Graco SaniForce 2150, SaniForce 3000, SaniForce 4000 Repair Manual

Repair/Parts

SaniForce® 2150, 3000, 4000,

Electric-Operated Diaphragm Pump	3A5133L
	EN

2-Inch, 3-Inch, and 4-Inch pumps with electric drive for fluid transfer applications.

Not approved for use in explosive atmospheres or hazardous (classified) locations unless otherwise stated. See Approvals page for more information. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual and in your Operation manual before using the equipment. Save these instructions.

For maximum working pressure, see

Technical Specification sheets.

See page 10 for approvals.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Related Manuals ................................................	2
Warnings ...........................................................	3
Configuration Number Matrix for 2150 FG
Pumps..................................................	6
Configuration Number Matrix for 2150, 3000,
and 4000 HS Pumps .............................	8
Approvals...........................................................	10
Ordering Information...........................................	11
Troubleshooting..................................................	12

Repair................................................................	14
Pressure Relief Procedure............................	14
Check Valve Repair .....................................	14
Standard Diaphragm Repair .........................	17
Overmolded Diaphragm Repair.....................	19
Center Section Repair..................................	21
Install Compressor Kits.................................	26
Replace the Compressor..............................	27
Parts..................................................................	28
Kits and Accessories....................................	38
Technical Specifications......................................	39

Related Manuals

Manual Number	Title
3A5132	SaniForce™ 2150, 3000, 4000, Electric-Operated Diaphragm Pump, Operation

3A5133L

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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

DANGER

SEVERE ELECTRIC SHOCK HAZARD

This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.

•Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

•This equipment must be grounded. Connect only to grounded power source.

•All electrical wiring must be done by a qualified electrician and comply with all local

codes and regulations.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent, in work area can ignite or explode. Solvent flowing through the equipment can cause static sparking. 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 sparking).

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

• 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.

• Use only grounded lines.

• 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.

Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable vapors. To help prevent fire and explosion:

•Clean plastic parts only in well ventilated area.

•Do not clean with a dry cloth.

3A5133L

Warnings

WARNING

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 fluid lines, tubes, and couplings daily. Replace worn or damaged parts immediately.

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 Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheet (SDS) from distributor or retailer.

•Turn off all equipment and follow the PressureReliefProcedurewhen 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 fluid lines and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

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

•Keep children and animals away from work area.

•Comply with all applicable safety regulations.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

•Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

•Do not use chlorine bleach.

•Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

3A5133L

Warnings

WARNING

THERMAL EXPANSION HAZARD

Fluids subjected to heat in confined spaces, including lines, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.

•Open a valve to relieve the fluid expansion during heating.

•Replace lines proactively at regular intervals based on your operating conditions.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

•Use only compatible solvents to clean plastic structural or pressure-containing parts.

•See Technical Specifications in all equipment manuals for materials of construction. Consult the solvent manufacturer for information and recommendations about compatibility.

•See Technical Specifications in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s Safety Data Sheet (SDS) and recommendations.

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 Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.

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

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.

3A5133L

Configuration Number Matrix for 2150 FG Pumps

Check the identification plate (ID) for the Configuration Number of your pump. Use the following matrix to define the components of your pump.

When you receive your pump, record the 9 character part number found on the shipping box (e.g., SP1B.0014):

_____________

Also record the configuration number on the pump ID plate to assist you when ordering replacement parts:

_____________________________________

Sample Configuration Number: 2150FG-EA04AS13SSPTPTPT21

2150

S13

Pump

Wetted

Drive

Center

Gear

Motor

Fluid Covers and

Seats

Balls

Diaphragms

Manifold

Certifica-

Model

Section

Box and

Manifolds

or Che-

Seals

tion

Compressor

cks

Pump

Wetted Section

Drive Type

Center Section

Gearbox and

Motor

Material

Compressor

2150

Food Grade

Electric

Aluminum

No Gearbox or

Standard

Compressor

Induction Motor

Stainless Steel

High Speed Gear

ATEX Induction

Ratio

Motor

High Speed

Flameproof

Gear Ratio/120V

Induction Motor

Compressor

High Speed

No Motor

Gear Ratio/240V

Compressor

Mid Speed Gear

Ratio

Mid Speed

Gear Ratio/120V

Compressor

Mid Speed

Gear Ratio/240V

Compressor

Low Speed Gear

Ratio

Low Speed

Gear Ratio/120V

Compressor

Low Speed

Gear Ratio/240V

Compressor

3A5133L

Configuration Number Matrix for 2150 FG Pumps

Fluid Covers and		Seat Material		Ball or Check		Diaphragm Material		Manifold		Certification
Manifolds				Material				Seals
S13	Stainless	SS	316	CW	Polychloro-	PT	PTFE/EPDM	EP	EPDM	blank	no certification
	steel,		Stainless		prene		2-Piece
	TriClamp		Steel		Weighted
S14	Stainless			PT	PTFE	SP	Santo-	PT	PTFE	21	EN 10204 type
	steel, DIN						prene/EPDM				2.1
							2–Piece
				SP	Santoprene					31	EN 10204 type
											3.1

