MILTON ROY INDIA (P) LTD Metering Pumps Instruction Manual PN-K PACKED PLUNGER PUMP This Manual should be made available to person responsible for installation, maintenance and operation. PUMP MODEL: SERIAL NO: CAPACITY: LPH: PRESSURE: No 4, Rajarajan Street, Visalakshi Nagar, Ekkaduthangal, Chennai 600032, India. Telephone: 044-42266333 Fax: 044-45540060 E-mail: Miltonroyindia@vsnl.net Web: www.miltonroyindia.com Issue Date: 07/2010 1
TABLE OF CONTENTS Page No WARRANTY 3 IMPORTANT SAFETY INSTRUCTION 4 QUICK START GUIDE 5 1.0 INTRODUCTION 1.1 General Description 6 1.2 Principles of Operation 6 1.3 Technical Details 7 2.0 INSTALLATION 2.1 Unpacking 8 2.2 Storage / Idle Service 8 2.3 Mounting 8 2.4 Electrical Installations 9 2.5 Piping 9 3.0 START UP 10 4.0 LUBRICATION SCHEDULE 11 5.0 MAINTENANCE 11 5.1 Method of changing Gland Packing 12 6.0 BASIC PARTS 14 7.0 TROUBLE SHOOTING 20 2
METERING PUMP PRODUCTS TWELVE MONTH LIMITED WARRANTY Milton Roy India private Limited Company warrants its metering pump product against defects in workmanship or material for one year under normal use from the date of shipment form our warehouses as indicated in our warranty certificate. All obligations and liabilities under this warranty are limited to refunding, repairing or replacing (at our option) f.o.b, our plant, such allegedly defectives units are returned to our plant, carrier charges prepaid. Repairs or replacement are made subject to factory inspection of returned items. This warranty does not extend to damage by corrosion or atmosphere. 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 s, do not constitute guarantees against wear and chemicals action. Expressly excluded from this warranty are defects caused by misuse, abuse or improper application/installation, employment or operation of the unit. Expendable items and damage resulting from unauthorized repair are not covered by this warranty. No liability for consequential damage or reinstallation labour is accepted. Milton Roy India Private Limited 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, CHENNAI - 600 032. PHONE NO.: (044) - 42266333 FAX NO.: 91-44-45540060. 3
IMPORTANT SAFETY INSTRUCTIONS WARNING WARNING WHEN INSTALLING, CALIBRATING, OR OPERATING THIS ACTUATOR, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE RISK OF FIRE, ELECTRIC SHOCK, AND PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS INJURY. Read all instructions before installation, calibration, or operation GENERAL SAFETY CONSIDERATIONS - Read this manual carefully. - Installation, calibration, and maintenance should be performed by trained and qualified personnel. Personnel should be familiar with the precautions required in working with hazardous voltages which exist inside the actuator. Personnel should also be adequately trained on any hazards inherent in the chemicals used in the metering pump. - Always wear protective clothing including gloves and safety glasses when working on or near chemical metering pumps. - Follow directions and warnings provided with the chemicals from the chemical manufacturer. User is responsible for determining the hazards associated with the chemicals being pumped and using the proper safety gear and procedures. - Hazardous voltages are present when cover is removed. Disconnect power when installing or servicing this unit. - Unit must be properly grounded. - Conform to local codes in wiring this equipment. - Pump must be adequately rated if it is to be used in a hazardous location. See product data plate for rating information. This rating must not be exceeded under any circumstances. To prevent ignition of hazardous atmospheres, cover must be tight while circuits are energized. - In order to comply with the requirements of agency approvals (see data plate), specifications for conduit connections, wire gauge and type, fastener torque ratings, and operating conditions must be adhered to. - 4
