Milton Roy MILROYAL G User manual

MILROYAL®G Pump
Instruction Manual
Manual No : 53942
Rev. : 01
Rev. Date : 05/2019

iInstruction Manual
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/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.

ii Instruction Manual
TABLE OF CONTENTS
SECTION 1 - DESCRIPTION................................................................. 1
1.1 GENERAL ...................................................................... 1
1.2 PRINCIPLES OF OPERATION ...................................................... 1
1.3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 PRODUCT CODE ................................................................ 4
SECTION 2 - INSTALLATION ................................................................ 5
2.1 UNPACKING .................................................................... 5
2.2 SAFETY PRECAUTIONS .......................................................... 5
2.3 STORAGE ...................................................................... 5
2.3.1 Temporary Storage .............................................................. 5
2.3.2 Long Term Storage .............................................................. 5
2.3.3 Pump Drive.................................................................... 5
2.3.4 Electrical Equipment............................................................. 6
2.4 MOUNTING ..................................................................... 6
2.5 CONVERSION PROCEDURE....................................................... 6
2.6 PIPING CONNECTIONS........................................................... 6
2.6.1 NPSH Considerations............................................................ 6
2.6.2 General Piping Considerations..................................................... 7
2.6.3 Suction Piping Considerations ..................................................... 7
2.6.4 Discharge Piping Considerations ................................................... 8
2.6.5 Back Pressure Valves ............................................................ 8
2.6.6 Pulsation Dampeners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6.7 Safety Valves .................................................................. 9
2.6.8 Check Valves .................................................................. 9
2.6.9 Shut- OFF Valves ............................................................... 9
2.7 ELECTRICAL CONNECTIONS ...................................................... 9
SECTION 3 - OPERATION ................................................................. 10
3.1 INITIAL START-UP............................................................... 10
3.1.1 Start- Up for New Pump ......................................................... 10
3.1.2 Start- Up of Pump Containing No Oil in Casing and Displacement Chamber................. 11
3.2 REFILL VALVE ADJUSTMENT ..................................................... 12
3.2.1 Relief Valve Adjustment (With an Adjustable System Back Pressure Valve). ................. 12
3.2.2 Relief Valve Adjustment (Without an Adjustable System Back Pressure Valve). ............... 13
3.3 USE OF AIR PURGE BUTTON ..................................................... 13
3.4 MANUAL CAPACITY CONTROL.................................................... 14
3.5 FILLING PUMPING SYSTEM ...................................................... 14
3.6 CAPACITY CALIBRATION ......................................................... 14

iii Instruction Manual
SECTION 4 - MAINTENANCE............................................................... 15
4.1 RECOMMENDED SPARE PARTS .................................................. 15
4.2 SHIPPING PUMPS FOR REPAIR .................................................. 15
4.3 ROUTINE PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3.1 Oil Replacement ............................................................... 15
4.3.2 Check Valves ................................................................. 16
4.3.3 Cleaning Fouled Check Valves .................................................... 16
4.3.4 Check Valve Replacement ....................................................... 16
4.3.5 Oil Strainer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 CORRECTIVE MAINTENANCE .................................................... 21
4.4.1 3- Function Hydraulic Valve....................................................... 21
4.4.2 “MARS” Valve Assembly ......................................................... 21
4.4.3 Rell Valve Assembly ........................................................... 22
4.4.4 Diaphragm Replacement ........................................................ 22
4.4.5 Removal of Pump Liquid End ..................................................... 23
SECTION 5 - TROUBLESHOOTING .......................................................... 24
5.1 SYMPTOMS & REMEDIES ........................................................ 24
SECTION 6 - PART NUMBERS.............................................................. 26
6.1 BASIC PARTS LIST- PUMP DRIVE.................................................. 26
6.2 BASIC PARTS LIST- LIQUID END................................................... 28
6.2.1 Mars Valve ................................................................... 28
6.2.2 Rell Valve ................................................................... 28
6.2.3 3- Function Valve .............................................................. 29
6.2.4 Check Valve Parts.............................................................. 29
6.2.5 PVC Liquid End ............................................................... 30
6.2.6 Metallic Liquid End ............................................................. 31
6.3 REMAINING LIQUID END PARTS .................................................. 33
LIST OF ILLUSTRATIONS
FIGURE 1. Model/Product Code ............................................................... 4
FIGURE 2. Sample Nameplate............................................................... 34
FIGURE 3. Mounting Hole Dimensions. ........................................................ 34
FIGURE 4. Typical Recommended Pump Installation Scheme ...................................... 34
FIGURE 5. Pump Drive Parts- Side View ....................................................... 35
FIGURE 6. Pump Drive Parts- Top View........................................................ 36
FIGURE 7. Liquid End- Top View.............................................................. 37
FIGURE 8. Liquid End- Cutaway View ......................................................... 38
FIGURE 9. Mars Value ..................................................................... 39
FIGURE 10. Double- Ball Check Valve Parts (1-1/4”-plastic;1-3/4, 2-1/2”-PVC & metallic).................. 40
FIGURE 11. Plastic Single- Ball Check Valve Parts: 1-3/4, 2-1/2, & 3” Plungers .......................... 40
FIGURE 12. Plastic Check Valves for 1-1/4” Plunger .............................................. 41
FIGURE 13. Metallic Check Valves for 1-1/4” Plunger.............................................. 42
FIGURE 14. PVC 4- Function Bleed Valve for 1-1/4” Plunger ........................................ 43

