Dover PSG Wilden PS1520 Instruction Manual

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Engineering
Operation &
Maintenance
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PS1520/PS1530
FIT Metal Pump

TABLE OF CONTENTS
SECTION 1 CAUTIONS—READ FIRST! ..............................................1
SECTION 2 WILDEN PUMP DESIGNATION SYSTEM.................................2
SECTION 3 HOW IT WORKS—PUMP & AIR DISTRIBUTION SYSTEM ................3
SECTION 4 DIMENSIONAL DRAWINGS .............................................4
SECTION 5 PERFORMANCE
PS1520/PS1530 Metal Rubber-Fitted..........................................6
PS1520/PS1530 Metal EZ-InstallTPE-Fitted ....................................6
PS1520/PS1530 Metal Full-Stroke PTFE-Fitted..................................7
PS1520/PS1530 Ductile Iron Full-Stroke PTFE-Fitted.............................8
Suction-Lift Curves ........................................................9
SECTION 6 SUGGESTED INSTALLATION, OPERATION & TROUBLESHOOTING.......10
SECTION 7 DISASSEMBLY / REASSEMBLY ........................................13
Air Valve / Center Section Disassembly ......................................16
Reassembly Hints &Tips ..................................................20
SECTION 8 EXPLODED VIEW & PARTS LISTING
PS1520/PS1530 Aluminum.................................................22
PS1520/PS1530 Metal.....................................................24
SECTION 9 ELASTOMER OPTIONS.................................................26

WIL-11520-E-07 1 WILDEN PUMP & ENGINEERING, LLC
CAUTION: Do not apply compressed air to the
exhaust port — pump will not function.
CAUTION: Do not over-lubricate air supply —
excess lubrication will reduce pump performance.
Pump is pre-lubed.
TEMPERATURE LIMITS:
Acetal –29°C to 82°C –20°F to 180°F
Buna-N –12°C to 82°C 10°F to 180°F
Geolast®–40°C to 82°C –40°F to 180°F
Neoprene –18°C to 93°C 0°F to 200°F
Nordel®EPDM –51°C to 138°C –60°F to 280°F
Nylon –18°C to 93°C 0°F to 200°F
PFA –7°C to 107°C 45°F to 225°F
Polypropylene 0°C to 79°C 32°F to 175°F
Polyurethane –12°C to 66°C 10°F to 150°F
PVDF –12°C to 107°C 10°F to 225°F
Saniflex™ –29°C to 104°C –20°F to 220°F
SIPD PTFE with EPDM-backed 4°C to 137°C 40°F to 280°F
SIPD PTFE with Neoprene-backed 4°C to 93°C 40°F to 200°F
PTFE
14°C to 104°C 40°F to 220°F
Viton®FKM –40°C to 177°C –40°F to 350°F
Wil-Flex™ –40°C to 107°C –40°F to 225°F
NOTE:
Not all materials are available for all models.
Refer to Section 2 for material options for your pump.
CAUTION: When choosing pump materials, be
sure to check the temperature limits for all wetted
components. Example: Viton®has a maximum
limit of 177°C (350°F) but polypropylene has a
maximum limit of only 79°C (175°F).
CAUTION: Maximum temperature limits are
based upon mechanical stress only. Certain
chemicals will significantly reduce maximum
safe operating temperatures. Please consult the
Wilden Chemical Resistance Guide.
WARNING: Prevent static sparking. If static
sparking occurs, fire or explosion could result.
Pump, valves and containers must be grounded
to a proper grounding point when handling
flammable fluids and whenever discharge of
static electricity is a hazard.
CAUTION: Do not exceed 8.6 bar (125 psig) air
supply pressure.
CAUTION: The process fluid and cleaning fluids
must be chemically compatible with all wetted
pump components. Please consult the Wilden
Chemical Resistance Guide.
1
4°C to 149°C (40°F to 300°F) - 13 mm (1/2") and 25 mm (1") models only.
CAUTION: Do not exceed 82°C (180°F) air inlet
temperature for Pro-Flo®SHIFT models.
CAUTION: Pumps should be thoroughly flushed
before installing into process lines. FDA- and
USDA-approved pumps should be cleaned and/
or sanitized before being used.
CAUTION: Always wear safety glasses when
operating pump. If diaphragm rupture occurs,
material being pumped may be forced out air
exhaust.
CAUTION: Before any maintenance or repair is
attempted, the compressed air line to the pump
should be disconnected and all air pressure
allowed to bleed from pump. Disconnect all
intake, discharge and air lines. Drain the pump
by turning it upside down and allowing any fluid
to flow into a suitable container.
CAUTION: Blow out air line for 10 to 20 seconds
before attaching to pump to make sure all pipeline
debris is clear. Use an in-line air filter. A 5μ
(micron) air filter is recommended.
NOTE: When installing PTFE diaphragms, it is
important to tighten outer pistons simultaneously
(turning in opposite directions) to ensure tight fit.
(See torque specifications in Section 7.)
NOTE: Some PTFE-fitted pumps come standard
from the factory with expanded PTFE gaskets
installed in the diaphragm bead of the liquid
chamber. PTFE gaskets cannot be re-used.
NOTE: Before starting disassembly, mark a line
from each liquid chamber to its corresponding air
chamber. This line will assist in proper alignment
during reassembly.
CAUTION: Pro-Flo®pumps cannot be used
in submersible applications. Pro-Flo®SHIFT
pumps do have a single-point exhaust option
for submersible applications. Do not use
standard Pro-Flo®SHIFT models in submersible
applications.
CAUTION: Tighten all hardware prior to installation.
Section 1
CAUTIONS—READ FIRST!

