PSG Wilden PS220 Series, Wilden PS230 Series Engineering, Operation & Maintenance

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EOM
Engineering
Operation &
Maintenance
PS220/PS230
FIT Metal Pump
Where Innovation Flows
wildenpump.com
Page 2
TABLE OF CONTENTS
SECTION 5 PERFORMANCE
PS220/PS230 Rubber-Fitted .................................................6
PS220/PS230 TPE-Fitted ....................................................6
PS220/PS230 Full-Stroke PTFE-Fitted .........................................7
SECTION 7 DISASSEMBLY / REASSEMBLY .............................................12
Air Valve Disassembly ....................................................15
Reassembly Hints & Tips ..................................................18
SECTION 8 EXPLODED VIEW & PARTS LISTING
PS220/PS230 Metal .............................................................20
Page 3
Section 1
CAUTIONS—READ FIRST!
CAUTION: Do not apply compressed air to the
exhaust port — pump will not function.
CAUTION: Do not over-lubricate air supply — excess
lubrication will reduce pump performance. Pump is pre-lubed.
TEMPERATURE LIMITS:
Acetal –29°C to 82°C –20°F to 180°F Buna-N –12°C to 82°C 10°F to 180°F Geolast® –40°C to 82°C –40°F to 180°F Neoprene –18°C to 93°C 0°F to 200°F Nordel® EPDM –51°C to 138°C –60°F to 280°F Nylon –18°C to 93°C 0°F to 200°F PFA –7°C to 107°C 45°F to 225°F Polypropylene 0°C to 79°C 32°F to 175°F Polyurethane –12°C to 66°C 10°F to 150°F PVDF –12°C to 107°C 10°F to 225°F Saniflex™ –29°C to 104°C –20°F to 220°F
SIPD PTFE SIPD PTFE
with
EPDM-backed 4°C to 137°C 40°F to 280°F
with
Neoprene-backed
4°C to 93°C 40°F to 200°F PTFE1 4°C to 104°C 40°F to 220°F FKM –40°C to 177°C –40°F to 350°F Wil-Flex™ –40°C to 107°C –40°F to 225°F
1
4°C to 149°C (40°F to 300°F) - 13 mm (1/2") and 25 mm (1") models only.
NOTE: Not all materials are available for all models.
Refer to Section 2 for material options for your pump.
CAUTION: When choosing pump materials, be
sure to check the temperature limits for all wet ted components. Example : FKM has a maximum limit of 177°C (350°F) but polypropylene has a maximum limit of only 79°C (175°F).
CAUTION: Maximum temperature limits are based
upon mechanical stress only. Certain chemicals will significantly reduce maximum safe operating temperatures. Consult Chemical Resistance Guide for chemical compatibility and temperature limits.
WARNING: Prevent static sparking. If static sparking
occurs, fire or explosion could result. Pump, valves and containers must be grounded to a proper grounding point when handling flammable fluids and whenever discharge of static electricity is a hazard.
CAUTION: Do not exceed 8.6 bar (125 psig) air supply
pressure.
CAUTION: The process fluid and cleaning fluids
must be chemically compatible with all wetted pump components. Consult Chemical Resistance Guide.
CAUTION: Pumps should be thoroughly flushed
before installing into process lines. FDA- and USDA­approved pumps should be cleaned and /or sanitized before being used.
CAUTION: A lways wear sa fety gla sses whe n operating
pump. If diaphragm rupture occurs, material being pumped may be forced out air exhaust.
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 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 co ntain er.
CAUTION: Blow out air line for 10 to 20 seconds
before attaching to pump to make sure all pipeline debris is clear. Use an in-line air filter. A 5μ (micron) air filter is recommended.
NOTE: When installing PTFE diaphragms, it is
important to tighten outer pistons simultaneously (turning in opposite directions) to ensure tight fit. (See torque specifications in Section 7.)
NOTE: Before star ting disassembly, mark a line
from each liquid chamber to its corresponding air chamber. This line will assist in proper alignment during reassembly.
CAUTION: Pro-Flo® pumps cannot be used in
submersible applications. Pro-Flo have a single-point exhaust option for submersible applications. Do not use standard Pro-Flo models in submersible applications..
CAUTION: Tighten all hardware prior to installation.
