ATED De Engineering Operation and Maintenance Ms METAL, M8 STALLION MODEL M8 METAL MODEL M8 CHAMP MODEL M8 STALLION MODEL M8 FOOD PROCESSING M8 FOOD PROCESSINGTHE WILDEN PUMP — HOW IT WORKS The Wilden diaphragm pump 's an air-operated, positive displacement, selfpriming pump. These drawings show flow patter {trough the pump upon its inital stroke. It is assumed the pump has no fluid in it prior to its initial stroke. vase 4 > oren cuosen oven | open costo TResuindervotebask RGURE2 When Pe mesutes epirpr daphegn A AGURES Acorn oe sole, he ara aan Srlsconind ny ‘cost to Ghee srcn'nde fossa Suc ang A Se stat agrnge fhe sone Petelread at free dgtoge 8 asp taw tie carat sgh Sarr parc oa dptagr hs Son gone ‘inpeised uranic, bang oad anromorng Bach tile ulingapnagin A oa conor tack. ina and oe dations x aun oe coe ‘recone soe rat hedge ais stows ket Oapvngm 8 row te cha eke rng oye Tnasonp a n svecyoeeo Tester ln Mecenrened ak mevs ine sein tat eiofesta dno tanec Sewlicypieapmargontwcoaiawa tara Diaphragm A is wortng agsksl amoghesc ak pure, Hock of he pun crests «vacum win Haul charter A tropuno canbe svesunuinn Curie’ @Aiveyfeie Re puto ne Pi vne afc fa sown WILDEN PUMP DESIGNATION SYSTEM | SUGGESTED INSTALLATION HR EK KKK 1 2 MODEL (SIZE) WETTED CONSTRUCTION NON-WETTED CONSTRUCTION DIAPHRAGMS VALVE BALLS VALVE SEATS (O-RINGS) CAUTION: WEAR SAFETY GLASS. WHEN DIAPHRAGM RUP- ‘TURE OCCURS, MATERIAL BEING PUMPED MAY BE FORCED OUT AIR EXHAUST. NOTE: UL-listed pumps must not exce pressure, 30 paig air supply Temperature Li Champ ser pumps are made of virgin plasic and are not UV Polypropylene «92°F to 175°F 0'C 10 79°C stabilzed. Direct sunigh for prolonged pevods can cause delerio- Pub HOF IowsF “12-Ct0 107°C raion of pases. CAUTION: Moximum temperature mits are based ugon mechanical stress ony. Cera chemicals wil sigiicanly reduce maximum sale | [ worey pump must be Mmreatea, wigen eupgests an ache peratngYarperatures, Consul engieeing gue for chomeal come | | NOTE: Puma must be ube es } patibilty and temperature limits It static sparking occurs, fie or explosion could result. Pump, valves, and containers must be WARNING: Prevention of static sparking uid regu. Pump, valves, and conta st ra. To grout fen “Champ,” all clamp ‘grounded when handling flammable fluids anid whenever dlecharge of static electricity Bands must be grounded to a proper grounding porn \BTEFLON IS A REGISTERED TRADEMARK OF E1, DUPONT CORP.DIMENSIONAL DRAWING MODEL M8 METAL PUMP [-F-SS, Cl, HAST, 2" NPT (MALE) DISCHARGE 1 _G-ALUM . if NPT et NPT FEMALE FEMALE EXHAUST AIR INLET E H Oo |—_j —_| / 2° NPT (MALE) INLET - ALUM. ) 2° NPT (FEMALE) INLET -C.l 3 fit KE T 8 2° NPT (MALE) INLET == TMENSIONS = WE THETA] 2 3 [TENT STANDARD (neh) [METRIC (mp a = z aoe nao & V7/8 476 "9 |r at i ez — 1421/32, 372.3. 7 a ‘oe TT a} az at Sait 30s ie Bt tt—r 10 | “io 5 ow 4241/32 313.5, im ae ts f re ae His te Soe TAL | — tea te 11s a Fie Se ai rare San au panps manta with 2° NPT (FEMALE) mdselopps Snes Sed nope eo T FOOTED BASE FOR STAINLESS STEEL & ALUMINUM BASE SCREEN MODEL HASTELLOY MODELS 1DIMENSIONAL DRAWING MODEL M8 STALLION PUMP 2° NPT (MALE) DISCHARGE 2° NPT (MALE) INLET Available in BSP threads, 4 64 J DIMENSIONS We (STALLION) TTEMT_[ STANDARD [chy | METRIC Grp A 1618 096 a 134 a4 C 258 | ~655 |] D 5 116 0852 € | —2ra6 600.8 F isi a7 6 z ios # 103 2535 J 1358 346.1 ik Tie 228 t i 274 ii VISOR. 143 ‘valable m BSP threads 2, Standard aluminum pumps are manufactured with mild stel nipples. Stainless ste! nipples are availableDIMENSIONAL DRAWING MODEL M8 FOOD PROCESSING PUMP 2412" TRECLANP. 3/4 NPT FEMALE EXHAUST ‘2 NPT FEMALE. AIR INLET 2.12" TALCLAMP. ps | TENSIONS WE FOOD GRADE c= TER STANDARD en) [ METATG Gy F A 1718 435.0 4 M 8 212 63.5 L C 24 5/8 625.5 D— | a6arte—} ass ep 810 ina: F 3 76.2 kn ¢—| 0a 35 | i888 Ms. Jp 3048 710 2540 ) L 9 228.6 i109 2540 nf 316 143DIMENSIONAL DRAWING MODEL M8 CHAMP PUMP (Plastic) a 412 NPT FEMALE : |= ARINLET D c ale NPT FEMALE AIR EXHAUST ‘ o i 2 9 8 a aa) == Z| | M ee 7 TOT PTE at SANDRA aT a ee as 5 oi 7 | ew | ato jin $[ enero of irae {ase , | ee —{— a8 Shera p | aw —[ se | {as eae 4 aa {13 ae 98 a s ANS! =| a » {rare —|—o PIPE FLANGE R 3: 1/32RAD. 76.2 RAD. is PON CLASS St Sgr [80 21D.‘ WILDEN MODEL M8 CHAMP (Rubber/TPE-Fitted) PUMP PERFORMANCE CURVE Height. 30%" Width....... 19%" BAR FEET PSIG Depth 13H 240 (20134), AIR CONSUMPTION Ship Weight.....Polypropylene 74 Ibs. 6.8 100 (40) 168) PVDF 96 Ibs, (SCFM) (14H) Air Inlet J€ Female NPT Inlet. gt 5A} 1804 80 Outlet. 2 Suction Lift Rubber 17" Dry 441 140} 60 (400) (170) 25' Wet ‘TPE 12' Dry asiwa — 274 1°) 40 Displacement per Stroke... .741 gal.’ Max. Size Solids soe dh Dia. 13 401 20 Example: To pump 100 gom against a discharge pressure of 40 psig requires 80 psig and 80 scfm air con- Water Discharge GPM 20 40 60 80 100 120 140 160 sumption. (See dot on chart.) Flowrates [de] (76) [151] [227] (808) [378] (454) (530) (605) ‘Displacement per stroke was calculated at 70 sig alr ietpressurs against & 90 psig head pressure. Volumes indicated on chart were determined by actually pumping water in calibrated tanks, WILDEN MODEL M8 CHAMP (Teflon°-| PUMP PERFORMANCE CURVE Height 30% "BAR FEET PSIG Width. 19'%" Depth. se Be 240 499 2084 AIR CONSUMPTION Ship Weight....Polypropylene 74 Ibs. 6.8 {) (702) (SCEM) (ttc) PVDF 96 Ibs. (80) (136) Aire conned Female NPT 5.4. 489) 80 (100) (170) Inlet. 