Académique Documents
Professionnel Documents
Culture Documents
S E R I E S O F M E T E R I N G P U M P S
CR P1000V800 A PE
C: Controller PE: Polyethylene (UHMW)
CR: Controller - Relay Control TC: Teflon® Composite
S: Solenoid Valve Method TG: Teflon® Graphite
Seal
SR: Solenoid Valve - Relay Material V: Viton ®
BR: Buna N
P125V125 P500V225 P750V400(1) K: Kalrez ®
P250V225 P500V300 P1000V400(1) Basic A: 17-4 ph EPR: Ethylene Propylene
P250V300 P500V400(1) P1000V600(1) Model(2) Plunger
B: 316 SS
P1000V800(1) Material
CR: Ceramic
NOTE: (1) The 400, 600 and 800 motor cylinders are only available with the CR (controller-relay) or SR (solenoid-relay) control methods.
TABLE OF CONTENTS
4.0 MAINTENANCE 12
4.1 General 12
4.2 Disassembly and Assembly 13
4.3 Preventive Maintenance 23
4.4 Troubleshooting 23
EXHAUST NO. 1
SINGLE ACTING The PNEUMATIC RELAY is a pilot operated valve designed to provide the higher
PO3-6S DOUBLE ACTING
air or gas flow rates necessary for PNEUMATIC DRIVE CYLINDER PO4-6S
diameters greater than 3 inches. The PNEUMATIC RELAY is actuated by the pulses produced by
the CONTROLLER. A single acting PNEUMATIC RELAY is used with pumps that have return springs as illustrated to the left.
The air or gas pressure is required to return the PISTON-PLUNGER ASSEMBLY on the CRP1000V800. Therefore a double
acting PNEUMATIC RELAY is required, illustrated to the right.
3. Solenoid Valves
The pumps can be automated by replacing the
CONTROLLER with a 3-way electro-pneumatic
SOLENOID VALVE. The SOLENOID VALVE can be
cycled in order to achieve the desired pump output.
Flow tracking can be accomplished by having a
FLOWMETER or PH METER signal interpreted by our
WPC9001 or a PLC. The typical arrangement for a
WPC-9001 installation is shown at right.
2
entering pump or relay, and opens the vent air/gas pressure. This relay has two poppet At the time the controller or relay exhausts
to let it exhaust. The spool then returns to valves. The upper valve operates in the the air/gas, if the pump has a motor return
its highest position and repeats the cycle. same way as the PO3-6S relay valves, spring, fluid pressure in the fluid chamber
while the lower valve operates in the and the motor return spring force the
1.1.2 Relays opposite order. That is, when the upper piston plunger upwards. If the pump has
A relay is a pilot operated servo valve. valve applies air/gas pressure to the pump, no motor return spring, supply pressure
Air/gas pressure from a controller forces a the lower valve exhausts it, and when the from a relay enters beneath the piston to
piston and one or more attached poppet upper valve exhausts the air/gas, the lower help force the piston/plunger assembly
valves to move. Then, when the controller valve applies pressure to the opposite side upwards. In either case, the plunger
removes the pressure, a spring forces both of the piston. assembly stops when the piston contacts
the piston and poppet valve(s) in the the end of the stroke adjuster.
reverse direction. 1.1.3 Pumps
The pneumatic V Series metering plunger The piston face area where the air/gas
Relay models differ in operation. The pump consists of a body, fluid chamber, pressure is applied is much greater than
PO3-6S relay has one poppet valve that and a motor cylinder or air chamber, the plunger face area, which works against
connects the supply air/gas to the pump separated by a piston/plunger assembly the pressure of the process fluid. This area
and blocks the exhaust when the controller and seals. In the fluid chamber, the inlet ratio, called the amplification ratio,
applies air/gas pressure to the relay piston. (suction) and discharge (outlet) ports have allows the pump to work against process
When the controller removes pressure check valves that control the direction of fluid pressures much greater than the
from the piston, the poppet valve stops the the fluid flow. In the motor cylinder, the air/gas supply pressure.
supply air/gas and connects the pump to air/gas supplied from the controller or relay Note: process pressure + 200psi /
the exhaust. enters and exhausts through a pipe nipple required air supply = amplification ratio
The PO4-6S relay, used on pumps that do that connects the controller or relay to the
not have a motor return spring, drives the motor cylinder.
air piston both up and down with the
CONTROLLER CONTROLLER
RELAY RELAY
35 TO 35 TO
CONTROLLER 100 PSIG 100 PSIG
35 TO
100 PSIG
50 TO
150 PSIG
50 TO
150 PSIG
TYPICAL CP125V, CP250V, CP500V TYPICAL CRP500V400, CRP750V400, CRP1000V400 & 600 TYPICAL CRP1000V800
(WITH 125, 225 & 300 CYLINDERS) (WITH PO3-6S RELAY) (WITH PO4-6S RELAY)
3
1.2 CAPABILITIES 1.2.1.1 Controller Supply Pressure when the air/gas supply pressure is
Controllers will operate with the following more than the maximum rating of your
1.2.1 Controllers and Relays supply pressures: controller.
Controllers and relays will require separate
Maximum Minimum 1.2.1.2 Relay Supply Pressure
supply sources, and fortunately will
psi bar psi bar Relays, which require a separate air
operate with air or any gas, such as carbon
MK XII 100 6.9 35 2.4 supply, operate with supply pressures
dioxide, nitrogen or natural gas.
between 35 psig (2.41 bar) and 150 psig
WARNING: TO PREVENT INJURY, MAKE
(10.3 bar). The supply pressure must be 35
SURE THAT ANY FLAMMABLE GAS To establish the proper air/gas supply
psig minimum or equal to or greater than
SUCH AS NATURAL GAS IS PROPERLY pressure for the controller or relay, add
the process pressure plus 200 psi, divided
VENTED FOR SAFETY. 200 psig or 13.8 barg to the process
by the pump amplification ratio. (EXAMPLE:
CAUTION: If the gas could possibly pressure the pump is working against.
CRP1000V400 @ 1000 PSI + 200 PSI
damage the standard elastomeric Then use the performance graphs located
divided by 15.38 = 78 air supply required.
material, please contact your in section 1.2.2.2.
Refer to section 1.1.3 for the amplification
distributor or Williams Instrument Remember for a controller-relay
ratio formula) When using a controller/relay
Incorporated for advice. combination the controller supply pressure
combination, hold the air/gas supply
need only be set at the minimum pressure
To increase the process fluid flow rate, two pressure to the controller to the minimum
of 35 psig or 2.4 barg. The relay supply
or more pumps can be multiplexed: their value of 35 psig, and the relay at 35 psig
would be established in the above
inlets and outlets connected in parallel. minimum.
procedure or refer to section 1.2.1.2.
