Graco 308441ZAD User Manual

Instructions – Parts List
ALUMINUM AND STAINLESS STEEL
Huskyt 1590 Air-Operated
308441ZAD
Diaphragm Pumps
1.5–inch AODD pump for fluid transfer applications. For professional use only.
See Models on page 2 for a list of pump models and descriptions.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure 120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
Patent No. CN ZL94102643.4 FR 9408894 JA 3517270 US 5,386,452
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
ENG
Model No. DB3777 shown
03263B
Table of Contents
Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Repairing the Air Valve 14. . . . . . . . . . . . . . . . . . . . . .
Ball Check Valve Repair 16. . . . . . . . . . . . . . . . . . . . .
Diaphragm Repair 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing and Air Gasket Removal 20. . . . . . . . . . . . .
Models
Model No. Description
*DB3______ Aluminum Pumps *DC3______ Aluminum Pumps, Remote *DB4______ Stainless Steel Pumps
Pump Matrix 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Matrix 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Chart 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranties 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*DC4______ Stainless Steel Pumps, Remote *DBC______ Aluminum BSPT Pumps *DCC______ Aluminum BSPT Pumps, Remote *DBD______ Stainless Steel BSPT Pumps *DCD______ Stainless Steel BSPT Pumps, Remote *DT4______ Stainless Steel Plus Pumps *DU4______ Stainless Steel Plus Pumps, Remote *DTD______ Stainless Steel BSPT Plus Pumps *DUD______ Stainless Steel BSPT Plus Pumps, Remote 253485 Aluminum Pump 232502 Private–Label Aluminum Pump 24B780 Stainless Steel Plus Pump with overmolded diaphragms 24B781 Stainless Steel Pump with overmolded diaphragms 24G411 Aluminum BSPT Pump with overmolded diaphragms 24J358 Aluminum Pump with overmolded diaphragms 24J359 Aluminum Pump with overmolded diaphragms
* Refer to the Pump Matrix on page 22 to determine the Model No. of your pump. NOTE: Plus Models include stainless steel center sections.
2 308441
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi (0.8 MPa, 8 bar) maximum incoming air pressure.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
308441 3
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas.
If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury.
Ground the equipment. Refer to Grounding on page 5.
If there is any static sparking or you feel an electric shock while using this equipment, stop
pumping immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm
fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.
Keep the work area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the work area.
Extinguish all open flames or pilot lights in the work area.
Do not smoke in the work area.
Do not turn on or off any light switch in the work area while operating or if fumes are present.
Do not operate a gasoline engine in the work area.
4 308441
Installation
General Information
The typical installation shown in Fig. 2 is only a
guide for selecting and installing system compo­nents. Contact your Graco distributor for assistance in planning a system to suit your needs.
Always use Genuine Graco Parts and Accessories.
Refer to Product Data Sheet 305646.
Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on pages 25–24.
Lift the pump by grasping the outlet manifold (1)
securely. See Fig. 3 on page 8.
WARNING
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or
swallowed.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before operating the pump, ground the system as explained below. Also, read the sec­tion FIRE AND EXPLOSION HAZARD, on page 4.
To reduce the risk of static sparking, ground the pump and all other equipment used or located in the pumping area. Check your local electrical code for detailed grounding instructions for your area and type of equip­ment. Ground all of this equipment:
Pump: Connect a ground wire and clamp as shown
in Fig. 1. Loosen the grounding screw (W). Insert one end of a 12 ga (1.5 mm) minimum ground wire (Y) behind the grounding screw and tighten the screw securely. Connect the clamp end of the ground wire to a true earth ground. Order Part No. 222011 Ground Wire and Clamp.
Y
1. Read TOXIC FLUID HAZARD on page 4.
2. Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manu­als. Read the fluid and solvent manufacturer’s warnings.
Tightening Screws Before First Use
Before using the pump for the first time, check and retorque all external fasteners. See Torque Se- quence, page 28. After the first day of operation, retorque the fasteners. Although pump use varies, a general guideline is to retorque fasteners every two months.
W
Fig. 1
Air and fluid hoses: Use only grounded hoses with
a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity.
Air compressor: Follow the manufacturer’s recom-
mendations.
All solvent pails used when flushing: Follow the
local code. Use only metal pails, which are conduc­tive. Do not place the pail on a non-conductive surface, such as paper or cardboard, which inter­rupts the grounding continuity.
02646B
Fluid supply container: Follow the local code.
308441 5
Installation
Mountings
CAUTION
The pump exhaust air may contain contaminants. Ventilate to a remote area if the contaminants could affect your fluid supply. See Air Exhaust Ventilation on page 9.
1. Be sure the mounting surface can support the weight of the pump, hoses, and accessories, as well as the stress caused during operation.
2. For all mountings, be sure the pump is bolted directly to the mounting surface.
3. For ease of operation and service, mount the pump so the air valve cover (2), air inlet, and fluid inlet and outlet ports are easily accessible.
