Haier 1590 SB User's Manual
Contents
1. iL 20 25 lt 1 4 0 14 0 7 0 0 20 40 60 80 100 120 140 160 76 152 227 303 379 454 531 606 Fluid Flow gpm Ipm AIR PRESSURES LEGEND A 120 psi 8 4 bar 0 84 MPa Air Consumption sess B 100 psi 7 0 bar 0 7 MPa Fluid Flow C 70 psi 4 8 bar 0 5 MPa D 40 psi 2 8 bar 0 3 MPa TI8645a 38 310622L Model 3150 310622L 39 Graco Warranties Graco Standard Pump Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of five years from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by G2. Model 1590 Dimensional Drawing 24 9 in 632 5 mm 35 8 in ery 909 3 mm N 8 6 in gt Ne 218 4 mm r2 N Na E 21 a mg 22 0in _ p 558 8 mm 23 5 in gt TI8778a A 596 9 mm TI8777a 310622L 33 Model 1590 Model 1590 Technical Data Maximum fluid working pressure 120 psi 0 8 MPa 8 bar Air pressure operating range 20 120 psi 0 14 0 8 MPa 1 4 8 bar Maximum air consumption a 125 scfm Air consumption at 70 psi air inlet pressure 60 gpm 50 scfm see chart Maximum free flow delivery 100 gpm 378 5 l min Maximum pump speed 0 000 ee o 200 cpm Gallons Liters per Cycle oooooooo 0 5 1 96 Maximum suction lift o o o oooooooooo 28 ft 8 5 m wet 15 ft 4 57 m dry Maximum size pumpable solids 5 8 in 15 9 mm Maximum Noise Level at 100 psi full flow 90 dBa Sound Power Level o ooooooomooo 103 dBa Noise Level at 70 psi and 50 cpm 85 dBa Maximum fluid operating temperature is based on the PTFE 220 F 104 4 C following maximum diaphragm ball and o ring tempera Santoprene 180 F 82 2 C Wre TAN Seas shige wim ants arses Sogn a a wie edo eae sown 3A Approved EPDM 275 F 135 C PAVE MMIC SIZE it Giclee eA 0 5 in npt f Wetted parts All fluid contact materials are
3. Use flexible hoses at pump inlet pipe and outlet Gasket does not seal Use a standard sanitary gasket of flexible material such as EPDM Buna N fluoroelastomer or silicon Fluid in exhaust air Diaphragm ruptured Replace See page 21 Loose diaphragm plate Tighten or replace See page 21 Pump exhausts excessive air at Worn air valve block plate pilot Repair or replace See page 16 stall block u cups or pilot pin o rings Worn shaft seals Replace See page 21 Pump leaks air externally Tighten screws See page 16 Air valve gasket or air cover gasket Inspect replace See page 16 is damaged Air cover clamps are loose Tighten clamps Pump leaks fluid externally from Loose manifolds damaged seal Tighten manifold clamps or replace ball check valves between manifold and seat dam seats or clamps 32 See page 19 aged gaskets Chattering Check balls not seating prop Reduce size diameter of inlet line erly cleanly due to imbalance relative to outlet line Outlet line between fluid inlet and outlet line size should not exceed pump size sizing Noise is accentuated with light viscosity fluids 310622L 15 Service Service Repairing the Air Valve Tool Required e Torque wrench e Torx T20 screwdriver or 7 mm 9 32 in socket wrench e Needle nose pliers e O ring pick e Lithium base grease SN Air Valve Repair Kit 255122 is available Refer to Parts on page 31 Parts included in the kit are
4. Description oy Model 3150 253224 3A Approved EPDM Overmolded includes 110 and 446 A ee aer onena 2 189298 PLATE diaphragm 2 air side 253225 Santoprene includes 110 446 E 112181 U CUP ssp omman p a a 150018 PLATE daphragm 2 Has 180298 PEATE depron 253223 7 253223 Buna N includes 110 448 N includes 110 446 a aot aa oo PUE cas 2 253222 8 253222 fluoroelastomer includes 110 448 includes 110 446 mo mel cur aot E 150018 PLATE daphragm 2 pas e02 PATE apap gt 28 part Description 0 Model 1590 255058 3A Approved EPDM Overmolded includes 110 and 446 112181 U UCUP 446 T ASSEMBLY 445 15K448 PLATE Diaphragm air side 255059 Santoprene includes 110 and 446 446 1 EY DIAPHRAGM E 143 15D021 IBOLT 2 es 150021 peor ill is PLATE Diaphragm fluid side 15K448 PLATE Diaphragm air 2 side 255060 PTFE includes 110 and 446 and 447 112181 U CUP 2 4461 Dt DIAPHRAGM q 444 15K288 PLATE Diaphragm kaa E side 15K448 PLATE Diaphragm air side N All diaphragm modules above include 2 u cups 110 to replace seals around shaft 121 See page 30 Indicates replacement parts t Indicates a recommended spare part 310622L Check Ball Material Parts List Ret Part Description Model 3150 3A Approved PTFE Flapper check CL ee a Santoprene O Tar EC BUNA N se oa fluoroelastomer ee Peat Model 15
5. Do not use equipment until you identify and correct the problem PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury e Follow Pressure Relief Procedure in this manual when you stop operating and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not exceed the maximum working pressure or temperature rating of the lowest rated system com ponent 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 Check equipment daily Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only Do not alter or modify equipment For professional use only Use equipment only for its intended purpose Call your Graco distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not use hoses to pull equipment Comply with all applicable safety regulations 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
