INSTRUCTION MANUAL
Contents
1. Desrp on RG 39 ea I 3 880 Purge Button Spring Relief Valve Adjustment Screw Relief Valve Locking Nut He 00 Ref vave toron meng 950 Relief Valve Spring 1 1 4 1 3 A plungers o JPVC Liquid End purple 1 ua Metallic Liguid End orange 1 33 NECIO Ba cea om WA SIE Note 1 Includes items 960 970 980 990 1000 1005 Note 2 Not sold separately Must purchase item 1015 Poppet Assembly CHECK VALVE PARTS see Figures 10 13 The Pump Model Number is used to identify the check valve parts The 4 amp 5 digits identify the plunger size digit 6 identifies the liquid end material MGH _ Digits 45 6 Codes for Digits 4 amp 5 Code 20 is a 1 1 4 32mm Plunger Code 28 is a 1 3 4 45mm Plunger Code 40 is a 2 1 2 63mm Plunger Code 48 is a 3 75mm Plunger Codes for Digit 6 Code 1 is 316SS Code 2 is PVC Code 5 is Alloy 20 PVC Liquid End see Figures 10 13 1 1 4 plunger Single Ball Check Valve see Figure 12 Item No Description Qty Req 71 Check Valve Assembly Tubing Conn includes 425 Cartri 71 425 435 TubingConcto 1 425 Cartridge Valve Assembly DD 4 Function PVC Bleed Valve see Figure 14 Va NPT Discharge Bleed Valve Assembly 446 72 Tube Conn Discharge Bleed Valve 1 Assembly 435 425 34 PVC Liquid End cont d 1 1 4 plunger Double Ball Check Valve see Figure 10 BEN NN La R2. MILTON ROY Milroyal G Pump INSTRUCTION MANUAL 339 0064 000 Issued 4 1 00 THIS PAGE INTENTIONALLY BLANK TABLE OF CONTENTS EISUOLINUSHAlO NS ars A A 2 NEE 3 Section 1 Description gees 4 SEHE Ale eher e Ee E ATESAT 4 Pnciple or AA A General Specifications ssec kennen naa 6 Product Code FIQUIS 1 DEE 7 Section 2 Installation 8 UNDAaCKING WEE 8 oalety Precautions See ee u ee 8 SE 8 MOUNINO WEE 9 Conversion Procedure S einen 9 A eo O 9 Electrical Connectors ses atas da bea Ca OP dea ecu Med ea ipea ido 12 Section 3 Operation EE 13 e A 13 Relief Valve Adjustment 0 00 cece cece cece nce e cece esas Re rea deep eee eee pe ee tenisi 15 USE OFA PWG BUOM Ia 16 Man al Capacity CONTO ictu tbt eb tee a tec ama erc eve ee 17 Flag PUMPING SI es ann 17 Capacity Cabral ii ri 17 Section 4 Maintenance un 18 Recommended Spare Par s aus 18 Shipping PUMPS for repair ssssssssssssemIHHHI rrr 18 Routine Preventive Maintenance 19 Gorreciive Malnterall6e d bei aes td li 24 Section 5 Troubleshooting Guide 29 section Un Sn 31 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 LIST OF ILLUSTRATIONS Located in back of manual Sample Nameplate Mounting Hole Dime
3. Suitable protective equipment must be provided Check that there is no system fluid pressure before proceeding with dismantling of liquid end components 19 Cleaning Fouled Check Valves Check valve assemblies are designed to be self cleaning and should seldom need servicing Fouled check valves can usually be cleaned by pumping a solution of mild detergent and warm water if compatible with liquid being pumped for 15 minutes followed by flushing with water Check Valve Replacement Before beginning work on the valve assemblies make sure the shut off valves are closed and that pressure has been bled from the system When replacing the valves take care to systematically change their O rings and or gaskets Take care to properly assemble the valve assemblies In valves that permit replacement of ball and seat the ball must be placed on the sharp edge of the seats For each plunger size check valves are supplied in three different configurations plastic single ball plastic double ball and metallic double ball Be sure to refer to the appropriate instructional set below pertaining to your plunger size and valve type Caution Be sure to follow instructions carefully and refer to the appropriate figure when reassembling check valves If check valve cartridges are installed incorrectly one of the following will occur a immediate severe damage to pump mechanism b no pumping c reverse pumping action from discharge line into sucti
4. 13 20 The check valve cartridge assemblies use an SAE straight thread with an O ring seal to facilitate port alignment with the connecting pipes To remove the cartridge from the liquid end first loosen the lock nut 435 one or two threads then unscrew the cartridge 444 445 Remove and discard the o ring 441 and split ring 439 Carefully clean any parts to be reused If any chemicals are used in the cleaning process ensure that they are compatible with the process liquid Reassembly refer to fig 13 To install the cartridge position the lock nut 435 toward the shoulder of the cartridge so that the recess on the face of the lock nut is adjacent to the O ring 441 Make certain the split ring 439 is coiled in a counterclockwise helix this is opposite the direction normally employed by suppliers of these rings Fit this split ring in the lock nut recess Push it firmly down in the recess as completely as possible Install a new O ring 435 against the split ring Note To assure a tight leak free seal new o rings and split rings should be used each time the check valves are disassembled Screw the cartridge assembly 444 445 into the liquid end until the O ring band is approximately level with the top of the spotface in the liquid end then screw it one 1 additional turn plus a partial turn as required to align the pipe thread port with connecting pipe Caution Suction and discharge check valve c
5. designed for industrial service and offers an accuracy of 1 of 100 rated flow between 10 and 100 of its flow range The High Performance Diaphragm HPD liquid end combines all of the best characteristics of traditional liquid ends into one technologically advanced design Its operating characteristics and simplicity of operation make it the best liquid end to consider first for most metering pump applications Milton Roy s HPD liquid end overcomes the net positive suction head NPSH restrictions associated with conventional disc diaphragm metering pumps This is accomplished by a unique mechanically actuated refill system MARS that eliminates the need for diaphragm support plates thereby lowering pump NPSH requirements The MARS also does away with the need for field adjustment of the refill mechanism by automatically compensating for process liquid modifications This combined with removable check valves makes the HPD an ideal choice for any process in which downtime is critical The HPD features a preformed PTFE faced elastomer diaphragm that is compatible with a wide range of process liquids and chemicals The convoluted design of this composite diaphragm also offers extended life over conventional flat disk designs The HPD liquid end is particularly suitable for pumping costly aggressive or hazardous liquids without leakage PRINCIPLE OF OPERATION Refer to Figures 5 through 10 The pump consists of two major assemblies the drive
6. discharge outlet from the piping system 2 Locate drain pan under diaphragm head to collect oil Approximately 1 pint of oil will drain from the displacement chamber after removal of the diaphragm 3 Remove the diaphragm head bolts 1025 which hold the head to the displacement chamber and remove diaphragm head 1020 Oil will begin to leak out In most cases the white teflon faced diaphragm will remain in the displacement chamber 26 4 Remove the diaphragm Oil will now drain out of the front of the displacement chamber B Installation of New Diaphragm Figures 7 amp 8 Make sure the contoured diaphragm support surface and o ring groove machined into displacement chamber are clean To prevent leakage from occurring be careful not to scratch the o ring groove when cleaning 2 Install the diaphragm into the displacement chamber with the black rubber side against the contoured surface of the displacement chamber Make sure the diaphragm sealing bead fits securely in the diaphragm groove of the displacement chamber The white teflon face of the diaphragm should be facing outward and visible 3 Align the two holes in the diaphragm head with the locating pins 610 in the displacement chamber and reinstall diaphragm head 1020 4 Reinstall head bolts 1025 flat washer 1040 lockwashers 1035 and nuts 1030 5 Tighten bolts firmly in a crisscross pattern Removal of Pump Liquid End Figures 7 amp 8 Milroyal G liqu
7. the displacement chamber The following steps describe the procedure for removal of the valve from the displacement chamber Figure 8 A Disassembly 1 Drain oil from the pump housing as described in the above Oil Replacement section 2 Unscrew the valve body 660 from the displacement chamber 600 3 Clean any debris from the valve cavity in the displacement chamber 4 Discard o rings 720 730 Note When reinstalling the valve assembly be sure to install new o rings 720 730 B Reassembly Install new o rings 720 730 and coat rings with o ring grease 2 Screw valve assembly back into displacement chamber until it reaches mechanical stop 3 Make sure the strainer 670 is installed and strainer plug 650 is tight Valve is now ready for service Refill pump casing with recommended oil as described in the Oil Replacement section Diaphragm Replacement Milroyal G liquid ends are designed to provide reliable service under normal operating circumstances and should not require replacement of the diaphragm However in the unlikely event of a failure the diaphragm can be replaced by the following the procedure A Removal of Diaphragm Figures 7 amp 8 WARNING Before beginning disassembly procedures relieve all pressure from system isolate the liquid end from all sources of process liquid with appropriate valving and purge liquid end of all process liquid 1 Disconnect both the suction inlet and
