Psb100 Owners Manual
User Manual: psb100-owners-manual
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187 E. 670 S., Kamas, UT 84036 435.783.6040 888.796.2476 https://wkfluidhandling.com PSB100 Owner’s Manual ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company 10/6/2016 Version 1.0.1 Table of Contents 1. Introduction........................................................................................................................................................2 2. Installation..........................................................................................................................................................3 3. 4. 5. 2.1. Unpacking ...............................................................................................................................................3 2.2. Tie Bolt Torque .......................................................................................................................................3 2.3. Utilities/Hookup .......................................................................................................................................3 Specifications and Performance......................................................................................................................3 3.1. Pump Specifications ...............................................................................................................................3 3.2. Performance Curve .................................................................................................................................4 3.3. Exploded View ........................................................................................................................................5 3.4. Dimensional ............................................................................................................................................7 Installation and Precautions ............................................................................................................................8 4.1. Precautions ............................................................................................................................................8 4.2. System and Pump Environment Recommendations/Requirements ................................................... 10 4.3. Installation Instructions ....................................................................................................................... 11 Pump Control and Monitoring ....................................................................................................................... 12 5.1. Pressure Switch Stroke Detection Attachment Instructions ................................................................ 12 5.2. Pressure Switch Stroke Detection Electrical Hookups and Dimensions ............................................. 12 6. Accessories .................................................................................................................................................... 14 7. Pump Warranty ............................................................................................................................................... 15 8. Pump Service and Rebuilds .......................................................................................................................... 16 8.1. Ordering Instructions ........................................................................................................................... 16 8.2. Maintenance Schedule ........................................................................................................................ 17 8.3. Disassembly......................................................................................................................................... 18 8.3.1. Head Disassembly ........................................................................................................................... 18 8.3.2. Body Disassembly ........................................................................................................................... 18 8.4. 8.4.1. Pilot Valve (Both Heads) .................................................................................................................. 19 8.4.2. Shuttle Spool Assembly ................................................................................................................... 20 8.4.3. Shuttle Assembly (Master Head) ..................................................................................................... 20 8.4.4. Quick Exhaust (Both Heads) ........................................................................................................... 21 8.4.5. Body Assembly ................................................................................................................................ 21 8.4.6. Final Assembly ................................................................................................................................ 23 8.5. 