Graco Hydra-Clean 1040 Instruction Manual

Operation
SaniForce®High Sanitation
Diaphragm Pumps
Models 1040, 1590, 2150, 3150, 4150
For use in sanitary applications. 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. Save these instructions.
3A5999D
EN

2 3A5999D
Contents
Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Configuration Number Matrix . . . . . . . . . . . . . . . . . 5
Material Temperature Range. . . . . . . . . . . . . . . . 6
Ordering Information . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Information . . . . . . . . . . . . . . . . . . . . . . 7
Tighten Clamps Before First Use . . . . . . . . . . . . 7
Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fluid Suction Line . . . . . . . . . . . . . . . . . . . . . . . . 8
Fluid Outlet Line . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 9
Air Exhaust Ventilation . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . 11
Sanitizing the Pump Before First Use . . . . . . . . 11
Starting and Adjusting the Pump . . . . . . . . . . . 11
Pump Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Routine Cleaning of Product Contact Section of
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tightening Connections . . . . . . . . . . . . . . . . . . . 12
Preventive Maintenance Schedule . . . . . . . . . . 13
1040 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 14
1040 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 14
1040 Performance Chart . . . . . . . . . . . . . . . . . . 15
1040 Technical Data . . . . . . . . . . . . . . . . . . . . . 16
1590 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 17
1590 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 17
1590 Performance Charts . . . . . . . . . . . . . . . . . 18
1590 Technical Data . . . . . . . . . . . . . . . . . . . . . 20
2150 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 21
2150 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 21
2150 Performance Chart . . . . . . . . . . . . . . . . . . 22
3150 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 23
3150 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 23
3150 Performance Chart . . . . . . . . . . . . . . . . . . 25
4150 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 26
4150 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 26
4150 Performance Chart . . . . . . . . . . . . . . . . . . 28
2150, 3150, 4150 Technical Data . . . . . . . . . . . 29
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 30
Related Manuals
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
3A5999D 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 and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire or 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Keep work area free of debris, including solvent, rags and gasoline.
• Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhenflammablefumes
are present.
• Use only grounded hoses.
• 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.
• Route exhaust away from all ignition sources. If diaphragm ruptures, fluid may be exhausted with
air.
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 hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Warnings
4 3A5999D
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
allequipment manuals. Read fluidand 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.
• 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.
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.
• 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
3A5999D 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 Sec- tion Material Drive Center Section and Air Valve Material Mani- folds Seats Checks Diaphragms Seals Certifica- tion
Pump Wetted Section
Material Drive Type Center Section and Air Valve Material Manifolds
1040 3A 3-A compliant P Pneumatic S01A Stainless Steel SSA Stainless steel,
TriClamp, center ported
1590 HS High Sanitation S02A Stainless Steel, leak
detector SSB Stainless steel, DIN, center ported
2150 PH Pharmaceutical S03A Stainless Steel, PH SSC Stainless steel,
TriClamp, unloader
3150 SP1A Stainless Steel, PS dia-
phragms SSD Stainless steel, DIN, unloader
4150 SP2A Stainless Steel, leak
detector, PS diaphragms SSE Stainless steel, Tri- Clamp, horizontal, WYE
manifold
SP3A Stainless Steel, PH, PS
diaphragms SSF Stainless steel, DIN, hor- izontal, WYE manifold
SSG Horizontal, no manifolds
Seat Material Checks Diaphragm Material Seals Certification
FL 316 stainless
steel, flapper — Stainless Steel Flapper EO EPDM Overmold EP EPDM 21 EN 10204 type 2.1
SS 316 stainless
steel, ball CW Polychloroprene Weighted Ball FK FKM Fluoroelastomer 31 EN 10204 type 3.1
FK FKM Fluoroelastomer
Ball PO PTFE/EPDM Over- mold
PT PTFE Ball PS PTFE/Santoprene
SP Santoprene Ball SP Santoprene

