Hitachi FD2 1590 User's Manual
Contents
1. as explained on page 19 N If you are removing only the diaphragm shaft bearing 19 skip step 4 4 Disassemble the air valve as explained on page 16 5 Using a 10 mm socket wrench remove the screws 25 holding the air covers 23 to the center housing 1 See FIG 14 6 Remove the air cover gaskets 22 Always replace the gaskets with new ones 7 Use a bearing puller to remove the diaphragm shaft bearings 19 air valve bearings 12 or pilot pin bearings 15 Do not remove undamaged bearings 8 If you removed the diaphragm shaft bearings 19 reach into the center housing 1 with an o ring pick and hook the u cup packings 402 then pull them out of the housing Inspect the packings See FIG 11 Reassembly ie If removed install the shaft u cup packings 402 so the lips face out of the housing 1 See FIG 11 24 The bearings 12 15 and 19 are tapered and can only be installed one way Insert the bearings into the center housing 1 tapered end first Using a press or a block and rubber mallet press fit the bearing so it is flush with the surface of the center housing Reassemble the air valve as explained on page 16 Align the new air cover gasket 22 so the pilot pin 16 protruding from the center housing 1 fits through the proper hole H in the gasket Align the air cover 23 so the pilot pin 16 fits in the middle hole M of the three small holes near the center2. Fluid Flow BA gpm Ipm AIR PRESSURES 120 psi 8 4 bar 0 84 MPa 100 psi 7 0 bar 0 7 MPa C 70 psi 4 8 bar 0 5 MPa O 40 psi 2 8 bar 0 3 MPa TI8742A 311879F 49 Graco Warranties Graco Standard Pump Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of five years from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the p
3. See FIG 11 Unscrew one bolt from the diaphragm shaft 24 and remove the o ring 108 fluid side diaphragm plate 105 diaphragm 403 backer 401 used only on PTFE models and air side diaphragm plate 104 See FIG 11 Pull the other diaphragm assembly and the dia phragm shaft 24 out of the center housing 1 Hold the shaft flats with a 19 mm open end wrench and remove the bolt 107 from the shaft Disassem ble the remaining diaphragm assembly Inspect the diaphragm shaft 24 for wear or scratches If it is damaged inspect the bearings 19 in place If the bearings are damaged refer to page 24 Reach into the center housing 1 with an o ring pick and hook the u cup packings 402 then pull them out of the housing This can be done with the bear ings 19 in place Clean all parts and inspect for wear or damage Replace parts as needed Reassembly 1 Install the shaft u cup packings 402 so the lips face out of the housing 1 Lubricate the packings See FIG 11 Install the diaphragm assembly on one end of the shaft 24 as follows a Install the o ring 108 on the shaft bolt 107 b Install the fluid side diaphragm plate 105 on the bolt so the rounded side faces the dia phragm 401 N The fluid side diaphragm plate 105 is stainless 20 steel This plate fs not stamped with its part num ber Be sure to install this plate on the fluid side of the diaphragm c Install the
4. or tighten the clamp equivalent to bolt not shown 4 Assemble the other diaphragm assembly to the shaft as explained in step 2 This diaphragm will be lifted off the air cover at this point FIG 13 5 Set the other fluid cover 101 in place on the dia phragm so the arrow A on the cover faces the same direction as the air valve B Supply the pump with low pressure air less than 7 psi 05 MPa 0 5 bar The diaphragm will very slowly pull onto the air cover 23 You can support the movement with your hand by gently pushing on the fluid cover 101 CAUTION Do not deform the diaphragm manually The dia phragm needs uniform pressure to deform properly 6 Assemble the fluid cover 101 and clamp 106 so the arrow A on the cover faces the same direction as the air valve B Securely tighten the clamp 7 Reassemble the ball check valves and manifolds as explained on page 18 311879F 23 Service Bearing and Air Gasket Removal Tools Required Torque wrench 10 mm socket wrench Bearing puller O ring pick Press or block and mallet Disassembly N Do not remove undamaged bearings To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pres sure Relief Procedure on page 11 Relieve the pressure 2 Remove the manifolds and disassemble the ball check valves as explained on page 18 3 Remove the fluid covers and diaphragm assemblies
5. 801 from the fluid covers 101 Reassembly 1 Clean all parts and inspect for wear or damage Replace parts as needed 2 Reassemble in the reverse order following all notes f T18932a in FIG 9 Be sure the ball checks and manifolds are assembled exactly as shown The arrows A on the FIG 9 fluid covers 101 must point toward the outlet man ifold 103 18 311879F Service Standard Diaphragm Repair N If your pump uses heavy duty diaphragms see page 22 Tools Required To reduce the risk of serious injury whenever you are e Torque wrench instructed to relieve pressure always follow the Pres e 15 mm socket wrench sure Relief Procedure on page 11 e 19mm open end wrench 1 Relieve the pressure e O ring pick e Lithium base grease 2 Remove the manifolds and disassemble the ball check valves as explained on page 18 Disassembly 3 Remove the clamps 106 holding the fluid covers 101 to the air covers 23 Pull the fluid covers N A Fluid Section Repair Kit is available Refer to 101 off the pump See Fic 10 page 27 35 or 43 to order the correct kit for your pump Parts included in the kit are marked with an asterisk for example 401 Use all the parts in the kit for the best results AN Arrow A must point toward air valve f 106 101 TI9091A FIG 10 311879F 19 Service Loosen but do not remove the diaphragm shaft bolts 107 using a 15 mm socket wrench on both bolts
6. E dia phragm Seat Parts List Matrix Column 4 CI 189410 BOLT M12 x 1 75 55 mm 2 16 in SST Digit 108 104319 O RING PTFE 112181 PACKING u cup nitrile 403 189296 DIAPHRAGM Santoprene Ret Parno Descriptor o 104 189298 PLATE air side These parts are included in the Pump Repair Kit which aluminum may be purchased separately Refer to the Repair Kit Matrix on page 42 to determine the correct kit for your pump 105 189299 PLATE fluid side SST ES A Replacement Danger and Warning labels tags and cards KI 189410 BOLT M12 x 1 75 are available at no cost 55 mm 2 16 in SST Ball Parts List Matrix Column 5 108 104819 o 289226 Kit heavy duty diaphragm PTFE og Ra parno pesormnon aw includes 403 and 104 402 112181 PACKING u cup 112359 BALL PTFE nitrile 403 253628 DIAPHRAGM Heavy Duty PTFE includes two dia phragms and two packings 402 15H811 PLATE air side aluminum These parts are included in the Pump Repair Kit which may be purchased separately Refer to the Repair Kit Matrix on page 42 to determine the correct kit for your pump 112361 BALL Santoprene 15H834 BALL neoprene SST core 46 311879F Dimensional Drawing 2150 Dimensional Drawing 2150 p i 2 1 2 in Outlet 22 0 in 559 mm n Sanitary Flange 276 mm ra Air Inlet 1 2 npt Pump Mounting Hole Pattern B fad a eet ee ne 2 5 in 6
