EOM
Engineering
Operation &
Maintenance
P100
Advanced™ Series
PLASTIC Pumps
Where Innovation Flows
www.wildenpump.com
WI L-1105 0-E
WIL-11050-E-05
REPLACES WIL-11050 -E- 04
TABLE OF CONTENTS
SECTION 1 CAUTIONS – READ FIRST! .............................................1
SECTION 2 PUMP DESIGNATION SYSTEM .........................................2
SECTION 3 HOW IT WORKS (PUMP & AIR SYSTEMS) ..............................3
SECTION 4 DIMENSIONAL DRAWING
A. P100 ADVANCED™ PLASTIC .............................................4
B. P100 ADVANCED™ PLASTIC - Center Ported ................................5
C. P100 ADVANCED™ PLASTIC - Vertical Ported ................................6
SECTION 5 PERFORMANCE CURVES
A. P100 ADVANCED™ PLASTIC Rubber-Fitted .................................7
B. P100 ADVANCED™ PLASTIC TPE-Fitted ....................................7
C. P100 ADVANCED™ PLASTIC PTFE-Fitted ...................................8
SECTION 6 SUCTION LIFT CURVES & DATA .........................................8
SECTION 7 INSTALLATION AND OPERATION
A. Installation ............................................................9
B. Operation & Maintenance ...............................................10
C. Troubleshooting .......................................................11
SECTION 8 DIRECTIONS FOR DISASSEMBLY/REASSEMBLY
A. P100 ADVANCED™ PLASTIC Wetted – Tools Required, Cautions ...............12
B. Pro-Flo® Air Valve/Center Block – Disassembly, Cleaning, Inspection ............15
C. Reassembly Hints & Tips, Torque Specifications ............................17
SECTION 9 EXPLODED VIEW/PARTS LISTING
A. P100 ADVANCED™ PLASTIC PTFE/PTFE-IPD-Fitted ..........................18
SECTION 10 ELASTOMER OPTIONS ................................................20
Section 1
CAUTIONS — READ FIRST!
TEMPERATURE LIMITS*
Wetted Path
Polypropylene (PP) 0°C to 79.4°C 32°F to 175°F
Polyvinylidene fluoride (PVDF)
-12.2°C to 107.2°C 10°F to 225°F
Elastomers
Neoprene -17.8°C to 93.3°C 0°F to 200°F
Buna-N -12.2°C to 82.2°C 10°F to 180°F
Viton
Wil-Flex™ -40°C to 107.2°C -40°F to 225°F
Polyurethane 12.2°C to 65.6°C 10°F to 150°F
Polytetrafluoroethylene (PTFE)
4.4°C to 104.4°C 40°F to 220°F
Saniflex™ -28.9°C to 104.4°C -20°F to 220°F
*Elastomer choice may change temperature limits
CAUTION: When choosing pump materials, be sure
to check the temperature limits for all wetted components. Example: Viton
(350°F) but polypropylene has a maximum limit of only
79.4°C (175°F).
CAUTION: Maximum temperature limits are based
upon mechanical stress only. Certain chemicals will
significantly 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 air exhaust.
WARNING: Prevention of static sparking — If static
sparking occurs, fire or explosion could result. Proper
grounding of pump, valves, and containers is critical
when handling flammable fluids or whenever discharge
of static electricity is a hazard.
CAUTION: Do not exceed 8.6 bar (125 psig) air supply
pressure.
CAUTION: Advanced™ series plastic pumps are made
with plastic that is not UV stabilized. Direct sunlight for
prolonged periods can cause deterioration of plastics.
®
-40°C to 176.7°C -40°F to 350°F
®
has a maximum limit of 176.7°C
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 container.
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 filter. A 5µ (micron) air filter is
recommended.
NOTE: Tighten all bolts prior to installation. Fasteners
may loosen during transportation. See torque specifications on page 15.
NOTE: When installing polytetrafluoroethylene (PTFE) dia-
phragms, it is important to tighten outer pistons simultaneously (turning in opposite directions) to ensure tight fit.
CAUTION: Verify the chemical compatibility of the
process and cleaning fluid 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.
CAUTION: Do not over-tighten the air inlet reducer
bushing. Additionally, too much torque on the muffler
may damage the air valve muffler plate.
