Graco E-Flo 4000 Instruction Manual

311593R
EN
Operation
E-Flo®4-Ball
Piston Pumps
Durable, energy efficient piston pumps for high volume paint circulation applications.
For professional use only.
See page 3 for model information, including maximum working pressure. See page 5 for approvals.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti8317c
E-Flo 4000 Pump Shown

Related Manuals
2 311593R
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E-Flo 4-Ball Piston Pumps . . . . . . . . . . . . . . . . . 3
Maximum Working Pressure and
Pump Operational Limits . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ground the System . . . . . . . . . . . . . . . . . . . . . . . . 11
Controls and Indicators . . . . . . . . . . . . . . . . . . . . 12
Variable Frequency Drive (VFD) . . . . . . . . . . . . 12
Local Control Box . . . . . . . . . . . . . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fill gear reducer reservoir with oil . . . . . . . . . . . 13
Fill TSL Reservoirs . . . . . . . . . . . . . . . . . . . . . . 13
Flush before using equipment . . . . . . . . . . . . . . 13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Procedure . . . . . . . . . . . . . . . . 14
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preventive Maintenance Schedule . . . . . . . . . . 16
Check Gear Reducer Oil Level . . . . . . . . . . . . . 16
Gear Box and Drive Lubrication . . . . . . . . . . . . 16
Clean the Slider Cylinder Collectors . . . . . . . . . 16
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Changing the TSL . . . . . . . . . . . . . . . . . . . . . . . 17
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 20
Related Manuals
Manual Description
311592 E-Flo Installation Manual
311594 E-Flo Repair-Parts Manual
311595 Pneumatic Back Pressure Regulator
311596 Variable Frequency Drive Instructions
311603 Sensor Circuit Option
3A0539 High-Flo Lowers

Models
311593R 3
Models
E-Flo 4-Ball Piston Pumps
Check your pump’s identification plate (ID) for the 6-digit part number of your
pump. Use the following matrix to define the construction of your pump, based
on the six digits. For example, Pump Part No. E P 2 1 6 0 represents electric
power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), 2000 cc
MaxLife lower (6), and no stand installed (0). To order replacement parts, see
the Repair-Parts manual 311594.
Maximum Working Pressure and Pump Operational Limits
E-Flo 1500: 425 psi (2.93 MPa, 29.3 bar) Maximum Working Pressure
E-Flo 2000: 460 psi (3.22 MPa, 32.2 bar) Maximum Working Pressure
E-Flo 3000: 330 psi (2.31 MPa, 23.1 bar) Maximum Working Pressure
E-Flo 4000: 250 psi (1.75 MPa, 17.5 bar) Maximum Working Pressure
See Technical Data, page 18, for pressure and flow limits.
ID
ti8912a
EP 2 1 6 0
First Digit Second Digit Third Digit Fourth Digit Fifth Digit Sixth Digit
Power
Source Equipment
Style Motor Sensor Circuit Lower Size Stand Option
E (electric) P (pump) 0 No motor 0 No circuit
installed 1 1000 cc Chrome 0 No stand installed
1 230/400V,5HP,
ATEX 1 Circuit installed 2 1500 cc Chrome 1 Stand installed
2 230/460V,5HP,
UL/CSA 3 2000 cc Chrome
3 230/400V,3HP,
ATEX 41000 cc MaxLife®
4 230/460V,3HP,
UL/CSA 5 1500 cc MaxLife
6 2000 cc MaxLife
7 750 cc Chrome
8 750 cc MaxLife

