Dover PSG Wilden Pro-Flo P800 Series Installation guide

WIL-11251-E-03
Where InnovationFlows
EOM
ENGINEERING OPERATION
& MAINTENANCE MANUAL
P800
Bolted Plastic Pump

WIL-11251-E-03 2
P800 Bolted Plastic
Copyright
Copyright 2018 PSG®, a Dover Company. All rights reserved.
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.
Certifications

WIL-11251-E-03 3
P800 Bolted Plastic
CONTENTS
SECTION 1: Precautions – Read First! ..................................................................................................... 4
SECTION 2: Wilden Pump Designation System ...................................................................................... 5
SECTION 3: How It Works .......................................................................................................................... 6
SECTION 4: Dimensional Drawings .......................................................................................................... 7
SECTION 5: Performance ........................................................................................................................... 9
P800 Plastic Rubber-Fitted ....................................................................................................................... 9
P800 Plastic TPE-Fitted ............................................................................................................................ 9
P800 Plastic Reduced-Stroke PTFE-Fitted............................................................................................. 10
P800 Plastic Full-Stroke PTFE-Fitted ..................................................................................................... 10
Suction Lift Capability.............................................................................................................................. 11
SECTION 6: Suggested Installation, Operation, Maintenance, and Troubleshooting ....................... 12
SECTION 7: Disassembly/Reassembly................................................................................................... 15
Pump Disassembly ................................................................................................................................. 15
Air Valve Disassembly ............................................................................................................................ 19
Reassembly Hints and Tips .................................................................................................................... 22
Shaft Seal Installation ............................................................................................................................. 23
SECTION 8: Exploded View and Parts List............................................................................................. 24
SECTION 9: Elastomer Options............................................................................................................... 26

WIL-11251-E-03 4
P800 Bolted Plastic
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: Do not apply compressed air to the exhaust
port – pump will not function.
CAUTION: Do not over-lubricate air supply– excess
lubrication will reduce pump performance. Pump is pre-
lubed.
TEMPERATURE LIMITS:
A
cetal -29°C to 82°
C
-20°F to 180°F
Buna-N -12°C to 82°
C
10°F to 180°
F
Geolast
®
-40°C to 82°
C
-40°F to 180°F
Neoprene -18°C to 93°
C
0°F to 200°F
Nordel EPDM -51°C to 138°
C
-60°F to 280°F
Nylon -18°C to 93°
C
0°F to 200°F
PF
A
-7°C to 107°
C
45°F to 225°F
Polypropylene 0°C to 79°
C
32°F to 175°F
Polyurethane -12°C to 66°
C
10°F to 150°
F
PVDF -12°C to 107°
C
10°F to 225°
F
Saniflex -29°C to 104°C -20°F to 220°F
SIPD PTFE with EPDM-backed 4°C to 137°
C
40°F to 280°
F
SIPD PTFE with Neoprene-backed 4°C to 93°
C
40°F to 200°
F
PTFE* 4°C to 104°
C
40°F to 220°
F
FKM -40°C to 177°
C
-40°F to 350°
F
Wil-Fle
x
-40°C to 107°
C
-40°F to 225°
F
*4°C to 149°C (40°F to 300°F) - 13 mm (1/2") and 25 mm (1") models
only.
NOTE: Not all materials are available for all models. See “Wilden
Pump Designation System” material options for your pump.
CAUTION: When choosing pump materials, be sure to
check the temperature limits for all wetted components.
Example: FKM has a maximum limit of 177°C (350°F),
but polypropylene has a maximum limit of only 79°C
(175°F).
CAUTION: Maximum temperature limits are based on
mechanical stress only. Certain chemicals will reduce
maximum safe operating temperatures significantly.
Consult the Chemical Resistance Guide for chemical
compatibility and temperature limits.
CAUTION: All Wilden pumps are capable of passing
solids. Use a strainer on the pump intake to ensure that
the pump's rated solids capacity is not exceeded.
CAUTION: Do not exceed 8.6 bar (125 psig) air supply
pressure.
CAUTION: Do not exceed 82°C (180°F) air inlet
temperature for all models.
CAUTION: The process fluid and cleaning fluids must be
compatible chemically with all wetted pump components.
CAUTION: Thoroughly flush pumps before installing
them into process lines. Clean and/or sanitize FDA- and
USDA- approved pumps before using them.
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.
CAUTION: Before attaching the air line to the pump, blow
out the air line for 10 to 20 seconds to make sure all
pipeline debris is clear. Use an in-line air filter. A 5µ
(micron) air filter is recommended.
CAUTION: Pro-Flo pumps cannot be used in submersible
applications.
CAUTION: Before installation, tighten all hardware.
NOTE: Materials of construction and elastomer material
may influence suction lift parameters. Please refer to
“Performance” for specifics.
NOTE: When installing PTFE diaphragms, it is important
to tighten outer pistons simultaneously (turning in
opposite directions) to ensure tight fit. (See “Maximum
Torque Specifications”).
NOTE: Some PTFE-fitted pumps come standard from the
factory with expanded PTFE gaskets installed in the
diaphragm bead of the liquid chamber. PTFE gaskets
cannot be re-used.
NOTE: In the event of a power failure, close the shut-off
valve if you do not want the pump to restart when the
power returns.
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!

