Metallic Diaphragm Liquid End

Metallic Diaphragm Liquid End
Metallic Diaphragm
Liquid End
INSTALLATION,
OPERATION, AND
MAINTENANCE
MANUAL
339-0077-000
Issued 6/02
TABLE OF CONTENTS
LIST OF ILLUSTRATIONS...................................................................................................................... 2
SECTION 1 – FUNCTIONAL DESCRIPTION ........................................................................................... 3
1.1 PHYSICAL DESCRIPTION .........................................................................................................3
1.2 PRINCIPLE OF OPERATION ......................................................................................................3
1.3 MODEL CODING .....................................................................................................................3
1.4 SPECIFICATIONS ....................................................................................................................4
SECTION 2 - INSTALLATION................................................................................................................. 5
2.1 UNPACKING ...........................................................................................................................5
2.2 STORAGE...............................................................................................................................5
2.3 SAFETY PRECAUTIONS............................................................................................................5
2.4 MOUNTING ............................................................................................................................6
2.5 PIPING CONNECTIONS............................................................................................................6
2.5.1 General..........................................................................................................................6
2.5.2 NPSH Considerations .......................................................................................................6
2.6 TYPICAL PIPING .....................................................................................................................6
SECTION 3 - OPERATION...................................................................................................................... 7
3.1 INITIAL START-UP..................................................................................................................7
3.2 RELIEF VALVE ADJUSTMENT ....................................................................................................8
SECTION 4 - MAINTENANCE............................................................................................................... 10
4.1 RECOMMENDED SPARE PARTS............................................................................................... 10
4.2 RETURNING UNITS TO THE FACTORY..................................................................................... 10
4.3 ROUTINE PREVENTIVE MAINTENANCE.................................................................................... 10
4.3.1 HYDRAULIC OIL REPLACEMENT ..................................................................................... 10
4.3.2 HYDRAULIC OIL STRAINER REPLACEMENT...................................................................... 11
4.3.3 CHECK VALVE MAINTENANCE ........................................................................................ 11
4.3.4 DIAPHRAGM AND SEAL REPLACEMENT ........................................................................... 12
4.4 CORRECTIVE MAINTENANCE.................................................................................................. 13
4.4.1 Relief Valve Assembly.................................................................................................... 13
4.4.2 Refill Valve Assembly..................................................................................................... 14
4.4.3 Air Bleed Valve Assembly ............................................................................................... 14
4.4.4 Liquid End Removal....................................................................................................... 14
SECTION 5 –TROUBLESHOOTING....................................................................................................... 26
SECTION 6 – PARTS ............................................................................................................................ 28
SECTION 7 - LIMITED WARRANTY ..................................................................................................... 29
1
LIST OF ILLUSTRATIONS
Figure 1: Metallic Diaphragm Liquid End.............................................................................................. 9
Figure 2: Discharge Check Valve, One Back-Up Ring ......................................................................... 16
Figure 3: Suction Check Valve, One Back-Up Ring ............................................................................. 17
Figure 4: Discharge Check Valve, Two Back-Up Rings ....................................................................... 18
Figure 5: Suction Check Valve, Two Back-Up Rings ........................................................................... 19
Figure 6: Cross Section of Liquid End (Milroyal C and Primeroyal).................................................... 20
Figure 7: Cross Section of Liquid End (Milroyal B) ............................................................................. 21
Figure 8: Bolt Tightening Sequence.................................................................................................... 22
Figure 9: Relief Valve Assembly ......................................................................................................... 23
Figure 10: Refill Valve Assembly ........................................................................................................ 24
Figure 11: Air Bleed Valve .................................................................................................................. 25
2
SECTION 1 – FUNCTIONAL DESCRIPTION
Milton Roy pumps are composed of two main
assemblies: the pump drive and the pump liquid
end. The drive generates the mechanical energy
and the liquid end displaces the process chemical.
This is an instruction manual for Milton Roy’s
Metallic Diaphragm liquid ends. This manual is
designed to serve as a supplement to the
appropriate pump drive instruction manuals:
Milroyal B (339-0007-000), Milroyal C (339-0009000) and Primeroyal R (339-0078-000), which
provide both general information and specific
instructions for installing, operating, and
maintaining Milton Roy pumps. Do not rely on this
manual alone when installing, maintaining and
operating Milton Roy pumps.
1.1
causes chemical to flow through the suction check
valve into the liquid end. As the plunger is drawn
back, the flexible diaphragm follows. With the
discharge ball check closed, flow is prevented
from flowing into the discharge line.
At the end of the suction stroke, the process
reverses, beginning the discharge stroke. The
plunger is then pushed into the liquid end,
decreasing the volume of the chamber and thus
raising the pressure in the chamber fluid. This
higher pressure causes the balls in the suction
check valve to seat and causes chemical to flow
through the discharge check valve into the
discharge line. The hydraulic oil presses against
the diaphragm, flexing it forward.
With the
suction ball check closed, flow is prevented from
flowing into the suction line. This suction/
discharge action is repeated with every stroke of
the pump plunger.
PHYSICAL DESCRIPTION
The Metallic Diaphragm liquid ends combine all of
the best characteristics of traditional liquid ends,
with a sufficiently increased pressure and
temperature
capability,
resulting
in
one
technologically advanced design. These liquid
ends are manufactured with a totally sealed
hydraulic chamber, in combination with integral air
bleed, high pressure relief and vacuum actuated
refill systems. The metallic diaphragm liquid ends
also come with an optional leak detection system
that prevents process chemical contamination.
