Metering Pumps Instruction Manualmiltonroyindia.com/distributor_pdf/MAD - M - Series... · 2013-04-13 · Milton Roy India (P) Ltd., warrants its metering pump products against defects

Instruction Manual

This Manual should be made available to personsresponsible for Installation, Operation and Maintenance.

MILTON ROY INDIA (P) LTD.Metering Pumps

LPH

Kg/cm2

M-Pump Model No.........................................................................

Serial No....................................................................................

Capacity.....................................................................................

Pressure....................................................................................

M -Series

4, Rajarajan Street, Visalakshi Nagar,Ekkaduthangal, Chennai - 600 097, India.Telephone : (044)-22254000 - 3Fax : 91-44-22254004 E-mail : [email protected] : www.miltonroyindia.com

Issue Date : 03/2005

WARRANTY Page No.

I. UNPACKING 1

II. LOCATION AND MOUNTING 1

III. ELECTRICAL AND DRIVE 1

IV. LUBRICATION 1

V. PLUMBING CONFIGURATION 1

VI. LIQUID HANDLING ASSEMBLY 1

VII. PUMP OPERATION 3

VIII. MAINTENANCE 4

TROUBLE SHOOTING GUIDE 5

SERIES M DRIVE ASSEMBLY PARTS LIST 7

LIQUID HANDLING ASSEMBLY PARTS LIST 9

TABLE OF CONTENTS

MILTON ROY INDIA (P) LTD.

M - Series Pumps

Milton Roy India (P) Ltd., warrants its metering pump products against defects in workmanship or materials for one

year under normal use from the date of shipment from our warehouse or the warehouse of our agent. All metering

pump components are warranted for one year, except that 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 control devices supplied with a Milton Roy India (P) Ltd.,

metering pump. These items are covered by the warranties offered by the manufacturer 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 allegedly defective units as are returned to our plant, carrier charges prepaid. Repairs or

replacements are made subject to factory inspection of returned items.

This 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 unauthorised repair are not covered by this

warranty. No liability for consequential damages or reinstallation labour is accepted. Milton Roy India (P) Ltd., will

not assume responsibility for contingent liability for alleged failure of its products.

RETURNING PUMPS TO THE FACTORY

Pumps will not be accepted for repair without a written consent from the Factory Service Department. Pumps

returned to the Factory for repairs 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 before the pump is

shipped.

NOTE

These safety precautions will aid the troubleshooting and repair procedure and preclude serious injury to

repair personnel from hazardous residue in pump liquid end.

All inquiries or parts orders should be addressed to your local Milton Roy India (P) Ltd., representatives or sent to :


M - Series Pumps

METERING PUMP PRODUCTS TWELVE MONTHLIMITED WARRANTY

MILTON ROY INDIA (P) Ltd.,NO.: 4, RAJARAJAN STREET, VISALAKSHI NAGAR

EKKADUTHANGAL, MADRAS - 600 097.

PHONE NO.: (044) - 22254000 - 3

FAX NO.: 91-44-22254004

I. UNPACKING

Remove tubing, injection check valve, pressure relief

valve and foot valve which are supplied loose. Notify

Factory and Insurance Company immediately if there are

any sings of damage to the metering pump or parts.

II. LOCATION AND MOUNTING

1. Locate the pump in an area that is convenient to

both chemical injection point and electrical

supply. MRIPL chemical metering pumps should

not be subjected to continuous high temperature 0

over 50 C

2. Mount the pump at a convenient operating height

on a firm foundation.

III. ELECTRICAL AND DRIVE

The pump is driven by a 0.5 H.P., 1440 RPM squirrel

cage induction motor. The input power supply is 415V

3 phase 50 C/S. The drive consists of a speed

reduction by means of a worm and worm wheel. The

worm is connected to the motor by a love-joy

coupling.

IV. LUBRICATION

Before operating the pump check oil drain plug for

tightness and fill unit with 250 ml. of SAE 140 Grade

Oil (Servo Gear HP-140 of Indian Oil or equivalent).

