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Operation &
Original Series PLASTIC Pumps Maintenance
WIL-10131-E-01
TA BL E OF CON T EN T S
SECTION 7 DISASSEMBLY/REASSEMBLY
A. Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
B. Pro-Flo Air Valve / Center Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
C. Pro-Flo XTM Air Valve / Center Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .28
D. Reassembly Hints & Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
E. PTFE Gasket Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
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Section 1
CAUTIONS READ FIRST
CAUTION: Do not apply compressed air to the exhaust CAUTION: Do not exceed 8.6 bar (125 psig) air supply
port pump will not function. pressure.
CAUTION: Do not over lubricate air supply excess CAUTION: Before any maintenance or repair is
lubrication will reduce pump performance. attempted, the compressed air line to the pump should
TEMPERATURE LIMITS: be disconnected and all air pressure allowed to bleed
Polypropylene 0C to 79C 32F to 175F from pump. Disconnect all intake, discharge and air
PVDF 12C to 107C 10F to 225F lines. Drain the pump by turning it upside down and
Neoprene 17.7C to 93.3C 0F to 200F allowing any fluid to flow into a suitable container.
Buna-N 12.2C to 82.2C 10F to 180F CAUTION: Blow out air line for 10 to 20 seconds
EPDM 51.1C to 137.8C 60F to 280F before attaching to pump to make sure all pipeline
Viton 40C to 176.7C 40F to 350F debris is clear. Use an in-line air filter. A 5 micron air
Wil-Flex 40C to 107.2C 40F to 225F filter is recommended.
Saniflex 28.9C to 104.4C 20F to 220F NOTE: When installing PTFE diaphragms, it is impor-
Polyurethane 12.2C to 65.6C 10F to 150F tant to tighten outer pistons simultaneously (turning in
Tetra-Flex 4.4C to 107.2C 40F to 225F opposite directions) to ensure tight fit.
PTFE 4.4C to 104.4C 40F to 220F
NOTE: P8 and PX8 PVDF pumps come standard from
the factory with expanded PTFE gaskets installed in
CAUTION: When choosing pump materials, be sure the diaphragm bead of the liquid chamber, in the
to check the temperature limits for all wetted compo- T-section and in the ball and seat area. PTFE gaskets
nents. Example: Viton has a maximum limit of 176.7C cannot be re-used. Consult PS-TG for installation
(350F) but polypropylene has a maximum limit of only instructions during reassembly.
79C (175F).
NOTE: Before starting disassembly, mark a line from
CAUTION: Maximum temperature limits are based each liquid chamber to its corresponding air cham-
upon mechanical stress only. Certain chemicals will ber. This line will assist in proper alignment during
significantly reduce maximum safe operating tempera- reassembly.
tures. Consult engineering guide for chemical compat-
ibility and temperature limits. CAUTION: The P8 Plastic pump is not submersible. If
your application requires your pump to be submersed,
CAUTION: Always wear safety glasses when operat- the PX8 model can be used with the submersible
ing pump. If diaphragm rupture occurs, material being option.
pumped may be forced out air exhaust.
CAUTION: Pumps should be flushed thoroughly with
Plastic series pumps are made of virgin plastic and are water before installation into process line.
not UV stabilized. Direct sunlight for prolonged periods
can cause deterioration of plastics. CAUTION: Tighten all hardware prior to installation.
WARNING: Prevention of static sparking If static
sparking occurs, fire or explosion could result. Pump,
valves, and containers must be grounded when
handling flammable fluids and whenever discharge
of static electricity is a hazard. To ground the Wilden
Champ, all clamp bands must be grounded to a
proper grounding point.