WIL-11050-E-05 1 WILDEN PUMP & ENGINEERING, LLC
Section 2
THE WILDEN PUMP DESIGNATION SYSTEM
P100 ADVANCED™
PLASTIC
13 mm (1/2") Pump
Maximum Flow Rate:
58.7 LPM (15.5 GPM)
MATERIAL CODES
WETTED PARTS & OUTER PISTON
KK = PVDF / PVDF
PP = POLYPROPYLENE /
CENTER SECTION
PP = POLYPROPYLENE
AIR VALVE
P = POLYPROPYLENE
LEGEND
POLYPROPYLENE
P100 / X XX XX / XXX / XX / XXX / XXXX
MODEL
VALVE BALLS
DIAPHRAGMS
AIR VALVE
CENTER SECTION
WETTED PARTS & OUTER PISTON
DIAPHRAGMS
BNS = BUNA-N (Red Dot)
FSS = SANIFLEX™
[Hytrel® (Cream)]
PUS = POLYURETHANE (Clear)
THU = PTFE W/HI-TEMP
BUNA-N BACK-UP (White)
TNL = PTFE W/NEOPRENE
BACK-UP, IPD (White)
TNU = PTFE W/NEOPRENE
BACK-UP (White)
VTS = VITON® (White Dot)
WFS = WIL-FLEX™ [Santoprene®
(Three Black Dots)]
O-RINGS
VALVE SEAT
VALVE BALL
BN = BUNA-N (Red Dot)
FS =
SANIFLEX ™
[Hytrel® (Cream)]
PU = POLYURETHA NE (Brown)
TF = PTFE (White )
VT = VI TON® (White Dot)
WF = W IL-FLE X™ [Santoprene®
(Three Black Dots )]
VALVE SEAT
K = PVDF
P = POLYPROPYLENE
VALVE SEAT O-RING
BN = BUNA-N
PU = POLYURETHANE (Brown)
TV = PTFE ENCAP. VITON®
WF = WIL-FLEX™ (Santoprene®)
VT = FKM
SPECIALTY
CODE
(if applicable)
SPECIALTY CODES
0014 BSPT
0102 Wil-Gard II™, sensor wires ONLY
0677 Center ported, NPT (Parts Only)
0678 Center ported, BSPT (Parts Only)
0680 P100 with OEM specific inlet manifold
0683 P100 with OEM specific inlet manifold, center
ported inlet and discharge manifolds, NPT
0790 P100 Advanced, drum pump inlet manifold
NOTES: MOST EL ASTOMERIC MATERIALS USE COLORED DOTS FOR IDEN TIFICATION.
Viton® is a registered trademark of DuPont Dow Elastomers.
WILDEN PUMP & ENGINEERING, LLC 2 WIL-11050-E-05
Section 3
THE WILDEN PUMP – HOW IT WORKS
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.
OUTLET
CLOSED CLOSED OPENOPEN
OPEN OPEN CLOSED
INLET
RIGHT 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 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 of the pump. The movement of diaphragm B
toward the center section 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).
OPEN
CLOSEDCLOSED
LEFT STROKE RIGHT STROKE
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 section
while pulling 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 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 section 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.
OUTLET
CLOSED
OPEN
INLET
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.
OUTLET
INLET
HOW IT WORKS—AIR DISTRIBUTION SYSTEM
The Pro-Flo® patented air distribution system
incorporates three moving parts: the air valve
spool, the pilot spool, and the main shaft/diaphragm assembly. The heart of the system is
the air valve spool and air valve. This valve
design 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
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.
The repositioning of the air valve spool routes
the air to the other air chamber.
