excess lubrication will reduce pump performance.
Pump is pre-lubed.
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
Wil-Flex™ –40°C to 107.2°C –40°F to 225°F
Sanifl ex™ –28.9°C to 104.4°C –20°F to 220°F
Polyurethane –12.2°C to 65.6°C 10°F to 150°F
Tetra-Flex™ PTFE w/Neoprene Backed
4.4°C to 107.2°C 40°F to 225°F
Tetra-Flex™ PTFE w/EPDM Backed
-10°C to 137°C 14°F to 280°F
PTFE 4.4°C to 104.4°C 40°F to 220°F
®
–40°C to 176.7°C –40°F to 350°F
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: Pumps should be thoroughly fl ushed
before installing into process lines. FDA and
USDA approved pumps should be cleaned and/
or sanitized before being used.
CAUTION: Always wear safety glasses when
operating pump. If diaphragm rupture occurs,
material being pumped may be forced out air
exhaust.
CAUTION: Before any maintenance or repair is
attempted, the compressed air line to the pump
should be disconnected and all air pressure
allowed to bleed from pump. Disconnect all
intake, discharge and air lines. Drain the pump
by turning it upside down and allowing any fl uid
to fl ow into a suitable container.
CAUTION: Blow out air line for 10 to 20 seconds
before attaching to pump to make sure all pipeline
debris is clear. Use an in-line air fi lter. A 5µ (micron)
air fi lter is recommended.
NOTE: When installing PTFE diaphragms, it is
important to tighten outer pistons simultaneously
(t urning in opp osite direc tions) to en sure tight fi t.
(See torque specifi cations in Section 7.)
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.
WARNING: Prevention of static sparking — If
static sparking occurs, fi re or explosion could
result. Pump, valves, and containers must be
grounded to a proper grounding point 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 pressure.
CAUTION: The process fl uid and cleaning fl uids
must be chemically compatible with all wetted
pump components (see E4).
CAUTION: Do not exceed 82°C (180°F) air inlet
temperature for Pro-Flo X™ models.
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.
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: 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 be used in submersible applications.
CAUTION: Tighten all hardware prior to installation.
WI L-11230-E-111 WILDEN PUMP & ENGINEERING, LLC
Page 4
Section 2
WILDEN PUMP DESIGNATION SYSTEM
PX1500 METAL
76 mm (3") Pump
Maximum Flow Rate:
1030 lpm (272 gpm)
LEGEND
PX1500/XXXXX/XXX/XX/XXX/ XXXX
MODEL
AIR CHAMBERS
WETTED PAR TS & OUTER PISTON
MATERIAL CODES
MODEL
PX1500 = 76 mm (3")
XPX150 0 = 76 mm (3 " ) ATEX
WETTED PARTS/OUTER PISTON
AA = ALUMINUM / ALUMINUM
HH = ALL OY C / ALL OY C
SS = STAINLESS STEEL /
STAINLESS STEEL
AIR CHAMBERS
A = ALUMINUM
S = STAINLESS STEEL
C = PFA COATED
CENTER BLOCK
A = ALUMINUM
S = STAINLESS STEEL
P = POLYPROPYLENE
AIR VALVE
A = ALUMINUM
S = STAINLESS STEEL
P = POLYPROPYLENE
BN = BUNA-N (Red Dot)
FS = SANIFLEX™
[Hytrel® (Cream)]
EP = EPDM (Blue Dot)
NE = NEOPRENE (Green Dot)
PU = POLYURETHANE (Brown)
TF = PTFE (White)
VT = VITON® (Silver or White Dot)
WF = WIL-FLEX™ [Santoprene
(Orange Dot)]
VALVE SEAT
BN = BUNA-N (Red Dot)
EP = EPDM (Blue Dot)
®
FS = SANIFLEX™ [Hytrel®
(Cream)]
NE = NEOPRENE (Green Dot)
PU = POLYURETHANE (Brown)
VT = VITON® (Silver or
White Dot)
WF = WIL-FLEX™ [Santoprene®
(Orange Dot)]
M = MILD STEEL
S = STAINLESS STEEL
H = ALLOY C
VALVE SEAT O-RING
TF = PTFE (White)
SPECIALTY
CODE
(if applicable)
2
2
®
2
2
SPECIALTY CODES
Drop-In:
0044 Stallion balls & seats ONLY
0100 Wil-Gard II™ 110V
0102 Wil-Gard II™ sensor wires ONLY
0103 Wil-Gard II™ 220V
0320 Submersible center block
0323 Submersible center block, DIN flange
0540 ANSI flange
0544 DIN flange
NOTE: MOST EL AS TOMERIC MATERIALS USE COLORED DO TS FOR IDENT IFICATION.
