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P800 PV800 Adv PLS Eom 04
P800 PV800 Adv PLS Eom 04
Engineering
Operation &
Advanced™ Series PLASTIC Pumps Maintenance
WIL-11120-E-04
Replaces WIL-11120-E-03
TA BL E OF CON T EN T S
SECTION 5 PERFORMANCE
A. P800 Performance Curves
Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Ultra-Flex™-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
PV800 Performance Curves
Rubber-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TPE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PTFE-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Ultra-Flex™-Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
B. Suction Lift Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CAUTION: Do not apply compressed air to the CAUTION: Pumps should be thoroughly flushed
exhaust port — pump will not function. before installing into process lines. FDA and
USDA approved pumps should be cleaned and/
CAUTION: Do not over-lubricate air supply — or sanitized before being used.
excess lubrication will reduce pump performance.
Pump is pre-lubed. CAUTION: Always wear safety glasses when
operating pump. If diaphragm rupture occurs,
TEMPERATURE LIMITS: material being pumped may be forced out air
Neoprene –17.7°C to 93.3°C 0°F to 200°F exhaust.
Buna-N –12.2°C to 82.2°C 10°F to 180°F
EPDM –51.1°C to 137.8°C –60°F to 280°F CAUTION: Before any maintenance or repair is
Viton® –40°C to 176.7°C –40°F to 350°F attempted, the compressed air line to the pump
Saniflex™ –28.9°C to 104.4°C –20°F to 220°F should be disconnected and all air pressure
Polytetrafluoroethylene (PTFE) allowed to bleed from pump. Disconnect all
4.4°C to 104.4°C 40°F to 220°F intake, discharge and air lines. Drain the pump
Polyurethane –12.2°C to 65.6°C 10°F to 150°F by turning it upside down and allowing any fluid
Tetra-Flex™ PTFE w/Neoprene Backed to flow into a suitable container.
4.4°C to 107.2°C 40°F to 225°F
Tetra-Flex™ PTFE w/EPDM Backed CAUTION: Blow out air line for 10 to 20 seconds
-10°C to 137°C 14°F to 280°F before attaching to pump to make sure all pipeline
debris is clear. Use an in-line air filter. A 5µ (micron)
NOTE: Not all materials are available for all
air filter is recommended.
models. Refer to Section 2 for material options
for your pump.
CAUTION: If the pipe plug in the inlet or discharge
CAUTION: When choosing pump materials, be manifold on the 51 mm (2") Advanced™ plastic
sure to check the temperature limits for all wetted center-ported model is removed, a triple density
components. Example: Viton® has a maximum (red) PTFE pipe tape is recommended to ensure
limit of 176.7°C (350°F) but polypropylene has a adequate sealing.
maximum limit of only 79°C (175°F).
NOTE: When installing PTFE diaphragms, it is
CAUTION: Maximum temperature limits are important to tighten outer pistons simultaneously
based upon mechanical stress only. Certain (turning in opposite directions) to ensure tight fit.
chemicals will significantly reduce maximum (See torque specifications in Section 7.)
safe operating temperatures. Consult Chemical
Resistance Guide (E4) for chemical compatibility NOTE: Cast Iron PTFE-fitted pumps come
and temperature limits. standard from the factory with expanded PTFE
gaskets installed in the diaphragm bead of the
WARNING: Prevention of static sparking — If liquid chamber. PTFE gaskets cannot be re-used.
static sparking occurs, fire or explosion could Consult PS-TG for installation instructions during
result. Pump, valves, and containers must be reassembly.
grounded to a proper grounding point when
handling flammable fluids and whenever NOTE: Before starting disassembly, mark a line
discharge of static electricity is a hazard. from each liquid chamber to its corresponding air
chamber. This line will assist in proper alignment
CAUTION: Do not exceed 8.6 bar (125 psig) air during reassembly.
supply pressure.
