B. Turbo-Flo™ Air Valve — Disassembly, Cleaning, Inspection ............................................ 18
C. Reassembly Hints & Tips ................................................................................................... 20
D. Gasket Kit Installation ........................................................................................................ 21
SECTION 9 — EXPLODED VIEW/PARTS LISTING
A. T4 PLASTIC Rubber/TPE-Fitted ........................................................................................ 22
B. T4 PLASTIC and Ultrapure PTFE-Fitted ............................................................................ 24
C. A4 PLASTIC Accu-Flo™ .................................................................................................... 26
SECTION 10 — REFERENCE
A. Air-Operated Elastomer Options ........................................................................................ 28
B. Accu-Flo™ Electrical Reference ........................................................................................ 28
O
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U.S. Clean Air Act
Amendm
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SECTION 1
T4 PLASTIC
CAUTIONS – READ FIRST!
TEMPERATURE LIMITS:
Polypropylene 0°C to 79°C 32°F to 175°F
PVDF –12°C to 107°C 10°F to 225°F
PTFE PFA –28.9°C to 107°C –20°F to 225°F
Neoprene –17.8°C to 93.3°C 0°F to 200°F
Buna-N
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
Polyurethane 12.2°C to 65.6°C 10°F to 150°F
Saniflex™ –28.9°C to 104.4°C –20°F to 220°F
PTFE 4.4°C to 104.4°C 40°F to 220°F
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°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 operating 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. Pump,
valves, and containers must be properly grounded when
handling flammable fluids and whenever discharge of
static electricity is a hazard.
CAUTION: Do not exceed 8.6 bar (125 psig) air supply
pressure.
CAUTION: “Champ” series pumps are made of virgin
plastic and are not UV stabilized. Direct sunlight for
prolonged periods can cause deterioration of plastics.
®
–12.2°C to 82.2°C 10°F to 180°F
®
–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 clamp bands and retainers prior to
installation. 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 fit.
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 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.
NOTE: Non lube-free pumps must be lubricated.
Wilden suggests an arctic 5 weight oil (ISO grade 15).
Do not over-lubricate air supply. Over-lubrication will
reduce pump performance.
CAUTION: Only explosion proof (NEMA 7) solenoid
valves should be used in areas where explosion proof
equipment is required.
1
WILDEN PUMP & ENGINEERING, LLCWIL-10220-E-02
SECTION 2
WILDEN PUMP DESIGNATION SYSTEM
T or A4X /XXXXX / XXX /XX/ XXX/ XXXX
MODEL
VALVE BALLS
DIAPHRAGMS
AIR VALVE
CENTER SECTION
WETTED PARTS & OUTER PISTON
AIR SYSTEM BASE TYPE
O-RINGS
VALVE SEAT
SPECIALTY
CODE
(if applicable)
T4 OR A4 PLASTIC MATERIAL CODES
AIR SYSTEM BASE TYPE
A = ACCU-FLO™
T = TURBO-FLO™
WETTED PARTS & OUTER PISTON
KK = PVDF / PVDF
PP = POLYPROPYLENE /
POLYPROPYLENE
TT = PTFE / PTFE
CENTER SECTION
PP = POLYPROPYLENE
AIR VALVE
A = ALUMINUM
B = BRASS
C = PTFE COATED
D = BRASS W/OIL BOTTLE
N = NICKEL PLATED
S = STAINLESS STEEL
(Cream)]
NE = NEOPRENE (Green Dot)
PU = POLYURETHANE (Brown)
TF = PTFE (White)
VT = VITON
®
(White Dot)
WF = WIL-FLEX™ [Santoprene
Dot)]
VALVE SEAT
K = PVDF
P = POLYPROPYLENE
T = PTFE PFA
VALVE SEAT O-RING
BN = BUNA-N
PU = POLYURETHANE (Brown)
TV = PTFE ENCAP. VITON
®
®
(Orange
SPECIALTY CODES
0100 Wil-Gard II™ 110V
0102 Wil-Gard II™ sensor wires ONLY
0103 Wil-Gard II™ 220V
0145 Accu-Flo™, 110V AC x-proof coil, Wil-Gard II™ 110V
0150 Accu-Flo™, 24V DC coil
