PSG Dover Wilden Unitec UX Series, Wilden UX.03, Wilden UX.05, WildenUX.07, Wilden UX3 Engineering, Operation & Maintenance
Page 1
TT4129 EOM-UX/UA 1/04
REPLACES EOM-UX/UA 1/03
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WILDEN PUMP & ENGINEERING, LLC
TABLE OF CONTENTS
PAGE #
SECTION 1 — PUMP DESIGNATION SYSTEM ........................................ 1
SECTION 2 — HOW IT WORKS (PUMP & AIR SYSTEM) ................ 2
SECTION 3 — CAUTIONS — READ FIRST! ................................................ 3
SECTION 4 — DIMENSIONAL DRAWING
A. Models UX.038, UX.050, UX.075 and UX3 Rubber/Teflon®-Fitted ........................................ 4
SECTION 5 — PERFORMANCE CURVES
A. Model UX.038 Rubber/Teflon®-Fitted .................................................................................... 5
B. Model UX.050 Rubber/Teflon®-Fitted .................................................................................... 5
C. Model UX.075 Rubber/Teflon®-Fitted .................................................................................... 6
D. Model UX3 Rubber/Teflon
®
-Fitted ........................................................................................ 6
SECTION 6 — INSTALLATION & OPERATION
A. Installation .............................................................................................................................. 7
B. Operation & Maintenance ...................................................................................................... 8
C. Troubleshooting ...................................................................................................................... 9
SECTION 7 — DIRECTIONS FOR DISASSEMBLY/REASSEMBLY
A. UNITEC™ UX Series Pumps ................................................................................................ 10
B. Reassembly Hints & Tips ...................................................................................................... 13
SECTION 8 — EXPLODED VIEW/PARTS LISTING
A. UNITEC™ UX Series Pump Drawing and Parts Listing ........................................................ 14
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1
WILDEN PUMP & ENGINEERING, LLC
UNITEC™ SERIES CONDUCTIVE
PLASTIC PUMP MATERIAL CODES
MODEL
SIZE
(INTERNAL)
CHECK VALVES
7:N
SECTION 1
WILDEN PUMP DESIGNATION SYSTEM
MODEL SIZES
UX.038 = 10 mm (₃⁄₈")
UX.050 = 13 mm (₁⁄₂")
UX.075 = 19 mm (₃⁄₄")
UX3 = 32 mm (1-₁⁄₄")
WETTED PATH
D = CONDUCTIVE
POLYETHYLENE
CENTER SECTION
DD = CONDUCTIVE
POLYETHYLENE
AIR VALVE
E = POLYETHYLENE
DIAPHRAGMS
ET = TEFLON®PTFE W/ INTEGRAL
OUTER PISTON (White)
EX = NORDEL®W/INTEGRAL OUTER
PISTON
CHECK VALVES
TF = TEFLON®PTFE (White) –
BALL
ND = NORDEL®– BALL
SS = STAINLESS STEEL – BALL
CE = POLYETHYLENE – CYLINDER
VALVE SEATS
D = CONDUCTIVE POLYETHYLENE
VALVE SEAT O-RINGS
TV = TEFLON®ENCAP. VITON
®
ND = NORDEL
®
Nordel®and Viton®are registered trademarks of DuPont Dow Elastomers.
Teflon®is a registered trademark of DuPont.
SPECIALTY CODES
812 Stroke sensor
814 Stroke counting pneumatic with pressure transmitter
816 Diaphragm sensor
Page 4
SECTION 2
THE UNITEC™ PUMP — HOW IT WORKS
The Wilden UNITEC™ pump is an air-operated, positive displacement, self-priming pump. These drawings show the flow pattern through
the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.
FIGURE 1: The air valve directs pressurized 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, balancing the load and removing
mechanical stress from the diaphragm. The
compressed air moves the diaphragm away from
the center block 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 the atmosphere through the exhaust
port of the pump. The movement of diaphragm B
toward the center block 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).
FIGURE 2: When the pressurized diaphragm,
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 block
while pulling diaphragm A to the center block.
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 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 is forced off its seat allowing the
fluid being pumped to fill the liquid chamber.
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.
THE UNI-FLO™ AIR SYSTEM –
HOW IT WORKS
The Uni-Flo™ air distribution system, the driving force
behind UNITEC™ pumps, is assembled inside the center
section of the pump, between the reciprocating
diaphragms. The Uni-Flo™ systems uses a main air valve
body and mechanically actuated pilot spool mechanism
to direct inlet air pressure alternately behind each
diaphragm while at the same time exhausting the air
behind the opposite diaphragm to atmosphere. Air inlet
pressure has a direct relation to the fluid discharge pressure that the pump can develop (head), while the volume
of air has a direct relation to how quickly the pump will
reciprocate (flow).