1Instruction Manual
1.1 GENERAL
MILROYAL®G pumps are reciprocating, chemical
dosing pumps capable of producing controlled
ows up to 130 gallons per hour (492 L/H) at
pressures up to 600 psi (41 BAR) (depending on
the model). These pumps feature the robust High
Performance Diaphragm (HPD) liquid end, which
eliminates the need for contour plates, and a
non-lost motion stroke adjustment mechanism
based on the variable eccentric principle. This non-
lost motion design substantially reduces pressure
and ow pulsations which in turn increases the
life of system components and results in a more
continuous chemical injection. It is designed
for industrial service and offers an accuracy of
±1% of 100% rated ow between 10% and 100%
of its ow range.
The High Performance Diaphragm (HPD) liquid end
combines all of the best characteristics of traditional
liquid ends into one technologically advanced
design. Its operating characteristics and simplicity
of operation make it the best liquid end to consider
rst for most metering pump applications.
Milton Roy’s HPD liquid end overcomes the
net positive suction head (NPSH) restrictions
associated with conventional disc diaphragm
metering pumps. This is accomplished by a unique
mechanically actuated rell system (MARS) that
eliminates the need for diaphragm support plates
thereby lowering pump NPSH requirements.
The MARS also does away with the need for eld
adjustment of the rell mechanism by automatically
compensating for process liquid modications.
This, combined with removable check valves,
makes the HPD an ideal choice for any process in
which downtime is critical.
The HPD features a preformed, PTFE faced
elastomer diaphragm that is compatible with a
wide range of process liquids and chemicals.
The convoluted design of this composite diaphragm
also offers extended life over conventional at disk
designs.
The HPD liquid end is particularly suitable for
pumping costly, aggressive or hazardous liquids
without leakage.
1.2 PRINCIPLE OF OPERATION
(Refer to Figure 5 Through 10)
The pump consists of two major assemblies;
the drive and the liquid end. Pump delivery is a
function of the drive’s stroke rate (strokes/minute),
plunger size and stroke length (% Capacity).
Stroke length can be adjusted while the pump is
running or stopped by turning the stroke adjustment
knob (330).
The drive motor transmits rotary motion to a
worm gear speed reduction unit (343, 50) which
in turn drives the variable eccentric crank (100).
The adjustable crank imparts reciprocating
motion to the plunger/connecting rod assembly
(60, 520, 525). The stroke length is adjusted by
changing the position of the variable eccentric
crank in the connecting rod assembly.
SECTION 1 - DESCRIPTION

