Milton Roy G Series User manual

INSTRUCTION MANUAL
FOR INSTALLATION
OPERATING, AND
MAINTENANCE.
Dosing pump ®G
GA DSD liquid end
This manual should be made available to the person responsible for installation, operating and
maintenance.
Translated version
03 12/ /2015
DATE : 00REV :

CONTENTS
I – DESCRIPTION
I - 1. Unpacking and storage
I - 2. Description
I - 3. Operating principle of the pump
I - 4. Accessories
I - 5. Safety and health instructions
II – INSTALLATION
II - 1. Hydraulic installation
II - 2. Drip collection
II - 3. Handling
II - 4. Setting up
II - 5. Electrical installation
III - START UP
III - 1. Procedures before start up
III - 2. Start up
III - 3. Failures on start up
III - 4. Operation - Schedule of checks and maintenance operations
IV - ROUTINE MAINTENANCE
IV - 1. Checking the pump capacity
IV - 2. Tracing causes of failure
IV - 3. Ordering spare parts
V - PREVENTIVE MAINTENANCE - ANNUAL OVERHAUL
V - 1. Spare parts required for annual overhaul
V - 2. Sequential actions
VI - CORRECTIVE MAINTENANCE
VI - 1. List of other spare parts
VI - 2 Sequential actions
VII - SERVICING THE LIQUID END AND THE LIQUID END MOUNTING ASSEMBLY
VII - 1. General and procedures
VIII - SERVICING THE MECHANICAL ASSEMBLY
VIII - 1 General
VIII - 2 Dismantling, Reinstalling the mechanical assembly
« EC » DECLARATION OF CONFORMITY
GUARANTEE
LIST OF « TECHNICAL ASSISTANCE » AND « SPARE PARTS » DEPARTMENTS

I - 1
PART I - DESCRIPTION
I - 1. UNPACKING AND STORAGE
UNPACKING
The packaging must be carefully examined on receipt in
order to ensure that the contents have not sustained
any obvious damage. Precautions must be taken when
opening the packaging in order to avoid damaging
accessories which may be secured inside the
packaging. Examine the contents and check them off
against the delivery note.
STORAGE PRECAUTIONS
Storage for less than six months
Equipment shall preferably be stored in its original
packaging and protected from adverse weather
conditions.
Storage for more than six months
Store the pump in its original packaging. In
addition, packaging in heat-sealing plastic cover
and dessicant bags must be provided for. The
quantity of dessicant bags should be adapted to
the storage period and to the packaging volume.
Store protected from adverse weather
conditions.
I - 2. DESCRIPTION
The « SERIES G » Model A pump is a compact
electromechanical metering pump that is life-lubricated
with oil in a sealed housing, with capacity adjustment in
operation or when stopped.
It is made up of the following components (Fig. 1.2a):
* a drive device comprising a motor [1],
* a mechanical assembly [2],
* a liquid end [3].
1Motor 8Stroke locking device
2Mechanical assembly 9Leak detection port
3Liquid end 10 4-function valve *
4Stroke adjustment knob 11 Valve assembly (suction)
5Control unit (frequency control) 12 Valve assembly (discharge)
6Liquid end mounting assembly
* Accessory supplied as optional equipment with pumps equipped with plastic liquid end <22 l/h.
Fig. 1.2a: Model A, series G pump

I - 2
*
Leak-tightness between the mechanical assembly and
the liquid end is ensured by means of a bellows.
Capacity adjustment is controlled either manually (by a
stroke adjustment knob [4]) or automatically by a
control box [5] (such as in the case of a G VARIPULSE
version single-phase motor).
Various components of the pump are shown in Figure
1.2a.
Note: For further information on the automatic control
system, see the relevant specific manual.
I - 3. OPERATING PRINCIPLE OF THE
PUMP
See Figures 1.3b and 1.3c.
Fig. 1.3b : Setting to zero stroke
Suction phase
Discharge phase
Fig. 1.3c : Setting to maximum stroke
1 Worm 4 Connecting rod
2 Tangential wheel 6 Crosshead
3 Eccentric 7 Diaphragm