®
SHIFT pumps do
®
SHIFT
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Page 4
Section 2
WILDEN PUMP DESIGNATION SYSTEM
PS220/PS230 FIT METAL
25 mm (1") Pump Maximum Flow Rate: 254 lpm (56 gpm)
LEGEND
XPS220 / XXXXX / XXX/ XX /X XX/ XXXX
MODEL VALVE SEATS
ATEX DIAPHRAGMS
MATERIAL CODES
MODEL
PS220 = PRO-FLO® SHIFT
PS230 = PRO-FLO® SHIFT
XPS220 = PRO-FLO® SHIFT ATEX
XPS230 = PRO-FLO® SHIFT ATEX
WETTED PARTS & OUTER PISTON
AA = ALUMINUM / ALUMINUM AZ = ALUMINUM / NO OUTER
SS = STAINLESS STEEL /
SZ = STAINLESS STEEL / NO
WW = DUCTILE IRON /
WZ = DUCTILE IRON / NO OUTER
CENTER SECTION
AA = ALUMINUM
AIR VALVE
A = ALUMINUM
THREADED-PORTS
FLANGED-PORTS
THREADED-PORTS
FLANGED-PORTS
PISTON
STAINLESS STEEL
OUTER PISTON
DUCTILE IRON
PISTION
VALVE BALLS
AIR VALVE
CENTER SECTION
WETTED PARTS & OUTER PISTON
DIAPHRAGMS
BNS = BUNA-N (Red Dot) EPS = EPDM (Blue Dot) FSL = FULL-STROKE SANITARY
SANIFLEX™ IPD [Hytrel® (Cream)]
FSS = SANIFLEX
TM
[Hytrel® (Cream)] NES = NEOPRENE (Green Dot) PUS = POLYURETHANE (Clear) TSS = FULL-STROKE PTFE
w/SANIFLEX™ BACKUP
TWS = FULL-STROKE PTFE w/
WIL-FLEX™ BACKUP [Santoprene® (Three
Black Dots)] VTS = FKM (White Dot) WFS = WIL-FLEXTM [Santoprene (Three Black Dots)] WWL
= FULL-STROKE WIL-FLEX™
IPD [Santoprene® (Three
Black Dots)] XBS = CONDUCTIVE BUNA-N
(Two Red Dots)
O-RINGS
SPECIALTY CODE
(if applicable)
VALVE BALLS
BN = BUNA-N (Red Dot) FS = SANIFLEXTM [Hytrel®
(Cream)] EP = EPDM (Blue Dot) NE = NEOPRENE (Green Dot) PU = POLYURETHANE (Brown) TF = PTFE (White) VT = FKM (White Dot) WF = WIL-FLEXTM [Santoprene
(Three Black Dots)]
VALVE SEATS
A = ALUMINUM M = MILD STEEL S = STAINLESS STEEL
®
VALVE SEATS & MANIFOLD O-RINGS
BN = BUNA-N FS = SANIFLEX
TM
[Hytrel® (Cream)] EP = EPDM NE = NEOPRENE PU = POLYURETHANE (Brown) TF = PTFE (White) VT = FKM WF = WIL-FLEXTM [Santoprene®]
®
SPECIALTY CODES
0014 BSPT 0100 Wil-Gard 110V 0102 Wil-Gard sensor wire ONLY 0103 Wil-Gard 220V 0319 Single-port exhaust, BSPT 0320 Single-port exhaust 0391 25 mm (1”) NPT center-ported inlet and discharge
manifold, CSA
0392 25 mm (1”) NPT side-ported inlet and discharge
manifold, CSA 0480 Pump cycle monitor (sensor & wires) 0483 Pump cycle monitor (module, sensor & wires) 0485 Pump cycle monitor (module, sensor & wires),
DIN flange 0492 U.L. Approved, Side-ported (1” inlet and discharge
manifolds)
0493 U.L. Approved, Center Ported NPT, Turbo
“drop-in” (1” Inlet facing air inlet, 3/4” discharge facing exhaust)
0494 U.L. Approved, Center Ported NPT, Pro-Flo
“drop-in” (1” inlet facing exhaust, 3/4” discharge
facing air inlet) 0504 DIN flange 0677 25 mm (1") NPT center-ported inlet and discharge
manifold 0678 25 mm (1") BSPT center-ported inlet and discharge
manifold 0687 25 mm (1") NPT center-ported inlet and discharge
manifold, Submersible Center Section 0688 25 mm (1") BSPT center-ported inlet and discharge
manifold, Submersible Center Section 0695 19 mm (3/4") NPT center-ported discharge manifold
(Turbo-Flo "Drop-in")
NOTE: NOT AL L PUMP MODE LS A RE AVAILABL E WITH ALL M ATERIA L OPTIONS.
NOTE: MOST ELASTOMERIC MATERIALS USE COLORED DOT FOR IDENTIFICATION
WILDEN PUMP & ENGINEERING, LLC 2 WIL-11560-E - 0 7
0696 19 mm (3/4") BSPT center-ported discharge manifold
(Turbo-Flo "Drop-in")
0697 19 mm (3/4") NPT center-ported discharge manifold
(Pro-Flo "Drop-in")
0698 19 mm (3/4") BSPT center-ported discharge manifold
(Pro-Flo "Drop-in") 0730 25 mm (1") NPT side-ported inlet and discharge 0735 19 mm (3/4") NPT center-ported discharge manifold
(Turbo-Flo "Drop-in"), Submersible Center Section 0736 19 mm (3/4") BSPT center-ported discharge manifold
(Turbo-Flo "Drop-in"), Submersible Center Section 0737 19 mm (3/4") NPT center-ported discharge manifold
(Pro-Flo "Drop-in"), Submersible Center Section 0738 19 mm (3/4") BSPT center-ported discharge manifold
(Pro-Flo "Drop-in"), Submersible Center Section
Page 5
Section 3
HOW IT WORKS—PUMP
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show flow pattern through the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.
CLOSED
OUTLET
OPEN
B A
INLET
FIGUR E 1 The air valve dire cts pre ssurized air to the back side of diaphragm A. The compressed air is applied directly to the liquid column separated by elastomeric diaphragms. The diaphragm acts as a separation membrane between the compressed air and liquid; a balanced load removes mechanical stress from the diaphragm. The compressed air moves the diaphragm away from the center of the pump. The opposite diaphragm is pulled in by the shaft connected to the pressurized diaphragm. Diaphragm B is on its suction stroke; air behind the diaphragm has been forced out to atmosphere through the exhaust port of the pump. The movement of diaphragm B toward the center of the pump creates a vacuum within chamber B. Atmospheric pressure forces fluid into the inlet manifold forcing the inlet valve ball off its seat. Liquid is free to move past the inlet valve ball and fill the liquid chamber (see shaded area).
CLOSEDOPEN
OPEN
OUTLET
CLOSED
B A
CLOSED OPEN
FIGURE 2 phragm
, diaphragm A, reaches the limit of its discharge stroke, the air valve redirects pressurized air to the back side of diaphragm B. The pressurized air forces diaphragm B away from the center while pulling diaphragm A to the center. Diaphragm B is now on its discharge stroke. Diaphragm B forces the inlet valve ball 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 opposite discharge valve ball is forced onto its seat, forcing fluid to flow through the pump discharge. The movement of diaphragm A toward the center 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 is forced off its seat allowing the fluid being pumped to fill the liquid chamber.
