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Dover PSG ALL-FLO F200 Series, Installation Operation & Maintenance

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Dover PSG ALL-FLO F200 Series Installation Operation & Maintenance Download Page 2

ALF-13080-E-01

All-Flo

2

TABLE OF 

CONTENTS

SECTION 1 

WARNINGS, DANGERS AND CAUTIONS 

3

SECTION 2 

MODEL DESIGNATION MATRIX & REPAIR KITS 

4

SECTION 3 

PRINCIPLES OF OPERATION 

5

SECTION 4 

DIMENSIONAL DRAWINGS 

6

SECTION 5 

PERFORMANCE CURVES

 

RUBBER DIAPHRAGMS ..........................................7

 

TPE DIAPHRAGMS ....................................................7

 

PTFE DIAPHRAGMS ..................................................7

SECTION 6 

INSTALLATION

 INSTALLATION....................................................... 8-9

 TROUBLESHOOTING ...............................................10

 OPERATION ................................................................. 11

 MAINTENANCE 

 ........................................................ 11

SECTION 7 

REPAIR AND ASSEMBLY

 

PUMP WET END REMOVAL ........................ 12-13

 

AIR VALVE REMOVAL .....................................14-15

 

PILOT VALVE REMOVAL ................................16-17

 

TORQUE SPECIFICATION CHART ......................17

SECTION 8 

EXPLODED VIEW AND PARTS LIST 

18-20 

SECTION 9 

ELASTOMERS 

21

SECTION 10 

ATEX PROTECTION SUMMARY 

22

SECTION 11 

WARRANTY AND REGISTRATION 

24

Summary of Contents for PSG ALL-FLO F200 Series

Page 1: ...IOM INSTALLATION OPERATION MAINTENANCE F200 2 INCH FDA AIR OPERATED DOUBLE DIAPHRAGM PUMP ...

Page 2: ...VES RUBBER DIAPHRAGMS 7 TPE DIAPHRAGMS 7 PTFE DIAPHRAGMS 7 SECTION 6 INSTALLATION INSTALLATION 8 9 TROUBLESHOOTING 10 OPERATION 11 MAINTENANCE 11 SECTION 7 REPAIR AND ASSEMBLY PUMP WET END REMOVAL 12 13 AIR VALVE REMOVAL 14 15 PILOT VALVE REMOVAL 16 17 TORQUE SPECIFICATION CHART 17 SECTION 8 EXPLODED VIEW AND PARTS LIST 18 20 SECTION 9 ELASTOMERS 21 SECTION 10 ATEX PROTECTION SUMMARY 22 SECTION 11...

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: ...elow 1 2 5 7 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 F A K 2 0 0 2 P R O D U C T S E R I E S P U M P S I Z E A I R E N D R E P A I R K I T 3 4 V A L V E V ...

Page 5: ...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 the left sid...

Page 6: ...m 13 5 343mm 4 0 102mm 1 8 46mm 5 4 137mm SECTION 4 2 1 2 3 047 O D Tri Clamp Sanitary Flange x2 Note Suction Discharge right are default ports See part number matrix option code for additional porting options Note A reducer bushing is included with the standard muffler which reduces the port to 3 4 14 FNPT 3 4 14 FNPT Air Inlet 1 1 4 11 5 FNPT Exhaust Port ...

Page 7: ...T Liquid Inlet 2 1 2 Tri Clamp Liquid Outlet 2 1 2 Tri Clamp Height 25 9 658 mm Width 20 5 521 mm Depth 13 5 343 mm Performance Specifications Max Flow 190 gpm 719 lpm Max Air Pressure 120 psi 8 3 bar Max Solids 1 4 6 4 mm Max Suction Lift Dry 24 4 ft H2O 7 4 m H2O Max Suction Lift Wet 31 7 ft H2O 9 7 m H2O Weight 115 lbs 52 kg Air Inlet 3 4 FNPT Liquid Inlet 2 1 2 Tri Clamp Liquid Outlet 2 1 2 Tr...

Page 8: ...tion 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 air...

Page 9: ...ALF 13080 E 01 All Flo 9 6 SECTION SUGGESTED INSTALLATION This illustration is a generic representation of an air operated double diaphragm pump ...

Page 10: ...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 11: ...d suction 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 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 record sh...

Page 12: ...nsure that the air and fluid lines are closed and disconnected While wearing personal protective equip ment flush drain and process liquid from the pump in a safe manner WARNING Maintenance must not be performed when a hazardous atmo sphere 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 ...

Page 13: ...hes remove Outer Diaphragm Plate Diaphragm Inner Diaphragm Plate and Nut from one side of the pump 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 the pump reverse the order of disassembl...

Page 14: ...drain and process liquid from the pump in a safe manner WARNING Maintenance must not be performed when a hazardous atmo sphere 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 Pla...

Page 15: ... of disassembly During 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 t...

Page 16: ...losed and disconnected While wearing personal protective equip ment flush drain and process liquid from the pump in a safe manner WARNING Maintenance must not be performed when a hazardous atmo sphere 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 personn...

Page 17: ... with a 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 2 Pumps Wrench Size Manifold Bolts 37 ft lbs 50 2 N m 3 4 Chamber Bolts 15 ft lbs 20 3 N m 3 4 Air Valve Bolts 40 in lb...

Page 18: ...IAPHRAGM PLATE A200 220 11338 75 1 SUCTION MANIFOLD TRI CLAMP SANITAR 230 12124 19 1 GASKET AIR VALVE A150 A200 240 10450 77 1 SHUTTLE PLATE 250 10430 00 1 SHUTTLE 260 11618 20 1 AIR VALVE BODY A150 A200 270 10483 31 1 AIR VALVE SPOOL A150 A200 280 12003 76 2 8500 SERIES U CUP 1 250 ID X 1 562 OD X 290 11913 11 1 O RING 918 1 355 ID X 1 587 OD X 116 300 11706 20 1 END PLUG AIR VALVE 310 13001 00 1...

Page 19: ...ll 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 2 F200 TAE 11113 20 Aluminum F200 T3E 11113 26 Stainless Steel 180 DIAPHRAGM BACKUP 2 F200 T E H 10611 18 Hytrel F200 T E 4 10611 80 Santoprene FDA F200 T 3 T B UP 10611 80 Santoprene FDA 190 OVERLAY DIAPHRAGM 2 F200 T 3 T ONLY 11408 59 PTFE 200 210 OUTER...

Page 20: ...less Steel 382 WASHER FLAT 1 4 4 All Models 12300 26 Stainless Steel 383 WASHER FLAT 5 16 10 All Models 12310 26 Stainless Steel 384 WASHER LOCK SPLIT 1 2 28 All Models 12323 26 Stainless Steel 385 WASHER FLAT 1 2 28 All Models 12306 26 Stainless Steel 390 N A 400 N A Magnalube 75 oz As Required ALL MODELS 13404 00 Grease Any Character Δ Only sold as part of assembly PILOT VALVE ASSEMBLY All Model...

Page 21: ...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 22: ... 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 23: ...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 24: ...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 25: ...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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