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PS230/XPS230

FIT Metal Pump

Where Innovation Flows


wilden-pumps.com
TA B L E O F C O N T E N T S

SECTION 1 CAUTIONS—READ FIRST! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 WILDEN PUMP DESIGNATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 3 HOW IT WORKS—PUMP & AIR DISTRIBUTION SYSTEM . . . . . . . . . . . . . . . . . . 3

SECTION 4 DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 5 PERFORMANCE
PS230 Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PS230 TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PS230 Full-Stroke PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 6 SUGGESTED INSTALLATION, OPERATION & TROUBLESHOOTING . . . . . . . . . 8


Section 1
CAUTIONS—READ FIRST!
CAUTION: Do not apply compressed air to the CAUTION: Do not exceed 8.6 bar (125 psig) air supply
exhaust port — pump will not function. pressure.
CAUTION: Do not over-lubricate air supply — excess CAUTION: The process fluid and cleaning fluids
lubrication will reduce pump performance. Pump is must be chemically compatible with all wetted pump
pre-lubed. components. Consult Chemical Resistance Guide.
TEMPERATURE LIMITS: CAUTION: Pumps should be thoroughly flushed
before installing into process lines. FDA- and USDA-
Acetal –29°C to 82°C –20°F to 180°F
approved pumps should be cleaned and/or sanitized
Buna-N –12°C to 82°C 10°F to 180°F
before being used.
Geolast® –40°C to 82°C –40°F to 180°F
Neoprene –18°C to 93°C 0°F to 200°F CAUTION: Always wear safety glasses when operating
Nordel® EPDM –51°C to 138°C –60°F to 280°F pump. If diaphragm rupture occurs, material being
Nylon –18°C to 93°C 0°F to 200°F pumped may be forced out air exhaust.
PFA –7°C to 107°C 45°F to 225°F CAUTION: Before any maintenance or repair is
Polypropylene 0°C to 79°C 32°F to 175°F attempted, the compressed air line to the pump
Polyurethane –12°C to 66°C 10°F to 150°F should be disconnected and all air pressure allowed
PVDF –12°C to 107°C 10°F to 225°F to bleed from pump. Disconnect all intake, discharge
Saniflex™ –29°C to 104°C –20°F to 220°F and air lines. Drain the pump by turning it upside
SIPD PTFE with EPDM-backed 4°C to 137°C 40°F to 280°F down and allowing any fluid to flow into a suitable
SIPD PTFE with Neoprene-backed 4°C to 93°C 40°F to 200°F container.
PTFE1 4°C to 104°C 40°F to 220°F CAUTION: Blow out air line for 10 to 20 seconds
Viton® FKM –40°C to 177°C –40°F to 350°F before attaching to pump to make sure all pipeline
Wil-Flex™ –40°C to 107°C –40°F to 225°F debris is clear. Use an in-line air filter. A 5μ (micron)
4°C to 149°C (40°F to 300°F) - 13 mm (1/2") and 25 mm (1") models only.
1  air filter is recommended.
NOTE: When installing PTFE diaphragms, it is
NOTE: Not all materials are available for all models.
 important to tighten outer pistons simultaneously
Refer to Section 2 for material options for your pump. (turning in opposite directions) to ensure tight fit.
(See torque specifications in Section 7.)
CAUTION: When choosing pump materials, be
sure to check the temperature limits for all wetted NOTE: Before starting disassembly, mark a line
components. Example: Viton® has a maximum limit from each liquid chamber to its corresponding air
of 177°C (350°F) but polypropylene has a maximum chamber. This line will assist in proper alignment
limit of only 79°C (175°F). during reassembly.
CAUTION: Maximum temperature limits are based CAUTION: Pro-Flo® pumps cannot be used in
upon mechanical stress only. Certain chemicals submersible applications. Pro-Flo® SHIFT pumps do
will significantly reduce maximum safe operating have a single-point exhaust option for submersible
temperatures. Consult Chemical Resistance Guide applications. Do not use standard Pro-Flo® SHIFT
for chemical compatibility and temperature limits. models in submersible applications..
WARNING: Prevent static sparking. If static sparking CAUTION: Tighten all hardware prior to installation.
occurs, fire or explosion could result. Pump, valves
and containers must be grounded to a proper
grounding point when handling flammable fluids and
whenever discharge of static electricity is a hazard.