9. Assembly ............................................................................................................................................. 19 Testing ................................................................................................................................................. 23 8.5.1. Performance Test ............................................................................................................................ 23 8.5.2. Dry Pump ......................................................................................................................................... 23 8.5.3. Dry Suction ...................................................................................................................................... 23 Trouble Shooting ............................................................................................................................................ 24 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |1 6 October 2016 1. Introduction Thank You for Purchasing White Knight Products You have purchased a White Knight product that has been built by a team of technicians with the highest commitment to quality! White Knight is the world leader in zero-metal, Ultra High-purity pumps and continues to drive the industry with new technology and products. Since the inception of White Knight in 1995, we have been awarded over 14 US patents for our designs and have multiple other patents pending! White Knight currently produces over 30 sizes/models of pumps in varying materials to meet our customers’ stringent requirements in numerous applications including ultra-high temperature re-circulation; slurry and high pressure chemical delivery systems. White Knight has been the recipient of multiple prestigious industry awards for its designs and continues to lead the industry in quality because White Knight manufactures products from raw material to finished goods in our own facility located in Kamas, UT. This allows us to rigorously manage our quality assurance process to ensure that our strict cleanliness procedures are always followed and that components are built using consistent methods and conditions to make our products reliable and consistent. Our strict process controls include assembling and testing our products in a class 100, temperature and humidity-controlled cleanroom. White Knight products also pass functional tests and are then dried with CDA and double bagged in the cleanroom to ensure cleanliness and operational integrity. Before installing your White Knight product, please carefully review the product manual. There are many helpful hints and ways to optimize the set up and use of your White Knight product as well as instructions and requirements for installation. In addition, there are many accessories in this manual will enhance the functionality of your White Knight product. Our team has gone to great lengths to provide you with the highest quality products at the best value and we back them up with excellent warranties and world class support! We hope you agree our products will serve your exacting needs and meet your stringent requirements every time you use a White Knight Product. Sincerely, Steve Smith CEO White Knight Fluid Handling ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |2 6 October 2016 2. Installation 2.1. Unpacking After unpacking, verify that no components of the pump have been damaged in shipping. Damage should be reported to the carrier immediately. In the box, the Pump and a Product Manual will be found, in addition to any accessories ordered with the pump (when possible). 2.2. Tie Bolt Torque The tie bolts on the pump are tightened before leaving the factory. However, relaxation may occur due to handling, material creep, or other unforeseen events. White Knights recommends that the pump is re-torqued on install, as well as after thermal cycling, or if the pump remains sitting for an extended period of time. To re-torque the pump: 1. Remove black tie bolt caps from both sides of the pump 2. Apply 60in-lbs of torque to each bolt on the slave head, while holding the master side bolt stationary. A star pattern is recommended. 3. Replace the bolt caps 2.3. Utilities/Hookup The pump is mounted with four ¼” bolts. It is recommended that the pump be mounted not more than 15° from level to maintain its self-priming ability and pumping efficiency. Air Inlet: 1/2in FNPT (3/8in Diam. (8mm) supply tube minimum) Air Supply: 25-80 PSI (1.4-4.1 bar) Clean Dry Air or nitrogen Fluid Ports: See Supplier Specifications 3. Specifications and Performance 3.1. Pump Specifications PSB100 Pump Specifications Flow Rate Fluid Connection Size1 Displacement Per Cycle2 Max Cycles Per Minute Fluid Path Materials Non Fluid Path Materials 25 GPM 94.64 LPM 3/4in 500ml 156 PTFE, PFA PTFE, PFA, PP, SS, PEEK Weight Sound Pressure dB(a) Sound Power dB(a) 1. Standard connection. Additional connection sizes are available 2. Displacement per cycle will vary based on air supply and fluid head pressures ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |3 6 October 2016 3.2. Performance Curve Please note that this flow curve represents actual testing with water at ambient temperatures at elevation, and has been mathematically adjusted to represent values at sea level. ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |4 6 October 2016 3.3. Exploded View ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |5 6 October 2016 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |6 6 October 2016 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 PART NUMBER 1125-TE-0027 5144-PF-0026 3300-TE-0001 2127-BP-0012 10010-TE-0020 2128-PKC-0002 2128-PKC-0001 10050-MP-0011 10050-MP-0012 6530-BP-0003 2127-BP-0013 10070-NP-0001 10070-NP-0002 10070-PF-0016 10010-SS-0048 10050-SS-0010 10010-SS-0049 4140-TE-0008 4137-TE-0009 4142-TE-0011 10080-TE-317-75 4100-TE-0004 10050-NE-0001 6560-CE-0006 6570-PK-0001 6570-PK-0003 6530-BP-0004 6530-BP-0005 6570-PK-0002 6550-CE-0006 10040-BP-0001 6140-PP-0007 DESCRIPTION BODY, PSB100 SHAFT, PSB100 STRIKE PLATE, PSB100 HEAD, SLAVE, PSB100 SHIFT PIN SCREW, PSB100 SHIFT PISTON, PSB100 PILOT VALVE SLEEVE PSB100 SHIFT PIN INNER CAP WASHER SEAL SHIFT PIN OUTER CAP WASHER SEAL SHIFT PIN OUTER CAP, PSB100 HEAD, MASTER, PSB100 AIR TUBE, SUPPLY AIR TUBE, SHIFT TIE BOLT SLEEVE TIE BOLT, PSB100 TIE BOLT WASHER FLANGE NUT, 1/4-20 TOP CHECK PLUG, PSB100 BOTTOM CHECK CAGE, PSB100 TOP CHECK CAGE, PSB100 317 O-RING CHECK BALL- 1-1/8" TIE BOLT RUBBER INSERT SHUTTLE SPOOL, PSB100 SHUTTLE DETENT SPOOL ADAPTER, PSB100 SHUTTLE DETENT LEG-ROUNDED ENDS SHUTTLE INNER CAP, PSB100 SHUTTLE OUTER CAP, PSB100 SHUTTLE RING DETENT, PSB100 SLEEVE, PSB100 TIE BOLT CAP MUFFLER FELT BAFFLE, PSB100 QTY. Material 1 PTFE 1 PFA 2 PTFE 1 BPP 2 PTFE CARBON PEEK 2 CARBON PEEK 2 2 MPTFE 2 MPTFE 2 BPP 1 BPP 2 NPP 2 NPP 8 PFA 8 SS 16 SS 16 SS 2 PTFE 2 PTFE 2 PTFE 4 PTFE 4 PTFE 8 CR 1 CE 1 PEEK 2 PEEK 1 BPP 1 BPP 1 PEEK 1 CERAMIC 16 BPP 6 NPP ITEM NO. 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 PART NUMBER 6140-BP-0001 10080-VI-014-75 10080-VI-010-75 10080-VI-262-75 10010-SS-0050 7200-PF-0010 7210-PF-0005 3200-PF-0001 6150-UH-0003 3200-VI-0001 7130-TE-0008 10010-TE-0021 5143-TE-0009 5143-TE-0010 6150-BP-0004 10040-BP-0002 10050-MP-0013 10050-MP-0004 1146-BP-0005 1146-BP-0006 10010-BP-0011 10010-TE-0022 10010-SS-0062 10040-NP-0009 6570-PI-0001 10050-GY-0001 10050-GY-0002 6140-BP-0002 10080-VI-123-75 10080-VI-018-75 10040-TE-0003 DESCRIPTION MUFFLER CAP, PSB100 014 O-RING 010, O-RING 262 O-RING 10-32 SCREW, .750 LONG 1" FLARETEK-30GPM 1" FLARETEK NUT (PFA) DIAPHRAGM, PSB100 QUICK EXHAUST SEAT, PSB100 DIAPHRAGM, n .782 OUTLET PLUG, PSB100 SHAFT LOCK SCREW, PSB100 SHAFT SEAL, PSB100 RETAINER SHAFT SEAL, PSB100 AIR DIFFUSER, PSB100 SECONDARY AIR PLUG, PSB100 SHUTTLE OUTER CAP SEAL, PSB100 CHECK SEAT WEAR WASHER, PSB100 QUICK CHANGE BASE PLATE, PSB100 QUICK CHANGE ADAPTER PLATE, PSB100 BASE PLATE SCREW, PSB100 FLAT HEAD PHILLIPS, .3125-18, .75 LONG THREADED INSERT 10-32 INTERNAL THREAD .0625 SHIFT AIR ORIFICE SHUTTLE DETENT LEG, PSB100 INLET/OUTLET WASHER SEAL, PSB100 CHECK PLUG WASHER SEAL, PSB100 MUFFLER CAP PLUG, PSB100 123 O-RING, 75 DUROMETER 018 O-RING, 75 DUROMETER NPT PLUG - 1/4" Material QTY. 2 BPP 4 FKM 7 FKM 2 FKM 4 SS 2 PFA 2 PFA PFA FILM 4 UHMW PE 2 2 FKM 2 PTFE 2 PTFE 1 PTFE 1 ddd 2 BPP 1 BPP 1 MPTFE 4 MPTFE 1 BPP 1 BPP 2 BPP 1 PTFE 4 SS 2 NPP 2 PAI 2 GYLON 2 GYLON 1 BPP 1 FKM 2 FKM 11 PTFE 3.4. Dimensional ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |7 6 October 2016 4. Installation and Precautions 4.1. Precautions High Temperature Operation Operating the pump at temperatures exceeding 60°C requires periodic tightening of the tie bolt nuts. The time period in between tie bolt nut tightening will be affected by ambient temperature, process fluid temperature as well as any temperature fluctuations (thermal cycling). Service Schedule Inspection of the torque placed on the tie bolts should be inspected every 6 months. Select Internal components should be inspected every 12 months Required Air Flow (White Knight shuttle valve) Required air flow for the PSB100 pump is 3/8” minimum orifice unrestricted. Required Air Flow (External Solenoid Valve) Required solenoid Cv for the PSB100 pump is 1.5 Cv. Using a pump with a reduced Cv will result in reduced flow rates as compared to White Knight published flow curves. Using a pump with a solenoid valve with over 20% greater Cv will result in the pump operating outside its normal operating parameters which will result in reduced pump life and will void the pump warranty. Liquid Inlet/Outlet THESE LIQUID PORTS ARE NOT NPT OR ANY OTHER STANDARD. Attempting to use connectors other than those supplied by White Knight will damage the pump, and will void warranty. Running Dry Wet shaft pumps use the liquid that they are pumping to lubricate the shaft. Running the pump dry causes it to cycle much faster than normal - accelerating normal wear. Running the pump dry for more than a couple of minutes will damage the pump, and it may cause it to lose its ability to self-prime. For applications requiring dry run situations, White Knight recommends an SD pump model Supply