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Dover DOVER PSG WILDEN PRO-FLO XPS820 AAAAA Series Engineering Operation & Maintenance Manual Download Page 25

 

WIL-11510-E-09  

25 

PS820/830 Bolted Metal 

 

 

Model Description 

XPS820/830/ 

AAAAA/…/ 

XPS820/830/ 

WWAAA/…/ 

PS820/830/ 

WWAPP/…/ 

Item Description 

Qty. 

P/N 

P/N 

P/N 

Air Distribution Components 

1 

Air Valve Assembly, Pro-Flo Shift 

1

 1 

04-2039-01 

04-2039-20 

2 

O-Ring, End Cap (-225, Ø1.859" x Ø.139") 

2 

04-2390-52-700 

3 End 

Cap 

2 

04-2340-01 

04-2330-20-700 

4 

Screw, SHC, Air Valve (1/4"-20 x 4-1/2") 

6 

01-6000-03 

5 

Nut, Square (1/4"-20) 

6 

 

00-6505-03 

6 

Muffler Plate, Pro-Flo Shift 

1 

04-3189-01 

04-3189-20 

7 

Gasket, Muffler Plate, Pro-Flo Shift 

1 

04-3509-56 

8 

Gasket, Air Valve, Pro-Flo Shift 

1 

04-2639-56 

9 

Center Block Assembly, Pro-Flo Shift 

2,3

 1 

04-3129-01 

04-3129-20 

10 

Sleeve, Threaded, Center Block 

4 

 

04-7710-08 

11 

Pilot Sleeve Assembly 

1 

04-3880-99 

12 

O-Ring, Pilot Spool Retaining (-009, Ø.208" x Ø.070") 

2 

04-2650-49-700 

13 Seal, 

Shaft 

2 

08-3210-55-225 

14 Bushing, 

Shaft 

2 

08-3306-13 

15 

Gasket, Center Block Pro-Flo Shift 

2 

04-3529-56 

16 

Seal, Air Control Spool 

2 

04-3219-49 

17 

Air Control Spool 

1 

04-3859-03 

18 

O-ring, Air Control Spool Retaining (-114, Ø.612" x Ø.103") 

2 

04-3879-50 

19 

Air Chamber, Pro-Flo X Drop-In 

2 

08-3694-01 

20 

Screw, HSFHS (3/8"-16 x 1") 

8 

71-6250-08 

21 Retaining 

Ring 

2 

04-3890-03 

22 

Grounding Screw, (10-32 x 1/2") Self Tapping 

1 

04-6345-08 

 

23 

Bushing, Reducer 1-1/2" MNPT to 1" FNPT 

1 

 

04-6959-17 

24 Muffler 

1" 

MNPT 

1 

 

15-3514-99 

25 Muffler 

1-1/2" 

MNPT 

1 

04-3518-99R 

 

26 Muffler 

1/4" 

MNPT 

1 

04-3240-07 

Wetted Path Components 

27 

Liquid Chamber, Bolted 

2 

08-5015-01 

08-5015-02 

28 

Manifold, Discharge (NPT) 1 

08-5035-01 

08-5035-02 

  

Manifold, Discharge (BSPT) 1 

08-5036-01 

08-5036-02 

  

Manifold, Discharge (ANSI) 1 

08-5045-01 

08-5045-02 

  

Manifold, Discharge (DIN) 

1 

08-5046-01 

08-5046-02 

29 

Manifold, Inlet (NPT) 

1 

08-5095-01 

08-5095-02 

  

Manifold, Inlet (BSPT) 

1 

08-5096-01 

08-5096-02 

  

Manifold, Inlet (ANSI) 

1 

08-5125-01 

08-5125-02 

  

Manifold, Inlet (DIN) 

1 

08-5126-01 

08-5126-02 

30 

Washer, Flat (Ø.531" x Ø1.062" x .095") 

32 

04-6730-08 

31 

Screw, HHC (1/2"-13 x 1-3/4") 

16 

08-6190-08 

32 

Screw, HHC (1/2"-13 x 2") 

16 

04-6210-08 

Gaskets/Valve Balls/Valve Seats/Valve O-Rings 

33 Ball, 

Valve 

4 

* 

34 Seat, 

Valve 

4 

* 

35 

O-Ring, Valve Seat PTFE Fitted, (-347, Ø4.225 x Ø.210) (not shown) 

