Milton Roy SERIES-GD-MANUAL
Milton Roy SERIES-GD-MANUAL
Milton Roy SERIES-GD-MANUAL
METERING
PUMP
INSTALLATION,
OPERATION, AND
MAINTENANCE
MANUAL
i
4.0 MAINTENANCE ......................................................................................................................................... 14
Change Bars
The areas in this manual which are different from previous editions are marked with change bars (as
shown to the right of this paragraph) to indicate the addition of new or revised information.
ii
MACROY D PUMP MODEL NUMBER AND OPTIONS
Connections
Motor
Frame and Liquid End (D Frame) Liquid End Material
Code Description Code Description
SD2 Max 0.7 GPH / 175 PSI 2 PVDF
SD4 Max 12.0 GPH 7 316ss
SD7 Max 50 GPH 8 PVC
SD8 Max 115 GPH P Polymer Service
L Slurry Applications
Stroking Speed N H2SO4 Applications
Code Description
1 43 SPM Connections
2 86 SPM Code Description
6 120 SPM P NPT
3 173 SPM T Tubing
B Outgassing Liquid Applications (NPT)
Motor C Outgassing Liquid Applications (Tubing)
Code Description
X NEMA 56C Flange Less Motor
8 115/230 VAC, 60 Hz,1 PH, 1800 RPM
9 115/230 VAC, 50 Hz,1 PH, 1500 RPM
J 230/460 VAC, 60 Hz, 3 PH, 1800 RPM
L 220/380 VAC, 50 Hz, 3 PH, 1500 RPM
P DC Variable Speed Drive
1
SECTION 1
DESCRIPTION
Figure 1:
Pump Assembly
7 2
6
5
2
Figure 2: 1
Stroke Control Operating
Principle
2
(A) (B)
(A) (B)
(A) (B)
1 Worm 5 Diaphragm
2 Worm Gear 6 Stroke: two times the distance between (A) and (B)
3 Eccentric 7 Position at rear neutral point
4 Connecting Rod 8 Position at forward neutral point
1.2 PRINCIPLES OF OPERATION below the suction line pressure, the suction ball check
is “pushed” upward and the process fluid in the suction
Drive Assembly (See Figure 2) line flows into the liquid end chamber (diaphragm head).
The pump consists of two major assemblies; the drive When the suction stroke ends, the diaphragm move-
and the liquid end. Pump delivery is a function of the ment momentarily stops and the pressure in the liquid
drive's stroke rate, liquid end size and stroke length. end equalizes with the pressure in the suction line caus-
Stroke length can be increased while the pump is run- ing the suction ball check to reseat.
ning by counterclockwise turning of the stroke adjust-
NOTE: It is important that the pressure in the
ment knob. The drive assembly works on the principle
liquid end remain above the vapor pressure of
of a variable eccentric. The rotational motion of the motor
the process fluid during the suction stroke. If
is transmitted by the worm (1) to the worm gear (2)
the fluid pressure drops below the vapor pres-
which is linked to an eccentric system (3). The eccen-
sure, cavitation will occur which will have a nega-
tric system then converts the rotary gear motion into
tive impact on the performance of the pump.
linear reciprocating motion of the connecting rod (4). At
If you suspect the possibility of cavitation, con-
0% capacity setting, the connecting rod axis (B) is
tact your dealer for assistance.
aligned with the gear axis (A) and no movement of the
connecting rod takes place. At 100% capacity setting, As the diaphragm starts forward on the discharge stroke
an eccentricity exists between the connecting rod axis the pressure immediately rises inside the liquid end.
(B) and the gear axis (A) which results in linear move- When the liquid end pressure rises above the discharge
ment of the connecting rod and resulting pumpage. line pressure, the discharge ball check is “pushed” up-
ward and the process fluid in the liquid end flows into
Mechanically Actuated Diaphragm Liquid End
the discharge line. When the discharge stroke ends,
(See Figure 2)
the diaphragm momentarily stops again. The pressure
The diaphragm assembly (5) is mechanically linked to in the liquid end equalizes with the discharge line pres-
the connecting rod (4) and has the same reciprocating sure and the discharge ball check reseats. The cycle
motion. As the diaphragm starts back on the suction then starts again.
stroke, the pressure immediately drops inside the liq-
uid end. When the pressure in the liquid end drops
3
1.3 GENERAL SPECIFICATIONS
FLOW RATE:
PRESSURE:
DRIVE TYPE:
Variable Eccentric
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 maximum
vacuum)
PAINT:
Two part epoxy, yellow RAL 1018
4
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5
SECTION 2
INSTALLATION
6
Figure 3:
Series G Model D
Dimensional Outline
7
Figure 4:
Typical Installation
4
6
5 3 4
1 5
1
3
4
6
1 9
7 8
8
Figure 5:
General Piping
Vent
Pulsation
Dampener
Safety
Pressure
Valve
Gauge
Back
Pressure
Valve
Calibration
Column
Supply Tank To Injection
Point
Prime/Air
Strainer Pulsation Purge Valve
Dampener
Metering
Pump
To Drain
2.6.1 NPSH CONSIDERATIONS Because vapor in the liquid end will cause inaccurate
pump delivery, piping should be sloped up from pump
Size piping to accommodate peak instantaneous flow. suction check to the supply tank to prevent formation of
Because of the reciprocating motion of the pump dia- vapor pockets.
