Wilden HX400S Manual de usuario

Where Innovation Flows

www.wildenpump.com

HX400S

Advanced™Series

Metal Pump

EOM

Engineering

Operation &

Maintenance

WIL-11111-E-03

TO REPLACE WIL-11111-E-02

TABLE OF CONTENTS

NON

USE

U.S. Clean Air Act

Amendments of 1990

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

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

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

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

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

A. HX400S PERFORMANCE

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

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

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

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

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

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

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

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

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

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

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

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

SECTION 8 EXPLODED VIEW AND PARTS LISTING

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

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

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

CAUTIONS  READ FIRST!

Section 1

TEMPERATURE LIMITS:

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

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

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

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

Saniﬂex™ –28.9°C to 104.4°C –20°F to 220°F

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

Polytetraﬂuoro-

ethylene (PTFE) 4.4°C to 104.4°C 40°F to 220°F

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

Tetra-Flex™ PTFE with

Neoprene backing 4.4°C to 107.2°C 40°F to 225°F

Tetra-Flex™ PTFE with

EPDM backing –10°C to 137°C 14°F to 280°F

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

material options for your pump.

CAUTION: Do not apply compressed air to the exhaust

port – pump will not function.

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

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

CAUTION: Maximum temperature limits are based upon

mechanical stress only. Certain chemicals will signiﬁcantly

reduce maximum safe operating temperatures. Consult

Chemical Resistance Guide (E4) for chemical compatibility

and temperature limits.

CAUTION: All piping, valves, gauges and other components

installed on the liquid discharge must have a minimum

pressure rating of 20.7 bar (300 psig).

CAUTION: The discharge pressure generated by this pump

is two times the inlet pressure supplied.

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

for Pro-Flo X™ models.

CAUTION: Pumps should be thoroughly ﬂushed before in-

stalling into process lines. FDA and USDA approved pumps

should be cleaned and/or sanitized before being used.

NOTE: Cast-iron PTFE-ﬁtted pumps come standard from

the factory with expanded PTFE gaskets installed in the

diaphragm bead of the liquid chamber. PTFE gaskets can-

not be re-used. Consult PS-TG for installation instructions

during reassembly.

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

applications. Pro-Flo X™ is available in both submersible

and non-submersible options. Do not use non-submersible

Pro-Flo X™ models in submersible applications. Turbo-Flo®

pumps can also be used in submersible applications.

CAUTION: When choosing pump materials, be sure to

check the temperature limits for all wetted components.

Example: Viton® has a maximum limit of 176.7°C (350°F)

but polypropylene has a maximum limit of only 79°C

(175°F).

CAUTION: Maximum temperature limits are based upon

mechanical stress only. Certain chemicals will signiﬁcantly

reduce maximum safe operating temperatures. Consult

engineering guide for chemical compatibility and tempera-

ture limits.

CAUTION: Always wear safety glasses when operat-

ing pump. If diaphragm rupture occurs, material being

pumped may be forced out of the air exhaust.

WARNING: Prevention of static sparking — If static spark-

ing occurs, ﬁre or explosion could result. Pump, valve, and

containers must be properly grounded when handling

ﬂammable ﬂuids and whenever discharge of static electric-

ity is a hazard.

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

sure.

CAUTION: Before any maintenance or repair is attempted,

the compressed air line to the pump should be discon-

nected and all air pressure allowed to bleed from the

pump. Disconnect all intake, discharge and air lines. Drain

the pump by turning it upside down and allowing any ﬂuid

to ﬂow into a suitable container.

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 5 (micron) air ﬁlter is recom-

mended.

NOTE: Tighten clamp bands and retainers prior to installa-

tion. Fittings may loosen during transportation.

NOTE: When installing PTFE diaphragms, it is important to

tighten outer pistons simultaneously (turning in opposite

directions) to ensure tight 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 consider-

able force. Hand protection such as a padded glove or rag

should be used to capture the end cap.

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

PUMP DESIGNATION SYSTEM

Section 2

NOTE: 1

Meets Requirements of FDA CFR21.177

MODEL

XHX400S = HIGH PRESSURE

SIMPLEX/ATEX

WETTED PARTS / OUTER PISTON

AS = ALUMINUM/STAINLESS STEEL

SS = STAINLESS STEEL/STAINLESS

STEEL

AIR CHAMBER

A = ALUMINUM

S = STAINLESS STEEL

CENTER BLOCK

A = ALUMINUM

S = STAINLESS STEEL

AIR VALVE

A = ALUMINUM

S = STAINLESS STEEL

DIAPHRAGM

FWS = SANITARY WIL-FLEX™ 1

VALVE BALL

WF = WIL-FLEX™ [Santoprene®

(orange dot)]

VALVE SEAT

A = ALUMINUM

S = STAINLESS STEEL

VALVE SEAT ORING

TF = PTFE (white dot)

HX400S METAL

38 mm (1-1/2") Pump

Maximum Flow Rate:

235 LPM (62 GPM)

LEGEND

MATERIAL CODES

SPECIALTY CODES

MODEL VALVE SEAT SPECIALTY

ORING CODE (if applicable)

VALVE SEAT

VALVE BALL

DIAPHRAGM

AIR VALVE

CENTER BLOCK

AIR CHAMBER

WETTED PARTS/OUTER PISTON

XHX400S / XXXXX / XXX / XX / XXX / XXXX

NOTE: Most elastomeric materials use colored dots for identification.