WIL-11050-E-05 3 WILDEN PUMP & ENGINEERING, LLC
Section 4A
DIMENSIONAL DRAWING
P100 Advanced™ Plastic
1/2" BSPT (FNPT)
LIQUID DISCHARGE
D
1/2" BSPT (FNPT)
LIQUID INLET
1/4" FNPT
AIR INLET
E
C
B
A
L
M
P
N
G
F
1/2" FNPT
AIR EXHAUST
K
H
J
DIMENSIONS – P100 ADVANCED™ PLASTIC
ITEM METRIC (mm) STANDARD (inch)
A 234 9.2
B 51 2.0
C 170 6.7
R
D 254 10.0
E 279 11.0
F 81 3.2
G 25 1.0
B
H 114 4.5
J 201 7.9
S
T
K 170 6.7
L 145 5.7
M 114 4.5
N 81 3.6
P 102 4.0
V
U
R 8 0.3
S 188 7.4
T 155 6.1
U 130 5.1
R
V 140 5.5
LW0347 REV B
ALTERNATE FOOTPRINT
WILDEN PUMP & ENGINEERING, LLC 4 WIL-11050-E-05
Section 4B
DIMENSIONAL DRAWING
P100 Advanced™ Plastic - Center Ported
1/4" FNPT
AIR INLET
C
B
1/2" BSPT (FNPT
LIQUID DISCHARGE
A
1/2" BSPT (FNPT)
LIQUID INLET
L
M
)
D
B
E
F
G
1/2" FNPT
AIR EXHAUST
K
H
J
DIMENSIONS – P100 ADVANCED™ CENTER PORTED PLASTIC
N P
ITEM METRIC (mm) STANDARD (inch)
A 234 9.2
B 51 2.0
C 170 6.7
D 254 10.0
E 279 11.0
R
F 81 3.2
G 25 1.0
H 114 4.5
J 201 7.9
K 170 6.7
L 145 5.7
M 114 4.5
S
T
N 81 3.6
P 102 4.0
R 8 0.3
S 188 7.4
V
U
T 155 6.1
U 130 5.1
V 140 5.5
LW0472 REV A
R
ALTERNATE FOOTPRINT
WIL-11050-E-05 5 WILDEN PUMP & ENGINEERING, LLC
Section 4C
DIMENSIONAL DRAWING
P100 Advanced™ Plastic - Vertical Ported
1/2" BSPT (FNPT)
LIQUID DISCHARGE
1/4" FNPT
AIR INLET
F
G
1/2" FNPT
AIR EXHAUST
D
B
1/2" BSPT (FNPT)
LIQUID INLET
E
C
A
L
M
H
J
K
DIMENSIONS – P100 ADVANCED™ VERTICAL PORTED PLASTIC
N
P
ITEM METRIC (mm) STANDARD (inch)
A 234 9.2
B 51 2.0
C 170 6.7
D 254 10.0
E 279 11.0
R
F 81 3.2
G 25 1.0
H 114 4.5
J 201 7.9
B
K 170 6.7
L 145 5.7
M 114 4.5
S
T
N 81 3.6
P 102 4.0
R 8 0.3
S 188 7.4
U V
T 155 6.1
U 130 5.1
V 140 5.5
LW0473 REV A
P
WILDEN PUMP & ENGINEERING, LLC 6 WIL-11050-E-05
Section 5
PERFORMANCE
P100 Plastic
RUBBER-FITTED
Est. Ship Weight ............Polypropylene 4 kg (8 lbs)
PVDF 5 kg (10 lbs)
Air Inlet ...................................... 6 mm (1/4")
Inlet ......................................... 13 mm (1/2")
Outlet ......................................13 mm (1/2")
Suction Lift ........................ 5.2 m Dry (17.0')
8.7 m Wet (28.4')
Displacement per
Stroke ....................... 0.10 l (0.027 gal.)
Max. Flow Rate ............. 56.0 lpm (14.8 gpm)
Max. Size Solids ...................1.6 mm (1/16")
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 32.9 lpm (8.7 gpm)
against a discharge head pressure of 4.1
bar (60 psig) requires 5.5 bar (80 psig) and
3
27.2 Nm
dot on chart.)
Caution: Do not exceed 8.6 bar (125
psig) air supply pressure.
/h (16 scfm) air consumption. (See
1
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.
P100 Plastic
TPE-FITTED
Est. Ship Weight ............Polypropylene 4 kg (8 lbs)
PVDF 5 kg (10 lbs)
Air Inlet ...................................... 6 mm (1/4")
Inlet ......................................... 13 mm (1/2")
Outlet ......................................13 mm (1/2")
Suction Lift ........................ 5.5 m Dry (17.0')
8.7 m Wet (28.4')
Displacement per
Stroke ....................... 0.11 l (0.029 gal.)
Max. Flow Rate ............. 58.7 lpm (15.5 gpm)
Max. Size Solids ...................1.6 mm (1/16")
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 34.8 lpm (9.2 gpm)
against a discharge head pressure of 2.4
bar (35 psig) requires 4.1 bar (60 psig) and
3
27.2 Nm
dot on chart.)
Caution: Do not exceed 8.6 bar (125
psig) air supply pressure.
/h (16 scfm) air consumption. (See
1
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.