NOTE: Not all models are available with all material options.
®
Viton
is a registered trademark of DuPont Dow Elastomers.
WILDEN PUMP & ENGINEERING, LLC 2 WI L-11230-E-11
0677 Center Ported, NPT Inlet & Discharge
0678 Center Ported, BSPT Inlet & Discharge
0685 Center Ported, NPT Inlet & Discharge, PCM Sensor & Wires
0687 Center Ported, NPT Inlet & Discharge, Single-point Exhaust
0688 Center Ported, BSPT Inlet and Discharge manifolds, Single-point Exhaust
0689 Center Ported, NPT inlet and discharge with external SS fasteners
0693 Center Ported, NPT, PFA Coated
Page 5
Section 3
HOW IT WORKS—PUMP
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show fl ow pattern
through the pump upon its initial stroke. It is assumed the pump has no fl uid in it prior to its initial stroke.
#,/3%$
/54,%4
/0%.
"!
).,%4
FIGURE 1 The air valve dir ects pre ssurized
air to the back side of diaphragm A. The
compressed air is applied directly to the
liquid column separated by elastomeric
diaphragms. The diaphragm acts as
a separation membrane between the
compressed air and liquid, balancing the
load and removing mechanical stress
from the diaphragm. The compressed
air moves the diaphragm away from
the center of the pump. The opposite
diaphragm is pulled in by the shaft
connected to the pressurized diaphragm.
Diaphragm B is on its suction stroke; air
behind the diaphragm has been forced
out to atmosphere through the exhaust
port of the pump. The movement of
diaphragm B toward the center of the
pump creates a vacuum within chamber B.
Atmospheric pressure forces fl uid into
the inlet manifold forcing the inlet valve
ball off its seat. Liquid is free to move
past the inlet valve ball and fi ll the liquid
chamber (see shaded area).
#,/3%$/0%.
#,/3%$/0%.
FIGURE 2
phragm
of its discharge stroke, the air valve
redirects pressurized air to the back side of
diaphragm B. The pressurized air forces
diaphragm B away from the center
while pulling diaphragm A to the center.
Diaphragm B is now on its discharge
stroke. Diaphragm B forces the inlet valve
ball onto its seat due to the hydraulic
forces developed in the liquid chamber
and manifold of the pump. These same
hydraulic forces lift the discharge valve
ball off its seat, while the opposite
discharge valve ball is forced onto its seat,
forcing fl uid to fl ow through the pump
discharge. The movement of diaphragm A
toward the center of the pump creates a
vacuum within liquid chamber A. Atmospheric pressure forces fl uid into the inlet
manifold of the pump. The inlet valve ball
is forced off its seat allowing the fl uid
being pumped to fi ll the liquid chamber.
/0%.
/54,%4
#,/3%$
"!
).,%4
When the pressurized dia-
, diaphragm A, reaches the limit
#,/3%$/0%.
"!
/0%.
FIGURE 3 At completion of the stroke,
the air valve again redirects air to the
back side of diaphragm A, which starts
diaphragm B on its exhaust stroke. As
the pump reaches its original starting
point, each diaphragm has gone through
one exhaust and one discharge stroke.
This constitutes one complete pumping
cycle. The pump may take several cycles
to completely prime depending on the
conditions of the application.
/54,%4
).,%4
#,/3%$
HOW IT WORKS—AIR DISTRIBUTION SYSTEM
-5&&,%2#%.4%23%#4)/.
!)2).,%4!)26!,6%
!)26!,6%30//,
-5&&,%20,!4%
-!).3(!&4
WI L-11230-E-113 WILDEN PUMP & ENGINEERING, LLC
0),/430//,
%.$#!0
The Pro -Flo
moving parts: the air valve spool and the pilot spool. 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.
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.
Page 11
Example 1
HOW TO USE THIS EMS CURVE
SETTING 4 PERFORMANCE CURVE
Figure 1Figure 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
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)
Page 12
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.