6. FDA compliant and meet the United States Code of Federal Regulations CFR Title 21 Section 177 All fluid contact materials are FDA compliant Wetted materials on all models 316 SST 3A Approved EPDM PTFE Wetted material depending on model Santoprene 3A Approved EPDM PTFE CAUTION Santoprene may be used only with non fatty non oily foods or alcohols up to 15 300 series stainless steel polyester labels LDPE foam gasket Weights id eee Ve eens eee eden ows 97 Ib 44 kg Santoprene is a registered trademark of the Monsanto Co Loctite is a registered trademark of the Loctite Corporation Displacement per cycle may vary based on suction condition discharge head air pressure and fluid type Noise levels measured with the pump mounted on the stand Sound power measured per ISO Standard 9614 1 The pump user must verify that the construction materials meet their specific application requirements 34 310622L Model 1590 Model 1590 Performance Chart Test Conditions Pump tested in water with inlet submerged To find Fluid Outlet Pressure To find Pump Air Pressure psi MPa bar at a specific fluid flow gpm lpm and scfm or m3 min at a specific fluid flow gpm Ipm and operating air pressure psi MPa bar operating air pressure psi MPa bar 1 Locate fluid flow rate along bottom of chart 1 Locate fluid flow rate along bottom of chart 2 Follow vertical l
7. Gasket Removal Tools Required Torque wrench 10 mm socket wrench Bearing puller O ring pick Press or block and mallet Disassembly SN Do not remove undamaged bearings A ll 2 Relieve the pressure Remove the manifolds and disassemble the ball check valves as explained on page 19 Remove the fluid covers and diaphragm assemblies as explained on page 21 SN If you are removing only the diaphragm shaft bearing 117 skip step 4 4 Disassemble the air valve as explained on page 16 5 Using a 10 mm socket wrench remove the screws 122 holding the air covers 120 to the center housing 101 122 o T14733a FIG 21 6 Remove the air cover gaskets 119 Always replace the gaskets with new ones 7 Use a bearing puller to remove the diaphragm shaft bearings 117 air valve bearings 112 or pilot pin bearings 113 Do not remove undamaged bear ings 23 Service 117 TI4731a FIG 22 8 If you removed the diaphragm shaft bearings 117 reach into the center housing 101 with an o ring pick and hook the u cups 110 then pull them out of the housing Inspect the u cups See FIG 22 Replace parts as needed Reassembly Adhesive must be applied to the outside surface of the bearing 112 and the inside surface of bore Z prior to assembly 1 Install the shaft u cups 110 so the lips face out of the housing 2 Insert new
8. bearings 112 113 and 117 into the center housing 101 tapered end first Using a press or a block and rubber mallet press fit the bearing so it is flush with the surface of the center housing 112 113 o 117 TI4731a FIG 23 3 Reassemble the air valve as explained on page 16 4 Align the new air cover gasket 119 so the pilot pin 114 protruding from the center housing 101 fits through the proper hole in the gasket 24 TI4730a FIG 24 5 Align the air cover 120 so the pilot pin 114 fits in the middle hole M of the three small holes near the center of the cover TI4790a FIG 25 6 Apply medium strength blue Loctite or equivalent to the threads of the screws 122 Install the screws 122 handtight Using a 10 mm socket wrench torque the screws oppositely and evenly to 130 150 in lb 15 17 Nem Install the diaphragm assemblies and fluid covers as explained on page 21 TI4790a FIG 26 7 Reassemble the ball check valves and manifolds as explained on page 19 310622L Pump Matrix Pump Matrix 3150 Stainless Steel Sanitary Pumps Your Model No is marked on the pump s serial plate To ball check pump with a three inch inlet and outlet San determine the Model No of your pump from the follow toprene balls and diaphragms a pump stand and no ing matrix select the six digits which describe your leak detector is model SB3661 To order replace pump working
9. inlet pressure 60 gpm Maximum free flow delivery Maximum pump speed Gallons Liters per cycle Maximum suction lift o o oooooooo Maximum size pumpable solids Maximum Noise Level at 100 psi full flow Sound Power Level Noise Level at 70 psi and 50 cpm Maximum fluid operating temperature is based on the Model 3150 120 psi 0 8 MPa 8 bar 20 120 psi 0 14 0 8 MPa 1 4 8 bar 175 scfm 50 scfm see chart 150 gpm 570 l min 145 cpm 1 03 3 90 Flapper 10 ft 3 5 m wet 5 ft 1 75 m dry Ball 18 ft 5 5 m wet 9 ft 2 75 m dry Flapper 2 5 in 63 5 mm Ball 1 0 in 25 4 mm 90 dBa 103 dBa 85 dBa PTFE 220 F 104 4 C following maximum diaphragm ball and seat temperature Santoprene 180 F 82 2 C AUDOS sesa hart cence NT Eade eal Ged GAN Air inlet size Wetted parts Buna N 180 F 82 2 C fluoroelastomer 250 F 121 1 C 3A Approved EPDM 275 F 135 C 0 5 in npt f All fluid contact materials are FDA compliant and meet the United States Code of Federal Regulations CFR Title 21 Section 177 Wetted materials on all models Wetted material depending on model CAUTION 316 SST 3A Approved EPDM 316 SST Santoprene Buna N Nitrile fluoroelastomer 3A Approved EPDM PTFE Santoprene may be used only with non fatty non oily foods or alcohols up to 15 300 series stainless steel
