Wilden HX400S User Manual

EOM

Engineering

Operation &

Maintenance

HX400S

Advanced™ Series
Metal Pump

Where Innovation Flows

www.wildenpump.com

WIL-11111-E-03

TO REPLACE WIL-11111-E-02

TABLE OF CONTENTS

SECTION 1 CAUTIONSREAD FIRST! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 WILDEN® PUMP DESIGNATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 3 HOW IT WORKSPUMP & AIR DISTRIBUTION SYSTEM. . . . . . . . . . . . . . . . 3

SECTION 4 DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 5 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

A. HX400S PERFORMANCE

Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TPE-Fitted Aluminum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TPE-Fitted Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

B. SUCTION LIFT CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 6 SUGGESTED INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 7 PUMP DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

HX400S Piston & Shaft Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Air Valve / Center Section Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Submersible Pro-Flo X™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Reassembly Hints & Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SECTION 8 EXPLODED VIEW AND PARTS LISTING

TPE-Fitted Aluminum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

TPE-Fitted Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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U.S. Clean Air Act

Amendments of 1990

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Section 1

CAUTIONS  READ FIRST!

TEMPERATURE LIMITS:

Neoprene –17.7°C to 93.3°C 0°F to 200°F

Buna®-N –12.2°C to 82.2°C 10°F to 180°F

EPDM –51.1°C to 137.8°C –60°F to 280°F

Viton® –40°C to 176.7°C –40°F to 350°F

Sanifl ex™ –28.9°C to 104.4°C –20°F to 220°F

Wil-Flex™ –40ºC to 107.2ºC –40ºF to 225°F

Polytetrafl uoro­ethylene (PTFE) 4.4°C to 104.4°C 40°F to 220°F

Polyurethane –12.2°C to 65.6°C 10°F to 150°F

Tetra-Flex™ PTFE with
Neoprene backing 4.4°C to 107.2°C 40°F to 225°F

Tetra-Flex™ PTFE with
EPDM backing –10°C to 137°C 14°F to 280°F

NOTE: Not all materials are available for all models. Refer to Section 2 for

material options for your pump.

CAUTION: Do not apply compressed air to the exhaust

port – pump will not function.

CAUTION: Do not over-lubricate air supply – excess lubrica-

tion will reduce pump performance. Pump is pre-lubricated.

CAUTION: Maximum temperature limits are based upon

mechanical stress only. Certain chemicals will signifi cantly
reduce maximum safe operating temperatures. Consult
Chemical Resistance Guide (E4) for chemical compatibility
and temperature limits.

CAUTION: When choosing pump materials, be sure to

check the temperature limits for all wetted components.
Example: Viton® has a maximum limit of 176.7°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 signifi cantly
reduce maximum safe operating temperatures. Consult
engineering guide for chemical compatibility and tempera­ture limits.

CAUTION: Always wear safety glasses when operat-

ing pump. If diaphragm rupture occurs, material being
pumped may be forced out of the air exhaust.

WARNING: Prevention of static sparking — If static spark-

ing occurs, fi re or explosion could result. Pump, valve, and
containers must be properly grounded when handling
fl ammable fl uids and whenever discharge of static electric­ity is a hazard.

CAUTION: Do not exceed 8.6 bar (125 psig) air supply pres-

sure.

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 fl uid
to fl ow into a suitable container.

CAUTION: All piping, valves, gauges and other components

installed on the liquid discharge must have a minimum
pressure rating of 20.7 bar (300 psig).

CAUTION: The discharge pressure generated by this pump

is two times the inlet pressure supplied.

CAUTION: Do not exceed 82°C (180°F) air inlet temperature

for Pro-Flo X™ models.

CAUTION: Pumps should be thoroughly fl ushed before in-

stalling into process lines. FDA and USDA approved pumps
should be cleaned and/or sanitized before being used.

NOTE: Cast-iron PTFE-fi tted pumps come standard from

the factory with expanded PTFE gaskets installed in the
diaphragm bead of the liquid chamber. PTFE gaskets can­not be re-used. Consult PS-TG for installation instructions
during reassembly.

CAUTION: Pro-Flo® pumps cannot be used in submersible

applications. Pro-Flo X™ is available in both submersible
and non-submersible options. Do not use non-submersible
Pro-Flo X™ models in submersible applications. Turbo-Flo®
pumps can also be used in submersible applications.

CAUTION: Blow out air line for 10 to 20 seconds before

attaching to pump to make sure all pipe line debris is clear.
Use an in-line air fi lter. A 5 (micron) air fi lter is recom­mended.