7. fluid SST 2 277267 MANIFOLD inlet SST 1 1 103 277268 MANIFOLD outlet SST Seat Parts List Matrix Column 4 189310 a a 104319 O RING PTFE 2 402 112181 PACKING u cup 2 nitrile 403 189426 DIAPHRAGM 2 Santoprene mian Ret paremo pescrpnon ay 1 201 15H825 SEAT 316 stainless 4 steel 15H830 O RING PTFE 2 201 15H825 SEAT 316 stainless 4 steel 104 15K448 PLATE air side aluminum 15H828 O RING EPDM 189309 PLATE fluid side SST These parts are included in the Pump Repair Kit which 107 189410 BOLT M12 x 1 75 2 may be purchased separately Refer to the Repair Kit Matrix on 35 mm 1 38 in SST age 35 to determine the correct kit for your pump ped Aa aala 104319 O RING PTFE A Replacement Danger and Warning labels tags and cards 289225 Kit heavy duty diaphragm PTFE are available at no cost includes 403 and 104 l l i 402 112181 PACKING u 2 Ball Parts List Matrix Column 5 foe ot menoa 2 on Tae maano porter Taw Jo a0 Bana includes two dia phragms and two packings 402 112419 BALL PTFE 104 15H810 PLATE air side 2 aluminum These parts are included in the Pump Repair Kit which may be purchased separately Refer to the Repair Kit Matrix on page 35 to determine the correct kit for your pump 112421 BALL Santoprene 3 301 15H833 BALL neoprene SST 4 core 38 311879F Dimensional Drawing 1590 Dimensional Drawing
8. from moving cient pump operation parts or contamination from hazardous fluids See FIG 2 4 Atinlet fluid pressures greater than 15 psi 0 1 MPa 1 bar diaphragm life will be shortened 1 Install the air line accessories as shown in FIG 2 Mount these accessories on the wall or ona 5 See the Technical Data on pages 32 40 and 48 for bracket Be sure the air line supplying the accesso maximum suction lift wet and dry 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 air See the WARNING above Locate the other master air valve E upstream from all air line accessories and use it to isolate them during cleaning and repair c The air line filter F removes harmful dirt and moisture from the compressed air supply 311879F 7 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 risk of serious injury including splashing in the eyes or 3 Install a fluid drain valve J near the fluid outlet See on the skin or
9. hoses Close the air regulator Remove the suction tube from the cleaning solution and drain pump Place suc tion tube in the fluid to be pumped Flush the pump often enough to prevent the fluid you are pumping from drying or freezing in the pump and damaging it Flushing schedule will be based on what the pump is being used for Use a compatible cleaning solution and always cycle the pump during the entire flushing process Always flush the pump and relieve the pressure before storing it for any length of time 311879F Maintenance Tightening Connections Before each use check all hoses for wear or damage and replace as necessary Check to be sure all connec tions are tight and leak free Preventive Maintenance Schedule Establish a preventive maintenance schedule based on the pump s service history This is especially important for prevention of spills or leakage due to diaphragm fail ure 13 Troubleshooting Troubleshooting e Relieve the pressure before checking or servicing the equipment To reduce the risk of serious injury whenever you are e Check all possible problems and causes before dis instructed to relieve pressure always follow the Pres assembling the pump sure Relief Procedure on page 11 PROBLEM CAUSE SOLUTION Pump cycles at stall or fails to hold Worn check valve balls 301 seats ewes _fruwn See 18 pressure at stall 201 or o rings 202 Pump will not cycle or cycles once Ai
10. in the parts drawings and parts lists 316 SST with PTFE o rings Santoprene Santoprene EPDM o rings blue blue 3 Neoprene with SST core 3 PTFE Heavy Duty 27 Parts 1040 Parts 1040 Av Used on pumps with PTFE diaphragms only 28 Detail of Heavy Duty Diaphragm 403 These parts are included in the Pump Repair Kit which may be purchased separately Refer to the Repair Kit Matrix on page 27 to determine the correct kit for your pump These parts are included in Air Valve Repair Kit 255061 which may be pur chased separately Replacement Danger and Warning labels tags and cards are available at no cost TI10634a 311879F Parts 1040 Air Motor Parts List Matrix Column 2 a iv o Jo 15K009 HOUSING center SST 15A735 COVER air valve SST CB 3 116344 SCREW mach hex go hd M5 x 0 8 12 mm 0 47 in a e easeercom DD OCC O RING nitrile m nae Took aaya fa aa paraaan A m awe row actrees la BC tL Par anas Gama BLOCK pilot acetal o ae oane maa e a ree senson ee ane CG a SCREW M8 x 1 25 25 mm 12 1 in stainless steel t These parts are included in Air Valve Repair kit 255061 which may be purchased separately 311879F 29 Parts 1040 Fluid Section Parts List Matrix Column 3 Diaphragm Parts List Matrix Column 6 ret PartNo Dessriion ay aa 277286 MANIFOLD ower SST 1 PartNo Description Kui Ba
11. parts refer to the part lists on pages 45 46 The digits in the matrix do not correspond to the refer ence numbers in the parts drawings and parts lists 2 PTFE 1 ings 2 316 SST with Santoprene 2 Santoprene EPDM o rings 3 Neoprene 3 PTFE with SST core Heavy Duty 311879F Repair Kit Matrix 2150 Repair Kit Matrix 2150 For 2150 Stainless Steel Sanitary Pumps Repair Kits may be ordered separately To repair the air Parts included in the kit are marked with an asterisk in valve order Part No 255061 see page 28 Parts the parts list for example 2017 For example if your included in the Air Valve Repair Kit are marked with a pump has stainless steel seats PTFE o rings PTFE symbol in the parts list for example 47 balls and PTFE diaphragms order Repair Kit FK3111 To repair your pump select the six digits which describe your pump from the following matrix working from left to The digits in the matrix do not correspond to the refer right The first three digits are always FD3 The remain ence numbers in the parts drawings and parts lists ing three digits define the materials of construction Diaphragm Seats and Pump O rings Diaphragms f l 1 316 SST ah 1 PTFE 1 PTFE 316 SST with Santoprene Santoprene EPDM o rings blue blue Neoprene PTFE a SST core o Duty Available Configurations e FK3111 e FK3122 e FK3211 e FK3222 e FK3113 e FK3213 e FK3132 e FK3
12. 00 dBa Noise Level at 70 psi and 50cpm 73 dBa PTFE 220 F 104 4 C Santoprene 180 F 82 2 C EPDM 275 F 135 C Maximum fluid operating temperature is based on the fol lowing maximum diaphragm ball and seat temperature AUINGSs 2424 ct te hae ite 8 gt ends Ga ie net E Neoprene 200 F 93 C Stainless steel 250 F 121 1 C Air inlet SiZe ass ores stata APAT eed waite ve BY ae a 0 5 in npt f RUI INIGUSIZ6 sc whos coheed dn an ata bea eed eaves 1 5 in sanitary flange Fluld OUtjet SIZE Soe a NENA GA BG ee ee ee 1 5 in sanitary flange Wetted parts All fluid contact materials are FDA compliant and meet the United States Code of Federal Regulations CFR Title 21 Section 177 Wetted materials on all models 316 SST Wetted material depending on model EPDM Neoprene PTFE Santoprene CAUTION Santoprene may be used only with non fatty non oily foods or alcohols up to 15 300 series stainless steel polyester labels LDPE foam Non wetted external parts gasket Weight ANM00d615 e aves ins haha ars Pane ee seeded Beam anes E 55 Ib 24 9 kg Santoprene is a registered trademark of the Monsanto Co Loctite is a registered trademark of the Loctite Corporation Displacement per cycle may vary based on suction condition discharge head air pressure and fluid type Noise levels measured with the pump mounted to
