Graco WHITE KNIGHT PCA300 User manual

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Copyright © 2021 White Knight Fluid Handling | A Graco company Version 1.0.1 | 3 December 2021 | Page 1
187 E. 670 S., Kamas, UT 84036
435.783.6040 888.796.2476
https://wkfluidhandling.com
Owner’s Manual
PCA300
140 LPM/37 GPM
4.75 BAR/69 PSI

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Cautions and Warnings:......................................................................................................................................4
1.1. Intended Use ..................................................................................................................................................4
Technical Specifications......................................................................................................................................5
2.1. System Components ......................................................................................................................................5
2.2. General Environmental Conditions.................................................................................................................6
2.3. Sealing and Material Compatibility .................................................................................................................6
2.4. Electrical Set up..............................................................................................................................................7
2.5. Power Consumption .......................................................................................................................................8
2.6. Hydraulic Specifications..................................................................................................................................8
2.7. Pump Dimensions........................................................................................................................................ 10
2.8. Controller Dimensions ................................................................................................................................. 11
2.9. Recommended 48 VDC power supply ........................................................................................................ 11
Thermal Management ...................................................................................................................................... 12
3.1. Temperature Monitoring .............................................................................................................................. 12
3.2. Pump Temperature Curves ......................................................................................................................... 12
3.3. Controller Temperature................................................................................................................................ 15
Equipment Installation...................................................................................................................................... 16
4.1. Electrical Equipment Installation.................................................................................................................. 16
4.2. Installation of the Pump............................................................................................................................... 19
Air-Cooling Module........................................................................................................................................... 20
5.1. Overview...................................................................................................................................................... 20
5.2. Installation of Air-Cooling Module................................................................................................................ 20
PCA300 System Operation .............................................................................................................................. 21
6.1. Overview...................................................................................................................................................... 21
6.2. PCA300 Interface Software......................................................................................................................... 21
6.3. PLC Interface............................................................................................................................................... 28
6.4. Command Line Interface ............................................................................................................................. 29
Maintenance..................................................................................................................................................... 33
7.1. Drain in Place .............................................................................................................................................. 33
7.2. Decontamination Process............................................................................................................................ 33
7.3. Rebuild Process........................................................................................................................................... 34
Troubleshooting................................................................................................................................................ 35
8.1. Troubleshooting with software..................................................................................................................... 35
8.2. Troubleshooting with LEDs.......................................................................................................................... 36
Technical Support ............................................................................................................................................ 36

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Appendix...................................................................................................................................................... 36
10.1. Ordering Instructions ............................................................................................................................... 36
10.2. Regulatory Status .................................................................................................................................... 36

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Cautions and Warnings:
1.1. Intended Use
The PCA300 pump system is designed for ultrapure fluid and chemical dispense and transfer in industrial
production machines and equipment. Only qualified personnel shall install the PCA300 system into equipment.
All safety precautions must be followed during the installation and use of the PCA300 system.
Equipment marked with this warning symbol has the following hazards.
ELECTRIC SHOCK HAZARD:
To reduce risk of electric shock.
•Connect only to grounded power source.
•Disconnect power before servicing.
•Wait 60 seconds to allow for capacitor discharge.
•340 VDC,16 amps, 2.3 KW
BURN HAZARD
Heat may transfer to exterior surfaces when pumps operate. To avoid severe burns, do not touch
hot fluid or equipment.
HIGH MAGNETIC FIELD STRENGTH PRESENT
Pump contains several large magnets that might influence pace makers. Keep distance from pace
makers and handle pump components with care.
TOXIC CHEMICALS MAY BE PRESENT
If system has been used to pump chemicals, use the proper personal protective equipment (PPE)
when handling. Reference Safety Data Sheet (SDS) for information specific to your chemicals.
HAZARDOUS CHEMICALS MAY BE PRESENT
If system has been used to pump chemicals, use the proper personal protective equipment (PPE)
when handling. Reference Safety Data Sheet (SDS) for information specific to your chemicals
PRESSURIZED MATERIAL MAY BE PRESENT
Pumps in use contain pressurized materials. Eliminate liquid and air pressure via shut off valves
before pump is serviced or removed from the system.
MOVING PARTS HAZARDS
Pump contains moving parts. Do not open or disassemble pump.