I - 3
MECHANICAL ASSEMBLY
The mechanical assembly works on the principle of a
variable eccentric.
The rotational motion of the motor is transmitted by the
worm [1] to the tangential gear [2] which is linked to an
eccentric system [3].
The connecting rod [4], attached to this eccentric
system, converts the rotary motion into a reciprocating
linear motion with variable stroke. The stroke depends
upon the eccentricity between the axis of rotation of the
tangential wheel [A] and an axis of the connecting rod
[B]. The stroke is adjusted by moving the crosshead [6]
by means of a stroke adjustment screw. The movement
of the crosshead causes movement of the male
eccentric piece which modifies the position of the
connecting rod axis.
When the connecting rod axis [B] is aligned with the
axis of the tangential wheel [A], the connecting rod does
not move and the stroke is zero.
Figure 1.3b shows the functional diagram at zero
stroke.
Figure 1.3c shows the functional diagram at maximum
stroke.
DIAPHRAM LIQUID END
In discharge phase the diaphragm [7] deformed it under
the pressure approve by hydraulic oil for moving an oil
volume defined
In suction phase the process is reversed due to the
diaphragm mechanical memory for sucking an oil
volume defined.
1 - 5. SAFETY AND HEALTH
INSTRUCTIONS
The personnel responsible for installing, operating and
maintaining this equipment must become acquainted
with, assimilate and comply with the contents of this
manual in order to:
* avoid any possible risk to themselves or to third
parties,
* ensure the reliability of the equipment,
* avoid any error or pollution due to incorrect
operation.
Any servicing on this equipment must be carried out
when it is stopped. Any accidental start-up must be
prevented (either by locking the switch or removing the
fuse on the power supply line).
A notice must be attached to the location of the switch
to warn that servicing is being carried out on the
equipment.
Switch off the power supply as soon as any fault is
detected during operation: abnormal heating or unusual
noise.
Special care has to be taken for chemicals used in the
process (acids, bases, oxiding/reducing solutions,).

II - 1
PART II - INSTALLATION
II - 1. HYDRAULIC INSTALLATION
All the information concerning the hydraulic installation
of a metering pump is detailed in a volume,
« Generalities about metering pumps installation ». You
should consult that manual to determine the installation
required for your application.
Certain essential points are, however, also briefly
covered in this document.
GENERAL
Piping layout
There must be no swan-necks or stagnant volumes
which are liable to trap air or gas.
Stresses due to incorrect alignment of piping with
respect to the centreline of valves must be avoided as
far as possible.
Remove burrs and clean the piping before fitting.
It is advisable to provide for a calibrating chamber in
order to calibrate the pump in service conditions.
PIPING ON THE SUCTION CIRCUIT
If your pump is flooded, a shutt-off valve will be
required
If your pump is not flooded (suction lift), install the
foot valve equiped with the filter upstream of the
above-mentioned item
For viscous products: consult us.
Check whether the diameter and length of pipe are
compatible with the pump's maximum capacity.
Install the pump as near as possible to the suction
tank.
PIPING ON THE DISCHARGE CIRCUIT
Provide for a safety valve on the discharge pipe,
designed to protect the installation.
It is advisable to install a priming valve on the
discharge circuit in order to make starting and
maintenance of the pump easier.
Note: The priming valve and the safety valve have no
purpose if your pump is equipped with a 4-function
valve.
Typical installations are shown schematically in Figure
2.1a.
II - 2. DRIP COLLECTION
Provide for outlets so that any leak or drips can be
easily drained off without any danger. This is especially
important in the case of harmful liquids.
See Figure 1.2a.
Position a tray under the plain hole (detection port [9])
located at the bottom of the liquid end mounting
assembly to collect leaks in the event of rupture of the
diaphragm or boot.
II - 3. HANDLING
The « SERIES G » Model A pump requires no special
precautions owing to its light weight.
Proceed with mounting as soon as it is set up on site
(see Chapter II - 4. Setting up).
II - 4. SETTING UP
Secure the pump to a horizontal support (see attaching
holes). Leave enough clear space around the pump to
be able to carry out servicing operations and
adjustments.
Pumps installed outdoors must be protected by a
shelter (according to the climatic conditions).