13. 120 psi 8 4 bar 0 84 MPa B 100 psi 7 0 bar 0 7 MPa 70 psi 4 8 bar 0 5 MPa O 40 psi 2 8 bar 0 3 MPa en 140 0 96 9 6 120 0 84 8 4 100 0 7 7 80 0 55 5 5 60 0 41 4 1 40 0 28 2 8 20 0 14 1 4 0 20 40 60 80 100 120 75 151 227 302 378 454 Fluid Flow TEA gpm Ipm AIR PRESSURES A 120 psi 8 4 bar 0 84 MPa B 100 psi 7 0 bar 0 7 MPa 70 psi 4 8 bar 0 5 MPa D 40 psi 2 8 bar 0 3 MPa TI8742A 41 Pump Matrix 2150 Pump Matrix 2150 2150 FDA Compliant Stainless Steel Sanitary Pumps Your Model No is marked on the pump s serial plate To determine the Model No of your pump from the follow ing matrix select the six digits which describe your pump working from left to right The first three digits are always FD3 designating 2150 SST FDA compliant dia phragm pumps The remaining three digits define the materials of construction For example a pump with an FDA Compliant Diaphragm Pump 2150 Stainless Steel Air Motor Stainless Steel Fluid Section 316 SST with PTFE FD3 All 2150 SST FDA Compliant Pumps Available Configurations e FD3111 e FD3122 e FD3211 e FD3222 e FD3113 FD3213 e FD3132 e FD3232 42 Seats and O rings 1 aluminum air motor stainless steel fluid section stain less steel seats PTFE o rings PTFE balls and PTFE diaphragms is Model No FD3111 To order replace ment
14. 1590 19 5in O O 2 in Outlet 495 mm 9 8 in Sanitary Flange 249 mm 16 9 in 429 mm 20 4 in 518 mm Pump Mounting Hole Pattern rh B P 6 0 in Four 0 46 in E NG pan 11 7 mm 2 4 in 152 mm diameter holes fm Br p Air Exhaust 2 in Inlet muffler included rer Sanitary Flange ee 7 8 in Lg 3 4 npt f 198 mm Overall Width 10 1 in 257 mm TI9095a 1590 FDA 311879F 39 Technical Data 1590 Technical Data 1590 Maximum fluid working pressure 120 psi 0 8 MPa 8 bar Air pressure operating range 20 120 psi 0 14 0 8 MPa 1 4 8 bar Maximum air consumption 0 000 0c ees 130 scfm Air consumption at 70 psi 50 gpm 42 scfm see chart Maximum free flow delivery 100 gpm 379 I min Maximum pump speed 2 00 cee ee ees 200 cpm Gallons Liters per cycle 0 5 1 9 Maximum suction lift 2 0 0 0 00 0000 29 ft 8 83 m wet 14 ft 4 26 m dry Maximum size pumpable solids 3 16 in 4 8 mm Maximum Noise Level at 100 psi full flow 88 dBa Sound Power Level 00000 e eee eens 95 dBa Noise Level at 70 psi and 50cpm 79 dBa PTFE 220 F 104 4 C Maximum fluid operating temperature is based on the fol Santoprene 180 F 82 2 C lowing maximum diaphragm ball and seat temp
15. 232 311879F 43 Parts 2150 Parts 2150 J Used on PTFE models only 44 Detail of Heavy Duty Diaphragm These parts are included in the Pump Repair Kit which may be purchased separately Refer to the Repair Kit Matrix on page 42 to determine the cor rect kit for your pump These parts are included in Air Valve Repair Kit 255061 which may be pur chased separately Replacement Danger and Warning labels tags and cards are available at no cost TI8929b 311879F Air Motor Parts List Matrix Column 2 er PartNo Deseipion Oly La ill ical SCREW mach hex ne hd gt M5 x 0 8 12 mm 0 47 in a reses GASKET cover a PT f9862 PISTON actuator aoei 2 i2 188619 BEARING pison ace 2 har osre Pue fe 1s fesen BEARING prias a pa aor at a N T 112178 SCREW M8 x 1 25 25 mm 12 1 in stainless steel t These parts are included in Air Valve Repair Kit 255061 which may be purchased separately 311879F Parts 2150 45 Parts 2150 Fluid Section Parts List Matrix Column 3 Diaphragm Parts List Matrix Column 6 Dt porne peser 401 DIAPHRAGM backer 2 EPDM 402 112181 PACKING u cup nitrile 403 15K313 DIAPHRAGM PTFE kag 189298 PLATE air side aluminum 105 189299 PLATE fluid side SST ea Description Fet Pare Desorption Jay or amo coven tuas fe ea aaa 1104 188621 LABEL warning 15G332 MUFFLER rar Te sen LAN ey a ka Kac CLAMP
16. 3 in L Four 0 46 in nani aasa 11 7 mm baa ee mm diameter holes Air Exhaust 8 2 in oz muffler included 208 mm Bal 2 plaka Un AE eee SS D 3 4 npt f y g BB 8 2 in Overall Width 12 3 in 312 mm TI9096a 209 mm 2150 FDA 311879F 47 Technical Data 2150 Technical Data 2150 Maximum fluid working pressure 120 psi 0 8 MPa 8 bar Air pressure operating range 20 120 psi 0 14 0 8 MPa 1 4 8 bar Maximum air consumption 00000 00 eee 175 scfm Air consumption at 70 psi 80 gpm 70 scfm see chart Maximum free flow delivery 20000 eee 160 gpm 568 lpm Maximum pump speed 2 a 165 com Gallons Liters per cycle 0 97 3 67 Maximum suction lift 2 0 20 0 00 0 0 29 ft 8 83 m wet 16 ft 4 87 m dry Maximum size pumpable solids 1 4 in 6 3 mm Maximum Noise Level at 100 psi full flow 95 dBa Sound Power Level 0000 eee eee eee 102 dBa Noise Level at 70 psi and 50cpm 84 dBa PTFE 220 F 104 4 C Maximum fluid operating temperature is based on the fol Santoprene 180 F 82 2 C lowing maximum diaphragm ball and seat temperature Neoprene 200 F 93 C ANIS keke aap aid WINAT NLA AN Seas wee eae ead EPDM 275 F 135 C Stainless steel 250 F 121 1 C Anne ES Ze a ki aa mn MANANG bhi ew Seis ow
17. 7 7 80 0 55 5 5 60 0 41 4 1 40 0 28 2 8 20 0 14 1 4 bar m MPa Fluid Outlet Pressure psi 0 40 152 10 38 30 114 35 133 15 57 20 25 76 95 Fluid Flow gpm Ipm AIR PRESSURES A 120 psi 8 4 bar 0 84 MPa B 100 psi 7 0 bar 0 7 MPa C 70 psi 4 8 bar 0 5 MPa 0 40 psi 2 8 bar 0 3 MPa 5 19 TI8736A TI8742A Air Consumption 40 152 10 38 30 114 35 133 15 57 20 25 76 95 Fluid Flow gpm Ipm 5 19 TI8737A AIR PRESSURES 100 psi 7 0 bar 0 7 MPa 70 psi 4 8 bar 0 5 MPa 40 psi 2 8 bar 0 3 MPa TI8742A 33 Pump Matrix 1590 Pump Matrix 1590 1590 FDA Compliant Stainless Steel Sanitary Pumps Your Model No is marked on the pump s serial plate To pump with a stainless steel motor stainless steel fluid determine the Model No of your pump from the follow section stainless steel seats PTFE o rings PTFE balls ing matrix select the six digits which describe your and PTFE diaphragms is Model No FD2111 To order pump working from left to right The first three digits are replacement parts refer to the part lists on pages 37 38 always FD2 designating 1590 SST FDA compliant dia oe phragm pumps The remaining three digits define the The digits in the matrix do not correspond to the refer materials of construction For example a 1590 FD
18. 7 A 17t 15 16 1 AN Tighten screws until they bottom out on the housing 7 TI9090A 17 Service Ball Check Valve Repair J Arrow A must point toward outlet manifold 103 Tools Required AB Radiused seating surface must face the ball 301 Large chamfer on O D must face o ring e O ring pick Disassembly N e A Fluid Section Repair Kit is available Refer 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 kit for the best results e To ensure proper seating of the balls 301 always inspect the seats 201 when replac ing the balls Replace seats as necessary if seating surface shows evidence of wear Also replace the o rings 202 as necessary PTFE o rings should be replaced every time mani folds are removed To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pres sure Relief Procedure on page 11 1 Relieve the pressure Disconnect all hoses 2 Remove the pump from its mounting 3 Remove the clamps 106 holding the outlet mani fold 103 to the fluid covers 101 See FIG 9 4 Remove the o rings 202 seats 201 and balls 301 from the manifold 103 5 Turn the pump over and remove the inlet manifold 102 Remove the o rings 202 seats 201 and balls
