0076 macroy d - pump supply inc

339-0076-000ISSUED 01 MAY 2010

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Model Number: _____________________________________

Serial Number: _____________________________________

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INSTALLATION,OPERATION, ANDMAINTENANCEMANUAL

MILTON ROY

MacRoy DMETERINGPUMP

i

Precautions

For Pumps with PVC & 316SS Liquid Ends

WHEN USED IN SWIMMING POOLS OR SPAS/HOT TUBS (ANSI/NSF 50)

1. Caution on Chemical Concentration: There is a potential for elevated chemical concentration during periods of no flow, for example, during backwash in the system. Steps, such as turning the pump off, should be taken during operation or installation to prevent this. Contact your sales representative or distributor about other external control options to help mitigate this risk.

2. Flow Indicating Device: To ensure operation of the pump it is recommended that some type of Flow Indicating Device be installed to measure water flow rates and be appropriate for the output of the pump. Contact your distributor or sales representative for further information. 3. Head Loss / Over Pressure Protection / Back Pressure-Anti-Siphon Valve: 3.1 Milton Roy metering pumps are positive displacement. Head loss is not applicable to the pump. 3.2 To ensure safe operation of the pump it is recommended that some type of safety/pressure-relief valve be installed to protect the piping and other system components from failing due to excessive pressure. 3.3 If you are pumping downhill or into low or no system pressure, a back pressure/anti-siphon device should be installed to prevent over pumping or siphoning. Contact your distributor or sales representative for further information. 4. Additional Operation and Installation Instructions for 316SS or PVC Liquid Ends: 4.1 Application of this pump to swimming pool/spas only evaluated to NSF/ANSI 50. 4.2 There is a potential for elevated chemical concentration during periods of no flow, for example, during backwash in the system. Steps, such as turning the pump off, should be taken during operation or installation to prevent this. See your sales representative or distributor about other external control options to help mitigate this risk. 4.3 Liquid Compatibility CAUTION: Determine if the materials of construction included in the liquid handling portion of your pump are adequate for the solution (chemical) to be pumped. ALWAYS wear protective clothing, face shield, safety glasses and gloves when working on or near your metering pump. Additional precautions should be taken depending on the solution being pumped. Refer to MSDS precautions from your solution supplier. Reference a Milton Roy Material Selection Chart for aid in selecting appropriate material of construction for fluids of your specific metering pump. Contact your sales representative or distributor for further information.

!

!

!

!

The following precautions should be taken when working with all metering pumps. Please read this section carefully prior to installation. Protective Clothing

ALWAYS wear protective clothing, face shield, safety glasses and gloves when working on or near your metering pump. Additional precautions should be taken depending on the solution being pumped. Refer to Material Safety Data Sheets for the solution being pumped.

Hearing Protection

! It is recommended that hearing protection be used if the pump is in an environment where the time-weighted average sound level (TWA) of 85 decibels is exceeded. (as measured on the A scale -- slow response)

Electrical Safety

!

• Remove power and ensure that it remains off while maintaining pump. • DO NOT FORGET TO CONNECT THE PUMP TO EARTH • Electric protection of the motor (Thermal protection or by means of fuses) is to correspond to

the rated current indicated on the motor data plate.

Liquid Compatibility

!

Verify if the materials of construction of the wetted components of your pump are recommended for the solution (chemical) to be pumped.

Pumps Water “Primed”

!

All pumps are tested with water at the factory. If your process solution is not compatible with water, flush the Pump Head Assembly with an appropriate solution before introducing the process solution

Plumbing and Electrical Connections

! Always adhere to your local plumbing and electrical codes.

Line Depressurization

!

To reduce the risk of chemical contact during disassembly or maintenance, the suction and discharge lines should be depressurized before servicing.

Over Pressure Protection

! To ensure safe operation of the system it is recommended that some type of safety/pressure-relief valve be installed to protect the piping and other system components from damage due to over-pressure.

Lifting

! This manual should be used as a guide only - Follow your company’s recommended lifting procedures. It is not intended to replace or take precedence over recommendations, policies and procedures judged as safe due to the local environment than what is contained herein.

! Use lifting equipment that is rated for the weight of the equipment to be lifted.

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General Precautions For All Pumps

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TABLE OF CONTENTS

iii

SECTION DESCRIPTION PAGE

MacRoy D Pump Model Number and Options ..............................................................................................v

1.0 DESCRIPTION ............................................................................................................................................ 1

1.1 General Information ........................................................................................................................... 1

1.2 Principles of Operation...................................................................................................................... 2

1.3 General Specifications ...................................................................................................................... 3

2.0 INSTALLATION........................................................................................................................................... 5

2.1 Unpacking ........................................................................................................................................... 5

2.2 Storage ................................................................................................................................................ 5

2.3 Safety Precautions ............................................................................................................................. 5

2.4 Mounting ............................................................................................................................................. 6

2.5 Drip Collection .................................................................................................................................... 6

2.6 Installation .......................................................................................................................................... 6

2.6.1 NPSH Considerations ............................................................................................................... 8

2.6.2 General Piping Considerations ............................................................................................... 8

2.6.3 Suction Piping Considerations................................................................................................ 8

2.6.4 Discharge Piping Considerations............................................................................................ 9

2.7 Valves .................................................................................................................................................. 9

2.8 Electrical Connections ..................................................................................................................... 10

3.0 OPERATION ............................................................................................................................................. 11

3.1 Start-Up Procedures and Checks.................................................................................................... 11

3.2 Checking the Electrical Connection of the Motor.......................................................................... 11

3.3 Start-Up .............................................................................................................................................. 11

3.4 Capacity Calibration ........................................................................................................................ 11

4.0 MAINTENANCE......................................................................................................................................... 13

4.1 Preventative Ma intenance............................................................................................................... 13

4.2 Returning Pumps to the Factory for Repair ................................................................................... 13

4.3 Routine Maintenance ....................................................................................................................... 13

4.4 Spare Parts ....................................................................................................................................... 14

4.4.1 Size D2 Liquid Ends - PVC, PVDF, Polypropylene, Polymer, and H2SO4 ........................... 14

4.4.2 Size D2 Liquid Ends - PVC, PVDF, Polypropylene, Polymer, H2SO4, and Slurry .............. 15

4.4.3 Size D2 and D4 Liquid Ends - Stainless Steel ...................................................................... 15

4.4.4 Size D7 and D8 - PVC, PVDF, Polypropylene, H2SO4, Polymer, and Slurry Liquid Ends . 16

4.4.5 Size D7 and D8 - Stainless Steel Liquid Ends...................................................................... 16

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SECTION DESCRIPTION PAGE

4.5 Corrective Maintenance................................................................................................................... 16

4.5.1 Check Valve Replacement: Liquid Ends D2 and D4 - PVC, PVDF, H2SO4,and Polypropylene ................................................................................................................. 17

4.5.2 Check Valve Replacement: Liquid End Sizes D2 and D4 - Polymer .................................. 17

4.5.3 Check Valve Replacement: Liquid End Sizes D2 and D4 - Metallic ................................... 18

4.5.4 Check Valve Replacement: Liquid End Sizes D2 and D4 - Slurry ...................................... 18

4.5.5 Replacement of Ball, Seat, and Seal: Liquid End D7 and D8 - PVC, PVDF, H2SO4, andPolypropylene ......................................................................................................................... 19

4.5.6 Check Valve Replacement: Liquid End Size D7 and D8 - Polymer .................................. 20

4.5.7 Check Valve Replacement: Liquid End Size D7 and D8 - Slurry ...................................... 20

4.5.8 Check Valve Replacement: Liquid End Size D7 and D8 - Stainless Steel ....................... 20

4.6 Diaphragm and Oil Seal Bellows Replacement ........................................................................... 20

4.6.1 Diaphragm Replacement: Liquid End Size D2 ................................................................... 21

4.6.2 Diaphragm Replacement: Liquid End Size D4, D7, and D8 ............................................... 21

4.7 Oil Seal Bellows Replacement ....................................................................................................... 22

4.8 Restarting the Pump ........................................................................................................................ 23

5.0 PARTS LIST ............................................................................................................................................. 25

5.1 Parts List for Drive ............................................................................................................................ 27

5.2 Parts List for D2 Plastic Liquid End PVC, PVDF, Black Poly, H2SO4, and Polymer-NPT / PVC, PVDF, and Black Poly-Tubing. ......................................................................................................... 29

5.3 Parts List for D2 Metallic Liquid End Stainless Steel-NPT ............................................................ 30

5.4 Parts List for D4 Metallic Liquid End Stainless Steel-NPT ............................................................ 31

5.5 Parts List for D4 Plastic Liquid End PVC, PVDF, Black Poly, H2SO4, Slurry, and Polymer-NPT / PVC, PVDF, Black Poly, and H2SO4 -Tubing .................................................................................... 33

5.6 Parts List for D7 and D8 Plastic Liquid End PVC-NPT/Tubing, PVDF-NPT, Black Poly-NPT, Polymer-NPT, Slurry-NPT, & H2SO4-NPT. ......................................................................................... 37

5.7 Parts List for D7 and D8 316SS-NPT Liquid End ............................................................................. 39

5.8 Leak Detection Parts List ................................................................................................................. 42

6.0 TROUBLESHOOTING............................................................................................................................... 44

Change BarsThe areas in this manual which are different from previous editions are marked with change bars (asshown to the right of this paragraph) to indicate the addition of new or revised information.

v

Frame and Liquid End (D Frame)

Code DescriptionD2 0.3 mL/strokeD4 4.4 mL/strokeD7 18 mL/strokeD8 42 mL/stroke

Stroking Speed

Code Description1 43 SPM2 86 SPM6 120 SPM3 173 SPM8 180 SPM @1450 RPM

Motor

Code DescriptionX NEMA 56C Mount Less Motor8 115/230 VAC, 60 Hz,1 PH, 1725 RPM9 115/230 VAC, 50 Hz,1 PH, 1450 RPMJ 230/460 VAC, 60 Hz, 3 PH, 1725 RPML 220/380 VAC, 50 Hz, 3 PH, 1450 RPMM IEC 71 Frame F130 Less MotorP DC VSD & Motor

Liquid End Material

Code Description2 PVDF4 Black Polypropylene (UV Stable)7 316ss8 PVCP Polymer ServiceL Slurry ApplicationsN H2SO4 ApplicationsA Acrylic

MACROY D PUMP MODEL NUMBER AND OPTIONS

Fram

e an

d Li

quid

End

Stro

king

Spe

ed

Mot

or

Liqu

id E

nd M

ater

ial

Con

nect

ions

Cap

acity

Con

trol

Dou

ble

Dia

phra

gm

Bas

e

Stro

ke C

ount

ing

Connections

Code DescriptionP NPTT TubingB Outgassing Liquid Applications (NPT)C Outgassing Liquid Applications (Tubing)

Capacity Control

Code DescriptionM4 ManualE1 4-20ma, NEMA 4 115 VACE2 4-20ma, NEMA 4 230 VACEA 4-20ma, Ex Prf 115 VACEB 4-20ma, Ex Prf 230 VAC

Double Diaphragm

Code DescriptionN NoneD Double Diaphragm3 Double Diaphragm w/Gauge4 Double Diaphragm w/NEMA 4 Rupture

Detection7 Double Diaphragm w/NEMA 7 Rupture

Detection

Base

Code DescriptionN None1 Simplex Optional Base

Stroke Counting

Code DescriptionN None

SECTION 1DESCRIPTION

1

1.1 GENERAL INFORMATION

The MacRoy D is a reciprocating, chemical dosing pumpcapable of producing flows up to 115 gallons per hour(430 liters per hour) at pressures up to 175 psi (12 Bar).These pumps feature a mechanically actuated diaphragmliquid end, which eliminates the need for flow-restrictingcontour plates, and a stroke adjustment mechanismbased on the variable eccentric principle instead of thetraditional lost-motion design. It is designed for indus-trial service and offers an accuracy of ±1% of full ratedflow between 10% and 100% of its flow range.

The basic pump components as illustrated in Figure 1are:

• a drive device comprising a motor (1)

• a mechanical assembly (2)

• a liquid end (3).

An elastomeric bellows provides a leak-tight seal be-tween the mechanical assembly and the liquid end.

