Graco ChemSafe 1040 Operation manual

Instructions-Parts
ChemSafe™ ChemSafe™
ChemSafe™1040 1040 1040
Air Air
Air- - -Operated Operated OperatedDiaphragm Diaphragm DiaphragmPump Pump Pump334795F
EN
1–inch 1–inch
1–inchhigh high highpurity purity puritypump pump pumpfor for forindustrial industrial industrialapplications.For applications.For applications.Forprofessional professional professionaluse use useonly. only. only.
Not Not
Notapproved approved approvedfor for foruse use usein in inEuropean European Europeanexplosive explosive explosiveatmosphere atmosphere atmospherelocations. locations. locations.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanual.Save Save
Savethese these these
instructions. instructions.
instructions.
100psi(0.7MPa,7.0bar)MaximumAir
SupplyPressure
100psi(0.7MPa,7.0bar)Maximum
FluidWorkingPressure
PROVENQUALITY.LEADINGTECHNOLOGY.
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Contents Contents
Contents
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................6
Installation..........................................................8
GeneralInformation.....................................8
TightenBolts...............................................8
TipstoReduceCavitation.............................8
MountThePump.........................................9
GroundTheSystem.....................................10
AirLines......................................................10
AirExhaustVentilation.................................11
FluidSupplyLine.........................................12
FluidOutletLine...........................................12
Operation...........................................................13
TightenBolts...............................................13
FlushthePumpBeforeFirstUse..................13
StartandAdjustthePump............................13
PressureReliefProcedure............................14
PumpShutdown..........................................14
Maintenance......................................................15
MaintenanceSchedule.................................15
Lubrication...................................................15
TightenThreadedConnections.....................15
FlushingandStorage...................................15
Troubleshooting..................................................16
Repair................................................................18
DisassembletheFluidSection......................18
DisassembletheCenterSection...................19
ReplacetheAirMotor...................................19
ReassembletheCenterSection....................20
ReassembletheFluidSection.......................21
TorqueInstructions.............................................24
Parts..................................................................25
Kits....................................................................28
Dimensions........................................................29
PerformanceCharts............................................30
TechnicalData...................................................31
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Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Tohelp
prevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
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Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalData Data Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand
solventmanufacturer’sMSDSsandrecommendations.
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Warnings
WARNING WARNING
WARNING
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto
theair.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
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CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number Number
Matrix Matrix
Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1040PT 1040PT
1040PT- - -P01APT3PTPTPOPT P01APT3PTPTPOPT P01APT3PTPTPOPT
1040PT 1040PT
1040PTP01A P01A P01APT3 PT3 PT3PT PT
PTPT PT PTPO PO
POPT PT
PT
PumpModelCenter
Section
andAir
Valve
Fluid
Covers
and
Manifolds
SeatsBallsDiaphragmsManifoldandSeatSeals
Pump Pump
PumpCenter Center
CenterSection Section Sectionand and andAir Air Air
Valve Valve
ValveMaterial Material Material
Fluid Fluid
FluidCovers Covers Coversand and andManifolds Manifolds Manifolds
1040 1040
1040PT PT PT
1in.PTFEP01A P01A
P01APolypropylene
centerwithnpt
airinlet
PT3 PT3
PT3PTFE,npt
1040 1040
1040UH UH UH
1in.UHMWPEP03A P03A
P03APolypropylene
centerwith
bsptairinlet
PT4 PT4
PT4PTFE,bspt
UH3 UH3
UH3UHMW,npt
UH4 UH4
UH4UHMW,bspt
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialManifold Manifold
Manifoldand and andSeat Seat Seat
Seal Seal
SealMaterial Material Material
PT PT
PTPTFEPT PT PTPTFEBN BN BNBunaNPT PT PTPTFE
UH UH
UHUHMWPEEP EP EPEPDM
PO PO
POPTFE/EPDMOvermolded
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CongurationNumberMatrix
Models Models
Models
Model Model
ModelPump Pump PumpAir Air
Air& & &Fluid Fluid Fluid
Connection Connection
Connection
Threads Threads
Threads
Fluid Fluid
FluidCovers, Covers, Covers,
Seats, Seats,
Seats,& & &
Manifolds Manifolds
Manifolds
Balls Balls
BallsDiaphragm Diaphragm DiaphragmManifold Manifold
ManifoldSeal Seal Seal
24X424 24X424
24X424bspt bspt
bspt
24X423 24X423
24X4231 1
1in. in. in.PTFE PTFE PTFEnpt npt
nptPTFE PTFE
PTFE
24X492 24X492
24X492bspt bspt
bspt
24X491 24X491
24X491npt npt
npt
PTFE/EPDM PTFE/EPDM
PTFE/EPDM
Overmolded Overmolded
Overmolded
24X544 24X544
24X544bspt bspt
bspt
24X545 24X545
24X545npt npt
nptEPDM EPDM
EPDM
24X490 24X490
24X490bspt bspt
bspt
24X489 24X489
24X489
1 1
1in. in. in.
