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24

Instruction Manual

SECTION 5 - TROUBLESHOOTING

Pump will not

operate

• Low process liquid level in tank. Add liquid.
• Worn or dirty check valves. Clean or replace.
• Blocked discharge line. Clear line.
• Frozen liquid: Thaw liquid throughout pumping system.
• Blown fuse. Replace fuse.
• Open thermal overload device in motor starter. Reset device.
• Broken wire. Locate and repair.
• Low voltage: Investigate and correct (wiring may be too light).
• Pump not primed. 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.

Insufficient delivery

• Relief valve relieving.

• Blocked discharge line. Clear line.

• Relief valve set too low. Adjust valve to 15% over operating pressure.
• Air in hydraulic system. Operate purge button.
• Clogged refill line: Remove oil strainer and clean or replace.
• Incorrect capacity adjustment: Readjust capacity setting.
• Incorrect pump speed. Match line voltage and frequency to pump motor data plate.
• Starved suction. Increase piping size or suction head.
• Leaky suction piping. Repair piping.
• 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

Factory 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.

Erratic delivery

• 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.
• Worn or dirty check valves. Clean or replace.
• Blocked suction line. Clean strainer.
• 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.

5.1 SYMPTOMS & REMEDIES

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Содержание MILROYAL G

Страница 1: ...MILROYAL G Pump Instruction Manual Manual No 53942 Rev 01 Rev Date 05 2019 ...

Страница 2: ...rials of construction of the wetted components of your pump are recommended for the solution chemical to be pumped Pumps Water Primed All pumps are tested with water at the factory If your process solution is not compatible with water flush the Pump Head Assembly with an appropriate solution before introducing the process solution Plumbing and Electrical Connections Always adhere to your local plu...

Страница 3: ...Piping Considerations 7 2 6 4 Discharge Piping Considerations 8 2 6 5 Back Pressure Valves 8 2 6 6 Pulsation Dampeners 8 2 6 7 Safety Valves 9 2 6 8 Check Valves 9 2 6 9 Shut OFF Valves 9 2 7 ELECTRICAL CONNECTIONS 9 SECTION 3 OPERATION 10 3 1 INITIAL START UP 10 3 1 1 Start Up for New Pump 10 3 1 2 Start Up of Pump Containing No Oil in Casing and Displacement Chamber 11 3 2 REFILL VALVE ADJUSTMEN...

Страница 4: ...8 6 2 1 Mars Valve 28 6 2 2 Refill Valve 28 6 2 3 3 Function Valve 29 6 2 4 Check Valve Parts 29 6 2 5 PVC Liquid End 30 6 2 6 Metallic Liquid End 31 6 3 REMAINING LIQUID END PARTS 33 LIST OF ILLUSTRATIONS FIGURE 1 Model Product Code 4 FIGURE 2 Sample Nameplate 34 FIGURE 3 Mounting Hole Dimensions 34 FIGURE 4 Typical Recommended Pump Installation Scheme 34 FIGURE 5 Pump Drive Parts Side View 35 FI...

Страница 5: ...tem 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...

Страница 6: ...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 pumpin...

Страница 7: ...f 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 130ºF Maximum 0ºF Minimum Note Limited by standard lubricants Modifications are available through Applications Engineering Liquid Temperature Limits Plastic Li...

Страница 8: ...5TC CC 86 spm 20 No motor Flange Mount NEMA 182TC CD 43 spm 30 No motor Flange Mount IEC80 F165 Flange MD Note SPM s for 60 Hz 1725 rpm motor Digits 11 12 Capacity Adjustment Connection Digit 13 14 Check Valve Description Code Description Code Manual Plastic micrometer knob Electronic 4 20 ma input M2 Pipe NPT SE NEMA 4 115V E1 Pipe BSP SN NEMA 4 230V E2 Pipe DN Socket Weld SQ Explosion Proof 115V...

Страница 9: ...conditions In condensing atmospheres follow the long term storage procedure 2 3 2 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...

Страница 10: ...t prior to motor installation Pumps installed outdoors should be protected by a shelter 2 5 CONVENTION PROCEDURE 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 2 6 PIPING CONNEC...

