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Advanced Series PLASTIC Pumps: Advance Your Process
Advanced Series PLASTIC Pumps: Advance Your Process
Engineering
Operation &
Advanced™ Series PLASTIC Pumps Maintenance
WIL-11050-E-02
®
TA B L E O F C O N T E N T S
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Section 1
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MATERIAL CODES
WETTED PARTS & OUTER PISTON DIAPHRAGMS VALVE BALL
KK = PVDF / PVDF BNS = BUNA-N (Red Dot) BN = BUNA-N (Red Dot)
PP = POLYPROPYLENE / FSS = SANIFLEX™ FS = SANIFLEX™
POLYPROPYLENE [Hytrel® (Cream)] [Hytrel® (Cream)]
PUS = POLYURETHANE (Clear) PU = POLYURETHANE (Brown)
CENTER SECTION THU = PTFE W/HI-TEMP TF = PTFE (White)
PP = POLYPROPYLENE BUNA-N BACK-UP (White) VT = VITON ® (White Dot)
TNL = PTFE W/NEOPRENE WF = WIL-FLEX™ [Santoprene ®
AIR VALVE BACK-UP O-RING, IPD (Orange Dot)]
P = POLYPROPYLENE (White)
TNU = PTFE W/NEOPRENE VALVE SEAT
BACK-UP (White) K = PVDF
VTS = VITON® (White Dot) P = POLYPROPYLENE
WFS = WIL-FLEX™ [Santoprene®
(Orange Dot)] VALVE SEAT O-RING
BN = BUNA-N
FS = SANIFLEX™
[Hytrel® (Cream)]
PU = POLYURETHANE (Brown)
TV = PTFE ENCAP. VITON®
WF = WIL-FLEX™ (Santoprene®)
SPECIALTY CODES
0014 BSPT
0102 Wil-Gard II™, sensor wires ONLY
0677 Center ported, NPT (Parts Only)
0678 Center ported, BSPT (Parts Only)
0680 P100 with OEM specific inlet manifold
0683 P100 with OEM specific inlet manifold, center
ported inlet and discharge manifolds, NPT
0790 P100 Advanced, drum pump inlet manifold
FIGURE 1 The air valve directs pressurized air to FIGURE 2 When the pressurized diaphragm, FIGURE 3 At completion of the stroke, the air valve
the back side of diaphragm A. The compressed diaphragm A, reaches the limit of its discharge again redirects air to the back side of diaphragm A,
air is applied directly to the liquid column sepa- stroke, the air valve redirects pressurized air to which starts diaphragm B on its exhaust stroke. As
rated by elastomeric diaphragms. The diaphragm the back side of diaphragm B. The pressurized air the pump reaches its original starting point, each
acts as a separation membrane between the forces diaphragm B away from the center section diaphragm has gone through one exhaust and one
compressed air and liquid, balancing the load and while pulling diaphragm A to the center section. discharge stroke. This constitutes one complete
removing mechanical stress from the diaphragm. Diaphragm B is now on its discharge stroke. pumping cycle. The pump may take several cycles
The compressed air moves the diaphragm away Diaphragm B forces the inlet valve ball onto its to completely prime depending on the conditions
from the center section of the pump. The opposite seat due to the hydraulic forces developed in the of the application.
diaphragm is pulled in by the shaft connected to liquid chamber and manifold of the pump. These
the pressurized diaphragm. Diaphragm B is on its same hydraulic forces lift the discharge valve ball
suction stroke; air behind the diaphragm has been off its seat, while the opposite discharge valve ball
forced out to the atmosphere through the exhaust is forced onto its seat, forcing fluid to flow through
port of the pump. The movement of diaphragm B the pump discharge. The movement of diaphragm
toward the center section of the pump creates a A toward the center section of the pump creates
vacuum within chamber B. Atmospheric pressure a vacuum within liquid chamber A. Atmospheric
forces fluid into the inlet manifold forcing the inlet pressure forces fluid into the inlet manifold of the
valve ball off its seat. Liquid is free to move past pump. The inlet valve ball is forced off its seat
the inlet valve ball and fill the liquid chamber (see allowing the fluid being pumped to fill the liquid
shaded area). chamber.
