Dover PSG ALL-FLO A200 Manual

IOM
INSTALLATION OPERATION
& MAINTENANCE
A200
PLASTIC 2 INCH
AIR-OPERATED DOUBLE-DIAPHRAGM PUMP

ALF-11070-E-02 All-Flo2
TABLE OF
CONTENTS
SECTION 1 WARNINGS, DANGERS AND CAUTIONS 3
SECTION 2 MODEL DESIGNATION MATRIX AND 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, TROUBLESHOOTING AND MAINTENANCE
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 SPECIFICATIONS.......................................................17
SECTION 8 EXPLODED VIEWS AND PARTS LISTS 18-20
SECTION 9 ELASTOMERS 21
SECTION 11 WARRANTY AND REGISTRATION 22

ALF-11070-E-02 All-Flo3
SECTION 1
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.
CAUTION Always wear safety glasses when operating a pump
to avoid eye injury. If diaphragm rupture occurs, material being pumped
may be forced out of the air exhaust.
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 The temperature of the process fluid and air
input must be no more than the maximum temperature allowed for the
appropriate non-metallic material. See the list of temperatures below for
each material’s maximum recommended temperature:
Buna-N (Nitrile): 10°F to 180°F (-12°C to 82°C)
Geolast®: 10°F to 180°F (-12°C to 82°C)
EPDM: -40°F to 280°F (-40°C to 138°C)
FKM: -40°F to 350°F (-40°C to 177°C)
Hytrel®: -20°F to 220°F (-29°C to 104°C)
Nylon: 0°F to 200°F (-18°C to 93°C)
PTFE: 40°F to 220°F (4°C to 104°C)
Polyethylene: 32°F to 158°F (0°C to 70°C)
Polypropylene: 32°F to 180°F (0°C to 82°C)
Polyurethane: 10°F to 150°F (-12°C to 66°C)
PVDF: 0°F to 250°F (-18°C to 121°C)
Santoprene®: -40°F to 225°F (-40°C to 107°C)
Urethane: -65°F to 220°F (-54°C to 104°C)
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
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 Ensure all wetted components are chemically
compatible with the process fluid and the cleaning fluid.
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.
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 Maintenance must not be performed when a
hazardous atmosphere is present.
CAUTION The equipment must be inspected for visible
damage prior to use.
CAUTION Ensure pump is thoroughly cleaned and flushed
prior to installation into a process line.
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.
WARNING Pump, valves and all containers must be properly
grounded prior to handling flammable fluids and/or whenever static
electricity is a hazard.
WARNING 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.

ALF-11070-E-02 All-Flo4
MODEL DESIGNATION MATRIX- BOLTED PLASTIC
SECTION 2
PRODUCT SERIES
FLUID CONNECTION TYPE
LIQUID SECTION
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
SPECIAL (OTHER)
SPECIAL (PORTING)
AIR SECTION
SPECIAL (HARDWARE,
MUFFLER)
A 2 0 0 -1 2 3- 4 5 6 7 - 8 9 10
FLUID CONNECTION TYPE
F = ANSI / DIN FLANGE
AIR SECTION
P = Polypropylene Intermediate-Pneumatic Shift
LIQUID SECTION
K = PVDF
P = Polypropylene
DIAPHRAGMS
G = Geolast®
S = Santoprene®
T = PTFE with Santoprene®Backup
V = FKM
VALVE/BALL
G = Geolast®
S = Santoprene®
T = PTFE
V = FKM
SPECIAL OPTION (HARDWARE
MUFFLER, LUG)
7 = Stainless Steel Hardware, Standard Muffler
8 = Stainless Steel Hardware, Premium Muffler
B = PTFE Coated Stainless Steel Hardware, Standard
Muffler
C = PTFE Coated Stainless Steel Hardware, Premium
Muffler
F = Stainless Steel Hardware, Standard Muffler, Ground-
ing Lug Installed
G = Stainless Steel Hardware, Premium Muffler,
Grounding Lug Installed
H = PTFE Coated Stainless Steel Hardware, Standard
Muffler, Grounding Lug Installed
I = PTFE Coated Stainless Steel Hardware, Premium
Muffler, Grounding Lug Installed
Note: Equipment must be grounded to acheive ATEX
rating. It is recommended to configure the pump
with a grounding lug option for ATEX applications.
SPECIAL OPTION (OTHER)
0 = Standard
1 = Cycle Counter Valve
A = Grease Free (No lubrication assembly)
SIZE
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.
1
2
6
7
8
9
10
Bold indicates recommended options
AIR END REPAIR KIT
Air end repair kit contains pilot
sleeve assembly and main air valve.
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
AWE-200-4567-P
PRODUCT
SERIES
WET END
REPAIR KIT
PUMP SIZE
MATERIAL
AAK-200-P
PRODUCT
SERIES
PUMP SIZE
AIR END
REPAIR KIT
3
4
5
MATERIAL
VALVE SEAT
K = PVDF
P = Polypropylene
O-RINGS
E = EPDM
N = Buna-N
T = PTFE
V = FKM
PORTING
A = Suction Center Front / Discharge Center Front
B = Suction Center Front / Discharge Center Rear
S = Default (Suction Right / Discharge Right)
T = Suction Right / Discharge Left
X = Suction Left / Discharge Right
Y = Suction Left / Discharge Left