10. marked with 4 symbol Use all the parts in the kit for the best results Disassembly A 1 Relieve the pressure 2 With a Torx T20 screwdriver or 7 mm 9 32 in socket wrench remove the six screws 103 air valve cover 102 and gasket 104 See Fia 6 TI4682b FIG 6 16 3 Move the valve carriage 105 to the center position and pull it out of the cavity Using a needle nose pli ers pull the pilot block 116 straight up and out of the cavity See FIG 7 1160 1050 4 Pull the two actuator pistons 111 Remove the u cups 110 from the pistons Pull the pilot pins 114 Remove the o rings 115 from the pilot pins See FIG 8 1100 TI4617b 114 1150 FIG 8 310622L Inspect the valve plate 108 in place If damaged use a Torx T20 screwdriver or 7 mm 9 32 in socket wrench to remove the three screws 103 Remove the valve plate 108 See FIG 9 103 5 10860 TI4618c FIG 9 6 Inspect the bearings 112 117 in place See Parts on page 31 The bearings are tapered and if dam aged must be removed from the outside This requires disassembly of the fluid section See page 23 Clean all parts and inspect for wear or damage Replace as needed Reassemble page 17 Reassembly 1 If you replaced the bearings 112 117 reinstall as explained on page 24 Reassemble the fluid section Install the valve plate 108 in the cavity se
11. over lubricate the pump Oil is exhausted through the muffler and could contaminate your fluid supply or other equipment Excessive lubrication can also cause the pump to malfunction Flushing NAS Insert suction tube into cleaning solution Open air regu lator to supply low pressure air to the pump Run the pump long enough to thoroughly clean the pump and hoses Close the air regulator Remove the suction tube from the cleaning solution and drain pump Place suc tion tube in the fluid to be pumped Flush the pump often enough to prevent the fluid you are pumping from drying or freezing in the pump and damaging it Flushing schedule will be based on what the pump is being used for Use a compatible cleaning solution and always cycle the pump during the entire flushing process Always flush the pump and relieve the pressure before storing it for any length of time 310622L Maintenance Routine Cleaning of Product Contact Section of Pump SN The pump and the system should be cleaned in accordance with your state sanitary standard codes and local regulations 1 Flush the system See Flushing above 2 Relieve pressure in the system See Pressure Relief Procedure on page 10 3 Disassemble the fluid section of the pump and accessories See Check Valve Repair on page 19 and Diaphragm Repair on page 21 4 Using a brush or other C I P methods wash all product contact pump parts with an a
12. swal lowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines Warning BURN HAZARD Equipment surfaces and fluids that are heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 4 310622 Installation General Information e The typical installation shown in FIG 3 is only a guide for selecting and installing system compo nents Contact your Graco distributor for assistance in planning a system to suit your needs e Always use genuine Graco parts and accessories e Reference numbers and letters in parentheses refer to the callouts in the figures and the parts lists on pages 26 31 NS The pump is very heavy see Technical Data on pages 34 and 37 for specific weights If the pump must be moved follow the Pressure Relief Proce dure on page
13. 10 and have two people lift the pump by grasping the outlet manifold securely or use appropriate lifting equipment Never have one person move or lift the pump Leak Detection System SN A leak detection system will be included with all UN approved pumps See manual 311200 included with leak detector for leak detector instal lation instructions 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 Stand SN See pages 30 and 31 for parts 1 Place the stand assembly on a level surface 2 Mount the pump securely to the brackets using bolts 659 3 Tighten the bolts V to hold the slotted bracket in place See FIG 1 SN Bolts V must be tightened to hold the bracket in place during operation 310622L Installation Moving Parts Hazard Keep clear of moving parts SN Bolts V may be loosened to allow the pump while still securely mounted to the bracket to be rotated for draining or servicing TI8765a FIG 1 Grounding 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 equip ment CA e Pump Connect a ground wire and clamp as shown in FIG 2 Loosen the grounding screw W Insert one end of a 12 ga 1 5 mm minimum grou
14. 339 gasket 129 and elbow 128 Clean all parts and inspect for wear or damage Replace parts as needed 20 3106221 7 Repeat for inlet manifold Reassembly SN Lubricate clamps clamping surfaces and gaskets with waterproof sanitary lubricant 1 Reassemble inlet and outlet fluid manifolds in reverse order See step 6 Tighten clamps handtight 2 Reassemble ball or flapper check assembly in reverse order See step 5 Tighten clamps handtight SN For flapper check make sure flapper check 251 is placed properly in housing 248 groove and flapper retainer 253 is aligned with housing groove Ensure that the flapper check moves freely 310622L Service Diaphragm Repair Tools Required Torque wrench 5 8 in wrench 19 mm open end wrench O ring pick Lithium base grease Spanner wrench Disassembly NA 1 Relieve the pressure 2 Remove the manifolds and disassemble the ball check valves as explained on page 19 3 Hold fluid covers in place and remove the clamps 135 Pull the fluid covers 234 off the pump DD T18771a FIG 16 4 Non 3A approved diaphragms With both fluid cov ers removed using two 5 8 in wrenches hold the wrench flats Y on the plates of each diaphragm assembly and loosen One diaphragm assembly will come free and the other will remain attached to the shaft 3A approved diaphragms Diaphragms are assem bled handtight To loosen grip both dia
