Dover Wilden WG Series Instruction Manual

WIL-19050-E-01
WG
W IL-1 9 05 0 - E - 0 2
TO REPLACE WIL-19050-E-01
Advance your process
Engineering
Operation &
Maintenance
Leak Detector

WILDEN PUMP & ENGINEERING 2 WIL-19050-E-02
SENSOR CABLE SPECIFICATIONS
CROSS SECTION OF SENSOR CABLE
Care should be used during the
installation process to protect the
sensor from being exposed to
fluid, or from fluid being trapped
between the diaphragms.
1. The location of the sensor
wire ends shall be between the outer PTFE dia-
phragms and the inner back-up diaphragms on
both sides of unit being assembled.
2. The sensor wire end should be 1/3 of the way
between the outer edge and the center hole of
the diaphragm. (Note: See chart [below right] for
precise measurement.)
3. Sensor wire ends shall be inserted to the 6:00
position and channeled out of the unit to the 3:00
position on the air valve side.
To ensure proper sealing and operation, torque outer
pistons to proper specification. The wires should be
routed straight down and along the outside of the
liquid chamber under the clamp band. Refer to illus-
tration (Figure 1). Refer to pump operation and main-
tenance manual for usage of expanded PTFE gasket
material to seal between PTFE primary diaphragm
and liquid chamber.
A
S
U
P
M
U
P
N
E
D
L
I
W
#
T
R
A
P
.
H
P
A
I
D
P
U
K
C
A
B
SIDE VIEW OF PUMP
Figure 1
The sensor cables utilize high Beryllium content
ultra fine strand copper wire to remain sensitive
even when subjected to millions of pump strokes in
a dynamic environment. PTFE and PFA materials
are used for insulation, binder, and jacket to provide
exceptional chemical resistance.
Conductivity Threshold: 75 micro-Siemens
Length of sensor cables: 36” (0.91m)
Length of extension cords: 100’ (30.48m)
(See page 6)
Connectors: Sealed. Housed in
composite material —
Ultem®
VIRGIN PTFE
TAPE WRAP
HIGH BERYLLIUM CONTENT
ULTRA FINE STRAND COPPER WIRE
PFA
INSULATION
PFA
JACKET
Sensor Wire Insertion Chart
Pump Size Inches
13 mm (½) ....... 1”
25 mm (1”) ....... 1 1/4”
38 mm (1½”) ...... 1 1/2”
51 mm (2”) ....... 2”
76 mm (3”) ....... 2 1/3”
102 mm (4”) ...... 2 1/3”
INSTALLATION OF SENSOR CABLE

WIL-19050-E-02 3 WILDEN PUMP & ENGINEERING
INSTALLATION
The Wil-Gard™ III is designed for use with Wilden
two-piece diaphragms that use a primary and backup
diaphragm on each side of the pump. The system
cannot be used with single-piece rubber or thermo-
plastic primary diaphragms that do not have a backup
diaphragm. This unit can be purchased as a factory
installed option in the Wilden pump or as an acces-
sory to be installed in existing pumps. The NEMA 4X
enclosure is constructed of Polycarbonate with stain-
less steel screws, nylon cable grip, and polycarbonate
label.
The Wil-Gard™ III can be powered by a variety of
electrical sources by using the supplied power adap-
tors (100-240 VAC, 50/60 Hz).
The control module is splash resistant, but should be
mounted in a dry, safe, accessible location. Upon com-
pletion of installation, verify the integrity of all connec-
tions. Cable grip, lid, and all wiring connections should
be secure to assure proper operation.
The Wil-Gard™ III system alone is designed to detect
diaphragm failure. However, with the addition of a
few electric components, it is simple to use the detec-
tion features of the module to actively intervene when
diaphragm failure occurs. In most applications, the
internal relay (2 amp, 125 volts max.) is used to direct
power to a solenoid valve installed on the pump air
inlet, which suspends pump operation when failure
occurs. In some situations, it is appropriate to isolate
the inlet and discharge piping from the pump to pre-
vent product contamination or product containment.
The sensors should be protected from fluids prior to
and during installation. If the sensor comes into con-
tact with a fluid prior to installation it may not perform
as designed. Please refer to page 2 for the installation
of the diaphragm and sensor cable.
CAUTION: Do not expose sensor to fluids before
sensor is installed in pump.
Sensors cannot be reused. Back-up diaphragms and
sensor cables must be replaced when primary dia-
phragm failure occurs.