Check oil level using dip-stick provided with the filler

plug.

V. PLUMBING CONFIGURTION

1. Figures 1 & 2 show typical chemical metering

pump installations. Note location of injection

check valve which is most important. Refer to

liquid handling assembly instructions section

regarding installation of injection check valve.

2. Back Pressure Requirement

All metering pumps are prone to overpumping

(excessive output) at low discharge pressure

and while pumping into open tanks. To prevent this

condition from occurring it is necessary to maintain

approximately 25 PSI (10 PSI for M-13 & M-14) back

pressure across the pump. This is achieved by a

spring loaded injection check/antisyphon valve.

Consult ALMI factory for injection check/antisyphon

valves with increased back pressure ratings.

3. If chemical level in flooded suction installations

are more than 3 metres consult factory.

4. Fluid Connections - M series metering pumps are

equipped with LDPE flexible tubing for both suction

and discharge. In case you wish to use rigid piping

contact factory for fittings with NPT threads. Following

precautions should be taken.

* Pressure test all plumbing before use to guard

against leaks.

* Prevent thread sealant from getting inside

plumbing.

* Install a ball valve in the suction side of flooded

suction installation to simplify maintenance.

* A foot valve is a must in suction lift installations.

* Do not use teflon tape on flexible tubing

connectors.

* Do not use pipe wrenches on flexible tubing

connectors.

VI. LIQUID HANDLING ASSEMBLY

A. Installing Injection Check Valve

1. The injection check/antisyphon valve should

always be installed as close as possible to the

point of chemical injection at the very end of the

tubing run.

2. Purpose of injection check/antisyphon valve is to

prevent backflow from treated line. It also

provides the back pressure required for the

pump.

3. A 1/2" NPT female fitting with sufficient depth will

accept the injection check/antisyphon valve.

4. In order to ensure correct seating of the ball inside

the check valve, the injection check/antisyphon

valve should be installed vertically upwards.

M-Series Pumps

1

CAUTION

When pumping chemicals make certain that all

tubing is securely attached to the fittings. It is

recommended that tubing or pipe lines be shielded

to prevent possible injury in case of rupture or

accidental damage. Always wear protective face

shield and clothing when working on or near a

chemical metering pump. All M Series pumps are

motor driven mechanical pumps. Your pump has

been equipped with a pressure relief valve supplied

by MRIPL & you have to install the same on the head

of pump before start-up.

CAUTION

Be sure installation does not constitute a cross

connection. Check local plumbing code.


5. Maximum pump pressure rating is reduced with

spring installed in injection check/antisyphon valve.

Remove spring if pressure at injection point is more

than 20 PSI.

B. Installing Pressure Relief Valve

1. MRIPL PRV consists of a pressure relief valve with a

mounting adaptor.

2. Screw in adaptor on the discharge valve plug. Take

care to see that the Quad seal sits on the taper nozzle.

Do not use teflon tape. Screw in the PRV into the

adapter taking care to see that the quad seal in

position.

C. Connecting Discharge Tubing

1. Cut tubing to length needed for discharge line.

2. Route tubing from injection check valve to chemical

metering pump making sure it does not touch hot

surfaces, sharp surfaces, or is bent so sharply that it

kinks.

3. Slide small end of coupling nut onto tubing.

4. Push tubing over tapped nozzle of discharge valve

housing so that tubing flares out and reaches the

shoulder. If tubing is stiff from cold, dip end in hot

water.

5. Slide down the coupling nut until threads are engaged.

Tighten by hand until tubing is held securely in place.

6. Follow the same procedure for connecting tubing to

injection valve.

D. Connecting Suction Tubing

1. Cut Suction tubing to length such that the foot valve

hangs just above the bottom of the chemical container.

Maximum recommended vertical suction lift 5 ft.

(1.5m).

2. Follow same procedure (see C) in connecting suction

tubing to suction valve and foot valve.