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Technical Specifications
2.1. System Components
Table 1
Item
Component
Characteristics
Values
1
PCA300 Pump
Materials in flow path
PTFE/PFA
Sealing Features
Tongue and Groove
Max Flow
140 LPM
Max Diff.-Pressure
69 PSI
Max Pressure
150 PSI
Max Fluid Temp
90 C
Thermal Protection
110 C (Internal Temperature Sensor)
Housing
ETFE coated Aluminum Water Resistant
(IP66)
Max RPM (230 VAC)
5500 RPM
Noise Level
70 dBA
Cables
ETFE Jacket/PTFE Insulation
2
PCA300 Controller
Voltage/ Max Current
(Controller Power Input)
1X 230 VAC, 50/60 Hz, 16 A
Voltage/Max Current
(48 VDC Input)
48 VDC, 20 A
Interface
(Serial I/O)
RS232 (Use with Service
Software/Command Line)
Interface
(Digital & Analog I/O)
PLC (PLC module not included)
Pump Connections
(Output Power)
Cable 1: Power
Cable 2: Sensors
Thermal Protection
80 C (Internal temperature sensor)
3
Recommended 48 VDC,
750 W Power Supply
Voltage/Max Current
100-240 VAC, 50/60 Hz, 10 A
4
Air Cooling Module
Material
Inlet Pressure
Cooling Medium
Connection
Polypropylene/ FKM
1-3 Bar
Compressed Air
¼ NPT

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2.2. General Environmental Conditions
Table 2
Usage
Indoor Use
Altitude
Up 2000 m
Operating ambient temperature
0-40 °C
Maximum Humidity
80%
AC Mains supply fluctuations
±10% of nominal voltage
Transient overvoltage’s typically present on the mains
supply
Surge immunity according to EN61000-4-5
Pollution degree
2
2.3. Sealing and Material Compatibility
2.3.1. Material Compatibility
All fluid path materials are PTFE or PFA
2.3.2. Sealing Methods
The method for sealing components of the fluid path is with PTFE tongue and groove seals.
2.3.3. Lifting the Pump
The pump should be lifted using the center of the product as shown in image. Where available make use of rolling
cart for transportation. Do not carry pump by liquid connections.

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2.4. Electrical Set up
2.4.1. Block Diagram
•Below is a simple block diagram showing how components connect together. There are 3 items in the figure
below; pump, controller, and 48 VDC power supply.
•Both the 48 VDC power supply and the controller can be powered off of the same AC power.
•Pump can be controlled by PLC inputs or by RS232 connection to a computer interface.

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2.5. Power Consumption
2.6. Hydraulic Specifications
2.6.1. Pump Performance Curves
020 40 60 80 100 120 140
0
250
500
750
1000
1250
1500
1750
2000
2250
2500
Flow Rate [LPM]
Power [Watts]
PCA300 Power Consumption
5500
3500
4000
2500
4500
5000
3000
010 20 30 40 50 60 70 80 90 100 110 120 130 140 150
0
20
40
60
80
0 5 10 15 20 25 30 35
0
1
2
3
4
5
Flow Rate [GPM]
Pressure [PSI]
Flow Rate [LPM]
Pressure [Bar]
PCA300 Performance Curves
5500
3500
4000
2500
4500
5000
3000

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2.6.2. NPSH3
2.6.3. Maximum Allowable Head vs Fluid Temperature
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
020 40 60 80 100 120 140 160
[meters]
[bar]
Flow Rate [LPM]
NPSHR Curves
5000
4000
3000
0
20
40
60
80
100
120
140
160
20 30 40 50 60 70 80 90
PSI
Degrees C
Maximum Static Pressure for Pump Head

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2.7. Pump Dimensions
Pump should be mounted to a solid, non-ferrous, and level surface. Pump can be mounted by fastening the
pump feet with bolts or fasteners. Pump must be mounted in a horizontal configuration. Review section 3 to
determine when a cooling jacket is required.

