Graco saniforce 1040 Instruction Manual
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Graco saniforce 1040 Instruction Manual

Graco saniforce 1040 Instruction Manual

Diaphragm pumps
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Instructions - Parts List
SaniForce
Diaphragm Pumps
1040, 1590, and 2150 Models
For use in sanitary applications. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
1040 Models
™
TI8924a
1590 Models
Refer to the appropriate Pump Matrix on page 26, 34,
or 42 to determine the model number of your pump.
See page 3 for approval information.
TI8926a
2150 Models
311879ZAC
EN
TI8928a

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  • Page 1 Instructions - Parts List ™ SaniForce Diaphragm Pumps 311879ZAC 1040, 1590, and 2150 Models For use in sanitary applications. For professional use only. Refer to the appropriate Pump Matrix on page 26, 34, Important Safety Instructions or 42 to determine the model number of your pump. Read all warnings and instructions in this See page 3 for approval information.

  • Page 2: Table Of Contents

    Performance Chart - 1040 Models ... . 33 Graco Warranties ......54 Pump and Repair Kit Matrix - 1590 Models .

  • Page 3: Models

    Models Models Model Connections Description Approvals FD1___ Flange FD7___ 1040 AODD Pump *FA1___ Flange *FA7___ II 2 G FD2___ Flange FD8___ 1590 AODD Pump *FA2___ Flange *FA8___ FD3___ Flange FD9___ 2150 AODD Pump *FA3___ Flange *FA9___ 24G743 Flange 2150 AODD Pump for Ram Mounting 24G744 Flange...
  • Page 4 3. SaniForce 1590, 3150 HS 3-A Certified Air-Operated Double Diaphragm Pumps 4. SaniForce 5:1, 6:1 and 12:1 Air-Operated Piston Pumps 5. SaniForce Diaphragm Pump and Piston Pump Drum Unloaders 6. SaniForce Diaphragm Pump and Piston Pump Bin Evacuation Systems Bradley A. Byron Quality Manager Graco Inc. 311879ZAC...

  • Page 5: Warnings

    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. When these symbols appear in the body of this manual, refer back to these Warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
  • Page 6 Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.

  • Page 7: Installation

    Contact your Graco distributor for assistance up or in the event of a short circuit. in planning a system to suit your needs.
  • Page 8 Installation Mountings NOTICE In the step below, do not connect the quick-disconnect The pump exhaust air may contain contaminants. Ven- coupler (D) on the air hose to the mating fitting on the tilate to a remote area if the contaminants could affect pump until you are ready to operate the pump.
  • Page 9 Installation Fluid Outlet Line 1. Use flexible grounded fluid hoses (L). 2. For best sealing results, use a standard tri-clamp or DIN style sanitary gasket of a flexible material such A fluid drain valve (J) is required to relieve pressure in as EPDM, Buna-N, fluoroelastomer, or silicon the hose if it is plugged.
  • Page 10 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.
  • Page 11 Installation Air Exhaust Ventilation To provide a remote exhaust: 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. Install a grounded air exhaust hose (T) and connect fluids, you must vent the exhaust to a safe place, away the muffler (P) to the other end of the hose.

  • Page 12: Operation

    Operation Operation Pressure Relief Procedure 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 The equipment stays pressurized until pressure is fluid inlet and outlet connections securely.

  • Page 13: Maintenance

    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.

  • Page 14: Troubleshooting

    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 12.
  • Page 15 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.

