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

Metal 1-1/2 inch air-operated double-diaphragm pump
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INSTALLATION OPERATION
& MAINTENANCE
A150
METAL 1-1/2 INCH
AIR-OPERATED DOUBLE-DIAPHRAGM PUMP

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Summary of Contents for Dover PSG ALL-FLO A150

  • Page 1 INSTALLATION OPERATION & MAINTENANCE A150 METAL 1-1/2 INCH AIR-OPERATED DOUBLE-DIAPHRAGM PUMP...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 WARNINGS, DANGERS AND CAUTIONS SECTION 2 MODEL DESIGNATION MATRIX & REPAIR KITS SECTION 3 PRINCIPLES OF OPERATION SECTION 4 DIMENSIONAL DRAWINGS SECTION 5 PERFORMANCE CURVES (RUBBER, TPE, & PTFE) 1-1/2” DISCHARGE PORTS ........10 1-1/4” TOP DISCHARGE PORT ......11 SECTION 6 INSTALLATION INSTALLATION...........

  • Page 3: Warnings, Dangers And Cautions

    SECTION CAUTIONS — READ FIRST! READ THESE WARNINGS AND SAFETY PRECAUTIONS PRIOR TO WARNING = Hazards or unsafe practices which INSTALLATION OR OPERATION. FAILURE TO COMPLY WITH THESE could result in severe personal injury, INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND OR death or substantial property damage PROPERTY DAMAGE.

  • Page 4: Model Designation Matrix & Repair Kits

    SECTION MODEL DESIGNATION MATRIX & REPAIR KITS - THREADED ALUMINUM FLUID CONNECTION TYPE VALVE SEAT SPECIAL OPTION (HARDWARE, MUFFLER, LUG) N = NPT P = Polypropylene 3 = Standard (Zinc Plated Hardware, Plastic Muffler) 4 = Zinc Plated Steel Hardware, Metal Muffler B = BSPT Y = Nylon A = Aluminum...
  • Page 5 SECTION MODEL DESIGNATION MATRIX & REPAIR KITS - THREADED STAINLESS STEEL FLUID CONNECTION TYPE VALVE SEAT SPECIAL OPTION (HARDWARE, MUFFLER, LUG) N = NPT 3 = Stainless Steel 7 = Standard (Stainless Steel Hardware, Plastic Muffler) A = Aluminum B = BSPT 8 = Stainless Steel Hardware, Metal Muffler P = Polypropylene B = PTFE Coated Stainless Steel Hardware,...
  • Page 6 SECTION MODEL DESIGNATION MATRIX & REPAIR KITS - FLANGED STAINLESS STEEL FLUID CONNECTION TYPE VALVE SEAT SPECIAL OPTION (HARDWARE, MUFFLER, LUG) F = ANSI/DIN Flange 3 = Stainless Steel 7 = Standard (Stainless Steel Hardware, Plastic Muffler) P = Polypropylene AIR SECTION 8 = Stainless Steel Hardware, Metal Muffler Y = Nylon...

  • Page 7: Principles Of Operation

    SECTION PRINCIPLES OF OPERATION HOW AN AIR OPERATED DOUBLE DIAPHRAGM PUMP WORKS The air-valve directs pressurized air behind the diaphragm on the right, causing the diaphragm on the right to move outward (to the right). Since both the right diaphragm and the left diaphragm are connected via a diaphragm rod, when the right diaphragm moves to the right, the left diaphragm (through the action of the diaphragm rod) moves to the right also.

  • Page 8: Dimensional Drawings

    SECTION PUMP DIMENSIONS THREADED ALUMINUM & STAINLESS STEEL 1.6” (41mm) 1.6” (41mm) 3/4”-14 FNPT (Air Inlet) 17.3” (439mm) 15.4” (391mm) 17.3” (439mm) 15.4” (391mm) 10.4” (264mm) 10.4” (264mm) 2.5” (64mm) 2.5” (64mm) 0.5” (13mm) 10.7” (272mm) 11.4” (290mm) 0.5” (13mm) 11.2”...
  • Page 9 SECTION PUMP DIMENSIONS FLANGED STAINLESS STEEL 3.2” 3.2” (81mm) (81mm) 3/4”-14 FNPT (Air Inlet) 23.9” (607mm) 23.9” (607mm) 20.9” (531mm) 0.9” 1mm) 12.6” (320mm) 12.6” (320mm) 3.1” (79mm) 3.1” (79mm) 18.8” (478mm) 18.8” (478mm) 10.7” (272mm) 0.6” (15mm) 10.7” (272mm) 11.2”...

