Graco ChemSafe 205 Instructions-Parts List Manual Download Page 17 | Manualshive

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Troubleshooting

Problem

Cause

Solution

Pump exhausts excessive air at

stall.

Spool valve seals are worn or

damaged.

Replace.

Fluid covers are loose.

Retorque.

Diaphragm is damaged.

Replace.

Pump leaks air externally.

Manifold ﬁttings are loose

Retorque.

Fluid covers are loose.

Retorque.

Pump leaks ﬂuid externally.

Diaphragms are damaged.

Replace.

334792E

17

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Summary of Contents for ChemSafe 205

Page 1: ...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 ...

Page 2: ...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 ...

Page 3: ...quipment in the work area See Grounding instructions Use only 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 Keep a working ﬁre extinguisher in the work area Route e...

Page 4: ... sure 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 ...

Page 5: ...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 ...

Page 6: ...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 center with bspt air inlet PT4 PTFE bspt UH3 UHMWPE npt UH4 UHMWPE bspt Seat Material Ball Material Diaphragm Material Manifol...

Page 7: ...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 ...

Page 8: ...ump 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 p...

Page 9: ...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 Ai...

Page 10: ...uctive 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 the same as the setting of the air reg...

Page 11: ...arately 2 Remove the mufﬂer U from the pump air exhaust port K 3 Install the adaptor from the kit 4 Install a grounded air exhaust hose S If a hose longer than 10 ft 3 m is required use a larger diameter hose Avoid sharp bends or kinks in the hose 5 Place a container T at the end of the air exhaust line to catch ﬂuid in case a diaphragm ruptures If the diaphragm ruptures the ﬂuid being pumped will...

Page 12: ...horten diaphragm life Approximately 3 5 psi 0 02 0 03 MPa 0 21 0 34 bar should be adequate for most materials 3 For maximum suction lift wet and dry see Technical Data page 29 For best results always install the pump as close as possible to the material source Minimize suction requirements to maximize pump performance Fluid Outlet Line 1 Use grounded ﬂexible ﬂuid hoses See Ground The System page 1...

Page 13: ...o be sure they are tight Use a compatible liquid thread sealant on male threads NOTICE Do not overtighten ﬂuid inlet and outlet ﬁttings The soft plastic threads can be stripped easily 3 Place the suction tube if used in ﬂuid to be pumped NOTE If ﬂuid inlet pressure to the pump is more than 25 of outlet working pressure the ball check valves will not close fast enough resulting in inefﬁcient pump o...

Page 14: ...yes or on skin follow the Pressure Relief Procedure when you stop pumping and before you clean check or service the equipment 1 Shut off the air supply to the pump 2 Open the dispensing valve if used 3 Open the ﬂuid drain valve to relieve ﬂuid pressure Have a container ready to catch the drainage Pump Shutdown At the end of the work shift and before you check adjust clean or repair the system foll...

Page 15: ...s Check bolts Tighten or retorque as necessary Although pump use varies a general guideline is to retorque bolts every two months See Torque Instructions page 22 Flushing and Storage Flush before ﬂuid can dry in the equipment at the end of the day before storing and before repairing equipment Flush at the lowest pressure possible Check connectors for leaks and tighten as necessary Use solvent that...

Page 16: ...n seat or manifold Replace ball and seat Dispensing valve is clogged Relieve pressure and clear valve Pump will not cycle or cycles once and stops Diaphragm is ruptured Replace Suction line is clogged Inspect clear Check valve balls are sticky or leaking Clean or replace Diaphragm is ruptured Replace Exhaust is restricted Remove restriction Spool valve is damaged or worn Replace spool valve Air su...

Page 17: ...all Spool valve seals are worn or damaged Replace Fluid covers are loose Retorque Diaphragm is damaged Replace Pump leaks air externally Manifold ﬁttings are loose Retorque Fluid covers are loose Retorque Pump leaks ﬂuid externally Diaphragms are damaged Replace 334792E 17 ...

Page 18: ...5 Use a 3 mm Allen wrench to remove the outlet manifold 8 and retainer 11 6 Without scratching the inner bore use a hook to remove the outlet ball retainer 19 Remove the ball 22 and check seat 21 7 Reattach the manifold bolts 29 to keep the ﬂuid cover nuts 18 aligned 8 Remove the nuts 28 and bolts 24 using two 7 mm sockets to hold on one side and to turn the other The nuts 28 will come off of one ...