8. 10 Description Required 425 Check Valve Assembly Check Valve assemblies include two seals 419 seat 420 balls 421 422 ball guide 424 O Ring viton Ball Stop Ball 14mm Ball 22mm Ball Guide Body Coupling Y BSP Female Coupling Y NPT Female Check Valve Assembly Check Valve assemblies include two O rings 419 seat 420 ball stop 420 seat 421 ball 422 body 424 36 O Ring viton Ball Stop Ball 22mm 5 REMAINING LIQUID END PARTS see Figure 8 item No Descipion LD RG Diaphragm 1 3 4 2 1 2 3 plungers Pow 880 Plunger Seeve pner 3 59 umerSeme TA plunger 3 840 O Ring 1 1 4 1 3 4 plungers only EE 950 Screw M6 x 18mm 1 1 4 1 3 4 plungers only E 89 Rm Displacement Chamber 1 1 4 plunger 060 Displacement Chamber 1 3 4 2 1 2 3 plungers 620 Breather Cap 630 Sight Glass 640 Hose Barb Union 650 Displacement Chamber Plug Ya NPT 1020 Diaphragm Head PVC 1 1 4 plunger 1020 Diaphragm Head PVC 1 3 4 2 1 2 3 plungers 1020 Diaphragm Head 316SS 1 1 4 plunger 1020 Diaphragm Head 316SS 1 314 2 112 3 plungers 1020 Diaphragm Head Alloy 20 1 1 4 plunger Diaphragm Head Alloy 20 1 3 4 2 1 2 3 plungers 1025 Head Bolt Stainless steel For 1 1 4 plunger sizes M6 x 55mm For 1 3 4 2 1 2 3 plunger sizes M12 x 90mm 1030 Nut M12 Stainless Steel 1 3 4 2 1 2 3 plungers 1035 Lockwasher S S M12 1 3 4 2 1 2 3 plun
9. 1000 SSU at 100 F 218 4 cSt at 40 C For operation in ambient temperatures below 50 F 10 C substitute AGMA No 2 EP with a viscosity of 400 SSU at 100 F 86 4 cSt at 40 C Manufacturers equivalent oils are shown below CAUTION Do not start up pump drive motor before filling gear box with oil or serious damage will occur ABOVE 50 F Chevron N L Gear Compound 220 Exxon Spartan E P 220 Mobil Mobilgear 630 Texaco Meropa 220 Shell Omaha 220 BELOW 50 F Chevron N L Gear Compound 68 Exxon Spartan E P 68 Mobil Mobilgear 626 Texaco Meropa 68 Shell Omaha 68 Start Up for New Pump For pumps received from the factory the displacement chamber 600 is already filled with oil Simply remove the orange oil fill cap from the pump casing and fill the casing with the specified oil to a level between the top two dashes on the dipstick DO NOT OVERFILL ABOVE TOP DASH Pump is now ready for operation Operation of the air purge button may be required to remove air that may have come out of solution from the oil during shipment and storage Refer to USE OF AIR PURGE BUTTON section for operation instructions The integral pump relief valve is factory adjusted according to customer specified setting For instructions on adjustment of the pump relief valve please refer to the next section CAUTION Before switching on power to the pump turn the capacity adjustment knob to zero Check that all shut off valves in the suction and di
10. 30 F Maximum 0 F Minimum Note Limited by standard lubricants Modifications are available through Applications Engineering Liquid Temperature Limits Plastic Liquid Ends 20 F to 140 F Metallic Liquid Ends 20 F to 190 F Suction Pressure Limits Minimum Internal Pressure 3 psia 12 psi maximum vacuum Maximum Suction Pressure 100 psig at 80 F and below Lubrication Oil bath drive lubrication Paint Two part epoxy yellow RAL 1018 PRODUCT CODE Milroyal G pumps are available in a variety of different configurations The complete product code is composed of the pump model number product code 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 MODEL NUMBER MGH l U 45 6 Digits 4 amp 5 Plunger Size Digit 6 Liquid End Material Description Code Description Code 1 1 4 32mm 20 316 SS 1 1 3 4 45mm 28 Plastic PVC 2 2 1 2 63mm 40 Alloy 20 5 3 75mm 48 PRODUCT CODE E a e E e Wd Wb ade 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Digits 7 8 Stroking Speed Description Code Digits 9 8 10 Motor Description Code 173 spm 10 No motor Flange Mount NEMA 56C CB 86 spm 20 No motor Flange Mount NEMA 145TC CC 43 spm 30 No motor flange mount NEMA 182TC CD Note SPM s for 60 Hz 1725 rpm motor No motor Fla
11. 90 in correct orientation on liquid end With vent cap 620 at 12 O clock gently slide liquid end over plunger Reinstall six displacement chamber bolts 570 and lockwashers 560 and tighten securely Follow procedure for filling pump housing and liquid end with oil described in Start Up of Pump Containing No Oil in Casing and Displacement Chamber 28 SECTION 5 TROUBLESHOOTING SYMPTOMS amp REMEDIES Pump will not operate Low process liquid level in tank Add liquid Insufficient delivery Erratic delivery Worn or dirty check valves Clean or replace e 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 e Pump not primed Allow suction line and pump head to fill with liquid before pumping against pressure Refer to Filling Pumping System in Section 3 Capacity adjustment set at zero Readjust capacity Relief valve relieving Blocked discharge line Clear line Relief valve set too low Adjust valve to 1596 over operating pressure e Air in hyrdraulic system Operate purge button Clogged refill line Remove oil strainer and clean or replace Incorrect capacity adjustment Readjust
12. MENDED SPARE PARTS To avoid delays in repairs a Routine Preventative Maintenance Kit should be ordered foreach pump The RPM kit contains an oil strainer and check valve parts Part orders must include the following information 1 Quantity required Part Number Part Description Pump serial number found on pump nameplate Pump model number found on pump nameplate Pump product code found on pump nameplate De DT Always include the serial number model number and product code in all correspondence regarding this unit SHIPPING PUMPS FOR REPAIR Pumps can not be accepted for repair vvithout a Return Material Authorization Pumps should be clearly labeled to indicate the liquid being pumped Process liquid should be flushed from the pump liquid end and oil should be drained from the pump housing and displacement chamber To drain oil from the displacement chamber unscrew the refill valve body 660 fig 8 from the displacement chamber Allow oil to drain into a waste container Remove diaphragm 510 and tilt up the back of the pump until oil ceases to drain from the front of the pump NOTE Federal law prohibits handling of equipment that is not accompanied by an OSHA Material Safety Data Sheet MSDS A completed MSDS must be packed in the shipping crate with any pump shipped for repair These safety precautions will aid the troubleshooting and repair procedure and preclude serious injury to repair personnel from hazardous residue in pum
13. Roy Service Department for recommended VPCI materials MOUNTING 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 Be sure to allow enough space around the pump for easy access during maintenance operations pump adjustments and or oil filling or draining procedures Milroyal G pumps are provided with mounting holes to accommodate anchor bolts Refer to Figure 3 for mounting hole dimensions some Milroyal G pumps are shipped with motors dismounted After anchoring pump in position install motor referring to Figure 5 To avoid damage to pump drive during operation make sure spring 360 provided with pump is installed in worm shaft prior to motor installation Pumps installed outdoors should be protected by a shelter CONVERSION PROCEDURES A Milroyal G pump can in some cases be converted from one liquid end plunger size or material of construction to another For more information on converting between different liquid end models please contact the Milton Roy factory or your local authorized representative PIPING CONNECTIONS NPSH Considerations The Milroyal G HPD liquid end is far superior to conventional diaphragm liquid ends for suction lift and many other NPSH critical applications In these demanding applications the patented diaphragm and refill mechanism give this liquid end t
14. and the liquid end Pump delivery is a function of the drive s stroke rate strokes minute plunger size and stroke length Capacity Stroke length can be adjusted while the pump is running or stopped by turning the stroke adjustment knob 330 The drive motor transmits rotary motion to a worm gear speed reduction unit 343 50 which in turn drives the variable eccentric crank 100 The adjustable crank imparts reciprocating motion to the plunger connecting rod assembly 60 520 525 The stroke length is adjusted by changing the position of the variable eccentric crank in the connecting rod assembly The mechanical drive system of the pump drives the plunger back and forth in the High Performance Diaphragm HPD liquid end supplied with the pump At the start of a suction stroke the plunger moves away from the liquid end drawing hydraulic fluid with it As the hydraulic fluid is drawn back the flexible diaphragm 510 follows lowering the pressure of the process fluid in the liquid end This pressure drop causes the ball s in the suction check valve Figure 10 to be lifted up thereby allowing process fluid to pass 4 through the suction line into the diaphragm head 1020 At the same time the pressure drop in the diaphragm head causes the ball s in the discharge check valve Fig 10 to be pulled closed blocking flow back through the discharge line Note It is important that the pressure in the liquid end remain above the vapor pressure of
