Graco E-Flo 4000 Instruction Manual

3A3385B
EN
Operation
E-Flo®4-Ball
Pumps
with Sealed or Open Wet Cup Lowers
Piston pumps for high-volume paint circulation applications.
For professional use only.
See page 3 for model information, including maximum working pressure. See page 4 for approvals.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti27591a
E-Flo 4000 Pump Shown
ti27597a

Related Manuals
23A3385B
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E-Flo 4-Ball Piston Pumps . . . . . . . . . . . . . . . . . 3
Maximum Working Pressure and Pump
Operational Limits . . . . . . . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ground the System . . . . . . . . . . . . . . . . . . . . . . . . . 9
Controls and Indicators . . . . . . . . . . . . . . . . . . . . 10
Variable Frequency Drive (VFD) . . . . . . . . . . . . 10
Local Control Box . . . . . . . . . . . . . . . . . . . . . . . 10
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fill Gear Reducer Reservoir with Oil . . . . . . . . . 11
Flush Before Using Equipment . . . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Relief Procedure . . . . . . . . . . . . . . . . 12
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Motor Speed and Flow Chart . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preventive Maintenance Schedule . . . . . . . . . . 14
Check Gear Reducer Oil Level . . . . . . . . . . . . . 14
Gear Box and Drive Lubrication . . . . . . . . . . . . 14
Clean the Slider Cylinder Collectors . . . . . . . . . 15
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 18
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 18
Related Manuals
Manual Description
311592 E-Flo Installation Manual
3A3386 E-Flo Repair Manual
311595 Pneumatic Back Pressure Regulator
311596 Variable Frequency Drive Instructions
311603 Sensor Circuit Option
333022 Sealed 4-Ball Lowers
3A3452 4-Ball Lowers with Open Wet Cup

Models
3A3385B 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. EP21D0represents electric
power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), 1000 cc
lower with an open wet cup (D), and no stand installed (0). To order replace-
ment parts, see Manual 3A3386.
Maximum Working Pressure and Pump Operational Limits
EPxxGx and EPxxHx: 425 psi (2.93 MPa, 29.3 bar) Maximum Working Pressure
EPxxAx and EPxxDx: 460 psi (3.22 MPa, 32.2 bar) Maximum Working Pressure
EPxxBx and EPxxEx: 330 psi (2.31 MPa, 23.1 bar) Maximum Working Pressure
EPxxCx and EPxxFx: 250 psi (1.75 MPa, 17.5 bar) Maximum Working Pressure
See Performance Charts, page 16, for pressure and flow limits.
EP 2 1 D 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) 0No motor 0No circuit
installed
A1000cc Sealed 0No stand
installed
1230/400V, 5 HP,
ATEX
1Circuit installed B1500cc Sealed 1Stand
installed
2230/460V, 5 HP,
UL/CSA
C2000cc Sealed
3230/400V, 3 HP,
ATEX
D1000cc Open Wet Cup
4230/460V, 3 HP,
UL/CSA
E1500cc Open Wet Cup
F2000cc Open Wet Cup
G750cc Sealed
H750cc Open Wet Cup
ID
ti8912a

Approvals
43A3385B
Approvals
The E-Flo Pump meets requirements of the following approval agencies.
Refer to the individual components for other specific hazardous location listings.
Component Description Approvals
Mechanical
Pump
Motor
ATEX
(for pump Models
EP1XXX and
EP3XXX)
UL/CSA
(for pump Models
EP2XXX and
EP4XXX)
IS Sensor
Circuit
(for pump Models
EPX1XX)
Ex h IIB T3 Gb
Ex de IIC T4 Gb - CESI 05 ATEX 110X
Class I, Div. 1, Group D, Class II, Div. 1, Group F and G, T3B
Hazardous Locations
EEx 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
3A3385B 5
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
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or sol-
vent flowing through the equipment can cause static sparking. 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• 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.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static 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.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-
tric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing 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 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.

Warnings
63A3385B
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 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 Safety Data Sheet (SDS) 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. 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.
MOVING PARTS HAZARD
Moving parts can pinch, cut 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 and disconnect all power sources.
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 Safety Data Sheet (SDS) 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.
BURN HAZARD
Equipment surfaces and fluid that is 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. 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.

Overview
3A3385B 7
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)
ti27597a
FIG. 2. Cutaway Showing Offset Stroke Positions
ti8321a

Overview
83A3385B
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
ti27599a
BC
F
G
J
E
Hazardous AreaNon-Hazardous Area
Hazardous
Area
Entrance
A
DH
K
N
PR
S
T
U
V
W
X
Y
AA
M
Hazardous AreaNon-Hazardous Area
L
ABZAC
AD
AD
M

Ground the System
3A3385B 9
Ground the System
Ground the following equipment:
•Pump: use ground screw (GS) to attach a ground
wire (Z) to the pump. Tighten the screw securely.
Connect the other end of the ground wire to a true
earth ground.
•Variable frequency drive: grounded through proper
connection to power source.
•Local control box: follow your local code.
•Fluid supply container: follow your local code.
•Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place pail on
a non-conductive surface, such as paper, plastic, or
cardboard, which interrupts grounding continuity.
•To maintain grounding continuity when flushing or
relieving pressure: Hold metal part of the spray gun
or valve firmly to the side of a grounded metal pail,
then trigger the gun or open the valve.
The equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric or
static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
FIG. 4. Oil Fill
ti9230a
Z
GS

Controls and Indicators
10 3A3385B
Controls and Indicators
Variable Frequency Drive (VFD)
Use a variable frequency drive (VFD) accessory to pro-
vide motor drive control to the pump. Graco supplies
accessory 240V and 480V VFDs that optimize pump
performance. See manual 311596.
Local Control Box
The local control box contains five controls. See FIG. 5.
Secure/Disable Switch
• Push in to secure.
• Pull out to disable.
Start/Stop Switch
• Set to START to start pump.
• Set to STOP to stop pump.
Alarm Reset Button
Press to clear an alarm.
Local/Remote Switch
• Set to LOCAL to control pump using local control
box.
• Set to REMOTE to control pump from a PC in a
remote location.
Jog Button
Press to enter jog mode.
FIG. 5: Local Control Box
SD
ST
AR
LR
JG
120991 ATEX Control Box
120373 UL/CSA Control Box
TI10719A
SD
ST
AR
LR
JG