Instruction Manual for PHL Updated 27-09-11 Rev-3miltonroyindia.com/distributor_pdf/HAD - PHL - Instruction Manual.pdf · PIPING LAYOUT • There must be ... PIPING ON THE SUCTION

PHL Series Pump

MILTONROY INDIA PVT LTD

1

Instruction

Manual

PHL PHL PHL PHL –––– DIAPHRAGM PUMPS (HPD 166 & HPD 266)DIAPHRAGM PUMPS (HPD 166 & HPD 266)DIAPHRAGM PUMPS (HPD 166 & HPD 266)DIAPHRAGM PUMPS (HPD 166 & HPD 266)

This Manual should be made available to person responsible for installation, maintenance and operation. No 4, Rajarajan Street, Visalakshi Nagar,

Ekkaduthangal, Chennai – 600032, India.

Telephone: 044-42266333

Fax: 044-45540060

Web: www.miltonroyindia.com

Issue Date: 10/2010, Rev-2

MILTON ROY INDIA (P) LTD Metering Pumps

PUMP MODEL: SERIAL NO: CAPACITY: LPH: PRESSURE:

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TABLE OF CONTENTS Page No WARRANTY (With Certificate) 3

IMPORTANT SAFETY INSTRUCTION 4

QUICK START GUIDE 5

1.0 DESCRIPTION

1.1 Unpacking & Storage 6 1.2 Description 6 1.3 Operating Principle of the Drive End 6 1.4 Operating Principle of the Liquid End 7 1.5 Safety Health Instructions 7

2.0 INSTALLATION

2.1 Hydraulic Installation 8 2.2 Drip Collection 8 2.3 Handling 8 2.4 Setting Up 9 2.5 Electrical Installation 9

3.0 START UP

3.1 Procedure before Startup 10 3.2 Start up 10 3.3 Failure on Start up 10 3.4 Schedule of Check & Maintenance Operations 11

4.0 ROUTINE MAINTENANCE

4.1 Strainer Cleaning 12 4.2 Oil Change 12 4.3 Other Maintenance of Operations 12 4.4 Ordering Spare Parts 12

5.0 PREVENTIVE MAINTENANCE 14

6.0 SERVICING THE DRIVE END ASSEMBLY 15

7.0 SERVICING THE LIQUID END 26

8.0 SPARE PARTS

8.1 Drive End 36 8.2 Liquid End 38

9.0 TROUBLE SHOOTING 41

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METERING PUMP PRODUCTS

TWELVE MONTH LIMITED WARRANTY Milton Roy India private Limited Company warrants its metering pump product against defects in workmanship or material for one year under normal use from the date of shipment form our warehouses as indicated in our warranty certificate. All obligations and liabilities under this warranty are limited to refunding, repairing or replacing (at our option) f.o.b, our plant, such allegedly defectives units are returned to our plant, carrier charges prepaid. Repairs or replacement are made subject to factory inspection of returned items. This warranty does not extend to damage by corrosion or atmosphere. The materials of construction offered are recommendations subject in all cases to verification and acceptance by the customer. These recommendations, based on previous company experience and best available information’s, do not constitute guarantees against wear and chemicals action. Expressly excluded from this warranty are defects caused by misuse, abuse or improper application/installation, employment or operation of the unit. Expendable items and damage resulting from unauthorized repair are not covered by this warranty. No liability for consequential damage or reinstallation labour is accepted. Milton Roy India Private Limited will not assume responsibility for contingent liability for alleged failure of its products.

RETURNING PUMPS TO THE FACTORY Pumps will not be accepted for repair without a written consent from the Factory Service Department. Pumps returned to the Factory for repairs should be clearly labeled to indicate the liquid being pumped. Process liquid should be flushed from the pump liquid end and oil should be drained from the pump housing before the pump is shipped. NOTE: These safety precautions will aid the troubleshooti ng and repair procedure and preclude serious injury to repair personnel from hazardous residue i n pump liquid end. All inquiries or parts orders should be addressed to your local Milton Roy India (P) Ltd., representatives or sent to: MILTON ROY INDIA (P) Ltd., NO.: 4, RAJARAJAN STREET, VISALAKSHI NAGAR EKKADUTHANGAL, MADRAS - 600 032. PHONE NO.: (044) - 42266333 FAX NO.: 91-44-45540060.

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IMPORTANT SAFETY INSTRUCTIONS

WARNING WHEN INSTALLING, CALIBRATING, OR OPERATING THIS PUM P, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE RISK OF FIRE, E LECTRIC SHOCK, AND PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIO NS COULD RESULT IN DEATH OR SERIOUS INJURY.

Read all instructions before installation, calibrat ion, or operation

GENERAL SAFETY CONSIDERATIONS

- Read this manual carefully.

- Installation, calibration, and maintenance should be performed by trained and qualified personnel. Personnel should be familiar with the precautions required in working with hazardous voltages which exist inside the pump. Personnel should also be adequately trained on any hazards inherent in the chemicals used in the metering pump.