Determine air consumption at a specific
EMS setting.
Step 1
: Determine air X Factor. In order to determine
the air X Factor, identify the two air EMS setting curves closest to the EMS setting established in example 2.1 (in this case, the point lies
between the air curves for EMS setting 1 and
2). The point representing your EMS setting
(1.8) must be approximated and plotted on the
EMS curve along the horizontal line representing your discharge pressure (in this case, 40
psig). This air point is different than the fl ow
point plotted in example 2.1. After estimating
(or interpolating) this point on the curve, draw
a vertical line downward until reaching the
bottom scale on the chart and identify the air
X Factor (fi gure 7).
EMS CURVE
EMS Air
Settings 1 & 2
Figure 7
Example data point =
Step 2
: Determine air consumption. Multiply your
setting 4 air consumption (14 scfm) value by
the air X Factor obtained above (0.40) to determine your actual air consumption.
1
4 scfm x 0.40 = 5.6 SCFM
In summary, for an application requiring 18.9 lpm
(5 gpm) against 2.8 bar (40 psig) discharge pressure,
the pump inlet air pressure should be set to 4.1 bar
(60 psig) and the EMS dial should be set to 1.8. The
pump would then consume 9.5 Nm3/h (5.6 scfm) of
compressed air.
Wilden pumps are designed to meet the performance
requirements of even the most demanding pumping
applications. They have been designed and manufactured
to the highest standards and are available in a variety of
liquid path materials to meet your chemical resistance
needs. Refer to the performance section of this manual for
an in-depth analysis of the performance characteristics of
your pump. Wilden offers the widest variety of elastomer
options in the industry to satisfy temperature, chemical
compatibility, abrasion resistance and fl ex concerns.
The suction pipe size should be at least the equivalent or
larger than the diameter size of the suction inlet on your
Wilden pump. The suction hose must be non-collapsible,
reinforced type as these pumps are capable of pulling a high
vacuum. Discharge piping should also be the equivalent
or larger than the diameter of the pump discharge which
will help reduce friction losses. It is critical that all fi ttings
and connections are airtight or a reduction or loss of pump
suction capability will result.
INSTALLATION: Months of careful planning, study,
and selection efforts can result in unsatisfactory pump
performance if installation details are left to chance.
Premature failure and long term dissatisfaction can be
avoided if reasonable care is exercised throughout the
installation process.
LOCATION: Noise, safety, and other logistical factors usually
dictate where equipment will be situated on the production
fl oor. Multiple installations with confl icting requirements
can result in congestion of utility areas, leaving few choices
for additional pumps.
Within the framework of these and other existing conditions,
every pump should be located in such a way that six key
factors are balanced against each other to maximum
advantage.
ACCESS: First of all, the location should be accessible. If
it’s easy to reach the pump, maintenance personnel will
have an easier time carrying out routine inspections and
adjustments. Should major repairs become necessary, ease
of access can play a key role in speeding the repair process
and reducing total downtime.
AIR SUPPLY: Every pump location should have an air line
large enough to supply the volume of air necessary to
achieve the desired pumping rate. Use air pressure up to
a maximum of 8.6 bar (125 psig) depending on pumping
requirements.
For best results, the pumps should use a 5µ (micron) air
fi lter, needle valve and regulator. The use of an air fi lter
before the pump will ensure that the majority of any pipeline
contaminants will be eliminated.
SOLENOID OPERATION: When operation is controlled by a
solenoid valve in the air line, three-way valves should be
used. This valve allows trapped air between the valve and
the pump to bleed off which improves pump performance.
Pumping volume can be estimated by counting the number
of strokes per minute and then multiplying the fi gure by the
displacement per stroke.
MUFFLER: Sound levels are reduced below OSHA
specifi cations using the standard Wilden muffl er. Other
muffl ers can be used to further reduce sound levels, but
they usually reduce pump performance.
ELEVATION: Selecting a site that is well within the pump’s
dynamic lift capability will assure that loss-of-prime issues will
be eliminated. In addition, pump effi ciency can be adversely
affected if proper attention is not given to site location.
PIPING: Final determination of the pump site should not be
made until the piping challenges of each possible location
have been evaluated. The impact of current and future
installations should be considered ahead of time to make
sure that inadvertent restrictions are not created for any
remaining sites.
The best choice possible will be a site involving the shortest
and straightest hook-up of suction and discharge piping.
