Dover Psg wilden pcmi Instruction Manual

WIL-19130-E-04

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ENGINEERING OPERATION

MAINTENANCE MANUAL

PCMI

Pump Cycle Monitor

WIL-19130-E-04 2

PCMI Pump Cycle Monitor

PSG reserves the right to modify the information and illustrations in this document without prior

notice. The product described in this document is furnished under a license agreement or

nondisclosure agreement. No part of this document may be reproduced, stored in a retrieval

system, or transmitted in any form or any means electronic or mechanical, including

photocopying and recording, without the written permission of PSG, a Dover Company, except

as described by the terms of those agreements.

This is a non-contractual document.

Trademarks

PSG and the PSG logo are registered trademarks of PSG. Wilden®is a registered trademark of

PSG California LLC. Pro-Flo®SHIFT and Pro-Flo®are registered trademarks of PSG California

LLC. Wil-Flex®is a trademark of PSG California LLC. Saniflex™ is a trademark of PSG

California LLC.

All trademarks, names, logos and service marks (collectively “trademarks”) in this document are

registered and unregistered trademarks of their respective owners. Nothing contained in this

document should be construed as granting any license or right to use any trademark without the

prior written permission of the trademark owner.

Warranty

Each and every product manufactured by Wilden is built to meet the highest standards of

quality. Every pump is functionally tested to ensure integrity of operation. Wilden 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.

For more information, and to register your Wilden pump for warranty, please visit

https://www.psgdover.com/wilden/support/warranty-registration.

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PCMI Pump Cycle Monitor

CONTENTS

SECTION 1: Precautions – Read First! ..................................................................................................... 4

SECTION 2: How It Works .......................................................................................................................... 5

SECTION 3: Dimensional Drawing ............................................................................................................ 6

SECTION 4: Suggested Installation and Troubleshooting ..................................................................... 7

SECTION 5: Reassembly ............................................................................................................................ 9

SECTION 6: Parts List............................................................................................................................... 11

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PCMI Pump Cycle Monitor

SECTION 1

WARNING: Always wear safety glasses

when operating a pump to avoid eye injury.

If diaphragm rupture occurs, material being

pumped may be forced out of the air

exhaust.

CAUTION: Before attempting any

maintenance or repair, disconnect the

compressed air line to the pump and allow

all air pressure to bleed from the pump.

Disconnect all intake, discharge, and air

lines. Drain the pump by turning it upside

down and allowing any fluid to flow into a

suitable container. Be aware of any

hazardous effects of contact with your

process fluid.

WARNING: Do not recharge, disassemble,

crush or expose lithium power cell to

temperatures above 100°C (212°F)

CAUTION: When removing the end cap

using compressed air, the air valve end

cap may come out with considerable force.

Hand protection such as a padded glove or

rag should be used to capture the end cap.

CAUTION: Use caution when mounting the

PCMI enclosure in areas where wash

down occurs.

NOTE: The PCMI is to be used with

Wilden sensor and embedded air valve

spool magnet ONLY.

CAUTION: When adding a remote

resetting switch, ensure that 24-gauge wire

or larger is used and that the remote switch

is mounted within 250 feet of the PCMI.

CAUTION: The PCMI enclosure must be

mounted within 250 feet of the pump to

ensure proper operation.

CAUTION: Penetrating the PCMI

enclosure for mounting purposes or to

install additional wiring will negate the

NEMA 4X enclosure rating.

WARNING: This product can expose you

to chemicals including Nickel, Chromium,

Cadmium, or Cobalt, which are known to

the State of California to cause cancer

and/or birth defects or other reproductive

harm. For more information, go to

www.P65Warnings.ca.gov.

PRECAUTIONS – READ FIRST!

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PCMI Pump Cycle Monitor

SECTION 2

The PCMI counts pump cycles by sensing the presence

of the Pro-Flo

and Pro-Flo

SHIFT air valve spool. The

sensor, located at the air valve end cap, detects the

presence of a magnet located at the end of the air valve

spool. The PCMI unit registers a complete pump cycle when

the spool shifts away from the sensor and subsequently

returns to the original position. The counter resets itself to

zero automatically after reaching 100 million cycles. The

PCMI has a reset switch located on the face of the PCMI

module that can be activated to allow “on the spot” resetting

of the counter or disabled to prevent inadvertent loss

of data. The unit also has the ability to be reset from

a remote location.

