Graco Husky 205 Operation manual

Huskyt205 Air–Operated
Diaphragm Pumps
100 psi (0.7 MPa, 7 bar) Maximum Incoming Air Pressure
100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure
Part No. D120XX
Polypropylene Pump with Air–Operated Motor
Part No. D110XX and DM10XX
Acetal Pump with Air–Operated Motor
Part No. D150XX and DM50XX
PVDF Pump with Air–Operated Motor
Part No. D220XX
Polypropylene Pump with Solenoid Ports
Part No. D210XX
Acetal Pump with Solenoid Ports
Part No. D250XX
PVDF Pump with Solenoid Ports
Patent No.
CH ZL01113998.6
EU 0942171
US 5,860,794
AR AR006617B1
KP 461707
CH ZL01124998.6
BR PI9701779_5
Instructions – Parts List
308652W
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
ti10660a

2 308652
Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Matrix 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Kit Matrix 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Lists 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Mounting Hole Layout 20. . . . . . . . . . .
Performance Charts 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 24. . . . . . . . . . . . . . . . . . . . . .
Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Any misuse of the equipment or accessories, such as overpressurizing, modifying parts, using
incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and
result in splashing in the eyes or on the skin, other serious injury, or fire, explosion or property dam-
age.
DThis equipment is for professional use only. Observe all warnings. Read and understand all
instruction manuals, warning labels, and tags before you operate this equipment. If you are not
sure, or if you have questions about installation or operation, call your Graco distributor.
DNever alter or modify any part of this equipment; doing so could cause it to malfunction. Use only
genuine Graco part numbers and accessories.
DCheck all equipment regularly and repair or replace worn or damaged parts immediately.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 19.
DDo not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi
(0.7 MPa, 7 bar, ) maximum incoming air pressure.
DBe sure that all fluids and solvents used are chemically compatible with the wetted parts shown in
the Technical Data on page 19. Always read the manufacturer’s literature before you use fluid
or solvent in the pump.
DNever move or lift a pump under pressure. If dropped, the fluid section may rupture. Always
follow the Pressure Relief Procedure on page 8 before you move or lift the pump.
DNever use a polypropylene or PVDF pump with non-conductive flammable fluids as specified by
your local fire protection code. Refer to Grounding on page 4 for additional information. Consult
your fluid supplier to determine the conductivity or resistivity of your fluid.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being pumped.
WARNING

3308652
HAZARDOUS FLUIDS
Improper handling of hazardous fluids or inhaling toxic vapors can cause extremely serious injury or
death from splashing in the eyes, ingestion, or bodily contamination. Observe all the following
precautions when you handle hazardous or potentially hazardous fluids.
DKnow what fluid you are pumping and its specific hazards. Take precautions to avoid a toxic fluid
spill.
DAlways wear appropriate clothing and equipment, such as eye protection and breathing appara-
tus, to protect yourself.
DStore hazardous fluid in an appropriate, approved container. Dispose of it according to all Local,
State, and Federal guidelines for hazardous fluids.
DSecure the fluid outlet hose tightly into the receiving container to prevent it from coming loose
and improperly draining the fluid.
DPipe and dispose of the exhaust air safely, away from people, animals, and food handling areas.
If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on
page 5.
FIRE AND EXPLOSION HAZARD
Static electricity is created by the flow of fluid through the pump and hose. If the equipment is not
properly grounded, sparking may occur. Sparks can ignite fumes from solvents and the fluid being
pumped, dust particles, and other flammable substances, whether you are pumping indoors or
outdoors, and can cause a fire or explosion and serious injury and property damage.
DTo reduce the risk of static sparking, ground the pump and all other equipment used or located in
the work area. Check your local electrical code for detailed grounding instructions for your area
and type of equipment. See Grounding on page 4.
DIf you experience any static sparking or even a slight shock while using this equipment, stop
pumping immediately. Check the entire system for proper grounding. Do not use the system
again until you have identified and corrected the problem.
DPipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm
fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 5.
DDo not smoke in the work area. Do not operate the equipment near a source of ignition or an
open flame, such as a pilot light.
WARNING
United States Government safety standards have been adopted under the Occupational Safety and Health Act.
You should consult these standards—particularly the General Standards, Part 1910, and the Construction Stan-
dards, Part 1926.

