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Dover PSG ALL-FLO A150, Installation, Operation & Maintenance Manual

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Dover PSG ALL-FLO A150 Installation, Operation & Maintenance Manual Download Page 2

ALF-12060-E-01

All-Flo

2

TABLE OF 

CONTENTS

SECTION 1 

WARNINGS, DANGERS AND CAUTIONS 

3

SECTION 2 

MODEL DESIGNATION MATRIX & REPAIR KITS 

4-6

SECTION 3 

PRINCIPLES OF OPERATION 

7

SECTION 4 

DIMENSIONAL DRAWINGS 

8-9

SECTION 5 

PERFORMANCE CURVES (RUBBER, TPE, & PTFE)

 

1-1/2” DISCHARGE PORTS ...................................10

 

1-1/4” TOP DISCHARGE PORT ........................... 11

SECTION 6 

INSTALLATION

 INSTALLATION................................................... 12-13

 TROUBLESHOOTING .............................................. 14

 OPERATION .................................................................15

 MAINTENANCE 

 ........................................................15

SECTION 7 

REPAIR AND ASSEMBLY

 

PUMP WET END REMOVAL .........................16-17

 

AIR VALVE REMOVAL ..................................... 18-19

 

PILOT VALVE REMOVAL .............................. 20-21

 

TORQUE SPECIFICATION CHART ......................21

SECTION 8 

EXPLODED VIEWS & PARTS LIST

 

THREADED ALUMINUM AND STAINLESS      

 

STEEL FULL STROKE .................................. 22-24

 

THREADED ALUMINUM AND STAINLESS      

 

STEEL PTFE SHORT STROKE ...................25-27

 

FLANGED STAINLESS STEEL FULL STROKE 

 

 ..................................................................................28-30

 

FLANGED STAINLESS STEEL PTFE SHORT   

 STROKE .................................................................31-33

SECTION 9 

ELASTOMERS 

34

SECTION 10 

ATEX PROTECTION SUMMARY 

35

SECTION 11 

WARRANTY AND REGISTRATION 

37

Summary of Contents for PSG ALL-FLO A150

Page 1: ...IOM INSTALLATION OPERATION MAINTENANCE A150 METAL 1 1 2 INCH AIR OPERATED DOUBLE DIAPHRAGM PUMP ...

Page 2: ...ION 12 13 TROUBLESHOOTING 14 OPERATION 15 MAINTENANCE 15 SECTION 7 REPAIR AND ASSEMBLY PUMP WET END REMOVAL 16 17 AIR VALVE REMOVAL 18 19 PILOT VALVE REMOVAL 20 21 TORQUE SPECIFICATION CHART 21 SECTION 8 EXPLODED VIEWS PARTS LIST THREADED ALUMINUM AND STAINLESS STEEL FULL STROKE 22 24 THREADED ALUMINUM AND STAINLESS STEEL PTFE SHORT STROKE 25 27 FLANGED STAINLESS STEEL FULL STROKE 28 30 FLANGED ST...

Page 3: ... to 70 C T6 Polypropylene 32 F to 180 F 0 C to 82 C T6 PVDF 0 F to 250 F 18 C to 121 C T4 Nylon 0 F to 200 F 18 C to 93 C T6 Temperature limits are solely based upon mechanical stress and certain chemicals will reduce the maximum operating temperature The allowable temperature range for the process fluid is determined by the materials in contact with the fluid being pumped Consult a chemical resis...

Page 4: ...Top 1 1 4 H Suction Center Rear Discharge Top 1 1 4 M Suction Right Discharge Top 1 1 4 W Suction Left Discharge Top 1 1 4 SPECIAL OPTION HARDWARE MUFFLER LUG 3 Standard Zinc Plated Hardware Plastic Muffler 4 Zinc Plated Steel Hardware Metal Muffler 7 Stainless Steel Hardware Plastic Muffler 8 Stainless Steel Hardware Metal Muffler B PTFE Coated Stainless Steel Hardware Plastic Muffler C PTFE Coat...