These liquid ends can be constructed in variable
materials, providing compatibility with a wide
range of process liquids and chemicals. Along with
serviceable diaphragms and removable check
valves, the liquid end’s design assures relatively
simple maintenance and operation, making it the
ideal choice for high temperature and high
pressure processes in which downtime is critical.
1.2
With each stroke of the plunger, a small quantity
of hydraulic oil is bled through the air bleed. In
addition, a small amount of hydraulic oil leaks
through the narrow clearance between the
plunger and the plunger bore into the catch-all of
the pump. This results in a shortage of hydraulic
oil in the displacement chamber. On the suction
stroke, the diaphragm will follow the plunger as it
is pulled out of the chamber until the diaphragm
hits the reverse side of the contoured cavity. At
this point, the plunger will continue to be pulled
out of the chamber causing a vacuum to be drawn
in the hydraulic oil. This vacuum causes the refill
valve to open, which replenishes the lost oil. In
this manner, proper hydraulic balance is
constantly maintained in the displacement
chamber.
PRINCIPLE OF OPERATION
1.3
The mechanical drive system of the pump drives
the piston back and forth in the Metallic
Diaphragm liquid end of the pump. The pump
operating cycle consists of fluid being discharged
from the liquid end and suctioned into it.
MODEL CODING
The presence of a Metallic Diaphragm liquid end
on a Milton Roy pump is indicated by an “M” in the
third position of the pump model code (xxM-xxxxxxxxx). This model code can be found on the
data plate attached to the pump. For more
information on pump model coding and data
plates, see the appropriate pump instruction
manual.
At the start of a suction stroke, the plunger is
pulled out of the liquid end, increasing the volume
of the chamber and thus lowering the pressure of
the chamber fluid. This lower pressure causes the
balls in the discharge check valve to seat and
3
1.4
SPECIFICATIONS
Steady State Accuracy/Turndown Ratio:
± 1% of pump full rated capacity over 10:1 turndown ratio
Liquid Temperature:
From -40oF to 800oF, dependent on liquid end
Minimum Suction Pressure:
Dependent on specific liquid end
Minimum Discharge Back Pressure:
35 psi above suction pressure
Maximum Discharge Back Pressure:
Up to 30,000 psi, depending on specific liquid end
Hydraulic Fluid:
Zurnpreen 15A - - Type A, ATF
Ball Checks:
Double ball checks in suction and discharge.
4
SECTION 2 - INSTALLATION
2.1
UNPACKING
contact Milton
preparation.
Pumps are shipped f.o.b. from the factory and the
title passes to the customer when the carrier signs
for receipt of it. 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. The shipping crate should be
carefully examined upon receipt from the carrier to
be sure there is no obvious damage to the contents.
Open the crate carefully, as there are sometimes
accessory items fastened to the inside of the crate
that may be lost or damaged. Examine all material
inside crate and check against the packing list to be
sure that all items are accounted for and
undamaged.
2.2
Roy
to
arrange
for
factory
Pump Drive
1. Remove motor and flood the gearbox
compartment with a high grade lubricating oil/
rust preventative such as Mobile Oil Corporation
product Mobilarma 524. Fill the compartment
completely to minimize air space and water
vapor condensation. After storage, drain this
material and refill the equipment with the
recommended
lubricant
for
equipment
commissioning.
2. Brush all unpainted metal surfaces with multipurpose grease (NLGI grade 2 or 3). Store these
unattached.
STORAGE
Electrical Equipment
Short Term 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.
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
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 Roy
Service Department for recommended VPCI
materials.
Long Term Storage (Longer than 6 Months)
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 greatest extent possible. When the
instructions given in this section are completed, the
equipment is to be stored in a shelter; 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,
2.3
(including
SAFETY PRECAUTIONS
WARNING
WHEN INSTALLING, OPERATING, AND MAINTAINING A METALLIC DIAPHRAGM 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 INSTRUC-
5
TIONS 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, TOXICS,
SOLVENTS, ACIDS, CAUSTICS, FLAMMABLES,
ETC.).
pump can be expected to perform satisfactorily
unless those recommendations are followed.
NOTE: Maximum safety and reliability may be
ensured by protecting liquid ends and
piping with an external relief valve
installed in the system discharge line.
2.5.2
CAUTION
Size the piping to accommodate peak instantaneous
flow. Because of the reciprocating motion of the
pump diaphragm, peak instantaneous flow is
approximately equal to 5 times the average flow. For
example, a pump rated for 16 gallons per hour (61
L/hr.) requires piping sufficient for 5 x 16 gph, or 80
gph (303 L/hr.).
THE PERSONNEL RESPONSIBLE FOR INSTALLATION, OPERATION AND MAINTENANCE OF
THIS EQUIPMENT MUST BECOME FULLY
ACQUAINTED WITH THE CONTENTS OF THIS
MANUAL.
ANY SERVICING OF THIS EQUIPMENT MUST
BE CARRIED OUT WHEN THE UNIT IS
STOPPED AND ALL PRESSURE HAS BEEN BLED
FROM THE LIQUID END. SHUT-OFF VALVES
IN SUCTION AND DISCHARGE SIDES OF THE
LIQUID END SHOULD BE CLOSED WHILE THE
UNIT IS BEING SERVICED. ACTIONS SHOULD
BE TAKEN TO ELIMINATE THE POSSIBILITY
OF ACCIDENTAL START-UP WHILE SERVICING
IS TAKING PLACE. A NOTICE SHOULD BE
POSTED BY THE POWER SWITCH TO WARN
THAT SERVICING IS BEING CARRIED OUT ON
THE EQUIPMENT. SWITCH OFF THE POWER
SUPPLY AS SOON AS ANY FAULT IS DETECTED
DURING OPERATION (EXAMPLES: ABNORMALLY HIGH DRIVE TEMPERATURE, UNUSUAL
NOISE, AND DIAPHRAGM FAILURE).