CAUTION: Pro-Flo® pumps cannot be used in
CAUTION: The process fluid and cleaning fluids submersible applications. Pro-Flo V™ is available
must be chemically compatible with all wetted in both submersible and non-submersible options.
pump components. Consult Chemical Resistance Do not use non-submersible Pro-Flo V™ models
Guide (E4). in submersible applications. Turbo-Flo™ pumps
can also be used in submersible applications.
CAUTION: Do not exceed 82°C (180°F) air inlet
temperature for Pro-Flo V™ models. CAUTION: Tighten all hardware prior to installation.
MATERIAL CODES
MODEL AIR VALVE VALVE BALL
P800 = PRO-FLO ® A = ALUMINUM (PV800 only) BN = BUNA-N (Red Dot)
PV800 = PRO-FLO V™ C = PTFE-COATED EP = EPDM (Blue Dot)
(PV800 only) FS = SANIFLEX™
WETTED PARTS N = NICKEL-PLATED [Hytrel® (Cream)]
KK = PVDF / PVDF (PV800 only) NE = NEOPRENE (Green Dot)
PK = POLYPROPYLENE / PVDF P = POLYPROPYLENE PU = POLYURETHANE (Clear)
(P800 only) TF = PTFE (White)
AIR CHAMBERS S = STAINLESS STEEL VT = VITON ® (White Dot)
P = POLYPROPYLENE (PV800 only) WF = WIL-FLEX™ [Santoprene®
(Orange Dot)]
CENTER BLOCK DIAPHRAGMS
BNS = BUNA-N (Red Dot) VALVE SEAT
A = ALUMINUM(PV800 only)
C = PTFE-COATED BNU = BUNA-N, ULTRA-FLEX™ K = PVDF
(PV800 only) EPS = EPDM (Blue Dot) P = POLYPROPYLENE
N = NICKEL-PLATED EPU = EPDM, ULTRA-FLEX™
(PV800 only) FSS = SANIFLEX™ VALVE SEAT & FLANGE O-RING
P = POLYPROPYLENE [Hytrel® (Cream)] BN = BUNA-N
(P800 only) NES = NEOPRENE (Green Dot) TV = PTFE ENCAP. VITON ®
S = STAINLESS STEEL NEU = NEOPRENE, ULTRA-FLEX™ WF = WIL-FLEX™ (Santoprene)
(PV800 only) PUS = POLYURETHANE (Clear)
TEU = PTFE W/EPDM
BACK-UP (White)
TNU = PTFE W/NEOPRENE
BACK-UP (White)
TSU = PTFE W/SANIFLEX™
BACK-UP (White)
VTS = VITON® (White Dot)
VTU = VITON®, ULTRA-FLEX™
WFS = WIL-FLEX™ [Santoprene®
(Orange Dot)]
XBS = CONDUCTIVE BUNA-N
SPECIALTY CODES
0100 Wil-Gard 110V 0502 PFA Coated 0733 Center-ported, Reversed ANSI/DIN combo
0102 Wil-Gard sensor wires ONLY 0504 DIN Flange flange (inlet facing air inlet/discharge facing
0103 Wil-Gard 220V 0506 DIN Flange, PFA Coated exhaust)
0206 PFA coated hardware, 0513 SS outer pistons 0734 Center-ported, Reversed ANSI/DIN combo
Wil-Gard II™ sensor wires ONLY 0604 DIN flange Wil-Gard II™ flange (inlet facing air inlet/discharge facing
0480 Pump Cycle Monitor (sensor & wires) 0608 PFA coated hardware, Wil-Gard II™ 220V exhaust), PFA coated fasteners
0483 Pump Cycle Monitor (module, sensor & wires) 0690 Center-Ported ANSI/DIN Combo
0485 Pump Cycle Monitor (module, sensor & wires), 0691 Center-ported, ANSI/DIN combo flange, PFA
DIN flange coated fasteners
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.
