Graco E-Flo Plus Operating instructions

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2007, Graco Inc. is registered to I.S. EN ISO 9001
311594 rev.B
Repair - Parts
E-Flo™Plus Electric
Circulation Pump
Durable, energy efficient piston pumps for high volume paint circulation
applications.
See page 3 for model information, including maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti8317a

2311594B
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E-Flo Plus Electric Circulation Pumps . . . . . . . . 3
Maximum Working Pressure and
Pump Operational Limits . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fluid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 13
Slider Cylinder Rebuild Kit 15H874 . . . . . . 14
Electrical Section . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Transducer Kit 15H876 . . . . . . . . 15
Pressure Sensor Calibration Information . . 16
Pressure Transducer Calibration Procedure 17
TDC Sensor Kit 15H877 . . . . . . . . . . . . . . . 19
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Slider Bearing Kit 15H882 . . . . . . . . . . . . . . 20
Drive Linkage Rebuild Kit 15H873 . . . . . . . 22
Crank Arm Kit 15H883 . . . . . . . . . . . . . . . . 23
Motor/Gear Reducer . . . . . . . . . . . . . . . . . . . . . 24
Motor Removal . . . . . . . . . . . . . . . . . . . . . . 24
Motor Installation . . . . . . . . . . . . . . . . . . . . . 24
Gear Reducer Seal Kit 15H871 . . . . . . . . . 26
Gear Reducer Replacement Kit 15H886 . . 28
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fluid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Model-Specific Parts . . . . . . . . . . . . . . . . . . . . . 35
15H886 Gear Reducer . . . . . . . . . . . . . . . . . . . 36
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 38
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 38

Models
311594B 3
Models
E-Flo Plus Electric Circulation 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. EP2160represents electric
power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), and 2000
cc Maxlife lower (6). The last digit (0) is unassigned. To order replacement
parts, see Parts, beginning on page 32.
Maximum Working Pressure and Pump Operational Limits
1000 cc Pumps: 460 psi (3.22 MPa, 32.2 bar) Maximum Working Pressure
1500 cc Pumps: 330 psi (2.31 MPa, 23.1 bar) Maximum Working Pressure
2000 cc Pumps: 250 psi (1.75 MPa, 17.5 bar) Maximum Working Pressure
See Technical Data, page 37, for pressure and flow limits.
Approvals
This equipment meets requirements of the following
approval agencies:
Refer to the individual components for other specific
hazardous location listings.
Related Manuals
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 Unassigned
E (electric) P (pump) 0 No motor 0 No circuit 1 1000 cc
Chromex
0 None
assigned
1 230/400V ATEX 1 Circuit installed 2 1500 cc
Chromex
2 230/460V
UL/CSA
3 2000 cc
Chromex
4 1000 cc Maxlife
5 1500 cc Maxlife
6 2000 cc Maxlife
II2G EExdIIA T3
Manual Description
311592 E-Flo Plus Installation Manual
311593 E-Flo Plus Operation Manual
311595 Pneumatic Back Pressure Regulator
311596 Variable Frequency Drive Instructions
311603 Sensor Circuit Option

Warnings
4311594B
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 symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found 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.
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.
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.

Warnings
311594B 5
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

Warnings
6311594B

Pressure Relief Procedure
311594B 7
Pressure Relief
Procedure
1. Set START/STOP switch (ST) to STOP.
2. Push in SECURE DISABLE (SD) switch.
3. Open the back pressure regulator and all fluid drain
valves in the system, having a waste container
ready to catch drainage. Leave open until you are
ready to pressurize system again.
4. Check that pressure gauges on fluid supply and
return lines read zero. If gauges do not read zero,
determine cause and carefully relieve pressure by
VERY SLOWLY loosening a fitting. Clear obstruc-
tion before pressurizing system again.
Flushing
1. Follow Pressure Relief Procedure, page 7.
2. Supply the appropriate flushing material to the sys-
tem.
3. Set pump to lowest possible fluid pressure, and start
the pump.
4. Flush long enough to thoroughly clean the system.
5. Follow Pressure Relief Procedure, page 7.
System pressure can cause the pump to cycle unex-
pectedly, which could result in serious injury from
splashing or moving parts.
• Flush before changing colors, before storing,
and before repairing equipment.
• Flush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the
fluid being dispensed and the equipment wetted
parts.

