Pump Not Utilizing All Material

First, check the level sensors on the pump. This pump is equipped with a newer-style fixed-field sensor. Inside the pump, behind the cover, there’s a bar that moves up and down as the ram moves. The sensor detects this bar’s position. In other pump types, like GDP pumps, the sensor detects a crossbar on the top. The sensor must be positioned correctly so that when the inductor seal reaches the bottom of the container, the sensor reads the bar in the correct position.

To adjust the sensor, lower the pump inductor to the approximate empty position, slightly above the container’s base plate. If the pump isn’t powered on, there won’t be indicator lights, but you can still adjust the sensor by removing the cover to see what it’s detecting. Note that you don’t need to remove the cover to make the adjustments.

Determine the “empty” level of your container. Most pails have a small gap at the bottom, typically about half an inch, or up to three-quarters of an inch in metal pails with rolled lips. Use a spacer that matches this gap, such as a piece of half-inch plywood or a one-by-two board. Place the spacer across the container’s bottom, then lower the inductor until it rests on the spacer. This position represents the empty level.

As you adjust the sensor, always operate safely—keep your hands clear and wear safety glasses. Once the inductor is set to the empty level, loosen the screws holding the sensor and adjust it until it correctly detects the bar at that position. Before starting, mark the sensor’s initial position with a marker or tape for reference. Adjust the sensor downward in small increments, checking for the correct reading. Tighten the screws once the sensor is properly aligned, and reinstall the cover. Finally, raise the inductor, remove the spacer, and test the system.

The empty level sensor stops the pump when the container is empty. A separate low-level sensor indicates when the material is running low, giving you time to prepare a new container. If the empty sensor isn’t set properly, the pump may stop prematurely, leaving material unused. Adjusting the sensor ensures you can fully utilize the material in the container.

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For older pumps equipped with a tubular capacitive sensor, the adjustment process is similar. Use a spacer to set the proper empty level, then loosen the screws holding the cover to access the sensor. Mark the initial position with tape, adjust the sensor as needed, and retighten the screws. If the pump doesn’t shut off when the container is empty, adjust the sensor upward to detect the proper empty level. Once the adjustment is complete, ensure all components are secured, reinstall the guard, and test the pump.

These adjustments should help you maximize material usage from your pail or drum. If you have further questions, refer to your operator’s manual or contact us for assistance.