Page 19: ...mble the Center Section 1 Install a plug 40 in each of the three unused ports 2 Install the mufﬂer media 15 38 into the mufﬂer Use the new felt mufﬂers 15 supplied in the rebuild kit Mufﬂer parts must be placed in the exact order shown in the illustration Use the supplied tool 46 to screw the mufﬂer 14 into the exhaust port the port with 2 holes on the bottom 3 Lubricate and install an o ring 32 a...

Page 20: ...ld bolts 29 a few turns into the nuts 18 just to keep the nuts from rotating 3 Repeat steps 1 and 2 for the other ﬂuid cover 4 Install the ﬂuid covers with the top checks toward the air inlet 5 Place a belleville washer 27 with the rounded side toward the nut then a ﬂat washer 26 on each tie bolt 24 Thread the ﬁrst tie bolt 24 through one ﬂuid cover retainer 9 and then the second tie bolt 24 throu...

Page 21: ...tener Install the bolts 29 just hand tight for now then ﬂip the pump over 13 Assemble the top checks Insert the seat 21 with the chamfered side up the ball 22 and the outlet ball retainer 19 14 Carefully remove the manifold bolts 29 from the top of the ﬂuid covers 6 keeping nuts 18 aligned 15 Align the outlet manifold 8 with the dowels on the top of the body 16 Align the outlet manifold retainers ...

Page 22: ...Remove the protective bolt covers 37 with a screwdriver Carefully work the screwdriver under the lip of each cap and gently pry it off 2 Start all ﬂuid cover screws a few turns Then turn down each screw just until head contacts cover 3 Turn each screw by 1 2 turn or less working in a crisscross pattern to speciﬁed torque 4 Repeat for ﬂuid manifolds Assembly Torque Re Torque Fluid Covers 20 in lb 2...

Page 23: ...Notes Notes 334792E 23 ...

Page 24: ...Parts Parts 1 Lubricate using PFPE grease 17G558 included in all Center and Fluid Section Rebuild kits 2 Follow Torque Instructions page 22 24 334792E ...

Page 25: ... 4 pack 1 18 17F187 NUT ﬂuid cover stainless steel 8 19 17F101 RETAINER ball outlet top PTFE 2 20 17F105 RETAINER ball inlet bottom PTFE 2 Ref Part Description Qty 21 SEAT 4 22 17F214 BALL check 3 8 in 4 pack PTFE 1 24 17F178 BOLT tie 6 DIAPHRAGM 2 pack 17F207 Buna n 17F208 EPDM 25 17F209 PTFE Overmolded 1 26 17F193 WASHER 4 mm stainless steel 20 pack 1 27 17F194 WASHER belleville 0 375 in diamete...

Page 26: ...clude Ref Description Qty 19 Outlet Ball Retainer 2 20 Inlet Ball Retainer 2 21 Seat 4 22 Check Ball 4 Diaphragm PTFE Overmolded Kit 17F113 EPDM Kit 17F114 25 Buna n Kit 17F118 2 37 Cap Plug 20 47 PFPE Lubricant 1 Air Motor Assembly Kit 17F596 Kit Includes Ref Description Qty 2 Main Sleeve Assembly 1 3 Sleeve Cap 2 4 Center Sleeve Assembly 1 17 Shaft Seal 6 32 13 O ring 6 Main Cap Assembly 17F591 ...

Page 27: ...ensions Ref US Metric A 1 1 in 28 mm B 4 3 in 113 mm C 2 7 in 69 mm D 5 5 in 139 mm E 4 2 in 107 mm F 6 5 in 166 mm G 3 3 in 83 mm H 2 5 in 64 mm J 2 8 in 70 mm K hole diameter 0 3 in 7 mm Mounting Layout 334792E 27 ...

Page 28: ... Air Pressure A 100 psi 0 7 MPa 7 0 bar B 70 psi 0 48 MPa 4 8 bar C 40 psi 0 28 MPa 2 8 bar Air Consumption Approximate Cycles per Minute How to Read the Charts 1 Locate ﬂuid ﬂow rate along bottom of chart 2 Follow vertical line up to intersection with selected operating air pressure curve 3 Follow left to scale to read ﬂuid outlet pressure top chart or air consumption bottom chart scfm m3 min 0 1...

Page 29: ...eezing or crystallization of the ﬂuid inside or outside of the pump Running the pump at temperatures below freezing may accelerate the wear of the elastomer components in the pump 32 F 0 C Air consumption at maximum ﬂow 4 8 scfm 0 14 scmm Fluid ﬂow per cycle 0 008 gallons 0 03 liters Maximum free ﬂow delivery 2 5 gpm 9 5 lpm Maximum pump speed 375 cycles per minute Weight PTFE UHMW 4 1 lb 3 0 lb 1...

Page 30: ...l damages for lost proﬁts lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENT...

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