Professional Documents
Culture Documents
Engineering
Operation &
Original™ Series PLASTIC Pumps Maintenance
WIL-10130-E-04
REPLACES WIL-10130-E-03
TA B L E O F C O N T E N T S
SECTION 5 PERFORMANCE
A. P8 PLASTIC Performance
Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Ultra-FlexTM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
B. Suction Lift Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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Section 1
CAUTIONS – READ FIRST
CAUTION: Do not apply compressed air to the exhaust CAUTION: Do not exceed 8.6 bar (125 psig) air supply
port — pump will not function. pressure.
CAUTION: Do not over lubricate air supply — excess CAUTION: Before any maintenance or repair is
lubrication will reduce pump performance. attempted, the compressed air line to the pump should
TEMPERATURE LIMITS: be disconnected and all air pressure allowed to bleed
Polypropylene 0°C to 79°C 32°F to 175°F from pump. Disconnect all intake, discharge and air
PVDF –12°C to 107°C 10°F to 225°F lines. Drain the pump by turning it upside down and
Neoprene –17.7°C to 93.3°C 0°F to 200°F allowing any fluid to flow into a suitable container.
Buna-N –12.2°C to 82.2°C 10°F to 180°F CAUTION: Blow out air line for 10 to 20 seconds
EPDM –51.1°C to 137.8°C –60°F to 280°F before attaching to pump to make sure all pipeline
Viton® –40°C to 176.7°C –40°F to 350°F debris is clear. Use an in-line air filter. A 5µ micron air
Wil-Flex™ –40°C to 107.2°C –40°F to 225°F filter is recommended.
Saniflex™ –28.9°C to 104.4°C –20°F to 220°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
Tetra-Flex™ 4.4°C to 107.2°C 40°F to 225°F opposite directions) to ensure tight fit.
PTFE 4.4°C to 104.4°C 40°F to 220°F
NOTE: P8 PVDF pumps come standard from the
factory with expanded PTFE gaskets installed in the
CAUTION: When choosing pump materials, be sure diaphragm bead of the liquid chamber, in the T-section
to check the temperature limits for all wetted compo- and in the ball and seat area. PTFE gaskets cannot
nents. Example: Viton® has a maximum limit of 176.7°C be re-used. Consult PS-TG for installation instructions
(350°F) but polypropylene has a maximum limit of only during reassembly.
79°C (175°F).
NOTE: Before starting disassembly, mark a line from
CAUTION: Maximum temperature limits are based each liquid chamber to its corresponding air cham-
upon mechanical stress only. Certain chemicals will ber. This line will assist in proper alignment during
significantly reduce maximum safe operating tempera- reassembly.
tures. Consult engineering guide for chemical compat-
ibility and temperature limits. CAUTION: The P8 Plastic pump is not submersible. If
your application requires your pump to be submersed,
CAUTION: Always wear safety glasses when operat- the T8 model can be used.
ing pump. If diaphragm rupture occurs, material being
pumped may be forced out air exhaust. CAUTION: Pumps should be flushed thoroughly with
water before installation into process line.
Plastic series pumps are made of virgin plastic and are
not UV stabilized. Direct sunlight for prolonged periods CAUTION: Tighten all hardware prior to installation.
can cause deterioration of plastics.
WARNING: Prevention of static sparking — If static
sparking occurs, fire or explosion could result. Pump,
valves, and containers must be grounded when
handling flammable fluids and whenever discharge
of static electricity is a hazard. To ground the Wilden
“Champ,” all clamp bands must be grounded to a
proper grounding point.
