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LMI PW4 Series Instruction Manual

Electronic metering pumps
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___ Instruction
!
before installing or servicing any metering pump.
CAUTION
For file 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.
Electronic Metering Pumps
Carefully read and understand all precautions
Manual
Replaces same of Rev. Q 7/09
!
CAUTION
201 Ivyland Road
Ivyland, PA 18974
TEL: (215) 293-0401
FAX: (215) 293-0445
www.lmipumps.com
1615.R 7/2010
1

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  • Page 1 For file 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. 201 Ivyland Road Ivyland, PA 18974...

  • Page 3: Table Of Contents

    Contents Introduction ..................4 1.1 Spare Parts ................4 Unpacking Check List ................ 6 Pre-Installation Instructions ..............8 Installation ..................10 4.1 Pump Location and Installation ..........10 4.2 Pump Mounting ..............10 4.3 Tubing Connections ............... 15 4.4 Multi-Function Valves ............. 16 4.5 4-Function Valve Installation ..........

  • Page 4: Introduction

    1.0 Introduction LMI is the world’s most versatile manufacturer of economical and efficient metering pumps. This manual addresses the instal- lation, 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 efficient service.
  • Page 5 Example: Your pump consists of two main components: 1. The Drive Assembly; and 2. The Liquid Handling Assembly. P 1 5 1 3 9 2 S I Drive Liquid Handling Assembly...

  • Page 6: Unpacking Check List

    2.0 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. Please refer to the enclosed Instruction Supplement for an illustration and electrical diagram of your complete pump.
  • Page 7 Instruction Supplement M I L T O NR O Y Injection Check Valve Instruction Supplement Optional Milliamp Input Cable Optional 4-Function Valve (pictured) or Optional 3-Function Valve...

  • Page 8: Pre-Installation Instructions

    CAUTION handling portion of your pump are adequate for the solution (chemical) to be pumped. LMI pumps are tested by NSF for use on muriatic acid (up to 37% hydrochloric acid), and sodium hypochlorite (up to 12.5% solution). Always refer to the solution supplier and the LMI Chemical Resistance Chart for compat- ibility of your specific LMI metering pump.
  • Page 9 SECURELY ATTACHED to fittings prior to start-up (see Section 4.3, Tubing Connections). ALWAYS use LMI supplied tubing with your pump, as the tubing is specifically designed for use with the pump fittings. It is recommended that all tubing be shielded to prevent possible injury in case of rupture or accidental damage.

  • Page 10: Installation

    The pump should be accessible for routine maintenance, and should not be subjected to ambient temperatures above 122°F (50°C). If the pump will be exposed to direct sunlight, LMI black, UV resistant tubing should be installed. Pump Mounting The pump can be mounted in one of two ways: A.
  • Page 11 When pumping downhill or into low or no pressure system, a back pressure/anti-syphon device should be installed to prevent overpumping or syphoning. CAUTION Although popular for all solutions, LMI recommends flooded suction installations for all high-viscosity fluid applications. Injection Check Valve...
  • Page 12 4.2.2 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.
  • Page 13 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.
  • Page 14 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.

  • Page 15: Tubing Connections

    3. Firmly hand tighten the Coupling Nut onto the fitting. Note: Tightening with pliers may cause the Ferrules to break. A. USE ONLY LMI TUBING—ALWAYS use LMI supplied tubing with your pump, as the tubing is specifically designed for CAUTION use with the pump fittings.

  • Page 16: Multi-Function Valves

    3-FV, 4-FV, or standard discharge valve. If your pump is not equipped with a multi-function valve and you feel it is needed in your application, it can be purchased as an accessory. Contact your local LMI stocking distributor. 4.4.1 Three Function Valve (3-FV) 1.
  • Page 17 Flow Flow DO NOT submerge return line in solution LMI 4-FV (Accessory) Prevents syphoning Recirculating when pumping into Pump suction side of recirculating pump LMI Pump (Vacuum) LMI 4-FV (Acces- sory) Prevents over pumping and syphoning when pumping downhill into low or...

  • Page 18: 4-Function Valve Installation

    90º to desired position. • Connect 1/4” tubing to the pressure relief port and route to supply container. • Connect discharge line using LMI tubing connection system or 1/2” pipe thread. The 4-Function Valve is designed for double¬ballchecks. A second valve cartridge is required when mounting a new 4-Function Valve to an existing pump with a 300, 400 or 700 liquid end.