  • Page 10: Performance Curves (Rubber, Tpe, & Ptfe)

    SECTION PERFORMANCE CURVES 1-1/2” DISCHARGE PORTS PERFORMANCE CURVE (1-1/2” RUBBER)* Performance Specifications Max. Flow: 115 gpm (435 lpm) Max. Air Pressure: 120 psi (8.3 bar) AIR CONSUMPTION (SCFM) Max. Solids: 1/4” (6.4 mm) Max. Suction Lift Dry: 22 ft-H O (6.7 m-H Max.

  • Page 11: 1-1/4" Top Discharge Port

    SECTION PERFORMANCE CURVES 1-1/4” TOP DISCHARGE PORT PERFORMANCE CURVE (1-1/4” RUBBER)* Performance Specifications Max. Flow: 105 gpm (398 lpm) Max. Air Pressure: 120 psi (8.3 bar) AIR CONSUMPTION (SCFM) Max. Solids: 1/4” (6.4 mm) Max. Suction Lift Dry: 22 ft-H O (6.7 m-H Max.

  • Page 12: Installation

    SECTION INSTALLATION, TROUBLESHOOTING AND MAINTENANCE INSTALLATION Ensure that the air supply is sufficient for the PIPING volume of air required by the pump. Refer to product specifications for further details. For reliable Whenever possible ensure the pump is installed using operation, install a 5 micron air filter, air-valve and the shortest possible pipe lengths with the minimum pressure regulator.
  • Page 13 SECTION SUGGESTED INSTALLATION This illustration is a generic representation of an air operated double-diaphragm pump. ALF-12060-E-01 All-Flo...

  • Page 14: Troubleshooting

    SECTION TROUBLESHOOTING PROBLEM EFFECT/SOLUTION Pump Will Not Cycle Discharge line closed or plugged Discharge filter blocked Check valve stuck Air filter blocked Air supply valve closed Air supply hooked up to muffler side of pump Compressor not producing air or turned off Muffler iced or blinded Diaphragm ruptured Air line in plant air supply lines ruptured...

  • Page 15: Operation

    SECTION OPERATION MAINTENANCE The Air-Operated Double Diaphragm Pump requires Due to the unique nature of each application, periodic a minimum of 20 psig of air to operate, with some inspection of the pump is the best method to determine variation according to diaphragm material. Increasing a proper maintenance schedule.

  • Page 16: Repair And Assembly

    SECTION REPAIR AND ASSEMBLY PUMP WET END REMOVAL WARNING TOOLS NEEDED Prior to servicing the pump, ensure that the air and fluid lines are closed and disconnected. While wearing personal 1) Two Wrenches, 9/16 Inch protective equipment, flush, drain and process liquid from the pump 2) Two Wrenches, 1 Inch in a safe manner.
  • Page 17 SECTION STEP 7 STEP 8 STEP 9 In order to remove both “Outer Remove both “Outer Chambers” Using two 1 inch wrenches, Chambers” use two 9/16 inch from the “Intermediate.” remove “Outer Diaphragm Plate”, wrenches. Remove ten “Hex- “Diaphragm”, “Inner Diaphragm Head Cap Screws (3/8”-16x1- Plate”...

  • Page 18: Air Valve Removal

    SECTION REPAIR AND ASSEMBLY AIR VALVE REMOVAL WARNING TOOLS NEEDED Prior to servicing the pump, ensure that the air and fluid lines are closed and disconnected. While wearing personal 1) One Wrench, 7/16 Inch protective equipment, flush, drain and process liquid from the pump 2) One Pick, General Purpose in a safe manner.
  • Page 19 SECTION STEP 7 STEP 8 STEP 9 Remove the “Air Valve Spool” from Using the pick, remove the “Lip Using the pick, remove the the main “Air-Valve Assembly”. Seal (Air Valve)” from the main second “Lip Seal (Air Valve)” from “Air-Valve Assembly”.