CAUTION: To prevent damage to the
CAUTION: To prevent damage to the
relay, always use a regulator between
controller, always use a regulator
the supply and the relay when the
between the supply and the controller
supply pressure is more than 150 psig
(10.3 bar).
1.2.2 Pumps
1.2.2.1 Flow Pressure Performance Table *:
*This data should only be used to provide you with an initial size selection. You must refer to the actual performance graphs in order to verify your pump selection.
4
0.08
AIR/GAS PRESSURE PSIG
0.07
FLOW - GPH
0.06 MA
0.054 XF
L OW
35 PSIG AIR
0.05 (G 100
PH
)
0.04 80
100 PSIG AIR/G
0.03 60
/GAS
50
0.02 40
35
AS
0.01 20
0.00 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
DISCHARGE PRESSURE - PSIG
5
STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM
0.09 0.80
0.08 0.70
0.06 MA
FLOW - GPH
0.50 100
0.054 XF
35 PSIG AI
L OW
35 PSIG AI
0.05 (G 100
PH 80
) 0.40
RE
SU
100 PSIG
0.04 80 S
RE RE
SU P 60
ES 0.30 AS
R
/G
R/GAS
0.03 S 60 R
GA AI
AIR/ 50
0.20 40
AIR
0.02 40 35
35
0.10 20
S
0.01 20
0.00 0 0.00 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0 1000 2000 3000 4000 5000 6000 7000 8000
DISCHARGE PRESSURE - PSIG DISCHARGE PRESSURE - PSIG
CP125V125 CP250V225
Discharge Pressure PSI 0 500 1000 1900 5000 8500 Discharge Pressure PSI 0 500 1000 1900 5000 6600
Gph .069 .066 .063 .059 .043 .025 gph .57 .565 .557 .552 .520 .502
Air Pressure PSI 35 35 35 35 62 98 Air Pressure PSI 35 35 35 35 70 90
0.90 90
E
R
SU
0.80 80
ES
PR
AS
0.70 70
AIR/GAS PRESSURE PSIG
/G
R
AI
FLOW - GPH
0.60 MAX 60
FLOW
(GPH
)
0.50 50
0.40 40
100
35
35 PSIG
PS
.030 30
IG
AIR
AIR/GA
0.20 20
/GA
S
S
0.10 10
0 0
0 1500 3000 4500 6000 7500 9000 10500 12000 13500 15000
DISCHARGE PRESSURE - PSIG
CP250V300
Discharge Pressure PSI 0 1000 3000 6000 10000 11000
gph .522 .502 .462 .402 .321 .301
Air Pressure PSI 35 35 35 47 77 85
6
2.00 80
35 PSIG AIR/GAS
RE
MAX F
LOW (G
U
SS
1.75 70
2.00 PH) 80
E
PR
FLOW - GPH
FLOW - GPH
AS
1.50 60 1.75 70
RE
G
R/
SU
AI
S
1.50 RE 60
100
100 PS
1.25 50 P
AS
1.25 /G 50
PSI
R
1.00 40 AI
IG AIR/G
G
35 40
1.00
0.75 30 35
0.75 30
35 PSIG
0.50 20
AS
0.50 20
0.25 10
0.25 10
0.00 0.00 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 500 1000 1500 2000 2500 3000 3500
DISCHARGE PRESSURE - PSIG DISCHARGE PRESSURE - PSIG
CP500V225 CP500V300
Discharge Pressure PSI 0 200 450 1000 1400 1500 Discharge Pressure PSI 0 500 800 1500 2000 2500
gph 2.26 2.26 2.26 2.23 2.21 2.21 gph 2.26 2.20 2.16 2.08 2.2 1.96
Air Pressure PSI 35 35 35 60 82 88 Air Pressure PSI 35 35 35 48 62 77
2.25 MAX F
LOW (G
PH)
35 PSIG AIR/GAS
2.00 160
AIR/GAS PRESSURE - PSIG
100 P
150
1.75 140
SIG A
FLOW - GPH
1.50 120
IR/G
AS
1.25 100
150 PS
RE
1.00 SU 80
ES
IG AIR
PR
0.75 G AS 60
R/
AI
AS /G
0.50 40
35
0.25 20
0.00
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
DISCHARGE PRESSURE - PSIG
CRP500V400
Discharge Pressure PSI 0 1500 3000 5000 7000 8100
Gph 2.26 2.20 2.15 2.07 1.99 1.96
Air Pressure PSI 35 35 52 80 110 130
7
8.00 160
8.00 160
100 PS
150 PS
35 PSIG AIR/GAS
P
AS
IG AIR
FLOW - GPH
IG AIR
MAX FLOW
(GPH)
/G
5.00 100 5.00 100
AS
E
UR
/GAS
4.00 80 4.00 S 80
150 P
ES
100 P
50 PSIG
PR
S
3.00 GA 60
SIG A
3.00 R/
SIG
60
50
AI
AIR/GAS
AIR/G
2.00 40
IR/GA
2.00 40 35
AS
1.00 20
S
1.00 20
0.00
0.00 0 500 1000 1500 2000 2500
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
DISCHARGE PRESSURE - PSIG
DISCHARGE PRESSURE - PSIG
CRP750V400 CRP1000V400
Discharge Pressure PSI 0 500 1500 2000 3000 3500 Discharge Pressure PSI 0 315 1000 1200 1750 2000
gph 5.00 4.90 4.80 4.70 4.60 4.50 gph 9.12 9.12 8.99 8.89 8.88 8.85
Air Pressure PSI 35 35 60 80 115 130 Air Pressure PSI 35 35 66 78 112 130
STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM & 35 SPM @ 150 PSIG STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM & 35 SPM @ 150 PSIG
10.00 10.00
MAX FLOW (GPH)
9.00 9.00 MAX FLOW (G
PH)
35 PSIG AI
150 150
125
FLOW - GPH
35 PSIG AIR/GAS
125
FLOW - GPH
R/GAS
150
150
RE
125
PS
U
SS
SIG
PSIG
RE 4.00
PSIG
4.00 E 80
PSIG
80
IG
PR
100 PSIG AIR
SSU
RE AS
AIR/G
AIR
AIR/G
P G
R/
AIR/G
3.00 S 60 3.00 60
AI
AIR/
GA
/GA
/
IR
AS
A
AS
AS
2.00 2.00
GAS
40
S
40
/GAS
35 35
1.00 20 1.00 20
0.00 0.00
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
DISCHARGE PRESSURE - PSIG DISCHARGE PRESSURE - PSIG
CRP1000V600 CRP1000V800
Discharge Pressure PSI 0 600 2000 2500 4000 4500 Discharge Pressure PSI 0 1000 1950 5500 7300 8500
Gph 9.05 9.00 8.84 8.79 1 1 gph 8.86 8.79 8.72 8.46 6.25 3
Air Pressure PSI 35 35 60 75 120 140 Air Pressure PSI 35 35 35 88 120 140
8
TG Mechanical -30 to 180°F 1,000 to 10,000 psi Tough material with excellent wear resistance. Excellent
Teflon® (Spring Loaded) -34 to 82°C 207 to 690 bar chemical inertness. Good for all types of chemicals, acids,
Graphite (High Pressure) bases or solvents. Recommended for use with the harder
ceramic plunger and higher pressures.
