Graco 232-504 Operation manual

308–550

Rev. H

Supersedes Rev. G

First

choice when

quality counts.





INSTRUCTIONS-PARTS

LIST

INSTRUCTIONS

This

manual contains important

warnings and information.

READ AND KEEP FOR REFERENCE.

POLYPROPYLENE

AND KYNAR



Husky

2150 Air-Operated

Diaphragm Pumps

120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure

120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure

*Model No. DF2– Polypropylene Pumps

*Model No. DF5– KynarPumps

Model No. 232–504 Private-Label Polypropylene 2150 Pump (See page 24.)

NOTE:

Refer to the Pump Matrix on page 24 to

determine the Model No. of your pump.

Patent No. 5,368,452.

Other US and Foreign Patents Pending.

GRACO INC. P.O. BOX 1441

MINNEAPOLIS, MN

55440–1441

http://www.graco.com

COPYRIGHT

1995, GRACO INC.

Graco

Inc. is registered to I.S. EN ISO 9001

 

Table

of Contents

Safety

arnings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service

Repairing

the Air V

alve 16.

. . . . . . . . . . . . . . . . . . . . .

Ball

Check V

alve Repair

18.

. . . . . . . . . . . . . . . . . . . .

Diaphragm

Repair

19.

. . . . . . . . . . . . . . . . . . . . . . . . .

Bearing

and Air Gasket Removal

22.

. . . . . . . . . . . .

Pump

Matrix

24.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair

Kit Matrix

25.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical

Data

30.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performance

Chart

31.

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco

Standard W

arranty 32.

. . . . . . . . . . . . . . . . . . . . .

Graco

Phone Number

32.

. . . . . . . . . . . . . . . . . . . . . . . . .

Symbols

Warning Symbol

WARNING

This

symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This

symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

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

echnical 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 ex

pose Graco hoses to temperatures above 82



C (180



F) or below –40



C (–40

F).



Do not lift pressurized equipment.

W

ear hearing protection when operating this equipment.



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

WARNING

INSTRUCTIONS

 

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 V

entilation

page 10.

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 4.



Never

use a polypropylene or Kynar pump with non-conductive flammable fluids as specified by

your local fire protection code. Refer to

Grounding

on page 4 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 sprayed, dispensed, or transferred.



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 V

entilation

on page 10.



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 of

f any light switch in the work area while operating or if fumes are present.



Do not operate a gasoline engine in the work area.

WARNING

4 308-550

Installation

General Information

The T

ypical Installation shown in Fig. 2 is only a

guide for selecting and installing system compo

nents. Contact your Graco distributor or Graco

echnical Assistance (see back page) for assis

tance 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 numbers and letters in parentheses refer

to the callouts in the figures and the parts lists on

pages 27–28.

V

ariations in color between the plastic components

of this pump are normal. Color variation does not

fect the performance of the pump.

OXIC 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.

1. Read T

OXIC FLUID HAZARD

on page 3.

Use fluids and solvents which are compatible

with the equipment wetted parts. Refer to the

echnical Data

section of all equipment manu

als. Read the fluid and solvent manufacturer

’s

warnings.

WARNING

Tighten Screws Before First Use

After

unpacking the pump and before using it for the

first time, check and retorque the manifold screws

(106, 1

12) and the cover screws (107, 108). See

pages 18, 19, and 20 for torque specifications.

After the first day of operation, check and retorque the

screws again. Repeat this process every 2 months.

Grounding

FIRE AND EXPLOSION HAZARD

This pump must be grounded. Before

operating the pump, ground the system

as explained below. Also, read the sec

tion

FIRE AND EXPLOSION HAZARD,

on page 3.

Polypropylene and Kynar

are

not

conductive.

Attaching the ground wire to the grounding lug will

ground only the air motor

. When pumping conduc

tive flammable fluids,

always

make sure the fluid

has an electrical path to a true earth ground.

Possible methods of grounding the fluid are

through the fluid containers or piping. Contact your

Graco distributor for assistance in grounding your

system.

Never

use a polypropylene or a Kynar

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 10

ohm-centimeters.

WARNING

 

Installation

Grounding (continued)

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 equip

ment.

Ground all of this equipment.



Air Motor

: Connect a ground wire and clamp as

shown in Fig. 1. Loosen the grounding lug locknut

(W) and washer (X). Insert one end of a 12 ga (1.5

mm

) minimum ground wire (Y) into the slot in the

lug (Z) and tighten the locknut securely

. Connect

the clamp end of the ground wire to a true earth

ground. Order Part No. 237–569 Ground Wire and

Clamp.

NOTE:

When pumping conductive flammable fluids

with a polypropylene or a Kynar pump,

always

ground

the fluid system. See the

WARNING

on page 4.



Air hoses

: Use only electrically conductive hoses.



Air compressor

: Follow the manufacturer

’

s recom

mendations.



All solvent pails used when flushing:

Follow the

local code. Use only metal pails, which are conduc

tive. Do not place the pail on a non-conductive

surface, such as paper or cardboard, which inter

rupts the grounding continuity



Fluid supply container:

Follow the local code.

Fig. 1

WXZ



6 308-550

Installation

Air Line

WARNING

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.

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 acces

sories is electrically conductive.

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

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

The air line filter (F) removes harmful dirt and

moisture from the compressed air supply

Install an electrically conductive, flexible air hose

(A) between the accessories and the 1/2 npt(f)

pump air inlet (N). See Fig. 2. Use a minimum 1/2”

(13 mm) ID air hose.