WIL-11560-E-01 1 WILDEN PUMP & ENGINEERING, LLC


Section 2
W I L D E N P U M P D E S I G N AT I O N S Y S T E M

PS230 LEGEND XPS230 / XXXX X / XXX / XX / X XX / XXXX


FIT METAL O-RINGS
MODEL VALVE SEATS SPECIALTY
25 mm (1") Pump VALVE BALLS CODE
ATEX DIAPHRAGMS (if applicable)
Maximum Flow Rate: AIR VALVE
CENTER SECTION
254 lpm (56 gpm) WETTED PARTS & OUTER PISTON

MATERIAL CODES
MODEL DIAPHRAGMS VALVE BALLS
PS230 = PRO-FLO® SHIFT BNS = BUNA-N (Red Dot) BN = BUNA-N (Red Dot)
FLANGED-PORTS EPS = EPDM (Blue Dot) FS = SANIFLEXTM [Hytrel®
FSL = FULL-STROKE SANITARY (Cream)]
XPS230 = PRO-FLO® SHIFT ATEX
SANIFLEX™ IPD [Hytrel® EP = EPDM (Blue Dot)
FLANGED-PORTS
(Cream)] NE = NEOPRENE (Green Dot)
FSS = SANIFLEXTM PU = POLYURETHANE (Brown)
WETTED PARTS & OUTER PISTON
[Hytrel® (Cream)] TF = PTFE (White)
SS = STAINLESS STEEL / NES = NEOPRENE (Green Dot) VT = VITON® (White Dot)
STAINLESS STEEL PUS = POLYURETHANE (Clear) WF = WIL-FLEXTM [Santoprene®
SZ = STAINLESS STEEL / NO TSS = FULL-STROKE PTFE (Three Black Dots)]
OUTER PISTON w/SANIFLEX™ BACKUP
TWS = FULL-STROKE PTFE w/ VALVE SEATS
CENTER SECTION WIL-FLEX™ BACKUP S = STAINLESS STEEL
AA = ALUMINUM [Santoprene® (Three
Black Dots)] VALVE SEATS & MANIFOLD
AIR VALVE VTS = VITON® (White Dot) O-RINGS
A = ALUMINUM WFS = WIL-FLEXTM [Santoprene®
BN = BUNA-N
(Three Black Dots)]
FS = SANIFLEXTM
WWL = FULL-STROKE WIL-FLEX™
[Hytrel® (Cream)]
IPD [Santoprene® (Three
EP = EPDM
Black Dots)]
NE = NEOPRENE
XBS = CONDUCTIVE BUNA-N
PU = POLYURETHANE (Brown)
(Two Red Dots)
TF = PTFE (White)
VT = VITON®
WF = WIL-FLEXTM [Santoprene®]

SPECIALTY CODES
0100 Wil-Gard 110V
0102 Wil-Gard sensor wire ONLY
0103 Wil-Gard 220V
0480 Pump cycle monitor (sensor & wires)
0483 Pump cycle monitor (module, sensor & wires)
0485 Pump cycle monitor (module, sensor & wires), DIN flange
0504 DIN flange

NOTE: NOT ALL PUMP MODELS ARE AVAILABLE WITH ALL MATERIAL OPTIONS.
NOTE: MOST ELASTOMERIC MATERIALS USE COLORED DOT FOR IDENTIFICATION
Viton® is a registered trademark of Dupont Dow Elastomers.

WILDEN PUMP & ENGINEERING, LLC 2 WIL-11560-E-01


Section 3
HOW IT WORKS—PUMP
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show flow pattern
through the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.