INLET
When the pressurized dia-
CLOSED OPEN
OUTLET
B A
OPEN
FIGURE 3 At completion of the stroke, the air valve again redirects air to the back side of diaphragm A, which starts diaphragm B on its exhaust stroke. As the pump reaches its original starting point, each diaphragm has gone through one exhaust and one discharge stroke. This constitutes one complete pumping cycle. The pump may take several cycles to completely prime depending on the conditions of the application.
INLET
CLOSED
HOW IT WORKS—AIR DISTRIBUTION SYSTEM
The heart of the patented Pro-Flo® SHIFT Air Distribution System (ADS) is the air valve assembly. The air valve design incorporates an unbalanced spool with the small end of the spool being pressurized continuously while the large end of the spool is alternately pressurized, then exhausted to move the spool. The air valve spool directs pressurized air to one chamber while exhausting the other. The air forces the main shaft/ diaphragm assembly to move to one side – discharging liquid on that side and pulling liquid in on the other side. When the shaft reaches the end of the stroke, the inner piston actuates the pilot spool, which controls the air to the large end of the air valve spool. The repositioning of the air valve spool routes the air to the other air chamber.
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Section 4
PS220 Metal
DIMENSIONAL DRAWINGS
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 361 14.2 B 36 1.4 C 163 6.4 D 254 10.0 E 287 11.3 F 56 2.2 G 417 16.4 H 71 2.8 J 140 5.5 K 155 6.1 L 206 8.1
M 173 6.8
N 104 4.1 P 127 5.0 R 10 0.4
LW0364 REV. A
PS220 Metal—Center-Ported
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 422 16.6 B 36 1.4 C 163 6.4 D 254 10.0 E 287 11.3 F 33 1.3 G 417 16.4 H 71 2.8 J 140 5.5 K 155 6.1 L 206 8.1
M 173 6.8
N 104 4.1 P 127 5.0 R 10 0.4
LW0365 REV. A
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DIMENSIONAL DRAWINGS
PS230 Metal—Stainless Steel
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 373 14.7 B 69 2.7 C 195 7.6 D 287 11.3 E 340 13.4
F 343 13.5 G 71 2.8 H 417 16.4 J 71 2.8 K 140 5.5
L 188 7.4
M 206 8.1 N 173 6.8
P 104 4.1 R 127 5.0 S 10 0.4 T 203 8.0
DIN (mm) ANSI (inch)
U 85 DIA. 3.1 DIA. V 115 DIA. 4.3 DIA.
W 14 DIA. 0.6 DIA.
LW0366 REV. A
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Section 5
PS220/PS230 METAL
RUBBER-FITTED
PERFORMANCE
Ship Weight Ductile Iron 29 kg (64 lb) 316 Stainless Steel 31 kg (68 lb)
Air Inlet ................................... 13 mm (1/2")
Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ....................... 6.9 m Dry (22.7')
9.0 m Wet (29.5')
Disp. Per Stroke1 ................... 0.30 L (0.08 gal)
Max. Flow Rate .............. 204 lpm (54 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
2.1 bar (30 psig) head pressure.
Example: To pump 140 lpm (37 gpm) against a discharge pressure head of
2.8 bar (40 psig) requires 5.5 bar (80 psig) and 60 Nm3/h (38 scfm) air consumption. (See dot on chart.)
...........Aluminum 19 kg (41 lb)
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation parameters will fall in the center of the pump's performance curve.
PS220/PS230 METAL
TPE-FITTED
Ship Weight ...........Aluminum 19 kg (41 lb)
Ductile Iron 29 kg (64 lb) 316 Stainless Steel 31 kg (68 lb)
Air Inlet ................................... 13 mm (1/2")
Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ....................... 5.9 m Dry (19.3')
9.0 m Wet (29.5')
Disp. Per Stroke1 ................... 0.26 L (0.07 gal)
Max. Flow Rate .............. 212 lpm (56 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
2.1 bar (30 psig) head pressure.
Example: To pump 144 lpm (38 gpm) against a discharge pressure head of
2.8 bar (40 psig) requires 5.5 bar (80 psig) and 63 Nm3/h (40 scfm) air consumption. (See dot on chart.)
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation parameters will fall in the center of the pump's performance curve.
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PS220/PS230 METAL
FULL-STROKE PTFE-FITTED
PERFORMANCE
Ship Weight Ductile Iron 29 kg (64 lb) 316 Stainless Steel 31 kg (68 lb)
Air Inlet ................................... 13 mm (1/2")
Inlet ............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ........................5.2 m Dry (17.0')
9.0 m Wet (29.5')
Disp. Per Stroke1 ................... 0.30 L (0.08 gal)
Max. Flow Rate .............. 197 lpm (52 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
2.1 bar (30 psig) head pressure.
Example: To pump 83.3 lpm (22 gpm) against a discharge pressure head of
2.8 bar (40 psig) requires 4.1 bar (60 psig) and 36 Nm3/h (23 scfm) air consumption. (See dot on chart.)
...........Aluminum 19 kg (41 lb)
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation parameters will fall in the center of the pump's performance curve.
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Page 10
SUCTION-LIFT CURVES
PS220/PS230 METAL SUCTION-LIFT CAPABILITY
Suction-lift curves are calibrated for pumps operating at 305 m (1,000') above sea level. This chart is meant to be a guide only. There are many variables that can affect your pump's operating characteristics. The number of intake and discharge elbows, viscosity of pumping fluid, elevation (atmospheric pressure) and pipe friction loss all affect the amount of suction lift your pump will attain.
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Section 6
SUGGESTED INSTALLATION
Wilden® pumps are designed to meet the performance requirements of even the most demanding pumping applications. They have been designed and manufactured to the highest standards and are available in a variety of liquid path materials to meet your chemical resistance needs. Refer to the performance section of this manual for an in-depth analysis of the performance characteristics of your pump. Wilden offers the widest variety of elastomer options in the industry to satisfy temperature, chemical compatibility, abrasion resistance and flex concerns.