Capacity adjustment is manually controlled by a strokeadjustment knob (4).

Figure 1:Pump Assembly

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MotorMechanical AssemblyLiquid EndStroke Adjustment Knob

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Liquid End Mounting AssemblyCheck Valve Assembly (Suction)Check Valve Assembly (Discharge)Stroke Lock Knob

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7

3

6

2

8

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1.2 PRINCIPLES OF OPERATION

Drive Assembly (See Figure 2)

The pump consists of two major assemblies; the driveand the liquid end. Pump delivery is a function of thedrive's stroke rate, liquid end size and stroke length.Stroke length can be increased while the pump is run-ning by counterclockwise turning of the stroke adjust-ment knob. The drive assembly works on the principleof a variable eccentric. The rotational motion of the motoris transmitted by the worm (1) to the worm gear (2)which is linked to an eccentric system (3). The eccen-tric system then converts the rotary gear motion intolinear reciprocating motion of the connecting rod (4). At0% capacity setting, the connecting rod axis (B) isaligned with the gear axis (A) and no movement of theconnecting rod takes place. At 100% capacity setting,an eccentricity exists between the connecting rod axis(B) and the gear axis (A) which results in linear move-ment of the connecting rod and resulting pumpage.

Drive parts (See Fig.8 for limited drive parts available)are no longer sold by Milton Roy. When drive parts arefound to be bad a complete new painted pump bodywith all gears, stroke controls, etc can be purchasedfrom Milton Roy. The customer will only need to mountthe liquid end/motor from the existing pump.

Mechanically Actuated Diaphragm Liquid End(See Figure 2)

The diaphragm assembly (5) is mechanically linked tothe connecting rod (4) and has the same reciprocatingmotion. As the diaphragm starts back on the suctionstroke, the pressure immediately drops inside the liq-uid end. When the pressure in the liquid end dropsbelow the suction line pressure, the suction ball checkis “pushed” upward and the process fluid in the suctionline flows into the liquid end chamber (diaphragm head).When the suction stroke ends, the diaphragm move-ment momentarily stops and the pressure in the liquidend equalizes with the pressure in the suction line caus-ing the suction ball check to reseat.

NOTE: It is important that the pressure in theliquid end remain above the vapor pressure ofthe process fluid during the suction stroke. Ifthe fluid pressure drops below the vapor pres-sure, cavitation will occur which will have a nega-tive impact on the performance of the pump.If you suspect the possibility of cavitation, con-tact Milton Roy Company for assistance.

Figure 2:Stroke Control OperatingPrinciple

(A) (B)

(A) (B)

(A) (B)

Zero Stroke Setting

Discharge PhaseSuction Phase

Setting to Maxmum Stroke

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WormWorm GearEccentricConnecting Rod

5678

DiaphragmStroke: two times the distance between (A) and (B)Position at rear neutral pointPosition at forward neutral point

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2

4

5

3

7 68

2

3

As the diaphragm starts forward on the discharge strokethe pressure immediately rises inside the liquid end.When the liquid end pressure rises above the dischargeline pressure, the discharge ball check is “pushed” up-ward and the process fluid in the liquid end flows intothe discharge line. When the discharge stroke ends,the diaphragm momentarily stops again. The pressurein the liquid end equalizes with the discharge line pres-sure and the discharge ball check reseats. The cyclethen starts again.

1.3 GENERAL SPECIFICATIONS

FLOW RATE:

Up to 115 GPH (430 L/H)

PRESSURE:

Up to 175 PSIG (12 BAR)

LIQUID END TYPE:

Mechanically Actuated Diaphragm

DRIVE TYPE:

Variable Eccentric

STEADY STATE ACCURACY:

±1% of pump full rated capacity between 10% and 100%of rated capacity.

CAPACITY ADJUSTMENT:

Lockable stroke adjustment knob is adjustable from 0%to 100% while pump is running.

LUBRICATION:

Drive is lubricated in an oil bath (Mobil SHC 629, 1 Quart).

TEMPERATURE:

Ambient and Liquid:

122 0F (50 0C) Maximum

14 0F (-10 0C) Minimum

SUCTION LIFT:

6.6 Ft (2 meters) of water column maximum

11.5 psia minimum internal pressure (3.2 psi maximumvacuum)

PAINT:

Powder Coating

WEIGHT:

38 lb (17.2 kg) Without EEC

48 lb (21.8 kg) With EEC

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THIS PAGE INTENTIONALLY BLANK

SECTION 2INSTALLATION

5

2.1 UNPACKING

Pumps are shipped f.o.b. factory or representative ware-house and the title passes to the customer when thecarrier signs for receipt of the pump. In the event thatdamages occur during shipment, it is the responsibilityof the customer to notify the carrier immediately and tofile a damage claim. Carefully examine the shippingcrate upon receipt from the carrier to be sure there is noobvious damage to the contents. Open the crate care-fully so accessory items fastened to the inside of thecrate will not be damaged or lost. Examine all materialinside the crate and check against packing list to besure that all items are accounted for and intact.

2.2 STORAGE

Short Term Storage (Less than 6 Months)

It is preferable to store the material under a shelter in itsoriginal package to protect it from adverse weather con-ditions. In condensing atmospheres, follow the long termstorage procedure.

Long Term Storage (Longer than 6 Months)

The primary consideration in storage of pump equipmentis to prevent corrosion of external and internal compo-nents. This corrosion is caused by natural circulationof air as temperature of the surroundings change fromday to night, day to day, and from season to season. Itis not practical to prevent this circulation which carrieswater vapor and other corrosive gasses, so it is neces-sary to protect internal and external surfaces from theireffects to the greatest extent possible.

When the instructions given in this section are com-pleted, the equipment is to be stored in a shelter; pro-tected from direct exposure to weather. The preparedequipment should be covered with a plastic sheet or atarpaulin, but in a manner which will allow air circulationand prevent capture of moisture. Equipment should bestored 12 inches or more above the ground.

If equipment is to be shipped directly from Milton Royinto long term storage, contact Milton Roy to arrangefor factory preparation.

Pump Drive

1. Remove motor and flood the gearbox compartment(Item 2 in Figure 1) with a high grade lubricating oil/rustpreventative such as Mobile Oil Corporation productMobilarma 524. Fill the compartment completely to mini-mize air space and water vapor condensation. After stor-age, drain this material and refill the equipment with therecommended lubricant for equipment commissioning.

2. Brush all unpainted metal surfaces with multipurposegrease (NLGI grade 2 or 3). Store these unattached.

Electrical Equipment

1. Motors should be prepared in the manner prescribedby their manufacturer. If information is not available,dismount and store motors as indicated in step 3 be-low.

2. Dismount electrical equipment (including motors) fromthe pump.

3. For all electrical equipment, place packets of VaporPhase Corrosion Inhibitor (VPCI) inside of the enclo-sure, then place the entire enclosure, with additionalpackets, inside a plastic bag. Seal the bag tightlyclosed. Contact Milton Roy Service Department for rec-ommended VPCI materials.

2.3 SAFETY PRECAUTIONS

WHEN INSTALLING, OPERATING, ANDMAINTAINING THIS MACROY D PUMP, KEEPSAFETY CONSIDERATIONS FOREMOST.USE PROPER TOOLS, PROTECTIVE CLOTH-ING, AND EYE PROTECTION WHEN WORK-ING ON THE EQUIPMENT AND INSTALL THEEQUIPMENT WITH A VIEW TOWARD ENSUR-ING SAFE OPERATION. FOLLOW THE IN-STRUCTIONS IN THIS MANUAL AND TAKEADDITIONAL SAFETY MEASURES APPRO-PRIATE TO THE LIQUID BEING PUMPED. BEEXTREMELY CAREFUL IN THE PRESENCEOF HAZARDOUS SUBSTANCES (E.G., COR-ROSIVES, T OXINS, SOLVENTS, ACIDS,CAUSTICS, FLAMMABLES, ETC.).

THE PERSONNEL RESPONSIBLE FOR IN-STALLATION, OPERATION AND MAINTE-NANCE OF THIS EQUIPMENT MUST BECOMEFULLY ACQUAINTED WITH THE CONTENTSOF THIS MANUAL.

ANY SERVICING OF THIS EQUIPMENT MUSTBE CARRIED OUT WHEN THE UNIT ISSTOPPED AND ALL PRESSURE HAS BEENBLED FROM THE LIQUID END. SHUT-OFFVALVES IN SUCTION AND DISCHARGESIDES OF THE LIQUID END SHOULD BECLOSED WHILE THE UNIT IS BEING SER-VICED. ACTIONS SHOULD BE TAKEN TOELIMINATE THE POSSIBILITY OF ACCIDEN-TAL START-UP WHILE SERVICING IS TAK

ING PLACE. A NOTICE SHOULD BE POSTEDBY THE POWER SWITCH TO WARN THATSERVICING IS BEING CARRIED OUT ON THEEQUIPMENT. SWITCH OFF THE POWERSUPPLY AS SOON AS ANY FAULT IS DE-TECTED DURING OPERATION (EXAMPLES:ABNORMALLY HIGH DRIVE TEMPERATURE,UNUSUAL NOISE, DIAPHRAGM FAILURE).

2.4 MOUNTING

Support the pump firmly in a level position on a solid,vibration-free foundation. The pump should preferablybe positioned with the base above floor level to protectthe pump from wash downs and to provide easier ac-cess for service. Be sure to allow enough space aroundthe pump for easy access during maintenance opera-tions and pump adjustments.

MacRoy D pumps are provided with mounting holes toaccommodate anchor bolts. Refer to Figure 3 for mount-ing hole dimensions.

Pumps installed outdoors should be protected by a shel-ter.

2.5 DRIP COLLECTION

In the event of a failure of the diaphragm or oil seal bel-lows, provisions need to be made to contain the pro-cess fluid or pump oil. This is particularly importantwhen handling fluids which may be harmful to plant per-sonnel.

To collect fluid in the event of a diaphragm or oil sealrupture, (See Figure 1) position a tray under the plainhole located at the bottom of the liquid end mountingassembly (5). For D7 or D8 pumps, position tray undertube fitting located at bottom of liquid end mountingassembly. Alternatively, a tube may be installed ontothis tube fitting to drain any leakage to a suitable con-tainer.

2.6 INSTALLATION

Figure 4 displays typical installations (both correct andincorrect). Figure 5 illustrates the recommended pipingand accessories in a metering pump installation.

As illustrated in the upper right portion of Figure 4, theremust be no swan-necks or stagnant volumes in the suc-tion line. In this illustration, the loop at the top of thetank forms an air trap. Eventually, air or gases will bubbleout of solution and accumulate in the trap leading to aloss of prime condition.

6

Figure 3:MacRoy DDimensional Outline

3

12345

TankFoot Valve (with Filter)Metering PumpProcess PipingBleed Valve

6789-

Injection NozzleShut-off ValveFilterPulsation Damper-

Figure 4:Typical Installation

46

5 3

1

2

15

4

6

3

1

4

9

3

5

87

6

7

2.6.1 NPSH CONSIDERATIONS

Size piping to accommodate peak instantaneous flow.Because of the reciprocating motion of the pump dia-phragm, peak instantaneous flow is approximately equalto 5 times the average flow. For example, a pump ratedfor 16 gallons per hour (61 L/hr.) requires piping suffi-cient for 5 x 16 gph, or 80 gph (303 L/hr.).

To minimize viscous flow losses when handling viscousliquids, it may be necessary to use suction piping up tofour times larger than the size of the suction connectionon the pump. If in doubt, contact your nearest MiltonRoy Company representative to determine the neces-sary pipe size.

2.6.2 GENERAL PIPING CONSIDERATIONS

Use extreme care in piping to plastic liquid end pumpswith rigid pipe such as PVC. If excessive pipe stress orvibration is unavoidable, flexible connections are rec-ommended.

Use piping materials that will resist corrosion by theliquid being pumped. Use care in selecting materials toavoid galvanic corrosion at pump liquid end connections.

Use piping heavy enough to withstand maximum pres-sures. Remove burrs, sharp edges, and debris frominside piping. Blow out all pipelines before making finalconnections to pump.

Because vapor in the liquid end will cause inaccuratepump delivery, piping should be sloped up from pumpsuction check to the supply tank to prevent formation ofvapor pockets.

