W HI PRESSURE - FLOW PLUNGER

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

S e r i e s o f M e t e r i n g P u m p s

Also for use with older

W, D & K Series Metering Pumps
 INTRODUCTION AND OVERVIEW

This manual contains specific, comprehensive procedures to help users install, operate, and maintain the Williams Plunger Series
of Pneumatic Metering Pump Assemblies consisting of a plunger pump and controller or a plunger pump, relay, and controller.

For user convenience, the manual is divided into five sections:

Section 1.0: SECTION 3.0: SECTION 5.0:

FUNCTIONAL DESCRIPTION STARTUP, OPERATION, AND SHUTDOWN DRAWINGS AND PARTS LISTS
Section 1.0 contains a physical Section 3.0 contains procedures for setup, Section 5.0 contains parts lists and
description, the capabilities, and the operation, shutdown, and storage of the assembly drawings.
operating sequence of the pumps. pumps.

SECTION 2.0: SECTION 4.0:

INSTALLATION OF PUMP AND CON- MAINTENANCE
TROLLER Section 4.0 contains procedures for regular
Section 2.0 contains specific proce- and corrective maintenance.
dures for installing the pumps and
their various components including
the controller.

TABLE OF CONTENTS
PAGE
SECTION 1.0: FUNCTIONAL DESCRIPTION 2
1.1 PHYSICAL DESCRIPTION 2
1.2 CAPABILITIES 2
1.2.2.5 SPECIFICATION TABLE 4
1.3 GENERAL OPERATING SEQUENCE 4

SECTION 2.0 INSTALLATION 6

2.1 GENERAL REQUIREMENTS 6

SECTION 3.0 START-UP, OPERATION AND SHUTDOWN 6

3.2 START-UP 6
3.3 OPERATION 8
3.4 SHUTDOWN AND STORAGE 8

SECTION 4.0 MAINTENANCE 8

4.2 DISASSEMBLY AND ASSEMBLY 8
4.2.3 CONTROLLER 9
4.2.4 RELAY 10
4.2.5 PUMPS: P125D AND P125W 11
4.2.6 PUMPS: P250D, P250K, P250W, P500W, P5002, P1000W400, AND P1000W600 13
4.2.7 PUMPS: P1000W800, P1500W400, P1500W600, P1500W800, P2250W600, AND P2250W800 16
4.2.8 DISCHARGE CHECK VALVES 17
4.2.9 SUCTION CHECK VALVES 17
4.3 PREVENTIVE MAINTENANCE 18
4.4 TROUBLESHOOTING 18
Section 1.0: Functional Description 1.1.2 Relay The piston face area where the air/gas
The relay is a pilot operated valve. Air/gas pressure is applied is much greater than
1.1 Physical Description pressure from a controller forces a piston the plunger face area which works against
The letters CP at the beginning of a pump and one or more attached poppet valves the pressure of the process fluid. This dif-
assembly model number indicate that the downward. Then, when the pressure from ference in area, called the amplification
model consists of a controller and pump. the controller is removed, a spring forces ratio, allows the pump to work against
The letters CRP indicate that the model both piston and poppet valve(s) upward. process fluid pressures much greater than
also has a relay. the air/gas supply pressure.
Relay models differ in operation. The PO3-
Controller types differ according to the 6S relay has one poppet valve that con- See page 3 for
pump model. nects the supply air/gas to the pump and GENERAL CONFIGURATION
• CP250K, CP125D and CP250D225 pump blocks the exhaust when air/gas pressure Drawing 1
assemblies use the MK-II controller. is applied to the relay piston. When the
• CP250D300 and CP500D pumps use the pressure is removed from the piston, the 1.2 Capabilities
MK-VII controller. poppet valve cuts off the supply air/gas
• All W series pumps--CP125W125, and moves up to connect the pump to the 1.2.1 Controllers and Relays
CP250W225, CP500W300. etc.--use the exhaust. Controllers and relays require separate
MK-X controller. supply sources, but fortunately will operate
The PO4-6S and PO4-8S relays, used on with air or virtually any gas, such as car-
Some W series pumps use relays which pumps that do not have a motor return bon dioxide, nitrogen or natural gas.
are of different sizes: spring, drive the air piston both up and
down with the air/gas pressure. Also, WARNING - TO PREVENT INJURY, MAKE
• CRP500W400, CRP1000W400, and these relays have two poppet valves. The SURE THAT ANY FLAMMABLE GAS SUCH
CRP1000W600 pumps use the PO3-6S upper valve operates in the same way as AS NATURAL GAS IS PROPERLY VENTED
relay. the PO3-6S relay valve. But the lower FOR SAFETY.
• CRP1000W800, CRP1500W400, valve operates in the opposite order. That
CRP1500W600, CRP1500W800, is, when the upper valve applies air/gas CAUTION
CRP2250W600S, CRP2250W600L and pressure to the pump, the lower valve If there is a chance that the gas could
CRP2250W800S pumps use the PO4-6S exhausts it, and when the upper valve damage the standard elastomeric mate-
relay. exhausts the air/gas, the lower valve rial, Buna-N rubber, used in the con-
• CRP2250W800L pumps use the PO4-8S applies pressure. troller or relay, please contact your dis-
relay. tributor or Williams Instrument
1.1.3 Pump Company for advice.
To increase the process fluid flow rate, two The pneumatic metering plunger pump
or more pumps can be multiplexed: their consists of a pump or fluid chamber, and a 1.2.1.1 Controller Supply Pressure:
inlets and outlets connected in parallel. motor or air chamber, separated by a pis- Controllers will operate with the following
ton plunger assembly and seals. In the supply pressures:
1.1.1 Controller fluid chamber, the suction (inlet) and dis-
The controller, consisting of an upper and charge (outlet) ports have check valves Maximum Minimum
lower chamber separated by a sliding that control the direction of the fluid flow. psi bar psi bar
spool, uses a capillary tube with a needle In the air chamber, the air/gas power sup- MK-II 65 4.5 35 2.4
valve to transfer the supply air/gas from ply from the controller or relay enters and MK-VII 90 6.2 50 3.4
the lower to the upper chamber. While exhausts through a pipe nipple that con- MK-X 100 6.9 35 2.4
controllers differ in their seals, MK-X using nects the controller or relay to the air
U-cup seals and MK-II and MK-VII using chamber. When establishing the proper air supply
diaphragm seals, their operation is essen- pressure, remember the process pressure
tially the same. When the sliding spool is When the controller or relay exhausts the is the pressure the pump plunger is work-
in its highest position, a pilot plug closes a drive air/gas, if the pump has a motor ing against; the amplification ratio of a
vent and moves the supply air/gas to the return spring, fluid pressure and the spring pump is the number listed on the specifi-
pump or relay. In the spool's lowest posi- force the piston plunger upwards. If the cation sheet for that pump. For controller
tion, the reverse is true; the pilot plug pre- pump has no motor return spring, supply or relay driven pumps, the air/gas supply
vents supply air/gas from entering pump pressure from a relay enters beneath the pressure must be equal to or greater than
or relay, and opens the vent to let it piston to help force the piston plunger the process pressure plus 200 psig, divid-
exhaust. The spool then returns to its assembly upwards. In either case, the ed by the pump amplification ratio. If the
highest position and repeats the cycle. plunger assembly stops when the piston controller is sending pilot pulses to a relay,
makes contact with the end of the stroke the air pressure must be set at 35 psig
adjuster. (2.4 bar).