  • Page 16: Service

    Service Service Repairing the Air Valve Reassembly 1. If you replaced the bearings (12, 15), reinstall as Tool Required explained on page 24. Reassemble the fluid sec- tion. • Torque wrench • Torx (T20) screwdriver or 7 mm (9/32 in.) socket 2.
  • Page 17 Service Insert narrow end first Torque to 52-60 in-lb (5.6-6.8 • Grease Install with lips facing narrow end of piston (11) Insert wide end first  4†  10† TI9086A TI9089A  17† Detail Tighten screws until they bottom out on the housing. See detail at right.
  • Page 18 Service Ball Check Valve Repair 1 Arrow (A) must point toward outlet manifold (103) Tools Required Radiused seating surface must face the ball (301). Large chamfer on O.D. must face o-ring. • O-ring pick Disassembly NOTE: • 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.
  • Page 19 Service Standard Diaphragm Repair NOTE: If your pump uses overmolded diaphragms, see page 22. Tools Required 1. Relieve the pressure. • Torque wrench • 15 mm socket wrench 2. Remove the manifolds and disassemble the ball • 19 mm open end wrench check valves as explained on page 18.
  • Page 20 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 F .
  • Page 21 Service 402* Cutaway view, with diaphragms in place 403* 24 104 401* TI8935a 401* 403* 108* TI8934a Lips face out of housing (1). Rounded side faces diaphragm (401). Air side must face center housing (1). Grease. ® Apply medium strength (blue) Loctite equivalent.
  • Page 22 Service Overmolded Diaphragm Repair NOTE: If your pump uses standard diaphragms, see 8. Reach into the center housing (1) with an o-ring pick page 19. and hook the u-cup packings (402), then pull them out of the housing. This can be done with the bear- Tools Required ings (19) in place.
  • Page 23 Service Reassembly To reduce the risk of serious injury, including 104 403* amputation, do not put your fingers or hand between the air cover and the diaphragm. 1. Install the shaft u-cup packings (402*) so the lips face out of the housing (1). Lubricate the packings. See F .
  • Page 24 Service Bearing and Air Gasket Removal bearing so it is flush with the surface of the center housing. Tools Required 3. Reassemble the air valve as explained on page 16. • Torque wrench • 10 mm socket wrench 4. Align the new air cover gasket (22) so the pilot pin •...
  • Page 25 Service Insert bearings tapered end first Press-fit bearings flush with surface of center housing (1) ® Apply medium strength (blue) Loctite or equivalent. Torque to 130-150 in-lb (15-17 N•m) Detail of air valve bearings TI9093A TI9092a . 14 311879ZAC...

  • Page 26: Pump And Repair Kit Matrix - 1040 Models

    Pump and Repair Kit Matrix - 1040 Models Pump and Repair Kit Matrix - 1040 Models SaniForce 1040 FDA-Compliant Sanitary Pumps Repair kits are numbered in the same manner. The first Your Model No. is marked on the pump’s serial plate.

  • Page 27: Available 1040 Configurations

    Pump and Repair Kit Matrix - 1040 Models Available 1040 Configurations Description Pump Repair Connecti Model Air Motor Seats O-rings Balls Diaphragms FD1111 FK1111 Flange 316 SST PTFE PTFE PTFE FD7111 FK1111 316 SST PTFE PTFE PTFE FD1113 FK1113 Flange 316 SST PTFE PTFE...

  • Page 28: Parts - 1040 Models

    Parts - 1040 Models Parts - 1040 Models Detail of Overmolded Diaphragm Tri-Clamp Model 403* Shown   †4  †10 108* 6†  301* 7†   †17 202* 8†  †18 55  1 401* 17†  403* 10†...
  • Page 29 Parts - 1040 Models Parts, 1040 Models, continued Air Motor (Digit 2 of 6 in Pump Model Fluid Section Number) Ref. Part No. Description Digit Ref. Part No. Description 277262 COVER, fluid; SST 15K009 HOUSING, center; SST MANIFOLD, inlet; SST 15K696 COVER, air valve;...
  • Page 30 Parts - 1040 Models Diaphragm (Digit 6 of 6 in Pump Model Number) 289224 Kit, overmolded diaphragm, PTFE; includes Digit Ref. Part No. Description 403 and 104 401* DIAPHRAGM; backer; EPDM 2 402* 112181 PACKING; u-cup; nitrile 402* 112181 PACKING; u-cup; nitrile 403* 253626 DIAPHRAGM;...