  • Page 19: Autoprime Liquid End

    AutoPrime™ Liquid End Return to Supply AutoPrime Valve Discharge Valve Discharge Suction Valve Inlet AutoPrime™ Liquid End AutoPrime™ Pumps installed with the AutoPrime™ Liquid End are equipped with a valve that allows for constant removal of vapors and gasses inherent with effervescent chemicals such as Sodium Hypochlorite and Hydrogen Peroxide.

  • Page 20: Foot Valve/Suction Tubing Installation

    Foot Valve/Suction Tubing Installation The Foot Valve acts as a check valve to keep the pump primed in suction lift applications. The foot valve is designed to be submersed in the solution tank or drum and must sit in a vertical position at the bottom. Position approximately 2 inches (50 mm) off the bottom if the tank or drum contains sediment.

  • Page 21: Injection Check Valve And Discharge Tubing Installation

    Injection Check Valve and Discharge Tubing Installation A. Installing Injection Check Valve (Figure 1) 1. The Injection Check Valve prevents backflow from a treated line. Install the injection check valve at the location where chemical is being injected into the system.

  • Page 22: Liquid End Parts List

    5.0 L iquid End Parts List Reference Liquid End Sheets on LMI Online Library at: www.lmipumps.com. 1. Select “Online Literature Library” in the Navigation Bar on left. 2. Once on Online Literature Library use “Product” drop down to select “Liquid Handling Assemblies.”...

  • Page 23: Start-Up And Adjustment

    6.0 Start-up and Adjustment a.)Thepumpisnormallyself-primingifsuctionliftis5ft(1.5m) orlessandthestepsbelowarefollowed. b.)Pumpsareshippedfromthefactorywithwaterinthepump headtoaidinpriming. Output Adjustment Controls Manual series pump controls are not equipped with pressure control. Pressure Control Adjustment (if equipped): Pressure control provides the adjustment of the pump’s pressure capability and power consumption, reducing heat, pipe shock and pulsation while increasing pump life.

  • Page 24: Start-Up/Priming For Pump Supplied With Multi-Function Valve

    Start-Up/Priming for Pump Supplied with Multi-Function Valve Read this entire section completely before proceeding. CAUTION When all precautionary steps have been taken, the pump is mounted, and the tubing is securely attached, you may now start priming the pump. 1. Plug in or switch the pump on. 2.

  • Page 25: Start-Up/Priming Without Multi-Function Valve

    Start-Up/Priming without Multi-Function Valve Read this entire section completely before proceeding. When all precautionary steps have been taken, the pump is CAUTION mounted, and the tubing is securely attached, you may now prime the pump. Plug in or switch on the pump. 2.

  • Page 26: Output Adjustment

    Output Adjustment Once the pump has been primed, an appropriate output adjust- ment MUST be made. Pump output should be calculated and adjustments made accordingly. Total Pump Output Calculate the total output of the pump as follows: PUMP OUTPUT = MAX PUMP OUTPUT x % SPEED x % STROKE Example: P151-392SI Use MAX Output (from dataplate on bottom center of pump control panel) = 24 GPD (24 gallons per day).
  • Page 28 7.0 Methods of Externally Triggering Method of Triggering LMI Pump Through 4-Pin Connector 1. Switch Closure Switch closing triggers pump + White 2. NPN Transistor Base goes high to trigger pump – Black + White 3. PNP Transistor Base goes low to trigger pump –...

  • Page 29: B7, C7 And P7 Pumps

    or Pacing B7, C7 and P7 Pumps...

  • Page 30: Calibration

    (Calibration cylinders may be purchased from your local LMI distributor, ref. publication 1798.) 1. Be sure the pump is primed, and discharge tubing and Injec- tion Check Valve are installed as they would be in normal service (i.e., including factors such as injection pressure,...

  • Page 31: Pressure Control

    Pressure Control Adjust Pressure Control: While unit is running, turn Pressure Control Potentiometer slowly counter-clockwise until unit just begins to stall. From this stall point, now turn Pressure Control Potentiometer clockwise halfway between the stall point and maximum setting. This is the optimum pressure control setting for your application.