WIL-11050-E-05 7 WILDEN PUMP & ENGINEERING, LLC
PERFORMANCE
P100 Plastic
PTFE-FITTED
Est. Ship Weight ............Polypropylene 4 kg (8 lbs)
PVDF 5 kg (10 lbs)
Air Inlet ...................................... 6 mm (1/4")
Inlet ......................................... 13 mm (1/2")
Outlet ......................................13 mm (1/2")
Suction Lift ........................ 4.5 m Dry (14.7')
9.3 m Wet (30.6')
Displacement per
Stroke ....................... 0.10 l (0.027 gal.)
Max. Flow Rate ............. 57.0 lpm (15.0 gpm)
Max. Size Solids ...................1.6 mm (1/16")
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 20.8 lpm (5.5 gpm)
against a discharge head pressure of 1.4
bar (20 psig) requires 2.8 bar (40 psig) and
13.6 Nm
dot on chart.)
Caution: Do not exceed 8.6 bar (125
psig) air supply pressure.
3
/h (8 scfm) air consumption. (See
1
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 6
SUCTION LIFT CURVES & DATA
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 which 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.
WILDEN PUMP & ENGINEERING, LLC 8 WIL-11050-E-05
Section 7A
INSTALLATION
The Pro-Flo® model P100 Advanced™ plastic has a 13 mm
(1/2") inlet and 13 mm (1/2") outlet and is designed for flows
to 58.7 lpm (15.5 gpm). The P100 Advanced™ plastic
pump is manufactured with wetted parts of pure, unpigmented Polypropylene or PVDF. The P100 Advanced™
plastic pump is constructed with a glass fiber filled PP center
section. A variety of diaphragms and o-rings are available
to satisfy temperature, chemical compatibility, abrasion, and
flex concerns.
The suction pipe size should be at least 13 mm (1/2”) diameter or larger if highly viscous material is being pumped. The
suction hose must be non-collapsible, reinforced type as the
P100 Advanced™ plastic pump is capable of pulling a high
vacuum. Discharge piping should be at least 13 mm (1/2”);
larger diameter can 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.
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 should 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 6
key factors are balanced against each other to maximum
advantage.
ACCESS: First, the location should be accessible. If it is
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 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 insure 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, thus allowing trapped air to bleed off and improving
pump performance. Pumping volume can be set by counting the number of strokes per minute and multiplying by
displacement per stroke.
SOUND: Sound levels are reduced using the standard
Wilden muffler. Other mufflers can be used, but usually
reduce pump performance.
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. 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 quick-closing valves are installed
at any point in the discharge system, or if pulsation within a
system becomes a problem, a surge suppressor should be
installed to protect the pump, piping and gauges from surges
and water hammer.
The P100 Advanced™ plastic Pro-Flo
can be installed in submersible applications only when both
the wetted and non-wetted portions are compatible with
the material being pumped. If the pump is to be used in
a submersible application, a hose should be attached to
the air and pilot spool exhaust ports of the pump. These
should then be piped above the liquid level. The exhaust
area for the pilot spool is designed to be tapped for a 1/8"
NPT fitting.
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.
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 ability of the model. 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
10 psig and higher.
THE MODEL P100 ADVANCED™ PLASTIC WILL PASS
1.6 mm (1/16") SOLIDS. WHENEVER THE POSSIBILITY
EXISTS THAT LARGER SOLID OBJECTS MAY BE SUCKED
INTO THE PUMP, A STRAINER SHOULD BE USED ON THE
SUCTION LINE.
CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR
SUPPLY PRESSURE.
®
equipped pump
WIL-11050-E-05 9 WILDEN PUMP & ENGINEERING, LLC
AIR SUPPLY
DISCHARGE
FLEXIBLE CONNECTION
SUGGESTED INSTALLATION
PRESSURE GAUGE
COMBINATION FILTER
AND REGULATOR
AIR SHUT OFF VALVE
Section 7B
NEEDLE
VALVE
FLEXIBLE CONNECTION
FLEXIBLE CONNECTION
FLEXIBLE CONNECTION
SUGGESTED OPERATION AND
MAINTENANCE INSTRUCTIONS
SHUT OFF VALVE
LINE
SHUT OFF VALVE
PRESSURE GAUGE
SHUT OFF VALVE
INLET LINE
SHUT OFF VALVE
OPERATION: 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 P100 pump runs solely on
compressed air and does not generate heat, therefore your
process fluid temperature will not be affected.