Unnecessary elbows, bends, and fi ttings should be avoided.
Pipe sizes should be selected to keep friction losses within
practical limits. All piping should be supported independently
of the pump. In addition, the piping should be aligned to
avoid placing stress on the pump fi ttings.
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 (SD Equalizer
should be installed to protect the pump, piping and gauges
from surges and water hammer.
If the pump is to be used in a self-priming application, make
sure that all connections are airtight and that the suction lift is
within the model’s ability. Note: Materials of construction and
elastomer material have an effect on suction lift parameters.
Please refer to the performance section for specifi cs.
When pumps are installed in applications involving fl ooded
suction or suction head pressures, a gate valve should be
installed in the suction line to permit closing of the line for
pump service.
Pumps in service with a positive suction head are most effi cient
when inlet pressure is limited to 0.5–0.7 bar (7–10 psig).
Premature diaphragm failure may occur if positive suction
is 0.7 bar (10 psig) and higher.
SUBMERSIBLE APPLICATIONS: Pro-Flo X™ pumps can be
used for submersible applications, when using the Pro-Flo
X™ submersible option. Turbo-Flo™ pumps can also be
used for submersible applications.
NOTE: Pro-Flo
ALL WILDEN PUMPS ARE CAPABLE OF PASSING SOLIDS.
A STRAINER SHOULD BE USED ON THE PUMP INTAKE TO
ENSURE THAT THE PUMP'S RATED SOLIDS CAPACITY IS
NOT EXCEEDED.
CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR
SUPPLY PRESSURE.
®
and Accu-Flo™ pumps are not submersible.
®
)
WILDEN PUMP & ENGINEERING, LLC 30 WI L-11230-E-11
Page 33
SUGGESTED INSTALLATION
This illustration is a generic
representation of an air-operated
double-diaphragm pump.
MUFFLER
FLEXIBLE
CONNECTION
SUCTION
EQUALIZER
SURGE DAMPENER
(OPTIONAL)
FLEXIBLE
CONNECTION
NEEDLE VALVE
COMBINATION
FILTER & REGULATOR
AIR SHUT OFF VALVE
GAUGE
(OPTIONAL)
SHUT OFF
VALVE
DISCHARGE
NOTE: In the event of a power failure, the shut off valve
should be closed, if the restarting of the pump is not
desirable once power is regained.
AIR OPERATED PUMPS: To stop the pump from
operating in an emergency situation, simply close the
FOOTPAD
shut off valve (user supplied) installed in the air supply
line. A properly functioning valve will stop the air supply
to the pump, therefore stopping output. This shut off
valve should be located far enough away from the
pumping equipment such that it can be reached safely
in an emergency situation.
WI L-11230-E-1131 WILDEN PUMP & ENGINEERING, LLC
Page 34
SUGGESTED OPERATION & MAINTENANCE
OPERATION: The PX1500 is pre-lubricated, and does
not require in-line lubrication. Additional lubrication
will not damage the pump, however if the pump is
heavily lubricated by an external source, the pump’s
internal lubrication may be washed away. If the pump is
then moved to a non-lubricated location, it may need to
be disassembled and re-lubricated as described in the
ASSEMBLY/DISASSEMBLY INSTRUCTIONS.
Pump discharge rate can be controlled by limiting the
volume and/or pressure of the air supply to the pump.
An air regulat or is used to regulate air pr essure. A nee dle
valve is used to regulate volume. Pump discharge rate
ca n a ls o b e co nt ro ll ed by th ro ttl in g t he pu mp di sc har ge
by partially closing a valve in the discharge line of the
pump. This action increases friction loss which reduces
fl ow rate. (See Section 5.) This is useful when the need
exists to control the pump from a remote location.
When the pump discharge pressure equals or exceeds
the air supply pressure, the pump will stop; no bypass
or pressure relief valve is needed, and pump damage
will not occur. The pump has reached a “deadhead”
situation and can be restarted by reducing the fl uid
TROUBLESHOOTING
discharge pressure or increasing the air inlet pressure.
The Wilden PX1500 pump runs solely on compressed
air and does not generate heat, therefore your process
fl uid 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 fl uid
all affect the parts life of a Wilden pump. Periodic
inspections have been found to offer the best
means for preventing unscheduled pump downtime.
