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Dover PSG Wilden PS1500, Manual

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Dover PSG Wilden PS1500 Manual Download Page 28

 

WIL-13001-E-01  

28 

ALLOY C PUMPS 

Model Description

 

XPS800/HHAAA/ XPS800/HHSSS/ 

Item Description 

Qty. 

P/N 

P/N 

Air Distribution Components 

1 

Air Valve Assembly, Pro-Flo Shift™ 

1

 1 

04-2039-01 

04-2039-03 

2 

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

2 

04-2390-52-700 

3 End 

Cap 

2 

04-2340-01 

04-2340-03 

4 

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

6 

01-6000-03 

5 

Muffler Plate, Pro-Flo Shift™ 

1 

04-3189-01 

04-3189-03 

6 

Gasket, Muffler Plate, Pro-Flo Shift™ 

1 

04-3509-56 

7 

Gasket, Air Valve, Pro-Flo Shift™ 

1 

04-2639-56 

8 

Center Block Assembly, Pro-Flo Shift™ 

2

 1 

04-3129-01 

04-3129-03 

9 

Pilot Sleeve Assembly 

1 

04-3880-99 

10 

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

2 

04-2650-49-700 

11 Seal, 

Shaft 

2 

08-3210-55-225 

12 Bushing, 

Shaft 

2 

08-3306-13 

13 

Gasket, Center Block Pro-Flo V™ 

2 

04-3529-56 

14 

Seal, Air Control Spool 

2 

04-3219-49 

15 

Air Control Spool 

1 

04-3859-03 

16 

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

2 

04-3879-50 

17 

Air Chamber, Pro-Flo V™ 2 

08-3690-01 

08-3690-03 

18 

Screw, HSFHS (3/8"-16 x 1") 

8 

71-6250-08 

71-6250-03 

19 Retaining 

Ring 

2 

04-3890-03 

20 

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

1 

04-6345-08 

21 Muffler 

1-1/2" 

MNPT 

1 

04-3518-99R 

04-3513-99 

22 Muffler 

1/4" 

MNPT 

1 

04-3240-07 

Wetted Path Components 

23 

Liquid Chamber, Bolted 

2 

08-5000-04-40 

24 

Manifold, Discharge (ANSI) 

1 

08-5020-04-42 

  

Manifold, Discharge (DIN) 

1 

08-5020-04-43 

25 

Manifold, Inlet (ANSI) 

1 

08-5080-04-42 

  

Manifold, Inlet (DIN) 

1 

08-5080-04-43 

26 

Screw, HHC (3/8"-16 x 1-3/4") 

28 

04-6181-03 

27 

Washer, Flat (Ø.390" x Ø.625" x .063") 

28 

02-6730-03 

28 

Washer,  Belleville (Ø.380" x Ø.750" x .056") 

28 

08-6820-03-42 

29 

Hex Nut (3/8"-16) 

28 

02-6430-03 

30 

Screw, HHC (5/16"-18 x 1") 

32 

08-6180-03-42 

31 

Washer, Flat (Ø.328" x Ø.562" x .063") 

32 

08-6730-03-42 

32 

Washer,  Belleville (Ø.317" x Ø.625" x .047") 

32 

08-6810-03-42 

33 

Hex Nut (5/16"-18) 

32 

08-6400-03 

Valve Balls/Valve Seats/Valve O-Rings 

34 Ball, 

Valve 

4 

* 

35 Seat, 

Valve 

4 

* 

36 

O-Ring, Valve Seat, PTFE Fitted (-334, Ø2.600 x Ø.210) 

4 

08-1200-55 

Full Stroke Rubber/TPE/PTFE Components 

37 Shaft 

(Rubber) 

1 

08-3810-03 

  

Shaft (PTFE) 

1 

08-3812-03 

38 Piston, 

Inner 

 

2 

08-3700-01 

08-3700-03 

39 Diaphragm, 

Primary 

2 

* 

40 Diaphragm, 

Back-Up 

2 

* 

41 Piston, 

Outer 2 

08-4550-04 

  

 

  

 

LW0505 Rev. A

 

 

* See elastomer chart - Section 9 

 

1

 Air Valve Assembly includes items 2 and 3. 

 

2

 Metal Center Block Assembly includes item 11, 12, and 14.  

All boldface items are primary wear parts. 