DIMENSIONAL DRAWING
P 10 0 Advance d ™ P l a s t i c
13 mm (1/2")
FNPT DIS- 6 mm (1/4")
FNPT AIR INLET F
CHARGE
13 mm
(1/2")
FNPT AIR
EXHAUST
D
E
13 mm (1/2")
FNPT INLET
C
J
A G
H
K
L
N M
PERFORMANCE
P10 0 Pla s t i c
RU BBE R - F I T T E D
Height .................................. 277 mm (10.9")
Width ..................................... 234 mm (9.2")
Depth .................................... 201 mm (7.9")
Est. Ship Weight............Polypropylene 4 kg (8 lbs)
PVDF 5 kg (10 lbs)
Air Inlet ......................................6 mm (1/4")
Inlet .........................................13 mm (1/2")
Outlet ......................................13 mm (1/2")
Suction Lift ........................ 5.2 m Dry (17.0')
8.7 m Wet (28.4')
Displacement per
Stroke ....................... 0.10 l (0.027 gal.)1
Max. Flow Rate ............. 56.0 lpm (14.8 gpm)
Max. Size Solids ...................1.6 mm (1/16")
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 32.9 lpm (8.7 gpm)
against a discharge head pressure of 4.1 Flow rates indicated on chart were determined by pumping water.
bar (60 psig) requires 5.5 bar (80 psig) and For optimum life and performance, pumps should be specified so that daily operation parameters
27.2 Nm3/h (16 scfm) air consumption. (See will fall in the center of the pump performance curve.
dot on chart.)
Caution: Do not exceed 8.6 bar (125
psig) air supply pressure.
P10 0 Pla s t i c
T PE -FIT T E D
Height .................................. 277 mm (10.9")
Width ..................................... 234 mm (9.2")
Depth .................................... 201 mm (7.9")
Est. Ship Weight............Polypropylene 4 kg (8 lbs)
PVDF 5 kg (10 lbs)
Air Inlet ......................................6 mm (1/4")
Inlet .........................................13 mm (1/2")
Outlet ......................................13 mm (1/2")
Suction Lift ........................ 5.5 m Dry (17.0')
8.7 m Wet (28.4')
Displacement per
Stroke ....................... 0.11 l (0.029 gal.)1
Max. Flow Rate ............. 58.7 lpm (15.5 gpm)
Max. Size Solids ...................1.6 mm (1/16")
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 34.8 lpm (9.2 gpm)
against a discharge head pressure of 2.4 Flow rates indicated on chart were determined by pumping water.
bar (35 psig) requires 4.1 bar (60 psig) and For optimum life and performance, pumps should be specified so that daily operation parameters
27.2 Nm3/h (16 scfm) air consumption. (See will fall in the center of the pump performance curve.
dot on chart.)
Caution: Do not exceed 8.6 bar (125
psig) air supply pressure.
PERFORMANCE
P 10 0 Pl as t i c
P TFE -FIT T E D
Height.................................. 277 mm (10.9")
Width ..................................... 234 mm (9.2")
Depth .................................... 201 mm (7.9")
Est. Ship Weight............Polypropylene 4 kg (8 lbs)
PVDF 5 kg (10 lbs)
Air Inlet ......................................6 mm (1/4")
Inlet .........................................13 mm (1/2")
Outlet ......................................13 mm (1/2")
Suction Lift ........................ 4.5 m Dry (14.7')
9.3 m Wet (30.6')
Displacement per
Stroke ....................... 0.10 l (0.027 gal.)1
Max. Flow Rate ............. 57.0 lpm (15.0 gpm)
Max. Size Solids ...................1.6 mm (1/16")
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 20.8 lpm (5.5 gpm)
against a discharge head pressure of 1.4 Flow rates indicated on chart were determined by pumping water.
bar (20 psig) requires 2.8 bar (40 psig) and For optimum life and performance, pumps should be specified so that daily operation parameters
13.6 Nm3/h (8 scfm) air consumption. (See will fall in the center of the pump performance curve.
dot on chart.)
