Graco E-Flo DCi User manual

3A7828B
EN
Instructions
E-Flo® DCi Sealed
4-Ball Pumps
Electric drive piston pumps for high volume paint circulation applications. For professional
use only.
See page 3 for model description and page 37 for
maximum working pressure.
Important Safety Instructions
Read all warnings and instructions in this
manual and in the Related Manuals
before using the equipment. Save all
instructions.

2 3A7828B
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hazardous Location Cabling and Conduit
Requirements . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Requirements . . . . . . . . . . . . . . . . . . . . . . 7
Location Requirements . . . . . . . . . . . . . . . . . . . . 7
Mount the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 7
Required System Accessories . . . . . . . . . . . . . . . 8
Required Fluid Line Accessories . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connect Supply Wiring . . . . . . . . . . . . . . . . . . . . 9
Install the Fill Cap. . . . . . . . . . . . . . . . . . . . . . . . 10
Flush Before Using the Equipment . . . . . . . . . . 10
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 11
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preventive Maintenance Schedule. . . . . . . . . . . 12
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . 12
Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . 12
Add Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Prepare Equipment for Service . . . . . . . . . . . . . 15
Disconnect the Pump Lower . . . . . . . . . . . . . . . 15
Reconnect the Lower and Motor . . . . . . . . . . . . 15
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 28
Mounting Hole Patterns . . . . . . . . . . . . . . . . . . . . . 35
Mounting Bracket Pattern . . . . . . . . . . . . . . . . . 35
Floor Stand Mounting Pattern . . . . . . . . . . . . . . 36
Technical Specifications . . . . . . . . . . . . . . . . . . . . 37
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 39
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 40
Related Manuals
Manual
No. Description Referenced Equipment
3A8352 E-Flo® DCi Motor
In s ta l la t io n and
Ope rati on Manual
Motor ★
333022 Sealed 4-Ball Lowers,
Repair/Parts Manual
Lower ★
3A5348 Sealed 4-Ball Plus Lowers,
Repair/Parts Manual
311619 Pump Mounting Kits
Instructions
Pump Mount
★ Find your specific motor and lower model in the
Pump Matrix on page 17.

Models
3A7828B 3
Models
The part number for your equipment is printed on the equipment identification label. The pump part number
consists of six alphanumeric digits which are based on pump configuration as shown in the following table. The full
pump model numbers and associated motor and lower model numbers are listed in the Pump Matrix on page 17.
For motor and lower repair manuals, see Related Manuals on page 2.
Approvals
First Digit Second Digit Third and Fourth
Digit Fifth Digit Sixth Digit
Intelligent Motor Controls, Motor Type,
and Motor Agency Approvals ‡
Motor Horsepower
and Lower
Displacement
Lower Type Mounting Type
Y:
Intelligent
B: Basic, three phase
ATEX, IECEx, SGS, UKEx
D: Basic, three phase
ATEX, IECEx, JPEx, KCs Ex,
CCC-Ex
31: 1 HP, 750 cc
21: 1 HP, 1000 cc
58: 2 HP, 750 cc
40: 2 HP, 1000 cc
30: 2 HP, 1500 cc
90: 3 HP, 750 cc
62: 3 HP, 1000 cc
45: 3 HP, 1500 cc
35: 3 HP, 2000 cc
28: 3 HP, 2500 cc
53: 5 HP, 2500 cc
44: 5 HP, 3000 cc
33: 5 HP, 4000 cc
4: Sealed Ultralife
7: Sealed Ultralife with
Surge Tank
8: Sealed with Chrome
9: Sealed Ultralife with
SiNi Check Ball
0: No mount
1: Stand
2: Wall Bracket
‡ Motor approvals are listed in the E-Flo DCi motor manual. See Related Manuals, page 2.
Pump
Model Pump Approvals
YBxxxx
YDxxxx

Warnings
4 3A7828B
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 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.
DANGER
SEVERE ELECTRIC SHOCK HAZARD
This equipment is powered by more than 240V. Contact with this voltage will cause death or serious
injury.
• Turn off and disconnect all incoming power before disconnecting any cables and before servicing
equipment.
• This equipment must be grounded. Connect only to a grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent 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.
• 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.
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
3A7828B 5
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer's warnings. For
complete information about your material, request Safety Data Sheets (SDSs) 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.
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 Sheets (SDSs) 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.
WARNING

Typical Installation
6 3A7828B
Typical Installation
The system accessories shown in FIG. 1 are not included. Contact your Graco distributor to design a complete
system.
Key:
A Electrical disconnect
B Fluid drain valve
C Fluid shutoff valve
D Fluid line
E Start/stop switch
F Ground wire connection
G Static ground wire
H Explosion proof conduit seal
I Pressure gauge
FIG. 1 Typical Installation
2
A
B
Non-Hazardous
Location
Hazardous
Location
C
D
D
E
Rear View
F
H
Explosion proof conduit seal required
within 457 mm (18 in.) of the motor for
U.S. and Canada.
2
C
I
G

