Series G Model G METERING PUMP INSTALLATION, OPERATION, AND MAINTENANCE MANUAL sales@novatech-usa.com www.novatech-usa.com Tel: (866) 433-6682 Fax: (866) 433-6684 Tel: (281) 359-8538 Fax: (281) 359-0084 201 Ivyland Road Ivyland, PA 18974 TEL: (215) 293-0401 FAX: (215) 293-0445 www.lmipumps.
Precautions For Pumps with PVC & 316SS Liquid Ends WHEN USED IN SWIMMING POOLS OR SPAS/HOT TUBS (ANSI/NSF 50) ! ! ! 1. Caution on Chemical Concentration: There is a potential for elevated chemical concentration during periods of no flow, for example, during backwash in the system. Steps, such as turning the pump off, should be taken during operation or installation to prevent this. Contact your sales representative or distributor about other external control options to help mitigate this risk. 2.
General Precautions For All Pumps The following precautions should be taken when working with all 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 Material Safety Data Sheets for the solution being pumped.
TABLE OF CONTENTS SECTION 1 - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (CONT.) 4.4.3 4.4.2.2 Disassembly (Only Those Units With a “Hex Head“ Diaphragm Cap Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.4.2.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.4.2.4 Reinstallation of Assembly (Refer to Figure 6 Through 13) . . . . . . . . . . . 19 Replacing Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 DESCRIPTION 1.1 GENERAL INFORMATION the fluid pressure drops below the vapor pressure, cavitation will occur, negatively impacting the performance of the pump. If you suspect the possibility of cavitation, contact your LMI Distributor for assistance. The Series G Model G is a reciprocating, chemical dosing pump capable of producing controlled flows up to 310 gallons per hour (1175 L/H) at pressures up to 150 psi (10 BAR) (depending on the model).
Figure 1. Model/Product Code.
1.3 GENERAL SPECIFICATIONS (CONT.) SUCTION LIFT TEMPERATURE 5 ft. (2.5 meters) of water column maximum. 11 psia minimum internal pressure (4 psi maximum vacuum).
1.4 PRODUCT CODE Series G Model G pumps are available in a variety of different configurations. For a breakdown of the options included in a specific pump, compare the pump model number and product code found on the pump nameplate with the model/product code breakdown shown in Figure 1. A sample nameplate is shown in Figure 2. Figure 2.
SECTION 2 INSTALLATION 2.1 UNPACKING Pumps are shipped f.o.b. factory or representative warehouse and the title passes to the customer when the carrier signs for receipt of the pump. In the event that damages occur during shipment, it is the responsibility of the customer to notify the carrier immediately and to file a damage claim. ANY SERVICING OF THIS EQUIPMENT MUST BE CARRIED OUT WHEN THE UNIT IS STOPPED AND ALL PRESSURE HAS BEEN BLED FROM THE LIQUID END.
The prepared equipment should be covered with a plastic sheet or a tarpaulin, but in a manner which will allow air circulation and prevent capture of moisture. Equipment should be stored 12 inches or more above the ground. Support the pump firmly in a level position on a solid, vibration-free foundation, preferably with the base above floor level to protect the pump from wash downs and to provide easier access for service.
To minimize viscous flow losses when handling viscous liquids, it may be necessary to use suction piping up to four times larger than the size of the suction connection on the pump. If in doubt, contact your nearest LMI Distributor to determine the necessary pipe size. • Use piping heavy enough to withstand maximum pressures. • Remove burrs, sharp edges, and debris from inside piping. Blow out all pipe lines before making final connections to pump.
Suction Piping Considerations • • • • It is preferable to have the suction of the pump flooded by locating the liquid end below the lowest level of the liquid in the supply tank. Installing the supply vessel on the suction line close to the pump can help ensure a flooded suction line. (Consult with your LMI distributor or the LMI/Milton Roy technical support team for assistance in such applications.
charging into a manifold having the slightest pressure difference between its several discharge connections can diminish metering accuracy as the outlet with the lowest pressure will receive more liquid than the other outlets. Install the safety valve in the discharge line between the pump and the nearest shut-off valve. (This will prevent pump damage from accidental valve closure.
Before operating the pump, check the direction of rotation of the motor to be sure it matches the direction of the arrow stamped on the motor (rotation should be clockwise when viewed from the top of the motor). If motor rotation is incorrect, refer to the motor data plate or motor manufacturer’s instructions for reversing.
