Graco FD2 1590 Instructions-Parts List Manual
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Graco FD2 1590 Instructions-Parts List Manual

Graco FD2 1590 Instructions-Parts List Manual

Sanitary series fda-compliant diaphragm pumps
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Instructions - Parts List
Sanitary Series
FDA-Compliant
Diaphragm Pumps
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.
Model 1040
TI8924a
Model 1590
TI8926a
Model 2150
311879F
TI8928a
II 2 G

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Summary of Contents for Graco FD2 1590

  • Page 1 Instructions - Parts List Sanitary Series FDA-Compliant Diaphragm Pumps 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.

  • Page 2: Table Of Contents

    Contents Certificate of Conformance ....3 Warnings ....... . . 4 Installation .

  • Page 3: Certificate Of Conformance

    Certificate of Conformance Bradley A. Byron QMS Management Representative Graco Inc. 311879F 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. Certificate of Conformance...

  • Page 4: 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. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
  • Page 5 TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swal- lowed. • Read MSDS’s to know the specific hazards of the fluids you are using. •...

  • Page 6: Installation

    Installation Installation General Information • 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. • Always use genuine Graco parts and accessories. •...

  • Page 7: Fluid Suction Line

    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.

  • Page 8: Fluid Outlet Line

    Installation Fluid Outlet Line 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.

  • Page 9: Changing The Orientation Of The Fluid Inlet And Outlet Ports

    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 10: Air Exhaust Ventilation

    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 installation. 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.

  • Page 11: Operation

    Operation Pressure Relief Procedure Read the PRESSURIZED EQUIPMENT HAZARD warnings on page 4. The equipment stays pressurized 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: •...
  • Page 12 Operation 311879F...

  • Page 13: Maintenance

    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.

  • Page 14: Troubleshooting

    Troubleshooting Troubleshooting To reduce the risk of serious injury, whenever you are instructed to relieve pressure, always follow the Pres- sure Relief Procedure on page 11. PROBLEM Pump cycles at stall or fails to hold pressure at stall. Pump will not cycle, or cycles once and stops.
  • Page 15 PROBLEM Leak in inlet or outlet sanitary fit- ting. Fluid in exhaust air. Pump exhausts excessive air at stall. Pump leaks air externally. Pump leaks fluid externally from ball check valves. 311879F CAUSE Loose sanitary clamp. Damaged or worn gasket. Misalignment of inlet/outlet hose or pipe.

  • Page 16: Service

    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 Air Valve Repair Kit 255061 is available. Parts included in the kit are marked with a symbol, for example (4†).
  • Page 17 Torque to 52-60 in-lb (5.6-6.8 • See detail at right Grease Grease lower face 311879F Insert narrow end first Grease Install with lips facing narrow end of piston (11) Insert wide end first 4† TI9086A Detail Tighten screws until they bottom out on the housing †6 †7...

  • Page 18: Ball Check Valve Repair

    Service Ball Check Valve Repair Tools Required • O-ring pick 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 exam- ple (202*).

  • Page 19: Standard Diaphragm Repair

    Standard Diaphragm Repair If your pump uses heavy-duty diaphragms, see page 22. Tools Required • Torque wrench • 15 mm socket wrench • 19 mm open end wrench • O-ring pick • Lithium-base grease Disassembly A Fluid Section Repair Kit is available. Refer to page 27, 35, or 43 to order the correct kit for your pump.
  • Page 20 Service 4. Loosen but do not remove the diaphragm shaft bolts (107), using a 15 mm socket wrench on both bolts. See F . 11. 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).
  • Page 21 Cutaway view, with diaphragms in place . 11 311879F 402* 24 104 401* TI8935a TI8933a 403* 401* 403* 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 Heavy-Duty Diaphragm Repair If your pump uses standard diaphragms, see page Tools Required • Torque wrench • 19 mm open end wrench • O-ring pick • Lithium-base grease Disassembly A Fluid Section Repair Kit is available. Refer to page 27, 35, or 43 to order the correct kit for your pump.
  • Page 23 Reassembly 1. Install the shaft u-cup packings (402*) so the lips face out of the housing (1). Lubricate the packings. See F . 13. 2. Assemble the air side plate (104) onto the dia- phragm (403). The wide, radiused side of the plate must face the diaphragm.

  • Page 24: Bearing And Air Gasket Removal

    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 Pres- sure Relief Procedure on page 11.
  • Page 25 Insert bearings tapered end first Press-fit bearings flush with surface of center housing (1) Apply medium strength (blue) Loctite Torque to 130-150 in-lb (15-17 N•m) Detail of air valve bearings . 14 311879F ® or equivalent. TI9092a Service TI9093A...