2 Outlet. vs ase Suction Lift B'dy 4.14 1407 60 (120) (204) 25' Wet Displacement per Stroke... .390 gal. 100 Max, Size Solids... 18 Dia, a7 40 Example: To pump 66 gpm against a discharge pressure of 48 psig 13~ 40+ 20 requires 80 psig and 100 scfm air consumption. (See dot on char.) Water Discharge GPM 20 40) 8) 100120140160 ‘Displacement per stoke nas calculated at 70 Flowrates [don] (76) (161) (227) (08) (378) (454) (680) 606) 9 air net pressure against a 30 psig head pressure Volumes indicated on chart were determined by actually pumping water in calibrated tanks.WILDEN MODEL M8 METAL (Rubber/TPE-Fitted) PUMP PERFORMANCE CURVE Heiatt... 261%: Width sn VPM Depth - 13% Ship Weight........Aluminur 67 Ibs, Cast Iron 112 Ibs. Stainless Steel 102 Ibs, Hastelloy 112 Ibs. Air Inlet. 2 Female NPT inlet 2 NPT” Outlet. seven! NBT Suction Lift Rubber 20° Dry 25' Wet TPE 13° Dry 25° Wet Displacement per Stroke... .725 gal: Max. Size Solids 1# Dia Example: To pump 85 gpm against a discharge pressure of 45 psig requires 80 psig and 80 scfm air con- sumption, (See dot on chart.) Displacement per stroke was cloulated at 70 sig air inlet pressure against a 30 psig ead assure BAR FEET PSIG 240 (20) (34) AIR CONSUMPTION 68 100 (89) £681 (69) 102) (SCFM) [Mir] 541 180] 80 (60) (736) (100) /170) 414 1404 60 (120) (204) 274 100} 40 1.34 494 20 80 100 120 140160 Water Discharge GPM = 20 [303] [378] [454] [530] (606) Flowrates (Uns) [76] 0 60 (151) [227] Volumes indicated on chart were determined by actually pumping water in calibrated tanks. “BSP threads available, WILDEN MODEL M8 METAL (Teflon®-Fitted) Pump Performance Curve Height 26%" Width 15% Depth. stoner VOR Ship Weight ‘Aluminum 67 Ibs, Cast Iron 112 Ibs, Stainless Steel 102 Ibs. Hastelloy 112 Ibs. Air Inlet 1 Female NPT Inlet. 2NPT* Outlet. 2°NPT* Suction Lit, v8! Dy 25° Wet, Displacement per Stroke... .376 gal.’ Max. Size Solids... Dia, Example: To pump 90 gpm against a discharge pressure of 40 psig requires 95 psig and 122 scfm air consumption. (See dot on chart.) Displacement per stroke was calculated at 70 sig ariel pressure against a 30 psig head pressure BAR FEET PSIG (20) (34) 240 AIR CONSUMPTION 66 i (60) /100) (SCFM) (1H) (80) [136] 5.44 1804 80 (100) 170) (120) (204) 414 1405 60 274 1007 40 131 49) 20 Water Discharge GPM 20 40 «60 80100120, 140160 Flowrates [émin) (76) (151) (227) [303] [378] [454] [530] [606] Volumes indicated on chart were determined by actually pumping water in wy calibrated tanks “BSP threads available,MODEL M8 STALLION (TPE-Fitted) PUMP PERFORMANCE CURVE wan eee BAR FEET PSIG Depth 36 240+ 499 (40) 8) ‘AIR CONSUMPTION Weight. Fabs, 6.8 100 10 ey (136) (SCFM) [Mfr] ane ‘Fel Pt » eoeicitar le : ute. “loner, 547 180 (120) (204) Suction Lif 9} Diy 2s'Wet 4.11 1407 60 Max. Sie Solids Dia Example: To pump $2 gpm against 2 2.7-| 100} 49 discharge pressure of 30 psig requires 60 psig and 80 scfm air con- sumption, (See dot on chart.) 13 4g4 20 PEEPS Water Discharge GPM = 20 Cy ao 80 6100) «120140 160 © Flowrates [mn [76] [151] [227] [303] [378] [454] [530] [606] Volumes indicated on chart were determined by actually pumping water in calibrated tanks, “BSP threads available OD ‘Torque Specifications for Model M8 (Metal and Plastic) Feed Torr tent | Despina Te ase 1 [Avan Tass, [LEME] — | — Boas, [SATAY © [2 Tooter Piston atone Tats (105 6m-i] | —s6 Rts. 786m 3_| Outer Pston (Rubber ited) Ta fils (105.8 m-N| | 58 -lbs. 786m] 4 Smal Clamp Band (Teton-Fe 58in-tbs (66 ml] 35 nibs. 62 m4] | Small Clamp Band (Rubber Fited) 25 nibs [28m-N] | §5in-bs. {62 m-N) {| Mesium clamp Band = 90 n-th [102 ml] 7 [Large lamp Ban (Al Bees [ATA mA | 28 ls. (40.0 mi) | Center Block Assembly Zito, [37.1 mew] | 28 obs. [9.2 mi} [| Piastic Screen Base 20 in-tbs. [2.3 m-N] = 10 | Weal Screen Base 80 in-bs. {90 m-N} = 1 | inet Gover a0in.tbs [80 m-N] =ee ———————————oO'n—_O_O_O_cevev—v—v—g eee El SECTION! INSTALLATION The Model M8 has a 2" inlet and 2" outlet and is designed for flows to 155 gpm. The MB Champ pump is manufactured with wetted parts of pure, unpigmented PVDF or Polypropylene. The M8 Metal is manufactured of aluminum, cast iron, stainless steel or Hastelloy. The center block of the MB is constructed of glass-filed polypropylene. A variety of diaphragms, valve balls, and O-rings are available to satisfy temperature, chemical compatibility, abrasion and flex con The suction pipe size should be at least 2° diameter or larger if highly viscous material is being pumped. The suction hose must be non-collapsible, reinforced type as the M8 is capable of pulling a high vacuum. Discharge piping should be at least 2"; larger diameter can be used to reduce friction losses. It is critical that al fitings and connections are airtight or a reduc- tion or loss of pump suction capability wll result. For M8 Champ models, a non-raised surfaced-flange adapter should be utlized when mating to the pump’s inlet and dis- charge manifolds for proper mechanical sealing. The MB can be used in submersible applications only when both wetted and non-wetted portions are compatible with the material being pumped. If the pump is to be used in a sub- SECTION I mersible application, a hose should be attached to the pump’s air exhaust and the exhaust air piped above the liquid level Ifthe pump is to be used in a selt-priming application, be sure that all connections are airtight and that the suction lift is with- in the pumps abilty. Note: Materials of construction and elas- tomer material have an effect on