NOTE: Tighten clamp bands and retainers prior to installa-

tion. Fittings may loosen during transportation.

NOTE: When installing PTFE diaphragms, it is important to

tighten outer pistons simultaneously (turning in opposite
directions) to ensure tight fi t.

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: Verify the chemical compatibility of the process

and cleaning fl uid to the pump’s component materials in
the Chemical Resistance Guide (see E4).

CAUTION: When removing the end cap using compressed

air, the air valve end cap may come out with consider­able force. Hand protection such as a padded glove or rag
should be used to capture the end cap.

WIL-11111-E-03 1 WILDEN PUMP & ENGINEERING, LLC

Section 2

PUMP DESIGNATION SYSTEM

HX400S METAL

38 mm (1-1/2") Pump
Maximum Flow Rate:
235 LPM (62 GPM)

LEGEND

XHX400S / XXXXX / XXX / XX / XXX / XXXX

MATERIAL CODES

MODEL

XHX400S = HIGH PRESSURE

SIMPLEX/ATEX

WETTED PARTS / OUTER PISTON

AS = ALUMINUM/STAINLESS STEEL
SS = STAINLESS STEEL/STAINLESS

STEEL

AIR CHAMBER

A = ALUMINUM
S = STAINLESS STEEL

MODEL VALVE SEAT SPECIALTY
ORING CODE (if applicable)

VALVE SEAT
VALVE BALL
DIAPHRAGM
AIR VALVE
CENTER BLOCK
AIR CHAMBER
WETTED PARTS/OUTER PISTON

CENTER BLOCK

A = ALUMINUM
S = STAINLESS STEEL

AIR VALVE

A = ALUMINUM
S = STAINLESS STEEL

DIAPHRAGM

FWS = SANITARY WIL-FLEX™

1

VALVE BALL

WF = WIL-FLEX™ [Santoprene®

(orange dot)]

VALVE SEAT

A = ALUMINUM
S = STAINLESS STEEL

VALVE SEAT ORING

TF = PTFE (white dot)

NOTE: 1 Meets Requirements of FDA CFR21.177

SPECIALTY CODES

0245 Reverse manifolds

0247 Discharge & inlet manifold

facing exhaust

0250 Discharge manifold

facing air inlet

NOTE: Most elastomeric materials use colored dots for identification.
NOTE: Not all models are available with all material options.

Hytrel® and Viton® are registered trademarks of DuPont Dow Elastomers.

WILDEN PUMP & ENGINEERING, LLC 2 WIL-11111-E-03

0320 Submersible center block

0504 DIN flange

Section 3

HOW IT WORKSPUMP DISTRIBUTION SYSTEM

The Wilden diaphragm 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 When air pressure is supplied to
the pump, the air valve directs pressure to the
back side of the diaphragm A. The compressed
air moves the diaphragm away from the
center section 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. The movement of
diaphragm B towards the center section of
the pump creates a vacuum within the cham­ber B. Atmospheric pressure forces fluid into
the inlet manifold forcing the inlet valve ball
off of its seat. Liquid is free to move past the
inlet valve ball and fill the liquid chamber (see
shaded area).

HOW IT WORKSAIR DISTRIBUTION SYSTEM

CENTER BLOCK

AIR

INLET

MAIN

SHAFT

PILOT SPOOL

AIR VALVE

END CAP

AIR VALVE

SPOOL

MUFFLER

PLATE

FIGURE 2 Once the shaft has reached the end
of its stroke, the air valve redirects pressurized
air to the back side of the diaphragm B. This
pressurized air is also directed to the opposite
side of the diaphragm A through a passage­way that is routed through the common shaft
and outer piston. The pressurized air forces
diaphragm B away from the center section
while also pushing diaphragm A to the center
section. 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 of its seat, forcing fluid
to flow through the pump discharge. The pres­sure on diaphragm A creates a force on the
shaft that is combined with the pressure from
diaphragm B. This total load is transferred to
the liquid creating a liquid pressure that is two
times greater than the supplied air pressure.

The Pro-Flo X™ patented air distribution system incorporates
two moving parts: the air valve spool and the pilot spool. The
heart of the system is the air valve. This valve design incor­porates an unbalanced spool. The smaller end of the spool is
pressurized continuously, while the large end is alternately
pressurized, then exhausted, to move the spool. The air valve
spool directs pressurized air to one air chamber while exhaust­ing the other. The air causes the main shaft/diaphragm assem­bly to shift to one side — discharging liquid on that side and
pulling liquid in on the other side. When the shaft reaches the
end of its stroke, the inner piston actuates the pilot spool, which
pressurizes and exhausts the large end of the air valve spool.

