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Instructions/Parts List
SaniForce
™
515
Diaphragm Pumps
For use in sanitary applications. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
100 psi (0.7 MPa, 6.9 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 6.9 bar) Maximum Air Input Pressure
3A1973H
EN ti17529a
II 2 GD c llA T4
Models
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . 6
Tighten Clamps Before First Use . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Suction Line . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Outlet Line . . . . . . . . . . . . . . . . . . . . . . . . . 8
Changing the Orientation of the Fluid Inlet and
Outlet Ports . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Exhaust Ventilation . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . 11
Sanitize the Pump Before First Use . . . . . . . . . 11
Starting and Adjusting the Pump . . . . . . . . . . . 11
Pump Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air Valve Lubrication . . . . . . . . . . . . . . . . . . . . . 12
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tightening Connections . . . . . . . . . . . . . . . . . . . 12
Preventive Maintenance Schedule . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ball Check Valve . . . . . . . . . . . . . . . . . . . . . . . . 16
Standard Diaphragms . . . . . . . . . . . . . . . . . . . . 16
Overmolded PTFE Diaphragms . . . . . . . . . . . . 18
Air Center Service . . . . . . . . . . . . . . . . . . . . . . . 19
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fluid Section Repair Kits . . . . . . . . . . . . . . . . . . . 22
Drum-Mount Suction Kit 262828 . . . . . . . . . . . . . . 22
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 24
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2
Models
Model Connections Seats
FD5111
*
Flange
FD6111
*
DIN
FD5113
*
Flange
FD6113
*
FD5122
DIN
Flange
Stainless
Steel
FD6122 DIN
FD5611
*
Flange
FD5613* Flange
FD5622 Flange
FD6622 DIN
*
EC 1935/2004 Compliant
O-Rings
PTFE
EPDM
Balls Diaphragms
PTFE
PTFE
PTFE
2-Piece PTFE
2-Piece PTFE
Overmolded PTFE
PTFE Overmolded PTFE
Santoprene Santoprene
Santoprene Santoprene
PTFE 2-Piece PTFE
PTFE Overmolded PTFE
Santoprene Santoprene
Santoprene Santoprene
3A1973H
3A1973H
Material Certification
Reference: SaniForce Product Family
Issue Date: November 1, 2011
All fluid contact materials in the SaniForce product family are FDA-Compliant and meet the United States
Code of Federal Regulations (CFR) Title 21, Section 177 or are of a corrosion resistant grade Stainless
Steel. This includes the below product groups:
1. SaniForce 515, 1040, 1590, 2150 Air-Operated Double Diaphragm Pumps
2. SaniForce 1590, 3150 HS Air-0perated Double Diaphragm Pumps
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.
Models
3
4
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. 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.
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 all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock .
Do not use equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing 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.
3A1973H
3A1973H
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. 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. For complete information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
• Protective eyewear and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
5
Installation
Installation
General Information
•
The typical installation shown in F IG . 2, page 8, is
only a guide 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.
The pump is heavy and may cause injury if dropped.
Lift the pump by grasping the outlet manifold securely.
If dropped, the pump may rupture. To avoid serious injury from splashing fluid, follow the
Procedure on page 11 before moving the pump.
Y
9a
8
9b
9c ti17654a
F
IG
. 1: Ground the pump
To reduce the risk of serious injury due to burns, insulate the pump before pumping hot fluids.
Tighten 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.
• 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.
Grounding
The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.
• Pump : Attach a ground wire (Y) to the grounding strip (8) with the screw (9a), lockwasher (9b), and
nut (9c), as shown in F IG . 1, and per local code.
Connect the clamp end of the ground wire to a true earth ground. Order Part No. 238909 Ground Wire and Clamp.
6 3A1973H
Installation
Mounting
NOTICE
Pump exhaust air may contain contaminants that can contaminate the fluid supply. Ventilate to a remote area. See Air Exhaust Ventilation
• 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, air inlet, and fluid inlet and outlet ports are easily accessible.