WILDEN PUMP DESIGNATION SYSTEM

HOW IT WORKS

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PCMI Pump Cycle Monitor

SECTION 3

PCMI

DIMENSIONS

ITEM

METRIC

(mm)

STANDARD

(inch)

86 3.4

61 2.4

104 4.1

117 4.6

135 5.3

61 2.4

43 1.7

25 1.0

J5 DIA. 0.2 DIA.

LW0224, REV A

DIMENSIONAL DRAWING

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PCMI Pump Cycle Monitor

SECTION 4

The PCMI is designed for use with Wilden Pro-Flo

and Pro-Flo

SHIFT pump models. The PCMI unit

can be purchased as a factory installed option in the

Wilden Pro-Flo and Pro-Flo SHIFT pump or as an

accessory to be installed in existing Wilden Pro-

Flo and Pro-Flo SHIFT.

If this system is purchased with a Wilden Pump, an

air valve fitted with a sensor will already be attached

to your pump. When purchased separately, you will

have to remove the existing air valve and attach the

new air valve, which is equipped with a sensor.

To mount the PCMI enclosure, simply remove the

front cover and insert a screw into the mounting holes

located in each corner of the enclosure.

Use caution when mounting the module in a wash-

down area to minimize exposure to moisture.

Proper care should be taken not to penetrate the

PCMI enclosure, as this will invalidate the NEMA 4X

rating.

To connect the sensor wires to PCMI module, secure

wires to wire terminals 1 (COM) and 4 (LS) at the

back of the LCD display.

The wiring can be extended up to 250 feet for ease of

installation.

To enable the front panel reset button, simply connect

a wire between terminals 1 (COM) and 3 (RST EN). A

momentary switch can be connected to terminals 1

(COM) and 5 (RST) for remote reset.

SUGGESTED INSTALLATION AND TROUBLESHOOTING

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PCMI Pump Cycle Monitor

Troubleshooting

Pump is running, but the PCMI is not counting

cycles.

1. Check to make sure that the sensor wiring is

secured to the proper wiring terminals to the back

of the LCD display on the cover of the module

enclosure. The correct wiring terminals are as

follows: LS-R and 1-com.

2. Check to ensure that the sensor wiring that

connects the sensor to the PCMI module is not

cut, broken or damaged.

3. Check to ensure that the magnet located at the

top end of the air valve spool is secured to the

end cap and has not become loose.

4. Check to ensure that the pump is operating

properly and that no mechanical malfunction has

occurred.

5. Check to ensure that discharge pressure is not

greater than inlet air pressure and that discharge

piping is free from obstruction.

6. Check to ensure that the sensor is not damaged.

7. If necessary, replace lithium power cell. Replace

lithium power cell by removing back cover of LCD

display unit.

SUGGESTED INSTALLATION AND TROUBLESHOOTING

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PCMI Pump Cycle Monitor

SECTION 5

PCMI REASSEMBLY

For detailed instructions on the disassembly/reassembly of your

pump’s air valve, please refer to the pump’s manual.

If the Set Screw is removed from the Air Valve Spool and/or the

Sensor is removed from the Air Valve End Cap, reassemble the

components per the following instructions:

SET SCREW REASSEMBLY

Step 1 Step 2 Step 3

Position the Magnet on the Set Screw, as

shown above.

Apply one (1) drop of Loctite 425 Assure

Plastic Fastener Blue Threadlocker* to the

Set Screw threads.

*Loctite 425 Assure Plastic Fastener Blue

Threadlocker is a fast setting, low strength

adhesive commonly used for threadlocking

and retention where metals and plastics are

used. Assembled parts may be handled in 2

minutes. 24-hour cure is required for full

chemical/solvent resistance.

