Instruction Manual. This Manual should be made available to persons responsible for Installation, Operation and Maintenance. Pump Model No...

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1 MILTON ROY INDIA (P) LTD. Metering Pumps Instruction Manual M -Series This Manual should be made available to persons responsible for Installation, Operation and Maintenance. M- Pump Model No... Serial No... LPH Capacity... Kg/cm 2 Pressure... 4, Rajarajan Street, Visalakshi Nagar, Ekkaduthangal, Chennai , India. Telephone : (044) Fax : miltonroyindia@vsnl.net Web : Issue Date : 03/2005

2 M - Series Pumps TABLE OF CONTENTS 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 MILTON ROY INDIA (P) LTD.

3 M - Series Pumps METERING PUMP PRODUCTS TWELVE MONTH LIMITED WARRANTY 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 : MILTON ROY INDIA (P) Ltd., NO.: 4, RAJARAJAN STREET, VISALAKSHI NAGAR EKKADUTHANGAL, MADRAS PHONE NO.: (044) FAX NO.: MILTON ROY INDIA (P) LTD.

4 M-Series Pumps 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. III. IV. 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. 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. 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. 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. CAUTION Be sure installation does not constitute a cross connection. Check local plumbing code. 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. MILTON ROY INDIA (P) LTD. 1

5 M-Series Pumps 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. SUCTION LIFT INSTALLATION 5. Slide down the coupling nut until threads are engaged. Tighten by hand until tubing is held securely in place. Excessive force will crack or distort fittings. DO NOT USE PIPE WRENCH 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. FLOODED SUCTION INSTALLATION helpful when pumping at very low rate Fig. 1 Fig. 2 MILTON ROY INDIA (P) LTD. 2

6 M-Series Pumps VII PUMP OPERATION Note : 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. (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 (0) mark on the dial when the knob is turned counterclockwise 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. Fig. 3 MILTON ROY INDIA (P) LTD. 3

7 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 Always wear protective clothing and face shield when working on or near a chemical metering pump. 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. M-Series Pumps 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 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. DATA SHEET FOR METERING PUMP MODEL TYPE M SERIES MECHANICALLY ACTUATED DIAPHRAGM TYPE MODEL M-09 M-10 M-11 M-12 M-13 M-14 MAX FLOW (IN LPH) MAX PRESSURE (KG/SQCM) STROKE PER MINUTE LINEAR SPEED (M/MIN) MILTON ROY INDIA (P) LTD.

8 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 Solution is too viscous Injection into excessive pressure. Check power supply. Dilute solution. 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 discharge. Follow priming instructions. Operate pump for a few minutes to purge head and valves of air. Suction lift is too high Loop in suction line permits air trap on suction side Improperly installed, or dirty valve seats Air in suction line. Reduce suction lift or arrange pump and tank for flooded suction installation. Straighten suction tubing. Pumps air bubbles or air. Suction tubing has leaks or pin holes. Replace suction tubing. Improperly installed, or dirty valve seats. Suction lift is too high. Solution supply is exhausted. Foot valve and strainer assembly is clogged Refer liquid Handling Assembly instructions. Clean and reassemble valves. Tighten suction valve fitting. Replace if necessary. Check for air leaks throughout suction line. Refer liquid Handling Assembly instruction. Clean and reassemble valves. Reduce suction lift or arrange pump and tank for flooded suction installation. Refill solution container. 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 valve.. Refer Liquid Handling Assembly instruction. Clean and 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 Excessive positive suction head. 5 Install injection check/antisyphon valve on pump. 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.

9

10 DRIVE ASSEMBLY - M PUMP KEY NO PART NO DESCRIPTION QTY X 3/4" PAN HEAD SCREW 12 (M14) & 8 ( others) SPACER ADAPTOR (M-14) ONLY S SPACER (M-09, M-10, M-11) 1SET S SPACER (M-12) 1SET S SPACER (M-13, M-14) 1SET GASKET SPACER SPRING 1 5A ADDITIONAL SPRING (M-12) ONLY RETAINER PLATE LIQUIFRAM SHAFT DOWEL 5 X N GEAR PLATE BALL BEARING (6200) WIDE CAM SPACER WORM WHEEL (M-11,M-12,M-13,M-14) WORM WHEEL (M-10) WORM WHEEL (M-09) CAM BEARING (6204) BALL BEARING (6201) N BEARING CAP S CAM SHAFT ASSY FOR M 1SET BALL BEARING (6000) WORM SHAFT (M-11,M-12,M-13,M-14) WORM SHAFT (M-10) WORM SHAFT (M-09) BALL BEARING (6001) ADJUSTMENT SHAFT 1