19. A ence numbers in the parts drawings and parts lists FDA Compliant Diaphragm 1590 Stainless Stainless Steel Seats and Pump Steel Air Motor Fluid Section O rings Diaphragms FD2 All 1590 Stainless Steel FDA Compliant Pumps kac wit o rings 316 SST with Santoprene Santoprene EPDM o rings Neoprene PTFE E SST core T Duty Available Configurations e FD2111 e FD2122 e FD2211 e FD2222 FD2113 e FD2213 e FD2132 e FD2232 34 311879F Repair Kit Matrix 1590 For 1590 Stainless Steel Sanitary Pumps Repair Kits may be ordered separately To repair the air valve order Part No 255061 see page 28 Parts included in the Air Valve Repair Kit are marked with a symbol in the parts list for example 47 To repair your pump select the six digits which describe your pump from the following matrix working from left to right The first three digits are always FK2 The remain ing three digits define the materials of construction Repair Kit Matrix 1590 Parts included in the kit are marked with an asterisk in the parts list for example 201 For example if your pump has stainless steel seats PTFE o rings PTFE balls and PTFE diaphragms order Repair Kit FK2111 The digits in the matrix do not correspond to the refer ence numbers in the parts drawings and parts lists Diaphragm Seats and Pump O rings Diaphragms f f 1 316 AA 1 PTFE 1 PTFE 316 SST with Santoprene Santoprene EP
20. DM o rings blue blue Available Configurations e FK2111 e FK2122 e FK2211 e FK2222 e FK2113 e FK2213 e FK2132 e FK2232 311879F Neoprene PTFE ie SST core o Duty 35 Parts 1590 Parts 1590 Al 36 Detail of Heavy Duty Diaphragm sos Po xy Ma Used on pumps with PTFE diaphragms only These parts are included in the Pump Repair Kit which may be purchased separately Refer to the Repair Kit Matrix on page 35 to determine the correct kit for your pump These parts are included in Air Valve Repair Kit 255061 which may be pur chased separately Replacement Danger and Warning labels tags and cards are available at no cost TI8927b 311879F Air Motor Parts List Matrix Column 2 ret parno Beeston aw SCREW mach hex flange hd M5 x 0 8 12 mm 0 47 in ee C27 BIT T o ens eno arcore 2 ICOC 1 reee e ammam fa 112178 SCREW M8 x 1 25 25 mm 1 in 12 stainless steel t These parts are included in Air Valve Repair Kit 255061 which may be purchased separately 311879F Parts 1590 37 Parts 1590 Fluid Section Parts List Matrix Column 3 Diaphragm Parts List Matrix Column 6 pon net Pano Descrpnon oy gn Ret PartNo Description 401 DIAPHRAGM backer 2 EPDM 402 112181 PACKING u cup 2 nitrile 15K312 DIAPHRAGM PTFE 104 15K448 PLATE air side 2 aluminum 189309 PLATE fluid side SST S 277263 COVER
21. Instructions Parts List Sanitary Series FDA Compliant Diaphragm Pumps For use in sanitary applications Model FO 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 Model 1590 4 V if WN a i TI8926a PROVEN QUALITY LEADING TECHNOLOGY 7 GRACO 311879F 7 NM Fi Fi gt L M TI8928a CE nae Contents Certificate of Conformance 3 NE AA AA 4 installation 6652524552 AREA NG NAA ees 6 Operanlon Ka nA ie eee eee GAN 11 Maintenance arw Oe ois eee LATERAL 13 Troubleshooting 0c eee aaa aan 14 SErVIC soos incite Deri enpi ee ews 16 Pump Matrix 1040 2 00008 26 Available Configurations 26 Repair Kit Matrix 1040 27 Available Configurations 27 Parts 1040 3 233 cca kee Aa DAGA een 28 Dimensional Drawing 1040 31 Technical Data 1040 05 32 Performance Chart 1040 33 Pump Matrix 1590 0202 eee 34 Available Configurations 34 2 Repair Kit Matrix 1590 35 Available Configurati
22. Pump tested in water with inlet submerged Fluid Pressure Curves at 120 psi 0 7 MPa 7 bar operating air pressure at 100 psi 0 7 MPa 7 bar operating air pressure at 70 psi 0 48 MPa 4 8 bar operating air pressure at 40 psi 0 28 MPa 2 8 bar operating air pressure LULOWS To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow gom lpm and operating air pressure psi MPa bar 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 Air Consumption Curves at 120 psi 0 7 MPa 7 bar operating air pressure at 100 psi 0 7 MPa 7 bar operating air pressure at 70 psi 0 48 MPa 4 8 bar operating air pres sure at 40 psi 0 28 MPa 2 8 bar operating air pres sure o OWS To find Pump Air Pressure scfm or m3 min at a specific fluid flow gpm Ipm and operating air pressure psi MPa bar 1 Locate fluid flow rate along bottom of chart 2 Read vertical line up to intersection with selected operating air pressure 3 Follow left to scale to read air consumption 311879F Fluid Outlet Pressure psi MPa bar ption Air Consum scfm m3 min 140 0 96 9 6 120 0 84 8 4 100 0 7 7 80 0 55 5 5 60 0 41 4 1 40 0 28 2 8 20 0 14 1 4 0 20 40 60 80 100 120 75 151 227 302 378 454 Fluid Flow AIR PRESSURES A
23. a 311879F 21 Service Heavy Duty Diaphragm Repair N If your pump uses standard diaphragms see page 19 Tools Required Torque wrench 19 mm open end wrench O ring pick Lithium base grease Disassembly N A Fluid Section Repair Kit is available Refer to page 27 35 or 43 to order the correct kit for your pump Parts included in the kit are marked with an asterisk for example 4017 Use all the parts in the kit for the best results To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pres sure Relief Procedure on page 11 1 Relieve the pressure 2 Remove the manifolds and disassemble the ball check valves as explained on page 18 3 Remove the clamps 106 holding the fluid covers 101 to the air covers 23 Pull the fluid covers 101 off the pump See FIG 12 4 Once the fluid covers are removed the diaphragm on the side of the pump which was last pressurized with air will be separated from the center section air cover This allows you to grip the diaphragms 5 Diaphragms are assembled handtight To loosen grip both diaphragms securely around the outer edge and rotate counterclockwise One diaphragm assembly will come free and the other will remain attached to the shaft Remove the freed diaphragm 403 and air side plate 104 6 Pull the opposite diaphragm assembly and shaft 24 out of the center housing 1 Hold the shaft flats with
24. a 0 5 in npt f Fluid inlet size oon devs Bane LABA ee ee De ew mat 2 5 in sanitary flange Fluid outlet SIZ Cos e ww aaa aa eg tiated men ae Bae ote em dele ea 25 in sanitary flange Wetted parts All fluid contact materials are FDA compliant and meet the United States Code of Federal Regulations CFR Title 21 Section 177 Wetted materials on all models 316 SST Wetted material depending on model EPDM Neoprene PTFE Santoprene CAUTION Santoprene may be used only with non fatty non oily foods or alcohols up to 15 300 series stainless steel polyester labels Non wetted external parts LDPE foam gasket Weight Ali models 2 42236 GA e See ee AA KAR LA 147 Ib 66 7 kg Santoprene is a registered trademark of the Monsanto Co Loctite is a registered trademark of the Loctite Corporation E Displacement per cycle may vary based on suction condition discharge head air pressure and fluid type Noise levels measured with the pump mounted to a solid surface Sound power measured per ISO Standard 9614 1 The pump user must verify that the construction materials meet their specific application requirements 48 311879F Performance Chart 2150 Performance Chart 2150 Test Conditions Pump tested in water with inlet submerged Fluid Pressure Curves at 120 psi 0 7 MPa 7 bar operating air pressure at 100 psi 0 7 MPa 7 bar operating air pre