II - 2
1 Tank 8 Injection nozzle
2 Foot valve (equipped with a filter) 9 Shutt-off valve
4 Metering pump 10 Filter
6 Utilization 11 Pulsation dampener
7 4-function valve*
* In case of plastic liquid end only <22 l/h
Provide for a safety valve on the discharge circuit in case of a stainless steel liquid end
Fig. 2.1a : Diagrams of typical installations

II - 3
II - 5. ELECTRICAL INSTALLATION
CONNECTING THE MOTOR
Check the specifications of the motor and compare
them with the voltage available on your installation
before making connections. Connect up the motor in
accordance with the instructions in the terminal box
(Fig. 2.5a).
A delta connection is required to connect up
to a 230 V 3-phase power supply (Fig. 2.5b).
A star connection is required to connect up to
a 400 V 3-phase power supply (Fig. 2.5c).
For connection in SINGLE-PHASE mode,
see Figure 2.5d.
Replace the existing wires with those of your electrical
power supply.
CAUTION : Do not forget to connect the earth terminal
on the motor [PE] (Fig. 2.5a) to the equipment earth
conductor.
The electrical protection installed for the motor (fuse or
thermal protection) must be suitable for the motor's
rated current.
Fig. 2.5a : Motor terminal box
Fig. 2.5b :
230 V delta connection Fig. 2.5c : 400 V star connection Fig. 2.5d :
Single-phase connection
Tri
Mono

III - 1
PART III - START UP
III - 1. PROCEDURES BEFORE START
UP
Special care has to be taken for chemicals used in the
process (acids, bases, oxiding/reducing solutions, ...).
See Figure 1.2a.
Check that the pump is secured to its support
(Chapter II - 4. Setting up).
Check the pipe fitting torque.
Check the opening of all the isolating valves
installed on the suction and discharge circuits. If
your pump is equipped with a 4-function valve, see
the relevant specific documentation. If the discharge
circuit is equipped with an injection nozzle or a
back-pressure valve, open the priming valve on the
discharge side (if there is no priming valve,
disconnect the piping on the discharge side). This
allows you to check for the presence of liquid if the
pump is installed in flooded suction or to prime the
pump if it is installed in suction lift.
Set the pump capacity adjustment to 0% (stroke
adjustment knob [4]).
Checking the electrical connection of the
motor
Start up the pump to check the motor's direction of
rotation. It must comply with that indicated by the arrow
marked on the pump cover.
To reverse the motor's direction of rotation,
invert A and B or A and C (See Figure 2.5b
or 2.5c).
III - 2. START UP
Once all the checks and procedures described in
the previous section have been carried out, start up
the pump.
Check visually and by listening. (In particular, check
that there are no suspicious noises).
Make sure that the stroke adjustment knob is
unlocked.
Adjust the pump capacity gradually from 0 % to 100
% and control
- either the liquid output at priming valve,
- either the noise of the liquid when it goes
through the discharge check valve (if your
installation is not equipped with a priming
valve).
Priming has been achieved if one of the two conditions
is carried out. Close the priming valve.
Set the pump to the desired capacity. Lock the
stroke adjustment knob with the stroke locking
device [8] (Fig. 1.2a).
III - 3. FAILURES ON START UP
PROBLEMS WITH MOTOR
The motor runs with difficulty and heats up.
The characteristics of the electrical power supply do
not match the specifications of the motor.
One phase is incorrectly connected.
The electrical connection used is not
suitable.
Check that the pressure on the discharge side is
compatible with the equipment’s capabilities.
Too many flow pulsations : a pulsation dampener is
required, or the pulsation dampener installed is of
the wrong size, or the pressurization of the pulsation
dampener is incorrect.
The direction of rotation of the motor is
incorrect. (Check using the arrow marked
on the cover). Reverse the direction of
rotation (see Chapter III - 1. Procedures
before start up, Checking the electrical
connection of motor).
PROBLEMS WITH FLOW RATE
The flow rate is lower than desired
The pump capacity is incorrectly adjusted: adjust
the capacity to the desired value and lock the stroke
adjustment knob.
The suction power is insufficient. (Piping cross-
section too small or piping too long): replace the
pipes with ones with a larger cross-section or install
the pump in flooded suction.
The leak-tightness of the suction pipes is
unsatisfactory.
The viscosity of the liquid is incompatible with the
capabilities offered by your pump version.
The capacity is greater than desired
The pump capacity is incorrectly adjusted: adjust
the capacity to the desired value and lock the stroke
adjustment knob.
A syphoning phenomenon is observed: check that
the discharge pressure is greater of 1.5 bard than
the suction pressure. Install a 4FV or a back-
pressure valve on the discharge side.
Too many flow pulsations: a pulsation dampener is
required, or the pulsation dampener installed is of
the wrong size, or the pressurization of the pulsation
dampener is incorrect.
Tri
Tri
Tri