phragm, peak instantaneous flow is approximately equal
to 5 times the average flow. For example, a pump rated When pumping suspended solids (such as slurries), in-
for 16 gallons per hour (61 L/hr.) requires piping suffi- stall plugged crosses at all 90° line turns to permit line
cient for 5 x 16 gph, or 80 gph (303 L/hr.). cleaning without dismantling piping.
To minimize viscous flow losses when handling viscous See Figure 5 for a typical recommended pump installa-
liquids, it may be necessary to use suction piping up to tion scheme.
four times larger than the size of the suction connection
on the pump. If in doubt, contact your dealer to deter-
2.6.3 SUCTION PIPING CONSIDERATIONS
mine the necessary pipe size.
It is preferable to have the suction of the pump flooded
2.6.2 GENERAL PIPING CONSIDERATIONS by locating the liquid end below the lowest level of the
liquid in the supply tank.
Use extreme care in piping to plastic liquid end pumps
with rigid pipe such as PVC. If excessive pipe stress or To minimize the chances of a loss-of-prime condition,
vibration is unavoidable, flexible connections are rec- the pump should be installed as close as possible to
ommended. the supply vessel.
Use piping materials that will resist corrosion by the Avoid negative suction pressure conditions (suction lift),
liquid being pumped. Use care in selecting materials to as such conditions adversely affect metering accuracy.
avoid galvanic corrosion at pump liquid end connections. A lift of 6.6 feet (2 meters) of water column is the maxi-
mum permissible suction lift.
Use piping heavy enough to withstand maximum pres-
sures. Remove burrs, sharp edges, and debris from Series G pumps are designed to operate with process
inside piping. Blow out all pipelines before making final liquid supplied at or above atmospheric pressure. Al-
connections to pump. though these pumps can move liquids supplied at less
than atmospheric pressure (suction lift), in these nega-
9
tive pressure applications it is important that all con- 2.7 VALVES
nections be absolutely drip free and vacuum tight, and
that a foot valve be installed at the bottom of the suction Back Pressure Valves
line (see upper left illustration of Figure 4). All metering pumps are prone to overpumping (exces-
sive output) at low discharge pressures. To prevent this
When pumping a liquid near its boiling point, provide
condition from occurring, it is necessary to maintain
enough suction head to prevent the liquid from “flash-
approximately 10 psi (0.7 bar) back pressure against
ing” into vapor when it enters the pump liquid end on the
the pump. This can be accomplished through the in-
suction stroke.
stallation of a back pressure valve in the discharge line.
If possible, use metal or plastic tubing for the suction Typically, the valve should be located near the pump.
line because tubing has a smooth inner surface and However, back pressure valves for large pumps with long
can be formed into long, sweeping bends to minimize and extremely small discharge lines may have to be
frictional flow losses. installed near the point of discharge into the process (to
minimize siphoning tendencies).
A strainer should be used in the suction line to prevent
foreign particles from entering the liquid end. This and Pulsation Dampeners
any other measures which prevent debris from entering An accumulator, surge chamber, surge suppressor, or
and fouling the liquid end check valves will give increased pulsation dampener should be used with the back pres-
maintenance-free service. Check strainer frequently to sure valve in the discharge line to absorb the flow peaks
prevent blockage which could lead to cavitation. Keep between the pump and the back pressure valve. With-
suction piping as short and straight as possible. out the pulsation dampener the valve mechanism will
Piping size should be larger than the liquid end suction snap open and close with the surge from each pump
fitting to prevent pump starvation. stroke. The pulsation dampener will allow the back pres-
sure valve to oscillate about a partly-closed position,
If long suction lines are unavoidable, install a stand pipe thus minimizing wear on the valve. Discharge line pul-
near the pump in the suction line. sation dampeners offer the further advantage of limiting
the flow and pressure variations characteristic of this
Suction piping must be absolutely airtight to ensure ac-
kind of pump. Installing a properly sized pulsation damp-
curate pumping. After installation, test suction piping
ener will improve pump performance and may reduce
for leaks with air and soap solution.
