Graco FD2 1590 Operation manual

311879F
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 1590 TI8926a
TI8924a
TI8928a
Model 2150
Model 1040
II 2 G

2311879F
Contents
Certificate of Conformance . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump Matrix - 1040 . . . . . . . . . . . . . . . . . . . . . . . . 26
Available Configurations . . . . . . . . . . . . . . . . . . 26
Repair Kit Matrix - 1040 . . . . . . . . . . . . . . . . . . . . . 27
Available Configurations . . . . . . . . . . . . . . . . . . 27
Parts - 1040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dimensional Drawing - 1040 . . . . . . . . . . . . . . . . . 31
Technical Data - 1040 . . . . . . . . . . . . . . . . . . . . . . 32
Performance Chart - 1040 . . . . . . . . . . . . . . . . . . . 33
Pump Matrix - 1590 . . . . . . . . . . . . . . . . . . . . . . . . 34
Available Configurations . . . . . . . . . . . . . . . . . . 34
Repair Kit Matrix - 1590 . . . . . . . . . . . . . . . . . . . . . 35
Available Configurations . . . . . . . . . . . . . . . . . . 35
Parts - 1590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensional Drawing - 1590 . . . . . . . . . . . . . . . . . 39
Technical Data - 1590 . . . . . . . . . . . . . . . . . . . . . . . 40
Performance Chart - 1590 . . . . . . . . . . . . . . . . . . . 41
Pump Matrix - 2150 . . . . . . . . . . . . . . . . . . . . . . . . 42
Available Configurations . . . . . . . . . . . . . . . . . . 42
Repair Kit Matrix - 2150 . . . . . . . . . . . . . . . . . . . . . 43
Available Configurations . . . . . . . . . . . . . . . . . . 43
Parts - 2150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Dimensional Drawing - 2150 . . . . . . . . . . . . . . . . . 47
Technical Data - 2150 . . . . . . . . . . . . . . . . . . . . . . . 48
Performance Chart - 2150 . . . . . . . . . . . . . . . . . . . 49
Graco Warranties . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 50

Certificate of Conformance
311879F 3
Certificate of Conformance
Part Number: All FD1, FD2, FD3 models
Description: FDA-Compliant Diaphragm Pump
Materials of
Construction: All fluid contacted materials are FDA-
compliant and meet CFR Title 21,
Section 177.
Bradley A. Byron
QMS Management Representative
Graco Inc.

Warnings
4311879F
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
Warning
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To 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.
• Follow Pressure Relief Procedure in this manual, when you stop operating and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• 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 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
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.

Warning
311879F 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.
• 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:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
Warning

Installation
6311879F
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.
• 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.
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 detailed
grounding instructions for your area and type of equip-
ment.
•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 mm²) 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
•Fluid hoses: Use only grounded hoses with a maxi-
mum of 500 ft. (150 m) combined hose length to
ensure grounding continuity.
•Air compressor: Follow the manufacturer’s recom-
mendations.
•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.
•Fluid supply container: Follow the local code.
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.
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).
Read the FIRE AND EXPLOSION HAZARD warnings
on page 4.
"
Y
W

Installation
311879F 7
Mountings
• 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.
• 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.
Air Line
1. Install the air line accessories as shown in FIG. 2.
Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the accesso-
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.
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.
Fluid Suction 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
EPDM, Buna-N, fluoroelastomer, or silicon.
3. If the fluid inlet pressure to the pump is more than
25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in ineffi-
cient pump operation.
4. At inlet fluid pressures greater than 15 psi (0.1 MPa,
1 bar), diaphragm life will be shortened.
5. See the Technical Data on pages 32, 40, and 48 for
maximum suction lift (wet and dry).
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.
A bleed-type master air valve (B) is required in the sys-
tem to relieve air trapped between this valve and the
pump. Trapped air can cause the pump to cycle unex-
pectedly, which could result in serious injury, including
splashing in the eyes or on the skin, injury from moving
parts, or contamination from hazardous fluids. See FIG.
2.
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.

Installation
8311879F
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
EPDM, Buna-N, fluoroelastomer, or silicon
3. Install a fluid drain valve (J) near the fluid outlet. See
the WARNING above, and FIG. 2.
4. Install a shutoff valve (K) in the fluid outlet line.
FIG. 2 Typical Floor-Mount Installation
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.
TI8930a
Key:
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Flexible fluid suction line
J Fluid drain valve (required)
K Fluid shutoff valve
L Flexible fluid line
Y Ground wire (required; see page
6 for installation instructions)
E
F
CB
A
K
L
J
G
Y
D

Installation
311879F 9
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.
FIG. 3
Key:
N 1/2 npt(f) air inlet port
P Muffler (air exhaust
port is 3/4 npt(f)
R Fluid inlet port
S Fluid outlet port
113 Manifold clamps
3 Air valve screws
Torque to
28-30 in-lb
(3.2-3.7 N•m)
1
1
N
3 113 S
R
P
106 TI8926a

Installation
10 311879F
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.
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.
FIG. 4 Venting Exhaust Air
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.
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:
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
PMuffler
T Grounded air exhaust hose
U Container for remote air exhaust
P
U
TD
A
B
C
F
E
TI8931a