2Instruction Manual
SECTION 1 - DESCRIPTION
The mechanical drive system of the pump drives
the plunger back and forth in the High Performance
Diaphragm (HPD) liquid end supplied with the
pump. At the start of a suction stroke, the plunger
moves away from the liquid end, drawing hydraulic
uid with it. As the hydraulic uid is drawn back,
the exible diaphragm (510) follows, lowering the
pressure of the process uid in the liquid end.
This pressure drop causes the ball(s) in the suction
check valve (Figure 10) to be lifted up thereby
allowing process uid to pass through the suction
line into the diaphragm head (1020). At the same
time, the pressure drop in the diaphragm head
causes the ball(s) in the discharge check valve
(Figure 10) to be pulled closed, blocking ow back
through the discharge line.
Note:
It is important that the pressure in the liquid
end remain above the vapor pressure of the
process uid during the suction stroke. If the
uid pressure drops below the vapor pressure,
cavitation will occur, negatively impacting the
performance of the pump. If you suspect the
possibility of cavitation, contact your Milton Roy
Representative for assistance.
At the end of the suction stroke, the process
reverses, beginning the discharge stroke.
Now the plunger moves forward, pushing hydraulic
uid before it. The hydraulic oil must therefore press
against the diaphragm, exing it forward and raising
the pressure of the process uid in the liquid end.
This pressure increase causes the process uid
to ow outward, forcing the discharge ball check
open and the suction ball check to seat, blocking
back ow through the suction line. The process
uid ows out of the diaphragm head and into the
discharge line. This suction/discharge action is
repeated with every stroke of the pump plunger,
and is the direct cause of the pumping action.
As the pump operates, a small quantity of hydraulic
oil is continuously bled through the air bleed system
(970, 960, 980 in Figure 8) in the three- function
hydraulic valve (air bleed/relief/purge- Figure 8).
An additional small quantity of hydraulic oil is
also lost on every stroke through the clearance
between the plunger and displacement chamber
bore. After a while, these normal losses result in
a shortage of hydraulic oil in the displacement
chamber. When this happens, the diaphragm will
be pulled back tight against the back contoured
surface of the displacement chamber, and part of
the diaphragm will press against the Mechanically
Actuated Rell System (MARS) valve (Figure 9).
Now, when the plunger draws back, a vacuum is
created in the displacement chamber. These two
factors (diaphragm pressing against MARS valve &
vacuum in the displacement chamber) must occur
together to trigger the MARS valve.
When both of these conditions are met, the MARS
valve is forced to its rearward position, and the
poppet (760) opens, allowing hydraulic oil from
the reservoir to enter through the refill valve
(740 in Figure 8) and replenish the lost oil. In this
manner, proper hydraulic balance is constantly
maintained in the displacement chamber.

3Instruction Manual
1.3 GENERAL SPECIFICATIONS
Maximum Capacity Range 20 GPH (76 LPH) to 130 GPH (492 LPH)
Maximum Pressure Range 100 PSIG (7 Bar) to 600 PSIG (41 BAR)
Liquid End Design Hydraulically Actuated Diaphragm with Mechanically Actuated Rell
System (MARS).
Drive Design Non-Lost Motion Variable Eccentric Type.
Plunger Diameters 1-1/4”(32mm), 1-3/4”(45mm), 2-1/2”(63mm), 3”(75mm)
Liquid End Materials of
Construction PVC, 316 SS, Alloy 20.
Steady State Accuracy ±1% of 100% rated ow between 10% and 100% of rated ow
Capacity Adjustment
Micrometer (Standard): Lockable micrometer is adjustable from
0% to 100% while pump is running or stopped
Electronic (Optional): Electronic stroke length adjustment from
4-20ma input.
Temperature Limits
Ambient Limit: 130ºF Maximum
0ºF Minimum
Note: Limited by standard lubricants. Modications are available through
Applications Engineering.
Liquid Temperature Limits:
Plastic Liquid Ends: 20ºF to 140ºF
Metallic Liquid Ends: 20ºF to 190ºF
Suction Pressure Limits Minimum Internal Pressure: 3 psia (11.5 psi maximum vacuum)
Maximum Suction Pressure: 100 psig at 80ºF and below.
Lubrication Oil bath drive lubrication.
Paint Two part epoxy, yellow RAL 1018
SECTION 1 - DESCRIPTION