0151 Accu-Flo™, 24V AC / 12V DC coil
0153 Accu-Flo™, 24V AC / 12V DC x-proof coil
0154 Accu-Flo™, 24V DC x-proof coil
0155 Accu-Flo™, 110V coil
0156 Accu-Flo™, 110V AC x-proof coil
0157 Accu-Flo™, 24 V DC x-proof coil, Intl. PTB approved
0159 Accu-Flo™, 24V DC coil, Intl. PTB approved, DIN flange
0164 Accu-Flo™, 110V AC coil, Wil-Gard II™ sensor wires ONLY
0166 Accu-Flo™, 24V DC coil, Wil-Gard II™ 110V
0167 Accu-Flo™, 24V AC / 12V DC coil, Wil-Gard II™ 110V
0168 Accu-Flo™, 110V AC coil, Wil-Gard II™ 110V
0169 Accu-Flo™, 110V AC coil, PFA coated hardware
0170 Accu-Flo™, 110V AC x-proof coil, PFA coated hardware
0180 Accu-Flo™, 24V AC / 12V DC coil, PFA coated hardware
0181 Accu-Flo™, 24V AC / 12V DC x-proof coil, PFA coated hardware
0183 Accu-Flo™, 24V AC / 12V DC x-proof coil, Wil-Gard II™ 110V
NOTE: MOST ELASTOMERIC MATERIALS USE COLORED DOTS FOR IDENTIFICATION.
Viton is a registered trademarks of DuPont Dow Elastomers.
WILDEN PUMP & ENGINEERING, LLCWIL-10220-E-02
0184 Accu-Flo™, 24V DC coil, PFA coated hardware
0185 Accu-Flo™, 24V DC x-proof coil, PFA coated hardware
0206 PFA coated hardware, Wil-Gard II™ sensor wires ONLY
0360 Accu-Flo™, 24V DC coil, DIN flange
0362 Accu-Flo™, 110V AC coil, PFA coated hardware, Wil-Gard II™ 110V
0502 PFA coated hardware
0504 DIN flange
0506 DIN flange, PFA coated hardware
0564 Split manifold, inlet ONLY
0567 Split manifold, Accu-Flo™ 24V DC coil
0570 Split manifold, Accu-Flo™, 24V AC / 12V DC coil
0603 PFA coated hardware, Wil-Gard II™ 110V
0604 DIN flange, Wil-Gard II™ 220V
0606 DIN flange, PFA coated hardware, Wil-Gard II™ 220V
0608 PFA coated hardware, Wil-Gard II™ 220V
0612 Ultrapure, PFA coated hardware, male connections
0618 Ultrapure, PFA coated hardware, Wil-Gard II™ 110V, male connections
0622 Ultrapure, male connections
0624 Ultrapure, Wil-Gard II™ 110V, male connections
0660 Split manifold, Wil-Gard II™ 110V
0661 Split manifold PFA coated hardware, Wil-Gard II™ 110V
2
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.
RIGHT STROKEMID STROKELEFT STROKE
FIGURE 1 The air valve directs pressurized air to the back side of diaphragm A.
The compressed air is applied directly to
the liquid column separated by elastomeric diaphragms. The diaphragm acts
as a separation membrane between the
compressed air and liquid, balancing the
load and removing mechanical stress
from the diaphragm. The compressed
air moves the diaphragm away from the
center block of the pump. The opposite diaphragm is pulled in by the shaft
connected to the pressurized diaphragm.
Diaphragm B is on its suction stroke;
air behind the diaphragm has been
forced out to the atmosphere through the
exhaust port of the pump. The movement
of diaphragm B toward the center block
of the pump creates a vacuum within
chamber B. Atmospheric pressure forces
fluid into the inlet manifold forcing the
inlet valve ball off its seat. Liquid is free to
move past the inlet valve ball and fill the
liquid chamber (see shaded area).
FIGURE 2 When the pressurized
diaphragm, diaphragm A, reaches the
limit of its discharge stroke, the air valve
redirects pressurized air to the back
side of diaphragm B. The pressurized
air forces diaphragm B away from the
center block while pulling diaphragm A
to the center block. Diaphragm B is now
on its discharge stroke. Diaphragm B
forces the inlet valve ball onto its seat
due to the hydraulic forces developed in
the liquid chamber and manifold of the
pump. These same hydraulic forces lift
the discharge valve ball off its seat, while
the opposite discharge valve ball is forced
onto its seat, forcing fluid to flow through
the pump discharge. The movement of
diaphragm A toward the center block of
the pump creates a vacuum within liquid
chamber A. Atmospheric pressure forces
fluid into the inlet manifold of the pump.