4 308652
Installation
Tightening Threaded Fasteners Before
First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Se-
quence, page 18. After the first day of operation,
retorque the fasteners. Although pump use varies, a
general guideline is to retorque fasteners every two
months.
Use a compatible thread sealant on all male threads.
Tighten all connections firmly to avoid air or fluid leaks.
CAUTION
To avoid pump damage, do not overtighten the
fittings to the pump.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
you operate the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 3.
The acetal pump contains stainless steel fibers
which make the wetted parts conductive. Attaching
the ground wire to one of the grounding locations
grounds the wetted parts.
The polypropylene and PVDF pumps are not
conductive. When you pump conductive flam-
mable fluids, always ground the entire fluid system
by making sure the fluid has an electrical path to a
true earth ground. See Fig. 1. Never use a poly-
propylene or PVDF pump with non-conductive
flammable fluids as specified by your local fire
protection code. Consult your fluid supplier to
determine the conductivity or resistivity of your
fluid.
US Code (NFPA 77 Static Electricity) recommends
a conductivity greater than 50 x 10–12 Siemans/me-
ter (mhos/meter) over your operating temperature
range to reduce the hazard of fire. Consult your
fluid supplier to determine the conductivity or
resistivity of your fluid. The resistivity must be less
than 2 x 1012 ohm-centimeters.
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.
Acetal Pump Grounding Instructions
For polypropylene and PVDF pumps, see the
warning above.
Ground all of this equipment.
Pump: Connect a ground wire (A) and clamp, Part No.
222011. See Fig. 1. The pump grounding locations
are on the manifold between the inlet and outlet ports.
Use the nut (B) and bolt (C) that are provided with the
pump, and install as follows:
1. Place the nut in the nut catcher on the underside
of the manifold.
2. Insert the bolt through the loop end of the ground
wire.
3. Insert the bolt through the hole on the pump man-
ifold and tighten it into the nut that you positioned
in step 1.
4. Connect the clamp end of the ground wire to a
true earth ground.
Fig. 1 06179A
Fig. 1
A
C
grounding hole
B
DAir and fluid hoses: Use only grounded hoses with
a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity.
DAir compressor: Follow the manufacturer’s recom-
mendations.
DAll solvent pails used when flushing: Follow the
local code. Use only grounded metal pails, which
are conductive. Do not place the pail on a non-con-
ductive surface, such as paper or cardboard, which
interrupts the grounding continuity.
DFluid supply container: Follow the local code.

5308652
Installation
Air Exhaust Ventilation
WARNING
TOXIC FLUID HAZARD
Read the USING HAZARDOUS FLUIDS
and FIRE AND EXPLOSION HAZARD
sections on page 3 before you operate
this pump.
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 or food handling
areas when pumping flammable or
hazardous fluids.
If the diaphragm ruptures, the fluid being pumped
is exhausted with the air. Place a container at the
end of the air exhaust line to catch fluid in case the
diaphragm ruptures, and disconnect the pump.
Mountings
CAUTION
The pump exhaust air may contain contaminants.
If needed, ventilate to a remote area to reduce
possible fluid contamination. See Air Exhaust
Ventilation on page 5.
DMounting Bracket:
The pump is shipped with a 90 degree mounting
bracket (60). Mount the pump to the bracket using
the four screws (61) provided. Secure the opposite
portion of the mounting bracket to a horizontal
surface. The mounting bracket must be used for
proper pump performance.
.
Fig. 2 ti10662a
DBe sure the mounting can support the weight of the
pump, hoses, and accessories, as well as the
stress caused during operation.
DFor all mountings, be sure the pump is secured with
screws and nuts.
WARNING
To reduce the risk of serious injury, splashing in
the eyes or on the skin, and toxic fluid spills,
never move or lift a pump under pressure. If
dropped, the fluid section may rupture. Always
follow the Pressure Relief Procedure on page
8 before you move or lift the pump.

