Milton Roy MILROYAL D Instruction Manual
MILROYAL® D Drive With
Packed Plunger Liquid End
Instruction Manual
Manual No : 53941
Rev. : 00
Rev. Date : 01/2016
PRECAUTIONS
The following precautions should be taken when working with 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 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/ GROUND.
• 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, ush 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/pressurerelief 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.
ii Instruction Manual
TABLE OF CONTENTS
SECTION 1 - INSTALLATION ................................................................1
1.1 INTRODUCTION .................................................................1
1.2 UNPACKING .................................................................... 1
1.3 MOUNTING ..................................................................... 1
1.4 PIPING ....................................................................... 1
1.4.1 General Information ............................................................. 1
1.4.2 Suction Piping .................................................................. 2
1.4.3 Discharge Piping................................................................ 2
1.5 SERVICE CONNECTIONS .........................................................2
1.5.1 Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5.2 Auxiliary (Accessory) Equipment.................................................... 3
1.5.3 Drains ....................................................................... 3
SECTION 2 - OPERATION .................................................................. 4
2.1 PRINCIPLES OF OPERATION ...................................................... 4
2.2 OPERATION .................................................................... 4
2.2.1 Pre- Operational Inspection ....................................................... 4
2.2.2 Capacity Adjustment: Stroke Length................................................. 4
2.2.3 Capacity Adjustment: Stroke Speed .................................................5
2.3 START-UP ...................................................................... 5
2.3.1 General.......................................................................5
2.3.2 Packing.......................................................................5
2.3.3 Capacity Calibration .............................................................5
SECTION 3 - MAINTENANCE INSTRUCTIONS- DRIVE SECTION................................... 6
3.1 LUBRICATION................................................................... 6
3.2 SPARE PARTS .................................................................. 6
3.3 RETURNING PUMPS TO THE FACTORY ............................................. 6
3.4 REPLACING SPARE PARTS........................................................ 7
3.4.1 Removal of Gear Cage ...........................................................7
3.4.2 Removal of Crosshead ........................................................... 7
3.4.3 Assembly and Installation of Crosshead.............................................. 7
3.4.4 Assembly of Gear cage into Pump Housing ...........................................8
SECTION 4 - MAINTENANCE INSTRUCTIONS- LIQUID END 1/8” and 1/4” DIAMETER PLUNGERS...... 10
4.1 SPARE PARTS ................................................................. 10
4.2 RETURNING PUMPS TO THE FACTORY ............................................ 10
4.3 LUBRICATION.................................................................. 11
4.4 CHECK VALVE MAINTENANCE .................................................... 11
4.5 PACKING ADJUSTMENT, START- UP AND REPLACEMENT ............................. 11
4.5.1 Replacing Packing ............................................................. 11
iiiInstruction Manual
SECTION 5 - MAINTENANCE INSTRUCTIONS- LIQUID END 7/16” and 5/8” DIAMETER PLUNGERS .... 13
5.1 SPARE PARTS ................................................................. 13
5.2 RETURNING PUMPS TO THE FACTORY ............................................ 13
5.3 LUBRICATION.................................................................. 14
5.4 CHECK VALVE MAINTENANCE ....................................................14
5.5 PACKING ADJUSTMENT, START- UP AND REPLACEMENT ............................. 14
5.5.1 Types of Packing............................................................... 15
5.5.2 Replacing Packing ............................................................. 15
SECTION 6 - TROUBLESHOOTING .......................................................... 17
LIST OF ILLUSTRATIONS
FIGURE 1. Pump dimensions ................................................................ 18
FIGURE 2. Polar Crank Mechanism ........................................................... 19
FIGURE 3. Basic Drive Assembly Drawing (102-2906-0001) ........................................ 20
FIGURE 4.1/8” and 1/4” Liquid Ends Assembly Drawing (102-290-600-015) ............................23
FIGURE 5. 7/16” and 5/8” Liquid Ends Assembly Drawing (102-290-600-012)........................... 25
LIST OF TABLES
TABLE 1. Drive Spare Parts .................................................................. 6
TABLE 2. Spare Parts for Liquid Ends with 1/8” and 1/4” Diameter Plunger. ............................ 10
TABLE 3. Spare Parts for Liquid Ends with 7/16” and 5/8” Diameter Plunger. ........................... 13
TABLE 4. Basic Drive Assembly Drawing Location Reference Chart .................................. 21
TABLE 5. 1/8” and 1/4” Liquid Ends Assembly Drawing Location Reference Chart ....................... 24
TABLE 6. 7/16” and 5/8” Liquid Ends Assembly Drawing Location Reference Chart ......................26
iv Instruction Manual
SECTION 1 - INSTALLATION
1.1 INTRODUCTION
The MILROYAL® D Controlled Volume Pump is a
reciprocating plunger, positive displacement pump
designed to deliver accurately measured liquid
volumes against a positive differential pressure
(or head) between pump suction and discharge.
