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.
Contents Certificate of Conformance . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Service . . . . . . . . . . . . . . . . . . . . . . . . .
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 FDAcompliant and meet CFR Title 21, Section 177. 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 exclamation 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.
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 swallowed. • 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.
Installation Installation General Information Grounding • The typical installations shown in Figs. 2-4 are only guides for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs. 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 detailed grounding instructions for your area and type of equipment.
Installation Mountings CAUTION The pump exhaust air may contain contaminants. Ventilate to a remote area if the contaminants could affect your fluid supply. See Air Exhaust Ventilation on page 10. • Be sure the mounting surface can support the weight of the pump, hoses, and accessories, as well as the stress caused during operation. • For all mountings, be sure the pump is bolted directly to the mounting surface.
Installation Fluid Outlet Line 1. Use flexible grounded fluid hoses (L). A fluid drain valve (J) is required to relieve pressure in the hose if it is plugged. The drain valve reduces the risk of serious injury, including splashing in the eyes or on the skin, or contamination from hazardous fluids when relieving pressure. Install the valve close to the pump fluid outlet. See FIG. 2. E 2.
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.
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 TOXIC FLUID OR FUMES HAZARD warnings on page 5 before operating this pump. Be sure the system is properly ventilated for your type of installation.
Operation Operation Pressure Relief Procedure Read the PRESSURIZED EQUIPMENT HAZARD warnings on page 4. The equipment stays pressurized until pressure is manually relieved. To reduce the risk of serious injury from pressurized fluid or splashing fluid, follow this procedure 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.
Operation 12 311879F
Maintenance Maintenance Lubrication Tightening Connections The air valve is designed to operate unlubricated, however if lubrication is desired, every 500 hours of operation (or monthly) remove the hose from the pump air inlet and add two drops of machine oil to the air inlet. Before each use, check all hoses for wear or damage, and replace as necessary. Check to be sure all connections are tight and leak-free. Preventive Maintenance Schedule CAUTION Do not over-lubricate the pump.
Troubleshooting Troubleshooting To reduce the risk of serious injury, whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11. • Relieve the pressure before checking or servicing the equipment. • Check all possible problems and causes before disassembling the pump. PROBLEM CAUSE SOLUTION Pump cycles at stall or fails to hold pressure at stall. Worn check valve balls (301), seats (201) or o-rings (202). Replace. See 18.
Troubleshooting PROBLEM CAUSE SOLUTION Leak in inlet or outlet sanitary fitting. Loose sanitary clamp. Tighten clamp. Damaged or worn gasket. Replace gasket. Misalignment of inlet/outlet hose or pipe. Use flexible hoses at pump inlet and outlet. Gasket does not seal. Use a standard sanitary gasket of flexible material such as EPDM, Buna-N, fluoroelastomer, or silicon. Diaphragm ruptured. Replace. See pages 19-21. Loose diaphragm shaft bolt (107). Tighten or replace. See pages 19-21.
Service Service Repairing the Air Valve 7. Clean all parts and inspect for wear or damage. Replace as needed. Reassemble. Tool Required • • Torque wrench Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench Needle-nose pliers O-ring pick Lithium base grease • • • Air Valve Repair Kit 255061 is available. Parts included in the kit are marked with a symbol, for example (4†). Use all the parts in the kit for the best results. Reassembly 1.
Service 2 Torque to 52-60 in-lb (5.6-6.8 N•m) 1 Insert narrow end first 3 2 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 FIG. 5 FIG. 7 Detail 1 See detail at right 2 Grease 3 Grease lower face 2 17† 15 16 1 TI9089A 1 Tighten screws until they bottom 5 out on the housing 31 2 †6 3 †7 8† TI9088A 18† 3 5 1 TI9090A FIG. 6 311879F TI9087A FIG.
Service Ball Check Valve Repair 1 Arrow (A) must point toward outlet manifold (103) Tools Required • O-ring pick 2 Radiused seating surface must face the ball (301). Large chamfer on O.D. must face o-ring. Disassembly • • 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 example (202*).
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 Pressure Relief Procedure on page 11. 1. Relieve the pressure. Torque wrench 15 mm socket wrench 19 mm open end wrench O-ring pick Lithium-base grease 2. Remove the manifolds and disassemble the ball check valves as explained on page 18. Disassembly 3.
Service 4. Loosen but do not remove the diaphragm shaft bolts (107), using a 15 mm socket wrench on both bolts. See FIG. 11. d. On PTFE models only, install the backer (401*) on the bolt. Make certain the side marked AIR SIDE faces the center housing (1). 5. 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. e.