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 1/4 npt(f) pump air inlet. Use a minimum 1/4 in. (6.3 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.
Air Line
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. A bleed-type master air valve (B) is required in the system to relieve air trapped between this valve and the pump.
1.
Install the air line accessories as shown in F IG . 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/filter assembly (C) and gauge to control the fluid pressure. The fluid outlet pressure will be the same as the setting of the air regulator. The air line filter removes harmful dirt and moisture from the compressed air supply.
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.
Fluid Suction Line
1.
Use flexible, grounded fluid hoses (F). The inlet fits sanitary tubing of 1 to 1.5-inch OD or DIN 25.
2.
For best sealing results, use a standard tri-clamp or
DIN style sanitary gasket of a flexible material such as EPDM or Buna-N.
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. Excessive inlet fluid pressure also will shorten diaphragm life. Approximately 3 - 5 psi (0.02 - 0.03 MPa, 0.21-0.34 bar) should be adequate for most materials.
4.
For maximum suction lift (wet and dry), see
Technical Data , page 26. For best results, always install
the pump as close as possible to the material source.
3A1973H 7
8
Installation
Fluid Outlet Line
A fluid drain valve (G) 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 (J).
2.
For best sealing results, use a standard tri-clamp or
DIN style sanitary gasket of a flexible material such as EPDM, Buna-N.
3.
Install a fluid drain valve (G) near the fluid outlet.
See the WARNING
4.
Install a shutoff valve (H) in the fluid outlet line.
E B
Key:
A Air supply line
B Bleed-type master air valve
(required for pump)
C Air regulator/filter assembly
D Air line quick disconnect
E Master air valve (for accessories)
F Flexible fluid suction line
G Fluid drain valve (required)
H Fluid shutoff valve
J Flexible fluid line
Y Ground wire (required; see
instructions).
C
D
A
Y
F IG . 2: Typical Floor-Mount Installation
H
J
G
F ti17652a
3A1973H
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 (12) holding the inlet and/or outlet manifold to the covers.
NOTE: Inspect the o-rings and replace if necessary.
2.
Reverse the manifold and reattach. Install and tighten clamps snugly.
12 ti17529a
F IG . 3: Reverse the Manifolds
3A1973H
Installation
9
Installation
Air Exhaust Ventilation
To avoid serious injury from explosion or hazardous fluids:
• be sure the system is properly ventilated for your type of installation.
• vent the exhaust away from people, animals, food handling areas, and all sources of ignition
• place an appropriate container at the end of the air exhaust line to catch fluid. If a diaphragm ruptures, the fluid being pumped will exhaust with the air.
See F IG . 4.
The air exhaust port is 3/8 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 3/8 in.
(9.5 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)
P Muffler
T Grounded air exhaust hose
U Container for remote air exhaust
E B
A
C
D
T
U
P ti17648a
F IG . 4: Venting Exhaust Air
10 3A1973H
Operation
Operation
Pressure Relief Procedure
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 stop pumping and before cleaning, checking, or servicing 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.
Have a container ready to catch the drainage.
Sanitize the Pump Before First
Use
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 Adjusting the Pump,
at right, under Flushing on page 12, or
Starting and Adjusting the Pump
1.
Be sure the pump is properly grounded. Refer to
2.
Check connections to be sure they are tight. Tighten fluid inlet and outlet connections securely.
3.
Connect suction line (F) to material supply.
NOTE: 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 (J) into an appropriate container.
5.
Close the fluid drain valve (G).
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
To avoid serious injury from splashing fluid, 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.
At the end of the work shift, relieve pressure.
3A1973H 11
Maintenance
Maintenance
Air Valve 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.
NOTICE
Do not over-lubricate the pump. Oil is exhausted through the muffler and could contaminate your fluid supply or other equipment. Excessive lubrication also can cause the pump to malfunction.