  • Page 32: Calibration Procedure - On-Site Volumetric Calibration In External Mode

    1. Since pump output is governed by an external device such as Flowmeter-Pulser, Liquitron Controller, or 4-20 mA ™ DC signal from an instrument with an LMI Analog-to- Digital Converter, only the output per stroke may be calibrated. 2. With pump primed and discharge tubing connected to the...

  • Page 33: Liquifram (Diaphragm) Replacement

    This involves replacing the Liquifram ™ cartridge valves or seal rings/valve balls, multi-function valve cap assemblies and the injection check valve spring. LMI recommends replacing these parts at least once a year; however, frequency will depend on your particular application.
  • Page 34 IftheliquidcannotbepumpedduetoLiquifram rupture ™ usingprotectiveclothing,glovesandfaceshield,carefully disconnectthesuctionanddischargetubing.Removethe fourscrewstotheheadandimmersetheheadinwateror otherneutralizingsolution. Start the pump. While running, set the stroke knob to zero and turn the pump off. SeeSection10.0forproperzero 3. With the unit off, unscrew the Liquifram by carefully ™ grasping the outer edge and turning it counter-clockwise .
  • Page 35 ™ Liquifram Stroke Setting Chart Pump Series Stroke Knob Setting All AA, B, J, P Series C10, C11, C12, C70, C71, C72, C76, C90, C91, C92, E70, E71, E72 C13, C14, C73, C74, C77, C93, C94, E73, E74 Liquifram on M Series pumps only, must be bottomed completely (turned ™...

  • Page 36: Cartridge Valves, Seal Rings/Valve Balls And Injection Check Valve Spring Replacement

    See MSDS information from CAUTION solution supplier for additional precautions. Refer to the LMI Metering Pump Price List for the proper Spare Parts Kit or RPM Pro Pac kit number or contact your ™...

  • Page 37: Checking Pump For Proper Zero Position (Stroke Knob)

    IMPORTANT:Notecorrectorientationofeachcheckvalve. 5. Install the new spring in the Injection Check Valve. Depressurize and drain pipeline (or isolate I.C.V. point using valves) so that I.C.V. can safely be disassembled. CAUTION 10.0 Checking Pump for Proper Zero Position (Stroke Knob) 1. With pump running, turn stroke knob counter-clockwise toward zero or end of black or red band on dial.
  • Page 38 7. Position the outer section of the knob so that the pointer aligns with zero on the nameplate or end of the black or red band. 8. Push down on the outer section (a snap sound indicates parts are locked together). 9.

  • Page 40: Troubleshooting

    11.0 Troubleshooting PROBLEM POSSIBLE CAUSE Pump Will Not Prime Pump not turned on or plugged in. Output dials not set properly. Foot Valve not in vertical position on bottom of tank. Pump suction lift too high. Suction tubing is curved or coiled in tank.
  • Page 41 Maximum suction lift is 5 ft (1.5 m). Pumps with High Viscosity Liquid Handling Assemblies require flooded suction. Suction tubing must be vertical. Use LMI tubing straightener supplied with pump (see Section 4.6). Do not overtighten fittings. This causes seal rings to distort and not seat properly which causes pump to leak back or lose prime.
  • Page 42 Troubleshooting (continued) PROBLEM POSSIBLE CAUSE Leakage at tubing Worn tubing ends. Loose or cracked fitting. Worn seal rings. Solution attacking Liquid Handling Assembly material. Low Output or Failure Pump’s maximum pressure rating to Pump Against is exceeded by injection pressure. Pressure Worn Seal Rings.
  • Page 43 Move injection point to a pressurized location or install an LMI 4-FV (see Section 4.4). 2. If pressure at injection point is less than 25 psi (1.7 Bar), an LMI 4-FV should be installed (see Section 4.4). 3. Replace pulser or resistor. Consult factory.

  • Page 44: Epu Resistance Chart

    12.0 EPU Resistance Chart Pump Series Voltage Coil Resistance (Ohms) @ 20 C (68 PW4, PW5, PW6 P04, P05, P06 115 VAC 76 - 87 P14, P15 P16 230 VAC 307 - 353 P74, P75, P76 (see Note 1) P02, P03 115 VAC 152 - 176 P12, P13 230 VAC...

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