Personnel familiar with the pump’s construction and
service should be informed of any abnormalities that
are detected during operation.
RECORDS: When service is required, a record should
be made of all necessary repairs and replacements.
Over a period of time, such records can become a
valuable tool for predicting and preventing future
maintenance problems and unscheduled downtime. In
addition, accurate records make it possible to identify
pumps that are poorly suited to their applications.
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 fi lter 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. Also, as the check
valve balls wear out, they become smaller and can
become stuck in the seats. In this case, replace balls
and seats.
6. Check for broken inner piston which will cause the
air valve spool to be unable to shift.
7. Remove plug from pilot spool exhaust.
Pump runs but little or no product fl ows.
1. Check for pump cavitation; slow pump speed
down to allow thick material to fl ow 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
seats with proper elastomers. Also, as the check
valve balls wear out, they become smaller and can
become stuck in the seats. In this case, replace balls
and seats.
Pump air valve freezes.
1. Check for excessive moisture in compressed
air. Either install a dryer or hot air generator for
compressed air. Alternatively, a coalescing fi lter
may be used to remove the water from the
compressed air in some applications.
Air bubbles in pump discharge.
1. Check for ruptured diaphragm.
2. Check tightness of outer pistons (refer to Section 7.)
3. Check tightness of fasteners and integrity of
o-rings and seals, especially at intake manifold.
4. Ensure pipe connections are airtight.
Product comes out air exhaust.
1. Check for diaphragm rupture.
2. Check tightness of outer pistons to shaft.
WILDEN PUMP & ENGINEERING, LLC 32 WI L-11230-E-11
Page 35
Section 7
PUMP DISASSEMBLY
Tools Required :
• 15/16" Wrench
• Adjustable Wrench
• Vise equipped w/
soft jaws (such as
plywood, plastic
or other suitable
material)
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. Be aware of
any hazardous effects of contact with your process fl uid.
NOTE: The model photographed for these instructions incorporates rubber
diaphragms, balls, and seats. Models with PTFE diaphragms, balls and seats are
the same except where noted.
Step 1
Please note alignment marks on
liquid chamber. Use to properly
align center section to liquid
chamber.
WI L-11230-E-1133 WILDEN PUMP & ENGINEERING, LLC
Step 2
Using a 15/16" wrench, loosen the
discharge manifold from the liquid
chambers.
Step 3
Remove the discharge manifold to
expose the valve balls and valve
seats. Inspect ball cage area of
manifold for excessive wear or
damage.
Page 36
PUMP DISASSEMBLY
Step 4
After removing discharge valve balls
and valve seats, from the discharge
manifold and liquid chamber, inspect
for nicks, gouges, chemical attack or
abrasive wear. Note: Replace worn
parts with genuine Wilden parts for
reliable performance.
Step 5
Using a 15/16" wrench, loosen
the inlet manifold from the liquid
chambers.
Step 6
Remove the inlet valve balls and
valve seats from the inlet manifold
and inspect for nicks, gouges,
chemical attack or abrasive wear.
Step 7
Using a 15/16" wrench, loosen the
liquid chamber from the center
section.
WILDEN PUMP & ENGINEERING, LLC 34 WI L-11230-E-11
Step 8
The liquid chamber should be
removed to expose the diaphragm
and outer piston.
Step 9
Using one adjustable wrench,
loosen the diaphragm assembly
from the center section assembly.
Page 37
PUMP DISASSEMBLY
Step 10A
Note: Due to varying torque values,
one of the following two situations
will occur. 1) The outer piston,
diaphragm and inner piston remain
attached to the shaft and the entire
assembly can be removed from the
center section.
Finding
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PRODUCTS:
AODDP
(Air Operated Double
Diaphragm Pumps)
• Warren-Rupp
• ARO
• Other
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®
Step 10B
2) The outer piston, diaphragm
and inner piston separate from the
shaft which remains connected to
the opposite side liquid chamber.
Inspect diaphragm assembly and
shaft for signs of wear or chemical
attack. Replace all worn parts with
genuine Wilden parts for reliable
performance.