QUICK START GUIDE NOTE: Read and understand safety instructions before proceeding. READ CONNECT VERIFY - Read and comply with all safety instructions presented in this manual. In order to comply with the requirements of agency approvals (see data plate), specifications for conduit connections, wire gauge and type, fastener torque ratings, and operating conditions must be adhered to. - Connect AC power. Use conduit connections or cable glands. - Ground unit. - Connect command signal. - Connect feedback signal. - Voltage selector switch is set to the required voltage (230 VAC). - Command input signal is set to desired operation 4-20 ma. Factory set at 4-20 ma or (1-5V DC). - Feedback signal output is set to desired operation 4-20 ma or (1-5 VDC). Factory set at 4-20 ma. WARNING HAZARDOUS VOLTAGES ARE PRESENT ON THE CIRCUIT BOARD. TO PREVENT IGNITION OF HAZARDOUS ATMOSPHERES, COVER MUST BE TIGHT WHILE CIRCUITS ARE ENERGIZED. APPLY POWER OBSERVE CALIBRATE FINISH - Apply command signal. - Apply AC power. - Actuator should run to command position and stop. - Full range of command signal should result in desired range of actuator travel (factory setting is for full - Travel of 0% to 100%). - If actuator was installed on the pump at the factory, it has been factory calibrated. - If actuator is a retrofit or a non-standard range is desired, follow the calibration instructions in this manual. - Install cover. 5
SECTION 1 INTRODUCTION 1.1 GENERAL DESCRIPTION The PN-K packed plunger pumps are dosing pumps equipped with a packed plunger liquid end, oil bath lubricated gears in a sealed casing. Adjustment of stroke length can be carried out as the pump is operating or at stop. It is designed for non-stop industrial service. 1.2 PRINCIPLE OF OPERATION The Worm and worm wheel drive by means of the connecting rod transmits the rotary motion into the reciprocating motion of the plunger. The stroke of the plunger can be adjusted by the double eccentric mechanism. The Double eccentric mechanism consists of a stroke adjustment screw, inner eccentric and outer eccentric. The outer eccentric moves in the slot in the inner eccentric. The connecting rod is connected to outer eccentric. By adjusting the stroke adjustment screw, the relative position of the center of slot in the inner eccentric and the outer eccentric can be varied. When both the eccentric are in 90 degree, maximum stroke is achieved. When both are in 0 degree, Zero stroke is achieved. At the intermediate angles intermediate stroke is achieved. 6
1.3 TECHNICAL DETAILS: Maximum Discharge Pressure : Kg/cm2 Maximum Flow : LPH @ Max Pressure. Stroke per Minute : SPM Reduction Ratio : Stroke Length : mm Motor Power : HP Plunger Diameter : mm Motor Speed : 1440 RPM Motor Input : 415V, 3 Phases, 50 HZ Weight : Kg (Approx.) Repeatability : +/- 3% Linearity : +/- 3% Steady State Accuracy : +/- 1% Flow Temperature : -5 to +10 % 7