2
 DRAWING 1
GENERAL CONFIGURATION

3
CAUTION 1.2.2.3 Operating Temperature Range: 1.3.2 Relays
To prevent damage to the controller, The range of operating temperatures
always use a regulator between the depends on the seal material. For the 1.3.2.1 PO3-8S Relay: When there is no
supply and the controller when the standard pump seal material, Teflon- pilot pulse (high pressure air or gas) from
air/gas supply pressure is more than Graphite, the range is -30°F (-30°C) to the controller, the piston spring pushes the
the maximum rating of your controller. 185°F (85°C). For information on seal piston and the poppet attached to the pis-
materials with different operating tempera- ton upwards until the O-ring on top of the
1.2.1.2 Relay Supply Pressure: Relays, ture ranges, contact your distributor or poppet presses against the upper body
which require a separate air supply, oper- Williams Instrument Co. section, sealing the pump port from the
ate with supply pressures of 50 psig (3.4 exhaust port. The space below the poppet
bar) minimum and 150 psig (10.3 bar) 1.2.2.4 Metered Fluids: Pumps can oper- provides a path between the supply and
maximum. The supply pressure must be ate with many kinds of acids, caustic, sol- pump ports.
equal to or greater than the process pres- vents, and slurries, depending on the
sure plus 200 psig divided by the pump pump and seal materials. For information When the controller sends a pilot pulse,
amplification ratio. (See 1.2.1.1 above for on seal and metallurgical materials to use the high pressure gas on top of the piston
definitions of process pressure and ampli- with a particular fluid, contact your distrib- overcomes the piston spring force; this
fication ratio.) utor or Williams Instruments Co. pushes the piston and the poppet attached
When using a controller/relay combination, to the piston downwards until the O-ring
the air/gas supply pressure to the con- 1.2.2.5 Specification Table (See following on the bottom of the poppet presses
troller should be held to the minimum page) against the lower body section, sealing the
value. (Ref. 1.2.1.1.) pump port from the supply pressure. The
1.3 GENERAL OPERATING SEQUENCE space above the poppet provides a path
CAUTION between the exhaust and pump ports.
To prevent damage to the relay, always 1.3.1 Controller
use a regulator between the supply and The spool spring forces the spool upward 1.3.2.2 PO4-6S and PO4-8S Relays:
the relay when the supply pressure is to its highest position and unseats the top When there is no pilot pulse (high pressure
more than 150 psig (10.3 bar). of the pilot plug from the upper seat. The air or gas) from the controller, the piston
exhaust spring forces the pilot plug spring pushes the piston and both poppets
1.2.2 Pumps upward and seats it on the lower seat, attached to the piston upwards until the O-
blocking the air/gas exhaust port. ring on top of the upper poppet presses
1.2.2.1 Viscosities: Pumps will provide against the middle body section. The
catalog performance on fluids with viscosi- When high pressure air/gas enters the upper poppet O-ring seals the number one
ties up to 4500 SSU (Saybolt Second supply port, it passes around and through pump port from the number one exhaust
Universal) or 960 CP (Centipoise). Pump the spool, pst the open upper seat to the port; the space below provides a path
can operate on higher viscosity fluids but motor cylinder port. From there it slowly between the supply and the number one
performance will be reduced. through the capillary tube, past the valve pump ports. The lower poppet O-ring
stem, and into the valve body volume seals the number two pump port from the
1.2.2.2 Static Suction Head: Pump dis- chamber, causing pressure to build in the supply port; the space below provides a
charge pressure determines suction head. chamber. path between the number two exhaust and
Because 100 psi check valves are stan- pump ports.
dard on all pumps, net positive suction Because the surface area of the upper U-
head must be less than 100 psi (6.9 bar) cup is much larger than the surface area When the controller sends a pilot pulse,
or 230 feet - head of water to prevent of the middle U-cup, downward force on the high pressure gas on top of the piston
free-flow through the pump. the spool is greater than the upward force. overcomes the piston spring force; this
This pushes the spool down until the pilot pushes the piston and both poppets
CAUTION plug seats itself on the upper valve seat, attached to the piston downwards until the
Because pumps will not work with net shutting off the air/gas supply. As the O-ring on the bottom of upper poppet
negative suction, Williams always rec- spool continues to move down, it pushes presses against the middle body section
ommends flooded suction. the pilot plug until it is unseated from the and the O-ring on the bottom of the lower
lower seat valve and the air/gas exhausts poppet presses against the lower body
To obtain suction pressures higher than through the lower valve from both the section. The upper poppet O-ring seals
100 psi, contact your authorized distributor motor cylinder and the valve body volume the number one pump port from the supply
or Williams Milton Roy. chamber. port; the space above provides a path
between the number one exhaust and
When the pressure in the valve body vol- pump ports. The lower poppet O-ring
ume chamber is low enough, the spool seals the number two pump port from the
spring starts pushing the spool upward, number two exhaust port; the space below
the exhaust spring pushes the pilot plug provides a path between the number two
upward, and the controller returns to it exhaust and supply ports.
initial position. 4
1.2.2.5 Specification Table

PNEUMATIC METERING PLUNGER PUMPS - W SERIES

Plunger Diameter (Inch)

Max. Air Usage At Max. Volume

Piston Diameter (Inch)

Approx.

Stroke length (Inch)

Maximum Maximum Amp Strokes Volume
Volume Pressure Ratio per Shipping
per
Models Minute stroke 100 PSI3 6.93 Bar 1503 PSI 10.33 Bar Weight
(SPM) (cc)

Gal./Hr Liter/Hr PSI BAR SCF/D SCM/D SCF/D SCM/D Lbs. Kg.

CP125W125B316TG 1/8 1 1/4 0.07 0.27 7,500 517 75:1 1-45 0.1 1/2 180 5 7 3.2
CP250W225B316TG 1/4 2 1/4 0.57 2.16 7,500 517 75:1 1-45 0.8 1 1150 32 9 4.1
CP250W300B316TG 1/4 3 0.57 2.16 10,000 690 120:1 1-45 0.8 1 2,100 59 9 4.1
CP500W225B316TG 1/2 2 1/4 2.30 8.64 1,400 97 14:1 1-45 3.2 1 1,500 42 10 4.5
CP500W300B316TG 1/2 3 2.30 8.64 3,000 207 30:1 1-45 3.2 1 2,100 59 10 4.5
CP500W400B316TG 1/2 4 1.5 5.76 4,000 276 60:1 1-30 3.2 1 2,374 67 12 5.4
CRP500W400B316TG 1/2 4 2.3 8.64 9,000 620 60”1 1-45 3.2 1 3,584 101 5,250 149 15 6.8
CP1000W400B316TG 1 4 5.10 19.20 1,400 97 14:1 1-25 12.8 1 1,996 56 24 10.9
CRP1000W400B316TG 1 4 8.13 30.72 2,100 145 14:1 1-40 12.8 1 3,194 90 4,607 130 29 13.2
CRP1000W600B316TG 1 6 8.13 30.72 4,500 310 30:1 1-40 12.8 1 7,190 203 10,210 289 39 17.7
CRP1500W400B316TG 1 1/2 4 22.90 86.40 600 41 4:1 1-40 36.0 1 1/4 8,064 228 11,543 326 33 15.0
CRP1500W600B316TG 1 1/2 6 22.90 86.40 1,950 134 13:1 1-40 36.0 1 1/4 8,144 230 26,000 736 39 17.7
CRP1500W800B316TG 1 1/2 8 22.90 86.40 3,450 238 23:1 1-40 36.0 1 1/4 32,256 913 46,000 1,302 44 20.0
CRP2250W600B316TG 2 1/4 6 45.00 168.00 900 62 6:1 1-35 80.0 1 1/4 16,000 453 23,000 651 50 22.7
CRP2250W600LB316TG 2 1/4 6 90.00 336.00 900 62 6:1 1-35 160.0 2 1/2 32,000 906 46,000 1,302 59 26.8
CRP2250W800SB316TG 2 1/4 8 45.00 168.00 1,800 124 12:1 1-35 160.0 2 1/2 57,000 1,614 81,000 2,293 84 38.2

Notes:
1. Minimum recommended stroke length is 1/8 inch for CP 125 to CRP500 and 1/4 inch for CP1000 to CRP2250 pumps.
2. Minimum recommended operating speed is 10 spm.
3. MK-X Controller.
4. MK-X Controller and Relay.

