Reciprocating pump with electronically monitored air valve and piston

A pump system comprising:

• a fluid pump;
• a reciprocating air motor that is connected to the fluid pump for driving the fluid pump, the reciprocating air motor including a piston and an air valve that moves between extreme positions;
• a plurality of sensors that produce signals indicative of air valve operation and piston position;
• a solenoid configured to extend a plunger into the air valve upon receiving an actuation command and to retract the plunger upon receiving a retract command;
• a user interface having inputs for receiving setup parameters including a runaway set point and a display that displays monitored operating parameters;
• and
• a controller that issues an actuation command and a retract command to the solenoid, controls operation of the reciprocating air motor based upon the setup parameters from the inputs of the user interface and the signals from the plurality of sensors, and controls the display to display at least one of:
• a diagnostic message indicating that the air motor continues to reciprocate when the solenoid has been commanded to extend the plunger into the air valve and the controller determines, based on signals indicative of air valve operation and piston position, that the air motor continues to reciprocate;
• a diagnostic message indicating that the plunger has failed to extend when the controller has commanded the solenoid to extend the plunger and the controller determines, based on signals indicative of air valve operation and piston position, that no extension of the plunger has occurred;
• or
• a diagnostic message indicating that the plunger has failed to retract when the controller has commanded the solenoid to retract the plunger and the controller determines, based on signals indicative of air valve operation and piston position, that the plunger has not retracted.