Dover PSG ALL-FLO A050 Owner's manual

IOM
INSTALLATION OPERATION
& MAINTENANCE
A050
METAL 1/2 INCH
AIR-OPERATED DOUBLE-DIAPHRAGM PUMP

ALF-12030-E-01 All-Flo2
TABLE OF
CONTENTS
SECTION 1 WARNINGS, DANGERS AND CAUTIONS 3
SECTION 2 MODEL DESIGNATION MATRIX & REPAIR KITS 4-5
SECTION 3 PRINCIPLES OF OPERATION 6
SECTION 4 DIMENSIONAL DRAWINGS 7-8
SECTION 5 PERFORMANCE CURVES
RUBBER DIAPHRAGMS..............................................................9
TPE DIAPHRAGMS........................................................................9
PTFE DIAPHRAGMS .....................................................................9
SECTION 6 INSTALLATION
INSTALLATION ................................................................................... 10-11
TROUBLESHOOTING ..................................................................12
OPERATION.....................................................................................13
MAINTENANCE ............................................................................13
SECTION 7 REPAIR AND ASSEMBLY
PUMP WET END REMOVAL............................................ 14-15
AIR VALVE REMOVAL .........................................................16-17
PILOT VALVE REMOVAL.................................................. 18-19
TORQUE SPECIFICATIONS.......................................................19
SECTION 8 EXPLODED VIEWS AND PARTS LISTS 20-25
SECTION 9 ELASTOMERS 26
SECTION 10 ATEX PROTECTION SUMMARY 27
SECTION 11 WARRANTY AND REGISTRATION 29

ALF-12030-E-01 All-Flo3
READ THESE WARNINGS AND SAFETY PRECAUTIONS PRIOR TO
INSTALLATION OR OPERATION. FAILURE TO COMPLY WITH THESE
INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND OR
PROPERTY DAMAGE. RETAIN THESE INSTRUCTIONS FOR FUTURE
REFERENCE.
WARNING Pump, valves and all containers must be properly
grounded prior to handling flammable fluids and/or whenever static
electricity is a hazard.
WARNING Prior to servicing the pump, ensure that the air 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 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.
WARNING Maintenance must not be performed when a
hazardous atmosphere is present.
WARNING Use only with liquid process fluid.
WARNING This equipment’s ambient temperature range is
32°F (0°C) to 104°F (40°C)
WARNING Do not operate the pump with fluids or in
temperatures which are less than 32°F (0°C)
WARNING The T6-T3 marking refers to the maximum
surface temperature depending not on the equipment itself, but mainly
on operating conditions. In this case, the maximum surface temperature
depends upon the temperature of the process fluids. Do not exceed the
maximum recommended process fluid temperature of the configured
materials.
CAUTION The temperature of the process fluid and
air input must be no more than 36°F (20°C) less of the maximum
temperature allowed for the appropriate non-metallic material. See the
list of temperatures below for each material’s maximum recommended
temperature and applicable ATEX temperature class:
Buna-N (Nitrile): 10°F to 180°F (-12°C to 82°C) T6
Geolast®: 10°F to 180°F (-12°C to 82°C) T6
EPDM: -40°F to 280°F (-40°C to 138°C) T4
Santoprene®: -40°F to 225°F (-40°C to 107°C) T5
FKM: -40°F to 350°F (-40°C to 177°C) T3
PTFE: 40°F to 220°F (4°C to 104°C) T6
Polyethylene: 32°F to 158°F (0°C 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 resistance
guide for chemical compatibility and a more precise safe temperature
CAUTIONS — READ FIRST!
WARNING
CAUTION
= Hazards or unsafe practices which
could result in severe personal injury,
death or substantial property damage
= Hazards or unsafe practices which
could result in minor personal injury,
product or property damage.
limit. Always use minimum air pressure when pumping at elevated
temperatures.
CAUTION It is the end user’s responsibility to maintain the
process fluid’s temperature during use.
CAUTION Do not connect a compressed air source to the
exhaust port of the pump.
CAUTION Do not lubricate air supply.
CAUTION Do not exceed 120 psig (8.3 bar)
air-inlet pressure.
CAUTION Do not exceed 10 psig (0.7 bar)
or 23 ft-H2O suction pressure.
CAUTION Ensure all wetted components are chemically
compatible with the process fluid and the cleaning fluid.
CAUTION Ensure pump is thoroughly cleaned and flushed
prior to installation into a process line.
CAUTION Always wear Personal Protective Equipment (PPE)
when operating pump.
CAUTION Close and disconnect all compressed air and bleed
all air from the pump prior to service. Remove all process fluid in a safe
manner prior to service.
CAUTION Blow out all compressed air lines in order to
remove any debris, prior to pump installation. Ensure that the muffler is
properly installed prior to pump operation.
CAUTION Ensure air exhaust is piped to atmosphere prior to a
submerged installation.
CAUTION Ensure all hardware is set to correct torque values
prior to operation.
CAUTION The equipment must be inspected for visible
damage prior to use.
This product can expose you to chemicals including
Nickel, Chromium, Cadmium, or Cobalt, which are known to the State of
California to cause cancer and/or birth defects or other reproductive harm.
For more information, go to www.P65Warnings.ca.gov.
SECTION 1
WARNING

