Graco ChemSafe 1040 Operation manual

Instructions-Parts

ChemSafe™ ChemSafe™

ChemSafe™1040 1040

1040

Air Air

Air- -

-Operated Operated

OperatedDiaphragm Diaphragm

DiaphragmPump Pump

Pump334795F

1–inch 1–inch

1–inchhigh high

highpurity purity

puritypump pump

pumpfor for

forindustrial industrial

industrialapplications.For applications.For

applications.Forprofessional professional

professionaluse use

useonly. only.

only.

Not Not

Notapproved approved

approvedfor for

foruse use

usein in

inEuropean European

Europeanexplosive explosive

explosiveatmosphere atmosphere

atmospherelocations. locations.

locations.

Important Important

ImportantSafety Safety

SafetyInstructions Instructions

Instructions

Readallwarningsandinstructionsinthismanual.Save Save

Savethese these

these

instructions. instructions.

instructions.

100psi(0.7MPa,7.0bar)MaximumAir

SupplyPressure

100psi(0.7MPa,7.0bar)Maximum

FluidWorkingPressure

PROVENQUALITY.LEADINGTECHNOLOGY.

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Website: www.springerpumps.com

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Contents Contents
Contents
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................6
Installation..........................................................8
GeneralInformation.....................................8
TightenBolts...............................................8
TipstoReduceCavitation.............................8
MountThePump.........................................9
GroundTheSystem.....................................10
AirLines......................................................10
AirExhaustVentilation.................................11
FluidSupplyLine.........................................12
FluidOutletLine...........................................12
Operation...........................................................13
TightenBolts...............................................13
FlushthePumpBeforeFirstUse..................13
StartandAdjustthePump............................13
PressureReliefProcedure............................14
PumpShutdown..........................................14
Maintenance......................................................15
MaintenanceSchedule.................................15
Lubrication...................................................15
TightenThreadedConnections.....................15
FlushingandStorage...................................15
Troubleshooting..................................................16
Repair................................................................18
DisassembletheFluidSection......................18
DisassembletheCenterSection...................19
ReplacetheAirMotor...................................19
ReassembletheCenterSection....................20
ReassembletheFluidSection.......................21
TorqueInstructions.............................................24
Parts..................................................................25
Kits....................................................................28
Dimensions........................................................29
PerformanceCharts............................................30
TechnicalData...................................................31
2334795F
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Warnings

Warnings Warnings

Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The

exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c

risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese

Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout

thebodyofthismanualwhereapplicable.

WARNING WARNING

WARNING

FIRE FIRE

FIREAND AND

ANDEXPLOSION EXPLOSION

EXPLOSIONHAZARD HAZARD

HAZARD

Flammablefumes,suchassolventandpaintfumes,inwork work

workarea area

areacanigniteorexplode.Tohelp

prevent󰘰reandexplosion:

•Useequipmentonlyinwellventilatedarea.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

plasticdropcloths(potentialstaticarc).

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable

fumesarepresent.

•Groundallequipmentintheworkarea.SeeGrounding Grounding

Groundinginstructions.

•Useonlygroundedhoses.

•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless

theyareantistaticorconductive.

•Stop Stop

Stopoperation operation

operationimmediately immediately

immediatelyifstaticsparkingoccursoryoufeelashock. .

.Donotuse

equipmentuntilyouidentifyandcorrecttheproblem.

•Keepaworking󰘰reextinguisherintheworkarea.

•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted

withair.

Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite

󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:

•Cleanplasticpartsonlyinwellventilatedarea.

•Donotcleanwithadrycloth.

•Donotoperateelectrostaticgunsinequipmentworkarea.

PRESSURIZED PRESSURIZED

PRESSURIZEDEQUIPMENT EQUIPMENT

EQUIPMENTHAZARD HAZARD

HAZARD

Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin

andcauseseriousinjury.

•FollowthePressure Pressure

PressureRelief Relief

ReliefProcedure Procedure

Procedurewhenyoustopspraying/dispensingandbefore

cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

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Warnings

WARNING WARNING

WARNING

EQUIPMENT EQUIPMENT

EQUIPMENTMISUSE MISUSE

MISUSEHAZARD HAZARD

HAZARD

Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated

systemcomponent.SeeTechnical Technical

TechnicalData Data

Datainallequipmentmanuals.