suction lift parameters. Please consult Wilden distributor's for specifies. Pumps in service with a positive suction head are most eff lent when inlet pressure is limited to 7-10 psig. Premature diaphragm failure may occur if positive suction is 11 psig and higher. ‘THE MODEL M8 WILL PASS 1/4" SOLIDS. THE M8 STAL- LION WILL PASS 3/4" SOLIDS. WHENEVER THE POSSI- BILITY EXISTS THAT LARGER SOLID OBJECTS MAY BE SUCKED INTO THE PUMP, A STRAINER SHOULD BE USED ON THE SUCTION LINE. CAUTION: DO NOT EXCEED 125 PSIG AIR SUPPLY PRESSURE. BLOW OUT AIR LINE FOR 10 TO 20 SECONDS BEFORE ATTACHING TO PUMP TO MAKE SURE ALL PIPE LINE DEBRIS IS CLEAR. SUGGESTED OPERATION AND MAINTENANCE INSTRUCTIONS INSTALLATION: Months of careful planning, study, and selection efforts can result in unsatisfactory pump perfor ‘mance if installation details are left to chance. Premature failure and long term dissatisfaction can be avoided if reasonable care is exercised throughout the instal lation process. LOCATION: Noise, safety, and other logistical factors usually dictate that “utlty” equipment be situated away from the pro- duction floor. Multiple installations with conflicting require- ments can result in congestion of ulility areas, leaving few choices for siting of additional pumps. Within the framework of these and other existing condi- tions, every pump should be located in such a way that four key factors are balanced against each other to maximum advantage. 1. ACCESS: First of all, the location should be accessible. It it's easy to reach the pump, maintenance personnel will have an easier time carrying out routine inspections and adjust- ments. Should major repairs become necessary, ease of access can play a key role in speeding the repair process and reducing total downtime. 2. AIR SUPPLY: Every pump location should have an airline large enough to supply the volume of alr necessary to achieve the desired pumping rate (see pump performance chart). Use air pressure up to a maximum of 125 psi depend- ing upon pumping requirements. For best results, the pumps should use an air fiter, regu- lator, and lubricator system. The use of an air fter before the pump will insure that the majority of any pipeline contami nants will be eliminated. The use of a lubricant, sultable for the application, helps perform a number of functions. Lubricants reduce friction to minimize required shitting forces land reduce wear. Lubricants provide a protective coating against some forms of corrosion and contaminants. Wilden suggests an oil with arctic characteristics (ISO 15-5Wt.) This oil is chemically compatible with the center block rings and has a low pour point to guard against problems associated with low temperatures. The amount of lubrica- tion required is directly related to the amount of oil introduced from the factory air system. We therefore suggest that the lowest sotting on the lubricator be utlized and then increased as necessary. Pump discharge rate can be controlled by limiting the volume andior pressure of the air supply to the pump (pre- {erred method). The use of a needle valve installed at the air inlet to the pump is suggested for this purpose. Pump dis- ‘charge rate can also be controlled by throttling the pump dis charge by installing a valve in the discharge line of the pump when the need to control the pump from a remote location exists. 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 damago will not occur. When operation is controlled by a solenoid valve in the air line, a three-way valve should be used. Pumping volume can be set by counting the number of strokes per minute. ‘A muffler installed on the pump’s air exhaust will give quiet exhaust. Sound levels are reduced below OSHA specif cations using a Wilden muffler. 3, 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 elevation (see pump pertormance chart), 4, 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 inad: vertent restrictions are not created for any remaining sites. ‘The best choice possible will be a site involving the shortest and the straightest hook-up of suction and discharge piping. Unnecessary elbows, bends, and fittings should be ‘avoided. Pipe sizes should be selected so as to keep friction losses within practical limits. All piping should be supported SECTION II independently of the pump. In addition, it should line up with- ‘out placing stress on the pump fitings Expansion joints can be installed to ald in absorbing the forces created by the natural reciprocating action of the pump. If the pump is to be bolted down to a solid foundation, ‘@ mounting pad placed between the pump and foundation wil assist in minimizing pump vibration. Flexible connections between the pump and rigid piping will also assist in minimiz- ing pump vibration. f 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. ‘When pumps are installed in applications involving flood- led suction or suction head pressures, a gate valve should be installed in the suction line to permit closing of the line for ump service. INSPECTIONS: Periodic inspections have been found to offer the best means for preventing unscheduled pump down- time. Individuals responsible for checking and maintaining lubrication levels in the pumps should also check for any abnormal noise or leakage. Personnel familiar with the pumps’ construction and service should be informed of any abnormalities that are detected, RECORDS: When service is required, a record should be made of all necessary repairs and replacements. Over a peti- od of time, such records can become a valuable tool for pre- dicting and preventing future maintenance problems and unscheduled downtime. In addition, accurate records make it possible to identify pumps that are poorly suited to their appli- cations. TROUBLESHOOTING Pump will not run or runs sfovly. 