- Always wear protective clothing including gloves and safety glasses when working on or near

chemical metering pumps.

- Follow directions and warnings provided with the chemicals from the chemical manufacturer. User is responsible for determining the hazards associated with the chemicals being pumped and using the proper safety gear and procedures.

- Hazardous voltages are present when cover is removed. Disconnect power when installing or

servicing this unit.

- Unit must be properly grounded.

- Conform to local codes in wiring this equipment.

- Pump must be adequately rated if it is to be used in a hazardous location. See product name plate for rating information. This rating must not be exceeded under any circumstances. To prevent ignition of hazardous atmospheres, cover must be tight while circuits are energized.

WARNING

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QUICK START GUIDE NOTE: Read and understand safety instructions before proceeding.

READ

- Read and comply with all safety instructions presented in this manual.

CONNECT

- Connect AC power. Use conduit connections or cable glands. - Ground unit. - Connect command signal. - Connect feedback signal.

VERIFY

- Voltage selector switch is set to the required voltage. - DIP switches are set for desired operation.

HAZARDOUS VOLTAGES ARE PRESENT ON THE CIRCUIT BOARD . TO PREVENT IGNITION IN HAZARDOUS ATMOSPHERES, COVER MUST BE TIGHT WHILE CI RCUITS ARE ENERGIZED. APPLY POWER

- Apply command signal. - Apply AC power.

OBSERVE

- Pump should run to command position and stop. - Full range of command signal should result in desired range of Pump travel (factory setting is for

full - Travel of 0% to 100%).

WARNING

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CHAPTER – 1

DESCRIPTION

1.1 UNPACKING & STORAGE

UNPACKING

The Packing 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 packing in order to avoid damaging accessories, which may be secured inside the packing. Examine the contents and check them against the delivery note.

STORAGE PRECAUTIONS

• Storage for less than six months - Equipment shall preferably be stored in its original packing and protected from adverse weather conditions.

• Storage for more than six months - Grease all visible unpainted sections. Rubber parts (such as semi-flexible couplings) must be protected from sunlight and sudden temperature changes. - Store the pump in its original packing. In addition, packing in heat-sealing plastic cover and desiccant bags must be provided for. The quantity of desiccant bags should be adapted to the storage period and to the packaging volume. - To be protected from adverse weather conditions.

1.2 DESCRIPTION

The PHL Pump is an electro-mechanical metering pump, oil-lubricated with a sealed housing, allowing adjustment of its capacity when stopped or in operation. It is designed for industrial operation in continuous mode. It is made up of the following items:

• a driving device consisting of a motor,

• a drive end assembly,

• a liquid end assembly.

1.3 OPERATING PRINCIPLE OF THE DRIVE END ASSEMBLY ( Figure-1)

The movement of rotation of the motor is transmitted by the worm shaft [17] to the tangent Worm wheel [18]. The system of connecting rod and eccentric transforms the rotary movement into a linear movement. The piston connected to the connecting rod [20] move with an adjusting linear stroke. The stroke of the piston depends to the position of the sliding crank [22] and the eccentric female [22A].

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1.4 OPERATING PRINCIPLE OF THE LIQUID END ASSEMBLY

During the suction phase, the displacement of the piston creates a partial vacuum in the displacement chamber. The diaphragm is hydraulically coupled to the piston and will suck a set volume (capacity) of fluid through the suction valve assembly and into the head. The discharge valve assembly seals off the discharge circuit. The process is then inverted and the return phase begins. The piston compresses the hydraulic oil in the displacement chamber. The oil then exerts pressure on the diaphragm, thus forcing the liquid through the discharge valve assembly. The suction valve assembly seals off the suction circuit.

1.5 SAFETY & 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.

During oil changing operations, the waste oil must be collected in a suitable receptacle. Any overflow of oil, which may result must be removed using a degreasing agent suitable for the operating conditions.

Soiled cleaning cloths must be stored in suitable receptacles. The oil, degreasing agent and cleaning cloths must be stored in accordance with the rules on pollution. 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, oxidizing / reducing solutions...).

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CHAPTER – 2

INSTALLATION 2.1 HYDRAULIC INSTALLATION

The Main items concerning the hydraulic installation of a metering pump are described hereafter.

GENERAL

PIPING LAYOUT

• There must be no swan-necks or stagnant volumes, which can trap air or gas. • Stresses due to incorrect alignment of piping with respect to the centerline of valves must be

avoided. • 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

• Provide for a filter with suitable mesh size upstream of the pump. • Check whether the diameter and length of pipe are compatible with the pump's maximum capacity.

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.

2.2 DRIP COLLECTION • It’s recommended to install a drain system to collect the leakage and the drip, especially if the liquid

pumped is harmful. 2.3 HANDLING

Handling the pump

The lifting equipment must be compatible with the pump weight.