SECTION 2 INSTALLATION 2.1 UNPACKING Pumps are shipped F.O.B factory and title passes to customer when carrier signs for receipt of pump. In the event that the 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 carrier to be sure there is no obvious damage to contents. Open the crate carefully so that the accessory items fastened to the inside of the crate will not be damaged or lost. Examine all material inside crate and check against packing specification to be sure that all items are accounted for and intact. 2.2 STORAGE & IDLE SERVICE Pumps that are not expected to put in service within 90 days of receipt should be stored in a dry place. Apply grease to all the non-painted surface of the pumps. Protect rubber parts from direct sun and from daily temperature variations. FAILURE TO PROPERLY STORE AND PROTECT THE EQUIPMENT MAY VOID ANY WARRANTY, EXPRESSED OR IMPLIED. OUTDOOR STORAGE IS NOT RECOMMENDED UNDER ANY CIRCUMSTANCES UNLESS SPECIFICALLY PREPARED FOR STORAGE PRIOR TO SHIPMENT FROM THE FACTORY. Maximum Estimated Storage Indoors, dry ambient controlled temperature: Initial - - - - - - - - - - - - - 12 months Extend preservation - - 12 additional months Indoors, dry ambient uncontrolled temperature: Initial - - - - - - - - - - - - - - - 6 months Extend preservation- - - - - 6 additional months Outdoor storage: Not recommended. 2.3 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. The Pump is provided with mounting holes to accommodate anchor bolts. A Roof should protect pumps installed outdoors. 8
2.4 ELECTRICAL INSTALLATION Verify the Motor data against your available main supply for the plant before carrying out connections. Connect the motor according to the indications given in the terminal box and the name plate of the motor. Before operating the pump, check the direction of rotation of motor which must be according to the arrow stamped on the motor adaptor base (Counter clockwise direction when seen from top). To reverse the direction of rotation just reverse either of the two phases of incoming power supply. DO NOT FORGET TO CONNECT THE PUMP TO EARTH Electric protection of the motor (Thermal protection or by means of fuse) is to correspond to the rated current indicated on the motor data plane. 2.5 PIPING Connect suitable sizing of suction and discharge piping. The piping material should be suitable for the chemical being pumped. Ensure that the thickness of pipe is suitable for withstanding the pressure requirements. Generally for high discharge pressures use seamless schedule 80 piping on the discharge line. Ensure that a strainer is fitted in the suction line and a suitable pressure relief valve is fitted in the discharge line. If required provide a pulsation dampner of suitable capacity. Capacity of the pulsation dampner is usually selected as 100 times the flow per stroke of the pump for fills and draw type. It is recommended to install a check valve at the point of dosing. 9
SECTION 3 START UP 1. Line up the pump with suitable suction piping and suitable accessories. 2. Open the isolation valves in suction and discharge piping. 3. Ensure that all the fasteners are fully tightened. 4. Fill the pump drive with 1 Lts of Hydrol 220 or equivalent oil. 5. Keep the stroke length at 15 to 20 %. 6. Run the motor and check the direction of rotation. It should be counter clockwise when viewed from Top. 7. At Zero discharge pressure ensure that the pump is delivering liquid. 8. Slowly increase the stroke length to 100%. 9. Allow the pump to run for some time. 10. Connect the discharge line with pressure relief valve. 11. Allow the pump to run for some time and ensure the pressure relief valve is relieving at the correct pressure. 12. Adjust the stroke knob to the required percentage and tighten the lock knob. 13. Observe for abnormal noise and vibration. 14. Check for any leak on the suction and discharge valves and tighten suitable. 15. Apply some grease or oil on the cross slide. This will help in reducing friction in the oil seal. Do not remove the cover on the cross slide without stopping the pump. 10