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical

TechnicalData Data

Data

inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete

informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

PressureRelief Relief

ReliefProcedure Procedure

Procedurewhenequipmentisnotinuse.

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine

manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals

andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

THERMAL THERMAL

THERMALEXPANSION EXPANSION

EXPANSIONHAZARD HAZARD

HAZARD

Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure

duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious

injury.

•Openavalvetorelievethe󰘱uidexpansionduringheating.

•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.

PLASTIC PLASTIC

PLASTICPARTS PARTS

PARTSCLEANING CLEANING

CLEANINGSOLVENT SOLVENT

SOLVENTHAZARD HAZARD

HAZARD

Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious

injuryorpropertydamage.

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing

parts.

•SeeTechnical Technical

TechnicalData Data

Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand

solventmanufacturer’sMSDSsandrecommendations.

4334795F

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Warnings

WARNING WARNING

WARNING

TOXIC TOXIC

TOXICFLUID FLUID

FLUIDOR OR

ORFUMES FUMES

FUMESHAZARD HAZARD

HAZARD

Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,

inhaled,orswallowed.

•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto

theair.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable

guidelines.

BURN BURN

BURNHAZARD HAZARD

HAZARD

Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid

severeburns:

•Donottouchhot󰘱uidorequipment.

PERSONAL PERSONAL

PERSONALPROTECTIVE PROTECTIVE

PROTECTIVEEQUIPMENT EQUIPMENT

EQUIPMENT

Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,

includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective

equipmentincludesbutisnotlimitedto:

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent

manufacturer.

334795F5

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Springer Pumps, LLC

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CongurationNumberMatrix

Con󰘰guration Con󰘰guration

Con󰘰gurationNumber Number

Number

Matrix Matrix

Matrix

Checktheidenti󰘰cationplate(ID)forthe

Con󰘰gurationNumberofyourpump.Usethe

followingmatrixtode󰘰nethecomponentsofyour

pump.

Sample Sample

SampleCon󰘰guration Con󰘰guration

Con󰘰gurationNumber: Number:

Number:1040PT 1040PT

1040PT- -

-P01APT3PTPTPOPT P01APT3PTPTPOPT

P01APT3PTPTPOPT

1040PT 1040PT

1040PTP01A P01A

P01APT3 PT3

PT3PT PT

PTPT PT

PTPO PO

POPT PT

PumpModelCenter

Section

andAir

Valve

Fluid

Covers

and

Manifolds

SeatsBallsDiaphragmsManifoldandSeatSeals

Pump Pump

PumpCenter Center

CenterSection Section

Sectionand and

andAir Air

Air

Valve Valve

ValveMaterial Material

Material

Fluid Fluid

FluidCovers Covers

Coversand and

andManifolds Manifolds

Manifolds

1040 1040

1040PT PT

1in.PTFEP01A P01A

P01APolypropylene

centerwithnpt

airinlet

PT3 PT3

PT3PTFE,npt

1040 1040

1040UH UH

1in.UHMWPEP03A P03A

P03APolypropylene

centerwith

bsptairinlet

PT4 PT4

PT4PTFE,bspt

UH3 UH3

UH3UHMW,npt

UH4 UH4

UH4UHMW,bspt

Seat Seat

SeatMaterial Material

MaterialBall Ball

BallMaterial Material

MaterialDiaphragm Diaphragm

DiaphragmMaterial Material

MaterialManifold Manifold

Manifoldand and

andSeat Seat

Seat

Seal Seal

SealMaterial Material

Material

PT PT

PTPTFEPT PT

PTPTFEBN BN

BNBunaNPT PT

PTPTFE

UH UH

UHUHMWPEEP EP

EPEPDM

PO PO

POPTFE/EPDMOvermolded

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CongurationNumberMatrix

Models Models

Models

Model Model

ModelPump Pump

PumpAir Air

Air& &

&Fluid Fluid

Fluid

Connection Connection

Connection

Threads Threads

Threads

Fluid Fluid

FluidCovers, Covers,

Covers,

Seats, Seats,

Seats,& &

Manifolds Manifolds

Manifolds

Balls Balls

BallsDiaphragm Diaphragm

DiaphragmManifold Manifold

ManifoldSeal Seal

Seal

24X424 24X424

24X424bspt bspt

bspt

24X423 24X423

24X4231 1

1in. in.

in.PTFE PTFE

PTFEnpt npt

nptPTFE PTFE

PTFE

24X492 24X492

24X492bspt bspt

bspt

24X491 24X491

24X491npt npt

npt

PTFE/EPDM PTFE/EPDM

PTFE/EPDM

Overmolded Overmolded

Overmolded

24X544 24X544

24X544bspt bspt

bspt

24X545 24X545

24X545npt npt

nptEPDM EPDM

EPDM

24X490 24X490

24X490bspt bspt

bspt

24X489 24X489

24X489

1 1

1in. in.

in.