4Instruction Manual
SECTION 1 - DESCRIPTION
1.4 PRODUCT CODE
MILROYAL® G pumps are available in a variety of different congurations. The complete product code
is composed of the pump “model number” + “product code”. For a breakdown of the options included
in a specic pump, compare the pump model number and product code found on the pump nameplate
with the model/product code breakdown shown in Figure 1. A sample nameplate is shown in Figure 2.
MODEL NUMBER
MGH
4 5 6
Digit 4 & 5: Plunger Size Digit 6: Liquid End Material
Description Code Description Code
1-1/4”(32mm) 20 316 SS 1
1-3/4”(45mm) 28 Plastic (PVC) 2
2-1/2”(63mm) 40 Alloy 20 5
3”(75mm) 48 PVDF 7
PRODUCT CODE
7 8 9 10 11 12 13 14 15 16 17 18 19 20
Digit 7 & 8: Stroking Speed Digits 9 & 10: Motor
Description Code Description Code
173 spm 10 No motor, Flange Mount, NEMA 56C CB
120 spm 14 No motor, Flange Mount, NEMA 145TC CC
86 spm 20 No motor, Flange Mount, NEMA 182TC CD
43 spm 30 No motor, Flange Mount, IEC80, F165 Flange MD
*Note: SPM’s for 60 Hz, 1725 rpm motor
Digits 11 & 12: Capacity Adjustment Connection Digit 13 & 14: Check Valve
Description Code Description Code
Manual, Plastic micrometer knob Electronic(4-20 ma input) M2 Pipe- NPT SE
NEMA 4, 115V E1 Pipe- BSP SN
NEMA 4, 230V E2 Pipe- DN (Socket Weld) SQ
Explosion Proof, 115V EA
Explosion Proof, 230V EB
Electronic 4-20 ma input, 24 VDC EG
Digit 15 & 16: Base Diaphragm Digits 17 & 18: Rupture Detection/Double
Description Code Description Code
No Base (Standard) NN No Rupture Detection, Single Diaphragm (Standard) NN
No Base (Optional) 11 No Rupture Detection, Double Diaphragm (Optional) DD
Rupture Detection (Gauge), Double Diaphragm (Optional) C5
Rupture Detection (Gauge + NEMA 4 Pressure Switch),
DD (Opt.) SN
Rupture Detection (Gauge + Exp Pr Switch), DD (Optional) SE
Digit 19 & 20: Check Valve Type
Description Code
Note: Degassing options are available. Consult
MRC factory or representative for details
Single Ball 11
Double Ball 22
Figure 1. Model/Product Code