2.4
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 Company representative to
determine the necessary pipe size.
2.6
TYPICAL PIPING
In order to adjust the Metallic Diaphragm relief
valve, it is necessary to have a pressure gauge and
a shut off valve installed in the discharge line. The
pressure gauge must have a higher range than the
desired pump relief pressure, and should be installed
as close to the pump discharge connection as
possible. The shut off valve should be installed
downstream of the pressure gauge. These items
are not required for normal operation, but for ease
of pump maintenance and adjustment, it is
suggested that they be permanently piped into the
line.
MOUNTING
The Metallic Diaphragm liquid end is shipped already
mounted to the appropriate pump.
Mounting,
therefore, is simply a matter of securing the pump
to a safe, level surface. For further information on
proper pump mounting, see the appropriate pump
instruction manual:
Milroyal B…….……………….... 339-0007-000
Milroyal C …….…………………. 339-0010-000
Primeroyal ………………………. 339-0078-000
2.5
2.5.1
NPSH Considerations
Due to high system pressures, all metallic diaphragm
pumps must have a filter installed in the suction line
in order to protect the diaphragms from premature
failure. The filter should be able to trap particles as
small as 40 µm, and should have a pressure drop
across the filter that is no greater than ½ psi at
peak instantaneous flow.
PIPING CONNECTIONS
General
Also see the instructions in the appropriate pump
instruction manual for additional typical piping
instructions.
General piping instructions are given in the pump
drive instruction manual. No reciprocating plunger
6
SECTION 3 - OPERATION
3.1
INITIAL START-UP
oil level reaches the very top. It may be helpful
to pulse the motor for a few seconds to dislodge
any air that may be in the displacement
chamber. Repeat this process until air bubbles
cease to come out of the port.
After installing the pump and the Metallic Diaphragm
liquid end, perform the following operations before
placing the pump into service. The numbers in
parenthesis refer to the bubble numbers shown in
the attached figures.
CAUTION
This process could cause oil to shoot out of
the open port.
Take appropriate precautions.
WARNING
The pump could be damaged if the motor is
run before all of the start-up steps have been
completed. Do not run the motor until all
start-up steps have been completed.
6. If the motor was pulsed, make sure to rotate
the coupling so that the plunger and crosshead
are returned to their full forward position.
Replace the air bleed valve and tighten snugly.
1. Parts may have shifted during shipping, so it is
crucial that all pump, motor and liquid end
attachment bolts be retightened prior to startup. It is also crucial to realign the motor prior
to starting, or damage could be done to the
motor and coupling.
7. Remove the catch-all cover (see Figure 1),
which is a small square cover over the front
chamber of the pump, and fill the chamber with
hydraulic oil (same oil as used in step 4) to a
level equal to the top of the oil seal which
surrounds the crosshead.
2. Disconnect the outlet tube from the air bleed
valve (See Figure 1) and remove the air bleed
valve from the liquid end. Make sure that the
O-ring between the displacement chamber and
the air bleed valve does not get lost or
damaged, and that the opening in the
displacement chamber remains clean.
8. Replace the air bleed valve outlet tube and the
front chamber cover. The gasket has an
adhesive backing that should be removed, and
the gasket should be firmly attached to the
cover using this adhesive.
3. Make sure that the capacity adjustment (hand
knob or automatic control) is set at 100%.
9. The pump liquid end hydraulic oil servicing is
now complete.
4. Rotate the motor coupling until the piston and
crosshead are in the full forward position
(closest to pump liquid end).
10. Before placing pump into operation, please refer
to the drive instruction manual furnished along
with this manual, which covers the lubrication
instructions for the pump gear box, the
instructions for bleeding all air from the suction
piping and pump head, and for proper direction
of motor rotation.
NOTE: It is important that the plunger be
in the full forward position when the
displacement chamber is filled with
oil. If the displacement chamber is
filled with the plunger fully rearward,
the diaphragms could rupture at
startup.
11. Do not start up pump drive motor before filling
gearbox with oil or serious damage will occur.
12. If your particular metallic diaphragm liquid end
has a minimum suction pressure requirement,
make sure that the priming pump is
running prior to starting your metallic
diaphragm pump. Failure to do so could
result in premature failure of the diaphragms.
5. Fill the displacement chamber through the port
uncovered by the removal of the air bleed valve
in step 1 with the hydraulic oil furnished with
the pump (Zurnpreen 15A). Fill the chamber
slowly, allowing air bubbles to escape, until the
7
3.2
RELIEF VALVE ADJUSTMENT
leakage past the relief valve, tighten the relief
valve adjustment nut (50-12) in the clockwise
direction to increase its setting. If you obtain
the desired pressure without any leakage past
the relief valve, then loosen the adjustment nut
in the counter-clockwise direction until the
gauge pressure begins to decrease. Continue
throttling the shut off valve to determine the
peak pressure. If the pressure exceeds the
desired value, quickly open the shut off valve to
relieve pressure and loosen the adjustment nut.
It is recommended that the relief valve be
set at a pressure of 15% over the
operating pressure.
All Metallic Diaphragm liquid ends have a built in
relief valve that allows hydraulic fluid to return to
the hydraulic fluid reservoir if excessive pressure
builds up in the discharge line or inside the liquid
end. 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. Please read the “Principle of Operation” for
more information.