3. If a suction tube straightener is desired, one may be

fabricated from a 3 ft. (1m) piece of 1/2" Schedule 80

PVC pipe.

4. In case of flooded suction use a tubing connector with

1/2 NPT threads. This is available from MRIPL as an

optional accessory.

Excessive force will crack or distort fittings.

DO NOT USE PIPE WRENCH

M-Series Pumps

SUCTION LIFT INSTALLATION FLOODED SUCTION INSTALLATION

Fig. 1 Fig. 2

helpful when pumping

at very low rate

2


VII PUMP OPERATION

A. Priming

Priming can be done only against atmospheric

pressure when using a suction lift installation. Flooded

suction installations will allow the unit to prime itself

even under pressure.

1. Temporarily remove tubing from injection check

valve and hold the end of tubing so that it is above

pump level.

2. Set pump at 100% stroke and start pump.

3. As soon as chemical is visible through translucent

discharge tubing just past the discharge valve,

stop the pump.

4. Pump is now primed.

5. Reconnect tubing to injection check valve.

Note :

(a) Pump is normally self-priming if suction lift is no

more than 5 ft. (1.5m) and the above steps (A1

thru A3) are followed.

(b) If the pump does not self prime, remove discharge

valve housing and ball and pour water or

chemical slowly into discharge port until it is filled.

Follow steps A2 thru A5 thereafter.

In all cases priming will be assisted by releasing or

reducing pressure on the pump. This is best

accomplished by pulling the lever of the ALMI

Pressure Relief Valve.

B. Output Adjustment

Pump output is adjusted using the knob located at the

top of the pump (fig.3). The lock knob holds the shaft

to prevent charge of setting. Before adjusting the

pump should be running. The dial under the knob

represents "% of total output" and provides accurate

output adjustment above the 10% setting. The knob is

set properly if the line on the knob lines up the zero

M-Series Pumps

Fig. 3

3


(0) mark on the dial when the knob is turned counter-

clockwise as far as it will go. This is the zero output

position. The maximum output position. The maximum

output position is reached by turning this knob fully

clockwise to 100% setting on dial. Output adjustment

should be done while the unit is running.

C. Output Adjustment knob Setting

With the pump operating, turn the output adjustment knob

counterclockwise until no stroking action is felt when

holding onto the knobs. At the point where stroking action

stops the line on the knob should be directly over the zero

mark on the dial. If alignment is not correct, knob position

on shaft should be adjusted as follows.

1. Loosen 2 Nos. set screws on the knob with suitable

Allen-wrench and remove the knob.

2. Loosen Lock knob.

3. With a griplier adjust shaft until a point is reached

where stroking action just ceases and can go longer

be felt when grasping shaft and stop the pump.

4. Place knob on shaft. Carefully line knob up so that

knob pointer is directly over the zero marking on the

dial.

5. Taking care not to move shaft or knob alignment,

tighten both set-screws.

6. Recheck alignment results.

D. Calibration

Pump output calibration can be easily done if required.

The pump is best calibrated after installation by using a

stopwatch to measure the time required to remove a

known volume of liquid from a tank (fig.4). Proper setting

of the pump's zero output position should be verified

before calibration and is explained is Section B.

VIII MAINTENANCE

A. Lubricant Change

The m series drive train is oil lubricated. Replace oil

every 1000hrs. of running with approximately 250 ml.

of SAE 140 Grade Oil (Servo Gear HP-140 of Indian

Oil or equivalent). Check oil level periodically using

dip-stick and top-up as required.

B. Liquifram Replacement

1. Disconnect suction supply line and shut off to

prevent chemical spill.

2. Operate pump until pump head is empited of

chemical. set output adjustment knob at 100% by

turning knob fully clockwise.

3. Stop the pump.

4. Release pressure from discharge line by pulling

the knob on the PRV.

5. Disconnect discharge line. Be prepared to catch

excess chemical during this procedure.