The pilot spool is pushed alternately left and right through
contact with the inside of the diaphragm as it moves
toward the center section on its exhaust stroke. The movement of the pilot spool from one side to the other changes
the inlet and exhaust porting to each diaphragm by reversing the air flow behind each diaphragm. The diaphragm
that pushed the pilot spool to shift the pump while on its
exhaust stroke is now pressurized with inlet air pressure
and pushed away from the center section displacing fluid.
This inherently safe design needs no electronic sensors or
switches to operate reliably while delivering product.
Speed and flow can be controlled with simple adjustments
to the air regulator, air inlet valve or fluid system valves.
The Uni-Flo™ system operates solely on compressed air
and is simple to use, specify and operate.
2
WILDEN PUMP & ENGINEERING, LLC
CLOSED
OPEN
CLOSEDOPEN
CLOSEDOPEN
SIDE B SIDE A SIDE B SIDE A SIDE B SIDE A
CLOSED
CLOSED OPENOPEN
CLOSED OPEN
RIGHT STROKE LEFT STROKEMID STROKE
Page 5
3
WILDEN PUMP & ENGINEERING, LLC
SECTION 3
WILDEN UNITEC™
CONDUCTIVE PLASTIC PUMPS
CAUTIONS – READ FIRST!
CAUTION: This pump is designed to run only on clean-dry
air at all times. If oil and water may migrate into pump from
air supply, a desiccant dryer must be installed.
CAUTION: Do not lubricate air supply — lubrication will
reduce pump performance.
TEMPERATURE LIMITS:
Polyethylene 0.0°C to 70.0°C 32°F to 158°F
Nordel
®
–51.1°C to 137.8°C –60°F to 280°F
Teflon
®
PTFE 4.4°C to 120°C 40°F to 248°F
NOTE: Conductive and unfilled plastics have the same
temperature range and chemical resistance.
CAUTION: When choosing pump materials, be sure to
check the temperature limits for all wetted components.
Example: Nordel
®
has a maximum limit of 137.8°C (280°F)
but polyethylene has a maximum limit of only 70.0°C (158°F).
CAUTION: Maximum temperature limits are based upon
mechanical stress only. Certain chemicals will significantly
reduce maximum safe operating temperatures. Consult
Wilden Chem Guide (E-04) for chemical compatibility and
temperature limits.
CAUTION:
Always wear safety glasses and appropriate
protection when operating pump. If diaphragm rupture occurs,
material being pumped may be forced out air exhaust.
WARNING: Prevention of static sparking — If static spark-
ing 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 a UX series pump, utilize the marked
grounding point on the face of the pump and connect to
suitable grounding location. As each application has different requirements, please consult the local, regional or
government regulatory agency for details on proper grounding for the application.
CAUTION: Do not exceed 7 bar (100 psig) air supply
pressure.
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. Before
disassembly of the pump, or removal from process lines, all
pressure must also be bled from the liquid side of the pump
and all fluid drained into a suitable container. Failure to do so
may result in product under pressure being sprayed from
system.
CAUTION: Blow out air line for 10 to 20 seconds before
attaching to pump to make sure all pipeline debris is
clear. A 5µ (micron) in-line air filter is recommended.
CAUTION:
When installing diaphragms, be sure to insert
the shaft stud into the outer piston first, tightening with a
hex head wrench. Then proceed to install diaphragms on
the end of shaft by rotating both diaphragms clockwise. If
diaphragms are hand-tight on the shaft and the bolt holes
do not line up, attempt to continue rotating clockwise until
holes align, if possible.
Reverse rotation to align holes only
if it is impossible to align holes through clockwise rotation.
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.
CAUTION: The UX conductive plastic pumps are not
submersible. If your application requires your pump to be
submersed, contact the factory for details on a different
Wilden pump model.
CAUTION: Pumps should be flushed thoroughly with water
before installation into process line.
CAUTION: Tighten all hardware prior to installation.
CAUTION: Conductive resins may have up to 2% carbon fill-
ing. Ensure your process media is compatible with this filling.
CAUTION: Long-term exposure to UV rays may damage
unfilled polyethylene. If located outside an unfilled polyethylene pump should be protected from UV rays.
CAUTION: Use caution not to overtighten air and liquid pipe
connections, or pump fasteners. Overtorque of fittings or
fasteners may damage the pump or cause leaking of
process fluid.