Precision built, the pump performs this function with
a repetitive accuracy of plus or minus one percent
of mean delivered volume.
Basically, the pump consists of a drive unit, plunger
and displacement chamber or liquid end in which
the plunger reciprocates. The pump delivers a
controlled volume of liquid with each discharge
stroke.
Pump capacity is adjustable by changing plunger
stroking speed and / or length. Capacity adjustment
can be made manually or automatically by
signal from remote process control instruments.
Selection of capacity control methods is determined
by the nature of the application.
1.3 MOUNTING (Refer to Figure 1)
Support the pump rmly in a level position on a
solid foundation, preferable with the base above
floor level to protect it from wash downs and
provide easier access for service. This model
pump is provided with three tie-down points to
accommodate anchor bolts. Table-top operation
is possible without need for tie-down with 1/8” or
1/4” plunger diameter liquid end, but tie-down is
necessary for 7/16” and 5/8” plunger diameter liquid
ends. Up to six units can be easily multiplexed to
a single standard motor without special support.
1.4 PIPING
1.4.1 General Information
1. Use piping materials that are resistant to
corrosion by the liquid being pumped. Use
care in selection of materials to avoid galvanic
corrosion at points of connection to the pump
liquid end.
1.2 UNPACKING
Pumps are shipped Free on Board (FOB) from
the factory and title passes to the customer
when carrier signs for receipt of it. The customer,
therefore, must le damage claims with the carrier.
The shipping crate should be carefully examined
upon receipt from carrier to be sure there is no
obvious damage to the contents. Open the crate
carefully, as there are sometimes accessory items
fastened to the inside of the crate which may be
lost or damaged. Examine all material inside crate
and check against packing list to be sure that all
items are accounted for and undamaged.
2. Use piping sufficiently heavy to withstand
maximum pressures.
3. Blow out all lines before making nal connections
to pump.
4. Provide for pipe expansion when hot uids are to
be pumped. Support piping so that pipe weight
is not placed on the pump. Never spring piping
to make connections.
5. Piping should be sloped in a manner to prevent
trapping of vapor pockets. Vapor present in liquid
end will cause inaccurate pump delivery.
1Instruction Manual
SECTION 1 - INSTALLATION
1.4.2 Suction Piping
1. If possible use metal or plastic tubing for the
suction line because tubing has a smooth inner
surface and can be formed into sweep bends,
thus decreasing frictional ow losses.
2. Suction piping must be absolutely air tight to
insure accurate pumping. After installation, test
suction piping with air and soap solution for
leaks.
3. A strainer should be used in the suction line to
prevent foreign particles from entering the liquid
end. Any measures which prevent foreign matter
from entering and fouling the ball checks will
give increased maintenance free service.
4. It is preferable to have the suction of the pump
ooded by having the liquid end located below
the level of the uid in the supply tank.
5. When pumping liquids at temperatures near the
boiling point, provide sufcient suction head to
prevent “ashing’’ of the liquid into vapor when
it enters the liquid end on the suction stroke.
6. Suction piping need to be one or two sizes larger
than the liquid end suction tting, ensure NPIP
(Net Positive Inlet Pressure).
7. Sealed piping, sufficient suction pressure,
and properly adjusted packing are absolutely
necessary for accurate and stable pump
operation.
1.4.3 Discharge Piping
1. Install adequate size pump to prevent excessive
pressure losses on the discharge stroke of the
pump. Maximum pressure at the discharge
fitting on the liquid end must be kept at or
below the maximum pressure rating as shown
on the pump data plate. The peak flow of
this type pump during the discharge stroke is
approximately three times the average ow rate
(because of harmonic motion of the plunger) and
discharge piping should be sized accordingly.
2. The pump will not deliver a controlled ow if
the discharge pressure is less than the suction
pressure. Piping should be arranged to provide
at least 5 psi (34.5 kPa) positive pressure
differential from the discharge side to the suction
side. There are a number of ways to create an
articial discharge pressure, such as the use of
a vented riser or a back pressure valve.