Service 19 402* 1 105 2 Cutaway view, with diaphragms in place 107 5 403* 3 6 1 24 104 4 2 401* TI8935a 3 24 4 104 2 401* 3 6 403* 3 105 2 108* 107 5 TI8934a 1 24 4 1 Lips face out of housing (1). 2 Rounded side faces diaphragm (401). 3 Air side must face center housing (1). 4 Grease. 5 Apply medium strength (blue) Loctite® or equivalent. Torque to 60-70 ft-lb (81-95 N•m) at 100 rpm maximum. 6 Backer used on pumps with PTFE diaphragms only. TI8933a FIG.
Service Heavy-Duty Diaphragm Repair If your pump uses standard diaphragms, see page 19. Tools Required • • • • Torque wrench 19 mm open end wrench O-ring pick Lithium-base grease 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 bearings (19) in place. 9. Clean all parts and inspect for wear or damage. Replace parts as needed.
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. B 24 2. Assemble the air side plate (104) onto the diaphragm (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).
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 Do not remove undamaged bearings. To reduce the risk of serious injury, whenever you are instructed to relieve pressure, always follow the Pressure 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.
Service 1 Insert bearings tapered end first 2 Press-fit bearings flush with surface of center housing (1) 3 Apply medium strength (blue) Loctite® or equivalent. 12 1 2 Torque to 130-150 in-lb (15-17 N•m) Detail of air valve bearings TI9093A 1 15 16 1 2 19 1 2 22 M 23 H 25 3 TI9092a FIG.
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 determine the Model No. of your pump from the following matrix, select the six digits which describe your pump, working from left to right. The first three digits are always FD1, designating 1040 SST FDA-compliant pumps. The remaining three digits define the materials of construction.
Repair Kit Matrix - 1040 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 (4†). 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*).
Parts - 1040 Parts - 1040 Detail of Heavy-Duty Diaphragm 403* 110▲ 104 103 3 2 †10 †4 11 113 105 5 108* †17 106 107 6† 7† 201 202* 16 †18 8† 3 301* 104 16 17† 401* 1 12 403* 101 10† 11 22 23 25 15 402* 20 1 24 19 301* 111 201 202* 1 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 27 to determine the correct kit for your pump.
Parts - 1040 Air Motor Parts List (Matrix Column 2) Ref. Part No. Description Qty 1 15K009 HOUSING, center; SST 1 2 15A735 COVER, air valve; SST 1 3 116344 SCREW, mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.
Parts - 1040 Fluid Section Parts List (Matrix Column 3) Diaphragm Parts List (Matrix Column 6) Ref. Part No. Description Qty Digit Ref. 101 277262 COVER, fluid; SST 2 1 401* 102 277265 MANIFOLD, inlet; SST 1 103 277266 MANIFOLD, outlet; SST 1 106 15G698 CLAMP, diaphragm 2 110▲ 188621 LABEL, warning 1 111 15G332 MUFFLER 113 620223 CLAMPS, sanitary Part No.
Dimensional Drawing - 1040 Dimensional Drawing - 1040 IN MM IN MM IN /UTLET 3ANITARY &LANGE !IR )NLET NPT F IN MM IN MM Pump Mounting Hole Pattern IN MM IN MM !IR %XHAUST MUFFLER INCLUDED NPT F IN MM /VERALL 7IDTH IN MM IN MM &OUR IN MM DIAMETER HOLES IN )NLET 3ANITARY &LANGE TI9094A IN MM 1040 FDA 311879F 31
Technical Data - 1040 Technical Data - 1040 Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . . . Air consumption at 70 psi/20 gpm . . . . . . . . . . . . . . . . . . Maximum free-flow delivery . . . . . . . . . . . . . . . . . . . . . . . Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . * Gallons (Liters) per cycle . . . . .
Performance Chart - 1040 Performance Chart - 1040 Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (gpm/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. 120 (0.84, 8.4) 100 (0.7, 7) psi (MPa, bar) at 120 psi (0.
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 determine the Model No. of your pump from the following matrix, select the six digits which describe your pump, working from left to right. The first three digits are always FD2, designating 1590 SST FDA compliant diaphragm pumps. The remaining three digits define the materials of construction.
Repair Kit Matrix - 1590 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 (4†). 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.