Flushing
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.
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.
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.
12 3A1973H
Troubleshooting
Troubleshooting
1.
Follow the Pressure Relief Procedure , page 11.
2.
Check all possible problems and causes before disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump will not cycle, or cycles once and stops.
Pump cycles at stall or fails to hold pressure at stall.
Pump operates erratically.
Air valve is stuck or dirty.
Check valve ball is severely worn and wedged in seat or manifold.
Disassemble and clean air valve.
See page 14. Use filtered air.
Replace ball and seat. See page 16.
Worn check valve balls, seats, or o-rings.
Check valve ball wedged in seat.
Repair or replace. See page 16.
Worn diaphragm shaft seals.
Replace. See page 16 (standard dia-
phragms).
Inspect; clear.
Clogged suction line.
Sticky or leaking check valve balls.
Clean or replace. See page 16.
Diaphragm ruptured.
Replace. See page 16 (standard dia-
phragms) or page 18 (overmolded
diaphragms).
Air bubbles in fluid.
Restricted exhaust.
Suction line is loose.
Diaphragm ruptured.
Remove restriction.
Tighten.
Replace. See page 16 (standard dia-
phragms) or page 18 (overmolded
diaphragms).
Tighten manifold clamps, or replace
seats or o-rings. See page 16.
Fluid in exhaust air.
Loose inlet manifold, damaged seal between manifold and seat, or damaged manifold o-rings.
Loose diaphragm shaft bolt or fluid side diaphragm plates.
Diaphragm ruptured.
Loose diaphragm shaft bolt or fluid side diaphragm plates.
Worn diaphragm shaft seals.
Tighten or replace. See page 16
(standard diaphragms).
Replace. See page 16 (standard dia-
phragms) or page 18 (overmolded
diaphragms).
Tighten. See page 16 (standard dia-
phragms).
Replace. See page 16 (standard dia-
phragms).
Pump exhausts air from clamps.
Loose manifolds, damaged seal between manifold and seat, or damaged manifold o-rings.
Air valve o-ring is damaged.
Tighten manifold clamps, or replace
seats or o-rings. See page 16.
Pump leaks air through the exhaust port.
Inspect; replace. See page 14.
Pump leaks fluid from check valves.
Worn or damaged check valve o-ring. Inspect; replace. See page 16.
No fluid output, and pump cycles rapidly.
Pump mounted incorrectly.
Mount the pump in the upright position.
Worn air valve u-cups.
Inspect; replace. See page 14.
3A1973H 13
Service
Service
Air Valve
NOTE: Air Valve Repair Kit 241657 is available. Parts included in the kit are marked † . Use all parts in the kit.
1.
Follow the Pressure Relief Procedure , page 11.
2.
Remove the air chamber cover (110) and the o-ring
(104).
3.
Remove the carriage plungers (107), carriages
(108), carriage pins (109), and valve plate (114) from the center housing (111).
4.
Remove the u-cups (102) from the carriage plungers (107).
5.
Clean all parts and inspect them for wear or damage.
NOTE: When instructed to lubricate, apply appropriate waterproof sanitary lubricant (such as Graco PN
111265).
6.
Lubricate the lapped surface of the valve plate
(114), and install with the lapped surface facing up.
7.
Lubricate and install the carriage pins (109).
8.
Install the carriages (108). Make sure the carriages engage the clip ends of the carriage pins (109).
9.
Lubricate the bores of the center housing (111), then install the u-cups (102) on the carriage plungers (107), with the u-cups facing toward smaller end.
10. Slide the carriage plungers into the bores, with the smaller ends facing toward the center of the center housing (111).
11. Lubricate and install the o-ring (104) on the cover
(110).
12. Screw the cover (110) into the center housing.
Torque to 80 to 100 in-lb. (9.0 to 13.6 N•m).
Note: The center housing may remain assembled to the air and fluid covers for this service.
