Graco Husky 1040 Bedienungsanleitung

Instructions - Parts List

ACETAL, POLYPROPYLENE, AND PVDF

Husky™1040 Air-Operated

Diaphragm Pumps 308443ZAE

1–inch AODD pump for fluid transfer applications. For professional use only.

Not approved to European explosive atmosphere requirements.

See Models on page 2 for a list of pump models and descriptions.

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 the manual.

Save these instructions.

2308443

Table of Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Repairing the Air Valve . . . . . . . . . . . . . . . . 16

Ball Check Valve Repair . . . . . . . . . . . . . . . 18

Diaphragm Repair . . . . . . . . . . . . . . . . . . . 19

Bearing and Air Gasket Removal . . . . . . . . 23

Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Repair Kit Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . 33

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Technical Data and Performance Chart . . . . . . . . . . 35

Graco Standard Husky Pump Warranty . . . . . . . . . . 36

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Models

*NOTE: Refer to the Pump Matrix on page 26 to determine the Model No. of your pump.

NOTE: Plus Models include stainless steel center sections.

**CERTIFICATION NOTE: Acetal Pump Models D71______ and D81______ are certified:

II 2 GD

Ex h IIC 66°...135°C Gb

Ex h IIIC T135°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 Technical Data for the maximum fluid operating temperature for

your specific pump model.

Model No. Description

**D71______ Acetal Pumps (see certification note below)

**D81______ Acetal Pumps, Remote (see certification note below)

*D72______ Polypropylene Pumps

*D82______ Polypropylene Pumps, Remote

*D75______ PVDF Pumps

*D85______ PVDF Pumps, Remote

*DR2______ Polypropylene Plus Pumps

*DS2______ Polypropylene Plus Pumps, Remote

*DR5______ PVDF Plus Pumps

*DS5______ PVDF Plus Pumps, Remote

24B754 PVDF Plus Pump with overmolded diaphragms

24B755 Polypropylene Plus Pump with overmolded diaphragms

24B756 Polypropylene Pump with overmolded diaphragms

24B757 Polypropylene Pump with overmolded diaphragms and sst seats

24B831 PVDF Pump with overmolded diaphragms

308443 3

Warnings

Symbols

Warning Symbol

WARNING

Caution Symbol

This symbol alerts you to the possibility of serious injury

or death if you do not follow the instructions.

CAUTION

This symbol alerts you to the possibility of damage to or

destruction of equipment if you do not follow the

instructions.

INSTRUCTIONS

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 component in your system. This

equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi (0.8 MPa,

8 bar) maximum incoming air pressure.

•Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the

Technical 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).

•Do not lift pressurized equipment.

•Comply with all applicable local, state, and national fire, electrical, and safety regulations.

WARNING

4308443

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.

•Pipe 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 11.

•To pump acids, always use a PVDF or a polypropylene pump. Take precautions to avoid acid or

acid fumes from contacting the pump housing exterior. Stainless steel parts will be damaged by

exposure to acid spills and fumes. Never use an acetal pump to pump acids.

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 6.

•Never use a polypropylene or PVDF pump with non-conductive flammable fluids as specified by

your local fire protection code. Refer to Grounding on page 6 for additional information. Consult

your fluid supplier to determine the conductivity or resistivity of your fluid.

•If there is any static sparking or you feel an electric shock while using this equipment, stop

pumping 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 pumped.

•Pipe 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 11.

•Keep the work area free of debris, including solvent, rags, and gasoline.

•Electrically disconnect all equipment in the work area.

•Extinguish all open flames or pilot lights in the work area.

•Do not smoke in the work area.

•Do not turn on or off any light switch in the work area while operating or if fumes are present.

•Do not operate a gasoline engine in the work area.

308443 5

Installation

General Information

•The Typical Installations shown in Figs. 2 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 and the parts lists on

pages 29–31.