III - 2
The capacity is variable
This problem may be due to particles from the
piping which interfere with the operation of the valve
assemblies: clean the piping and the valve
assemblies.
III - 4. OPERATION - SCHEDULE FOR
CHECKS AND MAINTENANCE
OPERATIONS
The programme of checks and maintenance operations
depends on the conditions in which the equipment is
used. For this reason, the following frequencies are
given as an example only. Individual users should
adapt these frequencies to their own specific operating
conditions.
When
Check
Servicing
See
Every 3 months Check by listening (no knocking)
- if unsatisfactory -> Chapter IV-4
Every 6 months (or
1,500 hours) Cleaning of foot valve and valve assemblies Chapter IV-2
Frequency to be
defined according to
process (approx.
1,000 hours)
Check on compliance of flow rate Check on pump capacity Chapter IV-3
Every year (or 3,000
hours) Annual overhaul Part V
A model maintenance sheet is shown in Figure 3.4a to help you ensure follow-up of your servicing actions (checking or
maintenance).

III - 3
MAINTENANCE SHEET
Pump code : D.M.R. internal no. :
Liquid pumped :
Date of commissioning :
Service Operation Date Hours Remarks
Fig. 3.4a : Model Maintenance Sheet

IV - 1
PART IV - ROUTINE MAINTENANCE
IV - 1. CHECKING THE PUMP
CAPACITY
This is a question of determining the curve representing
the pump’s capacity according to its setting.
Four measurements are sufficient (adjustment to 100
%,75 %, 50 % and 25 %).
Place the foot valve in a calibrating chamber (graduated
reservoir). Measure the volume of pumped liquid for a
given period of time at the various settings.
Plot the curve and use it to determine the adjustment
corresponding to the desired capacity.
IV - 2. TRACING CAUSES OF FAILURE
PROBLEMS WITH MOTOR
The motor does not run
The thermal relay has been tripped.
The motor is defective.
Wiring is defective.
Check the parts of the mechanical assembly.
The motor heats up abnormally
The quantity of lubricating oil is incorrect: trace the
leak (see Chapter IV - 1.)
The pump is used in conditions it was not designed
for.
PROBLEMS WITH NOISY MECHANICAL
PARTS
The tangential wheel is faulty. Replace the « wheel -
connecting rod » assembly [D] (see Part VI).
A bearing is faulty. Provide for the replacement of
either the « wheel - connecting rod » assembly [D],
the « male eccentric » assembly [12] or the whole
mechanical assembly [J] (see Part VI).

