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Metering Pumps
Instruction
Manual
INSTALLATION
MAINTENANCE
TROUBLE SHOOTING
A-Series Pumps
A-
Pump Model No.........................................................................
Serial No....................................................................................
LPH
Capacity.....................................................................................
Kg/cm 2
Pressure....................................................................................
TABLE OF CONTENTS
SECTION DESCRIPTION Page No.
1.0 INTRODUCTION 3
2.0 UNPACKING 3
4.0 INSTALLATION 5
7.0 CALIBRATION 13
-1/2" - NPT - M
2.0 UNPACKING
Your carton will contain the following items. Please Please refer to the enclosed drive Assembly and Parts List
notify the carrier immediately if there are any signs of Sheet for an illustration of your complete pump, electrical
damage to the pump or its parts. Notify your pump diagram and a parts list.
supplier if any of the following parts are missing.
Metering Pump
Foot Valve
MILTON ROY INDIA (P) LTD. 3
A-Series Pumps
Tubing
Your cartons contains one roll of tubing. Proper length to
be cut for suction piping and discharge piping.
2
Instruction Manual
WATER PRE-PRIME
TUBING CONNECTIONS use Teflon tape or pipe dope to seal threads. Teflon Tape
Inlet and outlet tubing or pipe sizes must not be reduced. may only be used on the 1/2” NPT thread side of the
Make certain that all tubing is SECURELY ATTACHED to Injection Check Valve before installing in a pipe line or tee.
fittings prior to start-up (See Section 4.3, Tubing PLUMBING
Connections). ALWAYS use MRIPL supplied tubing with Always adhere to your local plumbing codes and
your pump, as the tubing is specifically designed for requirements. Be sure installation does not constitute a
maximum compatibility with the pump operation. It is cross connection. Check local plumbing codes for
recommended that a tubing be shielded to prevent guidelines. MRIPL is not responsible for improper
possible injury in case of rupture or accidental damage. installations.
FITTINGS AND MACHINE THREADS. ELECTRICAL CONNECTIONS
All fittings should be hand tightened to a maximum of WARNING: To reduce the risk of electrical shock, the
1/8-1/4 turn after the fitting contact the seal ring. DO NOT metering pump must be plugged into a grounded outlet
OVERTIGHTEN FITTINGS. Overtightening or use of a with ratings conforming to the data on the pump control
pipe wrench can cause damage to the fittings, seal rings, panel. The pump must be connected to a good ground.
or pump head, causing the pump to LOSE PRIME OR DO NOT USE ADAPTERS! All wiring must conform to
MALFUNCTION. local electrical codes.
All MRIPL pumps have machine threads on the head and
fittings and are sealed by the seal rings. DO NOT
4.0 INSTALLATION
4.1 PUMP LOCATION AND INSTALLATION B. SUCTION LIFT- when suction lift is less than 1.5 m for
Locate pump in an area convenient to solution tank and solutions having a specific gravity of water. For denser
electrical supply. solutions, consult the factory.
* The pump is to be protected from sun and rain. If out The pump must be mounted in such a way the suction and
door installation is unavoidable, provide a canopy discharge valves are vertical. (NEVER POSITION
over the pump. PUMP HEAD AND FITTINGS HORIZONTALLY)
The pump should be accessible for routine maintenance, 4.2.A. Flooded Suction
and should not be subjected to ambient temperatures The pump is mounted at the base level of the storage
above 50 C. tank. This installation is the most trouble-free, and is
4.2 PUMP MOUNTING recommended for very low outputs, solutions that gasify,
and high viscosity solutions. Since the suction tubing is
The pump can be mounted in one or two ways: filled with solution, priming is accomplished quickly and
A. FLOODED SUCTION(ideal installation) or the chance of losing prime is reduced.
Note : Bleed/4-function valves permit an adjustable continuous bleed or degassing of entrapped vapours. This valve is ideal for
pumping small volumes of solutions having low vapour pressure. Consult factory for further details.
4.5 4-FV Installation WARNING : This return line tubing must be secured to
insure pumped solution will return to supply tank.