Configuration Number Matrix
6 3A5999D
Material Temperature Range
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.
Approvals
Except for 3-A pumps, all pumps
are certified to:
II 2 GD
Ex h IIA T6...T3 Gb X
Ex h IIIB T160°C Db 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 2150, 3150, 4150
Technical Data, page 29, for the
maximum fluid operating temperature
for your specific pump model.
Diaphragm materials coded EO,
PO, or PS combined with flapper or
PT ball checks are certified to: EC 1935
All Models are certified to FDA
standards and
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Installation
3A5999D 7
Installation
General Information
• The typical installation shown in FIG. 2 is only a
guide 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.
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.
Stand
Stand sizes:
1. Mount the stand assembly on a level surface.
2. Mount the pump securely to the brackets using bolts
provided.
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) minimum 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 hoses: Use only grounded hoses with a
maximum of 500 ft (150 m) combined hose length to
ensure grounding continuity. Check electrical resis-
tance of hoses. If total resistance to ground exceeds
29 megohms, replace hose immediately.
•Fluid supply container: Follow the local code.
•Solvent pails used when flushing: Follow local code.
Use only conductive metal pails, placed on a
grounded surface. Do not place the pail on a non-
conductive surface, such as paper or cardboard,
which interrupts rounding continuity.
The pump may be very heavy (see Technical Data
for specific weights). If the pump must be moved, fol-
low the Pressure Relief Procedure on page 11 and
have two people lift the pump by grasping the outlet
manifold securely, or use appropriate lifting equip-
ment. Never have one person move or lift the pump.
Pump Type Part No. Base Dimensions
Horiz. poultry,
4150 flapper 25N991 25P104 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)
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
8 3A5999D
Mountings
NOTE: The pump exhaust air may contain contami-
nants. Ventilate to a remote area if the contaminants
could affect your fluid supply. See Air Exhaust Ventila-
tion on page 10.
• Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as well
as the stress caused during operation.
• 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.
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 (B) and gauge to control
the fluid pressure. The resultant fluid outlet
pressure will be no higher than the setting of the
air regulator.
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 (B) removes harmful dirt and
moisture from the compressed air supply.
2. Install a grounded, flexible air hose (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 hose. Screw
an air line quick disconnect coupler (E) onto the end
of the air hose (D), and screw the mating fitting into
the pump air inlet snugly.
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.
Fluid Suction Line
1. Use flexible, grounded fluid hoses (G).
2. 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 Coor-
dination Bulletin Number 2011-3.
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. Excessive inlet fluid pressure
also will shorten diaphragm life. Approximately
3-5 psi (0.02-0.03 MPA, 0.21-0.34 bar) should be
adequate for most materials.
4. See the Technical Data for maximum suction lift
(wet and dry). For best results, always install the
pump as close as possible to the material source.
A bleed-type master air valve (C) is required in the sys-
tem to relieve air trapped between this valve and the
pump. Trapped air can cause the pump to cycle unex-
pectedly, which could result in serious injury including
splashing in the eyes or on the skin, or contamination
from hazardous fluids. See FIG. 2.
Do not connect the coupler (E) to the fitting until you
are ready to operate the pump. Connecting the coupler
too early can result in unintentional operation of the
pump, leading to splashing fluid in the eyes or on the
skin, and contact with hazardous fluids.

Installation
3A5999D 9
Fluid Outlet Line
1. Use flexible, grounded fluid hoses.
2. 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.
3. Install a fluid drain valve (K) near the fluid outlet.
See FIG. 2.
4. Install a shutoff valve (J) in the fluid outlet line.
Typical Installation
FIG. 2: Typical Floor-Mount Installation
A fluid drain valve (K) 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.
Key:
A Master air valve (for accessories)
B Air regulator and air line filter
C Bleed-type master air valve
(required for pump)
D Air supply line
E Air line quick disconnect
F 1/2 npt (f) air inlet
G Flexible fluid line
H Flexible fluid suction line
J Fluid shutoff valve (required, not
supplied)
K Fluid drain valve (required, not
supplied)
L Ground wire (required, not
supplied; see page 7 for
installation instructions)

Installation
10 3A5999D
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.
To provide a remote exhaust:
1. Remove the muffler (M) from the pump air exhaust
port. See FIG. 3.
2. Install a grounded air exhaust hose (N) and connect
the muffler (M) 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 grounded container (P) at the end of the air
exhaust line to catch fluid in case of a diaphragm
rupture. See FIG. 3.
FIG. 3: Venting Exhaust Air
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 can 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. 3.
Key:
A Master air valve (for accessories)
B Air line filter and air regulator
C Bleed-type master air valve
(required for pump)
D Air supply line
E Air line quick disconnect
F 1/2 npt (f) air inlet
M Muffler
N Grounded air exhaust hose
P Container for remote air exhaust