Graco ChemSafe 205 Bedienungsanleitung

Instructions-Parts

ChemSafe™ 205

Air-Operated Diaphragm Pump 334792E

1/4–inch high purity pump for industrial applications.For professional use only.

Not approved for use in European explosive atmosphere locations.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these

instructions.

100 psi (0.7 MPa, 7.0 bar) Maximum Air

Supply Pressure

100 psi (0.7 MPa, 7.0 bar) Maximum

Fluid Working Pressure

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

Warnings ........................................................... 3

Conﬁguration Number Matrix............................... 6

Installation.......................................................... 8

General Information ..................................... 8

Tighten Fasteners ........................................ 8

Tips to Reduce Cavitation............................. 8

Mount The Pump ......................................... 9

Ground The System ..................................... 10

Air Lines...................................................... 10

Air Exhaust Ventilation ................................. 11

Fluid Supply Line ......................................... 12

Fluid Outlet Line........................................... 12

Operation........................................................... 13

Tighten Fasteners ........................................ 13

Flush the Pump Before First Use .................. 13

Start and Adjust the Pump............................ 13

Pressure Relief Procedure............................ 14

Pump Shutdown .......................................... 14

Maintenance ...................................................... 15

Maintenance Schedule................................. 15

Lubrication................................................... 15

Tighten Threaded Connections ..................... 15

Flushing and Storage ................................... 15

Troubleshooting.................................................. 16

Repair................................................................ 18

Disassemble the Fluid Section ...................... 18

Disassemble the Center Section ................... 19

Reassemble the Center Section.................... 19

Reassemble the Fluid Section....................... 20

Torque Instructions ............................................. 22

Notes................................................................. 23

Parts.................................................................. 24

Kits.................................................................... 26

Dimensions ........................................................ 27

Performance Charts............................................ 28

Technical Data ...................................................29

Graco Standard ChemSafe Pump

Warranty............................................... 30

2334792E

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 symbols refer to procedure-speciﬁc

risks. When these symbols appear in the body of this manual or on warning labels, refer back to these

Warnings. Product-speciﬁc hazard symbols and warnings not covered in this section may appear 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. To help

prevent ﬁre and 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 arc).

•Keepwork

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.

• Ground all equipment in the work area. See Grounding instructions.

•Useonly

grounded hoses.

• Hold gun ﬁrmly to side of grounded pail when triggering into pail. Do not use pail liners unless

they are antistatic 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.

• Keepaw

orking ﬁre extinguisher in the work area.

• Route exhaust away from all ignition sources. If diaphragm ruptures, ﬂuid may be exhausted

with air.

Static charge may build up on plastic parts during cleaning and could discharge and ignite

ﬂammable vapors. To help prevent ﬁre and explosion:

• Clean plastic parts only in well ventilated area.

• Do not cleanwithadrycloth.

• Do not operate electrostatic guns in equipment work area.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin

and cause serious injury.

•Fol

low 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.

334792E 3

Warnings

WARNING

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 all equipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete

information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

•Turnoffall

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.

•Makesure

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.

THERMAL EXPANSION HAZARD

Fluids subjected to heat in conﬁned spaces, including hoses, can create a rapid rise in pressure

due to the thermal expansion. Over-pressurization can result in equipment rupture and serious

injury.

• Open a valve to relieve the ﬂuid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating conditions.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious

injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing

parts.

•SeeTechnical Data in this and all other equipment instruction manuals. Read ﬂuid and

solvent manufacturer’s MSDSs and recommendations.

4334792E

Warnings

WARNING

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 MSDSs 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’s 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 protective

equipment includes but is not limited to:

•Protect

ive eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent

manufacturer.

334792E 5

Conﬁguration Number Matrix

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.

Sample Conﬁguration Number: 205PT-P01APT3PTPTPOPT

205PT P01A PT3 PT PT PO PT

Pump

Model

Center

Section

and Air

Valve

Fluid

Covers

and

Manifolds

Seats Balls Diaphragms Manifold and Seat Seals

Pump Center Section and Air

Valve Material

Fluid Covers and Manifolds

205PT

1/4 in.PTFE

P01A Polypropylene

center with npt

air inlet

PT3 PTFE, npt

205 UH

1/4 in. UHMWPE

P03A Polypropylene

centerwith

bspt air inlet

PT4 PTFE, bspt

UH3 UHMWPE, npt

UH4 UHMWPE, bspt

Seat Material Ball Material Diaphragm Material Manifold and Seat

Seal Material

PT PTFE PT PTFE BN Buna NPT PTFE

EP EPDM

PO PTFE Overmolded

6334792E

Conﬁguration Number Matrix

Models

Model Pump Air & Fluid

Connection

Threads

Fluid Covers &

Manifolds

Balls &

Seats

Diaphragm Manifold Seal

24X430 bspt

24X429 1/4 in. PTFE npt PTFE

24X511 bspt

24X509 npt

PTFE/EPDM

Overmolded

24X532 bspt

24X533 npt EPDM

24X508 bspt

24X507

1/4 in.

