Graco 1590 SA Operation manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001
310622L
Instructions/Parts List
High Sanitation Pumps
For use in sanitary applications.
Models 1590 & 3150 SA__ Sanitary Diaphragm Pump
Models 1590 & 3150 SB__ Sanitary Ball Check Pump
Model 3150 SF__ Sanitary Flapper Check Pump
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
US and Foreign Patents Pending
US Patent No. 5,368,452
44-03
II 2 G c T6
II 2 G c T6
Model SA3AAA Shown TI8760a
Important Safety Instructions.
Read all warnings and instructions in
this manual. Save these instructions.
See page 2 for Table of Contents.

Contents
2310622L
Contents
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3150 Conversion Kits . . . . . . . . . . . . . . . . . . . . . . 32
Model 1590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . 33
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Performance Chart . . . . . . . . . . . . . . . . . . . . . . 35
Model 3150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . 36
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Performance Chart . . . . . . . . . . . . . . . . . . . . . . 38
Graco Warranties . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 40
Models
Refer to page 25 to determine the model number of your pump.

Warnings
310622L 3
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.
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 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. 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.
• Follow Pressure Relief Procedure in this manual, when you stop operating 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.
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 swal-
lowed.
• Read MSDS’s 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.

Warning
4310622L
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
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
Warning

Installation
310622L 5
Installation
General Information
• 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.
• Always use genuine Graco parts and accessories.
• Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 26 - 31.
Leak Detection System
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
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.
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.
•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 mm²) minimum ground 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.
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 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.
A leak detection system will be included with all
approved pumps. See manual 311200
included with leak detector for leak detector instal-
lation instructions.
See pages 30 and 31 for parts.
Bolts (V) must be tightened to hold the bracket in
place during operation.
Moving Parts Hazard
Keep clear of moving parts.
Bolts (V) may be loosened to allow the pump, while
still securely mounted to the bracket, to be rotated
for draining or servicing.
TI8765a
659
V

Installation
6310622L
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
• Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as well
as the stress caused during operation.
• 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.
Air Line
1. 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.
2. 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 inlet snugly.
Fluid Suction Line
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. 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 ineffi-
cient pump operation.
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 8.
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.
X
W
Ground Wire Connection
TI4736A
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.

Installation
310622L 7
4. At inlet fluid pressures greater than 15 psi (0.1 MPa,
1 bar), diaphragm life will be shortened.
5. See the Technical Data on pages 34 and 37 for
maximum suction lift (wet and dry).
Fluid Outlet Line
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.
1. Use flexible, grounded fluid hoses (L) 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. Install a fluid drain valve (J) near the fluid outlet. See
FIG. 3.
4. Install a shutoff valve (K) in the fluid outlet line.
Typical Installation
FIG. 3 Typical Floor-Mount Installation
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
G Flexible fluid suction line
J Fluid drain valve
K Fluid shutoff valve
L Flexible fluid line
M 1/2 npt (f) air inlet
X Ground wire (required; see page
5 for installation instructions)
EF CB
A
K
L
J
G
X
D
M
TI8766a

Installation
8310622L
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.
Air Exhaust Ventilation
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.
2. Install a grounded air exhaust hose (T) and connect
the muffler (P) to the other end of the hose. The
minimum size for the air exhaust hose is 3/4 in. (19
mm) ID. If a hose longer than 15 ft (4.57 m) is
required, use a larger diameter hose. Avoid sharp
bends or kinks in the hose.
3. 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.
FIG. 4 Orientation of Fluid Ports
130
339
TI5133e
P
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.

Installation
310622L 9
FIG. 5 Venting Exhaust Air
P
U
T
D
A
BCFE
TI8767a
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 Grounded air exhaust hose
U Container for remote air exhaust

Operation
10 310622L
Operation
Pressure Relief Procedure
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
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
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.
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.
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. If the 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.
The pump was built and tested using a food grade
lubricant.
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.