MUFFLER

The repositioning of the air valve spool routes the air to the
other air chamber.

FIGURE 3 At completion of the stroke, the
air valve again redirects air to the back side
of the 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 condition
of the application.

WIL-11111-E-03 3 WILDEN PUMP & ENGINEERING, LLC

Section 4

DIMENSIONAL DRAWINGS

HX400S ALUMINUM

C

B

A

M
N

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P

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E

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DIMENSIONS

G

ITEM METRIC (mm) STANDARD (inch)

A 345 13.6
B 79 3.1
C 318 12.5
D 528 20.8
E 605 23.8
F 127 5.0
G 323 12.7
H 48 1.9

J 132 5.2
K 310 12.2
L 518 20.4

M 241 9.5
N 203 8.0

P 152 6.0
R 170 6.7
S 10 0.4

DIN (mm) ANSI (inch)

T 150 DIA. 6.1 DIA.

U 110 DIA. 4.5 DIA.

V 18 DIA. 0.9 DIA.

REV A

S

HX400S STAINLESS STEEL

DIMENSIONS

ITEM METRIC (mm) STANDARD (inch)

A 384 15.1
B 89 3.5
C 277 10.9
D 528 20.8
E 279 11.0
F 48 1.9
G 132 5.2

H 310 12.2

J 508 20.0
K 84 3.3
L 274 10.8

M 224 8.8
N 178 7.0

P 203 8.0
R 10 0.4

DIN (mm) ANSI (inch)

S 150 DIA. 6.1 DIA.
T 110 DIA. 4.5 DIA.

U 18 DIA. 0.9 DIA.

REV B

WILDEN PUMP & ENGINEERING, LLC 4 WIL-11111-E-03

HX400S

HX400S ADVANCEDTM PERFORMANCE

WIL-11111-E-03 5 WILDEN PUMP & ENGINEERING, LLC

Section 5

PROFLO X™ OPERATING PRINCIPLE

Pro-Flo X

The Pro-Flo X™ air distribution system with the

revolutionary Effi ciency Management System (EMS)

offers fl exibility never before seen in the world of

AODD pumps. The

patent-pending EMS

is simple and easy

to use. With the

turn of an integrated

TM

Operating Principal

control dial, the operator can select the optimal

balance of fl ow and effi ciency that best meets the

application needs. Pro-Flo X™ provides higher

performance, lower

operational costs

and fl exibility that

exceeds previous

industry standards.

AIR CONSUMPTION

$

$

$

Turning the dial
changes the
relationship
between air inlet
and exhaust
porting.

WILDEN PUMP & ENGINEERING, LLC 6 WIL-11111-E-03

Each dial setting
represents an
entirely different
fl ow curve

Pro-Flo X™ pumps
are shipped from
the factory on
setting 4, which
is the highest
fl ow rate setting
possible

Moving the dial
from setting 4
causes a decrease
in fl ow and an even
greater decrease in
air consumption.

When the air
consumption
decreases more
than the fl ow
rate, effi ciency
is improved and
operating costs
are reduced.

Example 1

HOW TO USE THIS EMS™ CURVE

SETTING 4 PERFORMANCE CURVE

Figure 1 Figure 2

Example data point = Example data point =

This is an example showing how to determine fl ow rate and
air consumption for your Pro-Flo X™ pump using the Effi cien­cy Management System (EMS) curve and the performance
curve. For this example we will be using 4.1 bar (60 psig) inlet
air pressure and 2.8 bar (40 psig) discharge pressure and EMS
setting 2.

Step 1:

Identifying performance at setting 4. Locate

the curve that represents the fl ow rate of the
pump with 4.1 bar (60 psig) air inlet pressure.
Mark the point where this curve crosses the
horizontal line representing 2.8 bar (40 psig)
discharge pressure. (Figure 1). After locating
your performance point on the fl ow curve,
draw a vertical line downward until reaching
the bottom scale on the chart. Identify the fl ow
rate (in this case, 8.2 gpm). Observe location
of performance point relative to air consump­tion curves and approximate air consumption
value (in this case, 9.8 scfm).

8.2

GPM

curve, draw vertical lines downward until
reaching the bottom scale on the chart. This
identifi es the fl ow X Factor (in this case, 0.58)
and air X Factor (in this case, 0.48).

