Professional Documents
Culture Documents
Engineering
Operation &
Original™ Series PLASTIC Pumps Maintenance
WIL-10070-E-03
REPLACES WIL-10070-E-02
TABLE OF CONTENTS
PAGE #
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SECTION 1
A2 PLASTIC
CAUTIONS – READ FIRST!
TEMPERATURE LIMITS: CAUTION: Blow out air line for 10 to 20 seconds
Polypropylene 0°C to 79°C 32°F to 175°F before attaching to pump to make sure all pipe line
PVDF –12°C to 107°C 10°F to 225°F debris is clear. Use an in-line air filter. A 5µ (micron) air
Neoprene –17.8°C to 93.3°C 0°F to 200°F filter is recommended.
Buna-N –12.2°C to 82.2°C 10°F to 180°F NOTE: Tighten clamp bands and retainers prior to
EPDM –51.1°C to 137.8°C –60°F to 280°F installation. Fittings may loosen during transportation.
Viton ®
–40°C to 176.7°C –40°F to 350°F
Wil-Flex™ –40°C to 107.2°C –40°F to 225°F NOTE: When installing PTFE diaphragms, it is impor-
Polyurethane 12.2°C to 65.6°C 10°F to 150°F tant to tighten outer pistons simultaneously (turning in
Saniflex™ –28.9°C to 104.4°C –20°F to 220°F opposite directions) to ensure tight fit.
PTFE 4.4°C to 104.4°C 40°F to 220°F NOTE: Before starting disassembly, mark a line from
CAUTION: When choosing pump materials, be sure each liquid chamber to its corresponding air chamber.
to check the temperature limits for all wetted compo- This line will assist in proper alignment during reas-
nents. Example: Viton has a maximum limit of 176.7°C sembly.
(350°F) but polypropylene has a maximum limit of only CAUTION: Verify the chemical compatibility of the
79°C (175°F). process and cleaning fluid to the pump’s component
CAUTION: Maximum temperature limits are based materials in the Chemical Resistance Guide (see RBG
upon mechanical stress only. Certain chemicals will E4).
significantly reduce maximum safe operating tempera- CAUTION: Only explosion proof (NEMA 7) solenoid
tures. Consult engineering guide for chemical compat- valves should be used in areas where explosion proof
ibility and temperature limits. equipment is required.
CAUTION: Always wear safety glasses when operat- CAUTION: Do not lubricate lube-free pumps.
ing pump. If diaphragm rupture occurs, material being
pumped may be forced out air exhaust.
CAUTION: The A2 pump is not submersible.
WARNING: Prevention of static sparking — If static
sparking occurs, fire or explosion could result. Pump,
valves, and containers must be properly grounded when NOTE: When reinstalling the outer pistons, apply
handling flammable fluids and whenever discharge of two (2) drops of Loctite® 246 to the shaft internal
static electricity is a hazard. threads before the diaphragm assembly.
CAUTION: Do not exceed 8.6 bar (125 psig) air supply
pressure.
CAUTION: Plastic series pumps are made of virgin
plastic and are not UV stabilized. Direct sunlight for
prolonged periods can cause deterioration of plastics.
CAUTION: Before any maintenance or repair is
attempted, the compressed air line to the pump should
be disconnected and all air pressure allowed to bleed
from pump. Disconnect all intake, discharge and air
lines. Drain the pump by turning it upside down and
allowing any fluid to flow into a suitable container.
FIGURE 1 When the solenoid is ener- FIGURE 2 When the solenoid valve is FIGURE 3 Once the solenoid valve is
gized, the air valve directs pressure deenergized, the air valve redirects pres- reenergized, the air is directed to the
to the back side of diaphragm A. The surized air to the back side of diaphragm back side of diaphragm A, which starts
compressed air is applied directly to the B. The pressurized air forces diaphragm diaphragm B on its exhaust stroke. As
liquid column separated by elastomeric B away from the center section while the pump reaches its original starting
diaphragms. The diaphragm acts as pulling diaphragm A to the center point, each diaphragm has gone through
a membrane between the compressed section. Diaphragm B is now on its one intake and one discharge stroke.
air and the liquid, balancing the load discharge stroke. Diaphragm B forces This constitutes one complete pump-
and removing mechanical stress from the inlet valve ball onto its seat due ing cycle. The pump may take several
the diaphragm. The compressed to the hydraulic forces developed in cycles to completely prime depending
air moves the diaphragm away from the liquid chamber and manifold of the on the conditions of the application.