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2.8. Controller Dimensions
2.8.1. The figure below gives the basic dimensions for the controller.
2.9. Recommended 48 VDC power supply
The PCA300 system requires an external 48VDC power supply with capability of suppling 20 amps.
(Units in mm)

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Thermal Management
3.1. Temperature Monitoring
Temperatures of the Controller and of the Pump are continuously monitored with internal sensors to ensure safety
of user and equipment. If the Controller temperature ever reaches 80 C, the controller will report an alarm and
shut off pump operation. Pump will not restart automatically once the controller has cooled.A warning will be
provided if the controller reaches a temperature of 55 degrees C.
If the pump internal temperature reaches 110 degrees C, the controller will report a warning, but the pump
operation will remain unchanged. The user may clear a warning once the pump temperature has cooled to 105
degrees C without stopping the pump. Once the pump reaches 110 degrees C, the controller will start to throttle
down power to maintain pump temperature from climbing higher. If the pump temperature reaches 120 degrees
C, controller will report an alarm and shut off pump operation. The pump will not restart automatically once
temperature is in acceptable range.
3.2. Pump Temperature Curves
20
30
40
50
60
70
80
90
100
110
120
020 40 60 80 100 120 140
Motor Tempureature (°C)
Flow Rate
(LPM)
Motor Temperature Curves:
Passive Cooling, 30 °C Liquid Temperature
5000
4000
3000
2000
Recommened Operational Limit
Power Throttle Limit

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20
30
40
50
60
70
80
90
100
110
120
020 40 60 80 100 120 140
Motor Tempureature (°C)
Flow Rate (LPM)
Motor Temperature Curves:
Active Cooling, 30 °C Liquid Temperature
5000
4000
3000
2000
Recommended Operational Limit
Power Throttle Limit

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3.2.1. Influence of liquid temperature on Pump temperature.
Motor temperature is affected by the temperature of the liquid being pumped. The motor temperature at any
liquid temperature can be estimated by using information in the graph found in section 3.2.2, the graph below, and
the following equation.
       󰇛
 󰇜
Where
Tmotor = Estimated motor temperature
MotorTemp = Temperature of Motor found in graph located in section 3.2.2.
TLiquid = Temperature of the liquid in ° C at which motor temperature is wished to be estimated.
TG= Temperature Gradient found on graph located below.
TAmbient = Ambient temperature in ° C at which motor temperature is wished to be estimated.
Passive Cooling Temp. Gradiant
TG= 0.72
Active Cooling Temp. Gradiant
TG= 0.43
0
20
40
60
80
100
120
15 25 35 45 55 65 75 85 95
Motor Temperature (°C)
Water Temperature (°C)
Liquid Temperature Vs. Motor Temperature

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3.3. Controller Temperature
20
25
30
35
40
45
50
55
60
65
70
75
020 40 60 80 100 120 140
Controller Temperature
[°C]
Flow Rate [LPM]
Controller Temperature Curves
5000
4000
3000
2000