The suction pipe size should be at least the equivalent or larger than the diameter size of the suction inlet on your Wilden pump. The suction hose must be non-collapsible, reinforced type as these pumps are capable of pulling a high vacuum. Discharge piping should also be the equivalent or larger than the diameter of the pump discharge which will help reduce friction losses. It is critical that all fittings and connections are airtight or a reduction or loss of pump suction capability will result.
INSTALLATION: Months of careful planning, study and selection efforts can result in unsatisfactory pump performance if installation details are left to chance.
Premature failure and long-term dissatisfaction can be avoided if reasonable care is exercised throughout the installation process.
LOCATION: Noise, safety and other logistical factors usually dictate where equipment will be situated on the production floor. Multiple installations with conflicting requirements can result in congestion of utility areas, leaving few choices for additional pumps.
Within the framework of these and other existing conditions, every pump should be located in such a way that six key factors are balanced against each other to maximum advantage.
ACCESS: First of all, the location should be accessible. If it’s easy to reach the pump, maintenance personnel will have an easier time carrying out routine inspections and adjustments. Should major repairs become necessary, ease of access can play a key role in speeding the repair process and reducing total downtime.
AIR SUPPLY: Every pump location should have an air line large enough to supply the volume of air necessary to achieve the desired pumping rate. Use air pressure up to a maximum of 8.6 bar (125 psig) depending on pumping requirements.
For best results, the pumps should use a 5µ (micron) air filter, needle valve and regulator. The use of an air filter before the pump will ensure that the majority of any pipeline contaminants will be eliminated.
SOLENOID OPERATION: When operation is controlled by a solenoid valve in the air line, three-way valves should be used. This valve allows trapped air between the valve and the pump to bleed off which improves pump performance. Pumping volume can be estimated by counting the number of strokes per minute and then multiplying the figure by the displacement per stroke.
MUFFLER: Sound levels are reduced below OSHA specifications using the standard Wilden muffler. Other mufflers can be used to further reduce sound levels, but they usually reduce pump performance.
ELEVATION: Selecting a site that is well within the pump’s dynamic lift capability will assure that loss-of-prime issues will be eliminated. In addition, pump efficiency can be adversely affected if proper attention is not given to site location.
PIPING: Final determination of the pump site should not be made until the piping challenges of each possible location have been evaluated. The impact of current and future installations should be considered ahead of time to make sure that inadvertent restrictions are not created for any remaining sites.
For U.L. listed pumps, all installation must conform with NFPA 30, NFPA 30A and other applicable codes. All pipe connections are to be made using U.L. classified gasoline-resistant pipe compound. Exhaust port is to be connected to pipe or tubing to be routed outdoors or other location determined to be equivalent.
The best choice possible will be a site involving the shortest and straightest hook-up of suction and discharge piping. Unnecessary elbows, bends and fittings should be avoided. Pipe sizes should be selected to keep friction losses within practical limits. All piping should be supported independently of the pump. In addition, the piping should be aligned to avoid placing stress on the pump fittings.
Flexible hose can be installed to aid in absorbing the forces created by the natural reciprocating action of the pump. If the pump is to be bolted down to a solid location, a mounting pad placed between the pump and the foundation will assist in minimizing pump vibration. Flexible connections between the pump and rigid piping will also assist in minimizing pump vibration. If quick­closing valves are installed at any point in the discharge system, or if pulsation within a system becomes a problem, a surge suppressor (SD Equalizer pump, piping and gauges from surges and water hammer.
If the pump is to be used in a self-priming application, make sure that all connections are airtight and that the suction lift is within the model’s ability. NOTE: Materials of construction and elastomer material have an effect on suction-lift parameters. Please refer to the performance section for specifics.
When pumps are installed in applications involving flooded suction or suction head pressures, a gate valve should be installed in the suction line to permit closing of the line for pump service.
Pumps in service with a positive suction head are most efficient when inlet pressure is limited to 0.5–0.7 bar (7–10 psig). Premature diaphragm failure may occur if positive suction is 0.7 bar (10 psig) and higher.
SUBMERSIBLE APPLICATIONS: Pro-Flo® SHIFT pumps can be used for submersible applications when using the Pro-Flo® SHIFT's single-point exhaust option. Pro-Flo X™ and Turbo-Flo® Pumps are also available in a single-point exhaust (submersible) configuration.
®
NOTE: Pro-Flo
ALL WILDEN PUMPS ARE CAPABLE OF PASSING SOLIDS. A STRAINER SHOULD BE USED ON THE PUMP INTAKE TO ENSURE THAT THE PUMP'S RATED SOLIDS CAPACITY IS NOT EXCEEDED.
CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR SUPPLY PRESSURE.
and Accu-Flo™ pumps are not submersible.
®
) should be installed to protect the
WIL-11560-E - 0 7 9 WILDEN PUMP & ENGINEERING, LLC
Page 12
FOOTPAD
(OPTIONAL)
DISCHARGE
SUGGESTED INSTALLATION
This illustration is a generic representation of an air-operated double-diaphragm pump.
MUFFLER
FLEXIBLE
CONNECTION
SUCTION
EQUALIZER
SURGE DAMPENER
(OPTIONAL)
GAUGE
SHUT-OFF VALVE
FLEXIBLE CONNECTION
NEEDLE VALVE
COMBINATION
FILTER & REGULATOR
AIR SHUT-OFF VALVE
NOTE: In the event of a power failure, the shut-off valve should be closed, if the restarting of the pump is not desirable once power is regained.
AIR-OPERATED PUMPS: To stop the pump from operating in an emergency situation, simply close the shut-off valve (user­supplie d) installed in the air supp ly 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.