Page 5: ...Discharge Center Rear X Suction Left Discharge Right Y Suction Left Discharge Left C Suction Center Front Discharge Top 1 1 4 H Suction Center Rear Discharge Top 1 1 4 M Suction Right Discharge Top 1 1 4 W Suction Left Discharge Top 1 1 4 SPECIAL OPTION HARDWARE MUFFLER LUG 7 Standard Stainless Steel Hardware Plastic Muffler 8 Stainless Steel Hardware Metal Muffler B PTFE Coated Stainless Steel Ha...

Page 6: ...of 2 diaphragms back up diaphragms if required 4 balls 4 seats and 4 seat O rings See matrix below 1 2 6 7 9 10 AIR SECTION A Aluminum 3 Stainless Steel Bold indicates recommended options AIR END REPAIR KIT Air end repair kit contains pilot sleeve assembly and main air valve D I A P H R A G M O R I N G S P R O D U C T S E R I E S W E T E N D R E P A I R K I T P U M P S I Z E M A T E R I A L A A K ...

Page 7: ...and draws liquid into the left side chamber The air valve directs pressurized air behind the left diaphragm causing the left diaphragm to move outward to the left Since both the left diaphragm and the right diaphragm are connected via a diaphragm rod when the left diaphragm moves to the left the right diaphragm through the action of the diaphragm rod moves to the left also When the diaphragm on th...

Page 8: ... FBSPT 20 8 528mm 2 5 64mm 10 4 264mm 15 4 391mm 0 6 15mm 7 0 178mm 11 1 282mm 8 8 224mm ALUMINUM 5 3 135mm STAINLESS STEEL 6 0 152mm 4 0 102mm 1 8 46mm 5 8 147mm 10 7 272mm 11 2 284mm 17 3 439mm 1 6 41mm 0 5 13mm 11 4 290mm 20 8 528mm 2 5 64mm 10 4 264mm 15 4 391mm 0 6 15mm 7 0 78mm 11 1 282mm 8 8 224mm ALUMINUM 5 3 135mm STAINLESS STEEL 6 0 152mm 4 0 102mm 1 8 46mm 5 8 147mm 10 7 272mm 11 2 284m...

Page 9: ...FNPT 8 8 224mm 6 0 152mm 7 0 178mm 10 6 269mm 3 1 79mm 12 6 320mm 20 9 531mm 18 8 478mm 3 2 81mm 23 9 607mm 10 7 272mm 11 2 284mm 1 8 46mm 5 8 147mm 4 0 102mm 0 6 15mm 8 8 224mm 6 0 152mm 7 0 178mm 10 6 269mm 3 1 79mm 12 6 320mm 0 9 1mm 18 8 478mm 3 2 81mm 23 9 607mm 10 7 272mm 11 2 284mm 1 8 46mm 5 8 147mm 4 0 102mm 0 6 15mm SECTION 4 1 1 4 11 5 FNPT Exhaust Port 3 4 14 FNPT Air Inlet ...

Page 10: ... Performance Specifications Max Flow 115 gpm 435 lpm Max Air Pressure 120 psi 8 3 bar Max Solids 1 4 6 4 mm Max Suction Lift Dry 22 ft H2O 6 7 m H2O Max Suction Lift Wet 31 ft H2O 9 4 m H2O Weight Threaded AL 45 lbs 20 kg SS 70 lbs 32 kg Weight Flanged SS 84 lbs 38 kg Air Inlet 3 4 FNPT Liquid Inlet 1 1 2 FNPT 1 1 2 FBSPT or ANSI DIN Flanged Liquid Outlet 1 1 2 FNPT 1 1 2 FBSPT or ANSI DIN Flanged...

Page 11: ...3 439 mm Threaded Width 20 8 528 mm Threaded Depth 11 2 284 mm Threaded Performance Specifications Max Flow 105 gpm 398 lpm Max Air Pressure 120 psi 8 3 bar Max Solids 1 4 6 4 mm Max Suction Lift Dry 22 ft H2O 6 7 m H2O Max Suction Lift Wet 31 ft H2O 9 4 m H2O Weight Threaded AL 45 lbs 20 kg SS 70 lbs 32 kg Air Inlet 3 4 FNPT Liquid Inlet 1 1 2 FNPT 1 1 2 FBSPT Liquid Outlet 1 1 4 FNPT 1 1 2 FBSPT...

