Graco 3A1973B User Manual

Instructions/Parts List

™

SaniForce

515

Diaphragm Pumps

For use in sanitary applications. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

100 psi (0.7 MPa, 6.9 bar) Maximum Fluid Working Pressure 100 psi (0.7 MPa, 6.9 bar) Maximum Air Input Pressure

3A1973B

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Models

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

General Information . . . . . . . . . . . . . . . . . . . . . . 6

Tighten Clamps Before First Use . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fluid Suction Line . . . . . . . . . . . . . . . . . . . . . . . . 7

Fluid Outlet Line . . . . . . . . . . . . . . . . . . . . . . . . . 8

Changing the Orientation of the

Fluid Inlet and Outlet Ports . . . . . . . . . . . . . . 9

Air Exhaust Ventilation . . . . . . . . . . . . . . . . . . . 10

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Pressure Relief Procedure . . . . . . . . . . . . . . . . 11

Sanitize the Pump Before First Use . . . . . . . . . 11

Starting and Adjusting the Pump . . . . . . . . . . . 11

Pump Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Air Valve Lubrication . . . . . . . . . . . . . . . . . . . . . 12

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Tightening Connections . . . . . . . . . . . . . . . . . . . 12

Preventive Maintenance Schedule . . . . . . . . . . 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Ball Check Valve . . . . . . . . . . . . . . . . . . . . . . . . 16

Standard Diaphragms . . . . . . . . . . . . . . . . . . . . 16

Overmolded PTFE Diaphragms . . . . . . . . . . . . 18

Air Center Service . . . . . . . . . . . . . . . . . . . . . . . 19

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fluid Section Repair Kits . . . . . . . . . . . . . . . . . . . 22

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 24

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 28

Models

Model Seats O-Rings Balls Diaphragms

FD5111

FD5113

FD5122

FD5611

FD5613

FD5622

PTFE

Stainless Steel

EPDM

PTFE 2-Piece PTFE

PTFE Overmolded PTFE

Santoprene Santoprene

PTFE 2-Piece PTFE

PTFE Overmolded PTFE

Santoprene Santoprene

2 3A1973B

Material Certification

Reference: SaniForce Product Family

Issue Date: November 1, 2011

All fluid contact materials in the SaniForce product family are FDA-Compliant and meet the United States Code of Federal Regulations (CFR) Title 21, Section 177 or are of a corrosion resistant grade Stainless Steel. This includes the below product groups:

1. SaniForce 515, 1040, 1590, 2150 Air-Operated Double Diaphragm Pumps

2. SaniForce 1590, 3150 HS Air-0perated Double Diaphragm Pumps

3. SaniForce 1590, 3150 HS 3-A Certified Air-Operated Double Diaphragm Pumps

4. SaniForce 5:1, 6:1 and 12:1 Air-Operated Piston Pumps

5. SaniForce Diaphragm Pump and Piston Pump Drum Unloaders

6. SaniForce Diaphragm Pump and Piston Pump Bin Evacuation Systems

Models

Bradley A. Byron Quality Manager Graco Inc.

3A1973B 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. When these symbols appear in the body of this manual, refer back to these Warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

4 3A1973B

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

3A1973B 5

Installation

General Information

• The typical installation shown in FIG. 2, page 8, 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.

• Reference numbers and letters in parentheses refer to the callouts in the figures.

The pump is heavy and may cause injury if dropped. Lift the pump by grasping the outlet manifold securely.

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If dropped, the pump may rupture. To avoid serious injury from splashing fluid, follow the Pressure Relief Procedure on page 11 before moving the pump.

To reduce the risk of serious injury due to burns, insulate the pump before pumping hot fluids.

Tighten Clamps Before First Use

After you unpack the pump, and before you use it for the first time, check all clamps and tighten as necessary.

Grounding

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

FIG. 1: Ground the pump

• 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 recommendations.

• 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.

• Fluid supply container: Follow the local code.

• Pump: Attach a ground wire (Y) to the grounding strip (8) with the screw (9a), lockwasher (9b), and nut (9c), as shown in F Connect the clamp end of the ground wire to a true earth ground. Order Part No. 238909 Ground Wire and Clamp.

6 3A1973B

IG. 1, and per local code.

Mounting

Installation

NOTICE

Pump exhaust air may contain contaminants that can contaminate the fluid supply. Ventilate to a remote area. See Air Exhaust Ventilation on page 10.

• Be sure the mounting surface can support the weight of the pump, hoses, and accessories, as well as the stress caused during operation.

• For all mountings, be sure the pump is bolted directly to the mounting surface.

• For ease of operation and service, mount the pump so the air valve cover, air inlet, and fluid inlet and outlet ports are easily accessible.

Air Line

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. A bleed-type master air valve (B) is required in the system to relieve air trapped between this valve and the pump. See F

IG. 2, page 8.

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/filter assembly (C) and

gauge to control the fluid pressure. The fluid outlet pressure will be the same as the setting of the air regulator. The air line filter removes harmful dirt and moisture from the compressed air supply.

In the step below, do not connect the quick-disconnect coupler (D) on the air hose to the mating fitting on the pump until you are ready to operate the pump. Connecting the coupler too early can result in unintentional operation of the pump, leading to serious injury from moving parts, splashing fluid in the eyes or on the skin, and contact with hazardous fluids.

2. Install a grounded, flexible air hose (A) between the accessories and the 1/4 npt(f) pump air inlet. Use a minimum 1/4 in. (6.3 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.

Fluid Suction Line

1. Use flexible, grounded fluid hoses (F). The inlet fits sanitary tubing of 1 to 1.5-inch OD.

2. For best sealing results, use a standard Tri-Clamp® style sanitary gasket of a flexible material such as EPDM or Buna-N.

3. 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. Excessive inlet fluid pressure also will shorten diaphragm life. Approximately 3 - 5 psi (0.02 - 0.03 MPa, 0.21-0.34 bar) should be adequate for most materials.

4. For maximum suction lift (wet and dry), see Techni- cal Data, page 26. For best results, always install the pump as close as possible to the material source.

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.

3A1973B 7

Installation

Fluid Outlet Line

A fluid drain valve (G) 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 F

Key:

A Air supply line B Bleed-type master air valve

(required for pump) C Air regulator/filter assembly D Air line quick disconnect E Master air valve (for accessories) F Flexible fluid suction line G Fluid drain valve (required) H Fluid shutoff valve J Flexible fluid line Y Ground wire (required; see

page 6 for installation

instructions).

IG. 2.

1. Use flexible grounded fluid hoses (J).

2. For best sealing results, use a standard Tri-Clamp® style sanitary gasket of a flexible material such as EPDM, Buna-N.

3. Install a fluid drain valve (G) near the fluid outlet. See the WARNING, and F

IG. 2.

4. Install a shutoff valve (H) in the fluid outlet line.

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IG. 2: Typical Floor-Mount Installation

8 3A1973B

Changing the Orientation of the Fluid Inlet and Outlet Ports

The pump is shipped with the ports facing the same direction. To reverse the orientation of the ports:

1. Remove the clamps (12) holding the inlet and/or outlet manifold to the covers.

NOTE: Inspect the o-rings and replace as needed.

2. Reverse the manifold and reattach. Install and tighten clamps snugly.

Installation

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IG. 3: Reverse the Manifolds

3A1973B 9

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