system costs dramatically by permitting the substitu-
tion of smaller piping. Please contact your dealer for
2.6.4 DISCHARGE PIPING CONSIDERATIONS further information on pulsation dampeners.
Install pipe large enough to prevent excessive pressure Safety Valves and Priming Valves
losses on the discharge stroke of the pump. Maximum Motor-driven positive displacement pumps can develop
pressure at the discharge fitting on the liquid end must excessive discharge pressures long before thermal over-
be kept at or below the rated pressure (shown on the load devices interrupt the motor electrical circuit. To
pump nameplate). prevent a blocked discharge line from causing damage
The pump will not deliver a controlled flow unless the to the pump, piping, or process equipment, install a
discharge line pressure is 10 psi greater than the suc- safety valve in the pump discharge line. This valve is
tion line pressure. One way to create an artificial pres- designed and sized to handle system flow rates and
sure is the installation of a back pressure valve. (Please pressures safely while resisting corrosion by the pro-
contact your dealer for recommendations to increase cess liquid.
back pressure in slurry applications). To aid in pump start-up, it is advisable to install a prim-
When pumping water treatment chemicals directly into ing valve on the discharge side of the liquid end.
boiler drums, use one liquid end assembly for each boiler Shut-off Valves
drum. Discharging into a manifold having the slightest
pressure difference between its several discharge con- Provide shut-off valves in both suction and discharge
nections can diminish metering accuracy as the outlet lines next to the pump. Locate discharge line shut-off
with the lowest pressure will receive more liquid than valve downstream from the inlet connection of the safety
the other outlets. valve. Figure 5 shows recommended valve locations.
10
2.8 ELECTRICAL CONNECTIONS
11
14
SECTION 3
OPERATION
3.1 START-UP PROCEDURES AND CHECKS The pump can be calibrated by measuring the decrease
in liquid level pumped from a calibrated vessel. This
Check that the pump is secured to its support. method is recommended for hazardous liquids because
If oil was previously removed for any reason, make sure it eliminates operator contact with the liquid. Calibra-
pump drive has the correct volume (1 quart) of oil (Mobil tion columns are available for convenient and accurate
SHC 629). calibration of the pump. Contact your dealer for more
information.
Make sure all isolation valves installed on the suction
and discharge lines are open. If the discharge line is
equipped with an injection nozzle or a back-pressure
valve, open the priming valve for discharge (if there is no
priming valve, disconnect the discharge pipe). This al- THIS METHOD IS GENERALLY NOT RECOM-
lows for verification that liquid is present in the liquid MENDED AS IT MAY EXPOSE OPERATING
end when the pump is installed in flooded suction con- PERSONNEL TO HAZARDOUS LIQUIDS.
dition. If the pump is installed in a suction lift condition, FURTHERMORE, IF NO BACK PRESSURE IS
this allows for priming of the pump during start-up. PRESENT ON THE DISCHARGE SIDE, THE
PUMP MAY OVERPUMP DRAMATICALLY IN
Make sure that pump is set at 0% capacity. WHICH CASE THE POSITION OF THE CA-
PACITY ADJUSTMENT KNOB MAY HAVE
LITTLE EFFECT ON ACTUAL FLOW RATE.
3.2 CHECKING THE ELECTRICAL CONNECTION OF
THE MOTOR
12
15
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13
16
SECTION 4
MAINTENANCE
4.1 PREVENTATIVE MAINTENANCE packed in the shipping crate with any pump
shipped for repair. These safety precautions
Drive will aid the troubleshooting and repair proce-
Initially, change the oil in the pump drive assembly after dure and preclude serious injury to repair per-
the first 1000 hours of operation. Thereafter, change sonnel from hazardous residue in pump liquid
drive oil on an annual basis or after every 5000 hours of end. A Materials Safety Data Sheet must ac-
operation. company all returns.
The drive should be refilled with 1 quart of Mobil SHC All inquiries or parts orders should be addressed to your
629: local representative or distributor.
Viscosity @ 100 oF = 726 SSU
4.3 ROUTINE MAINTENANCE
Viscosity Index = 149
ISO Grade = 150 LMI/Milton Roy Series G pumps are carefully designed,
manufactured, assembled, and quality tested to give
Diaphragm Assembly reliable service with minimal maintenance. However, a
The Series G Model D diaphragm should be replaced weekly maintenance check is recommended to confirm
annually or every 5000 hours of operation to avoid the proper operation of the pump.
possibility of failure. Refer to the instructions in Sec- Visual Check of Seal Integrity of Mechanical
tion 4.6 Diaphragm and Oil Seal Bellows Replacement. Assembly
Oil Seal Bellows Check for leaks in the following components. If leaks
The Series G Model D oil seal bellows should also be exist, contact the factory for assistance.
replaced annually. Oil seal bellows replacement requires 1. Motor flange: If leaking, replace motor flange sealing
the removal of the diaphragm assembly, so it is recom- gasket (Item 11 in Figure 8).