15. artridges are not identical Be sure that the correct cartridge is being screwed into the proper port Discharge cartridges have hexagonal cap on the top suction cartridges do not If check valve cartridges are installed into the wrong port one of the following will occur a immediate severe damage to pump mechanism b no pumping c reverse pumping action fron discharge line into suction line 5 After completing pipe connection tighten lock nut securely against spotface so that O ring is trapped in chamfer of liquid end thread Make sure that the split ring is completely contained in its recess and not extending to the outside 1 3 4 2 1 2 and 3 Plungers Plastic Single Ball Check Valves see Figure 11 A 1 2 Disassembly Unscrew the union nut 435 The union end 445 is held in place by the union nut and will now separate easily from check valve ball guide 424 Unscrew the ball guide 424 from the liquid end 21 Screw the union nut partially one or two turns onto the end of the ball guide containing the seat Be sure the union nut is loosely installed to allow for a gap for the seat 420 to drop into as it is removed from the ball guide Sit the ball guide union nut onto a flat surface with the union nut down Looking into the top of the ball guide you will see four large holes surrounding one small hole Insert a thin blunt instrument such as a hex head screwdriver into the small center hole until it rest
16. capacity setting Incorrect pump speed Match line voltage and frequency to pump motor data plate e Starved suction Increase piping size or suction head Leaky suction piping Repair piping e High suction lift Insufficient NPSH Most common with long suction lines small diameter suction lines acid pumping polymer viscous liquids or drawing from a source lower than pump Consult your local representative or the Milton Roy Factor Aftermarket Department Liquid near boiling Cool liquid or increase suction head Leaky safety valve in discharge line Repair or replace safety valve High liquid viscosity Reduce viscosity e g heat or dilute liquid Worn or dirty check valve seats Clean or replace Leaky relief valve Repair or replace valve consult factory Leaky suction piping Repair piping Leaky safety valve Repair or replace safety valve Liquid near boiling Cool liquid or increase suction head e Worn or dirty check valves Clean or replace Blocked suction line Clean strainer e High suction lift Insufficient NPSH Most common with long suction lines small diameter suction lines acid 29 pumping polymer viscous liquids or drawing from a source lower than pump Consult your local representative or the Milton Roy Factor Aftermarket Department Excessive Delivery Low discharge line pressure Increase line pressure e g install a back pressure valve Motor and p
17. efer to Figure 8 Over time the oil strainer 670 which screws into the refill valve body 660 can become fouled or clogged It should therefore be replaced yearly and is included with the check valve parts in the RPM Kit If the strainer becomes clogged more frequently than once a year which is extremely unlikely it can be ordered separately Since the oil must first be drained from the pump casing it is a good idea to schedule strainer replacement with oil replacement 1 Drain oil as described in the above Oil Replacement section of this manual Unscrew the strainer 670 from the refill valve body 660 Clean any debris from the strainer cavity in the valve body screw a new Strainer into the refill valve body Refill pump casing with recommended oil as described in the Oil Replacement section Oh oq CORRECTIVE MAINTENANCE 3 Function Hydraulic Valve The 3 function hydraulic valve assembly see Figure 8 operates in filtered hydraulic oil and should require maintenance only if unusual circumstances occur such as if corrosive media contaminates the fluid Assembly and disassembly is straightforward Follow instructions in the Start Up of Pump Containing No Oil in Casing and Displacement Chamber section of the manual Field servicing should be limited to inspection and cleaning only Repairs of this critical component should only be carried out by an authorized Milton Roy repair facility 24 MARS Valve Ass
18. embly The Mechanically Activated Refill System MARS valve assembly see Figures 8 amp 9 requires no periodic maintenance Clean hydraulic oil is critical for proper operation Field servicing should be limited to inspection and cleaning only Repairs of this critical component should only be carried out by an authorized Milton Roy repair facility The valve is designed to be easily removed through the front of the pump without having to remove the displacement chamber The following steps describe the procedure for removal of the valve from the displacement chamber refer to Figure 9 A Disassembly 1 Remove liquid end according to instructions in the Removing the Liquid End portion of the Diaphragm Replacement section of the manual 2 Insert a small tip screw driver into one of the two small holes in the valve button 780 and gently pry out plastic cap 790 3 While pressing down on button 780 remove the retaining ring 820 using the appropriate retaining ring pliers Waldes Truarc External Type Waldes Truarc part M 1520 4 Slide off activation button 780 and spring 800 5 Remove large retaining ring 810 using the appropriate retaining ring pliers Waldes Truarc Internal Type Waldes Truarc part 0300 6 Reinstall small retaining ring 820 in groove in valve stem 770 7 To avoid damage to valve stem grip retaining ring with pliers and pull remaining valve assembly out of displacement chamber 8 Discard o ring
19. ement chamber 600 through the port uncovered by removal of the 3 function valve in step 1 with the same oil used to fill the pump casing Fill the chamber slowly allowing air bubbles to escape until the oil level reaches the level of the drain tube 640 4 Reinstall 3 function valve a Gently gripping the top of the relief valve poppet 960 with needle nose pliers drop the poppet assembly down into the empty relief valve port b Drop spring 950 back into relief valve port c Make sure washer 935 is in place above the o ring 940 on purge stem 930 and reinstall purge and relief valve adjustment assembly by screwing large adjustment nut 910 back into place Make sure adjustment nut 910 is tight d Reinstall relief valve cap piece 850 5 The pump is now properly filled with oil and ready for service If the relief valve locking nut 900 remained tight during the above procedure the relief valve setting should remain unchanged If not refer to next section for instructions on how to set relief valve CAUTION Before switching on power to the pump turn the capacity adjustment knob to zero Check that all shut off valves in the suction and discharge lines are open before increasing the capacity adjustment from zero 6 Make sure that all air has been bled from the suction piping and pump head This can be accomplished by opening all suction line valves as well as the system drain Prime Air Purge valve shown in Figure 4 and allow
20. end of the ball guide upwards Position seat on the ball guide trapping the ball inside When the seat is pressed into the ball guide the beveled edge of the seat must be facing outward The bevel should not face the inside of the check valve refer to Figure 11 Use a flat surface such as a board to press the seat into the ball guide with firm even pressure Caution If the seat is improperly positioned with ball against beveled surface the ball will not create a tight seal and poor pumping performance will result Fit new o rings into grooves in the ball guide and seat Note To assure a tight leak free seal new o rings should be used each time the check valves are disassembled Position the union end 445 onto the correct end of the ball guide Refer to Figure 11 as the correct end is determined by whether the valve is 22 intended for the suction or discharge port of the liquid end Slip the union nut 435 over the union end and screw tightly hand tight only onto the ball guide Caution The order of assembly of the suction and discharge check valves is different Refer to Figure 11 for proper assembly order If check valve cartridges are installed incorrectly one of the following will occur a immediate severe damage to pump mechanism b no pumping c reverse pumping action from discharge line into suction line 5 Screw the valve assembly into the liquid end body hand tight only DO NOT OVERTIGHTEN 1 1 4 Plunge
21. equired Assemblies include the following items O Ring viton 420 BalStop ZJ AJ 9 1 421 Bal ceramio 3 8 14 422 Ball ceramic mm 1 424jJBalGude J 14 Union End PVC 44 NPT Male Fo Ww 7j 435 Union Nut PVC Shown in Figure 11 1 1 3 4 2 1 2 plungers Double ball check valve Fiqure 10 B EN NEN Required Assemblies include the following items Union Nut PVC Shown in Figure 11 Union End PVC NPT Female 1 3 4 2 1 2 3 plungers Single Ball Check Valves Fiqure 11 DT Le A 7 Required 425 Check Valve Assembly 1 lH Assemblies include two seals 419 seat 420 MM ball 422 ball guide 424 Seal PTFE Encapsulated Rubber Ball 5 8 Ceramic Union End PVC NPT Female 35 Metallic Liquid End see Figure 10 316SS amp Alloy 20 Liquid End 1 1 4 Plunger Double Ball Check Valve Fig 13 Description Qty Required Check Valve assemblies include seal 419 seat 420 balls 421 ball guide 424 Lock Nut 2 316SS Liquid End 1 3 4 2 1 2 plungers Double Ball Check Valves Description Qty Required 425 Check Valve Assembly Check Valve assemblies include two seals 419 seat 420 balls 421 422 ball guide 424 O Ring viton Ball Stop Ball 14mm Ball 22mm Ball Guide Body Coupling Y BSP Female Coupling Y NPT Female Alloy 20 Liquid End 1 3 4 2 1 2 3 plungers Double Ball Check Valves Fig