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Equipment Installation
4.1. Electrical Equipment Installation
4.1.1. Warnings ELECTRIC SHOCK HAZARD:
Hazardous Voltage may be present. To reduce risk of electric shock.
•Connect only to grounded power source.
•Disconnect power before servicing.
•Wait 60 seconds to allow for capacitor discharge.
ELECTRIC SHOCK HAZARD:
•Controller and power supply should be placed in a spill protected environment (such as a
protected electronic cabinet).
•The Controller must be connected to Earth ground.
Since hazardous voltage may be present, always disconnect the electrical power before servicing any of the
connections on the controller or power supply. It is recommended that the controller and the external power
supply be installed inside a cabinet where untrained personnel are prohibited access.
4.1.2. Mechanical Connections
Mount the Controller and 48 VDC power supply to 35 mm din-rail inside the electrical cabinet. Din-rail clips can
be mounted to the bottom of the controller and 48 VDC power supplies. It is recommended that controller and the
48 VDC power supply be mounted near to each other.
4.1.3. Electrical Connections
The PCA300 system requires two power sources to function. The first power source is AC mains directly to the
controller. The second power source is a 48 voltage provided by external power supply. If both power supplies
are powered from the same AC main circuit, it is recommended that the circuit contains an external 20-amp rated
circuit breaker. It is recommended that the circuit-breaker be placed near the equipment. All electrical wiring
insulation shall, at a minimum, be rated for 60 C. Follow the directions below to make the necessary electrical
connections.
1. Ensure din rail clips are mounted to controller and 48 VDC power supply
2. Ensure din rail is properly earth grounded.
3. Mount controller and 48 VDC to din rail.
4. Connect output of 48 VDC power supply to 48 input connector with minimum 12 gauge wire (wire not
supplied with equipment). Ensure wires are wired correctly to plug connector per Table 3.
5. Connect the sensor and power cables from the pump to the Controller. Ensure cables are wired to the
plug connectors correctly per Table 3.
6. Connect PLC connector with desired wiring configuration; ensure cables are wired to the plug connectors
correctly per Table 4 (or if using PCA300 interface software connect RS232 connector.)
7. Connect Controller AC power input connector into the controller and AC power input to the 48 VDC power
supply screw terminals. Ensure cables are wired to the plug connectors correctly per Table 3.
8. Ensure all screw terminals are routinely tightened.

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The controller connections consist of 6 connections shown in image below: (Pin 1 starting on the left.)
TABLE 3
Controller 230 VAC MAINS
Pin 1 →LIVE
Pin 2 →NEUTRAL
Pin 3 →GROUND
Pump Drive
Pin 1 →RED
Pin 2 →WHITE
Pin 3 →BLACK
Pin 4 →DRAIN
Pin 5 →BLUE
Pin 6 →BROWN
EXTERNAL 48 VDC INPUT
Pin 1 →NEGITIVE
Pin 2 →POSITIVE
*Cable for MAINS power source
must contain minimum of 12-
gauge conductors.
*Connectors work best when
conductor insulation is stripped
back 0.25 inches [6 mm].
*Cable from 48 VDC power
supply must contain minimum of
12-gauge conductors.
RS232 Serial Interface
To communicate with the
controller using the software
PCA300 Interface a USB to Serial
Adapter is required. See Section
6.2 for details on the PCA300
Interface. To be sourced
separately
PLC Interface
See TABLE 4
*Wire not provided. 14-30 AWG.
Pump Signal
Pin 1 →ORANGE(A)
Pin 2 →RED(B)
Pin 3 →BLACK (Motor temp)
Pin 4 →BROWN(5V)
Pin 5 →BLUE (Sensor GND)
Pin 6 →GREEN(U)
Pin 7 →WHITE(V)
Pin 8 →YELLOW(W)
Pin 9 →DRAIN