  • Page 31: Dimensional Drawing - 1040 Models

    Dimensional Drawing - 1040 Models Dimensional Drawing - 1040 Models Tri-clamp model Pump Mounting Hole Pattern TI9094A 40 mm DIN 16.6 in. 11851 Outlet (422 mm) 8.8 in. (224 mm) DIN model Air Inlet 1/2 npt(f) 13.2 in. (335 mm) 16.2 in.

  • Page 32: Technical Data - 1040 Models

    Technical Data - 1040 Models Technical Data - 1040 Models 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 .

  • Page 33: Performance Chart - 1040 Models

    Performance Chart - 1040 Models Performance Chart - 1040 Models Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) operating air pressure (0.84, 8.4) B at 100 psi (0.7 MPa, 7 bar) operating air pressure C at 70 psi (0.48 MPa, 4.8 bar) operating air pressure (0.7, 7) D at 40 psi (0.28 MPa, 2.8 bar) operating air pressure...

  • Page 34: Pump And Repair Kit Matrix - 1590 Models

    Pump and Repair Kit Matrix - 1590 Models Pump and Repair Kit Matrix - 1590 Models SaniForce 1590 FDA-Compliant Sanitary Pumps Repair kits are numbered in the same manner. The first Your Model No. is marked on the pump’s serial plate. three digits are always FK2.

  • Page 35: Available 1590 Configurations

    Pump and Repair Kit Matrix - 1590 Models Available 1590 Configurations Description Pump Repair Model Connection Air Motor Seats O-rings Balls Diaphragms FD2111 FK2111 Flange 316 SST PTFE PTFE PTFE FD8111 FK2111 316 SST PTFE PTFE PTFE FD2113 FK2113 Flange 316 SST PTFE PTFE...

  • Page 36: Parts - 1590 Models

    Parts - 1590 Models Parts - 1590 Models Tri-Clamp Model Detail of Overmolded Diaphragm Shown  403*  †4 *301  †10 403* *202 108*  †17 6†  7†  8†  †18 55  1 17†  401* 10†...
  • Page 37 Parts - 1590 Models Parts, 1590 Models, continued Air Motor (Digit 2 of 6 in Pump Model Fluid Section Number) Ref. Part No. Description 277263 COVER, fluid; SST Digit Ref. Part No. Description 15K009 HOUSING, center; SST MANIFOLD, inlet; SST 15K696 COVER, air valve;...
  • Page 38 Parts - 1590 Models Diaphragm (Digit 6 of 6 in Pump Model Number) 289225 Kit, overmolded diaphragm, PTFE; includes Digit Ref. Part No. Description 403 and 104 401* DIAPHRAGM; backer; EPDM 2 402* 112181 PACKING; u-cup; nitrile 402* 112181 PACKING; u-cup; nitrile 403* 253627 DIAPHRAGM;...

  • Page 39: Dimensional Drawing - 1590 Models

    Dimensional Drawing - 1590 Models Dimensional Drawing - 1590 Models Tri-clamp model Pump Mounting Hole Pattern TI9095a 19.3 in. 50 mm DIN (490 mm) 11851 Outlet 9.6 in. (244 mm) DIN model Air Inlet 1/2 npt(f) 16.9 in. (429 mm) 20.4 in.

  • Page 40: Technical Data - 1590 Models

    Technical Data - 1590 Models Technical Data - 1590 Models 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 .

  • Page 41: Performance Chart - 1590 Models

    Performance Chart - 1590 Models Performance Chart - 1590 Models Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) operating air pressure (0.96, 9.6) B at 100 psi (0.7 MPa, 7 bar) operating air pressure (0.84, 8.4) C at 70 psi (0.48 MPa, 4.8 bar) operating air pressure D at 40 psi (0.28 MPa, 2.8 bar) operating air pressure...

  • Page 42: Pump And Repair Kit Matrix - 2150 Models

    Pump and Repair Kit Matrix - 2150 Models Pump and Repair Kit Matrix - 2150 Models SaniForce 2150 FDA-Compliant Sanitary Pumps Your Model No. is marked on the pump’s serial plate. Repair kits are numbered in the same manner. The first The first three digits are always either FD3, FD9, FA3, three digits are always FK3.