UHMWPE UHMWPE

UHMWPE

npt npt

npt

UHMW UHMW

UHMW

PTFE PTFE

PTFE

Buna Buna

BunaN N

PTFE PTFE

PTFE

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Installation

Installation Installation

Installation

General General

GeneralInformation Information

Information

TheTypicalInstallationshownisonlyaguidefor

selectingandinstallingsystemcomponents.Contact

yourGracodistributorforassistanceinplanninga

systemtosuityourneeds.AlwaysuseGenuine

GracoPartsandaccessories.Besureallaccessories

areadequatelysizedandpressureratedtomeetthe

system’srequirements.

Referencelettersinthetext,forexample(A),referto

thecalloutsinthe󰘰gures.

Variationsincolorbetweentheplasticcomponents

ofthispumparenormal.Colorvariationdoesnot

affecttheperformanceofthepump.

Storage: Storage:

Storage:Pumpsthatarenotputintooperation

upondeliverymustbestoredappropriately.See

FlushingandStorage,page15.

Tighten Tighten

TightenBolts Bolts

Bolts

Beforemountingandusingthepumpforthe

󰘰rsttime,checkandretorqueallexternalbolts.

Removeallprotectiveboltcovers(37).Follow

TorqueInstructions,page24,totightenallbolts.

Replacetheboltcovers(37).Afterthe󰘰rstdayof

operation,retorquethebolts.Retorquetheboltsifthe

pumphasbeenidleforanextendedtime,beenused

inthermalcyclingapplications,beendisassembled,

orifthereisalargedifferencebetweenenvironmental

temperaturesand󰘱uidtemperatures.

Tips Tips

Tipsto to

toReduce Reduce

ReduceCavitation Cavitation

Cavitation

CavitationinanAODDpumpistheformationand

collapseofbubblesinthepumpedliquid.Frequent

orexcessivecavitationcancauseseriousdamage,

includingpittingandearlywearof󰘱uidchambers,

balls,andseats.Itmayresultinreducedef󰘰ciencyof

thepump.Cavitationdamageandreducedef󰘰ciency

bothresultinincreasedoperatingcosts.

Cavitationdependsonthevaporpressureofthe

pumpedliquid,thesystemsuctionpressure,andthe

velocitypressure.Itcanbereducedbychangingany

ofthesefactors.

1.Reducevaporpressure:Decreasethe

temperatureofthepumpedliquid.

2.Increasesuctionpressure:

a.Lowertheinstalledpositionofthepump

relativetotheliquidlevelinthesupply.

b.Reducethefrictionlengthofthesuction

piping.Rememberthat󰘰ttingsaddfriction

lengthtothepiping.Reducethenumberof

󰘰ttingstoreducethefrictionlength.

c.Increasethesizeofthesuctionpiping.

3.Reduceliquidvelocity:Slowthecyclicrateof

thepump.

Pumpedliquidviscosityisalsoveryimportantbut

normallyiscontrolledbyfactorsthatareprocess

dependentandcannotbechangedtoreduce

cavitation.Viscousliquidsaremoredif󰘰culttopump

andmorepronetocavitation.

Gracorecommendstakingalltheabovefactors

intoaccountinsystemdesign.Tomaintainpump

ef󰘰ciency,supplyonlyenoughairpressuretothe

pumptoachievetherequired󰘱ow.

Gracodistributorscansupplysitespeci󰘰c

suggestionstoimprovepumpperformanceand

reduceoperatingcosts.

8334795F

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Installation

Mount Mount

MountThe The

ThePump Pump

Pump

Toavoidseriousinjuryfromtoxic󰘱uidorfumes:

•Ventilatetoaremotearea.Thepump

exhaustairmaycontaincontaminants.See

AirExhaustVentilation,page11.

•Nevermoveorliftapumpunderpressure.Ifdropped,

the󰘱uidsectionmayrupture.Alwaysfollowthe

PressureReliefProcedure,page14,beforemoving

orliftingthepump.