The 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.
Note: The relief valve may begin leaking at
pressures less than the maximum
setting, so do not assume that the
maximum pressure has been obtained
when leakage begins.
WARNING
The pressure relief valve (see Figures 1 and 9)
is factory set to open at a pressure slightly
above the pump maximum operating
discharge pressure; never set the valve at any
greater pressure.
WARNING
Do not leave the pump operating
unattended with the shut off valve closed!
Excessive pressure can build quickly,
possibly causing severe damage to the
pump and/or piping. Since the relief valve
is not yet properly adjusted, it can not be
relied on to limit excessive pressure buildup. Be sure to watch the pressure gauge
very carefully and open the shut off valve
immediately
if
excessive
pressure
develops.
1. A pressure gauge and shut off valve must be
installed in the discharge line to complete this
procedure. If the necessary equipment is not
installed, refer to the “Typical Piping”
instructions in Section 2.
2. Make sure the shut off valve is open. Start the
pump and pump the process liquid to a drain or
other safe point to establish proper pumping
action.
4.
3. Slowly throttle the shut off valve, while
observing the pressure increasing on the gauge.
Continue to throttle the shut off valve until the
desired relief pressure is obtained. If you are
unable to reach the desired pressure due to
8
After setting the relief valve, make sure that the
shut off valve is fully opened. Remove the
pressure gauge from the line or leave it in place,
as desired.
Figure 1: Metallic Diaphragm Liquid End
9
SECTION 4 - MAINTENANCE
This section contains procedures for disassembly
and assembly of the Metallic Diaphragm liquid end,
plus procedures for preventive and corrective
maintenance. To maintain the reliability, durability,
and performance of your pump and related
components, it is essential to follow these
procedures exactly and carefully. For consistent,
reliable performance, replace any O-rings or other
seals that you remove. Whenever you disconnect
any fluid piping, cover all open ports in the pump
assembly to prevent dirt from entering.
4.1
shipping crate with any pump returned to
the factory. 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 Material Safety
Data Sheet must accompany all returns.
All inquiries on part order should be addressed to
your local Milton Roy sales representative or sent to:
Parts Department
Milton Roy Company
Flow Control Division
201 Ivyland Road
Ivyland, PA 18974-0577
Phone: (215) 441-0800
Fax:
(215) 441-8620
RECOMMENDED SPARE PARTS
Be Prepared. To avoid delays in repairs, Routine
Preventive Maintenance (RPM) Kits should be
ordered for each pump. The RPM kits contain
replacements for those parts that are subject to
wear; specifically the ball checks, check valve seats,
gaskets, O-rings, diaphragms and the hydraulic fluid
strainer. Replacing these parts annually with an RPM
kit can reduce the possibility of unexpected
downtime and will help to extend the pump life.
4.3
WARNING
Before any maintenance, relieve all pressure
from the system, isolate the liquid end from
all sources of process liquid with appropriate
valving, and purge the liquid end of all
process liquid.
Parts orders must include the following information:
1.
2.
3.
4.
5.
Quantity required
Part number
Part description
Serial number (found on nameplate)
Model number (found on nameplate)
4.3.1
HYDRAULIC OIL REPLACEMENT
Inspect and replace the hydraulic oil and oil filter
(See Figure 1) on the same schedule as the pump’s
gear drive lubricant (see the appropriate pump drive
instruction manual for this information). The oil filter
strainer is included in the RPM Kit, but can be
ordered separately, if required.
Semiannual
replacement is recommended, and can be scheduled
to coincide with seasonal oil changes.
Always include the serial and model numbers in all
correspondence regarding the unit.
4.2
ROUTINE PREVENTIVE MAINTENANCE
RETURNING UNITS TO THE FACTORY
Pumps will not be accepted for repair without a
Return Material Authorization, available from the
factory or other authorized Customer 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 before the pump is
shipped.
To replace the hydraulic oil:
1. Remove the catchall cover by unscrewing the
four screws which hold it on (see Figure 1).
2. Place a container under the pump catchall to
catch the oil and unscrew the catchall drain
plug.
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
10
3. When the oil has finished draining, make sure
that the area around the drain hole is clean.
Apply thread sealant to the drain plug and screw
it back in securely.
8. Refill the catchall with fresh hydraulic oil
according to steps 5-7 of section 4.3.1.
4. Replace the strainer in the inline oil filter. See
section 4.3.2.
WARNING
4.3.3
Before performing any maintenance on
the check valves, relieve all pressure from
the system, isolate the liquid end from all
sources of process liquid with appropriate
valving, and purge the liquid end of all
process fluid.
5. Fill the catchall to the top of the oil seal that
surrounds the crosshead with new, clean oil.
Use Zurnpreen 15A hydraulic oil or an equivalent
replacement.
6. Replace the catchall cover and screw it firmly in
place.
Refer to Figures 2-5 for the following procedures.
NOTE: It is not necessary to purge the
liquid end displacement chamber of
oil during annual oil replacement.
Disassembly
1. After insuring that all system pressure has been
relieved and that all hazardous process liquids
have been flushed from the liquid end,
disconnect both the suction inlet and discharge
outlet from the system piping.
7. Dispose of oil according to federal, state, or
local codes that may apply.
4.3.2
CHECK VALVE MAINTENANCE
HYDRAULIC OIL STRAINER
REPLACEMENT
2. Remove the check valves from the pump liquid
end (see Figure 1).
1. Drain the hydraulic oil according to steps 1-3 of
section 4.3.1.
3. Clamp the check valve body (290) in a vice and
remove the retaining nut (250).