1. Check air inlet screen and air fiter for debris. 2. Check for sticking air valve, flush air valve in solvent, 3. Check for worn out air valve. If piston face in air valve is shiny instead of dul, air valve is probably wom beyond work ing tolerances and must be replaced. 4. Check center block O-rings. I wom excessively, they will rnot seal and air will simply flow through pump and out air ‘exhaust. Use only Wilden O-rings as they are of special con- struction. 5. Check for rotating piston in air valve. 6. Check type of lubricant being used. A higher viscosity oi than suggested may cause the piston to stick or run erratical- ly. Wilden suggests the use of a hydraulic oil with arctic char- acteristics (ISO 15-5 wt), Pump runs but litte or no product flows. 1. Check for pump cavitation; slow pump speed down to ‘match thickness of material being pumped. 2. Check for sticking ball checks. If material being pumped is not compatible with pump elastomers, swelling may occur. Replace ball checks and seal with proper elastomers. 3. Check to make eure all suction connections are al tight, ‘especially clamp bands around intake balls Pump air valves freezes. Check for excessive moisture in compressed ai. Either install yer or hot air generator for compressed air Alr bubbles in pump discharge. 1. Check for ruptured diaphragm. 2. Check tightness of clamp bands, especially at intake manifold. Product comes out air exhaust. 1. Check for diaphragm rupture. 2. Check tightness of piston plates to shatt.MAINTENANCE RECORD DATE SERVICE RENDERED SERVICED BY 10 SECTION IV MODEL M8 METAL DIRECTIONS FOR DISASSEMBLY/REASSEMBLY CAUTION: Before any maintenance or repair is attempt: 4, the compressed air line to the pump should be discon- nected 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 {low into a suitable container. Wear safety glasses. When diaphragm failure occurs, material being pumped may be forced out air exhaust. The M8 has a 2" inlet and 2" outlet and is designed for flow Up to 155 gpm. Its air distribution system is based upon design simplicity and proven efficiency. The model M8 is available in aluminum, cast iron, 316 stainless steel or Hastelloy wetted parts. itis avaliable with optional screened inlot base for sub: mersible applications. For highly corrosive applications, polypropylene and PVDF models are available and are cis: ‘cussed in Section VI NOTE: Before starting disassembly, mark a line from each li- uid chamber to its corresponding air chamber. This line will assist in proper alignment during reassembly. Disassembly: NOTE: Models used for these instructions incorporate rubber diaphragms, balls and seats. Step 1 Models with Teflon® diaphragms, balls and seats are the samo except where noted, ‘Start by removing the two clamp bands thal fasten the discharge manifold to the main body of the pump (Figure TA and Figure 18) The discharge valve balls and seats are now available for inspection, Figure 14 - Figure 1B "ASSEMBLY Remo Ghat hold the Inlet manifold to the main body of the pump. Lift the main body ofthe pumpfrom the ve the iwoclamP Pan". side. The inlet ball valves and seats are now available for examination (see Figure 2A). Next, rstmaniggasaee eg ie ae sare ose a ening oe Pu Sa Step 1 (RUBBER DIAPHRAGMS) Exploded View Figure 34 Figure 24 Figure 28 ie chamber from thecenter section. This will expose the diaphragm and its piston plate (see Figure 20). ¢ Troe onl one la nlale can beremioved by unscrewing them from the connecting shaft with anadjustable wrench, o The once et be held ity the opposite quid chamber (see Figure 20). Figure 20 Now remove the oppose liquid chamber. The second diaphragm is now available or inspection and cleaning (see Figure 26). ules untewobd blocksissuggestedasa method of securing the shaft while removing the second diaphragm. Itisimportant \. ba Fat or mark the chrome-plated shaft. (TEFLON® DIAPHRAGMS) Exploded View Figure 3B Figure 2E Figure 2F od gure 2 9 the ephragms, the inner piston is now exposed and available for inspection (see Figure 2F) 13Figure 44 Figure 48 Step 2 Before assembly, remave the O-fings Irom the canter block bushing and flush center block removing grit and contami- rants. Install new O-rings in center block (see page 8). To install shaft, push shalt firmly through the bushing in the center block. Be sure to lubricate bushing with an ISO grade 15-5 wi cil so that shaft may pass by the O-rings (see Figure 4A). Next, push diaphragm down so that it is into the lip of the air cham= ber (Figure 4B). Then turn center section over and push diaphragm from full stroke position to exhaust position, thus ‘exposing shaft so that other diaphragm can be positioned (Figure 40). Wi-Flex™ and Sanifiex™ diaphragms are rigid and cannot be pushed to the exhaust position. These diaphragms should be inverted prior to feeding the shaft through center bushing to allow for proper positioning. Next, place inner piston and opposite diaphragm in position for assembly. Once diaphragms are installed, it is important to tighten outer pistons simultaneously (turing in opposite direc tions) to