WIL-11251-E-03 5
P800 Bolted Plastic
SECTION 2
NOTE: Most elastomeric materials use colored dots for identification. NOTE: Not all models are available with all material options
MATERIAL CODES
MODEL
P800 = PRO-FLO
®
PLASTIC
WETTED PATH
K= PVDF
P = POLYPROPYLENE
OUTER PISTON
K = PVDF
P = POLYPROPYLENE
Z = NO OUTER PISTON
AIR CHAMBERS
P = POLYPROPYLENE
CENTER BLOCK
P = POLYPROPYLENE
AIR VALVE
P = POLYPROPYLENE
DIAPHRAGMS
BNS = BUNA-N (RED DOT)
BNU = BUNA-N, ULTRA-FLEX™
EPS = EPDM (BLUE DOT)
EPU = EPDM, ULTRA-FLEX™
FWL = FULL-STROKE SANITARY
WIL-FLEX™, IPD
[SANTOPRENE
®
(THREE
BLACK DOTS)]
FWS = SANITARY WIL-FLEX™,
[SANTOPRENE
®
(TWO BLACK DOTS)]
NES = NEOPRENE (GREEN DOT)
NEU = NEOPRENE, ULTRA-FLEX™
SSL = FULL-STROKE SANIFLEX
™
IPD [HYTREL
®
(CREAM)]
TEU = PTFE W/EPDM BACKUP
(WHITE)
TNU = PTFE W/NEOPRENE
BACKUP (WHITE)
TSS = FULL-STROKE PTFE
W/SANIFLEX™ BACK-UP
TSU = PTFE W/SANIFLEX™
BACK-UP (WHITE)
TWS = FULL-STROKE PTFE
W/WIL-FLEX™ BACKUP
VTS = FKM (WHITE DOT)
VTU = FKM, ULTRA-FLEX™
WWL = FULL-STROKE WIL-FLEX™ IPD
[SANTOPRENE
®
]
ZGS = GEOLAST
®
, EZ-INSTALL
ZPS = POLYURETHANE, EZ-INSTALL
ZSS = SANIFLEX™, EZ-INSTALL
ZWS = WIL-FLEX™, EZ-INSTALL
VALVE BALLS
BN = BUNA-N (RED DOT)
EP = EPDM (BLUE DOT)
FS = SANIFLEX™ [HYTREL
®
(CREAM)]
FW = SANITARY WIL-FLEX™
[SANTOPRENE
®
(TWO BLACK
DOTS)]
NE = NEOPRENE (GREEN DOT)
PU = POLYURETHANE (BROWN)
TF = PTFE (WHITE)
VT = FKM (SILVER OR WHITE DOT)
WF = WIL-FLEX™ [SANTOPRENE
®
(THREE BLACK DOTS)]
VALVE SEATS
K= PVDF
P =POLYPROPLYENE
VALVE SEATS & MANIFOLD
O-RING
BN = BUNA-N
TV = PTFE ENCAP, FKM
WF = WIL-FLEX™ [SANTOPRENE
®
]
SPECIALT
Y
CODES
0100 Wil - Gard II™ 110V
0102 Wil-Gard II™ sensor wires Only
0103 Wil-Gard II™ 220V
0206 PFA-coated hardware, Wil-Gard II™ sensor wires ONLY
0480 Pump Cycle Monitor (sensor & wires)
0483 Pump Cycle Monitor (module, sensor & wires)
0485 Pump Cycle Monitor (module, sensor & wires), DIN flange
0502 PFA coated hardware
0504 DIN flange
0506 DIN flange, PFA coated hardware
0604 DIN flange, Wil-Gard II™ 220V
0608 PFA-coated hardware, Wil-Gard II™ 220V
0690 Center-Ported ANSI/DIN Combo
0691 Center-Ported, ANSI/DIN combo flange,
PFA-coated fasteners
P800 PLASTIC
LEGEND P800
/
X X X X X
/
X X X
/
X X
/
X X X
/
X X X X
51 mm (2") Pump
Maximum Flow Rate:
624 lpm (165 gpm)
O-RING
MODEL VALVE SEAT SPECIALT
Y
VALVE BALL CODE
DIAPHRAGMS
AIRVALVE
CENTER BLOCK
AIR CHAMBERS
OUTER PISTON
WETTED PATHS
WILDEN PUMP DESIGNATION SYSTEM
(
if a
pp
licable
)

