Process & Transfer Equipment Division (PTE)
Husky AODD Pump Troubleshooting/Common Mistakes/FAQs –Air Supply
Husky AODD Pump Troubleshooting/Common Mistakes/FAQs –Air Supply
Q: How do I control an AODD pump?
A: We control the speed (and, thus flow rate) of Husky AODD pumps with a regulator.
Note: when we talk about controlling a pump, we mean air pressure (psi) and volume (cfm).
Q: Why can’t I control the diaphragm pump with a ball valve?
A: A ball valve is only serving to decrease the air volume (cfm) and increase the air pressure(psi) (pressure is a restriction of flow). This will cause erratic pump operation. A regulator must be used to increase or decrease the inlet air pressure (psi) while allowing the proper amount of air volume (cfm) to power the pump.
Q: Do I need an air filter and in line lubricator?
A: A air filter is necessary to eliminate any condensation or contamination coming through the air line.
A lubricator is not necessary and is not recommended due to the fact air tool oil will contaminate and possibly “wash out” the lithium-based grease Graco uses in the air valve.
Q: What size air line do I need?
A: Air line is to be determined based on the air valve inlet size (i.e. if the air valve has a ½”NPT fitting, ½”air line should be used). Using smaller diameter air line will significantly reduce air volume (cfm).
Note: all manuals indicate the diameter of the air valve fitting in the technical data section.
Examples of Incorrectly Plumbed Air Lines (and the consequences)
Determination: Air inlet line diameter is too small (in this case, 3/8” O.D. and ¼” I.D. Pump is starved for volume and is acting erratic (chattering) and won’t load. Air line was increased to ½” I.D. Lines were changed and pump began to function properly.
Example Two: Distributor calling to report pump is not performing properly. It is not cycling properly and seems to stall easily under fluid pressure.
Determination: Several issues were at play in this example.
• The pump is being starved for air due to the ¼” air line.
• The end user was trying to manipulate the speed of the pump with a ball valve (thus further starving the pump of air).
• It was determined the end user was trying to operate the pump (SF2150) at 30 psi to lower the flow rate, thus causing the stall condition.
• The material being pumped was high-viscosity shampoo and the user was attempting to get a lower flow rate than the pump was capable of producing (they should have been using a SF1590).
We do not want to see quick couplings on any of the Husky AODDs. In the example below, the ¼” quick couple fitting has an actual I.D. of less than 1/8”! This is severely restricting the volume (cfm) of air to the pump.
Tip: when sending in video for troubleshooting help, the video should be a minimum of 30 seconds long (and include sound). It should contain shots of the pump, the inlet/outlet lines, air inlet, and inlet air pressure gauge. Help me help you!
Husky Surge Suppressor FAQs
Q: What does a surge suppressor do?
A: A surge suppressor protects piping, valves, meters, and in-line instrumentation from potentially damaging pulsations. They prevent line vibration, product agitation, foaming, splashing, etc. They also ensure smooth flow in metering and spray applications.
This is accomplished by cushioning the fluid in the line using a bladder filled with compressed air.
Q: When should I specify a surge suppressor?
A: When consistent outlet fluid pressure is required (metering or spraying), instrumentation is present (flow meters or sensors), and/or product integrity is required.
Q: How do I size a surge suppressor?
A: Any pump with a manifold under 1”(Husky 716 and smaller)should use a Husky 750surge suppressor and any pump with a manifold 1”and over (Husky 1050 and larger) should use a Husky 2000surge suppressor.
Note: the Husky 750 has a ¾”NPTF fitting and the Husky 2000 has a 2” NPTF fitting.
Example: Husky 1050 (p/n640034)
Q: What materials are available?
A: Models are available with stainless steel or polypropylene fluid sections. Elastomers (bladders) available are PTFE(Teflon), FKM(Viton), and Buna-N.
Note: see manual 308703 for list of configurations.
Q: What is the difference between a manual and automatic surge suppressor?
A: A manual unit has a gauge and regulator to vary the pressure to the tank based on desired outlet fluid pressure.
An automatic unit has a gauge only and automatically varies the pressure the tank (utilizing a one-way internal check valve) based on the inlet air pressure being supplied to the pump.
Q: How do I know whether to specify a manual or automatic surge suppressor?
A: In general, a manual unit should be specified whenever outlet fluid pressure is going to remain static (vast majority of applications).
An automatic unit should be specified if the outlet fluid pressures need to be varied often.
Q: How do I install the surge suppressor?
A: The surge suppressor is mounted within ten pipe diameters from the outlet of the pump (i.e. when used with 2”pipe, the surge suppressor needs to be no more than 20”from the outlet of the pump). Air supply is typically shared with inlet air supply to the pump.
Note: air is continuously supplied to both the manual and automatic unit.
Q: I installed the surge suppressor, how do I operate it?
A: The air supply to the surge suppressor is always equal to or greater than the pressure being supplied to the pump. The charge pressure should be 2-10 psi less than system pressure. For manual units: once the pump is started, gradually decrease the regulated air to the tank by adjusting the regulator (automatic units are self regulating).
Note: the gauge on a manual unit will read the pressure in the tank. The gauge on the automatic unit will read “0” until it actually needs to start damping the pressure, then the automatic check valve will open allowing air into the tank.
Definitions:
• Supply pressure: the air pressure provided to the surge suppressor at the tank inlet.