the center section of the pump. The pump. These same hydraulic forces lift
opposite diaphragm is pulled in by the discharge valve ball off of its seat,
the shaft connected to the pressur- while the opposite discharge valve ball
ized diaphragm. Diaphragm B is on its is forced onto its seat, forcing fluid to
suction stroke; air behind the diaphragm flow through the pump discharge. The
has been forced out to the atmosphere movement of diaphragm A toward the
through the exhaust port. The move- center section of the pump creates a
ment of diaphragm B toward the center vacuum within liquid chamber A. Atmo-
section of the pump creates a vacuum spheric pressure forces fluid into the
within chamber B. Atmospheric pres- inlet manifold of the pump. The inlet
sure forces fluid into the inlet manifold valve ball is forced off of its seat allowing
forcing the inlet valve ball off of its seat. the fluid being pumped to fill the liquid
Liquid is free to move past the inlet chamber.
valve ball and fill the liquid chamber (see
shaded area).
N P
L
K
R
FLANGE
150 pound class
M
SECTION 4B
DIMENSIONAL DRAWING
A2B PLASTIC (T-SERIES CENTER SECTION)
A G H 25 mm (1”)
6 mm (1/4”) ANSI/DIN DIMENSIONS
BSP (FNPT) FLANGE
AIR INLET LIQUID ITEM METRIC (mm) STANDARD (inch)
DISCHARGE
A 297 11.7
C B 74 2.9
C 150 5.9
D 173 6.8
F E 251 9.9
F 335 13.2
E G 69 2.7
H 107 4.2
D
C J 239 9.4
B K 114 4.5
L 137 5.4
M 124 4.9
25 mm (1”) J N 157 6.2
K ANSI/DIN FLANGE
LIQUID INLET P 10 0.4
L
R 79 DIA. 3.1 DIA.
S 109 DIA. 4.3 DIA.
R T 15 DIA. 0.6 DIA.
S
N
M
T
FLANGE
150 pound class
P
U
FLANGE
R 150 pound class
SECTION 4D
DIMENSIONAL DRAWING
A2B PLASTIC (P-SERIES CENTER SECTION)
25 mm (1”) H
A ANSI/DIN G DIMENSIONS
FLANGE LIQUID
DISCHARGE ITEM METRIC (mm) STANDARD (inch)
A 297 11.7
B 74 2.9
C 168 6.6
D 188 7.4
E 307 12.1
F 356 14.0
G 66 2.6
F
H 107 4.2
E
J 239 9.4
6 mm D
(1/4”) K 114 4.5
BSP C
L 137 5.4
(FNPT) B
AIR M 124 4.9
INLET N 157 6.2
25 mm (1”) P 10 0.4
K ANSI/DIN FLANGE J
LIQUID INLET R 79 DIA. 3.1 DIA.
L
S 109 DIA. 4.3 DIA.
T 15 DIA. 0.6 DIA.
R S
N
M
T
FLANGE
P 150 pound class
SECTION 5B
PERFORMANCE CURVES
A2T PLASTIC PTFE-FITTED
Height.................................. 335 mm (13.2”)
Width ................................... 297 mm (11.7”)
Depth .................................... 239 mm (9.4”)
Est. Ship Weight..........Polypropylene 8 kg (18 lbs)
PVDF 10 kg (23 lbs) [Nm3/h]
Air Inlet ......................................6 mm (1/4”)
Inlet ............................................ 25 mm (1”)
Outlet ......................................... 25 mm (1”)
Suction Lift ....................... 3.5 m Dry ( 11.3’)
9.3 m Wet ( 30.6’)
Displacement per
Stroke ......................... 0.05 l (0.014 gal.)1
Max. Flow Rate ................... 61 lpm (16 gpm)
Max. Size Solids .....................3.2 mm (1/8”)
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 18.95 lpm (5 gpm)
[LPM]
against a discharge pressure head of 2.8
bar (40 psig) requires 4.1 bar (60 psig) and
15.3 Nm3/h (9 scfm) air consumption. (See
dot on chart.) Flow rates indicated on chart were determined by pumping water.
Caution: Do not exceed 8.6 bar (125 psig) air For optimum life and performance, pumps should be specified so that daily operation parameters
supply pressure. will fall in the center of the pump performance curve.