When pumping suspended solids (such as slurries), in-stall plugged crosses at all 90° line turns to permit linecleaning without dismantling piping.

See Figure 5 for a typical recommended pump installa-tion scheme.

2.6.3 SUCTION PIPING CONSIDERATIONS

It is preferable to have the suction of the pump floodedby locating the liquid end below the lowest level of theliquid in the supply tank.

To minimize the chances of a loss-of-prime condition,the pump should be installed as close as possible tothe supply vessel.

Avoid negative suction pressure conditions (suction lift),as such conditions adversely affect metering accuracy.A lift of 6.6 feet (2 meters) of water column is the maxi-mum permissible suction lift.

MacRoy D pumps are designed to operate with processliquid supplied at or above atmospheric pressure. Al-though these pumps can move liquids supplied at lessthan atmospheric pressure (suction lift), in these nega

Figure 5:General Piping

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3

2.7 VALVES

Back Pressure Valves

All metering pumps are prone to overpumping (exces-sive output) at low discharge pressures. To prevent thiscondition from occurring, it is necessary to maintainapproximately 10 psi (0.7 bar) back pressure againstthe pump. This can be accomplished through the in-stallation of a back pressure valve in the discharge line.Typically, the valve should be located near the pump.However, back pressure valves for large pumps with longand extremely small discharge lines may have to beinstalled near the point of discharge into the process (tominimize siphoning tendencies).

Pulsation Dampeners

An accumulator, surge chamber, surge suppressor, orpulsation dampener should be used with the back pres-sure valve in the discharge line to absorb the flow peaksbetween the pump and the back pressure valve. With-out the pulsation dampener the valve mechanism willsnap open and close with the surge from each pumpstroke. The pulsation dampener will allow the back pres-sure valve to oscillate about a partly-closed position,thus minimizing wear on the valve. Discharge line pul-sation dampeners offer the further advantage of limitingthe flow and pressure variations characteristic of thiskind of pump. Installing a properly sized pulsation damp-ener will improve pump performance and may reducesystem costs dramatically by permitting the substitu-tion of smaller piping. Please contact Milton Roy Com-pany for further information on pulsation dampeners.

Safety Valves and Priming Valves

Motor-driven positive displacement pumps can developexcessive discharge pressures long before thermal over-load devices interrupt the motor electrical circuit. Toprevent a blocked discharge line from causing damageto the pump, piping, or process equipment, install asafety valve in the pump discharge line. This valve isdesigned and sized to handle system flow rates andpressures safely while resisting corrosion by the pro-cess liquid.

To aid in pump start-up, it is advisable to install a prim-ing valve on the discharge side of the liquid end.

Shut-off Valves

Provide shut-off valves in both suction and dischargelines next to the pump. Locate discharge line shut-offvalve downstream from the inlet connection of the safetyvalve. Figure 5 shows recommended valve locations.

tive pressure applications it is important that all con-nections be absolutely drip free and vacuum tight, andthat a foot valve be installed at the bottom of the suctionline (see upper left illustration of Figure 4).

When pumping a liquid near its boiling point, provideenough suction head to prevent the liquid from “flash-ing” into vapor when it enters the pump liquid end on thesuction stroke.

If possible, use metal or plastic tubing for the suctionline because tubing has a smooth inner surface andcan be formed into long, sweeping bends to minimizefrictional flow losses.

A strainer should be used in the suction line to preventforeign particles from entering the liquid end. This andany other measures which prevent debris from enteringand fouling the liquid end check valves will give increasedmaintenance-free service. Check strainer frequently toprevent blockage which could lead to cavitation. Keepsuction piping as short and straight as possible.

Piping size should be larger than the liquid end suctionfitting to prevent pump starvation.

If long suction lines are unavoidable, install a stand pipenear the pump in the suction line.

Suction piping must be absolutely airtight to ensure ac-curate pumping. After installation, test suction pipingfor leaks with air and soap solution.

2.6.4 DISCHARGE PIPING CONSIDERATIONS

Install pipe large enough to prevent excessive pressurelosses on the discharge stroke of the pump. Maximumpressure at the discharge fitting on the liquid end mustbe kept at or below the rated pressure (shown on thepump nameplate).

The pump will not deliver a controlled flow unless thedischarge line pressure is 10 psi greater than the suc-tion line pressure. One way to create an artificial pres-sure is the installation of a back pressure valve. (Pleasecontact your Milton Roy representative for recommen-dations to increase back pressure in slurry applications).

When pumping water treatment chemicals directly intoboiler drums, use one liquid end assembly for each boilerdrum. Discharging into a manifold having the slightestpressure difference between its several discharge con-nections can diminish metering accuracy as the outletwith the lowest pressure will receive more liquid thanthe other outlets.

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xiv

2.8 ELECTRICAL CONNECTIONS

OPERATION WITH THE WRONG MOTOR RO-TATION MAY DAMAGE THE PUMP AND MO-TOR AND VOID THE WARRANTY.

DO NOT FORGET TO CONNECT THE EARTHTERMINAL ON THE MOTOR TO THE EQUIP-MENT EARTH CONDUCTOR.

Ensure that the electrical supply matches the pumpmotor nameplate characteristics. Connect the motorin accordance with the instructions and connection dia-grams on the motor (or in the motor terminal box).

Note: Before operating the pump, check thedirection of rotation of the motor to be sure itmatches the direction of the arrow on the motorfan cover (rotation should be clockwise whenviewed from the top of the motor).

The electrical protection installed for the motor (fuse orthermal protection) must be suitable for the motor's ratedcurrent.

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SECTION 3OPERATION

xv

3.1 START-UP PROCEDURES AND CHECKS

Check that the pump is secured to its support.

If oil was previously removed for any reason, make surepump drive has the correct volume (1 quart) of oil (MobilSHC 629).

Make sure all isolation valves installed on the suctionand discharge lines are open. If the discharge line isequipped with an injection nozzle or a back-pressurevalve, open the priming valve for discharge (if there is nopriming valve, disconnect the discharge pipe). This al-lows for verification that liquid is present in the liquidend when the pump is installed in flooded suction con-dition. If the pump is installed in a suction lift condition,this allows for priming of the pump during start-up.

Make sure that pump is set at 0% capacity.

3.2 CHECKING THE ELECTRICAL CONNECTION OFTHE MOTOR

Start up the pump to check the motor's direction of rota-tion. It must comply with that indicated by the arrowmarked on the motor fan cover (clockwise as viewedfrom the top of the motor). If the rotation is incorrect,refer to Section 2.8 Electrical Connections.

3.3 START-UP

FAILURE TO CHECK TORQUE ON NON-ME-TALLIC HEAD BOLTS PRIOR TO STARTUPAND AFTER ONE WEEK OF OPERATION MAYEXPOSE OPERATING PERSONNEL TO HAZ-ARDOUS LIQUIDS.

Check the torque on all non-metallic head bolts prior tostartup. Recheck torque on all non-metallic head boltsafter pump has been operating for one week. Torque thehead assembly screws in a crosswise pattern as fol-lows:

a) Liquid End Size D2 and D4 to 45 inch pounds.

b) Liquid End Size D7 and D8 to 90 inch pounds

Once all the checks and procedures described abovehave been carried out, start the pump.

Conduct a visual and audio check of the pump (in par-ticular, listen for the presence of any “suspicious” noises).

Make sure that the stroke adjustment knob is unlocked.

Gradually increase the capacity until liquid can be seen

flowing from the priming valve. If no priming valve is inplace, when the liquid end is primed, the dischargecheck valves can be heard to be operating (should heara clicking noise caused by movement of check valveballs). When liquid end is primed, stop the pump andclose the priming valve.

Adjust the pump to the desired capacity. Lock the strokeadjustment knob (Item 8 in Figure 1).

3.4 CAPACITY CALIBRATION

After the first 12 hours of operation, the pump may betested and calibrated to find the exact pump capacityunder specific operating conditions. Usually, calibrat-ing the pump at only 100, 50, and 10 percent capacitysettings is enough to indicate pump performance through-out the adjustment range.

The pump can be calibrated by measuring the decreasein liquid level pumped from a calibrated vessel. Thismethod is recommended for hazardous liquids becauseit eliminates operator contact with the liquid. Calibra-tion columns are available for convenient and accuratecalibration of the pump. Contact your local Milton Royrepresentative for more information.

THIS METHOD IS GENERALLY NOT RECOM-MENDED AS IT MAY EXPOSE OPERATINGPERSONNEL TO HAZARDOUS LIQUIDS.FURTHERMORE, IF NO BACK PRESSURE ISPRESENT ON THE DISCHARGE SIDE, THEPUMP MAY OVERPUMP DRAMATICALLY INWHICH CASE THE POSITION OF THE CA-PACITY ADJUSTMENT KNOB MA Y HAVELITTLE EFFECT ON ACTUAL FLOW RATE.

FOR SAFETY REASONS, A CHECK VALVEIS RECOMMENDED FOR USE IN THE DIS-CHARGE LINE NEAR THE POINT WHERETHE LINE ENTERS A HIGH-PRESSURE PRO-CESS VESSEL.

The pump can also be calibrated by collecting and mea-suring pumped liquid at the pump discharge port. Itmay be necessary to create backpressure at the col-lection point to allow for proper pump operation (seeSection 2.7 Back Pressure Valves for recommenda-tions).

11

xvi12

Figure 6. Drive Assembly

METI.ON

ERUTALCNEMON METI.ON



ERUTALCNEMON

01 gnisuoH 011 cirtneccEelameF 091 gnir-O 533 rekcitS11 teksaG 111 niPgnirpS 002 revoCediS 043 gniraeB91 gnir-O 021 yeKtsujdAekortS 502 wercS 243 mroW02 gulPniarDliO 121 yeKraeG 602 rehsaW 643 gnilpuoCrotoM05 raeG 031 gniRgniniateR 013 llaBkcoLekortS 743 wercS06 doRgnitcennoC 041 gniraeB 023 wercSkcoLekortS 063 wercSteS001 cirtneccEelaM 051 gniRgniniateR 223 gnir-O 015 gulPrehtaerB101 tfahSevirD 061 laeS 033 bonK.jdAekortS201 niPgnirpS 071 wercS.jdAekortS 233 wercS

SECTION 4MAINTENANCE

xvii

4.1 PREVENTATIVE MAINTENANCE

Drive

Initially, change the oil in the pump drive assembly afterthe first 1000 hours of operation. Thereafter, changedrive oil on an annual basis or after every 5000 hours ofoperation.

The drive should be refilled with 1 quart of Mobil SHC629:

Viscosity @ 100 oF = 726 SSU

Viscosity Index = 149

ISO Grade = 150

Diaphragm Assembly

The MacRoy D diaphragm should be replaced annuallyor every 5000 hours of operation to avoid the possibilityof failure. Refer to the instructions in Section 4.6 Dia-phragm and Oil Seal Bellows Replacement.

Oil Seal Bellows

The MacRoy D oil seal bellows should only be replacedif failure of the bellows has occurred. Oil seal bellowsreplacement requires the removal of the diaphragm as-sembly, so it is recommended that the oil seal and dia-phragm assembly be replaced at the same time. Referto the instructions in Section 4.6 Diaphragm and OilSeal Bellows Replacement.

Check Valves

As in the case of the diaphragm, Milton Roy Companyrecommends that check valve balls, seats, gaskets, andO-rings be replaced on an annual basis or every 5000hours of operation. If highly corrosive material (acids,slurries, etc.) is being pumped, more frequent replace-ment may be required. Complete instructions for re-placement of worn check valves are given in Section4.5 Corrective Maintenance.

4.2 RETURNING PUMPS TO THE FACTORY FORREPAIR

Pumps can not be accepted for repair without a ReturnMaterial Authorization. Pumps should be clearly labeledto indicate the liquid being pumped. Process liquidshould be flushed from the pump liquid end and oil shouldbe drained from the pump housing before the pump isshipped.

Note: United States of America Federal lawprohibits handling of equipment that is not ac-companied by an OSHA Material Safety DataSheet (MSDS). A completed MSDS must be

packed in the shipping crate with any pumpshipped for repair. These safety precautionswill aid the troubleshooting and repair proce-dure and preclude serious injury to repair per-sonnel from hazardous residue in pump liquidend. A Materials Safety Data Sheet must ac-company all returns.