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.
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.
WILDEN PUMP & ENGINEERING, LLC 10 WIL-11050-E-05
Section 7C
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).
3. Check for extreme air leakage (blow by) which would indicate worn seals/bores in the air valve, pilot spool, 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. In addition, valve balls become smaller
as the wear. This may cause them to become stuck in the
seats. In this case, replace balls and seats.
6. Check for broken inner piston, which will prevent the air
valve spool from shifting.
7. Remove plug from pilot spool exhaust, check pilot spool
exhaust for blockage.
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.
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. In addition, valve balls become smaller
as the wear. This may cause them to become stuck in the
seats. In this case, replace balls and seats.
Pump air valve freezes.
1. Check for excessive moisture in compressed air. Install
either a dryer, or hot air generator for compressed air.
Alternatively, a coalescing 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.
3. Check torque of bolts 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.
WIL-11050-E-05 11 WILDEN PUMP & ENGINEERING, LLC
Section 8A
DIRECTIONS FOR DISASSEMBLY/REASSEMBLY
Tools Required:
• 1/2" Box Wrench
• 2 – 1" Sockets or Adjustable
Wrench
• Vise equipped with soft jaws
(such as plywood, plastic or
other suitable material)
DISASSEMBLY:
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 any hazardous
effects of contact with your process fluid.
NOTE: The model used for these instructions incorporates PTFE diaphragms and balls.
Models with rubber diaphragms and balls are the same except where noted.
Step 1. Figure 1
Please see pre-molded alignment marks on the liquid chamber and center section.
WILDEN PUMP & ENGINEERING, LLC 12 WIL-11050-E-05
Step 2. Figure 2
Using the 1/2” box wrench, loosen the discharge manifold
from the liquid chambers.
5A
DIRECTIONS FOR DISASSEMBLY/REASSEMBLY
Step 3. Figure 3
Remove the discharge manifold to
expose the valve balls, valve seats and
valve seat o-rings.
Step 4. Figure 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. Replace
worn parts with genuine Wilden parts
for reliable performance.
Step 5. Figure 5
Using a 1/2" box wrench, remove the
inlet manifold.
Step 6. Figure 6
Remove the inlet valve balls, seats and
valve seat o-rings from the liquid chamber and discharge manifold, inspect
for nicks, gouges, chemical attack or
abrasive wear. Replace worn parts with
genuine Wilden parts for reliable performance.
WIL-11050-E-05 13 WILDEN PUMP & ENGINEERING, LLC
Step 7. Figure 7
With a 1/2" box wrench, remove the liquid chambers from the center section.
Step 8. Figure 8
The liquid chamber should be removed
to expose the diaphragm and outer piston. Rotate center section and remove
the opposite liquid chamber.
DIRECTIONS FOR DISASSEMBLY/REASSEMBLY
Step 9. Figure 9
Using two crescent wrenches or 1" sockets, remove diaphragm assembly from center section assembly.
Step 11. Figure 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. Figure 12
Inspect diaphragms, outer and inner pistons for signs of wear. Replace with genuine Wilden parts if necessary.
Step 10. Figure 10
After loosening and removing the outer piston the diaphragm
assembly can be disassembled.
WILDEN PUMP & ENGINEERING, LLC 14 WIL-11050-E-05
Section 8B
AIR VALVE / CENTER BLOCK — REPAIR / MAINTENANCE
Tools Required:
• 3/16" Allen Wrench
• Snap Ring Pliers
• O-Ring Pick
AIR VALVE DISASSEMBLY:
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 P100 Advanced™ Plastic Pump utilizes a revolutionary Pro-Flo
system. A 6 mm (1/4") air inlet connects the air supply to the center section. Proprietary composite seals reduce the co efficient of friction and allow the P100 to run lube-free. Constructed
of polypropylene, the Pro-Flo
freezing, non-stalling, tough duty applications.
®
air distribution system is designed to perform in on/off, non-
®
air distribution
Step 1. Figure 1
Loosen the air valve bolts utilizing a 3/16"
Allen wrench.
WIL-11050-E-05 15 WILDEN PUMP & ENGINEERING, LLC
Step 2. Figure 2
Remove muffler plate and air valve
bolts from air valve assembly exposing
muffler gasket for inspection. Replace if
necessary.
Step 3. Figure 3
Lift away air valve assembly and remove
air valve gasket for inspection . Replace
if necessary.