MATERIAL CODES
MODEL DIAPHRAGMS VALVE BALL
P8 = PRO-FLO BNS = BUNA-N (Red Dot) BN = BUNA-N (Red Dot)
PX8 = PRO-FLO XTM BNU = BUNA-N, ULTRA- EP = EPDM (Blue Dot)
FLEX NE = NEOPRENE (Green
WETTED PARTS & OUTER EPS = EPDM (Blue Dot) Dot)
PISTON EPU = EPDM, ULTRA- PU = POLYURETHANE
KK = PVDF / PVDF FLEX (Brown)
PK = POLYPROPYLENE / FSS = SANIFLEX TF = PTFE (White)
PVDF [Hytrel (Cream)] VT = VITON (White Dot)
NES = NEOPRENE (Green WF = WIL-FLEX
AIR CHAMBERS Dot) [Santoprene (Orange
A = ALUMINUM NEU = NEOPRENE, ULTRA- Dot)]
C = PTFE COATED ALUMINUM FLEX
S = STAINLESS STEEL PUS = POLYURETHANE VALVE SEAT
(Clear) K = PVDF
CENTER BLOCK TEU = PTFE W/EPDM P = POLYPROPYLENE
P = POLYPROPYLENE BACK-UP (White)
TNU = PTFE W/NEOPRENE VALVE SEAT O-RING
AIR VALVE BACK-UP (White) BN = BUNA-N (Red Dot)
P = POLYPROPYLENE VTS = VITON (White Dot) PU = POLYURETHANE
L = ACETAL (P8 only) VTU = VITON, ULTRA- (Brown)
FLEX TV = PTFE ENCAP. VITON
WFS = WIL-FLEX WF = WIL-FLEX
[Santoprene [Santoprene (Orange
(Orange Dot)] Dot)]
SPECIALTY CODES
0100 Wil-Gard II 110V 0513 SS outer pistons 0608 PFA coated hardware, Wil-
0102 Wil-Gard II, sensor wires ONLY 0560 Split manifold Gard II 220V
0103 Wil-Gard II 220V 0561 Split manifold, PFA coated 0660 Split manifold, Wil-Gard II 110V
0206 PFA coated hardware, hardware 0661 Split manifold, PFA coated
Wil-Gard II sensor wires only 0563 Split manifold, discharge only hardware, Wil-Gard II 110V
0502 PFA coated hardware 0564 Split manifold, inlet only
P 8 P l as t i c
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 490 19.3
B 76 3.0
C 414 16.3
D 693 27.3
E 770 30.3
F 89 3.5
G 417 16.4
H 333 13.1
J 381 15.0
K 307 12.1
L 227 8.9
M 254 10.0
N 15 0.6
METRIC (mm) STANDARD (inch)
P 122 DIA. 4.8 DIA.
R 152 DIA. 6.0 DIA.
S 20 DIA. 0.8 DIA.
P X8 Pl as t i c
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 490 19.3
B 76 3.0
C 414 16.3
D 693 27.3
E 770 30.3
F 89 3.5
G 422 16.6
H 173 6.8
J 356 14.0
K 447 17.6
L 381 15.0
M 307 12.1
N 227 8.9
P 254 10.0
R 15 .6
DIN/ANSI COMBO
S 122 DIA. 4.8 DIA.
T 155 DIA. 6.1 DIA.
U 20 DIA. .8 DIA.
P8 PLASTIC
RUBBER-FITTED
Height .................................. 770 mm (30.3")
Width ................................... 490 mm (19.3")
Depth .................................. 333 mm (13.1")
Est. Ship Weight...... Polypropylene 34 kg (75 lbs)
PVDF 43 kg (95 lbs)
Air Inlet ....................................13 mm (1/2")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ........................... 7.0 m Dry (23')
9.45 m Wet (31')
Displacement per
Stroke ......................... 2.91 l (0.77 gal.)1
Max. Flow Rate ............... 587 lpm (155 gpm)
Max. Size Solids .....................6.4 mm (1/4")
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 291.5 lpm (77 gpm)
against a discharge pressure head of 2.0 bar
(30 psig) requires 4.1 bar (60 psig) and 68 Flow rates indicated on chart were determined by pumping water.
Nm3/h (40 scfm ) air consumption. (See dot
on chart.) For optimum life and performance, pumps should be specified so that daily operation parameters
will fall in the center of the pump performance curve.
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
P8 PLASTIC
TPE-FITTED
Height .................................. 770 mm (30.3")
Width ................................... 490 mm (19.3")
Depth .................................. 333 mm (13.1")
Est. Ship Weight...... Polypropylene 34 kg (75 lbs)
PVDF 43 kg (95 lbs)
Air Inlet ....................................13 mm (1/2")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ......................... 5.18 m Dry (17')
9.45 m Wet (31')
Displacement per
Stroke .......................... 2.91 l (0.77 gal.)1
Max. Flow Rate ............... 575 lpm (152 gpm)
Max. Size Solids .....................6.4 mm (1/4")
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 283.9 lpm (75 gpm)
against a discharge pressure head of 2.1
bar (30 psig) requires 4.1 bar (60 psig) and
Flow rates indicated on chart were determined by pumping water.