TC Mechanical -30 to 180°F 750 to 9,000 psi Tough material with excellent wear resistance. Excellent
Teflon® (Spring Loaded) -34 to 82°C 52 to 620 bar chemical inertness. Good for all types of chemicals, acids,
Composite (Low Pressure) bases or solvents.
PE Mechanical -30 to 180°F 100 to 3,000 psi
Tough material with excellent wear resistance. Good for water
UHMW (Spring Loaded) -34 to 82°C 6.9 to 207 bar
and alcohol based chemicals. Not recommended for solvents.
Polyethylene
BR O-ring -40 to 200°F 100 to 750 psi Soft material with fair wear resistance. Limited chemical com-
Buna N -40 to 93°C 6.9 to 52 bar patibility. Used mainly in Methanol pumping at low pressure.
K O-ring 32 to 200°F 100 to 750 psi Soft material with fair wear resistance. Excellent chemical
Kalrez® 0 to 93°C 6.9 to 52 bar compatibility. Used when Viton® is not compatible and PE or TC
will not seal.
EPR O-ring -40 to 200°F 100 to 750 psi Material has very good abrasion resistance. Excellent chemi-
Ethylene -40 to 93°C 6.9 to 52 bar cal resistance to phosphate esters, good to excellent to mild
acids, alkalis, silicone oils and greases, ketones and alcohols.
Propylene
Not recommended for petroleum oils or di-esters.
Selecting the proper seal material for your application is important. We suggest using the harder plastic seals (PE, TC or TG) whenever possible
because they provide excellent wear life. The elastomers (V, BR, K or EPR) offer enhanced sealing at low pressure because they are soft and more
compliant than the plastics. However, the elastomers do not provide the same toughness or wear resistance.
9
1.3 GENERAL OPERATING SEQUENCE As the spool continues to move down, it pushes the piston and the poppet assembly
pushes the pilot plug until the plug is downward until the O-ring on the bottom of
1.3.1 Controller unseated from the lower valve seat and the poppet presses against the lower body
allows the air/gas to exhaust through the section, sealing the pump port from the
1.3.1.1 MK XII Controller
lower valve from both the motor cylinder supply pressure. The space above the
The spool spring forces the spool upward
and the valve body volume chamber. poppet provides a path between the pump
to its highest position and unseats the top
and exhaust ports.
of the pilot plug from the upper seat. The
When the pressure in the chamber is low
exhaust spring forces the pilot plug
enough, the spool spring starts pushing 1.3.2.2 PO4-6S Relay
upward and seats it on the lower seat. This
the spool upward. The exhaust spring When there is no pilot pulse (high pressure
blocks the air/gas exhaust port.
pushes the pilot plug upward, and the air or gas) entering the top of the relay
controller returns to its initial position. from the controller, the piston spring
When high pressure air/gas enters the
pushes the piston and two poppets
supply port, it passes around and through
attached to the piston upwards until the O-
the spool and past the open upper seat to 1.3.2 Relays ring on top of the upper poppet presses
the motor cylinder port. 1.3.2.1 PO3-6S Relay against the upper body section and at the
When there is no pilot pulse (high pressure same time the O-ring on the lower poppet
High pressure air/gas passes through the air or gas) entering the top of the relay presses against the middle body section.
control passage in the controller, past the from the controller, the piston spring
The upper poppet O-ring seals the number
valve stem, and into the valve body upper pushes the piston and the poppet one pump port from the number one
chamber which causes pressure to build assembly upwards until the O-ring on top exhaust port; the space below provides a
up in the chamber. Because the surface of the poppet presses against the upper path between the supply and the number
area of the upper U-cup diaphragm is body section, sealing the pump port from one pump ports. The lower poppet O-ring
much larger than that of the middle U-cup the exhaust port. The space below the seals the number two pump port from the
diaphragm, the downward force on the poppet provides a path between the supply supply port; the space below provides a
spool is greater than the upward force. and pump ports. path between the number two exhaust and
This pressure pushes the spool down until When the controller sends a pilot pulse, pump ports.