DISASSEMBLY, CLEANING, INSPECTION
Step 4. Figure 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. Figure 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.
NOTE: Seals should not be removed
from assembly. Seals are not sold
separately.
Step 6. Figure 6
Remove pilot spool sleeve retaining snap
ring on both sides of center section with
snap ring pliers.
Step 7. Figure 7
Remove pilot spool sleeve from center
section.
WILDEN PUMP & ENGINEERING, LLC 16 WIL-11050-E-05
Step 8. Figure 8
With o-ring pick, gently remove the oring from the opposite side of the “center
hole” cut on the spool. Gently remove
the pilot spool from sleeve and inspect
for nicks or gouges and other signs of
wear. Replace pilot sleeve assembly or
outer sleeve o-rings if necessary. During
re-assembly 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.
NOTE: Seals should not be removed
from pilot spool. Seals are not
sold separately.
Step 9. Figure 9
Check center section Glyd™ rings for
signs of wear. If necessary, remove
Glyd™ rings with o-ring pick and
replace.
Section 8C
REASSEMBLY HINTS & TIPS
ASSEMBLY:
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.
• Clean the inside of the center section shaft bore to ensure
no damage is done to new seals.
• Stainless bolts should be lubed to reduce the possibility of
seizing during tightening.
• Be sure to tighten outer pistons simultaneously on PTFEfitted pumps to ensure proper torque values.
• Apply a small amount of Loctite 242 to the shaft interval
threads before the diaphragm assembly.
• Concave side of disc spring in diaphragm assembly faces
toward inner piston.
MAXIMUM TORQUE SPECIFICATIONS
Component Description Torque
Pro-Flo® Air Valve 3.1 N•m (27 in-lbs)
Air Inlet Reducer Bushing 0.9 N•m (8 in-lbs)
Outer Piston 14.1 N•m (125 in-lbs)
Manifolds and Liquid Chambers 5.6 N•m (50 in-lbs)
WIL-11050-E-05 17 WILDEN PUMP & ENGINEERING, LLC
Section 9A
EXPLODED VIEW/PARTS LISTING
P100 ADVANCED™ PLASTIC
14
17
20
19
16
26
27
28
EXPLODED VIEW
8
13
4
11
5
6
7
1
30
31
3
2
15
20
10
12
9
21
OEM MANIFOLD
18
21
22
23
24
25
18
19
20
DRUM PUMP MANIFOLD
18
17
PTFE FITTED
26
28
27
29
30
PTFE IPD FITTED
26
28
29
30
31
WILDEN PUMP & ENGINEERING, LLC 18 WIL-11050-E-05
EXPLODED VIEW/PARTS LISTING
P100 ADVANCED™ PLASTIC
Item Part Description
1 Air Valve Assembly, Pro-Flo
™1
Qty.
Per
Pump
P100/PPPPP/…/
P/N P/N P/N P/N
P100/
PPPPP/…/0502
Air Distribution Components
1 01-2010-20
PARTS LISTING
P100/KKPPP/…/
KKPPP/…/0502
P100/
2 End Cap 1 01-2332-20
3
O-Ring (-126), End Cap (Ø1.362" x Ø.103")
4 Gasket, Air Valve, Pro-Flo
5 Gasket, Muffler Plate, Pro-Flo
6 Muffler Plate, Pro-Flo
7 Screw, SHC, Air Valve (1/4"-20 x 3") 4 01-6001-03 01-6001-05 01-6001-03 01-6001-05
8 Center Section Assembly, Pro-Flo
™
™
™
™ 2
1 01-2395-52
1 01-2615-52
1 01-3505-52
1 01-3181-20
1 01-3141-20
9 Assembly, Pilot Sleeve 1 01-3880-99
10 O-Ring (-009), Pilot Spool Retaining (Ø.208" x Ø.070") 2 04-2650-49-700
11 Seal, Shaft 2 01-3220-55
12 Retaining Ring 2 00-2650-03
13 Bushing, Reducer, 1/2" MNPT to 1/4" FNPT 1 01-6950-20
14 Muffler, 1/2" MNPT 1 02-3510-99
Wetted Path Components