1.2.2.5 Specification Table

PNEUMATIC METERING PLUNGER PUMPS - D SERIES
Plunger Diameter (Inch)

Max. Air Usage At Max. Volume

Piston Diameter (Inch)

Approx.
Stroke length (Inch)

Maximum Maximum Amp Strokes Volume

Volume Pressure Ratio per Shipping
per
Models Minute stroke 653 PSI 4.53 Bar 904 PSI 6.24 Bar Weight
(SPM) (cc)

Gal./Hr Liter/Hr PSI BAR SCF/D SCM/D SCF/D SCM/D Lbs. Kg.

CP125D125A316TG 1/8 1 1/4 0.07 0.27 4,500 310 75:1 1-45 0.1 1/2 124 4 324 9 4.0 1.8
CP250D225A316TG 1/4 2 1/4 0.57 2.16 5,000 345 75:1 1-45 0.8 1 800 23 1,040 29 7.0 3.2
CP250D300A316TG 1/4 3 0.57 2.16 10,000 690 120:1 1-45 0.8 1 960 27 1,248 35 7.5 3.4
CP500D225A316TG 1/2 2 1/4 2.30 8.64 1,250 86 14:1 1-45 3.2 1 800 23 1,040 29 7.5 3.4
CP500D300A316TG 1/2 3 2.30 8.64 2,700 186 30:1 1-45 3.2 1 960 27 1,248 35 8.0 3.6
CP500D400A316TG 1/2 4 1.50 5.76 6,000 345 60:1 1-30 3.2 1 1,700 48 2,220 63 805 3.8
CRP500D400A316TG 1/2 4 2.30 8.64 9,000 517 60:1 1-45 3.2 1 2,560 72 3,328 94 12.0 5.4

NOTES:
1. Minimum recommended stroke length is 1/8 inch.
2. Minimum recommended operating speed ia 10 spm.
3. MK-II Controller.
4. MK-VII Controller.

5
1.3.3 Pump Motor (Air Chamber) Refer to Illustration 2.1 - Typical Williams Example: A CP250W225B316TG operating
The motor forces the piston plunger to Pump Installation. at 35 psig is capable of generating 35 psig
move alternately into and out of the pump x 75 (amplification ration) or 2625 psig.
chamber. When the controller sends the 2.2 PUMP ASSEMBLY The pump will stop working when the
supply air/gas into the motor chamber Position the pump assembly with enough 2625 psif is reached.
through the nipple connector, the pressure space around it to allow easy access to all
on the U-cup and piston plunger over- components for maintenance. Install the SECTION 3.0: STARTUP, OPERATION,
comes the combined force of the process assembly with the pump inlet/suction SHUTDOWN, AND STORAGE
fluid pressure on the U-cup and piston check valve pointing straight down; the
plunger overcomes the combined force of pump will not work as efficiently in any 3.1 GENERAL
the process fluid pressure on the U-cup, other position since the inlet/suction check While these procedures for startup, opera-
piston plunger, and plunger return spring valve has no spring. tion, shutdown, and storage are easy to
and pushes the plunger into the fluid perform, following them carefully and cor-
chamber. When the external controller Exceptions to this procedure are the rectly will improve the performance and
exhausts the air/gas, the piston plunger P125D and P125W pumps which have a increase the life of your pump assembly.
return spring and process fluid pressure spring in their inlet/suction check valve.
push the piston plunger out of the fluid These pumps are mounted horizontally CAUTION
chamber. since the check valves oppose each other To avoid damaging the controller valve
in the vertical plane of the pump. Please stem, do not make a habit of turning
1.3.4 Pump (Fluid Chamber) contact the factory for approval if it is the pump ON and OFF with the stroke
The pump operating cycle consists of two impossible to mount these pumps horizon- rate control.
parts: discharge and suction. During dis- tally.
charge, the piston plunger moves into the 3.2 STARTUP
pump fluid chamber, decreasing the vol- NOTE
ume of the chamber and raising the pres- The pump assembly can be installed 3.2.1 Air/Gas Supply
sure on the chamber fluid. This higher directly in the process line piping with- Before starting up your pump assembly,
pressure closes the suction check valve out additional support brackets. make sure that the primary air/gas supply-
and opens the discharge check valve, -compressor, tank of gas, or other source--
sending the fluid into the discharge line. 2.3 SUPPLY RESERVOIR is turned to OFF. Also, set the pressure
regulator(s) to ZERO pressure.
During the suction part of the cycle, the Position the supply reservoir at the same
piston plunger moves out of the fluid level as the inlet valve (flooded suction). 3.2.1.1 Supply Pressure: The supply
chamber, increasing the volume of the While you can locate the reservoir above pressure must be large enough to produce
chamber and lowering the pressure on the the inlet valve (net positive suction head), a pump discharge pressure 200 psi higher
chamber fluid. This lower pressure opens the limit is 100 psig net positive suction than the process pressure. Therefore, if
the suction check valve and closes the dis- head which is the cracking pressure of the process pressure is 2800 psi, the
charge check valve, sending fluid from the the discharge valve. We do not recom- pump discharge pressure should be 3000
suction line into the fluid chamber. mend using the pumps in a suction lift psi. To set the supply pressure properly,
position since they were not designed for divide the pump discharge pressure
SECTION 2.0: INSTALLATION such operation. (required discharge pressure plus 200
psig) by the pump amplification ratio.
2.1 GENERAL 2.4 RELIEF VALVE Using the above example, if your pump's
To control net positive suction head, either amplification ratio is 75:1, the required
Always install separate pressure regulators a stand pipe or a relief valve can be supply pressure to the pump will be 40 psi
in the air/gas supply line for a controller installed. On the discharge side of the (3000 divided by 75 = 40).
and a relay. Also, for the most efficient pump, with a relief pressure no more than
performance of your pump assembly, we 1 or 2 psi (0.7 or 0.14 bar) greater than If there is no relay in your pump assembly,
recommend the following: the net positive suction head. the pressure regulator on the controller
• A dryer and a dump valve in the air/gas will already be set at the required supply
supply line to remove any moisture from A safety relief valve is not necessary if the pressure. If there is a relay, the regulator
the supply air/gas. downstream piping is designed to with- on the relay will already be set at the
• Isolation valves (ball type) on inlet and stand the maximum pressure the pump required supply pressure. It is essential,
discharge sides of the pump and in the can generate at the available air supply however, to make sure that the calculated
air/gas supply line to simplify mainte- pressure. The maximum pressure the supply pressure meets the minimum pres-
nance. pump can generate is calculated by multi- sure required for both the relay and the
• A check valve where the pump dis- plying the amplification ratio times the controller (Ref. 1.2).
charge line joins the main process line to controller air supply pressure. When this
prevent process fluid back flow. pressure is reached the pump will stop.
• Inlet filter on pump suction line.