76.5 Nm3/h (45 scfm) air consumption. (See
dot on chart.) For optimum life and performance, pumps should be specified so that daily operation parameters
Caution: Do not exceed 8.6 bar (125 psig ) air will fall in the center of the pump performance curve.
supply pressure.
P8 PLASTIC
PTFE-FITTED
P8 PLASTIC
ULTRA-FLEXTM-FITTED
Height.................................. 770 mm (30.3")
Width ................................... 490 mm (19.3")
Depth .................................. 333 mm (13.1")
Est. Ship Weight...... Polypropylene 34 kg (75 lbs)
PVDF 43 kg (95 lbs)
Air Inlet ....................................13 mm (1/2")
Inlet ............................................ 51 mm (2")
Outlet ......................................... 51 mm (2")
Suction Lift ......................... 4.88 m Dry (16')
8.84 m Wet (29')
Displacement per
Stroke ......................... 2.12 l (0.56 gal.)1
Max. Flow Rate ............... 560 lpm (148 gpm)
Max. Size Solids .....................6.4 mm (1/4")
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig) [LPM]
head pressure. Water Discharge Flow Rates
Example: To pump 257.4 lpm (68 gpm)
against a discharge pressure head of 2.0
bar (30 psig) requires 4.1 bar (60 psig) and Flow rates indicated on chart were determined by pumping water.
76.5 Nm3/h (45 scfm) air consumption. (See
dot on chart.) For optimum life and performance, pumps should be specified so that daily operation parameters
will fall in the center of the pump performance curve.
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
P8 PLASTIC
SUCTION LIFT
C A PA B I L I T Y
PTFE Diaphragms
AIR CONSUMPTION
$ $$
Turning the dial Each dial setting Pro-Flo X pumps Moving the dial When the air
changes the represents an are shipped from from setting 4 consumption
relationship entirely different the factory on causes a decrease decreases more
between air inlet flow curve setting 4, which in flow and an even than the flow
and exhaust is the highest greater decrease in rate, efficiency
porting. flow rate setting air consumption. is improved and
possible operating costs
are reduced.
Example 1
SETTING 4 PERFORMANCE CURVE EMS CURVE
Figure 1 Figure 2
0.58 flow multiplier
Example data point = 8.2 GPM Example data point =
0.48 air multiplier
This is an example showing how to determine flow rate and curve, draw vertical lines downward until
air consumption for your Pro-Flo X pump using the Efficien- reaching the bottom scale on the chart. This
cy Management System (EMS) curve and the performance
identifies the flow X Factor (in this case, 0.58)
curve. For this example we will be using 4.1 bar (60 psig) inlet
air pressure and 2.8 bar (40 psig) discharge pressure and EMS and air X Factor (in this case, 0.48).
setting 2.
Step 3: Calculating performance for specific EMS
Step 1: Identifying performance at setting 4. Locate setting. Multiply the flow rate (8.2 gpm)
the curve that represents the flow rate of the obtained in Step 1 by the flow X Factor multi-
pump with 4.1 bar (60 psig) air inlet pressure. plier (0.58) in Step 2 to determine the flow rate
Mark the point where this curve crosses the at EMS setting 2. Multiply the air consump-
horizontal line representing 2.8 bar (40 psig) tion (9.8 scfm) obtained in Step 1 by the air
discharge pressure. (Figure 1). After locating X Factor multiplier (0.48) in Step 2 to deter-
your performance point on the flow curve, mine the air consumption at EMS setting 2
draw a vertical line downward until reaching (Figure 3).
the bottom scale on the chart. Identify the flow
rate (in this case, 8.2 gpm). Observe location 8.2 gpm (flow rate for Setting 4)
of performance point relative to air consump-
tion curves and approximate air consumption
.58 (Flow X Factor setting 2)
value (in this case, 9.8 scfm). 4.8 gpm (Flow rate for setting 2)
Step 2: Determining flow and air X Factors. Locate 9.8 scfm (air consumption for setting 4)
your discharge pressure (40 psig) on the verti-
cal axis of the EMS curve (Figure 2). Follow
.48 (Air X Factor setting 2)
along the 2.8 bar (40 psig) horizontal line until 4.7 scfm (air consumption for setting 2)
intersecting both flow and air curves for your
Figure 3
desired EMS setting (in this case, setting 2).