22. er mm f e S70 Displacement Chamber Screw M8x30mm 6 Note 1 Worm Assembly 343 includes worm coupling 346 spring 360 and bearing cone 340 Note 2 For part numbers not listed consult local Milton Roy representative or Milton Roy Aftermarket Department 215 441 0800 B BASIC PARTS LIST Liquid End Refer to Figures 7 9 1 MARS VALVE see Figure 9 Memo Description Re 775 Wie 1 750 Note 2 Valve Body 760 Note 2 Poppet 770 Note 2 Valve Stem 32 Button 1 1 4 plunger Button 1 3 4 2 1 2 3 plungers Plug 1 1 4 plunger 1 3 4 2 1 2 3 plungers Plug 810 Valve Body Retaining Ring 820 Valve Stem Retaining Ring 840 O Ring Note 1 Includes items 750 760 770 810 820 830 840 Note 2 Not sold separately Must purchase item 775 MARS Valve Assembly 2 REFILL VALVE see Figure 8 Tem No Description Re gue Rei Valve Assemby J A 6 Oil Strainer Plug 4 NPT E wee VaweBody er for Stained 31 emoe Ba 5998962 em 789 Rn 1 meet Washer 1 geed RemngRmg 1 Tm 1 Note 1 Includes items 650 660 670 680 690 700 710 720 730 Note 2 Not sold separately Must purchase item 740 Refill Valve Assembly 3 3 FUNCTION VALVE see Figure 8 Ve
23. gers 1040 Washer S S M12 1 3 4 2 1 2 3 plungers 6 1050 Head Plate 1 114 PVC only stainless steel NN NEM NEE IS EE HE NN un uM 37 Model No MGH281 Product Code 10CDM2SE11NN22 S N1234567891 Flow Rate X X GPH XX PSI XXX PSIMAWP Tag No 12345678 XXX XX12345678 ze Milton Roy Company gt Madein USA Figure 2 Sample Nameplate E 9 228 6 mm 114 3 mm QUEE Re ee eae NG t 9 mm Dia Mounting Holes Figure 3 Mounting Hole Dimensions 38 euieu s uonejjejsur duind papuswwosey seridA p ainbi4 uleJq OL 3AJeA pojnys gt lt duung Bundlan Jauaduieg nn uonesind zuel Aldans uunjo uoneaque 3JnsSaJd J9ueduueq uones nd 39 gt ke 182TC MOTOR EC80 MOTOR 56C MOTOR I BR SJH E 8 9 B m RY dass Ole O ON 72029 7 F lay EN E EE SS Eon ANN ANa N N SS TIT TT Bel Ce H a V NN UN ass Ju i E 9 Sn 719 m e EEN A Figure 5 Drive Parts Side View OH El L t lo SS d a a Y WU le SAN GY lt RN go PA ree SE TALE NS Se NESH NS NEN Njo SS INE S TEE HN Nee li TEES OEP AS nii ZN i S O M a i FIN CE El WY di Y ej cL e ee m bad IA AAA E e Figure 6 Drive Part
24. h inner surface and can be formed into long sweeping bends to minimize frictional flow losses e A strainer should be used in the suction line to prevent foreign particles from entering the liquid end This and any other measures to prevent debris from entering and fouling the ball checks will give increased maintenance free service Check strainer frequently to prevent blockage which could lead to cavitation e Keep suction piping as short and straight as possible e Piping size should be larger than the liquid end suction fitting to prevent pump starvation e f long suction lines are unavoidable install a stand pipe near the pump in the suction line 10 e Suction piping must be absolutely airtight to ensure accurate pumping After installation test suction piping for leaks with air and soap solution Discharge Piping Considerations e Install pipe large enough to prevent excessive pressure losses on the discharge stroke of the pump Maximum pressure at the discharge fitting on the liquid end must be kept at or below the rated pressure Max allowable working pressure shown on the pump nameplate e The pump will not deliver a controlled flow unless the discharge line pressure is 10 psi greater than the suction line pressure There are a number of ways to create an artificial pressure such as by installing a back pressure valve Please contact Milton Roy for recommendations to increase back pressure in slurry applications e When pu
25. his section are completed the equipment is to be stored sheltered protected from direct exposure to weather 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 If equipment is to be shipped directly from Milton Roy into long term storage contact Milton Roy to arrange for factory preparation Pump Drive 1 Flood the pump drive housing with a high grade lubricating oil rust preventative such as Mobile Oil Corporation product Mobilarma 524 Fill the housing completely to minimize air space and water vapor condensation After storage drain this material and refill the equipment to the correct oil level with the recommended lubricant for equipment commissioning 2 Remove drive motor and brush all unpainted metal surfaces with multipurpose grease NLGI grade 2 or 3 Store motor unattached Electrical Equipment 1 Motors should be prepared in the manner prescribed by their manufacturer If information is not available dismount and store motors as indicated in step 3 below 2 Dismount electrical equipment including motors from the pump 3 For all electrical equipment place packets of Vapor Phase Corrosion Inhibitor VPCI inside of the enclosure then place the entire enclosure with additional packets inside a plastic bag Seal the bag tightly closed Contact Milton
26. his warranty does not extend to damage by corrosion or erosion The materials of construction offered are recommendations subject in all cases to verification and acceptance by the customer These recommendations based on previous Company experience and best available information do not constitute guarantees against wear or chemical action Expressly excluded from this warranty are defects caused by misuse abuse or improper application employment or operation of the unit Expendable items and damage resulting from unauthorized repair are not covered by this warranty No liability for consequential damages or reinstallation labor is accepted Milton Roy Company will not assume responsibility for contingent liability for alleged failure of its products This warranty is in lieu of all other warranties expressed or implied SECTION 1 DESCRIPTION GENERAL Milroyal G pumps are reciprocating chemical dosing pumps capable of producing controlled flows up to 130 gallons per hour 492 L H at pressures up to 600 psi 41 BAR depending on the model These pumps feature the robust High Performance Diaphragm HPD liquid end which eliminates the need for contour plates and a non lost motion stroke adjustment mechanism based on the variable eccentric principle This non lost motion design substantially reduces pressure and flow pulsations which in turn increases the life of system components and results in a more continuous chemical injection It is
27. id ends are designed to provide reliable service under normal operating circumstances and should not require removal of the liquid end However if the need arises the following describes the procedure Warning Before beginning disassembly procedures relieve all pressure from system isolate the liquid end from all sources of process liquid with appropriate valving and purge liquid end of all process liquid Disassembly Disconnect both the suction inlet and discharge outlet from the piping system Drain oil as described in the above Oil Replacement section of this manual Remove 3 Function Valve assembly as described in the Start Up of Pump Containing No Oil in Casing and Displacement Chamber Remove six displacement chamber bolts 570 and lockwashers 560 which secure liquid end to pump drive housing Locate a container under liquid end to catch approximately 1 pint of oil that will escape during next step Gently pull liquid end off drive housing being careful to avoid damage to plunger 520 fig 5 during removal Drain oil into waste container Discard displacement chamber gasket 590 Place the liquid end diaphragm head up on a bench or other clean flat convenient work area 2 Reassembly Make sure gasket surface on pump housing and displacement chamber are clean and free of markings which could serve as leak paths Install new displacement chamber gasket 5
28. inal connections to pump e Because vapor in the liquid end will cause inaccurate pump delivery piping should be sloped down to pump suction check valve to prevent vapor pockets e When pumping suspended solids such as slurries install plugged crosses at all 90 line turns to permit line cleaning without dismantling piping e See Figure 4 for a typical recommended pump installation scheme Suction Piping Considerations e t 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 in close proximity to the pump will help ensure a flooded suction line e Avoid negative suction pressure conditions suction lift as such conditions adversely affect metering accuracy A lift of 20 Ft of water column is the maximum suction lift permissible e Milroyal G pumps are intended to be operated with process liquid supplied at or above atmospheric pressure Although these pumps can move liquids supplied at less than atmospheric pressure in these negative pressure applications it is important that all connections be absolutely drip free and vacuum tight e When pumping a liquid near its boiling point provide enough suction head to prevent the liquid from flashing into vapor when it enters the pump liquid end on the suction stroke e f possible use metal or plastic tubing for the suction line because such tubing has a smoot