Page 6
K
(LIQUID
DISCHARGE)
L
(AIR INLET)
E
F
G
B
K
(LIQUID
DISCHARGE
OPTION)
K
(LIQUID INLET)
K
(LIQUID INLET)
K
(LIQUID INLET
OPTION)
K
LIQUID DISCHARGE)
K
(LIQUID
DISCHARGE OPTION)
D
A
J
J
C
K
(LIQUID INLET
OPTION)
H
4
WILDEN PUMP & ENGINEERING, LLC
SECTION 4A
DIMENSIONAL DRAWING
WILDEN UNITEC™ CONDUCTIVE PLASTIC MODELS
DIMENSIONS FOR ALL UX SERIES PUMPS
UX.038 UX.050 UX.075 UX3
A 137 mm (5.4") 155 mm (6.1") 206 mm (8.1") 269 mm (10.6")
B 86 mm (3.2") 124 mm (4.9") 175 mm (6.9") 240 mm (9.5")
C 96 mm (3.8") 128 mm (5.0") 173 mm (6.8") 225 mm (8.9")
D 113 mm (4.5") 125 mm (4.9") 170 mm (6.7") 225 mm (8.9")
E 41 mm (1.6") 53 mm (2.1") 75 mm (3.0") 100 mm (3.9")
F 8 mm (0.3") 17 mm (0.7") 17 mm (0.7") 17 mm (0.7")
G 15 mm (0.6") 25 mm (1.0") 25 mm (1.0") 25 mm (1.0")
H 15 mm (0.6") 19 mm (0.8") 22 mm (0.9") 33 mm (1.3")
J 27 mm (1.1") 34 mm (1.3") 48 mm (1.9") 63 mm (2.5")
K 10 mm (3/8") FNPT/BSP 13 mm (1/2") FNPT/BSP 19 mm (3/4") FNPT/BSP 32 mm (1-1/4") FNPT/BSP
L 6 mm (1/4") FNPT/BSP 6 mm (1/4") FNPT/BSP 6 mm (1/4") FNPT/BSP 6 mm (1/4") FNPT/BSP
Page 7
5
WILDEN PUMP & ENGINEERING, LLC
Height ..................................128 mm (5.0")
Width ....................................155 mm (6.1")
Depth ....................................124 mm (4.9")
Ship Weight: Conductive
Polyethylene ..........2 kg (4 lbs)
Air Inlet ......................6 mm (₁⁄₄") FNPT/BSP
Inlet..........................13 mm (₁⁄₂") FNPT/BSP
Discharge ................13 mm (₁⁄₂") FNPT/BSP
Suction Lift ........................2.0 m (6.6') Dry
1
8.0 m (26.2') Wet
1
Max. dry suction is achieved when pump is fitted
with cylinder check valves.
Sound: Max. dBA .................................... 83
Displacement Per Stroke.... 0.026 l (0.007 gal)
1
Maximum Viscosity ........................6,000 cP
Max. Flow Rate ..............20.0 lpm (5.3 gpm)
Max. Size Solids ..................2.0 mm (0.08")
1
Displacement per stroke was calculated at 6.9 bar
(100 psig) air inlet pressure against 0 bar (0 psig)
head pressure.
Example:
To pump 7.6 lpm (2.0 gpm) against
a discharge pressure head of 2.5 bar (36 psig)
requires 4.1 bar (60 psig) and 1.7 Nm
3
/h
(1.0 scfm) air consumption. (See dot on chart.)
Caution: Do not exceed 7 bar (100 psig)
air inlet supply pressure.
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 performance curve.
SECTION 5A
PERFORMANCE CURVES
UX.038 CONDUCTIVE PLASTIC
RUBBER/TEFLON
®
-FITTED
Height ....................................96 mm (3.8")
Width ....................................137 mm (5.4")
Depth ......................................86 mm (3.2")
Ship Weight : Conductive
Polyethylene ..........1 kg (2 lbs)
Air Inlet ......................6 mm (₁⁄₄") FNPT/BSP
Inlet..........................10 mm (₃⁄₈") FNPT/BSP
Discharge ................10 mm (₃⁄₈") FNPT/BSP
Suction Lift ........................1.5 m (4.9') Dry
1
8.0 m (26.2') Wet
1
Max. dry suction is achieved when pump is fitted
with cylinder check valves.
Sound: Max. dBA .................................... 83
Displacement Per Stroke.... 0.008 l (0.002 gal)
1
Maximum Viscosity ........................3,000 cP
Max. Flow Rate ..............10.0 lpm (2.6 gpm)
Max. Size Solids ..................1.5 mm (0.06")
1
Displacement per stroke was calculated at 6.9 bar
(100 psig) air inlet pressure against 0 bar (0 psig)
head pressure.
Example:
To pump 5.7 lpm (1.5 gpm) against
a discharge pressure head of 2.3 bar (33 psig)
requires 5.5 bar (80 psig) and 5.1 Nm
3
/h
(3.0 scfm) air consumption. (See dot on chart.)
Caution: Do not exceed 7 bar (100 psig)
air inlet supply pressure.
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 performance curve.
SECTION 5B
PERFORMANCE CURVES
UX.050 CONDUCTIVE PLASTIC
RUBBER/TEFLON
®
-FITTED
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6
WILDEN PUMP & ENGINEERING, LLC
SECTION 5C
PERFORMANCE CURVES
UX.075 CONDUCTIVE PLASTIC
RUBBER/TEFLON
®
FITTED
Height ..................................173 mm (6.8")
Width ....................................206 mm (8.1")
Depth ....................................175 mm (6.9")
Ship Weight: Conductive
Polyethylene ........5 kg (11 lbs)
Air Inlet ......................6 mm (₁⁄₄") FNPT/BSP
Inlet..........................19 mm (₃⁄₄") FNPT/BSP
Discharge ................19 mm (₃⁄₄") FNPT/BSP
Suction Lift ........................3.0 m (9.8') Dry
1
9.0 m (29.5') Wet
1
Max. dry suction is achieved when pump is fitted
with cylinder check valves.