Simplex pump without motor: 240Kg maximum

The handling requires the following precautions:

• Fit the sling through the rings on the pump • Check that the assembly is correctly balanced before starting to move it. • Fix the pump as soon as it is positioned in correct location (see Chapter 2.4. Setting up).

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Handling the Motor

The lifting equipment must be compatible with the motor weight (Refer to the motor name plate). Fit a sling in each ring on the motor. Check that the motor is correctly balanced before starting to move it. 2.4 SETTING UP

Pump Installation

Fix the pump by the fixing holes to a horizontal support correctly dimensioned. Leave enough clear space around the pump enabling to carry out servicing operations and adjustments. Pumps installed outdoors must be protected by a shelter (according to the climatic conditions). 2.5 ELECTRICAL INSTALLATION

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 to the indications specified in the connecting box. Check the motor rotation as indicated on the motor spacer. Do not forget to connect the earth terminal of the motor to the equipment earth conductor.

The electrical protection for the motor (fuse or thermal protection) must be suitable for the motor's rated current.

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CHAPTER – 3

START UP

3.1 PROCEDURE BEFORE START UP

Special care to be taken for chemicals used in process (acids, bases, oxidizing / reducing solutions...).

• Check the pump fixation (Chapter 2.4). • Fill the housing with the lubricating oil (Chapter 4.2) • Check the opening of all isolating valves installed on the suction and discharge circuits.

Disconnect discharge circuit (caution to the liquid pumped). This procedure is to verify that there is liquid present (pump is installed in flooded suction), or to prime the pump (pump installed in suction lift).

• Check that the pump capacity is set to "0%" (Stroke-knob).

3.2 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-knob is unlocked. • Proceed to the degassing (Chapter 7 - Servicing the liquid end). • Adjust the pump capacity gradually from 0 % to 100% and control the liquid output at Priming valve. • As soon as the liquid to be pumped flows out of the priming valve, priming on the Process side has been achieved. Close the priming valve or reconnect the discharge Pipe, as applicable. • Once the priming is obtained, adjust the pump to the desired capacity. • Lock the Stroke-knob with the locking screw.

3.3 FAILURES ON START UP / TRACING CAUSES OF FAILUR E

The motor runs with difficulty / heats up / Noisy

• One phase is incorrectly connected. • The characteristics of the electrical power supply do not match the specifications of the motor. • The electrical connection used is not suitable. • The Housing does not contain any oil. Fill up with oil (See Chapter 3.4). • The Motor coupling/bearings can be worn, replace them if necessary

The pump produces no flow

• The pump capacity is adjusted to « 0 % “: Adjust the capacity to the desired Value and lock the Stroke-knob.

• Check the leak-tightness of the piping Relief valve. • The liquid end is not primed: 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 presences of the particles in the valve assemblies are normal and take

corrective action if necessary. • If the problem is not solved check the mechanical assembly and liquid end functioning.

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The flow rate is lower than desired

• The pump capacity is incorrectly adjusted: adjust the capacity to the desired Value and lock the Stroke-knob. • The suction power is insufficient (pipe cross-section too small or pipe too long): replace the pipe

with ones that have a larger cross-section or install the Pump in flooded suction. • The leak-tightness of suction pipe is unsatisfactory. • The viscosity of the liquid is incompatible with the pump's capabilities.

The capacity is greater than desired

• The stroke adjustment of the pump is incorrect. • A siphoning phenomenon is observed: check if the suction pressure is not superior to the discharge

pressure. So necessary, to place a back-pressure valve on the discharge line.

The capacity is variable

• This problem may be due to particles from the piping which interferes with the operation of the valve assemblies: clean the piping and the valve assemblies (by checking the assembly sequence of different components).

3.4 SCHEDULE FOR CHECKS & MAINTENANCE OPERATION

• 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 Maintenance Reference

After 2000 hrs Change Oil

Chapter 4.2

Every Month Check the oil level of the housing -If incorrect

Trace lubricating oil leak

Chapter 4.2

Every 3 months Check oil temperature -If incorrect

Verify - The date of the last oil change - The oil contamination - the equipment operating conditions

Chapter 4.2

Every 8000 hours or 1 year

Change lubricating oil Change filter (y-strainer) Complete revision **

Chapter 4.0

Frequency to be defined according to process

Check conformity of capacity

Check the pump capacity Chapter 4.3

** Our Customer Support staffs are available for any maintenance matters on site (see addresses at the end of this manual).

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CHAPTER – 4

ROUTINE MAINTENANCE

4.1 STRAINER CLEANING

Clean the strainer element of the Y-strainer on the oil intake side connecting the housing (Fig-1. Item No 13) and the displacement chamber (Fig-8. Item No 22). Clogging in the strainer will lead to flow reduction.

4.2 OIL CHANGE

To avoid any risk of burning by the hot oil, protective gloves must be used.