CLOSED OUTLET OPEN OPEN OUTLET CLOSED CLOSED OUTLET OPEN

B A B A B A

OPEN INLET CLOSED CLOSED INLET OPEN OPEN INLET CLOSED

FIGURE 1 The air valve directs pressurized FIGURE 2 When the pressurized diaphragm, FIGURE 3 At completion of the stroke,
air to the back side of diaphragm A. The diaphragm A, reaches the limit of its discharge the air valve again redirects air to the
compressed air is applied directly to the stroke, the air valve redirects pressurized back side of diaphragm A, which starts
liquid column separated by elastomeric air to the back side of diaphragm B. The diaphragm B on its suction stroke. As
diaphragms. The diaphragm acts as pressurized air forces diaphragm B away the pump reaches its original starting
a separation membrane between the from the center while pulling diaphragm A point, each diaphragm has gone through
compressed air and liquid; a balanced to the center. Diaphragm B is now on its one suction and one discharge stroke.
load removes mechanical stress from the discharge stroke. Diaphragm B forces the This constitutes one complete pumping
diaphragm. The compressed air moves inlet valve ball onto its seat due to the cycle. The pump may take several cycles
the diaphragm away from the center hydraulic forces developed in the liquid to completely prime depending on the
of the pump. The opposite diaphragm chamber and manifold of the pump. These conditions of the application.
is pulled in by the shaft connected to same hydraulic forces lift the discharge
the pressurized diaphragm. Diaphragm valve ball off its seat, while the opposite
B is on its suction stroke; air behind discharge valve ball is forced onto its seat,
the diaphragm has been forced out to forcing fluid to flow through the pump
atmosphere through the exhaust port of discharge. The movement of diaphragm A
the pump. The movement of diaphragm toward the center of the pump creates a
B toward the center of the pump creates vacuum within liquid chamber A. Atmos­
a vacuum within chamber B. Atmospheric pheric pressure forces fluid into the inlet
pressure forces fluid into the inlet manifold of the pump. The inlet valve ball
manifold forcing the inlet valve ball off its is forced off its seat allowing the fluid being
seat. Liquid is free to move past the inlet pumped to fill the liquid chamber.
valve ball and fill the liquid chamber (see
shaded area).

HOW IT WORKS—AIR DISTRIBUTION SYSTEM


The heart of the patented Pro-Flo® SHIFT Air Distribution
System (ADS) is the air valve assembly. The air valve design
incorporates an unbalanced spool with the small end of the
spool being pressurized continuously while the large end of
the spool is alternately pressurized, then exhausted to move
the spool. The air valve spool directs pressurized air to one
chamber while exhausting the other. The air forces the main
shaft/diaphragm assembly to move to one side – discharging
liquid on that side and pulling liquid in on the other side. When
the shaft reaches the end of the stroke, the inner piston actuates
the pilot spool, which controls the air to the large end of the air
valve spool. The repositioning of the air valve spool routes the
air to the other air chamber.

WIL-11560-E-01 3 WILDEN PUMP & ENGINEERING, LLC


Section 4
DIMENSIONAL DR AWINGS

PS230 M et al — S t a i nl e s s S te el

DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 373 14.7
B 69 2.7
C 195 7.6
D 287 11.3
E 340 13.4
F 343 13.5
G 71 2.8
H 417 16.4
J 71 2.8
K 140 5.5
L 188 7.4
M 206 8.1
N 173 6.8
P 104 4.1
R 127 5.0
S 10 0.4
T 203 8.0
DIN FLANGE
U 85 DIA. 3.1 DIA.
V 115 DIA. 4.3 DIA.
W 14 DIA. 0.6 DIA.
LW0366 REV. A

WILDEN PUMP & ENGINEERING, LLC 4 WIL-11560-E-01


Section 5
PERFORMANCE

PS230 METAL
RUBBER-FITTED

Ship Weight ...........


316 Stainless Steel 31 kg (68 lb)

Air Inlet ................................... 13 mm (1/2")


Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ....................... 6.9 m Dry (22.7')
9.0 m Wet (29.5')
Disp. Per Stroke1 ................... 0.30 L (0.08 gal)
Max. Flow Rate .............. 245 lpm (54 gpm)
Max. Size Solids .................... 6.4 mm (1/4")
1
Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2.1 bar (30 psig) head pressure.
Example: To pump 140 lpm (37 gpm)
against a discharge pressure head of
2.8 bar (40 psig) requires 5.5 bar (80 psig)
and 60 Nm3/h (38 scfm) air consumption.
(See dot on chart.) Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.

PS230 METAL
TPE-FITTED
Ship Weight ...........
316 Stainless Steel 31 kg (68 lb)

Air Inlet ................................... 13 mm (1/2")


Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ....................... 5.9 m Dry (19.3')
9.0 m Wet (29.5')
Disp. Per Stroke1 ................... 0.26 L (0.07 gal)
Max. Flow Rate .............. 254 lpm (56 gpm)
Max. Size Solids .................... 6.4 mm (1/4")
1
Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2.1 bar (30 psig) head pressure.
Example: To pump 144 lpm (38 gpm)
against a discharge pressure head of
2.8 bar (40 psig) requires 5.5 bar (80 psig)
and 63 Nm3/h (40 scfm) air consumption.
(See dot on chart.) Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.

WILDEN PUMP & ENGINEERING, LLC 5 WIL-11560-E-01


PERFORMANCE
PS230 METAL
FULL-STROKE
PTFE-FITTED

Ship Weight ...........