Sound: Max. dBA .................................... 83
Displacement Per Stroke.... 0.110 l (0.029 gal)
1
Maximum Viscosity ......................10,000 cP
Max. Flow Rate ............50.0 lpm (13.2 gpm)
Max. Size Solids ..................3.0 mm (0.12")
1
Displacement per stroke was calculated at 6.9 bar
(100 psig) air inlet pressure against 0 bar (0 psig)
head pressure.
Example:
To pump 17 lpm (4.5 gpm) against
a discharge pressure head of 4.3 bar (62 psig)
requires 5.5 bar (80 psig) and 10.2 Nm
3
/h
(6.0 scfm) air consumption. (See dot on chart.)
Caution: Do not exceed 7 bar (100 psig)
air inlet supply pressure.
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 performance curve.
100
90
80
70
60
50
40
30
20
10
7
6
5
4
3
2
1
0
225
200
175
150
125
100
75
50
25
0
(2.0)
[3.4]
(4.0)
[6.8]
(6.0)
[10.2]
(8.0)
[13.6]
(10.0)
[17.0]
(15.0)
[25.5]
2.0 4.0 6.0 8.0 10.0 12.0 14.0
[7.6] [15.1] [22.7] [30.3] [37.9] [45.4] [53.0]
SECTION 5D
PERFORMANCE CURVES
UX3 CONDUCTIVE PLASTIC
RUBBER/TEFLON
®
FITTED
Height ..................................225 mm (8.9")
Width ..................................269 mm (10.6")
Depth ....................................240 mm (9.5")
Ship Weight:
Conductive
Polyethylene ..........10 kg (22 lbs)
Air Inlet ......................6 mm (₁⁄₄") FNPT/BSP
Inlet ......................32 mm (1-₁⁄₄") FNPT/BSP
Discharge ............32 mm (1-₁⁄₄") FNPT/BSP
Suction Lift ......................4.0 m (13.1') Dry
1
9.0 m (29.5') Wet
1
Max. dry suction is achieved when pump is fitted
with cylinder check valves.
Sound: Max. dBA .................................... 83
Displacement Per Stroke.... 0.330 l (0.087 gal)
1
Maximum Viscosity ......................15,000 cP
Max. Flow Rate ................130 lpm (34 gpm)
Max. Size Solids ..................4.0 mm (0.16")
1
Displacement per stroke was calculated at 6.9 bar
(100 psig) air inlet pressure against 0 bar (0 psig)
head pressure.
Example:
To pump 91 lpm (24 gpm) against a
discharge pressure head of 1.2 bar (18 psig)
requires 4.1 bar (60 psig) and 26 Nm
3
/h
(15 scfm) air consumption. (See dot on chart.)
Caution: Do not exceed 7 bar (100 psig)
air Inlet supply pressure.
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 performance curve.
100
90
80
70
60
50
40
30
20
10
7
6
5
4
3
2
1
0
225
200
175
150
125
100
75
50
25
0
(5)
[9]
(10)
[17]
(15)
[26]
(20)
[34]
(25)
[43]
(30)
[51]
4 8 12 16 20 24 28 32 36 40
[15] [30] [45] [61] [76] [91] [106] [121] [136] [151]
Page 9
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WILDEN PUMP & ENGINEERING, LLC
The UX conductive plastic pumps are manufactured with wetted
parts of conductive (less than 2% carbon filled) polyethylene.
The UX pumps are constructed with a conductive polyethylene
center housing. A variety of diaphragms and o-rings are available
to satisfy temperature, chemical compatibility, abrasion and flex
concerns.
The suction pipe size for all installations should be as large
as the pump inlet, or larger if highly viscous material is being
pumped. The suction hose must be a non-collapsible
reinforced type, as the UX pumps are capable of pulling a high
vacuum. Discharge piping should be as large as the pump discharge,
however, larger diameter pipe may be used to reduce friction losses.
It is critical that all fittings and connections are airtight or a reduction
or loss of pump suction capability will result. For all UX models,
Wilden offers FNPT/BSP liquid and air connections.
UX series pumps offer variable air and fluid connection configurations. The optional connection configuration can be achieved by
inverting the center section without affecting pump performance.
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 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 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 (see Section 5). Use air pressure up to a
maximum of 7 bar (100 psig) depending on pumping requirements.
For best results, the pumps should use a 5µ (micron) air filter,
needle valve and regulator. The pumps should also be run on
clean-dry air only at all times. If this is not possible, a desiccant
dryer must be installed and continually maintained on the air inlet
to prevent migration of condensation or air line oil into the air
system. The use of an air filter before the pump will insure that the
majority of any pipeline contaminants will be eliminated. Sound
levels are reduced below OSHA specifications using the standard
Wilden muffler element supplied with pump.