1.5 SERVICE CONNECTIONS
1.5.1 Pump Drive
1. Check the nameplate data on the pump drive
(motor) and insure proper power supply is
available before making any connections.
2. Preferred motor shaft rotation is marked on the
drive side ange of the pump. Although severe
immediate damage will not occur if motor
rotation is incorrect, preferred rotation should
be observed. (See Maintenance Instructions,
Assembly of Gear Cage into Pump Housing.)
Where possible, correct drive rotation will be
established at shipment by the factory.
2
3. For drives other than constant speed electric
motors, refer to complete manufacturer’s
instructions and service information included
with pump.
Instruction Manual
SECTION 1 - INSTALLATION
1.5.2 Auxiliary (Accessory) Equipment
1. Service connections for auxiliary or accessory
electrical equipment should be determined
by reference to wiring diagrams, instruction
manuals, and data plate requirements furnished
with the equipment.
2. Air operated equipment will normally require
two sources of air supply. A standard 60 psig
(414 kPa) (80-100 psi (552-690 kPa) at
compressor) plant air supply will usually
be satisfactory for the power elements.
An instrument air signal is required for control
instruments.
1.5.3 Drains
Provide drains convenient to the pump so that any
leakage may be easily removed. The pump catchall
area is provided with a cast hole which may be
drilled and tapped or otherwise altered to receive
desired piping for drainage.
3Instruction Manual
SECTION 2 - OPERATION
2.1 PRINCIPLES OF OPERATION
MILROYAL® D Pumps consist of two basic
mechanisms; the drive system and the liquid
end. The drive mechanism (Figure 1) is unique
and operates on a patented polar crank principle
(Figure 2). Essentially, a crank driven by a worm
gear reduction system rotates on a plane whose
slope is variable.
As the slope of the plane is changed OFF the
vertical, a link transmits the resulting reciprocating
motion from the crank to the plunger. Stroke length
of the pump is increased from zero to maximum
by adjusting the slope of the plane from vertical.
As the plunger reciprocates in the liquid end,
the pumped liquid is alternately drawn into
and discharged from the liquid end. On the
suction (rearward) stroke the liquid follows
the plunger, unseating the double suction ball
checks and seating the discharge ball checks
(Figure 4 or 5). The discharge ball checks prevent
back-ow of liquid into the displacement chamber.
On the discharge stroke (plunger moving forward)
the plunger exerts pressure on the liquid, causing
the discharge ball checks to rise, allowing liquid
to flow out of the displacement chamber and
seating the suction ball checks. Thus, by repetitive
reciprocating plunger strokes, liquid is caused to
ow in only one direction from the suction port,
through the displacement chamber, and out the
discharge port.
2.2 OPERATION
2.2.1 Pre-Operational Inspection
After the pump is installed, but before it is started for
the rst time, a number of checks should be made:
1. Be sure all tie down bolts are tight, piping is
installed properly, and the discharge line is
open.
2. Check the pump housing and ll to the correct
level with the recommended lubricant listed in
the table below. The nominal capacity of the
MILROYAL® D housing is 1 pint. Fill to the level
of the drain plug.
Liquid
End
Packed
Plunger
2.2.2 Capacity Adjustment: Stroke Length
Pump capacity is adjusted by turning the micrometer
type stroke adjustment knob clockwise to decrease
or counterclockwise to increase the capacity
as required. The adjustment scale is marked in
percent of full stroke, with calibration lines on
the knob at 1.0% intervals. There is a friction
plug and setscrew threaded into the side of the
boss enclosed by the stroke adjustment knob.
Periodic adjustment (tightening) may be required
to provide enough friction to keep the stroke
adjustment from creeping. The nylon friction plug
should be replaced when worn to keep from bearing
the steel setscrew against the stroke adjustment
screw threads and damaging this part.
Operating Oil
Temperature
15°F to 125°F
(-9°C to 52°C)
Type Oil
AGMA No. 7
Compounded
Nevastane SL 100,
Food Grade
4
Instruction Manual
SECTION 2 - OPERATION
2.2.3 Capacity Adjustment: Stroke Speed
Capacity of the MILROYAL® D Pump is
directly proportional to the input drive speed.
Most pumps are supplied with a constant speed
electric motor as the input power source. With a
constant speed input power source, the stroking
speed is established by the worm and worm gear
set installed in the pump housing, and may be
changed only by changing this gear set. The use
of a variable speed input power source, however,
allows continuous variation of stroking speed and,
therefore, output ow rate variation over a broader
range.