ALF-12030-E-01 All-Flo4
MODEL DESIGNATION MATRIX & REPAIR KITS- ALUMINUM
SECTION 2
PRODUCT SERIES
FLUID CONNECTION TYPE
LIQUID SECTION
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
SPECIAL (OTHER)
PORTING
AIR SECTION
SPECIAL (HARDWARE,
MUFFLER, LUG)
A 0 5 0 -1 2 3- 4 5 6 7 - 8 9 10
FLUID CONNECTION TYPE
N = NPT
B = BSPT
1 = Dual Suction / Dual Discharge NPT
AIR SECTION
A = Aluminum, Pneumatic Shift
P = Polypropylene, Pneumatic Shift
LIQUID SECTION
A = Aluminum
DIAPHRAGMS
G = Geolast®
S = Santoprene®
T = PTFE with Santoprene® Backup
V = FKM
VALVE/BALL
G = Geolast®
S = Santoprene®
T = PTFE
V = FKM
3 = Stainless Steel
VALVE SEAT
P = Polypropylene
3 = Stainless Steel
A = Aluminum
Y = Nylon
O-RINGS
E = EPDM
N = Buna-N
T = PTFE
V = FKM
PORTING
S = Standard (Suction Right / Discharge Right)
A = Suction Center Front / Discharge Center Front
B = Suction Center Front / Discharge Center Rear
D = Suction Center Front / Discharge Right
E = Suction Center Front / Discharge Left
F = Suction Center Rear / Discharge Center Front
G = Suction Center Rear / Discharge Center Rear
I = Suction Center Rear / Discharge Right
J = Suction Center Rear / Discharge Left
K = Suction Bottom / Discharge Center Front
L = Suction Bottom / Discharge Center Rear
N = Suction Bottom / Discharge Right
O = Suction Bottom / Discharge Left
P = Suction Right / Discharge Center Front
Q = Suction Right / Discharge Center Rear
T = Suction Right / Discharge Left
Y = Suction Left / Discharge Left
U = Suction Left / Discharge Center Front
V = Suction Left / Discharge Center Rear
X = Suction Left / Discharge Right
4 = All Ports Open (Standard ports will be left
un-plugged)
6 = Dual Section End Ports / Dual Discharge End
Ports
7 = All Ports on Pump Open - No Plugs Included
SPECIAL OPTION (HARDWARE, MUFFLER, LUG)
3 = Standard (Zinc Plated Steel 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 Coated Stainless Steel Hardware,
Metal Muffler
D = Zinc Plated Steel Hardware, Plastic Muffler,
Grounding Lug Installed
E = Zinc Plated Steel Hardware, Metal Muffler,
Grounding Lug Installed
F = Stainless Steel Hardware, Plastic Muffler,
Grounding Lug Installed
G = Stainless Steel Hardware, Metal Muffler,
Grounding Lug Installed
H = PTFE Coated Stainless Steel Hardware,
Plastic Muffler, Grounding Lug Installed
I = PTFE Coated Stainless Steel Hardware,
Metal Muffler, Grounding Lug Installed
SPECIAL OPTION (OTHER)
0 = Standard (None)
1 = Cycle Counter Valve
2 = Solenoid Adaptor Valve 110/50 Volt AC,
120/60 Volt AC, DIN 43650B Connector
3 = Solenoid Adaptor Valve 110/50 Volt AC,
120/60 Volt AC Explosion Proof
4 = Solenoid Adaptor Valve 220/50 Volt AC,
240/60 Volt AC, 12 Volt DC, DIN 43650B Connector
5 = Solenoid Adaptor Valve 220/50 Volt AC,
240/60 Volt AC, 12 Volt DC Explosion Proof
6 = Solenoid Adaptor Valve 220/50 Volt AC,
240/60 Volt AC, 125 Volt DC, DIN 43650B Connector
7 = Solenoid Adaptor Valve 220/50 Volt AC,
240/60 Volt AC, 125 Volt DC Explosion Proof
8 = Solenoid Adaptor Valve 24 Volt DC, DIN 43650B
Connector
9 = Solenoid Adaptor Valve 24 Volt DC,
Explosion Proof
A = Grease Free (No Lubrication Assembly)
SIZE
1
2
6
7
8
9
10
AIR SECTION
A = Aluminum
P = Polypropylene (Glass Filled)
Bold indicates recommended options
AIR END REPAIR KIT
Air end repair kit contains pilot sleeve
assembly and main air valve.
MATERIAL
AAK-050-2
PRODUCT
SERIES
PUMP SIZE
AIR END
REPAIR KIT
3
4
5
* Solenoid Adaptor Valves only available on select pump models with polypropylene intermediate
** For Drum Pump configurations, select porting option with Suction Bottom.
WET END REPAIR KIT
Wet end kits are available and
consist of diaphragms, (back-up
diaphragms if required), balls,
seats and seat O-rings.
See matrix below.
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
AWE-050-4567-M
PRODUCT
SERIES
WET END
REPAIR KIT
PUMP SIZE
METALLIC WET END