• Charge pressure: the air pressure present in the surge suppressor tank
• System pressure: actual pressure present in the outlet line
Q: I have an open transfer system (tank to tank, tank to drum, drum to drum, etc.), can I use a surge suppressor to lessen the pressure fluctuations?
A: No. A minimum of 5-10 psi of back pressure is required to benefit from the use of a surge suppressor.
Note: a back pressure valve can be installed to achieve the back pressure required.
Q: Are the Husky surge suppressors FDA compliant?
A: No. While, in the case of the stainless steel models, the materials of construction are FDA compliant, the surge suppressors, technically, are not.
Q: I have a surge suppressor installed and the lines continue to shake and make noise, why isn’t the surge suppressor working?
A: The most likely cause is water hammer. Water hammer is caused by a concussion of high velocity fluid contacting the sides of a pipe, a fitting, or a vessel.
Note: It is very important, when qualifying an end user for a surge suppressor, to determine if they truly have a pressure fluctuation issue or a water hammer issue. A surge suppressor will NOT resolve all water hammer issues.
Q: Why specify a Husky1050e instead of an AODD?
A: Electric operation is preferred, lack of available air, more control is desired (electronic and pressure), improved metering accuracy, replacement of existing electric pump.
Q: How do I specify a Husky 1050e?
A: The fluid section material and internal wetted components are specified the same as an AODD. At that point, we need to determine if the end user has compressed air available and what input voltage they require.
Note: all cart mounted units are specified with a BLDC motor and GMC.
Q: Why does the Husky 1050e require compressed air? (most frequently asked question)
A: An air compressor is needed to maintain fluid outlet pressure, allows the pump to stall under pressure (Graco exclusive), ability to reduce pulsation, and increases diaphragm life.
Q: How do I determine the correct pressure setting?
A: Using the Pressure Loss Calculator, determine the pressure loss across the outlet line and set pressure to 10 psi above that result.
Note: max inlet air pressure is 80 psi
Q: How much air does the Husky 1050e consume?
A: When using in standard flow mode, the Husky 1050e will consume approximately 0.2 CFM/H.
Note: more air will be consumed when used in low pulsation mode based upon the desired outlet fluid pressure.
Q: What input voltages are available?
A: Units fitted with AC motors can be supplied with 208-230 VAC single-phase or 460 VAC three-phase input. If 120VAC single phase voltage is desired, a unit with a BLDC and GMC must be specified.
Note: all AC motors are convertible 230/460 VAC and are prewired for 460VAC.
Q: Can I get a Husky 1050e pump with a BLDC motor without a Graco Motor Control (GMC)?
A: No. The GMC is needed to not only control flow rates, batch sizes, etc., but also to convert the AC input voltage to DC.
Q: If I specify an AC motor, why do I need a VFD?
A: A VFD is required not only for speed control (to control the fluid flow of the pump) but also for the soft start required for the 2HP, three-phase motor (we use a 20 second to 60 Hz ramp for our life and performance testing).
Q: How do I control the pump remotely?
A: Using port 4 on the GMC, the pump will accept a digital Start/Stop input and an analog 4-20mA input to control pump speed. VFDs will also accept these inputs. Note: See page 21 and 32 of manual 334188.
Q: Can I monitor my batches/pump speed (from GMC LED readout) remotely?
A: No. The GMC currently has no data output provision, it will only accept PLC input. It is important to remember, however, that the GMC can be remotely mounted. Such as, in a control room next to a PLC where batches, etc. can be monitored.
Q: Can I get a Husky 1050e without a motor?
A: Yes, the Husky 1050e is available without a motor with a NEMA or IEC flange gearbox (NEMA 56C or IEC 90 flange face).
Note: a Husky 1050e ordered without a motor cannot be specified with a compressor. A compressor, if needed, must be ordered separately.
Q: Is there an explosion-proof Husky 1050e option?
A: Yes, Graco can fit the Husky 1050e with an ATEX certified or Class 1, Division 1 explosion-proof motor. However, these units cannot be specified with a compressor as the compressor motors are not explosion-proof.
Note: a compressor can be ordered separately and mounted outside the hazardous area.
Q: What is the maximum amp draw of the Husky 1050e?
A: The max amp draw of the Husky 1050e is as follows:
• Motor
• BLDC with GMC: 16A
• AC motor (230VAC three-phase): 5.7A
• AC motor (460VAC three-phase): 2.85A
• AC motor ATEX (230VAC three-phase): 5.44A
• AC motor ATEX (460VAC three-phase): 3.14A
• AC motor CL 1, DIV 1(230VAC three-phase): 5.2A
• AC motor CL 1, DIV 1(460VAC three-phase): 2.6A
• Compressor
• 120VAC: 3.1A
• 240VAC: 1.3A
Q: Is a leak detector necessary?
A: Realistically, yes. A leak detector will alert the GMC or VFD of a leak and discontinue operation of the pump. This is especially important if the product being pumped is reactive or corrosive to the internal components of the center section.
Q: How do I wire the leak detector?
A: With the BLDC motor and GMC it is as simple as plugging the M8 cable into port 3 on the GMC. With AC motors, the leads must be wired into the VFD. Black wire to terminal 1, Blue wire to terminal 4, and a jumper wire between terminals 4 and 13A. This information is available in manual 334188, page 19.
Note: Leak detectors require an extension cable (except when wiring a cart mounted unit) . Cables are available in 10, 25, and 50 ft lengths.