WIL-11251-E-03 6
P800 Bolted Plastic
SECTION 3
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show 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 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; a
balanced load removes mechanical stress from
the diaphragm. The compressed air moves the
diaphragm away from the center 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
atmosphere through the exhaust port of the
pump. The movement of diaphragm B toward the
center 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
while pulling diaphragm A to the center.
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 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.
The Pro-Flo
®
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 spool and air valve. This valve design
incorporates 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 spool directs
pressurized air to one air chamber while exhausting the other. The
air causes the main shaft/diaphragm assembly 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-OPERATED DOUBLE-DIAPHRAGM PUMP
HOW IT WORKS – AIR DISTRIBUTION SYSTEM

WIL-11251-E-03 7
P800 Bolted Plastic
SECTION 4
P800 Polypropylene Center-Ported
DIMENSIONS
ITEM
METRIC
(mm)
STANDARD (inch)
A
584 23.0
B 77 3.0
C 396 15.6
D 688 27.1
E 765 30.1
F 89 3.5
G 91 3.6
H 175 6.9
J 353 13.9
K 508 20.0
L 399 15.7
M 423 16.7
N 360 14.2
P 306 12.1
R 208 8.2
S 226 8.9
T 254 10.0
U 15 0.6
DIN / ANSI COMBO
V 121 DIA. 4.8 DIA.
W 152 DIA. 6.0 DIA.
X 21 DIA. 0.8 DIA.
LW0332 REV. A
P800 PVDF Center-Ported DIMENSIONS
ITEM
METRIC
(mm)
STANDARD (inch)
A
582 22.9
B 77 3.0
C 394 15.5
D 683 26.9
E 759 29.9
F 89 3.5
G 91 3.6
H 175 6.9
J 358 13.3
K 508 20.0
L 396 15.6
M 419 16.5
N 356 14.0
P 306 12.1
R 208 8.2
S 226 8.9
T 254 10.0
U 15 0.6
DIN / ANSI COMBO
V 121 DIA. 4.8 DIA.
W 152 DIA. 6.0 DIA.
X 21 DIA. 0.8 DIA.
DIMENSIONAL DRAWING
LW0333 REV. A
DIMENSIONAL DRAWING

WIL-11251-E-03 8
P800 Bolted Plastic
P800 Polypropylene Side-Ported
DIMENSIONS
ITEM
METRIC
(mm)
STANDARD (inch)
A
604 23.8
B 151 5.9
C 92 3.6
D 729 28.7
E 406 16.0
F 800 31.5
G 807 31.8
H 353 13.9
J 508 20.0
K 406 16.0
L 84 3.3
M 122 4.8
N 423 16.7
P 360 14.2
R 208 8.2
S 234 9.2
T 14 0.6
DIN FLANGE
U 121 DIA. 4.9 DIA.
V 165 DIA. 6.5 DIA.
W 18 DIA. 0.7 DIA.
ANSI FLANGE
U 121 DIA. 4.8 DIA.
V 152 DIA. 6.0 DIA.
W 19 DIA. 0.8 DIA.
LW0330 REV. A
P800 PVDF Side-Ported DIMENSIONS
ITEM
METRIC
(mm)
STANDARD (inch)
A
597 23.5
B 150 5.9
C 92 3.6
D 720 28.3
E 403 15.9
F 796 31.3
G 802 31.6
H 353 13.9
J 508 20.0
K 404 15.9
L 84 3.3
M 122 4.8
N 419 16.5
P 356 14.0
R 205 8.1
S 231 9.1
T 14 0.6
DIN FLANGE
U125 DIA. 4.9 DIA.
V165 DIA. 6.5 DIA.
W18 DIA. 0.7 DIA.
ANSI FLANGE
V 121 DIA. 4.8 DIA.
W 152 DIA. 6.0 DIA.
X 21 DIA. 0.8 DIA.
LW0331 REV. A