mended that the oil seal and diaphragm assembly be
replaced at the same time. Refer to the instructions in 2. Stroke adjustment knob: If leaking, replace stroke
Section 4.6 Diaphragm and Oil Seal Bellows Replace- adjustment seal (Item 160 in Figure 8).
ment. Checking the Pump Capacity
Check Valves Assuming the pump has been calibrated as described
As in the case of the diaphragm, LMI/Milton Roy Com- in Section 3, the capacity can be checked by shutting
pany recommends that check valve balls, seats, gas- the valve from the supply vessel and opening the valve
kets, and O-rings be replaced on an annual basis or from the calibration column to the suction side of the
every 5000 hours of operation. If highly corrosive mate- liquid end. Measure the volume of pumped liquid for a
rial (acids, slurries, etc.) is being pumped, more fre- given period of time at the various settings.
quent replacement may be required. Complete instruc- If a calibration column is not installed in the suction
tions for replacement of worn check valves are given in piping, place the foot valve (or suction line) in a calibrat-
Section 4.5 Corrective Maintenance. ing chamber (graduated reservoir). Measure the volume
of pumped liquid for a given period of time at the various
settings.
4.2 RETURNING PUMPS TO THE FACTORY FOR
REPAIR Occurrence of Leak From Detection Ports
Pumps can not be accepted for repair without a Return Determine whether the product collected at the detec-
Material Authorization. Pumps should be clearly labeled tion port in the liquid end mounting assembly is lubri-
to indicate the liquid being pumped. Process liquid cating oil or the pumped fluid.
should be flushed from the pump liquid end and oil should
If the product is pumped fluid, the diaphragm has failed.
be drained from the pump housing before the pump is
If the product is lubricating oil, the oil seal bellows has
shipped.
failed. Proceed with its replacement (see Section 4.6
Note: United States of America Federal law Diaphragm and Oil Seal Bellows Replacement).
prohibits handling of equipment that is not ac-
companied by an OSHA Material Safety Data
Sheet (MSDS). A completed MSDS must be
14
17
Figure 6:
Diaphragm Assemblies
By Liquid End Size and Material
260 274
260
271
252 240
250
270
260
260
274 274
240 271 271
251
240
250 250
270
253
270
4.4 SPARE PARTS 4.4.1 SIZE SD2 AND SD4 LIQUID ENDS - PVC AND
PVDF
The following spare parts should be stocked for each
pump to prevent serious delays in repairs. (Refer to 1 each, Diaphragm: Item 260 in Figure 6.
Figures 6 thru 14).
1 each, Oil Seal Bellows: Item 70 in Figure 7.
Parts orders must include the following:
2 each, Cartridge Valve Assembly: Item 425 in Fig-
1. Quantity required ure 9.
2. Part number
3. Part description 4.4.2 SIZE SD2 AND SD4 LIQUID ENDS - STAIN-
LESS STEEL
4. Pump serial number (found on nameplate)
1 each, Diaphragm: Item 260 in Figure 6.
5. Pump product code (found on nameplate)
1 each, O-Ring: Item 253 in Figure 6 (SD4 only).
Note: Always include the serial number and
product code in all correspondence regarding 1 each, Oil Seal Bellows: Item 70 in Figure 7.
the unit.
2 each, Check Valve Assembly: Item 425 in Fig-
ures 10 & 11.
15
Note: Liquid end sizes SD2 and SD4 metallic Cleaning Fouled Check Valves
check valves are precision assembled at the
Check valve assemblies are designed to be self-clean-
factory. Do not attempt to disassemble these
ing and should seldom need servicing. Fouled check
cartridges.
valves can usually be cleaned by pumping a solution of
mild detergent and warm water (if compatible with liquid
4.4.3 SIZE SD7 AND SD8 - PVC AND PVDF LIQUID being pumped) for 15 minutes, followed by flushing with
ENDS water.
Check Valve Replacement
1 each, Diaphragm: Item 260 in Figure 6.
General
1 each, Oil Seal Bellows: Item 70 in Figure 7.
Before beginning work on the valve assemblies, make
2 each, Seat, O-Ring, Ball Set: Item 423 in Figure
sure the suction and discharge shut-off valves are closed
12.
and that pressure has been bled from the pump liquid
Note: Item 423 (Kit) contains the following: end. When replacing the valves, be sure to replace the
valve O-rings. Pay close attention to the proper assem-
• 1 each, Ball: Item 422 bly and orientation of the check valves as shown in each
Liquid End figure. In the case of plastic check valves for
• 1 each, Seat: Item 420 liquid end size SD7 and SD8, be certain that the ball is
• 2 each, O-rings: Item 419 placed on the sharp edge of the valve seat.