29. ing fluid to flow into drain until all air has been purged If drain valve not present with the pump capacity set to 100 operate the pump under no discharge pressure until the entire pumping system has been filled 14 RELIEF VALVE ADJUSTMENT All Milroyal G liquid ends have a built in relief valve which allows hydraulic fluid to return to the pump casing if excessive pressure builds up in the discharge line This effectively stops the pump from pumping since the forward stroke of the piston will not displace the hydraulic fluid and force the diaphragm to flex During operation of the pump a relief condition caused by overpressurization can easily be seen by looking through the sight glass 630 Fig 7 for excessive oil flow from the drain tube 640 Fig 8 NOTE Under normal operation a few drops of oil should escape from the drain tube during each pump stroke due to normal oil flow through the airbleed ball 970 fig 8 If a stream of oil from the drain tube is evident on each pump stroke the system pressure has exceeded the pump relief valve setting and the pump is in a relief condition The Milroyal G liquid end relief valve may be adjusted to operating conditions by the following procedure Adjust the relief valve after first installing the pump and after any maintenance procedures Warning The pressure relief valve is factory set to open at a pressure 15 over the customer specified operating pressure or at 15 above the maximum p
30. l 75 turn to provide an adequate buffer zone Lock in relief valve setting by tightening locking nut 900 while holding adjustment screw 890 stationary The relief valve is now properly adjusted Reinstall valve cover 850 2 If pump is not in a relief condition at normal operating pressure and the operator wishes to reset the valve setting to approximately 15 above operating pressure recommended use the following procedure Remove valve cover 850 and decrease the relief valve setting by turning the adjustment screw 890 counterclockwise until a stream of oil flows from the drain tube 640 on each pump stroke Now slowly turn adjustment screw clockwise until until only a few drops of oil escape on each pump stroke normal leakage past airbleed ball Turn screw an additional 72 turn to provide an adequate buffer zone Lock in relief valve setting by tightening locking nut 900 while holding adjustment screw 890 stationary The relief valve is now properly adjusted Reinstall valve cover 850 USE OF AIR PURGE BUTTON Refer to Figures 7 amp 8 As with any hydraulically actuated diaphragm pump dissolved air will come out of solution during normal operation which can negatively impact pump performance if not removed from the pump displacement chamber The Milroyal G hydraulic 3 function valve is equipped with two mechanisms for removal of this gas a continuous airbleed and an air purge button The continuous airbleed portion of the valve is compo
31. llic Double Ball Check Valve Parts 1 1 4 thru 2 1 2 Plunger sizes 420 419 424 CAEN NN UWE V 422 421 Metallic Double Ball Check Valve Parts 3 Plunger Only Figure 10 422 419 419 777177 EH AU EGIT SST T 424 SUCTION DISCHARGE PVC Single Ball Check Valve Parts Figure 11 45 PLASTIC CHECK VALVES SUCTION DISCHARGE SHOWN WITH TUBE CONNECTIONS SUCTION DISCHARGE SHOWN WITH NPT CONNECTIONS Figure 12 Plastic Check Valves 1 1 4 Plunger Size 46 METALLIC CHECK VALVES f YA DXX 4 inam En OMNI Nw Figure 13 Metallic Check Valves 1 1 4 Plunger Size 47 PVC LIQUID END WITH FOUR FUNCTION BLEED VALVE 1 25 PLUNGER 446 FOUR FUNCTION BLEED VALVE NPT CONNECTION SHOWN 425 Cartridge Valve Assembly 425 Cartridge Valve Assembly 71 Suction Valve Assembly NPT CONNECTION SHOWN Figure 14 Four Function Bleed Valve 48 THIS PAGE INTENTIONALLY BLANK Milton Roy Company 201 Ivyland Road Flow Control Division Ivyland PA 18974 0577 www miltonroy com 215 441 0800 FAX 215 441 8620
32. mping water treatment chemicals directly into boiler drums use one liquid end assembly for each boiler drum Discharging 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 outer outlets Back Pressure Valves A Milton Roy Back Pressure Valve should be installed in the discharge line near the pump to ensure sufficient discharge head pressure for proper pump metering action Normally the valve should be located near the pump However back pressure valves for large pumps with long and extremely small discharge lines may have to be installed near the point of discharge into the process to minimize siphoning tendencies Pulsation Dampeners An accumulator surge chamber surge suppressor or pulsation dampener should be used with the back pressure valve in the discharge line to absorb the flow peaks between the pump and the back pressure valve Without the pulsation dampener the valve mechanism will snap open and closed with the surge from each pump stroke The pulsation dampener will allow the back pressure valve to oscillate about a partly closed position thus minimizing wear on the valve Discharge line pulsation dampeners offer the further advantage of limiting the flow and pressure variations characteristic of this kind of pump Installing a properly sized pulsation dampener will improve pump perfo
33. nge Mount IEC80 F165 flange MD Digits 11 amp 12 Capacity Adjustment Digits 13 amp 14 Check Valve Connection Description Code Description Code Manual Plastic micrometer knob M2 Pipe NPT SE Electronic 4 20 ma input Pipe BSP SN NEMA 4 115V E1 Pipe DN socket weld SQ NEMA 4 230V E2 Explosion Proof 115V EA Explosion Proof 230V EB Digits 15 amp 16 Base Digits 17 amp 18 Rupture Detection Double Diaphragm Description Code Description Code No Base standard NN No Rupture Detection Single Diaphragm standard NN Base optional 11 No Rupture Detection Double Diaphragm optional DD Rupture Detection Gauge Double Diaphragm optional C5 Rupture Detection gauge NEMA 4 pressure switch DD opt SN Rupture Detection gauge Exp Pr Switch DD optional SE Digits 19 amp 20 Check Valve Type Description Code Single Ball 11 Double Ball 22 FIGURE 1 Model Product Code SECTION 2 INSTALLATION 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 Carefully examine the shipping crate upon receipt from the carrier to be sure there is no obvious damage to the contents Open the crate carefully so accessory items fastened to the inside of the crate will not be damaged or los
34. nnual basis If highly corrosive material acids slurries etc is being pumped some applications may require more frequent replacement Milton Roy recommends an annual tune up using a Routine Preventive Maintenance RPM Kit RPM kits contain replacements for those parts which are subject to wear specifically the ball checks check valve seats gaskets seals and the strainer Replacing these parts annually with an RPM kit can reduce the possibility of unexpected downtime and will help to extend pump life To determine if check valves need maintenance disassemble the check valves following the instructions in the following Check Valve Replacement section In valves that permit disassembly 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 smooth 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 If the ball and seat are both in good condition the replacement schedule can be lengthened Caution Before carrying out any servicing operation on the metering unit or pipes disconnect electrical power from the pump and take the necessary steps to ensure that the harmful liquid they contain cannot escape or come into contact with personnel
35. nsions Typical Recommended pump installation Scheme Pump Drive Parts Side View Pump Drive Parts Top View Liquid End Top View Liquid End Cutaway View MARS Valve Double Ball Check Valve Parts 1 1 4 plastic 1 3 4 2 1 2 PVC 8 metallic Plastic Single Ball Check Valve Parts 1 3 4 2 1 2 amp 3 Plungers Plastic Check Valves for 1 1 4 Plunger Metallic Check Valves for 1 1 4 Plunger PVC 4 Function Bleed Valve for 1 1 4 Plunger MILROYAL G METERING PUMP TWENTY FOUR MONTH LIMITED WARRANTY Milton Roy Company warrants its Milroyal G metering pumps against defects in workmanship or materials for two years under normal use from the date of shipment from our warehouse or the warehouse of our agent Warranties on equipment and accessories furnished with the pump but manufactured by others are limited to the warranties offered by the manufacturers of their respective products This warranty is not extended to electronic or pneumatic control devices supplied with a Milton Roy metering pump These items are covered by the warranties offered by the manufacturer or the Milton Roy Warranty for Electronic Controls and Actuators All obligations and liabilities under this warranty are limited to refunding repairing or replacing at our option f o b our plant such reported defective units as are returned to our plant carrier charges prepaid Repairs or replacements are made subject to factory inspection of returned items T