Page 12: ...ation it is recommended to pipe the exhaust air above the liquid source In the event of a diaphragm failure this will reduce or eliminate the possibility of liquid discharging through the exhaust onto the ground LOCATION Ensure that the pump is installed in an accessible location in order to facilitate future service and maintenance AIR Ensure that the air supply is sufficient for the volume of ai...

Page 13: ...ALF 12060 E 01 All Flo 13 6 SECTION SUGGESTED INSTALLATION This illustration is a generic representation of an air operated double diaphragm pump ...

Page 14: ...ainer clogged Suction valve closed Suction line plugged No liquid in the suction tank Suction lift excessive Debris stuck in valves Excessive wear of check valves Air leak on suction side with suction lift Pump Cycles with Closed Discharge Valve Debris stuck in check valve Excessive wear of check valves Pump Running Slowly Not Steady Air compressor undersized Leak in air supply Air line filter reg...

Page 15: ...tion valve restrict the suction line and may cause damage to the diaphragms Suction strainers may be employed to reduce or eliminate larger solids but routine maintenance is necessary in order to prevent a restriction on the suction SECTION 6 MAINTENANCE Due to the unique nature of each application periodic inspection of the pump is the best method to determine a proper maintenance schedule A reco...

Page 16: ... and fluid lines are closed and disconnected While wearing personal protective equipment flush drain and process liquid from the pump in a safe manner WARNING Maintenance must not be performed when a hazardous atmosphere is present WARNING For pump models with non metallic manifolds air valves or chambers When the relative humidity in the surrounding atmosphere is above 30 the equipment must not b...

Page 17: ...Inner Diaphragm Plate and Nut from one side of the pump Flat 3 4 wrench may be used on flat of diaphragm rod to assist in diaphragm removal STEP 10 Placing the 1 inch wrench on the Outer Diaphragm Plate and the 1 1 16 inch socket on the Nut remove the Inner Diaphragm Plate STEP 11 Remove Inner Diaphragm Plate and Outer Diaphragm Plate from Diaphragm PUMP WET END ASSEMBLY To assemble the wet end of...

Page 18: ...drain and process liquid from the pump in a safe manner WARNING Maintenance must not be performed when a hazardous atmosphere is present WARNING For pump models with non metallic manifolds air valves or chambers When the relative humidity in the surrounding atmosphere is above 30 the equipment must not be touched by personnel unless first wiped down with a damp cloth STEP 4 Remove the Shuttle Plat...

Page 19: ...ing assembly ensure that the open side of the lip seals are both facing each other inward Install the shuttle plate with the smooth shinny side toward the shuttle car Lubrication of the air valve assembly with a non synthetic lubricant is recommended Magna Lube or Magna Plate are recommended for assembly lubrication see detailed parts list for ordering information Note that if the lip seals are in...

Page 20: ... and disconnected While wearing personal protective equipment flush drain and process liquid from the pump in a safe manner WARNING Maintenance must not be performed when a hazardous atmosphere is present WARNING For pump models with non metallic manifolds air valves or chambers When the relative humidity in the surrounding atmosphere is above 30 the equipment must not be touched by personnel unle...

Page 21: ...non synthetic lubricant is recommended in order to facilitate re assembly into the intermediate Magna Lube or Magna Plate are recommended for assembly lubrication see detailed parts list for ordering information TORQUE SPECIFICATION CHART RECOMMENDED TORQUE SPECIFICATIONS 1 1 2 Pumps Wrench Size Manifold Bolts 30 ft lbs 40 7 N m 9 16 Chamber Bolts 15 ft lbs 20 3 N m 9 16 Air Valve Bolts 40 in lbs ...