6. Remove pump head by unscrewing the four/six head

retaining screws holding the head to the spacer.

7. Start the pump. With unit running at 100% output,

unscrew and remove and old Liquidfram.

8. With pump still running, set output adjustment knob

back to 90% for models M-09, M-10, M-11 and M-12,

70% for model M-13 and 50% for Model M-14.

9. Without changing these output settings, screw new

Liquifram in place.

10. Stop the pump. Rotate the shaft at Love-joy coupling

or Motor fan (after removing fanguard) and make sure

diaphragm is fully retracted. Then check Liquifram

alignment by using a straight edge held firmly against

the spacer (take care not to scratch the sealing flange

of Teflon-faced Liquiframs). Centre of Liquifram

should be flush with outer edges of spacer (fig. 5).

11. With new liquifram installed, turn on pump and set

knob at 100% output position. Reinstall pump head

making sure the part number stamped on the face of

the head is in upright position. Tighten the four/six

retaining screws in a criss cross pattern.

M-Series Pumps

4 MILTON ROY INDIA (P) LTD.

DATA SHEET FOR METERING PUMP

MODEL M SERIES

TYPE MECHANICALLY ACTUATED DIAPHRAGM TYPE

MODEL M-09 M-10 M-11 M-12 M-13 M-14

MAX FLOW (IN LPH) 5 10 17 30 50 100

MAX PRESSURE (KG/SQCM) 15 15 12 10 5 3

STROKE PER MINUTE 50 100 144 144 144 144

LINEAR SPEED (M/MIN) 0.4 0.8 1.152 1.152 1.152 1.152

Always wear protective clothing and face shield

when working on or near a chemical metering pump.

TROUBLE SHOOTING GUIDE

Problem Cause Remedy

Solution drips from hole in Liquifram is ruptured Replace Liquifram. See Liquifram Replacement

spacer instructions in maintenance section of this manual

Liquifram does not move Output adjustment knob is set at zero With pump running, rotate output adjustment knob to a higher setting.

Power is off Check power supply.

Solution is too viscous Dilute solution.

Injection into excessive pressure. Check and clean valves if clogged. Check system pressure against maximum injection pressure rating pump. If discharge pressure is within 20 PSI of pump's m a x i m u m rating, remove spring in injection check /antisyphon valve.

Liquifram moves, but no solution Trapped air in pump head Operate pump of 100% output setting. Release is pumped pressure on pump d ischarge. Fol low pr iming

instructions. Operate pump for a few minutes to purge head and valves of air.

Suction lift is too high Reduce suction lift or arrange pump and tank for flooded suction installation.

Loop in suction line permits air trap on Straighten suction tubing.

suction side

Improperly installed, or dirty valve seats Refer liquid Handling Assembly instructions. Clean and reassemble valves.

Air in suction line. Tighten suction valve fitting. Replace if necessary. Check for air leaks throughout suction line.

Pumps air bubbles or air. Suction tubing has leaks or pin holes. Replace suction tubing.

Improperly installed, or dirty valve seats. Refer liquid Handling Assembly instruction. Clean and reassemble valves.

Suction lift is too high. Reduce suction lift or arrange pump and tank for flooded suction installation.

Solution supply is exhausted. Refill solution container.

Foot valve and strainer assembly is clogged Clean foot valve assembly.

Pumps does not start under low Voltage Check your power supply

rated pressure Pressure rise due to discharge line Clean discharge line or dilute solution.

or viscosity of solution.

Clogged injection check/antisyphon Refer Liquid Handling Assembly instruction. Clean and

valve.. reassemble valves.

Suction tubing collapses Foot valve and strainer assembly is Refer Liquid Handling Assembly instruction. Clean and

clogged. reassemble valves. Replace strainer if necessary.

Excessive pump output output adjustment knob is improperly With pump running turn knob counter clockwise until set. pump stops stroking. Line on knob should be directly

over the zero mark on the dial. If setting is off, adjust by following Output Adjustment knob setting instructions in this manual.