6
TYPICAL PUMP INSTALLATION

ILLUSTRATION 2.1

7
If the controller stroke rate has not been 1. Set the stroke rate knob to a point on 3. You may leave the pump, controller, and
calibrated already, follow this procedure: the scale that will product a stroke rate relay assemble, but make sure to store
1. Rotate the stroke rate knob on the con- close to the one you want. them in a dry, protected place.
troller clockwise (CW) to ZERO on the
stroke rate scale. NOTE SECTION 4.0: MAINTENANCE
2. Turn the main air/gas supply to the reg- At the ZERO setting on the controller
ulator(s) to ON, and adjust. (See 3.1.1.1 stroke rate scale, the pump will not stroke, 4.1 GENERAL
above.) but as you rotate the knob toward 100 the This section contains procedures for disas-
3. Set the desired flow rate for your appli- rate will increase to the maximum strokes sembly and assembly of the controller,
cation by using the pump's stroke adjuster per minute for each pump (Ref. 1.2.2.5). pump, and check valves, as well as for
in combination with the controller's stroke To set the stroke rate correctly, you must preventive and corrective maintenance. To
rate adjustment. ( Ref. 1.2.2.5 FOR PUMP time the exhausts from the bottom of the maintain the reliability, durability, and per-
PERFORMANCE) controller. formance of your pump assembly and
related components, it is essential to fol-
Adjust the controller stroke rate knob, as 2. Count the number of pump strokes dur- low these procedures exactly and carefully.
follows: ing a one-minute interval.
3. Adjust the knob to correct the stroke For consistent, reliable performance,
1. Loosen the set screw and remove the rate as needed. replace any O-rings, U-cups, or other seals
knob. 4. Repeat the previous steps until you get that you remove. Order replacement seal
2. Adjust the valve stem to the desired the correct stroke rate. kits with detailed instructions from your
rate by hand by turning the stem clock- distributor or Williams Milton Roy.
wise (CW) to decrease the stroke rate or As an example, to get a stroke rate of 22
counterclockwise (CCW) to increase the strokes per minute, you might set the knob Whenever you disconnect any air/gas or
rate. to 50, which produces 25 strokes per fluid piping, cover all open ports in the
3. Attach and set the knob at the desired minute. To reduce the rate, reset the knob pump assembly to prevent dirt from enter-
position on the scale. to 48. If this produces 21 strokes a ing.
minute, move the knob to 49 which should
3.2.3 Pump Stroke Length be very close to the 22 strokes per minute 4.2 DISASSEMBLY AND ASSEMBLY
The adjuster scale for the pump's stroke you want.
length is factory set so that a ZERO read- 4.2.1 Required Tools
ing equal s ZERO stroke length. 3.4 SHUTDOWN AND STORAGE Necessary tools will vary by pump assem-
Calibrate the scale as follows: bly model.
To shut down the pump assembly, set the • Adjustable Wrench: 15"
1. Turn the stroke adjuster knob CW as far pressure regulator(s) to ZERO, and turn the • Bench Vise
as possible. air/gas supply to OFF. • Allen Wrenches: 7/64", 1/8", 9/64",
2. Loosen the slotted screw on the end of 5/32", and 3/16"
the knob. To store the pump assembly, do the follow- • Straight Blade Screwdrivers: 1/8" and
3. Rotate the knob until ZERO on the scale ing: 1/4"
lines up with the scale indicator. • MK-X Screwdriver in 1/4" Hex Socket
4. Tighten the screw. Once you have cali- 1. Flush out the pump chamber with • Drive (Drawing 1)
brated the scale, you can select the proper water or solvent, and blow it dry with com- • Snap Ring Removal Tool
pump stroke length. pressed air. • Brass Drift: 1/8"
• Hammer
3.3 OPERATION CAUTION • Silicone Grease GS102149
To prevent damage to the pump when
3.3.1 Bleeder Plug you clean it, be sure to use a solvent
Shortly after the pump assembly begins compatible with the metered fluid that NOTE
operating, the metered liquid begins flow- will not damage the pump's seals. For See 4.3 Preventive Maintenance for
ing through the pump. To bleed air a recommended solvent, contact your inspection and replacement of parts identi-
trapped in the pump chamber, turn the distributor or Williams Milton Roy. fied throughout these procedures.
bleeder plug CCW about a quarter turn.
When the liquid is flowing steadily from 2. Unscrew the silicone oil bottle from the 4.2.2 Pump, Controller, and Lubricator
the end of the bleeder plug, turn it CW oiler body on the pump. Drain the oil from Reservoir
until the flow stops. the pump into the bottle and put the cap Begin disassembly with these preliminary
on the bottle. procedures:
3.3.2 Stroke Rate
Set the operating stroke rate, as follows:

8
 4. Lift out the spool spring. (Fig.4)

Figure 4

5. Use the correct blade screwdriver (1/8"

for the MK-X) and unscrew the lower seat.
(Fig. 5&6)

1. Rotate the oiler body 180° until the sili-

cone oil bottle is in its normal upright posi-
tion. Unscrew and remove the bottle.
2. Rinse the pump, controller, lubricator
reservoir, and cap to remove any chemical
residue.
3. Unscrew the controller by hand and
remove it.

4.2.3 Controller

4.2.3.1 MK-X controller

Refer to the MK-X Controller.
Disassemble the controller as follows:

1. Clamp the lower end of the controller

Figure 5
body in a bench vise. (Fig. 1) Figure 2

3. Lift out the spool with the 3 attached U-

cups and the spool alignment O-ring.
(Fig.3)

Figure 1

2. Use an adjustable wrench on the flats

Figure 6
at the top of the valve body assembly to
unscrew and pull off the valve assembly. Figure 3
(Fig.2)

9
6. Lift out the pilot plug and exhaust spring.
(Fig.7)

Figure 12
Figure 9
6. Now with a 9/16" socket wrench
4. Now remove the upper spool and the
loosen the lower seat. Remove the lower
lower spool assembly (3 pieces). (Fig.10 &
seat, gasket, pilot plug and lower spring.
11)
(Fig. 13 & 14)
Figure 7

7. Remove the body O-ring that keeps the

capillary tube separate. (Fig.8)

Figure 13

Figure 8
Figure 10
To reassemble the controller, reverse the above
procedure. Be sure to replace all rubber com-
ponents. Flare the U-cup out with your finger
before installing the spool and apply a small Figure 14
amount of silicone grease (GS102149) to the
U-cups and the upper/lower body inside diam- 7. With a 9/16" wrench disassemble the
eter. lower spool assembly consisting of
diaphragm plate, snapper diaphragm,
4.2.3.2 MK-II & MK-VII Controllers lower spool, spacer, lower diaphragm and
Refer to the MK-II and MK-VII Controller Parts upper seat.
List. Disassemble the controller as follows:
To reassemble the controller reverse the
1. Clamp the lower end of controller body in a above procedure. Be sure to replace all
bench vise. Using a small standard screwdriv- rubber components.
er remove the set screw securing the rate
adjustment knob. Remove knob and spring. 4.2.4 Relay: PO3-6S, PO4-6S, and PO4-8S
2. With your fingers unscrew the valve stem Refer to the appropriate Parts List.
and remove. Disassembly instructions 1-9 apply to all
Figure 11
3. With a 5/32" allen wrench remove the six relays, instructions 10 & 11 apply only to
(6) 10-32 allen head cap screws that secure the PO3-6S and instructions 12-17 apply
5. Then remove the middle spring. (Fig.12)
the upper and lower valve body halves. Then to the PO4-6S and PO4-8S.
remove the valve body, the top diaphragm and
valve body O-ring (V-006). (Fig.9) 10
1. Use a 9/64" Allen wrench to remove 8. Put 7/64" Allen wrench through the 13. PO4-6S/8S: Separate the upper pop-
the top cap screws. (Fig.15) hole in the upper poppet stem. (Fig.19) pet stem from the middle and lower pop-
pet stems and the poppet body. The pop-
pet stem connector bolt will remain in one
of the stems.
14. PO4-6S/8S: Put a 7/64" Allen wrench
through the supply pressure port in the
middle body section, into the hole in the
middle poppet stem.
15. PO4-6S/8S: Use a flat blade screw-
driver to unscrew the lower poppet stem.
(Fig.19)
Figure 15 Figure 19 16. PO4-6S/8S: Pull out the middle and
lower poppet stems, and poppet body. The
2. Separate the top cap and data plate 9. Use a flat blade screwdriver to unscrew poppet stem connector bolt will remain in
from the upper body section. (Fig.15) the lower poppet stem. (Fig.19) one of the stems. (Fig.22)
3. Put a 7/64" Allen wrench through the 10. PO3-6S: Pull out the upper and lower
upper body exhaust port, into the hole in poppet stems, and poppet body; the pop-
the upper poppet stem. (Fig.16) pet stem connector bolt will remain in one
of the stems.
11. PO3-6S: Put 7/64" Allen wrench in the
holes of the poppet O-ring retainers and
pry them off. (Fig.20)