SECTION 3 OPERATION 3.1 INITIAL START-UP Exxon .....................Spartan E.P. 68 Mobil ......................Mobilgear 626 Texaco ...................Meropa 68 Shell .......................Omaha 68 WARNING FAILURE TO CHECK TORQUE ON NONMETALLIC HEAD BOLTS PRIOR TO STARTUP AND AFTER ONE WEEK OF OPERATION MAY EXPOSE OPERATING PERSONNEL TO HAZARDOUS LIQUIDS. BEFORE SWITCHING ON POWER TO THE PUMP, TURN THE CAPACITY ADJUSTMENT KNOB TO ZERO.
If the pump is idle for long periods, temperature changes in the process liquid may produce air in the system. To discharge the air, install a valve in the discharge line which will allow the process liquid to be pumped to exhaust when starting the pump. umns are available for convenient and accurate calibration of any pump. THE FOLLOWING METHOD IS NOT GENERALLY RECOMMENDED AS IT MAY EXPOSE OPERATING PERSONNEL TO HAZARDOUS LIQUIDS.
SECTION 4 MAINTENANCE 4.1 SPARE PARTS All Other Liquid Ends To avoid excessive downtime in the event of a parts malfunction, the spare parts shown below should be stocked for each pump to prevent serious delays in repairs. Refer to Figures 8–14 and the accompanying parts lists. For your convenience, these parts can be purchased either separately or packaged in the form of Routine Preventive Maintenance (RPM) Kits. RPM kit numbers are listed in Section 1.
ous residue in pump liquid end. A Materials Safety Data Sheet must accompany all returns. Inspect the ball check and seat for chemical or physical damage. The ball should be perfectly round and free of pits, mars, or scratches. The seat should retain a sharp edge where the ball contacts for proper sealing. If the seat edge is worn or damaged, or has any pits, mars, or scratches, it should be replaced. If the ball and/or seat is excessively damaged, the replacement schedule should be shortened accordingly.
properly assemble the valve assemblies; the ball must be placed on the sharp edge of the seats. Check valves are supplied in four different configurations: plastic, stainless steel, slurry, and polymer. Be sure to refer to the appropriate instructional set below. IF YOU ARE DISASSEMBLING UNIT FOR INSPECTION ONLY, BE SURE TO USE A BLUNT INSTRUMENT AND TAP GENTLY TO AVOID DAMAGING THE BALL. IF THE BALL AND/OR SEAT ARE DAMAGED DURING DISASSEMBLY, THEY WILL HAVE TO BE REPLACED.
bevel should not face the inside of the check valve (refer to Figure 14A or 14C). Use a flat surface such as a board to press the seat into the ball guide with firm, even pressure. ensure that they are compatible with the process liquid. Reassembly 1. Drop the ball into the curved inner chamber end of the ball guide. THE ORDER OF ASSEMBLY AND ORIENTATION OF THE SUCTION AND DISCHARGE CHECK VALVES IS DIFFERENT. REFER TO FIGURE 8, 10, 12, 14A, AND 14C FOR PROPER ASSEMBLY ORDER AND ORIENTATION.
three screws (441,442) and their split washers (439). Since one screw (441) is shorter than the others, be sure that it is screwed into the appropriate hole. NOTE: To assure a tight, leak free seal, new o-rings should be used each time the check valves are disassembled. 2. Screw the coupling (445) onto the check valve assembly, trapping a new o-ring (419, 423) between the coupling and the check valve assembly. 4.4.1.3 Model SG5 Liquid End - Stainless Steel Check Valve (Fig. 14B): Disassembly 4.4.1.
6. Screw coupling (445) onto check valve assembly, trapping a new o-ring (419) between coupling and check valve assembly. new o-ring (419) between liquid end and check valve assembly. 8. Screw coupling (445) onto check valve assembly, trapping a new o-ring (419) between coupling and check valve assembly. 4.4.1.5 Models SG5, SG6 & SG7 Liquid End Slurry Service Check Valves (Figure 14E & 14G): 4.4.1.
4.4.2.2 Disassembly (Only Those Units With a “Hex Head “ Diaphragm Cap Design, Figure 6) It is recommended that the oil seal and diaphragm be replaced at the same time. The instructions given under “Replacing the Oil Seal” are complete instructions for replacing both the oil seal and diaphragm. If you plan to replace both, refer to the “Replacing the Oil Seal” instructions, and disregard the instructions below.