15. 90 a 3A Approved PTFE SABAAA SBBAAA 541 T 112419 BALL 4 SBBA11 SBBA22 54114 112421 BALL Indicates replacement parts f Indicates a recommended spare part 310622L Parts List 29 Parts Drawing Parts Drawing a 1048 122 A 120 1150 114 1160 1050 EN AR AM Apply medium strength adhesive to outside surface of piston bearing and inside surface of center housing bore A Apply a medium strength thread locker to screw threads and torque to 130 150 in lbs 14 6 16 9 Nem A Torque to 50 60 in Ib 5 7 6 8 Nem TI8068a 30 310622L Parts List Parts List Air Section Parts Fluid Section Parts Ca Ca or iskon HOUSING center 1 az 155687 HOUSING coer o a Ret Pan Description Oty Models Model 3150 234531 ELBOW 15H459 GASKET sanitary EPDM 3 in 15D475 CLAMP sanitary 3 in 510490 CLAMP sanitary 4 in 15G323 CLAMP sanitary diaphragm 116344 SCREW mach torx Trove more GASKET cover r 3 me meon BEARING pin ma 0 CI a Model 1590 15H598 GASKET sanitary EPDM 2 In 130 500984 CLAMP CLAMP sanitary 2in Ki KA a sanitary 3 in a as CLAMP sanitary dia x phragm Leak Detector and Pump Stand Parts List aso 156071 GASKET upper Parts included in Air Valve Repair Kit 255122 purchase separately Pump Stand Only 3150 and 1590 SBBAAA SBBA11 SBBA22 A Replacement Danger and Warning labels tags and 15F694
16. FRAME CN cards are available at no cost je D008 BOLT sst 4 iat Ret Par CI 3A Approved Leak Detector and Pump Stand 3150 and 1590 SABAAA Bare Pump Indicates replacement parts ft Indicates a recommended spare part 310622L 31 Accessories Accessories 15D990 Leak Detector Sensor and control package that monitors the dia phragm condition In case of diaphragm failure the con trol will provide an audible alarm and relay contacts for remote alarms or solenoids See Leak Detector manual 311200 To be N approved a leak detection system must be used on the pump Any pump with a leak detec tor installed is NOT Atex approved 3150 Conversion Kits 15H461 3A Approved Ball Check Conversion Kit Converts flapper check valve to 3A ball check valve Includes four seats and four ball stops Balls need to be ordered separately a 15B406 SEAT ball 15H460 GASKET 4 in 510490 CLAMP 4 in STOP ball 32 15D989 Flapper Valve Conversion Kit Converts ball check valve to flapper check valve Includes four flapper assemblies See Flapper Valve Assembly page 26 Part No Description 513548 GASKET 4 in a 249535 MODULE flapper 15E285 Sanitary Ball Check Conversion Kit Converts flapper check valve to sanitary ball check valve Includes four seats and four ball stops Balls need to be ordered separately kai LK 15D026 SEAT ball 15D346 GASKET ball stop 310622L Model 1590
17. Instructions Parts List o High Sanitation Pum g Sanitatio UMPS 310622L For use in sanitary applications E Models 1590 amp 3150 SA__ Sanitary Diaphragm Pump HA Models 1590 amp 3150 SB__ Sanitary Ball Check Pump x i2Gete a z Model 3150 SF__ Sanitary Flapper Check Pump Ex 2GcT6 120 psi 0 8 MPa 8 bar Maximum Fluid Working Pressure 120 psi 0 8 MPa 8 bar Maximum Air Input Pressure Bs Important Safety Instructions Read all warnings and instructions in this manual Save these instructions NG See page 2 for Table of Contents Model SA3AAA Shown TI87602 US and Foreign Patents Pending US Patent No 5 368 452 gari wee a n Tan oe Pai s A Cer wate ae PROVEN QUALITY LEADING TECHNOLOGY Kia Graco Inc P O Box 1441 Minneapolis MN 55440 1441 C peros Copyright 2004 Graco Inc is registered to I S EN ISO 9001 EE Contents Contents o A bares boson eo ewe heed a 3 Installation ui isc O eee ee ae 5 Obperauion subas rra aca 10 Maintenance sica BANA BA 11 Troubleshootin9 0 0oooooooooo oo 14 SOIVICO dada reos rada ed te ae 16 Pump Matrix coi ad 25 PAR S pro aan 26 ACCOSSOMOS iia iaa 32 3150 Conversion Kits 0ooococococoocomo co 32 Models Model 1590 20000 tia dan ds sis 33 Dimensional Drawing 33 Technical Data o 34 Performance Chart crias ce aa baa ete 35 Model 31590 ic urraca 36 Dimensional Dr
18. M Buna N fluoroelastomer or silicon Install a fluid drain valve J near the fluid outlet See FIG 3 Install a shutoff valve K in the fluid outlet line N 8766a Installation Changing the Orientation of the Fluid Inlet and Outlet Ports The pump is shipped with the ports facing the same direction To re orientate the ports into any position 1 Remove the clamps 130 holding the inlet and or outlet tee to the elbows 2 Rotate the manifold tee 339 and reattach Install the clamps 130 and tighten handtight TI5133e Fic 4 Orientation of Fluid Ports Air Exhaust Ventilation 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 flam mable or hazardous fluids Diaphragm failure can cause the fluid being pumped to exhaust with the air Place an appropriate con tainer at the end of the air exhaust line to catch the fluid See FIG 5 The air exhaust port is 3 4 npt f Do not restrict the air exhaust port Excessive exhaust restriction can cause erratic pump operation To provide a remote exhaust 1 Remove the muffler P from the pump air exhaust port See FIG 5 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 hos