4 

08-1209-55 

Full Stroke Rubber/TPE/PTFE Components 

36 Shaft 

(Rubber) 

1 

08-3810-03 

  

Shaft (EZ TPE/PTFE) 

1 

08-3812-03 

37 Piston, 

Inner 

 

2 

08-3700-01 

38 Diaphragm, 

Primary 

2 

* 

  

Diaphragm, IPD Primary 

2 

* 

39 Diaphragm, 

Back-Up 

2 

* 

40 Piston, 

Outer 2 

08-4550-01 

08-4550-02 

  

  

 

 

 

LW0183 Rev. N 

* See elastomer chart - Section 9 

 

1

 Air Valve Assembly includes items 2 and 3. 

 

2

 Metal Center Block Assembly includes item 13, 14 and 16.  

 

3

 Plastic Center Block Assembly includes item 10, 13, 14 and 16.  

All boldface items are primary wear parts. 

 

 

 

EXPLODED VIEW AND PARTS LIST 

EXPLODED VIEW AND PARTS LIST 

Summary of Contents for DOVER PSG WILDEN PRO-FLO XPS820 AAAAA Series

Page 1: ...WIL 11510 E 09 Where InnovationFlows EOM ENGINEERING OPERATION MAINTENANCE MANUAL PS820 PS830 Bolted Metal Pump ...

Page 2: ...G 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 ...

Page 3: ...Rubber Fitted 9 PS820 PS830 Metal EZ Install TPE Fitted 9 PS820 PS830 Metal Full Stroke PTFE Fitted 10 Suction Lift Capability 11 SECTION 6 Suggested Installation Operation Maintenance and Troubleshooting 13 SECTION 7 Disassembly Reassembly 16 Pump Disassembly 16 Air Valve Center Section Disassembly 19 Single Point Exhaust 22 Reassembly Hints and Tips 22 SECTION 8 Exploded View and Parts List 24 S...

Page 4: ...ly with all wetted pump components 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 CAU...

Page 5: ...ALVE 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 WHITE DOT WF WIL FLEX SANTOPRENE THREE BLACK DOTS VALVE SEATS A ALUMINUM BN BUNA N RED DOT EP EPDM BLUE DOT FS SANIFLEX HYTREL CREAM FW SANITARY WIL FLEX SANTOPRENE TWO BLACK DOTS H ALLOY C M MILD STEEL NE NEOPRENE GR...

Page 6: ...ts 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 ...

Page 7: ...27 1 M 324 12 8 N 257 10 1 P 229 9 0 R 254 10 0 S 14 0 6 LW0238 REV C PS830 METAL DIMENSIONS ITEM METRIC mm STANDARD inch A 452 17 8 B 89 3 5 C 400 15 7 D 675 26 6 E 752 29 6 F 758 29 8 G 116 4 6 H 117 4 6 J 387 15 3 K 48 1 9 L 177 7 0 M 366 14 4 N 687 27 1 P 324 12 8 R 254 10 0 S 326 12 8 T 378 14 9 U 16 0 6 DIN mm ANSI Inch V 165 DIA 6 0 DIA W 125 DIA 4 8 DIA X 18 DIA 0 8 DIA LW0239 REV C DIMENS...

Page 8: ...687 27 0 N 679 26 8 P 305 12 0 R 254 10 0 S 229 9 0 LW0240 REV B PS830 STAINLESS STEEL DIMENSIONS ITEM METRIC mm STANDARD inch A 452 17 8 B 89 3 5 C 424 16 7 D 678 26 7 E 754 29 7 F 760 29 9 G 116 4 6 H 115 4 5 J 412 16 2 K 48 1 9 L 177 7 0 M 361 14 2 N 361 14 2 P 677 27 1 R 682 26 9 S 304 12 0 T 254 10 0 U 325 12 8 DIN mm ANSI Inch X 165 DIA 6 0 DIA Y 125 DIA 4 8 DIA Z 18 DIA 0 8 DIA LW0241 REV B...

Page 9: ... will fall in the center of the pump s performance curve Caution Do not exceed 8 6 bar 125 psig air supply pressure PS820 PS830 METAL EZ INSTALL TPE FITTED Ship Weight 820 Threaded AL 47 kg 104 lb 820 Threaded SS 73 kg 161 lb 820 Threaded Iron 71 kg 156 lb 830 Flanged AL 54 kg 118 lb 830 Flanged SS 81 kg 178 lb 830 Flanged Iron 82 kg 181 lb Air Inlet 3 4 Inlet 51 mm 2 Outlet 51 mm 2 Suction Lift 6...