Page 22: ...ALF 12060 E 01 All Flo 22 EXPLODED VIEW PARTS LIST THREADED ALUMINUM STAINLESS STEEL FULL STROKE A150 SECTION 8 ...

Page 23: ... non PTFE Models 35003 00 Stainless Steel FULL STROKE 80 VALVE SLEEVE 1 All Models 10107 31 Δ Acetal 100 INNER SPACER PILOT SLEEVE 3 All Models 10205 40 Δ Polypropylene 110 O RING PILOT SLEEVE 4 All Models 11919 16 Δ Urethane 120 END SPACER PILOT SLEEVE 2 All Models 10208 40 Δ Polypropylene 130 O RING END SPACER 2 All Models 11919 11 Δ Nitrile 140 LIP SEAL DIAPHRAGM ROD 2 All Models 12002 76 Δ Nit...

Page 24: ...tainless Steel 353 SCREW HEX HEAD CAP 3 8 16 X 1 3 4 28 A150 A 0 12581 25 Plated Steel A150 3 0 12581 26 Stainless Steel 361 NUT FLANGE 3 8 16 28 A150 A 0 12612 25 Plated Steel A150 3 0 12612 26 Stainless Steel 362 NUT 5 8 11 2 All Models 12579 25 Plated Steel 371 WASHER LOCK 1 4 4 A150 A 0 12350 25 Plated Steel A150 3 0 12350 26 Stainless Steel 372 WASHER SPLIT LOCK 3 8 28 A150 A 0 12316 25 Plate...

Page 25: ...ALF 12060 E 01 All Flo 25 THREADED ALUMINUM STAINLESS STEEL PTFE SHORT STROKE A150 T ...

Page 26: ...HORT STROKE 80 VALVE SLEEVE 1 All Models 10107 31 Δ Acetal 100 INNER SPACER PILOT SLEEVE 3 All Models 10205 40 Δ Polypropylene 110 O RING PILOT SLEEVE 4 All Models 11919 16 Δ Urethane 120 END SPACER PILOT SLEEVE 2 All Models 10208 40 Δ Polypropylene 130 O RING END SPACER 2 All Models 11919 11 Δ Nitrile 140 LIP SEAL DIAPHRAGM ROD 2 All Models 12002 76 Δ Nitrile 150 RETAINING PLATE 2 All Models 1271...

Page 27: ...50 A 0 12536 25 Plated Steel A150 3 0 12536 26 Stainless Steel 353 SCREW HEX HEAD CAP 3 8 16 X 1 3 4 28 A150 A 0 12581 25 Plated Steel A150 3 0 12581 26 Stainless Steel 361 NUT FLANGE 3 8 16 28 A150 A 0 12612 25 Plated Steel A150 3 0 12612 26 Stainless Steel 362 NUT 5 8 11 2 All Models 12579 25 Plated Steel 371 WASHER LOCK 1 4 4 A150 A 0 12350 25 Plated Steel A150 3 0 12350 26 Stainless Steel 372 ...

Page 28: ... FLANGED STAINLESS STEEL FULL STROKE A150 F 3 A150 FA3 ASS 100 120 70 250 240 270 180 50 170 210 260 300 290 230 381 371 351 340 200 362 361 353 150 280 110 130 140 220 40 20 10 80 311 312 30 160 90 63 320 383 382 372 352 61 62 ...

Page 29: ...E 1 All Models 10107 31 Δ Acetal 100 INNER SPACER PILOT SLEEVE 3 All Models 10205 40 Δ Polypropylene 110 O RING PILOT SLEEVE 4 All Models 11919 16 Δ Urethane 120 END SPACER PILOT SLEEVE 2 All Models 10208 40 Δ Polypropylene 130 O RING END SPACER 2 All Models 11919 11 Δ Nitrile 140 LIP SEAL DIAPHRAGM ROD 2 All Models 12002 76 Δ Nitrile 150 RETAINING PLATE 2 All Models 12717 54 Nylon 160 BUMPER 2 Al...