NOTE: Not all models are available with all material options.

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

0245 Reverse manifolds

0247 Discharge & inlet manifold

facing exhaust

0250 Discharge manifold

facing air inlet

0320 Submersible center block

0504 DIN flange

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

Section 3

HOW IT WORKSPUMP DISTRIBUTION SYSTEM

The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show the flow pattern through

the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.

FIGURE 1 When air pressure is supplied to

the pump, the air valve directs pressure to the

back side of the diaphragm A. The compressed

air moves the diaphragm away from the

center section of the pump. The opposite

diaphragm is pulled in by the shaft connected

to the pressurized diaphragm. Diaphragm Bis

on its suction stroke; air behind the diaphragm

has been forced out to the atmosphere

through the exhaust port. The movement of

diaphragm Btowards the center section of

the pump creates a vacuum within the cham-

ber B. Atmospheric pressure forces fluid into

the inlet manifold forcing the inlet valve ball

off of its seat. Liquid is free to move past the

inlet valve ball and fill the liquid chamber (see

shaded area).

FIGURE 2 Once the shaft has reached the end

of its stroke, the air valve redirects pressurized

air to the back side of the diaphragm B. This

pressurized air is also directed to the opposite

side of the diaphragm Athrough a passage-

way that is routed through the common shaft

and outer piston. The pressurized air forces

diaphragm Baway from the center section

while also pushing diaphragm Ato the center

section. Diaphragm Bis now on its discharge

stroke. Diaphragm Bforces the inlet valve ball

onto its seat due to the hydraulic forces devel-

oped in the liquid chamber and manifold of

the pump. These same hydraulic forces lift the

discharge valve ball off of its seat, forcing fluid

to flow through the pump discharge. The pres-

sure on diaphragm Acreates a force on the

shaft that is combined with the pressure from

diaphragm B. This total load is transferred to

the liquid creating a liquid pressure that is two

times greater than the supplied air pressure.

FIGURE 3 At completion of the stroke, the

air valve again redirects air to the back side

of the diaphragm A, which starts diaphragm

Bon 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 pump-

ing cycle. The pump may take several cycles to

completely prime depending on the condition

of the application.

The Pro-Flo X™ patented air distribution system incorporates

two moving parts: the air valve spool and the pilot spool. The

heart of the system is the air valve. This valve design incor-

porates an unbalanced spool. The smaller end of the spool is

pressurized continuously, while the large end is alternately

pressurized, then exhausted, to move the spool. The air valve

spool directs pressurized air to one air chamber while exhaust-

ing the other. The air causes the main shaft/diaphragm assem-

bly 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.

HOW IT WORKSAIR DISTRIBUTION SYSTEM

MUFFLER

AIR VALVE

CENTER BLOCK

AIR

INLET

MAIN

SHAFT

PILOT SPOOL END CAP

MUFFLER

PLATE

AIR VALVE

SPOOL

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

Section 4

DIMENSIONAL DRAWINGS

HX400S ALUMINUM

HX400S STAINLESS STEEL

ITEM METRIC (mm) STANDARD (inch)

A 345 13.6

B 79 3.1

C 318 12.5

D 528 20.8

E 605 23.8

F 127 5.0

G 323 12.7

H 48 1.9

J 132 5.2

K 310 12.2

L 518 20.4

M 241 9.5

N 203 8.0

P 152 6.0

R 170 6.7

S 10 0.4

DIN (mm) ANSI (inch)

T 150 DIA. 6.1 DIA.

U 110 DIA. 4.5 DIA.

V 18 DIA. 0.9 DIA.

REV A

REV B

DIMENSIONS

ITEM METRIC (mm) STANDARD (inch)

A 384 15.1

B 89 3.5

C 277 10.9

D 528 20.8

E 279 11.0

F 48 1.9

G 132 5.2

H 310 12.2

J 508 20.0

K 84 3.3

L 274 10.8

M 224 8.8

N 178 7.0

P 203 8.0

R 10 0.4

DIN (mm) ANSI (inch)

S 150 DIA. 6.1 DIA.

T 110 DIA. 4.5 DIA.

U 18 DIA. 0.9 DIA.

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

HX400S ADVANCEDTM PERFORMANCE

HX400S

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

Section 5

The Pro-Flo X™ air distribution system with the

revolutionary Efﬁciency Management System (EMS)

offers ﬂexibility never before seen in the world of

AODD pumps. The

patent-pending EMS

is simple and easy

to use. With the

turn of an integrated

control dial, the operator can select the optimal

balance of ﬂow and efﬁciency that best meets the

application needs. Pro-Flo X™ provides higher

performance, lower

operational costs

and ﬂexibility that

exceeds previous

industry standards.