4 2 107†
3 2 102†
2 108 † 104†
2
114†
2
110 1
1 Torque to 80-100 in-lb. (9.0-13.6 N•m).
2 Apply appropriate waterproof sanitary lubricant (such as Graco PN 111265).
3
4
Lips must face the smaller end of the carriage plunger.
Smaller ends must face toward the center of the center housing. Lubricate bores of center housing before installing.
F IG . 5. Disassemble/Reassemble the Air Valve
14
111 109† 2 108† 2 ti17557a
3A1973H
Service
2
30
1 12
16
13
31
13
6 1
20 3
21
1
105
1
9a
9b
25 5
16
13
31
13
1 12
34
2
8
9c
4 14
15
23
20 3
3
1 Apply appropriate waterproof sanitary lubricant to the threads and inside of clamp.
2
3
Torque to 80-90 in-lb (9-10 N•m). Do not use rotary power tools.
Air side markings on diaphragm must face housing.
4 Torque to 80-90 in-lb (9-10 N•m) at 100 rpm maximum.
5 Flat side must face toward shaft.
TI17530a
F IG . 6: Disassemble/Reassemble the Pump (tri-clamp model shown)
3A1973H 15
Service
Ball Check Valve
Disassembly
NOTE:
• PTFE o-rings should be replaced every time manifolds are removed.
Standard Diaphragms
NOTE: If your pump uses overmolded PTFE dia-
Disassembly
1.
Relieve the pressure. Disconnect all hoses.
2.
Remove the pump from its mounting.
3.
Remove the clamps (12) holding the outlet manifold
(2) to the fluid covers (1). See F IG . 6.
4.
Remove the o-rings (13), seats (31), and balls (16).
5.
Remove the clamps (12) and the inlet manifold (3).
Remove the o-rings (13), seats (31), and balls (16).
Reassembly
NOTE: When instructed to lubricate, apply appropriate waterproof sanitary lubricant.
1.
Clean all parts and inspect for wear or damage.
Replace parts as needed.
2.
Reassemble in the reverse order, following all notes in F IG . 6, page 15. Be sure the ball checks and manifolds are assembled exactly as shown. The arrows
(A) on the fluid covers (1) must point toward the outlet manifold (2).
1.
Relieve the pressure.
2.
Remove the manifolds and disassemble the ball check valves as explained at left.
3.
Remove the nuts (34) and the grounding strip (8), then remove the clamps (6) holding the fluid covers
(1) to the air covers (21). Pull the fluid covers (1) off the pump. See F IG . 6.
4.
Loosen but do not remove the diaphragm shaft bolts
(14), using a 10 mm socket wrench on both bolts.
5.
Unscrew one bolt from the diaphragm shaft (105) and remove the o-ring (15), fluid side diaphragm plate (23), diaphragm (20), backer (24) used only on
PTFE models, and air side diaphragm plate (25).
6.
Pull the other diaphragm assembly and the diaphragm shaft (105) out of the center housing. Hold the shaft flats with a 19 mm open end wrench, and remove the bolt (14) from the shaft. Disassemble the remaining diaphragm assembly.
7.
Clean all parts and replace o-rings as needed.
16 3A1973H
Service
Reassembly
1.
Install the diaphragm assembly on one end of the shaft (105) as follows: a.
Install the o-ring (15) on the shaft bolt (14). b.
Install the fluid side diaphragm plate (23) on the bolt so the rounded side faces the diaphragm
(20).
c.
Install the diaphragm (20). Make certain the side marked AIR SIDE faces the center housing.
d.
On PTFE models only, install the backer on the bolt. Make certain the side marked AIR SIDE faces the center housing.
e.
Install the air side diaphragm plate (25) so the rounded side faces the diaphragm (20). f.
Screw the bolt into the shaft (105) hand tight.
2.
Grease the length and ends of the diaphragm shaft
(105), and slide it through the housing.
3.