19. al down Install the three screws 103 using a Torx T20 screwdriver or 7 mm 9 82 in socket wrench Tighten until the screws bottom out on the housing See FIG 9 310622L 3 Y Service Install an o ring 115 on each pilot pin 114 Grease the pins and o rings Insert the pins into the bearings narrow end first See FIG 10 baa 11T 1108 T14617b FIG 10 4 N Install u cups 110 on each actuator piston 111 so the lips of the packings face the narrow end of the pistons See FIG 10 Lubricate the u cups 110 and actuator pistons 111 Insert the actuator pistons in the bearings wide end first Leave the narrow end of the pistons exposed See FIG 10 Grease the lower face of the pilot block 116 and install so its tabs snap into the grooves on the ends of the pilot pins 114 See FIG 11 Grease the lower face of the valve carriage 105 See FIG 11 17 Service 8 Install the valve carriage 105 so its tabs slip into 9 Align the valve gasket 104 and cover 102 with the grooves on the narrow end of the actuator pis the six holes in the center housing 101 Secure tons 111 See FIG 11 with six screws 103 using a Torx T20 screw driver or 7 mm 9 82 in socket wrench Torque to 50 60 in lb 5 7 6 8 Nem See FIG 12 1050 1160 TI4682b 18 3106221 Service Check Valve Repair Disassembly SN Reference numbers with an asterisk are re
20. awing 36 Technical DATA ie cast he a ahd A a ee AA anh we 37 Performance Chart o o oooooo 38 Graco Warranties 0 00 cee eee 40 Graco Information 000 cee aan 40 Refer to page 25 to determine the model number of your pump 310622L Warnings Warnings The following general warnings are for the safe setup use grounding maintenance and repair of this equipment The exclamation point symbols alert you to general warnings and the hazard symbols refer to procedure specific risks Refer back to these Warnings Additional product specific warnings may be found throughout the body of this manual where applicable 310622L N 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 e Use equipment only in well ventilated area e 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 equipment and conductive objects in work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately
21. e longer than 15 ft 4 57 m is required use a larger diameter hose Avoid sharp bends or kinks in the hose Place a grounded container U at the end of the air exhaust line to catch fluid in case of a diaphragm rupture See FIG 5 310622L Installation Key Air supply line Bleed type master air valve required for pump Air regulator Air line quick disconnect Master air valve for accessories Air line filter Muffler Grounded air exhaust hose Container for remote air exhaust WT CHUN MOUO TI8767a FiG 5 Venting Exhaust Air 310622L 9 Operation Operation Pressure Relief Procedure Na 1 Shut off the air to the pump 2 Open any available outbound fluid valve to relieve fluid pressure from the pump 3 If fluid is still in the outbound fluid lines isolate this fluid as follows a Close the outbound fluid valves b Slowly remove the fluid connections from the pump and have a container ready to catch any fluid that runs out Sanitizing the Pump Before First Use The pump was built and tested using a food grade lubricant It is the user s responsibility to properly sanitize the pump before first use It is up to the user whether this will include disassembling and cleaning individual parts or simply flushing pump with a sanitizing solution As necessary follow the steps under Starting and Adjust ing the Pump below under Flushing on page 11 or
22. from left to right The first digit is always ment parts refer to the part lists on pages 26 31 The S designating Graco Sanitary diaphragm pumps The digits in the matrix do not correspond to the reference remaining five digits define the pump configuration size numbers in the parts drawing and lists and materials of construction For example a sanitary Sanitary Pump Inlet and Outlet Diaphragm Check Ball Leak Detector Pump Configuration in Material Pump Stand S for all pumps 4 3A Approved 111 2x11 2 A 3A Approved A 3A Approved A Leak Detec EPDM PTFE tor and Pump Stand adb A LL O IO Pie ES tomer tomer A e po aaa A pp 1590 Stainless Steel Sanitary Pumps The table below shows all available configurations for 1590 Stainless Steel Sanitary Pumps Model Number Pump Inlet and Outlet Check Valve Check Ball Mate Diaphragm Configuration in Style rial Material SABAAA 3A Approved 3A Ball Checks 3A PTFE 3A Approved EPDM SBBA11 Non 3A Approved No Leak Detector SBBA22 Non 3A Approved No Leak Detector 3A Ball Checks 3A PTFE PTFE SBBAAA Non 3A Approved 2x2 3A Ball Checks 3A PTFE 3A Approved No Leak Detector EPDM 310622L 25 Parts Drawing Parts Drawing 3A Pump Shown 129 A 130 A 339 Sanitary Diaphragm Assembly 135 444 143 446 447 445 Sanitary Ball Check Valve Assembly A 242 MOD 2 NG TI4729c 46 AN Flapper Check Valve Assembly J Apply a hi