Installation
3A7828B 7
Installation
Hazardous Location Cabling
and Conduit Requirements
Explosion Proof Requirements
All electrical wiring in the hazardous locations must be
encased in approved explosion-proof conduit that is
suitable for Class I, Division I, Group C and D locations.
Follow all national, state, and local electrical codes and
regulations.
US and Canada Conduit Location Requirement:
Install a conduit seal within 457 mm (18 in.) of the motor
enclosure.
Cable Rating Requirement: Use cables with a
minimum rating of 70°C (158°F).
Use appropriate conduit, connectors, and cable glands
rated for Ex II 2 G. Follow all national, state, and local
electrical codes and regulations.
Cable Rating Requirement: Use cables with a
minimum rating of 70°C (158°F).
Power Requirements
The system requires a dedicated circuit protected with
a circuit breaker in each ungrounded phase.
Location Requirements
• There must be sufficient space on all sides of the
equipment for installation, operator access,
maintenance, and air circulation.
• The mounting surface and mounting hardware
must be strong enough to support the weight of the
equipment, fluid, hoses, and stress caused during
operation.
• There must be an electrical disconnect (A) within
easy reach of the equipment. See FIG. 1 Typical
Installation, page 6.
Mount the Pump
Follow the instructions in the pump mounting kit
manual to mount the pump on a stand or on the wall.
See Related Manuals, page 2.
Stand Mount
1. Use the Floor Stand Mounting Pattern, page 36.
2. Bolt the stand to the floor with M19 (5/8 in.) bolts.
Use bolts that engage at least 152 mm (6 in.) into
the concrete floor to prevent the pump from
tipping.
3. Use shims to level the pump if needed.
Installation of this equipment involves potentially
hazardous procedures. Only trained and qualified
personnel who have read and who understand the
information in this manual should install this
equipment. All electrical wiring must be done by a
qualified electrician and comply with all local codes
and regulations.
Flame Proof Requirements
Model by
Horse power
Voltage Phase Hz kVA
1 HP (0.75 kW) 380–480 Vac 3 50/60 1.4
2 HP (1.49 kW) 380–480 Vac 3 50/60 2.7
3 HP (2.24 kW) 380–480 Vac 3 50/60 3.4
5 HP (3.73 kW) 380–480 Vac 3 50/60 5.7

Installation
8 3A7828B
Wall Mount
1. Use the wall mount bracket as a template.
NOTE: The bracket has two mounting hole groups. See
Mounting Bracket Pattern, page 35
2. Drill four 7/16 in. (11 mm) holes into the wall. Bolt
the bracket securely to the wall. Always use bolts
and washers designed to hold in the wall’s
construction.
3. Attach the pump assembly to the mounting
bracket.
Required System Accessories
•Electrical disconnect (A): Required in the system
to disconnect and isolate electricity from the motor.
•Start stop switch (E): Temporarily runs or stops
the motor. Must be approved for hazardous
locations.
Required Fluid Line Accessories
Install accessories as shown in FIG. 1, using adapters
as necessary. Make sure they meet the system’s size
and pressure rating requirements. See Technical
Specifications, page 37.
•Fluid drain valve (B): Required in the system to
relief pressure in the hose and circulation system.
•Fluid shutoff valve (C): shuts off fluid flow.
Grounding
Static Grounding
Use a ground wire (G) to connect the motor to a true
earth ground.
1. Loosen the ground screw.
2. Insert the ground wire (G).
3. Tighten the ground screw securely.
4. Connect the other end of the ground wire (G) to a
true earth ground.
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. 2 Motor ground wire location

Installation
3A7828B 9
Electrical Grounding
1. Ensure that the electrical disconnect (A) is shut off
and locked out.
2. Remove the cover to access the motor electrical
wiring compartment (EC).
3. Connect the supply ground wire to GND.
4. Connect the other end of the supply ground wire to
a true earth ground.
Component Grounding
Fluid hoses: Use only electrically conductive hoses
with a maximum of 500 ft. (150 m) combined hose
length to ensure grounding continuity. Check the
electrical resistance of hoses. If total resistance to
ground exceeds 25 megohms, replace hose
immediately
Fluid supply container: Follow your local code.
Solvent pails used when flushing: Follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a non-conductive
surface, such as paper 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.
Connect Supply Wiring
1. Ensure that the electrical disconnect (A) is shut off
and locked out. See FIG. 3.
2. Bring the power wires (L1, L2, and L3) through the
3/4-14npt(f) inlet port of the electrical wiring
compartment. Connect the wires to the terminal
blocks.
NOTE: The maximum wire size that can be used with
the terminal block is 8AWG (10mm2).
NOTE: When using a communication module, the wire
orientation is important. L1 and L3 transmit
communication. Incorrectly wiring the communication
module will result in communication failure. See FIG. 4.
- L1 to W1 (black)
- L2 to W2 (red)
- L3 to W3 (blue)
3. Torque terminal screws (TS) to 7 in-lb (0.79 N•m).
Do not over-torque.
4. Close the electrical wiring compartment (EC).
Torque the cover screws (CS) to 15 ft-lb (20 N•m).
FIG. 3 Locked out disconnect example
FIG. 4 Motor wiring
A
GND
L1
L2
L3
W3
W1
W2
All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.

Installation
10 3A7828B
Install the Fill Cap
The motor is pre-filled with oil. Replace the shipping
plug with the fill cap (FC) before first use.
Flush Before Using the
Equipment
The pump fluid section was tested with lightweight oil,
which is left in the fluid passages to protect parts.To
avoid contaminating your fluid with oil, flush the
equipment with a compatible solvent before using the
equipment.
FIG. 5 Motor electrical compartment wires
Torque to 7 in-lb (0.79 N•m)
Torque to 15 ft-lb (20 N•m)
A conduit seal is required
within 457 mm (18 in.) of the
motor for US and Canadian
installations.
2
3
EC
A
1
3
2
CS
2
CS
2
CS
2
CS
1
TS
3/4 14 npt(f)
FIG. 6 Fill cap
FC