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 exhaust 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, balancing the to the center. Diaphragm B is now on its one exhaust and one discharge stroke.
load and removing mechanical stress discharge stroke. Diaphragm B forces the This constitutes one complete pumping
from the diaphragm. The compressed inlet valve ball onto its seat due to the cycle. The pump may take several cycles
air moves the diaphragm away from hydraulic forces developed in the liquid to completely prime depending on the
the center of the pump. The opposite chamber and manifold of the pump. These conditions of the application.
diaphragm is pulled in by the shaft same hydraulic forces lift the discharge
connected to the pressurized diaphragm. valve ball off its seat, while the opposite
Diaphragm B is on its suction stroke; air discharge valve ball is forced onto its seat,
behind the diaphragm has been forced forcing fluid to flow through the pump
out to atmosphere through the exhaust discharge. The movement of diaphragm A
port of the pump. The movement of toward the center of the pump creates a
diaphragm B toward the center of the vacuum within liquid chamber A. Atmos-
pump creates a vacuum within chamber B. pheric pressure forces fluid into the inlet
Atmospheric pressure forces fluid into manifold of the pump. The inlet valve ball
the inlet manifold forcing the inlet valve is forced off its seat allowing the fluid being
ball off its seat. Liquid is free to move pumped to fill the liquid chamber.
past the inlet valve ball and fill the liquid
chamber (see shaded area).
P800 PLASTIC
TPE-FITTED
Height ..................................804 mm (31.7")
Width .................................. 604 mm (23.8")
Depth .................................. 353 mm (13.9")
Est. Ship Weight
Polypropylene 32 kg (70 lbs)
PVDF 45 kg (99 lbs)
Air Inlet ....................................13 mm (1⁄2")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ................... 5.54 m Dry (18.16')
5.19 m Wet (17.0')
Displacement/Stroke .... 2.78 l (0.735 gal.)1
Max. Flow Rate ............ 615 lpm (162 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 321.8 lpm (85 gpm)
Flow rates indicated on chart were determined by pumping water.
against a discharge head pressure of
1.2 bar (17 psig) requires 2.8 bar (40 psig) For optimum life and performance, pumps should be specified so that daily operation
and 85 Nm3/h (50 scfm) air consumption. parameters will fall in the center of the pump performance curve.
(See dot on chart.)
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
P800 PLASTIC
ULTRA-FLEX™-FITTED
Height ..................................804 mm (31.7")
Width .................................. 604 mm (23.8")
Depth .................................. 353 mm (13.9")
Est. Ship Weight
Polypropylene 32 kg (70 lbs)
PVDF 45 kg (99 lbs)
Air Inlet ....................................13 mm (1⁄2")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ................... 4.84 m Dry (15.89')
8.65 m Wet (28.4')
Displacement/Stroke .... 1.73 l (0.457 gal.)1
Max. Flow Rate ............ 588 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 265 lpm (70 gpm)
Flow rates indicated on chart were determined by pumping water.
against a discharge head pressure of
1.7 bar (24 psig) requires 2.8 bar (40 psig) For optimum life and performance, pumps should be specified so that daily operation
and 85 Nm3/h (50 scfm) air consumption. parameters will fall in the center of the pump performance curve.
(See dot on chart.)
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
PV800 PLASTIC
TPE-FITTED
Height ..................................805 mm (31.7")
Width .................................. 605 mm (23.8")
Depth .................................. 353 mm (13.9")
Est. Ship Weight
Polypropylene 45 kg (100 lbs)
PVDF 59 kg (131 lbs)
Air Inlet ....................................19 mm (3/4")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ........................6.6 m Dry (21.6')
9.3 m Wet (30.6')
Displacement/Stroke ....... 2.84 l (0.75 gal.)1
Max. Flow Rate ............ 702 lpm (185 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 466 lpm (123 gpm)
against a discharge pressure head of 1.4
bar (20 psig) requires 4.1 bar (60 psig) Flow rates indicated on chart were determined by pumping water.