All inquiries or parts orders should be addressed to yourlocal Milton Roy representative or distributor.

4.3 ROUTINE MAINTENANCE

Milton Roy MacRoy D pumps are carefully designed,manufactured, and assembled to give reliable servicewith minimal maintenance. However, a weekly mainte-nance check is recommended to confirm proper opera-tion of the pump.

Visual Check of Seal Integrity of MechanicalAssembly, Figure 6.

Check for leaks in the following components. If leaksexist, contact Milton Roy for assistance.

1. Motor flange: If leaking, replace motor flange sealinggasket (Item 11 in Figure 6).

2. Stroke adjustment knob: If leaking, replace strokeadjustment seal (Item 160 in Figure 6).

Checking the Pump Capacity

Assuming the pump has been calibrated as describedin Section 3, the capacity can be checked by shuttingthe valve from the supply vessel and opening the valvefrom the calibration column to the suction side of theliquid end. Measure the volume of pumped liquid for agiven period of time at the various settings.

If a calibration column is not installed in the suctionpiping, place the foot valve (or suction line) in a calibrat-ing chamber (graduated reservoir). Measure the volumeof pumped liquid for a given period of time at the varioussettings.

Occurrence of Leak From Detection Ports

Determine whether the product collected at the detec-tion port in the liquid end mounting assembly is lubri-cating oil or the pumped fluid.

If the product is pumped fluid, the diaphragm has failed.If the product is lubricating oil, the oil seal bellows hasfailed. Proceed with its replacement (see Section 4.6Diaphragm and Oil Seal Bellows Replacement).

13

4.4 SPARE PARTS

The following spare parts should be stocked for eachpump to prevent serious delays in repairs. (Refer toFigures 7 thru 15).

Parts orders must include the following:

1. Quantity required

2. Part number

3. Part description

4. Pump serial number (found on nameplate)

5. Pump product code (found on nameplate)

Note: Always include the serial number andproduct code in all correspondence regardingthe unit.

4.4.1 SIZE D2 LIQUID ENDS - PVC, PVDF,POLYPR0PYLENE, POLYMER, AND H2SO4.

Liquid End Kit for D2 PVC/PVDF/Polypropylene

RPM 099, Includes:

1 each, Diaphragm: Item 260 in Figure 9.

1 each, Oil Seal Bellows: Item 70 in Figure 9.

2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item422, Cartridge: Item 426 and Washer: Item 427 inFigure 9.

Liquid End Kit for D2 Polymer

RPM 196, Includes:



14

Figure 7:Diaphragm AssembliesBy Liquid End Size and Material

D2 D4 (Plastic)

D7 and D8 D4 (316SS)

260252

260

240

274

271

250

270

260

274

271

250270

253

240

251

271

274

270

250

240

260

3

2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item422, Cartridge: Item 426, Washer: Item 427 andSpring: Item 428 (Discharge Only) in Figure 9.

Liquid End Kit for D2 H2SO4

Includes:



2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item422, Cartridge: Item 426, and Washer: Item 427Figure 9.

Liquid End Kit for D2 PVC/PVDF Double Diaphargm

RPM 161, Includes:




2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item422, Cartridge: Item 426 and Washer: Item 427 inFigure 9.

4.4.2 SIZE D4 LIQUID ENDS - PVC, PVDF, POLY-PROPYLENE, POLYMER, H2SO4, AND SLURRY.

Liquid End Kit for D4 PVC/PVDF/Polypropylene

RPM 102, Includes:



1 each, PTFE Washer: Item 274 in Figure 12.

2 each, Cartridge Assy.: (P/N 36306) Included inKit.

Liquid End Kit for D4 Polymer

RPM 196, Includes:




2 each, O-Ring: Item 419, Seat: Item 420, Ball: Item422, Fitting: Item 424, Cartridge: Item 426, Washer:Item 427 and Spring: Item 428 in Figure 12.

Liquid End Kit for D4 H2SO4 NPT

RPM 173, Includes:





Liquid End Kit for D4 H2SO4 Tubing

RPM 174, Includes:




2 each, Cartridge Assy.: (P/N 39461) Included inKit and Coupling Nut: Item 428 in Figure 12.

Liquid End Kit for D4 Slurry

RPM 212, Includes:



2 each, Check Valve Assembly: Item 425 in Figure12.

Liquid End Kit for D4 PVC/PVDF Double Diaphargm

RPM 163, Includes:


1 each, Oil Seal Bellows: Item 70 in Figure 12




Note: Liquid end sizes D2 and D4 metalliccheck valves (except Slurry) are precision as-sembled at the factory. Do not attempt to dis-assemble these cartridges.

4.4.3 SIZE D2 AND D4 LIQUID ENDS - STAINLESSSTEEL

Liquid End Kit for D2/D4 316SS

RPM 101/RPM 104, Includes:

1 each, Diaphragm: Item 260 in Figure 10/11.

1 each, O-Ring: Item 253 in Figure 11 (D4 only).

1 each, PTFE Washer: Item 274 in Figure 11 (D4only).

15

1 each, Oil Seal Bellows: Item 70 in Figure 10/11.

2 each, Check Valve Assembly: Item 425 in Fig-ures 10 & 11.

Liquid End Kit for D2/D4 316SS Double Diaphargm

RPM 162/164, Includes:

2 each(D4) 1 each (D2), Diaphragm: Item 260 inFigure 10/11.

1 each, Oil Seal Bellows: Item 70 in Figure 10/11.

1 each, Diaphragm: Item 264 in Figure 15 (D2 only).

1 each, O-Ring: Item 253 in Figure 11 (D4 only)

1 each, PTFE Washer: Item 274 in Figure 11 (D4only).

2 each, Check Valve Assembly: Item 425 in Fig-ures 10 & 11.

Note: The check valves for the size D7 andD8-PVC, PVDF, and Polypropylene liquid endscontain a removable seat, which permits thereplacement of the seat, O-ring, and ball into areusable valve body. The liquid end size D7and D8-Stainless Steel check valve has an in-tegral ball seat, which necessitates replacementof the entire check valve assembly.

4.4.4 SIZE D7 AND D8 - PVC, PVDF, POLYPROPY-LENE, H2SO4, POLYMER, AND SLURRY LIQUIDENDS

Liquid End Kit for D7/D8 PVC/PVDF/H2SO4

RPM 135/105(PVC & Black PP)

RPM 136/106(PVDF)

RPM 175/183(H2SO4), Includes:



1 each, PTFE Seal Ring: Item 210 in Figure 13.

2 each, Seat: Item 420, Ball: Item 422 in Figure 13.

4 each, O-Ring: Item 419 in Figure 13.

Liquid End Kit for D7/D8 Polymer





1 each, Spring: Item 422A in Figure 13.

1 each, Poppet: Item 426A in Figure 13.

2 each, Seat: Item 420, Ball: Item 422 in Figure 13.


Note: Figure 13, Item 423 (Kit) contains thefollowing:

• 1 each, Ball: Item 422

• 1 each, Seat: Item 420

• 2 each, O-rings: Item 419

Liquid End Kit for D7/D8 Slurry

RPM 215, Includes:





2 each, Check Valve Assembly: (P/N 60827) Item425 in Figure 13

4.4.5 SIZE D7 AND D8 - STAINLESS STEEL LIQUIDENDS

Liquid End Kit for D7/D8


1 each, Diaphragm: Item 260 in Figure 14

1 each, Oil Seal Bellows: Item 70 in Figure 14

2 each, Check Valve Assembly: Item 425 in Figure14

4.5 CORRECTIVE MAINTENANCE

BEFORE CARRYING OUT ANY SERVICINGOPERATION ON THE PUMP OR PIPING, DIS-CONNECT ELECTRICAL POWER FROM THEPUMP, AND TAKE THE NECESSARY STEPSTO ENSURE THAT ANY HARMFUL LIQUIDCANNOT COME INTO CONTACT WITH PER-SONNEL. SUITABLE PROTECTIVE EQUIP-MENT MUST BE PROVIDED. BE SURE THATTHERE IS NO FLUID PRESSURE IN THEPUMP LIQUID END AND PIPING.

16

3

Cleaning Fouled Check Valves

Check valve assemblies are designed to be self-clean-ing and should seldom need servicing. Fouled checkvalves can usually be cleaned by pumping a solution ofmild detergent and warm water (if compatible with liquidbeing pumped) for 15 minutes, followed by flushing withwater.

Check Valve Replacement

General

Before beginning work on the valve assemblies, makesure the suction and discharge shut-off valves are closedand that pressure has been bled from the pump liquidend. When replacing the valves, be sure to replace thevalve O-rings. Pay close attention to the proper assem-bly and orientation of the check valves as shown in eachLiquid End figure. In the case of plastic check valves forliquid end size D7 and D8, be certain that the ball isplaced on the sharp edge of the valve seat.

BE SURE TO FOLLOW INSTRUCTIONSCAREFULLY AND REFER TO THE APPRO-PRIATE FIGURE WHEN REASSEMBLINGCHECK VALVES. IF CHECK V ALVE CAR-TRIDGES ARE INSTALLED INCORRECTLY,ONE OF THE FOLLOWING WILL OCCUR:

(A) IMMEDIATE AND SEVERE DAMAGE TOPUMP MECHANISM.

(B) NO PUMPING OF FLUIDS.

(C) REVERSE PUMPING ACTION (FROMDISCHARGE LINE INTO SUCTION LINE).

Preliminary Operations

1. Set the pump capacity knob to 0%. If stroke lockingscrew was previously tightened, slightly loosen the lock-ing screw.

2. Disconnect power to pump motor. Check that theequipment cannot be accidentally started. Place a no-tice at the location of the power switch indicating thatthe pump is being serviced.

3. Disconnect the pump hydraulically by removing pipeor tubing connections to suction and discharge checkvalves.

4.5.1 CHECK VALVE REPLACEMENT: LIQUIDENDS D2 AND D4 - PVC, PVDF, H2SO4 ANDPOLYPROPYLENE (SEE FIGURE 9 OR 12)

NOTE THAT THE SEAT ORIENTATION IS DIF-FERENT INSIDE THE SUCTION AND DIS-CHARGE CHECK VALVES, BUT THE SEATMUST ALWAYS BE BELOW THE BALL WHENINSTALLED.

DO NOT APPLY PTFE T APE T O THETHREADS OF CHECK VALVE BODY THATSCREWS INTO THE HEAD (280), AS THISMAY PREVENT ADEQUATE SQUEEZE FROMBEING APPLIED T O THE V ALVE O-RINGWHICH COULD RESULT IN LEAKAGE.

1. Unscrew the valve body (424) from the pump head(280).

2. Remove the cartridge valve assembly: cartridge in-cludes ball (422), seat (420), ball guide (426), O-ring(419 and 421(D4 PVC/PVDF/POLY only)), and washer(427).

3. Clean the valve body (424) and threaded port in thehead (280).

4. Place a new washer (427) into valve body (424).

5. Install new check valve assembly in orientation shown.

On discharge side, drop cartridge assembly into threadedport in head. The O-ring should be stretched aroundoutside of cartridge on same end as ball seat. Screwvalve body into discharge side of diaphragm head untilvalve is hand tight. DO NOT OVERTIGHTEN.

On suction side, drop the cartridge assembly into checkvalve body. The O-ring should be stretched around out-side of cartridge on opposite end of ball seat. Screwthe suction valve body with cartridge valve into suctionside of head hand tight. DO NOT OVERTIGHTEN.

4.5.2 CHECK VALVE REPLACEMENT: LIQUIDENDS D2 AND D4 - POLYMER (SEE FIGURE 9 OR12)

NOTE THAT THE SEAT ORIENTATION IS DIF-FERENT INSIDE THE SUCTION AND DIS-CHARGE CHECK VALVES, BUT THE SEATMUST ALWAYS BE BELOW THE BALL WHENINSTALLED.

1717

DO NOT APPLY PTFE T APE T O THETHREADS OF CHECK VALVE BODY THATSCREWS INTO THE HEAD (280), AS THISMAY PREVENT ADEQUATE SQUEEZE FROMBEING APPLIED T O THE V ALVE O-RINGWHICH COULD RESULT IN LEAKAGE.