• Perform first oil change after 2000 hours' operation, subsequently every 8000 hours or 1-year. • Disconnect the pump electrically; check that the equipment cannot be switched on accidentally. • Unscrew the plug and drain the oil into a tray. Degrease the plug and screw it into Place. • Fit the plug (14) and fill up the housing to the middle of the oil level indicator (15) with mechanical oil

suitable for service conditions and displacement chamber by the relief valve hole (26). • Remove any overflow of oil immediately with a suitable degreasing agent for the operating

conditions.

Oil Details

COMPONENT OIL QUANTITY Housing & Displacement

chamber HYDROL 150 10 Liters

4.3 OTHER MAINTENANCE OF OPERATIONS

CHECKING THE PUMP CAPACITY

This is to determine the straight line representing the pump's capacity according to its adjustment. Four measurements are sufficient (adjustment at 100%, 75%, 50% and 25%). There are two possible methods:

If the pump is installed in flooded suction mode

Measure the volume of pumped liquid from a calibrating chamber for a given period of time. It may be necessary to reproduce actual operating conditions (suction pressure).

If the pump is installed in suction Lift or Negativ e suction mode

Measure the volume of discharged liquid. It may be necessary to reduce actual operating conditions (discharge pressure).

The Flooded suction method is recommended as this method avoids placing the operator in contact with the liquid, which is important if the pumped liquid is hazardous.

For a precise check, it may be necessary to use an electromagnetic flow meter.

4.4 ORDERING THE PARTS

To make it easier to register your order for spare parts and ensure a quick delivery, please provide us the following details:

• Information on the pump: Model and Serial number. These two items of information are shown on the Nameplate mounted on the pump.

• Information on the spare part: Part number, Description and Quantity. These items of information are specified in the spare parts list given in the later sections of this manual.

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CHAPTER – 5

PREVENTIVE MAINTENANCE

5.1 GENERAL

The preventive maintenance comprises replacing the worn-out parts included in the "spare parts list ".

The corresponding action is detailed in the chapter 6.0 and 7.0: Servicing of the mechanical assembly and servicing of the liquid end.

5.2 MECHANICAL ASSEMBLY PREVENTIVE MAINTENANCE

Renewal Frequency * (hours)

Gear and Worm assembly 20,000 hrs or 1 Year

Bearings 20,000 hrs or 1 Year

Setting Guide 20,000 hrs or 1 Year

5.3 LIQUID END ASSEMBLY PREVENTIVE MANTENANCE

Renewal Frequency * (hours)

Diaphragm 15,000 hrs or 1 Year

Check valves 8,000 hrs or 1 Year

* Approximate hours number when operating under max performances and normal using Conditions

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CHAPTER – 6

SERVICING THE DRIVE END ASSEMBLY

REMARKS

• By measure of simplification, the described procedure doesn’t mention the washers fitted with

fasteners (such as screws and nuts).

• Some parts have been bonded during the workshop assembly. Clean the residual glue before a

second assembly

• Replace the seal at each servicing.

PRECAUTION Before all servicing perform the following operations:

• Disconnect the electrical power. Any accidental start -up must be prevented. Position a notice at the

switch location to avoid start up.

• Check that there is no temperature before starting to operate

• Disconnect the hydraulic power

• Remove the suction valve to drain the liquid end, if necessary rinse the liquid end

• Drain the oil from the housing.

TO BE PREPARED BEFORE SERVICING

• Handling material compatible to the weight of the equipment

• Glue Loctite 221

• Degreasing agent.

• Grease.

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VI-1 Disassembly / Assembly of Sliding Crank (Figure: 2)

DISASSEMBLY ASSEMBLY

Perform the following steps before this disassembly

- disassemble the stroke adjusting system

- disassemble the Worm wheel – connecting rod assembly

1. Fit the parallel key (31) on the

Bearing Support (22B). 2. Insert the Sliding Crank Assembly

(22) inside the housing from Side-D With the key way alignment.

3. Fit the Adjuster (24) and locate

with the dowel holes. 4. Fix the screw (32) (Hand

operated). 5. Assemble the Stroke adjustment

system (VI-4).

6. Assemble the Worm Wheel & Connecting Rod (VI-2).

7. Assemble the Worm Shaft (VI-3). 8. Assemble the Motor Assembly

(VI-5).

1. Dismantle the Stroke

Adjustment System (VI-4)

2. Unscrew the screw (32)

3. Remove the Adjuster (24) 4. Dismantle the Motor Assembly

(VI-5).

5. Dismantle the Worm Shaft (VI-3). 6. Dismantle the Worm Wheel & the

Connecting Rod (VI-2). 7. Remove the Sliding Crank

Assembly (22) from Side-D as mentioned in the drawing.

8. Remove the parallel Key (31).

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VI-2 Disassembly / Assembly of the Worm wheel and C onnecting rod

(Figure: 1 & 3)


Perform the following steps before this

disassembly:

- Disassemble the worm Wheel.

1. Grease the connecting rod (20) With

Piston.

2. Position the connecting rod (20) on the

Eccentric (22A) from Side-C.