WARNING

1. Read TOXIC FLUID HAZARD on page 4.

2. Use fluids and solvents which are compatible with

the equipment wetted parts. Refer to the

Technical Data section of all equipment manuals.

Read the fluid and solvent manufacturer’s

warnings.

Tightening Screws Before First Use

Before using the pump for the first time, check and

retorque all external fasteners. See Torque Sequence,

page 32. After the first day of operation, retorque the

fasteners. Although pump use varies, a general

guideline is to retorque fasteners every two months.

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.

6308443

Grounding

WARNING

Ground all of this equipment.

•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.

NOTE: When pumping conductive flammable fluids with

a polypropylene or PVDF pump, always ground the

entire fluid system. See the WARNING at left. Fig. 2

shows a recommended method of grounding flammable

fluid containers during filling. This is only a guide;

contact your Graco distributor for assistance in

grounding your system.

Fig. 1

•Air and fluid hoses: Use only grounded hoses with a

maximum of 500 ft (150 m) combined hose length to

ensure grounding continuity.

•Air compressor: Follow the manufacturer’s

recommendations.

•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.

FIRE AND EXPLOSION HAZARD

This pump must be grounded. Before

operating the pump, ground the system as

explained below. Also, read the section

FIRE AND EXPLOSION HAZARD, on

page 4.

The acetal pump contains stainless steel fibers which

make the wetted parts conductive. Attaching the

ground wire to the grounding screw will ground the air

motor and the wetted parts.

The polypropylene and PVDF pumps are not

conductive. Attaching the ground wire to the

grounding screw will ground only the air motor. When

pumping conductive flammable fluids, always ground

the entire fluid system by making sure the fluid

system has an electrical path to a true earth ground

(see Fig. 2). Never use a polypropylene or PVDF

pump with non-conductive flammable fluids as

specified by your local fire protection code.

US Code (NFPA 77 Static Electricity) recommends a

conductivity greater than 50 x 10-12 Siemans/meter

(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 equipment.

308443 7

Installation

Air Line

WARNING

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 at left. 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. 2. Use a minimum 3/8” (10 mm) ID air

hose. Screw an air line quick disconnect coupler (D)

onto the end of the air hose (A), and screw the

mating fitting into the pump air inlet snugly. Do not

connect the coupler (D) to the fitting until you are

ready to operate the pump.

Key:

A Air supply hose

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 Fluid suction line

H Fluid supply

J Fluid drain valve (required)

K Fluid shutoff valve

L Fluid line

N 1/2 npt(f) air inlet port

R 1” fluid inlet port

S 1” fluid outlet port

Y Ground wire (required; see page 6 for

installation instructions)

ECBA

SKL

FLOOR MOUNT TYPICAL INSTALLATION

Fig. 2 _____________________________________________________________________________________

A bleed-type master air valve (B) is required in your

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.

8308443

Installation

Mountings

CAUTION

1. Be sure the mounting surface can support the

weight of the pump, hoses, and accessories, as well

as the stress caused during operation.

2. For all mountings, be sure the pump is bolted

directly to the mounting surface.

3. 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.

4. Rubber Foot Mounting Kit 236452 is available to

reduce noise and vibration during operation.

5. Prolonged exposure to UV radiation will degrade

natural polypropylene components of the pumps. To

prevent potential injury or equipment damage, do

not expose pump or the plastic components to direct

sunlight for prolonged periods.

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.

NOTE: by replacing the push type connectors, other

sizes or types of fittings may be used. The new fittings

will require 1/8 in. npt threads.

3. Connect remaining end of tubes to external air

signal, such as Graco’s Cycleflo (P/N 195264) or

Cycleflo II (P/N 195265) controllers.

NOTE: the air pressure at the connectors must be at

least 30% of the air pressure to the motor for the pump

to operate.

Fluid Suction Line

•If using a conductive (Acetal) pump, use conductive

hoses (G). If using a non-conductive (polypropylene

or PVDF) pump, ground the fluid system. See

Grounding on page 6.

