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Home My WebLink AboutTab 1 Citric Acid and Sodium Hydroxide Chemical Transfer Pumps© Copyright 2000, Wilden Pump & Engineering Company 22069 Van Buren St. • Grand Terrace, CA 92313-5607 • Telephone 909-422-1730 • Fax 909-783-3440 • www.wildenpump.com ® Specifications WETTED HOUSINGS (Water Chambers and Manifolds) MATERIAL SHIP WT. MATERIAL SHIP WT. Polypropylene 9 lbs. (4.1 kg.) PVDF 11 lbs. (5.1 kg.) Carbon-filled Acetal 10 lbs. (4.6 kg.) Teflon ®PFA 12 lbs. (5.5 kg.) NON-WETTED HOUSINGS DESCRIPTION MATERIAL Center Section Polypropylene or Acetal Air Valve Polypropylene or Acetal MAXIMUM SUCTION LIFT CAPABILITY DRY LIFT 20' (6.1 m) The above figure represents the rubber-fitted pump capability. MAXIMUM DIAMETER SOLIDS1⁄16" (1.6 mm) Diameter ELASTOMER OPTIONS MATERIAL TEMPERATURE LIMITS Polyurethane +10 (–12.2) to +150 ( 65.6) F° (C°) Buna-N®+10 (–12.2) to +180 ( 82.2) F° (C°) Viton®–40 (–40.0) to +350 (176.7) F° (C°) Saniflex™ –20 (–28.9) to +220 (104.4) F° (C°) Teflon®PTFE +40 ( 4.4) to +300 (148.9) F° (C°) Wil-Flex™ –40 (–40.0) to +225 (107.2) F° (C°) P1 Plastic Pump FLOW RATE TO 14.8 GPM (56.1 LPM) MAXIMUM OPERATING PRESSURE = 125 PSI (8.6 BAR) (12)[20.4] BAR FEET PSIG 120 100 60 40 20 80 Water Flowrates GPM [LPM] 2 [8] 4 [15] 6 [23] 8 [30] 10 [38] 12 [45] 14 [53] 1 2 3 4 5 6 7 8 300 250 200 150 100 50 AIR CONSUMPTION (SCFM)[Nm3/h] (8)[13.6](4)[6.8] (12)[20.4] BAR FEET PSIG 120 100 60 40 20 80 Water Flowrates GPM [LPM] 2 [8] 4 [15] 6 [23] 8 [30] 10 [38] 12 [45] 14 [53] 1 2 3 4 5 6 7 8 300 250 200 150 100 50 AIR CONSUMPTION (SCFM)[Nm3/h] (16)[27.2] (8)[13.6] (4)[6.8] TEFLON®-FITTED P1 PLASTIC PUMPR - Teflon®, GraphiteNM K L P S - Poly., PVDF1/4" FNPT Air Inlet 1/2" FNPT Inlet C B A D 1/2" FNPT Discharge E F 1/2" FNPT Air Exhaust J G H DIMENSIONS – P1 PLASTIC ITEM STANDARD METRIC (inch) (mm) A 1 5/32 29.3 B 5 1/8 130.2 C 7 11/16 195.3 D 8 3/16 207.8 E 8 5/8 219.1 F 2 5/32 54.8 G 4 17/32 115.1 H 5 127.0 J 8 1/32 204.0 K 5 21/32 143.7 L 4 1/2 114.2 M 3 1/4 82.6 N47.1 P 9/32 7.1 R 27/32 21.4 S 1 3/32 27.8 Refer to the EOM manual for TPE performance curve. RUBBER-FITTED P1 PLASTIC PUMP P-5115 - Acid Transfer - Wilden P1/PPPP/WF/WF/KWF P-5015 - Caustic Transfer - Wilden P1/PPPP/WF/WF/KWF PUG 6/99REPLACES PUG 2/99 ® PUMP USER’S GUIDE i WILDEN PUMP & ENGINEERING CO. 1. The Wilden Pump a. AODDP: Air-Operated Double-Diaphragm Pump 1 b. How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . 2 c. Pump Availability Charts . . . . . . . . . . . . . . . . . . 3 d. Why Buy a Wilden AODDP . . . . . . . . . . . . . . . . 3 2. Site Selection a. Self-Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 b. Positive Suction Head. . . . . . . . . . . . . . . . . . . . 4 c. Submerged. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3. Part Identification Chart a. Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 5 b. Part Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4. Air Distribution Systems a. System Availability and Product Line Strategy. . . . . . . . . . . . . . . . 6 b. Turbo-Flo™. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 c. Wil-Flo™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 d. Pro-Flo™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 e. Accu-Flo™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 f. Accu-Flo™ Solenoid Coil Options . . . . . . . . . . . 10 5. Elastomers a. Rubber Compounds . . . . . . . . . . . . . . . . . . . . . 10 Ultra-Flex™ Diaphragms. . . . . . . . . . . . . . . . . . 10 b. Thermoplastic Compounds . . . . . . . . . . . . . . . . 10 c. Teflon ®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 d. Specialty Diaphragms . . . . . . . . . . . . . . . . . . . . 10 e. Elastomer Options . . . . . . . . . . . . . . . . . . . . . . 12 6. Diaphragm Assembly a. Rubber/TPE Fitted Pumps . . . . . . . . . . . . . . . . 13 b. Teflon ®Fitted Pumps. . . . . . . . . . . . . . . . . . . . . 13 c. Ultra-Flex™ Fitted Pumps. . . . . . . . . . . . . . . . . 13 7. Pump Selection a. Pump Selection Chart . . . . . . . . . . . . . . . . . . . . 13 b. Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 c. Solids Handling Capability. . . . . . . . . . . . . . . . . 14 d. Suction Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 e. Performance Curves . . . . . . . . . . . . . . . . . . . . . 14 f. Total Dynamic Head Calculation . . . . . . . . . . . . 14 g. Chemical Compatibility . . . . . . . . . . . . . . . . . . . 14 h. Temperature Limitations . . . . . . . . . . . . . . . . . . 14 i. Abrasion Resistance . . . . . . . . . . . . . . . . . . . . . 15 j. Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 8. Pump Designation System . . . . . . . . . . . . . . . . . 16 9. Installation a. Pre-Installation Checklist. . . . . . . . . . . . . . . . . . 17 b. Suggested Installation. . . . . . . . . . . . . . . . . . . . 17 c. Accu-Flo™ Installation . . . . . . . . . . . . . . . . . . . 18 10. Maintenance a. Assembly/Re-assembly. . . . . . . . . . . . . . . . . . . 19 b. Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 c. Mean Time to Failure . . . . . . . . . . . . . . . . . . . . 19 d. Seal Replacement . . . . . . . . . . . . . . . . . . . . . . 19 e. Disassembly Overview . . . . . . . . . . . . . . . . . . . 19 11. Wilden Accessories a. SD Equalizer ®Surge Dampener . . . . . . . . . . . . 20 b. BF Equalizer ®Series. . . . . . . . . . . . . . . . . . . . . 20 c. FCSI (Flow Control System I) . . . . . . . . . . . . . . 20 d. Solenoid Pump Controller (SPC I). . . . . . . . . . . 20 e. Wil-Gard™ II. . . . . . . . . . . . . . . . . . . . . . . . . . . 21 f. Drum Pump Kit . . . . . . . . . . . . . . . . . . . . . . . . . 21 g. Automatic Powder Valve (APV) . . . . . . . . . . . . . 21 h. 2 for 1 System . . . . . . . . . . . . . . . . . . . . . . . . . 21 12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 22 13. Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 14. Safety Supplement . . . . . . . . . . . . . . . . . . . . . . . 23 15. Conversion Tables. . . . . . . . . . . . . . . . . . . . . . . . 25 TABLE OF CONTENTS Wilden’s “Pump User’s Guide” was designed to familiarize you with the operation and mechanics of Wilden air-operat- ed double-diaphragm pumps and accessories. This guide is to be used as a supplement with your pump’s Engineering Operation and Maintenance manual (EOM). The Pump User’s Guide is a resource for the following: Pump operation principles, application alternatives, air distribution systems, elastomers, pump selection, pump designation system, pump performance, pump installation, pump operation, trou- bleshooting, and pump maintenance. In addition, a list of applicable pump accessories, pump warranty, and safety precautions are discussed. For best results this guide should be used in conjunction with the EOM manual specific to your pump model. PAGE PAGE WILDEN PUMP & ENGINEERING CO.1 PUMP USER’S GUIDE 1a. THE WILDEN PUMP — AODDP 1. Air Chamber:The air chamber is the chamber that houses the air which powers the diaphragms. 2. Air Distribution System:The air distribution system is the heart of the pump. The air distribution system is the mechanism that shifts the pump in order to create suc- tion and discharge strokes. Wilden offers Wil-Flo™, Pro- Flo™, Turbo-Flo™, and Accu-Flo™ air distribution sys- tems for your specific pumping needs. Turn to the Air Distribution Systems section on page 6 for more details. 3. Outer Diaphragm Piston:The inner and outer diaphragm pistons provide a means to connect the diaphragms to the reciprocating common shaft and to seal the liquid side from the air side of the diaphragm. 4. Inner Diaphragm Piston:The inner piston is located on the air side of the pump and does not come into contact with the process fluid. 5. Check Valve Ball:Wilden air-operated pumps use suction and discharge check valves to produce direc- tional flow of process fluid in the liquid chamber. The check valve balls seal and release on the check valve seats allowing for discharge and suction of process fluid to occur. 6. Check Valve Seat:The removable seats provide the ball valves a site to check. 7. Discharge Manifold:Process fluid exits the pump from the discharge port located on the discharge manifold at the top of the pump. 8. Liquid Chamber:The liquid chamber is filled with the process fluid during the suction stroke and is emptied during the discharge stroke. It is separated from the compressed air by the diaphragms. 9. Diaphragm:The diaphragm membrane provides for separation of the process fluid and the compressed air power source. To perform adequately, diaphragms should be of sufficient thickness and of appropriate material to prevent degradation or permeation in specif- ic process fluid applications. Wilden offers a variety of diaphragm materials for your specific application requirements. Turn to the elastomers section on page 10 for more details. 10. Inlet Manifold:Process fluid enters the pump from the intake port located on the inlet manifold at the bottom of the pump. 1 AIR CHAMBER (Qty. 2) 2 AIR DISTRIBUTION SYSTEM 7 DISCHARGE MANIFOLD (Qty. 1) 8 LIQUID CHAMBER (Qty. 2) 9 DIAPHRAGM (Qty. 2) 10 INLET MANIFOLD (Qty. 1) 6 CHECK VALVE SEAT (Qty. 4) 5 CHECK VALVE BALL (Qty. 4) 4 INNER DIAPHRAGM PLATE (Qty. 2) 3 OUTER DIAPHRAGM PLATE (Qty. 2) PUMP USER’S GUIDE 2 WILDEN PUMP & ENGINEERING CO. INLET DISCHARGE BA Figure 1 — Right Stroke INLET DISCHARGE BA Figure 2 — Midstroke INLET DISCHARGE BA Figure 3 — Left Stroke FIGURES 2 & 3 When the pressurized diaphragm (diaphragm A) reaches the limit of its discharge stroke, the air valve redirects the compressed air supply to the back side of diaphragm B. The pressurized air forces diaphragm B away from the center block while the shaft pulls diaphragm A toward the center block. The air chamber on side A exhausts its air to atmosphere through the exhaust port of the pump. Diaphragm B is now on its discharge stroke while diaphragm A is on its suc- tion stroke. Diaphragm B forces the inlet valve ball (lower left) onto its seat due to the hydraulic forces developed in the liquid chamber and manifold of the pump. These same hydraulic forces lift the discharge valve ball off its seat, while the oppo- site discharge valve ball is forced onto its seat, forcing fluid to flow through the left side of the pump and out the discharge manifold. The movement of diaphragm A to the center block of the pump creates a vacuum within liquid chamber A. Atmospheric pressure forces fluid into the inlet manifold of the pump. The inlet valve ball (lower right) is forced off its seat allowing the fluid to enter the right liquid chamber. As the pump reaches its original starting point, each diaphragm has gone through one suction and one discharge stroke. This movement constitutes one pumping cycle. The pump will take several cycles to completely prime depending on the application variables. The Wilden air-operated pump is a reciprocating