UHMWPE UHMWPE
UHMWPE
npt npt
npt
UHMW UHMW
UHMW
PTFE PTFE
PTFE
Buna Buna
BunaN N N
PTFE PTFE
PTFE
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Installation
Installation Installation
Installation
General General
GeneralInformation Information Information
TheTypicalInstallationshownisonlyaguidefor
selectingandinstallingsystemcomponents.Contact
yourGracodistributorforassistanceinplanninga
systemtosuityourneeds.AlwaysuseGenuine
GracoPartsandaccessories.Besureallaccessories
areadequatelysizedandpressureratedtomeetthe
system’srequirements.
Referencelettersinthetext,forexample(A),referto
thecalloutsinthe󰘰gures.
Variationsincolorbetweentheplasticcomponents
ofthispumparenormal.Colorvariationdoesnot
affecttheperformanceofthepump.
Storage: Storage:
Storage:Pumpsthatarenotputintooperation
upondeliverymustbestoredappropriately.See
FlushingandStorage,page15.
Tighten Tighten
TightenBolts Bolts Bolts
Beforemountingandusingthepumpforthe
󰘰rsttime,checkandretorqueallexternalbolts.
Removeallprotectiveboltcovers(37).Follow
TorqueInstructions,page24,totightenallbolts.
Replacetheboltcovers(37).Afterthe󰘰rstdayof
operation,retorquethebolts.Retorquetheboltsifthe
pumphasbeenidleforanextendedtime,beenused
inthermalcyclingapplications,beendisassembled,
orifthereisalargedifferencebetweenenvironmental
temperaturesand󰘱uidtemperatures.
Tips Tips
Tipsto to toReduce Reduce ReduceCavitation Cavitation Cavitation
CavitationinanAODDpumpistheformationand
collapseofbubblesinthepumpedliquid.Frequent
orexcessivecavitationcancauseseriousdamage,
includingpittingandearlywearof󰘱uidchambers,
balls,andseats.Itmayresultinreducedef󰘰ciencyof
thepump.Cavitationdamageandreducedef󰘰ciency
bothresultinincreasedoperatingcosts.
Cavitationdependsonthevaporpressureofthe
pumpedliquid,thesystemsuctionpressure,andthe
velocitypressure.Itcanbereducedbychangingany
ofthesefactors.
1.Reducevaporpressure:Decreasethe
temperatureofthepumpedliquid.
2.Increasesuctionpressure:
a.Lowertheinstalledpositionofthepump
relativetotheliquidlevelinthesupply.
b.Reducethefrictionlengthofthesuction
piping.Rememberthat󰘰ttingsaddfriction
lengthtothepiping.Reducethenumberof
󰘰ttingstoreducethefrictionlength.
c.Increasethesizeofthesuctionpiping.
3.Reduceliquidvelocity:Slowthecyclicrateof
thepump.
Pumpedliquidviscosityisalsoveryimportantbut
normallyiscontrolledbyfactorsthatareprocess
dependentandcannotbechangedtoreduce
cavitation.Viscousliquidsaremoredif󰘰culttopump
andmorepronetocavitation.
Gracorecommendstakingalltheabovefactors
intoaccountinsystemdesign.Tomaintainpump
ef󰘰ciency,supplyonlyenoughairpressuretothe
pumptoachievetherequired󰘱ow.
Gracodistributorscansupplysitespeci󰘰c
suggestionstoimprovepumpperformanceand
reduceoperatingcosts.
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Installation
Mount Mount
MountThe The ThePump Pump Pump
Toavoidseriousinjuryfromtoxic󰘱uidorfumes:
•Ventilatetoaremotearea.Thepump
exhaustairmaycontaincontaminants.See
AirExhaustVentilation,page11.