IV - 2
PROBLEMS WITH FLOW RATE
The pump produces no flow
The pump capacity is adjusted to « 0 % » : Adjust
the capacity to the desired value and lock the stroke
adjustment knob.
The liquid end is unprimed: release the pressure on
the discharge pipe and prime the liquid end, or
check the leak-tightness of the suction circuit.
The balls of the valve assemblies are blocked by
particles: clean or replace the valve assemblies.
First, check whether the presence of these particles
is normal and take corrective action if necessary.
The diaphragm is faulty (rupture): see Chapter IV -
1. And replace the diaphragm (see Part V).
The pump does not provide the required flow
rate
The pump capacity is incorrectly adjusted: adjust the
capacity to the desired value and lock the stroke
adjustment knob.
The ball seats and/or the balls are dirty or worn:
clean or replace the ball seats and the balls or the
valve assemblies.
The tangential wheel is faulty. Replace the « wheel -
connecting rod » assembly [D] (see Part VI).
A bearing is faulty. Provide for the replacement of
either the « wheel - connecting rod » assembly [D],
the « male eccentric » assembly [12] or the whole
mechanical assembly [J] (see Part VI).
The leak-tightness of the suction circuit is
unsatisfactory: repair or replace the piping.
IV - 3. ORDERING SPARE PARTS
To make it easier to register your order for spare parts
and ensure quicker delivery, please provide us with the
following details:
information onthe pump: Codel [1] and D.M.R.
internal no. [2]. These two items of information are
shown on the identification plate mounted on the
pump (see Fig. 4.5a).
Information on the spare part: reference, description
and quantity. These items of information are
specified in the relevant sheets supplied with the
pump.
You will find the phone and fax number of the Spare
Parts Department at the end of this documentation.
1
Model : Pump code
4 Pmax : Maximum pressure
2
SERIAL : D.M.R. internal No.
5 Date : Date of manufacture
3 Qmax : Maximum capacity
Fig. 4.5a : Identification plate

V - 1
PART V - PREVENTIVE MAINTENANCE
ANNUAL OVERHAUL
V - 1. SPARE PARTS REQUIRED FOR ANNUAL OVERHAUL
Annual overhaul (after one year or 3,000 hours’ operation) involves the replacement of the following wear parts:
Balls and seats kits or sets of cartridges (depending on model),
Diaphragm,
Every two years (or 6,000 hours’ operation), during the annual overhaul, replace also:
Secondary diaphragm,
The servicing action required for the replacement of balls and seats kits, diaphragm and secondary diaphragm are
described in Part VII: Servicing the liquid end and the liquid end mounting assembly. The procedures must be carried out
in the specified order.
Chapter V - 2. Sequential actions allow partial servicing operations to be carried out.
Note: For full list of spare parts refer to the relevant liquid end sheet and mechanical assembly sheet.
V - 2. SEQUENTIAL ACTIONS
Carry out the procedures in the specified order having read the general information (in Chapter VII - 1).
SERVICING THE FOOT VALVE
See Process: valve Mounting/Disassembly
SERVICING THE VALVE ASSEMBLIES
See Process: liquid end Mounting/Disassembly

VI - 1
PART VI - CORRECTIVE MAINTENANCE
VI - 1. LIST OF OTHER SPARE PARTS
This completes the list given in Chapter V - 1 which covers the set of spare parts required for annual overhaul of the
pump.
Motor (with worm)
Mechanical assembly (without cover or base, with bellows and lubricating oil)
« Wheel - connecting rod » assembly
« Male eccentric » assembly
Lubricating oil

VII - 1
PART VII - SERVICING THE LIQUID END AND THE LIQUID END
MOUNTING ASSEMBLY
Carry out the procedures described below:
in the order of the text in the case of annual overhaul (or 3,000 hours’ operation), except for the secondary
diaphragm which has to be removed every two years (or 6,000 hours ’ operation).
VII - 1. GENERAL
Note
For the sake of simplicity, the procedures described do not mention the washers fitted with fasteners (such as
screws and nuts). Do not forget to reinstall washers after removing them.
Verify that parts are undamaged before reinstalling.
Clean the recess for O-rings when they are removed. Apply tallow in the recess before reinstalling the new O-ring.
Special care has to be taken for chemicals used in the process (acids, bases, oxiding/reducing solutions,).