Assemble the other diaphragm assembly to the shaft as explained in step 1.
4.
Hold one shaft bolt (14) with a wrench and torque the other bolt to 80-90 in-lb (9-10 N • m) at 100 rpm maximum .
NOTE: When you install the clamps in Step 5, orient the center housing so the air inlet is approximately 45° above horizontal and the muffler is approximately horizontal.
5.
Position the fluid covers (1) and the center housing so the arrows (A) on the covers face the same direc-
tion. See F IG . 7. Apply appropriate, waterproof sani-
tary lubricant and install the clamps around the fluid and air covers. Install the grounding strip on the clamps, and torque the t-handle nuts to 80-90 in-lb
(9-10 N•m). Do not use rotary power tools.
6.
Reassemble the ball check valves and manifolds as
4 14
15
25
5
105
1
23
20
3
1
6 1 2
1 ti17650a
A
Apply appropriate waterproof sanitary lubricant to the threads and inside of clamp.
2
3
Torque to 80-90 in-lb (9-10 N•m). Do not use rotary power tools..
Air side markings on diaphragm must face housing.
4 Torque to 80-90 in-lb (9-10 N•m) at 100 rpm maximum.
5 Flat side must face toward shaft.
F IG . 7: Standard Diaphragm
3A1973H 17
Service
Overmolded PTFE Diaphragms
NOTE: If your pump uses standard diaphragms, see
Disassembly
20 25
3
6
105
1
1.
Relieve the pressure.
2.
Remove the manifolds and disassemble the ball
check valves as explained on page 16.
3.
Remove the clamps (6) holding the fluid covers (1) to the air covers (21). Pull the fluid covers (1) off the
4.
Once the fluid covers are removed, the diaphragm on the side of the pump which was last pressurized with air will be separated from the center section/air cover. This allows you to grip the diaphragms.
5.
Diaphragms are assembled handtight. To loosen, grip both diaphragms securely around the outer edge and rotate counterclockwise. One diaphragm assembly will come free and the other will remain attached to the shaft. Remove the freed diaphragm
(20) and air side plate (25).
6.
Pull the opposite diaphragm assembly and shaft
(105) out of the center housing. Hold the shaft flats with a 19 mm open end wrench and remove the diaphragm and air side plate from the shaft.
7.
Clean all parts and replace as needed.
1
6 1 2
1 ti17651a
A
Apply appropriate waterproof sanitary lubricant to the threads and inside of clamp.
2 Torque to 80-90 in-lb (9-10 N•m).
3 Flat side must face toward shaft.
F IG . 8: Overmolded PTFE Diaphragm
Reassembly
To reduce the risk of serious injury, including amputation, do not put your fingers or hand between the air cover and the diaphragm.
1.
Assemble the air side plate (25) onto the diaphragm
(20). The wide, radiused side of the plate must face the diaphragm. Screw the assembly (diaphragm and plate) onto the shaft (105) hand tight.
2.
Grease the length and ends of the diaphragm shaft
(105). Insert the shaft/diaphragm assembly into one side of the pump.
3.
Assemble the other diaphragm assembly to the
4.
Push the assembly down on the work surface to raise the diaphragm up and out so the edges can be gripped. Hand tighten the second diaphragm onto the shaft.
18 3A1973H
Service
NOTE: When you install the clamps in Step 5, orient the center housing so the air inlet is approximately 45° above horizontal and the muffler is approximately horizontal.
5.
Position the fluid covers (1) and the center housing so the arrows (A) on the covers face the same direc-
tion. See F IG . 8. Apply appropriate, waterproof sani-
tary lubricant and install the clamps around the fluid and air covers. Install the grounding strip on the clamps, and torque the t-handle nuts to 80-90 in-lb
(9-10 N•m). Do not use rotary power tools.
6.
Reassemble the ball check valves and manifolds as
Air Center Service
Remove air covers for easier replacement of u-cups and to replace the poppet o-ring, if needed. See parts illus-
1.