  • Page 43: Available 2150 Configurations

    Pump and Repair Kit Matrix - 2150 Models Available 2150 Configurations Description Pump Repair Connections Model Air Motor Seats O-rings Balls Diaphragms FD3111 FK3111 Flange 316 SST PTFE PTFE PTFE FD9111 FK3111 316 SST PTFE PTFE PTFE FD3113 FK3113 Flange 316 SST PTFE PTFE PTFE Overmolded...

  • Page 44: Parts - 2150 Models

    Parts - 2150 Models Parts - 2150 Models See page 47 for 2150 models designed for ram mounting. Detail of Overmolded Diaphragm Tri-Clamp Model Shown  403*  †4  †10 6†  *301  †17 7†  108* 8† ...
  • Page 45 Parts - 2150 Models Parts, 2150 Models, continued Air Motor (Digit 2 of 6 in Pump Model Fluid Section Number) Ref. Part No. Description 277264 COVER, fluid; SST Digit Ref. Part No. Description 15K009 HOUSING, center; SST MANIFOLD, inlet; SST 15K696 COVER, air valve;...
  • Page 46 Parts - 2150 Models Diaphragm (Digit 6 of 6 in Pump Model Number Digit Ref. Part No. Description 401* DIAPHRAGM; backer; EPDM 402* 112181 PACKING; u-cup; nitrile 403* 15K313 DIAPHRAGM; PTFE 189298 PLATE, air side; aluminum 189299 PLATE, fluid side; SST 189410 BOLT;...
  • Page 47 Parts - 2150 Models 311879ZAC...

  • Page 48: Parts - 2150 Models For Ram Mounting

    Parts - 2150 Models for Ram Mounting Parts - 2150 Models for Ram Mounting Models 24G743 and 24G744 Detail of Overmolded Diaphragm 403*  †4 †10 *301 6† †17 108* †18 *202 7† 8† 17† 403* 10† *301 *202 * These parts are included in the Pump Repair Kit which may be pur- chased separately.
  • Page 49 Parts - 2150 Models for Ram Mounting 2150 Models 24G743 and 24G744 (for Ram Mounting) 24G855 ADAPTER, for ram plate Ref. Part No. Description 15H826 SEAT; 316 SST 15K009 HOUSING, center; SST 202*‡ 15H831 O-RING; PTFE 15K696 COVER, air valve; SST 301* 112359 BALL;...

  • Page 50: Dimensional Drawing - 2150 Models

    Dimensional Drawing - 2150 Models Dimensional Drawing - 2150 Models Tri-clamp model Pump Mounting Hole Pattern TI9096a 22.1 in. 65 mm DIN (561 mm) 11.0 in. 11851 Outlet (278 mm) DIN model Air Inlet 1/2 npt(f) 21.99 in. (556 mm) 26.0 in.
  • Page 51 Dimensional Drawing - 2150 Models 20.3 in. (516 mm) 10.15 in. Models 24G743 and (258 mm) 3 in. Outlet ™ Sanitary Flange 24G744 (for SaniForce Sanitary Ram) Air Inlet 1/2 npt(f) 27.5 in. (699 mm) Air Exhaust (muffler included) 3/4 npt(f) ti25356 4 in.

  • Page 52: Technical Data - 2150 Models

    Technical Data - 2150 Models Technical Data - 2150 Models 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 .

  • Page 53: Performance Chart - 2150 Models

    Performance Chart - 2150 Models Performance Chart - 2150 Models Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) operating air pressure (0.84, 8.4) B at 100 psi (0.7 MPa, 7 bar) operating air pressure C at 70 psi (0.48 MPa, 4.8 bar) operating air pressure (0.7, 7) D at 40 psi (0.28 MPa, 2.8 bar) operating air pressure...

  • Page 54: Graco Warranties

    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 manual is also suitable for:

Saniforce 2150Saniforce 1590

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