36. o Figure 5 amp 6 emNo escipion T DER ag AT sn 39 jm I 30 Gear Thrust Fange Bearing IT me o 5 Jim 5 en 4 a en 80 Connecting Rod 120 i40 m Stroke Adjustment Screw Assembly 7 E I 1 39 om 35 a en CT 55 Cover Serene x Tem I 310 ton Stroke Locking Ball f 320 Stroke Lotina koo ooo a IS WAA 339 wWeAdwsmenKmb J oo 35 one 14 33061 Bearing Cone I Anote 1 Worm Assembly 173 spm 580 7 Worm Assembly 173 spm 145TC orm Assembly 173 spm 182TC orm Assembly 180 spm IEC80 F165 Worm Assembly 144 spm IEC80 F165 Worm Assembly 86spm 56C HT a A W W Worm Assembly 86 spm 145TC Worm Assembly 86 spm 182TC Worm Assembly 72 spm IEC 80 F165 43 spm 56C TS Worm Assembly 31 Worm Assembiy 43 spm 14519 _ 1 Worm Assembiy a3 spm 18270 1 WormAssembly 36 spm 1EC80 F165 1 1 Worm MotorCouplingl14570 1 1 WormiMotorCouping 1 0 1 Worm Motor Coupling IEC80 F165 pem RN jme Fir Springs 1 400 Motorscrews 18210 1 213x 4 4 450 Plunger 1 1 4 Plunger Pin 1 1 4 plunger Plunger Pin 1 3 4 plunger Plunger Pin 2 1 2 3 plungers 860 lockwash
37. o verify that pump is now in relief condition If it is not reduce relief valve setting by turning adjustment screw 890 counterclockwise until relief is observed in sight glass drain tube at a pressure equal to 15 greater than desired operating pressure Lock in relief valve setting by tightening locking nut 900 while holding 15 adjustment screw 890 stationary The relief valve is now properly adjusted Reinstall valve cover 850 5 For condition b in step 4 the setting of the relief valve should be reduced Remove valve cover 850 and turn adjustment screw 890 counterclockwise until relief is observed in sight glass drain tube at a pressure equal to 15 greater than desired operating pressure Lock in relief valve setting by tightening locking nut 900 while holding adjustment screw 890 stationary The relief valve is now properly adjusted Reinstall valve cover 850 Relief Valve Adjustment Without an Adjustable System Backpressure Valve If no adjustable backpressure valve is present in the discharge line use the following simplified procedure to check and or set the relief valve setting 1 If pump is in a relief condition at normal operating pressure the relief valve setting should be increased Remove valve cover 850 and increase relief valve setting by turning the adjustment screw 890 clockwise until only a few drops of oil escape on each pump stroke normal leakage past airbleed ball 970 Turn adjustment screw an additiona
38. on line 1 1 4 E Plastic Single Ball Check Valves see Figure 12 Unscrew the valve body 445 i Remove the cartridge assembly 425 includes cartridge ball seat ball guide o ring and washer 3 Clean the valve housing and mating port in the liguid end 4 Press a new clear plastic washer into valve body 5 Install new cartridge valve assembly in orientation shown in figure 12 e Make sure that seat end of cartridge white is always facing down e On discharge side drop cartridge assembly into threaded port in head The o ring should be stretched around outside of cartridge on same end as ball seat Screw valve body into discharge side of diaphragm head until valve is hand tight Do not overtighten e On suction side drop cartridge assembly into check valve body The o ring should be stretched around outside of cartridge on opposite end of ball seat Screw suction valve housing with cartridge valve into suction side of head Do not overtighten 1 1 4 Plunger Metallic Double Ball Check Valves see Figure 13 The metallic check valves used on the 1 1 4 plunger size pumps are precision assembled at the factory Do not attempt to disassemble these cartridges lf they become inoperative flush them with solvent wash them with warm detergent and blow them out with compressed air to remove any foreign matter If this treatment does not eliminate the trouble the cartridge assembly should be replaced A Disassembly refer to fig
39. p liquid end A Materials Safety Data Sheet must accompany all returns All inquiries or parts orders should be addressed to your local Milton Roy representative or distributor Alternatively inquiries and or parts orders may be sent to Milton Roy Company Flow Control Division 201 Ivyland Road Ivyland PA USA 18974 0577 Attn Aftermarket Department 18 ROUTINE PREVENTATIVE MAINTENANCE Warning Before any maintenance relieve all pressure from system isolate liquid end from all sources of process liquid with appropriate valving and purge liquid end of all process liquid Oil Replacement Initially change oil in pump casing after the first 250 hours of operation Then change oil after every 4000 hours of operation or every six months whichever comes first Oil can be drained by removing the drain plug 20 fig 6 When oil has finished draining make sure that the area around the drain hole is clean Screw drain plug back in securely Fill the pump housing with the recommended oil until the level is between the top two marks on the dipstick DO NOT OVERFILL above top mark Replace the oil fill cap and screw firmly in place Dispose of oil according to any federal state or local codes which may apply Note It is not necessary to purge the liquid end displacement chamber of oil during annual oil replacement Check Valves Milton Roy company recommends that check valve balls seats gaskets and o rings be replaced on an a
40. parts to be reused If any chemicals are used in the cleaning process ensure that they are compatible with the process liquid B Reassembly Refer to Figure 10 1 Drop the balls 422 421 into the valve body 424 Drop ball stop 420 into place making sure that side with o ring groove is facing up Install new o rings 419 on both ends of valve body Note To assure a tight leak free seal new o rings should be used each time the check valves are disassembled 23 2 Screw the correct end of the check valve assembly into the liquid end hand tight only trapping a new o ring between the liquid end and the check valve assembly DO NOT OVERTIGHTEN Caution The end of the check valve that is screwed into the pump head is different for the suction and discharge check valves Refer to Figure 10 for proper assembly order If check valve cartridges are installed incorrectly one of the following will occur a immediate severe damage to pump mechanism b no pumping c reverse pumping action from discharge line into suction line 3 If metallic check valve screw the coupling 445 onto the check valve assembly trapping a new o ring 419 between the coupling and the check valve assembly If plastic check valve position the union end 445 onto the correct end of the ball guide Slip the union nut 435 over the union end and screw tightly hand tight only onto the ball guide DO NOT OVERTIGHTEN Oil Strainer Replacement R
41. r Plastic Double Ball Check Valves 1 3 4 2 1 2 3 Plungers Plastic amp Metallic Double Ball Check Valves A Disassembly Refer to Figure 10 Double ball check valves differ from the plastic single ball check in that the ball seat is now integral to the ball guide The seats cannot easily be inspected for damage or wear f you suspect that the check valve may be damaged or worn replace the entire check valve assembly as per instructions below d lf metallic valve unscrew the coupling 445 from the ball guide 424 If plastic unscrew the union nut 435 fig 11 and remove union end 445 fig 11 from the ball guide 424 Unscrew the ball guide 424 from the liquid end Remove and discard the o rings 419 Remove ball stop 420 and balls 421 422 Inspect the balls carefully If they are smooth round and free of deposits or pits they are suitable for continued use Examine the ball seat areas in the valve body 424 A magnifying glass is recommended for this inspection The seat must be in near perfect condition for continued use Any visible imperfection on the seating surface pits erosion cracks renders the seat unusable thereby requiring replacement of the valve body 424 If both the balls and the seats are in good condition then the length of time between parts replacement may be increased If the balls and seats are severely damaged then the length of time between parts replacement should be shortened Carefully clean any
42. ressure rating of the pump if no operating pressure is specified by the customer When adjusting the valve setting never set the valve at a pressure greater than 15 over the pump maximum pressure rating Relief Valve Adjustment With an Adjustable System Backpressure Valve Refer to Figures 7 amp 8 The following procedure assumes that a backpressure valve and pressure gauge are installed in the discharge line If these components are not installed refer to next section 1 Make sure all system shut off valves are open and that the backpressure valve is backed out to allow for flow against zero discharge pressure 2 Start pump and set capacity at 100 f a drain valve is present in the discharge line pump process liquid to drain or other safe point to establish proper pumping action Close drain 3 Slowly increase system pressure until a significant flow is observed from the drain tube 640 fig 8 as viewed through the sight glass 630 fig 7 or b the system pressure reaches 15 over the desired system pressure 4 For condition a in step 4 if relief condition occurs at less than 15 above desired pump operating pressure the relief valve setting must be increased Remove valve cover 850 and increase relief valve setting by turning the adjustment screw 890 clockwise until only a few drops of oil escape on each pump stroke normal leakage past airbleed ball 980 Increase system pressure to 15 above desired operating pressure t