316 Stainless Steel 31 kg (68 lb)

Air Inlet ................................... 13 mm (1/2")


Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ........................ 5.2 m Dry (17.0')
9.0 m Wet (29.5')
Disp. Per Stroke1 ................... 0.30 L (0.08 gal)
Max. Flow Rate .............. 238 lpm (52 gpm)
Max. Size Solids .................... 6.4 mm (1/4")
1
Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2.1 bar (30 psig) head pressure.
Example: To pump 83.3 lpm (22 gpm)
against a discharge pressure head of
2.8 bar (40 psig) requires 4.1 bar (60 psig)
and 36 Nm3/h (23 scfm) air consumption.
(See dot on chart.) Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.

WIL-11560-E-01 6 WILDEN PUMP & ENGINEERING, LLC


SUCTION-LIFT CURVES

PS 2 3 0 ME TA L
SUCTION-LIFT Traditional Rubber Diaphragms
CAPABILIT Y
Suction-lift curves are calibrated for
pumps operating at 305 m (1,000')
above sea level. This chart is meant TPE Diaphragms
to be a guide only. There are many
variables that can affect your pump's
operating characteristics. The number
of intake and discharge elbows, Full-Stroke PTFE Diaphragms
viscosity of pumping fluid, elevation
(atmospheric pressure) and pipe
friction loss all affect the amount of
suction lift your pump will attain.

WILDEN PUMP & ENGINEERING, LLC 7 WIL-11560-E-01


Section 6
SUGGES T ED INS TA L L AT ION

Wilden® pumps are designed to meet the performance ELEVATION: Selecting a site that is well within the pump’s
requirements of even the most demanding pumping applications. dynamic lift capability will assure that loss-of-prime issues will be
They have been designed and manufactured to the highest eliminated. In addition, pump efficiency can be adversely affected
standards and are available in a variety of liquid path materials to if proper attention is not given to site location.
meet your chemical resistance needs. Refer to the performance
PIPING: Final determination of the pump site should not be made
section of this manual for an in-depth analysis of the performance
until the piping challenges of each possible location have been
characteristics of your pump. Wilden offers the widest variety of
evaluated. The impact of current and future installations should be
elastomer options in the industry to satisfy temperature, chemical
considered ahead of time to make sure that inadvertent restrictions
compatibility, abrasion resistance and flex concerns.
are not created for any remaining sites.
The suction pipe size should be at least the equivalent or larger
For U.L. listed pumps, all installation must conform with NFPA 30,
than the diameter size of the suction inlet on your Wilden
NFPA 30A and other applicable codes. All pipe connections are to
pump. The suction hose must be non-collapsible, reinforced
be made using U.L. classified gasoline-resistant pipe compound.
type as these pumps are capable of pulling a high vacuum.
Exhaust port is to be connected to pipe or tubing to be routed
Discharge piping should also be the equivalent or larger than
outdoors or other location determined to be equivalent.
the diameter of the pump discharge which will help reduce
friction losses. It is critical that all fittings and connections The best choice possible will be a site involving the shortest and
are airtight or a reduction or loss of pump suction capability straightest hook-up of suction and discharge piping. Unnecessary
will result. elbows, bends and fittings should be avoided. Pipe sizes should
be selected to keep friction losses within practical limits. All piping
INSTALLATION: Months of careful planning, study and selection
should be supported independently of the pump. In addition, the
efforts can result in unsatisfactory pump performance if installation
piping should be aligned to avoid placing stress on the pump
details are left to chance.
fittings.
Premature failure and long-term dissatisfaction can be avoided if
Flexible hose can be installed to aid in absorbing the forces created
reasonable care is exercised throughout the installation process.
by the natural reciprocating action of the pump. If the pump is
LOCATION: Noise, safety and other logistical factors usually to be bolted down to a solid location, a mounting pad placed
dictate where equipment will be situated on the production floor. between the pump and the foundation will assist in minimizing
Multiple installations with conflicting requirements can result pump vibration. Flexible connections between the pump and
in congestion of utility areas, leaving few choices for additional rigid piping will also assist in minimizing pump vibration. If quick-
pumps. closing valves are installed at any point in the discharge system,
or if pulsation within a system becomes a problem, a surge
Within the framework of these and other existing conditions,
suppressor (SD Equalizer®) should be installed to protect the
every pump should be located in such a way that six key factors
pump, piping and gauges from surges and water hammer.
are balanced against each other to maximum advantage.
If the pump is to be used in a self-priming application, make sure
ACCESS: First of all, the location should be accessible. If it’s easy
that all connections are airtight and that the suction lift is within
to reach the pump, maintenance personnel will have an easier
the model’s ability. NOTE: Materials of construction and elastomer
time carrying out routine inspections and adjustments. Should
material have an effect on suction-lift parameters. Please refer to
major repairs become necessary, ease of access can play a key
the performance section for specifics.
role in speeding the repair process and reducing total downtime.
When pumps are installed in applications involving flooded
AIR SUPPLY: Every pump location should have an air line large
suction or suction head pressures, a gate valve should be installed
enough to supply the volume of air necessary to achieve the
in the suction line to permit closing of the line for pump service.
desired pumping rate. Use air pressure up to a maximum of 8.6
bar (125 psig) depending on pumping requirements. Pumps in service with a positive suction head are most efficient
when inlet pressure is limited to 0.5–0.7 bar (7–10 psig). Premature
For best results, the pumps should use a 5µ (micron) air filter,
diaphragm failure may occur if positive suction is 0.7 bar (10 psig)
needle valve and regulator. The use of an air filter before the pump
and higher.
will ensure that the majority of any pipeline contaminants will be
eliminated. SUBMERSIBLE APPLICATIONS: Pro-Flo® SHIFT pumps can be
used for submersible applications when using the Pro-Flo®
SOLENOID OPERATION: When operation is controlled by a
SHIFT's single-point exhaust option. Pro-Flo X™ and Turbo-Flo®
solenoid valve in the air line, three-way valves should be used.
Pumps are also available in a single-point exhaust (submersible)
This valve allows trapped air between the valve and the pump to
configuration.
bleed off which improves pump performance. Pumping volume
can be estimated by counting the number of strokes per minute NOTE: Pro-Flo® and Accu-Flo™ pumps are not submersible.
and then multiplying the figure by the displacement per stroke.
ALL WILDEN PUMPS ARE CAPABLE OF PASSING SOLIDS. A
MUFFLER: Sound levels are reduced below OSHA specifications STRAINER SHOULD BE USED ON THE PUMP INTAKE TO ENSURE
using the standard Wilden muffler. Other mufflers can be THAT THE PUMP'S RATED SOLIDS CAPACITY IS NOT EXCEEDED.
used to further reduce sound levels, but they usually reduce
CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR SUPPLY
pump performance.
PRESSURE.