15 Chamber, Liquid 2 01-5005-20 01-5005-21
16 Manifold, Discharge (NPT) 1 01-5035-20 01-5035-21
Manifold, Discharge (BSPT) 1 01-5036-20 01-5036-21
Manifold, Discharge Center Ported (NPT) 1 01-5035-20-677 01-5035-21-677
Manifold, Discharge Center Ported (BSPT) 1 01-5036-20-678 01-5036-21-678
Manifold, Discharge Vertical Ported (NPT) 1 01-5035-21-672
Manifold, Discharge Vertical Ported (BSPT) 1 01-5036-20-673 01-5036-21-673
17 Plug, 1/2" NPT 2 01-7010-20 01-7010-21
18 Manifold, Inlet (NPT) 1 01-5095-20 01-5095-21
Manifold, Inlet (BSPT) 1 01-5096-20 01-5096-21
Manifold, Inlet Drum Pump (NPT only) 1 01-5094-20 01-5094-21
Manifold, OEM Inlet (NPT) 1 01-5097-20 01-5097-21
Manifold, OEM Inlet (BSPT) 1 01-5098-20 01-5098-21
19 Washer, (.343 I.D. X .750 O.D. X .050 THK.) 24 01-6732-03 01-6732-05 01-6732-03 01-6732-05
20 Bolt, HHCS, 5/16"-18 X 1-3/8" 24 08-6100-03 01-6191-05 08-6100-03 01-6191-05
Valve Balls/Valve Seats/Valve O-Rings
21 O-Ring, (-222) Manifold (Ø1.484 x Ø.139) 4 *
22 Ball Cage 4 01-5355-20 01-5355-21
23 Ball, Valve 4 *
24 Seat, Valve 4 01-1125-20 01-1125-21
25 O-Ring (-119),Valve Seat (Ø.924 x Ø.139) 4 *
Rubber/TPE/PTFE/IPD Components
26 Shaft 1 01-3810-03
27 Spring, Disk (Ø.331" x Ø.512") 2 01-6802-08
28 Piston, Inner 2 01-3711-08
29 Diaphragm, Back-Up 2 *
30 Diaphragm, Primary 2 *
Diaphragm, IPD Primary 2 *
31 Piston, Outer 2 01-4570-20-500 01-4570-21-500
1
Air Valve Assembly includes items 2 and 3.
2
Center Section Assembly includes item 11 and 13.
All boldface items are primary wear parts.
LW0489 Rev. A
WIL-11050-E-05 19 WILDEN PUMP & ENGINEERING, LLC
Section 10
ELASTOMER OPTIONS
P100 ADVANCED™ PLASTIC
MATERIAL DIAPHRAGM
Polyurethane 01-1010-50 01-1080-50 01-1200-50 02-1230-50
Neoprene 01-1060-51
Buna-N 01-1010-52 01-1080-52 00-1260-52 02-1230-52
High Temp. Buna-N 01-1060-61
®
Viton
PTFE 01-1010-55 01-1030-55 01-1080-55
™
Saniflex
™
Wil-Flex
PTFE Encapsulated/Viton
Polypropylene 01-1125-20
PVDF 01-1125-21
01-1010-53 01-1080-53 01-1205-53 01-1370-53
01-1010-56 01-1080-56
01-1010-58 01-1080-58 00-1260-58 01-1370-58
®
IPD
DIAPHRAGMS
BACK-UP
DIAPHRAGMS VALVE BALLS VALVE SEATS
VALVE SEATS
O-RINGS
01-1205-60 05-1370-60
MANIFOLD
O-RINGS
LW0489 Rev. A
WILDEN PUMP & ENGINEERING, LLC 20 WIL-11050-E-05
Warrant y
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 InformatI on
Item # Serial #
Company Where Purchased
Your InformatIon
Company Name
Industry
Name Title
Street Address
City State Postal Code 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
NOTE: WARRANTY VOID IF PAGE IS NOT FAXED TO WILDEN
Trade Journal
Trade Show
onCE ComPLEtE, faX to (909) 783-3440
WILDEN PUMP & ENGINEERING, LLC
Internet/E-mail
Distributor
Where Innovation Flows
22069 Van Buren Street,
Grand Terrace, CA 92313-5607
Telephone: (909) 422-1731
Fax: (909) 783-3440
22069 Van Buren St.
Grand Terrace, CA 92313-5651
T: +1 (909) 422-1731
www.maag.com
F: +1 (909) 783-3440
PSG® reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document. 08-2014
Authorized PSG Representative:
Copyrigh t ©2014, Pump Solutions Gr oup (PSG®), A Dover Company
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