the pilot plug seats itself on the upper the high pressure gas on top of the piston
valve seat, shutting off the air/gas supply. overcomes the piston spring force, and
Physical Specifications
Model A B C D E F G H I J WT
Inch/mm Inch/mm Inch/mm Diameter (IN) Connector Connector Inch/mm Inch/mm Inch/mm Inch/mm LBS/KG
CP125V125 4.50/114.3 9.25/235 8.12/206.2 1 7/8”47mm 1
/4” NPT (F) 1
/4” NPT (M) 13/4”45mm 13/4”45mm 6 1/4”159mm n/a 7.0/3.2
CP250V225 6.00/152.4 11.68/296.7 11.00/279.4 2 1/2”63.5mm 1
/4” NPT (F) 1
/4” NPT (M) 2 9/16”65mm 2 11/16”68mm 8 7/8”214mm n/a 9.0/4.1
CP250V300 6.25/158.8 11.68/296.7 11.00/279.4 3 1/4”82.5mm 1
/4” NPT (F) 1
/4” NPT (M) 2 9/16”65mm 2 11/16”68mm 8 7/8”214mm n/a 9.0/4.1
CP500V225 5.50/139.7 12.00/304.8 11.00/279.4 2 1/2”63.5mm 1
/4” NPT (F) 1
/2” NPT (M) 2 5/8”67mm 2 13/16”69mm 8 9/16”217mm n/a 10.0/4.5
CP500V300 6.00/152.4 12.00/304.8 11.00/279.4 3 1/4”82.5mm 1
/4” NPT (F) 1
/2” NPT (M) 2 5/8”67mm 2 13/16”69mm 8 9/16”217mm n/a 10.0/4.5
CRP500V400 9.12/232 16.00/406 11.00/279.4 4 1/4”108mm 1
/4” NPT (F) 1
/2” NPT (M) 2 5/8”67mm 2 13/16”69mm 12 3/4”324mm 9 7/16”240mm 15.0/6.8
CRP750V400 9.75/247.6 16.25/412.7 11.31/287.2 4 9/16”116mm 1
/2” NPT (F) 3
/4” NPT (M) 35/8”92mm 3”76mm 13”332mm 7 9/16”240mm 16.7/7.5
CRP1000V400 10.50/266.7 19.00/482.6 14.12/358.6 4 3/8”111mm 1
/2” NPT (F) 3
/4” NPT (M) 4”102mm 3 3/8”86mm 14 5/8”365mm 8 7/8”225mm 29.0/13.2
CRP1000V600 12.50/317.5 19.00/482.6 14.12/358.6 6 3/8”162mm 1
/2” NPT (F) 3
/4” NPT (M) 4”102mm 3 3/8”86mm 17 3/4”451mm 12 1/4”214mm 35.5/16.1
CRP1000V800 14.50/368.3 19.00/482.6 14.12/358.6 8 3/8”213mm 1
/2” NPT (F) 3
/4” NPT (M) 4”102mm 3 3/8”86mm 16”406mm 11”279mm 47.6/21.6
10
When the controller sends a pilot pulse, the 1.3.4 Pump (Fluid Chamber) • Isolation valves (ball type) on inlet and
high pressure gas on top of the relay piston The pump operating cycle consists of fluid discharge lines of the pump and in the
overcomes the piston spring force and being discharged and suctioned into the air/gas supply line to simplify
pushes the piston and two poppets fluid chamber. During discharge, the piston maintenance.
assemblies downward. The piston and two plunger moves into the pump fluid • A check valve where the pump
poppets assemblies move down until the O- chamber, decreasing the volume of the discharge line joins the main process
ring on the bottom of the upper poppet chamber and raising the pressure in the line to prevent process fluid back flow.
presses against the middle body section chamber fluid. This higher pressure closes • An inlet filter, with filtration
and the O-ring on the bottom of the lower the suction check valve and opens the approximately 25 microns, on pump
poppet presses against the lower body discharge check valve, sending the fluid suction line.
section. The upper poppet O-ring seals the into the discharge line. • A flow meter or a rate setting gauge in
number one pump port from the supply the suction line or process fluid
port; the space above provides a path During the suction part of the cycle, the discharge line, if you need precise flow
between the number one pump and piston plunger moves out of the fluid rate adjustment or recording.
exhaust ports. The lower poppet O-ring chamber, increasing the volume of the
seals the number two pump port from the chamber and lowering the pressure of the 2.2 PUMP ASSEMBLY
number two exhaust port; the space below chamber fluid. This lower pressure opens
provides a path between the number two the suction check valve and a spring closes
Position the pump assembly with enough
pump port and the supply port. the discharge check valve, sending fluid
space around it to allow easy access to all
from the suction line into the fluid
components for maintenance. Install the
1.3.3 Pump Motor (Air Chamber) chamber.
assembly with the pump inlet/suction
The motor forces the piston plunger to move check valve pointing straight down. The
alternately into and out of the pump
SECTION 2.0: INSTALLATION OF pump will not work as efficiently in any
chamber. When the controller sends the other position since the inlet/suction check
PUMP AND CONTROLLER
supply air/gas into the motor chamber valve has no spring.
through the nipple connector, the pressure NOTE: The pump assembly can be
on the piston and diaphragm overcomes installed directly in the process line
2.1 GENERAL
the combined force of the process fluid piping without any additional support
pressure on the piston plunger and plunger brackets.
Always install separate pressure regulators
return spring, and pushes the plunger into
in the air/gas supply lines for the controller
the fluid chamber. When the external
and the relay. Also, for the most efficient
controller exhausts the air/gas, the piston
performance of your pump assembly, we
plunger return spring and process fluid
recommend the following:
pressure push the piston plunger out of the
• A dryer and a dump valve in the air/gas
fluid chamber.
supply line to remove any moisture from
the supply air/gas.
CONTROLLER SPECIFICATIONS
Below you will find a schematic for a typical “V” plunger pump installation. The key ingredients for a successful installation are: 1: Clean, dry
regulated air for the controller 2: A flooded inlet supply 3: An inlet filter 4: A rate setting gauge 5: A line check valve at the point of injection
6: Isolation valves for maintenance on each component.
AIR/GAS
AIR/GAS DRYER
PRESSURE DRYER DUMP DUMP
REGULATOR VALVE VALVE PRESSURE
REGULATOR
PUMP RATE
AIR/GAS PUMP
SUPPLY SETTING AIR/GAS
RATE & GAUGE SUPPLY
SETTING CONTROLLER
3-WAY
4-20mA 24VDC GAUGE
SOLENOID VALVE
SIGNAL PULSE
WPC9001
CHEMICAL
600 STROKES
PER MINUTE
APU,
12345678 TOTAL
CHECK VALVE
RATE
INLET
PUMP 1
FLOW
PUMP 2
OR PLC INLET
FILTER
AUTO
LOSS MANUAL
CONTROL OF I/P ADJUST
OR PH
MANUAL
0 100 %
FILTER
METER FLOWMETER
CHEMICAL FLOWMETER PROCESS FLUID
SUPPLY
PROCESS FLUID TOTALIZER
TOTALIZER
3.2.2 Controller Stroke Rate middle of the pin is at the desired stroke rate by resetting the knob to 48. If this
The controller is preset at the factory to length on the scale. produces 21 strokes a minute, move
provide each pump the maximum number 5. Tighten the tee knob clockwise until the the knob to 49, which should be very
of strokes per minute at 35 psig (Ref. stroke adjuster knob is locked. close to the 22 strokes per minute you
1.2.2.1 Performance Table). This setting want. Confirm the rate by timing it.
falls at 100 on the controller scale. At 3.3 OPERATION
ZERO on the scale, the pump will not cycle 3.4 SHUTDOWN AND STORAGE
and there will be no output.