23. gh strength thread locker to diaphragm plate side of screw threads A Apply a medium strength thread locker to shaft side of screw threads A Apply a waterproof sanitary lubricant to clamps clamping surfaces and gaskets TI7645c VW A 129 130 26 3106221 Parts List Pump Configuration Parts List Model 3150 A 3A Approved Ball Check 132 510490 oan xe 06 SEAT zai at COVER nue 2 240 15H460_ GASKET 4n EPDM 12 XA 184407 soro fa Ball Check SEAT COVER mud f 240 15H460 GASKET 4 in EPDM 4 15D346 GASKET ball stop Flapper Check a maki COVER nala az or aHa00 GASKET in EPDM fe 249535 MODULE PIT includes items 232 248 250 251 252 253 CLAMP din Go To HOUSING lower flapper bar kad GASKET 4 in EPDM 4 ollie lll a weldment Papes flapper Model 1590 3A Approved Ball Check AT pe peos CLAMS An e 15481 SEAT Br pa CO E All A bab STOP Ball A Indicates replacement parts 310622L Parts List Inlet and Outlet Parts List Model 3150 1 1 1 2 x 1 1 2 in tee ml matt TEE inlet LA A pag zeasa6 TEE outet 2x2 in tee 2 331 234534 TEE inlet 1 sar pasa TEE inlet OT Maca 3 3x3 in tee U 8811 pee TEE inlet A 4 x 4 in tee 3x 2 in tee mali 234532 TEE inlet AR us bog 294594 TEE outlet Model 1590 2 x2in Tee Indicates replacement parts 27 Parts List Diaphragm Material Parts List fet part
24. ine up to intersection with selected 2 Read vertical line up to intersection with selected air fluid outlet pressure curve consumption curve 3 Follow left to scale to read fluid outlet pressure 3 Follow left to scale to read fluid outlet pressure 1590 3A Performance Chart 120 120 8 4 0 84 3 4 r 100 100 2 7 0 7 2 8 D 80 80 5 cS 5 5 0 55 2 2 os D Co 60 60 50m Q ST 4 2 0 42 1 7 ce Os G E yo 40 40 3 5 2 8 0 28 1 1 z LL 20 20 1 4 0 14 0 6 00 20 40 60 80 100 120 76 152 227 303 379 454 TI8646 Fluid Flow gpm lpm AIRPRESSURES _____________ LEGEND ________ A 120 psi 8 4 bar 0 84 MPa Air Consumption 100 psi 7 0 bar 0 7 MPa Fluid Flow C 70 psi 4 8 bar 0 5 MPa D 40 psi 2 8 bar 0 3 MPa E 20 psi 1 4 bar 0 14 MPa TI8647 310622L 35 Model 3150 Model 3150 Dimensional Drawing 3A Ball Check Valve Pumps ARI 28 4 in l 721 4 mm 37 6 in 955 0 mm cA 6 5 in 165 1 mm 23 5 in TI4929d 596 9 mm TI7610c Sanitary Ball Check Valve Pumps Flapper Check Valve Pumps CN A 28 3 in 29 5 in 38 1 in 718 8 mm 37 5 in 749 3 mm 967 7 mm 952 5 mm 6 5 in 5 9 in 165 1 mm 149 9 mm 19 3 in 490 2 mm TI4685d 490 2 mm ka 36 3106221 Model 3150 Technical Data Maximum fluid working pressure Air pressure operating range Maximum air consumption Air consumption at 70 psi air
25. ion Remove heat from system after operation Inspect diaphragm for wear Inspect check valve compo a aa for wear ee fluid connec tions Check tighten air connec tions 12 310622L 310622L Maintenance 13 Troubleshooting Troubleshooting ap e Relieve the pressure before checking or servicing the equipment e Check all possible problems and causes before disassembling the pump Pump cycles at stall or fails to hold Worn check valve balls 541 Replace See page 19 pressure at stall seats 233 Pump will not cycle or cycles once Air valve is stuck or dirty Disassemble and clean air valve and stops See page 16 Use filtered air Check valve ball 541 severely Replace ball and seat See page worn and nae in seat 233 or 19 manifold Check valve ball 541 is wedged Follow Pressure Relief Proce into seat 233 due to overpressur dure page 10 Disassemble ball ization check assembly and inspect for damage see page 19 Dispensing valve clogged Relieve pressure and clear valve down solenoid detector Loose inlet manifold damaged seal Tighten manifold clamps or replace between manifold and seat dam seats or gaskets See page 19 aged gaskets 14 3106221 Troubleshooting eee Leak in inlet or outlet sanitary fit Loose sanitary clamp Tighten clamp ting Damaged or worn gasket Replace gasket Misalignment of inlet outlet hose or
26. lkaline deter gent at the manufacturer s recommended tempera ture and concentration 5 Rinse these parts again with water and allow parts to completely dry 6 Inspect the parts and reclean any soiled parts 7 Immerse all product contact parts in an approved sanitizer before assembly Leave the parts in the sanitizer taking them out only one by one as needed for assembly See Check Valve Repair on page 19 and Diaphragm Repair on page 21 8 Lubricate the clamps clamping surfaces and gas kets with waterproof sanitary lubricant 9 Circulate the sanitizing solution through the pump and the system prior to use Cycle the pump as the sanitizing solution is circulated Tightening Connections Before each use check all hoses for wear or damage and replace as necessary Check to be sure all connec tions are tight and leak free 17 Maintenance Preventive Maintenance Schedule Establish a preventive maintenance schedule based on The following is a list of recommended maintenance the pump s service history This is especially important procedures and frequencies to operate your equipment for prevention of spills or leakage due to diaphragm safely Maintenance must be performed by trained per failure sonnel per this schedule to assure safety and reliability of the equipment Operator Maintenance Person Inspect system for leaks system Inspect system for leaks leaks Depressurize fluid after operat