P8 ORIGINAL™ LEGEND
PLASTIC P8 / X X X X X / XXX / XX / X XX / XXXX
O-RINGS
51 mm (2") Pump MODEL VALVE SEAT SPECIALTY
VALVE BALLS CODE
Maximum Flow Rate: DIAPHRAGMS
AIR VALVE
(if applicable)
MATERIAL CODES
WETTED PARTS & OUTER DIAPHRAGMS VALVE BALL
PISTON BNS = BUNA-N (Red Dot) BN = BUNA-N (Red Dot)
KK = PVDF / PVDF BNU = BUNA-N, ULTRA- EP = EPDM (Blue Dot)
PP = POLYPROPYLENE / FLEX™ NE = NEOPRENE (Green
POLYPROPYLENE EPS = EPDM (Blue Dot) Dot)
EPU = EPDM, ULTRA- PU = POLYURETHANE
AIR CHAMBERS FLEX™ (Brown)
A = ALUMINUM FSS = SANIFLEX™ TF = PTFE (White)
C = PTFE COATED [Hytrel® (Cream)] VT = VITON® (White Dot)
ALUMINUM NES = NEOPRENE (Green WF = WIL-FLEX™
S = STAINLESS STEEL Dot) [Santoprene® (Orange
V = HALAR® COATED NEU = NEOPRENE, ULTRA- Dot)]
ALUMINUM FLEX™
PUS = POLYURETHANE VALVE SEAT
CENTER BLOCK (Clear) K = PVDF
P = POLYPROPYLENE TEU = PTFE W/EPDM P = POLYPROPYLENE
BACK-UP (White)
AIR VALVE TNU = PTFE W/NEOPRENE VALVE SEAT O-RING
P = POLYPROPYLENE BACK-UP (White) BN = BUNA-N (Red Dot)
VTS = VITON® (White Dot) PU = POLYURETHANE
VTU = VITON®, ULTRA- (Brown)
FLEX™ TV = PTFE ENCAP. VITON®
WFS = WIL-FLEX™ WF = WIL-FLEX™
[Santoprene® [Santoprene® (Orange
(Orange Dot)] Dot)]
SPECIALTY CODES
0100 Wil-Gard II™ 110V 0513 SS outer pistons 0608 PFA coated hardware, Wil-
0102 Wil-Gard II™, sensor wires ONLY 0560 Split manifold Gard II™ 220V
0103 Wil-Gard II™ 220V 0561 Split manifold, PFA coated 0660 Split manifold, Wil-Gard II™ 110V
0206 PFA coated hardware, hardware 0661 Split manifold, PFA coated
Wil-Gard II™ sensor wires only 0563 Split manifold, discharge only hardware, Wil-Gard II™ 110V
0502 PFA coated hardware 0564 Split manifold, inlet only
P 8 P l as t i c
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 490 19.3
13 mm B 76 3.0
(1/2") FNPT 19 mm
C 693 27.3
(3/4") FNPT
D 770 30.3
E 409 16.1
F 89 3.5
G 417 16.4
H 333 13.1
J 386 15.2
K 307 12.1
L 229 9.0
M 254 10.0
N 15 0.6
METRIC (mm) STANDARD (inch)
P 61 RAD. 2.4 RAD.
R 76 RAD. 3.0 RAD.
S 20 RAD. 0.8 DIA.
P8 PLASTIC
RUBBER-FITTED
Height .................................. 770 mm (30.3")
Width ................................... 490 mm (19.3")
Depth .................................. 333 mm (13.1")
Est. Ship Weight...... Polypropylene 34 kg (75 lbs)
PVDF 43 kg (95 lbs)
Air Inlet ....................................13 mm (1/2")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ........................... 7.0 m Dry (23')
9.45 m Wet (31')
Displacement per
Stroke ......................... 2.91 l (0.77 gal.)1
Max. Flow Rate ............... 587 lpm (155 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 bar (30 psig)
head pressure.
Example: To pump 291.5 lpm (77 gpm)
against a discharge pressure head of 2.0 bar
(30 psig) requires 4.1 bar (60 psig) and 68 Flow rates indicated on chart were determined by pumping water.
Nm3/h (40 scfm ) air consumption. (See dot
on chart.) For optimum life and performance, pumps should be specified so that daily operation parameters
will fall in the center of the pump performance curve.
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
P8 PLASTIC
ULTRA-FLEXTM-FITTED
Height .................................. 770 mm (30.3")
Width ................................... 490 mm (19.3")
Depth .................................. 333 mm (13.1")
Est. Ship Weight...... Polypropylene 34 kg (75 lbs)
PVDF 43 kg (95 lbs)
Air Inlet ....................................13 mm (1/2")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ......................... 4.88 m Dry (16')
8.84 m Wet (29')
Displacement per
Stroke ......................... 2.12 l (0.56 gal.)1
Max. Flow Rate ............... 560 lpm (148 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 bar (30 psig) [LPM]
head pressure. Water Discharge Flow Rates
Example: To pump 257.4 lpm (68 gpm)
against a discharge pressure head of 2.0
bar (30 psig) requires 4.1 bar (60 psig) and Flow rates indicated on chart were determined by pumping water.