Caution: Do not exceed 8.6 bar (125
psig) air supply pressure.
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 a (atmospheric pressure) and pipe friction loss all affect the
guide only. There are many variables which can affect your amount of suction lift your pump will attain.
pump’s operating characteristics. The number of intake
INS TA L L AT ION
The Pro-Flo® model P100 Advanced™ plastic has a 13 mm ELEVATION: Selecting a site that is well within the pump’s
(1/2") inlet and 13 mm (1/2") outlet and is designed for flows dynamic lift capability will assure that loss-of-prime trou-
to 58.7 lpm (15.5 gpm). The P100 Advanced™ plastic bles will be eliminated. In addition, pump efficiency can be
pump is manufactured with wetted parts of pure, unpig- adversely affected if proper attention is not given to site
mented Polypropylene or PVDF. The P100 Advanced™ location.
plastic pump is constructed with a glass fiber filled PP center
section. A variety of diaphragms and o-rings are available PIPING: Final determination of the pump site should not
to satisfy temperature, chemical compatibility, abrasion, and be made until the piping problems of each possible loca-
flex concerns. tion have been evaluated. The impact of current and future
installations should be considered ahead of time to make
The suction pipe size should be at least 13 mm (1/2”) diam- sure that inadvertent restrictions are not created for any
eter or larger if highly viscous material is being pumped. The remaining sites.
suction hose must be non-collapsible, reinforced type as the
P100 Advanced™ plastic pump is capable of pulling a high The best choice possible will be a site involving the shortest
vacuum. Discharge piping should be at least 13 mm (1/2”); and straightest hook-up of suction and discharge piping.
larger diameter can be used to reduce friction losses. It is Unnecessary elbows, bends, and fittings should be avoided.
critical that all fittings and connections are airtight or a reduc- Pipe sizes should be selected to keep friction losses within
tion or loss of pump suction capability will result. practical limits. All piping should be supported independently
of the pump. In addition, the piping should be aligned to
INSTALLATION: Months of careful planning, study, and avoid placing stresses on the pump fittings.
selection efforts can result in unsatisfactory pump perfor-
mance if installation details are left to chance. Flexible hose can be installed to aid in absorbing the forces
created by the natural reciprocating action of the pump. If
Premature failure and long term dissatisfaction can be the pump is to be bolted down to a solid location, a mount-
avoided if reasonable care is exercised throughout the instal- ing pad placed between the pump and the foundation will
lation process. assist in minimizing pump vibration. Flexible connections
between the pump and rigid piping will also assist in mini-
LOCATION: Noise, safety, and other logistical factors usually mizing pump vibration. If quick-closing valves are installed
dictate where equipment should be situated on the produc- at any point in the discharge system, or if pulsation within a
tion floor. Multiple installations with conflicting requirements system becomes a problem, a surge suppressor should be
can result in congestion of utility areas, leaving few choices installed to protect the pump, piping and gauges from surges
for additional pumps. and water hammer.
Within the framework of these and other existing condi- The P100 Advanced™ plastic Pro-Flo® equipped pump
tions, every pump should be located in such a way that 6 can be installed in submersible applications only when both
key factors are balanced against each other to maximum the wetted and non-wetted portions are compatible with
advantage. the material being pumped. If the pump is to be used in
ACCESS: First, the location should be accessible. If it is a submersible application, a hose should be attached to
easy to reach the pump, maintenance personnel will have an the air and pilot spool exhaust ports of the pump. These
easier time carrying out routine inspections and adjustments. should then be piped above the liquid level. The exhaust
Should major repairs become necessary, ease of access can area for the pilot spool is designed to be tapped for a 1/8"
play a key role in speeding the repair process and reducing NPT fitting.
total downtime. When pumps are installed in applications involving flooded
AIR SUPPLY: Every pump location should have an air suction or suction head pressures, a gate valve should be
line large enough to supply the volume of air necessary to installed in the suction line to permit closing of the line for
achieve the desired pumping rate (see Section 5). Use air pump service.
