Graco 3A2977K Parts list manual

Instructions/Parts
SaniForce® 2:1 Sanitary Piston
Pumps
3A2977K
EN
For use in sanitary applications to transfer low- to medium-viscosity fluids. Use with non-flammable
liquids only. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Maximum Fluid Working Pressure: 250
psi (1.7 MPa, 17.0 bar)
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Models............................................................... 3
Warnings ........................................................... 4
Installation.......................................................... 6
Grounding ................................................... 6
Mounting ..................................................... 6
Setup .......................................................... 6
Operation........................................................... 8
Pressure Relief Procedure............................ 8
lush Before irst Use.................................. 8
Adjusting the Pump Speed and
Pressure ........................................ 8
Pump Shut Down......................................... 8
Maintenance ...................................................... 9
lushing Procedure...................................... 9
Cleaning...................................................... 9
Tighten Threaded Connections..................... 9
Troubleshooting.................................................. 10
Repair................................................................ 11
Disconnect the Air Motor .............................. 11
Air Motor Disassembly ................................. 11
Air Motor Reassembly.................................. 13
Disassemble the Pump.................................15
Reassemble After Cleaning .......................... 16
Reconnect The Pump...................................17
Parts.................................................................. 18
Kits and Accessories........................................... 24
Dimensions........................................................ 25
Performance Chart ............................................. 26
Technical Data ................................................... 27
Graco Standard Warranty.................................... 28
23 2977K

Models
Models
See ID tag on side of air motor
(located under the motor cover) for
model number.
Maximum Air Inlet Pressure: 100 psi (0.7 MPa, 6.9 bar)
Maximum Fluid Wor ing Pressure: 250 psi (1.7 MPa, 17.0 bar)
Pump Model Pump Type Pump Description Packings
24N300 Double Ball Tall Drum Length (42 in., 107 cm Drum) U-Cup, UHMWPE
24N344 Double Ball Tall Drum Length (42 in., 107 cm Drum) U-Cup, PT E
24R046 Double Ball Standard Drum Length (34 in., 86 cm Drum) U-Cup, UHMWPE
24R047,
24R047C31† Double Ball Standard Drum Length (34 in., 86 cm Drum) U-Cup, PT E
NOTE: See page 4 for DA
Material Certification.
II2GDcIIAT3
EC 1935/2004 compliant pumps may be subject to individual national provisions in addition to those
specified in the EC regulation. It is the users responsibility to know and follow local laws.
† Model 24R047C31 is the same as 24R047, except that it is type 3.1 certified per DS/EN 10204.
3 2977K 3

Warnings
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
risks. When these symbols appear in the body of this manual or on 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.
WARNING
IRE AND EXPLOSION HAZARD
lammable fumes, such as solvent and paint fumes, in work area canigniteorexplode.Tohelp
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.
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.
• Donotcleanwithadrycloth.
PRESSURIZED EQUIPMENT HAZARD
luid from the equipment, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
• ollow 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.
43 2977K

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. or complete
information about your material, request MSDS from distributor or retailer.
• 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.
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 water-based solvents to clean plastic structural or pressure-containing
parts.
•See Technical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
TOXIC LUID OR UMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs 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.
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.
3 2977K 5