Mark the points where the EMS curves inter- The flow rate and air consumption at Setting
sect the horizontal discharge pressure line. 2 are found to be 18.2 lpm (4.8 gpm) and 7.9
After locating your EMS points on the EMS Nm3/h (4.7 scfm) respectively.
Example 2.1
SETTING 4 PERFORMANCE CURVE EMS CURVE
EMS Flow
Settings 1 & 2
Figure 4 Figure 5
Example data point = 10.2 gpm 0.49 flow multiplier
This is an example showing how to determine the inlet air In our example it is 38.6 lpm (10.2 gpm). This
pressure and the EMS setting for your Pro-Flo X pump to is the setting 4 flow rate. Observe the loca-
optimize the pump for a specific application. For this exam- tion of the performance point relative to air
ple we will be using an application requirement of 18.9 lpm
consumption curves and approximate air
(5 gpm) flow rate against 2.8 bar (40 psig) discharge pressure.
This example will illustrate how to calculate the air consump- consumption value. In our example setting
tion that could be expected at this operational point. 4 air consumption is 24 Nm3/h (14 scfm).
See figure 4.
DETERMINE EMS SETTING
Step 3: Determine flow X Factor. Divide the required
Step 1: Establish inlet air pressure. Higher air pres-
flow rate 18.9 lpm (5 gpm) by the setting 4 flow
sures will typically allow the pump to run
rate 38.6 lpm (10.2 gpm) to determine the flow
more efficiently, however, available plant air
X Factor for the application.
pressure can vary greatly. If an operating
pressure of 6.9 bar (100 psig) is chosen when 5 gpm / 10.2 gpm = 0.49 (flow X Factor)
plant air frequently dips to 6.2 bar (90 psig)
pump performance will vary. Choose an oper- Step 4: Determine EMS setting from the flow
ating pressure that is within your compressed X Factor. Plot the point representing the flow
air system's capabilities. For this example we X Factor (0.49) and the application discharge
will choose 4.1 bar (60 psig). pressure 2.8 bar (40 psig) on the EMS curve.
This is done by following the horizontal 2.8
Step 2: Determine performance point at setting 4. For bar (40 psig) psig discharge pressure line until
this example an inlet air pressure of 4.1 bar it crosses the vertical 0.49 X Factor line. Typi-
(60 psig) inlet air pressure has been chosen. cally, this point lies between two flow EMS
Locate the curve that represents the perfor- setting curves (in this case, the point lies be-
mance of the pump with 4.1 bar (60 psig) inlet tween the flow curves for EMS setting 1 and
air pressure. Mark the point where this curve 2). Observe the location of the point relative
crosses the horizontal line representing 2.8 to the two curves it lies between and approxi-
bar (40 psig) discharge pressure. After locat- mate the EMS setting (figure 5). For more pre-
ing this point on the flow curve, draw a verti- cise results you can mathematically interpo-
cal line downward until reaching the bottom late between the two curves to determine the
scale on the chart and identify the flow rate. optimal EMS setting.
For this example the EMS setting is 1.8.
WILDEN PUMP & ENGINEERING, LLC 12 PX8 Plastic Performance
HOW TO USE THIS EMS CURVE
Example 2.2
SETTING 4 PERFORMANCE CURVE EMS CURVE
EMS Air
Settings 1 & 2
Figure 6 Figure 7
Example data point = 10.2 gpm Example data point = 0.40 air multiplier
Determine air consumption at a specific Step 2: Determine air consumption. Multiply your
EMS setting. setting 4 air consumption (14 scfm) value by
the air X Factor obtained above (0.40) to deter-
Step 1: Determine air X Factor. In order to determine mine your actual air consumption.
the air X Factor, identify the two air EMS set-
ting curves closest to the EMS setting estab- 14 scfm x 0.40 = 5.6 SCFM
lished in example 2.1 (in this case, the point lies
In summary, for an application requiring 18.9 lpm
between the air curves for EMS setting 1 and
(5 gpm) against 2.8 bar (40 psig) discharge pressure,
2). The point representing your EMS setting
the pump inlet air pressure should be set to 4.1 bar
(1.8) must be approximated and plotted on the
(60 psig) and the EMS dial should be set to 1.8. The
EMS curve along the horizontal line represent-
pump would then consume 9.5 Nm3/h (5.6 scfm) of
ing your discharge pressure (in this case, 40
compressed air.
psig). This air point is different than the flow
point plotted in example 2.1. After estimating
(or interpolating) this point on the curve, draw
a vertical line downward until reaching the
bottom scale on the chart and identify the air
X Factor (figure 7).