pressure up to a maximum of 8.6 bar (125 psig) depending If the pump is to be used in a self-priming application, be
on pumping requirements. sure that all connections are airtight and that the suction-lift
For best results, the pumps should use a 5µ (micron) air filter, is within the ability of the model. Note: Materials of construc-
needle valve and regulator. The use of an air filter before the tion and elastomer material have an effect on suction lift
pump will insure that the majority of any pipeline contami- parameters. Please consult Wilden distributors for specifics.
nants will be eliminated. Pumps in service with a positive suction head are most effi-
SOLENOID OPERATION: When operation is controlled by cient when inlet pressure is limited to 0.5–0.7 bar (7– 10 psig).
a solenoid valve in the air line, three-way valves should be Premature diaphragm failure may occur if positive suction is
used, thus allowing trapped air to bleed off and improving 10 psig and higher.
pump performance. Pumping volume can be set by count- THE MODEL P100 ADVANCED™ PLASTIC WILL PASS
ing the number of strokes per minute and multiplying by 1.6 mm (1/16") SOLIDS. WHENEVER THE POSSIBILITY
displacement per stroke. EXISTS THAT LARGER SOLID OBJECTS MAY BE SUCKED
SOUND: Sound levels are reduced using the standard INTO THE PUMP, A STRAINER SHOULD BE USED ON THE
Wilden muffler. Other mufflers can be used, but usually SUCTION LINE.
reduce pump performance. CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR
SUPPLY PRESSURE.
Section 7B S U G G E S T E D O P E R AT I O N A N D
MAINTENANCE INSTRUCTIONS
OPERATION: Pump discharge rate can be controlled by RECORDS: When service is required, a record should be
limiting the volume and/or pressure of the air supply to the made of all necessary repairs and replacements. Over a
pump (preferred method). An air regulator is used to regu- period of time, such records can become a valuable tool
late air pressure. A needle valve is used to regulate volume. for predicting and preventing future maintenance problems
Pump discharge rate can also be controlled by throttling the and unscheduled downtime. In addition, accurate records
pump discharge by partially closing a valve in the discharge make it possible to identify pumps that are poorly suited to
line of the pump. This action increases friction loss which their applications.
reduces flow rate. This is useful when the need exists to
control the pump from a remote location. When the pump MAINTENANCE AND INSPECTIONS: Since each applica-
discharge pressure equals or exceeds the air supply pres- tion is unique, maintenance schedules may be different
sure, the pump will stop; no bypass or pressure relief valve for every pump. Frequency of use, line pressure, viscosity
is needed, and pump damage will not occur. The pump and abrasiveness of process fluid all affect the parts life
has reached a “deadhead” situation and can be restarted of a Wilden pump. Periodic inspections have been found
by reducing the fluid discharge pressure or increasing the to offer the best means for preventing unscheduled pump
air inlet pressure. The Wilden P100 pump runs solely on downtime. Personnel familiar with the pump’s construction
compressed air and does not generate heat, therefore your and service should be informed of any abnormalities that
process fluid temperature will not be affected.
are detected during operation.
TROUBLESHOOTING
Pump will not run or runs slowly. 3. Check for sticking ball check valves. If material being
1. Ensure that the air inlet pressure is at least 0.4 bar (5 psig) pumped is not compatible with pump elastomers, swell-
above startup pressure and that the differential pressure ing may occur. Replace ball check valves and seals with
(the difference between air inlet and liquid discharge pres- proper elastomers. In addition, valve balls become smaller
sures) is not less than 0.7 bar (10 psig). as the wear. This may cause them to become stuck in the
2. Check air inlet filter for debris (see recommended instal- seats. In this case, replace balls and seats.
lation).
3. Check for extreme air leakage (blow by) which would indi- Pump air valve freezes.
cate worn seals/bores in the air valve, pilot spool, main 1. Check for excessive moisture in compressed air. Install
shaft. either a dryer, or hot air generator for compressed air.
4. Disassemble pump and check for obstructions in the air Alternatively, a coalescing filter may be used to remove
passageways or objects which would obstruct the move- the water from the compressed air in some applications.
ment of internal parts.
