Dover PSG WILDEN PRO-FLO XPS820 AAAAA Series Engineering Operation & Maintenance Manual
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Dover PSG WILDEN PRO-FLO XPS820 AAAAA Series Engineering Operation & Maintenance Manual

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ENGINEERING OPERATION
& MAINTENANCE MANUAL
PS820/PS830
Bolted Metal Pump
Where Innovation Flows
WIL-11510-E-09

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

  • Page 1 ENGINEERING OPERATION & MAINTENANCE MANUAL PS820/PS830 Bolted Metal Pump Where Innovation Flows WIL-11510-E-09...
  • Page 2 No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or any means electronic or mechanical, including photocopying and recording, without the written permission of PSG, a Dover Company, except as described by the terms of those agreements.

  • Page 3: Table Of Contents

    PS820/830 Bolted Metal CONTENTS SECTION 1: Precautions – Read First! ..................... 4 SECTION 2: Wilden Pump Designation System ..................5 SECTION 3: How It Works .......................... 6 SECTION 4: Dimensional Drawings ......................7 SECTION 5: Performance ........................... 9 PS820/PS830 Metal Rubber-Fitted ......................9 PS820/PS830 Metal EZ-Install TPE-Fitted ....................

  • Page 4: Section 1: Precautions - Read First

    PS820/830 Bolted Metal SECTION 1 PRECAUTIONS – READ FIRST! WARNING: Always wear safety glasses when operating CAUTION: Before attempting any maintenance or repair, a pump to avoid eye injury. If diaphragm rupture occurs, disconnect the compressed air line to the pump and allow material being pumped may be forced out of the air all air pressure to bleed from the pump.

  • Page 5: Section 2: Wilden Pump Designation System

    PS820/830 Bolted Metal SECTION 2 WILDEN PUMP DESIGNATION SYSTEM PS820/830 METAL LEGEND XPS 820 / / X X X / X X / X X / X X X X 51 mm (2") Pump O-RINGS MODEL VALVE SEATS SPECIALTY Maximum Flow Rate: VALVE BALLS CODE (if applicable)

  • Page 6: Section 3: How It Works

    PS820/830 Bolted Metal SECTION 3 HOW IT WORKS – AIR-OPERATED DOUBLE-DIAPHRAGM PUMP The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show flow pattern through the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke. FIGURE 1 The air valve directs pressurized air to FIGURE 2 When the pressurized diaphragm, FIGURE 3 At completion of the stroke, the air...

  • Page 7: Section 4: Dimensional Drawings

    PS820/830 Bolted Metal SECTION 4 DIMENSIONAL DRAWING PS820 METAL DIMENSIONS METRIC STANDARD ITEM (mm) (inch) 17.9 14.1 24.8 26.4 13.6 14.4 27.1 12.8 10.1 10.0 LW0238 REV. C PS830 METAL DIMENSIONS METRIC STANDARD ITEM (mm) (inch) 17.8 15.7 26.6 29.6 29.8 15.3 14.4...
  • Page 8 PS820/830 Bolted Metal DIMENSIONAL DRAWING PS820 STAINLESS STEEL DIMENSIONS METRIC STANDARD ITEM (mm) (inch) 17.8 14.3 24.4 25.9 14.0 14.4 14.2 27.0 26.8 12.0 10.0 LW0240 REV. B PS830 STAINLESS STEEL DIMENSIONS METRIC STANDARD ITEM (mm) (inch) 17.8 16.7 26.7 29.7 29.9 16.2...

  • Page 9: Section 5: Performance

    PS820/830 Bolted Metal SECTION 5 PERFORMANCE PS820/PS830 METAL RUBBER-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"...

  • Page 10: Ps820/Ps830 Metal Full-Stroke Ptfe-Fitted

    PS820/830 Bolted Metal PERFORMANCE PS820/PS830 METAL FULL-STROKE PTFE-FITTED 20[34] 40[68] Ship Weight...820 Threaded AL 47 kg (104 lb) 820 Threaded SS 73 kg (161 lb) 60[102] 820 Threaded Iron 71 kg (156 lb) 830 Flanged AL 54 kg (118 lb) 80[136] 830 Flanged SS 81 kg (178 lb) 830 Flanged Iron 82 kg (181 lb)

  • Page 11: Suction Lift Capability

    PS820/830 Bolted Metal SUCTION LIFT CAPABILITY PS820/PS830 ALUMINUM 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.
  • Page 12 PS820/830 Bolted Metal SUCTION LIFT CAPABILITY PS820/PS830 DUCTILE IRON 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.

  • Page 13: Section 6: Suggested Installation, Operation, Maintenance, And Troubleshooting

    PS820/830 Bolted Metal SECTION 6 SUGGESTED INSTALLATION, OPERATION, MAINTENANCE AND TROUBLESHOOTING Wilden pumps are designed to meet the performance requirements of be eliminated. In addition, pump efficiency can be adversely even the most demanding pumping applications. They have been affected if proper attention is not given to site location. designed and manufactured to the highest standards and are ...
  • Page 14 PS820/830 Bolted Metal SUGGESTED INSTALLATION, OPERATION, MAINTENANCE AND TROUBLESHOOTING to control the pump from a remote location. When the pump discharge pressure equals or exceeds the air supply pressure, the NOTE: In the event of a power failure, close the shut- pump will stop.

  • Page 15: Section 7: Disassembly/Reassembly

    PS820/830 Bolted Metal SUGGESTED INSTALLATION, OPERATION, MAINTENANCE AND TROUBLESHOOTING Troubleshooting Pump air valve freezes. Pump will not run or runs slowly. Check for excessive moisture in the compressed air. Remove plug from pilot spool exhaust. Either install a dryer or a hot air generator for compressed Ensure that the air inlet pressure is at least 0.4 bar (5 psig) air.