double- diaphragm, positive displacement type. The pump displaces fluid from one of its two liquid chambers upon each stroke completion. The following drawings and paragraphs detail the liquid flow pattern through the pump from its initial unprimed position. There are a few wetted parts (parts that contact the fluid) which are dynamic: The two diaphragms which are connect- ed by a common shaft, the two inlet valve balls, and the two discharge valve balls. The diaphragms act as a separation membrane between the compressed air supply and the liquid. Driving the diaphragms with compressed air instead of the shaft balances the load on the diaphragm which removes mechanical stress and therefore extends diaphragm life. The valve balls open and close on the valve seats to direct liquid flow. FIGURE 1 The air distribution sys- tem directs the air supply to the right air chamber and therefore, the back side of diaphragm A. The compressed air moves diaphragm A away from the center block toward the liquid cham- ber. The opposite diaphragm (diaphragm B) is pulled in by the shaft connected to the pressurized dia- phragm (diaphragm A). Diaphragm B is now on its suction stroke; air behind the diaphragm has been forced out to atmosphere through the exhaust port of the pump. Diaphragm A is currently working against atmospheric pressure. The movement of diaphragm B toward the center block of the pump creates a vacuum within liquid chamber B. Atmospheric pressure forces fluid into the inlet manifold forcing the inlet valve ball off its seat. Liquid is now free to move past the inlet valve ball (lower left) and fill the liquid chamber. 1b. THE WILDEN PUMP — HOW IT WORKS WILDEN PUMP & ENGINEERING CO.3 PUMP USER’S GUIDE TURBO-FLO™ WIL-FLO™ ACCU-FLO™ PRO-FLO™ STALLION™ Solids Pump Passage Pump Size Model T-Series W-Series A-Series P-Series Pump Wetted Construction Wetted Construction Wetted Construction Wetted Construction Wetted Construction Plastic Metal Plastic Metal Plastic Metal Plastic Metal Plastic Metal 1⁄4" (6.35 mm) .025 • • 1⁄2" (12.7 mm) .050 • 1⁄2" (12.7 mm) 1 • • • • • • 1" (25.4 mm) 2 • • • • • • 11⁄2" (38.1 mm) 4 • • • • • • • • • 2" (50.8 mm) 8 • • • • • • • • • 3" (76.2 mm) 15 • • • • • 4" (101.6 mm) 20 • • HIGH PRESSURE SANIFLO™ SANIFLO™ SANIFLO™ UL-LISTED T8 Pump HP250 50 psi Max. Pump Size Model (250 psi) FDA USDA 3A Air Supply 1⁄4" (6.35 mm) .025 1⁄2" (12.7 mm) .050 1⁄2" (12.7 mm) 1 • 1" (25.4 mm) 2 • • • 11⁄2" (38.1 mm) 4 • • 2" (50.8 mm) 8 • • • • 3" (76.2 mm) 15 • • 4" (101.6 mm) 20 NOTE: A dot on the chart denotes availability. Example: The Wil-Flo™ series pump is available in the 11⁄2", 2", and 3" (W4, W8, and W15). 1c. PUMP AVAILABILITY CHARTS 1d. WHY BUY A WILDEN AODDP Metal Wetted Construction Only Plastic or Metal Wetted Construction For the last 43 years, Wilden Pump & Engineering Co., the world’s largest manufacturer of air-operated double- diaphragm pumps, has been providing the industry experts with the most reliable pumps on the market. Wilden pumps are self-priming, can handle viscous and abrasive products, can run dry without damage, and are capable of passing up to 13⁄8" (34.9 mm) solids. Wilden pumps do not employ costly motors, variable speed drives, by-pass plumbing or mechan- ical trip rods. Please see the matrix below for a comparison of the Wilden AODDP versus Rotary and Centrifugal pumps: SOLIDS SHEAR ABRASIVES SOLVENTS DRY VISCOUS FLUIDS MAINTENANCE PASSAGE SENSITIVITY HANDLING HANDLING PRIMING HANDLING COSTS Wilden Pumps AAAAAAA Vane Pumps DDDABCC Internal Gear Pumps DDBBCAD External Gear Pumps DDDBCAD Lobe Pumps ACBCCAD Centrifugal Pumps DDBBCDB Progressive Cavity Pumps DCABAAD Piston/Plunger Pumps CDBCAAD A = Excellent B = Good C = Fair D = Poor PUMP USER’S GUIDE 4 2. SITE SELECTION a. SELF-PRIMING The Wilden pump is capable of pulling high vacuum. Design characteristics enable the pump to run dry without damage to create a pressure differential. This pressure differential creates suction lift up to 21' (6.4 m) of water. Suction lift capability is dependent on pump size and operating conditions (see Section 5 of your EOM for suction lift curve). b. POSITIVE SUCTION HEAD The pumping system can be designed so that a positive suction head condition is created. This condition is experienced when it is necessary to draw off the bottom of holding tanks, mixing tanks, clarifiers, etc. Pumps operate most efficiently and parts life is maximized when inlet pressure is limited to 10 psig (.68 Bar). c. SUBMERGED Many Wilden pumps can be completely submerged. The pump’s materials of construction must be chemically compatible with the process fluid and the air exhaust must be plumbed to atmosphere. WILDEN PUMP & ENGINEERING CO.5 PUMP USER’S GUIDE The following exploded view represents the bill of material of a generic T8 metal pump. Please note there are differences in pump builds due to size, wetted construction, and elas- tomer choice. Please refer to Section 9 of your EOM (Engineering, Operation, and Maintenance manual) for your pump’s exploded view and bill of materials. 7 3 4 5 16 14 28 24 28 29 25 26 27 29 17 42 31 18 41 16 8 9 10 11 121 15 13 30 17 18 19 35 22 21 31 6 2 39 37 23 38 32 33 34 36 20 Ultra-Flex® Assembly T8 METAL Rubber/ TPE-Fitted Sample Exploded View Item Part Description Qty. 1 Air Valve Assembly 1 1 2 Air Valve Screen 1 3 Air Valve End Cap w/Guide (Top) 1 4 Air Valve End Cap w/o Guide (Bottom) 1 5 Air Valve Snap Ring 2 6 Air Valve Bushing (Optional) 1 7 Air Valve Cap O-Ring 2 8 Oil Bottle (Optional) w/Air Valve 08-2050-07 1 9 Plug (Optional) 1 10 Capillary Rod (Optional) 1 11 Air Valve Gasket — Buna-N ®1 12 Air Valve Screw 5⁄16"-18 x 21⁄4"4 13 Center Block 1 14 Center Block Glyd™ Ring 7 15 Block Gasket — Buna-N ®2 16 Shaft 1 Shaft, Ultra-Flex™ 1 17 Piston, Outer 2 Piston, Outer, Ultra-Flex™ 2 18 Piston, Inner 2 Piston, Inner, Ultra-Flex™ 2 19 Air Chamber, Counter Sunk 2 20 Air Chamber Screw 3⁄8"-16 x 39⁄16"3 21 Air Chamber Cone Nut 3⁄8"-16 3 22 Liquid Chamber 2 23 Discharge Manifold 1 24 Inlet Housing for Screened Base 1 25 Screen Base for Item 24 1 26 Suction Hook Up Cover for Item 24 1 27 Cap Screw for Item 24 3⁄8"-16 x 7⁄8"1 28 Cap Screw Nut 3⁄8"-16 2 29 Cap Screw 3⁄8"-16 x 3" 2 30 Inlet Housing for Footed Base 1 31 Diaphragm* 2 32 Valve Ball* 4 33 Valve Seat* 4 34 Large Clamp Band 2 35 Large Carriage Bolt 3⁄8"-16 x 3" 4 36 Large Hex Nut 3⁄8"-16 4 37 Small Clamp Band 4 38 Small Hex Head Cap Screw 5⁄16"-18 x 13⁄8"8 39 Small Hex Nut 5⁄16"-18 8 40 Muffler (Optional — not shown) 1 41 Spacer, Ultra-Flex™ 2 42 Stud, Ultra-Flex™1 WILDEN MODEL T8 METAL WITH RUBBER-FITTED ELASTOMERS 3. IDENTIFICATION CHART All boldface items are primary wear parts. PUMP USER’S GUIDE 6 WILDEN PUMP & ENGINEERING CO. 4. AIR DISTRIBUTION SYSTEMS SYSTEM AVAILABILITY PUMP PUMPSIZE MODEL ✓✓ 1 ✓ ✓✓ ✓ ✓✓ ✓ ✓✓✓✓ ✓✓✓✓ ✓◆✓✓ ✓◆✓ ✓= Product available immediately for sale. ◆= Product currently being developed for release in first quarter 1999.1 = The A.025 pump does not utilize Glyd™ rings. 4a. System Availability and Product Line Strategy T-Series P-Series W-Series A-Series 1⁄4" (6.35 mm).025 1⁄2" (12.7 mm).050 1⁄2" (12.7 mm)1 1" (25.4 mm)2 11⁄2" (38.1 mm)4 2" (50.8 mm)8 3" (76.2 mm)15 4" (101.6 mm)20 WILDEN PUMP & ENGINEERING CO.7 PUMP USER’S GUIDE 4. AIR DISTRIBUTION SYSTEMS (Cont’d.) PRODUCT LINE STRATEGY MARKET POSITION •Durability •Low initial cost •Ease of maintenance •Low maintenance cost FEATURES •Design simplicity •Breadth of size and material •Largest installed base •Fewest number of parts APPLICATION TRAITS •Utilitarian-type application •Submersible •Priority consideration=price MARKET POSITION •ON/OFF reliability •Longest lasting wear parts •Lube-free operation •Anti-freezing FEATURES •Plastic C-block and A.V. •Non-stalling unbalanced spool •Few replaceable parts APPLICATION TRAITS •Maximum reliability •Process applications •Max. mean time between failures •Plastic air system required MARKET POSITION •Superior anti-freezing •ON/OFF reliability •Most efficient (GPM/SCFM) or (L/Nm3/h) •Superior flow rate •Lube-free operation FEATURES •Metal C-block and A.V. •Pressure relief valves •Quick air exhaust •Dbl. muffler configuration APPLICATION TRAITS •Maximum reliability •Very wet air supply •Priority consideration=efficiency •NFPA/UV stabilized (metal block) MARKET POSITION •Direct electrical interface •Superior ON/OFF reliability •Reduced system costs •Lube-free operation FEATURES •Externally controlled •Various voltage and currents •Nema 4, Nema 7, or Cenelec •Simple installation •Wilden accessory interface APPLICATION TRAITS •System automation •4-20 mA (pH adjusting) •Batching applications •OEM accounts The following section represents a quick overview of the heart of the pump: the air distribution system. The pump’s air distribution system alternately routes air supply from one side of the pump to the next, shifting the pump. Wilden Pump & Engineering Co. offers four different air distribution sys- tems to meet your specific pumping needs: Turbo-Flo™, Wil-Flo™, Pro-Flo™, and Accu-Flo™. 4b. Turbo-Flo™ The patented Wilden Turbo-Flo™ air distribution system consists of a ported air valve body which houses a piston. This piston is the only moving component of the air distribu- tion system. The system utilizes differential pressure only to shift the pump. There are no mechanical trip rods, bearings, or springs to repair due to wear. The air valve attaches to a center block which has matching ports. As air is supplied to the air valve, differential pressure causes the piston to move vertically. The vertical movement alternately supplies the power ports with pressurized air. The ports then direct the air to the back side of the diaphragms. Air valve tolerances allow for the passage of some moisture and air line particulates allowing free movement of the piston. The Turbo-Flo™ air distribution system utilizes Glyd™ rings. Glyd™ rings are Teflon®composite seals that offer long-lasting chemically resistant center block seals. The Turbo-Flo™ straight shaft used in conjunction with the Glyd™ rings enhances sealing characteristics and improves seal life. The anodized hollow aluminum piston provides a clean crisp shift. All air valve components can be inspected without disassembling the pump. The Turbo-Flo™ air distribution system is available in the T1, T2, T4, T8, T15, and T20 models. Shaft and Glyd™ ring configuration for the T1 and T2 pumps. 1, 3, 6, and 8 are seal grooves while 4 and 5 are air bleed grooves. Shaft and Glyd™ ring configuration for the T4, T8, T15, and T20 pumps. 1, 2, 4, 6, 8, 10, and 11 are seal grooves while 3, 5, 7, and 9 are air channeling grooves. 