3A5133L

Configuration Number Matrix for 2150, 3000, and 4000 HS Pumps

Configuration Number Matrix for 2150, 3000, and 4000

HS Pumps

Check the identification plate (ID) for the Configuration Number of your pump. Use the following matrix to define the components of your pump.

When you receive your pump, record the 9 character part number found on the shipping box (e.g., SP1B.0014):

_____________

Also record the configuration number on the pump ID plate to assist you when ordering replacement parts:

_____________________________________

Sample Configuration Number: 2150HS-ES04ASSASSPTPSEP21

2150

SSA

Pump

Wetted

Drive

Center

Gear

Motor

Fluid Covers and

Seats

Balls

Diaphragms

Manifold

Certifica-

Model

Section

Box and

Manifolds

or Che-

Seals

tion

Compressor

cks

Pump

Wetted Section

Drive Type

Center Section

Gearbox and

Motor

Material

Compressor

2150

High Sanitation

Electric

Stainless Steel

No Gearbox or

Standard

Compressor

Induction Motor

3000

3A Certified

High Speed Gear

ATEX Induction

Ratio

Motor

4000

Pharmaceutical

High Speed

Flameproof

Gear Ratio/120V

Induction Motor

Compressor

High Speed

No Motor

Gear Ratio/240V

Compressor

Mid Speed Gear

Ratio

Mid Speed

Gear Ratio/120V

Compressor

Mid Speed

Gear Ratio/240V

Compressor

Low Speed Gear

Ratio

Low Speed

Gear Ratio/120V

Compressor

Low Speed

Gear Ratio/240V

Compressor

3A5133L

Configuration Number Matrix for 2150, 3000, and 4000 HS Pumps

Fluid Covers and

Seat Material

Ball or Check

Diaphragm Material

Manifold

Certification

Manifolds

Material

Seals

SSA

Stainless

316

—

Flapper, check,

Buna-N

EN 10204 type

Steel,

Stainless

Stainless Steel

2.1

Tri-Clamp

Steel

(HS/ 3-A/

Flapper

PH)

SSB

Stainless

316

Buna-N

EPDM

EN 10204 type

Steel, DIN

Stainless

Overmolded

3.1

(HS/3-

Steel

A/PH)

Polychloro-

FKM

prene

Fluoroelastomer

Weighted

FKM Fluoroe-

PTFE/Santo-

lastomer

prene 2-Piece

PTFE

Santo-

prene/EPDM

2Piece

Santoprene

3A5133L

Approvals

	Approvals
Pumps with motor code C are approved to:	II 2 G
	Ex h d IIB T3 Gb
Pumps with motor code G are approved to:	II 2 G
	Ex h IIB T3 Gb

	Motors coded D are approved to:	Class I, Div 1, Group D, T3B
	Motors coded D are approved to:	Class II, Div 1, Group F & G, T3B
		Class II, Div 1, Group F & G, T3B

Diaphragm materials coded EO, PT, or PS

combined with check materials coded FL or EC 1935/2004 PT comply with:

All Models (except gearbox and compressor codes 05, 15, and 25, or motor code D) are approved to:

Diaphragm materials coded EO, PT or PS

combined with check materials coded FL or Class VI PT comply with:

All fluid contact materials are FDA-compliant and meet the United States Code of Federal Regulations (CFR).

3A5133L

Ordering Information

To Find Your Nearest Distributor

Visit www.graco.com

To Specify the Configuration of a New Pump

Please call your distributor.

Use the Online Diaphragm Pump Selector Tool at www.graco.com. Search for Selector.

To Order Replacement Parts

Please call your distributor.

3A5133L

Troubleshooting

•Follow the Pressure Relief Procedure, page 14, before checking or servicing the equipment.

•Check all possible problems and causes before disassembly.

Problem	Cause	Solution

Pump cycles but will not	Pump is running too fast, causing	Slow down the controller (VFD)
prime and/or pump.	cavitation before prime.
	Center section has no air pressure,	Apply air pressure to center section
	or air pressure is too low.	per your application requirements.
	Check valve ball is severely worn or	Replace the ball and seat.
	wedged in seat or manifold.
	The pump has insufficient suction	Increase the suction pressure. See
	pressure.	the Operation manual.
	Seat is severely worn.	Replace the ball and seat.