11 N ADJUSTMENT STOP 1 22A GROMMET FOR ADJUSTMENT STOP 'M' DIAL (M-09,M-10, M-11) DIAL (M-12) DIAL (M-13, M-14) S ADJUSTMENT KNOB WITH GRUB SCREW 1 SET HOUSING S VENT CAP WITH GASKET 1SET LOCK KNOB 'M' 1 27A LOCK KNOB INSERT 'M' S DRAIN PLUG WITH O-RING 1SET MOUNTING BASE (STD MOTOR) HP MOUNTING BASE (FLP MOTOR) HP STUD SS M8 X 35 (FT) NUT M OIL SEAL LIQUIFRAM SHAFT COUPLING (STD MOTOR) HP S COUPLING (FLP MOTOR) HP WITH GRUB SCREW 1 SET N OIL SEAL 1 34A N OIL SEAL HOLDER N BEARING RING CSK SCREW 3/16" X 1/2" S ALLEN SCREW M5 X 30 WITH SPRING WASHER 4 SET 39 M01677S HEX BOLT M6 X 35 WITH NUT AND WASHER 4 SET 39 M01267S HEX BOLT M8 X 45 WITH NUT AND WASHER ( 0.5 HP FLP MOTOR) OIL LEVEL INDICATOR 1 4 SET S GEAR PLATE ASSEMBLY M-09 1SET D GEAR PLATE ASSEMBLY - M-10 1SET T GEAR PLATE ASSEMBLY -M11, M12, M13, M14 1SET

12

13 LIQUID END ASSY FOR PUMPS WITH PP HEAD KEY NO DESCRIPTION M-09,M- 10,M-11. M-12 M-13 M-14 QTY 2 SPRING BALL CERAMIC RING SEAL TEFLON N 3 5 SUCTION VALVE SEAT ASSY SET 6 QUAD SEAL TUBING I I I I 13FT 8 DISCHARGE VALVE HOUSING ASSY SET 9 3/16 X 3/4" PAN HEAD SCREW NA 4 10 LIQUIFARM (DIAPHRAGM) HEAD N PRV ADAPTOR N N N N 1 14 Y-STRAINER ASSY S S S S 1SET 15 ANTISYPHON VALVE ASSY SET 16 FOOT VALVE ASSY SET 17 PRESSURE RELIEF VALVE N N N N 1 18 M6 X 60 HEX BOLT,NUT WITH WASHER NA NA NA M01639S 6 SETS LIQUID END ASSY FOR PUMPS WITH PVDF HEAD WITH PVC FITTING KEY NO DESCRIPTION M-09,M- 10,M-11 M-12 M-13 M-14 QTY 2 SPRING BALL CERAMIC RING SEAL TEFLON N 3 5 SUCTION VALVE SEAT ASSY SET 6 QUAD SEAL TUBING I I I I 13FT 8 DISCHARGE VALVE HOUSING ASSY SET 9 3/16 X 3/4" PAN HEAD SCREW NA 4 10 LIQUIFARM (DIAPHRAGM) HEAD 29611M 27214M 31053M 32234M 1 12 PRV ADAPTOR N N N N 1 14 Y-STRAINER ASSY S S S S 1SET 14A ONLINE STRAINER ASSY S S S S 1SET 15 ANTISYPHON VALVE ASSY SET 16 FOOT VALVE ASSY SET 17 PRESSURE RELIEF VALVE N N N N 1 18 M6 X 60 HEX BOLT,NUT WITH WASHER NA NA NA M01639S 6 SETS

14 LIQUID END ASSY FOR PUMPS WITH SS HEAD KEY NO DESCRIPTION M-09,M- 10,M-11. M-12 M-13 M-14 QTY 2 SPRING BALL CERAMIC RING SEAL TEFLON N 3 5 SUCTION VALVE SEAT ASSY S S S S 2SET 6 QUAD SEAL TUBING I I I I 13FT 8 DISCHARGE VALVE HOUSING ASSY S S S S 1SET 9 3/16 X 3/4" PAN HEAD SCREW NA 4 10 LIQUIFARM (DIAPHRAGM) HEAD N N 1 12 PRV ADAPTOR N N N N 1 14 Y-STRAINER ASSY SET 15 ANTISYPHON VALVE ASSY SET 16 FOOT VALVE ASSY SET 17 PRESSURE RELIEF VALVE N N N N 1 18 M6 X 40 HEX BOLT,NUT WITH WASHER NA NA NA S 6 SETS LIQUID END ASSY FOR PUMPS WITH PVC HEAD KEY NO DESCRIPTION M-09,M- 10,M-11. M-12 M-13 M-14 QTY 2 SPRING BALL CERAMIC RING SEAL TEFLON N 3 5 SUCTION VALVE SEAT ASSY SET 6 QUAD SEAL TUBING I I I I 13FT 8 DISCHARGE VALVE HOUSING ASSY SET 9 3/16 X 3/4" PAN HEAD SCREW NA 4 10 LIQUIFARM (DIAPHRAGM) HEAD N PRV ADAPTOR N N N N 1 14 Y-STRAINER ASSY S S S S 1SET 14A ONLINE STRAINER ASSY S S S S 1SET 15 ANTISYPHON VALVE ASSY SET 16 FOOT VALVE ASSY SET 17 PRESSURE RELIEF VALVE N N N N 1 18 M6 X 60 HEX BOLT,NUT WITH WASHER NA NA NA M01335S 6 SETS

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