14
TECHNICAL DATA EXAMPLE
The Efficiency Management System (EMS)
Height . . . . . . . . . . . . . . . . . . . . . . . . . .770 mm (30.3) can be used to optimize the performance of A PX8 polypropylene, rubber-fitted pump operating at EMS setting
Width. . . . . . . . . . . . . . . . . . . . . . . . . . .490 mm (19.3) your Wilden pump for specific applications. 4, achieved a flow rate of 231 lpm (61 gpm) using 75 Nm3/h (44 scfm)
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . .356 mm (14.0) The pump is delivered with the EMS adjusted of air when run at 4.1 bar (60 psig) air inlet pressure and 2.8 bar (40
Ship Weight . . . . . . . . Polypropylene 34 kg (75 lbs.) to setting 4, which allows maximum flow. psig) discharge pressure (See dot on performance curve).
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (3/4)
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2) The EMS curve allows the pump user to The end user did not require that much flow and wanted to reduce
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2) determine flow and air consumption at air consumption at his facility. He determined that EMS setting 2
Suction Lift . . . . . . . . . . . . . . . . . . . . .6.9 m Dry (22.7) each EMS setting. For any EMS setting and would meet his needs. At 2.8 bar (40 psig) discharge pressure and
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 m Wet (30.6) discharge pressure, the X factor is used EMS setting 2, the flow X factor is 0.69 and the air X factor is
Disp. Per Stroke. . . . . . . . . . . . . . . . . 2.9 l (0.77 gal.)1 as a multiplier with the original values from 0.53 (see dots on EMS curve).
Max. Flow Rate . . . . . . . . . . . . . . .594 lpm (157 gpm) the setting 4 performance curve to calculate Multiplying the original setting 4 values by the X factors provides
Max. Size Solids . . . . . . . . . . . . . . . . . . 6.4 mm (1/4) the actual flow and air consumption values the setting 2 flow rate of 159 lpm (42 gpm) and an air consumption
for that specific EMS setting. Note: you can of 40 Nm3/h (23 scfm). The flow rate was reduced by 31% while
1
Displacement per stroke was calculated at 4.8 bar (70 psig) interpolate between the setting curves for
air inlet pressure against a 2.1 bar (30 psig)head pressure. the air consumption was reduced by 47%, thus providing increased
operation at intermediate EMS settings. efficiency.
15
TECHNICAL DATA EXAMPLE
The Efficiency Management System (EMS)
Height . . . . . . . . . . . . . . . . . . . . . . . . . .770 mm (30.3) can be used to optimize the performance of A PX8 polypropylene, TPE-fitted pump operating at EMS setting 4,
Width. . . . . . . . . . . . . . . . . . . . . . . . . . .490 mm (19.3) your Wilden pump for specific applications. achieved a flow rate of 291 lpm (77 gpm) using 82 Nm3/h (48 scfm)
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . .356 mm (14.0) The pump is delivered with the EMS adjusted of air when run at 4.1 bar (60 psig) air inlet pressure and 2.1 bar (30
Ship Weight . . . . . . . . Polypropylene 34 kg (75 lbs.) to setting 4, which allows maximum flow. psig) discharge pressure (See dot on performance curve).
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (3/4)
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2) The EMS curve allows the pump user to The end user did not require that much flow and wanted to reduce
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2) determine flow and air consumption at air consumption at his facility. He determined that EMS setting 3
Suction Lift . . . . . . . . . . . . . . . . . . . . .6.6 m Dry (21.6) each EMS setting. For any EMS setting and would meet his needs. At 2.1 bar (30 psig) discharge pressure and
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 m Wet (30.1) discharge pressure, the X factor is used EMS setting 3, the flow X factor is 0.90 and the air X factor is
Disp. Per Stroke. . . . . . . . . . . . . . . . . 3.0 l (0.79 gal.)1 as a multiplier with the original values from 0.81 (see dots on EMS curve).