43. rmance and may reduce system costs dramatically by permitting the substitution of smaller piping Please contact Milton Roy Company for further information on pulsation dampeners Safety Valves Maximum safety and reliability may be ensured by protecting liquid ends and piping with an external relief valve installed in the system discharge line Although the pump is protected against excessive pressure by an internal relief valve to prevent a blocked discharge line from causing damage to the piping or process equipment install a Milton Roy Safety Valve in the pump discharge line This valve is designed and sized to handle system flow rates and pressures safely while resisting corrosion by the process liquid Install the safety valve in the discharge line between the pump and the nearest shut off valve This will prevent potential system damage from accidental valve closure Pipe the safety valve outlet back to the suction tank or to drain but in either case ensure that the pipe end is continuously visible so safety valve leakage may be detected Milton Roy 11 safety valves must be installed at top of supply tank in order to function properly see Figure 4 Check Valves A check valve should be installed at the point where the discharge line enters a boiler or other high pressure vessel This will prevent back flow through the discharge piping and will isolate the pump discharge from system pressures a safety consideration Shut off Valve
44. rom the drain tube 640 is seen through the sight glass 630 Immediately after activation of the purge button a temporary reduction in flow will occur as the refill system replenishes oil lost during the purge However the pump should return to normal operation within 1 to 2 minutes after activation of the purge button If after that time the pump flow rate is still less than it should be repeat the purge operation and wait another 2 minutes If flow has still not resumed to expected levels consult the troubleshooting section of this manual MANUAL CAPACITY CONTROL To adjust pump capacity on standard pumps equipped with manual stroke adjustment first loosen the stroke locking screw located in the pump side cover Pump capacity is then adjusted by turning the micrometer type stroke adjustment knob clockwise to decrease capacity or counterclockwise to increase capacity as required The adjustment scale is marked in percent of full stroke with calibration lines on the knob at 1 intervals After adjusting the knob to the desired capacity setting hand tighten the stroke locking screw to maintain the capacity setting FILLING PUMPING SYSTEM For proper pump operation it is especially important that pump suction and discharge lines be free of entrained air To ensure this condition operate the pump without any discharge pressure and fill the entire pumping system with liquid before starting pressure tests A simple method to assure priming of
45. ruly exceptional performance For more NPSH information refer to the Practical Handbook for NPSH bulletin 220 but apply a 3 psia limitation instead of 9 psia in evaluating applications for this liquid end Size piping to accommodate peak instantaneous flow Because of the reciprocating motion of the pump diaphragm pump delivery follows an approximate sine curve with a peak instantaneous flow equal to pi 3 14 times the average flow Therefore piping must be designed for a flow 3 14 times the pump capacity this means that a pump rated for 100 gallons per hour 379 L hr requires piping sufficient for 3 14 x 100 gph or 314 gph 1188 L hr 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 Milton Roy representative to determine the necessary pipe size General Piping Considerations e Use extreme care in piping to plastic liquid end pumps with rigid pipe such as PVC If excessive stresses or vibration is unavoidable flexible connections are recommended e Use piping materials that will resist corrosion by the liquid being pumped Use care in selecting materials to avoid galvanic corrosion at pump liquid end connections e Use piping heavy enough to withstand maximum pressures e Remove burrs sharp edges and debris from inside piping Blow out all pipelines before making f
46. s In order to isolate the pump during maintenance provide shut off valves in both suction and discharge lines next to the pump Locate discharge line shut off valve downstream from the inlet connection of the safety valve Figure 4 shows recommended valve locations ELECTRICAL CONNECTIONS Ensure that the electrical supply matches the pump motor nameplate characteristics 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 Caution Operation with the wrong motor rotation will damage the pump and motor and void the warranty Caution Do not forget to connect the pump to an earth ground Electric protection of the motor fuses overload meters or relays should correspond to the rated current indicated on the motor data plate 12 SECTION 3 OPERATION INITIAL START UP Check that all mounting bolts are tight piping is installed properly and the discharge line is open Check oil drain plug for tightness Remove the orange oil fill cap and fill the pump casing until level is between the top two marks on the oilcap dipstick approximately 3 1 2 quarts DO NOT OVERFILL ABOVE TOP DASH NOTE The oil furnished with the pump is grade AGMA No 5 EP with a viscosity of
47. s Top Vievv LIQUID END TOP VIEW PLASTIC ONLY PLATE IS USED ON 1 1 4 PLUNGER SIZE ONLY LARGER PLUNGER SIZES USE WASHERS TORQUE TO 40 IN LB METALIC 20 IN LB PLASTIC View for 1 1 4 Plunger Ssize m E TORQUE TO u 125 IN LB FOR PLASTIC HEAD 250 IN LB FOR METAL HEAD ui E SEE DRIVE HOUSING View for 1 3 4 2 1 2 and 3 Plunger sizes Figure 7 Liquid End Top View 42 LIQUID END Section A A CHECK VALVES MARS VALVE SEE FIGURE NEXT SHEET UJ LJ u OS DS S E AE SN AKA VALUE NZ E SI QA Wale oon Nr tte Hide SN NS quum IE A ES N rg YA 7 3 FUNCT ION HYORAUL C VALVE De Ys YA AR LISS SS INS Ne AN a u el NISE eis SS 2 Gel VE E SL gt lt Ly ik vy z SIS VI Qe Y gt e ASS E Se DE 9 SON TU ISSN SS KKK SI SN LA OIS e baad E ee R VODDE d DES SS T OY e TORQUE TO 125 IN LB Figure 8 Liquid End Section A A 43 MARS VALVE Mechanically Activated Refill System MARS valve assembly Except for O rings the valve may only be purchased as an assembly Y Ly IL El IS ISS RS ZAI SSS AREA zu OS Xs ass IN d 770 800 The MARS valve is located between the plunger and the diaphragm Figure 9 MARS VALVE 44 CHECK VALVE PARTS SUCTION DISCHARGE PVC and Meta
48. s 830 840 and retaining rings 810 820 NOTE When reinstalling make certain that new o rings and retaining rings are installed on MARS assembly B Reassembly 1 Install new o rings 830 840 on valve body 750 and apply a light layer of o ring grease to o rings 2 Push assembly into place until it reaches stop in displacement chamber 3 Reinstall large bowed retaining ring 810 Using a hammer and flat tipped screwdriver gently tap the ring to insure that it is securely seated in the retaining groove machined into the displacement chamber 4 Reinstall spring 800 and activation button 780 5 While pressing button 780 reinstall small retaining ring 820 Gently tap on the ring to insure that it is securely seated in the retaining ring groove machined into the valve stem 770 6 Press plastic cap piece 790 into activation button 780 7 Valve is now ready for service Refill Valve Assembly see Figure 8 The only required periodic maintenance for the refill valve assembly is the suggested annual replacement of the oil strainer see above Oil Strainer Replacement section Clean hydraulic oil is critical for proper operation Field 25 servicing of the valve assembly is limited to inspection and cleaning only Repairs of this critical component should only be carried out by an authorized Milton Roy repair facility The valve is designed to be easily removed through the bottom of the pump without having to remove
49. s on the top of the ball 422 Tap screwdriver gently with a hammer until ball and seat are released from the ball guide Caution 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 need to be replaced To avoid damage if available it is advisable to use gentle air pressure applied at end opposite the seat 420 for ball and seat removal Carefully remove the two o rings 419 from the ball guide and seat Inspect the balls carefully If they are smooth round and free of deposits or pits they are suitable for continued use Examine the check valve seats The area of the seat in contact with the ball the un chamfered side must be in near perfect condition for continued use Any visible imperfection on the seating surface pits erosion cracks necessitates replacement of the seat If both the balls and the seats are in good condition then the length of time between parts replacement may be increased If the balls and seats are severely damaged then the length of time between parts replacement should be shortened Carefully clean any parts to be reused If any chemicals are used in the cleaning process ensure that they are compatible with the process liquid B Reassembly 1 2 Sit the ball guide on a flat surface so that the side with the ball faces Drop the ball into the curved inner chamber