4. Torque the six diaphragm head bolts to the following inch pounds in a crisscross pattern: diaphragm from the connecting rod (60), using a 30mm hex socket on diaphragm cap (240). (1) Liquid End Size SG5 and SG6 metallic and non-metallic head bolts to 90 inch pounds. 7. Remove the diaphragm support ring (230). 8. Remove the retaining ring (220) from the connecting rod. (2) Liquid End Size SG7 non-metallic head bolts to 125 inch pounds. 9. Slide the small oil seal clamp (210) off the connecting rod.
7. Fit the diaphragm head back into place on the pump body. 8. Torque the six diaphragm head bolts to the following inch pounds in a crisscross pattern: (1) Liquid End Size SG5 and SG6 metallic and non-metallic head bolts to 90 inch pounds. (2) Liquid End Size SG7 non-metallic head bolts to 125 inch pounds. (3) Liquid End Size SG7 metallic head bolts to 250 inch pounds. 4. Add oil to pump, following directions given in “Initial Start-up” in Section 3.
SECTION 5 TROUBLESHOOTING GUIDE SYMPTOMS Pump will not operate REMEDIES • • • • • • • • • • Low process liquid level in the tank. Add liquid Worn or dirty check valves. Clean or replace. Blocked discharge line. Clear line. Frozen liquid. Thaw liquid throughout pumping system. Blown fuse. Replace fuse. Open thermal overload device in motor starter. Reset device Broken wire. Locate and repair. Low voltage. Investigate and correct (wiring may be too light). Pump not primed.
SYMPTOMS REMEDIES Pump still pumps even at zero capacity setting • Improperly adjust micrometer knob. Readjust capacity setting. • Insufficient discharge pressure. Correct condition (e.g., install a back pressure valve). Gear noise • Excessive backlash. Consult service facility. • Worn bearings. Consult service facility. • Wrong or insufficient lubricant. Replace or replenish lubricant. Loud knock with each stroke • Excessive gear set wear. Consult service facility. • Worn bearings.
SECTION 6 PARTS 6.1 GENERAL This section gives information regarding replaceable components. 6.2 ILLUSTRATED PARTS LIST 1. Figure and Item Number Column a) The item numbers shown in the detailed parts list correspond to the item numbers appearing on the exploded view illustration. To find an unknown part number, locate the part on the illustration and note the item number. Look for the item number on the detailed parts list. The part number is on the same line.
Figure 7 (Sheet 1 of 2).
6.
7 346 Worm Shaft Coupling, IEC 80 (See Note 1) 60194 1 360 Spring (56C) (See Note 2) 60264 1 360 Spring (IEC 80) (See Note 2) 60225 1 370 Vent with Dip Stick 70067 1 376 IEC 80 Motor Adapter Ring 60199 1 377 Hex Head Screw, M10 x 25MM Steel (IEC 80 motor) 4350001732 4 390 Motor (1 hp, 1 ph, 1800 rpm, 115/230, 60 hz, 56C) 4112008010 1 390 Motor (1 hp, 3 ph, 1500 rpm, 220/380, 50 hz, 56C) 4112008315 1 390 Motor ( 1hp, 3 ph, 1800 rpm, 230/460, 60 hz, 56C) 4112008310 1 390
Figure 7 (Sheet 2 of 2).
6.
7 - M12 Lockwasher, 18-8 SS 4340009095 6 - M12 Hex Nut, 304 SS 4350000085 6 310 Ball 5/16, Nylon 60152 1 320 Stroke Locking Knob 60398 1 322 O-Ring, 2-012 Bunan N 4080109091 1 330 Stroke Adjustment Knob 70066 1 331 Flat Washer 1/4”, 18.8 SS 4040005012 1 332 Pan Head Screw #8 x 1-1/2”, 18.
Figure 8.
6.
Figure 9.
6.6 SG5 METALLIC LIQUID END - STAINLESS STEEL- NPT Model: Liquid End: Material: SG5_ _ _ _ _ _7_ _ _ _ _ _ FIGURE ITEM NUMBER NUMBER 9 DESCRIPTION PART NUMBER QTY 230 Diaphragm Support Ring 60035 1 240 Diaphragm Cap, Part of Item 261 60631 1 250 Set Screw, Dog Pt.
Figure 10.
6.
Figure 11.
6.8 SG6 METALLIC LIQUID END - STAINLESS STEEL - NPT Model: Liquid End: Material: SG6_ _ _ _ _ _7_ _ _ _ _ _ FIGURE ITEM NUMBER NUMBER 11 DESCRIPTION PART NUMBER QTY 230 Diaphragm Support Ring 60070 1 240 Diaphragm Cap, Part of Item 261 60636 1 250 Set Screw, Dog Pt.