Max. Flow Rate . . . . . . . . . . . . . . .606 lpm (160 gpm) the setting 4 performance curve to calculate Multiplying the original setting 4 values by the X factors provides
Max. Size Solids . . . . . . . . . . . . . . . . . . 6.4 mm (1/4) the actual flow and air consumption values the setting 3 flow rate of 262 lpm (69 gpm) and an air consumption
for that specific EMS setting. Note: you can of 66 Nm3/h (39 scfm). The flow rate was reduced by 10% while
1
Displacement per stroke was calculated at 4.8 bar (70 psig) interpolate between the setting curves for
air inlet pressure against a 2.1 bar (30 psig)head pressure. the air consumption was reduced by 19%, thus providing increased
operation at intermediate EMS settings. efficiency.
For a detailed example for how to set your EMS, see beginning of
performance curve section.
The Efficiency Management System (EMS) can be used to optimize the performance of your Wilden pump for
Caution: Do not exceed 8.6 bar (125 psig) air supply pressure.
16
TECHNICAL DATA EXAMPLE
The Efficiency Management System (EMS)
Height . . . . . . . . . . . . . . . . . . . . . . . . . .770 mm (30.3) can be used to optimize the performance of A PX8 polypropylene, PTFE-fitted pump operating at EMS setting 4,
Width. . . . . . . . . . . . . . . . . . . . . . . . . . .490 mm (19.3) your Wilden pump for specific applications. achieved a flow rate of 409 lpm (108 gpm) using 141 Nm3/h (83 scfm)
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . .356 mm (14.0) The pump is delivered with the EMS adjusted of air when run at 5.5 bar (80 psig) air inlet pressure and 0.7 bar (10
Ship Weight . . . . . . . . Polypropylene 34 kg (75 lbs.) to setting 4, which allows maximum flow. psig) discharge pressure (See dot on performance curve).
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (3/4)
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2) The EMS curve allows the pump user to The end user did not require that much flow and wanted to reduce
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2) determine flow and air consumption at air consumption at his facility. He determined that EMS setting 1
Suction Lift . . . . . . . . . . . . . . . . . . . . .3.8 m Dry (12.5) each EMS setting. For any EMS setting and would meet his needs. At 0.7 bar (10 psig) discharge pressure and
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 m Wet (30.1) discharge pressure, the X factor is used EMS setting 1, the flow X factor is 0.35 and the air X factor is
Disp. Per Stroke. . . . . . . . . . . . . . . . . 1.8 l (0.47 gal.)1 as a multiplier with the original values from 0.17 (see dots on EMS curve).
Max. Flow Rate . . . . . . . . . . . . . . .503 lpm (133 gpm) the setting 4 performance curve to calculate Multiplying the original setting 4 values by the X factors provides
Max. Size Solids . . . . . . . . . . . . . . . . . . 6.4 mm (1/4) the actual flow and air consumption values the setting 1 flow rate of 143 lpm (38 gpm) and an air consumption
for that specific EMS setting. Note: you can of 24 Nm3/h (14 scfm). The flow rate was reduced by 65% while
1
Displacement per stroke was calculated at 4.8 bar (70 psig) interpolate between the setting curves for
air inlet pressure against a 2.1 bar (30 psig)head pressure. the air consumption was reduced by 83%, thus providing increased
operation at intermediate EMS settings. efficiency
17
TECHNICAL DATA EXAMPLE
The Efficiency Management System (EMS)
Height . . . . . . . . . . . . . . . . . . . . . . . . . .770 mm (30.3) can be used to optimize the performance of A PX8 polypropylene, Ultra-Flex-fitted pump operating at EMS
Width. . . . . . . . . . . . . . . . . . . . . . . . . . .490 mm (19.3) your Wilden pump for specific applications. setting 4, achieved a flow rate of 307 lpm (81 gpm) using 99 Nm3/h
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . .356 mm (14.0) The pump is delivered with the EMS adjusted (58 scfm) of air when run at 4.1 bar (60 psig) air inlet pressure and 1.4
Ship Weight . . . . . . . . Polypropylene 34 kg (75 lbs.) to setting 4, which allows maximum flow. bar (20 psig) discharge pressure (See dot on performance curve).