3.3.1 Bleeder Plug
To calibrate the controller stroke rate, Shortly after the pump assembly begins To shut down the pump assembly, set the
follow this procedure: operating, the metered liquid should begin pressure regulator(s) to ZERO, and turn the
1. Rotate the stroke rate knob on the flowing through the pump. To bleed air air/gas supply to OFF.
controller clockwise (CW) to ZERO on trapped in the pump chamber, turn the To store the pump assembly or if it will not
the stroke rate reference scale. bleeder plug CCW about a quarter turn. be used for a long time, do the following:
2. Turn the main air/gas supply to the When the liquid is flowing steadily with 1. Remove pump from the system.
regulator(s) to ON, and adjust the each pump stroke from the end of the 2. Flush out the pump chamber and check
regulator to the desired pressure. (see bleeder plug, turn it CW until the flow valves with water or solvent; drain and
3.2.1.1 for determining pressure.) stops. It is best to close the bleeder plug then blow the pump dry with
3. Set the flow rate for your application by when the pump is discharging and before compressed air.
using the controller's stroke rate knob the suction stroke. CAUTION: To prevent damage to the
in combination with the pump's stroke NOTE: To catch the escaping liquid, slip pump when you clean it, be sure to use
adjuster. (Ref. 1.2.2.1 Performance a length of 1/4” plastic or rubber tubing a solvent compatible with the metered
Table) over the hose barb of the bleeder plug. fluid that will not damage the pump
seals. For a recommended solvent,
If necessary, adjust the controller stroke 3.3.2 Stroke Rate contact your distributor or Williams
rate knob as follows: Set the operating stroke rate, as follows: Instrument Incorporated.
1. Loosen the set screw and remove the 1. Set the stroke rate knob to a mark on 3. Cap off the suction and discharge
knob. the scale that will produce a stroke rate check valve ports.
2. Adjust the valve stem to the desired close to the one you want. Keep in 4. You may leave the pump, controller,
rate by hand by turning the stem mind that the scale reading is only an and relay assembled, but make sure to
clockwise (CW) to decrease the stroke approximate percent indication of the store them in a dry, protected place.
rate or counterclockwise (CCW) to actual rate; generally the pump
increase the rate. Use a timer, such as maximum stroke rate will be set at 100
a stop watch, to determine the actual on the scale. NOTE: At the ZERO SECTION 4.0: MAINTENANCE
stroke rate. setting on the controller stroke rate
3. Attach and set the knob at the desired scale, the pump will not stroke, but
position on the scale (100 on scales for as you rotate the knob toward 100,
45 spm, for example). the rate will increase to the 4.1 GENERAL
maximum strokes per minute for
3.2.3 Pump Stroke Length each pump. (Ref. 1.2.2.1 Performance This section contains procedures for
The adjuster scale for the pump's stroke Table) To set the stroke rate correctly, disassembly and assembly of the
length is factory set so that a ZERO reading you must time the exhausts as they controller, pump, and check valves, plus
equals ZERO stroke length. Calibrate the leave the bottom of the controller. procedures for preventive and corrective
scale as follows: 2. Count the number of pump strokes maintenance. To maintain the reliability,
1. Turn the stroke adjuster tee set screw during a one minute interval, using a durability, and performance of your pump
counterclockwise until the stroke timer such as a stop watch to assembly and related components, it is
adjuster knob is unlocked. determine the actual stroke rate. essential to follow these procedures
2. Turn the stroke adjuster knob 3. Adjust the knob to correct the stroke exactly and carefully.
counterclockwise as far as it can go. rate as needed. Confirm by timing the For consistent, reliable performance,
The piston/plunger will be fully stroke rate. replace any O-rings, U-cups, or other seals
bottomed in the pump. 4. Repeat the above steps until you get that you remove. Order replacement seal
3. Loosen the two screws holding the data the correct stroke rate. EXAMPLE: To kits with detailed instructions from your
plate; move the data plate until the get a stroke rate of 22 strokes per distributor or Williams Instrument
middle of the pin is at ZERO on the minute, set the knob to 50 which Incorporated.
scale. Tighten the two screws. should produce approximately 25
4. Turn the stroke adjuster knob until the strokes per minute. Then reduce the
13
Whenever you disconnect any air/gas or remove. Separate upper valve body 3. Lift off the upper body and diaphragm.
fluid piping, cover all open ports in the from the lower section. (Fig. 2 & 3) Lift out the inner diaphragm assembly.
pump assembly to prevent dirt from Set aside. (Fig. 4 & 5)
entering. 4. Lift out the spool spring. (Fig. 6)
5. Turn lower controller body upside down.
4.2 DISASSEMBLY AND ASSEMBLY Use a 3/16” hex wrench to unscrew
bottom plug. Remove the bottom plug,
4.2.1 Required Tools and Materials lower spring and pilot plug. (Fig. 7 & 8)
Necessary tools will vary by pump
assembly model but the following are
typical: Figure 2
• Adjustable wrench: 12”
• Belt-spanner or web wrench
• Open-end wrenches: various sizes
• Hex wrenches: 7/64”, 1/8”, 9/64”,
3/16”, and 5/32”, 1/4”, 3/8”
• Socket wrenches: various sizes with 2”
extension Fig. 7
• Flat-blade Screwdrivers: 1/8” (2
required) and 1/4”
• MK X Screwdriver in 3/16” hex Socket
Drive (Drawing 1) Figure 3
• Brass or plastic O-ring pick (1)
• Torque wrench (15 in-lb to 122 in-lb
range)
• Bench vise
• Silicone grease, (Williams G321M4), or
synthetic grease (Williams GS102149)
Fig. 8
• Teflon tape 1/4”
• Thread sealing compound 6. Return controller body as before and
unscrew lower seat with a 3/16” hex
NOTE: See 4.3 Preventive Maintenance wrench. Remove lower seat.
for inspection and replacement of parts Figure 4 (Fig. 9 & 10)
identified throughout these procedures.
4.2.2 Controllers
4.2.2.1 Mark XII Controller
Refer to the Mark XII Controller Parts List.