Страница 11: ...tering accuracy A lift of 20 Ft of water column straight out of a supply tank is the maximum suction lift permissible 3 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 d...

Страница 12: ... 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 2...

Страница 13: ...8 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 2 6 9 Shut OFF Valves In order to isolate the pump during maintenance provide shut OFF valves in both suction and discharge lines...

Страница 14: ... F Chevron N L Gear Compound 68 Exxon Spartan E P 68 Mobil Mobilgear 626 Texaco Meropa 68 Shell Omaha 68 Food Grade Alteration Nevastane EP220 3 1 1 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 dash...

Страница 15: ...covered 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 sprin...

Страница 16: ...are not installed refer to next section 1 Make sure all system shut OFF valves are open and that the back pressure valve is backed out to allow for flow against zero discharge pressure SECTION 3 OPERATION 2 Start pump and set capacity at 100 If 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 inc...

Страница 17: ...ef valve is now properly adjusted Reinstall valve cover 850 3 3 USE OF AIR PURGE BUTTON Refer to Figure 7 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 remov...

Страница 18: ...at 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 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 t...

Страница 19: ...accompanied by an OSHA Safety Data Sheet SDS A completed SDS 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 pump liquid end A Safety Data Sheet must accompany all returns All inquiries or parts orders should be addressed to your...

Страница 20: ...ICAL 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 SUITABLE PROTECTIVE EQUIPMENT MUST BE PROVIDED CHECK THAT THERE IS NO SYSTEM FLUID PRESSURE BEFORE PROCEEDING WITH DISMANTLING OF LIQUID END COMPONENTS 4 3 3 Cleaning Fouled Check Valves Check valve assemblies are designed to be self cleaning and sh...

Страница 21: ... 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 If they become inoperative flush them with solvent wash them with warm detergent and blow them out w...

Страница 22: ...ting pipe connection tighten lock nut securely against spot face 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 Disassembly 1 Unscrew the union nut 435 The union end 445 is held in place by the union nut and will...

Страница 23: ... 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 4 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 intended for the suction or discharge port of the liquid end Slip the union nut 435 over the union end and...

Страница 24: ...ALVE 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 t...

Страница 25: ...he 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 appropri...

Страница 26: ...k 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 4 4 4 Diaphragm Replacement MILROYAL G liquid ends are designed to provide reliable service under normal operating circumstances and should not require...

Страница 27: ...QUID WITH APPROPRIATE VALVING AND PURGE LIQUID END OF ALL PROCESS LIQUID A Disassembly 1 Disconnect both the suction inlet and discharge outlet from the piping system 2 Drain oil as described in the above Oil Replacement section of this manual 3 Remove 3 Function Valve assembly as described in the Start Up of Pump Containing No Oil in Casing and Displacement Chamber 4 Remove six displacement chamb...

Страница 28: ...motor data plate Starved suction Increase piping size or suction head Leaky suction piping Repair piping 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 Factory Aftermarket Department Liquid near boiling Cool liquid o...

Страница 29: ...roper amount of recommended lubricant Pump still pumps even at zero capacity setting Misadjusted micrometer knob Readjust capacity setting Insufficient discharge pressure Correct condition e g install a back pressure valve Gear noise Excessive backlash Consult service facility Worn bearings Consult service facility Wrong or insufficient lubricant Replace or replenish lubricant Loud knock with each...

Страница 30: ...40 Ball Bearing 1 150 Retaining Ring 1 160 O ring 1 171 Stroke Adjustment Screw Assembly 1 175 Stroke Scale 1 190 O ring 1 200 Side Cover 1 205 Cover Screw M8 x 16mm 4 310 Nylon Stroke Locking Ball 1 320 Stroke Locking Knob 1 322 O ring 1 330 Stroke Adjustment Knob 1 335 Knob Sticker 1 340 note 1 Worm Assembly 173 spm 56C 1 343 note 1 Worm Assembly 173 spm 145TC 1 Worm Assembly 173 spm 182TC 1 Wor...