76.5 Nm3/h (45 scfm) air consumption. (See
dot on chart.) For optimum life and performance, pumps should be specified so that daily operation parameters
will fall in the center of the pump performance curve.
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
P8 PLASTIC
TPE-FITTED
Height.................................. 770 mm (30.3")
Width ................................... 490 mm (19.3")
Depth .................................. 333 mm (13.1")
Est. Ship Weight...... Polypropylene 34 kg (75 lbs)
PVDF 43 kg (95 lbs)
Air Inlet ....................................13 mm (1/2")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ......................... 5.18 m Dry (17')
9.45 m Wet (31')
Displacement per
Stroke .......................... 2.91 l (0.77 gal.)1
Max. Flow Rate ............... 575 lpm (152 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 bar (30 psig)
head pressure.
Example: To pump 283.9 lpm (75 gpm)
against a discharge pressure head of 2.1
bar (30 psig) requires 4.1 bar (60 psig) and
Flow rates indicated on chart were determined by pumping water.
76.5 Nm3/h (45 scfm) air consumption. (See
dot on chart.) For optimum life and performance, pumps should be specified so that daily operation parameters
Caution: Do not exceed 8.6 bar (125 psig ) air will fall in the center of the pump performance curve.
supply pressure.
P8 PLASTIC
PTFE-FITTED
P8 PLASTIC
SUCTION LIFT
C A PA B I L I T Y
PTFE Diaphragms
Suction lift curves are calibrated for pumps operating at and discharge elbows, viscosity of pumping fluid, elevation
305 m (1,000') above sea level. This chart is meant to be (atmospheric pressure) and pipe friction loss all affect the
a guide only. There are many variables which can affect amount of suction lift your pump will attain.
your pump’s operating characteristics. The number of intake
AIR-OPERATED PUMPS: To stop the pump from operating in an emergency NOTE: In the event of a power failure, the shutoff valve should be closed, if the
situation, simply close the “shut-off” valve (user supplied) installed in the air restarting of the pump is not desirable once power is regained.
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.
OPERATION: The P8 is pre-lubricated, and does not require The Wilden P8 pump runs solely on compressed air and does
in-line lubrication. Additional lubrication will not damage the not generate heat, therefore your process fluid temperature
pump, however if the pump is heavily lubricated by an external will not be affected.
source, the pump’s internal lubrication may be washed away.
MAINTENANCE AND INSPECTIONS: Since each application
If the pump is then moved to a non-lubricated location, it may
is unique, maintenance schedules may be different for every
need to be disassembled and re-lubricated as described in
pump. Frequency of use, line pressure, viscosity and abra-
the ASSEMBLY/DISASSEMBLY INSTRUCTIONS.
siveness of process fluid all affect the parts life of a Wilden
Pump discharge rate can be controlled by limiting the volume pump. Periodic inspections have been found to offer the best
and/or pressure of the air supply to the pump (preferred means for preventing unscheduled pump downtime. Person-
method). An air regulator is used to regulate air pressure. nel familiar with the pump’s construction and service should
A needle valve is used to regulate volume. Pump discharge be informed of any abnormalities that are detected during
rate can also be controlled by throttling the pump discharge operation.
by partially closing a valve in the discharge line of the pump.
RECORDS: When service is required, a record should be
This action increases friction loss which reduces flow rate.
made of all necessary repairs and replacements. Over a
(See Section 5.) This is useful when the need exists to control
period of time, such records can become a valuable tool for
the pump from a remote location. When the pump discharge
predicting and preventing future maintenance problems and
pressure equals or exceeds the air supply pressure, the
unscheduled downtime. In addition, accurate records make
pump will stop; no bypass or pressure relief valve is needed,
it possible to identify pumps that are poorly suited to their
and pump damage will not occur. The pump has reached a
applications.
“deadhead” situation and can be restarted by reducing the
fluid discharge pressure or increasing the air inlet pressure.
TROUBLESHOOTING
Pump will not run or runs slowly. 2. Verify that vacuum required to lift liquid is not greater
1. Ensure that the air inlet pressure is at least 0.4 bar (5 psig) than the vapor pressure of the material being pumped
above startup pressure and that the differential pressure (cavitation).