Note: The check valves for the size SD7 and (A) IMMEDIATE AND SEVERE DAMAGE TO
SD8-PVC and PVDF liquid ends contain a re- PUMP MECHANISM.
movable seat, which permits the replacement (B) NO PUMPING OF FLUIDS.
of the seat, O-ring, and ball into a reusable
valve body. The liquid end size SD7 and SD8- (C) REVERSE PUMPING ACTION (FROM
Stainless Steel check valve has an integral ball DISCHARGE LINE INTO SUCTION LINE).
seat, which necessitates replacement of the Preliminary Operations
entire check valve assembly.
1. Set the pump capacity knob to 0%. If stroke locking
screw (Item 320 in Figure 8) was previously tightened,
4.5 CORRECTIVE MAINTENANCE slightly loosen the locking screw.
2. Disconnect power to pump motor. Check that the
equipment cannot be accidentally started. Place a no-
tice at the location of the power switch indicating that
BEFORE CARRYING OUT ANY SERVICING the pump is being serviced.
OPERATION ON THE PUMP OR PIPING, DIS-
CONNECT ELECTRICAL POWER FROM THE 3. Disconnect the pump hydraulically by removing pipe
PUMP, AND TAKE THE NECESSARY STEPS or tubing connections to suction and discharge check
TO ENSURE THAT ANY HARMFUL LIQUID valves.
CANNOT COME INTO CONTACT WITH PER-
SONNEL. SUITABLE PROTECTIVE EQUIP-
MENT MUST BE PROVIDED. BE SURE THAT
THERE IS NO FLUID PRESSURE IN THE
PUMP LIQUID END AND PIPING.
16
4.5.1 CHECK VALVE ASSEMBLIES REPLACEMENT: Disassembly
LIQUID ENDS SD2 AND SD4 - PVC AND PVDF
Remove the check valves by unscrewing them from the
(SEE FIGURE 9 OR 12)
pump head.
Reassembly
Apply a small amount of thread sealing compound and
IMPROPER BALL AND SEAT INSTALLATION PTFE pipe tape to check valve threads and install check
CAN CAUSE DAMAGE TO THE PUMP. SEE valves by screwing them into the pump head with the
FIGURE 9 OR 11 FOR PROPER BALL AND flow arrows pointing up. DO NOT OVERTIGHTEN
SEAT ORIENTATION FOR BOTH THE SUC- CHECK VALVES.
TION AND DISCHARGE VALVES
17
IF THE UNIT IS DISASSEMBLED FOR IN- DO NOT APPLY PTFE TAPE TO THREADS
SPECTION ONLY, BE SURE TO USE A BLUNT OF CHECK VALVE BODY (424) AS THIS MAY
INSTRUMENT AND TAP GENTLY TO AVOID PREVENT ADEQUATE SQUEEZE FROM BE-
DAMAGING THE BALL. IF THE BALL AND/ ING APPLIED TO THE VALVE O-RING WHICH
OR SEAT ARE DAMAGED DURING DISAS- WOULD RESULT IN LEAKAGE.
SEMBLY, THEY WILL HAVE TO BE RE-
PLACED. IF AVAILABLE, TO AVOID DAM- Note: To assure a tight, leak free seal, new O-
AGE, IT IS ADVISABLE TO USE GENTLE AIR rings should be used each time the check
PRESSURE (APPLIED AT END OPPOSITE valves are disassembled.
THE SEAT (420) FOR BALL AND SEAT RE- 4. Position the union end (445) onto the correct end of
MOVAL. the body. Refer to Figure 12, as the correct end is
6. Carefully remove the two O-rings (419) from the ball determined by whether the valve is intended for the suc-
guide and seat. tion or discharge port of the liquid end. Slip the union
nut (435) over the union end and screw tightly (hand
7. Carefully clean any parts to be reused. If any chemi- tight only) onto the body.
cals are used in the cleaning process, ensure that they
are compatible with the process liquid. 5. Screw the valve assembly into the pump head (hand
tight only). DO NOT OVERTIGHTEN.
Reassembly
(B) NO PUMPING 2. Unscrew the check valve assembly (425) from the
liquid end.
(C) REVERSE PUMPING ACTION (FROM
DISCHARGE LINE INTO SUCTION LINE) Reassembly
1. Drop the ball (422) into the curved inner chamber end
of the body (424).
2. Set the body on a flat surface so that the end with the THE ORDER OF ASSEMBLY AND ORIENTA-
ball faces upward. Position seat (420) on the body, TION OF THE SUCTION AND DISCHARGE
with the beveled edge of the seat facing outward. When CHECK VALVES IS DIFFERENT. REFER TO
the seat is pressed into the body, the ball should be FIGURE 14 FOR PROPER ASSEMBLY OR-
sitting on the side with sharp corners as shown in Fig- DER AND ORIENTATION. IF CHECK VALVE
ure 13. The bevel should not face the inside of the CARTRIDGES ARE INSTALLED INCOR-
check valve. Use a flat surface such as a board to RECTLY, ONE OF THE FOLLOWING WILL
press the seat into the body with firm, even pressure. OCCUR:
If the seat is improperly positioned, the ball will not cre- (A) IMMEDIATE SEVERE DAMAGE TO PUMP
ate a tight seal and poor pumping performance will re- MECHANISM
sult.