2. The oil filter (See Figure 1) is piped in-line just
before the refill valve. Support the oil filter and
loosen the large union nut with an open-end
wrench.
4. Remove the check valve body (290) from the
vice and using a narrow rod, tap out the ball
seats (220), ball cages (270), balls (280) and
washer (245). The washer is not used in all
designs, so it may not be found in your check
valve. With the check valve body standing
vertically on a flat surface, it will be necessary to
tap out some of the components, remove them,
and then continue taping out the rest.
3. Unscrew the union nut and remove the
assembly. (Note: union nut, bonnet, spring and
retaining ring remain together as an assembly.)
Be careful not to loose the small metallic gasket.
4. Tap the strainer element lightly on the side with
a nonmetallic object to break it loose from the
tapered seating area.
5. Once disassembled, the O-rings (230) and backup rings (240) on both of the seats (220) and
the retaining nut (250) should be discarded.
5. Insert a new strainer element. Tap it lightly
with a smooth faced tool to reseat the element
in the tapered bore.
6. Inspect the balls (280) carefully. If they are
smooth, round and free of deposits or pits, then
they are suitable for continued use. Examine
the check valve seats (220). The area of the
seat where it meets the ball (the un-chamfered
side) must be in near perfect condition for
continued use. Any imperfection visible on the
seating surface (pits, erosion, cracks, or a ball
shaped contour greater than 0.030 deep) makes
6. Inspect the gasket and mating surfaces on the
bonnet and body. Clean as required.
7. Replace the bonnet assembly and tighten
securely.
11
the seat unusable. If both the balls and seats
are in good condition, then the length of time
between parts replacement may be lengthened.
If the balls and seats are severely damaged,
then the length of time between parts
replacement should be shortened. Note that the
ball cages (270) are not included with the RPM
kit. If these parts are damaged, they must be
ordered separately.
Disassembly:
1. Stop the pump and relieve all pressure from the
system. Isolate the liquid end from all sources
of process liquid with appropriate valving and
purge the liquid end of all process fluid.
2. Disconnect both the suction inlet and discharge
outlet from the piping system.
Re-assembly
3. Remove the catchall cover of the pump drive
and drain the catchall of the hydraulic oil by
removing the pipe plug at the bottom of the
housing. (Note: Some oil will still be present in
the displacement chamber, which will be
released when the diaphragms are removed.
Prepare your work area accordingly.)
1. Install new O-rings (230) and back-up rings
(240) onto the ball seats (220) and onto the
retention nut (250), being sure to apply O-ring
lubricant to the O-rings. Note: some of the
check valves use two back-up rings for
each O-ring and others only use one backup ring. Be sure to install the back-up
rings as shown in the appropriate figure.
4. Remove the check valves to prevent any
damage.
2. Insert the washer (245), if applicable, ball seats
(220), ball guides (270) and balls (280) into the
check valve body (290), being sure to maintain
the orientation as shown in the appropriate
figure.
5. Remove the diaphragm head nuts or bolts (90,
100) that hold the diaphragm head (120) to the
displacement chamber (130) and remove the
diaphragm head. Note: the diaphragm head
can weigh several hundred pounds, so it should
not be removed by hand. There are threaded
holes provided in the head and displacement
chamber for lift eyes.
3. Apply anti-seize thread lubricant to the back-up
nut (250) and insert it into the check valve body
(290). Insert the check valve body in a vice and
tighten the back-up nut. Do not over-tighten
this nut.
6. Place the diaphragm head (120) on a flat
surface, with the side containing the diaphragms
at the top. Remove the 4 screws (370), which
hold the diaphragms in place. Remove the
diaphragms (380, 390, 380), O-ring (410) and
back-up ring (400).
Inspect and clean all
sealing surfaces on the diaphragm head (120)
and the displacement chamber (130).
4. Insert the O-ring (260) into the groove at the
bottom of the check valve body (290), using Oring lubricant.
5.
Apply anti-seize thread lubricant to the check
valve body (290) and insert the check valve into
the diaphragm head, tightening snugly.
4.3.4
Reassembly:
DIAPHRAGM AND SEAL REPLACEMENT
1. It is recommended that all O-rings, back-up
rings and diaphragms be replaced when the
diaphragm head (120) is removed. Install a
new O-ring (410)—do not apply any
lubricant to the O-ring. Install a new backup ring (400) being sure that it fully fits into the
groove and does not hang over the edge of the
groove.
The metallic diaphragms are extremely durable and
often last for many years of service. As a preventive
measure,
however,
Milton
Roy
Company
recommends that the diaphragms be replaced yearly
to coincide with annual check valve replacement.
Refer to Figures 6 and 7 for the following diaphragm
replacement procedure.
2. Place new diaphragms (380, 390, 380) into the
recessed pocket one at a time, applying a thin
layer of clean hydraulic oil between each
12
diaphragm. If the diaphragms have a slight
curvature to them, orient them such that they
create a cavity between themselves and the
diaphragm head (120). Be sure to put the
diaphragm, which has small scribe lines on
it (390), in the middle. Orient the scribes
about 22.5 degrees from the 4 bolt holes.
final torque value be applied twice, following the
appropriate pattern.
NOTE: It is essential that the correct
torque value is used. Over-torquing can
cause the diaphragms to seize up and can
cause yielding of the diaphragm head.
Under-torquing can cause the diaphragm
head to separate, resulting in a failure of
the O-ring seals.
3. Secure the diaphragms with the 4 screws (370),
tightening the screws finger tight only. Be sure
that the diaphragms are approximately
centered in the cavity and that they do not
hang over the edge of the recessed
pocket.
