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Instructions - Parts List
Sanitary Series
FDA-Compliant
Diaphragm Pumps
311879F
For use in sanitary applications.
Model FD1___ 1040 FDA
Model FD2___ 1590 FDA
Model FD3___ 2150 FDA
120 psi (0.8 MPa, 8 bar) Maximum Air/Fluid Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Refer to the appropriate Pump Matrix on page 26, 34, or 42 to
determine the model number of your pump.
TI8924a
Model 1040
TI8926a
Model 1590
Model 215
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Contents Certificate of Conformance . . . . . . . . . . . . . . . . . . 3 Repair Kit Matrix - 1590 . . . . . . . . . . . . . . . . . . . . . 35 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Available Configurations . . . . . . . . . . . . . . . . . . 35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Parts - 1590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Operation . . . . . . . . . . . . . . . . . . . . .
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Certificate of Conformance Certificate of Conformance Part Number: All FD1, FD2, FD3 models Description: FDA-Compliant Diaphragm Pump Materials of Construction: All fluid contacted materials are FDA- compliant and meet CFR Title 21, Section 177. Bradley A. Byron QMS Management Representative Graco Inc. 311879F 3
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Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. 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 explode. To
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Warning Warning TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swal- lowed. � Read MSDS’s to know the specific hazards of the fluids you are using. � Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help pro
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Installation Installation General Information Grounding � The typical installations shown in Figs. 2-4 are only To reduce the risk of static sparking, ground the pump guides for selecting and installing system compo- and all other equipment used or located in the pumping nents. Contact your Graco distributor for assistance area. Check your local electrical code for detailed in planning a system to suit your needs. grounding instructions for your area and type of equip- ment. � Always use gen
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Installation Mountings CAUTION In the step below, do not connect the quick-disconnect The pump exhaust air may contain contaminants. coupler (D) on the air hose to the mating fitting on the Ventilate to a remote area if the contaminants could pump until you are ready to operate the pump. Connect- affect your fluid supply. See Air Exhaust Ventilation ing the coupler too early can result in unintentional oper- on page 10. ation of the pump, leading to serious injury from moving parts, splash
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Installation Fluid Outlet Line 1. Use flexible grounded fluid hoses (L). 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 if it is plugged. The drain valve reduces the 3. Install a fluid drain valve (J) near the fluid outlet. See risk of serious injury, including splashing in the eyes or the WARNING above, and FIG. 2. on t
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Installation Changing the Orientation of the Fluid Inlet and Outlet Ports The pump is shipped with the ports facing the same direction. To reverse the orientation of the ports: 1. Remove the clamps holding the inlet and/or outlet manifold to the covers. 2. Reverse the manifold and reattach. Install and tighten clamps snugly. Key: N 1/2 npt(f) air inlet port 1 3 113 S P Muffler (air exhaust port is 3/4 npt(f) R Fluid inlet port S Fluid outlet port 113 Manifold clamps 3 Air valve screws 1 Tor
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Installation Air Exhaust Ventilation The air exhaust port is 3/4 npt(f). Do not restrict the air exhaust port. Excessive exhaust restriction can cause erratic pump operation. Read the FIRE AND EXPLOSION HAZARD and To provide a remote exhaust: TOXIC FLUID OR FUMES HAZARD warnings on page 5 before operating this pump. 1. Remove the muffler (P) from the pump air exhaust port. Be sure the system is properly ventilated for your type of installation. When pumping flammable or hazardous 2. In
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Operation Operation Pressure Relief Procedure 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 inef- ficient pump operation. Read the PRESSURIZED EQUIPMENT HAZARD 4. Place the end of fluid hose (L) into an appropriate warnings on page 4. container. The equipment stays pressurized until pressure is man- 5. Close the fluid drain valve (J). ually relieved. To reduce the risk of serious injury from
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Operation 12 311879F
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Maintenance Maintenance Lubrication Tightening Connections The air valve is designed to operate unlubricated, how- Before each use, check all hoses for wear or damage, ever if lubrication is desired, every 500 hours of opera- and replace as necessary. Check to be sure all connec- tion (or monthly) remove the hose from the pump air tions are tight and leak-free. inlet and add two drops of machine oil to the air inlet. Preventive Maintenance Schedule Establish a preventive maintenance schedule,
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Troubleshooting Troubleshooting � Relieve the pressure before checking or servicing the equipment. � Check all possible problems and causes before dis- To reduce the risk of serious injury, whenever you are assembling the pump. instructed to relieve pressure, always follow the Pres- sure Relief Procedure on page 11. PROBLEM CAUSE SOLUTION Pump cycles at stall or fails to hold Worn check valve balls (301), seats Replace. See 18. pressure at stall. (201) or o-rings (202). Pump will not cycle, o
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Troubleshooting PROBLEM CAUSE SOLUTION 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 and pipe. outlet. Gasket does not seal. Use a standard sanitary gasket of flexi- ble material such as EPDM, Buna-N, fluoroelastomer, or silicon. Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19-21. Loose diaphragm shaft bolt (107). Tighten or replace. S
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Service Service 7. Clean all parts and inspect for wear or damage. Repairing the Air Valve Replace as needed. Reassemble. Tool Required Reassembly � Torque wrench 1. If you replaced the bearings (12, 15), reinstall as � Torx (T20) screwdriver or 7 mm (9/32 in.) socket explained on page 24. Reassemble the fluid section. wrench � Needle-nose pliers 2. Install the valve plate (8) in the cavity, seal down. � O-ring pick Install the three screws (3), using a Torx (T20) � Lithium base grease scr
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Service 1 2 Insert narrow end first Torque to 52-60 in-lb 2 3 (5.6-6.8 N�m) 2 Grease 2 3 Install with lips facing narrow end of piston (11) 4 Insert wide end first 4† 10† 2 3 11 4 12 TI9086A TI9089A 2 17† 1 16 15 FIG. 5 FIG. 7 Detail 1 See detail at right 1 Tighten screws until they bottom 5 out on the housing 2 Grease 3 1 3 Grease lower face †6 2 3 †7 8† TI9088A 18† 3 1 5 TI9090A TI9087A FIG. 6 FIG. 8 311879F 17
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Service Ball Check Valve Repair Arrow (A) must point toward outlet manifold (103) 1 Tools Required Radiused seating surface must face the ball (301). 2 Large chamfer on O.D. must face o-ring. � O-ring pick Disassembly � A Fluid Section Repair Kit is available. Refer 103 to the Repair Kit Matrix parts section for the appropriate pump size so that the correct kit for your pump is ordered. Parts included in the kit are marked with an asterisk, for exam- ple (202*). Use all the parts in the ki
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Service Standard Diaphragm Repair If your pump uses heavy-duty diaphragms, see page 22. Tools Required To reduce the risk of serious injury, whenever you are instructed to relieve pressure, always follow the Pres- � Torque wrench sure Relief Procedure on page 11. � 15 mm socket wrench 1. Relieve the pressure. � 19 mm open end wrench � O-ring pick 2. Remove the manifolds and disassemble the ball � Lithium-base grease check valves as explained on page 18. Disassembly 3. Remove the clamps (106)
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Service 4. Loosen but do not remove the diaphragm shaft bolts d. On PTFE models only, install the backer (401*) (107), using a 15 mm socket wrench on both bolts. on the bolt. Make certain the side marked AIR See FIG. 11. SIDE faces the center housing (1). 5. Unscrew one bolt from the diaphragm shaft (24) and e. Install the air side diaphragm plate (104) so the remove the o-ring (108), fluid side diaphragm plate rounded side faces the diaphragm (401). This (105), diaphragm (403), backer (