ensure a tight, secure fit. Tighten to the required torque specifications” (Item #2 or #3). (Figure 4). Figure 4F Figure 4G ‘Now install water chamber with large clamp band on one side. Center section should then be turned over so that diaphragm can be pushed up with pry bars to full stroke position so that opposite water chamber can be installed, Tighten to the required torque specifications* (Item #7). (Figure 4F and Figure 4G). CAUTION: Both the top and bottom flange surfaces of the water chambers ‘must be aligned so that they are level and in the same planes to prevent leakage. Figure 4 | Figure 4H Figure 41 Install the valve seats inthe water chambers and inlet manifold with the molded seat O-ring down inside the seat recess. Next, securely tighten small amp bands around init manifold and water chamber tothe required torque specications” (tom #4 or | #8). (Fique 4H) Final, place discharge manifold over assembled center section (Figure 4!) and tighten clamp bands to the | Figure 4 required torque specications” (item #4 or #5). Blow out a ine for 10 to 20 seconds to make sure all pipeline debris is | lear. Connect the airline and run pump dry. Good suction should be observed a niet. ler to pages 5-7 for suction it data | Figure 4D “Refer to page 7 for the required torque specifications, “Rofer to page 7 for required torque specications, 14 15SECTION V AIR VALVE / CENTER BLOCK DISASSEMBLY / REASSEMBLY The air valve assembly consists of both the air valve body andpiston and the center block The unique design of the alr valve relies only on differential pressure to effect the di phragm shift Itis reliable and simple to maintain. The bush- ing in the center block, along with the diaphragm shaft, provides the trigger’ totell theairvalvetoshitt. The following procedure will ensure that the air valve on your Wilden pump will provide long trouble-free service. AIR VALVE BODY AND PISTON ASSEMBLY AND DISASSEMBLY: The air valve body and piston can be disconnected from the pump by removing the four socket head cap screws which attach ito the center block The piston in the alr valve is aluminum with a dark gray anodized coating. The piston should move freely and the ports on the face of the air valve body should align with the ports in the air valve piston (see Figure D). The piston should also appear to be dull, dark gray ‘color. If the piston appears to be a shiny aluminum color, the air valveis probably worn beyond working tolerances and. should be replaced. AIRINLET ——AIRVALVE: PISTON CENTER BLOCK AIR FILTER BUSHING ‘SCREEN END CAP ‘CAPILLARY ROD (OPTIONAL) | ot BoTTLe (PTIONAL) NOTE: Air valve available with or Figure B 16 without oll bottle and capillary rod CENTER AIR VALVE BLOCK ASSEMBLY Center Section Assembly Figure A If the piston does not move freely in the air valve, the entire air valve should be immersed in a cleaning solution. (NOTE: Do not force the piston by inserting a metal object) This soaking should remove any accumulation of sludge and grit which is preventing the air valve piston from moving freely. Also, remove and clean the air valve screen If the air valve piston does not move freely after the above cleaning, the air valve should be disassembled as follows: remove the snap ring from the topendof the airvalve cylinder ‘and apply an air jet tothe 3/ 16-inch hole on the opposite end of the air valve face (see Figure ©). CAUTION: The air valve endcap may come outwith considerable force. Hand protec: tion such as a padded glove orrag should be used tocapture the end cap. Figure D o Inspect the piston and cylinder bore for nicks and scoring ‘Small nicks can usually be dressed out the piston returned to service. Inspect the cylinder end caps. Make sure that the guide pin is straight and smooth or the piston will not move freely in the cylinder. New O-rings should be installed oin the end caps, assuring that proper alignment of the piston and cylinder ports is maintained (see Figure D). Reinstall air valve 10 conter block of pump. Tighten to the required torque specif- ceations* (Item #1), O-RING REPLACEMENT: ‘When the O-rings become worn or fat, they will nolonger seal and must be replaced. This is most easily accomplished by using a tool called an O-ring pick, available through most industrial supply companies. CENTER BLOCK ASSEMBLY: The pump's center block consists of a polypropylene or die cast housing with a cast-in bronze bushing. The bushing has leven grooves cut on the inside diameter. There are seven O- rings that fit in these grooves (see Figure E). Since these O- rings form a part of the shifting function of the pump, itis nec ‘essary that they be located in the proper grooves, The bronze bushing is replaceable in cast iron blocks only. When bushing ‘wear becomes excessive, a new center block must be used. NOTE: Use an ISO grade 15 cil to lubricate O-rings. Grooves in bushing which ‘contain O-rings “Refer to page 7 for the required torque specications. Figure F (Side View) “@ Ss. + ‘Se | BLEED-OFF \@ es S| Fo ay a (Front View) IN 20N Bronze Bushing can be pressed Ino a stainless steel or cast iron center section (Bee Figure A. When Installing @ new bush: ing, two bleeder holes \whichaliow the pumpto exhaustair mustbediled, ‘A7/82" drill should be used (See Figure @) 17Wilden Model M8 Metal with Rubber Fitted Elastomers Mg Stallion Pump lm [8 le elm [ales [oe [eae = klein oy ARE _ | | | —— a | j se i a eT t = - ete ‘ Fee ——t Hee fe tebe 1 Peco a HET Pe Her