Figure 16 Figure 22

4. Use a 9/64" Allen wrench to remove 17. PO4-6S/8S: Put a 7/64" Allen wrench
the piston lock screw. (Fig.16) in the holes of the poppet O-ring retainers
5. Pull out the piston, O-ring, and spring. Figure 20 and pry them off.(Fig.20)
(Fig.17)
NOTE: Reassemble the PO3-6S relay by NOTE
coating the poppet stems, seals and Reassemble the PO4-6S/8S relay by coat-
mating surfaces with Williams GS102149 ing the poppet stems, seals and mating
silicone grease, and then reversing the surfaces with Williams GS102149 silicone
above process. grease, and then reversing the above pro-
cedure.
12. PO4-6S/8S: At this point, usually the
Figure 17 upper and middle poppet stems will sepa- 4.2.5 Pumps: P125D and P125W
rate. If the lower and middle poppet stems Refer to the appropriate parts list. The "D"
6. Use a 5/32" Allen wrench to remove should separate, however, modify the rest series has a green anodized aluminum
the bottom cap screws. (Fig.18) of this procedure accordingly. (Fig.21) motor cylinder, where as the "W" series is
all 316 SS. Disassemble the pumps as
follows.

1. Use a 5/64" Allen wrench to remove

the motor cylinder set screws that hold the
motor cylinder to the oil chamber body. In
the "D" series the screws are on the bot-
tom of the motor cylinder and on the "W"
Figure 18 series they are on the side. Hold the
7. Separate the lower body section from motor cylinder firmly to avoid losing the
the upper body section (Fig. 18) Figure 21 motor return spring, which is compressed
beneath the motor cylinder. (Fig.24 & 25)
11
 2. Remove the stroke adjuster. Unscrew it 6. Clamp the fluid cylinder in a bench
from the motor cylinder by loosening the vise.
knurled lock/set nut on top of the cylinder 7. Use an adjustable wrench to remove
body. (Fig.26) the discharge check valve from the fluid
cylinder and Teflon O-ring. (Fig.30 & 31)
8. Remove the suction check valve from
the fluid cylinder and Teflon O-ring.(Fig. 30
& 31)

Figure 23

Figure 26
Figure 30
3. Remove the piston plunger assembly U-
cup and motor return spring, plus the
plunger seal retainer.(Fig.27)

Figure 27
Figure 24
4. Unscrew the oil chamber from the fluid
cylinder on the pump body assembly. Figure 31
(Fig.28)
9. Remove the bleeder plug from the fluid
cylinder. (Fig.32)

Figure 28

5. Remove the seals from the fluid cylin-

der and oil chamber. (Fig.29)

Figure 32

10. Remove the body seal O-rings. (Fig.33)

Figure 25 Figure 29

12 Figure 33
11. Clamp the oil chamber in the bench 15.Reinstall the motor cylinder over the
vise. piston plunger U-cup; hold the motor cylin-
12. Remove the faceplate locknut and the der, top up, at a 45° angle from vertical,
faceplate from the oil chamber. (Fig.34 & and lower it into position, turning it into the
35) vertical position as you lower it to ensure
that the U-cup seats properly.
16.Hold the motor cylinder in the proper
position, and hand tighten the 5/64" Allen
set screws.
17.Position the motor cylinder so that the
Figure 36 pump/controller connector nipple is
approximately 180° from the oiler nipple.
18.Use the 5/64" Allen wrench to tighten
the set screws.
19.Reinstall the O-ring in the oiler body.

4.2.6 Pumps: P250D, P250K, P250W,

P500D, P500W, P1000W400, and
P1000W600

Refer to the appropriate parts list. The "D"

series has a green anodized aluminum
Figure 34 motor cylinder, where as the motor cylin-
der the "W" is all 316 SS. Disassemble
the pumps as follows:
Figure 37 1. For all pumps except the P250K, use a
1/8" Allen wrench to remove the motor
cylinder set screws that hold the motor
Reassemble the pump as follows: cylinder to the oil chamber body. In the
1. Reinstall the stroke adjuster in the "D" series the screws are on the bottom of
motor cylinder. the motor cylinder and on the “W” series
2. Install new seals in the fluid chamber they are on the side. For the P250K,
and oil chamber. unscrew the motor cylinder from the oil
3. Install new body seal O-rings. chamber body. For all pumps, hold the
4. Reconnect oil and fluid chambers. motor cylinder firmly to avoid losing the
5. Replace faceplate and faceplate nut. motor return spring. (Fig.38 & 39)
6. Reinstall check valves with Teflon O-
rings in the proper fluid cylinder ports.
7. Reinstall bleeder valve, oiler nipple, and
then oiler body.
8. Clamp the fluid chamber in a bench
vise and tighten both check valves.
Figure 35 9. Clamp oil chamber in the bench vise,
and tighten faceplate, faceplate nut, and
13. Remove the oiler body and pump/oiler oiler nipple.
connector from the oil chamber. (Fig. 36 & 10.Reinstall piston plunger. (Replace it if
37) necessary)
NOTE 11.Install the U-cup on the piston, making
Before reassembling the pump, clean both sure it seats properly in the piston groove.
chambers, motor cylinder, and faceplate 12.Apply a coat of silicone grease to the
with an approved solvent. Contact your plunger shaft, the outside of the U-cup,
distributor or Williams Milton Roy for a rec- and the inside of the motor cylinder.
ommended solvent. 13.Reinstall the piston plunger spring.
(Replace if necessary.)
14.Reinstall the plunger seal retainer, and
position the piston plunger in the spring
retainer sleeve.