4c. Wil-Flo™ The patent-pending Wil-Flo™ air distribution system greatly improves the performance characteristics of the air- operated, double-diaphragm pump. This innovative design incorporates instantaneous shift mechanisms and an enhanced exhaust configuration. As air is supplied to the air valve, differential pressure caus- es the thermoplastic air valve piston to move vertically. The vertical movement alternately supplies air pressure to the power ports, through the spring-energized shuttle located directly behind each of the diaphragms. Piston shifting is ini- tiated by inner piston contact with one of the pressure relief valves located on each side of the center block. This contact bleeds air pressure from one end of the air valve piston cre- ating a pressure differential in the air valve body and forcing the piston to shift vertically. Upon the shifting of the air valve piston, compressed air in the air chamber moves the sliding check assembly into its recess within the center block, thus exposing the exhaust channel. This channel vents exhaust air directly to atmosphere, bypassing the air valve and eliminating a major cause of freezing while maximizing flow rates and efficiency. Wil-Flo™ retrofit kits are available for your T4, T8, and T15 pumps to easily convert your T-series pump to a Wil-Flo™ pump. NOTE: Wil-Flo™ pumps employ unique W-series straight shafts. NOTE: Wil-Flo™ pumps require a 5 (micron) air filter. PUMP USER’S GUIDE 8 WILDEN PUMP & ENGINEERING CO. ENHANCED SHAFT ENHANCED CONFIGURATION 13 68 4. AIR DISTRIBUTION SYSTEMS (Cont’d.) 4d. Pro-Flo™ The Pro-Flo™ patented air distribution system incorporates three moving parts: the air valve spool, the pilot spool, and the main shaft/diaphragm assembly. The heart of the system is the air valve spool and air valve. This valve design incor- porates an unbalanced spool. The smaller end of the spool is pressurized continuously, while the large end is alternate- ly pressurized then exhausted to move the spool. The spool directs pressurized air to one air chamber while exhausting the other. The air causes the main shaft/diaphragm assem- bly to shift to one side — discharging liquid on that side and pulling liquid in on the other side. When the shaft reaches the end of its stroke, the inner piston actuates the pilot spool, which pressurizes and exhausts the large end of the air valve spool. The repositioning of the air valve spool routes the air to the other air chamber. The Pro-Flo™ air distribution system provides superior on/off reliability in industrial processing applications where the pump is critical to process integrity. Seal technology and porting tolerance diminish blow-by in dead head conditions. Freezing is diminished due to the Pro-Flo™ porting and muf- fler design. Mating parts and seal configuration have a low coefficient of friction, allowing the pump to operate without in-line lubricants. Pro-Flo™ pumps are available in 1⁄4” (P.025), 1⁄2" (P1), 1" (P2), 11⁄2” (P4), and 2” (P8). Pro-Flo™ retrofit kits are available for your T1, T2, T4 and T8 pumps to easily convert your T-series pump to a Pro-Flo™ pump. NOTE: Pumps equipped with Pro-Flo™ air distribution sys- tem are non submersible. NOTE: Pro-Flo™ pumps utilize a unique Pro-Flo™ straight shaft. NOTE: Pro-Flo™ pumps require a 5 (micron) air filter. 4e. Accu-Flo™ Wilden Accu-Flo™ pumps use electrical impulses to stroke the pump instead of differential pressure. The solenoid air valve is a two position, four-way solenoid valve that has a single operator and spring return. The valve is internally air piloted for long coil and operator life. When the solenoid is unpowered, one air chamber within the pump is pressurized with air, while the opposite chamber is exhausted. When electric power is applied, the solenoid shifts, and the pres- surized air chamber is exhausted while the opposite cham- ber is pressurized. By alternately applying and removing power, the Accu-Flo™ pump runs like a standard Wilden Pump. Wilden’s Accu-Flo™ pumps interface directly with electronic devices, need no lubrication, and offer On/Off reli- ability. Three coil voltage options are available in both Nema 4 and Nema 7 ratings. One coil allows for 110 V AC opera- tion. The second coil option allows for 24 V DC operation and the third option allows for either 24 V AC or 12 V DC opera- tion at 60 Hz. The chart at the top of page 10 shows the options available by pump model. NOTE: Accu-Flo™ pumps are not submersible. Shaft and Glyd™ ring configuration for the A.025, A1, and A2 pumps. 1, 3, 6, and 8 are seal grooves. Shaft and Glyd™ ring configuration for the A4, A8, A15, and A20 pumps. 1, 2, 4, 6, 8, 10, and 11 are seal grooves. WILDEN PUMP & ENGINEERING CO.9 PUMP USER’S GUIDE ENHANCED SHAFT ENHANCED CONFIGURATION 13 68 4. AIR DISTRIBUTION SYSTEMS (Cont’d.) PUMP USER’S GUIDE 10 WILDEN PUMP & ENGINEERING CO. Solenoid Coil Options Nema 4 UL CSA Approved Nema 7 UL CSA Approved International Explosion Proof / Cenelec / PTB file# EX-91.C.2027 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 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 00-2110-99-157 24 VDC 3.3 .135 .135 177 60 Hz 50 Hz Inrush Holding Voltage ±10% Current (A) AC ACDCDC Coil Part Number Resistivity () Power(W) ±10%Models Available: A.025 (1/4” ) A1 (1/2” ) A2 (1” ) A4 (1 1/2” ) A8 (2” ) A15 (3” ) A20 (4” ) Diaphragms, valve balls, valve seats and O-rings are collec- tively known as pump elastomers. Wilden diaphragm pumps can be fitted with a wide range of elastomer compounds to meet virtually any application requirement. Considerations for specifying elastomers include: tempera- ture limitations, chemical compatibility, flex-life, abrasion resistance, initial investment, suction lift capabilities, and sanitary standards. There are 3 types of elastomers: Rubber compounds, Thermoplastics, and Teflon®PTFE. Please see the Elastomer Options on page 12 for a comprehensive guide of material availability for each pump type and size. CAUTION:Verify the chemical compatibility of the process and cleaning fluid to the pump’s component materials in the Chemical Resistance Guide (RBG-E4.) 5a. Rubber Compounds: These compounds consist of natural rubber and man-made additives to increase their resistance to specific types of flu- ids. Diaphragms made of these compounds utilize a nylon fabric mesh. The fabric mesh is centered within the diaphragm during the molding process. The fabric mesh lends dimensional stability and strength to the compound. Temperature Elastomer Usage Limitations Neoprene An excellent general purpose elastomer for use in non-aggressive applications. Exhibits excellent flex 0°F to +200°F life and low cost. Available for the T2, A2, P2, T4, A4, P4,– 17.7°C to +93.3°C W4, T8, A8, P8, W8, T15, A15, W15, T20 and A20 pumps. Buna-N®Excellent for applications involving petroleum/oil- based fluids. Exhibits good flex life. Available for +10°F to +180°F the A.025, P.025, T1, A1, P1, T2, A2, P2, T4, A4, P4, W4,– 12.2°C to +82.2°C T8, A8, P8, W8, T15, A15, W15, T20 and A20 pumps. Nordel®Excellent for use in applications requiring extremely (EPDM) cold temperatures. May also be used as a low cost – 60°F to +280°F alternative when pumping dilute acids or caustics.– 51.1°C to +137.8°C Not oil resistant. Available for the T2, A2, P2, T4, A4, P4, W4, T8, A8, P8, W8, T15, A15, W15, T20 and A20 pumps. Viton®Excellent for use in applications requiring extremely hot temperatures. May also be used with aggressive fluids such as aromatic or chlorinated hydrocarbons – 40°F to +350°F and acids. The high cost and poor flex life of Viton®– 40°C to +175.7°C limit its use. Available for the T1, A1, P1, T2, A2, P2, T4, A4, P4, W4, T8, A8, P8, W8, T15, A15, W15, T20 and A20 pumps. 5. ELASTOMERS 4. AIR DISTRIBUTION SYSTEMS (Cont’d.) 4f. Accu-Flo™ Solenoid Coil Options WILDEN PUMP & ENGINEERING CO.11 PUMP USER’S GUIDE Ultra-Flex™ Diaphragms Wilden’s latest breakthrough in diaphragm design is the Ultra-Flex™ diaphragm series. Neoprene, Buna-N ®, Nordel®, and Viton®Ultra-Flex ™ diaphragms are available for the T4 Metal, Stallion, and Plastic, A4 Metal and Plastic, P4 Metal and W4 Metal, T8 Metal, Stallion, and Plastic, A8 Metal and Plastic, P8 Metal and Plastic, W8 Metal and Plastic, T15 Metal and Stallion, W15 Metal, T20 Metal and A20 Metal pumps. Wilden’s Ultra-Flex™ patented technology dia- phragms are guaranteed to deliver longer life than pie- shaped, dome-shaped, or any other competitive diaphragm technology. Ultra-Flex™ diaphragms are ideal for applica- tions where the pump runs many hours per day and greater flex life is needed. Field results also show the Ultra-Flex™ to be an excellent diaphragm choice for powder transfer appli- cations. 5b. Thermoplastic Compounds These compounds are made up entirely of man-made elements. Diaphragms made of these compounds require no fabric reinforcement due to the dimensional stability and tensile strength inherent in TPE (Thermoplastic Elastomers) compounds. Temperature Elastomer Usage Limitations Wil-Flex™ (Santoprene) A low-cost alternative to Teflon ®in many acidic and caustic applications. Exhibits excellent abrasion – 40°F to +225°F resistance and flex life. Available for the A.025, P.025,– 40°C to +107.2°C T1, A1, P1, T2, A2, P2, T4, A4, P4, W4, T8, A8, P8, W8, T15, A15, W15, T20 and A20 pumps. Polyurethane A general purpose diaphragm for use in non- aggressive and/or highly abrasive applications.+10°F to +150°F Available for the T1, A1, P1, T2, A2, P2, T4, A4, P4, W4,– 12.2°C to +65.6°C T8, A8, P8, W8, T15, A15, W15, T20 and A20 pumps. Sani-Flex™ (Hytrel) Excellent abrasion resistance, flex life and durability. This material is FDA approved for food processing – 20°F to +220°F applications. An outstanding general purpose – 28.9°C to +104.4°C diaphragm. Good for oil and coolants. Available for the T1, A1, P1, T2, A2, P2, T4, A4, P4, W4, T8, A8, P8, W8, T15, A15, W15, T20 and A20 pumps. Temperature Elastomer Usage Limitations Teflon®PTFE Excellent choice when pumping highly aggressive fluids +40°F to +220°F such as aromatic or chlorinated hydrocarbons, acids, caustics,+4.4°C to +104.4°C ketones and acetates. Exhibits good flex life compared to a standard diaphragm. Available for the A.025, P.025, P.050,For T1, A1, P1 & T2, A2, P2: T1, A1, P1, T2, A2, P2, T4, A4, P4, W4, T8, A8, P8, W8, T15,+40°F to +300°F A15, W15, T20 and A20 pumps.+4.4°C to +142°C 5c. Teflon ®PTFE (Polytetrafluoroethylene) Teflon®PTFE is one of the most chemically inert man-made compounds known. Wilden engineers were the first to dis- cover that by reinforcing a molded Teflon®PTFE diaphragm with concentric ribs they could control the flex pattern of the diaphragm. Wilden’s patented ribbed design extends flex life 5 to 10 times longer than that of any other Teflon®diaphragm. This innovation made the use of Teflon®elastomers in diaphragm pumps cost effective, greatly expanding the range of applications for diaphragm pumps. Teflon®is not an elastic material, therefore when utilizing Teflon®diaphragms, a back-up diaphragm is required to provide flexibility and memory in every size except A.025 and P.025. Material options for back-up diaphragms are Neoprene, Sani-Flex®, and high temperature Buna-N®. When using Teflon® diaphragms, flow rates will be reduced by up to 20%. This is due to the inability of Teflon®to flex as far as rubber diaphragms, thus decreasing the displacement of process fluid per stroke. 