Suction


2. Remove the valve assembly: assembly includes ball(422), seat (420), Cartridge (426), O-ring (419), andwasher (427).


4. Place a new washer (427) into valve body (424). Placenew seat (420) and new ball (422) inside new cartridge(426) and place into valve body.

5. Add O-ring (419) and install new check valve assem-bly in orientation shown.

On suction side, drop the cartridge assembly into checkvalve body. The O-ring should be stretched around out-side of cartridge on opposite end of ball seat. Screwthe suction valve body with cartridge valve into suctionside of head hand tight. DO NOT OVERTIGHTEN.

Discharge


2. Remove the valve assembly: assembly includes O-ring (419), seat (420), ball (422), spring (428), cartridge(426), and washer (427).


4. Place a new washer (427) into valve body (424). Placenew spring (428), new ball (422), and new seat (420)inside new cartridge (426) and place into valve body.

5. Add O-ring (419) and install new check valve assem-bly in orientation shown.

On discharge side, drop cartridge assembly into threadedport in head. The O-ring should be stretched aroundoutside of cartridge on same end as ball seat. Screwvalve body into discharge side of diaphragm head untilvalve is hand tight. DO NOT OVERTIGHTEN.

4.5.3 CHECK VALVE REPLACEMENT: LIQUID ENDSIZES D2 AND D4 - METALLIC (SEE FIG. 10 OR 11)

The metallic check valves used on liquid end sizes D2and D4 (except slurry) are precision assembled at thefactory. Do not attempt to disassemble these cartridges.If they become inoperative, flush them with solvent, washthem with warm detergent and blow them out with com-pressed air to remove any foreign matter. If this treat-ment does not eliminate the trouble, the cartridge as-sembly should be replaced.

Disassembly

Remove the check valves by unscrewing them from thepump head.

Reassembly

Apply a small amount of thread sealing compound andPTFE pipe tape to check valve threads and install checkvalves by screwing them into the pump head with theflow arrows pointing up. DO NOT OVERTIGHTENCHECK VALVES.

4.5.4 CHECK VALVE REPLACEMENT: LIQUID ENDSIZE D4 - SLURRY (SEE FIGURE 11)


2. Remove the valve assembly: assembly includes ball(422), check valve body (424), and retainer sleeve (428).



On discharge side, drop cartridge assembly into threadedport in head. Screw valve body into discharge side ofdiaphragm head until valve is hand tight. DO NOT OVER-TIGHTEN.

On suction side, drop the cartridge assembly into checkvalve body. Screw the suction valve body with cartridgevalve into suction side of head hand tight. DO NOTOVERTIGHTEN.

THE CHECK VALVES WILL NOT OPERATEIF THEY ARE INSTALLED UPSIDE DOWN.INSTALL CHECK VALVES WITH THE FLOWARROW POINTING IN THE DIRECTION OFPROCESS FLOW (UP). TURN CHECK VALVEASSEMBLIES INTO LIQUID END BY HANDAND TIGHTEN. DO NOT OVERTIGHTEN,DAMAGE TO THE CHECK VALVES MAY OC-CUR.

18

3

4.5.5 REPLACEMENT OF BALL, SEAT, & SEAL:LIQUID END D7 AND D8 - PVC, PVDF, H2SO4 ANDPOLYPROPYLENE (SEE FIGURE 13)

Disassembly

1. Unscrew the union nut (435). The union end (445) isheld in place by the union nut and will separate easilyfrom the other liquid end parts.


3. Screw the union nut part way (one or two turns) ontothe end of the ball guide that has the seat in it. Be surethe union nut is on loosely. This will allow a gap for theseat (420) to fall into as it is removed from the ball guide.

4. Set the ball guide/union nut on a flat surface with theunion nut down. Looking into the top of the ball guide,you will see four large holes surrounding one small hole.Insert a thin, blunt instrument such as a hex head screw-driver into the small center hole until it rests on the topof the ball (422).

5. Tap screwdriver gently with a hammer until the balland seat are released from the ball guide.

IF THE UNIT IS DISASSEMBLED FOR IN-SPECTION ONLY, BE SURE TO USE A BLUNTINSTRUMENT AND TAP GENTLY TO AVOIDDAMAGING THE BALL. IF THE BALL AND/OR SEAT ARE DAMAGED DURING DISAS-SEMBLY, THEY WILL HAVE T O BE RE-PLACED. IF AVAILABLE, TO AVOID DAM-AGE, IT IS ADVISABLE TO USE GENTLE AIRPRESSURE (APPLIED AT END OPPOSITETHE SEAT (420) FOR BALL AND SEAT RE-MOVAL.

6. Carefully remove the two O-rings (419) from the ballguide and seat.

7. Carefully clean any parts to be reused. If any chemi-cals are used in the cleaning process, ensure that theyare compatible with the process liquid.

Reassembly

THE ORDER OF ASSEMBLY AND ORIENTA-TION OF THE SUCTION AND DISCHARGECHECK VALVES IS DIFFERENT. REFER TOFIGURE 13 FOR PROPER ASSEMBLY OR-

DER AND ORIENTATION. IF CHECK VALVECARTRIDGES ARE INSTALLED INCOR-RECTLY, ONE OF THE FOLLOWING WILLOCCUR:

(A) IMMEDIATE SEVERE DAMAGE TO PUMPMECHANISM

(B) NO PUMPING

(C) REVERSE PUMPING ACTION (FROMDISCHARGE LINE INTO SUCTION LINE)

1. Drop the ball (422) into the curved inner chamber endof the body (424).

2. Set the body on a flat surface so that the end with theball faces upward. Position seat (420) on the body,with the beveled edge of the seat facing outward. Whenthe seat is pressed into the body, the ball should besitting on the side with sharp corners as shown in Fig-ure 13. The bevel should not face the inside of thecheck valve. Use a flat surface such as a board topress the seat into the body with firm, even pressure.

If the seat is improperly positioned, the ball will not cre-ate a tight seal and poor pumping performance will re-sult.

3. Fit new O-rings (419) into position on the body (424)and seat (420).

DO NOT APPLY PTFE TAPE TO THREADSOF CHECK VALVE BODY (424) AS THIS MAYPREVENT ADEQUATE SQUEEZE FROM BE-ING APPLIED TO THE VALVE O-RING WHICHWOULD RESULT IN LEAKAGE.

Note: To assure a tight, leak free seal, new O-rings should be used each time the checkvalves are disassembled.

4. Position the union end (445) onto the correct end ofthe body. Refer to Figure 13, as the correct end isdetermined by whether the valve is intended for the suc-tion or discharge port of the liquid end. Slip the unionnut (435) over the union end and screw tightly (handtight only) onto the body.

5. Screw the valve assembly into the pump head (handtight only). DO NOT OVERTIGHTEN.

19

4.5.6 CHECK VALVE REPLACEMENT: LIQUID ENDSIZES D7 AND D8 - POLYMER (SEE FIGURE 13)

Suction

Follow the instruction for replacement of ball, seat, &seal: liquid end D7 and D8 - PVC, PVDF, H2SO4 andpolypropylene paragraph 4.5.5. The procedures arethe same.

Discharge


2. Remove the valve assembly: assembly includes twoO-rings (419), seat (420), ball (422), poppet (426), spring(423) and check valve body (424).

3. Replace O-rings (419), seat (420), ball (422), poppet(426), and spring (423).




4.5.7 CHECK VALVE REPLACEMENT: LIQUID ENDSIZES D7 AND D8 - SLURRY (SEE FIGURE 13)


2. Remove the valve assembly: assembly includes twoO-rings (419), slurry seal ring (420), ball (422), checkvalve body (424), and dowel pin.




On suction side, drop the cartridge assembly into checkvalve body. Screw the suction valve body with cartridgevalve into suction side of head hand tight. DO NOTOVERTIGHTEN.

4.5.8 CHECK VALVE REPLACEMENT: LIQUID ENDSIZES D7 AND D8 - STAINLESS STEEL (SEEFIGURE 14)

Disassembly

Stainless steel check valves differ from the plastic ver-sions in that the ball seat is integral to the ball guide.The seats cannot easily be inspected for damage orwear. If you suspect that the check valve may be dam-aged or worn, replace the entire check valve assemblyas per the instructions below.

1. Unscrew the coupling (445).

2. Unscrew the check valve assembly (425) from theliquid end.

Reassembly

THE ORDER OF ASSEMBLY AND ORIENTA-TION OF THE SUCTION AND DISCHARGECHECK VALVES IS DIFFERENT. REFER TOFIGURE 14 FOR PROPER ASSEMBLY OR-DER AND ORIENTATION. IF CHECK VALVECARTRIDGES ARE INSTALLED INCOR-RECTLY, ONE OF THE FOLLOWING WILLOCCUR:

(A) IMMEDIATE SEVERE DAMAGE TO PUMPMECHANISM

(B) NO PUMPING

(C) REVERSE PUMPING ACTION (FROMDISCHARGE LINE INTO SUCTION LINE)

1. Screw the correct end of the check valve assemblyinto the pump head, trapping a new O-ring between thepump head and the check valve assembly.

DO NOT APPLY PTFE TAPE TO THREADSOF CHECK VALVE BODY AS THIS MAY PRE-VENT ADEQUATE SQUEEZE FROM BEINGAPPLIED TO THE V ALVE O-RING WHICHWOULD RESULT IN LEAKAGE.

Note: To assure a tight, leak free seal, new O-rings should be used each time the checkvalves are disassembled.

2. Screw the coupling (445) onto the check valve as-sembly, trapping a new O-ring (419) between the cou-pling and the check valve assembly.

4.6 DIAPHRAGM AND OIL SEAL BELLOWS RE-PLACEMENT

20

3

BEFORE BEGINNING DIAPHRAGM RE-PLACEMENT, MAKE SURE THAT ALL SHUT-OFF VALVES ARE CLOSED AND ALL PRES-SURE IS BLED FROM THE LIQUID END.

If failure of the oil seal bellows has occurred, it is rec-ommended that the diaphragm assembly and oil sealbellows be replaced at the same time.

4.6.1 DIAPHRAGM REPLACEMENT: LIQUID ENDSIZE D2 (SEE FIGURES 7, 9 AND 10)

1. Loosen the head screws (290) and remove the dia-phragm head (280). Mark the suction and dischargeports on the diaphragm head prior to removal.

2. Remove the motor fan cover and turn the motor byhand while adjusting the capacity control knob to 100%.With the capacity set at 100%, turn the motor fan untilthe diaphragm (260) is in the full forward position (topdead center).

3. Hold the outer edge of the diaphragm and turn it coun-terclockwise to unscrew it from the pump drive.

4. Discard and replace with new diaphragm. Make surethat adaptor (252) is screwed in tightly to connectingrod (Item 60. in Figure 6). Make sure that seat ring(Item 230 in Figure 9 & 10) is in place. Apply a thinlayer of silicone grease to back (rubber side) of dia-phragm before installation. Holding the edges of thediaphragm, screw the diaphragm assembly onto the malethread of the adaptor piece (252) until it reaches its me-chanical stop.

5. With the capacity still set at 100% turn the motor fanuntil the new diaphragm is in the farthest rearward posi-tion (bottom dead center).

6. Reattach the diaphragm head with the suction anddischarge ports in the correct positions. Tighten thescrews in a crosswise pattern to a torque of 45 in-lb.

7. While turning the motor fan, set the stroke adjust-ment knob to the 0% position.

8. Reinstall motor fan cover.

4.6.2 DIAPHRAGM REPLACEMENT: LIQUID ENDSIZES D4, D7, AND D8 (SEE FIGURES 7, 11- 14)

1. Mark the suction and discharge ports on the dia-phragm head prior to removal. Loosen the head screws(290) and remove the diaphragm head (280).

2. Remove the motor fan cover and turn the motor byhand while adjusting the capacity control knob to 100%.With the capacity set at 100%, turn the motor fan untilthe diaphragm cap (240) is in the full forward position(top dead center).

3. Hold the outer edge of the diaphragm (260) and turn itcounterclockwise to unscrew it from the pump drive.

4. While clamping on the hex on the diaphragm cap(240), disassemble diaphragm assembly by removingthe hex nut (271) on the back of the diaphragm supportnut (270).

