Graco B52100 Parts list manual

Instruction - Parts
C
Solar Control Box
For accurately metering and injecting chemicals at well sites. For professional use only.
See page 3 for model information.
Important Safety Instructions
Read all warnings and instructions in this manual
and other related manuals on page 2 before using
the equipment. Save these instructions.
3A5083C
EN

23A5083C
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 2
Single Plastic Battery Box Configuration Number
Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Single Metal Battery Box Solar Configurations . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring and Fuse Diagram . . . . . . . . . . . . . . . . . . 8
Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . 9
Before Installing . . . . . . . . . . . . . . . . . . . . . . . . . 9
Attach Metal Box to Pole (Optional) . . . . . . . . . . 9
Solar Panel Installation . . . . . . . . . . . . . . . . . . . . 9
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . 10
Battery Installation . . . . . . . . . . . . . . . . . . . . . . 10
Controller Installation and Operation . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . 11
Solar Panel and Charge Controller Maintenance 11
Replacing the Fuses . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Plastic Control Box . . . . . . . . . . . . . . . . . . . . . . 13
Single Metal Battery Box and Solar Panel Kit . . 13
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . 14
Technical Specifications . . . . . . . . . . . . . . . . . . . . 15
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 16
Related Manuals
Manual No. Description
334513 Wolverine™Chemical Injection Pump
3A5028 G-Chem™Chemical Injection Pump
3A4700 Harrier®EZ Chemical Injection Controller
3A8109 G-JR Chemical Injection Pump
334993 Harrier®EZ-JR Chemical Injection Controller
3A5131 Mongoose Chemical Metering Pump
3A5025 Stand Kits
-- Charge Controller manual (provided by manufacturer)
-- Solar Panel manual (provided by manufacturer)

Single Plastic Battery Box Configuration Number Matrix
3A5083C 3
Single Plastic Battery Box Configuration Number
Matrix
Check the identification plate (ID) for the 12-digit Configuration Number of your box. Use the following matrix to
define the components of your box.
NOTE: Not all possible configurations are available.
Sample Configuration Number: CI-P12-1111-00
Single Metal Battery Box Solar Configurations
CI P12 111100
Chemical
Injection Box Box Style Voltage SolarCharge Controller Pump Controller Number of Batteries Number of Solar Panels Option #1 Option #2
Box Style Voltage Solar Charge
Controller Pump Controller Numberof Batteries Number of Solar Panels Option #1 Option #2
P Single Plas-
tic Batter Box 12 12 VDC 1 ASC 12/12 0 None 1 1 1 1 0 None 0 None
8 ASC 12/8 1 Harrier EZ
Part
Number Voltage G-Jr Pump Solar System 50 W Solar Panel
25T652 12 VDC 
25T653 12 VDC 
25T564 12 VDC 
25T620 12 VDC 

Warnings
43A5083C
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 symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area be aware that flammable fumes can ignite or
explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Ground all equipment in the work area.
• Keep work area free of debris, including rags and spilled or open containers of solvent.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Use only grounded hoses.
•Stop operation immediatelyifstaticsparking occursoryou feela shock.Donotuse equipmentuntil
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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 com-
ponent. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-
tions in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete infor-
mation about your material, request Safety Data Sheet (SDS) from distributor or retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Checkequipment regularly.Repairorreplacewornor damaged parts immediately with genuine man-
ufacturer’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.
BATTERY HAZARD
Lead-acid batteries produce explosive gases and contain sulfuric acid that can cause severe burns. To
avoid sparks and injury when handling or working with a lead-acid battery:
• Read and follow the battery manufacturer’s warnings.
• Exercise caution when working with metallic tools or conductors to prevent short circuits and sparks.
• Keep all sparks, flames, and cigarettes away from batteries.
• If you have direct contact with battery fluid, flush with water and consult a physician immediately.
• Installation and maintenance must be performed by knowledgeable personnel only.

Warnings
3A5083C 5
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. 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.

Installation
63A5083C
Installation
Grounding
Plastic Box: Contains ground lug (see Parts on page
13). Connect box to earth ground. You can connect to
earth ground through motor wires. See Pump Installa-
tion on page 10.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.