and 136 Nm3/h (80 scfm) air consumption. For optimum life and performance, pumps should be specified so that daily operation
(See dot on chart.) parameters will fall in the center of the pump performance curve.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
PV800 PLASTIC
ULTRA-FLEX™-FITTED
Height ..................................805 mm (31.7")
Width .................................. 605 mm (23.8")
Depth .................................. 353 mm (13.9")
Est. Ship Weight
Polypropylene 45 kg (100 lbs)
PVDF 59 kg (131 lbs)
Air Inlet ....................................19 mm (3/4")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ....................... 4.1 m Dry (13.6')
9.3 m Wet (30.6')
Displacement/Stroke ........1.97 l (0.52 gal.)1
Max. Flow Rate ............ 637 lpm (168 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 303 lpm (80 gpm)
against a discharge pressure head of 2.5
bar (36 psig) requires 4.1 bar (60 psig) and Flow rates indicated on chart were determined by pumping water.
102 Nm3/h (60 scfm) air consumption. (See For optimum life and performance, pumps should be specified so that daily operation
dot on chart.) parameters will fall in the center of the pump performance curve.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
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NOTE: In the event of a power failure, the shut off valve shut off valve (user supplied) installed in the air supply
should be closed, if the restarting of the pump is not line. A properly functioning valve will stop the air supply
desirable once power is regained. to the pump, therefore stopping output. This shut off
valve should be located far enough away from the
AIR OPERATED PUMPS: To stop the pump from pumping equipment such that it can be reached safely
operating in an emergency situation, simply close the in an emergency situation.
TROUBLESHOOTING
Pump will not run or runs slowly. 2. Verify that vacuum required to lift liquid is not
1. Ensure that the air inlet pressure is at least 0.4 bar greater than the vapor pressure of the material
(5 psig) above startup pressure and that the differential being pumped (cavitation).
pressure (the difference between air inlet and liquid 3. Check for sticking ball check valves. If material being
discharge pressures) is not less than 0.7 bar (10 psig). pumped is not compatible with pump elastomers,
2. Check air inlet filter for debris (see recommended swelling may occur. Replace ball check valves and
installation). seats with proper elastomers. Also, as the check
3. Check for extreme air leakage (blow by) which valve balls wear out, they become smaller and can
would indicate worn seals/bores in the air valve, become stuck in the seats. In this case, replace balls
pilot spool, main shaft. and seats.
4. Disassemble pump and check for obstructions
Pump air valve freezes.
in the air passageways or objects which would
obstruct the movement of internal parts. 1. Check for excessive moisture in compressed
5. Check for sticking ball check valves. If material being air. Either install a dryer or hot air generator for
pumped is not compatible with pump elastomers, compressed air. Alternatively, a coalescing filter
swelling may occur. Replace ball check valves and may be used to remove the water from the
seals with proper elastomers. Also, as the check compressed air in some applications.
valve balls wear out, they become smaller and can
Air bubbles in pump discharge.
become stuck in the seats. In this case, replace balls
and seats. 1. Check for ruptured diaphragm.
6. Check for broken inner piston which will cause the 2. Check tightness of outer pistons (refer to Section 7).
air valve spool to be unable to shift. 3. Check tightness of fasteners and integrity of
7. Remove plug from pilot spool exhaust. o-rings and seals, especially at intake manifold.
4. Ensure pipe connections are airtight.
Pump runs but little or no product flows.
1. Check for pump cavitation; slow pump speed Product comes out air exhaust.
down to allow thick material to flow into liquid 1. Check for diaphragm rupture.
chambers. 2. Check tightness of outer pistons to shaft.
WIL-11120-E-04 13 WILDEN PUMP & ENGINEERING, LLC
Section 7
P U M P DIS A S SE M BLY
To o l s R e q u i r e d : 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
• 3/4" Wrench pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
• Adjustable Wrench upside down and allowing any fluid to flow into a suitable container. Be aware of
any hazardous effects of contact with your process fluid.