(the difference between air inlet and liquid discharge 3. Check for sticking ball check valves. If material being
pressures) is not less than 0.7 bar (10 psig). pumped is not compatible with pump elastomers, swell-
2. Check air inlet filter for debris (see recommended instal- ing may occur. Replace ball check valves and seals with
lation). proper elastomers. Also, as the check valve balls wear
3. Check for extreme air leakage (blow by) which would out, they become smaller and can become stuck in the
indicate worn seals/bores in the air valve, pilot spool and seats. In this case, replace balls and seats.
main shaft.
4. Disassemble pump and check for obstructions in the air Pump air valve freezes.
passageways or objects which would obstruct the move- 1. Check for excessive moisture in compressed air. Either
ment of internal parts. install a dryer or hot air generator for compressed air.
5. Check for sticking ball check valves. If material being Alternatively, a coalescing filter may be used to remove
pumped is not compatible with pump elastomers, swell- the water from the compressed air in some applications.
ing may occur. Replace ball check valves and seals with
proper elastomers. Also, as the check valve balls wear Airbubbles in pump discharge.
out, they become smaller and can become stuck in the 1. Check for ruptured diaphragm.
seats. In this case, replace balls and seats. 2. Check tightness of outer pistons. (Refer to Section 8C.)
6. Check for broken inner piston which will cause the air 3. Check tightness of clamp bands and integrity of o-rings
valve spool to be unable to shift. and seals, especially at intake manifold.
7. Remove plug from pilot spool exhaust. 4. Ensure pipe connections are airtight.
Pump runs but little or no product flows. Product comes out air exhaust.
1. Check for pump cavitation; slow pump speed down to 1. Check for diaphragm rupture.
allow thick material to flow into the liquid chambers. 2. Check tightness of outer pistons to shaft.
TOOLS REQUIRED:
1/2" Wrench
11/16" Wrench
Adjustable Wrench
Vise equipped with soft jaws (such as plywood, plastic
DISASSEMBLY: Figure 1
or other suitable material)
NOTE: The model used for these instructions incorporates Step 1.
rubber diaphragms, balls, and seats. Models with PTFE Before starting disassembly, mark a line from each liquid
diaphragms, balls and seats are the same except where chamber to its corresponding air chamber. This line will assist
noted. in proper alignment during reassembly.
TOOLS REQUIRED:
3/16" Hex Head Wrench
7/32" Hex Head Wrench
Snap Ring Pliers Step 1. Figure 1
Phillips Head Screwdriver
Loosen the air valve bolts utilizing a 3/16" hex head wrench
O-ring Pick
and then remove muffler plate screws with a Phillips head
screwdriver.
Figure A Figure B
NEEDLE NOSE
PLIERS
GLIDE RING
TAPE
GLIDE RING
TAPE
P8 PLASTIC R U B B E R / T P E - F I T T E D O R U LT R A - F L E X TM- F I T T E D PA R T S L I S T I N G
P8 PLASTIC PTFE-FITTED PA R T S L I S T I N G
P8 Plastic
Traditional ULTRA-FLEX™ VALVE SEAT O- MANIFOLD O-
MATERIAL Diaphragms (2) DIAPHRAGMS (2) RINGS (4) RINGS (4) VALVE BALL (4)
Polyurethane 08-1010-50 N/A 08-1200-50-500 08-1300-50-500 08-1080-50
Neoprene 08-1010-51 08-1020-51 N/A N/A 08-1080-51
Buna-N 08-1010-52 08-1020-52 08-1200-52-500 08-1300-52-500 08-1080-52
EPDM 08-1010-54 08-1020-54 N/A N/A 08-1080-54
Viton® 08-1010-53 08-1020-53 N/A N/A 08-1080-53
Saniflex™ 08-1010-56 N/A N/A N/A 08-1080-56
PTFE 08-1010-553 N/A N/A N/A 08-1080-55
Neoprene Backup 08-1060-51 N/A N/A N/A N/A
Wil-Flex™ 08-1010-58 N/A 08-1200-58-500 08-1300-58-500 08-1080-58
PTFE Encap. (Viton®) N/A N/A 08-1200-60-500 08-1300-60-500 N/A
NOTES
PTFE-encapsulated Viton® O-rings, P/N 08-1200-60-500 and P/N 08-1300-60-500, are standard on all PTFE-fitted pumps.
PTFE diaphragm, P/N 08-1010-55, must be used with Neoprene back-up diaphragms, P/N 08-1060-51.
Item # Serial #
Y O U R I N F O R M AT I O N
Company Name
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Street Address
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