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easier
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WI L-11230-E-1135 WILDEN PUMP & ENGINEERING, LLC
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Page 38
AIR VALVE / CENTER SECTION DISASSEMBLY
Tools Required :
• 3 /16" Hex Head Wrench
• 1/4" Hex Head Wrench
• Snap Ring Pliers
• O-Ring Pick
CAUTION: Before any maintenance or repair is attempted, the compressed air line
to the pump should be disconnected and all air pressure allowed to bleed from the
pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
upside down and allowing any fl uid to fl ow into a suitable container. Be aware of
hazardous effects of contact with your process fl uid.
®
The Wilden PX1500 metal pumps utilize a revolutionary Pro-Flo
air distribution
system. Proprietary composite seals reduce the co effi cient of friction and allow the
PX1500 to run lube-free. Constructed of polypropylene or aluminum, the Pro-Flo
air distribution system is designed to perform in on/off, non-freezing, non-stalling,
tough duty applications.
®
Step 1
Using a 3/16" Hex head wrench,
loosen air valve bolts.
Step 2
Remove muffl er plate and air valve
bolts from air valve assembly
exposing muffl er gasket for
Step 3
Lift away air valve assembly
and remove air valve gasket for
inspection. Replace if necessary.
inspection. Replace if necessary.
WILDEN PUMP & ENGINEERING, LLC 36 WI L-11230-E-11
Page 39
AIR VALVE / CENTER SECTION DISASSEMBLY
Step 4
Remove air valve end cap to expose
air valve spool by simply lifting
up on end cap once air valve bolts
are removed. Note: Pro-Flo X™ air
valve incorporates an end cap at
both ends of the air valve.
Step 5
Remove the air valve spool from
the air valve body by threading one
air valve bolt into the end of the
air valve 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
Remove pilot sleeve retaining snap
ring on both sides of center section
with snap ring pliers.
NOTCHED
END
Step 7
Remove pilot spool sleeve from
center section.
Step 8
Using an o-ring pick, gently remove the o-ring from the opposite side of the
“notched end“ on one side of the pilot spool. Gently remove the pilot spool
from pilot spool sleeve and inspect for nick, gouges and wear. Replace
pilot sleeve or outer sleeve o-rings if necessary. During re-assembly, never
insert the pilot spool into the sleeve with the “notched end“ fi rst, 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.
WI L-11230-E-1137 WILDEN PUMP & ENGINEERING, LLC
Page 40
AIR VALVE / CENTER SECTION DISASSEMBLY
Step 9
Check center section shaft seals for
signs of wear. If necessary, remove
the shaft seals with o-ring pick
and replace.
SUBMERSIBLE PRO-FLO X™
Non-SubmersibleSubmersible
Step 1
Install a 6 mm (1/4”) NPT pipe plug
(00-7010-08) into the pilot spool
bleed port located at the front of the
center block.
Step 2
Next, install an optional submersible air valve gasket
(04-2621-52). The submersible air valve gasket can
be purchased as a spare part or included with the
purchase of a new Pro-Flo X™ pump.
WILDEN PUMP & ENGINEERING, LLC 38 WI L-11230-E-11
Page 41
REASSEMBLY HINTS & TIPS
ASSEMBLY:
Upon performing applicable maintenance to the air
distrib ution system, the p ump can now be reass embled.
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 fi rst, then
the diaphragms and fi nally the wetted path. Please fi nd
the applicable torque specifi cations on this page. The
following tips will assist in the assembly process.
• Lubricate air valve bore, center section shaf t
and pilot spool bore with NLGI grade 2 white EP
bearing grease or equivalent.
• Clean the inside of the center section shaft bore to
ensure no damage is done to new shaft seals.
• A small amount of NLGI grade 2 white EP bearing
grease can be applied to the muffl er and air valve
gaskets to locate gaskets during assembly.
• Make sure that the exhaust port on the muffl er plate
is centered between the two exhaust ports on the
center section.
• Stainless bolts should be lubed to reduce the
possibility of seizing during tightening.
Pro-Flo X™ MAXIMUM TORQUE SPECIFICATIONS
Description of Par tTorque
Air Valve13.6 N•m (120 in-lbs)
Air Chamber/Center Block27.1 N•m(20 ft-lbs)
I
nner Piston Ring19.0 N•m (14 ft-lbs)
Outer Pistons, Rubber & PT FE
Outer Pistons, Ult ra-Flex
TM
Figure A
135.6 N•m (100 ft-lbs)
135.6 N•m (100 ft-lbs)
SHAFT SEAL
SHAFT SEAL INSTALLATION:
PRE-INSTALLATION
• Once all of the old seals have been removed, the
inside of the bushing should be cleaned to ensure
no debris is left that may cause premature damage
to the new seals.
