Graco Hydra-Clean 1040 Instruction Manual

Operation
SaniForce®High Sanitation
Diaphragm Pumps
Models 1040, 1590, 2150, 3150, 4150
For transfer of fluids in sanitary applications. Not approved for use in explosive
atmospheres or hazardous (classified) locations unless otherwise stated. See Approvals
page for more information. For professional use only.
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 before using the
equipment. Save these instructions.
3A5999E
EN

2 3A5999E
Contents
Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Configuration Number Matrix . . . . . . . . . . . . . . . . . 5
Fluid Temperature Range . . . . . . . . . . . . . . . . . . . . 6
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Information . . . . . . . . . . . . . . . . . . . . . . . 8
Tighten Clamps Before First Use. . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Stand and Mounting. . . . . . . . . . . . . . . . . . . . . . . 9
Air Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fluid Suction and Outlet Lines. . . . . . . . . . . . . . 10
Tips to Reduce Cavitation . . . . . . . . . . . . . . . . . 10
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 11
Air Exhaust Ventilation. . . . . . . . . . . . . . . . . . . . 12
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure. . . . . . . . . . . . . . . . . 13
Sanitize the Pump Before First Use. . . . . . . . . . 13
Start and Adjust the Pump. . . . . . . . . . . . . . . . . 14
Pump Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flushing and Storage. . . . . . . . . . . . . . . . . . . . . 15
Routine Cleaning of Product Contact
Section of Pump . . . . . . . . . . . . . . . . . . . . . 15
Tightening Connections . . . . . . . . . . . . . . . . . . . 15
1040 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 16
1040 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 16
1040 Performance Chart . . . . . . . . . . . . . . . . . . 17
1040 Technical Specifications . . . . . . . . . . . . . . 18
1590 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 19
1590 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 19
1590 Performance Charts . . . . . . . . . . . . . . . . . 20
1590 Technical Specifications . . . . . . . . . . . . . . 22
2150 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 23
2150 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 23
2150 Performance Chart . . . . . . . . . . . . . . . . . . 24
3150 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 25
3150 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 25
3150 Performance Chart . . . . . . . . . . . . . . . . . . 27
4150 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 28
4150 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 28
4150 Performance Chart . . . . . . . . . . . . . . . . . . 30
2150, 3150, 4150 Technical Specifications. . . . . . 31
Graco Information. . . . . . . . . . . . . . . . . . . . . . . . . . 32
Related Manuals
English Manual
Number Title
3A6780 SaniForce High Sanitation Diaphragm Pump, Model 1040, Repair/Parts
3A6781 SaniForce High Sanitation Diaphragm Pump, Model 1590, Repair/Parts
3A6782 SaniForce High Sanitation Diaphragm Pump, Models 2150, 3150, 4150, Repair/Parts
3A6976 Leak Detection System

Warnings
3A5999E 3
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 risk.
When these symbols appear in the body of this manual, 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, in work area can ignite or explode. Solvent flowing through the
equipment can cause static sparking. To help prevent fire or explosion:
• Use equipment only in well ventilated area.
• Eliminateallignitionsources;suchas pilotlights,cigarettes,portableelectriclamps,andplasticdrop
cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• 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.
• Use only grounded fluid lines.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static 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.
• Routeexhaust awayfromall ignitionsources. Ifdiaphragm ruptures, fluidmay beexhausted withair.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow 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 fluid lines, tubes, and couplings daily. Replace worn or damaged parts immediately.

Warnings
4 3A5999E
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheet (SDS) 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.
• Donotalterormodifyequipment.Alterationsormodificationsmayvoidagencyapprovalsandcreate
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 fluid lines and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend fluid lines or use fluid lines to pull equipment.
• Keep children and animals away from work area.
• 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
swallowed.
• Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
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 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.
WARNING

