provide a leak-proof seal. Excessive overtightening or use of a pipe
wrench can cause damage to the ttings, seals, or pump head.

All LMI pumps have straight screw machine threads on the head and ttings and are
sealed by the O-rings. DO NOT use Teon

may only be used on the 1/2" NPT thread side of the Injection Check Valve, the stainless
steel liquid end connections, or if piping is directly connected to the pipe threads of the suc­tion or discharge ttings.

4

™

Head and must not be used as discharge tubing.

®

tape or pipe dope to seal threads. Teon® Tape

Plumbing

Always adhere to your local plumbing codes and requirements. Be sure installation does
not constitute a cross connection. Check local plumbing codes for guidelines. LMI is not
responsible for improper installations.

Back Pressure/Anti-Syphon Valve

If you are pumping downhill or into low or no system pressure, a back pressure/anti­syphon device such as LMI’s Four-Function Valve should be installed to prevent over­pumping or syphoning. Contact your LMI distributor for furthur information.

Electrical Connections

WARNING: To reduce the risk of electrical shock, the metering pump must be plugged
into a properly grounded grounding-type receptacle with ratings conforming to the data
on the pump control panel. The pump must be connected to a good ground. Do not use
adapters! All wiring must conform to local electrical codes. If the supply cord is damaged,
it must be replaced by the manufacturer, stocking distributor, or authorized repair center
in order to avoid a hazard.

PRECAUTIONS

Ground Fault Circuit Interrupter

WARNING: To reduce the risk of electric shock, install only on a circuit protected by a
Ground Fault Circuit Interrupter (GFCI).

Line Depressurization

To reduce the risk of chemical splash during disassembly or maintenance, all installations
should be equipped with line depressurization capability. Using LMI’s Four-Function
Valve (4-FV) is one way to include this feature.

Over Pressure Protection

To ensure safe operation of the pump it is recommended that some type of safety/pressure­relief valve be installed to protect the piping and other system components from failing
due to excessive pressure.

Chemical Concentration

There is a potential for elevated chemical concentration during periods of no ow, for
example, during backwash in the system. Steps, such as turning the pump off, should be
taken during operation or installation to prevent this.

See your distributor about other external control options to help mitigate this risk.

Retightening Components

Plastic materials will typically exhibit creep characteristics when under pressure over a
period of time and to insure a proper t it may be necessary to retighten the head bolts
periodically. To insure proper operation, we recommend tightening the bolts to 25 inch­pounds after the rst week of operation and on a monthly basis thereafter.

5

INTRODUCTION

2.0 Introduction

LMI is the world’s most versatile manufacturer of economical and efcient metering
pumps. This manual addresses the installation, maintenance and troubleshooting proce­dures for manually and externally controlled pumps. LMI has a worldwide network of
stocking representatives and authorized repair centers to give you prompt and efcient
service.

Please review this manual carefully. Pay particular attention to warnings and precautions.
Always follow good safety procedures, including the use of proper clothing, eye and face
protection.

This manual is for Roytronic

2.1 Specications

Operating
Temperature

Voltage 110 to 120 V 220 to 240 V

Frequency 50 to 60 Hz 50 to 60 Hz

Max. Current 0.66 A 0.34 A

Wattage 39 W 42 W

Fuse Specication 1.25 AHT (5 x 20 mm) 1.25 AHT (5 x 20 mm)

®

Series A pumps.

AXX1, AXX8 AXX2-AXX7, AXX9

14 to 113°F
–10 to 45°C

14 to 113°F
–10 to 45°C

6

2.2 Unpacking Check List

Your carton will contain many or all of the following items. Please notify the carrier
immediately if there are any signs of damage to the pump or its parts.

UNPACKING CHECK LIST

Metering Pump

Ceramic Foot Valve

Weight

Foot Valve

Injection Check

Valve

Tubing (0 to 3 Rolls)

Four-Function Valve

(Optional)

Low-Level Sensor

(Optional)

External Control
Cable (Optional)

Tube Connection

Hardware

7

INSTALLATION

3.0 Installation

3.1 Pump Location and Installation

Locate pump in an area convenient to solution tank and electrical supply.

The pump should be accessible for routine maintenance, and should not be operated in
ambient temperatures above 113°F (45°C). If the pump will be exposed to direct sunlight,
LMI black, UV resistant tubing should be installed.

This pump is cord connected and not intended for permanent mounting to a building.
However, temporary mounting to stabilize the pump during operation may be necessary
as long as tools are not required for the installation or removal of the pump.

3.2 Pump Mounting

The pump can be mounted in one of two ways:

A. FLOODED SUCTION (ideal installation); or

SUCTION LIFT - when suction lift is less than 5 feet (1.5 m) for solutions having a

B.

specic gravity of water or viscosity of less than 100 cSt (centistokes). For denser or
more viscous solutions, consult distributor.

Note that suction conditions can affect the performance of the pump. This effect is
more pronounced with lower pressure pumps. Consult your distributor for additional
information.

Your LMI metering pump must be mounted so that the suction and discharge valves
are vertical. NEVER position pump head and ttings horizontally.

3.2.1 Flooded Suction

For ooded suction the pump is mounted at the base of the storage tank. This installation
is the most trouble-free, and is recommended for very low outputs, solutions that gasify,
and high-viscosity solutions. Since the suction tubing is lled with solution, priming is
accomplished quickly and the chance of losing prime is reduced. A foot valve is not
necessary in a ooded suction installation.