25. a 19 mm open end wrench and remove the diaphragm and air side plate from the shaft 7 Inspect the diaphragm shaft 24 for wear or scratches If it is damaged inspect the bearings 19 22 in place If the bearings are damaged refer to page 24 8 Reach into the center housing 1 with an o ring pick and hook the u cup packings 402 then pull them out of the housing This can be done with the bear ings 19 in place 9 Clean all parts and inspect for wear or damage Replace parts as needed ti10630a FIG 12 311879F Service Reassembly 1 Install the shaft u cup packings 402 so the lips face out of the housing 1 Lubricate the packings See FIG 13 2 Assemble the air side plate 104 onto the dia phragm 403 The wide radiused side of the plate must face the diaphragm Apply medium strength blue Loctite or equivalent to the threads of the diaphragm assembly Screw the assembly into the shaft 24 hand tight 3 Grease the length and ends of the diaphragm shaft 24 Determine the orientation of the air valve by checking which side the pilot pins 16 protrude far thest see FIG 14 This side will be supplied with air first Insert the shaft diaphragm assembly into this side of the pump Assemble the fluid cover 101 and clamp 106 so the arrow A on the cover faces i10631a the same direction as the air valve B Securely Tee salamat h blue Loctite pply medium strengt ue Loctite
26. a solid surface Sound power measured per ISO Standard 9614 1 The pump user must verify that the construction materials meet their specific application requirements 32 311879F Performance Chart 1040 Performance Chart 1040 Test Conditions Pump tested in water with inlet submerged Fluid Pressure Curves at 120 psi 0 7 MPa 7 bar operating air pressure at 100 psi 0 7 MPa 7 bar operating air pressure at 70 psi 0 48 MPa 4 8 bar operating air pressure at 40 psi 0 28 MPa 2 8 bar operating air pressure LULOWS To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow gom lpm and operating air pressure psi MPa bar 1 2 Locate fluid flow rate along bottom of chart Follow vertical line up to intersection with selected operating air pressure curve 3 Follow left to scale to read fluid outlet pressure Air Consumption Curves at 120 psi 0 7 MPa 7 bar operating air pressure at 100 psi 0 7 MPa 7 bar operating air pressure at 70 psi 0 48 MPa 4 8 bar operating air pressure at 40 psi 0 28 MPa 2 8 bar operating air pressure o ouv To find Pump Air Consumption scfm or m3 min at a specific fluid flow gpm Ipm and operating air pressure psi MPa bar 1 2 Locate fluid flow rate along bottom of chart Read vertical line up to intersection with selected operating air pressure curve 3 Follow left to scale to read air consumption 311879F 120 0 84 8 4 100 0
27. ainless Steel Seats and Pump Steel Air Motor Fluid Section O rings Diaphragms FD1 All 1040 Stainless Steel FDA Compliant pumps 1 316 SST with 1 PTFE PTFE PTFE o rings 2 1 ings 2 316 SST with Santoprene 2 Santoprene EPDM o rings 3 Neoprene 3 PTFE with SST core Heavy Duty Available Configurations e FD1111 e FD1122 e FD1211 e FD1222 e FD1113 e FD1213 e FD1132 e FD1232 26 311879F Repair Kit Matrix 1040 For 1040 Stainless Steel Sanitary Pumps Repair Kits may be ordered separately To repair the air valve order Part No 255061 see page 28 Parts included in the Air Valve Repair Kit are marked with a symbol in the parts list for example 47 To repair your pump select the six digits which describe your pump from the following matrix working from left to right The first three digits are always FK1 The remain PTFE PTFE ai a FK1 for all 1040 SST FDA Compliant Pumps Available Configurations e FK1111 e FK1122 e FK1211 e FK1222 e FK1113 e FK1213 e FK1132 e FK1232 311879F 2 316 SST with Repair Kit Matrix 1040 ing three digits define the materials of construction Parts included in the kit are marked with an asterisk in the parts list for example 201 For example if your pump has stainless steel seats PTFE o rings PTFE balls and PTFE diaphragms order Repair Kit FK1111 The digits in the matrix do not correspond to the refer ence numbers
28. ate to a remote area if the contaminants could affect your fluid supply See Air Exhaust Ventilation on page 10 e Be sure the mounting surface can support the weight of the pump hoses and accessories as well as the stress caused during operation 2 Install a grounded flexible air hose A between the accessories and the 1 2 npt f pump air inlet N See Fig 5 Use a minimum 3 8 in 9 5 mm ID air hose Screw an air line quick disconnect coupler D onto the end of the air hose A and screw the mat ing fitting into the pump air inlet snugly e For all mountings be sure the pump is bolted directly to the mounting surface e For ease of operation and service mount the pump so the air valve cover 2 air inlet and fluid inlet and outlet ports are easily accessible Fluid Suction Line Air Line 1 Use flexible grounded fluid hoses 2 For best sealing results use a standard Tri Clamp style sanitary gasket of a flexible material such as i EPDM Buna N fluoroelastomer or silicon A bleed type master air valve B is required in the sys tem to relieve air trapped between this valve and the 3 Ifthe fluid inlet pressure to the pump is more than pump Trapped air can cause the pump to cycle unex 25 of the outlet working pressure the ball check pectedly which could result in serious injury including valves will not close fast enough resulting in ineffi splashing in the eyes or on the skin injury
29. contamination from hazardous fluids the WARNING above and FIG 2 when relieving pressure Install the valve close to the pump fluid outlet See FIG 2 4 Install a shutoff valve K in the fluid outlet line Key Air supply line Bleed type master air valve required for pump Air regulator Air line quick disconnect Master air valve for accessories Air line filter Flexible fluid suction line Fluid drain valve required Fluid shutoff valve Flexible fluid line Ground wire required see page 6 for installation instructions lt TACOTMVUO WT TI8930a FiG 2 Typical Floor Mount Installation 8 311879F 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 N 1 2 npt f airinletport P Muffler air exhaust Ma s a port is 3 4 npt f yy R Fluid inlet port S Fluid outlet port 113 Manifold clamps 3 Air valve screws AN Torque to 28 30 in Ib 3 2 3 7 Nem Ro TI8926a FIG 3 311879F 9 Installation Air Exhaust Ventilation Read the FIRE AND EXPLOSION HAZARD and TOXIC FLUID OR FUMES HAZARD warnings on page 5 before operating this pump Be sure the system is properly ventilated for your type of instal
30. diaphragm 403 Make certain the side marked AIR SIDE faces the center housing 1 d On PTFE models only install the backer 401 on the bolt Make certain the side marked AIR SIDE faces the center housing 1 e Install the air side diaphragm plate 104 so the rounded side faces the diaphragm 401 This plate is stamped with its part number f Apply medium strength blue Loctite or equiv alent to the bolt 107 threads Screw the bolt into the shaft 24 hand tight Grease the length and ends of the diaphragm shaft 24 and slide it through the housing 1 Assemble the other diaphragm assembly to the shaft as explained in step 2 Hold one shaft bolt 107 with a wrench and torque the other bolt to 60 70 ft Ib 81 95 Nem at 100 rpm maximum Align the fluid covers 101 and the center housing 1 so the arrows A on the covers face the same direction as the air valve B Secure covers with the clamps See FIG 10 Reassemble the ball check valves and manifolds as explained on page 18 311879F Service Cutaway view with diaphragms in place 24 1042 40A 6 403 3 105 2 108 107 A J Lips face out of housing 1 JEN Rounded side faces diaphragm 401 A Air side must face center housing 1 A Grease A Apply medium strength blue Loctite or equivalent Torque to 60 70 ft Ib 81 95 Nem at 100 rom maximum A Backer used on pumps with PTFE diaphragms only T18933