Models
4 311593R

Approvals
311593R 5
Approvals
The E-Flo Pump meets requirements of the following approval agencies.
Refer to the individual components for other specific hazardous location listings.
Component Part No. Approvals
Mechanical Pump
Motor
ATEX
EP1XXX
EP3XXX
UL/CSA
EP2XXX
EP4XXX
IS Sensor Circuit EPX1XX
Ex h IIB T3 Gb
Ex de IIC T4 - CESI 05 ATEX 110X
Class I, Group D, Class II, Group F and G, Division 1, T3B
Hazardous Locations
Ex ib IIB Ta = 0°C - 50°C - FM 06 ATEX 0025U
Class 1, Div. 1, Group C & D T3 Hazardous Locations
Ex ib IIB Ta = 0°C - 50°C - KTL 13-KB4BO-0088

Warnings
6 311593R
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, 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.
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.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
vapors. To help prevent fire and explosion:
• Clean plastic parts only in a well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment 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
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 forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.

Warnings
311593R 7
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
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 spraying 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.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
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.
• Always wear impervious gloves when spraying or cleaning equipment.
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
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. Wait until equipment/fluid has cooled completely.
WARNING

Overview
8 311593R
Overview
An electric motor (B) provides input to a 75:1 gear
reducer (GR), which drives two fluid pumps (FP). See
FIG. 1. The stroke positions of the two pumps are offset
to achieve consistent flow from the pump assembly. See
FIG. 2.
The optional sensor circuit includes a top dead center
(TDC) sensor which assists software in measuring
motor speed, and a pressure transducer (PT) with circuit
board, which measures fluid pressure at the pump out-
let. The Graco VFD software mimics the effect of a cam-
shaft, constantly adjusting motor speed to keep steady
fluid flow and achieve minimal pressure variation. The
output shaft of the gearbox and the connecting rods
experience the effect of the imaginary camshaft by
speeding up when the pressure drops (pump lower is at
a changeover) and slowing down when pressure
increases (both lowers are pumping).
The VFD can be controlled by a local control box
mounted in the hazardous area, via communication pro-
tocol (such as modbus), or directly from the keypad.
FIG. 3 shows a layout of a typical North American sys-
tem. The pump (A) may be controlled by a local control
box (C) mounted in the hazardous area, a variable fre-
quency drive (D) mounted in the non-hazardous area, or
remotely from a computer (Y). See manual 311592 for
pump and accessory installation information.
FIG. 1. E-Flo Electric Circulation Pump
B
GR
PT
FP
FP
TDC (behind
cover)
ti8317c
FIG. 2. Cutaway Showing Offset Stroke Positions
ti8321a

Overview
311593R 9
Key:
AE-Flo Electric Circulation Pump
B* Explosion-Proof Electric Motor
C* Local Control Box
D* Variable Frequency Drive (VFD)
E** System Power Disconnect Switch
F* Electrical Noise Filter
G* Power Module
H* VFD/BPR Pneumatic Control Kit
J** Electric Power Cable, VFD to Electric Motor
K** Electric Control Cable, Local Control Box to VFD
L** Explosion-Proof Seal Fittings
M** Electric IS Control Cable, Power Module to Pump Sensor
Circuit
N** Electric Cable, VFD to 3-Way Solenoid Valve (2 meters
provided by Graco)
P* Pump Stand
R** Fluid Inlet Line
S** Fluid Outlet Line
T** Fluid Return Line
U* Pneumatic Back Pressure Regulator
V** Air Supply Lines to 3-Way Solenoid Valve
W** Air Line, Solenoid Valve to Back Pressure Regulator
X** Ethernet Cable, VFD to Computer
Y** Personal Computer
Z** Pump Ground Wire
AA* Explosion-Proof Electric Agitator
AB** Pressure Relief
AC* Fluid Filters
AD* Fluid Line Isolation Valves
*Option available from Graco.
** Supplied by integrator.
FIG. 3: Typical Installation
ti8651c
BC
F
G
J
E
Hazardous AreaNon-Hazardous Area
Hazardous
Area
Entrance
A
DH
K
N
PR
S
T
U
V
W
X
YAA
M
Hazardous AreaNon-Hazardous Area
L
ABZ AC
AD
AD
M

Overview
10 311593R