2.3 START- UP
2.3.1 General
All pumps are thoroughly tested under simulated
operating conditions before they leave the factory
to verify the pump capacity and to check the drive
motor for satisfactory operation at maximum rated
pressure. With the pump housing lled to the proper
oil level and all piping and electrical connections
made, the pump is now ready for start- up.
2.3.2 Packing
New packing, installed and shipped from the factory
in a complete pump or liquid end, has been “set’’
and run-in during production quality assurance
testing and requires no further breaking in for
start- up. During operation, if leakage does occur,
the gland nut should be tightened a little at a time
(1/6 turn or less) until leakage is minimized or
stopped. The packing should be allowed to resettle
at least ve minutes between adjustments. If it is
possible to tolerate a little leakage at the gland,
the leaking liquid will help to lubricate and cool
the packing and plunger, greatly extending the life
of both.
2.3.3 Capacity Calibration
After the initial break-in period and adjustment of
the packing, test runs should be made to determine
the exact capacity of these controlled volume pump
under the specic operating conditions for various
stroke length settings. Usually it is necessary to
calibrate the pump at only three stroke length
settings to determine its characteristics throughout
the entire range. The settings normally used are
full stroke (100%), 50%, and 20% stroke length.
Two methods of measuring the capacity in a given
time limit can be used:
1. Measure the drop in liquid level from calibrated
vessel (preferred).
2. Measure the quantity collected from the
discharge side of the pump.
It is essential that the suction lines of controlled
volume pumps be absolutely free of entrapped
air or vapor to prevent gas movement into the
liquid end. Milton Roy liquid ends are designed
to rapidly discharge any small bubbles which
may enter. However, any large amounts of gas
in the liquid end is alternately compressed and
expanded with each plunger stroke and causes
inaccuracies in pumping. In severe case the liquid
end may become vapor bound and cease pumping
altogether.
5Instruction Manual
SECTION 3 - MAINTENANCE INSTRUCTIONS-DRIVE SECTION
The MILROYAL® D Pump has been carefully
designed, manufactured, assembled, and tested
to give reliable service with a minimum amount
of maintenance. However, in normal operation,
a periodic check of the pump is recommended to
visually conrm proper operation of the pump.
3.1 LUBRICATION
Fill the gear section of the MILROYAL® D housing
with recommended gear lubricant (see page 8 for
oil type) to the oil level plug hole. The oil should be
changed every 2500 hours of operation or every
six months, whichever comes rst. This can often
be scheduled with winter and summer oil change.
3.2 SPARE PARTS (Figure 3)
It is recommended that a standard group of spare
parts (shown in Table 4) be kept on hand at all times
to prevent serious delays in repairs. The following
list of spare parts represents those which should
be kept on hand for each pump drive (see liquid
end section for spare parts for liquid end).
Parts orders must include the following information:
1. Quantity required.*
2. Part number.*
3. Part description.*
4. Pump serial number (include in all
correspondence regarding the pump).**
5. Full model number.**
* Found in this manual.
** Found on pump nameplate.
EXAMPLE:
Two No. 200 Clevis Pins for model DB2-C-175R,
serial number IP-0009 Milton Roy Pump.
3.3 RETURNING PUMPS TO THE FACTORY
Pumps will not be accepted for repair without a
Return Material Authorization, available from the
Factory Repair Department. Pumps returned to
the Factory for repairs should be clearly labeled
to indicate the liquid being pumped. Process liquid
should be ushed from the pump liquid end and oil
should be drained from the pump housing before
the pump is shipped.
Note:
Federal law prohibits handling of equipment that
is not accompanied by an OSHA Safety Data
Sheet (SDS). A completed SDS must be packed
in the shipping crate with any pump returned to
the factory. These safety precautions will aid
the troubleshooting and repair procedure and
preclude serious injury to repair personnel from
hazardous residue in pump liquid end. A Safety
Data Sheet must accompany all returns.
All inquiries or parts orders should be addressed
to your local Milton Roy representative or sent to:
www.miltonroy.com.
Item
Number
160 Crank Pin 1
165 Crank Pin Shoulder 1
142
270 Friction Plug 2
152 Dowel Pin 1
210 Snap Ring 2
40 Shaft Oil Seal 4
112 Worm Shaft Bearing 2
211-0042-006 Journal Nut Tool 1
None
Part Name Qty
Connecting Rod
Assembly (Includes
Spherical Bearing)
Coupling Insert for
300 Coupling
1
1
6
None LOCTITETM Grade 222
Instruction Manual
0.10 cc
tube
Table 1. Drive Spare Parts.
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