Pressure Recommendations The life of your pump may be extended significantly by operating your pump 30%-40% below redline operating supply pressures. A minimal operating supply pressure of 20 PSI is required. Operating a Pulsation Dampener with a White Knight Shuttle Valve When using a pulsation dampener with a White Knight shuttle valve driven pump, the air operating pressure of the pump should be at least ten PSI higher than that of the liquid line. Failure to do so may cause the pump to run erratically. Orientation White Knight does not recommend installing your pump in any position other than its upright position. Check valves within White Knight high purity pumps are actuated by gravity and/or flow and perform most effectively in the upright position. Restriction of Liquid Inlet Line Restricting the liquid supply of the pump forces the pump to work harder than normal and should be avoided when possible. Pumping against a closed liquid inlet will cause serious damage to your pump. All White Knight high purity diaphragm pumps may be controlled by closing off the liquid outlet. ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |8 6 October 2016 Under Supply of Air Undersupplying air to a pump will cause it to run erratically or stall. For best results, White Knight recommends running pumps at air pressures slightly above the averaged air consumption curves found on the performance curves graph. Additionally, air supply lines and fittings must meet the minimal ID (inner diameter) requirements published in the installation instructions. Cross Contamination PTFE and many other plastics are very porous and may retain chemicals in the pores of the material. Record chemistries used in a pump to avoid cross contamination. WARNING: Liquids and Gasses Under Pressure While in a live system, pumps contain pressurized liquids and gasses. All pressure, liquid and air must be eliminated via shut off valves before the pump may be removed or detached from the system. WARNING: Potential for High Surface Temperatures When pumps are operated with high temperature fluids, heat may transfer to the exterior surfaces of the pump. Avoid direct contact with the pump when high temperature fluids are present. WARNING: Handling of Chemicals In the event that hazardous chemicals are used in or around the pump, ensure that appropriate personal protective equipment is used before handling. Reference the chemistry’s Material Safety Data Sheet (MSDS) for handling instructions or other information specific to that chemical. WARNING: Noise Potential The exiting of exhaust air from the pump will contribute to a work area’s noise level. Always operate White Knight pumps with the approved muffler media. When working in noisy conditions, use the necessary ear protection. ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |9 6 October 2016 4.2. System and Pump Environment Recommendations/Requirements Oversized Inlet Line Pumps operate optimally with liquid inlet lines larger than the liquid outlet lines. This reduces strain on the diaphragms and may reduce pulsation in the pump outlet. Clean Supply Air (CDA) White Knight high purity bellows pumps require the use of class 2 air for particles and moisture per ISO 8573-1. (Use 10 micron filter, maintain -40° C dew point) Flammable Solvents White Knight high purity diaphragm pumps are not constructed from conductive materials. Any system used to pump flammable solvents should be properly grounded to avoid ignition by static charge. A test from River’s Edge on using isolative pumps to pump flammable liquids indicated that the liquid itself must be grounded and that other procedures should be followed. A copy of the test is available upon request from White Knight. Pumping Liquids Near Boiling Point Minimizing suction lift in a system reduces pulsation and the potential boiling or outgassing of liquid in the inlet of the pump. Reciprocating pumps are designed to pull suction lift, but pump performance and life will increase when suction lift can be minimized or eliminated. Abrasive Slurries Pumping of abrasive slurries will shorten the life of any pump. White Knight high purity pumps are still warrantied when used in abrasive applications however; wear of components will be accelerated. Normal wear is not a condition covered by warranty. Environmental Temperature This pump is rated to withstand environmental temperatures up to 50°C. ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |10 6 October 2016 4.3. Installation Instructions 1. 2. Align pump to base plate and lower onto stand, ensuring base is fully seated. Tighten set screws on front of base. Attach base plate to work space using 4 bolts, in predrilled holes. 4. 3. Attach liquid fittings per manufacturer’s instructions. Attach air supply using 1/2in FNPT port (CDA Port) on pump head ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |11 6 October 2016 5. Pump Control and Monitoring PROGRAMMABLE CONTROLLING: White Knight offers the CPT-1 pump controller as a solution to control a White Knight pump. Run mode, flow rate and leak detection are a few items the CPT-1 controls or monitors. 