WILDEN PUMP & ENGINEERING 4 WIL-19050-E-02
INSTALLATION OF SENSOR
RECEPTACLE AND EXTENSION CORDS
Once the sensor cables have been installed within the pump as discussed on page
1, they must be connected to the control module via the sensor receptacle which is
factory installed. The sensor cables are connected to the sensor receptacle by simply
inserting the in-line plug into the receptacle, aligning the key notch, and turning the
connector clockwise one-half turn until a click is heard.
If the sensor cables extending from the pump are not long enough to reach the
control module, the user can lengthen the wiring with a 100’ (30.48m) extension
cord(s) available from Wilden. These extension cords utilize the same connectors
as the sensor cable and receptacle for compatibility and ease of use (see Fig. 2). In
lieu of the Wilden extension cords, the user may supply his own wire (AWG 24) up to
500 feet (152m). It is critical that the Wilden sensor cable is installed in the pump for
proper operation.
It is important that all wiring connections are waterproof and secure. It may be
necessary to run all wiring through conduit. The cable grip located on the bottom of
the control module should be tightened so that the penetration is resistant to liquid
intrusion.
INSTALLATION OF EXTERNAL
COMPONENTS TO INTERNAL RELAY
There is a single-pole, double-throw (SPDT) relay on the control module circuit board.
The relay is provided so that external components can be controlled by the module.
External wiring can be connected to this relay through the screw terminals on the
edge of the circuit board. The relay is energized and the common (COM.) pole is
connected to the normally open (N.O.) pole when the module is energized and a
diaphragm failure is not detected. When an alarm occurs or power is lost, the relay
is de-energized and the common (COM.) pole is connected to the normally closed
(N.C.) pole. The relay rating is 2 Amps at 125 Volts. Therefore, to attach more than
one component or a large inductive load, it may be necessary to use the internal
relay to drive an external multi-pole relay which can handle more components and/or
higher amperage (See Fig. 3).
Figure 2

WIL-19050-E-02 5 WILDEN PUMP & ENGINEERING
N/O
C
C
N/C
N/O
N/C
C
N/C
C
N/C
C
N/O
N/C
C C C
N/O N/C
N/C N/O
N/C N/O
N/C
N/O
C
N/O
N/O
ALARM INITIATION • RELAY CLOSURE • COMPONENT ACTIVATION
Figure 3

WILDEN PUMP & ENGINEERING 6 WIL-19050-E-02
CONDUCTIVE LIQUIDS — AN OVERVIEW
MODEL NUMBER, OPTIONAL AND
REPLACEMENT PARTS
WIL-GARD™ III KIT: 65-8115-99
Kit includes:
Wil-Gard™ III Control Module 65-8015-99
Wil-Gard™ III Conductive Sensor Cables 65-8020-99
Replacement Parts
Wil-Gard™ III Control Module 65-8015-99
Wil-Gard™ III Conductive Sensor Cables 65-8020-99
Optional Parts
100’ PE Extension w/In-Line Receptacle & Plug 65-8080-99
Liquids that conduct an electrical charge are said
to be conductive. Conductive liquids may contain a
percentage of water and are usually inorganic. For
example, acids and caustics are typically conduc-
tive, whereas solvents and hydrocarbons in 100%
concentration are typically non-conductive.
The introduction of a conductive liquid such as ordi-
nary water will introduce conductivity to non-con-
ductive liquids. For any given non-conductive liquid,
it is not possible to predict the volume of conductive
media which must be added to result in a con-
ductive liquid. Therefore, a conductivity test must
be performed to verify that the Wil-Gard™ III will
detect the process fluid upon diaphragm failure.
The test for conductivity can be performed in two
ways:
1) Contact your authorized Wilden distributor
for an on-site review. In this event, the actual
sensor cable of the Wil-Gard™ III is dipped
into the process fluid in question, to determine
whether the conductivity of the process fluid is
sufficient for detection.
2) A conductivity meter can be utilized to mea-
sure the conductivity of the process fluid. The
Wil-Gard™ III will detect any fluid that has a
conductivity of more than 75 micro-Siemens.
TROUBLESHOOTING
Audible alarm, LED and relay do not activate upon
diaphragm failure.
• 6” wire receptacle is not connected correctly to
the control module terminal block.
• Sensor wires (P/N 65-8020-99), 6” recep tacle
and/or the extension cords are crushed or bro-
ken.
• Verify the integrity of the 4 pin connector.
• Verify the sensor wire placement within the pump.
• Check the sensor for contamination; sensors can-
not be reused.
Wil-Gard™ III functioned correctly upon diaphragm
failure, not noticed by personnel.
• Install external alarm system to internal relay.
• Install solenoid valve to provide active inter vention
upon diaphragm failure.
• Utilize latching, external relay to ensure inter-
vention.
Unit is alarming, but diaphragm has not failed.
• Verify the torque specification of the outer piston.
• Verify the torque specification of the clamp bands.
• Verify that new expanded PTFE gasket kit on liq-
uid chambers was utilized upon installation.
• Check the ends of the sensor wire to ensure that
the two copper conductors are not touching. In
some cases, it may be desirable to remove a 0.5”
(13mm) portion of the jacket and tape wrap and
separate the two conductors by a small distance
to prevent inadvertent contact.

NOTES:

Your Local Authorized Distributor:
Printed in the U.S.A.
Copyright 2011, Wilden Pump & Engineering, LLC
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