8. If the check valves were removed, make sure
that they were not switched and that the
directional arrows on the check valve bodies
(290) are pointing up. Verify that the O-rings
(260) are in their grooves. Insert the check
valves, being sure to apply anti-seize thread
lubricant, and tighten snugly.
4. Install a new O-ring (430) into the displacement
chamber (130)—do not apply any lubricant
to the O-ring. Install a new back-up ring
(420) being sure that it fully fits into the groove
and does not hang over the edge of the groove.
9. Reconnect the suction inlet and discharge outlet
to the piping system.
5. Install a new O-ring (360) into the displacement
chamber.
10. Fill the liquid end with hydraulic oil (refer to the
above “INITIAL START-UP” procedure).
6. If the diaphragm head (120) is attached with
studs (90) and nuts (100), as in Figure 6, then
reinstall the diaphragm head (120) on the
displacement chamber (130), using the studs as
a guide. If the diaphragm head is attached with
cap screws (90), as in Figure 7, then line up the
diaphragm head with the displacement
chamber, keeping a gap between the parts, and
insert a few of the screws to act as a guide.
Then slide the head against the chamber. It is
important to line up the parts before they
contact each other so that the diaphragms are
not dislodged.
4.4
CORRECTIVE MAINTENANCE
4.4.1
Relief Valve Assembly
The relief valve assembly operates in filtered
hydraulic oil and should require maintenance only if
unusual circumstances occur, such as if corrosive
media contaminates the fluid, or if the relief valve
was operating excessively. Refer to Figure 9 for the
following procedures.
Disassembly:
Note: Be sure to apply anti-seize thread
lubricant to the threads of the studs
or screws.
CAUTION
The relief valve contains a compressed
spring (50-7). The spring is normally
completely unloaded when the adjustment
nut (50-12) is unthreaded, but care should
be used as the adjustment nut is removed.
7. Torque the nuts or screws (90, 100) in
sequence, to one half of the final torque value,
which is stamped on the diaphragm head (120)
or found on the assembly drawing included with
your pump. Follow the bolt torque pattern which
may be stamped on the head, or according to
Figure 8. Repeat the torque sequence with the
full torque value two times. Do to the large
torque values on many of the metallic
diaphragm designs, it is recommended that the
1. Unlock the lock nut (50-10) and unthread the
adjustment nut (50-12). Observe the precaution
about the internal spring.
2. Remove the ball (50-9), spring retainer (50-8),
spring (50-7), poppet (50-6) and ball (50-5)
from the body (50-4).
13
3. Remove the back-up nut (50-1) at the valve
inlet. Carefully remove the tungsten carbide
seat (50-2) which is very hard and brittle. Do
not drop the seat.
4.4.3
The air bleed valve assembly operates in filtered
hydraulic oil and should require maintenance only if
unusual circumstances occur, such as if corrosive
media contaminates the fluid. See Figure 11 for the
following procedure.
4. Inspect all parts, paying special attention to the
seat (50-2) and ball (50-5) for wear and erosion.
Replace any parts if necessary.
Disassembly:
Reassembly:
1. Unscrew the inner body (320) from the outer
body (340). Be careful not to lose the ball (310)
and ball stem (330).
1. Slide the tungsten carbide seat (50-2) into the
body (50-4). Carefully tighten the back-up nut
and torque to 70-75 ft.-lbs.
2. Remove the ball retainer (300) and ball (310).
2. Assemble the spring retainer (50-8), spring (507) and poppet (50-6). Carefully place the ball
(50-5) into the poppet. Carefully insert this
assembly into the body (50-4), so as not to
damage the seat (50-2).
3. Clean and inspect all parts, paying special
attention to the balls (310) and the
corresponding seats in the inner body (320).
Replace any worn parts.
3. Thread the adjustment nut (50-12), complete
with the lock nut (50-10) and O-ring (50-11),
into the body (50-4). Load the spring lightly.
4.4.2
Air Bleed Valve Assembly
Reassembly:
1. Carefully drop the upper ball (310) into the inner
body (320). Screw in the ball retainer (300)
snugly.
2. Hold the inner body (320) upside down and
drop in the ball stem (330), followed by the ball
(310). Insert the O-ring (315).
Refill Valve Assembly
The refill valve assembly operates in filtered
hydraulic oil and should require maintenance only if
unusual circumstances occur, such as if corrosive
media contaminates the fluid. See Figure 10 for the
following procedure.
3. While continuing to hold the subassembly upside
down, screw it into the outer body (340).
Torque to 50-55 ft.-lbs.
Disassembly:
4.4.4
1. Unscrew the retaining nut (80-6) from the body
(80-1). Remove the spring (80-2), poppet (803), O-ring (80-4) and seat (80-5).
Liquid End Removal
2. Clean and inspect all parts, paying special
attention to the poppet (80-3) and seat (80-5)
for wear. Replace any worn parts.
Under normal operating conditions, it should not be
necessary to remove the liquid end. If, however,
corrosive media contaminates the hydraulic oil,
causing excessive wear or ceasing of the plunger,
this may be necessary. See Figures 6 and 7 for the
following procedure.
Reassembly:
Disassembly:
1. Insert the poppet (80-3) and spring (80-2),
making sure that the spring rests in the pocket
of the body (80-1).
1. Stop the pump and relieve all pressure from the
system. Isolate the liquid end from all sources
of process liquid with appropriate valving and
purge the liquid end of all process fluid.
2. Insert the seat (80-5) and retaining nut (80-6).
Torque to 50-55 ft.-lbs.