5.1. Pressure Switch Stroke Detection Attachment Instructions 2. 1. Attach tubing using air gripper assembly Attach the elbow to the EXH port in the head. 3. Attach the gripper elbow to the Pressure Switch 5. 4. Attach pressure switch to tubing For Dual Pressure Switch, repeat all steps for second head. 5.2. Pressure Switch Stroke Detection Electrical Hookups and Dimensions ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |12 6 October 2016 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |13 6 October 2016 6. Accessories Control and Monitoring Options Stroke Detection Solid State Pressure Switch SP1 Solid State Dual Pressure Switch SP2 Leak Detection Conductivity Leak Detection LC0 Control Options – Run mode and flow rate are two of the items which the CPT-1 can control/monitor Pump Catcher In-line and pump-mounted options available Large through holes to avoid loading Filter may be removed without removing the Catcher™ from the pump or the line If a pump were damaged by passing solids while using the Catcher™ it would be repaired under warranty Filter Housing 100% Non-metallic Allows for filter changing without disconnecting the inlet/outlet lines Options available for up to 210°C Available with industry standard fluid connections Designed to allow for thermal cycling Upright and invert installation options available Space saving manifold options available in series and parallel configurations Quick Exhaust Valves Allows for immediate escape of exhaust air, reducing pulsation and exposure of solenoid valve to corrosive fumes In-line and pump mounted options available Polypropylene and PTFE designs available Comes standard with a one-year warranty Pulse Dampeners Operates with self-adjusting Auto Level Valve regulated by liquid line pressure Operates with the same CDA supplied to the pump Inline and pump-mounted options available Available with compatible sizes for all White Knight high purity pumps ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |14 6 October 2016 7. Pump Warranty White Knight Fluid Handling® follows strict procedures in all phases of manufacturing, assembly and testing to ensure reliability of its products. Each pump is individually tested to assure its functional operation integrity. White Knight Fluid Handling® warrants PSB100 pumps, subassemblies and components to be free from defects in materials and workmanship for the period of Two years from the date of start-up or 30 months from the date of shipment, whichever applies. Failures due to misuse, abuse or any unauthorized disassembly of a White Knight® pump will nullify this warranty. Pump warranty subject to recommended service at intervals during the warranty period. PSB100 pumps are warranted for up to 80 PSI air supply pressures. They are not covered under dry run condition. Wearable parts are not covered if used to pump abrasive slurries. Due to the broad and ever-evolving applications for usage of White Knight® pumps we cannot guarantee the suitability of any pump component or subassembly for any particular or specific application. White Knight Fluid Handling shall not be liable for any consequential damage or expense arising from the use or misuse of its products in any application. Responsibility is limited solely to the replacement or repair of defective White Knight® pumps, components or subassemblies. All options to rebuild or replace aforementioned items shall remain under the judgment of White Knight Fluid Handling. Decisions as to the cause of failure shall be solely determined by White Knight Fluid Handling. PRIOR WRITTEN, FAXED OR EMAILED APPROVAL MUST BE OBTAINED FROM WHITE KNIGHT FLUID HANDLING BEFORE RETURNING ANY PUMP COMPONENT OR SUBASSEMBLY FOR WARRANTY CONSIDERATION. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY WARRANTIES OF SUITABILITY FOR ANY PARTICULAR PURPOSE. NO VARIATIONS OF THIS WARRANTY BY ANYONE OTHER THAN THE PRESIDENT OF WHITE KNIGHT FLUID HANDLING IN A SELF-SIGNED AGREEMENT SHALL BE HONORED OR CONSIDERED LEGALLY BINDING. Steve Smith, CEO White Knight Fluid Handling ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |15 6 October 2016 8. Pump Service and Rebuilds 8.1. Ordering Instructions White Knight Fluid Handling, Inc. PSB100 Ordering Instructions Additional Options (Not Required) Required Configurations - PSB100 F ① - 16 ② LC0 ③ - SP1 ④ - T ⑤ Rev S ⑥ 12 ⑦ = standard option Bold ⑧ Please select one option from each of the required fields (1 - 2). To configure your pump with different inlet and outlet fittings, leak or stroke detection, or request a specific revision level, please select options from the appropriate additional options (3-8). ① ② Liquid Fitting Configuration Pump Configuration PSB100 ① Fitting Style Inlet Style Standard Configuration Front Straight Only ② Fitting Size F = Flaretek® compatible 12 = 3/4" T = Tube Out 16 = 1" = Weldable 20 = 1-1/4" W *Not available in 1-1/4" If the liquid inlet and outlet fitting styles are different, please define the liquid inlet fitting from section 12 and use the liquid outlet section below (5-7) to differentiate. = Pillar S-300® P = Female NPT N *Not available in 1-1/4" D =Accessible Disk Seal Liquid Connection (NO FITTING) Optional Configurations ③ Leak Detection LC0 = 15' conductivity cable ④ Stroke Detection SP1 SP2 SP3 SP4 SP5 = Pressure Switch (NPN) (single pressure switch) = Pressure Switch Dual (NPN) (comes with two each DP2 pressure switches)* = Pressure Switch Dual (no Pressure switches supplied)* = Pressure Switch (PNP) (single pressure switch) = Pressure Switch Dual (PNP) (comes with two each DP2 pressure switches)* ⑤ ⑥ ⑦ Liquid Outlet and Fitting Configuration (if different from inlet) ⑤ Outlet Style ⑥ Fitting Style ⑦ Fitting Size F Front Straight Outlet F = Flaretek® compatible 12 = 3/4" T Top Straight Outlet T = Tube Out 16 = 1" = Weldable 20 = 1-1/4" W *Not available in 1-1/4" P N = Pillar S-300® = Female NPT *Not available in 1-1/4" D =Accessible Disk Seal Liquid Connection (NO FITTING) If the liquid inlet and outlet fitting styles are different, please define the liquid outlet fitting from section 5-7 and use the fitting section above (1-2) to differentiate. ⑧ Revision Level: Contact factory for copy exact code activation information. Operating this pump in timer mode requires the use of an end of stroke detection mechanism (pressure switch) to prevent the pump from over stroking. Failure to use end of stroke detection as a safety while operating in timer mode will void the warranty of this pump. White Knight Fluid Handling, Inc. www.wkfluidhandling.com 435-783-6040 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |16 6 October 2016 Rebuild Parts for the PSB100 Pump (12 Month Kit) Kit Number: RBPSB100-1 Part Number Description Qty. 5143-TE-0009 Shaft Seal, PSB100 1 6570-PI-0001 Shuttle Detent Leg, PSB100 2 6570-PK-0002 Shuttle Ring Detent, PSB100 1 6570-PK-0003 Shuttle Detent Leg – Rounded Ends 2 10010-TE-0020 Shift Pin Screw, PSB100 2 10040-BP-0001 Tie Bolt Cap 16 10080-TE-317-75 317 PTFE O-ring 4 10080-VI-010-75 010 O-Ring 4 10080-VI-014-75 014 O-Ring 4 10080-VI-262-75 262 O-ring 2 10050-GY-0001 Inlet/Outlet Washer Seal, PSB100 2 10050-GY-0002 Check Plug Washer Seal, PSB100 2 10050-MP-0004 Wear Seat 4 Rebuild Parts for PSB100 Pump (24 Month Kit) Kit Number: RBPSB100-2 Part Number Description Qty. 3200-PF-0001 Diaphragm, PSB100 4 3200-VI-0001 QEV Diaphragm, 0.782 2 4100-TE-0004 Check Ball - 1-1/8in 4 5143-TE-0009 Shaft Seal, PSB100 1 6570-PI-0001 Shuttle Detent Leg, PSB100 2 6570-PK-0002 Shuttle Ring Detent, PSB100 1 6570-PK-0003 Shuttle Detent Leg – Rounded Ends 2 10010-TE-0020 Shift Pin Screw, PSB100 2 10040-BP-0001 Tie Bolt Cap 16 10080-TE-317-75 317 PTFE O-ring 4 10080-VI-010-75 010 O-Ring 4 10080-VI-014-75 014 O-Ring 4 10080-VI-262-75 262 O-ring 2 10050-GY-0001 Inlet/Out let Washer Seal, PSB100 2 10050-GY-0002 Check Plug Washer Seal, PSB100 2 5144-PF-0026 Shaft, PSB100 1 10050-MP-0004 Wear Seat 4 Tie Bolt (60Lb-in) C-Ring and Detent Legs Pilot Button Check Seat Wear Rings Shaft Bushing Shaft (High Suction Applications) Shaft Diaphragms and Main Seal Quick Exhaust Seal Check Balls and Seals Check Balls and Seals (High Suction Applications) Exhaust Muffler Media I=Inspect, R=Replace I I I R R R R R I 24 Months 18 Months 12 Months 6 Months PSB100 Maintenance Schedule Install 8.2. Maintenance Schedule I R R R R R R ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |17 6 October 2016 8.3. Disassembly Throughout a pumps life, rebuilds will be performed to ensure consistent, quality operation. The instructions below are included to facilitate the disassembly required to service the pump. Ensure the pump is purged and clean of any chemistry in the pump. White Knight recommends the pump be flushed for 30 minutes with Deionized water, under its own power if possible. If the pump is not functional, deionized water should be pumped into the inlet of the pump, and out of the outlet for 1 hour. Remove tie bolt caps from the slave head Remove nuts from the tie bolts (Slave Head Side). Leave tie bolts in place Lay the pump on its side with slave side up Lift off the slave head Remove the main seal and diaphragms Remove the O-rings from the shuttle transfer tube Remove the body assembly Remove the second set of diaphragms and main seal Remove the transfer tube and O-rings from the heads and body Remove the remaining tie bolt caps and tie bolts NOTE: All plastic pump components should be immersed in Deionized water to ensure complete neutrality of any residual fluid on the components and reduce the risk of chemical exposure. 