The inlet valve ball is forced off its seat
allowing the fluid being pumped to fill the
liquid chamber.
FIGURE 3 At completion of the stroke,
the air valve again redirects air to the
back side of diaphragm A, which starts
diaphragm B on its exhaust stroke. As
the pump reaches its original starting
point, each diaphragm has gone through
one exhaust and one discharge stroke.
This constitutes one complete pumping
cycle. The pump may take several cycles
to completely prime depending on the
conditions of the application.
Height .................................. 528 mm (20.8")
Width ................................... 394 mm (15.5")
Depth ..................................284 mm (11.2")
Est. Ship Weight ........Polypropylene 17 kg (38 lbs)
Air Inlet .................................... 10 mm (3/8")
Inlet ..................................... 38 mm (1-1/2")
Outlet .................................. 38 mm (1-1/2")
Suction Lift ......................... 5.49 m Dry (18')
8.53 m Wet (28')
Displacement per
Stroke ........................... 1.02 l (0.27 gal.)
Max. Flow Rate ................. 288 lpm (76 gpm)
Max. Size Solids ...................4.8 mm (3/16")
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 159 lpm (42 gpm) against
a discharge pressure head of 2.7 bar (40
psig) requires 4.1 bar (60 psig) and 40.8
3
Nm
/h (24 scfm) air consumption. (See dot
on chart.)
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
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 5B
PERFORMANCE CURVES
T4 PLASTIC ULTRA-FLEX™-FITTED
Height .................................. 528 mm (20.8")
Width ................................... 394 mm (15.5")
Depth ..................................284 mm (11.2")
Est. Ship Weight ........Polypropylene 17 kg (38 lbs)
Air Inlet .................................... 10 mm (3/8")
Inlet ..................................... 38 mm (1-1/2")
Outlet .................................. 38 mm (1-1/2")
Suction Lift ......................... 4.88 m Dry (16')
8.23 m Wet (27')
Displacement per
Stroke ........................... 0.68 l (0.18 gal.)
Max. Flow Rate ................. 235 lpm (62 gpm)
Max. Size Solids ...................4.8 mm (3/16")
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 132.5 lpm (35 gpm)
against a discharge pressure head of 2.7 bar
(40 psig) requires 4.1 bar (60 psig) and 51
3
Nm
/h (30 scfm) air consumption. (See dot
on chart.)
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
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.
5
WILDEN PUMP & ENGINEERING, LLCWIL-10220-E-02
SECTION 5C
PERFORMANCE CURVES
T4 PLASTIC TPE-FITTED
Height .................................. 528 mm (20.8")
Width ................................... 394 mm (15.5")
Depth ..................................284 mm (11.2")
Est. Ship Weight ........Polypropylene 17 kg (38 lbs)
Air Inlet .................................... 10 mm (3/8")
Inlet ..................................... 38 mm (1-1/2")
Outlet .................................. 38 mm (1-1/2")
Suction Lift ......................... 4.27 m Dry (14')
8.23 m Wet (27')
Displacement per
Stroke ......................... 1.17 l (0.31 gal.)
Max. Flow Rate ................. 307 lpm (81 gpm)
Max. Size Solids ...................4.8 mm (3/16")
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 143.9 lpm (38 gpm)
against a discharge pressure head of 2.7
bar (40 psig) requires 4.1 bar (60 psig) and
3
35.7 Nm
dot on chart.)
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
/h (21 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 5D
PERFORMANCE CURVES
T4 PLASTIC PTFE-FITTED
Height .................................. 528 mm (20.8")
Width ................................... 394 mm (15.5")
Depth ..................................284 mm (11.2")
Est. Ship Weight ........Polypropylene 17 kg (38 lbs)
Air Inlet .................................... 10 mm (3/8")
Inlet ..................................... 38 mm (1-1/2")
Outlet .................................. 38 mm (1-1/2")
Suction Lift ........................... 2.74 m Dry (9')
8.53 m Wet (28')
Displacement per
Stroke ........................... 0.53 l (0.14 gal.)
