Graco 308549ZAD User Manual
Instructions – Parts List
POLYPROPYLENE AND PVDF
Huskyt 1590 Air-Operated
308549ZAD
Diaphragm Pumps
1.5–inch AODD pump for fluid transfer applications. For professional
use only.
Not approved to European explosive atmosphere requirements.
See Models on page 2 for a list of pump models and descriptions.
120 psi (0.84 MPa, 8.4 bar) Maximum Fluid Working Pressure
120 psi (0.84 MPa, 8.4 bar) Maximum Air Input Pressure
EN
Important Safety Instructions
Read all warnings and instructions in
this manual. Save these instructions.
04700B
Table of Contents
Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Repairing the Air Valve 16. . . . . . . . . . . . . . . . . . . . . .
Ball Check Valve Repair 18. . . . . . . . . . . . . . . . . . . . .
Diaphragm Repair 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing and Air Gasket Removal 23. . . . . . . . . . . . .
Models
Model No. Description
*DB2______ Polypropylene Pumps
*DC2______ Polypropylene Pumps, Remote
Pump Matrix 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Matrix 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart 35. . . . . . . . . . .
Graco Standard Warranty 36. . . . . . . . . . . . . . . . . . . . . .
Graco Information 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*DB5______ PVDF Pumps
*DC5______ PVDF Pumps, Remote
*DT2______ Polypropylene Plus Pumps
*DU2______ Polypropylene Plus Pumps, Remote
*DT5______ PVDF Plus Pumps
*DU5______ PVDF Plus Pumps, Remote
24B758 PVDF Plus Pump with overmolded diaphragms
24B759 Polypropylene Plus Pump with overmolded diaphragms
24B760 Polypropylene Pump with overmolded diaphragms
24B761 Polypropylene Pump with overmolded diaphragms and sst seats
24B832 PVDF Pump with overmolded diaphragms
* See the Pump Matrix on page 26 to determine the Model No. of your pump.
NOTE: Plus Models include stainless steel center sections.
2 308549
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
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call Graco your Graco
distributor.
D Do not alter or modify this equipment.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 120 psi (0.84 MPa, 8.4 bar) maximum working pressure at 120 psi
(0.84 MPa, 8.4 bar) maximum incoming air pressure.
D 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.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82_ C (180_ F) or below –40_ C (–40_ F).
D Do not lift pressurized equipment.
D Wear hearing protection when operating this equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
308549 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.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
D 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 11.
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.
D Ground the equipment. Refer to Grounding on page 6.
D Never use a polypropylene or PVDFR pump with non-conductive flammable fluids as specified
by your local fire protection code. Refer to Grounding on page 6 for additional information.
Consult your fluid supplier to determine the conductivity or resistivity of your fluid.
D 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.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed, dispensed, or transferred.
D 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 11.
D Keep the work area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the work area.
D Extinguish all open flames or pilot lights in the work area.
D Do not smoke in the work area.
D Do not turn on or off any light switch in the work area while operating or if fumes are present.
D Do not operate a gasoline engine in the work area.
4 308549
Installation
General Information
D The Typical Installation shown in Fig. 2 is only a
guide for selecting and installing system components. Contact your Graco distributor or Graco
Technical Assistance (see back page) for assistance in planning a system to suit your needs.
D Always use Genuine Graco Parts and Accessories.
Be sure all accessories are adequately sized and
pressure-rated to meet the system’s requirements.
D Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 30 to 31.
D Variations in color between the plastic components
of this pump are normal. Color variation does not
affect the performance of the pump.
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.
Tighten Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Se-
quence, page 32. After the first day of operation,
retorque the fasteners. Although pump use varies, a
general guideline is to retorque fasteners every two
months.
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.
308549 5
Installation
B
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.
Polypropylene and PVDF are not conductive.
Attaching the ground wire to the grounding lug
grounds only the air motor. When pumping conductive flammable fluids, always ground the entire
fluid system by making sure the fluid has an electrical path to a true earth ground. See Fig. 1.
Never use a polypropylene or a PVDF pump with
non-conductive flammable fluids as specified by
your local fire protection code.
US Code (NFPA 77 Static Electricity) recommends
a conductivity greater than 50 x 10
ter (mhos/meter) over your operating temperature
range to reduce the hazard of fire. Consult your
fluid supplier to determine the conductivity or
resistivity of your fluid. The resistivity must be less
than 2 x 1012 ohm-centimeters.
–12
Siemans/me-
Ground all of this equipment:
D 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. 237569 Ground Wire and Clamp.
NOTE: When pumping conductive flammable fluids
with a polypropylene or a PVDF pump, always ground
the entire fluid system. See the WARNING on
page 6.
D Air and fluid hoses: Use only electrically conductive
hoses.
D Air compressor: Follow the manufacturer’s recom-
mendations.