  • Page 16: Pump Disassembly

    PS820/830 Bolted Metal SECTION 7 DISASSEMBLY / REASSEMBLY PUMP DISASSEMBLY Tools Required: 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 1"...
  • Page 17 PS820/830 Bolted Metal DISASSEMBLY / REASSEMBLY Step 4 Step 5 Step 6 Remove the discharge valve balls and Using the appropriate-sized wrench, Remove the inlet manifold to expose the valve seats from the liquid chambers and loosen the inlet manifold from the liquid valve balls and valve seats.
  • Page 18 PS820/830 Bolted Metal DISASSEMBLY / REASSEMBLY Step 10 Step 11 Step 12 Inspect the diaphragm assembly for wear, To remove the diaphragm assembly from Remove outer piston and stud if damage or chemical attack. Replace any shaft, secure shaft with soft jaws equipped.

  • Page 19: Air Valve/Center Section Disassembly

    PS820/830 Bolted Metal DISASSEMBLY / REASSEMBLY AIR VALVE / CENTER SECTION DISASSEMBLY Tools Required: 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 3/16"...
  • Page 20 PS820/830 Bolted Metal DISASSEMBLY / REASSEMBLY Step 7 Step 8 Step 9 Gently remove the pilot spool from the Remove the modulator spool from Using the appropriate-sized wrench, sleeve and inspect for nicks, wear or the center section. Check for wear to the loosen the fasteners and lift away damage.
  • Page 21 PS820/830 Bolted Metal DISASSEMBLY / REASSEMBLY Step 13 Step 14 Loosen and remove the four (4) air valve bolts from the center section assembly. Remove the air valve end cap to expose the air valve spool by lifting up on the end cap. Lift the muffler plate and muffler plate gasket away from the center block.

  • Page 22: Single-Point Exhaust

    PS820/830 Bolted Metal DISASSEMBLY / REASSEMBLY SINGLE-POINT EXHAUST Step 1 Step 2 Remove the pilot exhaust muffler in the pilot Optional: Install a single-point exhaust gasket (04-2639-52). The single-point air valve bleed port located at the front of the center gasket can be purchased as a spare part or included with the purchase of a new block.
  • Page 23 PS820/830 Bolted Metal DISASSEMBLY / REASSEMBLY SHAFT SEAL INSTALLATION Pre-Installation Tools After all the old seals have been removed, the inside of the bushing The following tools can be used to aid in the installation of should be cleaned to ensure no debris is left that may cause premature the new seals: damage to the new seals.

  • Page 24: Section 8: Exploded View And Parts List

    PS820/830 Bolted Metal SECTION 8 EXPLODED VIEW AND PARTS LIST PS820/PS830 METAL FULL-STROKE PTFE FULL-STROKE IPD FLANGED METAL ADS PLASTIC ADS LW0182 REV. G ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS WIL-11510-E-09...
  • Page 25 PS820/830 Bolted Metal EXPLODED VIEW AND PARTS LIST EXPLODED VIEW AND PARTS LIST XPS820/830/ XPS820/830/ PS820/830/ Model Description AAAAA/…/ WWAAA/…/ WWAPP/…/ Item Description Qty. Air Distribution Components Air Valve Assembly, Pro-Flo Shift 04-2039-01 04-2039-20 O-Ring, End Cap (-225, Ø1.859" x Ø.139") 04-2390-52-700 End Cap 04-2340-01...
  • Page 26 PS820/830 Bolted Metal EXPLODED VIEW AND PARTS LIST PS820/PS830 STAINLESS STEEL FULL-STROKE PTFE FULL-STROKE IPD FLANGED METAL ADS PLASTIC ADS LW0030 REV. J ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS WIL-11510-E-09...
  • Page 27 PS820/830 Bolted Metal EXPLODED VIEW AND PARTS LIST EXPLODED VIEW AND PARTS LIST XPS820/830/ XPS820/830/ PS820/830/ Model Description SSAAA/…/ SSSSS/…/ SSSPP/…/ Item Description Qty. Air Distribution Components Air Valve Assembly, Pro-Flo Shift 04-2039-01 04-2039-03 04-2039-20 O-Ring, End Cap (-225, Ø1.859" x Ø.139") 04-2390-52-700 End Cap 04-2340-01...

  • Page 28: Section 9: Elastomer Options

    PS820/830 Bolted Metal SECTION 9 ELASTOMER OPTIONS PS820/PS830 METAL FULL-STROKE FULL-STROKE FULL-STROKE EZ-INSTALL VALVE SEAT DIAPHRAGM BACK-UP VALVE BALLS VALVE SEATS MATERIAL DIAPHRAGMS DIAPHRAGMS O-RING DIAPHRAGMS DIAPHRAGMS Polyurethane 08-1022-50 08-1080-50 08-1128-50 Neoprene 08-1010-51 08-1080-51 08-1128-51 Buna-N 08-1010-52 08-1080-52 08-1128-52 Geolast 08-1022-15 EPDM 08-1010-54...
  • Page 29 PS820/830 Bolted Metal NOTES WIL-11510-E-09...
  • Page 30 PS820/830 Bolted Metal NOTES WIL-11510-E-09...
  • Page 31 PS820/830 Bolted Metal NOTES WIL-11510-E-09...
  • Page 32 P: +1 (909) 422 -1730 psgdover.com Where Innovation Flows ® ® Copyright 2021 PSG , a Dover Company ® 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...

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