5d. Specialty Diaphragms Wilden offers a variety of specialty diaphragms such as the IPD (Integral Piston Diaphragm) for the A.025, P.025, P.050, T2, A2 and P2 pump series, as well as the non-pigmented Wil-Flex™ diaphragm for the HP250 high-pressure pump. 5. ELASTOMERS (Cont’d.) TM PUMP USER’S GUIDE 12 WILDEN PUMP & ENGINEERING CO. DIAPHRAGM AND VALVE BALL PUMP MODEL T1 T2 T4 T8 T15 T20 A1 P1 A2 P2 A4 P4 W4 A8 P8 W8 A15 W15 A20 Neoprene • • • • • • • • • • Polyurethane • • • • • • • • • • • • • Buna-N®•••••••• •••• Nordel®•••••• •••• Viton®•••••••• ••••• 1 Wil-Flex™ • • • • • • • • • • • • • 1 Sani-Flex™ • • • • • • • • • • • • • 1 Teflon®PTFE • • • • • • • • • • • • • 2 METAL PUMPS PLASTIC PUMPS VALVE SEATS PUMP MODEL T1 T2 T4 T8 T15 T20 A1 P1 A2 P2 A4 P4 W4 A8 P8 W8 A15 W15 A20 Neoprene • • •••••• Polyurethane • • ••••••• Buna-N®•••••••• Nordel®•••••••• Viton®• ••••••••• Wil-Flex™ • • •••••• Sani-Flex™ • • •••••• Aluminum • • • • • • •••••• Stainless Steel • • • • • • •••••• Carbon Steel • • •••••• Hastelloy C • • • • • • •••••• VALVE SEAT O-RINGS PUMP MODEL T1 T2 T4 T8 T15 A1 P1 A2 P2 A4 P4 W4 A8 P8 W8 A15 W15 Polyurethane • • • • • • • • Buna-N®•••• •• •• Nordel®•• Sani-Flex™ • • • • • • • Teflon®PTFE • • • • • • • • • • • • Fluoro-Seal™ • • • • • • • Wil-Flex™ • • 1Diaphragm only. 2Valve balls only. DIAPHRAGM AND VALVE BALL PUMP MODEL T1 T2 T4 T8 A.025 P.025 P.050 A1 P1 A2 P2 A4 P4 W4 A8 P8 W8 Neoprene • • • • • • • • Polyurethane • • • • • • • • • • Buna-N®•1 •1 •••••••••• Nordel®•••••••• Viton®•••••••••• Wil-Flex™ • 1 •1 •••••••••• Sani-Flex™ • • • • • • • • • • Teflon®PTFE • • • • • • • • • • • • VALVE SEAT O-RINGS PUMP MODEL T1 T2 T4 T8 A.025 P.025 P.050 A1 P1 A2 P2 A4 P4 W4 A8 P8 W8 Polyurethane • • • • • • • • • Buna-N®•• ••••••••• Teflon®(Encapsulated)••••••••••••• Wil-Flex™ • • • • • Chemraz®•• Sani-Flex™ • • • Nordel®• VALVE SEATS PUMP MODEL T1 T2 T4 T8 A.025 P.025 P.050 A1 P1 A2 P2 A4 P4 W4 A8 P8 W8 Polypropylene • • • • • • • • • • PVDF • • • • • • • • • • • • Carbon-Filled Acetal •• ••• Teflon®PFA • •• ••• Viton®•• MANIFOLD O-RINGS PUMP MODEL T1 T2 T4 T8 A.025 P.025 P.050 A1 P1 A2 P2 A4 P4 W4 A8 P8 W8 Polyurethane • • • • • • • • • • Buna-N®• • •••••••••• Teflon®(Encapsulated)••••••••••••• Wil-Flex™ • • • • • Chemraz®• Viton®• Sani-Flex™ • 1Diaphragm only. MANIFOLD O-RINGS The only metal pumps utilizing manifold O-rings are the T8 Sani-Flo™ , models T20 and A20, which use Viton®or polyurethane, and the T1, P1 and A1 pumps, which utilize the same options as the T1, P1 and A1 Plastic. The Teflon®manifold O-rings utilized in the T1, P1 and A1 Metal pumps are Teflon®PTFE versus the Teflon®encapsulated Viton®O-rings utilized in the T1, P1 and A1 Plastic pumps. Fluoro-Seal™ is a trademark of Wilden Pump & Engineering Co. Sani-Flex™ and Wil-Flex™ are registered trademarks of Wilden Pump & Engineering Co. Buna-N®, Nordel®and Viton®are registered trademarks of DuPont Dow Elastomers. Teflon®is a registered trademark of DuPont. 5e. ELASTOMER OPTIONS Model Pump Size Maximum Flow Rates Maximum Solids Passage A.025 1⁄4" inlet 2.8 gpm (10.6 LPM) 1⁄64" (0.4 mm) T1, A1 1⁄2" inlet 14.5 gpm (54.9 LPM) 1⁄16" (1.6 mm) T2, A2, T2R, A2R 1" inlet 35 gpm (132.5 LPM) 1⁄8" (3.2 mm) T2 Saniflo3A 11⁄2" Tri-clamp 32.9 gpm (125 LPM) 1⁄4" (6.4 mm) T4, A4 1 1⁄2" inlet 93 gpm (352.0 LPM) 3⁄16" (4.8 mm) T4 Stallion 1 1⁄2" inlet 57 gpm (216.6 LPM) 1⁄2" (12.7 mm) T8, A8 2" inlet 163 gpm (617 LPM) 1⁄4" (6.4 mm) T8 SanifloUSDA 2" inlet 140 gpm (532 LPM) 1⁄2" (12.7 mm) T8 Stallion 2" inlet 148 gpm (562.4 LPM) 3⁄4" (19.1 mm) T8 HP250 2" inlet 96 gpm (359 LPM) 1⁄4" (6.4 mm) T15, A15 3" inlet 232 gpm (878.1 LPM) 3⁄8" (9.5 mm) T15 Stallion 3" inlet 183 gpm (695.4 LPM) 1" (25.4 mm) T20, A20 4" inlet 275 gpm (1040 LPM) 1 3⁄8" (34.9 mm) P.025 1⁄4" inlet 5.0 gpm (18.9 LPM) 1⁄64" (0.4 mm) P1 1⁄2" inlet 15 gpm (56.8 LPM) 1⁄16" (1.6 mm) P2 1" inlet 45 gpm (170.3 LPM)1⁄8" (3.2 mm) P4 11⁄2" inlet 93 gpm (352.0 LPM) 3⁄16" (4.8 mm) P8 2" inlet 156 gpm (590.5 LPM)1⁄4" (6.4 mm) W4 11⁄2" inlet 99 gpm (374.8 LPM) 3⁄16" (4.8 mm) W8 2" inlet 206 gpm (779.8 LPM)1⁄4" (6.4 mm) W15 3" inlet 287 gpm (1086.4 LPM)3⁄8" (9.5 mm) WILDEN PUMP & ENGINEERING CO.13 PUMP USER’S GUIDE The following drawings represent generic diaphragm assem- blies for a Wilden pump. Your specific diaphragm configura- tion might be different. Please consult Section 9A of your EOM for your pump’s specific diaphragm assembly. 6a. Rubber/Thermoplastic Elastomer-fitted pumps: 1. Main shaft 2. Inner piston 3. Primary diaphragm in contact with the process fluid 4. Outer piston holds the diaphragm to the shaft (in contact with process fluid) 6b. Teflon ®-fitted pumps (except A.025 and P.025): 1. Main shaft 2. Inner piston 3. Back-up diaphragm not in contact with process fluid (employed with Teflon®primary diaphragms, except 1⁄4" pumps) 4. Primary Teflon ®PTFE diaphragm in contact with process fluidon the outer piston side 5. Outer piston holds the diaphragm to the shaft (in contact with process fluid) Teflon®-fitted A.025 and P.025 pumps diaphragm assembly: 1. Main shaft 2. Bellville washer 3. Inner piston 4. Back-up O-ring not in contact with process fluid (employed with Teflon®primary diaphragms only) 5. Primary Teflon ®PTFE diaphragm 6. Outer piston 6c. Ultra-Flex™-fitted pumps: 1. Main shaft 2. Spacer 3. Inner piston 4. Primary diaphragm — Ultra-Flex™ 5. Outer piston Note: Pro-Flo™ (P4 & P8) models fitted with Ultra-Flex™ diaphragms do not use a spacer. Note:1⁄4",1⁄2", and 1" pump shaft assemblies utilize Bellville washers, installed between the shaft and inner piston, and 242 Loctite. 12 4 3 1 25 43 1 2 4 5 3 6 1 2 5 4 3 6. DIAPHRAGM ASSEMBLY 7. PUMP SELECTION T-Series & A-Series* P-Series W-Series 7a. Pump Selection Chart *A-series pumps have a significant reduction in flow rate as compared to the T-series pumps. Refer to Section 5 of your EOM manual for specifics. PUMP USER’S GUIDE 14 WILDEN PUMP & ENGINEERING CO. 7b. Size A pump’s critical dimensions must be checked against exist- ing piping to eliminate the need for costly re-plumbing. Please refer to Section 4 of your EOM manual for details. 7c. Solids Handling Capability Maximum slurry particle size must not be greater than the pump’s solids passage capability. A strainer may be placed on the inlet line to eliminate particles larger than the pump’s capability. Please refer to Section 5 of your EOM manual for your pump’s specific solids passage capabilities. 7d. Suction Lift An application’s suction lift requirements must not be greater than the pump’s suction lift capabilities. Suction lift will vary depending on the number of inlet and discharge elbows, the viscosity of the process fluid, elevation (atmospheric pres- sure) and pipe friction loss. Wilden suction lift curves are cali- brated for pumps operating at 1,000' (305m) above sea level pumping water. When reading suction lift curves, locate the curve on the chart that represents your pump (Teflon®, TPE, Ultra-Flex™, or Rubber fitted). On the Inlet Air Pressure axis, locate the amount of air pressure you are running to the pump, follow that point straight up until you locate the curve. Once you locate the curve, trace that point to the left until you locate the Dry Vacuum vertical axis. The point you reach corresponds to the dry vacuum or suction lift your pump will achieve at that specific inlet air pressure. Please refer to Section 6 of your EOM for your pump’s spe- cific suction lift capabilities. 7e. Performance Curves Pump performance capabilities must be matched with flow rate requirements. Please consult Section 5 of your EOM for your pump’s performance curve. • Discharge head (vertical axis). • Required flow rate (horizontal axis). A pump should be selected which will operate between the 25 and 75 percentile range of capacity. For optimum life and performance, pumps should be speci- fied so that daily operation parameters will fall in the middle of the pump performance curve. Wilden publishes 4 different performance curves for most metal and plastic pump mod- els. These performance curves are unique due to the differ- ent stroke lengths of the diaphragm assemblies. The four classifications are: 1) Rubber-fitted pumps; 2) Ultra-Flex™- fitted pumps; 3) Thermoplastic (TPE)-fitted pumps; and 4) Teflon®-fitted pumps. When applicable, all four of these curves are included in the Engineering, Operation, and Maintenance manuals (EOM’s). How to read a Wilden performance curve:Determine the flow rate your application requires and calculate the Total Discharge Head (page 15). Plot the intersection of the dis- charge head on the vertical axis to the flow rate on the hori- zontal axis. Now the air supply pressure and air supply vol- ume can be extracted from the curve. Simply locate the solid black line closest to this intersection and follow it to the ver- tical axis to the left. This is the air supply pressure needed to provide the flow rate you require at the given discharge head. Next locate the closest gray line to the intersection and follow it up to where the numbers are provided. These num- bers indicate the air supply volume needed to provide the flow rate you require at the given discharge head. To pump 40 gpm (151 lpm) against a discharge pressure head of 40 psig (2.7 Bar) requires 60 psig (4.1 Bar) and 18 scfm (30.6 Nm3/h) air consumption. Dot on chart represents the plotted intersection and the circled numbers are the air pressure and volume figures. 7f. Total Dynamic Head Calculation: Please refer to the example at the top of page 15 for calcu- lating your TDH (Total Dynamic Head). Wilden publishes a Pump Viscosity and Cavitation Chart (RBG-E6) that needs to be used in accordance with the boxed worksheet to obtain the Total Dynamic Head. Process fluid viscosity plays an integral part in calculating TDH. The more viscous a product, the more head a pump has to overcome to move that product. Please contact your authorized Wilden distributor for more information. 7g. Chemical Compatibility Wilden’s chemical resistance guide (RBG-E4) should be used in conjunction with personal experience to select wetted pump construction and elastomers for chemical com- patibility with the process fluid. 