27. nd wire X behind the grounding screw and tighten the screw securely Connect the clamp end of the ground wire to a true earth ground To order a ground wire and clamp order part number 222011 Installation TI4736A Ground Wire Connection FIG 2 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 Fluid supply container Follow the local code Mountings CAUTION Install the air line accessories as shown in FIG 3 Mount these accessories on the wall or on a bracket Be sure the air line supplying the accesso ries 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 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 Install a grounded flexible air hose A between the accessories and the 1 2 npt f pump air inlet M Use a minimum 3 8 in 9 5 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 inle
28. ounded side of plate 445 should face diaphragm Make sure the side marked AIR SIDE faces the center housing 3A approved diaphragms Assemble plate 445 onto diaphragm assembly 446 Round side of plate should face diaphragm Thread locker must be applied to screw 143 and to threads of 3A diaphragm assembly as shown in FIG 19 for all diaphragm assemblies diaphragm plate side high strength thread lock 121 445 446 447 143 444 Sanitary Pump shaft side TI8774a medium strength thread lock bolt not shown TI8775a FIG 19 3 Screw assembled diaphragm assembly into shaft 121 and hand tighten 310622L 4 Grease the length of the diaphragm shaft 121 and slide it through the housing 101 5 Assemble the other diaphragm assembly to the shaft as explained in step 2 6 Non 3A approved diaphragms Using a 5 8 in wrench hold the wrench flats of one diaphragm assembly and torque the other diaphragm to 60 70 ft lb 81 94 Nem 3A approved diaphragms Grip both diaphragms securely around the outer edge and handtighten Waterproof sanitary lubricant may be applied to the clamp 135 and clamping surface of the cover 234 to ease assembly 7 Align the fluid covers 234 and the center housing Secure the covers with the clamps 135 and hand tighten TI8771a FIG 20 8 Reassemble the ball check valves and manifolds as explained on page 19 310622L Service Bearing and Air
29. phragms securely around the outer edge and rotate counter clockwise One diaphragm assembly will come free and the other will remain attached to the shaft Con tinue to step 6 Disassemble the free diaphragm assembly Remove plate 444 with bolt 148 installed dia phragm 446 backer 447 if present and plate 445 21 Service 121 445 446 447 143 444 5 TI8772a FIG 17 7 Pull the other diaphragm assembly and the dia phragm shaft 121 out of the center housing 101 Hold the shaft flats with a 19 mm open end wrench and remove the diaphragm assembly from the shaft Disassemble the remaining diaphragm assembly T14789a FIG 18 8 Inspect the diaphragm shaft 121 for wear or scratches If it is damaged inspect the bearings 117 in place If the bearings are damaged refer to Bearing and Air Gasket Removal on page 23 9 Reach into the center housing 101 with an o ring pick and hook the u cups 110 then pull them out of the housing This can be done with the bearings 117 in place See FIG 22 10 Clean all parts and inspect for wear or damage Replace parts as needed 22 Reassembly 1 Install the shaft u cups 110 so the lips face out of the housing 101 Lubricate the u cups See reas sembly of bearing and air gasket removal page 24 2 Non 3A approved diaphragms Assemble dia phragm 446 backer 447 if present and plate 445 onto plate 444 with screw 143 R
30. placement parts For a complete list of replace ment parts see Parts page 26 A 1 Relieve the pressure Disconnect all hoses 2 Remove the pump from its mounting Drain 3 From the outlet manifold remove both upper clamps 132a 4 Remove outlet manifold leaving elbows 128 gas kets 129 clamps 130 and tee 339 assembled 5 For 3A Ball Check pumps remove ball gasket 240 Remove middle clamp 132c and ball stop housing 2XA Remove middle gasket 240 and ball 541 Remove lower clamp 132b seat 2XB and gasket 240 Clean all parts and inspect for wear or dam age Replace parts as needed 3A Ball Check Assembly TI8768a FIG 13 310622L 19 Service For Sanitary Ball Check pumps remove ball gasket For Flapper Check pumps remove gasket 240 242 and ball 541 Remove lower clamp 132b Remove middle clamp 232 and housing 252 seat 233 and gasket 240 Clean all parts and Remove middle gasket 250 flapper retainer 253 inspect for wear or damage Replace parts as and flapper valve 251 Remove lower clamp needed 132b lower flapper housing 248 and gasket 240 Clean all parts and inspect for wear or dam age Replace parts as needed m YG if O 130 179 ES a 1822 Qu 240 Q T18769a Sanitary Ball Check Assembly E Flapper Check Assembly FIG 15 TI8770a 6 Disassemble the outlet manifold Remove clamps 130 tee