VI – Assembly / Disassembly of the displacement chamber
Draw: 1066167100D00 Position Torque ** Tools
* Tools :
Provide a tool kit available for selling at the after sales
department. [435] 5 N.m. BTR n°4
[275] 3 N.m. Flat
screwdriver
[438A] [O]
[068] Thread lock
Glue
Disassembly Assembly
1. Carry out the procedure « Mounting of the liquid
end ». 1. Put the glue on the thread of the part [068].
2. Unscrew the screws [275]. 2. Screw the part [004] with the part [068] like
indicated on the drawing.
3. Remove the part [072]. 3. Fit the seal [438] on the part [037].
4. Remove the parts [080], [012]. 4. Oil and Fit the seal [438A] on the part [037] with
help of the tool [O]*.
5. Unscrew the screws [435]. Pay attention at the mounting direction of the
part [438A].
6. Remove the parts [037], [438], [434A], [438A]. 5. Fit the part [434A].
6. Place the part [080] on the part [012].
7. Oil and insert the part [012] into the part [037].
8. Insert delicately the part [012] when you arrive
at the part [438A].
9. Fit the part [037] into the part [072].
10. Screw the screws [435]**.
11. Fit the part [072] on the part [M].
12. Screw the screws [275]**.

A
A
275
004
068
438
037
438A
434A
072
080
012
M
435
275
O
438A
037
K (6 : 4)
2
F
1
E
D
3
2
C
B
A
1 3 4
6
Ech - Scale
FORMAT
Folio - Page
7
Numéro Plan
Texte de la modification - Modification
EMISSION INITIALE
Date
Dessiné-Drawned / Visa
8
Dwg-Nr
F
SOLIDWORKS
Révision
Vérifié-Checked / Visa
E
D
6 5 7
C
B
8
A
DOSEUR / Liquid end DSD47
MONTAGE / Assembly
1066.167.100.D00
2
/
7
A3
4:3
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY
04/06/13
Y.Chevallier
00
27360 PONT-SAINT-PIERRE
Tel : [phone]
Fax : [phone]
B.Picard

VI - Assembly / Disassembly of the liquid end CR - VR
Draw: 1066167000D02 Position Torque ** Tools
* Tools :
Provide a tool kit available for selling at the after sales
department. [435B] 10 N.m. BTR n°6
[L] [02]
Disassembly Assembly
1. Execute the procedure «hydraulic oil change ». 1. Place the part [098] on the part [072].
2. Unscrew the screws [435B] + [434]. 2. Fit the seal [438B] on the part [021].
3. Remove the parts [021], [438B], [098]. 3. Fit the part [021] on the part [072].
4. Remove the parts assembly [021A]. 4. Place the part [004] on the part [021].
5. Screw the screws [435B] + [434]**.
6. Place the parts assembly [021A] in the part
[072] like indicated on the drawing.
Take care on the part [021A] mounting
direction.

C
C
004
435B
021
021A 438B
098
072
434
435B
434
2
F
1
E
D
3
2
C
B
A
1 3 4
6
Ech - Scale
FORMAT
Folio - Page
7
Numéro Plan
Texte de la modification - Modification
EMISSION INITIALE
Date
Dessiné-Drawned / Visa
8
Dwg-Nr
F
SOLIDWORKS
Révision
Vérifié-Checked / Visa
E
D
6 5 7
C
B
8
A
DOSEUR / Liquid end DSD47
MONTAGE / Assembly
CR47 & VR47
1066.167.000.D02
2
/
2
A3
1:1
Propriété exclusive - Communication et reproduction interdites. All rights reserved - Copyright DOSAPRO MILTON ROY COMPANY
04/06/13
Y.Chevallier
00
27360 PONT-SAINT-PIERRE
Tel : [phone]
Fax : [phone]
B.Picard