Configuration Number Matrix
3A5999E 5
Configuration Number Matrix
Check the identification plate (ID) for the Configuration
Number of your pump. Use the following matrix to define
the components of your pump.
When you receive your pump, record the 9 character
part number found on the shipping box (e.g.,
SP3F.0018): _____________
Also record the configuration number on the pump ID
plate to assist you when ordering replacement parts:
_____________________________________
NOTE: Some combinations are not possible. Please check with your local supplier.
Sample Configuration Number: 2150HS.PSP1ASSASSPTPSEP21
2150 HS P SP1A SSA SS PT PS EP 21
Pump
Model Wetted Section Material Drive Center Section and Air Valve Material Manifolds Seats Checks Diaphragms Seals Certificati on
Pump Wetted Section Material Drive Type Center Section and Air Valve
Material Manifolds
1040 3A 3-A compliant P Pneumatic S01A Stainless Steel, for all but
2-piece PS diaphragms SSA Stainless steel, TriClamp, center ported
1590 HS High Sanitation S02A Stainless Steel, leak
detector, for all but 2-piece
PS diaphragms
SSB Stainless steel, DIN,
center ported
2150 PH Pharmaceutical S03A Stainless Steel, PH, for all
but 2-piece PS diaphragms SSC Stainless steel, TriClamp, unloader
3150 SP1A Stainless Steel, for 2-piece
PS diaphragms only SSD Stainless steel, DIN, unloader
4150 SP2A Stainless Steel, leak
detector, PS diaphragms SSE Stainless steel, TriClamp, horizontal, WYE manifold
SP3A Stainless Steel, PH, for
2-piece PS diaphragms only SSF Stainless steel, DIN, horizontal, WYE manifold
SSG Horizontal, no manifolds
Seat Material Checks Diaphragm Material Seals Certification
FL 316 stainless
steel, flapper — Stainless Steel Flapper BN Buna-N BN Buna-N 21 EN 10204 type 2.1
SS 316 stainless
steel, ball BN Buna-N EO EPDM Overmold EP EPDM 31 EN 10204 type 3.1
CW Polychloroprene Weighted
Ball FK FKM Fluoroelastomer FK FKM
EP EPDM PO PTFE/EPDM Overmold
FK FKM Fluoroelastomer Ball PS PTFE/Santoprene
PT PTFE Ball SO Santoprene Overmold
SP Santoprene Ball SP Santoprene

Configuration Number Matrix
6 3A5999E
Fluid Temperature Range
Approvals
ATEX T-code rating is dependent on
the temperature of the fluid being
pumped. Fluid temperature is limited
by the materials of the pump interior
wetted parts. See Fluid Temperature
Range for the maximum fluid
operatingtemperature foryour specific
pump model.
Except for 3-A pumps, all
pumps are approved to:
II 2 GD
Ex h IIA T6...T3 Gb
Ex h IIIB T160°C Db
Diaphragm materials coded
EO, PO, or PS combined with
flapper or PT ball checks
comply with:
EC 1935/2004
Diaphragmmaterials codedEO
or PS combined with flapper or
PT ball checks comply with: Class VI
All models are approved to:
All fluid contact materials are FDA compliant and meet the United States
Code of Federal Regulations (CFR)
NOTICE
Temperature limits are based on mechanical stress only. Certain chemicals will further limit the
fluid temperature range. Stay within the temperature range of the most-restricted wetted compo-
nent. Operating at a fluid temperature that is too high or too low for the components of your pump
may cause equipment damage.
Diaphragm/Ball/Seat Material Fluid Temperature Range
Fahrenheit Celsius
Buna-N 10° to 180°F -12° to 82°C
FKM Fluoroelastomer (FK) -40° to 275°F -40° to 135°C
EPDM overmolded diaphragm or check balls (EO) -40° to 250°F -40° to 121°C
Polychloroprene check balls (CW) 14° to 176°F -10° to 80°C
PTFE overmolded diaphragm (PO) -40° to 180°F -40° to 82°C
PTFE check balls (PT) -40° to 220°F -40° to 104°C
2-piece PTFE/Santoprene diaphragm (PS) -40° to 180°F -40° to 82°C
Santoprene™ diaphragm or check balls (SP) -40° to 180°F -40° to 82°C
The maximum temperature listed is based on the ATEX standard for T4 temperature classification.

Configuration Number Matrix
3A5999E 7
Ordering Information
To Find Your Nearest Distributor
1. Visit www.graco.com.
2. Click on Where to Buy and use the Distributor Locator.
To Specify the Configuration of a New Pump
Please call your distributor.
OR
Use the Online Diaphragm Pump Selector at www.graco.com. Search for Selector.
To Order Replacement Parts
Please call your distributor.

Installation
8 3A5999E
Installation
General Information
• A typical installation is shown in FIG. 2. It is only a
guide for selecting and installing system
components. 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.
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.
Grounding
•Pump: Connect a ground wire and clamp as shown
in FIG. 1. Loosen the grounding screw (W). Insert
one end of a 12 AWG (1.5 mm²) or thicker 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.
FIG. 1: Ground Wire Connection
•Air and fluid lines: Use only conductive lines with a
maximum of 500 ft (150 m) combined line length to
ensure grounding continuity. Check electrical
resistance of lines. If total resistance to ground
exceeds 29 megohms, replace line immediately.
•Fluid supply container: Follow the local codes and
regulations.
•Pails for solvents and sanitizing solution used when
flushing: Follow local codes and regulations. 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 rounding continuity.
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 electric current.
X
WTI4736A