WIL-11560-E-01 8 WILDEN PUMP & ENGINEERING, LLC


S U G G E S T E D I N S TA L L AT I O N

This illustration is a generic GAUGE


representation of an air-operated (OPTIONAL)
double-diaphragm pump. EQUALIZER SHUT-OFF
SURGE DAMPENER
VALVE
(OPTIONAL)
DISCHARGE

FLEXIBLE
CONNECTION

MUFFLER

FLEXIBLE
CONNECTION
SUCTION NEEDLE VALVE

COMBINATION
FILTER & REGULATOR

AIR SHUT-OFF VALVE

FOOTPAD

NOTE: In the event of a power failure, the shut-off valve AIR-OPERATED PUMPS: To stop the pump from operating in
should be closed, if the restarting of the pump is not an emergency situation, simply close the shut-off valve (user-
desirable once power is regained. supplied) installed in the air supply line. A properly functioning
valve will stop the air supply to the pump, therefore stopping
output. This shut-off valve should be located far enough away
from the pumping equipment such that it can be reached
safely in an emergency situation.

S U G G E S T E D O P E R AT I O N
OPERATION: The Pro-Flo X™ pumps are pre-lubricated Pump discharge rate can be controlled by limiting the
and do not require in-line lubrication. Additional volume and/or pressure of the air supply to the pump. A
lubrication will not damage the pump, however if the regulator is used to control air pressure while a needle
pump is heavily lubricated by an external source, the valve is used to control volume. Pump discharge rate
pump’s internal lubrication may be washed away. If the can also be controlled by throttling the pump discharge
pump is then moved to a non-lubricated location, it may by partially closing a valve in the discharge line of the
need to be disassembled and re-lubricated as described pump. This action increases friction loss which reduces
in the EOM DISASSEMBLY / REASSEMBLY flow rate. (See Section 5.) This is useful when the need
INSTRUCTIONS. exists to control the pump from a remote location.
When the pump discharge pressure equals or exceeds
the air supply pressure, the pump will stop; no bypass
or pressure relief valve is needed, and pump damage
will not occur. The pump has reached a “deadhead”
situation and can be restarted by reducing the fluid
discharge pressure or increasing the air inlet pressure.
The Pro-Flo X™ pumps run solely on compressed air
and do not generate heat, therefore your process fluid
temperature will not be affected.

WILDEN PUMP & ENGINEERING, LLC 9 WIL-11560-E-01


Where Innovation Flows
PSG® reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document. 09-2017

wilden-pumps.com

WIL-11560-E-01