Follow all disassembly directions for diaphragm ser-
vice. See Standard Diaphragms , page 16, or
Overmolded PTFE Diaphragms , page 18.
2.
Remove the muffler (103).
3.
Use a phillip’s screwdriver to remove 6 screws (22), and remove one air cover (21) and gasket (112).
4.
Remove u-cup (102) and poppet o-ring (101).
5.
Lubricate and install new u-cup (102) and poppet o-ring (101). U-cup lips must face out of center housing.
6.
Reinstall the gasket (112) and air cover (21). Torque screws (22) to 35-45 in-lb (4-5 N•m).
7.
Repeat for other side.
8.
Reinstall the muffler (103).
9.
Follow all reassembly directions for diaphragm ser-
vice. See page 17 for standard diaphragms or page
3A1973H 19
16
13
31
13
12
30
12
16
13
31
13
1
Parts
Parts
20
2
6 1
8 1
110
Tri-Clamp Model
Shown
6
7 1 107
108
1 102
20
TI18040a
3
34
2
8
9a
9b
9c
3
104
108
109
1
114 1
111
1 101
104
113
112
102 1 9
22
5
21
103
105
1
25
10
4 14
15
23
20 3
1 Apply appropriate waterproof sanitary lubricant.
2 Torque to 80-90 in-lb (9-10 N•m). Do not use rotary power tools.
3 Air side markings on diaphragm must face housing.
4
5
Torque to 80-90 in-lb (9-10 N•m) at 100 rpm maximum.
Torque to 35-45 in-lb (4-5 N•m).
6 Lips must face the smaller end of the carriage plunger.
7 Smaller ends must face toward the center of the center housing.
8 Torque to 80-100 in-lb (9-11 N•m).
9 Lips must face out of center housing.
10 Flat side must face toward shaft.
3A1973H
Parts
Ref. Part Description
Qty
.
1
2
278379 COVER, fluid
MANIFOLD, outlet
278378
24U147
Tri-Clamp
DIN
3
278377
24U146
MANIFOLD, inlet
Tri-Clamp
DIN
290045 PLATE, identification, not shown 4
6 262684 CLAMP, vee; includes t-handle nut
(Ref. 34)
191079 STRIP, grounding 8
9 262687 KIT, ground fasteners, stainless steel; includes Refs. 9a, 9b, and
9c
9a ----SCREW, phillips head,
#10-24 x 0.75
9b -----
9c -----
WASHER, #10, flat
NUT, #10-24 x 0.125
12 118598 CLAMP, sanitary, 1.5 in.
13* O-RING
14
110954
16J453
17H255
PTFE
EPDM
Encapsulated FKM
SCREW, 1/4-20 x 1
1
1
1
113747
16H912
15* 110004 O-RING (not used with overmolded diaphragms)
16* BALL
112946
Hex head flange (for standard diaphragms)
Socket head set (for overmolded diaphragms)
108639
Santoprene (FD5122 and
FD5622)
PTFE (FD5111, FD5611,
FD5113, FD5613)
2
2
2
4
17 111183 RIVET, pop, not shown 2
19 262640 AIR MOTOR, see Air Motor Parts 1
20*
-----
-----
DIAPHRAGM
Santoprene (FD5122, FD5162)
2
-----
Overmolded PTFE (FD5113 and FD5163)
PTFE (FD5111 and FD5611)
2
1
1
2
4
8
1
1
21 278380 COVER, air
22 114882 SCREW, phillips, pan head
#12-14 x 7/8
2
12
Ref. Part Description
23 16M908 PLATE, diaphragm, fluid side (not used with overmolded diaphragms)
24* 16H681 DIAPHRAGM, backup (FD5111 and FD5611)
25 PLATE, diaphragm, air side
195025
16M001 For use with overmolded diaphragms
30
188621
198382
LABEL, warning
English
Multilingual
31 262785 KIT, seats, ball check, set of 4
34 -----
For use with standard diaphragms
NUT, t-handle; included with vee clamp (Ref. 6)
Qty
.