Installation
3A5083C 7
Typical Installation
FIG. 1 is an example of solar system installation with a
chemical injection system. Your installation may differ
from what is shown here.
Components Supplied by Graco
The following components, see FIG. 1, are supplied by
Graco with the Modular System DC control box:
Additional Modular System Components
The following components, see FIG. 1, are available
from Graco or supplied by the customer:
FIG. 1 Chemical Injection System Layout
AB
C
D
P
E
F
G
H
J
M
N
N
L
K
BControl Box (batteries provided by customer)
APump (includes Inlet (K) and Outlet (L) ports)
CSolar Panel
DStand Unit
ETank
FPressure Relief Valve
GInlet Line
HOutlet Line
JPressure Relief Line
KInlet Port
LOutlet Port
MManifold Assembly [includes y-strainer and fluid
shutoff valve (N)]
NFluid Shutoff Valve (inlet & outlet)
PConduit from Control Box to the Pump
-- Power Cable from Solar Panel to Control Box
(not shown)

Installation
83A5083C
Wiring and Fuse Diagram
The following wiring diagram shows the locations of the fuses (F1, F2, and F3) used with the Harrier EZ and EZ-JR
controllers. See Fuse Ratings on page 11 for fuse identification and current ratings.
NOTE: The F3 fuses are only on the cables leading to the positive terminals of the batteries.
Incorrect wiring to the charge controller or battery
may result in an electrical or fire risk, and can damage
the equipment.
FIG. 2 Wiring and Fuse Diagram
MC4 Connections to
Solar Array Motor Connections
5
4RVoltage Input from posi-
tive (+) battery terminal to
positive (+) BATT terminal
on charge control (5).
(Red)
SVoltage Input from posi-
tive (+) BATT terminal on
charge control (5) to Har-
rier EZ (4). (Red)
TGround wire from Harrier
EZ (4) to negative (-) BATT
terminal on charge control
(5). (Black)
UGround wire from negative
(-) BATT terminal on
charge control to negative
(-) battery terminal. (Black)
VPump wire (-) from Harrier
EZ (4) to negative (-) motor
connection. (Green)
WPump wire (+) from Harrier
EZ (4) to positive motor
connection. (White)
XArray wire from positive (+)
ARRAYterminalon charge
control (5) to solar array.
(Black)
YArray wire from negative
(-) ARRAY terminal on
charge control (5) to solar
array. (Black)
R
S
T
U
V
W
XY

Setup and Operation
3A5083C 9
Setup and Operation
Before Installing
Place box on the ground before installing battery. Do not
move box with a battery installed.
Attach Metal Box to Pole
(Optional)
1. Set the control box (B) on the base of the stand unit.
2. Using two U-bolts (B1), and their corresponding
mounting plates (B2) and nuts (B3), loosely attach
the control box (B) to the pole (S). See FIG. 3.
NOTE: It is recommended that the control box (B) be
mounted facing the opposite direction as the solar panel
(C), and that the control box (B) be mounted before the
battery is placed inside.
3. Slide the control box (B) up the to the desired height
and tighten the nuts (B3) so that the control box is
securely attached to the stand unit (S).
Solar Panel Installation
Refer to Stand Kits manual for panel installation. (See
Related Manuals on page 2.)
Connect the solar panel cable to the MC4 connectors
extending from the grommet at the back of the control
box, ensuring the positive and negative leads are con-
nected as labeled. See FIG. 2.
Incorrect wiring to the charge controller or battery
may result in an electrical or fire risk, and can damage
the equipment.
LIFTING HAZARD
The battery is heavy. To avoid injury or possible dam-
age to equipment, remove battery before handling the
control box.
FIG. 3 Control Box Attachment
B
B1
B2
B3
S
Incorrect wiring to the charge controller or battery
may result in an electrical or fire risk, and can damage
the equipment.
• Donot reversepositive(+)andnegative(-)battery
or array connections on the charge controller.
• Do not reverse positive (+) and negative (-) con-
nections on the battery.
• Do not use a jumperacross array negative (-)and
battery negative (-) terminals.

Setup and Operation
10 3A5083C
Pump Installation
Refer to your pump manual for pump installation. (See
Related Manuals on page 2.)
Verify that the fuses are removed before attaching pump
wires. See Wiring and Fuse Diagram on page 8.
Crimp included connectors on positive and negative
pump leads. Plug into controller wires as shown in FIG.
2.
Battery Installation
NOTE: Batteries are provided by customer. See Tech-
nical Specifications on page 15 for recommended bat-
tery size.
1. Ensure all fuses are removed. See Wiring and
Fuse Diagram on page 8.
2. Leave the battery terminal covers installed, if
included from the battery manufacturer, until the
battery is in place and ready to be wired.
3. Carefully lift the battery up and into the control box.
4. Connect the red battery cable from charge controller
Batt + to the positive battery terminal, and the black
battery cable from charge controller Batt - to the
negative battery terminal.
Controller Installation and
Operation
Refer to your controller manual for controller installation
and operation. (See Related Manuals on page 2.)
To reduce the risk of fire and explosion, keep battery
terminal covers in place at all times, except for when
necessary during battery maintenance.
Unexpected activation could occur when power is
applied to the controller. Power to the controller
comes from the battery and solar panel. To reduce
the risk of serious injury, including skin injection, do
not wire the battery or solar panel until all fluid lines
are connected.
Battery acid could leak out if the system tips over. To
reduce the risk of injury, handle the system with care
and wear appropriate Personal Protective Equipment.