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Instructions/Parts List
High Sanitation Pumps
310622L
For use in sanitary applications.
Models 1590 & 3150 SA__ Sanitary Diaphragm Pump
44-03
Models 1590 & 3150 SB__ Sanitary Ball Check Pump II 2 G c T6
Model 3150 SF__ Sanitary Flapper Check Pump II 2 G c T6
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.
See page 2 for Table of
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Contents Contents Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Model 1590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . 33 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Maintenance . . . . . . . . . .
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Warnings Warnings The following general warnings are for the safe setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbols alert you to general warnings and the hazard symbols refer to procedure-specific risks. 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 e
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Warning Warning BURN HAZARD Equipment surfaces and fluids that are heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This e
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Installation Installation General Information � The typical installation shown in FIG. 3 is only a guide for selecting and installing system compo- Moving Parts Hazard nents. Contact your Graco distributor for assistance Keep clear of moving parts. in planning a system to suit your needs. � Always use genuine Graco parts and accessories. Bolts (V) may be loosened to allow the pump, while � Reference numbers and letters in parentheses refer still securely mounted to the bracket, to be rotated
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Installation 1. Install the air line accessories as shown in FIG. 3. Mount these accessories on the wall or on a X 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 W TI4736A air. Locate the other master air valve (E) Ground
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Installation 4. At inlet fluid pressures greater than 15 psi (0.1 MPa, 5. See the Technical Data on pages 34 and 37 for 1 bar), diaphragm life will be shortened. maximum suction lift (wet and dry). Fluid Outlet Line 1. Use flexible, grounded fluid hoses (L) where possi- ble. 2. For best sealing results, use a standard Tri-Clamp® style sanitary gasket of a flexible material such as A fluid drain valve (J) is required to relieve pressure in EPDM, Buna-N, fluoroelastomer, or silicon the hose i
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Installation Changing the Orientation of the Fluid Inlet Air Exhaust Ventilation and Outlet Ports The pump is shipped with the ports facing the same direction. To re-orientate the ports into any position: Be sure the system is properly ventilated for your type 1. Remove the clamps (130) holding the inlet and/or of installation. You must vent the exhaust to a safe outlet tee to the elbows. place, away from people, animals, food handling areas, and all sources of ignition when pumping flam-
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Installation Key: A Air supply line B Bleed-type master air valve (required for pump) E F C B C Air regulator D Air line quick disconnect E Master air valve (for accessories) F Air line filter A P Muffler T Grounded air exhaust hose U Container for remote air exhaust T D U P TI8767a FIG. 5 Venting Exhaust Air 310622L 9
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Operation Operation 2. Check connections to be sure they are tight. Tighten Pressure Relief Procedure fluid inlet and outlet connections securely. 3. Place the suction tube (if used) in fluid to be pumped. 1. Shut off the air to the pump. If fluid inlet pressure to the pump is more than 25% of the outlet working pressure, the ball check 2. Open any available outbound fluid valve to relieve valves will not close fast enough, resulting in inef- fluid pressure from the pump. ficient pump ope
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Maintenance Maintenance Lubrication Routine Cleaning of Product Contact Section of Pump The air valve is designed to operate unlubricated, how- ever if lubrication is desired, every 500 hours of opera- The pump and the system should be cleaned in tion (or monthly) remove the hose from the pump air accordance with your state sanitary standard inlet and add two drops of machine oil to the air inlet. codes and local regulations. 1. Flush the system. See Flushing above. CAUTION Do not over-lubr
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Maintenance Preventive Maintenance Schedule Establish a preventive maintenance schedule based on The following is a list of recommended maintenance the pump’s service history. This is especially important procedures and frequencies to operate your equipment for prevention of spills or leakage due to diaphragm safely. Maintenance must be performed by trained per- failure. sonnel per this schedule to assure safety and reliability of the equipment. Operator Maintenance Person Task Daily Weekly
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Maintenance 310622L 13
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Troubleshooting Troubleshooting � Relieve the pressure before checking or servicing the equipment. � Check all possible problems and causes before disassembling the pump. CAUSE SOLUTION PROBLEM Pump cycles at stall or fails to hold Worn check valve balls (541) or Replace. See page 19. pressure at stall. seats (233). Pump will not cycle, or cycles once Air valve is stuck or dirty. Disassemble and clean air valve. and stops. See page 16. Use filtered air. Check valve ball (541) severely Replace
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Troubleshooting CAUSE SOLUTION PROBLEM Leak in inlet or outlet sanitary fit- Loose sanitary clamp. Tighten clamp. ting. Damaged or worn gasket. Replace gasket. Misalignment of inlet/outlet hose or Use flexible hoses at pump inlet pipe. and outlet. Gasket does not seal. Use a standard sanitary gasket of flexible material such as EPDM, Buna-N, fluoroelastomer, or silicon. Fluid in exhaust air. Diaphragm ruptured. Replace. See page 21. Loose diaphragm plate. Tighten or replace. See page 21. Pump
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Service Service 3. Move the valve carriage (105) to the center position Repairing the Air Valve and pull it out of the cavity. Using a needle-nose pli- ers, pull the pilot block (116) straight up and out of Tool Required the cavity. See FIG. 7. � Torque wrench � Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench 116◆ 105◆ � Needle-nose pliers � O-ring pick � Lithium base grease Air Valve Repair Kit 255122 is available. Refer to Parts on page 31. Parts included in the kit are marked wi
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Service 5. Inspect the valve plate (108) in place. If damaged, 3. Install an o-ring (115) on each pilot pin (114). use a Torx (T20) screwdriver or 7 mm (9/32 in.) Grease the pins and o-rings. Insert the pins into the socket wrench to remove the three screws (103). bearings, narrow end first. See FIG. 10. Remove the valve plate (108). See FIG. 9. 111 110◆ 103 108◆ 114 115◆ TI4618c FIG. 9 TI4617b FIG. 10 6. Inspect the bearings (112, 117) in place. See Parts on page 31. The bearings are tapered
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Service 8. Install the valve carriage (105) so its tabs slip into 9. Align the valve gasket (104) and cover (102) with the grooves on the narrow end of the actuator pis- the six holes in the center housing (101). Secure tons (111). See FIG. 11. with six screws (103), using a Torx (T20) screw- driver or 7 mm (9/32 in.) socket wrench. Torque to 50-60 in-lb (5.7-6.8 N�m). See FIG. 12. 105◆ 116◆ 103 102 104◆ TI4616b TI4682b FIG. 11 FIG. 12 18 310622L
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Service Check Valve Repair 128 Disassembly 132a Reference numbers with an asterisk (*) are *240 replacement parts. For a complete list of replace- ment parts see Parts, page 26. 2XA 129* 130 132c *240 *541 2XB *240 1. Relieve the pressure. Disconnect all hoses. 132b 2. Remove the pump from its mounting. Drain. 3. From the outlet manifold, remove both upper clamps (132a). 4. Remove outlet manifold leaving elbows (128), gas- kets (129), clamps (130), and tee (339) assembled. 5. For 3A Ball Check
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Service For Sanitary Ball Check pumps: remove ball gasket For Flapper Check pumps: remove gasket (240). (242) and ball (541). Remove lower clamp (132b), Remove middle clamp (232) and housing (252). seat (233), and gasket (240). Clean all parts and Remove middle gasket (250), flapper retainer (253), inspect for wear or damage. Replace parts as and flapper valve (251). Remove lower clamp needed. (132b), lower flapper housing (248), and gasket (240). Clean all parts and inspect for wear or da