•Nevermoveorliftapumpunderpressure.Ifdropped,
the󰘱uidsectionmayrupture.Alwaysfollowthe
PressureReliefProcedure,page14,beforemoving
orliftingthepump.
•ProlongedexposuretoUVradiationwilldegrade
naturalpolypropylenecomponentsofthepumps.To
preventpotentialinjuryorequipmentdamage,do
notexposepumportheplasticcomponentstodirect
sunlightforprolongedperiods.
1.Besurethemountingsurfacecansupportthe
weightofthepump,hoses,andaccessories,as
wellasthestresscausedduringoperation.
2.Forallmountings,besurethepumpissecured
withscrewsthroughthemountingfeet.Always
mountthepumpupright.
3.Makesurethesurfaceis󰘱atandthatthepump
doesn’twobble.
4.Foreaseofoperationandservice,mountthe
pumpsoairvalve,airinlet,󰘱uidinletand󰘱uid
outletportsareeasilyaccessible.
Accessories/Components Accessories/Components
Accessories/ComponentsNot Not NotSupplied Supplied SuppliedSystem System SystemComponents Components Components
AAirsupplylineJAirinletport(notvisible)
BBleed-typemasterairvalve(requiredfor
yourpump)
KExhaustportandmuf󰘱er
CAir󰘰lter/regulatorassemblyLFluidinletport
DMasterairvalve(toisolatethe󰘰lter/regulator
forservice)
MFluidoutletport
EGrounded󰘱exible󰘱uidsupplylineNMountingfeet
FFluiddrainvalve(requiredforyourpump)
GFluidshutoffvalve
HGrounded,󰘱exible󰘱uidoutletline
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Installation
Ground Ground
GroundThe The TheSystem System System
Theequipmentmustbegroundedtoreducethe
riskofstaticsparking.Staticsparkingcancause
fumestoigniteorexplode.Groundingprovidesan
escapewirefortheelectricalcurrent.
•Always Always
Alwaysgroundtheentire󰘱uidsystemas
describedbelow.
•Thepumpsarenot not
notconductive.Anysystem
usedtopump󰘱ammable󰘱uidsmustbeproperly
grounded.
•Followyourlocal󰘰recodes.
Beforeoperatingthepump,groundthesystemas
explainedbelow.
•Pump: Pump:
Pump:Always Always Alwaysgroundtheentire󰘱uidsystemby
makingsurethe󰘱uidhasanelectricalpathtoa
trueearthground.
•Air Air
Airand and and󰘱uid 󰘱uid 󰘱uidhoses: hoses: hoses:Useonly󰘱exiblegrounded
hoseswithamaximumof500ft(150m)combined
hoselengthtoensuregroundingcontinuity.
•Air Air
Aircompressor: compressor: compressor:Followmanufacturer’s
recommendations.
•Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followlocalcode.
•Solvent Solvent
Solventpails pails pailsused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:Followlocal
code.Useonlyconductivemetalpails,placed
onagroundedsurface.Donotplacethepail
onanonconductivesurface,suchaspaperor
cardboard,whichinterruptsgroundingcontinuity.
Checkyoursystemelectricalcontinuityafterthe
initialinstallation,andthensetuparegularschedule
forcheckingcontinuitytobesurepropergrounding
ismaintained.
Air Air
AirLines Lines Lines
1.Installanairregulatorandgauge(C)tocontrol
the󰘱uidpressure.The󰘱uidstallpressurewillbe
thesameasthesettingoftheairregulator.
2.Locateableed-typemasterairvalve(B)closeto
thepumpanduseittorelievetrappedair.Be
surethevalveiseasilyaccessiblefromthepump
andlocateddownstreamfromtheregulator.
Trappedaircancausethepumptocycle
unexpectedly,whichcouldresultinserious
injuryfromsplashing.
3.Locateanothermasterairvalve(D)upstream
fromallairlineaccessoriesanduseittoisolate
themduringcleaningandrepair.
4.Anairline󰘰lter(C)removesharmfuldirtand
moisturefromthecompressedairsupply.
5.Installagrounded,󰘱exibleairhose(A)between
theaccessoriesandthe1/4npt(f)or1/4bspt
pumpairinlet.Useahosewithaminimum1/4in.
ID.Ifahoselongerthan10ft(3m)isrequired,
usealargerdiameterhose.
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