3. Fit the slider sound (23) equipped with the key (25) to the pump.

4. Tighten the screws (29).

5. Fix the parts (18) matching one of the radius with the keyway on the part (26).


7. Position the worm gear (18), gear support (26) on the slider round (23) Matching the key (25).

8. Insert the assembly into the pump.

9. Fit the o-ring (28) on the gear bearing (16).

10. Fit the gear bearing with o-ring (16) to the pump.

11. Tighten the screw (29*)

12. Assemble the Worm Shaft (VI-3).

1. Dismantle the Worm Shaft (VI-3)

2. Unscrew the screw (29*).

3. Remove the Gear Bearing with o-ring (16).

4. Remove the Gear support (26) & worm gear (18) from Side-D as mentioned in the drawing.

5. Unscrew the screws (32).

6. Separate the gear support (26) from worm gear (18).


8. Remove the slider round (23).

9. Remove the Connecting Rod (20)

With the Piston Arrangement from

Side-C

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VI-3 Disassembly / Assembly of the Worm Shaft

(Figure: 4)


Perform the following steps before this disassembly:

- Disassemble the worm Shaft

1. Dismantle the Motor Assembly (VI-5).


3. Remove the bottom cap (38).

4. Unscrew the screw (2) from the Coupling (33).

5. Remove the key (40).

6. Remove the worm shaft (17) from

the bottom of the housing.

7. Remove the Oil Seal (30)

1. Insert the worm shaft (17) from the

bottom of the housing.

2. Insert the bearing cup from the

bottom of the housing.

3. Fix the O-Ring (39) on the top of

bottom Cap (38).


5. Insert the Oil Seal (30) into the top

Of the worm Shaft.

6. Fit the key (40).

7. Mount the Motor Assembly (VI-5).

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VI-4 Disassembly/ Assembly of the stroke adjusting system

(Figure: 5)


1. Set the Stroke Knob to 100%.

2. Remove the Handle (1)


4. Remove the assembly (1).


6. Unscrew the screw (12).

7. Remove and rotate the assembly (4) and

Adjustment screw (8) in clockwise direction.

8. Remove the O-Ring (5).

9. Remove the screw (8) from cover (4).

10. Remove the O-ring (7) form adjustment screw (8).

1. Position the cover (4) on the Housing from

Side-A.

2. Unscrew the screw (6) till it was outside

the cover.

3. Insert the O-ring (7) on the adjustment screw (8).

4. Fix the O-ring (5) into the cover (4).

5. Screw the screw (8) into the cover (4). Care should be taken that the o-ring (7) should not be outside the cover (4).

6. Move the adjuster (24) to the maximum of Outside from the housing (13) towards Side-A.

7. Fit the assembly to the adjuster (24) and rotate adjustment screw (8) & cover (4) in such a way to move the cover till It touches the housing without any movement between them.

8. Fix the screw (12) into the cover (4) to housing (13).

9. Tighten the screw (9) to avoid any risk on rotation between the cover (4) and adjustment screw (8).

10. Fix the Knob (1).

11. Tighten the screw (2).

12. Turn of 10 turns to set the << 0 >> (no

piston movement)

13. Unscrew the screw (2). Set the << 0 >> of the knob (1) with the << 0 >> of the adjustment scale (3).

14. Push the knob (1) to the adjustment screw (8).


16. Set the pump << 100% >> (10 turns).

17. Tighten the screw (6) and place the loctite666

Anabond.

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VI-5. Disassembly / Assembly of the motor

(Figure: 1 & 6)


1. Disconnect the Power Supply. 2. Unscrew the screws (37) or (35) &

(36). 3. Remove the motor. 4. Unscrew the screws (36) & (12). 5. Remove the motor mount (34), motor

adaptor (34A). 6. Unscrew the screws (2*). 7. Remove the coupling (33*), bush

(34B).

1. Fix the key (40) on the worm shaft

(17).

2. Fix the coupling (33*) or bush (34B) &

coupling (33*) on the worm shaft (17).

3. Tighten the screws (2*).

4. Fix the motor mount (34) or motor

mount (34) & motor adaptor (34A) on

the housing (13).

5. Tighten the screw (12) & (36).

6. Fit the Spider with the coupling (33*).

7. Keep a clearance of 2mm between

the two couplings (33) & (33*).

8. Fit the motor.

9. Tighten the screws (37) or (35).

Start Up: Refer to Chapter – 3.

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CHAPTER – 7

SERVICING THE LIQUID END

7.1 GENERAL

REMARKS By measure of simplification, the described procedures don't mention the washers fitted with fasteners (such as screws and nuts). Replace the seal at each servicing. PRECAUTION Special care has to be taken for chemicals used in the process (acids, bases, oxidizing / reducing solutions...). Provide for the rinsing of the liquid end, if necessary, and provide for appropriate protective equipment. Check that there is no pressure and the temperature of components before starting to dismantle. Before all servicing perform the following operations:

• Adjust the pump capacity at « 0% »

• Disconnect the electrical power. Any accidental start-up must be prevented. Position a notice at the switch location to avoid start up.