ELEVATION: Selecting a site that is well within the pump’s dynamic
lift capability will assure that loss-of-prime troubles 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 problems 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.
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 stresses
on the pump fittings.
Flexible hose can be installed to aid in absorbing the forces
created by the natural reciprocating action of the pump. Flexible
connections between the pump and rigid piping will also assist in
minimizing pump vibration. If quick-closing valves are installed at
any point in the discharge system, or if pulsation within a system
becomes a problem, a conductive SD pulsation dampener should
be installed to protect the pump, piping and gauges from surges
and water hammer.
Valves should be installed in the suction and discharge lines to
permit closing of the lines for pump service. The use of isolation
valves prevents the media being pumped from flowing back into
the pump and out any loosened connections. Note: When inlet and
discharge valves are closed, pressure may still remain trapped in
the pump and piping. Use caution when performing any maintenance on the pump. Be sure to properly drain all air and liquid pressure from the pump before servicing.
Proper care should always be taken to ensure a tight liquid and air
seal for all installations. 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 model’s ability. Note: Materials of construction and elastomer material have an effect on suction lift parameters. Please consult Wilden distributors for specifics.
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 higher than
0.7 bar (10 psig).
THE MODEL UX SERIES PUMPS HAVE LIMITED SOLIDS
PASSAGE CAPABILITY. WHENEVER THE POSSIBILITY EXISTS
THAT LARGER SOLID OBJECTS MAY BE SUCKED INTO THE
PUMP, A STRAINER SHOULD BE USED ON THE SUCTION LINE.
(See Section 5 for Max. Size Solids.)
CAUTION: DO NOT EXCEED 7 BAR (100 PSIG) AIR SUPPLY
PRESSURE.
UX PUMPS CANNOT BE SUBMERGED. FOR SUBMERGED
APPLICATIONS, CONTACT THE FACTORY FOR AN ALTERNATIVE
WILDEN MODEL.
SECTION 6A
INSTALLATION
UX SERIES CONDUCTIVE PLASTIC PUMPS
Page 10
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WILDEN PUMP & ENGINEERING, LLC
SUGGESTED INSTALLATION
SECTION 6B
SUGGESTED OPERATION AND
MAINTENANCE INSTRUCTIONS
OPERATION: UX pumps do not require in-line lubrication. Lubrication will damage the pump! If the pump is lubricated by an external source, the pump’s internal seals may be damaged causing
premature failure of the pump.
Pump discharge rate can be controlled by limiting the volume
and/or pressure of the air supply to the pump (preferred method).
An air regulator is used to regulate air pressure. A needle valve is
used to regulate 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. 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”
situation and can be restarted by reducing the fluid discharge pressure or increasing the air inlet pressure. The Wilden UX pump runs
solely on clean-dry air and generates little 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. Read all cautions
before performing any service on a Wilden pump.
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.
GROUNDING POINT
FLEXIBLE
CONNECTION
FLEXIBLE
CONNECTION
FLEXIBLE CONNECTION
SHUT OFF VALVE
SHUT OFF VALVE
SUCTION LINE
PRESSURE / VACUUM GAUGE
AIR INLET
NEEDLE VALVE
AIR SHUT OFF VALVE
COMBINATION FILTER
AND REGULATOR
AIR SUPPLY
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WILDEN PUMP & ENGINEERING, LLC
SECTION 6C
TROUBLESHOOTING
Pump will not run or runs slowly.
1. Ensure that the air inlet pressure is at least 0.4 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 recommended installation).
A 5µ (micron) air filter must be installed in the air inlet line of the
pump to prevent air line particulate from entering and damaging
air system.
3. Check for extreme air leakage (blow by) which 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 which 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. Diaphragms may have a pinhole allowing air to escape to the liquid
side of the pump reducing performance. Check and replace
diaphragms as necessary.
7. Air valve may have debris from inlet air system. A 5µ (micron) air filter
must be installed in the air inlet line of the pump to prevent air line
particulate from entering and damaging air system.
Pump does not run.
1. Air supply line or discharge fluid line is blocked or a valve is closed.
Check valves for system and ensure they are set as desired, or
disassemble pump and check for blockage.
2. Muffler may be blocked with debris or other contaminates. This will
prevent air from exhausting. Replace muffler.
Pump runs and then stops with no external visible reason.
1. Ice within the air system may be blocking a port. Check system for
blockage and add a dryer in air inlet line to prevent moisture from
entering air system.
2. System air pressure may have dropped below system requirements.
This will not hurt the pump but will put the pump into a dead-head
condition. The pump will restart once air supply pressure is increased
or discharge head decreases below air inlet pressure.
3. Air system may have become blocked by debris. A 5µ (micron) air
filter must be installed in the air inlet line of the pump to prevent air
line particulate from entering and damaging air system.