Parts - 1590 Parts - 1590 Detail of Heavy-Duty Diaphragm 110▲ 403* 103 104 3 113 2 †4 *301 †10 105 5 106 11 108* 16 †18 *202 107 6† 7† 8† †17 201 104 16 17† 3 401* 1 403* 12 10† 11 22 23 25 101 24 *301 402* 1 15 19 201 20 111 *202 13 113 1 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.
Parts - 1590 Air Motor Parts List (Matrix Column 2) Ref. Part No. Description Qty 1 15K009 HOUSING, center; SST 1 2 15A735 COVER, air valve; SST 1 3 116344 SCREW, mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.
Parts - 1590 Fluid Section Parts List (Matrix Column 3) Diaphragm Parts List (Matrix Column 6) Digit Ref. Part No. Description Qty S 101 277263 COVER, fluid; SST 2 102 277267 MANIFOLD, inlet; SST 1 103 277268 MANIFOLD, outlet; SST 1 402* 106 15G699 CLAMP, diaphragm 2 110▲ 188621 LABEL, warning 1 111 15G332 MUFFLER 1 113 15D475 CLAMP, sanitary 4 Digit Ref. 1 401* Seat Parts List (Matrix Column 4) Digit Ref. Part No.
Dimensional Drawing - 1590 Dimensional Drawing - 1590 IN MM IN MM IN /UTLET 3ANITARY &LANGE !IR )NLET NPT F IN MM IN MM Pump Mounting Hole Pattern IN MM IN MM IN MM !IR %XHAUST MUFFLER INCLUDED NPT F IN MM /VERALL 7IDTH IN MM IN )NLET 3ANITARY &LANGE &OUR IN MM DIAMETER HOLES IN MM TI9095a 1590 FDA 311879F 39
Technical Data - 1590 Technical Data - 1590 Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . . . Air consumption at 70 psi/50 gpm . . . . . . . . . . . . . . . . . . Maximum free-flow delivery . . . . . . . . . . . . . . . . . . . . . . . Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . * Gallons (Liters) per cycle . . . . .
Performance Chart - 1590 Performance Chart - 1590 Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (gpm/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. 140 (0.96, 9.6) 120 (0.84, 8.4) psi (MPa, bar) at 120 psi (0.
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 following 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 diaphragm pumps. The remaining three digits define the materials of construction.
Repair Kit Matrix - 2150 Repair Kit Matrix - 2150 For 2150 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 (4†). 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 FD3.
Parts - 2150 Parts - 2150 Detail of Heavy-Duty Diaphragm 110▲ 403* 104 103 3 2 †4 †10 113 5 11 *301 6† 105 †17 106 16 †18 201 108* *202 7† 8† 3 107 104 16 17† 12 10† 11 401* 1 403* 23 25 15 24 101 1 402* 19 *301 20 22 111 13 201 *202 113 1 Used on PTFE models only. * 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.
Parts - 2150 Air Motor Parts List (Matrix Column 2) Ref. Part No. Description 1 15K009 HOUSING, center; SST 1 2 15A735 COVER, air valve; SST 1 3 116344 SCREW, mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.
Parts - 2150 Fluid Section Parts List (Matrix Column 3) Ref. Part No. Description Qty 101 277264 COVER, fluid; SST 2 102 277269 MANIFOLD, inlet; SST 1 103 277270 MANIFOLD, outlet; SST 1 106 15H513 CLAMP, sanitary, diaphragm 2 110▲ 188621 LABEL, warning 1 111 15G332 MUFFLER 1 113 510490 CLAMP, sanitary 4 Diaphragm Parts List (Matrix Column 6) Digit Ref. 1 401* Seat Parts List (Matrix Column 4) Digit Ref. Part No.
Dimensional Drawing - 2150 Dimensional Drawing - 2150 IN MM IN MM IN /UTLET 3ANITARY &LANGE !IR )NLET NPT F IN MM IN MM Pump Mounting Hole Pattern IN MM IN MM IN MM !IR %XHAUST MUFFLER INCLUDED NPT F IN MM /VERALL 7IDTH IN MM &OUR IN MM DIAMETER HOLES IN )NLET 3ANITARY &LANGE TI9096a IN MM 2150 FDA 311879F 47
Technical Data - 2150 Technical Data - 2150 Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . . . Air consumption at 70 psi/80 gpm . . . . . . . . . . . . . . . . . . Maximum free-flow delivery . . . . . . . . . . . . . . . . . . . . . . . Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . * Gallons (Liters) per cycle . . . . .
Performance Chart - 2150 Performance Chart - 2150 Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (gpm/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. 120 (0.84, 8.4) 100 (0.7, 7) psi (MPa, bar) at 120 psi (0.
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.