ee [asi Grime Son 59 + bebe [pe ne bg] Fae artim ee + ee]: Se eae a eee —t eeeheu ete te eee eee : es oe) : J O ee a = =|} Before 5 aaecinrsrmr ——— [7 rf Caan er —| 1 zfaxwet “ 30 So sa} [3 fesey te ar t sree eH s tas ieee te ry wreioan ie |e [a [a ie ain a i pines a : : ehatate [ee aerate 7 foreseen 1 Wf WAR eA eel acco H ‘a [rk Pa 0 eed States Tease t ae Pk » OF ere tete + fee ——H fee te eet aoe wo - Stee Heaters etetete Ae ee 2 [aoa © fm ) eee tT Ht ar Ct Me 7 |e fganmtarey omar Se [Ser S sas] ewes sces—[! se pet ata tee ‘War ae wn su ste ST 1, moe ma ESSA 19 18 er rathNOTE: Tetlon® Diaphragm Models Assembled With Tefon® Gasket Kit At Factory (Not Shown) Wilden Model M8 Metal with Teflon® Elastomers We ro wt mo or iar lem) pr oeseiptin oy, | Pa Pan PR a [=a t = [7a a | Fa i et co a 7} = = —{— i Te 2 [ane | ora oe sa [se a $8 a =| — Ser a | — sr Se ‘Sr oe ar cu a ne ie mM Mv fum| par oesrpion ay, [ra PA Pm + [ara {a = ara ee were —|—werse—|—mse * aca eay [T— ee ead at_——— EE Elastomers for M8 Metal Pumps VALVE BALLS (4) | VALVE SEATS (4) | DIAPHRAGMS | VALVE SEAT MATERIAL ITEM #92 ITEM #33, ITEM #34 O-RING (4) Polyurethane (08-1080-50 08-1120-50 Pu24 = Neoprene a 40 24 = Buna-NV BNAT BNA BNE 08° Node! NAT N40 ozs = Viton Vrat v140 vi2g = Sanifiex™ FGST FB40 Fe2d 08-1200-55" Tellon® PTFE zi} = Tr24 aor Sanifiex™ Baok-up® = = (08-1060-56" WikFlex™ (08-1080-58 08-1120-58 (08-1060-58 Use Saniflex™ back-up diaphragms with Teflon® ‘Neoprene back-up diaphragms, PIN TE24B, are av Utilized in conjunction with metallic seat Elastomers for M8 Stallion aphragms only. llable upon request. Please consult your local Distributor VALVE BALLS (4) | VALVESEATS (4) | _DIAPHRAGHS MATERIAL ITEM #32 ‘TEM #33, ITEM #34 Polyurethane 08-1090-62 (08-1130-62 PU24 Buna-N (08-1090-52 (08-1130-52 = Wil-Fiex™ (08-1090-58 (08-1730-58 08-1060-58 Sanifiex™ (08-1090-56 08-1730-56 FG24 Elastomers for M8 Champ Pumps (Plastic) VALVE SEAT MANIFOLD DIAPHRAGM | VALVE BALL ‘O-RING (4) O-RING (4) (2) () MATERIAL ITEM #28, ITEM #29 ‘eM #30, eM #32 Polyurethane PaOP PRP PU24 08-1080-50 Neoprene = - 24 a Buna-N Pa0B P38 BN2e BNAT Nordel = = Naa NDAT Viton = = VvI24 iat Saniflex™ = = FG24 FGaT Teflon® PTFE = = Trea Trat Sanifex™ Back-up = = (08-1060-56" = WiFFlex™® = = 08-1070-58 | 08-7080-58 Teflon®-Eneapsulated Silicone TFE4OB! TFES2BV" = = Teffon®-Encapsulated Viton TFE4OBV" TFES2BV" = = VOTES Teflon®-encapsulated silicone O-rings, TFE40B and TFE328, are standard on al Teflon®-fited polypropylene ums. Teflon®-encapsulated Viton O-rings, TFE4OBV and TFE32BV, are standard on all Teffon*-fited PVDF pumps. Teflon® diaphgram, TF24, must be used with Saniflex™ back-up diaphragms, P/N ;08-1060-56, Neoprene back-up diaphragm, P/N TF24B, is available upon request. Please consult your local distributor. a SECTION VI ~MODEL M8 CHAMP (Plastic) DIRECTIONS FOR DISASSEMBLY/REASSEMBLY CAUTION: Before any maintenance or repairisattempted, the compressed airline to the pump should be discon- nected and all air pressure allowed to bleed from pump. Disconnectall intake, discharge, andairlines, Drainthe pump by turning it upside down and allowing any fluidto flow into a suitable container. The Wilden“ Champ" is Wilden model M8 pump (2-inch) with alkwetted parts of injection molded polypropylene or PVDF material. Performance and operation of the “Champ” are essentially the same as other Wilden model M8 pumps of metal construction subject to temperature and chemical compatiblity of the material being pumped with polypro- pylene and PVOF. The air valve, Center section, and diaphragms are stan- dard M8 components. The “Champ” pump differs, however, _pinthat flanges 150 psi American Standard Pipe) are utlized instead of threaded inlet and discharge parts; increased extemal dimensions; and 10 sets of clamp bands instead of 8. Performance and operation are the same as a metal con- ‘struction M8 with one exception: the maximum temperature for the polypropylene 3d to 175 degrees Fahrenheit and 225 degrees Fahrenheit for the PVOF. NOTE: Before starting disassembly, mark a line from each liquid chamber toits corresponding air chamber. This line will assist in proper alignment during reassembly. DISASSEMBLY : NOTE: Modelusedor hese instructions incorporates Teton claphragms balls and valve seat Step (O-rings. Models with rubber diaphragms, balls and O-rings are the same except where noted. Start by removing the two clamp bands that fasten the discharge manifold to the main body of the pump. Figure 14 Figure 18 23Figure 28 Figure 2A Step2 ‘The valve ball, round O-ring and the seat are now exposed for inspection If the O-ring is flattened or out-of round, itmustbe (™) replaced Valve ball and seat should be inspected for damage or excessive wear. = & Figure 3A Figure $B Step 3 Remove the two clamp bands that hold the inlet manifoldto the main body of the pump Liftthe main body of the pumpfrom the inlet manifold and set it to one side. The inlet ball valves, cages, seats and O-rings are now available for examination. 