To install the 4-FV, on top of the Pumphead, screw in the 4.6 Foot Valve/Suction Tubing Straightener
4-FV so that valve contacts the seal ring. An additional 1/8 Installation.
- 1/4 turn may be necessary to prevent leakage. DO NOT The Foot Valve acts as a check valve to keep the pump
OVERTIGHTEN. Overtightening can cause fittings and primed in suction lift applications.
seal rings to distort, crack and function improperly.
The valve is designed to be submerged in the solution
tank or drum and must sit in a vertical position at the
1/4" O.D. tubing connects to the side of the 4-FV and acts
bottom. Position approximately 2 inches (50 mm) off the
as a return line to the solution tank. This tubing must NOT
bottom if the tank or drum contains sediment.
be submerged in the solution.
The suction tubing straightener, when assembled,
positions the foot valve and suction tubing in vertical
position.
1. Attach the foot valve to one end of the suction tubing
(see tubing connections, section 4.3)
2. Assemble the suction tubing straightener such that the
length of the tubing straightener when placed over the
suction tubing and sitting on the foot valve,
approximately 50 mm of tubing exits over the tubing
straightener on the side to be connected to the pump.
3. Place foot valve, tubing and suction tubing straightener
into the solution tank. Check that the foot valve is
vertical and approximately 2 inches (50 mm) from the
bottom of the tank or drum (see illustration). Connect
the other end of the tubing to the suction side of the
pump head (bottom side).
4.7 Injection Check Valve Installation pipe in vertical position. Variations left and right within
The Injection Check Valve prevents backflow from a 80 C are acceptable. (See illustration below).
treated line. Connect the Injection Check Valve to your After cutting an appropriate length of tubing, connect
"DISCHARGE" (outlet) line. Any size NPT fitting or pipe tubing to injection check valve then back to the discharge
to with a reducing bushing to 1/2" NPT will accept the side of the pump head (top side), making sure it does not
Injection check valve. Use Teflon tape or pipe dope to seal crimp or come into contact with hot or sharp surfaces.
the pipe threads only.
When installing the Injection Check Valve, be sure to
position it so that the valve enters the bottom of your
1. Speed Adjustment : Speed control provides When all precautionary steps have been taken, the pump
adjustment of the percent of maximum strokes per is mounted, and the tubing is securely attached, you may
minute. Turning this knob clockwise increases stroke now prime the pump.
frequency. 1. Plug in or switch the pump on.
Note A7 Series only : When operating pump in external 2. While the pump is running, set the speed knob at 80%
mode, the speed control knob should be turned fully and the stroke knob at 100%.
counter clockwise. A click indicates pump is in external
mode. 3. The suction tubing should begin to fill with solution from
the tank.
2. Stroke Adjustment : Stroke control provides
adjustment of percent maximum Liquifram 4. Once the solution begins to exit the pump head on the
(diaphragm) travel. Turning this knob clockwise discharge side, SHUT THE PUMP OFF. (If pump is not
increases percent output per stroke. equipped with an on/off switch disconnect the power
cord).
6.2 Start-up/Priming for Pump Supplied with 4-FV
5. The pump is now primed.
CAUTION : Read this entire section completely before
proceeding 6. Proceed to out put adjustment, Section 6.4
When all precautionary steps have been taken, the pump NOTE : If the pump does not self prime, remove the
is mounted, and the tubing is securely attached, you may fitting on the discharge side of the pump head.
now start priming the pump. Remove the ball and pour water or solution into the
port until the head is filled. Replace valve, then follow
1. Plug in or switch the pump on. start up/priming steps.
2. While the pump is running, set the speed knob at 80% 6.4 Output Adjustment
and the stroke knob at 100%
Once the pump has been primed, an appropriate output
3. If your pump is equipped with a 4-FV, grip both the adjustment MUST be made. Pump output should be
yellow and black knobs, 1/4 turn or pull and hold open. calculated and adjustments made accordingly.
4. The suction tubing should begin to fill with solution TOTAL PUMP OUTPUT
from the tank.