Page 10: ...m Dry 21 8 Iron 9 0 m Wet 29 5 Iron Disp per Stroke1 2 4 L 0 63 gal AL 2 4 L 0 63 gal SS 2 5 L 0 65 gal Iron Max Flow Rate 655 lpm 173 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 326 lpm 86 gpm against a discharge head of 2 8 bar 40 psig requires 5 5 bar 80 psig and 102 Nm3 h 60...

Page 11: ...n atmospheric pressure and pipe friction loss all affect the amount of suction lift your pump will attain PS820 PS830 STAINLESS STEEL SUCTION LIFT CAPABILITY Suction lift curves are calibrated for pumps operating at 305 m 1 000 above sea level This chart is meant to be a guide only There are many variables that can affect your pump s operating characteristics The number of intake and discharge elb...

Page 12: ...05 m 1 000 above sea level This chart is meant to be a guide only There are many variables that can affect your pump s operating characteristics The number of intake and discharge elbows viscosity of pumping fluid elevation atmospheric pressure and pipe friction loss all affect the amount of suction lift your pump will attain SUCTION LIFT CAPABILITY ...

Page 13: ...d then multiplying that figure by the displacement per stroke Muffler Using the standard Wilden muffler sound levels are reduced below OSHA specifications You can use other mufflers to reduce sound levels farther but they usually reduce pump performance Elevation Selecting a site that is well within the pump s dynamic lift capability will assure that loss of prime issues will be eliminated In addi...

Page 14: ...used to regulate volume Pump discharge rate also can be controlled by throttling the pump discharge by partially closing a valve in the discharge line of the pump This action increases friction loss which reduces flow rate See Performance This is useful when the need exists to control the pump from a remote location When the pump discharge pressure equals or exceeds the air supply pressure the pum...

Page 15: ...o be unable to shift Pump runs but little or no product flows 1 Check for pump cavitation Slow pump speed down to allow thick material to flow into liquid chambers 2 Verify that vacuum required to lift liquid is not greater than the vapor pressure of the material being pumped cavitation 3 Check for sticking ball check valves a If material being pumped is not compatible with pump elastomers swellin...

Page 16: ...container Be aware of any hazardous effects of contact with your process fluid NOTE Your specific pump model may vary from the configuration shown however pump disassembly procedure will be the same NOTE Replace worn parts with genuine Wilden parts for reliable performance Step 1 Step 2 Step 3 Before starting disassembly mark a line from each liquid chamber to its corresponding air chamber This li...

Page 17: ...old to expose the valve balls and valve seats Inspect ball cage area of manifold for excessive wear or damage Step 7 Step 8 Step 9 Remove the inlet valve balls and valve seats from the inlet manifold and liquid chambers and inspect for nicks gouges chemical attack or abrasive wear Replace worn parts with genuine Wilden parts for reliable performance Using the appropriate sized wrench remove the li...

Page 18: ...with genuine Wilden parts for reliable performance To remove the diaphragm assembly from shaft secure shaft with soft jaws aluminum plastic or plywood to ensure the shaft is not damaged Using an adjustable wrench remove the diaphragm assembly from the shaft Remove outer piston and stud if equipped Inspect for wear and replace if necessary DISASSEMBLY REASSEMBLY ...

Page 19: ...ur process fluid NOTE Replace worn parts with genuine Wilden parts for reliable performance Step 1 Step 2 Step 3 Using a pair of snap ring pliers remove the snap ring from the pilot sleeve Using an O ring pick remove the O ring from modulator spool Using the appropriate sized wrench loosen and remove the fasteners that attach the air chamber to the center section Step 4 Step 5 Step 6 Lift the air ...

Page 20: ...r to the spool or O rings and replace if necessary Using the appropriate sized wrench loosen the fasteners and lift away remaining air chamber and center block gasket from center section Replace gasket if necessary Step 10 Step 11 Step 12 Using an O ring pick remove the two 2 shaft bushings from center block Inspect and replace if necessary Using an O ring pick gently remove the two 2 Glyd rings f...