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (3/4)
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2) The EMS curve allows the pump user to The end user did not require that much flow and wanted to reduce
Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2) determine flow and air consumption at air consumption at his facility. He determined that EMS setting 2
Suction Lift . . . . . . . . . . . . . . . . . . . . .5.7 m Dry (18.7) each EMS setting. For any EMS setting and would meet his needs. At 1.4 bar (20 psig) discharge pressure and
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 m Wet (30.1) discharge pressure, the X factor is used EMS setting 2, the flow X factor is 0.74 and the air X factor is
Disp. Per Stroke. . . . . . . . . . . . . . . . . 2.0 l (0.52 gal.)1 as a multiplier with the original values from 0.54 (see dots on EMS curve).
Max. Flow Rate . . . . . . . . . . . . . . .568 lpm (150 gpm) the setting 4 performance curve to calculate Multiplying the original setting 4 values by the X factors provides
Max. Size Solids . . . . . . . . . . . . . . . . . . 6.4 mm (1/4) the actual flow and air consumption values the setting 2 flow rate of 227 lpm (60 gpm) and an air consumption
for that specific EMS setting. Note: you can of 53 Nm3/h (31 scfm). The flow rate was reduced by 40% while
1
Displacement per stroke was calculated at 4.8 bar (70 psig) interpolate between the setting curves for
air inlet pressure against a 2.1 bar (30 psig)head pressure the air consumption was reduced by 69%, thus providing increased
operation at intermediate EMS settings. efficiency.
For a detailed example for how to set your EMS, see beginning of
performance curve section.
The Efficiency Management System (EMS) can be used to optimize the performance of your Wilden pump for
Caution: Do not exceed 8.6 bar (125 psig) air supply pressure.
PSIG
[BAR]
Inlet Air Pressure
AIR-OPERATED PUMPS: To stop the pump from operating in an emergency NOTE: In the event of a power failure, the shutoff valve should be closed, if the
situation, simply close the shut-off valve (user supplied) installed in the air restarting of the pump is not desirable once power is regained.
supply line. A properly functioning valve will stop the air supply to the pump,
therefore stopping output. This shut-off valve should be located far enough
away from the pumping equipment such that it can be reached safely in an
emergency situation.
OPERATION: The P8 and PX8 are pre-lubricated, and do The Wilden P8 and PX8 pump run solely on compressed
not require in-line lubrication. Additional lubrication will not air and does not generate heat, therefore your process fluid
damage the pump, however if the pump is heavily lubricated temperature will not be affected.
by an external source, the pumps internal lubrication may be MAINTENANCE AND INSPECTIONS: Since each application
washed away. If the pump is then moved to a non-lubricated is unique, maintenance schedules may be different for every
location, it may need to be disassembled and re-lubricated as pump. Frequency of use, line pressure, viscosity and abra-
described in the ASSEMBLY/DISASSEMBLY INSTRUCTIONS. siveness of process fluid all affect the parts life of a Wilden
Pump discharge rate can be controlled by limiting the volume pump. Periodic inspections have been found to offer the best
and/or pressure of the air supply to the pump (preferred means for preventing unscheduled pump downtime. Person-
method). An air regulator is used to regulate air pressure. nel familiar with the pumps construction and service should
A needle valve is used to regulate volume. Pump discharge be informed of any abnormalities that are detected during
rate can also be controlled by throttling the pump discharge operation.
by partially closing a valve in the discharge line of the pump. RECORDS: When service is required, a record should be
This action increases friction loss which reduces flow rate. made of all necessary repairs and replacements. Over a
(See Section 5.) This is useful when the need exists to control period of time, such records can become a valuable tool for
the pump from a remote location. When the pump discharge predicting and preventing future maintenance problems and
pressure equals or exceeds the air supply pressure, the unscheduled downtime. In addition, accurate records make
pump will stop; no bypass or pressure relief valve is needed, it possible to identify pumps that are poorly suited to their
and pump damage will not occur. The pump has reached a applications.
deadhead situation and can be restarted by reducing the
fluid discharge pressure or increasing the air inlet pressure.
TROUBLESHOOTING
Pump will not run or runs slowly. 2. Verify that vacuum required to lift liquid is not greater
1. Ensure that the air inlet pressure is at least 0.4 bar (5 psig) than the vapor pressure of the material being pumped
above startup pressure and that the differential pressure (cavitation).