WIL-11251-E-03 9
P800 Bolted Plastic
SECTION 5
P800 PLASTIC
RUBBER-FITTED
Ship Weights.……Polypropylene 32 kg (70 lb)
PVDF 45 kg (99 lb)
Air Inlet…………..………………..13 mm (1/2")
Inlet…...……………...………………51 mm (2")
Outlet………………...………………51 mm (2")
Suction Lift….………………6.23 m Dry (18.5’)
8.65 m Wet (28.4’)
Disp. per Stroke1……..….......2.75 L (0.73 gal)
Max. Flow Rate……………624 lpm (165 gpm)
Max. Size Solids……………......6.4 mm (1/4")
1Displacement per stroke was calculated at 4.8
bar (70 psig) air inlet pressure against a 2 bar (30
psig) head pressure.
Example: To pump 246 lpm (65 gpm)
against a discharge head pressure of
2.8 bar (40 psig) requires 4.1 bar (60 psig)
and 85 Nm
3
/h (50 scfm) air consumption.
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's performance curve.
Caution: Do not exceed 8.6 bar (125 psig) air supply pressure.
P800 PLASTIC
TPE-FITTED
Ship Weights.……Polypropylene 32 kg (70 lb)
PVDF 45 kg (99 lb)
Air Inlet…………..………………..13 mm (1/2")
Inlet…...……………...………………51 mm (2")
Outlet………………...………………51 mm (2")
Suction Lift….……………..5.54 m Dry (18.16’)
8.66 m Wet (28.4’)
Disp. per Stroke1……..….......2.85 L (0.74 gal)
Max. Flow Rate……………615 lpm (162 gpm)
Max. Size Solids……………......6.4 mm (1/4")
1Displacement per stroke was calculated at 4.8
bar (70 psig) air inlet pressure against a 2 bar (30
psig) head pressure.
Example: To pump 322 lpm (85 gpm) against
a discharge head pressure of1.2 bar (17 psig)
requires 2.8 bar (40 psig) and 85 Nm3/h (50
scfm) air consumption.
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's performance curve.
Caution: Do not exceed 8.6 bar
(
125 psi
g)
air suppl
y
pressure.
PERFORMANCE

WIL-11251-E-03 10
P800 Bolted Plastic
P800 PLASTIC
FULL-STROKE
PTFE-FITTED
Ship Weights.……Polypropylene 32 kg (70 lb)
PVDF 45 kg (99 lb)
Air Inlet…………..………………..13 mm (1/2")
Inlet…...……………...………………51 mm (2")
Outlet………………...………………51 mm (2")
Suction Lift….………………..5.9 m Dry (19.5’)
9.0 m Wet (29.5’)
Disp. per Stroke1….…..............2.5 L (0.67 gal)
Max. Flow Rate……………615 lpm (162 gpm)
Max. Size Solids……………......6.4 mm (1/4")
1Displacement per stroke was calculated at 4.8
bar (70 psig) air inlet pressure against a 2.1 bar
(30 psig) head pressure.
Example: To pump 371 lpm (98 gpm)
against a discharge head of 2.8 bar
(40 psig) requires 5.5 bar (80 psig)
and 147.9 Nm3/h
(
92 scfm
)
air consumption.
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's performance curve.
Caution: Do not exceed 8.6 bar (125 psig) air supply pressure.
P800 PLASTIC
REDUCED-STROKE
PTFE-FITTED
Ship Weights.……Polypropylene 32 kg (70 lb)
PVDF 45 kg (99 lb)
Air Inlet…………..………………..13 mm (1/2")
Inlet…...……………...………………51 mm (2")
Outlet………………...………………51 mm (2")
Suction Lift….……………..4.15 m Dry (18.16’)
8.65 m Wet (28.4’)
Disp. per Stroke1….…..........1.73 L (0.457 gal)
Max. Flow Rate……………504 lpm (133 gpm)
Max. Size Solids……………......6.4 mm (1/4")
1Displacement per stroke was calculated at 4.8
bar (70 psig) air inlet pressure against a 2 bar (30
psig) head pressure.
Example: To pump 220 lpm (58 gpm)
against a discharge head pressure
of 3.4 bar (50 psig) requires 5.5 bar (80 psig)
and 128 Nm3/h
(
75 scfm
)
air consumption.
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's performance curve.
Caution: Do not exceed 8.6 bar (125 psig) air supply pressure.
PERFORMANCE