 

 

 

EXPLODED VIEW AND PARTS LIST 

EXPLODED VIEW AND PARTS LIST 

Summary of Contents for PSG Wilden PS1500

Page 1: ...WIL 13001 E 01 Where InnovationFlows EOM ENGINEERING OPERATION MAINTENANCE MANUAL PS400 PS800 and PS1500 Advanced Metal Alloy C Pump ...

Page 2: ...lifornia 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 perm...

Page 3: ...PS800 ALLOY C Rubber Fitted 10 PS800 ALLOY C Full Stroke PTFE Fitted 10 PS1500 ALLOY C Rubber Fitted 11 PS1500 ALLOY C Full Stroke PTFE Fitted 11 Suction Lift Capability 12 SECTION 6 Suggested Installation Operation Maintenance and Troubleshooting 14 SECTION 7 Disassembly Reassembly 17 Pump Disassembly 17 Air Valve Center Section Disassembly 20 Single Point Exhaust 23 Reassembly Hints and Tips 23 ...

Page 4: ...e 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 Before attempting any maintenance or repair disconnect the compressed air line to the pump and allo...

Page 5: ... VT FKM WHITE DOT VALVE SEAT O RING TF PTFE SPECIALTY CODES 0100 Wil Gard 110V 0102 Wil Gard sensor wires ONLY 0103 Wil Gard 220V 0320 Single Point Exhaust 0480 Pump Cycle Monitor sensor wires 0483 Pump Cycle Monitor module sensor wires 0485 Pump Cycle Monitor module sensor wires DIN flange 0504 DIN flange NOTE Most elastomeric materials use colored dots for identification NOTE Not all models are ...

Page 6: ...eat 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...

Page 7: ... 8 0 T 11 0 4 DIN DN 40 ANSI 150 U 150 DIA 5 0 DIA V 110 DIA 3 8 DIA W 18 DIA 0 6 DIA LW0230 REV D PS800 ALLOY C DIMENSIONS ITEM METRIC mm STANDARD inch A 432 17 0 B 89 3 5 C 407 16 1 D 678 26 7 E 754 29 7 F 760 29 9 G 117 4 6 H 398 15 7 J 48 1 9 K 161 6 4 L 350 13 8 M 344 13 6 N 671 26 4 P 664 26 2 R 330 13 0 S 254 10 0 T 325 12 8 U 378 14 9 V 15 0 6 DIN DN 40 ANSI 150 W 165 DIA 6 0 DIA X 125 DIA...

Page 8: ...4 2 C 445 17 5 D 795 31 3 E 892 35 1 F 89 3 5 G 91 3 6 H 433 17 1 J 48 1 9 K 211 8 3 L 189 7 4 M 184 7 3 N 719 28 3 P 714 28 1 R 356 14 0 S 305 12 0 T 257 10 1 U 279 11 0 V 15 0 6 DIN DN 40 ANSI 150 W 200 DIA 7 5 DIA X 160 DIA 6 0 DIA Y 18 DIA 0 8 DIA LW0257 REV D DIMENSIONAL DRAWING DIMENSIONAL DRAWING ...

Page 9: ... fall in the center of the pump s performance curve Caution Do not exceed 8 6 bar 125 psig air supply pressure PS400 ALLOY C FULL STROKE PTFE FITTED Ship Weight Alloy C 45 kg 100 lb Air Inlet 3 4 Inlet 38 mm 1 1 2 Outlet 38 mm 1 1 2 Suction Lift 6 7 m Dry 22 1 8 6 m Wet 28 4 Disp per Stroke1 0 9 L 0 25 gal Max Flow Rate 348 lpm 92 gpm Max Size Solids 4 8 mm 3 16 1Displacement per stroke was calcul...

Page 10: ...all in the center of the pump s performance curve Caution Do not exceed 8 6 bar 125 psig air supply pressure PS800 ALLOY C RUBBER FITTED Ship Weight Alloy C 107 kg 236 lb Air Inlet 3 4 Inlet 51 mm 2 Outlet 51 mm 2 Suction Lift 6 4 m Dry 21 0 8 6 m Wet 28 4 Disp per Stroke1 2 6 L 0 69 gal Max Flow Rate 647 lpm 171 gpm Max Size Solids 6 4 mm 1 4 1Displacement per stroke was calculated at 4 8 bar 70 ...

Page 11: ...s will fall in the center of the pump s performance curve Caution Do not exceed 8 6 bar 125 psig air supply pressure PS1500 ALLOY C RUBBER FITTED Ship Weight Alloy C 130 kg 287 lb Air Inlet 3 4 Inlet 76 mm 3 Outlet 76 mm 3 Suction Lift 6 4 m Dry 21 0 8 6 m Wet 28 4 Disp per Stroke1 5 3 L 1 39 gal Max Flow Rate 939 lpm 248 gpm Max Size Solids 9 5 mm 3 8 1Displacement per stroke was calculated at 4 ...