Page 30: ... 8 16 X 1 3 4 28 A150 3 0 12581 26 Stainless Steel 361 NUT FLANGE 3 8 16 28 A150 3 0 12612 26 Stainless Steel 362 NUT 5 8 11 2 All Models 12579 25 Plated Steel 371 WASHER LOCK 1 4 4 A150 3 0 12350 26 Stainless Steel 372 WASHER SPLIT LOCK 3 8 28 A150 3 0 12316 26 Stainless Steel 381 WASHER FLAT 1 4 4 A150 3 0 12300 26 Stainless Steel 382 FLAT WASHER 5 16 10 A150 3 0 12310 26 Stainless Steel 383 WAS...

Page 31: ...ALF 12060 E 01 All Flo 31 FLANGED STAINLESS STEEL PTFE SHORT STROKE A150 F 3 T ...

Page 32: ... 4 All Models 11919 16 Δ Urethane 120 END SPACER PILOT SLEEVE 2 All Models 10208 40 Δ Polypropylene 130 O RING END SPACER 2 All Models 11919 11 Δ Nitrile 140 LIP SEAL DIAPHRAGM ROD 2 All Models 12002 76 Δ Nitrile 150 RETAINING PLATE 2 All Models 12717 54 Nylon 160 BUMPER 2 All Models 12317 16 Urethane 170 INNER DIAPHRAGM PLATE SHORT STROKE 2 A150 A T 11114 20 Aluminum PTFE MODELS ONLY A150 33 T 11...

Page 33: ... NUT 5 8 11 2 All Models 12579 25 Plated Steel 371 WASHER LOCK 1 4 4 A150 3 0 12350 26 Stainless Steel 372 WASHER SPLIT LOCK 3 8 28 A150 3 0 12316 26 Stainless Steel 381 WASHER FLAT 1 4 4 A150 3 0 12300 26 Stainless Steel 382 FLAT WASHER 5 16 10 A150 3 0 12310 26 Stainless Steel 383 WASHER 3 8 28 A150 3 0 12303 26 Stainless Steel 390 N A 400 GROUNDING LUG NOT SHOWN 1 Optional 13481 20 Aluminum Mag...

Page 34: ...mperature range 10 F to 180 F 12 C to 82 C EPDM is a general purpose elastomer with good resistance to many acids and bases Temperature range 40 F to 280 F 40 C to 138 C SANTOPRENE is an injection molded material with characteristics similar to EPDM Has excellent abrasion resistance Temperature range 40 F to 225 F 40 C to 107 C PTFE POLYTETRAFLUOROETHYLENE is a thermoplastic polymer that is inert ...

Page 35: ... air valve assembly and prevents overheating The equipment cannot run without compressed air Hot Surface Insulation effects due to dust layering Due to no heat rise during normal operation there is no additional heat rise due to dust layering Testing shows equipment has no heat rise during normal operation Flames and Hot Gases Overheating of non metallic materials The maximum allowed temperature f...

Page 36: ...complies with the relevant requirements of the following standards BS EN ISO 12100 2010 BS EN 809 2009 and BS EN 12162 2009 The ATEX Directive 2014 34 EU Annex II and complies with the relevant requirements of the following standards EN ISO 80079 36 2016 and EN ISO 80079 37 2016 All Flo pumps meet the following ATEX ratings II 3 GD Ex h IIC T6 T3 Gb Ex h IIIC T85 C T157 C Db or 20 C Ta 40 C ...

Page 37: ...NTIES WHETHER EXPRESS IMPLIED OR ORAL INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND ANY IMPLIED WARRANTIES OTHERWISE ARISING FROM A COURSE OF DEALING OR TRADE All Flo will not in ANY event be liable for any loss of profit interruption of business or any other special consequential or incidental damages suffered or sustained by Custom...

Page 38: ...designing and manufacturing the highest quality product available to industry Since the beginning in 1986 All Flo engineers have used their extensive knowledge of today s engineered materials advanced air system logic and manufacturing techniques to develop the superior group of lube free air operated diaphragm pumps found in this catalog Every pump is performance engineered and quality built to p...

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