WILDEN PUMP & ENGINEERING, LLC 2 WIL-11520-E-07
NOTE: Most elastomeric materials use colored dots for identification.
NOTE: Not all models are available with all material options.
Viton®is a registered trademark of DuPont Dow Elastomers.
Section 2
WILDEN PUMP DESIGNATION SYSTEM
PS1520/PS1530 METAL
76 mm (3") Pump
Maximum Flow Rate:
1026 lpm (271 gpm)
LEGEND
XPS1520 /XXXXX / XXX /XX / XXX /XXXX
O-RINGS
MODEL VALVE SEATS
VALVE BALLS
DIAPHRAGMS
AIR VALVE
CENTER BLOCK
AIR CHAMBERS
WETTED PARTS & OUTER PISTON
SPECIALTY
CODE
(if applicable)
MATERIAL CODES
MODEL
XPS1520 = PRO-FLO®SHIFT
THREADED PORTS
XPS1530 = PRO-FLO®SHIFT
FLANGED PORTS
XPS1520 = PRO-FLO®SHIFT ATEX
THREADED PORTS
XPS1530 = PRO-FLO®SHIFT ATEX
FLANGED PORTS
WETTED PARTS/OUTER PISTON
AA = ALUMINUM / ALUMINUM
AZ = ALUMINUM/NO PISTON
SS = STAINLESS STEEL /
STAINLESS STEEL
SZ = STAINLESS STEEL/
NO PISTON
WW = DUCTILE IRON / DUCTILE
IRON
WZ = DUCTILE IRON / NO OUTER
PISTON
AIR CHAMBERS
A = ALUMINUM
S = STAINLESS STEEL
CENTER BLOCK
A = ALUMINUM
P = POLYPROPYLENE
S = STAINLESS STEEL
AIR VALVE
A = ALUMINUM
P = POLYPROPYLENE
R = ANODIZED ALUMINUM
S = STAINLESS STEEL
DIAPHRAGMS
BNS = BUNA-N (Red Dot)
EPS = EPDM (Blue Dot)
FWL = SANITARY WIL-FLEXTM IPD
FWS = SANITARY WIL-FLEXTM,
EZ-INSTALL [Santoprene®
(Two Orange Dots)]
NES = NEOPRENE (Green Dot)
TSS = FULL-STROKE PTFE
W/SANIFLEX™ BACK-UP
TWS = FULL-STROKE PTFE
W/WIL-FLEX™ BACK-UP
VTS = VITON®(White Dot)
WWL = WIL-FLEX™ IPD [Santoprene®
(Orange Dot)]
XBS = CONDUCTIVE BUNA-N
(Two Red Dots)
ZGS = GEOLAST®, EZ-INSTALL
ZPS = POLYURETHANE, EZ-INSTALL
ZSS = SANIFLEX™, EZ-INSTALL
ZWS= WIL-FLEX™, EZ-INSTALL
VALVE BALLS
BN = BUNA-N (Red Dot)
FS = SANIFLEX™ [Hytrel®(Cream)]
FW = SANITARY WIL-FLEXTM
[Santoprene®
(Two Orange Dots)]
EP = EPDM (Blue Dot)
NE = NEOPRENE (Green Dot)
PU = POLYURETHANE (Brown)
TF = PTFE (White)
VT = VITON®(Silver or White Dot)
WF = WIL-FLEX™ [Santoprene®
(Orange Dot)]
VALVE SEATS
BN = BUNA-N (Red Dot)
EP = EPDM (Blue Dot)
FS = SANIFLEX™ [Hytrel®(Cream)]
FW = SANITARY WIL-FLEXTM
[Santoprene®
(Two Orange Dots)]
M = MILD STEEL
NE = NEOPRENE (Green Dot)
PU = POLYURETHANE (Brown)
S = STAINLESS STEEL
VT = VITON®(White Dot)
WF = WIL-FLEX™ [Santoprene®
(Orange Dot)]
VALVE SEAT O-RINGS
TF = PTFE (White)
SPECIALTY CODES
0014 BSPT
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