INSTALLATION
The following tools can be used to aid in the installation
of the new seals:
Needle Nose Pliers
Phillips Screwdriver
Electrical Tape
• Wrap electrical tape around each leg of the needle nose
pliers (heat shrink tubing may also be used). This is done
to prevent damaging the inside surface of the new seal.
• With a new seal in hand, place the two legs of the needle
nose pliers inside the seal ring. (See Figure A.)
• Open the pliers as wide as the seal diameter will allow,
then with two fi ngers pull down on the top portion of
the seal to form kidney bean shape. (See Figure B.)
• Lightly clamp the pliers together to hold the seal into
the kidney shape. Be sure to pull the seal into as tight
of a kidney shape as possible, this will allow the seal to
travel down the bushing bore with greater ease.
• With the seal clamped in the pliers, insert the seal into
the bushing bore and position the bottom of the seal
into the correct groove. Once the bottom of the seal is
seated in the groove, release the clamp pressure on the
pliers. This will allow the seal to partially snap back to its
original shape.
• After the pliers are removed, you will notice a slight
bump in the seal shape. Before the seal can be properly
resized, the bump in the seal should be removed as
much as possible. This can be done with either the
Phillips screwdriver or your fi nger. With either the side
of the screwdriver or your fi nger, apply light pressure
to the peak of the bump. This pressure will cause the
bump to be almost completely eliminated.
• Lubricate the edge of the shaft with NLGI grade 2
white EP bearing
• Slowly insert the center shaft with a rotating motion.
This will complete the resizing of the seal.
2O-Ring (-225), End Cap (Ø1.859" x Ø.139")204-2390-52-70004-2390-52-70004-2390-52-70004-2390-52-700
3End Cap204-2340-0104-2330-20-70004-2340-0104-2330-20-700
4Screw, SHC, Air Valve (1/4"-20 x 4 1/2")401-6000-03N/A01-6000-03N/A
Screw, SHC, Air Valve (1/4"-20 x 4 1/2")6N/A01-6000-03N/A01-6000-03
5Muffl er Plate, Pro-Flo V™104-3185-0108-3185-2004-3185-0108-3185-20
6Gasket, Muffl er Plate, Pro-Flo V™104-3502-5208-3502-5204-3502-5208-3502-52
7Gasket, Air Valve, Pro-Flo V™104-2620-5208-2620-5204-2620-5208-2620-52
T-Section, Bolted (DIN)215-5185-0115-5185-0115-5185-0115-5185-01
27Screw, HHC (5/8"-11 x 2")5615-6180-0815-6180-0815-6180-0815-6180-08
28Washer, Flat (Ø.656" x Ø1.312" x .095")5615-6732-0815-6732-0815-6732-0815-6732-08
Diaphragm, Primary, Full Stroke PTFE Fitted215-1040-55-4215-1040-55-4215-1040-55-42N/A
40Diaphragm, Full Stroke Back-Up215-1065-5715-1065-5715-1065-57N/A
41Piston, Outer, Full Stroke Rubber/TPE/PTFE Fitted 215-4550-0115-4550-0115-4550-03N/A
*See elastomer chart - Section 9
1
Air Valve Assembly includes items 2 and 3.
2
Metal Center Block Assembly includes item 13, 15 and 16. Plastic Center Block Assembly includes item 9, 10, 13, 15 and 16.
All boldface items are primary wear parts.