Page 21: ...n the end cap using an O ring pick Replace the O ring s if necessary NOTE The Pro Flo SHIFT air valve incorporates an end cap at both ends of the air valve Step 15 Remove the air valve spool from the air valve body by threading one air valve bolt into the end of the air valve spool and gently sliding the spool out of the air valve body Inspect seals for signs of wear and replace the entire air val...

Page 22: ...rocess Lubricate the air valve bore center section shaft and pilot spool bore with NLGI grade 2 white EP bearing grease or equivalent Clean the inside of the center section shaft bore to ensure no damage is done to new shaft seals A small amount of NLGI grade 2 white EP bearing grease can be applied to the muffler and air valve gaskets to lubricate gaskets during assembly Make sure that the exhaus...

Page 23: ...5 With the seal clamped in the pliers insert the seal into the busing bore and position the bottom of the seal into the correct groove When the bottom of the seal is seated in the groove release the clamp pressure on the pliers This will allow the seal to partially snap back to its original shape 6 After removing the pliers you will notice a slight bump in the seal shape Before the seal can be res...

Page 24: ... 24 PS820 830 Bolted Metal SECTION 8 PS820 PS830 METAL LW0182 REV G ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS EXPLODED VIEW AND PARTS LIST FULL STROKE PTFE FULL STROKE IPD FLANGED METAL ADS PLASTIC ADS ...

Page 25: ...Reducer 1 1 2 MNPT to 1 FNPT 1 04 6959 17 24 Muffler 1 MNPT 1 15 3514 99 25 Muffler 1 1 2 MNPT 1 04 3518 99R 26 Muffler 1 4 MNPT 1 04 3240 07 Wetted Path Components 27 Liquid Chamber Bolted 2 08 5015 01 08 5015 02 28 Manifold Discharge NPT 1 08 5035 01 08 5035 02 Manifold Discharge BSPT 1 08 5036 01 08 5036 02 Manifold Discharge ANSI 1 08 5045 01 08 5045 02 Manifold Discharge DIN 1 08 5046 01 08 5...

Page 26: ...RS ARE INCLUDED IN REPAIR KITS 38 38 29 30 36 37 28 33 34 30 32 28 29 40 39 38 36 37 31 30 36 19 10 20 21 40 27 37 31 12 11 8 1 3 25 4 6 7 16 15 2 2 18 17 14 13 26 9 12 15 11 5 8 1 22 3 23 4 24 6 7 16 18 17 14 13 26 9 FULL STROKE PTFE FULL STROKE IPD FLANGED METAL ADS PLASTIC ADS EXPLODED VIEW AND PARTS LIST ...

Page 27: ...rounding Screw 10 32 x 1 2 Self Tapping 1 04 6345 08 04 6345 08 23 Bushing Reducer 1 1 2 MNPT to 1 FNPT 1 04 6959 17 24 Muffler 1 MNPT 1 15 3514 99 25 Muffler 1 1 2 MNPT 1 04 3518 99R 04 3513 99 26 Muffler 1 4 MNPT 1 04 3240 07 Wetted Path Components 27 Liquid Chamber Bolted 2 08 5015 03 28 Manifold Discharge NPT 1 08 5035 03 Manifold Discharge BSPT 1 08 5036 03 Manifold Discharge ANSI 1 08 5045 0...

Page 28: ...8 58 Aluminum 08 1129 01 Mild Steel 08 1129 08 Stainless Steel 08 1129 03 LW0183 Rev O 1 Used in conjunction with metallic valve seat PS820 PS830 STAINLESS STEEL MATERIAL DIAPHRAGM 2 FULL STROKE DIAPHRAGMS 2 FULL STROKE BACK UP DIAPHRAGMS 2 EZ INSTALL DIAPHRAGMS 2 FULL STROKE IPD DIAPHRAGMS 2 VALVE BALLS 4 VALVE SEATS 4 VALVE SEAT O RING 4 Polyurethane 08 1022 50 08 1080 50 08 1128 50 Neoprene 08 ...

Page 29: ...WIL 11510 E 09 29 PS820 830 Bolted Metal NOTES ...

Page 30: ...WIL 11510 E 09 30 PS820 830 Bolted Metal NOTES ...

Page 31: ...WIL 11510 E 09 31 PS820 830 Bolted Metal NOTES ...

Page 32: ... USA P 1 909 422 1730 psgdover com Copyright 2021 PSG a Dover Company PSG reserves the right to modify the information and illustrations contained in this document without prior notice This is a non contractual document WIL 11510 E 09 Where InnovationFlows ...

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