(B) NO PUMPING
3. Fit new O-rings (419) into position on the body (424) (C) REVERSE PUMPING ACTION (FROM
and seat (420). DISCHARGE LINE INTO SUCTION LINE)
18
1. Screw the correct end of the check valve assembly diaphragm, screw the diaphragm assembly onto the male
into the pump head, trapping a new O-ring between the thread of the adaptor piece (Item 252 in Figure 9) until it
pump head and the check valve assembly. reaches its mechanical stop.
5. With the capacity still set at 100% turn the motor fan
until the new diaphragm is in the farthest rearward posi-
tion (bottom dead center).
DO NOT APPLY PTFE TAPE TO THREADS
6. Reattach the diaphragm head with the suction and
OF CHECK VALVE BODY AS THIS MAY PRE-
discharge ports in the correct positions. Tighten the
VENT ADEQUATE SQUEEZE FROM BEING
screws in a crosswise pattern to a torque of 45 in-lb.
APPLIED TO THE VALVE O-RING WHICH
WOULD RESULT IN LEAKAGE. 7. While turning the motor fan, set the stroke adjust-
ment knob to the 0% position.
Note: To assure a tight, leak free seal, new O-
rings should be used each time the check 8. Reinstall motor fan cover.
valves are disassembled.
2. Screw the coupling (445) onto the check valve as- 4.6.2 DIAPHRAGM REPLACEMENT: LIQUID END
sembly, trapping a new O-ring (419) between the cou- SIZE SD4, SD7, AND SD8 (SEE FIGURES 6, 11 - 14)
pling and the check valve assembly.
1. Mark the suction and discharge ports on the dia-
phragm head prior to removal. Loosen the head screws
4.6 DIAPHRAGM AND OIL SEAL BELLOWS RE- (290) and remove the diaphragm head (280).
PLACEMENT
2. Remove the motor fan cover and turn the motor by
hand while adjusting the capacity control knob to 100%.
With the capacity set at 100%, turn the motor fan until
the diaphragm cap (240) is in the full forward position
BEFORE BEGINNING DIAPHRAGM RE- (top dead center).
PLACEMENT, MAKE SURE THAT ALL SHUT-
3. Hold the outer edge of the diaphragm (260) and turn it
OFF VALVES ARE CLOSED AND ALL PRES-
counterclockwise to unscrew it from the pump drive.
SURE IS BLED FROM THE LIQUID END.
4. While clamping on the hex on the diaphragm cap
If failure of the oil seal bellows has occurred, it is rec-
(240), disassemble diaphragm assembly by removing
ommended that the diaphragm assembly and oil seal
the hex nut (271) on the back of the diaphragm support
bellows be replaced at the same time.
nut (270).
5. Make sure that stainless steel support nut (270) is
4.6.1 DIAPHRAGM REPLACEMENT: LIQUID END clean and free of corrosion. When cleaning the support
SIZE SD2 (SEE FIGURES 6, 9, AND 10) nut, take care not to scratch the smooth angled surface
1. Loosen the head screws (Item 290 in Figure 9) and of the support nut. If corrosion cannot be removed with-
remove the diaphragm head (Item 280 in Figure 9). Mark out damaging the support nut, replace with a new one.
the suction and discharge ports on the diaphragm head 6. Install new diaphragm (260) onto diaphragm cap (240)
prior to removal. with the convolution in correct orientation. As shown in
2. Remove the motor fan cover and turn the motor by Figure 6, the convolution in the Teflon diaphragm should
hand while adjusting the capacity control knob to 100%. be facing down away from diaphragm cap (240) and
With the capacity set at 100%, turn the motor fan until against (or pointing towards) the stainless steel sup-
the diaphragm (Item 260 in Figure 9) is in the full for- port nut (270)
ward position (top dead center). 7. For Size SD4-stainless steel liquid ends, slide bolt
3. Hold the outer edge of the diaphragm and turn it coun- (250), washer (251), and O-ring (253) through the dia-
terclockwise to unscrew it from the pump drive. phragm cap and diaphragm as shown in Figure 6. For
all other liquid ends, install set screw (Item 250 in Fig-
4. Discard and replace with new diaphragm. Make sure ure 6) into diaphragm cap (240), with hex hole in screw
that adaptor (Item 252 in Figure 9) is screwed in tightly facing outward, until it is bottomed out (hand tight only)
to connecting rod (Item 60. in Figure 7). Make sure that in the diaphragm cap.
seat ring (Item 230 in Figure 9) is in place. Apply a thin
layer of silicone grease to back (rubber side) of dia- 8. Slide support nut (270) onto set screw in correct ori-
phragm before installation. Holding the edges of the entation shown in Figure 6.