ALF-11070-E-02 All-Flo5
PRINCIPLES OF OPERATION
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.
When the diaphragm on the left side is moving to the right, it is referred
to as suction stroke. When the left diaphragm is in its suction stroke,
the left suction ball moves upward (opens) and the left discharge ball
moves downward (closes). This action creates suction and draws 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 side moves outward, the left discharge ball
moves upward (opens) and the left suction ball moves downward (closes).
This causes the liquid to leave the left side liquid outlet of the pump.
Simultaneously, the right diaphragm moves inward (to the left), which
causes the right suction ball to open and the right discharge to close,
which in turn causes suction, drawing liquid into the right chamber.
The process of alternating right suction / left discharge (and vice-versa)
continues as long as compressed air is supplied to the pump.
HOW AN AIR OPERATED DOUBLE
DIAPHRAGM PUMP WORKS
SECTION 3

ALF-11070-E-02 All-Flo6
2” PUMP DIMENSIONS
BOLTED PLASTIC
SECTION 4
23.6 [600]
28.7
[729]
3.6
[91]
17.6
[446]
31.7
[805]
13.7 [349]
12.2 [310]
1.9 [49]
7.6
[194]
6.0
[153]
4.0
[101]
14.2 [360]
16.7 [423]
0.6 [14]
8.2
[208]
9.2
[234]

ALF-11070-E-02 All-Flo7
PERFORMANCE CURVES
Performance Specifications
Max. Flow: 160 gpm (605 lpm)
Max. Air Pressure: 120 psi (8.3 bar)
Max. Solids: 1/4” (6.4 mm)
Max. Suction Lift Dry: 17 ft-H
2
O (5.2 m-H
2
O)
Max. Suction Lift Wet: 29 ft-H
2
O (8.8 m-H
2
O)
Weight Polypropylene: 56 lbs (25 kg)
Weight PVDF: 84 lbs (38 kg)
Air Inlet: 3/4” FNPT
Liquid Inlet: 2” ANSI / DIN FLANGE
Liquid Outlet: 2” ANSI / DIN FLANGE
Height: 31.7” (805 mm)
Width: 23.6” (600 mm)
Depth: 12.2” (310 mm)
5
SECTION
*Flow rates indicated on the chart(s) shown were determined by pumping water at flooded suction. For optimum life and performance, pumps should be
specified so that daily operation parameters will fall in the center of the pump performance curve.
AIR CONSUMPTION (SCFM)
Performance Specifications
Max. Flow: 160 gpm (605 lpm)
Max. Air Pressure: 120 psi (8.3 bar)
Max. Solids: 1/4” (6.4 mm)
Max. Suction Lift Dry: 17 ft-H
2
O (5.2 m-H
2
O)
Max. Suction Lift Wet: 29 ft-H
2
O (8.8 m-H
2
O)
Weight Polypropylene: 56 lbs (25 kg)
Weight PVDF: 84 lbs (38 kg)
Air Inlet: 3/4” FNPT
Liquid Inlet: 2” ANSI / DIN FLANGE
Liquid Outlet: 2” ANSI / DIN FLANGE
Height: 31.7” (805 mm)
Width: 23.6” (600 mm)
Depth: 12.2” (310 mm)
Performance Specifications
Max. Flow: 150 gpm (568 lpm)
Max. Air Pressure: 120 psi (8.3 bar)
Max. Solids: 1/4” (6.4 mm)
Max. Suction Lift Dry: 15 ft-H
2
O (4.6 m-H
2
O)
Max. Suction Lift Wet: 29 ft-H
2
O (8.8 m-H
2
O)
Weight Polypropylene: 56 lbs (25 kg)
Weight PVDF: 84 lbs (38 kg)
Air Inlet: 3/4” FNPT
Liquid Inlet: 2” ANSI / DIN FLANGE
Liquid Outlet: 2” ANSI / DIN FLANGE
Height: 31.7” (805 mm)
Width: 23.6” (600 mm)
Depth: 12.2” (310 mm)
0 76 152 228 304 380 456 532 608 684
0 20 40 60 80 100 120 140 160 180
DISCHARGE FLOW-Liters/Min.
PRESSURE INLET/OUTLET PSIG (BARS)
TOTAL HEAD IN FEET (METERS)
DISCHARGE FLOW-U.S. Gals./Min.
276
(83,9)
230
(69,9)
184
(55,9)
138
(41,9)
92
(27,9)
46
(13,9)
120
(8,2)
100
(6,8)
80
(5,4)
60
(4,1)
40
(2,7)
20
(1,3)
PERFORMANCE CURVE (2'' RUBBER)*
80
100
60
40
20
AIR CONSUMPTION (SCFM)
PERFORMANCE CURVE (2” RUBBER)
0 76 152 228 304 380 456 532 608 684
0 20 40 60 80 100 120 140 160 180
DISCHARGE FLOW-Liters/Min.
PRESSURE INLET/OUTLET PSIG (BARS)
TOTAL HEAD IN FEET (METERS)
DISCHARGE FLOW-U.S. Gals./Min.
276
(83,9)
230
(69,9)
184
(55,9)
138
(41,9)
92
(27,9)
46
(13,9)
120
(8,2)
100
(6,8)
80
(5,4)
60
(4,1)
40
(2,7)
20
(1,3)
PERFORMANCE CURVE (2'' TPE)*
20 40
60
80
100
AIR CONSUMPTION (SCFM)
PERFORMANCE CURVE (2” TPE)
0 76 152 228 304 380 456 532 608 684
0 20 40 60 80 100 120 140 160 180
DISCHARGE FLOW-Liters/Min.
PRESSURE INLET/OUTLET PSIG (BARS)
TOTAL HEAD IN FEET (METERS)
DISCHARGE FLOW-U.S. Gals./Min.
276
(83,9)
230
(69,9)
184
(55,9)
138
(41,9)
92
(27,9)
46
(13,9)
120
(8,2)
100
(6,8)
80
(5,4)
60
(4,1)
40
(2,7)
20
(1,3)
PERFORMANCE CURVE (2'' PTFE)*
80
100
20 40
60
AIR CONSUMPTION (SCFM)
PERFORMANCE CURVE (2” PTFE)