4. Air system may need maintenance. Disassemble pump and replace
worn parts as necessary.
5. Diaphragm has ruptured and the product being pumped has flooded
the air system stalling the pump. Disassemble the pump, clean air
system of process fluid and replace diaphragms.
6. Air inlet line filter may be blocked with debris not allowing enough
volume into pump for proper operation. Check and replace air inlet
filter as necessary. A 5µ (micron) air filter must be installed in the air
inlet line of the pump to prevent air line particulate from entering and
damaging air system.
Pump runs but discharge flow decreases over time.
1. Ice within the air system may be reducing air flow in the pump.
Check system for blockage and add a dryer in air inlet line to prevent
moisture from entering air system.
2. Check air inlet line pressure to confirm a pressure drop has not
occurred. If air pressure has decreased, locate the source of the air
pressure loss and correct.
3. Debris from the air inlet line may have migrated into air system
prematurely wearing the seals. Disassemble pump and replace
parts as necessary. A 5µ (micron) air filter must be installed in the air
inlet line of the pump to prevent air line particulate from entering and
damaging air system.
Product comes out air exhaust.
1. Check for diaphragm rupture.
Pump runs but little or no product flows.
1. Check for pump cavitation; slow pump speed down to allow thick
material to flow into the liquid chambers.
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 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.
4. Pump may be operating too fast. Often to prime the pump, especially when at the maximum capability of the pump with the system
design, you must lower the air inlet pressure to achieve maximum
suction lift. Once primed, line pressure can be raised to meet system
requirements.
5. Abrasives in the product have deteriorated the valve ball or check valve
and a good seal against the valve seat is no longer being achieved.
Disassemble pump and replace worn parts as necessary.
6. Ensure a vacuum is not present inside the source fluid container.
Check that the tank/tote vent is open and air is allowed into the
tank/tote as product is being removed.
7. Check suction line for leaks and tight connections. In the event a
union is loose the pump will be unable to pull the product efficiently
into the pump. Tighten any loose suction line connections.
8. Check EOM for details on suction capabilities and ensure the
system design is within the suction capabilities of the pump.
Pump air valve freezes.
1. Condensation from the air line is most likely bypassing the
desiccant dryer or the dryer is beyond its useful life.
Replace/service dryer.
2. No dryer is installed ahead of pump, allowing moisture into air
system. This will damage air system and may render it inoperable.
Install a desiccant dryer on the air inlet line with a 5µ (micron) air filter.
Air bubbles in pump discharge.
1. Check for ruptured diaphragm.
2. Check tightness of housing bolts and integrity of o-rings and seals,
especially at intake manifold.
3. Ensure pipe connections are airtight.
Pump leaks between center section and liquid chambers.
1. Tighten all tie rods on pump to ensure a tight fit with the
center section.
2. The o-rings on the sleeves between the liquid chambers and center
section may be damaged. Disassemble pump and check o-rings for
damage and replace as necessary.
3. Diaphragms and/or o-rings may have been damaged due to incompatibility with chemical being pumped. Check chemical use chart
and select a material more appropriate for the process fluid.
4. Sleeves between center section and liquid chambers may be
damaged during maintenance. Disassemble pump and replace
worn or damaged parts as necessary.
Page 12
DISASSEMBLY:
STEP 1. Figure 1
Before disassembly, note orientation of center housing. This
portion of the pump is reversible and noting direction now may
prevent additional assembly time later. Remove muffler by turning
counter-clockwise by hand.
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. Use extreme caution as
the pump liquid path may still be under pressure even though air line
is disconnected. 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.
The UX conductive plastic pumps are available with conductive
polyethylene wetted parts.
TOOLS REQUIRED:
Metric Socket Wrench Set
Metric Open-end / Box-end Wrench Set
Adjustable Wrench
Medium Flat Head Screwdriver
Air Valve Tool Included with Pump
NOTE: The model used for these instructions incorporates Teflon
®
diaphragms, balls, and seat o-rings. Models with rubber
diaphragms and balls are the same except where noted.
10
WILDEN PUMP & ENGINEERING, LLC
STEP 2. Figure 2
Place pump on back side (where muffler was removed). Utilizing
a metric socket and box wrench, loosen and remove cap nut,
washers, and tie rods.
STEP 3. Figure 3
Remove the two liquid chambers from center housing by gently
pulling apart by hand. The use of a screwdriver or other tool may
damage center housing or liquid chambers, preventing proper
reassembly.
SECTION 7A
UX CONDUCTIVE PLASTIC PUMPS
DIRECTIONS FOR DISASSEMBLY/REASSEMBLY
Grounding Point
Page 13
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WILDEN PUMP & ENGINEERING, LLC
STEP 4. Figure 4
REASSEMBLY NOTE:
When reinstalling
top retainers, be sure not to over tighten as
this may reduce pump performance. The
edge of the retainer, under the wrench
landing, must be flush with the top of the
liquid chamber.