24 Dg Pm Figure 4A Figure 48 Step4 Both inlet (Figure4A) and discharge (Figure 4B) manifolds can now be disassembled by removing their clamp bands. Make ‘sure the round O-rings are not damaged or swollen. These O-rings form the seal between the manifold ports and will not perform their function if damaged. NOTE: Manifolds need not normally be disassembled for maintenance. Figure 5A Step 5 Remove only one liquid chamber from the center section. This will expose the diaphragm andits piston plate. By grasp ing the outer edges of the diaphragm and turning counter clockwise, the diaphragm and piston plate can be removed by unscrewing them from the connecting shaft The opposite diaphragm will be held tight by the opposite liquid chamber. f NOTE: The shaft may unscrew from the opposite dia- phragm. Flats are provided on the piston plate fora wrench if necessary If needed, a vise with wood blocks is the recom- , ‘mended method of securing the shaft while removing the second outer piston. Nowremove the opposite liquid chamber. The second diaphragm is now available for inspection and cleaning. At this point of disassembly, all liquid contact areas of the pump are available for inspection and cleaning. _/ —Winspection andlor servicing of the non-wetted air section is, necessary please see Section Vil Figure 5C 25\SSEMBLY: Exploded View Figure 64 step 1 (Teflon® Diaphragms) irs, install diaphragm and inner and outer piston plates on shaft. Observe the “This Side Out” marking on the convex side of the iaphragm. Hand-tighten the outer piston to the shaft only, at this time (Figure 7A). Lubricate the center block bushing with a Swt 30 grade 15 oil and insert the shaft through the bushing until the outer bead of the diaphragm just touches the circumference roove of the air chamber. Exploded View Figure 6B Rubber Diaphragms) Figure 7A Step 2 instal the opposite diaphragm and Inner and outer pistons: hand:tghten. Now tighten both diaphragm cuter pistons (we 7) suggest two agjstable wrenches) simultaneously (turning in opposite arections) tothe require torque specticatons” (item #210" #6). Install water chambers over the daphragms using the alignment marks thet were made during dsassemtly 26 @ guide, (Direction of ow through the pump 's bottom f0 top} Install and tighten clamp bands to the required torque spect cations" (tem #7) (Figures 7Band 70) “Refer to page 7 for the required torque specitications. Figure 7C Figure 6A Step 3 install inlet ball vaive, O-ring and seat in sequer order as shown in Figures 84 and 8B. EyStep 4 (Teflon® Elastomers only) ‘M8“Champ” pumps with Teflon® elastomers require the use of Teflon” gasket kit(P/NTF4/8GK). The Teflon® gasket material Jn this kit i in expanded type of Teflon® which is very strong, but soft Its use assures a positive seal between the Teflon? diaphragm cuter bead and its corresponding groove in the water chamber. This gasket material should be replaced each time the pump is disassembled, Figure 9A Selecta strip of9:6'-wide material and carefully remove the covering from the adhesive strip (see Figure 94). Ensure that the adhesive strip remains attached to the gasket material. Figure 9C Figure 98 Starting at any point lay the gasket strip in the center of the diaphragm bead groove on the chamber and press lightly on the gasket to ensure that adhesive holds it in place during assembly (Figure 9B). The ends of the gasket should overlap approximately ‘2". Figure 9D All PVDF pumps with Teflon* elastomers utiize gasket material around the seat area as well. If sealing is a problem, the gasket ‘material can be used with polypropylene pumps as well. Notice that the adhesive strip for the inlet and discharge manifold is Yeinch, and that it, too, is wrapped in much the same way as in Figure 9A and 9B. Make sure that adhesive strip covers the round, (O-ring completely 28 Figure 108 Step 5 Manifold Assembly: If the inlet and/or discharge manifold was taken apart, it should be reassembled now. The easiest way to do this is 10 take one half clamp band and wedge it onto the flanges of the elbow and center T-section, (See Figure 10A) This holds the two parts together while the second half band is installed and the bolts are hand-tightened. Attach the other elbow to the center T-section and tighten to the required torque specifications* (Item #4 or #5). (Figure 108). Align the manifold parts as in Figure 10C, and tighten the clamps to the required torque specifications* (Item #6). NOTE: On pumps equipped with Teflon® gaskets should be used between the flanges of the manifold. (See Step 90). Step 6 ‘Next, instal the valve seat, O-ring, and valve ball on top of the liquid chamber, piace the ball valve cage over the valve ball, if Previously removed. (See Figures 114 and 11B.) Tighten clamps to the required torque specitications* (Item #6). Figure 11 Step7 Figure 108 Figure 100 Figure 118 Retighten all clamp bands, Blow out air line for 10 to 20 seconds to make sure all pipeline debris Is clear. connect ai ine to the pump and run it dry. The pump should shift evenly and good suction should be observed at the inlet. Refer to pages 5-7 for suction lt data, “Refer to page 7 for the required torque specifications. 