31. e pins into the bear ings 15 narrow end first See FIG 7 Install a u cup packing 10T on each actuator pis ton 11 so the lips of the packings face the narrow end of the pistons See FIG 7 Lubricate the u cup packings 10T and actuator pis tons 11 Insert the actuator pistons in the bearings 12 wide end first Leave the narrow end of the pis tons exposed See FIG 7 Grease the lower face of the pilot block 187 and install so its tabs snap into the grooves on the ends of the pilot pins 16 See FIG 6 Grease the o ring 6T and install it in the valve block 7t Push the block onto the valve carriage 5 Grease the lower face of the valve block See FIG 6 Install the valve carriage 5 so its tabs slip into the grooves on the narrow end of the actuator pistons 11 See FIG 6 Align the valve gasket 41 and cover 2 with the six holes in the center housing 1 Secure with six screws 3T using a Torx T20 screwdriver or 7 mm 9 32 in socket wrench Torque to 52 60 in Ib 5 6 6 8 Nem See FIG 5 311879F 2 Torque to 52 60 in Ib 5 6 6 8 Nem FIG 5 AN See detail at right A Grease Grease lower face FIG 6 311879F TI9086A Detail 5 Po ae Ate NF At7 mO y TI9088A 18t 3 A 1 Service AN Insert narrow end first A Grease A Install with lips facing narrow end of piston 11 Ay Insert wide end first i pa 4 1 TI9089A Fic
32. ed grounding instructions for your area and type of equip ment NN o Read the FIRE AND EXPLOSION HAZARD warnings on page 4 e Pump Connect a ground wire and clamp as shown in Fig 1 Loosen the grounding screw W Insert one end of a 12 ga 1 5 mm minimum ground wire Y behind the grounding screw and tighten the screw securely Connect the clamp end of the ground wire to a true earth ground Order Part No 222011 Ground Wire and Clamp FIG 1 02646B e Fluid hoses Use only grounded hoses with a maxi mum of 500 ft 150 m combined hose length to ensure grounding continuity e Air compressor Follow the manufacturers recom mendations e All solvent pails used when flushing Follow the local code Use only metal pails which are conductive Do not place the pail on a non conductive surface such as paper or cardboard which interrupts the grounding continuity e Fluid supply container Follow the local code 311879F Installation Mountings MG L CAUTION In the step below do not connect the quick disconnect coupler D on the air hose to the mating fitting on the pump until you are ready to operate the pump Connect ing the coupler too early can result in unintentional oper ation of the pump leading to serious injury from moving parts splashing fluid in the eyes or on the skin and con tact with hazardous fluids The pump exhaust air may contain contaminants Ventil
33. ent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground equipment and conductive objects in work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury e Follow Pressure Relief Procedure in this manual when you stop operating and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not exceed the maximum working pressure or temperature rating of the lowest rated system com ponent See Technical Data in all equipment manuals Use fluids and solvents that are compatible
34. erature Neoprene 200 F 93 C ANIS keke aap aid WINAT NLA AN Seas wee eae ead EPDM 275 F 135 C Stainless steel 250 F 121 1 C Anne ESIZe niet cra ay aa oem BAUANG beak ead Soa ee oe a 0 5 in npt f Fluid inlet Size aa ot Lael a ved a ae KALA 2 0 in Sanitary flange FIUIG outlet SIZE 5 2 dca ao ato Ra eee oleae 2 Qin Sanitary flange Wetted parts All fluid contact materials are FDA compliant and meet the United States Code of Federal Regulations CFR Title 21 Section 177 Wetted materials on all models 316 SST Wetted material depending on model EPDM Neoprene PTFE Santoprene CAUTION Santoprene may be used only with non fatty non oily foods or alcohols up to 15 300 series stainless steel polyester labels LDPE foam Non wetted external parts gasket Weight Ali models pama a OA e See ee Aa KA LA 89 Ib 40 3 kg Santoprene is a registered trademark of the Monsanto Co Loctite is a registered trademark of the Loctite Corporation Displacement per cycle may vary based on suction condition discharge head air pressure and fluid type kk Noise levels measured with the pump mounted to a solid surface Sound power measured per ISO Standard 9614 1 The pump user must verify that the construction materials meet their specific application requirements 40 311879F Performance Chart 1590 Performance Chart 1590 Test Conditions
35. heck valves will not close fast enough resulting in inef ficient pump operation 4 Place the end of fluid hose L into an appropriate container 5 Close the fluid drain valve J 6 Back out the air regulator C knob and open all bleed type master air valves B E 7 If the fluid hose has a dispensing device hold it open while continuing with the following step 8 Slowly increase air pressure with the air regulator C until the pump starts to cycle Allow the pump to cycle slowly until all air is pushed out of the lines and the pump is primed Pump Shutdown At the end of the work shift relieve pressure 11 Operation N 12 311879F Maintenance Lubrication The air valve is designed to operate unlubricated how ever if lubrication is desired every 500 hours of opera tion or monthly remove the hose from the pump air inlet and add two drops of machine oil to the air inlet CAUTION Do not over lubricate the pump Oil is exhausted through the muffler and could contaminate your fluid supply or other equipment Excessive lubrication can also cause the pump to malfunction Flushing To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pres sure Relief Procedure on page 11 Insert suction tube into cleaning solution Open air regu lator to supply low pressure air to the pump Run the pump long enough to thoroughly clean the pump and
36. lation When pumping flammable or hazardous fluids you must vent the exhaust to a safe place away from people animals food handling areas and all sources of ignition Diaphragm failure will cause the fluid being pumped to exhaust with the air Place an appropriate container at the end of the air exhaust line to catch the fluid See FIG 4 Key Air supply line Bleed type master air valve required for pump WT Grounded air exhaust hose Container for remote air exhaust C Air regulator D Air line quick disconnect E Master air valve for accessories F Airline filter P Muffler T U OGO pe Fic 4 Venting Exhaust Air 10 The air exhaust port is 3 4 npt f Do not restrict the air exhaust port Excessive exhaust restriction can cause erratic pump operation To provide a remote exhaust 1 Remove the muffler P from the pump air exhaust port 2 Install a grounded air exhaust hose T and connect the muffler P to the other end of the hose The minimum size for the air exhaust hose is 3 4 in 19 mm ID If a hose longer than 15 ft 4 57 m is required use a larger diameter hose Avoid sharp bends or kinks in the hose 3 Place a container U at the end of the air exhaust line to catch fluid in case a diaphragm ruptures See FIG 4 T18931a 311879F Operation Pressure Relief Procedure Read the PRESSURIZED EQUIPMENT HAZARD warnings on page 4 The equipment stays pre