Screw an air line quick disconnect coupler (D) onto

the end of the air hose (A); be sure the coupler

porting is large enough to not restrict the air flow

which will af

fect pump performance. 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

FOR FIG. 2

Electrically conductive air supply hose

Bleed-type master air valve

(required for pump)

Air regulator

Air line quick disconnect

Master air valve (for accessories)

Air line filter

Fluid suction hose

Fluid supply

Fluid drain valve (required)

Fluid shutof

f valve

Fluid hose

1/2 npt(f) air inlet port

2” fluid inlet flange

2” fluid outlet flange

Ground wire (required; see page 5

for installation instructions)

Fig.

TYPICAL FLOOR-MOUNT INST

ALLATION

FBEC

308-550 7

Installation

Mountings

CAUTION

The pump exhaust air may contain contaminants.

entilate to a remote area if the contaminants

could af

fect your fluid supply

. See

Air Exhaust

Ventilation

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 all mountings, be sure the pump is bolted

directly to the mounting surface.



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.



Rubber Foot Mounting Kit 236–452 is available to

reduce noise and vibration during operation.

Fluid Suction Line

1. The

pump fluid inlet (R) is a 2” raised face flange.

Refer to

Flange Connections

on page 8.

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

inef

ficient pump operation.

At inlet fluid pressures greater than 15 psi

(0.1 MPa, 1 bar), diaphragm life will be shortened.

See the

echnical Data

on page 30 for maximum

suction lift (wet and dry).

Fluid Outlet Line

WARNING

fluid drain valve (J) is required to relieve pres

sure in the hose if it is plugged. The drain valve

reduces the risk of serious injury

, including splash

ing 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.

The pump fluid outlet (S) is a 2” raised face flange.

Refer to

Flange Connections

on page 8.

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

See the

WARNING

above.

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

 

Installation

Flange Connections

The

fluid inlet and outlet ports are 2” raised face,

standard 150 lb class pipe flanges. Connect 2” flanged

plastic pipe to the pump as follows. You will need:

T

orque wrench



Adjustable wrench

6” diameter

, 1/8” thick T

eflon gasket, with four 0.75”

diameter holes on a 4.75” diameter bolt circle, and

a 2.20” diameter center



Four 5/8” x 3” bolts



Four 5/8” spring lockwashers



Eight 5/8” flat washers

Four 5/8” nuts.

Place a flat washer (E) on each bolt (C). Refer to

Fig. 3.

Align the holes in the gasket (B) and the pipe

flange (A) with the holes in the pump outlet

flange (S).

Lubricate the threads of the four bolts. Install the

bolts through the holes and secure with the wash

ers (E), lockwashers (D), and nuts (F).

Hold the nuts with a wrench. Refer to the tighten

ing sequence in Fig. 3 and torque the bolts to

20–30 ft–lb (27–41 N.m).

Do not over-torque.

Repeat for the pump inlet flange (R).

04405

04615

Fig. 3

BOL

T TIGHTENING SEQUENCE

1Lubricate

threads. T

orque to 20–30 ft–lb

(27–41 N.m). Do not over-torque.

KEY FOR FIG. 3

Flanged plastic pipe

eflon gasket

C Bolt

D Lockwasher

Flat washer

F Nut

2” fluid inlet flange

2” fluid outlet flange

308-550 9

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. T

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

Remove the screws (106 and 1

12) holding the inlet

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

(101).

Reverse the manifold and reattach. Install the

screws and torque to 80–90 in–lb (9–10 N.m).

04613

Fig. 4

1Torque

to 80–90 in-lb (9–10 N.m).

KEY

1/2 npt(f) air inlet port

P Muffler

Air exhaust port is 3/4

npt(f) .

2” fluid inlet flange

2” fluid outlet flange

101

Fluid covers

102

Fluid inlet manifold

103

Fluid outlet manifold

106

Fluid outlet manifold

screws (top)

112

Fluid inlet manifold

screws (bottom)

103

102

101

106

112

Fluid Pressure Relief Valve

Some

systems may require installation of a pres

sure 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 ambi

ent 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.

CAUTION

04616

Fig. 5

2Connect

fluid inlet line here.

KEY

2” fluid inlet flange

2” fluid outlet flange

Pressure relief valve

Part No. 1

10–134 (aluminum)

Part No. 1

12–1

19 (stainless steel)

Connect fluid outlet line here.

Install valve between fluid inlet and outlet ports.

10 308-550

Installation

Air Exhaust Ventilation

FIRE

AND EXPLOSION HAZARD

Be sure to read and follow the warnings

and precautions regarding

TOXIC

FLUID HAZARD,

and

FIRE OR EXPLO

SION HAZARD

on page 3, before op

erating this pump.

Be sure the system is properly ventilated for your

type of installation. Y

ou must vent the exhaust to a

safe place, away from people, animals, food handl

ing areas, and all sources of ignition when pumping

flammable or hazardous fluids.

Diaphragm failure will cause the fluid being

pumped to exhaust with the air

. Place an appropri

ate container at the end of the air exhaust line to

catch the fluid. See Fig. 6.

WARNING

The air exhaust port is 3/4 npt(f). Do not restrict the air

exhaust port. Excessive exhaust restriction can cause

erratic pump operation.

o provide a remote exhaust:

Remove the muf

fler (P) from the pump air exhaust

port.

Install an electrically conductive air exhaust hose

(T) and connect the muf

fler (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.

void sharp bends or kinks in the hose. See Fig. 6.

Place a container (U) at the end of the air exhaust

line to catch fluid in case a diaphragm ruptures.

04617

Fig. 6

KEY

A Air

supply line

Bleed-type master air valve

(required for pump)

Air regulator

Air line quick disconnect

Master air valve (for accessories)

Air line filter

P Muffler

Electrically conductive air exhaust hose

Container for remote air exhaust

FBEC

VENTING

EXHAUST AIR

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