7h. Temperature Limitations Temperature limitations are based on mechanical stress only. Certain chemicals will significantly reduce the maximum safe operating temperatures. Consult Wilden’s Chemical Resistance Guide (RBG-E4) for chemical compat- ibility and temperature limits for specific fluids. Process fluid and environmental temperatures must be considered. Temperature limits for materials of construction and elas- tomers are listed below: Additionally, temperature limitations are listed in Section 3 of your EOM. TEMPERATURE LIMITS: Polypropylene +32°F to +175°F 0°C to +79°C PVDF Kynar®+10°F to +225°F -12°C to +107°C Teflon®PFA +20°F to +300°F +7°C to +143°C (T1 and P1 UP III) Teflon®PFA +20°F to +225°F +7°C to +107°C (T1 and P1 UP I and T4, A4, W4, P4 only) Neoprene 0°F to +200°F -17.7°C to +93.3°C Buna-N®+10°F to +180°F -12.2°C to +82.2°C Nordel®-60°F to +280°F -51.1°C to +137.8°C Viton®-40°F to +350°F -40°C to +176.7°C Wil-Flex™ -40°F to +225°F -40°C to +107.2°C Saniflex™ -20°F to +220°F -28.9°C to +104.4°C Polyurethane +10°F to +150°F -12.2°C to +65.6°C Teflon®PTFE +40°F to +220°F +4.4°C to +104.4°C Carbon-filled Acetal -20°F to +150°F -28.9°C to +65.6°C Teflon®(P.050 only) +32°F to +248.9°F 0°C to +120°C 120 100 80 60 40 20 GPM 10 20 30 40 50 60 70 80 90[l/min] [38] [76] [114] [151] [189] [227] [265] [303] [340] Water Discharge Flowrates 300 250 200 150 100 50 0 8 7 6 5 4 3 2 1 0 AIR CONSUMPTION (SCFM)[Nm3/h] (60)[102] (50)[85] (40)[68](30)[52](20)[34] BAR FEET PSIG (10) [17] AIR INLET PRESSURE (PSI) 20 40 60 80 100 120 7. PUMP SELECTION (Cont’d.) WILDEN PUMP & ENGINEERING CO.15 PUMP USER’S GUIDE TOTAL DYNAMIC HEAD WORKSHEET Need to Know:G.P.M. Specific Gravity (s.g., ) Pipe Size () Viscosity() Need to Have:Wilden Cavitation/Pipe Friction Chart and Viscosity Chart (RBG-E6) TOTAL DYNAMIC HEAD = +/- TOTAL SUCTION LIFT + TOTAL DISCHARGE HEAD I. Static Suction Head/Lift Static Discharge Head Static Lift (head) = vertical distance Discharge Head = vertical distance from liquid surface to center line from center line of pump to point of pump of free discharge ______ (Vertical feet) x _____ s.g.=______feet ______ (Vertical feet) x _____ s.g.=______feet ______feet x .433 (or Divide by 2.31)=______PSI ______feet x .433 (or Divide by 2.31)=______PSI II. Dynamic Suction Dynamic Discharge (A) Pipe Diameter _____(inches) (A) Pipe Diameter _____(inches) (B) Viscosity _____(ssu) (B) Viscosity _____(ssu) (C) Pipe _____ (C) Pipe _____ + elbows* _____ + elbows* _____ = total pipe _____(feet) = total pipe _____(feet) Viscosity Chart Figure ______(PSI loss/100 ft) Viscosity Chart Figure ______(PSI loss/100 ft) _________ x ____s.g. x ____ total pipe=____PSI _________ x ____s.g. x ____ total pipe=____PSI (PSI loss 100) (PSI loss 100) II. Total Suction Lift/Head Total Discharge Head ______ (PSI figure from calculation I) ______ (PSI figure from calculation I) + ______ (PSI figure from calculation II) + ______ (PSI figure from calculation II) = ______ PSI = ______ PSI +/- ________Total Suction Lift _______Total Discharge Head = ________ PSI Total Dynamic Head * Assume 10 ft loss for every 90° elbow. 7i. Abrasion Resistance When a highly abrasive fluid is pumped, damage can occur to the pump’s internals if the given internals do not exhibit the abrasion resistance needed. Certain powders, as well as, slurries containing rocks, metal fines, or sand tend to be highly abrasive “scratching” the pump’s internals as they go through the pump. Pump internals most likely to get dam- aged are a pump’s ball cages and elastomers: diaphragms, balls, and seats. If the given elastomers do not exhibit the abrasion resistance required, they will wear prematurely. This premature wear will affect the pump’s performance. Note: When pumping highly abrasive substances, it is sug- gested to install an oversize pump in order to reduce the velocity of the process fluid and hence reduce elastomer abrasion. Ultra-Flex™ diaphragms exhibit exceptional abra- sion resistance given special fabric placement that allows for more sacrificial rubber. In addition, Wilden Pump & Engineering Co. offers a complete line of abrasion resistant materials to revolutionize the way you solve your toughest pumping problems. 7j. Cavitation Cavitation is a hydraulic condition which can exist in any type of pump. It is primarily a situation in which the pump is dis- charging less liquid than its rated capacity due to reduction or lack of fluid supply to the pump. Common causes of cavi- tation are excessive suction lift, insufficient Net Positive Suction Head (NPSH), or operation at too high a speed. Pitting, vibration, and noise are common troubles stemming from cavitation. While severe cavitation is usually accompa- nied by excessive noise, mild cavitation may produce nothing more than a small reduction in pump efficiency and moderate wear of pump parts. You should: • Slow pump down • Reduce suction lift • Increase positive head pressure • Use a larger pump if you are not getting the required flow rates • Consult Wilden’s Cavitation and Pump Friction Guide (RBG-E6) for more details 7. PUMP SELECTION (Cont’d.) Please refer to page 25 for conversion tables. PUMP USER’S GUIDE 16 WILDEN PUMP & ENGINEERING CO. The following is a generic pump designation system to famil- iarize you with Wilden’s nomenclature. Please refer to Section 1 of your EOM for the Material Code designation system for your pump size. Your specific pump model is located on your pump’s serial tag. Please note some model descriptions include a three digit specialty code at the end. This specialty code signifies an additional feature for the specific pump. See your authorized Wilden distributor for additional information. WILDEN PUMP DESIGNATION SYSTEM A, P, T, or W / XXXX / XX / XX / XXX / (xxx) O-RINGS VALVE SEAT VALVE BALLS DIAPHRAGMS AIR VALVE CENTER BLOCK OR CENTER SECTION AIR CHAMBERS OR CENTER SECTION WETTED PARTS SPECIALTY CODE (IF APPLICABLE) MODEL PUMP MODEL — INLET A or P.025 = 1/4" P.050 = 1/2" A, T, or P1 = 1/2" A, T, or P2 = 1" A, T, P, or W 4 = 1 1/2" A, T, P, or W 8 = 2" A, T, or W 15 = 3" A or T 20 = 4" WETTED PARTS A = Aluminum G = Acetal, Carbon-Filled H = Hastelloy K = Kynar ®/PVDF P = Polypropylene S = Stainless Steel T = Teflon ®(PFA) W = Cast Iron AIR CHAMBERS A = Aluminum C = Teflon ®-Coated G = Acetal, Carbon-Filled (A.025, P.025, A1, T1) K = Kynar (P.050 only) L = Virgin Acetal M = Mild Steel (A4, T4) N = Nickel-Plated P = Polypropylene R = Carilon ® S = Stainless Steel V = Halar-Coated W = Cast Iron Y = Nylon CENTER BLOCK A = Aluminum C = Teflon ®-Coated G = Acetal, Carbon-Filled K = Kynar ® L = Virgin Acetal N = Nickel-Plated P = Polypropylene R = Carilon ® S = Stainless Steel Y = Nylon AIR VALVE A = Aluminum B = Brass C = Teflon ®-Coated D = Brass w/Oil Btl. L = Virgin Acetal N = Nickel-Plated P = Polypropylene Q = Conductive Isoplast S = Stainless Steel Z = Lube-Free DIAPHRAGMS BN = Buna-N ® ET = Teflon ®w/Integral Piston & Rubber Laminate 3A Model FG = Sani-Flex™ ND = Nordel ® NE = Neoprene PU = Polyurethane TF = Teflon ®(Primary) TX = Teflon ®w/Integral Piston A.025, P.025, P.050 VT = Viton ® WF = Wil-Flex™ DIAPHRAGMS, ULTRA-FLEX™ UB = Buna-N ® UE = Nordel ® UN = Neoprene UV = Viton ® VALVE BALL BN = Buna-N ® FG = Sani-Flex™ FV = Food Grade Viton ® ND = Nordel ® NE = Neoprene PU = Polyurethane SS = Stainless Steel TF = Teflon ®PTFE VT = Viton ® WF = Wil-Flex™ VALVE SEAT A = Aluminum BN = Buna-N ® FG = Sani-Flex™ H = Hastelloy K = Kynar ®/PVDF M = Mild Steel ND = Nordel ® NE = Neoprene P = Polypropylene PU = Polyurethane S = Stainless Steel T = Teflon ®PFA VT = Viton ® WF = Wil-Flex™ VALVE SEAT O-RING BN = Buna-N ® CR = Chemraz (UP) FG = Sani-Flex™ FS = Fluoro-Seal (Metal) ND = Nordel ® PU = Polyurethane TF = Teflon ®PTFE (Metal) TV = Teflon ®Encap. Viton® WF = Wil-Flex™ 8. WILDEN PUMP DESIGNATION SYSTEM NOTE: Not all combinations are available on all pump models. Please contact your local authorized distributor for more information. WILDEN PUMP & ENGINEERING CO.17 PUMP USER’S GUIDE SUCTION NEEDLEVALVE MUFFLER PIPE CONNECTION(STYLE OPTIONAL) DISCHARGE SHUT OFFVALVE FLEXIBLECONNECTION FLEXIBLECONNECTION COMBINATIONFILTER,REGULATOR &LUBRICATOR AIRSHUTOFFVALVE GAUGE(OPTIONAL) EQUALIZERSURGE DAMPENER(OPTIONAL) FOOT PAD FLEXIBLECONNECTION DISCHARGE SHUT OFFVALVE GAUGE(OPTIONAL) FLEXIBLECONNECTION EQUALIZERSURGE DAMPENER(OPTIONAL) FOOTPAD NEEDLEVALVE FLEXIBLECONNECTION COMBINATIONFILTER &REGULATOR AIRSHUTOFFVALVE SUCTION MUFFLERFLEXIBLECONNECTION 9. SUGGESTED INSTALLATION Turbo-Flo™ Suggested Installation Pro-Flo™ Suggested Installation Wil-Flo™ Suggested Installation SUCTION NEEDLEVALVE DISCHARGE SHUT OFFVALVE FLEXIBLECONNECTION FLEXIBLECONNECTION COMBINATIONFILTER &REGULATOR AIRSHUTOFFVALVE GAUGE(OPTIONAL) EQUALIZERSURGE DAMPENER(OPTIONAL) FOOTPAD MUFFLERS PIPE CONNECTION(STYLE OPTIONAL) FLEXIBLECONNECTION Accu-Flo™ Electrical Connections POWER SWITCHED (CONTROL) CONNECTION GROUND (SAFETY) CONNECTION COMMONCONNECTION FLICKER MODE RELAY OR BATCH CONTROLLER ** * * * AIR OPERATED DOUBLE DIAPHRAGM PUMPS StartStopPowerOn/Off DecreasePump SpeedIncreasePump Speed PresetSelector EnergizedDe-energizedLeak Detect Coil StatusStroke Counter Totalizer Preset Stroke Interval (sec.) Accu-Flo™ Plumbing Connections 9a. Pre-Installation Checklist: Cautions • Verify pump model received against purchase order or spec sheet. • Re-torque all bolts to specifications on torque table. • Remove shipping plugs. • Pumps that need to be submersed must have both wetted and non-wetted parts compatible with material being pumped. • Submersed pumps must have a hose attached to pump’s air exhaust and the exhaust air piped above liquid level. • Pumps should be thoroughly flushed with water before installation. • FDA, USDA, and 3A pumps should be sanitized prior to usage. • Do not exceed 125 psi air supply pressure (50 psi on UL models). • Blow out air line for 10 to 20 seconds before attaching to pump to make sure all pipe line debris is clear. 