19
9. Install hex nut onto back of support nut and tighten to 4.7 OIL SEAL BELLOWS REPLACEMENT (ITEM 70
the following torque values dependent on liquid end size IN FIGURE 7)
and material. Torque diaphragm assembly as follows:
a) Liquid End Size SD7 and SD8 to 20 foot pounds.
b) Liquid End Size SD4-Plastic to 45 inch pounds.
BEFORE BEGINNING OIL SEAL REPLACE-
c) Liquid End Size SD4-Stainless Steel tighten MENT, MAKE SURE ALL SHUT-OFF VALVES
until washer (Item 251 in Figure 6) is ARE CLOSED AND ALL PRESSURE HAS
contacting diaphragm cap (Item 240 in Figure BEEN BLED FROM THE LIQUID END (PUMP
6). HEAD). WHEN REPLACING THE OIL SEAL,
THE DIAPHRAGM ASSEMBLY MUST BE RE-
10. Make sure that support ring (230) is in place and MOVED FIRST. FOR EASE OF SERVICE, IT
then reinstall diaphragm assembly. IS RECOMMENDED THAT THE OIL SEAL BE
11. Apply thin layer of O-ring type grease to back of hex REPLACED IN CONJUNCTION WITH THE DIA-
nut (271) and reinstall thin PTFE washer (274) to back PHRAGM ASSEMBLY.
of support nut. 1. Disconnect connections to the pump motor terminal
12. Make sure that oil seal clamp ring (Item 210 in Fig- box. Be sure to note the wiring layout before discon-
ure 12) is in place. Screw diaphragm assembly into necting from box.
connecting rod (Item 60 in Figure 7) until it reaches its 2. Set the stroke adjusting knob to 100%.
mechanical stop.
3. Disconnect the suction and discharge connections
Note: Steps 11 and 12 are applicable to Liquid to the pump head check valves.
End Size SD4 (See Figure 6).
4. Mark the suction and discharge ports on the dia-
13. Apply a thin layer of grease to the back of hex nut phragm head prior to removal. Loosen the head screws
(271). (Item 290 in Figure 12) and remove the diaphragm head
14. Make sure that spring (Item 272 in Figure 13) is in (Item 280 in Figure 12).
place and connecting rod is in full-forward position (at 5. Remove the motor fan cover and turn the motor by
100% capacity setting). Screw diaphragm assembly hand while adjusting the capacity control knob to 100%.
into connecting rod cross piece (Item 61 in Figure 13) With the capacity set at 100%, turn the motor fan until
until it reaches its mechanical stop. the diaphragm assembly (Figure 6) is in the full forward
Note: Steps 13 and 14 are applicable to Liquid position (top dead center).
End Size SD7 and SD8 (See Figure 6). 6. Hold the outer edge of the diaphragm assembly (Item
15. With the capacity still set at 100% turn the motor 260 in Figure 6) and turn it counterclockwise to unscrew
fan until the diaphragm is pulled back to the rearward it from the pump drive.
position (bottom dead center). 7. Remove the diaphragm support ring (Item 230 in Fig-
16. Reattach the diaphragm head with the suction and ure 12) from the spacer (225).
discharge ports in the correct positions. Torque the 8. Drain the oil out of the pump drive by removing the
head assembly screws in a crosswise pattern as fol- drain plug from the pump housing (Item 20 in Figure 8).
lows:
9. Remove oil seal bellows clamping components as
a) Liquid End Size SD2 and SD4 to 45 inch pounds. follows:
b) Liquid End Size SD7 and SD8 to 90 inch pounds. a) On Liquid End Size SD2 models (Figures 9 &
17. While turning the motor fan, set the stroke adjust- 10), remove adaptor piece (252), clamp ring
ment knob to the 0% position. (210), mounting screws (227), and spacer (225).
18. Reinstall motor fan cover. b) On Liquid End Size SD4 models (Figures 11 &
12), remove oil seal clamp ring (210), mounting
screws (227), and spacer (225).
c) On Liquid End Size SD7 and SD8 models
(Figure 13 & 14), remove spring (272), unscrew
adapter (61), seal ring (210) mounting
screws (227& 228), and spacer (225).
20
10. Pull the oil seal (70) off the connecting rod (60).
11. Install a new oil seal onto connecting rod.
12. Apply a thin layer of O-ring type grease to top of oil
seal (part adjacent to connecting rod).
13. Reinstall parts removed in step 9. For Liquid ends
SD2, SD7, and SD8, install adaptor piece (252) or cross
piece (61) before mounting spacer.
14. Remove the motor and refill pump drive with oil (1
quart of Mobil SHC 629).