2
2
2
1
1
2
Air Motor Parts
Ref.
Part Description
101* 114866 O-RING
102†* 108808 U-CUP
103 112933 MUFFLER
104†* 162942 O-RING; included with exhaust cover (Ref. 113) and air chamber cover (Ref. 110)
105 192601 SHAFT
107† 15Y825 PLUNGER, carriage
108† 192595 CARRIAGE
109† 192596 PIN, carriage
110 262686 COVER, air chamber; includes o-ring (Ref. 104)
111 ----HOUSING, center
112* 192765 GASKET
113 262685 COVER, exhaust; includes o-ring
(Ref. 104)
114† 194269 PLATE, valve
Qty
.
1
1
2
4
1
2
2
1
2
1
1
2
1
* These parts are included the the Fluid Section
Repair Kit, sold separately. See page 22 for the cor-
rect kit for your model.
† These parts are included in Air Valve Repair Kit
241657, sold separately.
Replacement Warning labels, signs, tags, and cards are available at no cost.
----- These parts are not sold separately.
3A1973H 21
Fluid Section Repair Kits
Fluid Section Repair Kits
Fluid Section Repair Kits follow the numbering of your pump model, but use FK instead of FD for the first two digits.
For example, order repair kit FK5111 for pump FD5111 .
Pump Model
FD5111
FD6111
FD5113
FD6113
FD5122
FD6122
FD5611
FD5613
FD5622
FD6622
Repair Kit
FK5111
FK5111
FK5113
FK5113
FK5122
FK5122
FK5611
FK5613
FK5622
FK5622
Drum-Mount Suction Kit 262828
(Use with tri-clamp models only)
Suction Kit 262828 allows the pump to draw fluid from a 55-gallon (200 liter) drum. Includes suction tube, elbow, clamps, and bung adapter. The kit also includes a mounting bracket and mounting hardware so the pump can be mounted near or on the drum.
22 3A1973H
Dimensions
Dimensions
6.4 in.
(163 mm)
10.9 in.
(277 mm)
Tri-Clamp Model
12.7 in.
(323 mm)
10.0 in.
(254 mm)
1.6 in.
(41 mm)
8.4 in.
(213 mm)
Pump Mounting
Hole Pattern
7.0 in.
(178 mm) ti17653a
6.5 in.
(165 mm)
4.3 in.
(109 mm)
7.0 in.
(178 mm)
11.0 in.
(280 mm)
DIN Model
12.7 in.
(323 mm)
10.0 in.
(254 mm)
8.4 in.
(213 mm)
3A1973H
1.6 in.
(41 mm)
7.0 in.
(178 mm) ti22572a
23
Performance Charts
Performance Charts
Fluid Outlet Pressure
Test Conditions: Pump tested in water with inlet submerged.
24
100
(0.7, 7)
80
(0.55, 5.5)
60
(0.41, 4.1)
40
(0.28, 2.8)
20
(0.14, 1.4)
46; 64
CYCLES PER MINUTE standard diaphragms; overmolded diaphragms
91; 128 137; 192 182; 256 228; 319 273; 383 319; 447 364; 511
A
Fluid Pressure Curves
A
at 100 psi (0.7 MPa, 7 bar) air pressure
B
at 70 psi (0.48 MPa, 4.8 bar) air pressure
C
at 40 psi (0.28 MPa, 2.8 bar) air pressure
B
C
2
(7.6)
4
(15.2)
6
(22.7)
8
(30.3)
10
(37.9)
FLUID FLOW—gpm (lpm)
12
(45.4)
14
(53.0)
16
(60.6)
To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (gmp/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 fluid outlet pressure curve.
3.
Follow left to scale to read fluid outlet pressure.
3A1973H
Performance Charts
Air Consumption
Test Conditions: Pump tested in water with inlet submerged.