  • Page 20: Pilot Valve Removal

    SECTION REPAIR AND ASSEMBLY PILOT VALVE REMOVAL WARNING TOOLS NEEDED Prior to servicing the pump, ensure that the air and fluid lines are closed and disconnected. While wearing personal 1) One Screwdriver, Phillips #2 protective equipment, flush, drain and process liquid from the pump 2) Two Wrenches, 3/4 Inch in a safe manner.

  • Page 21: Torque Specification Chart

    SECTION PILOT VALVE ASSEMBLY To assemble the pilot valve, reverse the order of disassembly. Should process fluid have contact with the pilot valve O-rings, they should be replaced as swelling may occur and cause irregular operation. During assembly, ensure that the open side of the lip-seals are facing outward. Lubrication of the pilot sleeve assembly, with a non-synthetic lubricant, is recommended in order to facilitate re-assembly into the intermediate.

  • Page 22: Threaded Aluminum And Stainless Steel Full Stroke

    SECTION EXPLODED VIEW & PARTS LIST THREADED ALUMINUM & STAINLESS STEEL FULL STROKE, A150-***-****-*** ALF-12060-E-01 All-Flo...
  • Page 23 PARTS LIST - THREADED ALUMINUM & STAINLESS STEEL FULL STROKE, A150-***-****-*** ITEM DESCRIPTION PUMP MODEL PART NO. MATERIAL DISCHARGE MANIFOLD - THREADED A150-N*A-****-*** 11332-20-NPT Aluminum A150-N*3-****-*** 11332-26-NPT Stainless Steel A150-B*A-****-*** 11332-20-BSPT Aluminum A150-B*3-****-*** 11332-26-BSPT Stainless Steel BALL A150-***-*V**-*** 11010-13 † A150-***-*E**-*** 11010-15 †...
  • Page 24 PARTS LIST - THREADED ALUMINUM & STAINLESS STEEL FULL STROKE, A150-***-****-*** ITEM DESCRIPTION PUMP MODEL PART NO. MATERIAL AIR VALVE BODY A150-*A*-****-*** 11618-20 ‡ Aluminum A150-*33-****-*** 11618-26 ‡ Stainless Steel AIR VALVE SPOOL All Models 10483-31 ‡ Acetal LIP SEAL (AIR VALVE) All Models 12003-76 ‡...

  • Page 25: Threaded Aluminum And Stainless Steel Ptfe Short Stroke

    THREADED ALUMINUM & STAINLESS STEEL PTFE SHORT STROKE, A150-***-T***-*** ALF-12060-E-01 All-Flo...
  • Page 26 SECTION PARTS LIST - THREADED ALUMINUM & STAINLESS STEEL PTFE SHORT STROKE, A150-***-T***-*** ITEM DESCRIPTION QTY PUMP MODEL PART NO. MATERIAL DISCHARGE MANIFOLD - THREADED A150-N*A-****-*** 11332-20-NPT Aluminum A150-N*3-****-*** 11332-26-NPT Stainless Steel A150-B*A-****-*** 11332-20-BSPT Aluminum A150-B*3-****-*** 11332-26-BSPT Stainless Steel BALL A150-***-*V**-*** 11010-13 †...
  • Page 27 PARTS LIST - THREADED ALUMINUM & STAINLESS STEEL PTFE SHORT STROKE, A150-***-T***-*** ITEM DESCRIPTION PUMP MODEL PART NO. MATERIAL LIP SEAL (AIR VALVE) All Models 12003-76 ‡ Nitrile O-RING (AIR VALVE END PLUG) All Models 11913-11 ‡ Nitrile AIR VALVE END PLUG A150-*A*-****-*** 11706-20 ‡...

