DUAL SEAL PLUNGER S INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

DUAL SEAL PLUNGER Series of Metering Pumps PART NUMBER DESIGNATION CR P1000V800 A PE C: Controller CR: Controller - Relay S: Solenoid Valve SR: Solenoid Valve - Relay Plunger Material A: 17-4 ph B: 316 SS CR: Ceramic Seal Material NOTE:(,) The 400, 600 and 800 motor cylinders are only available with the CR (controller-relay) or SR (solenoid-relay) control methods. PE: Polyethylene (UHMW) TC: Teflon® Composite TG: Teflon® Graphite V: Viton® BR: Buna N K: Kalrez® EPR: Ethylene Propylene

Section Description Page 5.0 PARTS LIST AND REPAIR KIT ORDERING REFERENCE 26 5.1 Controller Part Lists and Repair Kits 26 5.2 Relay Part Lists and Repair Kits

CP500V300. The letters CRP mean that the model also has a relay (R). For example: CRP500V400, CRP750V400, CRP1000V400, CRP1000V600, and CRP1000V800. SECTION 1.0: FUNCTIONAL DESCRIPTION 1.1 PHYSICAL DESCRIPTION Some pumps use different relay sizes: • CRP500V400, CRP750V400, CRP1000V400, and CRP1000V600 pumps use the PO3-6S relay. • CRP1000V800 pump uses the PO4-6S relay. The letters CP at the beginning of a pump assembly model number mean that the model consists of a controller (C) and pump (P) For example: CP125V125, CP250V225, CP250V300, CP500V225, and 1.1.1 Controller The controller, consisting...

entering pump or relay, and opens the vent to let it exhaust. The spool then returns to its highest position and repeats the cycle. 1.1.2 Relays A relay is a pilot operated servo valve. Air/gas pressure from a controller forces a piston and one or more attached poppet valves to move. Then, when the controller removes the pressure, a spring forces both the piston and poppet valve(s) in the reverse direction. Relay models differ in operation. The PO3-6S relay has one poppet valve that connects the supply air/gas to the pump and blocks the exhaust when the controller applies air/gas pressure to...

1.2.1 Controllers and Relays Controllers and relays will require separate supply sources, and fortunately will operate with air or any gas, such as carbon dioxide, nitrogen or natural gas. WARNING: TO PREVENT INJURY, MAKE SURE THAT ANY FLAMMABLE GAS SUCH AS NATURAL GAS IS PROPERLY VENTED FOR SAFETY. CAUTION: If the gas could possibly damage the standard elastomeric material, please contact your distributor or Williams Instrument Incorporated for advice. To increase the process fluid flow rate, two or more pumps can be multiplexed: their inlets and outlets connected in parallel. 1.2.1.1 Controller...

1.2.2.2 Using The Graphs* Use the following Performance Flow Curves* in order to: 1) Determine the flow capability of the pump you have selected. If you have sized the pump too close to the upper or lower stroke rate limit, you may wish to change to a different pump size. Of course you can also change your flow for a given stroke rate by adjusting the stroke length. Example: These Settings Will Produce The Same Pump Flow Rate STROKE RATE 10 20 40 2) Determine the air pressure necessary to provide the desired pump discharge pressure. A) The flow curves show the maximum flow/pressure limit of the...

Performance Flow Curves STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM AIR/GAS PRESSURE PSIG AIR/GAS PRESSURE PSIG AIR/GAS PRESSURE PSIG CP250V300 Discharge Pressure PSI gph Air Pressure PSI

Performance Flow Curves (cont.) STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM AIR/GAS PRESSURE - PSIG AIR/GAS PRESSURE - PSIG AIR/GAS PRESSURE PSIG CRP500V400 Discharge Pressure PSI Gph Air Pressure PSI

Performance Flow Curves (cont.) STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM AIR/GAS PRESSURE - PSIG STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM & 35 SPM @ 150 PSIG STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM & 35 SPM @ 150 PSIG AIR/GAS PRESSURE - PSIG AIR/GAS PRESSURE - PSIG STROKE LENGTH: 100% • PLUNGER SPEED: 45 SPM AIR/GAS PRESSURE - PSIG Discharge Pressure PSI gph Air Pressure PSI

8 1.2.2.3 Plunger & Seal Material 1.2.2.3.1 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...

1.3 GENERAL OPERATING SEQUENCE 1.3.1.1 MK XII Controller The spool spring forces the spool upward to its highest position and unseats the top of the pilot plug from the upper seat. The exhaust spring forces the pilot plug upward and seats it on the lower seat. This blocks the air/gas exhaust port. When high pressure air/gas enters the supply port, it passes around and through the spool and past the open upper seat to the motor cylinder port. High pressure air/gas passes through the control passage in the controller, past the valve stem, and into the valve body upper chamber which causes pressure...

When the controller sends a pilot pulse, the high pressure gas on top of the relay piston overcomes the piston spring force and pushes the piston and two poppets assemblies downward. The piston and two poppets assemblies move down until the O-ring on the bottom of the upper poppet presses against the middle body section and the O-ring on the bottom of the lower poppet presses against the lower body section. The upper poppet O-ring seals the number one pump port from the supply port; the space above provides a path between the number one pump and exhaust ports. The lower poppet O-ring seals the...

2.3 TYPICAL INSTALLATION 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 DRYER PRESSURE REGULATOR DUMP VALVE DUMP VALVE PUMP AIR/GAS SUPPLY PUMP & CONTROLLER RATE SETTING GAUGE AIR/GAS DRYER PRESSURE REGULATOR RATE SETTING GAUGE AIR/GAS SUPPLY CHEMICAL SUPPLY AUTO CONTROL MANUAL CHECK VALVE...