(the difference between air inlet and liquid discharge 3. Check for sticking ball check valves. If material being
pressures) is not less than 0.7 bar (10 psig). pumped is not compatible with pump elastomers, swell-
2. Check air inlet filter for debris (see recommended instal- ing may occur. Replace ball check valves and seals with
lation). proper elastomers. Also, as the check valve balls wear
3. Check for extreme air leakage (blow by) which would out, they become smaller and can become stuck in the
indicate worn seals/bores in the air valve, pilot spool and seats. In this case, replace balls and seats.
main shaft.
4. Disassemble pump and check for obstructions in the air Pump air valve freezes.
passageways or objects which would obstruct the move- 1. Check for excessive moisture in compressed air. Either
ment of internal parts. install a dryer or hot air generator for compressed air.
5. Check for sticking ball check valves. If material being Alternatively, a coalescing filter may be used to remove
pumped is not compatible with pump elastomers, swell- the water from the compressed air in some applications.
ing may occur. Replace ball check valves and seals with
proper elastomers. Also, as the check valve balls wear Airbubbles in pump discharge.
out, they become smaller and can become stuck in the 1. Check for ruptured diaphragm.
seats. In this case, replace balls and seats. 2. Check tightness of outer pistons. (Refer to Section 8C.)
6. Check for broken inner piston which will cause the air 3. Check tightness of clamp bands and integrity of o-rings
valve spool to be unable to shift. and seals, especially at intake manifold.
7. Remove plug from pilot spool exhaust. 4. Ensure pipe connections are airtight.
Pump runs but little or no product flows. Product comes out air exhaust.
1. Check for pump cavitation; slow pump speed down to 1. Check for diaphragm rupture.
allow thick material to flow into the liquid chambers. 2. Check tightness of outer pistons to shaft.
TOOLS REQUIRED:
1/2" Wrench
11/16" Wrench
Adjustable Wrench
Vise equipped with soft jaws (such as plywood, plastic
DISASSEMBLY: Figure 1
or other suitable material)
NOTE: The model used for these instructions incorporates Step 1.
rubber diaphragms, balls, and seats. Models with PTFE Before starting disassembly, mark a line from each liquid
diaphragms, balls and seats are the same except where chamber to its corresponding air chamber. This line will assist
noted. in proper alignment during reassembly.
TOOLS REQUIRED:
3/16" Hex Head Wrench
7/32" Hex Head Wrench
Snap Ring Pliers
Phillips Head Screwdriver
O-ring Pick Step 1. Figure 1
Loosen the air valve bolts utilizing a 3/16" hex head wrench
and then remove muffler plate screws with a Phillips head
screwdriver.
Figure A Figure B
NEEDLE NOSE
PLIERS
GLIDE RING
TAPE
GLIDE RING
TAPE
P8 PLASTIC R U B B E R / T P E - F I T T E D O R U LT R A - F L E X TM- F I T T E D PA R T S L I S T I N G
P8 PLASTIC PTFE-FITTED PA R T S L I S T I N G
P8/PX8 Plastic
Traditional ULTRA-FLEX VALVE SEAT O- MANIFOLD O-
MATERIAL Diaphragms (2) DIAPHRAGMS (2) RINGS (4) RINGS (4) VALVE BALL (4)
Polyurethane 08-1010-50 N/A 08-1200-50-500 08-1300-50-500 08-1080-50
Neoprene 08-1010-51 08-1020-51 N/A N/A 08-1080-51
Buna-N 08-1010-52 08-1020-52 08-1200-52-500 08-1300-52-500 08-1080-52
EPDM 08-1010-54 08-1020-54 N/A N/A 08-1080-54
Viton 08-1010-53 08-1020-53 N/A N/A 08-1080-53
Saniflex 08-1010-56 N/A N/A N/A 08-1080-56
PTFE 08-1010-553 N/A N/A N/A 08-1080-55
Neoprene Backup 08-1060-51 N/A N/A N/A N/A
Wil-Flex 08-1010-58 N/A 08-1200-58-500 08-1300-58-500 08-1080-58
PTFE Encap. (Viton) N/A N/A 08-1200-60-500 08-1300-60-500 N/A
NOTES
PTFE-encapsulated Viton O-rings, P/N 08-1200-60-500 and P/N 08-1300-60-500, are standard on all PTFE-fitted pumps.
PTFE diaphragm, P/N 08-1010-55, must be used with Neoprene back-up diaphragms, P/N 08-1060-51.
Item # Serial #
Y O U R I N F O R M AT I O N
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