50. scharge lines are open before increasing the capacity adjustment from zero 13 Start Up of Pump Containing No Oil in Casing and Displacement Chamber The following instructions assume that both the pump casing and liquid end displacement chamber contain no oil This condition typically exists when the pump is subjected to annual maintenance during which oil may be drained from the pump casing and oil may escape from the displacement chamber during diaphragm replacement New pumps received from the factory will have an empty pump casing and a filled displacement chamberlliquid end Please refer to the previous section for start up of new pumps After pump casing is filled to correct oil level between top two dashes on oil cap dipstick perform the following operations before placing the pump into service Numbers refer to item numbers shown in assembly drawings Figures 7 9 located in the back of this manual 1 Remove hydraulic 3 function valve refer to Figure 8 a Remove relief valve cap piece 850 b Make sure relief valve locknut 900 is tight to maintain previous relief valve setting upon start up c Remove purge button and relief valve adjustment assembly by removing large adjustment nut 910 d Using needle nose pliers remove spring 950 e Using same pliers remove relief valve poppet by gently gripping the top of the valve body 960 2 Make sure pump capacity adjustment is set to 100 3 Fill the opening in the displac
51. sed of a sealed ball 970 which allows for a controlled leakage of a few drops of oil and any small accumulations of evolved gas on each pump stroke Larger quantities of air can be quickly removed by pressing the spring loaded purge button 860 until it reaches its mechanical stop for a few seconds Upon doing so the operator will observe a stream of oil and air escaping from the drain tube 640 The need for use of the purge button to remove a large quantity of air can be caused by several factors 1 Blocked suction line A partially or fully blocked suction line can create a vacuum pressure condition in the hydraulic system which pulls significant quantities of dissolved gas from solution 2 Oil Change The recommended annual changing of the oil in the pump drive can lead to the presence of air pockets in the displacement chamber 600 16 3 Diaphragm Replacement Results in significant loss of oil from the displacement chamber 4 Pump Start up After Long Idle Period If the pump has sat idle for a significant time gas may come out of solution from the oil and collect into pockets which can negatively impact pump flow Depression of the purge button will quickly evacuate these pockets and restore the pump to desired performance The operator should only activate the purge button if some type of pump upset occurs such as the above 4 examples When activating the purge only press button for 2 3 seconds or until a stream of oil flowing f
52. t Examine all material inside the crate and check against packing list to be sure that all items are accounted for and intact SAFETY PRECAUTIONS When installing operating and maintaining the Milroyal G pump keep safety considerations foremost Use proper tools protective clothing and eye protection when working on the equipment and install the equipment with a view toward ensuring safe operation Follow the instructions in this manual and take additional safety measures appropriate to the liquid being pumped Be extremely careful in the presence of hazardous substances e g corrosives toxins solvents acids caustics flammables etc STORAGE Temporary Storage Less than 6 Months It is preferable to store the material under a shelter in its original package to protect it from adverse weather conditions In condensing atmospheres follow the long term storage procedure Long Term Storage Longer than 6 Months Primary Considerations The primary consideration in storage of pump equipment is to prevent corrosion of external and internal components This corrosion is caused by natural circulation of air as temperature of the surroundings change from day to night day to day and from season to season It is not practical to prevent this circulation which carries water vapor and other corrosive gasses so it is necessary to protect internal and external surfaces from their effects to the extent possible When the instructions given in t
53. t the back contoured surface of the displacement chamber and part of the diaphragm will press against the Mechanically Actuated Refill System MARS valve Fig 9 Now when the plunger draws back a vacuum is created in the displacement chamber These two factors diaphragm pressing against MARS valve amp vacuum in the displacement chamber must occur together to trigger the MARS valve When both of these conditions are met the MARS valve is forced to its rearward position and the poppet 760 opens allowing hydraulic oil from the reservoir to enter through the refill valve 740 in Fig 8 and replenish the lost oil In this manner proper hydraulic balance is constantly maintained in the displacement chamber GENERAL SPECIFICATIONS Maximum Capacity Range 20 GPH 76 LPH to 130 GPH 492 LPH Maximum Pressure Range 100 PSIG 7 Bar to 600 PSIG 41 BAR Liquid End Design Hydraulically Actuated Diaphragm with Mechanically Actuated Refill System MARS Drive Design Non Lost Motion Variable Eccentric Type Plunger Diameters 1 1 4 32mm 1 3 4 45mm 2 1 2 63mm 3 75mm Liquid End Materials of Construction PVC 316 SS Alloy 20 Steady State Accuracy 1 of 100 rated flow between 10 and 100 of rated flow Capacity Adjustment Micrometer Standard Lockable micrometer is adjustable from 0 to 100 while pump is running or stopped Electronic Optional Electronic stroke length adjustment from 4 20ma input Temperature Limits Ambient Limit 1
54. the process fluid during the suction stroke If 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 Milton Roy Representative for assistance At the end of the suction stroke the process reverses beginning the discharge stroke Now the plunger moves forward pushing hydraulic fluid before it The hydraulic oil must therefore press against the diaphragm flexing it forward and raising the pressure of the process fluid in the liquid end This pressure increase causes the process fluid to flow outward forcing the discharge ball check open and the suction ball check to seat blocking back flow through the suction line The process fluid flows out of the diaphragm head and into the discharge line This suction discharge action is repeated with every stroke of the pump plunger and is the direct cause of the pumping action As the pump operates a small quantity of hydraulic oil is continuously bled through the air bleed system 970 960 980 in Fig 8 in the three function hydraulic valve air bleed relief purge Fig 8 An additional small quantity of hydraulic oil is also lost on every stroke through the clearance between the plunger and displacement chamber bore After a while these normal losses result in a shortage of hydraulic oil in the displacement chamber When this happens the diaphragm will be pulled back tight agains
55. the pump is to install a tee and a shut off valve at the discharge connection of the pump 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 a drain when starting the pump CAPACITY CALIBRATION After the first 12 hours of operation the pump should be tested and calibrated to find the exact pump capacity under specific operating conditions and capacity settings for the specific fluid being pumped Typically calibrating the pump at 100 50 and 10 percent capacity settings is enough to establish a pump performance curve throughout the adjustment range The pump can be calibrated by measuring the decrease in liquid level pumped from a calibrated vessel This method is recommended for hazardous liquids because it eliminates operator contact with the liquid Milton Roy test tube Calibration Columns are available for convenient and accurate calibration of any pump The pump can also be calibrated by collecting and measuring pumped liquid at the pump discharge port in which case it will be necessary to create discharge head at the liquid takeoff point so that the pump will operate properly See Section 2 for recommended ways to do this 17 CAUTION This method is not generally recommended as it may expose operating personnel to hazardous liquids SECTION 4 MAINTENANCE RECOM
56. ump body hot Normal operating temperature of both motor and pump body is frequently uncomfortable to the touch However neither should exceed 200 F 93 C Power supply does not match electrical requirement of motor Insure proper matching of power supply and motor e Pump is being operated at greater than rated performance Reduce pressure or stroke speed If this is not practical contact service facility e Pump improperly lubricated Drain oil and refill with proper amount of recommended lubricant Pump still pumps even at zero capacity setting Misadjusted micrometer knob Readjust capacity setting e Insufficient discharge pressure Correct condition e g install a back pressure valve Gear noise Excessive backlash Consult service facility e 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 e Worn bearings Consult service facility e Incorrect motor rotation Should be clockwise as viewed from top of motor e Worm shaft spring 360 missing Noisy operation in liquid end Noise in check valves Ball checks move up and down with some force A distinct clicking noise is normal especially in metal piping systems 30 SECTION 6 PARTS A BASIC PARTS LIST Pump Drive Refer t
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