Figure 12.
6.
Figure 13.
6.10 SG7 METALLIC LIQUID END - STAINLESS STEEL - NPT Model: Liquid End: Material: SG7_ _ _ _ _ _7_ _ _ _ _ _ FIGURE ITEM NUMBER NUMBER 13 DESCRIPTION PART NUMBER QTY 60165 1 4350003473 6 225 Adapter Ring, Aluminum 227 Socket Head Screw (M8 x 25 mm), Zinc PLT 230 Diaphragm Support Ring 60159 1 240 Diaphragm Cap, Part of Item 261 60641 1 250 Set Screw, Dog Pt.
FIGURE 14. CHECK VALVE PARTS Figure 14C. Model SG6 & SG7 Plastic Check Valve Parts (Item Number 425) Figure 14A. Model SG5 Plastic Check Valve Parts (Item Number 425) Figure 14D. Model SG6 & SG7 Metallic Check Valve Parts (Item Number 425) Figure 14B.
FIGURE 14. CHECK VALVE PARTS (CONT.) CHECK VALVE CONNECTOR (445) IS PART OF THE PUMP. CONNECTORS ARE INTERCHANGEABLE WITH NEW CHECK VALVES. DISCHARGE SHOWN Figure 14G. Model SG6 & SG7 Slurry Check Valve Parts (Item Number 425) Figure 14E. Model SG5 Slurry Check Valve Parts (Item Number 425) Figure 14F.
6.
FIGURE NUMBER ITEM NUMBER 14 420 DESCRIPTION PART NUMBER QTY REFERENCE CODE Seat, 316SS, Used after 1 June 2008 69022 2 A7 420 Seat, 1 inch CA20 61216 2 B8, C8 420 Seat, 5/8 CA20 60855 2 A8 421 Ball, 14mm 316SS, (See Note 1 and 4) 60709 2 A1 421 Ball, 14mm 316SS, Not used after 1 June 2008, Use PN CV102314 (See Note 1 and 4) 60709 2 A7 421 Ball, 14mm Ceramic, Double Ball 4370000140 2 A2 422 Ball, 22mm 316SS, ( See Note 2) 60710 2 A1 422 Ball, 5/8 inch Ceramic 4070
FIGURE NUMBER ITEM NUMBER DESCRIPTION PART NUMBER QTY REFERENCE CODE 14 424 Ball Guide, 316SS, (See Note 2) 210696016 2 A1 424 Ball Guide, 316SS 2920052016 2 B1, C1 424 Ball Guide, PVDF 60024 2 A2, A3, A4, A8 424 Ball Guide, PVC 60030106071 2 B2, C2, C8 424 Ball Guide, PP 030106070 2 B3, C3 424 Ball Guide, PVDF 60030106078 2 B4, C4, B8 424 Ball Guide, PVDF, Polymer (Suction) 60024 1 A6 424 Ball Guide, PVC, Spring Loaded, Polymer (Discharge) 030156071 1 A6 424
FIGURE NUMBER ITEM NUMBER 14 425 DESCRIPTION PART NUMBER QTY REFERENCE CODE Check Valve Assembly, Polymer (Discharge) 61645 1 B6, C6 425 Check Valve Assembly, Polymer (Suction) 61646 1 B6, C6 425 Check Valve Assembly, Slurry used for pumps built before 1 June 2008, Replaced with PN 69026 (See Note 1 and 4) 60827 2 A7 425 Check Valve Assembly, Slurry, used for pumps built after 1 June 2008 69026 2 A7 425 Check Valve Assembly, Slurry 61277 2 B7, C7 425 Ball Guide PVC For Sprin
FIGURE NUMBER ITEM NUMBER 14 442 DESCRIPTION PART NUMBER QTY REFERENCE CODE Hex Head Screw (M10 x 75 mm) 304 SS 4350035785 4 B1, B2, B3, B4, C1, C2, C3, C4 445 Union End, PVC (1/2” NPT Female) 60117 2 A2, A3, A6, A7 445 Union End (1” NPT) 60132 2 B2, B3, B6, B7 C2, C3, C6, C7, C8 445 Union End (Metric Socket 15 x 20) 4320350028 2 A2, A3 445 Union End (Metric Socket 25 x 32), PVC w/Solvent Weld 4320350008 2 B2, B3, C2, C3 445 Union End (1/2” NPT) 60119 2 A4 445 Union End