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Page 13
SUGGESTED OPERATION & MAINTENANCE
OPERATION: The Pro-Flo® SHIFT pumps are pre­lubricated and do not require in-line lubrication. Additional lubrication will not damage the pump, however if the pump is heavily lubricated by an external source, the pump’s internal lubrication may be washed away. If the pump is then moved to a non­lubricated location, it may need to be disassembled and re-lubricated as described in the REASSEMBLY/ DISASSEMBLY INSTRUCTIONS.
Pump discharge rate can be controlled by limiting the volume and/or pressure of the air supply to the pump. A regulator is used to control air pressure while a needle valve is used to control volume. Pump discharge rate can also be controlled by throttling the pump discharge by partially closing a valve in the discharge line of the pump. This action increases friction loss which reduces flow rate. (See Section 5.) This is useful when the need exists to control the pump from a remote location. When the pump discharge pressure equals or exceeds the air supply pressure, the pump will stop; no bypass or pressure relief valve is needed, and pump damage will not occur. The pump has reached a “deadhead”
TROUBLESHOOTING
situation and can be restarted by reducing the fluid discharge pressure or increasing the air inlet pressure. The Pro-Flo air and do not generate heat, therefore your process fluid temperature will not be affected.
MAINTENANCE AND INSPECTIONS: Since each application is unique, maintenance schedules may be different for every pump. Frequency of use, line pressure, viscosity and abrasiveness of process fluid all affect the parts life of a Wilden pump. Periodic inspections have been found to offer the best means for preventing unscheduled pump downtime. Personnel familiar with the pump’s construction and service should be informed of any abnormalities that are detected during operation.
RECORDS: When service is required, a record should be made of all necessary repairs and replacements. Over a period of time, such records can become a valuable tool for predicting and preventing future maintenance problems and unscheduled downtime. In addition, accurate records make it possible to identify pumps that are poorly suited to their applications.
®
SHIFT pumps run solely on compressed
Pump will not run or runs slowly.
1. Ensure that the air inlet pressure is at least 0.3 bar (5 psig) above startup pressure and that the differential pressure (the difference between air inlet and liquid discharge pressures) is not less than 0.7 bar (10 psig).
2. Check air inlet filter for debris (see SUGGESTED INSTALLATION).
3. Check for extreme air leakage (blow by) that would indicate worn seals /bores in the air valve, pilot spool and main shaft.
4. Disassemble pump and check for obstructions in the air passageways or objects that would obstruct the movement of internal parts.
5. Check for sticking ball check valves. If material being pumped is not compatible with pump elastomers, swelling may occur. Replace ball check valves and seals with proper elastomers. Also, as the check valve balls wear out, they become smaller and can become stuck in the seats. In this case, replace balls and seats.
6. Check for broken inner piston that will cause the air valve spool to be unable to shif t.
7. Remove plug from pilot spool exhaust.
Pump runs but little or no product flows.
1. Check for pump cavitation; slow pump speed down to allow thick material to flow into liquid chambers.
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2. Verify that vacuum required to lift liquid is not greater than the vapor pressure of the material being pumped (cavitation).
3. Check for sticking ball check valves. If material being pumped is not compatible with pump elastomers, swelling may occur. Replace ball check valves and seats with proper elastomers. Also, as the check valve balls wear out, they become smaller and can become stuck in the seats. In this case, replace balls and seats.
Pump air valve freezes.
1. Check for excessive moisture in compressed air. Either install a dryer or hot air generator for compre ssed air. Alternativel y, a coal escing filter may be used to remove the water from the compressed air in some applications.
Air bubbles in pump discharge.
1. Check for ruptured diaphragm.
2. Check tightness of outer pistons (refer to Section 7).
3. Check tightness of fasteners and integrity of O-rings and seals, especially at intake manifold.
4. Ensure pipe connections are airtight.
Product comes out air exhaust.
1. Check for diaphragm rupture.
2. Check tightness of outer pistons to shaft.
Page 14
Section 7
PUMP DISASSEMBLY
Tools Required:
• 13 mm (1/2") Box Wrench
• 2 – 25 mm (1") Sockets or Adjustable Wrench
• Adjustable Wrench
• Vise equipped with soft jaws (such as plywood, plastic or other suitable material)
CAUTION:
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. Be aware of any hazardous effects of contact with your process fluid.
NOTE: The model photographed is a metal PX200 25 mm (1") pump. Your specific pump model may vary from configuration shown; however, pump disassembly procedure will be the same.
Before any maintenance or repair is attempted, the compressed air line
Step 1
Please note alignment marks on center section. Use to properly align liquid chamber to center section.
WILDEN PUMP & ENGINEERING, LLC 12 WIL-115 6 0 - E-07
Step 2
Using a 13 mm (1/2") wrench, loosen the discharge manifold from the liquid chambers.
Step 3
Remove the discharge manifold to expose the valve balls, valve seats and valve seat O-rings.
Page 15
PUMP DISASSEMBLY
Step 4
Remove the discharge valve balls, seats and valve seat O-rings from the discharge manifold and liquid chamber, inspect for nicks, gouges, chemical attack or abrasive wear. NOTE: Replace worn parts with genuine Wilden part for reliable performance.
Step 5
Using a 13 mm (1/2") wrench, remove the inlet manifold.
Step 6
Remove the inlet valve balls, seats and valve seat O-rings from the liquid chamber and inlet manifold, inspect for nicks, gouges, chemical attack or abrasive wear.
Step 7
Using a 13 mm (1/2") wrench, remove the liquid chambers from the center section.
WIL-11560-E - 0 7 13 WILDEN PUMP & ENGINEERING, LLC
Step 8
The liquid chamber should be removed to expose the diaphragm and outer piston. Rotate center section and remove the opposite liquid chamber.
Step 9
Using two adjustable wrenches or 25 mm (1”) sockets, remove diaphragm assembly from center section assembly.