6 308652
Installation
Air Lines
WARNING
Bleed-Type Master Air Valve and Fluid Drain
Valve
A bleed-type master air valve and a fluid drain
valve are required on your system.
The bleed-type master air valve relieves air
trapped between itself and the pump. Trapped air
can cause the pump to cycle unexpectedly, which
could result in serious bodily injury, including
splashing in the eyes, injury from moving parts, or
contamination from hazardous fluids.
The fluid drain valve reduces the risk of serious
bodily injury, including splashing in the eyes or on
the skin, or contamination from hazardous fluids.
Install the fluid drain valve close to the pump’s
fluid outlet to relieve pressure in the hose if the
hose becomes plugged.
1. Mount the air line accessories on the wall or on a
bracket. Be sure the air line supplying the acces-
sories is grounded.
a. The pump speed can be controlled in one of
two ways: To control it on the air side, install
an air regulator. To control it on the fluid side,
install a fluid valve near the outlet.
b. Install a bleed-type master air valve down-
stream from the air regulator, and use it to re-
lieve trapped air. See the Bleed-Type Master
Air Valve and Fluid Drain Valve warning
above. Locate another bleed-type master air
valve upstream from all air line accessories,
and use it to isolate the accessories during
cleaning and repair.
c. The air line filter removes harmful dirt and
moisture from the compressed air supply.
2. Install a flexible air hose between the accessories
and the pump air inlet. Screw the air line fitting
into the air inlet.
3. Do not restrict the exhaust port. Excessive ex-
haust restriction can cause erratic pump operation.
Fluid Lines
Fig. 3. On each end of the fluid manifold are a fluid IN
port and a fluid OUT port. NOTE: Make sure the fluid
OUT port on the fluid manifold is mounted up. This
will assure proper pump priming. Fluid-in and fluid-
out lines can be connected on the same end, or
opposite ends of the manifold. Plug ports that are not
used (plugs provided).
Fi
g
. 3 06179A
ti10661a
Typical Installation
The installations shown in Fig. 4 are only a guide to
help select and install a pump; they are not actual
system designs.
Typical installation includes (not supplied by Graco):
DFor solenoid operation: a four-way, 5-port, 3-posi-
tion solenoid valve with 1/4-in. ports, or two 3–posi-
tion 3–way valves. Mac series 44 (4–way), or series
35 (3–way). Either way, air pressure should be
released if not cycling.
DPLC or timer. Consult your local industrial controls
distributor.
For solenoid operation, the pump must exhaust
through the solenoid. Failure to exhaust through
solenoid could cause the diaphragms to fail.
CAUTION

7308652
Installation
Fig. 4
KEY
A Husky 205 pump
B Bleed-type master air valve
(required for pump)
C Air line(s)
E Master air valve (for accessories)
F Air line filter
G Muffler
H Pump air regulator
J Fluid drain valve
(required on fluid outlet side of pump)
L Fluid suction line
N Fluid supply hose
T Bung adapter
U 4-way solenoid
Y Ground wire (required)
See page 4 for installation instructions.
C
J
L
N
T
YA
U
Air line to inlet
Internal Air Valve Operated
Remote Solenoid Operated
EH
B
G
F
Remote Solenoid View
Internal Air Valve View
(shown upright for clarity)
C
J
N
A
L
L
C
Air line to Port A Air line to Port B
Y
ti10663a

8 308652
Operation
Pressure Relief Procedure
WARNING
To reduce the risk of serious injury, including
splashing fluid in the eyes or on the skin, follow this
procedure whenever you are instructed to relieve
pressure, when you shut off the pump, and before
you check, adjust, clean, move, or repair any
system equipment.
1. Shut off air and reserve air to the pump.
2. Open the dispensing valve if the system has one.
3. Open the fluid drain valve to relieve all system
pressure, and have a container ready to catch the
drainage.
Flushing the Pump Before First Use
The pump was tested in water. If water could contami-
nate the fluid you are pumping, flush it thoroughly with
a compatible solvent. Follow the procedure in Start-
ing and Adjusting the Pump.
Starting and Adjusting the Pump
WARNING
To reduce the risk of serious injury, splashing in
the eyes or on the skin, and toxic fluid spills,
never move or lift a pump under pressure. If the
pump is dropped, the fluid section could rupture.
Always follow the Pressure Relief Procedure
above before you move or lift the pump.
1. Be sure the pump is properly grounded. Read and
follow the instructions in Grounding on page 4.
2. Check all fittings to be sure they are tight. Be sure
to use a compatible liquid thread sealant on all
male threads. Tighten the fluid inlet and outlet fit-
tings and plugs securely. Retorque all fasteners
before start-up. See Torque Sequence, page 18.
3. Place the suction tube (if used) in the fluid to be
pumped.
4. Place the end of the outlet hose into an appropri-
ate container.
5. Close the fluid drain valve.
6. With the air regulator closed, open all bleed-type
master air valves.
7. If the outlet hose has a dispensing device, hold it
open while continuing with step 8.
8. Slowly open the air regulator until the pump starts
to cycle. Allow the pump to cycle until all air is
pushed out of the lines and the pump is primed.
NOTE: To prime a remote solenoid-operated
air valve, operate the pump at a minimum 60 cpm
rate until the pump is fully primed.
Pump Shutdown
At the end of the work shift, and before you check,
adjust, clean, or repair the system, relieve air and
fluid pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.