•The pump fluid inlet (R) is a 1” raised face flange.

See Flange Connections on page 9.

•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

inefficient pump operation.

•At inlet fluid pressures greater than 15 psi (104 kPa,

1 bar), diaphragm life will be shortened.

•See the Technical Data on page 34 for maximum

suction lift (wet and dry).

Fluid Outlet Line

WARNING

1. Use grounded fluid hoses (L). The pump fluid out-

let (S) is 1” npt(f). See Fig. 5. Refer to Flange Con-

nections on page 9.

2. Install a fluid drain valve (J) near the fluid outlet. See

the WARNING above.

3. Install a shutoff valve (K) in the fluid outlet line.

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 11.

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.

308443 9

Installation

Flange Connections

The fluid inlet and outlet ports are 1” raised face flanges.

Connect 1” flanged plastic pipe to the pump as follows.

You will need:

•Torque wrench

•Adjustable wrench

•One 4.25” diameter, 1/8” thick PTFE gasket, with

four 0.62 diameter holes and a 1.15” diameter

center

•Four 1/2” x 2.5” bolts

•Four 1/2” spring lockwashers

•Eight 1/2” flat washers

•Four 1/2” nuts.

1. Place a lockwasher and a flat washer on each bolt.

Refer to Fig. 3.

2. Align the holes in the gasket and the pipe flange

with the holes in the pump flange.

3. Lubricate the threads of the four bolts. Install the

bolts through the holes and secure with the washers

and nuts.

4. Hold the nuts with a wrench. Refer to the tightening

sequence in Fig. 3 and torque the bolts to 10 to 15

ft-lb (14 to 20 N-m). Do not Over-torque.

BOLT TIGHTENING SEQUENCE

KEY

A Flanged plastic pipe

B PTFE gasket

C Bolt

D Lockwasher

E Flat washer

F Nut

R 1”fluid inlet flange

S 1” fluid outlet flange

Torque to 10 to 15 ft-lb (14-20 N-m).

Do not over-torque.

Fig. 3

10 308443

Installation

Changing the Orientation of the Fluid Inlet

and Outlet Ports

The pump is shipped with the fluid inlet (R) and outlet

(S) ports facing the same direction. See Fig. 4. To

change the orientation of the inlet and/or outlet port:

1. Remove the screws (106 or 112) holding the inlet

(102) and/or outlet (103) manifold to the covers

(101).

2. Reverse the manifold and reattach. Install the

screws (106 or 112). Torque the manifold screws to

80 to 90 in-lb (9 to 10 N-m). See Fig. 4. See Torque

Sequence, page 32.

KEY

N 1/2 npt(f) air inlet port

P Muffler; air exhaust port

is 3/4 npt(f)

R 1” fluid inlet port

S 1” fluid outlet port

101 Covers

102 Fluid inlet manifold

103 Fluid outlet manifold

106 Manifold screws

112 Manifold screws

Acetal Model Shown

103

106 S

101

112

102

Torque to 80 to 90ft-lb (9 to 10 N-m).

See Torque Sequence, page 32

Fig. 4

Fluid Pressure Relief Valve

CAUTION

KEY

R 1” fluid inlet port

S 1” fluid outlet port

V Pressure relief valve

Part No. 112119 (stainless steel)

Install valve between fluid inlet and outlet ports

Connect fluid inlet line here.

Connect fluid outlet line here.

Fig. 5

Some systems may require installation of a pressure

relief valve at the pump outlet to prevent

overpressurization and rupture of the pump or hose.

See Fig. 5.

Thermal expansion of fluid in the outlet line can

cause overpressurization. This can occur when using

long fluid lines exposed to sunlight or ambient heat,

or when pumping from a cool to a warm area (for

example, from an underground tank).

Overpressurization can also occur if the Husky pump

is being used to feed fluid to a piston pump, and the

intake valve of the piston pump does not close,

causing fluid to back up in the outlet line.

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