Figure 38

13
 Figure 43

Figure 41

Figure 39

2. Loosen the knurled lock/setnut on top

of the motor cylinder body to unscrew and
remove the stroke adjuster from the motor
cylinder. (Fig.40)

Figure 44

Figure 42
Figure 40

3. Remove the piston plunger assembly

and motor return spring, and then remove
the piston U-cup from the piston.
(Fig.41 & 42)
4. Unscrew the oil chamber from the fluid
cylinder on the pump body assembly.
(Fig.43)
Figure 45
5. Use a 3/16" Allen wrench to remove the
plunger seal set-Teflon graphite from the 7. Use the same wrench to remove the
fluid cylinder. (Fig.44) suction check valve from the fluid cylinder.
6. Clamp the fluid cylinder in a bench (Fig.46)
vise, and use the adjustable wrench to
remove the discharge check valve from
the cylinder. (Fig.45)
Figure 43

14
 7. Install check valves in proper ports of
fluid chamber.
8. Install the bleeder valve.
9. Install the oiler nipple.
10.Install the oiler body.
11.Clamp the fluid chamber in the bench
vise and tighten both check valves.
12.Clamp the oil chamber in the bench
vise, and tighten faceplate, faceplate nut,
and oiler nipple.
13.Inspect the piston plunger; replace it if
Figure 50 necessary.
14.Install the U-cup on the piston, and
Figure 46 11.clamp the pump/oiler connector in the make sure it seats properly in the piston
bench vise, and unscrew it from the oil groove. (Fig.52)
8. Use the same wrench to remove the chamber.(Fig.51)
bleeder plug from the fluid cylinder.
(Fig.47)

Figure 52

Figure 47 Figure 51 15.Apply a coat of GS102149 silicone

grease to the plunger shaft, outside of the
9. Remove the body seal O-ring. (Fig.48) NOTE U-cup, and inside of the motor cylinder.
Before reassembling the pump, clean both 16.Install the spring retainer sleeve.
chambers, motor cylinder, and faceplate 17.Install the piston plunger in the spring,
with an approved solvent. Contact your and install the spring in the spring retainer
distributor or Williams Milton Roy for a sleeve; replace spring if necessary.
recommended solvent. 18.Install the motor cylinder over the
plunger U-cup; hold the motor cylinder, top
Reassemble the pump as follows: up, at a 45° angle from vertical and lower
1. Install the stroke adjuster in the motor it into position, turning it into the vertical
cylinder. position as you lower it to make sure the
2. Install new seals in the fluid chamber. U-cup seats properly.
Figure 48 3. Install a new body O-ring. 19.For all pumps except the P250K, hold
4. Connect oil and fluid chambers. the motor cylinder so that the pump/con-
10.Clamp the oil chamber in the bench 5. Replace faceplate, spring retainer, and troller connector is directly above the dis-
vise, and use the adjustable wrench to faceplate nut. charge check valve, and hand tighten the
remove the faceplate locknut, spring 6. Apply Teflon tape to the check valve motor cylinder set screws. For the P250K
retainer sleeve, and faceplate from the oil threads. pump, screw in the motor cylinder so that
chamber. (Fig. 49 & 50) the pump/controller connector nipple is in
CAUTION line over the discharge check valve.
To prevent loose ends from tearing off 20.Use the 1/8" Allen wrench to tighten
and jamming the pump, do not allow the motor cylinder set screws.
Teflon tape to extend past the ends of 21.Install the O-ring in the oiler body.
the threads.

Figure 49 15
4.2.7 Pumps: P1000W800, P1500W400, 3. For all pumps except the P1500W400,
P1500W600, P1500W800, P2250W600, remove the piston plunger assembly and
and P2250W800 the two O-rings. For the 1500W400 pump,
remove two U-cups instead of the O-rings
Refer to the appropriate parts list. in this step. (Fig.55)
Disassemble the pump as follows:

1. For all pumps except the P1500W400,

use a 1/4" Allen wrench to remove the
motor cylinder set screws that hold the
motor cylinder to the oil chamber body and
remove the motor cylinder. For the
P1500W400 pump, use a 1/8" Allen
wrench for this step. (Fig.53)

Figure 57
Figure 55
6. Clamp the fluid cylinder in a bench
4. Unscrew the connector section for the vise, and use and adjustable wrench to
oil chamber and fluid cylinder on the pump remove the discharge check valve from
body assembly. (Fig.56) the cylinder. (Fig.58)

Figure 53
Figure 58
2. Remove the stroke adjuster. Loosen
the knurled lock/set nut on top of the 7. Remove the suction check valve and
motor cylinder body to unscrew the the bleeder plug from the fluid cylinder.
adjuster from the motor cylinder. (Fig.54) (Fig. 59 & 60)

Figure 56

5. Remove the seals from the fluid cylin-

der and oil chamber. (fig.57)

Figure 59

Figure 60

Figure 54
16
8. Clamp the oil chamber in a bench vise, CAUTION 4.2.8 Discharge Check Valve
and remove the body seal 0-ring. (Fig.61) To prevent loose ends from tearing off
and jamming the pump, do not allow 4.2.8.1 P125D and P125W Pumps
Teflon tape to extend past the ends of Refer to the appropriate parts list.
the threads. disassemble the check valve as follows:
1. Use the flat blade screwdriver to
6. Reinstall check valves in the proper unscrew and carefully lift the retainer from
fluid cylinder ports. the check valve body.
7. Reinstall the bleeder valve, oiler nipple, 2. Use the snap ring removal tool to com-
and oiler body. press and lift the second retainer from the
8. Clamp the fluid chamber in the bench check valve body.
vise, and tighten both check valves. 3. Carefully tip the valve body and dump
9. Clamp the oil chamber in a bench vise, out the spring, sleeve, ball, and Teflon O-
and tighten the oiler nipple. ring.
Figure 61 10.Reinstall the piston plunger; replace it if
scratched or scored. Reassemble the valve as follows:
9. Remove the oiler body O-ring and 11.For all pumps except the P1500W400, 1. Insert the Teflon O-ring and make sure
pump/oiler connector nipple from the oil install the two O-rings on the piston, and it seats properly in the sleeve.
chamber. (Fig.62 & 63) make sure they seat properly in the piston 2. Insert the sleeve.
groove. for the P1500W400 pump, install 3. Drop in the ball.
the two U-cups on the piston, and make 4. Install the spring with the tapered end
sure they seat properly in the piston towards the ball.
groove, one up and one down. 5. Use the snap ring removal tool to com-
12.for all pumps except the P1500W400, press and install the second retainer.
apply a coat of silicone grease to the 6. Install the retainer and tighten with a
plunger shaft, the outside of the O-rings, flat blade screwdriver.
and the inside of the motor cylinder. For
the P1500W400 pump, apply the grease to 4.2.8.2 P250, P500, P1000W, P1500W,
the outside of the U-cups instead of the O- P2250 Pumps
rings in this step. Disassemble the check valve as follows:
Figure 62 13.Reinstall the piston plunger in the con- 1. Use the flat blade screwdriver to
nector section. unscrew and carefully lift the retainer from
14.For all pumps except the P1500W400, the check valve body.
install the motor cylinder over the piston 2. Carefully tip the valve body and dump
plunger O-rings; hold the motor cylinder, out the spring, sleeve, ball, and Teflon O-
top up, at a 45° angle from vertical and ring.
lower it into position, turning it into the
Figure 63 vertical position as you lower it to make Reassemble the valve as follows:
sure the O-rings seat properly. For the 1. Insert the Teflon O-ring and make sure
NOTE P1500W400 pump, install the motor cylin- it seats properly in the sleeve.
Before reassembling the pump, clean the der over the piston plunger U-cups and as 2. Insert the sleeve.
three chambers and the motor cylinder you lower it make sure the U-cup seats 3. Drop in the ball.
with an approved solvent. Contract your properly. 4. Install the spring with the tapered end
distributor or Williams Milton Roy for a 15.Hold the motor cylinder in the proper towards the ball.
recommended solvent. position, and hand tighten the 1/8" Allen 5. Install the retainer, and hand tighten
set screws. with the flat blade screwdriver.
Reassemble the pump as follows: 16.Position the motor cylinder so that the
1. Reinstall the stroke adjuster in the pump/controller connector nipple is 4.2.9 Suction Check Valve
motor cylinder. approximately in line over the discharge
2. Install new seals in the fluid chamber check valve. 4.2.9.1 P125 Pumps
and oil chamber. 17. For all pumps except the P1500W400, Refer to the appropriate parts list.
3. Install new body seal O-rings. use a 1/4" Allen wrench to tighten the set Disassemble the check valve as follows:
4. Reconnect the connector section to the screws. For the P1500W400 pump, use a 1. Use the snap ring tool to compress and
oil chamber and the fluid chambers. 1/8" Allen wrench for this step. remove the retainer.
5. Apple Teflon tape to the check valve 18.Reinstall the O-ring in the oiler body. 2. Carefully tip the valve body and dump
threads. out the ball and the spring.