SECTION 5D
PERFORMANCE CURVES
A2P PLASTIC PTFE-FITTED
Height .................................. 356 mm (14.0”)
Width ................................... 297 mm (11.7”)
Depth .................................. 259 mm (10.2”)
Est. Ship Weight..........Polypropylene 8 kg (18 lbs)
PVDF 10 kg (23 lbs) [Nm3/h]
Air Inlet ......................................6 mm (1/4”)
Inlet ............................................ 25 mm (1”)
Outlet ......................................... 25 mm (1”)
Suction Lift ....................... 5.2 m Dry ( 17.0’)
9.0 m Wet ( 29.5’)
Displacement per
Stroke ......................... 0.11 l (0.028 gal.)1
Max. Flow Rate ................. 110 lpm (29 gpm)
Max. Size Solids .....................3.2 mm (1/8”)
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 37.9 lpm (10 gpm)
[LPM]
against a discharge pressure head of 3.2
bar (48 psig) requires 4.1 bar (60 psig) and
32.3 Nm3/h (19 scfm) air consumption. (See
dot on chart.) Flow rates indicated on chart were determined by pumping water.
Caution: Do not exceed 8.6 bar (125 psig) air For optimum life and performance, pumps should be specified so that daily operation parameters
supply pressure. will fall in the center of the pump performance curve.
These curves
demonstrate the
flow created when
the stroke rate is
modified under
static air and fluid
pressure condition.
This curve can be
applied to different
pressure conditions
to estimate the
change in flow due
to stroke rate.
SECTION 6B
70/30 OPERATING CONDITION
A2P PLASTIC PLASTIC ACCU-FLO™
These curves
demonstrate the
flow created when
the stroke rate is
modified under
static air and fluid
pressure condition.
This curve can be
applied to different
pressure conditions
to estimate the
change in flow due
to stroke rate.
The suction pipe used for installation should be sized equal The best choice possible will be a site involving the shortest
to, or greater than, the pump liquid inlet connection. This and straightest hook-up of suction and discharge piping.
will minimize pump cavitation and potential blockages of the Unnecessary elbows, bends, and fittings should be avoided.
pump inlet. The discharge piping should also be sized equal Pipe sizes should be selected so as to keep friction losses
to, or greater than, the pump liquid discharge connection. within practical limits. All piping should be supported inde-
If the pump is to be used in a self-priming application, be pendently of the pump to avoid damage. In addition, the
sure that all connections are airtight and that the suction lift piping should be aligned so as to avoid placing stress on the
pump fittings.
is within the pump’s ability. (Consult manual for suction lift
information.) Note: Materials of construction and elastomer Flexible hose can be installed to aid in absorbing the forces
materials have an effect on suction lift parameters. created by the natural reciprocating action of the pump. If
the pump is to be bolted down to a solid location, a mounting
INSTALLATION: Months of careful planning, study and selec-
pad placed between the pump and the foundation will assist
tion efforts can result in unsatisfactory pump performance if
in minimizing pump vibration. Flexible connections between
installation details are left to chance.
the pump and rigid piping will also assist in minimizing pump
Premature failure and long term dissatisfaction can be vibration. If quick-closing valves are installed at any point
avoided if reasonable care is exercised throughout the instal- in the discharge system, or if pulsation within a system
lation process. becomes a problem, a Wilden Equalizer surge dampener
should be installed to protect the pump, piping and gauges
LOCATION: Noise, safety, and other logistical factors from surges and water hammer. Installation of a tee at the
usually dictate that “utility” equipment be situated away from discharge of the pump will allow the addition of an Equalizer
the production floor. Multiple installations with conflicting to the system at a later date without requiring piping modifi-
requirements can result in congested utility areas, leaving few cations. Installation of inlet and discharge isolation valves are
choices for siting additional pumps. also recommended to make service and repair easier.
Within the framework of these and other existing conditions, Pumps in service with a positive suction head are most effi-
every pump should be located in such a way that four key cient when pressure is limited to 0.4 - 0.7 bar (7-10 psig).
factors are balanced against each other to maximum advan- Premature diaphragm failure may occur if positive suction
tage. exceeds these recommended pressures.
1. ACCESS: First of all, the location should be accessible. A STRAINER SHOULD BE USED ON THE SUCTION LINE
If it is easy to reach the pump, maintenance personnel will OF THE SYSTEM IF THERE IS A POSSIBILITY THAT
have an easier time carrying out routine inspections and SOLIDS ENTERING THE PUMP MAY EXCEED THE
adjustments. Should major repairs become necessary, ease PUMP’S SOLIDS HANDLING CAPABILITIES.
of access can play a key role in speeding the repair process
PLEASE READ AND FOLLOW ALL CAUTIONS NOTED IN
and reducing total downtime.
THIS MANUAL.
2. AIR SUPPLY: Every pump location should have an air
Pump should be thoroughly flushed before installing into
line large enough to supply the volume of air necessary to
process line.
achieve the desired pumping rate. (Consult manual for perfor-
mance information.) The use of an air filter before the pump Blow out air line for 10 to 20 seconds before attaching
will ensure that the majority of pipeline contaminants will be pump to clear all pipe line debris.