Very low pressure at injection point Install injection check/antisyphon valve on pump.

Excessive positive suction head. When flooded suction installation is used, chemical supply should be no more than 20 feet (6 metres) above pump when using standard injection check/ antisypon valve and zero discharge pressure. Alter location of pump or consult factory.

5

KEY NO PART NO DESCRIPTION QTY

1 13531 10-24 X 3/4" PAN HEAD SCREW 12 (M14) & 8 ( ot hers)

2 130420 SPACER ADAPTOR (M-14) ONLY 1

3 131120S SPACER (M-09, M-10, M-11) 1SET

3 131220S SPACER (M-12) 1SET

3 131320S SPACER (M-13, M-14) 1SET

4 130552 GASKET SPACER 1

5 133525 SPRING 1

5A 11531 ADDITIONAL SPRING (M-12) ONLY 1

6 11711 RETAINER PLATE 1

7 130631 LIQUIFRAM SHAFT 1

8 133626 DOWEL 5 X 15 2

9 130713N GEAR PLATE 1

10 131826 BALL BEARING (6200) 1

11 131511 WIDE CAM SPACER 1

12 131444 WORM WHEEL (M-11,M-12,M-13,M-14) 1

12 131344 WORM WHEEL (M-10) 1

12 131244 WORM WHEEL (M-09) 1

13 134026 CAM BEARING (6204) 1

15 131926 BALL BEARING (6201) 1

16 132011N BEARING CAP 1

17 130931S CAM SHAFT ASSY FOR M 1SET

18 131526 BALL BEARING (6000) 1

19 131722 WORM SHAFT (M-11,M-12,M-13,M-14) 1

19 131522 WORM SHAFT (M-10) 1

19 131622 WORM SHAFT (M-09) 1

20 131726 BALL BEARING (6001) 1

21 132331 ADJUSTMENT SHAFT 1

DRIVE ASSEMBLY - M PUMP

22 132311N ADJUSTMENT STOP 1

22A 134052 GROMMET FOR ADJUSTMENT STOP 'M' 1

23 134511 DIAL (M-09,M-10, M-11) 1

23 134911 DIAL (M-12) 1

23 134811 DIAL (M-13, M-14) 1

24 132431S ADJUSTMENT KNOB WITH GRUB SCREW 1 SET

25 132613 HOUSING 1

26 152131S VENT CAP WITH GASKET 1SET

27 132531 LOCK KNOB 'M' 1

27A 132641 LOCK KNOB INSERT 'M' 1

28 132841S DRAIN PLUG WITH O-RING 1SET

29 133721 MOUNTING BASE (STD MOTOR) - 0.5 HP 1

29 133821 MOUNTING BASE (FLP MOTOR) - 0.5 HP 1

30 135531 STUD SS M8 X 35 (FT) 4

31 126231 NUT M8 4

32 11252 OIL SEAL LIQUIFRAM SHAFT 1

33 133120 COUPLING (STD MOTOR) - 0.5 HP 1

33 133220S COUPLING (FLP MOTOR) - 0.5 HP WITH GRUB SC REW 1 SET

34 132952N OIL SEAL 1

34A 133011N OIL SEAL HOLDER 1

35 130811N BEARING RING 1

36 134931 CSK SCREW 3/16" X 1/2" 8

37 134831S ALLEN SCREW M5 X 30 WITH SPRING WASHER 4 SE T

39 M01677S HEX BOLT M6 X 35 WITH NUT AND WASHER 4 SET

39 M01267SHEX BOLT M8 X 45 WITH NUT AND WASHER ( 0.5 HP FLP MOTOR)

4 SET

42 183511 OIL LEVEL INDICATOR 1

43 130713S GEAR PLATE ASSEMBLY M-09 1SET

43 130713D GEAR PLATE ASSEMBLY - M-10 1SET

43 130713T GEAR PLATE ASSEMBLY -M11, M12, M13, M14 1SE T

KEY NO DESCRIPTIONM-09,M-10,M-11.