SECTION 4 LUBRICATION SCHEDULE The Pump drive should be filled with the specified oil till half of the sight glass (app. 1.0 Lts). The recommended hydraulic oils for the pump are shown below. MANUFACTURER TYPE BHARATH PETROLEUM HYDROL 220 INDIAN OIL CORPORATION SERVO SYSTEM 220 HINDUSTAN PETROLEUM ENCLO - 220 SECTION 5 MAINTENANCE The Pumps are designed to provide maintenance free operation for long periods. However, certain maintenance precautions are required for trouble free operation. 1. Ensure oil level in the pump drive unit at least once in 15 days. 2. Ensure that the cross slide is suitably lubricated at least once a week by applying small amounts of oil on the oil seal area to ensure friction free running. 3. Tighten the bolts of the cross slide guide and head periodically once in 15 days. 4. Change the entire drive oil after 500 Hrs of initial running and later every 2000 Hrs of operation. 5. Ensure that the check valves are not blocked or clogged once a month by flushing the liquid end. Clogging of the check valves will result in erratic discharge or no discharge. Complete blockage of the check valves will result in damage to the pump drive. 6. Lubricate the stroke adjustment mechanism once a month through the lock knob with grease or oil. 11
5.1 METHOD OF CHANGING GLAND PACKING 1. Loosen the packing gland nut. 2. Remove the entire head from the pump along with the plunger. 3. The Gland rope is to be cut to correct length and the edges have to be cut at 45 degree angle. Use the correct size of the Teflon rope ( For Length and size refer to point 16 in 6.2) 4. Insert the plunger into the head and pack the rope around the plunger using a blunt tool. 5. Remove the plunger. 6. Insert gland bush and gland nut into the head. Ensure that the gland bush is guided into the head. 7. Insert the cross slide lock nut and the cross slide nut into the plunger. 8. Apply grease on to the plunger and the gland packing. 9. Insert the plunger into the head. 10. Assemble the head along with the plunger on to the pump. 11. Hands tighten the cross slide nut. 12. Keep the stroke setting at 15 to 20% and run the pump at atmospheric pressure for 20 minutes. 13. Tighten the cross slide nut and cross slide lock nut. 14. Tighten the gland nut so as to tighten the gland packing slightly. Over tightening of the gland nut will lead to excessive heating of the liquid end even at 100% stroke. 15. Ensure that the plunger does not hit the liquid end even at 100% stroke. 16. Take care to assemble the head in the correct direction of the suction and discharge check valves. 12