2. Disconnect both the suction inlet and discharge
outlet from the piping system.
14
3. Remove all tubing which connects the liquid end
to the pump housing.
Reassembly:
1. Verify that the stroke adjuster is set at 100%
and manually turn the motor until the plunger is
at bottom dead center (the crosshead is furthest
from the liquid end).
4. Remove the catchall cover of the pump drive
and drain the catchall of the hydraulic oil by
removing the pipe plug at the bottom of the
housing.
2. Coat the plunger (200) with clean hydraulic oil
and insert it into the liquid end. The plunger
should be free to slide in and out of the liquid
end, but there should not be any noticeable
side-to-side motion. Insert the plunger until it
bottoms out in the liquid end.
5. Set the stroke adjuster to 100% and manually
turn the motor until the plunger is at bottom
dead center (the crosshead is furthest from the
liquid end).
6. Remove the air bleed valve to relieve any
hydraulic pressure. Cover the port to prevent
any contaminates from entering the hydraulic
system.
3. Using an overhead crane, carefully lift the liquid
end and mount it onto the pump housing.
Attach it with the supplied hardware and tighten
snugly.
7. The Milroyal B drive uses a different plunger
attachment mechanism than the Milroyal C and
Primeroyal drives.
For the Milroyal C and
Primeroyal drives, unscrew the set-screws (170).
On all drives, unscrew the plunger adapter nut
(180) and move it away from the crosshead.
Disengage the plunger (195, 200) from the
crosshead and push the plunger into the liquid
end until it bottoms out. Oil may be pumped
out of the air bleed port. For Milroyal B drives,
the thrust disk (165) will be loose inside the
crosshead. Be careful not to loose it.
4. For Milroyal C and Primeroyal drives (See
Figure 6): Slide the plunger (200) into the
crosshead and tighten the plunger adapter nut
(180) until it bottoms out. Back the plunger
adapter nut out about 1/8 of a turn and tighten
the set-screws (170). The plunger should be
free to rotate, and there should be minimal axial
play (less than 1/64”). If the plunger does not
rotate, remove the assembly and check for any
foreign material.
5. For Milroyal B drive (See Figure 7): Arrange
the thrust disk (165), floating retainer (160),
plunger (195, 200) and plunger adapter nut
(180) so that the thrust disk, plunger and
floating retainer are contained inside the plunger
adapter nut.
Slide this assembly into the
crosshead and tighten the plunger adapter nut
until it has 2-3 threads of engagement. Using a
small screwdriver, knock the floating retainer
until it bottoms out inside the crosshead.
Tighten the plunger adapter nut snugly. The
plunger should be free to rotate, and there
should be minimal axial play (less than 1/64”).
If the plunger does not rotate, remove the
assembly and check for any foreign material.
8. Attach an overhead crane to the liquid end,
using lift eyes. Remove the nuts or screws
which attach the liquid end to the pump housing
and remove the liquid end, being careful not to
bump the plunger into anything.
9. Withdraw the plunger (195, 200) from the liquid
end. Inspect the plunger and the bore of the
plunger sleeve (190). Both surfaces should be
smooth and free of scoring (longitudinal
grooves), excessive wear, or other irregularities.
Replace any worn parts. The plunger and
plunger sleeve are machined as a set and must
be ordered together.
6. Install any tubing that was previously removed.
15
Figure 2: Discharge Check Valve, One Back-Up Ring
16
Figure 3: Suction Check Valve, One Back-Up Ring
17
Figure 4: Discharge Check Valve, Two Back-Up Rings
18
Figure 5: Suction Check Valve, Two Back-Up Rings
19
Figure 6: Cross Section of Liquid End (Milroyal C and Primeroyal)
20
Figure 7: Cross Section of Liquid End (Milroyal B)
21
Figure 8: Bolt Tightening Sequence
22
Figure 9: Relief Valve Assembly
23
Figure 10: Refill Valve Assembly
24
Figure 11: Air Bleed Valve
25
SECTION 5 –TROUBLESHOOTING
The pump drive instruction manuals list the most possible malfunctions, their causes and cures. The following
problems peculiar to Metallic Diaphragm liquid ends may be remedied as indicated below.
Excessive delivery. . . . . . . . . . . . . . . . . . . . . . •
Low discharge line pressure. Increase line pressure
(e.g., install a back pressure valve).
Insufficient delivery. . . . . . . . . . . . . . . . . . . . . •
Air in hydraulic system. Stop pump and relieve system
pressure, isolate liquid end from system. Remove the air
bleed valve. Oil should reach the top of the through hole. If
oil is low, follow the instructions in Section 3.1, items 2-6.
•
Flow increases after performing the above step and then the
flow drops off again.
— Bad refill valve. Stop the pump. Disconnect the piping
that connects refill valve to pump housing. Attach a
section of 3/8” OD clear tubing (5-6 ft long) to the refill
valve; elevate it and fill it with clean hydraulic oil.
Restart the pump. The oil level in the tube may drop
rapidly for a few pump strokes, but it should then
stabilize and drop a small amount with each stroke. The
flow may be too small to notice—make a mark on the
tubing and observe the oil level after several minutes.
If the oil level oscillates back and forth, service the refill
valve as per Section 4.4.2. Be sure to stop the
pump before the oil in the line depletes or else
air will be introduced into the hydraulic system.
— Bad air bleed valve. Disconnect the piping that
connects the air bleed valve to the pump. Attach a
section of 3/8” OD clear tubing to the air bleed valve.