Pro-Flo XTM Operating Principal

Turning the dial

changes the

relationship

between air inlet

and exhaust

porting.

Each dial setting

represents an

entirely different

ﬂow curve

Pro-Flo X™ pumps

are shipped from

the factory on

setting 4, which

is the highest

ﬂow rate setting

possible

Moving the dial

from setting 4

causes a decrease

in ﬂow and an even

greater decrease in

air consumption.

When the air

consumption

decreases more

than the ﬂow

rate, efﬁciency

is improved and

operating costs

are reduced.

AIR CONSUMPTION

PROFLO X™ OPERATING PRINCIPLE

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

HOW TO USE THIS EMS™ CURVE

SETTING 4 PERFORMANCE CURVE EMS CURVE

8.2 GPM

Example data point = Example data point =

Figure 1 Figure 2

0.58

0.48

ﬂow multiplier

air multiplier

This is an example showing how to determine ﬂow rate and

air consumption for your Pro-Flo X™ pump using the Efﬁcien-

cy 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 ﬂow 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 ﬂow curve,

draw a vertical line downward until reaching

the bottom scale on the chart. Identify the ﬂow

rate (in this case, 8.2 gpm). Observe location

of performance point relative to air consump-

tion curves and approximate air consumption

value (in this case, 9.8 scfm).

Step 2:

Determining flow and air X Factors. Locate

your discharge pressure (40 psig) on the verti-

cal axis of the EMS curve (Figure 2). Follow

along the 2.8 bar (40 psig) horizontal line until

intersecting both ﬂow and air curves for your

desired EMS setting (in this case, setting 2).

Mark the points where the EMS curves inter-

sect the horizontal discharge pressure line.

After locating your EMS points on the EMS

curve, draw vertical lines downward until

reaching the bottom scale on the chart. This

identiﬁes the ﬂow 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 ﬂow rate (8.2 gpm)

obtained in Step 1 by the ﬂow X Factor multi-

plier (0.58) in Step 2 to determine the ﬂow rate

at EMS setting 2. Multiply the air consump-

tion (9.8 scfm) obtained in Step 1 by the air

X Factor multiplier (0.48) in Step 2 to deter-

mine the air consumption at EMS setting 2

(Figure 3).

Figure 3

The ﬂow 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.

.58

4.8 gpm

(Flow X Factor setting 2)

(Flow rate for setting 2)

(air consumption for setting 4)

(Air X Factor setting 2)

(air consumption for setting 2)

9.8 scfm

.48

4.7 scfm

8.2 gpm (ﬂow rate for Setting 4)

Example 1

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

HOW TO USE THIS EMS™ CURVE

EMS CURVE

SETTING 4 PERFORMANCE CURVE

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 speciﬁc application. For this exam-

ple we will be using an application requirement of 18.9 lpm

(5 gpm) ﬂow rate against 2.8 bar (40 psig) discharge pressure.

This example will illustrate how to calculate the air consump-

tion that could be expected at this operational point.

Step 1

: Establish inlet air pressure. Higher air pres-

sures will typically allow the pump to run

more efﬁciently, however, available plant air

pressure can vary greatly. If an operating

pressure of 6.9 bar (100 psig) is chosen when

plant air frequently dips to 6.2 bar (90 psig)

pump performance will vary. Choose an oper-

ating pressure that is within your compressed

air system's capabilities. For this example we

will choose 4.1 bar (60 psig).

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 perfor-

mance 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 locat-

ing this point on the ﬂow curve, draw a verti-

cal line downward until reaching the bottom

scale on the chart and identify the ﬂow rate.

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

is the setting 4 ﬂow rate. Observe the loca-

tion 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 ﬁgure 4.

Step 3

: Determine flow X Factor. Divide the required

ﬂow rate 18.9 lpm (5 gpm) by the setting 4 ﬂow

rate 38.6 lpm (10.2 gpm) to determine the ﬂow

X Factor for the application.

Step 4

: Determine EMS setting from the flow

X Factor. Plot the point representing the ﬂow

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

bar (40 psig) psig discharge pressure line until

it crosses the vertical 0.49 X Factor line. Typi-

cally, this point lies between two ﬂow EMS

setting curves (in this case, the point lies be-

tween the ﬂow curves for EMS setting 1 and

2). Observe the location of the point relative

to the two curves it lies between and approxi-

mate the EMS setting (ﬁgure 5). For more pre-

cise results you can mathematically interpo-

late between the two curves to determine the

optimal EMS setting.

gpm / 10.2 gpm = 0.49 (flow X Factor)

DETERMINE EMS SETTING

For this example the EMS setting is 1.8.

Figure 4

Example data point = 10.2 gpm ﬂow multiplier

Figure 5

EMS Flow

Settings 1 & 2

Example 2.1

0.49

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