5. Make sure that stainless steel support nut (270) isclean and free of corrosion. When cleaning the supportnut, take care not to scratch the smooth angled surfaceof the support nut. If corrosion cannot be removed with-out damaging the support nut, replace with a new one.

6. Install new diaphragm (260) onto diaphragm cap (240)with the convolution in correct orientation. As shown infigures, the convolution in the Teflon diaphragm shouldbe facing down away from diaphragm cap (240) andagainst (or pointing towards) the stainless steel sup-port nut (270)

7. For Size D4-stainless steel liquid ends, slide bolt(250), washer (251), and O-ring (253) through the dia-phragm cap and diaphragm as shown in Figure 7. Forall other liquid ends, install set screw (Item 250 in Fig-ure 6) into diaphragm cap (240), with hex hole in screwfacing outward, until it is bottomed out (hand tight only)in the diaphragm cap.

8. Slide support nut (270) onto set screw in correct ori-entation shown in Figure 7.

9. Install hex nut onto back of support nut and tighten tothe following torque values dependent on liquid end sizeand material. Torque diaphragm assembly as follows:

a) Liquid End Size D7 and D8 to 20 foot pounds.

b) Liquid End Size D4-Plastic to 45 inch pounds.

c) Liquid End Size D4-Stainless Steel tightenuntil washer (251) is contacting diaphragm cap(240).

10. Make sure that support ring (230) is in place andthen reinstall diaphragm assembly.

11. Apply thin layer of O-ring type grease to back ofsupport nut (270) and reinstall thin PTFE washer (274)to back of support nut.

12. Make sure that oil seal clamp ring (210) is in place.Screw diaphragm assembly into connecting rod (Item60 in Figure 6) until it reaches its mechanical stop.

21

22

Note: Steps 11 and 12 are applicable to LiquidEnd Size D4.

13. Apply a thin layer of grease to the back of hex nut(271).

14. Make sure that spring (Item 272 in Figure 13 & 14)is in place and connecting rod is in full-forward position(at 100% capacity setting). Screw diaphragm assem-bly into connecting rod cross piece (61) until it reachesits mechanical stop.

Note: Steps 13 and 14 are applicable to LiquidEnd Size D7 and D8.

15. With the capacity still set at 100% turn the motorfan until the diaphragm is pulled back to the rearwardposition (bottom dead center).

16. Reattach the diaphragm head with the suction anddischarge ports in the correct positions. Torque thehead assembly screws in a crosswise pattern as fol-lows:

a) Liquid End Size D2 and D4 to 45 inch pounds.

b) Liquid End Size D7 and D8 to 90 inch pounds.

17. While turning the motor fan, set the stroke adjust-ment knob to the 0% position.

18. Reinstall motor fan cover.

4.7 OIL SEAL BELLOWS REPLACEMENT (ITEM 70IN FIGURES 9 THROUGH 14)

BEFORE BEGINNING OIL SEAL REPLACE-MENT, MAKE SURE ALL SHUT-OFF VALVESARE CLOSED AND ALL PRESSURE HASBEEN BLED FROM THE LIQUID END (PUMPHEAD). WHEN REPLACING THE OIL SEAL,THE DIAPHRAGM ASSEMBLY MUST BE RE-MOVED FIRST. FOR EASE OF SERVICE, ITIS RECOMMENDED THAT THE OIL SEAL BEREPLACED IN CONJUNCTION WITH THE DIA-PHRAGM ASSEMBLY.

1. Disconnect connections to the pump motor terminalbox. Be sure to note the wiring layout before discon-necting from box.

2. Set the stroke adjusting knob to 100%.

3. Disconnect the suction and discharge connectionsto the pump head check valves.

4. Mark the suction and discharge ports on the dia-

phragm head prior to removal. Loosen the head screws(290) and remove the diaphragm head (280).

5. Remove the motor fan cover and turn the motor byhand while adjusting the capacity control knob to 100%.With the capacity set at 100%, turn the motor fan untilthe diaphragm assembly is in the full forward position(top dead center).

6. Hold the outer edge of the diaphragm assembly (260)and turn it counterclockwise to unscrew it from the pumpdrive.

7. Remove the diaphragm support ring (230) from thespacer (225).

8. Drain the oil out of the pump drive by removing thedrain plug from the pump housing.

9. Remove oil seal bellows clamping components asfollows:

a) On Liquid End Size D2 models (Figures 9 &10), remove adaptor piece (252), clamp ring(210), mounting screws (227), and spacer (225).

b) On Liquid End Size D4 models (Figures 11 &12, remove oil seal clamp ring (210), mountingscrews (227), and spacer (225).

c) On Liquid End Size D7 and D8 models (Figure13 & 14), remove spring (272), unscrew adapter(61), seal ring (210) mounting screws (227 &228), and spacer (225).

10. Pull the oil seal (70) off the connecting rod.

11. Install a new oil seal onto connecting rod.

12. Apply a thin layer of O-ring type grease to top of oilseal (part adjacent to connecting rod).

13. Reinstall parts removed in step 9. For Liquid endsD2, D7, and D8, install adaptor piece (252) or crosspiece (61) before mounting spacer.

14. Remove the motor and refill pump drive with oil (1quart of Mobil SHC 629).

15. Reinstall motor.

16. Reinstall liquid end components in accordance withthe procedures found in the following:

a) For Liquid End Size D2 models, refer toparagraph 4.6.1, steps 4 thru 7.

b) For Liquid End Size D4, D7, and D8 modelsrefer to paragraph 4.6.2, steps 10 thru 17.

23

17. Connect the motor in compliance with the direc-tions marked during the prior disconnection (see alsoSection 2: ELECTRICAL CONNECTIONS).

4.8 RESTARTING THE PUMP

1. Reconnect the pump to the piping system.

2. Check that capacity is set to 0%.

3. Open system suction and discharge shut-off valvesand restart pump.

4. Set the pump to 100% to obtain faster priming ofliquid end.

5. After priming, set the pump to the desired capacity.Retighten locking screw (320, Figure 6).

24

THIS PAGE INTENTIONALLY BLANK

SECTION 5PARTS LIST

25

GENERAL

1. This section gives information regardingreplaceable components.

ILLUSTRATED PARTS LIST

1. Figure and Item Number Column

(a) The item numbers shown in the detailed partslist correspond to the item numbersappearing on the exploded view illustration.To find an unknown part number, locate thepart on the illustration and note the itemnumber. Look for the item number on thedetailed parts list. The part number is on thesame line. A dash (-) precedes non-illustrateditem numbers.

2. Description Column

(a) The name of the item is in the descriptioncolumn.

3. Additional Information

(a) When “Consists of” is indented under a part,that part consists of the corresponding partsreferenced by part number.

4. Part Number Column

(a) The supplier’s part number is listed in the partnumber column.

5. Quantity Column

(a) The numbers appearing in the quantitycolumn are the total quantity of the listed partrequired in its immediate assembly.

6. Reference Code Column

(a) This column is used to denote assembly anddetail part variations among similarcomponents (models) covered by thispublication. When the symbol “A”, “B”, etc.is entered in this column, the part is usedonly in the model at which the symbolappears. If the column is blank, the part isused in all models.

26

Figure 8. Drive Assembly

3

5.1 PARTS LIST FOR DRIVE

SD-40-01-NE56CSD-40-01-IEC71SD-20-01-NE56CSD-20-01-IEC71SD-10-01-NE56CSD-10-01-IEC71SD-15-01-NE56CSD-15-01-IEC71SD-40-06-NE56CSD-40-06-IEC71SD-20-06-NE56CSD-20-06-IEC71SD-10-06-NE56CSD-10-06-IEC71SD-15-06-NE56CSD-15-06-IEC71SD-40-10-NE56CSD-40-10-IEC71SD-20-10-NE56CSD-20-10-IEC-71SD-10-10-NE56CSD-10-10-IEC71SD-15-10-NE56CSD-15-10-IEC71

225011509922501210994080068031

6008660064

40999940004040107231

2502110067NH6076661331

4350003375N4340009065N

70066700546099661116

4010003031435003852240500181194340009002

4047661266

405001811940476

40500660164070324030

41065

10

11111920

130140150160

170205206330332335340

----

- ---- -

510

11111111111111111111111111111221113312113444

4144411

Drive Housing Assembly, D2, 43 SPM, (NE56C)Drive Housing Assembly, D2, 43 SPM, (IEC71)Drive Housing Assembly, D2, 86 SPM, (NE56C)Drive Housing Assembly, D2, 86 SPM, (IEC71)Drive Housing Assembly, D2, 173 SPM, (NE56C)Drive Housing Assembly, D2, 173 SPM, (IEC71)Drive Housing Assembly, D2, 120 SPM, (NE56C)Drive Housing Assembly, D2, 120 SPM, (IEC71)Drive Housing Assembly, D4/7, 43 SPM, (NE56C)Drive Housing Assembly, D4/7, 43 SPM, (IEC71)Drive Housing Assembly, D4/7, 86 SPM, (NE56C)Drive Housing Assembly, D4/7, 86 SPM, (IEC71)Drive Housing Assembly, D4/7, 173 SPM, (NE56C)Drive Housing Assembly, D4/7, 173 SPM, (IEC71)Drive Housing Assembly, D4/7, 120 SPM, (NE56C)Drive Housing Assembly, D4/7, 120 SPM, (IEC71)Drive Housing Assembly, D8, 43 SPM, (NE56C)Drive Housing Assembly, D8, 43 SPM, (IEC71)Drive Housing Assembly, D8, 86 SPM, (NE56C)Drive Housing Assembly, D8, 86 SPM, (IEC71)Drive Housing Assembly, D8, 173 SPM, (NE56C)Drive Housing Assembly, D8, 173 SPM, (IEC71)Drive Housing Assembly, D8, 120 SPM, (NE56C)Drive Housing Assembly, D8, 120 SPM, (IEC71)Gasket Motor (NEMA 56C Flanged Motor)Gasket Motor (IEC71, V1 Flanged Motor)O-RingOil Drain PlugRetaining RingBearingRetaining RingSeal (Gasket), Side Cover, Use Through 2005Seal, Oil, Use After 2005Stroke Adjust ScrewSocket Head Screw, M6 X 16, 304SSWasher M6 304SSStroke Adjust KnobPan Head Screw, M6 X 20Knob, Sticker MacRoyBearingSpring Pin (for IEC Motors Only)Motor Mounting Bolt (IEC Motors: M8 X 25)Motor Mounting Bolt (NEMA 56C Motors: 3/8-16 X 1)Motor Mount Washer (IEC Motors: Spring

Lockwasher 8mm)Motor Mount Washer (NEMA 56C Motors: 3/8 SAE)Base (Optional)HEX HD, Screw, 3/8-16X1 GR5Washer, 3/8HEX Nut, 3/8-16NC Z PLGear Oil - 1 quartBreather Plug/Oil Fill Cap, P/O Item 10

ITEMNUMBER DESCRIPTION PART

NUMBER8

FIGURENUMBER

QUANTITYPUMP

1

27

- Items not shown.

28

Figure 9:D2 Plastic Liquid End 426

227

252

424

425427422

420

430419

290

300

260

280

419

426

422

420

425 427

225

ASSEMBLY

PLASTICLIQUID ENDONLY

ASSEMBLY

21070

3

5.2 PARTS LIST FOR D2 PLASTIC LIQUID END PVC, PVDF, BLACK POLY, H2SO4, AND POLYMER-NPT /PVC, PVDF, AND BLACK POLY-TUBING.

Model: Reference Code: Model: Reference Code:

D2_ _ 8P _ _ _ _ A (PVC NPT) D2_ _ 4P _ _ _ _ E (BLACK PP NPT)

D2_ _ 8T _ _ _ _ B (PVC TUBE) D2_ _ 4T _ _ _ _ F (BLACK PP TUBE)

D2_ _ 2P _ _ _ _ C (PVDF NPT) D2_ _ NP _ _ _ _ G (H2SO4 NPT)

D2_ _ 2T _ _ _ _ D (PVDF TUBE) D2_ _ PP _ _ _ _ H (POLYMER NPT)

- Items not shown.