8.3.1. Head Disassembly Remove Label Cap Remove pilot cap from both heads Remove the pilot valve and seals from the Master and Slave heads Remove the shuttle spool assembly from the adapter detent Remove C-ring and detent legs from shuttle spool assembly Remove detent adapter DO NOT REMOVE the shuttle sleeve assembly from the shuttle bore Remove the muffler spool and muffler pads from each head Remove quick exhaust ports from heads Remove quick exhaust seals Remove remote exhaust plugs (if necessary) 8.3.2. Body Disassembly Remove check bore caps using appropriate pin tool Remove sleeves, balls, O-rings and check seat wear rings. DO NOT USE EXCESSIVE FORCE Unthread push plate locking screw and push plate from the one side of the shaft Remove remaining shaft and push plate from body Unthread second locking screw and push plate from shaft Unthread shaft bushing locking screw from body Using appropriate pin tool, insert pins in shaft bushing locking ring located in the master head side of chamber and rotate CCW to remove bushing. Then push out bushing from the slave head chamber side ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |18 6 October 2016 8.4. Assembly Prior to beginning assembly, inspect all parts to ensure they are clean and dry. Wear clean protective gloves. 8.4.1. Pilot Valve (Both Heads) NOTE: Do not use any tools to install the pilot button. Use of tools may damage the button. Remove existing pilot button and discard Replacement pilot button should be tightened enough that the underside of the head touches the pilot piston Replacement pilot button should be tightened enough that the underside of the head touches the pilot piston No light should be visible between the bottom of the button head and the piston Pilot Assembly Pilot piston PTFE Screw (Pilot Button) Slide seal onto pilot valve body until even engagement with the shoulder is reached. The shoulder is located in the center of the pilot valve body Thread the pilot valve assembly into the pilot bore of the head as shown in the image below. Tighten to 25 in-lbs. Do not over tighten Pilot Cap Pilot Cap Seal Pilot Sleeve Seal Pilot Valve Assembly Install pilot cap seal Thread pilot valve cap to engage seal. Tighten to 30 in-lbs Repeat process for both heads Install label cap (Slave Head Only) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |19 6 October 2016 8.4.2. Shuttle Spool Assembly Hold shuttle spool upright and align slot in detent legs with notch on shuttle spool Apply pressure upward onto base of detent legs with thumb and index finger Tilt the detent ring over one of the left and align the groove on the inside of the detent ring with the end of the detent leg. Tilt the other side of the ring down, expanding it slightly, so that the other detent leg snaps into the detent ring groove. The completed assembly should look like the final image. 8.4.3. Shuttle Assembly (Master Head) NOTE: Ensure that the spool moves freely inside the sleeve prior to installation Thread detent adapter into shuttle bore until flush against head. Tighten to 45 in-lbs Insert shuttle spool assembly into adapter detent and Shuttle Sleeve (DO NOT LUBRICATE) Shuttle Cap Seal Spool ASSY External Detent Adapter Shuttle Sleeve Shuttle Bore Seal Groove Shoulder Install the seal onto the seal groove shoulder of the shuttle cap Thread shuttle cap onto detent adapter. Tighten to 40 in-lbs ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |20 6 October 2016 8.4.4. Quick Exhaust (Both Heads) Insert quick exhaust seal Insert quick exhaust port in each head as shown. Tighten to 20in-lbs. Do not over tighten Quick Exhaust Seal Quick Exhaust Port Head Bottom Surface Install 3 each muffler pads onto muffler spool and insert into exhaust port. Tighten to 40 in-lbs 8.4.5. Body Assembly NOTE: For easy installation, check sleeves that do not install easily (minimal effort) can be placed in a freezer prior to assembly to assist insertion. Body must be upside down with check port extending over a table edge so that parts remain assembled during insertion of sleeves Insert suction sleeve, check ball, and wear ring carefully into check bore Pump Body Check Seat/Wear Ring Check Ball Slot – Note Position While Installing Check Sleeve NOTE: the suction sleeves are 2.5in (6.35 cm) long. The discharge sleeves are 2.846in (7.2cm) long Repeat insertion process with the discharge sleeve, check ball, and wear ring Place seal and tighten check bore caps to 60 in-lbs Repeat process for second check bore ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |21 6 October 2016 Shaft Bushing Locking Ring Locking Screw Install shaft bushing per image above Install locking ring until flush with fluid cavity face and resistance is met Tighten until next available notch aligns with locking screw hole, check to assure that the shaft bushing does not move Insert locking screw into hole and tighten until flush with locking ring Thread one push plate onto shaft until push plate bottoms out on shaft shoulder Tighten push plate to 48 oz-in, and then rotate CW until locking screw hole is aligned with the next available hole in shaft. The first push plate can be visually aligned separate from the body Install push plate locking screw. Tighten to 12 oz-in Push Plate Push Plate Shaft Push Plate Screw Push Plate Screw Insert shaft through shaft bore as show in the image above Thread on remaining push plate until push plate bottoms out on shaft shoulder The second push plate, while in the pump body, cannot be visually aligned. Tighten push plate to 48 ozin, then insert alignment pin into locking screw hole. Rotate push plate CW until locking screw hole is aligned with the