31. polyester labels LDPE foam gasket 145 Ib 66 kg Santoprene is a registered trademark of the Monsanto Co Loctite is a registered trademark of the Loctite Corporation Displacement per cycle may vary based on suction condition discharge head air pressure and fluid type kk Noise levels measured with the pump mounted on the stand Sound power measured per ISO Standard 9614 1 The pump user must verify that the construction materials meet their specific application requirements 310622L 37 Model 3150 Model 3150 Performance Chart Test Conditions Pump tested in water with inlet submerged To find Fluid Outlet Pressure To find Pump Air Pressure psi MPa bar at a specific fluid flow gpm pm and scfm or m3 min at a specific fluid flow gpm Ipm and operating air pressure psi MPa bar operating air pressure psi MPa bar 1 Locate fluid flow rate along bottom of chart 1 Locate fluid flow rate along bottom of chart 2 Follow vertical line up to intersection with selected 2 Read vertical line up to intersection with selected air fluid outlet pressure curve consumption curve 3 Follow left to scale to read fluid outlet pressure 3 Follow left to scale to read fluid outlet pressure 3150 3A Performance Chart 120 150 8 4 0 84 4 2 100 425 p 7 0 7 3 5 5 o 80 100 gt v 5 5 0 55 2 8 O a BE SY 60 75 s2 4 2 0 42 2 1 BE D gt 032 40 50 Gg O 2 8 0 28 14 O
32. purchaser Normal wear of items such as packings or seals are not considered to be defects in material and workmanship Five years Graco will provide parts and labor Six to Fifteen years Graco will replace defective parts only Graco Information TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice This manual contains English MM 310622 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com 5 2004 Revised 4 2007
33. raco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and the buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within six years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with acce
34. ssories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du presente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Extended Product Warranty Graco warrants all 205 307 515 716 1040 1590 2150 3150 and 3275 air valve center sections to be free from defects in material and workmanship for a period of fifteen years from date installed in service by the original
35. t snugly 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 8 e Be sure the mounting surface can support the weight of the pump hoses and accessories as well as the stress caused during operation Na A Do not connect the coupler D to the fitting until you are ready to operate the pump Connecting the cou pler too early can result in unintentional operation of the pump leading to serious injury from to moving parts splashing fluid in the eyes or on the skin and contact with hazardous fluids For ease of operation and service mount the pump so the air valve cover 2 air inlet and fluid inlet and Fluid Suction Line outlet ports are easily accessible Air Line A bleed type master air valve B is required in the 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 3 Nw 1 Use flexible grounded fluid hoses G where possi ble 2 For best sealing results use a standard Tri Clamp style sanitary gasket of a flexible material such as EPDM Buna N fluoroelastomer or silicon 3 Ifthe fluid inlet press
36. under Disassembly in the Service section on pages 19 21 Starting and Adjusting the Pump 1 Be sure the pump is properly grounded Refer to Grounding on page 5 10 2 Check connections to be sure they are tight Tighten fluid inlet and outlet connections securely 3 Place the suction tube if used in fluid to be pumped If 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 inef ficient pump operation 4 Place the end of fluid hose L into an appropriate container 5 Close the fluid drain valve J 6 Back out the air regulator C knob and open all bleed type master air valves B E 7 Ifthe fluid hose has a dispensing device hold it open while continuing with the following step 8 Slowly increase air pressure with the air regulator C until the pump starts to cycle Do not exceed the maximum operating air pressure as listed in the Technical Data section on pages 34 and 37 Allow the pump to cycle slowly until all air is pushed out of the lines and the pump is primed Pump Shutdown At the end of the work shift relieve pressure 310622L Maintenance Lubrication The air valve is designed to operate unlubricated how ever if lubrication is desired every 500 hours of opera tion or monthly remove the hose from the pump air inlet and add two drops of machine oil to the air inlet CAUTION Do not
37. ure to the pump is more than 25 of the outlet working pressure the ball check valves will not close fast enough resulting in ineffi cient pump operation 310622L 4 Atinlet fluid pressures greater than 15 psi 0 1 MPa 1 bar diaphragm life will be shortened Fluid Outlet Line 2 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 3 De Typical Installation 4 CN pw LI Ib O UU fu Sai le y CE nn Key Air supply line Bleed type master air valve required for pump WT C Air regulator D Air line quick disconnect E Master air valve for accessories F Airline filter G Flexible fluid suction line J Fluid drain valve K Fluid shutoff valve a ST L Flexible fluid line Jil VI M 1 2 npt f air inlet e VA X Ground wire required see page WELL 5 for installation instructions FIG 3 Typical Floor Mount Installation 310622L Installation See the Technical Data on pages 34 and 37 for maximum suction lift wet and dry Use flexible grounded fluid hoses L where possi ble For best sealing results use a standard Tri Clamp style sanitary gasket of a flexible material such as EPD
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