17
Reassemble the valve as follows: NOTE 4. Is the I.D. (inner diameter) of the air/gas
1. Insert the spring, and the ball. Sometimes, the oil in the lubricator turns supply line correct for the pump model
2. Use the snap ring tool to compress and dark as the seals wear. While this darken- currently in use?
insert the retainer. ing is not a sign of seal failure, we do rec- 5. Is the pump correct for the nature and
ommend changing the oil when it hap- characteristics of the material(s) it han-
4.2.9.2 P250 Pumps: Disassemble the pens. dles: composition, viscosity, necessary line
check valve as follows: Use the 3/16" pressure, etc.?
allen wrench to carefully remove the 4.3.1.3 Every Six Months 6. Is the source of the process fluid--
retainer and ball from the valve body, Perform this procedure at least every six drum, day tank, or large storage tank--
months. Inspect the piston-plunger clean and free of contaminants?
Reassemble the valve as follows: Insert assembly and seals. Replace the seals 7. Is the filtration adequate?
the ball and then the retainer. and check for wear; if the assembly is 8. Is the size of the process fluid line cor-
cracked, rough, or discolored, replace it. rect for the pump?
4.2.9.3 P500, P1500, and P2250 Pumps 9. Is the pump located at the correct dis-
Disassemble the check valve as follows: 4.3.1.4 Every Twelve Months tance from the supply?
Clamp the valve in a bench vise; use the Perform these procedures at least every 10.Is the pump working in the proper
1/8" brass drift and a hammer to remove twelve months. enclosed, protected area or in an open,
the retainer and then the ball. 1. Disassemble and inspect the pump exposed location?
inlet and outlet check valves. 11.Have the minimum and maximum tem-
Reassemble the valve as follows: Insert 2. Inspect the piston plunger, return peratures the pump will be exposed to
the ball and then the retainer. spring, and seals. If the piston plunger is been considered for its current use(s)?
scratched or if the seals are nicked, 12.Is the pump being used for more than
4.2.9.4 P1000 Pumps replace them. one purpose?
Disassemble the check valve as follows: 13.Is the proper cleaning fluid used to
1. Clamp the valve in a bench vise; use 4.3.2 Cleaning and Lubrication flush out the pump when it is not in serv-
the 1/8" brass drift and a hammer to Perform this procedure whenever the ice or when it is pumping more than one
remove the retainer pin. pump assembly is disassembled. Clean all chemical?
2. remove the retainer and then the ball inside and outside surfaces with an 14.Is there a current and accurate serv-
from the valve body. approved solvent, and blow them dry with ice/maintenance breakdown record for the
compressed air. pump?
Reassemble the valve as follows: 15.Is the pump operated by trained,
1. Insert the ball and then the retainer in CAUTION skilled, reliable, and responsible employ-
the valve body. To prevent damage to the pump when ees? (This is an important factor in proper
2. Install the retainer pin. you clean it, use a solvent that is com- pump use, not to be underestimated!)
patible with the metered fluid but will
4.3 PREVENTIVE MAINTENANCE not damage pump seals. Contact your 4.4.2 Proper Amount of Use
distributor or Williams Milton Roy for a While answers to the questions on the
4.3.1 Periodic Maintenance recommended solvent. above checklist will provide considerable
information about how the pump is being
4.3.1.1 Once a Week 4.4 TROUBLESHOOTING used, it is equally important to determine
Perform these procedures each week. whether or not it is overworked.
1. Check the oil level in the lubricator bot- 4.4.1 Proper Pump Use Fortunately, you can use the amplification
tle to make sure the seals never run dry. When a pump is either not working or is ratio of the pump (listed as a number on
2. When you check the oil level, also working incorrectly, there are two basic the specification sheet for your pump) and
check for signs of a chemical in the oiler areas where trouble develops: the pneu- the process pressure (the pressure the
bottle or at the weep hole above the seal. matic or the fluid ends of the pump. pump plunger is working against) to check
If any chemical is present, replace the However, since factors other than the this, as follows:
pump seals; use SF96-100 William's sili- pump are involved, the first step in trou- • Process pressure is 2800 psi.
cone oil to lubricate the new seals. bleshooting is to see if the pump is being • Add 200 psi to the process pressure so
used properly. The checklist below will that the chemical is positively injected:
4.3.1.2 Once a Month help you determine this: 2800 psi + 200 psi = 3000 psi.
Perform this procedure at least once each • Assume an amplification ratio of 75:1.
month. 1. Is the air/gas supply available in suffi- • Divide the total psi (3000) by the amplifi-
Unscrew the plug from the top of the fit- cient volume and at the proper pressure? cation ratio of 75; the resulting figure, 40
ting tee between the relay and the con- 2. Is the ir/gas supply of clean instrument psi, is the supply of air/gas pressure to the
troller; put a few drops of William's SF 96- quality, or is it dirt or wet? controller.
100 silicone oil in the hole. 3. Is a pressure regulator in use to main-
tain a constant air supply?

18
 From this information you can determine if
the pump is overworked because of exces-
sive air/gas supply. In the above example,
if the supply had been 100 psi instead of
40, it would be excessive, resulting in pre-
mature failure of the pump's moving parts
and sealing capabilities.

4.4.3 Troubleshooting Guide

The Troubleshooting Guide on the following
pages identifies the most common prob-
lems, their possible causes, and corrective
action for each situation.

TROUBLESHOOTING GUIDE
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

CONTROLLER NOT OSCILLATING Foreign material in controller Put finger over exhaust port; alternately seal & vent port to
clear exhaust valve.

No air/gas supply Connect 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 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.

Reconnect supply & rotate knob CCW until oscillations start.

Adjust stroke rate to proper strokes per min. according to

Specification Sheet; loosen knob set screw, slip knob CCW to
peg, & tighten screw.

Leak between valve body & controller Loosen; then retighten the connection between valve & con-
body troller.

Continuous air flow from controller Inspect & replace damaged O-ring seal.
exhaust port (Pilot plug not seating prop-
erly)

Air flowing from equalizer hole on side of Inspect & replace ruptured or improperly seated u-cups.
lower controller body
Put finger over exhaust port; alternately seal & vent port to
clear exhaust valve.

Broken pilot plug, exhaust spring, or Replace pilot plug, exhaust spring, or spool return spring.
spool return spring

Excessive water in controller Install an air/gas dryer in air supply line.

Broken piston return spring Replace return spring.

RELAY NOT OPERATING

19
TROUBLESHOOTING GUIDE
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

RELAY NOT OPERATING Poppet stem loosened from connector Tighten poppet stem to connector bolt.
bolt

Air blow-by caused by O-rings poorly Improve quality of air supply & clean dirt from unit.
seated due to excessive dirt in air supply

Inadequate air supply Check air regulator for proper pressure.

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.

Broken motor return spring Replace return spring.

Plunger stuck due to tight or dry seal If seal is swollen, check its chemical compatibility with
process fluid, replace with compatible seal material

If seal is dry, lubricate & fill reservoir.

Plunger bottomed Readjust plunger stroke length.