4. Rubber Foot Mounting Kit 236452 is available to reduce noise and vibration during operation.
Air Line
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
2. Install a grounded, flexible air hose (A) between the accessories and the 1/2 npt(f) pump air inlet (N). See Fig. 3. Use a minimum 1/2 in. (13 mm) ID air hose. Screw an air line quick disconnect cou­pler (D) onto the end of the air hose (A), and screw the mating fitting into the pump air inlet snugly. Do not connect the coupler (D) to the fitting until you are ready to operate the pump.
Installation of Remote Pilot Air Lines
1. Refer to Parts Drawings. Connect air line to pump as in preceding steps.
2. Connect 1/4 in. O.D. tubing to push type connec­tors (14) on air motor of pump.
NOTE: by replacing the push type connectors, other sizes or types of fittings may be used. The new fittings will require 1/8 in. npt threads.
WARNING
A bleed-type master air valve (B) is required in your system to relieve air trapped between this valve and the pump. Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury, including splashing in the eyes or on the skin, injury from moving parts, or contamination from hazardous fluids. See Fig. 2.
1. Install the air line accessories as shown in Fig. 2. Mount these accessories on the wall or on a bracket. Be sure the air line supplying the acces­sories is grounded.
a. Install an air regulator (C) and gauge to control
the fluid pressure. The fluid outlet pressure will be the same as the setting of the air regulator.
b. Locate one bleed-type master air valve (B)
close to the pump and use it to relieve trapped air. See the WARNING above. Locate the other master air valve (E) upstream from all air line accessories and use it to isolate them during cleaning and repair.
3. Connect remaining ends of tubes to external air signal, such as Graco’s Cycleflo (P/N 195264) or Cycleflo II (P/N195265) controllers.
NOTE: the air pressure at the connectors must be at least 30% of the air pressure to the air motor for the pump to operate.
Fluid Suction Line
1. Use grounded fluid hoses (G). The pump fluid inlet (R) is 1–1/2 in. npt(f). Screw the fluid fitting into the pump inlet securely.
2. If the fluid inlet pressure to the pump is more than 25% of the outlet working pressure, the ball check valves will not close fast enough, resulting in inefficient pump operation.
3. At inlet fluid pressures greater than 15 psi (0.1 MPa, 1 bar), diaphragm life will be shortened.
4. See the Technical Data on page 30 for maximum suction lift (wet and dry).
6 308441
Installation
Fluid Outlet Line
WARNING
A fluid drain valve (J) is required to relieve pres­sure in the hose if it is plugged. The drain valve reduces the risk of serious injury, including splash­ing in the eyes or on the skin, or contamination from hazardous fluids when relieving pressure. Install the valve close to the pump fluid outlet. See Fig. 2.
TYPICAL FLOOR-MOUNT INSTALLATION
KEY
A Air supply hose B Bleed-type master air valve
(required for pump) C Air regulator D Air line quick disconnect E Master air valve (for accessories) F Air line filter G Fluid suction hose H Fluid supply J Fluid drain valve (required) K Fluid shutoff valve L Fluid hose R 1.5 npt(f) fluid inlet port S 1.5 npt(f) fluid outlet port Y Ground wire (required; see page 5
for installation instructions)
Y
1. Use grounded fluid hoses (L). The pump fluid
outlet (S) is 1–1/2 in. npt(f). Screw the fluid fitting into the pump outlet securely.
2. Install a fluid drain valve (J) near the fluid outlet.
See the WARNING above.
3. Install a shutoff valve (K) in the fluid outlet line.
BE
F
C
A
K
D
S
H
J
L
Fig. 2
Muffler not included on Model No. 253485
R
G
03265B
308441 7
Installation
s
Changing the Orientation of the Fluid Inlet and Outlet Ports
The pump is shipped with the fluid inlet (R) and outlet (S) ports facing the same direction. See Fig. 3. To change the orientation of the inlet and/or outlet port:
1. Remove the screws (106) holding the inlet (102) and/or outlet (103) manifold to the covers (101).
2. Reverse the manifold and reattach. Install the screws, and torque according to the torque notes in Fig. 3.
KEY
N 1/2 npt(f) air inlet port P Muffler. Air exhaust port
is 3/4 npt(f) . (Not included
on Model No. 253485)
R 1.5 npt(f) fluid
inlet port
S 1.5 npt(f) fluid
outlet port
Apply medium-strength (blue) Loctite or equivalent to the
1
threads. Torque to 120–150 in-lb (14–17 Nm). See Torque Sequence, page 28.
Apply medium-strength (blue) Loctite or equivalent to the
2
threads. Torque to 190–220 in-lb (22–25 Nm). See Torque Sequence, page 28.
N
101Covers 102 Fluid inlet manifold 103 Fluid outlet manifold 106 Manifold and cover screw 112 Bottom cover screws
103
1
106
S
Fluid Pressure Relief Valve
CAUTION
Some systems may require installation of a pres­sure relief valve at the pump outlet to prevent overpressurization and rupture of the pump or hose. See Fig. 4.
Thermal expansion of fluid in the outlet line can cause overpressurization. This can occur when using long fluid lines exposed to sunlight or ambi­ent heat, or when pumping from a cool to a warm area (for example, from an underground tank).