Max. Flow Rate ................. 235 lpm (62 gpm)
Max. Size Solids ...................4.8 mm (3/16")
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 94.6 lpm (25 gpm)
against a discharge pressure head of 2.7 bar
(40 psig) requires 4.1 bar (60 psig) and 51
3
Nm
/h (30 scfm) air consumption. (See dot
on chart.)
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
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.
WILDEN PUMP & ENGINEERING, LLCWIL-10220-E-02
6
SECTION 5E
PERFORMANCE CURVES
A4 PLASTIC ACCU-FLO™ TPE-FITTED
Height .................................. 528 mm (20.8")
Width ................................... 394 mm (15.5")
Depth ..................................284 mm (11.2")
Est. Ship Weight ........Polypropylene 16 kg (36 lbs)
PVDF 21 kg (47 lbs)
PTFE PFA 23 kg (50 lbs)
Air Inlet .................................... 10 mm (3/8")
Inlet ..................................... 38 mm (1-1/2")
Outlet .................................. 38 mm (1-1/2")
Suction Lift ......................... 3.66 m Dry (12')
8.84 m Wet (29')
Displacement per
Stroke ........................... 0.87 l (0.23 gal.)
Max. Flow Rate ................. 235 lpm (62 gpm)
Max. Size Solids .....................6.4 mm (1/4")
1
Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 90.85 lpm (24 gpm)
against a discharge pressure head of 2.7 bar
(40 psig) requires 4.1 bar (60 psig), 17 Nm
(14 scfm) air consumption, and a pump speed
of 120 strokes/minute. (See dot on chart.)
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
1
3
/h
Flow curves are for “optimal speed” conditions only. The “optimal speed” is that speed which
provides the maximum flow under a particular air and fluid pressure condition. The optimal speed
varies for different fluid and air pressures. Recommendations for optimal speed can be found on
the right side of the flow curve.
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 5F
70/30 OPERATING CONDITION
A4 PLASTIC ACCU-FLO™ TPE-FITTED
This curve demonstrates the flow
created when the stroke rate is modified under a static air and fluid pressure condition. This curve can be
applied to different pressure conditions
to estimate the change in flow due to
stroke rate.
7
WILDEN PUMP & ENGINEERING, LLCWIL-10220-E-02
SECTION 5G
PERFORMANCE CURVES
A4 PLASTIC ACCU-FLO™ PTFE-FITTED
Height .................................. 528 mm (20.8")
Width ................................... 394 mm (15.5")
Depth ..................................284 mm (11.2")
Est. Ship Weight ........Polypropylene 16 kg (36 lbs)
PVDF 21 kg (47 lbs)
PTFE PFA 23 kg (50 lbs)
Air Inlet .................................... 10 mm (3/8")
Inlet ..................................... 38 mm (1-1/2")
Outlet .................................. 38 mm (1-1/2")
Suction Lift ........................... 2.13 m Dry (7')
8.84 m Wet (29')
Displacement per
Stroke ........................... 0.42 l (0.11 gal.)
Max. Flow Rate ................. 144 lpm (38 gpm)
Max. Size Solids ...................4.8 mm (3/16")
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 38 lpm (10 gpm) against
a discharge pressure head of 2.7 bar (40
psig) requires 4.1 bar (60 psig), 17 Nm
scfm) air consumption, and a pump speed of
115 strokes/minute. (See dot on chart.)
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure.
3
/h (10
1
Flow curves are for “optimal speed” conditions only. The “optimal speed” is that speed which
provides the maximum flow under a particular air and fluid pressure condition. The optimal speed
varies for different fluid and air pressures. Recommendations for optimal speed can be found on
the right side of the flow curve.
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 5H
70/30 OPERATING CONDITION
A4 PLASTIC ACCU-FLO™ PTFE-FITTED
This curve demonstrates the flow
created when the stroke rate is modified under a static air and fluid pressure condition. This curve can be
applied to different pressure conditions
to estimate the change in flow due to
stroke rate.
WILDEN PUMP & ENGINEERING, LLCWIL-10220-E-02
8
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