Page 16
PUMP DISASSEMBLY
Step 10
After loosening and removing the outer piston the diaphragm assembly can be disassembled.
Step 11
To remove the remaining diaphragm assembly from the shaft, secure shaft with soft jaws (a vise fitted with plywood or other suitable material) to ensure shaft is not nicked, scratched, or gouged. Using an adjustable wrench, remove diaphragm assembly from shaft. Inspect all parts for wear and replace with genuine Wilden parts if necessary.
Step 12
Inspect diaphragms, outer and inner pistons for signs of wear. Replace with genuine Wilden parts if necessary.
WILDEN PUMP & ENGINEERING, LLC 14 W IL-115 6 0 - E- 07
Page 17
AIR VALVE DISASSEMBLY
Tools Required:
• 3/16" Hex-Head
• Snap-Ring Pliers
• O-Ring Pick
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. Be aware of hazardous effects of contact with your process fluid.
®
The Wilden Pro-Flo
SHIFT metal pumps utilize a revolutionary Pro-Flo® SHIFT air
distribution system. Proprietary composite seals reduce the coefficient of friction and
®
allow the Pro-Flo
SHIFT to run lube free. The Pro-Flo® SHIFT air distribution system
is designed to perform in on/off, non-freezing, non-stalling, tough duty applications..
Step 1
Loosen the air valve bolts utilizing a 5 mm (3 ⁄16") Allen wrench.
Step 2
Remove muffler plate and air valve bolts from air valve assembly exposing muffler gasket for inspec-
Step 3
Lift away air valve assembly and remove air valve gasket for inspection. Replace if necessary.
tion. Replace if necessary.
WIL-11560-E - 0 7 15 WILDEN PUMP & ENGINEERING, LLC
Page 18
AIR VALVE DISASSEMBLY
Step 4
Remove air valve end cap to expose air valve spool by simply lifting up on end cap once air valve bolts are removed.
Step 5
Remove air valve spool from air valve body by threading one air valve bolt into the end of the spool and gently sliding the spool out of the air valve body. Inspect seals for signs of wear and replace entire assembly if necessary. Use caution when handling air valve spool to prevent damaging seals.
Seals should not be
NOTE:
removed from assembly. Seals are not sold separately.
Step 6
Remove pilot spool sleeve retaining snap ring on both sides of center section with snap ring pliers.
Step 7
Remove pilot spool sleeve from center section.
WILDEN PUMP & ENGINEERING, LLC 16 WIL-115 6 0 - E-07
Step 8
With O-ring pick, gently remove the O-ring from the opposite side of the center hole cut on the spool. Gently remove the pilot spool from sleeve and inspect for nicks, gouges or other signs of wear. Replace pilot sleeve assembly or outer sleeve O-rings if necessary. During reassembly never insert the pilot spool into the sleeve with the center cut side first, this end incorporates the urethane O-ring and will be damaged as it slides over the ports cut in the sleeve.
Seals should not be removed from pilot spool.
NOTE:
Seals are not sold separately.
Page 19
AIR VALVE DISASSEMBLY
Step 9
Check center section Glyd™ rings for signs of wear. If necessary, remove Glyd™ rings with O-ring pick and replace.
SUBMERSIBLE PRO-FLO® SHIFT
Step 1
Remove pilot exhaust muffler in pilot bleed port located at the front of the center block. Install 1/4" NPT pipe plug (00-7010-08) into bleed port.
Non-Submersible
Step 2
Next, install an optional single-point exhaust gasket (02-2621-52). The single-point air valve gasket can be purchased as a spare part or included with the purchase of a new Pro-Flo
®
SHIFT pump.
Submersible
WIL-11560-E - 0 7 17 WILDEN PUMP & ENGINEERING, LLC
Page 20
REASSEMBLY HINTS & TIPS
RE AS SEM BLY:
Upon performing applicable maintenance to the air distribution system, the pump can now be reassembled. Please refer to the disassembly instructions for photos and parts placement. To reassemble the pump, follow the disassembly instructions in reverse order. The air distribution system needs to be assembled first, then the diaphragms and finally the wetted path. Please find the applicable torque specifications on this page. The following tips will assist in the assembly process.
• Lubricate air valve bore, center section shaft and pilot spool bore with NLGI grade 2 white EP bearing grease or equivalent.
• Clean the inside of the center section shaft bore to ensure no damage is done to new shaft seals.
• A small amount of NLGI grade 2 white EP bearing grease can be applied to the muffler and air valve gaskets to locate gaskets during assembly.
• Make sure that the exhaust port on the muffler plate is centered between the two exhaust ports on the center section.
• Stainless steel bolts should be lubed to reduce the possibility of seizing during tightening.
PRO-FLO® SHIFT MAXIMUM TORQUE
SPECIFICATIONS
Description of Part Torque
Air Valve 11.3 N•m (100 in-lb)
Dial Set Screw 11.3 N•m (100 in-lb)
Outer Pistons, All diaphragms 47.1 N•m (30 ft-lb)
Top and Bottom Manifold 8.5 N•m (75 in-lb)
Liquid Chamber to Center Section 8.5 N•m (75 in-lb)
Figure A
SHA FT SE AL
SHAFT SEAL INSTALLATION:
PRE-INSTALLATION
• Once all of the old seals have been removed, the inside of the bushing should be cleaned to ensure no debris is left that may cause premature damage to the new seals.
INSTALLATION
The following tools can be used to aid in the installation of the new seals:
Needle-Nose Pliers Phillips Screwdriver Electrical Tape
• Wrap electrical tape around each leg of the needle­nose pliers (heat shrink tubing may also be used). This is done to prevent damaging the inside surface of the new seal.
• With a new seal in hand, place the two legs of the needle-nose pliers inside the seal ring. (See Figure A.)
• Open the pliers as wide as the seal diameter will allow, then with two fingers pull down on the top portion of the seal to form a kidney shape. (See Figure B.)