next available hole in shaft and alignment pin drops into the shaft hole. Remove alignment pin Install push plate locking screw. Tighten to 12 oz-in ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |22 6 October 2016 8.4.6. Final Assembly Insert tie bolts into master head (press fit) and lay head flat with tie bolts sticking up Insert main transfer tub and O-ring into head Install shuttle transfer tube with two O-rings Place main seal into the main seal groove in master head Install two diaphragms, removing all air from between diaphragms, onto the tie bolts and shuttle transfer tube. Note main seal groove alignment Place body assembly onto tie bolts and master head, ensuring alignment of shuttle transfer tube and its corresponding body passage hole Place remaining two diaphragms onto tie bolts, body and shuttle transfer tube. Note main seal groove alignment Place two O-rings onto shuttle transfer tube Place the main seal O-ring into the formed groove of the slave head Place a second main transfer tube and O-ring into slave head Lift the slave head and body, while maintaining compression of the seal, flip the head and body over and insert the tie bolts into the master head. Ensure that the main seal of the master head is not dislodged. Place all bushing and flat washers onto tie bolt threaded ends Install flange nuts onto tie bolts, tighten evenly in a star pattern (do not overload one side before applying torque to another as dislodgment of main seal can occur), final torque is 60 in-lbs Snap in tie bolt caps 8.5. Testing 8.5.1. Performance Test With the air supply at 0 psi open the air supply valve Increase the air pressure until the pumps starts to cycle Record the start pressure, Target = <20psig Pump must prime once even cycling is achieved Increase pressure to 60 psi Check for fluid leaks, listen for air leaks, check for irregularity Close the discharge valve and deadhead for 2 minutes Pump must not experience jog, erratic cycling or leaks Open discharge valve and expel the remaining DI water Prepare the pump for drying 8.5.2. Dry Pump Connect vacuum hose to discharge line Connect purge line to fluid inlet (CDA) 60psig Supply Pressure Cycle pump and vacuum dry by rotating pump side to side for 30 seconds Turn off air supply and allow the pump to purge for 5 minutes 8.5.3. Dry Suction 20 psig Supply pressure target Record suction value Target – 14 in-Hg. ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |23 6 October 2016 9. Trouble Shooting Pump will not Start, Fails to Operate Cause: Solution: Insufficient air pressure (must be enough to energize the pilot and shuttle valves). Pilot valves ‘buzzing’. Insufficient air volume There must be minimum 20 psig at pump air hook-up Dirty or damaged shuttle valve. Clean shuttle spool assembly and sleeve until free movement is assured, or replace. Damaged, sticky pilot valve (not following diaphragm properly) Pilot valve piston must slide freely, full travel, in pilot valve sleeve. Fluid discharge line blocked. Remove pilot pistons and check for debris or chemical attack Downstream valve closed, filter plugged or other obstruction. Replace damaged valve assembly Remove Obstruction. See Performance Charts (3.1) for requirements. Reference regulator and control valve capacity specifications Bubbles in Fluid Discharge Cause: Solution: Leaking fluid inlet fitting. Tighten, liquid fittings. If using competitor fluid ports, PTFE tape may be used on the liquid connection, or consider replacing the adapter O-ring. Leaking main seal. Pump inlet line pressure reached saturation point (due to high suction requirement). Ruptured (perforated) diaphragm Fluid Leaks Cause: Tie Bolt torque not enough to affect seal Damaged main seal. Check Bore Cap. Ruptured diaphragm(s) can result in fluid leaks through air exhaust port. Tighten tie bolt nuts to 60 in-lbs. Replace main seals if damaged Increase diameter of suction supply line (reduces restriction) Reduce output flow Replace diaphragms Solution Tighten all nuts to 60 in-lbs Replace check for irregularities in diaphragm groove on pump body Tighten, or remove and replace seal Replace diaphragms, and any parts that may have been damaged by fluid exposure. ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |24 6 October 2016 Erratic Cycling Cause: Solution Leaking detent cap. Tighten and/or replace seal Supply line restricted (cavitation). Reduce fluid restriction Quick exhaust seal not seating Check for particles between seal and port, Replace seal. Pilot valve not following diaphragm correctly. Pilot valve piston must slide freely, full travel in pilot valve sleeve. Check ball(s) not seating. Verify no damage to check seals; replace if necessary. Make sure check balls move freely in sleeves. Pilot transfer leak Tighten tie bolts to 60 in-lbs Replace transfer seals ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |1 6 October 2016 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Copyright © 2015 White Knight Fluid Handling | A Graco company P a g e |2 6 October 2016
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