Page 12: ... atmospheric pressure and pipe friction loss all affect the amount of suction lift your pump will attain PS800 ALLOY C 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 elbows viscosity o...

Page 13: ... 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 14: ...en 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 addition...

Page 15: ... 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 pump wi...

Page 16: ... 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 swelling ma...

Page 17: ... 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 line will assi...

Page 18: ...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 liquid...

Page 19: ...erformance Inner piston hardware location and fastener type may vary Use an appropriately sized socket wrench to disassemble the diaphragm assembly if replacement is necessary Step 13 Step 14 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 R...

Page 20: ...ocess 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 chamb...

Page 21: ...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 from t...

Page 22: ... 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 valve as...

Page 23: ... 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 exhaust port on the muffler plate is cent...

Page 24: ...th 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 resized...

Page 25: ...WIL 13001 E 01 25 ALLOY C PUMPS SECTION 8 PS400 ALLOY C LW0502 REV B ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS EXPLODED VIEW AND PARTS LIST ...

Page 26: ...rounding Screw 10 32 x 1 2 Self Tapping 1 04 6345 08 21 Muffler 1 MNPT 1 15 3510 99R 15 3513 99 22 Bushing Reducer 1 1 2 MNPT to 1 FNPT 2 04 6959 08 04 6959 03 23 Muffler 1 4 MNPT 1 04 3240 07 Wetted Path Components 24 Liquid Chamber 2 04 5000 04 42 25 Manifold Discharge ANSI 1 04 5020 04 42 Manifold Discharge DIN 1 04 5020 04 43 26 Manifold Inlet ANSI 1 04 5080 04 42 Manifold Inlet DIN 1 04 5080 ...

Page 27: ...WIL 13001 E 01 27 ALLOY C PUMPS PS800 ALLOY C LW0504 REV B ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS EXPLODED VIEW AND PARTS LIST ...

Page 28: ...ping 1 04 6345 08 21 Muffler 1 1 2 MNPT 1 04 3518 99R 04 3513 99 22 Muffler 1 4 MNPT 1 04 3240 07 Wetted Path Components 23 Liquid Chamber Bolted 2 08 5000 04 40 24 Manifold Discharge ANSI 1 08 5020 04 42 Manifold Discharge DIN 1 08 5020 04 43 25 Manifold Inlet ANSI 1 08 5080 04 42 Manifold Inlet DIN 1 08 5080 04 43 26 Screw HHC 3 8 16 x 1 3 4 28 04 6181 03 27 Washer Flat Ø 390 x Ø 625 x 063 28 02...

Page 29: ...WIL 13001 E 01 29 ALLOY C PUMPS PS1500 ALLOY C LW0506 REV B ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS EXPLODED VIEW AND PARTS LIST ...

Page 30: ...5 6740 08 50 04 6740 03 22 Retaining Ring 2 04 3890 03 23 Grounding Screw 10 32 x 1 2 Self Tapping 1 04 6345 08 26 Muffler 1 1 2 MNPT 1 04 3518 99R 04 3513 99 27 Muffler 1 4 MNPT 1 04 3240 07 Wetted Path Components 28 Liquid Chamber Bolted 2 15 5005 04 29 Manifold Discharge ANSI 1 15 5030 04 Manifold Discharge DIN 1 15 5031 04 30 Manifold Inlet ANSI 1 15 5090 04 Manifold Inlet DIN 1 15 5091 04 31 ...

Page 31: ...FULL STROKE BACK UP DIAPHRAGMS 2 VALVE BALLS 4 VALVE SEATS 4 VALVE SEAT O RING 4 FKM 08 1010 53 08 1080 53 08 1120 53 PTFE 08 1040 55 42 08 1080 55 08 1200 55 1 Saniflex 08 1065 56 FDA Wil Flex 08 1065 57 Alloy C 08 1121 04 1 Used in conjunction with metallic valve seat LW0505 Rev A PS1500 ALLOY C MATERIAL DIAPHRAGM 2 FULL STROKE DIAPHRAGMS 2 FULL STROKE BACK UP DIAPHRAGMS 2 VALVE BALLS 4 VALVE SE...

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 13001 E 01 Where InnovationFlows ...

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