WIL-11520-E-07 3 WILDEN PUMP & ENGINEERING, LLC
Section 3
HOW IT WORKS—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 the back side of diaphragm A. The
compressed air is applied directly to the
liquid column separated by elastomeric
diaphragms. The diaphragm acts as
a separation membrane between the
compressed air and liquid; a balanced
load removes mechanical stress from the
diaphragm. The compressed air moves
the diaphragm away from the center
of the pump. The opposite diaphragm
is pulled in by the shaft connected to
the pressurized diaphragm. Diaphragm
B is on its suction stroke; air behind
the diaphragm has been forced out to
atmosphere through the exhaust port of
the pump. The movement of diaphragm
B toward the center of the pump creates
a vacuum within chamber B. Atmospheric
pressure forces fluid into the inlet
manifold forcing the inlet valve ball off its
seat. Liquid is free to move past the inlet
valve ball and fill the liquid chamber (see
shaded area).
FIGURE 2 When the pressurized dia-
phragm , diaphragm A, reaches the limit
of its discharge stroke, the air valve
redirects pressurized air to the back side of
diaphragm B. The pressurized air forces
diaphragm B away from the center
while pulling diaphragm A to the center.
Diaphragm B is now on its discharge
stroke. Diaphragm B forces the inlet valve
ball onto its seat due to the hydraulic
forces developed in the liquid chamber
and manifold of the pump. These same
hydraulic forces lift the discharge valve
ball off its seat, 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. Atmos-
pheric 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 completion of the stroke,
the air valve again redirects air to the
back side of diaphragm A, which starts
diaphragm B on its exhaust stroke. As
the pump reaches its original starting
point, each diaphragm has gone through
one exhaust and one discharge stroke.
This constitutes one complete pumping
cycle. The pump may take several cycles
to completely prime depending on the
conditions of the application.
OUTLET
CLOSED
CLOSEDOPEN
OPEN
INLET
B A
OUTLET
CLOSED
CLOSED OPEN
OPEN INLET
B A
OUTLET CLOSED
CLOSED OPEN
OPEN
INLET
B A
HOW IT WORKS—AIR DISTRIBUTION SYSTEM
The heart of the patented Pro-Flo®SHIFT Air Distribution
System (ADS) is the air valve assembly. The air valve design
incorporates an unbalanced spool with the small end of the
spool being pressurized continuously while the large end of
the spool is alternately pressurized, then exhausted to move
the spool. The air valve spool directs pressurized air to one
chamber while exhausting the other. The air forces the main
shaft/diaphragm assembly to move to one side – discharging
liquid on that side and pulling liquid in on the other side. When
the shaft reaches the end of the stroke, the inner piston actuates
the pilot spool, which controls the air to the large end of the air
valve spool. The repositioning of the air valve spool routes the
air to the other air chamber. The air control spool allows air to
flow freely into the air chamber for the majority of each pump
stroke, but it significantly restricts the flow of air into the air
chamber when activated by the inner piston near the end of the
each stroke.