Страница 31: ...mm 4 400 Motor screws 182TC 1 2 13 x 4 400 Motor screws 56C 145TC 3 8 16 x 1 4 410 Washer 56C 145TC 3 8 4 450 Base 1 460 Base Screws M8 x 35mm 4 465 Lock Washers 8mm 4 470 Nut M8 4 520 Plunger 1 1 4 1 520 Plunger 1 3 4 1 520 Plunger 2 1 2 1 520 Plunger 3 1 525 Plunger Pin 1 1 4 plunger 1 525 Plunger Pin 1 3 4 plunger 1 525 Plunger Pin 2 1 2 3 plungers 1 560 Lock Washer 8mm 6 570 Displacement Chamb...

Страница 32: ... Retaining Ring 1 820 Valve Stem Retaining Ring 1 830 O Ring 1 840 O Ring 1 Note 1 Include items 750 760 770 810 820 830 840 Note 2 Not sold separately Must purchase item 775 MARS Valve Assembly 6 2 2 REFILL VALVE see Figure 8 Item No Description Qty Req 740 Note 1 Refill Valve Assembly 1 650 Oil Strainer Plug NPT 1 660 Note 2 Valve Body 1 670 Oil Strainer 1 680 Note 2 Ball 1 690 Note 2 Spring 1 7...

Страница 33: ... Assembly 1 960 note 2 Air Bleed Valve Body 1 970 note 2 Ball 1 980 note 2 O Ring 1 990 note 2 Air Bleed Ball Seat 1 1000 note 2 Spring 1 1005 note 2 Air Bleed Body Seat 1 Note 1 Includes items 960 970 980 990 1000 1005 Note 2 Not sold separately Must purchase item 1015 Poppet Assembly 6 2 4 CHECK VALVE PARTS see Figures 10 13 The Pump Model Number is used to identify the check valve parts The 4 5...

Страница 34: ...embly 1 446 Tube Conn Discharge Bleed Valve Assembly 1 1 1 4 plunger Double Ball Check Valve see Figure 10 Item No Description Qty Req 425 Check Valve Assembly Assemblies include the following items 1 419 O Ring viton 2 420 Ball Stop 1 421 Ball ceramic 3 8 1 422 Ball ceramic 14mm 1 424 Ball Guide 1 445 Union End PVC NPT Female 1 435 Union Nut PVC Shown in Figure 11 1 1 3 4 2 1 2 plungers Double ba...

Страница 35: ...Plunger Double Ball Check Valve Figure 13 Item No Description Qty Req 425 Suction Valve Assembly 316SS 2 425 Suction Valve Assembly Alloy 20 2 426 Discharge Valve Assembly 316SS 2 426 Discharge Valve Assembly Alloy 20 2 Check Valve assemblies include seal 419 seat 420 balls 421 ball guide 424 435 Lock Nut 2 439 Back up Ring 2 441 O Ring Viton 2 Item No Description Qty Req 425 Check Valve Assembly ...

Страница 36: ...2 Ball 22mm 1 424 Ball Guide Body 1 445 Coupling BSP Female 1 445 Coupling NPT Female 1 Alloy 20 Liquid End 1 3 4 2 1 2 3 plungers Double Ball Check Valves Figure 10 316SS Liquid End 3 plungers Single Ball Check Valves Item No Description Qty Req 425 Check Valve Assembly 1 Check Valve assemblies include two O rings 419 seat 420 ball stop 420 seat 421 ball 422 body 424 419 O Ring 2 420 Ball Stop 1 ...

Страница 37: ...lass 2 640 Hose Barb Union 1 650 Displacement Chamber Plug NPT 1 1020 Diaphragm Head PVC 1 1 4 plunger 1 1020 Diaphragm Head PVC 1 3 4 2 1 2 3 plungers 1 1020 Diaphragm Head 316SS 1 1 4 plunger 1 1020 Diaphragm Head 316SS 1 3 4 2 1 2 3 plungers 1 1020 Diaphragm Head Alloy 20 1 1 4 plunger 1 1020 Diaphragm Head Alloy 20 1 3 4 2 1 2 3 plungers 1 1025 Head Bolt Stainless steel For 1 1 4 plunger sizes...