  • Page 28: Flanged Stainless Steel Full Stroke

    FLANGED STAINLESS STEEL FULL STROKE A150-F*3-****-*** ALF-12060-E-01 All-Flo...
  • Page 29 PARTS LIST - FLANGED STAINLESS STEEL FULL STROKE A150-F*3-****-*** ITEM DESCRIPTION QTY PUMP MODEL PART NO. MATERIAL DISCHARGE MANIFOLD - FLANGED A150-F*3-****-*** 11336-26 Stainless Steel BALL A150-***-*V**-*** 11010-13 † A150-***-*E**-*** 11010-15 † EPDM A150-***-*G**-*** 11010-19 † Geolast ® A150-***-*N**-*** 11010-21 † Buna-N A150-***-*S**-*** 11010-23 †...
  • Page 30 PARTS LIST - FLANGED STAINLESS STEEL FULL STROKE A150-F*3-****-*** ITEM DESCRIPTION PUMP MODEL PART NO. MATERIAL LIP SEAL (AIR VALVE) All Models 12003-76 ‡ Nitrile O-RING (AIR VALVE END PLUG) All Models 11913-11 ‡ Nitrile AIR VALVE END PLUG A150-*A*-****-*** 11706-20 ‡...

  • Page 31: Flanged Stainless Steel Ptfe Short Stroke

    FLANGED STAINLESS STEEL PTFE SHORT STROKE A150-F*3-T***-*** ALF-12060-E-01 All-Flo...
  • Page 32 PARTS LIST - FLANGED STAINLESS STEEL SHORT STROKE A150-F*3-T***-*** ITEM DESCRIPTION QTY PUMP MODEL PART NO. MATERIAL DISCHARGE MANIFOLD - FLANGED A150-F*3-****-*** 11336-26 Stainless Steel BALL A150-***-*V**-*** 11010-13 † A150-***-*E**-*** 11010-15 † EPDM A150-***-*G**-*** 11010-19 † Geolast ® A150-***-*N**-*** 11010-21 † Buna-N A150-***-*S**-*** 11010-23 †...
  • Page 33 PARTS LIST - FLANGED STAINLESS STEEL SHORT STROKE A150-F*3-T***-*** ITEM DESCRIPTION PUMP MODEL PART NO. MATERIAL INNER CHAMBER GASKET All Models 12123-19 Nitrile SCREW, SELF-LOCKING PHILLIPS All Models 12571-26 Stainless Steel (#6-32 X 3/8”) SCREW, HEX HEAD CAP (1/4”-20 X 3”) A150-**3-****-*0* 12516-26 Stainless Steel...

  • Page 34: Elastomers

    SECTION ELASTOMERS WETTED ELASTOMERS BUNA-N (NITRILE) GEOLAST® is a general purpose elastomer used with water and is an injection molded thermoplastic material with many oils. Temperature range 10°F to 180°F (-12°C characteristics similar to Nitrile. Has excellent to 82°C). abrasion resistance. Temperature range 10°F to 180°F (-12°C to 82°C).

  • Page 35: Atex Protection Summary

    SECTION ATEX PROTECTION SUMMARY POTENTIAL IGNITION CAUSE DESCRIPTION OF PROTECTION MEASURES APPLIED SOURCE The maximum surface temperature of the equipment does not depend on the equipment itself, but mainly the process. Friction between stationary Hot Surface The relevant information has been given in the instructions and moving parts for use and the equipment has been marked T6-T3 in order to inform the user about this special situation.
  • Page 36 All-Flo Pumps comply with the following European Union directives: The Machinery Directive 2006/42/EC: Annex I, and 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.

  • Page 37: Warranty And Registration

    SECTION WARRANTY AND REGISTRATION WARRANTY. All All-Flo products shall be covered by the standard All-Flo Limited Warranty in effect at the time of shipment. This warranty (which may be modified by All-Flo at any time) provides: MATERIALS SOLD ARE WARRANTED TO THE ORIGINAL USER AGAINST DEFECTS IN WORKMANSHIP OR MATERIALS UNDER NORMAL USE (RENTAL USE EXCLUDED) FOR FIVE YEARS AFTER PURCHASE DATE.
  • Page 38 22069 Van Buren Street Grand Terrace, CA 92313-5651 USA P: +1 (440) 354-1700 F: +1 (440) 354-9466 all-flo.com All-Flo is committed to the pursuit of 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.

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