• Disconnect the hydraulic power if used

• Drain the oil from the housing (refer to chapter 4.2for oil change)

DEGASSING

Degassing the displacement chamber .

Pressurize the return circuit (if necessary by closing the return circuit valve, in order to force the safety valve to release any air contained in the displacement chamber).

Gradually increase the pump flow until the safety valve begins to clear oil into the housing.

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VII-2 Assembly / Disassembly of the displacement ch amber (Figure: 7, 8 and 12)


Dismantle the Liquid end Assembly (VII-4).

MARS Valve

1. Remove the contour plate (09). It is advisable to use a hook between the upper section of the pilot and the contour plate.

2. Remove the O-Ring (10) in order to

replace it. 3. Remove the MARS valve (23) using

an extractor. 4. Remove the O-ring (27) if they have

to be replaced.

Displacement Chamber 1. Unscrew the mounting screws (7). 2. Extract the displacement chamber assembly. 3. Unscrew the mounting screws (8). 4. If required remove the O-ring (4) or (6A) in Order to replace it. 5. If necessary replace the O-ring (6).

Displacement Chamber

1. Where applicable, fit the O-ring (4) or (6A) on the cylinder (3). Fit the adaptor piece (5) on the displacement chamber with the screws (8).

2. Fix the O-Ring (6) on the adaptor (5). 3. Position the displacement chamber to assembly over the piston (1) and Attach the housing with screws (7).

MARS valve

1. Where applicable, fit the O-ring (24) on the MARS Valve (23). 2. Apply Hydraulic fluid on the O-ring (24) and in the MARS valve recess. 3. Place the MARS valve in the extractor; center the MARS valve in the displacement chamber (22). It must, mandatory be correctly positioned as shown in the figure below. 4. Fit the MARS valve in the

displacement chamber by gently striking it with a wooden or nylon hammer.

5. Fix the O-ring (10) on the contour

plate (9) facing the displacement chamber.

6. Assemble the Liquid End Assembly

(VII-4).

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VII-3 Disassembly / Assembly of the liquid end (Figure: 7 or 8 (SS), 12 (PLASTIC))

(Section - AA)


1. Unscrew the screws (20) and (21).

2. Remove the Head (11). 3. Remove the diaphragm (12) (provide

for a Receptacle to collect oil drops).

1. Fit the diaphragm (12) (blue side visible Positioned with care).

2. Position head (11).

3. Tighten the screws (20), (21)

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VII-4 Disassembly / Assembly of the check valve (Figure: 10 or 13)


1. Unscrew the screws (19). Remove (17), (13), (14), (15) and (16). There will be a possibility of the components getting Spilled. Please ensure the components are not misplaced.

2. Clean the valve adaptor (13), ball guide (14), ball seat (15) and ball (16). If necessary replace them. 3. Replace the gaskets/o-rings (18) as the Case may be.

Discharge

1. Place the valve adaptor (13), ball guide (14), ball seat (15) and ball (16) along with the gaskets/O-rings (18) as the Case may be as shown in the Figure. 2. Screw the screws (19).

Suction

1. Place the valve adaptor (13), ball guide (14), ball seat (15) and ball (16) along with the gaskets /O-rings (18) as the case may be as shown in the Figure: 2. Screw the screws (19).

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PHL Series Pump


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PHL Series Pump


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PHL Series Pump


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CHAPTER – 8

SPARE PARTS

VIII-1 Drive End: Ref Fig-1, 2, 3,4,5,6

SERIES PHL - DRIVE END PART LIST

KEY NO PART NO DESCRIPTION QUANTITY RECOMMENDED

SPARES

1 235431S STROKE ADJUSTMENT KNOB WITH HANDLE 1 SET

2 M01629 GRUB SCREW M8 X 12 (HT) 3+3

3 235679 ADJUSTMENT SCALE 1

4 236720 COVER 1

5 235252 O-RING 110.72 X 3.53 1

6 M01630 GRUB SCREW M10 X 35 (HT) 1

7 235852 O-RING 29.5 X 3.6 1

8 233921 ADJUSTMENT SCREW 1

9 152231S STROKE LOCKING KNOB ASSEMBLY 1 SET

10 153452 O-RING LOCK KNOB (9.3 X 12.8) 2

11 156352 LOCK BOLT STOPPER GB,(PN-B,K,P) 1

12 M01512 ALLEN CAP SCREW M12 X 30 (HT) 6+4

13 236520 HOUSING 1

14 183231 Oil Filling Plug "B-145" 1

15 183511 OIL LEVEL INDICATOR "B-145" 1

16 236320S GEAR BEARING WITH O-RING 1 SET

17 238219S WORM SHAFT 1/8 (FOR 120 SPM-MODEL CODE-B) ASSY

1 SET

230119S WORM SHAFT 1/10 (FOR 100&150 SPM-MODEL CODE-A&C)