Full Stroke Rubber/TPE/PTFE Fitted 1215-6130-0815-6130-08N/AN/A
2O-Ring (-225), End Cap (Ø1.859" x Ø.139")204-2390-52-70004-2390-52-70004-2390-52-70004-2390-52-700
3End Cap204-2340-0104-2340-0104-2340-0304-2330-20-700
4Screw, SHC, Air Valve (1/4"-20 x 4 1/2")401-6000-0301-6000-0301-6000-03N/A
Screw, SHC, Air Valve (1/4"-20 x 4 1/2")6N/AN/AN/A01-6000-03
5Muffl er Plate, Pro-Flo V™104-3185-0104-3185-0104-3185-0308-3185-20
6Gasket, Muffl er Plate, Pro-Flo V™104-3502-5204-3502-5204-3502-5208-3502-52
7Gasket, Air Valve, Pro-Flo V™104-2620-5204-2620-5204-2620-5208-2620-52
Manifold, Inlet (DIN)115-5091-0315-5091-0415-5091-0315-5091-03
26Screw, HHC (5/8"-11 x 2")1615-6180-0315-6180-0315-6180-0315-6180-03
27Washer,, Flat (Ø.656" x Ø1.312" x .095")1615-6732-0315-6732-0315-6732-0315-6732-03
28Screw, HHC (1/2"-13 x 1-3/4")1615-6182-0315-6182-0315-6182-0315-6182-03
29Washer, Flat (Ø.516" x Ø.875" x .063")3208-6840-03-6008-6840-03-6008-6840-03-6008-6840-03-60
30Hex Nut (1/2"-13)1615-6420-0315-6420-0315-6420-0315-6420-03
2O-Ring (-225), End Cap (Ø1.859" x Ø.139")204-2390-52-70004-2390-52-70004-2390-52-700
3End Cap204-2340-0104-2340-0304-2330-20-700
4Screw, SHC, Air Valve (1/4"-20 x 4 1/2")401-6000-0301-6000-03N/A
Screw, SHC, Air Valve (1/4"-20 x 4 1/2")6N/AN/A01-6000-03
5Muffl er Plate, Pro-Flo V™104-3185-0104-3185-0308-3185-20
6Gasket, Muffl er Plate, Pro-Flo V™104-3502-5204-3502-5208-3502-52
7Gasket, Air Valve, Pro-Flo V™104-2620-5204-2620-5208-2620-52
Manifold, Inlet (DIN)115-5126-0315-5126-0315-5126-03
26Screw, HHC (5/8"-11 x 2")1615-6180-0315-6180-0315-6180-03
27Washer, Flat (Ø.656" x Ø1.312" x .095")1615-6732-0315-6732-0315-6732-03
28Screw, HHC (1/2"-13 x 1-1/2")1604-6180-0304-6180-0304-6180-03
29Washer, Flat (Ø.516" x Ø.875" x .063")1608-6840-03-6008-6840-03-6008-6840-03-60
Each and every product manufactured by Wilden Pump and Engineering, LLC is built to meet the highest
standards of quality. Every pump is functionally tested to insure integrity of operation.
Wilden Pump and Engineering, LLC warrants that pumps, accessories and parts manufactured or supplied by
it to be free from defects in material and workmanship for a period of five (5) years from date of installation or
six (6) years from date of manufacture, whichever comes first. Failure due to normal wear, misapplication, or
abuse is, of course, excluded from this warranty.
Since the use of Wilden pumps and parts is beyond our control, we cannot guarantee the suitability of any pump
or part for a particular application and Wilden Pump and Engineering, LLC shall not be liable for any consequential
damage or expense arising from the use or misuse of its products on any application. Responsibility is limited
solely to replacement or repair of defective Wilden pumps and parts.
All decisions as to the cause of failure are the sole determination of Wilden Pump and Engineering, LLC.
Prior approval must be obtained from Wilden for return of any items for warranty consideration and must be
accompanied by the appropriate MSDS for the product(s) involved. A Return Goods Tag, obtained from an
authorized Wilden distributor, must be included with the items which must be shipped freight prepaid.
The foregoing warranty is exclusive and in lieu of all other warranties expressed or implied (whether written or oral)
including all implied warranties of merchantability and fitness for any particular purpose. No distributor or other
person is authorized to assume any liability or obligation for Wilden Pump and Engineering, LLC other than expressly
provided herein.
PLEASE PRINT OR TYPE AND FAX TO WILDEN
PUMP INFORMATION
Item # Serial #
Company Wher e Purchased
YOUR INFORMATION
Company Name
Industry
Name Title
Street Address
City State Postal Code Country
Telephone Fax E-mail Web Addre ss
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
Page 56
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SYSTEM ONE®
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WILDEN®
AIROPERATED
DIAPHRAGM PUMPS
wildenpump.com
22069 Van Buren Street,
Grand Terrace, CA 92313-5607
Telephone: (909) 422-1730
Fax: (909) 783-3440
www.wildenpump.com
PSG reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document. 06-2012
Authorized Representative:
Copyright 2012, Pump So lutions Group (PSG®), A Dover Company
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