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6.1 BASIC PARTS: DRIVE END ITEM NO 1 PART NO DESCRIPTION QUANTITY 501250B Motor (3 HP) 501150 Motor (2 HP) 501050 Motor (1.5 HP) 500950 Motor (1 HP) 1A 232021S Motor Adaptor (3 HP) Assy 1Set 3 245131 Coupling Spring (3 HP) 245331 Coupling Spring (3 HP) New 152025 Coupling Spring (1 HP), GB 4 183511 Oil Level Indicator 1 1 1 RECOMMENDED SPARES 241521A Worm Shaft (1/8) for 80 Frame Motor (PNK XXD) 241521B Worm Shaft (1/8) for 90 Frame Motor (PNK XXD) 241521C Worm Shaft (1/8) for 100 Frame Motor (PNK XXD) 244221A Worm Shaft (1/10) for 80 Frame Motor (PNK XXC) 5 244221B 244221C Worm Shaft (1/10) for 90 Frame Motor (PNK XXC) Worm Shaft (1/10) for 100 Frame Motor (PNK XXC) 1Set 244321A Worm Shaft (1/15) for 80 Frame Motor (PNK XXB) 244321B Worm Shaft (1/15) for 90 Frame Motor (PNK XXB) 244421A Worm Shaft (1/25) for 80 Frame Motor (PNK XXA) 244421B Worm Shaft (1/25) for 90 Frame Motor (PNK XXA) 6 154425 Spring Dowel 5 X 35 (HT) 1 7 244120S Housing Assy 1 Set 8 183431S Oil Drain with O-Ring 1 Set 9 183231 Oil Filling Cap with Gasket 1 10 241821S Adjustment Shaft With Inner Eccentric 1 set 11 124626 Bearing - 6305 2 12 241644 Worm Gear 1/8 (PRIMEROYAL-K) P.B (for PNK XX D with 3 HP motor) 1 14
244544 244644 244744 244720 244620 244520 241620 Worm Gear 1/10 (PRIMEROYAL-K) P.B (for PNK XX C with 2, 3 HP motors) Worm Gear 1/15 (PRIMEROYAL-K) P.B (for PNK XX B with 1.5HP motors) Worm Gear 1/25 (PRIMEROYAL-K) P.B (for PNK XX A with 1.5HP motors) Worm Gear 1/25 (PRIMEROYAL-K) CI (for PNK XX A with 1HP motors) Worm Gear 1/15 (PRIMEROYAL-K) CI (for PNK XX B with 1HP motors) Worm Gear 1/10 (PRIMEROYAL-K) CI (for PNK XX C with 1, 1.5 HP motors) Worm Gear 1/8 (PRIMEROYAL-K) CI (for PNK XX D with 1, 1.5, 2 HP motor) 13 240921 Guide Pin 1 14 241720 Connecting Rod 1 15 240421 Outer Eccentric 1 16 240612 Cover 1 17 240121 Stroke Adj. Screw 1 18 246412S Stroke Adj. Knob With Grub Screw 1 Set 19 152231S Lock Knob with O-ring 1 Set 20 240821 Cam Pin (PN-K) 1 21 M01305 Stud SS M10 X 85 (HT) 4 22 180826 Solid Dowel M10 X 20 (HT) 2 23 241221 Cross Slide 1 244020 Cross Slide Guide (8~40) 24 244220 Cross Slide Guide (50~70) 1 244920 Cross Slide Guide (71~90) 25 170121 Cross Slide Nut 1 25A 170221 Cross Slide Lock Nut 1 26 170352 Oil Seal 2 27 245021 Mounting Base 1 28 241021 Dowel Pin (PN-K) 1 29 246919S PNK Drive End Fastener Kit 1 set 30 153452S Seal Kit for PNK Drive End 1 Set 31 246819 Gear Bearing 1 32 245512 Stroke Label (PN-K) 1 33 156352 Lock Bolt Stopper GB,(PN-B,K,P) 1 34 247021 Bearing Cap (PN-K) 1 15
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6.2 BASIC PARTS - LIQUID END (DIA 16 20 MM) ITEM NO DESCRIPTIONS QUANTITY 16mm 20mm RECOMMENDED SPARES 1 Packing End Ring 2 995779 996879 6 Nos 2 Packing Gland Rope Size 1 Set 5 mm 2 5mm 2 1 Set 3 Plunger Fixing Nut 1 995021 995021 4 Plunger 1 245232 245732 5 Gland Nut 1 222032 222432 6 Gland Bush 1 222132 996932 7 Head 1 991132 996732 8 Suction & Discharge Valve Adaptor 2 993032 993032 9 Gasket 6 994679 994679 10 Nos 10 Ball 4 994532 994532 4 Nos 11 Ball Guide 4 992932 992932 4 Nos 12 L.E.Fixing Flange 1 996432 996432 13 Suction & Discharge Valve 2 SETS 992932S 992932S 14 Ball Retainer 4 965432 965432 4 Nos 15 Allen Bolt Size M8x20 (HT) 4 184826 184826 16 Allen Bolt Size M12x30 (HT) 2 M01512 M01512 17
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6.2 BASIC PARTS - LIQUID END (DIA 25-40 MM) ITEM NO DESCRIPTIONS QUANTITY 25mm 32mm 40mm RECOMMENDED SPARES 1 Packing End Ring 2 997379 997979 992179 6 Nos 2 Packing Gland Rope Size 1 Set 5mm 2 8mm 2 8mm 2 1 set 3 Plunger Fixing Nut 1 995021 172632 172632 4 Plunger 1 245832 245932 240332 5 Gland Nut 1 222232 224032N 224132N 6 Gland Bush 1 997432 997732N 992332N 7 Head 1 997232 997532N 992032N 8 Suction & Discharge Valve Adaptor 2 161332 161332 161332 9 Retainer Plate 2 991432 991432 991432 10 Gasket 6 162479 162479 162479 10 Nos 11 Suction Ball Seat 1 161932 161932 161932 1 12 Ball Seat 1 161532 161532 161532 1 13 Ball 2 161632 161632 161632 2 14 Ball Guide 2 161232 161232 161232 2 15 L.E.Fixing Flange 1 996432 -- -- 16 Discharge Valve Assy 1 SET 161232S 161232S 161232S 17 Suction Valve Assy 1 SET 161932S 161932S 161932S 18 Allen Bolt Size M8x20 (HT) 4 184826 - - 19 Allen Bolt Size M12x30 (HT) 2 M01512 M01512 M01512 20 Hex Nut 1 - M01268 M01268 21 HEX BOLT M10 X 65 4 M01682 M01682 M01682 20