5. Check for sticking ball check valves. If material being Air bubbles in pump discharge.
pumped is not compatible with pump elastomers, swell- 1. Check for ruptured diaphragm.
ing may occur. Replace ball check valves and seals with 2. Check tightness of outer pistons.
proper elastomers. In addition, valve balls become smaller
3. Check torque of bolts and integrity of o-rings and seals,
as the wear. This may cause them to become stuck in the
especially at intake manifold.
seats. In this case, replace balls and seats.
4. Ensure pipe connections are airtight.
6. Check for broken inner piston, which will prevent the air
valve spool from shifting.
7. Remove plug from pilot spool exhaust, check pilot spool Product comes out air exhaust.
exhaust for blockage. 1. Check for diaphragm rupture.
2. Check tightness of outer pistons to shaft.
Pump runs but little or no product flows.
1. Check for pump cavitation; slow pump speed down to
allow thick material to flow into liquid chambers.
2. Verify that vacuum required to lift liquid is not greater than
the vapor pressure of the material being pumped (cavita-
tion).
D I R E C T I O N S F O R D I S A S S E M B LY / R E A S S E M B LY
Tools Required: 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 the pump.
• 1/2" Box Wrench Disconnect all intake, discharge, and air lines. Drain the pump by turning it upside down
• 2 – 1" Sockets or Adjustable and allowing any fluid to flow into a suitable container. Be aware of any hazardous
Wrench effects of contact with your process fluid.
• Vise equipped with soft jaws NOTE: The model used for these instructions incorporates PTFE diaphragms and balls.
(such as plywood, plastic or Models with rubber diaphragms and balls are the same except where noted.
other suitable material)
DISASSEMBLY:
D I R E C T I O N S F O R D I S A S S E M B LY / R E A S S E M B LY
D I R E C T I O N S F O R D I S A S S E M B LY / R E A S S E M B LY
A I R VA LV E / C E N T E R B L O C K — R E PA I R / M A I N T E N A N C E
D I S A S S E M B LY, C L E A N I N G , I N S P E C T I O N
R E A S SE M BLY HI N T S & T I P S
ASSEMBLY:
Upon performing applicable maintenance to the air distribution
system, the pump can now be reassembled. Please refer to
the disassembly instructions for photos and parts placement.
To reassemble the pump, follow the disassembly instructions in
reverse order. The air distribution system needs to be assem-
bled first, then the diaphragms and finally the wetted path.
Please find the applicable torque specifications on this page.
The following tips will assist in the assembly process.
• Clean the inside of the center section shaft bore to ensure
no damage is done to new seals.
• Stainless bolts should be lubed to reduce the possibility of
seizing during tightening.
• Be sure to tighten outer pistons simultaneously on PTFE-
fitted pumps to ensure proper torque values.
• Apply a small amount of Loctite 242 to the shaft interval
threads before the diaphragm assembly.
• Concave side of disc spring in diaphragm assembly faces
toward inner piston.
20
18
17 23
16
6
7
9
14
15 16
4
8 22
1
12 10 21
11 27
13 5 3
28
2 24
25
26
19
22
21
OEM MANIFOLD DRUM PUMP MANIFOLD
29 30
31
1
Air Valve Assembly includes items 2 and 3.
*Refer to corresponding elastomer chart in Section 10.
0502 Specialty Code = PTFE - Coated Hardware
0680 Specialty Code = OEM Specific Inlet Manifold
0790 Specialty Code = Drum Pump Inlet Manifold
20
18
23
24
6
7
9
14
15 16
4 17
1 8 22
12 10 21
11
3 28
13 5
2
29
25
26
27
19
22
21
30 31
32
1
Air Valve Assembly includes items 2 and 3.
*Refer to corresponding elastomer chart in Section 10.
0502 Specialty Code = PTFE - Coated Hardware
0680 Specialty Code = OEM Specific Inlet Manifold
0790 Specialty Code = Drum Pump Inlet Manifold
ELASTOMER OPTIONS
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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