When pumping downhill or into low or no pressure system, a back pressure/anti-syphon
device should be installed to prevent overpumping or syphoning.

Although popular for all solutions, LMI recommends ooded suction installations for
all high-viscosity uid applications.

INCORRECT

Avoid this type of false ooded suction.

8

CORRECT

3.2.2 Suction Lift - Wall Bracket Mount

The pump may be mounted using an LMI Wall Mount Bracket Assembly (part no. 34643)
directly above the solution tank. A pump mounted in this manner allows for easy chang­ing of solution tanks or drums.

3.2.3 Suction Lift - Tank Mount

The pump may be mounted on a molded tank provided there is a recess to keep the pump
stationary. LMI 10-gallon tank (part no. 27421), 35-gallon tank (part no. 27400), and
50-gallon tank (part no. 26350) have molded recesses for pump mounting.

3.2.4 Suction Lift - Shelf Mount

The pump may be mounted on a shelf (customer supplied) maintaining a suction lift of
less than 5 ft (1.5 m). An LMI mounting kit (part number 10461) is available for securing
the pump to a shelf.

INSTALLATION

9

INSTALLATION

3.3 Tubing Connections

Use only LMI tubing.

DO NOT USE CLEAR VINYL TUBING ON THE DISCHARGE SIDE OF THE

PUMP. The pressure created by the pump can rupture vinyl tubing, which is only for
connection to the return line of the FastPrime

Before installation, all tubing must be cut with a clean square end.

Valve and head connections from the factory are capped or plugged to retain pre-prime

water. Remove and discard these caps or plugs before connecting tubing.

DO NOT USE PLIERS OR PIPE WRENCH ON COUPLING NUTS OR FITTINGS.

To assemble tubing into the ttings:

1. Put coupling nut over tubing.

2. Press on Ferrule – Female about one inch (25 mm).

3. For 1⁄4" or 6mm OD tubing cut tubing so that only 1⁄4" to 3⁄8" (5-10 mm) protrudes
from the Ferrule. For all other tubing push the tube to the bottom of the groove in the
Ferrule – Male.

™

tting.

Replacement
Ferrules, and

Coupling Nuts

are available as

the following kit

numbers:

¼” Tube – 77382

3

8

⁄

” Tube – 77383

½” Tube – 77384

One kit is needed

for each end of

the tube.

4. Firmly hand tighten the coupling nut onto the tting. Tightening with pliers may cause
the ferrules to break.

Coupling Nut

Ferrule - Female

Ferrule - Female

" Tubing

4

⁄

1

" Tubing

8

⁄

3

" Tubing

2

⁄

1

Ferrule - Male

10

Fitting

3.4 Four-Function Valves (4-FV)

Your pump may be equipped with a 4-FV, or standard discharge valve. If your pump is
not equipped with a four-function valve and you feel it is needed in your application, it
can be purchased as an accessory. Contact your local LMI stocking distributor. The
features of a 4-FV are listed below.

1. Pressure Relief: If the discharge line is over pressurized, the valve opens sending solu­tion back to the supply tank.

2. Line Depressurization: Opening the relief knob provides line drain back to the supply
tank.

3. Anti-Syphon: Prevents syphoning when pumping solution downhill or into a vacuum.

4. Back Pressure: Supplies approximately 25 psi back pressure to prevent overpumping

when little or no system back pressure is present.

INSTALLATION

4-FV prevents syphoning when

pumping downhill into

low or no pressure.

Typical Installations Requiring the Anti-Syphon

4-FV prevents syphoning when
pumping into a vacuum such as the
suction side of a recirculating pump.

Feature of a Four-Function Valve

11

INSTALLATION

3.5 Four-Function Valve Installation

Discharge

1/4"

Through

1/4" Tubing

Four-Function

Bleed Nut

4-FV Fitting

To Solution

Tank or Drum

Coupling Nut

To Pump Head

Four-Function Valve Tubing Connection

This return line tubing must be secured to ensure pumped solution will safely return to supply
tank.

3.6 FastPrime™

Valve Body

To install a 4-FV, the 4-FV Fitting and Coupling Nut should be
assembled with the appropriate cartridges into the discharge port
of the pump. Use a 13/16” or 20 mm socket to tighten tting. Tight­ening to 50 inch-pounds is recommended. Do not over tighten.

To assemble the Four-Function Valve Body, assemble the coupling
nut and the threads at the bottom of the body. Firmly hand tighten
the body in the desired orientation. Next, insert the ¼” tubing
through the Bleed Nut. Ensure that about ¼” (6 mm) of tubing is
protruding through the tip of the Bleed Nut. Firmly hand tighten
the Bleed Nut in the hole on the side of the 4-FV. This tubing should
be routed back to the supply tank. To ensure proper function of the
priming function, the end of this tubing should not be submerged
in the solution..

The FastPrime™ Head is equipped with a valve that allows for opening the head to at-

™

mospheric pressure. When installing a pump equipped with a FastPrime

Head connect
the 3/8" outer diameter clear vinyl tubing provided with the pump to the barbed nozzle.
Route the vinyl return line back to the solution tank. This tubing must not be submerged
in the solution.

FastPrimeTM Valve

3/8" Clear Vinyl Tubing

12

FastPrime™ Head