18 238144 WORM GEAR 1/8 (FOR 120 SPM-MODEL CODE-B)

1

230244 WORM GEAR 1/10 (FOR 100&150 SPM-MODEL CODE-A&C)

19 235521 DOWEL PIN 1

20 236020 CONNECTING ROD 1

21 M01631 GRUB SCREW M6X16 (HT) 2

22 234727S SLIDING CRANK ASSY 1 SET

23 235821 SLIDER ROUND 1

24 235721 ADJUSTER 1

25 237926 KEY 10X8X40 1

26 236221 GEAR SUPPORT 1

27 234231 Drain Plug 3/4" BSP 1

28 235952 O Ring 139 X 3.53 1

29 M01632 Allen Cap Screw M12 X 35 (HT) 4+4

30 237052 Oil Seal 30 X 62 X 7 1

31 M01724 Parallel Key 6 X 6 X 25 1

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32 M01693 Allen Cap Screw M6 X 16 (HT) 5+6+3

33 237020S Coupling (100&112 FRAME) with Grub Screw

1 SET

237120S Coupling 90, 2HP with Grub Screw

34 236120 Motor Mount 1

34A 234419 MOTOR ADAPTOR 90 L 1

34B 234521 BUSH FOR MOTOR FRAME 90L 1

35 M01266 Hex Bolt M10 X 25 SS 4

36 183221 Allen Cap Screw M12 X 25 (HT) 4

37 M01634 Hex Bolt M12 X 30 SS 4

38 234220S Bottom Cap assembly 1 SET

39 235352 O Ring 66.34 X 2.62 1

40 238026 KEY 8X7X40 1

41 235252S PHL DRIVE END SEAL KIT 1 SET

42

500752 MOTOR 2HP,960 RPM

1

501270B MOTOR 3HP,960 RPM

501150C MOTOR 2HP,1440 RPM



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VIII-2 Liquid End (HPD-166-SS 316): Ref Fi g: 7, 8,9,10

VIII-2 SERIES PHL HPD 166 - METALLIC LIQUID END PAR T LIST

KEY NO DESCRIPTION QUANTITY

PISTON DIAMETER RECOMMENDED

SPARES 40 50 63

1 PISTON 1 291719S 292619S 291819

2 PISTON SEAL 1 314152 316252 316152

3 PISTON SLEEVE WITH O-RING 1SET 314221S 317019S 316221S

4 SLEEVE O-RING 75.3 (HPD 166) 2 312752

5 ADAPTOR WITH O-RING 1 SET 291919S

6 O-RING 164.5X3 1 326052

7 HEX BOLT M12X40 (SS) 4 M01651

8 ALLEN BOLT M12 X 60 (HT) 2 M01711

9 CONTOUR PLATE HPD 166 WITH O-RING 1 SET 292419S

10 O-ring 178 x 3.5 1 314752

11 HEAD 166 SS 316 1 312532

12 DIAPHRAGM HPD 166 1 312652

13 VALVE ADAPTOR - B145 SS 2 911432

14 BALL GUIDE - B145 SS 2 910532

15 BALL SEAT 2 911732

16 BALL 25MM S316 2 911332

17 RETAINER PLATE 2 314832

18 GASKET 6 986179

19 HEX BOLT M12X50 SS WITH SPRING WASHER 4 SET M01655S

20

HEX BOLT M14X90 SS WITH SPRING WASHER, PLAINWASHER , NUT T FOR SS HEAD 8 SET M01716S

21

HEX BOLT M14X140 SS WITH SPRING WASHER, PLAINWASHER , NUT FOR SS HEAD 4 SET M01713S

22 DISPLACEMENT CHAMBER HPD 166 1 290920

23 MARS VALVE ASSEMBLY 1 SET 320000S

24 O-RING 69.22X5.33 2 320752

26 RELIEF VALVE ASSEMBLY HPD 166 1 SET 292120S

27 LE SEAL KIT SS 316 LE 1 SET SK14032 SK15032 SK16332

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PHL Series Pump


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VIII-2 Liquid End (HPD-266-SS316): Ref Fig: 7, 8,9,10