To disassemble, do the following:
1. Remove red cap. (Fig. 1)
Fig. 9
Figure 5
Figure 1
2. The Mark XII has (4) four socket head
cap screws holding the controller
together. Use a 5/32” hex wrench to Fig. 10
Fig. 6
14
Figure 17
Figure 15
Figure 11
Figure 18
Figure 16
Remove the lower diaphragm from the
Figure 12 upper seat. (Fig. 18)
Figure 25
6. Use a 5/32” hex wrench to remove the
Figure 20
bottom cap screws. (Fig. 26 & 27)
Figure 30
11. PO3-6S: Put a screwdriver in the holes
of the poppet O-ring retainers and pry
them off. (Fig. 31 & 32)
Figure 21
2. Separate the top cap with data plate
from the upper body section. (Fig. 22) Figure 26
Figure 31
Figure 22
3. Put a 7/64” hex wrench through the
side of the relay into the upper body Figure 27
exhaust port and into the hole in the 7. Separate the lower body section from
upper poppet stem. (Fig. 23) the upper body section. (Fig. 26 & 27)
Figure 32
NOTE: You can now reassemble the
PO3-6S relay by coating the poppet
stems, seals, and mating surfaces with
silicone grease, and then reversing the
above procedure.
Figure 23 Figure 28
4. Use a 9/64” hex wrench to remove the 8. Again, put the 7/64” hex wrench
piston lock screw (Fig. 23) through the hole in the upper poppet
5. Pull out the piston, O-ring, and spring. stem. (Fig. 29)
(Fig. 24 & 25)
16
Figure 36
NOTE: Reassemble the PO4-6S relay by
Figure 40
coating the poppet stems, seals, and
b. Remove the motor cylinder by unfastening
mating surfaces with silicone grease,
the 4 to 10 screws (depending on the
and then reversing the above
pump model) holding the motor cylinder
procedure.
to the faceplate. (Fig. 41)
4.2.4 P125, P250, P500, P750 & P1000
Figure 33
Pumps
4.2.4.1 Changing Plunger Seals
1. Disassembly:
a. Unscrew the pump body from the fluid
cylinder. The primary seal is visible in
the pump body. The plunger will
protrude from the pump body, through
the seal. (Fig. 37, 38, 39 & 40)
Figure 34 Figure 41
13. PO4-6S: Separate the upper poppet c. Remove the piston plunger guide ring
stem from the middle stem and the and return spring. (Fig. 42 & 43)
poppet body. The poppet stem
connector bolt will remain on one of
the stems. (Fig. 35)
Figure 37
Figure 42
Figure 35
14. PO4-6S: Use the flat-blade
screwdriver to unscrew the lower
poppet stem.
15. PO4-6S: Pull out the middle stem and Figure 38
poppet body. The poppet stem
connector bolt will remain in one of Figure 43
the stems. (Fig. 35) d. Now remove the retaining ring and
16. PO4-6S: Put a 7/64” hex wrench or spring seat. The secondary seal (and
screwdriver in the holes of the poppet associated backup ring if O-rings are
O-ring retainers and pry them off. being used), will be found beneath the
(Fig. 31) Then use the screwdriver to spring seat. (Fig. 44 & 45)
pry out the O-rings.
Figure 39
17
Figure 46
Figure 54
Figure 51
f. Thoroughly clean all internal pump
surfaces. Then inspect all metal sealing
surfaces such the seal gland and
plunger for scratches, nicks or
irregularities.
18
Retaining Ring
Spring Seat
(Seal Retainer)
O-ring Seal
Faceplate
Pump Body
Backup Ring
(Plunger Guide)
O-ring Seal
Fluid Cylinder
Illustration I Illustration II
f. Lubricate the seals as follows: Refer to the appropriate parts list, for 4. Remove the piston/plunger assembly,
1. Both 1/8” NPT plugs should have the pump you are rebuilding.(Fig.62) piston U-cup (piston O-ring on the
been removed during the disassembly P1000V800), piston guide ring and the
of the pump to facilitate cleaning. If piston return spring (on all pumps
this was not done, please do it now. except the P1000V800). The piston
2. Thread the tube of grease (GS102149) guide ring will fall away from the
that came with the seal kit into one of piston. Remove the piston U-cup
the lubrication access ports. (Fig. 60) (piston O-ring on the P1000V800).
(Fig.66 &67)
Figure 63
Disassemble the pumps as follows:
1. Clamp the pump at the fluid cylinder in
a vice. Use jaw protectors to avoid
scratching the pump. (Fig. 64)
Figure 60 Figure 66
3. Now, squeeze the grease into the
lubrication cavity. Hold your finger over
the opposite lubrication cavity access
hole, alternately removing it to allow
air to escape and to feel the grease
pressurize the lube cavity. (Fig. 61)
Figure 64
2. Use the belt-spanner wrench to loosen
the body from fluid cylinder. Clamp on
the body or the motor cylinder. Continue Figure 67
turning the assembly by hand until the NOTE: Before doing the next step, put a
two parts separate. (Fig. 65) piece of tape or other mark on the
outside surface of the cylinder
faceplate to align it with a body part for
Figure 61 reassembly.
4. When all the air have been expelled 5. Use the 5/16” open end wrench to
from the lubrication cavity and only unscrew and remove the vent plug, and
grease is exiting the opposite access the 3/16” hex wrench to unscrew and
hole, the cavity is full. remove the two grease chamber plugs.
5. Apply Swagelok SWAK thread sealant Use the appropriate hex wrench to
to both 1/8” NPT plugs and replace in unscrew and remove the cap screws
Figure 65
pump housing. (Fig. 62) and split washers fastening the cylinder
NOTE: The fluid cylinder of the pump
faceplate to the body. Slide the
can remain installed on the plumbing if
faceplate off the body. On the
only the pump and not the check valves
P1000V800, remove the two faceplate
are to be serviced. Also, since the body
O-rings. (Fig. 68, 69, 70 & 71)
and the fluid cylinder are made as a
matched set, keep them together. do
not substitute parts from other pumps
of the same model.
3. Use the appropriate hex wrench to
Figure 62 remove the socket-head cap screws
4.2.4.2 Complete Pump Rebuild: and washers fastening the motor
Although there are some differences cylinder to the body. If the pump has a
between the pumps, they are piston return spring it will push the two
disassembled and reassemble in pieces apart (exception: CRP1000V800);
if not, separate the motor cylinder from Figure 68
approximately the same way. The
procedures describe the differences. the body and faceplate.
20
Figure 74
Figure 69 CAUTION: Do not remove the face plate
plug from the P1000V800. The filter plug
retainers are permanently pressed into
place at the factory. DO NOT REMOVE
THEM.
Figure 78
7. Use a pick if necessary to remove the
body seal O-ring, the primary plunger
seal, and the plunger seal backup ring
from the body. The piston-plunger can
also be used to push out the primary
Figure 70 seal and backup ring by reinstalling it in
the body faceplate assembly.(Fig. 75,
76 & 77)
Figure 79
10. Remove the spring seat. On the
P1000V800 remove the two spring
seat O-rings. (Fig. 80 & 81)
Figure 71
6. On the P250 and P500, use a small
Figure 75
screwdriver or punch to push the filter
plugs from the cylinder faceplate. (Fig.