Installation
3A5999E 9
Stand and Mounting
For pumps that are provided with a stand, the pump
must be mounted to the stand before securing the pump
to the mounting surface. Ensure that the pump is
securely mounted to the stand.
Stand sizes:
1. Ensure that the mounting surface is level and can
support the weight of the pump, lines, and
accessories, as well as the stress caused during
operation.
2. Mount the pump and stand assembly on a level
surface and secure the assembly to the mounting
surface. See Pump Dimensions, pages 16–28, for
dimensions of the mounting holes for your pump.
NOTE: For ease of operation and service, mount
the pump so the air valve cover, air inlet, and fluid
inlet and outlet ports are easily accessible.
Air Line
1. Install the air line accessories as shown in FIG. 2.
Verify that the air line supplying the accessories is
grounded.
a. Install an air regulator (B) and air pressure
gauge (T) to control the fluid pressure.
Reducing the supplied air pressure will reduce
the pump’s fluid outlet pressure.
b. Locate one bleed-type master air valve (C)
close to the pump and use it to relieve trapped
air. Locate the other master air valve (A)
upstream from all air line accessories and use it
to isolate them during cleaning and repair.
c. The air line filter (R) removes harmful dirt and
moisture from the compressed air supply.
2. Install a conductive, grounded, flexible air line (D)
between the accessories and the 1/2 npt(f) pump air
inlet (F). Use a minimum 3/8 in. (9.5 mm) ID air line.
If necessary, install an air line coupler (E) between
the air line (D) and the pump air inlet (F), and tighten
until snug.
3-A Pumps: If a leak sensor kit was supplied with
your 3-A pump, see the provided kit manual for
information on installing the sensors. See Related
Manuals, page 2.
The pump may be very heavy (see Technical
Specifications for specific weights). If the pump must
be moved, follow the Pressure Relief Procedure on
page 13 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.
Pump Type Part No. Base Dimensions
Vertical
4150 flapper 25P104 18.0 in x 23.0 in (45.72 cm x 58.42 cm)
Horizontal
flapper 25N991 15.75 in x 14.0 in (40.00 cm x 35.56 cm)
Rotatable 24L978 17.3 in. x 23.8 in.
(43.94 cm x 60.45 cm)
1040 25P103 10.5 in x 12.0in.
(26.67 cm x 30.48 cm)
A bleed-type master air valve (C) 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. See FIG.
2.

Installation
10 3A5999E
Fluid Suction and Outlet Lines
For best sealing results, use a standard tri-clamp or DIN
style sanitary gasket of a flexible material such as
EPDM, Buna-N, fluoroelastomer, or silicone.
NOTE: Compliance with 3-A sanitary standards requires
DIN connections to use certain gaskets. See CCE
Coordination Bulletin Number 2011-3.
1. Install flexible, conductive fluid lines (G and H).
2. Install a fluid drain valve (K) close to the pump fluid
outlet. See FIG. 2.
3. Install a fluid shutoff valve (J) in the fluid outlet line
(G) downstream from the fluid drain valve (K).
NOTE: For best results, always install the pump as
close as possible to the material source. See the
Technical Specifications for maximum suction lift (wet
and dry).
Tips to Reduce Cavitation
Cavitation in a diaphragm pump is the formation and
collapse of bubbles in the pumped liquid. Frequent or
excessive cavitation can cause serious damage,
including pitting and early wear of fluid chambers, balls,
and seats. It may result in reduced efficiency of the
pump. Cavitation damage and reduced efficiency both
result in increased operating costs.
Cavitation depends on the vapor pressure of the
pumped liquid, the system suction pressure, and the
velocity pressure. It can be reduced by changing any of
these factors.
1. Reduce vapor pressure: Decrease the temperature
of the pumped liquid.
2. Increase suction pressure:
a. Lower the installed position of the pump relative
to the liquid level in the supply.
b. Reduce the friction length of the suction lines.
Remember that fittings add friction length to the
lines. Reduce the number of fittings to reduce
the friction length.
c. Increase the diameter of the suction lines.
d. Ensure the inlet fluid pressure does not exceed
25% of the outlet working pressure.
3. Reduce liquid velocity: Slow the cyclic rate of the
pump.
Pumped liquid viscosity is also very important but
normally is controlled by factors that are process
dependent and cannot be changed to reduce cavitation.
Viscous liquids are more difficult to pump and more
prone to cavitation.
Graco recommends taking all of the above factors into
account in system design. To maintain pump efficiency,
supply only enough air to the pump to achieve the
required flow.
Graco distributors can supply site-specific suggestions
to improve pump performance and reduce operating
costs.
A fluid drain valve (K) is required to relieve pressure
in the fluid outlet line if it is plugged. The drain valve
reduces the risk of serious injury, including splashing
in the eyes or on the skin, when relieving pressure.
NOTICE
The pump can be damaged if flexible fluid lines are
not used. If hard-plumbed fluid lines are used in the
system, use a short length of flexible, conductive fluid
line to connect to the pump.