NOTE: To avoid potential damage to the

plastic components, use only Loctite 425,

as specified.

Immediately install the Set Screw into the

Air Valve Spool, positioning it flush +/- ½

turn to the face of the Spool, as shown.

REASSEMBLY

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PCMI Pump Cycle Monitor

SENSOR REASSEMBLY

Step 1 Step 2

Apply one (1) drop of Loctite 425 Assure

Plastic Fastener Blue Threadlocker* to the

Sensor threads.

*Loctite 425 Assure Plastic Fastener Blue

Threadlocker is a fast setting, low strength

adhesive commonly used for threadlocking

and retention where metals and plastics are

used. Assembled parts may be handled in 2

minutes. 24-hour cure is required for full

chemical/solvent resistance.

NOTE: To avoid potential damage to the

plastic components, use only Loctite 425,

as specified.

Immediately install the Sensor into the Air

Valve End Cap, positioning it flush +/- ½

turn to the face of the End Cap, as shown

above.

REASSEMBLY

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PCMI Pump Cycle Monitor

SECTION 6

Part

Description

Pump

Type

Part

No.

Assy, Air Valve, P1/P2, PCMI P1 & P2

01-2011-13

End

Cap,

P1/P2,

PCMI

P1 & P2

01-2333-13

Assy, Air Valve, P1/P2, PCMI P1 & P2

01-2011-20

End

Cap,

P1/P2,

PCMI

P1 & P2

01-2333-20

ASSY, AIR VALVE, PX1, PCMI PX1

01-2031-01

ASSY, AIR VALVE, PX2, PCMI PX2

02-2031-01

End

Cap,

PX1/PX2,

PCMI

PX1 & PX2

01-2343-01

Assy, Air Valve, P4/P8, PCMI P4 & P8

04-2011-13

End

Cap,

P4/P8,

PCMI

P4 & P8

04-2333-13

Assy, Air Valve, P4/P8, PCMI P4 & P8

04-2011-20

End

Cap,

P4/P8,

PCMI

P4 & P8

04-2333-20

Assy, Air Valve, P15, PCMI P15

15-2011-20

End

Cap,

P15,

PCMI

P15

15-2333-20

Assy, Air Valve, PV4-PV15,PCMI

PV4,

PV8,

PV15,

PX4,

PX8

PX15

04-2031-01

End

Cap,

PV4/PX4,

PCMI

PV4,

PV8,

PV15,

PX4,

PX8

PX15

04-2343-01

ASSY, AIR VALVE, PV4-PV15,PCMI

PV4,

PV8,

PV15,

PX4,

PX8

PX15

04-2031-03

End

Cap,

PV4/PX4,

PCMI

PV4,

PV8,

PV15,

PX4,

PX8

PX15

04-2343-03

ASSY, AIR VALVE, PX4-15, PCMI PX4, PX8 & PX15

08-2031-20

End

Cap,

P4/P8,

PCMI

PX4, PX8 & PX15

04-2333-20

ASSY, AIR VALVE, PS 4-15, PCMI PS4, PS8 & PS15

04-2038-01

End Cap, PV/PX4, PCM I PX4, PX8 & PX15

04-2343-01

ASSY, AIR VALVE, PS4, ANO PCMI PS4, PS8 & PS15

04-2038-11

End Cap, PV/PX4, PCM I PS4, PS8 & PS15

04-2343-01

Set Screw, Shcp, 1/4”-20 ALL but P15

99-6340-08

Set Screw, Shcp, 7/16”-14 P15

99-6341-08

PCMI Counter

ALL

99-8150-99

Magnet,

Round,

Ndfeb,

.200

All but P15

99-8320-99

Magnet,

Round,

Ndfeb,

.375

P15

99-8321-99

Sensor W/ 36” Leads

ALL

99-8330-99

EXPLODED VIEW AND PARTS LIST

PARTS LIST

PSG

22069 Van Buren Street

Grand Terrace, CA 92313-5651 USA

P: +1 (909) 422 -1730

psgdover.com

PSG®reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document.

WIL-19130-E-04