9b. Suggested Installation: The suction pipe should be at least the diameter of the pump’s inlet manifold connection or larger if highly viscous material is being pumped. The suction hose must be non- collapsible, reinforced type as Wilden pumps are capable of pulling a high vacuum. Discharge piping should be at least the diameter of the pump’s discharge manifold connection; larger piping can be used to reduce friction losses. It is criti- cal that all fittings and connections are airtight or a reduction or loss of pump suction capability will result. The pump should not be used as a support mechanism for the piping system.Wilden suggests the use of flexible connections for inlet/outlet ports and air line (see diagrams). Due to the reciprocating action of the pump, lateral instabili- ties can occur during normal operation, thus footed pumps should be bolted to the ground and pads should be used. Ensure the operating surface is level and flat. Most Wilden pumps can be used in submersible applications only when both wetted and non-wetted portions are compat- ible with the material being pumped. If the pump is to be used in a submersible application, a hose should be attached to the pump’s air exhaust and the exhaust air piped above the liquid level. NOTE: Pro-Flo™ and Accu-Flo™ pumps cannot be submerged. FLUID INLET FLUID OUTLET DISCHARGESHUTOFF VALVE COMBINATION FILTER AND REGULATOR FLEXIBLECONNECTION AIR SUPPLY SUCTION LINE DISCHARGE LINE AIR INLET FLEXIBLE CONNECTION INTAKESHUTOFF VALVE FLEXIBLECONNECTION PUMP USER’S GUIDE 18 WILDEN PUMP & ENGINEERING CO. If the pump is to be used in a self-priming application, be sure that all connections are airtight and that the suction lift is within the pump’s ability. Note: Materials of construction and elastomer material have an effect on suction lift para- meters. Refer to Section 6 of your EOM for your pump’s spe- cific suction lift capability. Pumps in service with a positive suction head are most effi- cient when inlet pressure is limited to 0.5–0.7 bar (7–10 psig). Premature diaphragm failure may occur if positive suction head is 0.8 bar (11 psig) and higher, particularly when using Teflon®and Thermoplastic diaphragms. All pos- itive suction head applications should include a “check valve” at the pump liquid inlet to allow for the pump to be disconnected. Each Wilden pump has a specific maximum solids capabili- ty. Whenever the possibility exists that larger solid objects may be sucked into the pump, a strainer should be used on the suction line. (See page 13 for maximum solids passage.) CAUTION:Do NOT exceed 8.6 bar (125 psig) air supply pressure. (50 psi for UL-listed and 85 psi for HP250.) CAUTION: Blow out air line for 10 to 20 seconds before attaching to pump to make sure all pipe line debris is clear. Use a 5 (micron) air filter on all Pro-Flo™ and Wil-Flo™ models. NOTICE:All fasteners should be checked to match the pump’s given torque specifications listed in Section 8 of the Engineering, Operation and Maintenance manual. CAUTION:Ensure proper ventilation of tanks/vessels that house liquid supply. Due to the pump’s high vacu- um ability, improper ventilation of these supply tanks can lead to implosion of tanks when fluid is complete- ly evacuated. CAUTION:Thermal expansion: Some liquids present in piping may expand at elevated temperatures, result- ing in pipe and/or pump damage and subsequent risk to operator. ELECTRICAL HAZARDS Static Spark can cause explosion resulting in severe injury or death. Electrostatic hazard is eliminated by properly ground- ing the pump and the pumping system. For some applica- tions the A.025, P.025, T1 and A1 Carbon Filled Acetal (CFA) pumps will provide a more adequate dispersal of static elec- tricity. Consult local building codes and electrical codes for specific grounding requirements. Conductivity: Certain Wilden pumps provide for safe transfer of flammable materials. UL 79, Carbon-Filled Acetal pumps (CFA), and Nema 7 coils are available to meet your specific conductivity needs. Please contact Wilden at (909) 422-1730 for more information. TEMPERATURE HAZARDS Fluid being pumped should be compatible with the pump’s material of construction and temperature limits as stated in the Wilden Chemical Resistance Guide (RBG-E4). HAZARDS GENERATED BY NOISE Pump noise can be excessive under certain operating conditions, e.g. high air pressure supply and little or no discharge head. Extended periods of operation under such conditions can create a hazard to operators working in proximity to the pumps. Ways to avoid this hazard are listed as follows: • Use proper hearing protection devices. • Use mufflers on the pump’s air exhaust. • Plumb the pump’s exhaust air to an area not in proximity of plant workers. • Use elastomeric valve balls in lieu of Teflon ®valve balls since soft balls reduce noise. (Ensure proper chemical resistance of ball elastomer used) HAZARDOUS MATERIALS Handler should obtain Material Safety Data Sheet (MSDS) from the chemical supplier for all materials being pumped for appropriate handling instructions. When pumping hazardous fluids, Wilden pumps should be fitted with the Wil-Gard™ II diaphragm monitoring system, which will detect a diaphragm failure before hazardous mate- rial exits the pump. Wil-Gard™ II diaphragm monitoring sys- tem is only available with Teflon®fitted pumps. In case of diaphragm failure, material being pumped may exit pump via air exhaust, in which case contact with the haz- ardous material is possible. CHEMICAL COMPATIBILITY When selecting a pump for a particular application, pump wetted materials of construction and elastomer materials must be compatible with the material being pumped. Please consult Wilden Chemical Resistance Guide (RBG-E4) or your local authorized distributor for more information. CAUTION:Some materials such as halogenated sol- vents should not be pumped with an aluminum con- struction pump due to a possible explosive reaction. Consult your chemical supplier. 9c. Accu-Flo™ Installation All wiring used to operate the pumps should be placed and connected according to the proper electrical codes. It is important that the wiring is of adequate gauge to carry the current required to operate the pump. In addition, it is nec- essary that the electrical power supply is large enough to supply the current required to operate the pump. Wiring should be above ground level if possible (in case of fluid spill or leakage), and all wiring and connections which could become wet or damp should be made watertight. The solenoid valve is rated for continuous duty; however, stopping an even number stroke count insures that the elec- trical power is off when the pump is stopped. This practice is safer and also eliminates unwanted strokes when the system is shut down and electrical power is off. Solenoid valve fitted pumps should not be used in an area where explosion proof equipment is required unless an explosion proof coil is utilized. Nema 7 explosion proof coils are available for all Accu-Flo™ pumps. 9. SUGGESTED INSTALLATION (Cont’d.) WILDEN PUMP & ENGINEERING CO.19 PUMP USER’S GUIDE 10a. Directions for disassembly/re-assembly The following are generic directions for disassembly/ reassembly of the Wilden pump. Please refer to Section 8 of your EOM for detailed disassembly/reassembly instructions and photographs pertaining to your specif- ic pump. 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. 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. Wear safety glasses. When diaphragm failure occurs, material being pumped may be forced out the air exhaust. NOTE:Before starting disassembly, mark a line from each liquid chamber to its corresponding air chamber. This line will assist in proper alignment during reassembly. Before you disassemble the pump: • Wear safety glasses • Shut off main air supply • Disconnect air hose from air valve to drain air pressure in hose • Isolate pump using isolation valves to avoid product spillage from pipe • Turn pump upside down to drain all liquid trapped by valve balls • Mark a line from each liquid chamber to its corresponding air chamber to assist in proper alignment during reassembly 10b. Inspection Air Valve Piston/Spool and Casing • Ensure piston/spool can move freely • Clean out debris Diaphragms • Make sure no swelling, cracking, or other damage is apparent Balls/Seats/O-rings • Make sure no swelling, cracking, or other damage is apparent • Lubricate shaft if needed 10c. Mean Time to Failure A Preventative Maintenance Schedule (PMS) should be set up for the following parts to ensure pump is serviced prior to part wear • Diaphragms • Valve Seats • Valve Balls • O-rings 10d. Seal Replacement Proper seal installation is critical to pump performance when employing AODDPs in your application. Great care must be taken to ensure that seals are placed in the proper grooves and not damaged during installation. Incorrect seal location will render the pump inoperable. Damaged seals may cause decreased performance and shorter seal life. The Ringer™ seal installation kit, containing an installation tool and locator bushings simplifies seal installation on the T4, T8, T15, and T20 Turbo-Flo™ pumps. 10e. Disassembly Overview The following instructions are to be used as a reference for disassembly/reassembly of your Wilden pump. These instructions are meant solely to give you an idea on how to disassemble/reassemble a Wilden pump. Your pump size and build may vary substantially. Please refer to Section 8 of your EOM for specific detailed instructions on disassembly/reassembly of your Wilden pump. Before starting disassembly, mark a line from each liquid chamber to its corresponding air chamber. This line will assist in proper alignment during reassembly. Utilizing a box wrench, remove the two small clamp bands that fasten the discharge manifold to the liquid chambers. Remove the discharge manifold to expose the valve balls and seats. Inspect the ball cage area of the manifold for excessive wear or damage. Remove the discharge valve balls, seats, and O-rings from the discharge manifold and inspect for nicks, gouges, chemical attack or abrasive wear. Replace worn parts with genuine Wilden parts for reliable performance. Remove the small clamp bands that fasten the intake mani- fold to the liquid chamber. Lift the intake manifold away to expose the valve balls and seats. Inspect intake valve ball cage for excessive wear or damage. Remove the intake valve balls, seats and O-rings from the discharge manifold and inspect for nicks, gouges, chemical attack or abrasive wear. Replace worn parts with genuine Wilden parts for reliable performance. Remove one set of large clamp bands that attach the liquid chamber to the center section assembly. Lift liquid chamber away from the center section to expose the diaphragm and outer piston. Using an adjustable wrench remove the diaphragm assembly. Inspect diaphragm assembly and shaft for signs of wear or chemical attack. Repeat disassembly instructions for opposite liquid chamber. Please see Section 8 of your EOM for detailed disassembly/reassembly instruction of your pump’s air distrib- ution system. 10. MAINTENANCE PUMP USER’S GUIDE 20 WILDEN PUMP & ENGINEERING CO. 11a. SD Equalizer ®Surge Dampener An inherent characteristic of reciprocating pumps is the pres- sure change between each pump stroke. The Equalizer®can be used to provide a supplementary pumping action between pump strokes, thus minimizing pressure fluctuation while offering protection to your pumping system. The Equalizer®reduces water hammer, absorbs acceleration head, lowers system maintenance costs, and minimizes pipe strain protecting in-line equipment. Sizes available are SD1⁄2 (1⁄2" inlet/discharge), SD1 (1" inlet/discharge), and SD2 (2" inlet/discharge). Materials of Construction Available: SD1⁄2 SD1 SD2 Aluminum ✓✓✓ 316 Stainless Steel ✓✓✓ Cast Iron —✓✓ Polypropylene ✓✓✓ PVDF ✓✓✓ Carbon-Filled Acetal ✓—— Teflon®PTFE ✓✓— 11b. BF Equalizer ®Series BF Equalizers®utilize an elastomeric bladder which prevents contact between the process fluid and the compressed air or gas. When a pulse is created, fluid enters the wetted cham- ber of the BF Equalizers®, displacing the bladder, compress- ing the air/gas, and absorbing the shock. When the liquid pressure decreases, the gas expands, pushing the fluid back into the process line. Wilden offers the BF Equalizers®in sizes ranging from 3⁄8" (.953 cm) to 3" (7.62 cm), bolted, as well as flanged connections (ANSI and DIN). Wilden also offers high pressure dampeners, food grade with tri-clamp, sanitary with tri-clamp, as well as an extended Teflon®fami- ly. The following two options are available: Adjustable Automatic • Self-relieving regulator • Automatic valve • Permanent air supply • Permanent air supply • Easy adjustment of internal • Self-adjusting air pressure • Discharge siding on • Inlet & discharge for constant varying pressure pressure systems systems 11c. FCSI The Flow Control System™ I (FCSI) counts the strokes of the Wilden pump and controls the pump so that specific repeatable quantities can be batched. The system has man- ual entry screens which allow the user to customize the data based on specific application calculations. Once the unit is programmed, the data is held in memory even when the unit is off or disconnected. To aid the user, the FCSI provides help screens where additional information concerning every system setup is displayed at the touch of a button. The FCSI can be used with either standard Wilden air-shifted pumps or Wilden Accu-Flo™ pumps. Three separate batch quantities can be programmed. 