WILDEN PUMP & ENGINEERING, LLC 4 WIL-11520-E-07
Section 4
DIMENSIONAL DRAWINGS
PS1520 Aluminum
PS1520 Stainless Steel
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 635 25.0
B 61 2.4
C 426 16.8
D 759 29.9
E 818 32.2
F 84 3.3
G 414 16.3
H 48 1.9
J 211 8.3
K 189 7.4
L 720 28.4
M 358 14.1
N 307 12.1
P 257 10.1
R 282 11.1
S 15 0.6
LW0258 REV. B
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 650 25.6
B 71 2.8
C 443 17.5
D 765 30.1
E 815 32.1
F 71 2.8
G 431 17.0
H 48 1.9
J 211 8.3
K 189 7.4
L 184 7.3
M 721 28.4
N 715 28.2
P 356 14.0
R 305 12.0
S 257 10.1
T 279 11.0
U 15 0.6
LW0259 REV. C

WIL-11520-E-07 5 WILDEN PUMP & ENGINEERING, LLC
DIMENSIONAL DRAWINGS
PS1530 Metal DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 673 26.5
B 105 4.1
C 477 18.8
D 796 31.3
E 890 35.1
F 891 35.3
G 90 3.6
H 88 3.5
J 465 18.3
K 48 1.9
L 211 8.3
M 189 7.4
N 184 7.3
P 721 28.4
R 715 28.2
S 356 14.0
T 305 12.0
U 256 10.1
V 279 11.0
W 14 0.6
DIN (mm) ANSI (inch)
X 200 DIA. 7.5 DIA.
Y 160 DIA. 6.0 DIA.
Z 18 DIA. 0.8 DIA.
LW0260 REV. C
PS1520 Ductile Iron
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 670 26.5
B 61 2.4
C 437 17.2
D 757 29.8
E 810 31.9
F 71 2.8
G 425 16.7
H 48 1.9
J 211 8.3
K 189 7.4
L 721 28.4
M 360 14.2
N 305 12.0
P 257 10.1
R 279 11.0
S 15 0.6
LW0350 REV. A

WILDEN PUMP & ENGINEERING, LLC 6 WIL-11520-E-07
PS1530 Aluminum
DIMENSIONAL DRAWINGS
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 615 24.2
B 127 5.0
C 545 21.5
D 934 36.8
E 1031 40.6
F 165 6.5
G 533 21.0
H 48 1.9
J 211 8.3
K 400 15.8
L 721 28.4
M 363 14.3
N 307 12.1
P 259 10.2
R 282 11.1
S 18 0.7
DIN (mm) ANSI (inch)
T 200 DIA. 7.5 DIA.
U 160 DIA. 6.0 DIA.
V 18 DIA. 0.8 DIA.
LW0363 REV. A

Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.
PS1520/PS1530 METAL
EZ-INSTALL TPE-FITTED
1520Threaded AL.................. 69 kg (152 lb)
1520Threaded SS ............... 126 kg (278 lb)
1520Threaded Iron .............. 114 kg (251 lb)
1530 Flanged AL...................101 kg (223 lb)
1530 Flanged SS ................. 137 kg (300 lb)
1530 Flanged Iron ............... 124 kg (272 lb)
Air Inlet .................................................. 3/4”
Inlet ............................................ 76 mm (3”)
Outlet ......................................... 76 mm (3”)
Suction Lift .................. 6.4 m Dry (21.1’) AL
9.0 m Wet (29.5’) AL
5.4 m Dry (17.6’) SS
8.6 m Wet (28.4’) SS
5.2 m Dry (17.0’) Iron
9.7 m Wet (31.8’) Iron
Disp. per Stroke1............ 5.1 L (1.35 gal) AL
5.4 L (1.43 gal) SS
5.1 L (1.34 gal) Iron
Max. Flow Rate .......... 1026 lpm (271 gpm)
Max. Size Solids..................12.7 mm (1/2”)
1Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2.1 bar (30 psig) head pressure.
Example: To pump 337 lpm (89 gpm)
against a discharge head of 2.8 bar (40
psig) requires 4.1 bar (60 psig) and 85
Nm3/h (50 scfm) air consumption.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.
PS1520/PS1530 METAL
RUBBER-FITTED
1520Threaded AL.................. 69 kg (152 lb)
1520Threaded SS ............... 126 kg (278 lb)
1520Threaded Iron .............. 114 kg (251 lb)
1530 Flanged AL ..................101 kg (223 lb)
1530 Flanged SS ................. 137 kg (300 lb)
1530 Flanged Iron ............... 124 kg (272 lb)
Air Inlet .................................................. 3/4”
Inlet ............................................ 76 mm (3”)
Outlet ......................................... 76 mm (3”)
Suction Lift ...................7.2 m Dry (23.8’) AL
9.0 m Wet (29.5’) AL
6.0 m Dry (19.7’) SS
8.6 m Wet (28.4’) SS
6.7 m Dry (22.1’) Iron
9.7 m Wet (31.8’) Iron
Disp. per Stroke1............ 5.1 L (1.35 gal) AL
5.0 L (1.32 gal) SS
5.0 L (1.31 gal) Iron
Max. Flow Rate .......... 1026 lpm (271 gpm)
Max. Size Solids..................12.7 mm (1/2”)
1Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2.1 bar (30 psig) head pressure.
Example: To pump 700 lpm (185 gpm)
against a discharge head of 1.4 bar (20
psig) requires 5.5 bar (80 psig) and 161
Nm3/h (95 scfm) air consumption.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
WIL-11520-E-07 7 WILDEN PUMP & ENGINEERING, LLC
Section 5
PERFORMANCE

Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.
PS1520/PS1530 METAL
FULL-STROKE PTFE-FITTED
1520Threaded AL.................. 69 kg (152 lb)
1520Threaded SS ............... 126 kg (278 lb)
1530 Flanged AL...................101 kg (223 lb)
1530 Flanged SS ................. 137 kg (300 lb)
Air Inlet .................................................. 3/4”
Inlet ............................................ 76 mm (3”)
Outlet ......................................... 76 mm (3”)
Suction Lift ..................6.2 m Dry (20.2’) AL
8.6 m Wet (28.4’) AL
5.9 m Dry (19.3’) SS
8.6 m Wet (28.4’) SS
Disp. per Stroke1............ 4.9 L (1.30 gal) AL
5.0 L (1.32 gal) SS
Max. Flow Rate ............ 992 lpm (262 gpm)
Max. Size Solids..................12.7 mm (1/2”)
1Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2.1 bar (30 psig) head pressure.
Example: To pump 420 lpm (111 gpm)
against a discharge head of 2.8 bar (40
psig) requires 4.8 bar (70 psig) and 110
Nm3/h (65 scfm) air consumption.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.
PS1520/PS1530 DUCTILE IRON
FULL-STROKE PTFE-FITTED
1520Threaded Iron .............. 114 kg (251 lb)
1530 Flanged Iron ............... 124 kg (272 lb)
Air Inlet .................................................. 3/4”
Inlet ............................................ 76 mm (3”)
Outlet ......................................... 76 mm (3”)
Suction Lift ..................... 5.94 m Dry (19.5’)
9.66 m Wet (31.7’)
Disp. per Stroke1..................4.8 L (1.26 gal)
Max. Flow Rate ............ 874 lpm (231 gpm)
Max. Size Solids..................12.7 mm (1/2”)
1Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2.1 bar (30 psig) head pressure.
Example: To pump 360 lpm (95 gpm)
against a discharge head of 3.4 bar (50
psig) requires 5.5 bar (80 psig) and 118
Nm3/h (75 scfm) air consumption.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
WILDEN PUMP & ENGINEERING, LLC 8 WIL-11520-E-07
PERFORMANCE