Graco Husky Sanitary Series Operation manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 3 for List of Models
TI2238
Model 2150
309528L
Instructions/Parts List
Husky™Sanitary Series
FDA-Compliant
Diaphragm Pump
II 2 G
Patent No.
CN ZL94102643.4
FR 9408894
JA 3517270
US 5,368,452

2309528L
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pump Matrix - 1040 . . . . . . . . . . . . . . . . . . . . . . . . 26
Repair Kit Matrix - 1040 . . . . . . . . . . . . . . . . . . . . . 27
Parts - 1040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dimensional Drawing - 1040 . . . . . . . . . . . . . . . . . 31
Technical Data - 1040 . . . . . . . . . . . . . . . . . . . . . . 32
Performance Chart - 1040 . . . . . . . . . . . . . . . . . . . 33
Pump Matrix - 1590 . . . . . . . . . . . . . . . . . . . . . . . . 34
Repair Kit Matrix - 1590 . . . . . . . . . . . . . . . . . . . . . 35
Parts - 1590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensional Drawing - 1590 . . . . . . . . . . . . . . . . . 39
Technical Data - 1590 . . . . . . . . . . . . . . . . . . . . . . . 40
Performance Chart - 1590 . . . . . . . . . . . . . . . . . . . 41
Pump Matrix - 2150 . . . . . . . . . . . . . . . . . . . . . . . . 42
Repair Kit Matrix - 2150 . . . . . . . . . . . . . . . . . . . . . 43
Parts - 2150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Model 234361 . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Model 234362 . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Dimensional Drawing - 2150 . . . . . . . . . . . . . . . . . 49
Technical Data - 2150 . . . . . . . . . . . . . . . . . . . . . . . 50
Performance Chart - 2150 . . . . . . . . . . . . . . . . . . . 51
Graco Warranties . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 52

Models
309528L 3
Models
Refer to your Pump Matrix on page 26, 34, or 42 to determine the model number of your pump.
† Plus models include stainless steel center sections.
Manual Conventions
Warning Caution
Note
Model No. Description
D7S_____ Husky 1040 FDA
D8S_____ Husky 1040 FDA Remote Operated
†
DRS_____ Husky 1040 FDA Plus
†
DSS_____ Husky 1040 FDA Plus Remote Operated
DBS_____ Husky 1590 FDA
DCS_____ Husky 1590 FDA Remote Operated
†
DTS_____ Husky 1590 FDA Plus
†
DUS_____ Husky 1590 FDA Plus Remote Operated
DFS_____ Husky 2150 FDA
DGS_____ Husky 2150 FDA Remote Operated
†
DVS_____ Husky 2150 FDA Plus
†
DWS_____ Husky 2150 FDA Plus Remote Operated
WARNING
A warning alerts you to the possibility of serious injury
or death if you do not follow the instructions.
Symbols, such as fire and explosion (shown above),
alert you to a specific hazard and direct you to read
the indicated hazard warnings (pages 4-5) for detailed
information.
CAUTION
A caution alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
A note calls attention to additional helpful informa-
tion.

Warning
4309528L
Warning
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
• This equipment is for professional use only.
• Read all instruction manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
• Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 32, 40, or 50 for the maximum working pressure of this equipment.
• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer's warnings.
• Do not use hoses to pull equipment.
• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82°C (180°F) or below -40°C (-40°F).
• Wear hearing protection when operating this equipment.
• Do not lift pressurized equipment.
• Comply with all applicable local, state, and national fire, electrical, and safety regulations.
PRESSURIZED EQUIPMENT HAZARD
Spray, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and cause serious
injury.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure on page 11 whenever you are instructed to relieve pressure;
stop spraying; clean, check, or repair the equipment.
• Tighten all fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.

Warning
309528L 5
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result
in a fire or explosion and serious injury.
• Ground the equipment. Refer to Grounding on page page 6.
• If there is any static sparking or you feel an electric shock while using this equipment, stop the
equipment immediately. Do not use the equipment until you identify and correct the problem.
• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being
sprayed.
• Keep the work area free of debris, including solvent, rags, and gasoline.
• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop cloths.
Do not plug in or unplug power cords or turn lights on or off in the spray area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
• If a diaphragm fails, fluid is exhausted along with the air. When pumping hazardous fluids, place the
pump in an appropriate container to catch the fluid if a diaphragm ruptures.
• Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the Technical
Data section of all equipment manuals.
BURN HAZARD
This equipment may be used with heated fluid, which can cause equipment surfaces to become very hot.
To avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
• Wear gloves if fluid temperature exceeds 110°F (43°C)
MOVING PARTS HAZARD
Moving parts, such as the diaphragm shaft, can pinch or amputate your fingers.
• Keep clear of all moving parts when starting or operating the pump.
• Before servicing the equipment, follow the Pressure Relief Procedure on page page 11 to prevent
the equipment from starting unexpectedly.
Warning