Installation
Installation
Grounding
The equipment must be grounded to reduce the
risk of static sparking. Static sparking can cause
fumes to ignite or explode. Grounding provides an
escape wire for the electrical current.
Pump: Connect a ground wire (Graco PN 238909) to
the ground screw on the air motor base. Connect the
other end of the ground wire to a true earth ground.
Air and fluid hoses: Use only electrically conductive
hoses with a maximum of 500 ft. (150 m) combined
hose length to ensure grounding continuity. Check
electrical resistance of hoses. If total resistance
to ground exceeds 25 megohms, replace hose
immediately.
Air compressors: ollow manufacturer’s
recommendations.
Dispense valve: Ground through connection to a
properly grounded fluid hose and pump.
Material supply container: ollow local code.
Container(s) that receive material: ollow local code.
Solvent pails used when flushing: ollow local
code. Use only conductive metal pails, placed on
a grounded surface. Do not place the pail on a
nonconductive surface, such as paper or cardboard,
which interrupts grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: Hold metal part of the dispense
valve firmly to the side of a grounded metal pail, then
trigger the valve.
Mounting
Mount the pump to fully support the weight of the
pump and accessories, as well as the stress caused
during operation. Do not use air or fluid lines to
support the pump.
Setup
To avoid contaminating the fluid, pipe the exhaust
air to vent outside of the fluid product area, away
from people, animals, or food handling areas.
Note
Reference numbers and letters in
parentheses in the text refer to the callouts in
the figures and the parts drawings.
Accessories are available from Graco. Make certain
all accessories are sized and pressure rated to meet
your system requirements.
igure 1 is only a guide for selecting and installing
system components and accessories. Contact your
Graco distributor for assistance in designing a system
to suit your particular needs.
Install a fluid drain valve (P) close to the fluid outlet to
relieve fluid pressure in the hose.
Install a bleed-type master air valve (G) close to the
pump air inlet (D), to relieve air trapped between it
and the air motor.
Install an air filter/regulator ( ) in the pump air
line, upstream from the bleed valve, to control
air inlet pressure and to remove harmful dirt and
contaminants from your compressed air supply.
Install a pump runaway valve (L) in the pump air line
to shut off air to the air motor automatically if the
pump starts to run too fast.
Install another bleed-type master air valve (G)
upstream from all air line accessories and use it to
isolate the accessories during cleaning and repair.
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Installation
igure 1 Typical Installation
Key
Pump Components (Included) System Components/Accessories (sold separately)
A Bung-mounted sanitary pump Air line filter/regulator (Graco PN 234398)
BAir exhaust muffler (may be mounted on pump or
remotely, using exhaust hose, ref. M) GBleed
-type master air valve (required)
C3/8np
t exhaust air outlet HAirli ne drain pipe and valve
D3/8np
t air inlet JMaina ir line
KPump ground wire (required, Graco PN 238909)
L Pump runaway valve
E1 in. tri-clamp flanged fluid outlet (Order Kit 24R649
for adapter to 25 mm threaded DIN 11851. See
Accessories, page 24.) MExh
aust hose, Kit 24R646, see
Accessories, page 24.
N Sanitary bung adapter
P luid drain valve (required)
3 2977K 7

Operation
Operation
NOTICE
Do not expose the air motor to temperatures
higher than 120° (49°C) or the immersed fluid
pump to temperatures higher than 250° (121°C).
Excessive temperatures may damage the pump
packings and seals.
To avoid injury from exhaust hose whip, never
operate the pump without a muffler installed.
Secure the exhaust hose to a solid, stationary
object.
Pressure Relief Procedure
ollow 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
in the eyes or on skin, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
1. Shut off the air supply to the pump.
2. Close the bleed-type master air valve (required
in system).
3. Open the fluid ball valve and/or dispensing valve
to relieve fluid pressure.
4. Open all fluid drain valves in the system, having
a waste container ready to catch drainage.
Leave drain valve(s) open until you are ready to
dispense again.
Flush Before First Use
The sanitary pump was assembled using sanitary
lubricant on moving parts and was tested in
water. lush the pump thoroughly with an
appropriate cleaning solution or disassemble and
sanitize the parts before using the pump. See
lushing Procedure, page 9 . Check national, state,
and local codes for specific limitations.
Adjusting the Pump Speed and
Pressure
Set pressure regulator to 0 psi. Open the bleed-type
master air valve. Adjust the pump air regulator until
the pump is running smoothly.
Allow the pump to cycle slowly until all air is pushed
out of the lines (the fluid will flow in a steady stream
from the fluid outlet) and the pump is primed.
With the air supply turned on, the pump will start
when the dispensing valve is opened and stall
against pressure when the valve is closed. In a
circulatingsystem,thepumpoperatesuntiltheair
supply is turned off.
NOTICE
Neverallowthepumptorundryoffluid. Adry
pump will accelerate to a high speed, possibly
damaging itself.
If the pump accelerates quickly, or is running too
fast, stop the pump immediately and check the fluid
supply. If the supply is empty and air has been
pumped into the lines, replace the container and
prime the pump and lines with fluid. Be sure to
eliminate all air from the system.
Pump Shut Down
ollow the Pressure Relief Procedure, page 8 .
83 2977K