Calculate the total output of the pump as follows :
5. A small amount of solution will begin to discharge out
the return line of the 4-FV. Once this happens, 1/4 turn PUMP OUTPUT = MAX PUMP OUTPUT X % SPEED X
or release the knobs and SHUT THE PUMP OFF. (If % STROKE
pump is not equipped with an on/off switch, disconnect
Example : Pump - A12
the power cord)
Use MAX Output (From dataplate on bottom centre of
6. The pump is now primed.
pump control panel) = 6 litres/hr
7. Proceed to output adjustment, Section 6.4
Note : The pump discharge is at rated Max. injection
NOTE : If the pump does not self-prime, remove the pressure with variation of +25%
4-FV on the discharge side of the pump head. Remove
If the pump is set at 60% speed and 70% stroke length the
the ball and pour water or solution into the port until the
approximate pump output is :
head is filled. Replace valve, then follow
start up/priming steps. 6.0 x 60/100 x 70/100 = 2.52 Litres / hour
7.0 CALIBRATION
Once installation is complete and the approximate output 5. Using a stopwatch or timer, turn the pump on for
has been determined, the pump should be calibrated to a measured amount of time (50 pump strokes
adjust speed and stroke for your actual desired output. minimum). The longer the time period, the more
1. Be sure the pump is primed, and discharge tubing confident you can be of the results, Be sure to count
and Injection Check Valve are installed as they w o u l d the number of strokes during the calibration period
be in normal service (i.e. including factors such as when making comparisons.
injection pressure, fluid viscosity, and suction lift). 6. Turn the pump off. Note the time elapsed in relation to
2. Place the Foot Valve in a graduated container with a volume displaced in the graduate. Now, calculate the
volume of 1000 ml or more. output in the time unit you choose (minutes, hours,
days, etc.)
3. Plug in and switch on pump. Pump until all the air is
exhausted from the suction line and head. 7. If the output is too low or too great, adjust speed and or
stroke, estimating required correction and repeat
4. Turn the pump off. Refill graduated container to a level steps 1-6
starting point.
7.1 Calibration Procedure - On-site Volumetric graduated container. Refill graduated to a starting
Calibration in External Mode point.
1. Since pump output is governed by an external device 5. Switch pump ON and count the number of strokes for
such as Flowmeter-Pulser, Almitron, Current-to- exactly one minute. Then switch pump OFF.
Frequency Converter or 4-20 mA DC signal from 6. Note volume pumped during the calibration period of
an instrument with an Analog-to-Digital one minute. Divide into this the number of strokes to
Converter, only the output per stroke may be determine the volume of solution pumped per stroke.
calibrated.
Example : 500 ml in 100 strokes = 5.0 ml per stroke.
2. With pump primed and discharge tubing connected to
the injection point as it would be in normal service, Multiply this by your expected stroke rate per minute,
place Foot Valve and Strainer Assembly in a per hour or per day and compare with desired output
graduated container with a volume of 500ml or more. requirements.
3. Switch pump to internal mode with Speed Knob set at 7. Adjust Stroke Length Knob (lower knob) to your best
100 until air is exhausted from suction line and pump estimate of required correction and repeat calibration
head. procedure.
WARNING : Read steps 1 and 2 below before proceeding. 1. Carefully depressurize, drain and disconnect the
discharge line (See section 8.1 in this manual). Place
1. Be sure the Injection Check Valve is properly the Foot Valve into a container of water or other
installed and is operating. If a shut off valve has neutralizing solution. Turn the pump on to flush the head
been installed downstream of the Injection Valve, assembly. Once the pump head has been flushed, lift
it should be closed to off. the Foot Valve out of the solution and continue to pump
WARNING : Be sure your relief tubing is connected to air into the pump head until the pump head is purged of
your 4-FV and runs back to your solution drum or tank. water or neutralizing solution.
2. 1/4 turn or pull on both the yellow and black knobs on Note : If the liquid cannot be pumped due to Liquifram
the 4-FV. The discharge line is now depressurized. rupture, using protective gloves, carefully disconnect
Keep valve open until solution drains back down the the suction and discharge tubing. Remove the four
discharge tubing into solution drum or tank. Then screws to the head and immerse the head in water or
release or 1/4 turn knobs to normal position. other neutralizing solution.