M-12 M-13 M-14 QTY

2 SPRING 37341 37341 37341 37341 1

3 BALL CERAMIC 10338 10338 10338 10138 3

4 RING SEAL TEFLON 902079 902079 902079 902179N 3

5 SUCTION VALVE SEAT ASSY 902667 902667 902667 902967 2SET

6 QUAD SEAL 905755 905755 905755 905755 2

7 TUBING 10142 I 10142 I 10142 I 10142 I 13FT

8 DISCHARGE VALVE HOUSING ASSY 902767 902767 902767 903067 1SET

9 3/16 X 3/4" PAN HEAD SCREW 13531 13531 13531 NA 4

10 LIQUIFARM (DIAPHRAGM) 30917 31420 31419 25719 1

11 HEAD 900568 900468 900368N 900268 1

12 PRV ADAPTOR 904867N 904867N 904867N 904867N 1

14 Y-STRAINER ASSY 913267S 913267S 913267S 913267S 1SET

15 ANTISYPHON VALVE ASSY 906267 906267 906267 906467 1SET

16 FOOT VALVE ASSY 907067 907067 907067 907167 1SET

17 PRESSURE RELIEF VALVE 904767N 904767N 904767N 904767N 1

18 M6 X 60 HEX BOLT,NUT WITH WASHER NA NA NA M01639S 6 SETS

KEY NO DESCRIPTIONM-09,M-10,M-11

M-12 M-13 M-14 QTY

2 SPRING 37341 37341 37341 37341 1

3 BALL CERAMIC 10338 10338 10338 10138 3



6 QUAD SEAL 905755 905755 905755 905755 2

7 TUBING 10142 I 10142 I 10142 I 10142 I 13FT




11 HEAD 29611M 27214M 31053M 32234M 1

12 PRV ADAPTOR 904867N 904867N 904867N 904867N 1


14A ONLINE STRAINER ASSY 909867S 909867S 909867S 909867S 1SET





LIQUID END ASSY FOR PUMPS WITH PP HEAD

LIQUID END ASSY FOR PUMPS WITH PVDF HEAD WITH PVC FITTING


M-12 M-13 M-14 QTY

2 SPRING 37341 37341 37341 37341 1

3 BALL CERAMIC 10338 10338 10338 10138 3


5 SUCTION VALVE SEAT ASSY 902632S 902632S 902632S 902932S 2SET

6 QUAD SEAL 905755 905755 905755 905755 2

7 TUBING 10142 I 10142 I 10142 I 10142 I 13FT

8 DISCHARGE VALVE HOUSING ASSY 902732S 902732S 902732S 903032S 1SET



11 HEAD 900532 900432 900332N 900232N 1

12 PRV ADAPTOR 904832N 904832N 904832N 904832N 1

14 Y-STRAINER ASSY 913232 913232 913232 913232 1SET




18 M6 X 40 HEX BOLT,NUT WITH WASHER NA NA NA 133431S 6 SETS


M-12 M-13 M-14 QTY

2 SPRING 37341 37341 37341 37341 1

3 BALL CERAMIC 10338 10338 10338 10138 3



6 QUAD SEAL 905755 905755 905755 905755 2

7 TUBING 10142 I 10142 I 10142 I 10142 I 13FT




11 HEAD 900567 900467 900367N 900267 1

12 PRV ADAPTOR 904867N 904867N 904867N 904867N 1


14A ONLINE STRAINER ASSY 909867S 909867S 909867S 909867S 1SET





LIQUID END ASSY FOR PUMPS WITH PVC HEAD

LIQUID END ASSY FOR PUMPS WITH SS HEAD

Documents

Metering Pumps Instruction Manualmiltonroyindia.com/distributor_pdf/MAD - M - Series... · 2013-04-13 · Milton Roy India (P) Ltd., warrants its metering pump products against defects