Excessive grease between piston & face- Remove excess grease.

plate

Air/gas supply pressure too low to over- Increase supply pressure.

come process line pressure

Discharge or suction line plugged Clear the line.

Air/gas flow to controller too low (con- Install a larger capacity regulator or supply line. Vent supply
troller locked up & won't cycle) side of controller & try to start pump at slowest speed:
increase speed slowly if controller starts to cycle.

Motor cylinder-air piston blow-by Check piston seal: replace as needed.

Check motor cylinder surface for damage from dirt or sand;

install a filter on bottom of faceplate.
LOW PUMP OUTPUT
Viscosity of the chemical being pumped Review and correct size of supply & discharge lines to
too high improve flow of chemical.

Pump mounted too high to pump ade- Remount pump to create a flooded suction condition.
quate supply of chemical to fluid cylinder

Pump not mounted close enough to con- Remount pump as close to controller & relay as possible to
troller & relay allow the air to exhaust quickly.

Suction lift condition Change tank elevation to get flooded suction, if change not
possible, add foot valve at end of suction line, & reduce suc-
tion line diameter.

Blocked suction filter Clean or replace filter element.

Supply & discharge lines too small Install correct tubing size.

Erratic controller operation Rebuild & clean controller; add air inlet filter or air/gas dryer.
20
TROUBLESHOOTING GUIDE
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

LOW PUMP OUTPUT Check valves leaky or contaminated Rebuild or replace damaged parts.

Improper chemical supply Make sure top of chemical supply tank is vented to atmos-
phere or pressured.

SHORT SEAL LIFE Excessive wear on plunger seals from Maintain proper lubrication in oil bottle.
lack of lubrication

Excessive wear on plunger seals from Calculate proper air supply pressure. (Refer to amplification
excessive pump speed ratio principle.)

Foreign material in process fluid Check to see if chemical supply is clean; if not, install chemi-
cal filter in supply line.

Seals incorrectly assembled, or damaged Refer to instructions for installing seals.

during installation

Plunger nicked, burred or scratched Replace plunger.

Seal or plunger materials not compatible Refer to compatibility charts; contact distributor or Williams
with process fluid Instrument Co.

Crystallized chemical on plunger scoring Maintain visible lubricant level.

seal

Lubricant incompatible with process fluid Change lubricant; contact distributor or Williams Milton Roy

Suction valve or discharge valve not Clean or replace valves.

NO PUMP DISCHARGE seating
Add filter on suction line to prevent recurrence.

Suction line or discharge line clogged Inspect line for closed valve.

Air entering suction line Tighten fittings; inspect & replace damaged seals.

Pump vapor locked Open bleeder plug, & prime pump.

21
Section 5.0

The parts list and cross section drawing(s) for the Williams Metering Pump and Accessories you purchased
were inserted in this section. If they are missing, please contact your distributor or Williams Milton Roy for
additional copies. Select from the appropriate parts lists shown below.

“D” SERIES CONTROLLERS

Pump Parts List Controller Parts List

P125D PL-P125D MK-X PL-MK-X

P250D PL-P250D MK-II PL-MK-II
P500D PL-P500D MK-VII PL-MK-VII

“W”SERIES RELAY
Pump Parts List Relay Parts List

P125W PL-P125W PO3-4S PL-PO3-4S

P250W PL-P250W PO4-4S PL-PO4-4S
P500W PL-P500W PO4-8S PL-PO4-8S
P1000W PL-P1000W
P1500W PL-P1500W
P2250W PL-P2250W

“K” SERIES
Pump Parts List *Note: These repair kits are direct replacements for PO3-6K and PO4-6K

P250K PL-P250K

EXAMPLE

1 CR 250W 300 - V

Seal Material
PLUNGER MATERIAL PE- Polyethylene (UHMW)**
A- 17-4 ph TC- Teflon® Composite **
B*- 316 SS TG- Teflon® Graphite
CR- Ceramic V- Viton®
BR- Buna N
K- Kalrez®
EPR- Ethylene Propylene

PUMP MODEL
W- 316SSl
Motor Cylinder Size in 100ths of an inch
lD- Aluminum
P125W or D- 125
K- 316SS
P250W or D- 225 or 300
P250K- 150
P500W or D 225, 300 or 400
*Note: B plunger (316SWS) not available on K series. P1000W- 400, 600 or 800
** Note: PE and TC seals not available on P1500W and P2250W Pumps. P1500W- 400, 600 or 800
P2250W- 660L, 600S, 800L or 800S

22
 SEAL MATERIAL SELECTION
The seal material must be chosen to satisfy both the chemical compatibility and the pressures/temperatures at which you are operating. Below is a general guideline for seal material selection.

Seal Temp Suggested

Material Type Range Pressure Range Comments

PE Mechanical -30 to 180°F 100 to 3000 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

TC Mechanical -30 to 180°F 100 to 3000 psi Tough material with excellent wear resistance. Excellent
Teflon® (spring Loaded) -34 to 82°C 6.9 to 70 bar chemical inertness. Good for all types of chemicals, acids, bases
Composite of solvents

TG Mechanical -30 to 180°F 1000 to 10,000 psi Tough material with excellent wear resistance. Excellent
Teflon® (Spring Loaded) -34 to 82°C 70 to 690 bar chemical inertness. Good for all types of chemicals, acids, bases
Graphite or solvents. Recommended for use with the harder ceramic
plunger and higher pressures.

V O-ring -10 to 200°F 100 to 750 psi Soft material with fair wear resistance. Broad chemical
Viton® -23 to 93°C 6.9 to 52 bar compatibility but its not to be used with ethyl or methyl alcohols.
Suggested only for hard to seal fluids in low pressure
applications when PE or TC will not seal.

BR O-ring -40 to 200°F 100 to 750 psi Soft material with fair wear resistance. Limited chemical
Buna N -40 to 93°C 6.9 to 52 bar compatibility. 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 chemical
Ethylene -40 to 93°C 6.9 to 52 bar resistance to phosphate ester, good to excellent to mild acids,
Propylene alkalis, silicone oils and greases, ketones and alcohols. 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.

PLUNGER MATERIAL SELECTION

The materials available vary in hardness and chemical compatibility. We offer three materials based on our many years of industry experience with
various chemicals. Hardness is a key property when selecting the proper plunger material. Our experience has shown that the harder plunger
materials not only provide longer plunger life, they also provide greater seal life. A hard plunger is a must when pumping a chemical that is prone
to crystallization or if the chemical is contaminated. Of course both of the preceding conditions will affect seal life. Below ia a table that compares
the chemical compatibility and hardness properties of each material.

DESIGNATION MATERIAL HARDNESS CHEMICAL COMPATIBILITY

CR Ceramic Between Sapphire and Diamond on the Excellent Chemical Inertness in all
Mohs’ Scale Acids, Bases, Solvents

A 17-4 ph 40 Rc General Corrosion-Resistant Stainless

Steel Limited Acid-Resistance

B8 316 SS 28 Rc Excellent Corrosion-Resistant Stainless

Steel Limited Acid-Resistance

We recommend the use of ceramic because of its extreme hardness and excellent chemical inertness.

*Note: B plunger (316 SS) not available on K series.

PENNSYLVANIA: 201 Ivyland Road • Ivyland, PA 18974-0577 • TEL: (800) 235-3421 • (215) 293-0415 • FAX: (215) 293-0498 • E-mail: [email protected]
SINGAPORE: 23 Tagore Lane #03-06 • Tagore 23 Warehouse Complex • Singapore 787601 • Tel: 6242-9182 • Fax: 6243-4249 • E-mail: [email protected]

www.williamspumps.com

Literature #30960 7/07