15. Reinstall motor.
16. Reinstall liquid end components in accordance with
the procedures found in the following:
a) For Liquid End Size SD2 models, refer to
paragraph 4.6.1, steps 4 thru 7.
b) For Liquid End Sizes SD4, SD7, and SD8
models, refer to paragraph 4.6.2, steps 10 thru
17.
17. Connect the motor in compliance with the direc-
tions marked during the prior disconnection (see also
Section 2: ELECTRICAL CONNECTIONS).
21
24
SECTION 5
PARTS LIST
GENERAL
22
25
Figure 7:
Drive Side View
400
410
380
EIC MOTOR
ONLY
346
347
60
342
360
340
150
70 10
23
5.1 PARTS LIST FOR DRIVE SIDE VIEW
24
Figure 8:
Drive End View
11
100
335
121
332
600
101
330 50
160
110
200
310
322 320
19 190 130
205 20
206
25
5.2 PARTS LIST FOR DRIVE END VIEW
26
Figure 9:
SD2 Plastic Liquid 426
End
424
ASSEMBLY
427 227
425
422
252
420
419 430
290
PLASTIC
LIQUID END 300
ONLY
260
280
419
426
422 225
210
420
425 427
ASSEMBLY
27
5.3 PARTS LIST FOR SD2 PLASTIC LIQUID END PVC-NPT AND PVC-TUBING
Model: Code:
SD2_ _ 8P A
SD2_ _ 8T B
SD2_ _ 2P C
SD2_ _ 2T D
28
Figure 10:
SD2 Metallic Liquid End 227
ASSEMBLY 252
425
230
290
260
280
ASSEMBLY
225
425
210
5.4 PARTS LIST FOR SD2 METALLIC LIQUID END STAINLESS STEEL-NPT
Model: SD2 _ _ 7P
29
Figure 11: 230
SD4 Metallic Liquid End
227
ASSEMBLY 225
425
271
280
290
240
251
250
253
ASSEMBLY
425 270 210
274
260
5.5 PARTS LIST FOR SD4 METALLIC LIQUID END STAINLESS STEEL-NPT
Model: SD4 _ _ 7P
420
419
290
PLASTIC
LIQUID END 300
ONLY 240
280
PLASTIC
LIQUID END 250
DIAPHRAGM 219
ASSEMBLY
426
422
270 210
420
425
427 274
ASSEMBLY
260
31
5.6 PARTS LIST FOR SD4 PLASTIC LIQUID END PVC-NPT AND PVC-TUBING
Model: Code:
SD4_ _ 8P A
SD4_ _ 8T B
SD4_ _ 2P C
SD4_ _ 2T D
32
Figure 13: SD7 & SD8 Plastic
Liquid End
CHECK VALVE 227 228
ASSEMBLY 445
425
419 435
273
422
KIT 424
423 420
62
419
260
271
280
240
250
270
290 300
302 305
419 61 225
CHECK VALVE
ASSEMBLY
424
425 272
422
KIT
423 420
419
230 448 302 305
435 445
33
5.7 PARTS LIST FOR SD7 AND SD8 PLASTIC LIQUID END PVC-NPT AND PVDF-NPT
Model: Code:
SD7_ _ 8P or SD8_ _ 8P A
SD7_ _ 2P or SD8_ _ 2P B
34
Figure 14: SD7 & SD8 316SS
Liquid End 445 61
272
ASSEMBLY
273
425
62
419
260
240
280
250
270
290 300
302 304 305
271 210
419
ASSEMBLY
425
445 230
35
5.8 PARTS LIST FOR SD7 AND SD8 316SS-NPT LIQUID END
36
THIS PAGE INTENTIONALLY BLANK
37
40
SECTION 6
TROUBLESHOOTING
1. Pump motor won't operate. a) Low process liquid level in the a) Add liquid.
tank.
38
41
SYMPTOMS POSSIBLE CAUSE REMEDY
5. Pump still pumps even at zero a) Misadjusted capacity knob. a) Readjust capacity setting.
capacity setting.
b) Insufficient discharge pressure. b) Correct condition (e.g., install a
back pressure valve).
7. Loud knock with each stroke. a) Excessive gear set wear. a) Consult service facility.
8. Noisy operation in liquid end. a) Noise in check valves. a) Ball checks move up and down
with some force. A distinct
"clicking" noise is normal,
especially in metal piping
systems.
39
42
SECTION 7
LIMITED WARRANTY
The LMI/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 twelve
months from shipment by the Company. The Company additionally warrants that all of its other products, includ-
ing 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, as
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 prod-
ucts 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.
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.
40
201 Ivyland Road • Ivyland, PA 18974 USA • (215) 293-0401 • Fax: (215) 293-0445• www.lmipumps.com
E-mail: info@lmipumps.com