Страница 38: ...I MA WP Tag No 12345678 XXXXX12345678 Milton Roy Company Made in USA Figure 2 Sample Nameplate 9 228 6 mm 41 2 114 3 mm Motor C L Liquid End C L 0 354 9 mm Dia Mounting Holes Figure 3 Mounting Hole Dimensions Pressure Relief Valve Suction Accumulator Dampener Figure 4 Typical Recommended Pump Installation Scheme ...

Страница 39: ...35 Instruction Manual 182TC MOTOR 56C MOTOR 376 370 400 520 525 60 460 465 470 450 40 340 417 343 EC80 MOTOR 390 400 376 410 377 346 360 Figure 5 Drive Parts Side View ...

Страница 40: ...36 Instruction Manual 570 560 335 330 160 171 175 310 322 320 190 110 10 19 20 30 100 120 SEE LIQUID END 200 205 130 140 150 50 Figure 6 Drive Parts Top View ...

Страница 41: ...N LB FOR METAL HEAD SEE DRIVE HOUSING View for 1 3 4 2 1 2 and 3 Plunger Sizes 1035 1030 630 1040 1025 610 630 560 570 1020 1050 PLATE IS USED ON 1 1 4 PLUNGER ONLY LARGER PLUNGER SIZES USE WASHERS PLASTIC ONLY 1025 TORQUE TO 40 IN LB FOR METALIC 20 IN LB FOR PLASTIC View for 1 1 4 PLUNGER Size ...

Страница 42: ...N HYDRAULIC VALVE 850 860 880 620 935 950 650 640 550 TORQUE TO 125 IN LB 540 530 600 580 590 740 REFILL VALVE 650 670 660 730 MARS VALVE SEE FIGURE NEXT SHEET 1020 510 930 890 SEE CHECK VALVE 940 920 910 920 900 680 690 700 710 720 1010 1005 900 1015 980 970 1000 990 ...

Страница 43: ... MARS VALVE Mechanically Activated Refill System MARS Valve assembly Except for O rings the valve may only be purchased as an assembly 820 810 840 760 830 750 775 770 780 790 800 The MARS Valve is located between the plunger and the diaphragm ...

Страница 44: ...Double Ball Check Valve Parts 1 1 4 thru 2 1 2 Plunger Sizes 419 422 424 421 Metallic Double Ball Check Valve Parts 3 Plunger Only 420 419 424 422 419 419 420 422 421 424 445 419 DISCHARGE SUCTION PVC Single Ball Check Valve Parts 445 435 419 424 422 419 420 424 419 445 435 419 420 422 ...

Страница 45: ...nstruction Manual Figure 12 Plastic Check Valves 1 1 4 Plunger Size 425 425 SUCTION DISCHARGE SHOWN WITH NPT CONNECTIONS SHOWN WITH TUBE CONNECTIONS 435 445 425 435 445 445 425 445 SUCTION DISCHARGE 071 071 ...

Страница 46: ...42 Instruction Manual Figure 13 Metallic Check Valves 1 1 4 Plunger Size 437 419 445 424 421 420 421 426 425 424 421 421 444 420 435 439 441 439 435 441 METALLIC CHECK VALVES ...

Страница 47: ... Valve 425 071 Cartridge Valve Assembly Suction Valve Assembly NPT CONNNECTION SHOWN 447 425 Cartridge Valve Assembly 448 SPACER 0 040 SPACER 0 020 FOUR FUNCTION BLEED VALVE NPT CONNNECTION SHOWN 446 PVC LIQUID END FOUR FUNCTION BLEED VALVE 1 25 PLUNGER ...

Страница 48: ...able sustainable and efficient environments Our people and our family of brands including Club Car Ingersoll Rand Thermo King and Trane work together to enhance the quality and comfort of air in homes and buildings transport and protect food and perishables and increase industrial productivity and efficiency We are committed to a world of sustainable progress and enduring results ...

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