STEP 5. Figure 5
Remove top retainers from both liquid
chambers using an adjustable wrench.
STEP 6. Figure 6
Remove and inspect valve ball and top
retainer for wear or damage. Replace with
genuine Wilden parts when required.
STEP 7. Figure 7
Remove and inspect top retainer o-ring for
wear or damage. It is located on a landing
just under the threads for the top retainer.
Replace with genuine Wilden parts when
required.
STEP 8. Figure 8
Remove the valve housing from the liquid
chamber by using a medium-sized flat
head screwdriver to gently pry it up. The
screwdriver is placed through a hole
located in the liquid chamber into an opening just above the inlet valve ball.
STEP 9. Figure 9
Remove the valve housing and inlet valve
ball from the liquid chamber and inspect for
wear or damage. Replace with genuine
Wilden parts when required.
STEP 10. Figure 10
REASSEMBLY NOTE:
When reinstalling
valve housing, be sure to align hole in side of
valve housing with fluid port in liquid chamber. If inserted incorrectly, fluid will not pass
to the discharge of the pump.
STEP 11. Figure 11
Four o-rings are located on the inlet and
discharge ports of the center assembly
(two on each side). Inspect and replace if
necessary to ensure leak-free operation.
Note: If o-ring is removed, it must be
replaced with a new o-ring.
STEP 12. Figure 12
Grasp edge of each diaphragm. Turn
counter-clockwise to loosen and remove
one diaphragm. Pull diaphragm with shaft
attached to it out of center housing.
Remove diaphragm from shaft. Inspect and
replace diaphragms as needed.
Page 14
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WILDEN PUMP & ENGINEERING, LLC
STEP 13. Figure 13
Use tool shipped with pump to remove
Uni-Flo™ end caps (one on each side)
from center assembly.
STEP 14. Figure 14
Turn tool counterclockwise to loosen. Use
caution not to force it as the small pins on
the removal tool can shear off. If one side
is not coming loose, turn over and try the
second side.
STEP 15. Figure 15
After removing the Uni-Flo™ end caps,
remove pilot pin and o-ring. Inspect for
damage. If air valve internals are damaged or
worn, a complete Uni-Flo™ air valve assembly must be purchased as a replacement.
STEP 16. Figure 16
Place tool such that pins are sticking
upward and push the valve out the bottom
end with your thumbs (you may need to
use a rubber mallet to gently tap the tool to
initiate movement.) Do not hit the valve
directly with a tool.
STEP 17. Figure 17
Take apart Uni-Flo™ air valve with your
fingers. Inspect o-rings and seals and
replace entire assembly if required.
STEP 18. Figure 18
Complete air valve assembly.
Page 15
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WILDEN PUMP & ENGINEERING, LLC
1. Before installing or inserting any components, moisten all parts
with distilled water for lubrication. DO NOT use any oil or silicone lubricants as these may damage the pump or render it
inoperable.
2. When tightening the air valve end into the center section, be
sure to use the tool included with pump upon arrival.
3. Continue to tighten the air valve ends until the top of the end
cap is flush with the center housing.
4. To prevent damage to o-rings in center block from being
damaged upon insertion, carefully fold into a kidney shape
before insertion. (See figure.) After insertion, carefully smooth
o-rings with a tie rod before inserting shaft.
5. When reattaching diaphragms to the shaft, first insert and
tighten the shaft stud into the diaphragm piston using a hex
head wrench. Then proceed to hand-tighten onto end of shaft.
6.
When installing diaphragms, be sure to insert the shaft stud into
the outer piston first, tightening with a hex head wrench. (Note:
UX.038 and UX.050 have an integral stud on diaphragm.) Then
proceed to install diaphragms on the end of shaft by rotating
both diaphragms clockwise. If diaphragms are hand-tight on
the shaft and the bolt holes do not line up, alternate to continue
rotating clockwise until holes align if possible. Reverse rotation
to align holes only if it is impossible to align holes through
clock-wise rotation.
7. When reinstalling valve housing, be sure to align hole in side of
valve housing with fluid port in liquid chamber. If inserted incorrectly fluid will not pass to the discharge of the pump. Remember to insert inlet valve ball into liquid chamber before installing
valve housing.
8. After reinserting discharge valve ball, reinstall top retainers. Be
sure not to over-tighten as this may reduce pump performance.
The edge of the retainer, under the wrench landing, must be
flush with the top of the liquid chamber.
9. Reassemble both liquid chambers against the center housing,
aligning all bolt holes. Insert all tie rods and install all cap nuts
and washers. Be sure the Belleville washers have the concave
side of the washer facing toward the center housing. Continue to
tighten until all three pieces meet tightly, but do not over-tighten.
Over-torque of the tie rod cap nuts will cause pump damage.
10. To prevent seizing of hardware upon reassembly, spray an
anti-seize Teflon
®
lubricant on the tie-rod threads before
tightening.