11d. SPCI The Solenoid Pump Controller I (SPCI) is designed to pro- vide an intuitive interface between you and your Accu-Flo™ pump. The SPCI energizes and de-energizes the solenoid coil at a programmed rate to control Wilden Accu-Flo™ pumps. The pump speed can be easily adjusted by simply pushing the appropriate (increase or decrease) buttons on the keypad. To expedite your pump speed selection, three programmable presets are available. The LCD screen and LED’s (light emitting diodes) display operational status which allows you to operate the pump from a remote location. The preset number, the stroke interval in seconds (pump speed), the stroke counter, and stroke totalizer are indicated on the LCD screen. The leak detection LED informs you of the optional Wil-Gard™ II leak detection device status. The SPCI will stop pump operation if a leak is detected by the Wil-Gard™ diaphragm monitoring system. An external input can be utilized to remotely start and stop the pump to cus- tomize the application. Liquid level controllers, proximity switches, temperature switches, etc. can easily interface with the SPCI by simply wiring the external component to the terminal strip and selecting the external input mode. The SPCI can be powered by three different voltages: 110 V AC, 220 V AC, and 12 V DC. The output voltage of the SPCI is 12 V DC which must be used with Wilden’s Nema 4 or Nema 7 12 V DC Accu-Flo™ pumps. 11. WILDEN ACCESSORIES 11e. Wil-Gard™ II The Wil-Gard™ II diaphragm monitoring system will sense the presence of fluid between the primary Teflon®PTFE diaphragm and back-up diaphragm once installed on a Teflon®fitted pump. Upon sensing the fluid, a high brightness LED, and an internal relay are activated while the back-up diaphragm offers product containment. The sensor cables are engineered to withstand millions of pump cycles while detecting conductive fluids. The Wil-Gard™ II can be factory installed on Wilden Teflon®fitted pumps and can be pur- chased as an accessory to an existing pump. The Wil- Gard™ II reduces chemical attack on non-wetted parts, reduces hazardous emissions passing through the air exhaust and detects a leak while the back-up diaphragm offers containment protecting from product contamination. The Wil-Gard™ II can easily be connected to the FCSI or SPCI in order to detect diaphragm failure while offering prod- uct containment. 11f. Drum Pump Kit The Wilden Universal Drum Pump Kit is designed as a light- weight, portable means of adapting your Wilden pump to drum pumping applications. The Wilden Drum Pump Kit is used in conjunction with the Wilden P.025, A.025, P1, T1 and A1 models. The drum base adapter is available in Nylon and Polypropylene, and the pick-up tube is available in Nylon, Polypropylene, and Teflon®PTFE. The drum adapter is avail- able with a 2” NPT male connection suitable for installation on most drums. The pick-up tube can be cut to length to accommodate various drum sizes. 11g. Automatic Powder Valve The Wilden pump can be used to successfully transfer many low density powders. The Automatic Powder Valve (APV) is a spring loaded valve that is installed on the inlet line to the Wilden pump. The APV introduces atmospheric air to the inlet line of the pump and lightens or fluidizes the material being transferred before it reaches the pump. While best results have been achieved transferring powders with a den- sity up to 25 lbs. per cubic foot (400 Kg/m3), a test should be performed to determine if desired capacities can be obtained in your specific application. 11h. 2 for 1 System Wilden’s split manifold kit allows users of the Wilden plastic “Champ” pump line to turn one pump into two. This simple kit contains four adapters to allow one Wilden pump to transfer two different products, pump a product from one side and return it with the other, blend two separate products using one pump, or fill two separate con- tainers with two different products. Wilden pumps can be purchased equipped with a 2 for 1 split manifold kit. Existing pumps can also be retrofitted with the 2 for 1 kit. A1, T1, P1, A2 cross bolted, T2 cross bolted, A4, T4, P4, W4, A8, T8, P8, and W8 plastic Champ pump line available in Polypropylene or Kynar can be equipped with the 2 for 1 system. A4, T4, P4, and W4 Aluminum bolt- ed pumps are also available in the 2 for 1 configuration. 11. WILDEN ACCESSORIES (Cont’d.) WILDEN PUMP & ENGINEERING CO.21 PUMP USER’S GUIDE PUMP USER’S GUIDE 22 WILDEN PUMP & ENGINEERING CO. The following is a concise set of troubleshooting suggestions. Contact your local Wilden distributor for a comprehensive Troubleshooting Guide (RBG-E9), or turn to Section 7 of your EOM for your pump’s specific troubleshooting techniques. Pump Will Not Run or Runs Slowly: 1. Check air inlet screen and air filter for debris. 2. Check for sticking air valve, flush air valve with cleaning fluid. 3. Check for worn out air valve. Replace if necessary. 4. Check center block seals. If worn excessively, they will not seal and air will simply flow through the pump and out the air exhaust. Use only Wilden seals as they are of special construction. 5. Check for rotating piston in air valve. 6. Check type of lubricant being used if you are using a pump that needs lubrication. A higher viscosity oil than suggested may cause the piston to stick or run erratically. Wilden sug- gests the use of a hydraulic oil with arctic characteristics (ISO grade 15/5wt. arctic oil). Pump Runs But Little or No Product Flows: 1. Check for pump cavitation; slow pump speed down to allow material to enter pumping chambers. Increase speed accordingly. 2. Check for sticking ball checks. If material being pumped is not compatible with pump elastomers, swelling may occur. Replace balls with the proper elastomers. 3. Check to make sure all suction connections are air tight, especially clamp bands around intake balls. Pump Air Valve Freezes: Check for excessive moisture in compressed air. Install either a dryer or a hot air generator for compressed air. Air Bubbles In Pump Discharge: 1. Check for rupture diaphragm. 2. Check tightness of clamp bands, especially at the intake manifold. Product Comes Out Air Exhaust: 1. Check for diaphragm rupture. 2. Check tightness of large clamp bands. 3. Check tightness of piston plates to shaft if applicable. Pump Rattles: 1. Use softer balls. 2. Create false discharge head or suction lift. 3. See RBG-E9 Troubleshooting Guide. 12. TROUBLESHOOTING 13. WARRANTY Each and every pump manufactured by Wilden Pump and Engineering Co. is built to meet the highest standards of quality. Every pump is functionally tested to ensure the integrity of operation. Wilden Pump and Engineering Co. warrants that pumps, accessories and parts manufactured or supplied by it are free from defects in material and work- manship for a period of one year from date of startup or two years from date of shipment, whichever comes first. Failure due to normal wear, misapplication, or abuse is excluded from this warranty. Since the use of Wilden pumps and parts is beyond our control, we cannot guarantee the suit- ability of any pump or part for a particular application and Wilden Pump and Engineering Co. shall not be liable for any consequential damage or expense arising from the use or misuse of its products on any application. Responsibility is limited solely to replacement or repair of defective Wilden pumps and parts. All decisions as to the cause of failure are the sole determination of Wilden Pump and Engineering Co. Prior approval must be obtained from Wilden for return of any items for warranty consideration. A Return Goods Tag, obtained from an authorized Wilden distributor, must be included with the items which must be shipped freight prepaid. The foregoing warranty is exclusive and in lieu of all other warranties expressed or implied (whether written or oral), including all implied warranties of merchantability and fitness for any particular purpose. No distributor or other person is authorized to assume any liability or oblig- ation for Wilden Pump and Engineering Co. other than expressly provided herein. WILDEN PUMP & ENGINEERING CO.23 PUMP USER’S GUIDE 14. SAFETY SUPPLEMENT WILDEN PUMP & ENGINEERING CO. SAFETY MANUAL Supplement to Engineering, Operation and Maintenance Manual ALWAYS FIRST READ THIS MANUAL BEFORE INSTALLATION, START-UP OR MAINTENANCE. This safety manual applies to all Wilden pumps and comprises instructions for safe installation, use, and maintenance of your pump. In addition to this manual, more detailed instructions on installation, suggested operation and maintenance instructions and troubleshooting are given in the Engineering, Operation and Maintenance manual of the pump type in question. In this manual you may be warned for remaining hazards. This kind of information is preceded by the following label. CAUTION =Hazards or unsafe practices which could result in severe personal injury, death or in substantial product or property damage. CAUTION • Verify pump model received against purchase order or spec sheet. • Retorque all bolts to specifications on torque table. • Remove shipping plugs. • Pumps that need to be submersed must have both wet- ted and non-wetted parts compatible with material being pumped. • Submersed pumps must have a hose attached to pump’s air exhaust and the exhaust air piped above liquid level. • Pumps should be thoroughly flushed with water before installation. • FDA, USDA, and 3A pumps should be sanitized prior to usage. CAUTION • Blow out air line for 10 to 20 seconds before attaching to pump to make sure all pipe line debris is clear. • Always wear safety glasses when operating pump. If diaphragm rupture occurs, material being pumped may be forced out air exhaust. CAUTION:All suction and discharge piping/hoses should be designed to withstand the pressure and temperature of the specific application. CAUTION:Do not exceed 0.7 bar (10 psig) liquid inlet pressure to pump port; this creates potential for pre- mature wear and parts failure. 