• Lightly clamp the pliers together to hold the seal into the kidney shape. Be sure to pull the seal into as tight of a kidney shape as possible, this will allow the seal to travel down the bushing bore easier.
• With the seal clamped in the pliers, insert the seal into the bushing bore and position the bottom of the seal into the correct groove. Once the bottom of the seal is seated in the groove, release the clamp pressure on the pliers. This will allow the seal to partially snap back to its original shape.
• After the pliers are removed, you will notice a slight bump in the seal shape. Before the seal can be properly resized, the bump in the seal should be removed as much as possible. This can be done with either the Phillips screwdriver or your finger. With either the side of the screwdriver or your finger, apply light pressure to the peak of the bump. This pressure will cause the bump to be almost completely eliminated.
• Lubricate the edge of the shaft with NLGI grade 2 white EP bearing grease.
• Slowly insert the center shaft with a rotating motion. This will complete the resizing of the seal.
• Perform these steps for the remaining seals.
NEEDLE-NOSE
Figure B
PLIERS
TAPE
WILDEN PUMP & ENGINEERING, LLC 18 WIL-115 6 0 - E-07
SHA FT SE AL
TAPEAV
Page 21
NOTES
Page 22
Section 8 exploded view & parts listing
Section 8
EXPLODED VIEW & PARTS LISTING
PS220/PS230 METAL
EXPLODED VIEW
FULL-STROKE PTFE
FULL-STROKE IPD
STAINLESS-STEEL FLANGED
METAL ADS
LW0367 REV. C
ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS (see Section 9).
WILDEN PUMP & ENGINEERING, LLC 20 W IL-115 6 0 - E- 07
Page 23
EXPLODED VIEW & PARTS LISTING
PS220/PS230 METAL
No. Description Qty.
PS220/230/
AAAAA/…/
P/N
PS220/230/
WWAAA/…/
P/N
PARTS LISTING
PS220/230/
SSAAA/…/
P/N
AIR DISTRIBUTION COMPONENTS
1 Pro-Flo X® Air Valve Assembly 2 O-Ring, End Cap (-126, Ø1.362 x Ø.103) 2 01-2395-52 01-2395-52 01-2395-52
3 End Cap 2 01-2340-01 01-2340-01 01-2340-01 4 Screw, SHC, Air Valve (1/4"-20 x 3") 4 01-6001-03 01-6001-03 01-6001-03 5 Muffler Plate, Pro-Flo X 6 Gasket, Muffler Plate, Pro-Flo X 7 Gasket, Air Valve, Pro-Flo X 8 Center Section Assembly, Pro-Flo® SHIFT
9 Pilot Sleeve Assembly 1 02-3880-99 02-3880-99 02-3880-99 10 Pilot Spool Retaining O-Ring (-009. Ø.208 x Ø.070) 1 04-2650-49-700 04-2650-49-700 04-2650-49-700 11 Shaft Seal 2 02-3210-55-225 02-3210-55-225 02-3210-55-225
12 Retaining Ring 1 00-2650-03 00-2650-03 00-2650-03 13 Grounding Screw, (10-32 x 1/2") Self-Tapping 1 04-6345-08 04-6345-08 04-6345-08 14 Muffler, 3/4" MNPT 1 08-3510-99R 08-3510-99R 08-3510-99R 15 Muffler, 1/4" MNPT 1 04-3240-07 04-3240-07 04-3240-07
1
®
®
®
2
1 02-2030-01 02-2030-01 02-2030-01
1 02-3185-01 02-3185-01 02-3185-01 1 02-3502-52 02-3502-52 02-3502-52 1 02-2620-52 02-2620-52 02-2620-52 1 02-3138-01 02-3138-01 02-3138-01
WETTED PATH COMPONENTS
16 Liquid Chamber 2 02-5015-01 02-5015-02 02-5015-03 17 Inlet Manifold, Side Ported, 1" NPT 1 02-5095-01 02-5095-02 02-5095-03
Inlet Manifold, Side Ported, 1" BSPT 1 02-5096-01 02-5096-02 02-5096-03 Inlet Manifold, Center Ported, 1" NPT 1 02-5095-01-677 02-5095-02-677 02-5095-03-677 Inlet Manifold, Center Ported, 1" BSPT 1 02-5096-01-678 02-5096-02-678 02-5096-03-678 Inlet Manifold, ANSI Flange 1 02-5090-01 02-5090-02 02-5090-03 Inlet Manifold, DIN Flange 1 02-5091-01 02-5091-02 02-5091-03
18 Discharge Manifold, Side Ported, 1" NPT 1 02-5035-01 02-5035-02 02-5035-03
Discharge Manifold, Side Ported, 1" BSPT 1 02-5036-01 02-5036-02 02-5036-03 Discharge Manifold, Center Ported, 3/4" NPT 1 02-5035-01-697 02-5035-02-697 02-5035-03-697 Discharge Manifold, Center Ported, 3/4" BSPT 1 02-5036-01-698 02-5036-02-698 02-5036-03-698 Discharge Manifold, Center Ported, 1" NPT 1 02-5035-01-677 02-5035-02-677 02-5035-03-677 Discharge Manifold, Center Ported, 1" BSPT 1 02-5036-01-678 02-5036-02-678 02-5036-03-678 Discharge Manifold, ANSI Flange 1 02-5030-01 02-5030-02 02-5030-03
Discharge Manifold, DIN Flange 1 02-5031-01 02-5031-02 02-5031-03 19 Screw, HHC, 5/16"-18 x 1" 32 08-6180-03-42 08-6180-03-42 08-6180-03-42 20 Washer, 5/16" 21 Pipe Plug, 1" NPT 2 02-7010-01 02-7010-02 02-7010-03
Pipe Plug, 1" BSPT 2 02-7011-01 02-7011-02 02-7011-03
32 02-6731-03 02-6731-03 02-6731-03
VALVE BALLS/VALVE SEATS/VALVE O-RINGS/MANIFOLD O-RING
22 Ball, Valve 4 * * * 23 O-ring, Manifold (-229, Ø2.359 x Ø.139) 4 * * * 24 Valve Seat 4 02-1125-01 02-1125-08 02-1125-03 25 O-ring, Valve Seat (-224, Ø1.734 x Ø.139) 4 * * *
FULL-STROKE RUBBER/TPE/PTFE/FSIPD COMPONENTS
26 Shaft 1 02-3810-03 02-3810-03 02-3810-03 27 Stud, 3/8"-16 x 1-1/4" 2 N/A 02-6150-08 02-6150-08 28 Disc Spring 2 02-6802-08 02-6802-08 02-6802-08 29 Inner Piston 2 02-3701-01 02-3701-01 02-3701-01
30 Diaphragm, Primary 2 * * *
Diaphragm, IPD Primary 2 * * *
Diaphragm, Backup 2 * * *
31
32
Outer Piston 2 02-4550-01 02-4550-02 02-4550-03
* Refer to Elastomer Options in Section 9
1
Air Valve Assembly includes items 2 and 3
All boldface items are primary wear parts.