29SECTION VII AIR VALVE / CENTER BLOCK DISASSEMBLY / REASSEMBLY ‘Theairvalve assembly consists of both the air valve bodyand piston and the center block. The unique design of the air valve relies only on differential pressure to effect the diax phragm shift Itis reliable and simple to maintain, The bush- ing in the center block, along with the diaphragm shaft, provides the ‘trigger’ totell theair valve to shift. The following, procedure will ensure that the ar valve on your Wilden pump. will provide long trouble-free service. AIR VALVE BODY AND PISTON ASSEMBLY AND DISASSEMBLY: The air valve body and piston can be disconnected from the pump by removing the four socket head. cap screws ‘which attach it to the center block The piston in the air valve is aluminum with a dark gray anodized coating. The piston should move freely and the ports in the piston should line up with the ports on the face of the air valvbe body (see below). The piston should also appear to be a dull, dark gray in color. If the piston appears to be a shiny aluminum color, the alr valve is probably worn beyond working tolerance and should be replaced If the piston does not move freely in the air valve, the entire air valve should be immersed in a cleaning solution. AIRINLET AIR VALVE: PISTON CENTER BLOCK BUSHING AIR FILTER ‘SCREEN END CAP ‘CAPILLARY ROD (OPTIONAL) lL BOTTLE (OPTIONAL) NOTE: Air valve available with or without oll bottle and capillary rod. Figure 8 AIR VALVE ASSEMBLY ‘CENTER SECTION ASSEMBLY [NOTE: Do not force the piston by inserting a metal object] ‘This soaking should remove any accumulation of sludge and arit which is preventing the air valve piston from moving free- ly.Also, remove and clean the air valve screen. Ifthe air valve piston does not move freely after the above cleaning, the air valve should be disassembled as follows: remove the snap ring from the top end of the air valve cylinder and apply an air jet to the 3/16-inch hole on the opposite end ofthe alr valve face. (See Figure C) CAUTION: The air valve end may come ‘out with considerable force. Hand protection such as a added glove or rag should be used to capture the end cap. Figure C Figure © oO Small nicks can usually be dressed out and the piston retumed to service. Make sure that the guide pin is straight ‘and smooth or the piston will not move freely in the cylinder. New O-tings should be installed on the end caps. Lubricate the O-rings and install the end caps, assuring that proper alignment of the piston and cylinder ports is maintained. (See Figure D). Reinstall air valve to center block of pump. Tighten to the require torque specifications” (Item #1). O-RING REPLACEMENT: When the O-rings become worn or fla, they will no longer seal and must be replaced. Thisis most easily accomplished by using a tool called an O-ring pick, available through most industrial supply companies. CENTER BLOCK ASSEMBLY ‘The pump's center block consists of a polypropylene or a dle cast housing with a castin-bronze bushing. The bushing has eleven grooves cut on the inside diameter. There are seven O-rings that fit in these grooves (see Figure E). Since these O-rings form a part of the shiting function of the pump, it is necessary that they be located in the proper grooves. The bronze bushing is replaceable in cast iron or stainless steel canter blocks only. When bushing wear becomes excessive, a ‘new center block must be used. Grooves in bushing which contain Cringe Figure E “Refer to page 7 for the required torque specifications, Figure F (Side View) PORT BLEED-OFF PORT ape = S -@. Figure G Center Block (Front View) PIN 20N Bronze Bushingcan be pressed into a stainless steel or ‘cast ron canter section, (See Figure F. When instaling anew bush ing, two bleeder holes which alow the pump to ‘exhaustalrmustbe dled. 7/32" drill should be used. (See Figure G). atZ N ZI Bree Gu 9 0% | NOTE: Tefton® diaphragm models assembled with Tetion? gasket Kt at factory (not shown). Wilden Model Mg Plastic Pump Parts er Par oeseigton oy. eae 7 Po alas] al Ie | se Fer rene ngEee ECSS a a Me STALLION SOLENOID-OPERATED ‘Mi ULTRAPURE It FOOD PROCESSING oat Sis fies ot "ie Tet oneatat wn Senate pop entld Pernt ‘hae uit to handle by electrical eee err ‘mavens: bead rp eat ingest so rele Seale oe ier teen erat Sti Si a sy py tating i oe casi ie Sten wnt foe ey cor tesa samp pring ad aa rinsaseg econ sing re. shige soca MO sists Foon _ a safer wark envi ‘ured) is USDA bese ronment aoceptad, See MODEL M.025 MODEL M4 To4 5 GPM yf inlet + Up To73 Gem ois! lax. Paticle + Max. Particle psig * 8 Matorils ot Construction: PDF. Ansa, Polprepene, Carbone Beet Motors of Constueion: Nin eon Stes PD, Teo eA Suction Lit: (rubber) On: 45) Suelion Lit: Plastic, Metal Wat:28 (uote) Oy tht 025 (Tol) Oy 45 MA PLASTIC. Wet:25" 25 M4 BEAL (CHATAP SERIES) Wat:25 (CHAMPSERIES) (Teflon) Dy Wet: 25° 25 oO LUBE-FREE AVAILABLE MODEL M1 MODEL Ms + \Finlt = UpTo14 GPM 2 i0ldax. = Hox Particle sia She: ie" sof Construction: Palyropylee, PUD. Teton, Granite fled Polypropylene, ‘Auminum, Stainless Ste! ‘Suetion Li: Plastic. Metal (fubber- Dry t0 10 + 2 Inlet = Up To155 GPM 2 iosihiax. > Ma. Particle, Psig Sie: i Materials of Construction: ‘luminum, Catron, Stainless Steel, Hasieloy, PVDF Polypropylene Suclion Li: Plastic, Metal (Fubbey Ont 20" tnt PLASTIC Wt: 28° 25" a1 meTAL PLASTIC Wet 25° 25 M9 METAL (CHM SERIES) (Teflon?) Ory 3 (CHAMP SERIES) (Tefor”) Oy. 3 fet: 25° 25° Wet: 25° 25° MODEL M2 MODEL M15 svtinet up: sS'lnet + UpTo230 apm Matlin, SMa Panicet Saphir, + Noe Parte sie Sire Psign Size: Materials of Construction: Materials of Construction: Y slominum,Sanlss Ste ‘Aum, Cast Won, Staiess Steel Hesteloy Hasteby: Polypropylene, PVDF Suction Lit Suction Lit: Plastic, Metal (Gunter) ye 17 ihubbey Oates Wat 25 We 25° 28 (Toten) Da Men LasTiC (Teion®) Dry M2 METAL Wat 25 (chat SERIES) W228 For further information contact your local Wilden distributor: MODEL M20 ss inlet» Up Tove GPA Saas. 1 Mou Panicle Paige * Sie: Materias of Construction: Cast Iron, Y Suetn it, Wa 25 WILDEN PUMP & ENGINEERING COMPANY 22089 Van Buren St., Coton, CA 92324 (909) 422-1730 » FAX (909) 783-3440