ALF-12030-E-01 All-Flo5
MODEL DESIGNATION MATRIX & REPAIR KITS - STAINLESS STEEL
Bold indicates recommended options
PRODUCT SERIES
FLUID CONNECTION TYPE
LIQUID SECTION
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
SPECIAL (OTHER)
PORTING
AIR SECTION
SPECIAL (HARDWARE,
MUFFLER, LUG)
A 0 5 0 -1 2 3- 4 5 6 7 - 8 9 10
FLUID CONNECTION TYPE
N = NPT
B = BSPT
1 = Dual Suction / Dual Discharge NPT
AIR SECTION
P = Polypropylene, Pneumatic Shift
A = Aluminum, Pneumatic Shift
LIQUID SECTION
3 = Stainless Steel
DIAPHRAGMS
S = Santoprene®
T = PTFE with Santoprene® Backup
V = FKM
G = Geolast®
VALVE/BALL
S = Santoprene®
T = PTFE
V = FKM
G = Geolast®
3 = Stainless Steel
VALVE SEAT
3 = Stainless Steel
P = Polypropylene
A = Aluminum
Y = Nylon
O-RINGS
E = EPDM
T = PTFE
N = Buna-N
V = FKM
PORTING
S = Standard (Suction Right / Discharge Right)
A = Suction Center Front / Discharge Center Front
B = Suction Center Front / Discharge Center Rear
D = Suction Center Front / Discharge Right
E = Suction Center Front / Discharge Left
F = Suction Center Rear / Discharge Center Front
G = Suction Center Rear / Discharge Center Rear
I = Suction Center Rear / Discharge Right
J = Suction Center Rear / Discharge Left
K = Suction Bottom / Discharge Center Front
L = Suction Bottom / Discharge Center Rear
N = Suction Bottom / Discharge Right
O = Suction Bottom / Discharge Left
P = Suction Right / Discharge Center Front
Q = Suction Right / Discharge Center Rear
T = Suction Right / Discharge Left
Y = Suction Left / Discharge Left
U = Suction Left / Discharge Center Front
V = Suction Left / Discharge Center Rear
X = Suction Left / Discharge Right
4 = All Ports Open (Standard ports will be left
un-plugged)
6 = Dual Suction End Ports / Dual Discharge End
Ports
7 = All Ports on Pump Open - No Plugs Included
SPECIAL OPTION (HARDWARE, MUFFLER, LUG)
7 = Standard (Stainless Steel Hardware, Plastic Muffler)
8 = Stainless Steel Hardware, Metal Muffler
B = PTFE Coated Stainless Steel Hardware, Plastic
Muffler
C = PTFE Coated Stainless Steel Hardware,
Metal Muffler
F = Stainless Steel Hardware, Plastic Muffler,
Grounding Lug Installed
G = Stainless Steel Hardware, Metal Muffler, Ground-
ing Lug Installed
H = PTFE Coated Stainless Steel Hardware, Plastic
Muffler, Grounding Lug Installed
I = PTFE Coated Stainless Steel Hardware,
Metal Muffler, Grounding Lug Installed
SPECIAL OPTION (OTHER)
0 = Standard (None)
1 = Cycle Counter Valve
2 = Solenoid Adaptor Valve 110/50 Volt AC,
120/60 Volt AC, DIN 43650B Connector
3 = Solenoid Adaptor Valve 110/50 Volt AC,
120/60 Volt AC Explosion Proof
4 = Solenoid Adaptor Valve 220/50 Volt AC,
240/60 Volt AC, 12 Volt DC, DIN 43650B Connector
5 = Solenoid Adaptor Valve 220/50 Volt AC,
240/60 Volt AC, 12 Volt DC Explosion Proof
6 = Solenoid Adaptor Valve 220/50 Volt AC,
240/60 Volt AC, 125 Volt DC, DIN 43650B
Connector
7 = Solenoid Adaptor Valve 220/50 Volt AC,
240/60 Volt AC, 125 Volt DC Explosion Proof
8 = Solenoid Adaptor Valve 24 Volt DC, DIN 43650B
Connector
9 = Solenoid Adaptor Valve 24 Volt DC,
Explosion Proof
A = Grease Free (No Lubrication Assembly)
SIZE
1
2
6
7
8
9
10
AIR SECTION
P = Polypropylene (Glass Filled)
A = Aluminum
MATERIAL
AAK-050-2
PRODUCT
SERIES
PUMP SIZE
AIR END
REPAIR KIT
3
4
5
AIR END REPAIR KIT
Air end repair kit contains pilot
sleeve assembly and main air valve.
* Solenoid Adaptor Valves only available on select pump models with polypropylene intermediate
** For Drum Pump configurations, select porting option with Suction Bottom.
METALLIC WET END
AWE-050-4567-M
PRODUCT
SERIES
WET END REPAIR KIT
Wet end kits are available and
consist of diaphragms, (back-up
diaphragms if required), balls,
seats and seat O-rings.
See matrix below.
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
WET END
REPAIR KIT
PUMP SIZE