37. lt 107 Tighten or replace See pages 19 21 Damaged o ring 108 Replace See pages 19 21 Pump exhausts excessive air at Worn air valve block 7 o ring 6 Repair or replace See page 16 Stall plate 8 pilot block 18 u cups 10 or pilot pin o rings 17 Worn shaft seals 402 Replace See pages 19 21 Pump leaks air externally Air valve cover 2 or air valve cover Tighten screws See page 16 screws 3 are loose Air valve gasket 4 or air cover Inspect replace See pages 16 22 23 gasket 22 is damaged Air cover screws 25 are loose Tighten screws See pages 22 23 Pump leaks fluid externally from Loose manifolds 102 103 dam Tighten manifold clamps 113 or ball check valves aged seal between manifold and replace seats 201 or o rings 202 seat 201 damaged o rings 202 See page 18 311879F 15 Service Service Repairing the Air Valve Tool Required Torque wrench Torx T20 screwdriver or 7 mm 9 32 in socket wrench Needle nose pliers O ring pick Lithium base grease N Air Valve Repair Kit 255061 is available Parts included in the kit are marked with a symbol for example 47 Use all the parts in the kit for the best results Disassembly To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pres sure Relief Procedure on page 11 16 Relieve the pressure With a Torx T20 screwdriver or 7 m
38. m 9 32 in socket wrench remove the six screws 3 air valve cover 2 and gasket 4 See FIG 5 Move the valve carriage 5 to the center position and pull it out of the cavity Remove the valve block 7 and o ring 6 from the carriage Using a nee dle nose pliers pull the pilot block 18 straight up and out of the cavity See FIG 6 Pull the two actuator pistons 11 out of the bearings 12 Remove the u cup packings 10 from the pis tons Pull the pilot pins 16 out of the bearings 15 Remove the o rings 17 from the pilot pins See FIG 7 Inspect the valve plate 8 in place If damaged use a Torx T20 screwdriver or 7 mm 9 32 in socket wrench to remove the three screws 3 Remove the valve plate 8 See Fia 8 Inspect the bearings 12 15 in place See FIG 7 The bearings are tapered and if damaged must be removed from the outside This requires disassem bly of the fluid section See page 24 NG Clean all parts and inspect for wear or damage Replace as needed Reassemble Reassembly 1 If you replaced the bearings 12 15 reinstall as explained on page 24 Reassemble the fluid section Install the valve plate 8 in the cavity seal down Install the three screws 3 using a Torx T20 screwdriver or 7 mm 9 82 in socket wrench Tighten until the screws bottom out on the housing See FIG 8 Install an o ring 17T on each pilot pin 16 Grease the pins and o rings Insert th
39. of the cover Install the screws 25 handtight Apply medium strength blue Loctite or equivalent to the threads of the screws 25 See FIG 14 Using a 10 mm socket wrench torque the screws oppositely and evenly to 130 150 in lb 15 17 Nem Install the diaphragm assemblies and fluid covers as explained on page 19 Reassemble the ball check valves and manifolds as explained on page 18 311879F Service A Insert bearings tapered end first A Press fit bearings flush with surface of center housing 1 EN Apply medium strength blue Loctite or equivalent Torque to 130 150 in Ib 15 17 Nem Detail of air valve bearings TI9092a 311879F 25 Pump Matrix 1040 Pump Matrix 1040 1040 FDA Compliant Stainless Steel Sanitary Pumps Your Model No is marked on the pump s serial plate To PTFE o rings stainless steel seats PTFE balls and determine the Model No of your pump from the follow PTFE diaphragms is Model FD1111 To order replace ing matrix select the six digits which describe your ment parts refer to the part lists on pages 29 30 pump working from left to right The first three digits are always FD1 designating 1040 SST FDA compliant The digits in the matrix do not correspond to the refer pumps The remaining three digits define the materials ence numbers in the parts drawings and parts lists of construction For example a 1040 FDA pump with FDA Compliant Diaphragm 1040 Stainless St
40. ons 35 Pana 15904223 AA aa 36 Dimensional Drawing 1590 39 Technical Data 1590 22acananan 40 Performance Chart 1590 41 Pump Matrix 2150 paa GARA AA hea 42 Available Configurations 42 Repair Kit Matrix 2150 43 Available Configurations 43 Panis 215023 AG Gee ee ae 44 Dimensional Drawing 2150 47 Technical Data 2150 aaananan 48 Performance Chart 2150 49 Graco Warranties 000 eee eee eee 50 Graco Information 0 000e eee eeee 50 311879F 311879F Certificate of Conformance GRACO 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 Belly AM Byer Bradley A Byron QMS Management Representative Graco Inc 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 A Warning FIRE AND EXPLOSION HAZARD Flammable fumes such as solv
41. place defective parts only Graco Information TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice This manual contains English MM 311879 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2006 Graco Inc is registered to I S EN ISO 9001 www graco com Revised 02 2008
42. r e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection Installation Installation General Information e The typical installations shown in Figs 2 4 are only guides for selecting and installing system compo nents Contact your Graco distributor for assistance in planning a system to suit your needs e Always use genuine Graco parts and accessories e Reference numbers and letters in parentheses refer to the callouts in the figures and the parts lists on pages 28 30 36 38 and 44 46 Ns The pump is very heavy see Technical Data on pages 32 40 and 48 for specific weights If the pump must be moved follow the pressure relief procedure on page 11 and have two people to lift the pump by grasp ing the outlet manifold securely or use appropriate lift ing equipment 7 AN a m a m Read the TOXIC FLUID OR FUMES HAZARD warn ings on page 5 Read the BURN HAZARD warnings on page 4 To reduce the risk of serious injury due to burns insulate and or label the pump before pumping fluids above 110 F 43 C Tightening Clamps Before First Use After you unpack the pump and before you use it for the first time check all clamps and tighten as necessary Grounding To reduce the risk of static sparking ground the pump and all other equipment used or located in the pumping area Check your local electrical code for detail
43. r valve is stuck or dirty Disassemble and clean air valve See and stops page 16 Use filtered air Check valve ball 801 severely Replace ball and seat See page 18 worn and nom in seat 201 or manifold 102 or 103 Check valve ball 801 is wedged Install Pressure Relief Valve into seat 201 due to overpressur see page 10 ization Loose inlet manifold 102 dam Tighten manifold clamps 113 or aged seal between manifold and replace seats 201 or o rings 202 seat 201 damaged o rings 202 See page 18 Loose diaphragm shaft bolt 107 Tighten or replace pages 19 21 Damaged o ring 108 Replace See pages 19 21 Chattering noisy operation Check valve balls do not seat prop Reduce size diameter of inlet line rela erly cleanly due to imbalance tive to outline line Outlet line size between fluid inlet and outlet line should not exceed pump size sizing Noise is accentuated with light viscosity fluids 14 311879F 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 bo
44. repaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and the buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential 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 six 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 components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warran
45. so AN backer EPDM 112181 PACKING u cup nitrile z 1403 188605 DIAPHRAGM PTFE pr 188607 PLATE air side aluminum 190992 MUPRLER 105 150039 PLATE fluid side SST 620223 CLAMPS sanitary z paa 189044 BOLT M12 x 1 75 35 mm 1 38 in SST These parts are included in the Pump Repair Kit which TAOIS AG z may be purchased separately Refer to the Repair Kit Matrix on 402 112181 PACKING u cup nitrile page 27 to determine the correct kit for your pump 188857 DIAPHRAGM Santo rene A Replacement Danger and Warning labels tags and cards j are available at no cost po 188607 MA a ali side id Seat Parts List Matrix Column 4 1105 15C039 PLATE fluid side SST _ CB Binira Bano lo M12 x 1 75 pan beh ANDTO Gn 35 mm 1 38 in SST 1 15H824 SEAT 316 SST 104319 O RING PTFE 15J280 O RING PTFE ee ea cay diaphragm PTFE includes an 15H824 SEAT 316 SST 15G698 CLAMP TEA KANG 1104 188621 LABEL warning 402 112181 PACKING u cup nitrile 202 15H827 O RING EPDM 4 ae 202 15H827 EB 253626 DIAPHRAGM includes two dia phragms and two pack ings 402 Heavy Duty PTFE Ball Parts List Matrix Column 5 Bist Ret PartNo besoipion Tay aor ne 15H809 PLATE air side aluminum Baa a a Be rower fe These parts are included in the Pump Repair Kit which may be purchased separately Refer to the Repair Kit Matrix on page 27 to determine the correc
46. ssure at 70 psi 0 48 MPa 4 8 bar operating air pressure at 40 psi 0 28 MPa 2 8 bar operating air pressure 00OW gt To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow gpm Ipm and operating air pressure psi MPa bar 1 Locate fluid flow rate along bottom of chart 2 Follow vertical line up to intersection with selected operating air pressure curve Fluid Outlet Pressure psi MPa bar 3 Follow left to scale to read fluid outlet pressure g ba NG an 80 100 120 140 4160 75 151 227 302 378 454 530 605 Fluid Flow MAR gpm Ipm AIR PRESSURES A 120 psi 8 4 bar 0 84 MPa B 100 psi 7 0 bar 0 7 MPa 70 psi 4 8 bar 0 5 MPa 40 psi 2 8 bar 0 3 MPa TI8742A Air Consumption Curves A at 120 psi 0 7 MPa 7 bar operating air pressure 124 124 B at 100 psi 0 7 MPa 7 bar operating air pressure aa C at70psi 0 48 MPa 4 8 bar operating air pressure 0 98 9 6 D at 40 psi 0 28 MPa 2 8 bar operating air pressure 2 0 84 82 T 079 To find Pump Air Consumption SE one ee scfm or m3 min at a specific fluid flow gpm Ipm and me ee operating air pressure psi MPa bar lo 2s 3 1 Locate fluid flow rate along bottom of chart 0 14 9 2 Read vertical line up to intersection with selected ar cr Tr E meer cerca operating air pressure curve 75 151 227 302 378 454 530 605 681 3 Follow left to scale to read air consumption
47. ssurized until pressure is man ually relieved To reduce the risk of serious injury from pressurized fluid or splashing fluid follow this proce dure whenever you are instructed to relieve pressure stop pumping check clean or service any system equipment 1 Shut off the air to the pump 2 Open the dispensing valve if used 3 Open the fluid drain valve to relieve fluid pressure having a container ready to catch the drainage Sanitize the Pump Before First Use It is the user s responsibility to properly sanitize the pump before first use It is up to the user whether this will include disassembling and cleaning individual parts or simply flushing pump with a sanitizing solution As necessary follow the steps under Starting and Adjust ing the Pump below under the Service section on page 16 or under Flushing on page 13 Read the TOXIC FLUID OR FUMES HAZARD warn ings on page 5 Never move or lift a pump under pres sure If dropped the fluid section may rupture Always follow the Pressure Relief Procedure before lifting the pump Starting and Adjusting the Pump 1 Be sure the pump is properly grounded Refer to Grounding on page 4 2 Check connections to be sure they are tight Tighten fluid inlet and outlet connections securely 3 Place the suction tube if used in fluid to be pumped 311879F Operation N If fluid inlet pressure to the pump is more than 25 of outlet working pressure the ball c
48. t kit for your pump 13017 i 1 112092 BALL BALL Santoprene 30 311879F Dimensional Drawing 1040 Dimensional Drawing 1040 16 3in 1 1 2 in Outlet 414 mm 8 5 in Sanitary Flange 216 mm s Air Inlet 1 2 npt f 13 2 in 335 mm 16 2 in 411 mm 10 2 in Pump Mounting 259 mm Hole Pattern H O 7 Four 0 42 in 2 0 in 5 0 in 10 7 mm o mm 127mm 7 7 3 diameter holes Air Exhaust LK 7 4 in 2G 1 1 2 in Inlet ee an PAA es D 188 mm Sanitary Flange muffler included 3 4 npt f kapa 7 4 in a Overall Width 8 2 in 208 mm TI9094A 188 mm 1040 FDA 311879F 31 Technical Data 1040 Technical Data 1040 Maximum fluid working pressure 120 psi 0 8 MPa 8 bar Air pressure operating range 20 120 psi 0 14 0 8 MPa 1 4 8 bar Maximum air consumption 0 0000 eee 50 scfm Air consumption at 70 psi 20 Op Xmas NEA NY Baal 18 scfm see chart Maximum free flow delivery 41 gpm 159 l min Maximum pump speed 0000 e eee eens 256 com Gallons Liters per cycle 0 16 0 57 Maximum suction lift 00 0000 eee eee 29 ft 8 83 m wet 16 ft 4 87 m dry Maximum size pumpable solids 1 8 in 3 2 mm Maximum Noise Level at 100 psi full flow 92 dBa Sound Power Level 0000 eee ee eee 1
49. ty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intentes a la suite de ou en rapport directement ou indirectement avec les procedures concernees Extended Product Warranty Graco warrants all 205 307 515 716 1040 1590 2150 3150 and 3275 air valve center sections to be free from defects in material and workmanship for a period of fifteen years from date installed in service by the original purchaser Normal wear of items such as packings or seals are not considered to be defects in material and workmanship Five years Graco will provide parts and labor Six to Fifteen years Graco will re
50. with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings Check equipment daily Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only Do not alter or modify equipment For professional use only Use equipment only for its intended purpose Call your Graco distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not use hoses to pull equipment Comply with all applicable safety regulations BURN HAZARD af 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 4 311879F 311879F 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 e Read MSDS s to know the specific hazards of the fluids you are using e 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 protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewea
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