Step 3:

Calculating performance for specific EMS

setting. Multiply the fl ow rate (8.2 gpm)

obtained in Step 1 by the fl ow X Factor multi­plier (0.58) in Step 2 to determine the fl ow rate
at EMS setting 2. Multiply the air consump­tion (9.8 scfm) obtained in Step 1 by the air
X Factor multiplier (0.48) in Step 2 to deter­mine the air consumption at EMS setting 2
(Figure 3).

8.2

gpm

.58

4.8

gpm

0.58

0.48

(fl ow rate for Setting 4)

(Flow X Factor setting 2)

(Flow rate for setting 2)

EMS CURVE

fl ow multiplier

air multiplier

Step 2:

Determining flow and air X Factors. Locate
your discharge pressure (40 psig) on the verti­cal axis of the EMS curve (Figure 2). Follow
along the 2.8 bar (40 psig) horizontal line until
intersecting both fl ow and air curves for your
desired EMS setting (in this case, setting 2).
Mark the points where the EMS curves inter­sect the horizontal discharge pressure line.
After locating your EMS points on the EMS

WIL-11111-E-03 7 WILDEN PUMP & ENGINEERING, LLC

9.8

scfm

(air consumption for setting 4)

.48

4.7

Figure 3

The fl ow rate and air consumption at Setting
2 are found to be 18.2 lpm (4.8 gpm) and 7.9
Nm3/h (4.7 scfm) respectively.

(Air X Factor setting 2)

scfm

(air consumption for setting 2)

HOW TO USE THIS EMS™ CURVE

Example 2.1

SETTING 4 PERFORMANCE CURVE

Figure 4

Example data point =

This is an example showing how to determine the inlet air
pressure and the EMS setting for your Pro-Flo X™ pump to
optimize the pump for a specifi c application. For this exam­ple we will be using an application requirement of 18.9 lpm
(5 gpm) fl ow rate against 2.8 bar (40 psig) discharge pressure.
This example will illustrate how to calculate the air consump­tion that could be expected at this operational point.

10.2

gpm

DETERMINE EMS SETTING

Step 1

: Establish inlet air pressure. Higher air pres-

sures will typically allow the pump to run
more effi ciently, however, available plant air
pressure can vary greatly. If an operating
pressure of 6.9 bar (100 psig) is chosen when

EMS Flow

Settings 1 & 2

0.49

In our example it is 38.6 lpm (10.2 gpm). This

is the setting 4 fl ow rate. Observe the loca­tion of the performance point relative to air
consumption curves and approximate air
consumption value. In our example setting
4 air consumption is 24 Nm3/h (14 scfm).
See fi gure 4.

Step 3

: Determine flow X Factor. Divide the required

fl ow rate 18.9 lpm (5 gpm) by the setting 4 fl ow
rate 38.6 lpm (10.2 gpm) to determine the fl ow
X Factor for the application.

5

gpm / 10.2 gpm = 0.49 (flow X Factor)

EMS CURVE

Figure 5

fl ow multiplier

plant air frequently dips to 6.2 bar (90 psig)

Step 4

pump performance will vary. Choose an oper­ating pressure that is within your compressed
air system's capabilities. For this example we
will choose 4.1 bar (60 psig).

: Determine EMS setting from the flow

X Factor. Plot the point representing the fl ow

X Factor (0.49) and the application discharge
pressure 2.8 bar (40 psig) on the EMS curve.
This is done by following the horizontal 2.8

Step 2

: Determine performance point at setting 4. For

this example an inlet air pressure of 4.1 bar
(60 psig) inlet air pressure has been chosen.
Locate the curve that represents the perfor­mance of the pump with 4.1 bar (60 psig) inlet
air pressure. Mark the point where this curve
crosses the horizontal line representing 2.8
bar (40 psig) discharge pressure. After locat­ing this point on the fl ow curve, draw a verti­cal line downward until reaching the bottom
scale on the chart and identify the fl ow rate.

bar (40 psig) psig discharge pressure line until
it crosses the vertical 0.49 X Factor line. Typi­cally, this point lies between two fl ow EMS
setting curves (in this case, the point lies be­tween the fl ow curves for EMS setting 1 and

2). Observe the location of the point relative
to the two curves it lies between and approxi­mate the EMS setting (fi gure 5). For more pre­cise results you can mathematically interpo­late between the two curves to determine the
optimal EMS setting.

For this example the EMS setting is 1.8.

WILDEN PUMP & ENGINEERING, LLC 8 WIL-11111-E-03