9308652
Maintenance
Lubrication
The air valve is lubricated at the factory and designed
to operate without additional lubrication.
If added lubrication is desired, every 500 hours of
operation (or monthly), remove the hose from the
pump air inlet and add two drops of machine oil to the
air inlet.
CAUTION
Do not over-lubricate the pump. Excess oil is
exhausted through the muffler, which could con-
taminate your fluid supply or other equipment.
Tightening Threaded Connections
Before each use, check all hoses for wear or damage,
and replace as necessary. Be sure all threaded con-
nections are tight and free of leaks.
Check fasteners. Tighten or retorque as necessary.
Although pump use varies, a general guideline is to
retorque fasteners every two months. See Torque
Sequence, page 18.
Flushing and Storage
Flush the pump to prevent the fluid from drying or
freezing in the pump and damaging it. Always flush
the pump and relieve the pressure before storing for
any length of time. Use a compatible solvent.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses, close the air
regulator, and remove the suction hose from the
solvent and place it in the fluid to be pumped.
If you are shutting down the pump, remove the suction
hose from the fluid container, run the pump until the
fluid is forced out of the system, and shut off the air
supply immediately.

10 308652
Troubleshooting
Relieve the pressure before you check or service the
equipment.
Check all possible problems and causes before you
disassemble the pump.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Internal Air Valve-Operated and Remote Solenoid-Operated Pumps
PROBLEM CAUSE SOLUTION
The pump cycles at stall, or it fails
to hold pressure at stall. The check valves (20) or o-rings (21) are leaking. Replace the check valves and/or o-rings. See page 14.
The check valves (20) are worn. Replace the check valves.
See page 14.
Debris is stuck between the a check
valve (20) and the seat. Clean the check valve/seat area. See page 14.
The pump operates erratically. The suction line is clogged. Inspect and clear the line.
The check valves (20) are sticking
or leaking. Replace the check valves, or clean and check the valve/seat area.
See page 14.
A diaphragm (30) is ruptured. Replace the ruptured diaphragm.
See page 13.
There are air bubbles in the fluid. The suction line is loose. Tighten the suction line.
A diaphragm (30) is ruptured. Replace the ruptured diaphragm.
See page 13.
The manifold (52) is loose, or the
o-rings (21) are damaged. Tighten the manifold screws (58). Replace the o-rings (21).
See page 14.
The fluid covers (51) are loose. Tighten the fluid cover screws (58).
See page13.
There is fluid in the exhaust air. A diaphragm (30) is ruptured. Replace the ruptured diaphragm.
See page 13.
A diaphragm plate (50) is loose. Tighten the diaphragm plate.
See page13.
The pump exhausts air near the
fluid covers. The fluid covers (51) are loose, or the o-rings (57) are damaged. Tighten the fluid cover screws (58), or replace the o-rings. See page13.
The pump exhausts air near the air
valve. The air valve cover screws (14) are loose. Tighten the screws. See page 12.
The top (5) and/or side (6) air valve
o-rings are damaged. Replace these o-rings. See the Parts Drawing on
page 17.
The pump leaks fluid from the
check valves. The o-rings (21) are leaking, or the screws (58) are loose. Replace these o-rings, and tighten the screws. See page 14.