60048600436103570054610886108330916610896109061377690016053461059

40400050124040002053

361034090561107

614396127035751

416554070014112

3610636081611416114236113

3611636107612751029928663

RPM 099

RPM 196

70210225227230252260280280280280-281290300300419419420

420420422

422422424424425425426

426427428-435-445

-

-

111411111111444222

222

2222222

222221

1

A, B, GC, DE, FH

A, E, GB, C, D, F

HA, B, C, D, E,

FGH

A, B, C, D, E,FGH

A, C, E, G, HB, D, FA, C, EB, D, F

A, B, C, E, F,GH

HB, D, FB, D, F

A, B, C, D, E,FH

Diaphragm/Oil Seal BellowsOil Seal Clamp RingSpacerPan Head Screw, M6 X 20Diaphragm Seat RingAdapterDiaphragm, PTFEDiaphragm Head, PVCDiaphragm Head, PVDFDiaphragm Head, BLACK PPDiaphragm Head, POLYMERDecalPan Head Screw, #10-24 X 3/4Flat Washer, 1/4 18.8SSFlat Washer, #10 18.8SSO-Ring, 0.549 ID X 103W(AFLAS)O-Ring, 2-113 VitonBall Seat, 9/32 Ball, C-22

Ball Seat, CA20Ball Seat, 3/8 Ball, 316SSBall 9/32 Ceramic

Ball 9/32, CA20Ball 3/8, 316SSValve Body 1/4” NPTFitting, 1/4 PVDFCheck Valve Assembly, PVC/PVDF/BLACK PP - NPTCheck Valve Assembly, PVC/PVDF/BLACK PP - TUBEBall Cartridge

Ball CartridgeMolded Washer, Cartridge ValveSpring, HAST-CCoupling Nut, PP 3/8Ferrule, 1/4” ODLiquid End Kit, PVC/PVDF/BLACK PP

Liquid End Kit, POLYMER


NUMBERQUANTITY

PUMPREF.

CODE9

FIGURENUMBER

29

30

Figure 10:D2 Metallic Liquid End

425

290

260

280

425

252

225

210

ASSEMBLY

ASSEMBLY

230

227

5.3 PARTS LIST FOR D2 METALLIC LIQUID END STAINLESS STEEL-NPT

Model: D2 _ _ 7P _ _ _ _

- Items not shown.

60048600436103570054610886108330916611066105921082

RPM 101

70210225227230252260280290425

-

11141111421

Diaphragm/Oil Seal BellowsOil Seal Clamp RingSpacerPan Head Screw, M6 X 20Diaphragm Seat RingAdapterDiaphragm, PTFEDiaphragm HeadPan Head Screw, #10-24 X 3/4Check Valve Assembly - NPTLiquid End Kit, 316 SS


NUMBERQUANTITY

PUMPREF.

CODE10

FIGURENUMBER

70

3

Figure 11:D4 Metallic Liquid End

ASSEMBLY

ASSEMBLY

230

227

225

271425

280

290

240

251

250

253

425 270 210

274

260

- Items not shown.

5.4 PARTS LIST FOR D4 METALLIC LIQUID END STAINLESS STEEL-NPT

Model: D4 _ _ 7P _ _ _ _ A (316SS)

Diaphragm/Oil Seal BellowsOil Seal Clamp RingSpacerPan Head Screw, M6 X 20Supporting RingDiaphragm Cap, 316SSHex Head Screw, M8 X 50, 316SSWasher, 8M, 316SSO-Ring, VitonDiaphragm, PTFESupport Nut, 316SSHex Nut, M8 ThinPTFE WasherDiaphragm Head, 316SS

6004860043610357005461075610746107161072610736099561051610546105561070

70210225227230240250251253260270271274280

11141111111111


NUMBERQUANTITY

PUMPREF.

CODE11

FIGURENUMBER

31

70

32

Figure 12:

D4 Plastic Liquid End

5.4 PARTS LIST FOR D4 METALLIC LIQUID END STAINLESS STEEL-NPT. (CONT.)

Model: D4 _ _ 7P _ _ _ _ A (316SS)

- Items not shown.

Pan Head Screw, #10-24 X 3/4Check Valve AssemblyLiquid End Kit, 316SS

61059CV202294RPM 104

290425

-

421


NUMBERQUANTITY

PUMPREF.

CODE11

FIGURENUMBER

3

5.5 PARTS LIST FOR D4 PLASTIC LIQUID END PVC, PVDF, BLACK POLY, H2SO4, SLURRY, AND POLY-MER-NPT / PVC, PVDF, BLACK POLY, AND , H2SO4-TUBING.


D4_ _ 8P _ _ _ _ A (PVC NPT) D4_ _ 4T _ _ _ _ F (BLACK PP TUBE)

D4_ _ 8T _ _ _ _ B (PVC TUBE) D4_ _ NP _ _ _ _ G (H2SO4 NPT)

D4_ _ 2P _ _ _ _ C (PVDF NPT) D4_ _ NT _ _ _ _ H (H2SO4 TUBE)

D4_ _ 2T _ _ _ _ D (PVDF TUBE) D4_ _ PP _ _ _ _ I (POLYMER)

D4_ _ 4P _ _ _ _ E (BLACK PP NPT) D4 _ _ LP _ _ _ _ J (SLURRY)

- Items not shown. * Item 425 includes items 419, 420, 422, 424, 426, and 427.

6004860043610357005461075610526107461053610586107161073609956105161054610556105661057612366107060534

253011809961059

40400020536103409053942561316612703941310338

40700141124070014113CV102313

3610636081361382231336366363603630639461

70210225227230240240240250250253260270271274280280280280

--

290300419419420420420421422422422422424424424424425* 425*425425

111411

1111111111111144222222222222222222

A, B, E, F, G, H, IJ

C, D

JJ

A, B, G, H, IC, DE, F

J

E, F, G, HI , J

A, B, C, D, E, FG,H

IA, B, C, D, E, FA, B, C, D, E, F

IG,H

JE, G, I

FHJ

A, CB, DE, FG, H

Diaphragm/Oil Seal BellowsOil Seal Clamp RingSpacerPan Head Screw, M6 X 20Diaphragm Support RingDiaphragm Cap - PVCDiaphragm Cap - 316SSDiaphragm Cap - PVDFSocket Set Screw, M8 X 50Socket Set Screw, M8 X 50, 316SSO-Ring, 8MM ID, T=2MM, VitonDiaphragm, PTFESupport Nut, 316SSHex Nut, M8 X 50Washer, PTFEDiaphragm Head - PVCDiaphragm Head - PVDFDiaphragm Head - Black PPDiaphragm Head - 316SS (SLURRY)DecalDecal, EAC LogoPan Head Screw, #10-24 X 3/4Flat Washer, #10 18.8SSO-Ring, AFLASO-Ring, VitonBall Seat, 0.375, PTFEBall Seat, 3/8” Ball, CA-20Ball Seat, 3/8” Ball, 316SSO-Ring, AFLASBall, 3/8” CERAMIC,+/-.001Ball, 3/8” 316SS, Grade 50Ball, 3/8” CA-20, Grade 50Ball, 7/16” 316SS, P/O 22312, Item 425Fitting, 1/4 PVDF - NPTFitting, 1/4 PVDF - TUBEFitting, 1/2 PVDF - TUBECheck Valve Body, P/O 22312, Item 425Check Valve Assembly - NPT, 1/4”Check Valve Assembly - TUBE, 1/2”Check Valve Assembly - PPCheck Valve Assembly - H

2SO4


NUMBERQUANTITY

PUMPREFERENCE

CODE

12

FIGURENUMBER

33

5.5 PARTS LIST FOR D4 PLASTIC LIQUID END PVC, PVDF, BLACK POLY, H2SO4, SLURRY, AND POLY-MER-NPT / PVC, PVDF, BLACK POLY, AND , H2SO4-TUBING. (CONT.)


D4_ _ 8P _ _ _ _ A (PVC NPT) D4_ _ 4T _ _ _ _ F (BLACK PP TUBE)

D4_ _ 8T _ _ _ _ B (PVC TUBE) D4_ _ NP _ _ _ _ G (H2SO4 NPT)

D4_ _ 2P _ _ _ _ C (PVDF NPT) D4_ _ NT _ _ _ _ H (H2SO4 TUBE)

D4_ _ 2T _ _ _ _ D (PVDF TUBE) D4_ _ PP _ _ _ _ I (POLYMER)

D4_ _ 4P _ _ _ _ E (BLACK PP NPT) D4 _ _ LP _ _ _ _ J (SLURRY)

Check Valve Assembly - SLURRYCartridge, 0.375 PVDFWasherCoupling Nut, 1/2”Spring, Lee LC-016C-8-HAST-C, (Suction Only)Retainer SleeveCoupling NutFerrule, 1/4” ODLiquid End Kit, PVC, PVDF, BLACK PP NPT/TUBELiquid End Kit, H2SO4 NPTLiquid End Kit, H2SO4 TUBELiquid End Kit, POLYMERLiquid End Kit, SLURRY

2231236116361071041161275610711029928663

RPM 102RPM 173RPM 174RPM 196RPM 212

2222112211111


NUMBERQUANTITY

PUMPREF.

CODE12

FIGURENUMBER

425426427

-428428

-------

JE, F, G, H, IE, F, G, H, I

HIJFF

A,B,C,D,E,FGHIJ

34

335

Figure 13: D7 & D8 PlasticLiquid End

5.6 PARTS LIST FOR D7 AND D8 PLASTIC LIQUID END PVC-NPT/TUBING, PVDF-NPT, BLACK POLY-NPT, POLYMER-NPT, SLURRY-NPT, & H2SO4-NPT.


D7/D8_ _ 8P _ _ _ _ A (PVC NPT) D7/D8_ _ PP _ _ _ _ E (POLYMER NPT)

D7/D8_ _ 2P _ _ _ _ B (PVDF NPT) D7/D8_ _ 4P _ _ _ _ F (BLACK PP NPT)

D7/D8_ _ LP _ _ _ _ C (SLURRY NPT) D7/D8_ _ 8T _ _ _ _ G (PVC TUBE)

D7/D8_ _ NP _ _ _ _ D (H2SO4 NPT)

- Items not shown.

* Items included as part of item number 425.

611554350016075N

600486115461156

4350003375N4350047395N

6003560628

606304350071284

606186106561068700816115360033

600316088260534

253011809943500016554340005085

607544340009005

6115243500000454080068075

403482240173078

60819240173016

6085560709

407001517140700151714070014173

616270-

225227228230240

240250260270271272273280

280280281282290300

-302-304305

419*

419* 420* 420*420420422

422*422422

11112211

111111111

111661

66644

222222222

A, C, D, E,F, GB

A, C, D, E,GBF

A, B, C, D,E, G

F

A, C, D, E,F, GB

A, B, F, GCEDC

A, B, GFD

AdapterSocket Head Set Screw, M8 X 20Oil Seal BellowsPTFE Seal RingSpacerSocket Head Set Screw, M6 X 16, 304SSSocket Head Set Screw, M6 X 30, 304SSDiaphragm Support RingDiaphragm Cap - PVC

Diaphragm Cap - PVDFSocket Set Screw, Dog PT M10 X 45Diaphragm, PTFESupport NutHex Nut, M10 Thin, 316SSSpringSpring CupHead PVC

Head PVDFHead Black PolypropyleneDecal, Tighten MacRoy PlasticDecal, EAC LogoHex Head Screw, M8 X 110mm, LG 304SSFlat Washer, M8, Regular 304SS

Back-up PlateSplit Washer M8, 304SSNut SpacerHex Nut, M8, 304SSO-Ring, Viton, 2-117

O-Ring, PTFE, TEFLEX 2-117Seat, PVDFSlurry Seal Ring, 316SSSeat, 5/8” Ball 316SSSeat, 5/8” Ball CA20Ball, 14MM 316SSBall, 5/8 CeramicBall, 5/8 CeramicBall, 5/8 CA20

ITEMNO. DESCRIPTION D7

PART NO.QTY.

PUMPREF.

CODE61155

4350016075N600486115461156

4350003375N4350047395N

6007060633

606354350071284

606246114661068700816115361148

611476123760534

253011809943500016554340005085

607544340009005

6115243500000454080068075

403482240173078

60819240173016

6085560709

4070015171

4070014173

D8PART NO.

13

FIG.NO.