SECTION 7B
REASSEMBLY HINTS & TIPS
When reassembling a UX series pump, it is important to pay particular attention to specific details to avoid damaging the pump or limiting pump performance. To reassemble a UX pump follow disassembly instructions 1 through 18 in reverse order and be sure to adhere to
the following assembly hints & tips:
CENTER SECTION
O-RING
TAPE
NEEDLE NOSE
PLIERS
Page 16
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WILDEN PUMP & ENGINEERING, LLC
SECTION 8A
EXPLODED VIEW / PARTS LISTING
UX.075 and UX3 Pumps
UX.038 and UX.050 Pumps
Page 17
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WILDEN PUMP & ENGINEERING, LLC
UNITEC™ UX SERIES PUMPS – RUBBER/TEFLON®-FITTED
Pump Model UX.038 UX.050 UX.075 UX3
Item Description Qty. P/N P/N P/N P/N
1 Chamber, Liquid, Right 1 U4-10-310-55 U4-15-310-55 U4-20-310-55 U4-32-310-55
2 Chamber, Liquid, Left 1 U4-10-311-55 U4-15-311-55 U4-20-311-55 U4-32-311-55
3 Sleeve 4 U4-10-312-55 U4-15-312-55 U4-20-312-55 U4-32-312-55
4 o-ring, sleeve, ND 4 U9-12-619-72 U9-14-617-72 U9-20-502-72 U9-33-526-72
o-ring, sleeve, TV 4 U9-12-619-59 U9-14-617-59 U9-20-552-59 U9-33-553-59
5 Valve Ball, ND 4 U1-10-032-72 U4-15-032-72 U1-15-032-72 U1-25-032-72
Valve Ball, SS 4 U1-10-032-22 U4-15-032-22 U1-15-032-22 U1-25-032-22
Valve Ball, TF 4 U1-10-032-60 U4-15-032-60 U1-15-032-60 U1-25-032-60
Valve, Cylinder, PE 4 U4-10-313-52 U4-15-313-52 U4-20-313-52 U4-32-313-52
6 Valve Housing 2 U4-10-314-55 U4-15-314-55 U4-20-314-55 U4-32-314-55
7 Retainer, Top Valve 2 U4-10-317-55 U4-15-317-55 U4-20-317-55 U4-32-317-55
8 o-ring, top retainer, ND 2 U9-16-623-72 U9-20-602-72 U9-25-610-72 U9-40-613-72
o-ring, top retainer, TV 2 U9-16-623-59 U9-20-602-59 U9-25-610-59 U9-40-613-59
9 Tie Rod, Housing * U4-10-020-22 U4-15-020-22 U4-20-020-22 U4-32-020-22
10 Foot, Pump Base 4 U1-08-022-85 U4-15-022-85 U4-15-022-85 U4-15-022-85
11 Shaft, Unitec 1 U2-08-030-22** U2-08-030-22** U2-15-030-22 U2-25-030-22
11a Screw, Set, Shaft Unitec 2 - - U9-10-220-22 U9-12-221-22
12 Diaphragm, EX 2 - U1-10-031-72 U1-15-031-72 U1-25-031-72
Diaphragm, ET 2 U1-08-031-67 U1-10-031-67 U1-15-031-67 U1-25-031-67
13 Center housing 1 U4-10-340-55 U4-15-340-55 U4-20-340-55 U4-32-340-55
14 Piston Ring, Shaft 2 - - U1-15-041-64 U1-25-041-64
15 Muffler, Complete 1 U4-15-044-51 U4-15-044-51 U4-20-044-51 U4-20-044-51
22 Uni-Flo™ Air Valve Assembly 1 U2-08-001-84 U2-08-001-84 U2-15-001-84 U2-15-001-84
24 o-ring, air valve housing 6 U9-26-519-71** U9-26-519-71** U9-36-504-71** U9-36-504-71**
* U.038 & U.050: 4 pieces; U.075 & U3: 6 pieces
** included in item 22
Page 18
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 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, 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
Item #_______________________________ Serial # ______________________________________
Company Purchased From __________________________________________________________
Your Company Name ________________________________________________________________
Industry ____________________________________________________________________________
Your Name ___________________________ Title ________________________________________
Your Address (Street) ________________________________________________________________
(City)_________________ (State)________ (Postal Code)_________ (Country) ________________
(Telephone)______________ (Fax)__________________ (e-mail)____________________________
Number of pumps in facility? _________Diaphragm _________Centrifugal
________Gear ________Submersible ________Lobe ________Other ______________________
Chemical(s) being pumped __________________________________________________________
How did you hear of Wilden Pump? ________Trade Journal ________Trade Show
________Internet/E-mail ________Distributor ________Other ______________________________
ONCE COMPLETE, FAX TO (909) 783-3440
NOTE: WARRANTY VOID IF PAGE IS NOT FAXED TO WILDEN
WILDEN PUMP & ENGINEERING, LLC
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