Hitachi FD2 1590 User Manual
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.
311879F
Model 1040
TI8924a
Model 1590
TI8926a
Model 2150
TI8928a
II 2 G
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
2 311879F
Certificate of Conformance
Part Number: All FD1, FD2, FD3 models
Description: FDA-Compliant Diaphragm Pump
Certificate of Conformance
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.
311879F 3
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. 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 component. 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.
4 311879F
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.
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
311879F 5
Installation
Installation
General Information
• 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.
• 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.
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 grasping the outlet manifold securely or use appropriate lifting equipment.
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 equipment.
Read the FIRE AND EXPLOSION HAZARD warnings
on page 4.
• 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.
Y
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.
F
W
IG. 1
"
• Fluid hoses: Use only grounded hoses with a maximum of 500 ft. (150 m) combined hose length to
ensure grounding continuity.
• Air compressor: Follow the manufacturer’s recommendations.
• 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.
6 311879F
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.
• 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.
Installation
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. Connecting the coupler too early can result in unintentional operation of the pump, leading to serious injury from moving
parts, splashing fluid in the eyes or on the skin, and contact with hazardous fluids.
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 mating fitting into the pump air inlet snugly.
Fluid Suction Line
Air Line
A bleed-type master air valve (B) is required in the system to relieve air trapped between this valve and the
pump. Trapped air can cause the pump to cycle unexpectedly, 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 F
2.
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 accessories 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.
IG.
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 inefficient 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).
c. The air line filter (F) removes harmful dirt and
moisture from the compressed air supply.
311879F 7
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. Install the valve close to the
pump fluid outlet. See F
IG. 2.
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 F
IG. 2.
4. Install a shutoff valve (K) in the fluid outlet line.
E
C
F
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)
F
IG. 2 Typical Floor-Mount Installation
B
A
K
D
J
Y
L
G
TI8930a
8 311879F
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.
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
1
3 113
Installation
S
1
Torque to
28-30 in-lb
(3.2-3.7 N•m)
F
IG. 3
N
P
106
R
TI8926a
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 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
F
IG. 4.
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
F
IG. 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
C
E
F
U
P
B
A
T
D
TI8931a
F
IG. 4 Venting Exhaust Air
10 311879F
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. Open the fluid drain valve to relieve fluid pressure,
having a container ready to catch the drainage.
Sanitize the Pump Before First Use
If fluid inlet pressure to the pump is more than
25% of outlet working pressure, the ball check
valves will not close fast enough, resulting in inefficient 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
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 pressure. 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.
At the end of the work shift, relieve pressure.
3. Place the suction tube (if used) in fluid to be
pumped.
311879F 11
Operation
12 311879F
Maintenance
Maintenance
Lubrication
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.
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 regulator to supply low pressure air to the pump. Run the
pump long enough to thoroughly clean the pump and
hoses. Close the air regulator. Remove the suction tube
from the cleaning solution and drain pump. Place suction tube in the fluid to be pumped.
Tightening Connections
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
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 failure.
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 13
Troubleshooting
Troubleshooting
• Relieve the pressure before checking or servicing
the equipment.
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 CAUSE SOLUTION
Pump cycles at stall or fails to hold
pressure at stall.
Pump will not cycle, or cycles once
and stops.
Pump operates erratically. Clogged suction line. Inspect; clear.
Worn check valve balls (301), seats
(201) or o-rings (202).
Air valve is stuck or dirty. Disassemble and clean air valve. See
Check valve ball (301) severely
worn and wedged in seat (201) or
manifold (102 or 103).
Check valve ball (301) is wedged
into seat (201), due to overpressurization.
Dispensing valve clogged. Relieve pressure and clear valve.
• Check all possible problems and causes before disassembling the pump.
Replace. See 18.
page 16. Use filtered air.
Replace ball and seat. See page 18.
Install Pressure Relief Valve
(see page 10).
Sticky or leaking balls (301). Clean or replace. See page 18.
Diaphragm ruptured. Replace. See pages 19-21.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 19-21.
Loose inlet manifold (102), damaged seal between manifold and
seat (201), damaged o-rings (202).
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-
erly/cleanly due to imbalance
between fluid inlet and outlet line
sizing. Noise is accentuated with
light viscosity fluids.
Tighten manifold clamps (113), or
replace seats (201) or o-rings (202).
See page 18.
Reduce size/diameter of inlet line relative to outline line. Outlet line size
should not exceed pump size.
14 311879F
PROBLEM CAUSE SOLUTION
Troubleshooting
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
pipe.
Use flexible hoses at pump inlet and
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 bolt (107). Tighten or replace. See pages 19-21.
Damaged o-ring (108). Replace. See pages 19-21.
Pump exhausts excessive air at
stall.
Worn air valve block (7), o-ring (6),
plate (8), pilot block (18), u-cups
Repair or replace. See page 16.
(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.
Pump leaks fluid externally from
ball check valves.
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.
Loose manifolds (102, 103), damaged seal between manifold and
seat (201), damaged o-rings (202).
Tighten manifold clamps (113), or
replace seats (201) or o-rings (202).
See page 18.
311879F 15
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