72, 73 & 74)
Figure 80
Figure 76
Figure 72
Figure 81
11. Use a pick if necessary to remove the
secondary plunger seal located
beneath the spring seat or remove the
seal by installing the plunger in the
Figure 77 opposite end of the body-faceplate
8. Clamp the body in the bench vise, assembly and pushing the seal out.
faceplate side up. (Fig. 82 & 83)
Figure 73 9. Use a pick or small screwdriver to lift
21
8. Remove the body from the bench vise. torque the socket-head cap screws spring cavity on the wide end (not the
At the threaded end of the body install and split lock washers to the values in slotted end) of the ball seat. Drop the
the body seal O-ring and the plunger the table. two parts, ball seat first, into the body.
seal backup ring followed by the 4. Drop the retainer, spring cavity first, if it
PUMP TORQUE (in-lb)
plunger seal. Face the open side of the has one, into the body and use the
P125 15 - 20
seal away from the grease chamber. appropriate hex wrench to torque to the
P250 15 - 20
9. Place the fluid cylinder in the vise with values in the table.
P500 15 - 20
the body mating end facing up. Use the
P750 15 - 20
adjustable wrench to screw in the PUMP TORQUE (in-lb)
P1000 118 - 122
suction check valve (ball end or hex P125 230 - 240
plug end into the pump), discharge P250/500 230 - 240
17. To lubricate the seals for running, hold
check valve, and bleeder plug. Arrows P750/P1000 118 - 122
a finger over one vent hole and insert
on the check valves indicate flow
the end of the synthetic grease tube
direction. Use thread sealant and teflon 4.2.6 Suction Check Valves: All Pumps
into the other vent hole. Squeeze
tape on the suction and discharge Although there are several sizes of check
synthetic grease into the grease
check valves. valves with minor construction differences,
chamber until you feel it pressing
10. Apply synthetic grease to the body they are all disassembled and reassembled
against your finger. Vent all the air.
threads and body seal O-ring. Screw the same way. The procedures describe
Wipe off excess synthetic grease,
the body into the fluid cylinder until it is the differences. Refer to the appropriate
apply thread sealing compound to the
hand tight, then tighten with the web or parts list. Disassemble the check valve as
vent plugs, and replace them.
belt-spanner wrench per the following follows:
torque values. 1. Clamp the check valve body in the vise.
4.2.5 Discharge Check Valves:
PUMP MODEL TORQUE (Ft-lbs) 2. Use the appropriate hex wrench to
All Pumps
P125V (all) 50 unscrew and remove the retainer.
Although there are several sizes of
P250V (all) 50 (Fig. 93)
discharge check valves, they are all
P500V 225 50 disassembled and reassembled the same
P500V 300 100 way. Refer to the appropriate parts list.
P500V 400 100 Disassemble the check valve as follows:
P750V 400 100 1. Clamp the check valve body in the vise.
P1000V (all) 100 2. Use the appropriate hex wrench to
unscrew and remove the retainer.
11. On all pumps except the P1000V800,
3. Remove the body from the vise and
put one end of the piston return spring
dump out the spring, ball seat, ball,
in the spring seat. Install the piston U-
sleeve, and Teflon® O-ring (Fig. 92) Figure 93
cup (piston O-ring on the P1000V800)
3. Remove the body from the vise and
on the piston. Face the open side of
dump out the ball, sleeve, and O-ring.
the U-cup away from the plunger.
NOTE: On the P125 and P250 you
12. Apply synthetic grease liberally to the
may need a pick or small tool to
piston/plunger assembly and inside
remove the Teflon® O-ring inside the
the motor cylinder; install the
body. (Fig. 94)
piston/plunger assembly, without the
piston guide ring, into the body.
13. Put the piston guide ring on the piston;
while holding the ends of the guide Figure 92
ring together with a finger or thumb, 4. Remove the Teflon O-ring from the
®
4. On the P500, P750 and P1000, remove 4.3.1.4 At least every twelve months: 9. Is the distance between the pump and
the Teflon® O-ring from the sleeve. Perform the following procedures: supply air/gas correct?
(Fig. 95) 1. Disassemble and inspect the pump inlet 10. Is the pump operating within
and outlet check valves. Replace worn acceptable minimum and maximum
parts. temperature limits?
2. Inspect the piston/plunger assembly, 11. Is the pump being used for more than
piston return spring (on all pumps one purpose? Plunger seals are
except the P1000V800), and all seals. affected by this.
Replace the piston/plunger assembly 12. Is the proper cleaning fluid being used
and the seals. to flush out the pump?
13. Is there a current and accurate
Figure 95 4.3.2 Cleaning and Lubrication service/maintenance/breakdown
Whenever the pump assembly is record for the pump?
Reassemble the check valve as follows: disassembled: Clean all inside and
1. On the P500, P750 and P1000, put the outside surfaces with an approved solvent, 4.4.2 Proper Amount of Use
Teflon® O-ring in the sleeve and drop and blow them dry with compressed air. While answers to the questions on the
the sleeve, O-ring first, into the body. CAUTION: To prevent damage to the above checklist will provide considerable
On the P125 and P250, drop the O-ring pump when you clean it, use a solvent information about how the pump is being
into the body, followed by the sleeve, that is compatible with the process used, it is equally important to determine if
the end with a shoulder first. fluid and that will not damage pump it is overworked.
2. Drop the ball into the body. seals. Contact your distributor or
Williams Instrument Incorporated for a Fortunately, you can use the amplification
3. On the P125 and P250, use the
recommended solvent. ratio of the pump (ref. 1.1.3 Pumps) and
appropriate hex wrench to screw the
the process pressure (the pressure the
retainer into the body. On the P125 and
pump plunger is working against) to check
P250, tighten until you feel the Teflon® 4.4 TROUBLESHOOTING
this. Use the following example:
O-ring resistance, then tighten another
• Example: process pressure is 2800 psi.