36

337

5.6 PARTS LIST FOR D7 AND D8 PLASTIC LIQUID END PVC-NPT/TUBING, PVDF-NPT, BLACK POLY-NPT, POLYMER-NPT, SLURRY-NPT, & H2SO4-NPT. (CONT.)


D7/D8_ _ 8P _ _ _ _ A (PVC NPT) D7/D8_ _ PP _ _ _ _ E (POLYMER NPT)

D7/D8_ _ 2P _ _ _ _ B (PVDF NPT) D7/D8_ _ 4P _ _ _ _ F (BLACK PP NPT)

D7/D8_ _ LP _ _ _ _ C (SLURRY NPT) D7/D8_ _ 8T _ _ _ _ G (PVC TUBE)

D7/D8_ _ NP _ _ _ _ D (H2SO4 NPT)

- Items not shown.

* Items included as part of item number 425.

4070014172

8001230263050879500

3050879700

61238

60024

03015607160818

3050870007

3050870008

60827

60820440090078

432023603860117

60119

61396470096073N

RPM 135

RPM 136RPM 215RPM 211RPM 175

422422423423

423

423

424*

424424425

425

425

- 426435445

445 - -

448-

----

2212

2

2

2

122

2

2

2122

22211

1111

EFEA

B

C

A, B, D, E,F, GECA

B

C

CE

A, C, D,E, F, G

BGG

A, F, G

BCED

Ball, 5/8 316SSBall, 5/8 316SSSpring, Hastelloy, (Discharge Only)Kit - Ball, Seat & O-Rings, PVC, Includesitems 419, 420, and 422Kit - Ball, Seat & O-Rings, Includes items419, 420, and 422Kit-Ball, Body, & Dowel Pin, Includes Items422, 424, & 426Cartridge Body, PVDF

Slurry Valve BodyBall Guide, PVC, Spring LoadedCheck Valve Assembly, PVC, IncludesItems 423 and 424Check Valve Assembly, PVDFIncludesItems 423 and 424Check Valve Assembly, Slurry, IncludesItems 419, 420, & 423Dowel Pin, 3/16 X 1.5, 416SSPoppet, PVDFUnion Nut, 1/2” PVCUnion End, 1/2” NPT PVC

Union End, 1/2” NPT PVDFElbow 1” MPT X 1” BARB PVDFElbow 1/2” MPT X 1/2” BARB PVDFBlow-Off NozzleLiquid End Kit, PVCNPT/TUBE and BlackPP NPTLiquid End Kit, PVDF NPTLiquid End Kit, Slurry NPTLiquid End Kit, Polymer NPTLiquid End Kit, H2SO4 NPT


PART NO.QTY.

PUMPREF.

CODE40700141724070014172800123026

3050879500

3050879700

61238

60024

03015607160818

3050870007

3050870008

60827

60820440090078

432023603860117

6011961395

470096073NRPM 105

RPM 106

RPM 210RPM 183

D8PART NO.

13

FIG.NO.

38

Figure 14: D7 & D8 316SSLiquid End

ASSEMBLY

290 300

304 305

302 305

445

227 228419

425

419

260

240

250280

270

302

61

272

273

62

271 210

448 225

230445

419

425

ASSEMBLY

419

70

3

5.7 PARTS LIST FOR D7 AND D8 316SS-NPT LIQUID END

Model: D7 _ _ 7P _ _ _ _ _ or D8 _ _ 7P _ _ _ _ _

- Items not shown.

611554350016075N

600486115461156

4350003375N4350047395N

6003560631

43500712846061861065610687008161153

210760016435000165543400050854340009005

61152435000004540800680753050876602

60135470096073N

RPM137

616270

210225227228230240250260270271272273280290300302304305419425445448

-

11111221111111116666642211

AdapterSocket Head Set Screw, M8 X 20Oil Seal BellowsPTFE Seal RingLE AdapterSocket Head Set Screw, M6 X 16, 304SSSocket Head Set Screw, M6 X 30, 304SSSupport RingDiaphragm Cap - 316SSSocket Set Screw, Dog PT M10 X 45Diaphragm, PTFESupport NutHex Nut, M10 Thin, 316SSSpringSpring CupHead, 316SSHex Head Screw, M8 X 110mm, LG 304SSFlat Washer, M8, Regular 304SSSplit Washer M8, 304SSNut SpacerHex Nut, M8, 304SSO-Ring, 2-117 VitonCheck Valve AssemblyCoupling, 1/2” NPTBlow-Off NozzleRPM Kit, 316SS


PART NO.QTY.

PUMPREF.

CODE61155

4350016075N600486115461156

4350003375N4350047395N

6007060636

4350071284606246114661068700816115361149

435000165543400050854340009005

61152435000004540800680753050876602

60135470096073N

RPM107

D8PART NO.

14

FIG.NO.

39

40

Figure 15: Leak Detection, Switch and/or Gauge (Optional)

3

Figure 16: Double Diaphgram, D4 Pressure Type Configured (Optional)

Figure 17: Double Diaphgram,D7 & D8 Pressure Type Config-ured (Optional)

41

5.8 LEAK DETECTION PARTS LIST

Model: Code: Model: Code:

D2 _ _ _ _ _ _ _ A D7 _ _ _ _ _ _ _ C

D4 _ _ _ _ _ _ _ B D8 _ _ _ _ _ _ _ D

250250250252261262262262262263263263264264264264266266266290290290290300300302304305750760760770780790800810820830840850860870880

1220

- Items not shown.

6137961262

435007133461380610756138661258

980367071980369071

61256980366071980368071

6138160995606186062461378405966020861385410696020661319

404000205343400050854340009005

611524350000045204019900640603880014060389001

40064400624006340061

2490136016400674006640065

24901371164050016095404003902240500640124050263050

11111111111111111114466466661111213111112223

Stud, Modified, 1/4 X 1-3/8Set Screw, M8Set Screw, Socket, Dog Pt. M10X70MMAdapter, Double DiaphramSupport Ring D4Ring, Seat, Double DiaphramSpacer, Double Diaphram, PVCSpacer, Double Diaphram, PVCSpacer, Double Diaphram, PVCRing, Spacer, Double DiaphramRing, Intermed. - PVCRing, Intermed. - PVCDiaphram, PTFEDiaphram, PTFEDiaphram, PTFEDiaphram, PTFEConnector, Male, 1/16 NPTM X 1/8 TubeNipple, Hex, 1/8NPTNipple, Hex, 1/4 NPT X 1/4 BSPScrew, Panhead, 10-24 x 1-1/2Screw, Socket Head, #10 - 24 X 1-3/4Screw, Hex Head, M8 X 130 MM - 304 SSScrew, Hex Head, M8 X 140 MM - 304 SSFlat Washer, #10, 18.8SS, For PVDF HeadFlat Washer, M8, 304SSLock Washer, M8, 304SSSpacerNut, M8, 304SSBracketSwitch, NEMA 4 Pressure, 5 - 30 PSISwitch, NEMA 7 Pressure, 5 - 30 PSINipple, Reducing Hex 1/2 X 1/8 NPTTee, 1/8 NPT Female, 316 SSValve, Bleed, 1/8 NPT, 316 SSConnector, Tube, 1/8 TUBEX, NPTTubing, Gauge to SwitchAdapter, Reducing, 1/4F X 1/8M NPTGage, Pressure, 0-400 PSI, (Dual Face)Check Valve, 1/8 Tube (1/3 PSI) - 316 SSTubing, Pump to Gauge - 316 SSScrew, Hex Head, 1/4 - 20 X 3/4 18-8 SSLock Washer, Spring, 1/4 - 18-8 SSNut, Hex, 1/4-20 - 18.8 SSScrew, Pan Head, #4-40 X 1/2

ITEMNO. DESCRIPTION PART NO. QUANTITY

PUMPREF.

CODE15,16, &

17

FIG.NO.

AB

C, DABABCDBCDABCDAB

C, DABCD

A, BC, DC, DC, DC, D

A

42

3

5.8 LEAK DETECTION PARTS LIST (CONT.)

Model: Code: Model: Code:

D2 _ _ _ _ _ _ _ A D7 _ _ _ _ _ _ _ C

D4 _ _ _ _ _ _ _ B D8 _ _ _ _ _ _ _ D

44

12301240

----

40400950234050182012

RPM 161RPM 162RPM163RPM 164

331111

Lockwasher, Spring, #4, 18.8 SSNut, Hex, #4 - 40, 18.8 SSLiquid End Kit, PVC, PVDF, BLACK PP DDLiquid End Kit, 316 SS, DDLiquid End Kit, PVC, PVDF, BLACK PP DDLiquid End Kit, 316 SS, DD

DESCRIPTION PART NO. QUANTITYPUMP

REF.CODE

15,16, &17

FIG.NO.

AABB

ITEMNO.

- Items not shown.

43

xlviii

SECTION 6TROUBLESHOOTING

1. Pump motor won't operate

2. Insufficient pump delivery.

SYMPTOMS POSSIBLE CAUSE REMEDY

a) Low process liquid level in thetank.

b) Worn or dirty check valves.

c) Blocked discharge line.

d) Frozen liquid.

e) Blown fuse.

f) Open thermal overload device inmotor starter.

g) Broken wire.

h) Low voltage.

i) Pump not primed.

j) Capacity adjustment set at zero.

a) Incorrect capacity adjustment.

b) Incorrect pump speed.

c) Starved suction.

d) Leaky suction piping.

e) High suction lift.

f) Liquid near boiling.

g) Leaky safety valve in dischargeline.

h) High liquid viscosity.

i) Worn or dirty check valve seats.

a) Add liquid.

b) Clean or replace.

c) Clear line.

d) Thaw liquid throughout pumpingsystem.

e) Replace fuse.

f) Reset device.

g) Locate and repair.

h) Investigate and correct (wiringmay be too tight)

i) Allow suction line and pumphead to fill with liquid beforepumping against pressure.

j) Readjust capacity.

a) Readjust capacity setting.

b) Match line voltage and frequencyto pump motor data plate.

c) Increase piping size or suctionhead.

d) Repair piping.

e) Rearrange equipment to de-crease lift and/or install foot valvein suction line.

f) Cool liquid or increase suctionhead.

g) Repair or replace valve.

h) Reduce viscosity (e.g., heat ordilute liquid), or consult MiltonRoy for a special check valveoptions.

i) Clean or replace.

44

xlix

3. Erratic pump delivery

4. Motor and pump body hot

5. Pump still pumps even at zerocapacity setting

6. Gear noise

7. Loud knock with each stroke

8. Noisy operation in liquid end

SYMPTOMS POSSIBLE CAUSE REMEDY

a) Leaky suction piping.

b) Leaky safety valve.

c) Insufficient suction head.

d) Liquid near boiling.

e) Worn or dirty check valves.

f) Clogged or dirty line strainer.

a) Normal operating temperature ofboth motor and pump body isfrequently uncomfortable to thetouch. However, neither shouldexceed 200°F (93°C).

b) Power supply does not matchelectrical requirement of motor.

c) Pump is being operated atgreater than rated performance.

d) Pump improperly lubricated.

a) Misadjusted capacity knob.

b) Insufficient discharge pressure.

a) Excessive backlash.

b) Worn bearings.

c) Wrong or insufficient lubricant.

a) Excessive gear set wear.

b) Worn bearings.

a) Noise in check valves.

a) Repair piping.

b) Repair or replace valve.

c) Raise suction tank level and/orinstall foot valve in suction line.

d) Cool liquid or increase suctionhead.

e) Clean or replace.

f) Clean strainer.

a) N/A

b) Insure proper matching of powersupply and motor.

c) Reduce pressure or strokespeed. If this is not practical,contact service facility.

d) Drain oil and refill with properamount of recommendedlubricant.

a) Readjust capacity setting.

b) Correct condition (e.g., install aback pressure valve).

a) Consult service facility.

b) Consult service facility.

c) Replace or replenish lubricant.

a) Consult service facility.

b) Consult service facility.

a) Ball checks move up and downwith some force. A distinct"clicking" noise is normal,especially in metal pipingsystems.

4845

www.miltonroy.com

201 Ivyland Road • Ivyland, PA 18974 USA • (215) 441-0800 • Fax: (215) 441-8620 • E-mail: [email protected]

0076 macroy d - pump supply inc

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