ACCU-FLO™ PLUMBING
CONNECTIONS
SECTION 7C – ACCU-FLO™
SUGGESTED OPERATION AND
MAINTENANCE INSTRUCTIONS
OPERATION: The speed of the pump is controlled electrically. RECORDS: When service is required, a record should be
Since each stroke is controlled by an electrical signal, the made of all necessary repairs and replacements. Over a
pump is ideal for batching and other electrically controlled period of time, such records can become a valuable tool for
dispensing applications. predicting and preventing future maintenance problems and
unscheduled downtime. In addition, accurate records make
The pump will not shift reliably unless the minimum supply it possible to identify pumps that are poorly suited to their
pressure is supplied. For the A2T the minimum supply pres- applications.
sure for reliable operation is 2.7 bar (40 psig).
MAINTENANCE AND INSPECTIONS: Since each applica-
The solenoid operated pump is permanently lubricated during tion is unique, maintenance schedules may be different for
assembly, and requires no additional lubrication under normal every pump. Frequency of use, line pressure, viscosity and
operation. If the unit runs under extreme conditions (continu- abrasiveness of process fluid all effect the parts life of a
ous operation at high speeds), it may be necessary to relubri- Wilden pump. Periodic inspections have been found to offer
cate the center block with a Buna-N compatible NLGI Grade the best means for preventing unscheduled pump downtime.
2 grease every 50 million cycles. Continuous lubrication with Personnel familiar with the pump’s construction and service
a compatible oil is not harmful, and will provide longer seal should be informed of any abnormalities that are detected
life, but it may flush all grease out of the unit. during operation. Internal maintenance is not recommended
A red button on the side of the air valve is a manual override; for Accu-Flo™ solenoid air valves. When worn or damaged,
when actuated it will shift the valve as if an electric current a new air valve body, coil or terminal connector must be
had actuated the solenoid. purchased. Please consult section 9 for part numbers.
TOOLS REQUIRED:
1/2” Box Wrench
1/2” Socket
3/16” Allen Wrench
1/2” Socket Drive DISASSEMBLY: Figure 1
2 – 1” Sockets or Adjustable Wrench Step 1.
Adjustable Wrench
Before starting disassembly, mark a line from each liquid
Vise equipped with soft jaws (such as plywood, plastic
chamber to its corresponding air chamber. This line will assist
or other suitable material)
in proper alignment during reassembly.
NOTE: The model used for these instructions incorporates PTFE
diaphragms, balls, and seats. Models with rubber diaphragms,
balls and seats are the same except where noted.
A2T
PLASTIC
ACCU-FLO™
Solenoid-Operated Valve Assembly Options (consists of valve body, coil and connector)
Pump Models Designating Specialty Code # Part Number Description
151 02-2000-99-151 24V AC / 12V DC Valve Assembly
153 02-2000-99-153 24V AC / 12V DC Valve Assembly (Nema 7)
150 02-2000-99-150 24V DC Valve Assembly
154 02-2000-99-154 24V DC Valve Assembly (Nema 7)
157 02-2000-99-157 International 24V DC Valve Assembly1
155 02-2000-99-155 110V AC Valve Assembly
156 02-2000-99-156 110V AC Valve Assembly (Nema 7)
A2P
PLASTIC
ACCU-FLO™
Standard
Assembly
SECTION 10B
ELECTRICAL INFORMATION
NEMA 4 / UL / CSA
Voltage ±10% Current (A)
AC AC
DC Power (W) DC Resistivity
Part Number 60 Hz 50 Hz ±10% Inrush Holding (Ω)
00-2110-99-150 24 48 44 4.8 .20 .20 .20 121
00-2110-99-151 12 24 22 4.8 .40 .40 .40 32
00-2110-99-155 60 120 110 4.8 .08 .08 .06 840
NEMA 7 / UL / CSA
Voltage ±10% Current (A)
AC AC
DC Power (W) DC Resistivity
Part Number 60 Hz 50 Hz ±10% Inrush Holding (Ω)
00-2110-99-153 12 24 22 7 .60 .55 .32 19
00-2110-99-154 24 48 44 7 .30 .30 .18 75
00-2110-99-156 60 120 110 7 .12 .13 .06 475
Item # Serial #
Y O U R I N F O R M AT I O N
Company Name
Industry
Name Title
Street Address
Types of pumps in facility (check all that apply): Diaphragm Centrifugal Gear Submersible Lobe
Other
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