Fill it with enough oil to fill the tubing connector, so that
the oil level can be seen through the tubing. If the oil
level in the tubing increases a small amount with each
stroke, it is performing correctly. However, oil does not
always flow out through the valve. Depending on the
suction conditions of your pump, you may not notice oil
flowing through the air bleed valve. Over time, you
should see small air bubbles coming up the tubing.
Make a mark on the tubing and observe the oil level
after several minutes. If the oil level does not change
and you do not notice any air bubbles coming out, the
air bleed valve could be clogged—service it according to
Section 4.4.3. If an excessive amount of oil is flowing
through the air bleed valve, it may not be sealing
properly—service it as per Section 4.4.3.
— Clogged refill line. Remove strainer from oil filter and
clean or replace, as per Section 4.3.2.
26
Insufficient delivery (cont’d). . . . . . . . . . . . .
•
Relief valve relieving.
— System shut-off valve closed. Open valve.
— Blocked discharge piping. Clear line.
— External back pressure valve set too high. Reset valve.
— Internal relief valve set too low. Adjust valve to
operating conditions. See Section 3.2.
— Diaphragms are stuck forward. Relieve system
pressure from the pump. Install a pressure gauge and
back pressure valve into the discharge line and bypass
the system by pumping into a bucket or other
temporary container. Set the back pressure valve so
that it develops at least 35 psi more than the suction
pressure, but make sure that the pressure setting is
much less than the normal operating pressure of the
pump. If the relief valve continues to relieve, replace
the diaphragms and seals according to Section 4.3.4.
Make sure that you tighten the head bolts to the
appropriate torque value—over torqueing can cause the
diaphragms to stick forward.
•
Leaky check valves. Install a shut off valve and column in
the suction line, near to the inlet of the pump. Close the
shut off valve so that the pump draws from the column.
The chemical should drop with each pump stroke. If the
level drops and then rises a little, the check valves could be
leaking. Service the check valves according to section 4.3.3.
•
Oil contamination. Condensation or gear oil may have mixed
with the hydraulic oil. It is necessary that the appropriate
synthetic hydraulic oil be used in the catch-all of the pump.
Replace oil as per Section 4.3.1.
Leak detection port leaking . . . . . . . . . . . . . . . •
Diaphragm failure. Leak detection switch is tripped and/or
chemical is being pumped out of the leak detection port.
Replace the diaphragms and seals according to Section
4.3.4.
Leaky valve . . . . . . . . . . . . . . . . . . . . . . . . . . •
Chemical or oil is leaking from the joint between the pump
and one of the valves. Remove the valve and inspect the
seal. Some of the valves are attached with HIP style coned
tubing. Inspect and clean the sealing surface. Some of the
valves have face seal O-rings. Inspect and replace the Oring.
Erratic delivery . . . . . . . . . . . . . . . . . . . . . . . . •
•
•
Leaky relief valve. Repair or replace valve.
Blocked suction line. Clean line, particularly the line strainer.
Insufficient NPSH. Most common with long suction lines,
small diameter suction lines, acid pumping, polymer
(viscous) liquids, or drawing from a source lower than the
pump. Consult your local representative or the Milton Roy
factory.
27
SECTION 6 – PARTS
Please refer to the bill of material and assembly drawing for spare parts. Use the assembly drawing to
identify the sequence number for the desired part. The sequence number is used on the drawing and the Bill of
Material. When ordering parts, please refer to the parts ordering instructions listed under “Recommended Spare
Parts” in the Maintenance Section (Section 4.1). Be sure to include all required information with your parts order,
or Milton Roy Company may be unable to process your order.
28
SECTION 7 - LIMITED WARRANTY
The Milton Roy Company (“Company”) warrants that its pumping products will be free from defects in title, and
so far as of its own manufacture, will be free from defects in materials and workmanship for a period of thirty six
months from shipment by the Company. The Company additionally warrants that all of its other products,
including actuators, will be free from defects in title, and so far as of its own manufacture, will be free from
defects in materials and workmanship for a period of twelve months from shipment by the Company. The
Company will, at its option, repair or replace its products provided the Company’s inspection reveals the products
to have been defective or nonconforming within the terms of this warranty. This warranty is expressly
conditioned upon the following: (a)proper installation, maintenance, and use under the Company specified
service conditions, (b)prompt notice of nonconformance or defect, (c)the Company’s prior written authorization
for return, (d)the products being returned to the Company, or at the Company’s discretion, to a Factory
Authorized Service Center, all at no cost to the Company. The Company will deliver repaired or replacement
products Ex Works its factory or Factory Authorized Service Center. Products not of the Company’s manufacture
are warranted only to the extent provided by the original manufacturer. The Company shall not be liable for
damage of any kind resulting from erosive, corrosive or other harmful action of any liquids, gases, or any other
substance handled by the Company’s products.
THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, OBLIGATIONS, OR LIABILITIES,
WHETHER EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR ANY INCIDENTAL,
CONSEQUENTIAL, OR SPECIAL DAMAGES, LOSSES, OR EXPENSES ARISING FROM THIS CONTRACT,
ITS PERFORMANCE, OR IN CONNECTION WITH THE USE OF, OR INABILITY TO USE THE COMPANY’S
PRODUCTS.
The liability of the Company in respect of all damages, losses, costs or expenses, whether suffered or incurred by
the Purchaser or any third party arising in any manner or incident related to this contract or the performance
hereunder, shall be limited in the aggregate to the actual price paid by the Purchaser to the Company.
Revision A
17 March 1998
29
www.miltonroy.com
201 Ivyland Road • Ivyland, PA 19874 USA • (215) 441-0800 • Fax: (215) 441-8620 • E-mail [email protected]
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