1.0 Due to the reciprocating action of the pump, lateral instabilities can occur during normal operation, thus footed pumps should be bolted to the operating surface wherever possible. Ensure the operating surface is level and flat. 1.1 Most Wilden pumps can be used in submersible appli- cations only when both wetted and non-wetted portions are compatible with the material being pumped. If the pump is to be used in a submersible application, a hose should be attached to the pump’s air exhaust and the exhaust air piped above the liquid level. 1.2 Each Wilden pump has a particular maximum solids capability. Whenever the possibility exists that larger solid objects may be sucked into the pump, a strainer should be used on the suction line to prevent damage to the pump and subsequent risk to the operator. 1.3 Solenoid Valve-Fitted Pumps a.All wiring used to operate the pumps should be placed and connected according to the proper electrical codes. It is important that the wiring is of adequate gauge to carry the current required to operate the pump. In addition, it is nec- essary that the electrical power supply is large enough to supply the current required to operate the pump. Wiring should be above ground level (in case of fluid spill or leak- age), and all wiring and connections which could become wet or damp should be made watertight. b.The solenoid valve is rated for continuous duty; however, stopping on an even number stroke count insures that the electrical power is off when the pump is stopped. This prac- tice is safer and also eliminates unwanted strokes when the system is shut down and electrical power is off. CAUTION: c.Solenoid valve-fitted pumps should not be used in an area where explosion proof equipment is required, unless the solenoid valve is specified for the subjective area classification. CAUTION: 1.4 Do not exceed 8.5 bar (125 psig) air supply pressure. UL-listed models should not exceed 50 psi air supply. NOTICE: 1.5 All fasteners should be checked to match the pump’s given torque specifications, listed in Section 8 of the Engineering, Operation and Maintenance Manual. CAUTION: 1.6 Ensure proper ventilation of tanks/vessels that house liquid supply. Due to a pump’s high vacuum ability, improper ventilation of these supply tanks can lead to implosion of tanks when fluid is completely evacuated. CAUTION: 1.7 ELECTRICAL HAZARDS a.Static Spark: Can cause explosion resulting in severe injury or death. Electrostatic hazard is eliminat- ed by proper grounding of the pump and pumping sys- tem. For some applications the A.025, P.025, T1, and A1 graphite-filled pumps will provide a more adequate dispersal of static electricity. Consult local building codes and electrical codes for specific grounding requirements. b.Conductivity: Certain Wilden models provide for safe transfer of flammable materials. Please consult local authorized Wilden distributor for more informa- tion. PUMP USER’S GUIDE 24 WILDEN PUMP & ENGINEERING CO. CAUTION: 1.8 TEMPERATURE HAZARDS a.Material being pumped should be compatible with pump’s materials of construction and stated tempera- ture limits as stated in Wilden Chemical Resistance Guide (RBG-E4). b.Steps must be taken to eliminate any risk of injury caused by contact with or proximity to pump parts at high temperatures because of the high temperature of the process fluid being pumped. c.Thermal expansion: Some liquids present in piping may expand at elevated temperatures, resulting in pipe and/or pump damage and subsequent risk to operator. CAUTION: 1.9 HAZARDS GENERATED BY NOISE a.Pump noise can be excessive under certain oper- ating conditions, e.g. high air pressure supply and little or no discharge head. Extended periods of operation under such conditions can create a hazard to opera- tors working in proximity of the pumps. Ways to avoid this hazard are listed as follows: • Use proper hearing protection devices. • Reduce air supply pressure and/or increase dis- charge head pressure. • Plumb pump exhaust to area outside of building where pump is located. • Use elastomeric ball valve checks in lieu of Teflon ® valve balls, while ensuring proper chemical resis- tance of elastomer used. CAUTION: 1.10 HAZARDOUS MATERIALS a.In case of diaphragm failure, material being pumped may exit pump via air exhaust, in which case contact with hazardous material is possible. b.Where possible, Teflon®fitted Wilden pumps should be fitted with the Wil-Gard™ II Diaphragm Monitoring System, which will detect a diaphragm failure before hazardous material exits pump. c.Handler should obtain Material Safety Data Sheet from the supplier for all materials being pumped for appropriate handling instructions. 1.11 CHEMICAL COMPATIBILITY CAUTION: a.When specifying a pump for a particu- lar application, pump wetted materials of construction and elastomer materials must be compatible with the process fluid. Please consult Wilden Chemical Resistance Guide (RBG-E4) or your local authorized Wilden distributor for more information. CAUTION: b.Explosive reaction: Some materials such as halogenated hydrocarbon solvents should not be pumped with an aluminum construction pump due to a possible explosive reaction. CAUTION: c.Certain materials’ chemical compatibil- ity with a particular pump construction, in particular plastic wetted parts, can change as material concen- tration and temperature vary. Please consult your local authorized Wilden distributor for more information. 2.0 OPERATION CAUTION: 2.1 Ensure all operators are properly trained and employ safe operating and maintenance practices as outlined in this Safety Manual and the pump’s Engineering, Operation and Maintenance Manual. In addition, all proper safety eyewear and ear protection should be used when necessary. 14. SAFETY SUPPLEMENT (Cont’d.) CELSIUS/FAHRENHEIT DEGREES DEGREES ‘C’ ‘F’ ‘C’ ‘F’ 0 32 56 132.8 2 35.6 58 136.4 4 39.2 60 140.0 6 42.8 62 143.6 8 46.8 64 147.2 10 50.0 66 150.8 12 53.6 68 154.4 14 57.2 70 158.0 16 60.8 72 161.6 18 64.4 74 165.2 20 68.0 76 168.8 22 71.6 78 172.4 24 75.2 80 176.0 26 78.8 82 179.6 28 82.4 84 183.2 30 86.0 86 186.8 32 89.6 88 190.4 34 93.2 90 194.0 36 96.8 92 197.6 38 100.4 94 201.2 40 104.0 96 204.8 42 107.6 98 208.4 44 111.2 100 212.0 46 114.8 102.2 216.0 48 118.4 104.4 220.0 50 122.0 107.8 226.0 52 125.6 110.0 230.0 54 129.2 115.6 240.0 VISCOSITY CONVERSION POISE CENTIPOISE SSU 00.00 1 32 .1 10 60 .2 20 100 .4 40 210 .6 60 320 .8 80 430 1.0 100 530 1.4 140 690 2.0 200 1000 2.6 260 1280 3.0 300 1475 3.6 360 1730 4.0 400 1950 4.6 460 2270 5.0 500 2480 6.0 600 2900 8.0 800 3880 10.0 1000 4600 12.0 1200 5620 14.0 1400 6480 16.0 1600 7500 18.0 1800 8500 22.0 2200 10300 26.0 2600 12100 30.0 3000 14500 35.0 3500 16500 40.0 4000 18500 45.0 4500 21000 50.0 5000 23500 55.0 5500 26000 60.0 6000 28000 WILDEN PUMP & ENGINEERING CO.25 PUMP USER’S GUIDE 15. CONVERSION TABLES PARTICLE SIZE U.S. MESH MICRONS INCHES MILLIMETERS 3 6730 .265 6.73 3.5 5660 .223 5.66 4 4760 .187 4.76 5 4000 .157 4.00 6 3360 .132 3.36 7 2830 .111 2.83 8 2380 .0937 2.38 10 2000 .0787 2.00 12 1680 .0661 1.68 14 1410 .0555 1.41 16 1190 .0469 1.19 18 1000 .0394 1.00 20 841 .0331 .84 25 707 .0280 .71 30 595 .0232 .59 35 500 .0197 .50 40 420 .0165 .42 45 354 .0138 .35 50 297 .0117 .297 60 250 .0098 .250 70 210 .0083 .210 80 177 .0070 .177 100 149 .0059 .149 120 125 .0049 .125 140 105 .0041 .105 170 88 .0035 .088 200 74 .0029 .074 230 63 .0024 .063 270 53 .0021 .053 325 44 .0017 .044 400 37 .0015 .037 FLOW Lbs of Water/Hr x .002 = Gal Min Gal/Min x 500 = Lbs of Water/Hr Lbs of Fluid/Hr x .002 = Gal Min Specific Gravity Liter Min x .264 = Gal/Min (US) GPM x 3.785 = Liters/Min Cu Meters/Hr x 4.4 = Gal/Min (US) Gal/Min x 227 = C Meters/Hr Kg of Water/Min x .264 = Gal/Min (US) Gal Min x 3.8 = Kg of Water/Min VOLUME Ft3 x .0283 = M 3 Lbs Water x .119 = Gal Gal (Brit) x 1.2 = Gal (US) Gal x 128 = Fluid Ounces Cubic Ft x 7.48 = Gal Cubic In x .00433 = Gal Gal x 3.785 = Liters Liter x .264 = Gal Cubic Meters x 264.2 = Gallons Cubic Meter x 1000 = Liter Liters x 100 = Cubic Centimeters Cubic Centimeters x 0338 = Fluid Ounces Fluid Ounces x 29.57 = Cubic Centimeters PRESSURE Ft of Water x .433 = PSI PSI x 2.31 = Ft of Water Inches Hg x .491 = PSI Inches Hg x 1.133 = Ft of Water ATM x 14.7 = PSI ATM x 33.9 = Ft of Water Kg/Sq cm x 14.22 = PSI Meters of Water x 1.42 = PSI ATM x 760 = mm Hg mm Hg x .039 = Inches Hg Bar x 14.5 = PSI Newton/Meter2 x 1 = Pascal PSI x 6.9 = kPa (Kilopascal) kPa x .145 = PSI LENGTH Mils x .001 = Inches Meters x 3.281 = Feet Centimeters x .394 = Inches Millimeters x .0394 = Inches Microns x .0000394 = Inches MASS Gal of Water x 8.336 = Lbs Cubic Ft of Water x 62.4 = Lbs Ounces x .0625 = Lbs Kilograms x 2.2 = Lbs Lbs x .454 = Kilograms Metric Ton x 2205 = Lbs FRAC. DEC. METRIC FRAC. DEC. METRIC 1/64 .0156 .39688 33/64 .5156 13.0968 1/32 .0312 .79375 17/32 .5312 13.4937 3/64 .0468 1.19063 35/64 .5468 13.8906 1/16 .0625 1.58750 9/16 .5625 14.2875 5/64 .0781 1.98438 37/64 .5781 14.6843 3/32 .0937 2.38125 19/32 .5937 15.0812 7/64 .1093 2.77813 39/64 .6093 15.4781 1/8 .125 3.17500 5/8 .625 15.8750 9/64 .1406 3.57188 41/64 .6406 16.2718 5/32 .1562 3.96875 21/32 .6562 16.6687 11/64 .1718 4.36563 43/64 .6718 17.0656 3/16 .1875 4.76250 11/16 .6875 17.4625 13/64 .2031 5.15938 45/64 .7031 17.8593 7/32 .2187 5.55625 23/32 .7187 18.2562 15/64 .2343 5.95313 47/64 .7343 18.6531 1/4 .25 6.35000 3/4 .75 19.0500 17/64 .2656 6.74688 49/64 .7656 19.4468 9/32 .2812 7.14375 25/32 .7812 19.8437 19/64 .2968 7.54063 51/64 .7968 20.2406 5/16 .3125 7.93750 13/16 .8125 20.6375 21/64 .3281 8.33438 53/64 .8281 21.0343 11/32 .3437 8.73125 27/32 .8437 21.4312 23/64 .3593 9.12813 55/64 .8593 21.8381 3/8 .375 9.52500 7/8 .875 22.2250 25/64 .3906 9.92188 57/64 .8906 22.6218 13/32 .4062 10.31875 29/32 .9062 23.0187 27/64 .4218 10.71563 59/64 .9218 23.4156 7/16 .4375 11.11250 15/16 .9375 23.8125 29/64 .4531 11.50938 61/64 .9531 24.2093 15/32 .4687 11.90625 31/32 .9687 24.6062 31/64 .4843 12.30313 63/64 .9843 25.0031 1/2 .5 12.70000 1 1.0000 24.4000 FRACTIONAL EQUIVALENTS Metric equivalents are in millimeters. 26WILDEN PUMP & ENGINEERING CO. 22069 Van Buren St., Grand Terrace, CA 92313-5607 Telephone (909) 422-1730 • Fax (909) 783-3440 www.wildenpump.com Your local authorized distributor: “Revolutionizing the way you solve your toughest pumping problems” PlasticPlastic MetalMetal• Polypropylene • Carbon-Filled Acetal • PVDF • Teflon ®PTFE • Teflon ®PFA • Aluminum • 316 S.S. • Cast Iron • Hastelloy FDA USDA 3A • Teflon ®PFA • Teflon ®PTFE • SPCI • FCSI • Drum Pump Kits • Wil-Gard • Equalizers • APV AccessoriesAccessories