VIII-2 SERIES PHL HPD 266 - METALLIC LIQUID END PA RT LIST



SPARES 70 80 90 100 115

1 PISTON 1 327020 328020 329020 320020 321520

2 PISTON SEAL 1 327052 328052 329052 320052 321552

3 PISTON SLEEVE WITH O-RING 1 SET 327021S 328021S 329021S - -

4 O-RING 98X3.53 2 322352 - -

5 ADAPTOR WITH O-RING 1 SET 327120S 320120S 321820S

6 O-RING 164.5X3 1 326052

6A O-RING 134.5X3 1 - - - 323052

7 HEX BOLT M12X40 4 M01651

8 ALLEN BOLT M16 4 M01666 M01635 ( M16 X40)


10 O-RING 274X3 1 322752

11 HEAD 266 SS 316 1 322532


13 VALVE ADAPTOR SS 2 993432

14 BALL GUIDE SS 2 993732

15 BALL SEAT SS 2 993532

16 BALL 40MM S316 2 990232

17 RETAINER PLATE FOR SS HEAD 2 322832

18 GASKET 6 994579

19

HEX BOLT M12X80 SS WITH SPRING WASHER FOR SS HEAD

8 SET M01642S

20

HEX BOLT M16X100 SS WITH SPRING WASHER, PLAINWASHER , NUT FOR SS HEAD

10 SET

M01636S

21

HEX BOLT M16X160 SS WITH SPRING WASHER, PLAINWASHER , NUT FOR SS HEAD

4 SET

M01637S

22 DISPLACEMENT CHAMBER HPD 266 1 322920 323520

23 MARS VALVE ASSEMBLY 1 320000S

24 O-RING 69.22X5.33 2 320752


27 LE SEAL KIT SS 316 LE 1 SET SK27032 SK28032 SK29032 SK20032 SK21532

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PHL Series Pump


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VIII-2 Liquid End (HPD-266-PP/PVC): Ref Fig: 7 , 8, 9, 10 and 12, 13

VIII-2 SERIES PHL HPD 266 - PLASTIC LIQUID END PART LIST (REF FIG: 7,8,9,10,12,13)



SPARES 70 80 90 100 115

1 PISTON 1 327020 328020 329020 320020 321520

2 PISTON SEAL 1 327052 328052 329052 320052 321552

3 PISTON SLEEVE WITH O-RING 1 SET 327021S 328021S 329021S - -

4 O-RING 98X3.53 2 322352 - -

5 ADAPTOR WITH O-RING 1 SET 327120S 320120S 321820S

6 O-RING 164.5X3 1 326052

6A O-RING 134.5X3 1 - - - 323052

7 HEX BOLT M12X40 4 M01651

8 ALLEN BOLT M16 4 M01666 M01635 ( M16 X40)


10 O-RING 274X3 1 322752

11 HEAD 266 PP 322568


13 VALVE ADAPTOR PVC 323967

14 BALL GUIDE PP 323168

15 BALL SEAT PVC 323267

16 BALL 40MM GLASS 990259

17 RETAINER PLATE FOR PP HEAD

323732

18 O-RING 59.92X3.53 323952

19

HEX BOLT M12X100 WITH SPRING WASHER FOR PP HEAD

M01653S

20

HEX BOLT M16X175 WITH PLAIN WASHER , SPRING WASHER , NUT FOR PP HEAD

M01668S

21

STUD M16 WITH PLAIN WASHER, SPRING WASHER, 2 NUTS FOR PP HEAD

323832S

22 DISPLACEMENT CHAMBER HPD 266 1 322920 323520

23 MARS VALVE ASSEMBLY 1 320000S

24 O-RING 69.22X5.33 2 320752

25 BACK UP PLATE 1 323620


27 LE SEAL KIT PP LE 1 SET SK27068 SK28068 SK29068 SK20068 SK21568

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CHAPTER – 9

TROUBLE SHOOTING SYMPTOMS CAUSES REMEDIES

Pump does not Operate

Blown Fuse Check for Short Circuit

Motor Trip

Check for Overload, Correct current

setting in relay.

Low Liquid Level Fill Liquid

Worn or Dirty Check Valves Clean and Replace

Blocked Discharge Line Clear Line

Broken Wire Locate and Repair

Low Voltage Investigate and Correct

Pump not primed

Allow Suction Line and pump head to fill

with liquid before pumping against

pressure.

Capacity Adjustment Set at Zero. Readjust.

Insufficient Delivery

Incorrect Capacity Adjustment Readjust Capacity

Incorrect Pressure Relief valve

Settings.

Correct the Pressure Relief Valve

Settings

Starved Suction Increase Pipe Sizing or Suction Head.

Leaky Suction Piping Repair Piping

Leaky Pressure Relief Valve Repair or Replace Pressure Relief Valve.


Erratic Delivery

Leaky Suction Piping Repair Piping

Leaky Pressure Relief Valve Repair or Replace Pressure Relief Valve.


Settings.


Settings


Clogged or Dirty line Strainer Clean Strainer

Gear Shaft Breakage

Plunger or cross slide hitting against

liquid end. Correct and change the gear shaft.

Pump not developing Pressure

Leaky Gland Packing

Tighten Gland Packing

Add Rope

Change Entire Packing

Leaky Pressure Relief Valve Correct or replace pressure relief valve


Settings.


Settings

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PHL Series Pump


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Documents

Instruction Manual for PHL Updated 27-09-11 Rev-3miltonroyindia.com/distributor_pdf/HAD - PHL - Instruction Manual.pdf · PIPING LAYOUT • There must be ... PIPING ON THE SUCTION