  • Page 26: Pump Matrix - 1040

    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 follow- ing matrix, select the six digits which describe your pump, working from left to right.

  • Page 27: 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†).

  • Page 28: Parts - 1040

    Parts - 1040 Parts - 1040 †4 †10 6† †17 7† †18 402* 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.

  • Page 29: Air Motor Parts List (Matrix Column 2)

    Air Motor Parts List (Matrix Column 2) Ref. Part No. Description 15K009 HOUSING, center; SST 15A735 COVER, air valve; SST 116344 SCREW, mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.) 4† 188618 GASKET, cover 188855 CARRIAGE; aluminum 6†...
  • Page 30 Parts - 1040 Fluid Section Parts List (Matrix Column 3) Ref. Part No. Description 277262 COVER, fluid; SST 277265 MANIFOLD, inlet; SST 277266 MANIFOLD, outlet; SST 15G698 CLAMP, diaphragm 110▲ 188621 LABEL, warning 15G332 MUFFLER 620223 CLAMPS, sanitary These parts are included in the Pump Repair Kit which may be purchased separately.

  • Page 31: Dimensional Drawing - 1040

    Dimensional Drawing - 1040 Dimensional Drawing - 1040 Pump Mounting Hole Pattern TI9094A 1040 FDA 311879F...

  • Page 32: Technical Data - 1040

    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 .

  • Page 33: Performance Chart - 1040

    Performance Chart - 1040 Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) operating air pressure 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 D at 40 psi (0.28 MPa, 2.8 bar) operating air pressure To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (gpm/lpm) and...

  • Page 34: Pump Matrix - 1590

    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 follow- ing matrix, select the six digits which describe your pump, working from left to right.

  • Page 35: 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†).

  • Page 36: Parts - 1590

    Parts - 1590 Parts - 1590 †4 †10 6† †17 7† †18 402* 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.
  • Page 37 Air Motor Parts List (Matrix Column 2) Ref. Part No. Description 15K009 HOUSING, center; SST 15A735 COVER, air valve; SST 116344 SCREW, mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.) 4† 188618 GASKET, cover; 188855 CARRIAGE; aluminum 6†...
  • Page 38 Parts - 1590 Fluid Section Parts List (Matrix Column 3) Digit Ref. Part No. Description 277263 COVER, fluid; SST 277267 MANIFOLD, inlet; SST 277268 MANIFOLD, outlet; 15G699 CLAMP, diaphragm 110▲ 188621 LABEL, warning 15G332 MUFFLER 15D475 CLAMP, sanitary Seat Parts List (Matrix Column 4) Digit Ref.

  • Page 39: Dimensional Drawing - 1590

    Dimensional Drawing - 1590 1590 FDA 311879F Dimensional Drawing - 1590 Pump Mounting Hole Pattern TI9095a...

  • Page 40: Technical Data - 1590

    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 .

  • Page 41: Performance Chart - 1590

    Performance Chart - 1590 Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) operating air pressure 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 D at 40 psi (0.28 MPa, 2.8 bar) operating air pressure To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (gpm/lpm) and...

  • Page 42: Pump Matrix - 2150

    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.

  • Page 43: 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†).

  • Page 44: Parts - 2150

    Parts - 2150 Parts - 2150 †4 †10 6† †17 †18 17† 402* 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 cor- rect kit for your pump.
  • Page 45 Air Motor Parts List (Matrix Column 2) Ref. Part No. Description 15K009 HOUSING, center; SST 15A735 COVER, air valve; SST 116344 SCREW, mach, hex flange hd; M5 x 0.8; 12 mm (0.47 in.) 4† 188618 GASKET, cover 188855 CARRIAGE; aluminum 6†...
  • Page 46 Parts - 2150 Fluid Section Parts List (Matrix Column 3) Ref. Part No. Description 277264 COVER, fluid; SST 277269 MANIFOLD, inlet; SST 277270 MANIFOLD, outlet; SST 15H513 CLAMP, sanitary, dia- phragm 110▲ 188621 LABEL, warning 15G332 MUFFLER 510490 CLAMP, sanitary Seat Parts List (Matrix Column 4) Digit Ref.

  • Page 47: Dimensional Drawing - 2150

    Dimensional Drawing - 2150 Dimensional Drawing - 2150 Pump Mounting Hole Pattern TI9096a 2150 FDA 311879F...

  • Page 48: Technical Data - 2150

    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 .

  • Page 49: Performance Chart - 2150

    Performance Chart - 2150 Test Conditions: Pump tested in water with inlet submerged Fluid Pressure Curves A at 120 psi (0.7 MPa, 7 bar) operating air pressure 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 D at 40 psi (0.28 MPa, 2.8 bar) operating air pressure To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (gpm/lpm) and...

  • Page 50: 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.

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