Overpressurization can also occur if the Husky pump is being used to feed fluid to a piston pump, and the intake valve of the piston pump does not close, causing fluid to back up in the outlet line.
KEY
R 1.5 npt(f) fluid inlet port S 1.5 npt(f) fluid outlet port V Pressure relief valve (Order Part No. 112119 for stainless steel
pumps)
1
Install valve between fluid inlet and outlet ports.
2 Connect fluid inlet line here.
Connect fluid outlet line here.
3
4 Muffler not included on Model No. 253485
S
3
P
102
Aluminum Model Shown
Fig. 3
8 308441
106
112
2
101
R
03263B
1
V
2
4
R
2
03461B
Fig. 4
Installation
Air Exhaust Ventilation
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings and precautions regarding TOXIC
FLUID HAZARD, and FIRE OR EXPLO­SION HAZARD on page 4, before op-
erating this pump.
Be sure the system is properly ventilated for your type of installation. You must vent the exhaust to a safe place, away from people, animals, food handl­ing areas, and all sources of ignition when pumping flammable or hazardous fluids.
Diaphragm failure will cause the fluid being pumped to exhaust with the air. Place an appropri­ate container at the end of the air exhaust line to catch the fluid. See Fig. 5.
VENTING EXHAUST AIR
The air exhaust port is 3/4 npt(f). Do not restrict the air exhaust port. Excessive exhaust restriction can cause erratic pump operation.
If the muffler (P) is installed directly to the air exhaust port, apply PTFE thread tape or anti–seize thread lubricant to the muffler threads before assembly.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust port.
2. Install a grounded air exhaust hose (T) and con­nect the muffler (P) to the other end of the hose. The minimum size for the air exhaust hose is 3/4 in. (19 mm) ID. If a hose longer than 15 ft (4.57 m) is required, use a larger diameter hose. Avoid sharp bends or kinks in the hose. See Fig. 5.
3. Place a container (U) at the end of the air exhaust line to catch fluid in case a diaphragm ruptures.
Fig. 5
FBEC
D
KEY
A Air supply line B Bleed-type master air valve
(required for pump) C Air regulator D Air line quick disconnect E Master air valve (for accessories) F Air line filter
A
P Muffler (not included on
Model No. 253485)
T Grounded air exhaust hose U Container for remote air exhaust
T
U
P
03267A
308441 9
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is manually relieved. To reduce the risk of serious injury from pressurized fluid, accidental spray from the gun or splashing fluid, follow this procedure whenever you:
Are instructed to relieve pressure,Stop pumping,Check, clean or service any system equipment,Install or clean fluid nozzles.
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve all fluid pres­sure, having a container ready to catch the drain­age.
NOTE: If the fluid inlet pressure to the pump is more than 25% of the outlet working pressure, the ball check valves will not close fast enough, resulting in inefficient pump operation.
4. Place the end of the fluid hose (L) into an appropri­ate container.
5. Close the fluid drain valve (J). See Fig. 2.
6. Close the pump air regulator (C). Open all bleed­type master air valves (B, E).
7. If the fluid hose has a dispensing device, hold it open while continuing with the following step.
8. Slowly open the air regulator (C) until the pump starts to cycle. Allow the pump to cycle slowly until all air is pushed out of the lines and the pump is primed.
If you are flushing, run the pump long enough to thoroughly clean the pump and hoses. Close the air regulator. Remove the suction tube from the solvent and place it in the fluid to be pumped.
Flush the Pump Before First Use
The pump was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contam­inating your fluid with oil, flush the pump with a com­patible solvent before using the equipment. Follow the steps under Starting and Adjusting the Pump.
Starting and Adjusting the Pump
WARNING
TOXIC FLUID HAZARD
To reduce the risk of serious injury, splashing in the eyes or on the skin, and toxic fluid spills, never move or lift a
pump under pressure. If dropped, the fluid section may rupture. Always follow the Pressure Relief Procedure above before lifting the pump.
1. Be sure the pump is properly grounded. Refer to
Grounding on page 5.
Operation of Remote Piloted Pumps
1. Follow preceding steps 1 through 7 of Starting and Adjusting Pump.
2. Open air regulator (C).
WARNING
The pump may cycle once before the external sig­nal is applied. Injury is possible. If pump cycles, wait until end before proceeding.
3. Pump will operate when air pressure is alternately applied and relieved to push type connectors (14).
NOTE: Leaving air pressure applied to the air motor for extended periods when the pump is not running may shorten the diaphragm life. Using a 3–way solenoid valve to automatically relieve the pressure on the air motor when the metering cycle is complete prevents this from occurring.
Pump Shutdown
2. Check all fittings to be sure they are tight. Be sure to use a compatible liquid thread sealant on all male threads. Tighten the fluid inlet and outlet fittings securely.
3. Place the suction tube (if used) in the fluid to be pumped.
10 308441
WARNING
To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure at left.
At the end of the work shift, relieve the pressure.
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