• Vise equipped w/soft jaws
(such as plywood, plastic NOTE: The model photographed for these instructions incorporates PTFE diaphragms,
or other suitable material) balls, and seats. Models with rubber diaphragms, balls and seats are the same except
where noted.
Step 10 Step 11
Due to varying torque values, one of the Remove diaphragm assembly from
following two situations may occur: shaft, secure shaft with soft jaws (a
1) The outer piston, diaphragm and vise fitted with plywood, plastic or
inner piston remain attached to the other suitable material) to ensure
shaft and the entire assembly can be shaft is not nicked, scratched or
removed from the center section. gouged. Using an adjustable wrench
or rotating counterclockwise by
2) The outer piston, diaphragm and hand, remove diaphragm assembly
inner piston separate from the shaft, from shaft.
which remains connected to the
opposite side diaphragm assembly.
To o l s R e q u i r e d : 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
• 3/16" Wrench pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
• O-ring Pick upside down and allowing any fluid to flow into a suitable container. Be aware of
hazardous effects of contact with your process fluid.
NOTCHED
END
Step 7 Step 8
Using an o-ring pick, gently remove the o-ring from the opposite side of the Inspect center section seals for signs
“notched end” on one side of the pilot spool. Gently remove the pilot spool of wear. If necessary, remove seals
from pilot spool sleeve and inspect for nicks, gouges and wear. Replace with o-ring pick and replace.
pilot sleeve or outer sleeve o-rings if necessary. During re-assembly, never
insert the pilot spool into the sleeve with the “notched end” first, this end
incorporates the urethane o-ring and will be damaged as it slides over the
ports cut in the sleeve. Note: Seals should not be removed from pilot
spool. Seals are not sold separately.
Non-Submersible Submersible
Step 1 Step 2
Install a 1/4" NPT pipe plug (00-7010-08) Next, install an optional submersible air valve gasket
into the pilot spool bleed port located (04-2621-52). The submersible air valve gasket can be
at the front of the center block. purchased as a spare part or included with the purchase
of a new Pro-Flo V™ pump.
TAPE
SHAFT SEAL
TAPE
WILDEN PUMP & ENGINEERING, LLC 20 WIL-11120-E-04
WIL-11120-E-04 21 WILDEN PUMP & ENGINEERING, LLC
Section 8
E XPLODED VIE W AND PARTS LISTING
ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS (see section 9).
WILDEN PUMP & ENGINEERING, LLC 22 WIL-11120-E-04
E X PL ODED V IE W A ND PA R T S L IS T ING
ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS (see section 9).
WILDEN PUMP & ENGINEERING, LLC 26 WIL-11120-E-04
E X PL ODED V IE W A ND PA R T S L IS T ING
ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS (see section 9).
WILDEN PUMP & ENGINEERING, LLC 28 WIL-11120-E-04
E X PL ODED V IE W A ND PA R T S L IS T ING
Back-up diaphragms used with PTFE diaphragms only. Neoprene is the standard back-up material used, unless otherwise specified.
NOTE: Saniflex™ back-up diaphragms (04-1060-56) are available upon request. Please consult your local Wilden distributor.
PRO-FLO® PLASTIC
DESCRIPTION NEOPRENE BUNA-N VITON® EPDM PTFE WIL-FLEX™ SANIFLEX™ POLYURETHANE
Pro-Flo® Advanced™ Plastic 08-9553-51 08-9553-52 08-9553-53 08-9553-54 08-9553-55 08-9553-58 08-9553-56 08-9553-50
PRO-FLO V™ PLASTIC
DESCRIPTION NEOPRENE BUNA-N VITON® EPDM PTFE WIL-FLEX™ SANIFLEX™ POLYURETHANE
Pro-Flo V™ Advanced™ Plastic 08-9581-51 08-9581-52 08-9581-53 08-9581-54 08-9581-55 08-9581-58 08-9581-56 08-9581-50
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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