ALF-11070-E-02 All-Flo8
SECTION 6
INSTALLATION, TROUBLESHOOTING
AND MAINTENANCE
INSTALLATION
PIPING
Whenever possible ensure the pump is installed using
the shortest possible pipe lengths with the minimum
amount of pipe fittings. Ensure all piping is supported
independent of the pump.
Suction and discharge piping should not be smaller
than the connection size of the pump. When pumping
liquids of high viscosity, larger piping may be used, in
order to reduce frictional pipe loss.
Employ flexible hoses in order to eliminate the vibration
caused by the pump. Mounting feet can also be used to
reduce vibration effects.
All hoses should be reinforced, non-collapsible and be
capable of high vacuum service. Ensure that all piping
and hoses are chemically compatible with the process
and cleaning fluid.
For processes where pulsation effects should be
reduced, employ a pulsation dampener on the discharge
side of the pump.
For self-priming applications, ensure all connections
are airtight and the application is within the pumps
dry-lift capability. Refer to product specifications for
further details.
For flooded suction applications, install a gate valve
on the suction piping in order to facilitate service.
For unattended flooded suction operation, 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 required by the pump. Refer to product
specifications for further details. For reliable
operation, install a 5 micron air filter, air-valve and
pressure regulator. Do not exceed the pumps
maximum operating pressure of 120 psig.
REMOTE OPERATION
Utilize a three way solenoid valve for remote
operation. This ensures that air between the solenoid
and the pump is allowed to “bleed off,” ensuring
reliable operation. Liquid transfer volume is estimated
by multiplying displacement per stroke times the
number of strokes per minute
NOISE
Correct installation of the muffler reduces sound
levels. Refer to product specifications for
further details.
SUBMERGED OPERATION
For submersible operation, pipe the air exhaust to
atmosphere
GROUNDING THE PUMP
Loosen grounding screw and install a grounding wire.
Tighten grounding screw. Wire size should be a 12
gauge wire or larger. Connect the other end of the wire
to a true earth ground. Equipment must be grounded
to achieve ATEX rating and it is recommended to
configure the pump with a grounding lug option.

ALF-11070-E-02 All-Flo9
SUGGESTED INSTALLATION
This illustration is a generic
representation of an air operated
double-diaphragm pump.

ALF-11070-E-02 All-Flo10
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
Plant air supply line ruptured
Air valve wear/debris
Pilot sleeve wear/debris
Diaphragm rod broken
Diaphragm plate loose
Pumped Fluid Coming Out of Muffler
Diaphragm ruptured
Diaphragm plate loose
Inlet liquid pressure excessive (above 10 psig)
Pump Cycles but no Flow
Inlet strainer 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 regulator or needle valve undersized
Muffler partially iced or blinded
Air valve gasket leak or misalignment
Air valve wear/debris
Pilot sleeve wear/debris
Liquid fluid filter blocked
Pump may be cavitating, reduce speed of operation
Suction strainer clogged
Pump Will Not Prime
Air leak in suction pipe
Air leak in pump manifold connections
Suction strainer and lines clogged
Excessive lift conditions
Check valve wear
Debris in check valve