30
(0.84)
25
(0.70)
CYCLES PER MINUTE standard diaphragms; overmolded diaphragms
46; 64 91; 128 137; 192 182; 256 228; 319 273; 383 319; 447 364; 511
Air Consumption Curves
A
at 100 psi (0.7 MPa, 7 bar) air pressure
B
at 70 psi (0.48 MPa, 4.8 bar) air pressure
C
at 40 psi (0.28 MPa, 2.8 bar) air pressure
A
20
(0.56)
B
15
(0.42)
10
(0.28)
5
(0.14)
C
2
(7.6)
4
(15.2)
6
(22.7)
8
(30.3)
10
(37.9)
FLUID FLOW—gpm (lpm)
12
(45.4)
14
(53.0)
16
(60.6)
To find Pump Air Consumption (scfm or m
3
/min) at a specific fluid flow (gmp/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 air consumption curve.
3.
Follow left to scale to read air consumption.
3A1973H 25
Technical Data
Technical Data
SaniForce 515
Maximum fluid working pressure
Air pressure operating range*
Maximum air consumption
Air consumption at 70 psi/20 gpm
Maximum free-flow delivery
Maximum recommended cycle rate for continuous duty
18 scfm
16 gpm
0.5 m
3
/minute
61 l/min
182 cycles per minute
Maximum size pumpable solids
Maximum viscosity
Environmental temperature range
Minimum fluid temperature
3/32 in.
40°–120°F
40°F
2.4 mm
10,000 cps
4°–49°C
4°C
Maximum fluid operating temperature
(Do not exceed the lowest maximum depending on the diaphragm, ball, and seat used in your pump.)
PTFE
Santoprene®
EPDM
Stainless steel
Maximum suction lift
Dry
100 psi
20-100 psi
28 scfm
220°F
180°F
275°F
250°F
15 ft.
US Metric
0.7 MPa, 7 bar
0.14-0.7 MPa, 1.4-7 bar
0.8 m
3
/minute
104.4°C
(82.2°C)
(135°C)
(121.1°C)
4.6 meters
Wet
25 ft.
7.6 meters
Maximum pump speed
Standard Diaphragms
Overmolded Diaphragms
Fluid flow per cycle*
Standard Diaphragms
Overmolded Diaphragms
0.04 gallons
0.03 gallons
400 cycles per minute
500 cycles per minute
0.14 liters
0.11 liters
Noise (dBa)
Maximum sound pressure
78 dBa @ 70 psi (0.48 MPa, 4.8 bar)
Inlet/Outlet Sizes
Air inlet size
1/4 in. npt(f)
Air exhaust port size
Fluid inlet size
Fluid outlet size
3/8 npt(f)
1 in. sanitary flange or 25 mm DIN
1 in. sanitary flange or 25 mm DIN
26 3A1973H
Technical Data
Materials of Construction**
Wetted materials on all models 316 SST
Wetted material depending on model
Non-wetted external parts
EPDM, PTFE, Santoprene® ( CAUTION: Santoprene® may be used only with non-fatty, non-oily foods or alcohols up to
15%.)
300 series stainless steel, FDA-compliant polypropylene, polyester (labels)
Weight
All models 23 lb.
10 kg
Notes
* Startup pressures and displacement per cycle may vary based on suction condition, discharge head, air pressure, and fluid type.
** All fluid contact materials are FDA-compliant and meet the United States Code of Federal Regulations
(CFR) Title 21 for repeated use in food-processing machinery. The pump user must verify that the construction materials meet their specific application requirements.
Santoprene ® is a registered trademark of the Monsanto Co.
Loctite ® is a registered trademark of the Loctite Corporation.
3A1973H 27
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is 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 twelve months 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 warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com
.
For patent information see www.graco.com/patents .
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original Instructions. This manual contains English. MM 3A1973
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2011, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Rev. H, June 2015
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