1/4 to 1/3 turn to compress the O-ring. 4.4.1 Proper Pump Use
• Add 200 psi to the example process
On the other pumps, tighten securely. When a pump is either not working or
pressure. This additional 200 psi will
No Loctite #277 is required. working incorrectly, the trouble can be in
insure that the chemical is positively
two basic areas: the pneumatic or the fluid
injected: 2800 psi + 200 psi = 3000
4.3 PREVENTIVE MAINTENANCE ends of the pump. However, since factors
psi.
other than the pump can affect its
• To set the air/gas supply pressure use
operation, first check that the pump is
4.3.1 Periodic Maintenance the performance graphs in 1.2.2.1.
being used properly. To help you
4.3.1.1 Once a week: Perform the determine this, use the following checklist: From this information you can determine if
following procedures: 1. Is the air/gas supply available in the pump is working properly. In the above
1. Check for process fluid leaking from the sufficient volume and at the proper example, if the supply pressure had been
plumbing. pressure? 100 psi instead of 35, it would have been
2. Check for process fluid leaking from the 2. Is the air/gas supply of clean excessive, resulting in premature failure of
pump's vent hole, cylinder faceplate, instrument quality, not dirty or wet? the pump's moving parts and sealing
and body O-ring. 3. Is a pressure regulator in use to capabilities.
3. Check for air/gas leaks. maintain a constant air supply?
4. Check for loose fittings and screws. 4. Is the tube or pipe size of the air/gas 4.4.3 Troubleshooting Guide
supply line correct for your pump The Troubleshooting Guide on the
4.3.1.2 At least once a month: Unscrew model? following pages identifies the most
the plug from the top of the tee fitting 5. Is the pump correct for the nature and common problems, their possible causes,
between the relay and the controller; put a characteristics of the material(s) it and corrective action for each problem.
few drops of Williams SF96-100 silicone handles: composition, viscosity,
oil in the hole. necessary line pressure, etc.?
6. Is the process fluid container–drum, day
4.3.1.3 At least every six months: tank or large storage tank–clean and
Inspect the piston-plunger assembly and free of contaminants?
seals. Replace the seals and check the 7. Is the filtration adequate? Disassemble
plunger for wear; replace the piston/ and inspect.
plunger assembly if it is scored, rough, or 8. Is the size of the process fluid line
discolored. correct for the pump?
24
TROUBLESHOOTING GUIDE
CONTROLLER NOT • Foreign material in controller • Put finger over exhaust port; alternately seal & vent port to
OSCILLATING clear exhaust valve.
• No air/gas supply • Connect pressure gauge to port opposite supply line; verify
required supply pressure.
• Supply pressure too high or too low • Reset regulator to proper pressure.
• Too much pressure drop in air/gas line • Increase connecting tube size or clean air lines.
• Stroke rate valve open too much • Disconnect air/gas supply. Rotate stroke rate knob CCW to
peg, wait 5 seconds, & rotate knob CW until it stops.
DO NOT FORCE KNOB.
• Leak between valve body & • Loosen; then retighten the connection between valve &
controller body controller body. If dirty, disassemble, wipe clean and
reassemble.
• Continuous air flow from controller • Inspect & replace damaged lower seat and pilot plug.
exhaust port (Pilot plug not seating
properly)
• Air flowing from equalizer hole on • Inspect & replace ruptured or improperly seated seals.
side of lower control body
Put finger over exhaust port; alternately seal & vent port to
clear exhaust valve.
RELAY NOT OPERATING • Broken piston return spring • Replace return spring. See page 15
• Poppet stem loosened from connector bolt • Tighten poppet stem to connector bolt. See page 15
• Air blow-by caused by poorly sealed O-rings • Improve quality of air supply and clean dirt from unit.
Replace O-rings if damaged.
PLUNGER NOT STROKING • Controller control knob set at ZERO • Turn knob to proper setting on dial.
• Air/gas supply turned OFF • Open valve to allow air supply to flow to controller.
• Plunger stuck due to tight or dry seal • If seal is swollen, check its chemical compatibility with
process fluid; replace with compatible seal material.
• Excessive grease between cylinder and • Remove excess grease. Piston seal may be leaking; check
faceplate and replace if necessary.
• Air/gas supply pressure too low to • Increase supply pressure to controller or relay.
overcome process line pressure
PLUNGER NOT STROKING • Air/gas flow to controller too low (controller • Install a larger capacity regulator or supply line. Vent supply
(Cont.) locked up and will not cycle) side of controller and try to start pump at slowest speed;
increase speed slowly if controller starts to cycle.
LOW PUMP OUTPUT • Viscosity of the chemical being pumped • Review and enlarge size of supply and discharge lines to
too high. improve flow of chemical.
• Pump mounted too high to suck adequate • Remount pump to create a flooded suction (six inch
supply of chemical to fluid cylinder minimum).
• Pump appears sluggish in stroking. Piston • Remount pump as close to controller and relay as possible
not returning all the way. to allow the controller and relay to exhaust quickly. Check
for ice in exhaust port.
• Suction lift condition inadequate. • Change tank elevation to get flooded suction if change not
possible, add foot valve at end of suction line, and increase
suction line diameter.
• Supply and discharge lines too small. • Install correct tubing size.
See pump sluggish
• Erratic controller operation • Rebuild, clean and lubricate controller; add air inlet filter or
air/gas dryer.
• Improper chemical supply • Make sure top of chemical supply tank is vented
to atmosphere or pressurized.
PROCESS FLUID IN • Premature wear on plunger seals from • Calculate proper speed and air supply pressure. (Refer to
GREASE CHAMBER OR excessive pump speed amplification ratio principle.) Replace seals and plunger.
LEAKING FROM BODY
OR CYLINDER • Foreign material in process fluid • Check to see if chemical supply is clean; if not, install
FACEPLATE VENT HOLE chemical filter in supply line.
PROCESS FLUID IN • Seal or plunger materials not compatible • Refer to compatibility charts; contact distributor or
GREASE CHAMBER OR with process fluid Williams Instrument Incorporated
LEAKING FROM BODY
OR CYLINDER • Crystallized chemical on plunger • Maintain lubricant and decrease time between inspections.
FACEPLATE VENT HOLE scoring seal
(cont.)
• Lubricant incompatible with process fluid • Change lubricant; contact distributor or Williams
Instrument Incorporated
NO PUMP DISCHARGE • Suction check valve or discharge check • Clean or replace check valves.
valve not seating
• Suction or discharge line clogged • Inspect line for closed connections or valves.
• Air entering suction line • Tighten fittings; Inspect and replace sealants.
SECTION 5.0
PARTS LIST & REPAIR KIT
ORDERING REFERENCE
5.1 CONTROLLER
5.2 RELAYS
NOTES
28
www.williamspumps.com
)VYLAND 2OAD s )VYLAND 0! 53! s s s &AX s % MAIL INFO WILLIAMSPUMPSCOM