•ProlongedexposuretoUVradiationwilldegrade

naturalpolypropylenecomponentsofthepumps.To

preventpotentialinjuryorequipmentdamage,do

notexposepumportheplasticcomponentstodirect

sunlightforprolongedperiods.

1.Besurethemountingsurfacecansupportthe

weightofthepump,hoses,andaccessories,as

wellasthestresscausedduringoperation.

2.Forallmountings,besurethepumpissecured

withscrewsthroughthemountingfeet.Always

mountthepumpupright.

3.Makesurethesurfaceis󰘱atandthatthepump

doesn’twobble.

4.Foreaseofoperationandservice,mountthe

pumpsoairvalve,airinlet,󰘱uidinletand󰘱uid

outletportsareeasilyaccessible.

Accessories/Components Accessories/Components

Accessories/ComponentsNot Not

NotSupplied Supplied

SuppliedSystem System

SystemComponents Components

Components

AAirsupplylineJAirinletport(notvisible)

BBleed-typemasterairvalve(requiredfor

yourpump)

KExhaustportandmuf󰘱er

CAir󰘰lter/regulatorassemblyLFluidinletport

DMasterairvalve(toisolatethe󰘰lter/regulator

forservice)

MFluidoutletport

EGrounded󰘱exible󰘱uidsupplylineNMountingfeet

FFluiddrainvalve(requiredforyourpump)

GFluidshutoffvalve

HGrounded,󰘱exible󰘱uidoutletline

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Installation

Ground Ground

GroundThe The

TheSystem System

System

Theequipmentmustbegroundedtoreducethe

riskofstaticsparking.Staticsparkingcancause

fumestoigniteorexplode.Groundingprovidesan

escapewirefortheelectricalcurrent.

•Always Always

Alwaysgroundtheentire󰘱uidsystemas

describedbelow.

•Thepumpsarenot not

notconductive.Anysystem

usedtopump󰘱ammable󰘱uidsmustbeproperly

grounded.

•Followyourlocal󰘰recodes.

Beforeoperatingthepump,groundthesystemas

explainedbelow.

•Pump: Pump:

Pump:Always Always

Alwaysgroundtheentire󰘱uidsystemby

makingsurethe󰘱uidhasanelectricalpathtoa

trueearthground.

•Air Air

Airand and

and󰘱uid 󰘱uid

󰘱uidhoses: hoses:

hoses:Useonly󰘱exiblegrounded

hoseswithamaximumof500ft(150m)combined

hoselengthtoensuregroundingcontinuity.

•Air Air

Aircompressor: compressor:

compressor:Followmanufacturer’s

recommendations.

•Fluid Fluid

Fluidsupply supply

supplycontainer: container:

container:Followlocalcode.

•Solvent Solvent

Solventpails pails

pailsused used

usedwhen when

when󰘱ushing: 󰘱ushing:

󰘱ushing:Followlocal

code.Useonlyconductivemetalpails,placed

onagroundedsurface.Donotplacethepail

onanonconductivesurface,suchaspaperor

cardboard,whichinterruptsgroundingcontinuity.

Checkyoursystemelectricalcontinuityafterthe

initialinstallation,andthensetuparegularschedule

forcheckingcontinuitytobesurepropergrounding

ismaintained.

Air Air

AirLines Lines

Lines

1.Installanairregulatorandgauge(C)tocontrol

the󰘱uidpressure.The󰘱uidstallpressurewillbe

thesameasthesettingoftheairregulator.

2.Locateableed-typemasterairvalve(B)closeto

thepumpanduseittorelievetrappedair.Be

surethevalveiseasilyaccessiblefromthepump

andlocateddownstreamfromtheregulator.

Trappedaircancausethepumptocycle

unexpectedly,whichcouldresultinserious

injuryfromsplashing.

3.Locateanothermasterairvalve(D)upstream

fromallairlineaccessoriesanduseittoisolate

themduringcleaningandrepair.

4.Anairline󰘰lter(C)removesharmfuldirtand

moisturefromthecompressedairsupply.

5.Installagrounded,󰘱exibleairhose(A)between

theaccessoriesandthe1/4npt(f)or1/4bspt

pumpairinlet.Useahosewithaminimum1/4in.

ID.Ifahoselongerthan10ft(3m)isrequired,

usealargerdiameterhose.

10334795F

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