UHMWPE

npt

UHMW

PTFE

Buna N

PTFE

334792E 7

Installation

General Information

The Typical Installation shown 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. Be sure all accessories

are adequately sized and pressure rated to meet the

system’s requirements.

Reference letters in the text, for example (A), refer to

the callouts in the ﬁgures.

Variations in color between the plastic components

of this pump are normal. Color variation does not

affect the performance of the pump.

Storage: Pumps that are not put into operation

upon delivery must be stored appropriately. See

Flushing and Storage, page 15.

Tighten Fasteners

Before mounting and using the pump for the

ﬁrst time, check and retorque all external bolts.

Remove all protective bolt covers (37). Follow

Torque Instructions, page 22, to tighten all bolts.

Replace the bolt covers (37). After the ﬁrst day of

operation, retorque the bolts. Retorque the bolts if the

pump has been idle for an extended time, been used

in thermal cycling applications, been disassembled,

or if there is a large difference between environmental

temperatures and ﬂuid temperatures.

Tips to Reduce Cavitation

Cavitation in an AODD 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

piping. Remember that ﬁttings add friction

length to the piping. Reduce the number of

ﬁttings to reduce the friction length.

c. Increase the size of the suction piping.

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 the above factors

into account in system design. To maintain pump

efﬁciency, supply only enough air pressure to the

pump to achieve the required ﬂow.

Graco distributors can supply site speciﬁc

suggestions to improve pump performance and

reduce operating costs.

8334792E

Installation

Mount The Pump

To avoid serious injury from toxic ﬂuid or fumes:

• Ventilate to a remote area. The pump

exhaust air may contain contaminants. See

Air Exhaust Ventilation, page 11.

• Never move or lift a pump under pressure. If

dropped, the ﬂuid section may rupture. Always

follow the Pressure Relief Procedure, page 14,

before moving or lifting the pump.

1. Mount the pump so the exhaust port remains

clear of the production area. Exhaust air may

contain debris and condensation from the air

supply and air chamber.

2. Be sure the mounting surface can support the

weight of the pump, hoses, and accessories, as

well as the stress caused during operation.

3. For all mountings, be sure the pump is secured

with screws through the mounting feet. Always

mount the pump upright.

4. Make sure the surface is ﬂat and that the pump

doesn’t wobble.

5. For ease of operation and service, mount the

pump so air inlet, ﬂuid inlet and ﬂuid outlet ports

are easily accessible.

Accessories/Components Not Supplied System Components

A Air supply line J Air inlet port

BBleed-type master air valve (required

for your pump)

KExhaust port and mufﬂer

C Air ﬁlter/regulator assembly L Fluid inlet port

DMaster air valve (to isolate the

ﬁlter/regulator for service)

M Fluid outlet port

EGrounded ﬂexible ﬂuid supply line NMounting feet

FFluid drain valve (required for your

pump)

luid shutoff valve

HGrounded, ﬂexible ﬂuid outlet line

334792E 9

Installation

Ground The System

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 electrical current.

•Always ground the entire ﬂuid system as

described below.

• The pumps are not conductive. Any system

used to pump ﬂammable ﬂuids must be properly

grounded.

• Follow your local ﬁre codes.

Before operating the pump, ground the system as

explained below.

•Pump: Always ground the entire ﬂuid system by

making sure the ﬂuid has an electrical path to a

true earth ground.

•Air and ﬂuid hoses: Use only ﬂexible grounded

hoses with a maximum of 500 ft. (150 m) combined

hose length to ensure grounding continuity.

•Air compressor: Follow manufacturer’s

recommendations.

•Fluid supply container: Follow 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 nonconductive surface, such as paper or

cardboard, which interrupts grounding continuity.

Check your system electrical continuity after the

initial installation, and then set up a regular schedule

for checking continuity to be sure proper grounding

is maintained.

Air Lines

1. Install an air regulator and gauge (C) to control

the ﬂuid pressure. The ﬂuid stall pressure will be

thesameasthesetting of the air regulator.

2. Locate a bleed-typemasterairvalve(B)closeto

the pump and use it to relieve trapped air. Be

sure the valve is easily accessible from the pump

and located downstream from the regulator.

Trapped air can cause the pump to cycle

unexpectedly, which could result in serious

injury from splashing.

3. Locate another master air valve (D) upstream

from all air line accessories and use it to isolate

them during cleaning and repair.

4. An air line ﬁlter (C) removes harmful dirt and

moisture from the compressed air supply.

5. Install a grounded, ﬂexible air hose (A) between

the accessories and the 1/8 npt(f) or 1/8 bspt

pump air inlet. Use a hose with a minimum 1/4 in.

ID.Ifah

ose longer than 10 ft. (3 m) is required,

use a larger diameter hose.

10 334792E

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