LW0368 REV. A
WIL-11560-E - 0 7 21 WILDEN PUMP & ENGINEERING, LLC
Page 24
Section 9
ELASTOMER OPTIONS
PS220/PS230 METAL
MATERIAL
Polyurethane Neoprene
®
Buna-N Conductive Buna-N FKM EPDM PTFE Saniflex™ Wil-Flex™ Food-Grade Wil-Flex™ Aluminum Mild Steel Stainless Steel
®
DIAPHRAGMS
(2)
02-1010-50 N/A N/A N/A 02-1085-50 N/A 02-1205-50 02-1372-50 02-1010-51 N/A N/A N/A 02-1085-51 N/A 02-1205-51 02-1372-51 02-1010-52 N/A N/A N/A 02-1085-52 N/A 02-1205-52 70-1280-52 02-1010-86 N/A N/A N/A N/A N/A N/A N/A 02-1010-53 N/A N/A N/A 02-1085-53 N/A 02-1205-53 02-1372-53 02-1010-54 N/A N/A N/A 02-1085-54 N/A 02-1205-54 02-1372-54
N/A 02-1040-55 N/A N/A 02-1085-55 N/A 02-1205-55 70-1280-55 02-1010-56 N/A 02-1065-56 02-1031-56 02-1085-56 N/A 02-1205-56 02-1372-56 02-1010-58 N/A N/A 02-1031-58 02-1085-58 N/A 02-1205-58 02-1372-58
N/A N/A 02-1065-57 N/A N/A N/A N/A
N/A N/A N/A N/A N/A 02-1125-01 N/A N/A
N/A N/A N/A N/A N/A 02-1125-08 N/A N/A
N/A N/A N/A N/A N/A 02-1125-03 N/A N/A
FULL-STROKE DIAPHRAGMS
(2)
FULL-STROKE
BACKUP
DIAPHRAGMS
(2)
FULL-STROKE
IPD
DIAPHRAGMS
(2)
VALVE BALLS
(4)
VALVE SEATS
(4)
VALVE SEAT
O-RINGS
(4)
MANIFOLD
O-RINGS
LW0368 REV. A
(4)
N/A
WILDEN PUMP & ENGINEERING, LLC 22 W IL-115 6 0 - E- 07
Page 25
NOTES
Page 26
NOTES
Page 27
WARRANTY
Each and every product manufactured by Wilden Pump and Engineering, LLC is built to meet the highest standards of quality. Every pump is functionally tested to insure integrity of operation.
Wilden Pump and Engineering, LLC warrants that pumps, accessories and parts manufactured or supplied by it to be free from defects in material and workmanship for a period of five (5) years from date of installation or six (6) years from date of manufacture, whichever comes first. Failure due to normal wear, misapplication, or abuse is, of course, excluded from this warranty.
Since the use of Wilden pumps and parts is beyond our control, we cannot guarantee the suitability of any pump or part for a particular application and Wilden Pump and Engineering, LLC 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, LLC.
Prior approval must be obtained from Wilden for return of any items for warranty consideration and must be accompanied by the appropriate MSDS for the product(s) involved. 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 obligation for Wilden Pump and Engineering, LLC other than expressly provided herein.
PLEASE PRINT OR TYPE AND FAX TO WILDEN
PUMP INFORMATION
Item # Serial #
Company Where Purchased
YOUR INFORMATION
Company Name
Industry
Name Title
Street Address
City State Postal C ode Country
Telephone Fax E-mail Web Address
Number of pumps in facility? Number of Wilden pumps?
Types of pumps in facility (check all that apply): Diaphragm
Media being pumped?
Other
Centrifugal
Gear
Submersible
Lobe
How did you hear of Wilden Pump?
Other
Trade Journal
Trade Show
Internet/E-mail
Distributor
ONCE COMPLETE, FAX TO (909) 783-3440
OR GO TO PSGDOVER.COM > WILDEN > SUPPORT TO COMPLETE THE WARRANTY REGISTRATION ONLINE
NOTE: WARRANTY VOID IF PAGE IS NOT FAXED TO WILDEN OR SUBMIT TED ONLINE VIA THE PSGDOVER.COM WEBSITE
WILDEN PUMP & ENGINEERING, LLC
Page 28
PSG
22069 Van Buren St., Grand Terrace, CA 92313-5607
P: +1 (909) 422-1730
• F: +1 (909) 783-3440
wildenpump.com
Where Innovation Flows
PSG® reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document. 11-2018
Authorized PSG Representative:
Copyrigh t ©2018, PS G®, A Dover Compa ny
REPLAC ES WI L-1156 0 -E- 07
WI L-115 60 -E -0 7
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