Maintenance
Maintenance
Flushing Procedure
Note:
• lush before fluid can dry in the equipment, at the
end of the day, before storing, and before repairing
equipment.
• lush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• lush with an appropriate cleaning solution.
1. ollow Pressure Relief Procedure, page 8 .
2. Remove the pump from the fluid container. Place
it in an empty drum. Operate it to pump out as
much fluid as possible.
3. Place siphon tube in grounded metal pail
containing an appropriate cleaning solution.
4. Set pump air regulator to lowest possible fluid
pressure, and start pump.
5. Run the pump long enough to thoroughly clean
the pump and hoses.
6. ollow Pressure Relief Procedure, page 8 .
Cleaning
• Be sure to follow your national and state sanitary
standard codes and local regulations.
• Use appropriate cleaning and disinfecting agents,
at intervals appropriate for product processed.
• ollow cleaning product manufacturer’s
instructions.
Note: Thepumplower must be disassembled to
thoroughly clean it.
1. ollow the Pressure Relief Procedure, page 8 .
2. Remove the pump from the fluid container. Place
it in an empty drum Operate it to pump out as
much fluid as possible.
3. lush the system thoroughly with an
appropriate cleaning solution. See
lushing Procedure, page 9 .
4. ollow the Pressure Relief Procedure, page 8 .
5. Remove the air and fluid hoses and fittings from
the pump.
6. Disassemble the fluid pump and accessories.
See Disassemble the Pump, page 15.
7. Wash all pump parts with an appropriate cleaning
solution at the cleaning product manufacturer’s
recommended temperature and concentration.
8. Rinse all pump parts again with water and allow
them to dry.
9. Inspect all pump parts and reclean if needed.
Note
Any damaged rubber parts must
be replaced as they could harbor
microorganisms that can contaminate
the fluid.
10. Immerse all pump parts in an appropriate
sanitizer before assembly. Take the pump parts
out of the sanitizer one-by-one as needed.
11. Lubricate the moving pump parts and o-rings,
packings, and seals with appropriate waterproof
sanitary lubricant.
12. Circulate the sanitizing solution through the pump
and the system prior to use.
ighten hreaded Connections
Before each use, check all hoses for wear or damage.
Replace as necessary. Check that all connections
are tight and leak-free.
3 2977K 9

Troubleshooting
Troubleshooting
1. ollow Pressure Relief Procedure, page 8 .
2. Check all possible remedies in the
Troubleshooting Chart before disassembling the
pump.
Problem Cause Solution
Pump cycles, but no fluid comes out. luid supply is empty. Replace fluid supply.
Air supply flow or pressure is
inadequate. Improve air supply flow, increase pressure, or increase air line size.
Air valves are closed or clogged. Open air line. Use dry air.
Air line is closed or clogged. Remove obstruction.
luid line is obstructed. Remove obstruction.
luid line is too small. Increase size of fluid line.
Pump cycles, but fluid flow is too
slow.
luid is too thick. Reduce viscosity of fluid by heat or
dilution.
Pump dives and/or does not pump
on upstroke. Pump rod check seat or seals are worn out or missing. Replace check seat or seals.
Inlet check seat or seals are worn
out or missing. Replace inlet check seat or seals.Pump dives and/or does not pump on downstroke.
luid inlet is obstructed. Clear obstructions away from inlet.
Raise pump off of drum bottom.
Pump cycles unevenly or erratically. Air motor is obstructed by ice chunks
or other material. Remove obstruction. Use dry air.
Pump dives at fast speeds only. luid is too thick, causing cavitation. Reduce viscosity of fluid by heat
or dilution or slow down the pump.
Raise pump off the bottom of the
drum.
Ice has built up in the air motor. Use dry air.
Air motor has a broken or missing
seal. Replace air motor seals.
Air motor stalls and hisses air.
Air motor has a broken part. Replace broken item.
Air motor hisses air while running. Air motor has a damaged o-ring or
upper gasket. Replace damaged item.
Throat seals are worn or missing. Replace throat seals.
luid comes out of exhaust port.
Air line contains too much water. Use dry air.
Pump rod locks up. Throat cartridge weep hole is
clogged. Clear.
Cover won’t stay on. Air motor cylinder has a leak. Tighten air motor cylinder or cover;
replace square cylinder seals.
10 3 2977K