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6.2 BASIC PARTS - LIQUID END (DIA 50-70 MM) ITEM NO DESCRIPTIONS QUANTITY 50mm 55mm 63mm 70mm RECOMMENDED SPARES 1 Packing End Ring 2 998479 999079 999579 990179 6 2 Packing Gland Rope Size 1 Set 8mm 2 8mm 2 8mm 2 8mm 2 1 set 3 Plunger Adaptor 1 172632 172632 172632 239032 4 Plunger 1 246032 246132 246232 246332 5 Gland Nut 1 998132N 998732N 999232N 999732N 6 Gland Bush 1 998232 998832 999332 999832 7 Head 1 998032 998632 999132 999632 8 Suction & Discharge Valve Adaptor 2 911432 911432 911432 911432 9 Retainer Plate 2 991432 991432 991432 991432 10 Gasket 6 986179 986179 986179 986179 10 11, 12 Ball Seat 2 911732 911732 911732 911732 2 13 Ball 2 911732 911332 911332 911332 2 14 Ball Guide 2 911332 910532 910532 910532 2 16, 17 19 SUCTION / DISCHARGE VALVE Hex Bolt M12X35 HT 2 sets 910532 910532S 910532S 910532S 4 180926 180926 180926 180926 20 Hex Nut 1 M01268 M01268 M01268 M01432 21 Hex Bolt M10X70 SS 4 M01685 M01685 M01685 M01685 22
6.2 BASIC PARTS - LIQUID END (DIA 90MM) ITEM NO DESCRIPTIONS QUANTITY 90mm RECOMMENDED SPARES 1 Packing End Ring 2 994379 6 2 Packing Gland Rope Size 1 Set 8mm 2 1 set 3 Plunger Adaptor 1 239032 4 Plunger 1 244832 5 Gland Nut 1 993932N 6 Gland Bush 1 994032N 7 Head 1 993832N 8 Suction & Discharge Valve Adaptor 2 993432 9 Retainer Plate 2 991532 10 Gasket 6 994579 10 11,12 Ball Seat 2 993532 2 13 Ball 2 990232 2 14 Ball Guide 2 993732 2 16.17 SUCTION / DISCHARGE VALVE 2 SETS 993732S 19 Hex Bolt M12X35 HT 4 180926 20 Hex Nut 1 M01432 21 Hex Bolt M10X100 SS 4 M01313 23
SECTION 7 TROUBLE SHOOTING SYMPTOMS CAUSES REMEDIES Pump does not Operate Insufficient Delivery Erratic Delivery Gear Shaft Breakage Blown Fuse Motor Trip Low Liquid Level Worn or Dirty Check Valves Blocked Discharge Line Broken Wire Low Voltage Pump not primed Capacity Adjustment Set at Zero. Incorrect Capacity Adjustment Incorrect Pressure Relief valve Settings. Starved Suction Leaky Suction Piping Leaky Pressure Relief Valve Worn or Dirty Check Valves Leaky Suction Piping Leaky Pressure Relief Valve Incorrect Pressure Relief valve Settings. Worn or Dirty Check Valves Clogged or Dirty line Strainer Plunger or cross slide hitting against liquid end. Check for Short Circuit Check for Overload, Correct current setting in relay. Fill Liquid Clean and Replace Clear Line Locate and Repair Investigate and Correct Allow Suction Line and pump head to fill with liquid before pumping against pressure. Readjust. Readjust Capacity Correct the Pressure Relief Valve Settings Increase Pipe Sizing or Suction Head. Repair Piping Repair or Replace Pressure Relief Valve. Clean and Replace Repair Piping Repair or Replace Pressure Relief Valve. Correct the Pressure Relief Valve Settings Clean and Replace Clean Strainer Correct and change the gear shaft. Pump not developing Pressure Leaky Gland Packing Leaky Pressure Relief Valve Incorrect Pressure Relief valve Settings. 24 Tighten Gland Packing Add Rope Change Entire Packing Correct or replace pressure relief valve Correct the Pressure Relief Valve Settings
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