D All solvent pails used when flushing: Follow your
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.
D Fluid supply container: Follow your local code.
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.
6 308549
Fig. 1
Y
W
02646
Installation
Air Line
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 electrically conductive.
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 at left. Locate the other
master air valve (E) upstream from all air line
accessories and use it to isolate them during
cleaning and repair.
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
2. Install an electrically conductive, flexible air hose
(A) between the accessories and the 1/2 npt(f)
pump air inlet (N). See Fig. 2. Use a minimum 1/2”
(13 mm) ID air hose.
3. Screw an air line quick disconnect coupler (D) onto
the end of the air hose (A); be sure the coupler
porting is large enough to not restrict the air flow,
which will affect pump performance. 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.
Floor Mount Typical Installation
KEY FOR FIG. 2
A Electrically conductive 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
N 1/2 npt(f) air inlet port
R 1–1/2” fluid inlet flange
S 1–1/2” fluid outlet flange
Y Ground wire (required; see page 6
for installation instructions)
Y J
B
C
E
F
A
D
S
KL
N
H
R
G
Fig. 2
04701B
308549 7
Installation
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.
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.
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 11.
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.
Fluid Suction Line
1. The pump fluid inlet (R) is a 1–1/2 in. raised face
flange. Refer to Flange Connections on page 9.
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 35 for maximum
suction lift (wet and dry).
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.
1. The pump fluid outlet (S) is a 1–1/2 in. raised face
flange. Refer to Flange Connections on page 9.
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.
8 308549
Installation
Flange Connections
The fluid inlet and outlet ports are 1–1/2 in. raised
face, standard 150 lb class pipe flanges. Connect
1–1/2 in. flanged plastic pipe to the pump as follows.
You will need:
D Torque wrench
D Adjustable wrench
D a 5 in. diameter, 1/8 in. thick PTFE gasket, with
four 0.63 in. diameter holes on a 3.88 in. diameter
bolt circle, and a 1.75 in. diameter center
D four 1/2 in. x 3 in. bolts
D four 1/2 in. spring lockwashers
D eight 1/2 in. flat washers
D four 1/2 in. nuts.
1. Place a flat washer (E) on each bolt (C). Refer to
Fig. 3.
2. Align the holes in the gasket (B) and the pipe
flange (A) with the holes in the pump outlet flange
(S).
3. Lubricate the threads of the four bolts. Install the
bolts through the holes and secure with the washers (E), lockwashers (D), and nuts (F).
4. Hold the nuts with a wrench. Refer to the tightening sequence in Fig. 3 and torque the bolts to 10 to
15 ft-lb (14 to 20 NSm). Do not over-torque.
5. Repeat for the pump inlet flange (R).
BOLT TIGHTENING SEQUENCE
1
3
F
D
E
2
1
4
S
B
04405
A
E
C
1
R
KEY FOR FIG. 3
A Flanged plastic pipe
B PTFE gasket
C Bolt
D Lockwasher
E Flat washer
FNut
R 1–1/2” fluid inlet flange
S 1–1/2” fluid outlet flange
Fig. 3
Lubricate threads. Torque to 10 to 15 ft-lb
1
(14–20 N-m). Do not over-torque.
04703B
308549 9
Installation
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. 4. To
change the orientation of the inlet and/or outlet port:
1. Remove the screws (106 and 112) holding the inlet
(102) and/or outlet (103) manifold to the covers
(101).
2. Reverse the manifold and reattach. Install the
screws and torque to 80 to 90 in-lb (9 to 10 NSm).
See Torque Sequence, page 32.
KEY
N 1/2 npt(f) Air Inlet Port
P Muffler; Air Exhaust Port
is 3/4 npt(f)
R 1–1/2” Fluid Inlet Flange
S 1–1/2” Fluid Outlet Flange
1
Torque to 80 to 90 in-lb (9 to 10 NSm).
See Torque Sequence, page 32.
101 Fluid Covers
102 Fluid Inlet Manifold
103 Fluid Outlet Manifold
106 Fluid Outlet Manifold
Screws (Top)
112 Fluid Inlet Manifold
Screws (Bottom)
103
106
1
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. 5.
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 1–1/2” fluid inlet flange
S 1–1/2” fluid outlet flange
V Pressure relief valve
Part No. 112119 (stainless steel)
N
P
Fig. 4
102
112
S
1
Install valve between fluid inlet and outlet ports.
2
Connect fluid inlet line here.
3
Connect fluid outlet line here.
S
3
101
R
1
04700B
R
Fig. 5
V
2
1
04702B
10 308549
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. 6.
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 an electrically conductive 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. 6.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
Venting Exhaust Air
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
P Muffler
T Electrically conductive air exhaust hose
U Container for remote air exhaust
A
T
U
P
Fig. 6
04704
308549 11
Loading...