5Instruction Manual
SECTION 2 - INSTALLATION
2.1 UNPACKING
Pumps are shipped Free on Board (FOB) factory
or representative warehouse and the title passes to
the customer when the carrier signs for receipt of
the pump. In the event that damages occur during
shipment, it is the responsibility of the customer to
notify the carrier immediately and to le a damage
claim.
Carefully examine the shipping crate upon receipt
from the carrier to be sure there is no obvious
damage to the contents. Open the crate carefully so
accessory items fastened to the inside of the crate
will not be damaged or lost. Examine all material
inside the crate and check against packing list to
be sure that all items are accounted for and intact.
2.2 SAFETY PRECAUTIONS
When installing, operating, and maintaining the
MILROYAL®G pump, keep safety considerations
foremost. Use proper tools, protective clothing, and
eye protection when working on the equipment
and install the equipment with a view toward
ensuring safe operation. Follow the instructions
in this manual and take additional safety
measures appropriate to the liquid being pumped.
Be extremely careful in the presence of hazardous
substances (e.g., Corrosives, toxins, solvents,
acids, caustics, ammables etc.).
2.3 STORAGE
2.3.1 Temporary Storage (Less than 6 Months)
It is preferable to store the material under a shelter
in its original package to protect it from adverse
weather conditions. In condensing atmospheres,
follow the long term storage procedure.
2.3.2 Long Term Storage
(Longer than 6 Months)
Primary Considerations
The primary consideration in storage of pump
equipment is to prevent corrosion of external and
internal components. This corrosion is caused
by natural circulation of air as temperature of the
surroundings change from day to night, day to day,
and from season to season. It is not practical to
prevent this circulation which carries water vapor
and other corrosive gasses, so it is necessary to
protect internal and external surfaces from their
effects to the extent possible.
When the instructions given in this section are
completed, the equipment is to be stored sheltered/
protected from direct exposure to weather.
The prepared equipment should be covered with a
plastic sheet or a tarpaulin, but in a manner which
will allow air circulation and prevent capture of
moisture. Equipment should be stored 12” or more
above the ground.
If equipment is to be shipped directly from
Milton Roy into long term storage, contact
Milton Roy to arrange for factory preparation.
2.3.3 Pump Drive
1. Flood the pump drive housing with a high grade
lubricating oil/rust preventative such as Mobile
Oil Corporation product “Mobilarma 524”.
Fill the housing completely to minimize air space
and water vapor condensation. After storage,
drain this material and rell the equipment to the
correct oil level with the recommended lubricant
for equipment commissioning.
2. Remove drive motor and brush all unpainted
metal surfaces with multipurpose grease
(NLGI grade 2 or 3). Store motor unattached.

6Instruction Manual
SECTION 2 - INSTALLATION
2.3.4 Electrical Equipment
1. Motors should be prepared in the manner
prescribed by their manufacturer. If information
is not available, dismount and store motors as
indicated in step 3 below.
2. Dismount electrical equipment (including
motors) from the pump.
3. For all electrical equipment, place packets of
Vapor Phase Corrosion Inhibitor (VPCI) inside of
the enclosure, then place the entire enclosure,
with additional packets, inside a plastic bag.
Seal the bag tightly closed. Contact Milton Roy
Service Department for recommended VPCI
materials.
2.4 MOUNTING
Support the pump rmly in a level position on a
solid, vibration- free foundation, preferably with
the base above oor level to protect the pump
from wash downs and to provide easier access
for service. Be sure to allow enough space around
the pump for easy access during maintenance
operations, pump adjustments, and/or oil lling or
draining procedures.
MILROYAL®G pumps are provided with mounting
holes to accommodate anchor bolts. Refer to
Figure 3 for mounting hole dimensions.
Some MILROYAL®G pumps are shipped with
motors dismounted. After anchoring pump in
position, install motor, referring to Figure 5.
To avoid damage to pump drive during
operation, make sure spring (360) provided with
pump is installed in worm shaft prior to motor
installation. Pumps installed outdoors should be
protected by a shelter.
2.5 CONVENTION PROCEDURE
A MILROYAL®G pump can, in some cases, be
converted from one liquid end plunger size or
material of construction to another. For more
information on converting between different liquid
end models, please contact the Milton Roy factory
or your local authorized representative.
2.6 PIPING CONNECTIONS
2.6.1 NPSH Considerations
The MILROYAL® G HPD liquid end is far superior
to conventional diaphragm liquid ends for suction
lift and many other NPSH- critical applications.
In these demanding applications, the patented
diaphragm and rell mechanism give this liquid
end truly exceptional performance.
For NPSH apply a 3 psia limitation (instead of
9 psia) in evaluating applications for this liquid end.
Size piping to accommodate peak instantaneous
flow. Because of the reciprocating motion of
the pump diaphragm, pump delivery follows an
approximate sine curve with a peak instantaneous
ow equal to pi (3.14) times the average ow.
Therefore, piping must be designed for a ow
3.14 times the pump capacity; this means that a
pump rated for 100 gallons per hour (379 L/hr.)
requires piping sufcient for 3.14 x 100 gph, or
314 gph (1188 L/hr.).
To minimize viscous ow losses when handling
viscous liquids, it may be necessary to use suction
piping up to four times larger than the size of
the suction connection on the pump. If in doubt,
contact your nearest Milton Roy representative to
determine the necessary pipe size.