8.2 Liquifram (Diaphragm) Replacement 2. Start the pump. While running, set the stroke knob to
zero and turn the pump off.
WARNING : ALWAYS wear protective clothing, face
shield, safety glasses and gloves when working near or Note : See Section 9.0 for proper zeroing.
performing any maintenance of replacement on your 3. With the unit off, unscrew the Liquifram by carefully
pump. grasping the outer edge of the Liquifram and turning it
MRIPL metering pumps are designed for trouble - free counter clockwise. Discard old liquifram. Remove the
operation, yet routine maintenance of elastomeric parts is Liquifram disk if so equipped (located behind the
essential for optimum performance. This involves Liqufram and check that the size code matches the size
replacing the Liquifarm, seal rings, valve balls, and the code on the replacement liquifram (see illustration)
Injection Check Valve spring. MRIPL recommends 4. Reinstall the disk.
replacing these parts at least once a year, however,
frequency will depend on your particular application. WARNING : Take care not to scratch the Teflon face of
the new Liquifarm.
5. Start the pump and turn the store knob to the setting Liquifarm is flush with the outside of the spacer edge
indicated below on stroke setting chart which (see illustration).
matches the pump model number located on the 7. Once the liquifarm is properly positioned, remount
pump data plate. With the pump stroking (running), the pump head to the spacer using the four(4)
screw on the new liquifram clockwise until the center screws. Tighten in a crisscross pattern. After one
begins to buckle inwards. Stop the pump. week of operation, recheck the screws and tighten if
6. Grasp the outer edge of the Liquifram and adjust by necessary.
screwing it in or out so that the center of the
8.3 Seal Ring, Ball and injection check valve spring Foot Valve into a container of water or other neutralizing
replacement. solution. Turn the pump on to flush the head assembly.
WARNING : ALWAYS wear proctective clothing, face Once the pump has been flushed, lift the Foot valve out
shield, safety glasses and gloves when working on or and continue to pump to let air into the pump head until
performing any maintenance or replacement on your pump is purged of water or neutralizing solution.
pump. If the liquid cannot be pumped due to Liquifram rupture,
1. Refer to parts list included with your pump for the with protective gloves, carefully disconnect the tubing
proper spare parts. and four screws to remove the head.
2. Carefully depressurize and disconnect the discharge
line (Refer Section 8.1 in this manual). Place the
Immerse the head in water or other neutralizing 4. Install new seal ring and ball in each location.
solution. IMPORTANT : Note correct orientation.
IMPORTANT : Before disassembling valves, note 5. Install the new spring in the Injection check valve.
the orientation of seal rings and ball. (see
illustration) WARNING : Depressurize and drain pipeline (or
isolate Injection Check Valve point using valves)
3. Carefully disconnect one tubing connection and fitting so that Injection Check Valve can safely be
at a time and remove the worn seal ring and ball. disassembled.
Carefully loosen sealing by prying side to side using a
small screw driver through the center hole of the seal
ring.
Ball
Seal Ring
Ball
Seal Ring
Valve Seat
Order of Installation
1. With pump running, turn stroke knob counter clockwise 9.2 STROKE KNOB FOR 'A' SERIES PUMPS
towards zero or end of black or red band.
Rezeroing and Stroke Knob Disassembly and Assembly.
2. LISTEN to the clicking as the pump is running. The
pump should operate quietly at the zero position (no 1. Remove Yellow Cap.
clicking). 2. Remove knob by pulling towards you.
3. If the pump continues to click at zero or stops clicking 3. With pump running, zero the pump using a grip plier/
before zero is reached, the pump zero must be nose plier to turn the stroke shaft counter-clockwise
reset.(See Section 9.1 & 9.2) until the pump just stops clicking.
9.1 SPEED KNOB FOR 'A' SERIES PUMPS 4. Pump is now zeroed.
Push the slipon knob on to the speed control shaft such that 5. To fit the knobs at zero percentage
the pointer is positioned at 'O' by adjusting the fixing
position of potentiometer. 6. Replace Yellow Cap.
EPU checked within 10 hours of operation can increase coil resistance as much as 20%
6 10178 HOUSING-A 1
8 013299S VARISTOR 1