	Outlet or inlet is restricted.	Remove the restriction.

	Inlet fittings or manifolds are loose.	Tighten.

	Manifold o-rings are damaged.	Replace o-rings.

The center section is	The drive shaft is broken.	Replace.
excessively hot.
Pump fails to hold fluid	Check valve balls, seats, or o-rings	Replace.
pressure at stall.	are worn.
NOTE: Flapper checks
NOTE: Flapper checks	Manifold screws or fluid cover	Tighten.
are not 100% fluid tight.	Manifold screws or fluid cover	Tighten.
	screws are loose.
	Diaphragm shaft bolt is loose.	Tighten.

	Flap valves installed upside-down.	Install the flapper valve with the text
		side facing the seat.
Pump will not cycle.	Motor or controller is wired	Wire per manual.
	improperly.
	The leak detector (if installed) has	Check diaphragm for rupture or
	tripped.	incorrect installation. Repair or
		replace.
The motor is operating,	The jaw coupling between the	Check the connection.
but the pump will not	motor and gearbox is not connected
cycle.	properly.
Pump flow rate is erratic.	Suction line is clogged.	Inspect; clear.

	Checks are sticky or leaking.	Clean or replace.

	Diaphragm (or backup) ruptured.	Replace.

Pump makes unusual	Pump is operating near or at stall	Adjust air pressure or slow the pump
noises.	pressure.	speed.

3A5133L

		Troubleshooting

Problem	Cause	Solution

Air consumption is higher	A fitting is loose.	Tighten. Inspect thread sealant.
than expected.
than expected.	Loose or damaged o-rings or shaft	Replace.
	Loose or damaged o-rings or shaft	Replace.
	seal.

	Diaphragm (or backup) ruptured.	Replace.

Air bubbles in fluid.	Suction line is loose.	Tighten.

	Diaphragm (or backup) ruptured.	Replace.

	Loose manifolds, damaged seats or	Tighten manifold bolts or replace
	o-rings.	seats or o-rings.
	Loose diaphragm shaft bolt.	Tighten.
Pump leaks fluid	Loose manifold screws or fluid cover	Tighten.
externally from joints.	screws.
	Manifold o-rings worn out.	Replace o-rings.
The controller faults or	A GFCI has tripped.	Remove the controller from the
shuts down.		GFCI circuit.
	Supply power is poor.	Determine and fix the source of the
		power problem.
	Operational parameters are	See performance chart; ensure
	exceeded.	pump is operating within the
		continuous duty range.
Excessive motor	Inlet check clogged/improperly	Remove debris/install properly
regeneration fault from	installed
VFD
VFD	Broken diaphragm bolt	Replace bolt
	Broken diaphragm bolt	Replace bolt

NOTE: For problems with a Variable Frequency Device (VFD), see your VFD manual.

3A5133L

Repair

NOTE:When reassembling fluid section components, loosely assemble initially to ensure acceptable alignment. Once all components are in place, tighten all clamps.

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as splashing fluid, follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing the equipment.

1.Turn off the pump and disconnect power to the system.

2.Close the master air valve (J) to shut off the air to the pump.

3.Open the fluid drain valve (L) to relieve fluid pressure. Have a container ready to catch the drainage.

4.Close the pump air inlet port (E) on the pneumatic enclosure.

Check Valve Repair

Tools Required

• O-ring pick

NOTE: Kits are available for new check valve balls and seats in a range of materials. O-ring kits also are available.

NOTE: To ensure proper seating of the check balls, always replace the seats when replacing the balls. Also, replace the o-rings every time the manifold is removed.

Disassemble the Ball Check Valve

1.Follow the Pressure Relief Procedure, page 14. Disconnect power from the motor. Disconnect all fluid and air lines.

2.Remove the clamps (31) holding the outlet manifold (3) to the fluid covers (2), then remove the outlet manifold.

3.Remove the ball check valve assemblies:

a.On the 2150FG, remove the seats (6), balls (7), and o-rings (8).

b.On the 2150HS, remove the ball stops (28), balls (7), and gaskets (8a).

4.Repeat for the inlet manifold.

5.To continue with diaphragm disassembly, see Disassemble the Standard Diaphragms, page 17.

Reassemble the Ball Check Valve

1.Clean all parts and inspect for wear or damage. Replace parts as needed.

2.Reassemble in the reverse order, following all notes in the illustration. Put the inlet manifold on first. Be sure the ball checks and manifolds are assembled exactly as shown. If present on the fluid covers (2), the arrows (A) must point toward the outlet manifold (3). For fluid covers without arrows, the tallest opening in the fluid cover must be attached to the outlet manifold.

3A5133L

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