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Copyright © 2021 White Knight Fluid Handling | A Graco company Version 1.0.1 | 3 December 2021 | Page 18
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TABLE 4 PLC Interface Connections
Pinouts
Function
Connection
Conditions
Notes
Pin 1
Reset
Digital Input 1
If Digital Input Reference
Voltage is low then:
•High Signal = True
•Low Signal = False.
If Digital Input Reference
Voltage is high then:
•Low Signal = True
•High Signal = False
Input voltage range for
high signal is 10-30
VDC.
Send Error Reset for 1 second
when an error occurs, then turn off.
If an error occurred that cause the
pump to stop then turn off enable
pump signal before clearing the
error.
Pin 2
Process
Mode
Digital Input 2
Turn on process mode signal
before enabling the pump and the
pump will enter process mode
which does a closed loop control on
the process input relative to the
setpoint input.
Pin 3
Enable
Digital Input 3
Turn on enable signal to operate
pump. If no errors are present then
pump will start operation at
minimum speed. Status signal will
turn on when system starts up.
Pin 4
Digital
Input Ref
Digital Input
Reference
Pin 5
Set Point
Analog Input 1 +
4-20 mA current loop
input. Where signal + is
current input, and signal
–is the return signal.
Input impedance is 400
ohms.
If not in process mode then input
sets the pump speed with 4 mA=
minimum speed and 20 mA =
maximum speed.
When in process mode then input
sets the target value for the process
loop
Pin 6
Analog Input 1 -
Pin 7
Process
Input
Analog Input 2 +
Sensor input for process loop.
Pin 8
Analog Input 2 -
Pin 9
Status
Digital Output 1
Relay style output.
When true relay is
closed to Relay voltage.
When false relay is
open, or no connection.
Relay’s rated for 10-30
VDC and 50ma
Indicates if the pump is being
operated. If the pump has been
enabled and status does not turn on
then an error is present. Clear error
then try again.
Pin 10
Ready
Digital Output 2
When the pump has no errors and
is ready to operate the signal is on.
When the signal is off then an
warning or error is present.
Pin 11
Digital
Output Ref
Digital Output
Common
Pin 12
RPM
Analog Output 1
0-10 VDC analog output
signals. Where 0 VDC =
0% signal and 10 VDC =
100% signal.
When pump is operational then
signal indicates pump speed as a
percentage from min to max speed.
0 VDC = 0 RPM;
10 VDC = 5500 RPM
Pin 13
Process
Output
Analog Output 2
This output echoes out the process
signal input even if process control
is not enabled.
Pin 14
Analog
Output
Reference
Analog Output
Common

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Copyright © 2021 White Knight Fluid Handling | A Graco company Version 1.0.1 | 3 December 2021 | Page 19
187 E. 670 S., Kamas, UT 84036
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4.2. Installation of the Pump
4.2.1. Overview of the Pump
The pump consists of two main parts, the motor and the pump housing. The motor levitates and rotates the
impeller creating a pressure differential between the inlet and the outlet of the pump housing. The pump housing
contains and directs the fluid from the inlet to the outlet.
4.2.1.1. Pump Cables
The motor is controlled by the power cable and the signal cable. When the motor is installed the cables should
maintain a minimum bend radius of 3 inches. Cables can be routed separately or together from the motor to the
controller.
4.2.1.2. Pump Inlet
Pump inlet can be a number of different fitting depending on the ordering instructions. Recommended tube size
for pump inlet is 1 inch. Using smaller tube sizes on the inlet may increase cavitation and reduce flow.
4.2.1.3. Pump Outlet
Pump outlet can be a number of different fittings. Recommended tube sizing for pump outlet is 1 inch. Using
smaller sizes may result in reduced flow.
4.2.1.4. Pump Mounting
Pump should be mounted with four fasteners to a non-ferrous surface. Pump should be installed on a level
horizontal surface. For appropriate cooling, there should be 1” of air flow all around the pump. See section 2.5
for mounting hole dimensions.
4.2.1.5. Operating the Pump Dry
In some cases, a user may want to run the pump dry before running it with fluid in it. It is recommended that when
operating the pump dry that the max pump speed be kept below 3000 RPM.

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Copyright © 2021 White Knight Fluid Handling | A Graco company Version 1.0.1 | 3 December 2021 | Page 20
187 E. 670 S., Kamas, UT 84036
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Air-Cooling Module
5.1. Overview
There are operation applications in which the pump will require additional cooling by external forced air. These
parameters might include pumping higher temperature fluid, recirculation, high pressure applications, etc. To
understand whether the application needs to be cooled with forced air, review section 3 details.
5.2. Installation of Air-Cooling Module
1.
Remove the three fastener cover caps and 5/8-inch
length, 10-32 fasteners from back of pump.
2.
Ensure the two O-rings are seated in their
corresponding grooves on the air-cooling module.
3.
Place air-cooling module on back of pump and
secure with 1.5-inch length 10-32 fasteners.
4.
Replace fastener cover caps over fasteners and
plumb air supply into air-cooling module using ¼
NPT adapter. Apply 15-30 PSI (1- Bar) of air
pressure.