Installation
6309528L
Installation
General Information
• The Typical Installations shown in Figs. 2-4 are only
guides 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 28-30, 36-38, and 44-48.
Tightening Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Sequence,
pages 24-25. After the first day of operation, retorque
the fasteners. Although pump use varies, a general
guideline is to retorque fasteners every two months.
Grounding
•Pump: Connect a ground wire and clamp as shown
in Fig. 1. Loosen the grounding screw (W). Insert
one end of a 12 ga (1.5 mm²) minimum ground wire
(Y) behind the grounding screw and tighten the
screw securely. Connect the clamp end of the
ground wire to a true earth ground. Order Part No.
222011 Ground Wire and Clamp.
FIG. 1
•Fluid hoses: Use only grounded hoses with a maxi-
mum of 500 ft. (150 m) combined hose length to
ensure grounding continuity.
•Air compressor: Follow the manufacturer’s recom-
mendations.
•All solvent pails used when flushing: Follow the local
code. Use only metal pails, which are conductive.
Do not place the pail on a non-conductive surface,
such as paper or cardboard, which interrupts the
grounding continuity.
•Fluid supply container: Follow the local code.
CAUTION
The pump is very heavy (see Technical Data on
pages 32, 40, and 50 for specific weights). If the pump
must be moved, follow the pressure relief procedure
on page 11 and have two people to lift the pump by
grasping the outlet manifold securely or use appropri-
ate lifting equipment.
WARNING
Read the TOXIC FLUID HAZARD warnings on page 5.
Read the BURN HAZARD warnings on page 5. To
reduce the risk of serious injury due to burns, insulate
and/or label the pump before pumping fluids above
110°F (43°C).
WARNING
Read the FIRE AND EXPLOSION HAZARD warnings
on page 5
02646
B
Y
W

Installation
309528L 7
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 all mountings, be sure the pump is bolted
directly to the mounting surface. Rubber mounting
feet are supplied with the pump. They should be
used to mount the pump to a cart or to the floor.The
rubber mounts have 3/8-16 in. internal and external
threads that allow a variety of mounting options. The
mounts reduce noise and vibration during operation
and provide clearance for the sanitary inlet clamps.
• 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. 2.
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. See the WARNING above. 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 (N).
See Fig. 5. 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 mat-
ing fitting into the pump air inlet snugly. Do not con-
nect the coupler (D) to the fitting until you are ready
to operate the pump.
Installation of Remote Pilot Air Lines
1. Refer to Parts Drawings. Connect air line to pump
as in preceding steps.
2. Connect 1/4 in. O.D. tubing to push type connectors
(14) on air motor of pump.
3. Connect remaining ends of tubes to external air sig-
nal, such as Graco’s Cycleflo (P/N 195264) or
Cycleflo II (P/N195265) controllers.
Fluid Suction Line
1. Use flexible, grounded fluid hoses.
2. For best sealing results, use a standard Tri-Clamp®
style sanitary gasket of a flexible material such as
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.
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 32, 40, and 50 for
maximum suction lift (wet and dry).
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 10.
WARNING
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. 2.
By replacing the push type connectors, other
sizes or types of fittings may be used. The new fit-
tings will require 1/8 in. npt threads.
The air pressure at the connectors must be at
least 30% of the air pressure to the air motor for
the pump to operate.

Installation
8309528L
Fluid Outlet Line 1. Use flexible grounded fluid hoses (L).
2. For best sealing results, use a standard Tri-Clamp®
style sanitary gasket of a flexible material such as
Buna-N, fluoroelastomer, or silicon
3. Install a fluid drain valve (J) near the fluid outlet. See
the WARNING above, and FIG. 2.
4. Install a shutoff valve (K) in the fluid outlet line.
FIG. 2 Typical Floor-Mount Installation
WARNING
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. 2.
TI2240A
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 (required)
K Fluid shutoff valve
L Flexible fluid line
Y Ground wire (required; see page
6 for installation instructions)
EF CB
A
KL
J
G
Y

Installation
309528L 9
Changing the Orientation of the Fluid Inlet
and Outlet Ports
The pump is shipped with the ports facing the same
direction. To reverse the orientation of the ports:
1. Remove the screws and nuts holding the inlet
and/or outlet manifold to the covers.
2. Reverse the manifold and reattach. Install the
screws and torque to 120-150 in-lb (14-17 N•m) on
1040 and 1590 pump models. Torque to 190-220
in-lb (22-25 N•m) on 2150 pump models. See
Torque Sequence, pages 24-25.
FIG. 3
Key:
N 1/2 npt(f) air inlet port
P Muffler (air exhaust
port is 3/4 npt(f)
R Fluid inlet port
S Fluid outlet port
106 Manifold and cover
screws
3 Air valve screws
Torque to
50-60 in-lb
(5.6-6.8 N•m)
1
1
N
3 106 S
R
P
106
TI2238

Installation
10 309528L
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.
If the muffler (P) is installed directly to the air exhaust
pot, apply PTFE thread tape or anti-seize thread lubri-
cant to the muffler threads before assembly.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust
port.
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 container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures. See
FIG. 4.
FIG. 4 Venting Exhaust Air
WARNING
Read the FIRE AND EXPLOSION HAZARD and
TOXIC FLUID HAZARD warnings on page 5 before
operating 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, food handling
areas, and all sources of ignition when pumping flam-
mable or hazardous fluids.
Diaphragm failure will cause the fluid being pumped to
exhaust with the air. Place an appropriate container at
the end of the air exhaust line to catch the fluid. See
FIG. 4.
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
P
U
T
D
A
B
C
F
E
TI02650