Troubleshooting
8311594B
Troubleshooting
1. Relieve the pressure.
2. Check all possible problems and solutions before
disassembling pump.
PROBLEM CAUSE SOLUTION
Pump does not operate. Insufficient power supply. Verify that power supply meets require-
ments. See Technical Data, page 37.
No flow rate input to VFD. Select speed/flow setting.
START/STOP switch set to STOP. Set START/STOP switch to START.
SECURE DISABLE switch not activated. Pull out to activate.
Outlet valve not open. Open valve.
Damaged electric motor. Repair, page 15.
Damaged gear reducer. Disconnect pumps and operate. If speed
is consistent, gear reducer is good. If
speed is erratic, gear reducer is bad.
Fluid dried on piston rod. Disassemble and clean lower. See lower
manual 311690. In future, stop lower at
bottom of stroke.
Throat packing nut is too tight. Loosen packing nut and re-torque.
3-phase wiring to motor is not correct. Inspect and confirm wiring continuity.
Pressure too low. Incorrect transducer calibration. Check calibration. Replace transducer if
necessary.
Lowers need repair. Check and repair. See lower manual
311690.
Restricted pump fluid inlet. Clear.
Air in the fluid. Check fluid level. Check inlet fittings for
leaks.
Pump output low on both strokes. Insufficient power supply. Verify that power supply meets require-
ments. See Technical Data, page 37.
Exhausted fluid supply. Refill and reprime pump.
Held open or worn ball check valves. Check and repair.
Wrong fluid lowers installed. Verify size of lowers installed and config-
ured.
Pump output low on only one stroke. Held open or worn ball check valves. Check and repair.
Worn piston packings. Replace. See lower manual 311690.
Air in the fluid. Check fluid level. Check inlet fittings for
leaks.
Erratic flow or pressure. Pump cavitation; suction/supply line leak. Check and repair.
Exhausted fluid supply. Refill and reprime pump.
Restricted fluid supply to pump. Ensure all valves are fully open.
Held open or worn ball check valves. Check and repair.
Pump packings are too tight. Loosen and re-torque.
Worn piston packing. Replace. See lower manual 311690.
Air in the fluid. Check fluid level. Check inlet fittings for
leaks.
Motor rotation direction is backwards. Check direction of rotation.
3-phase wiring to motor is not correct. Inspect and confirm wiring continuity.

Troubleshooting
311594B 9
Pump will not prime Suction line clogged. Clear. Flush more frequently.
Held open or worn ball check valves. Check and repair.
Lower piston assembled with wrong nut. Use only the large, round, special nut.
Excessive throat leakage. Worn piston rod or throat packings. Replace. See lower manual 311690.
High current trip (t043). Pressure setting is too high. Reduce pressure.
Pump packings are too tight. Loosen and re-torque.
Gear reducer oil level is low. Fill to correct oil level.
Incorrect transducer calibration. Perform calibration procedure.
Wrong fluid lowers installed. Verify size of lowers installed and config-
ured.
High pressure trip (t040). Downstream restriction is too high. Open line and remove restriction.
Circulation valve is closed. Open back pressure regulator.
Check solenoid.
Clogged fluid filters. Clean.
Incorrect transducer calibration. Perform calibration procedure.
Excessive noise. Pump packings are too tight. Loosen and re-torque.
Gear reducer oil level is low. Fill to correct oil level.
Loose or worn drive linkage. Inspect; repair or replace.
Worn motor coupling. Inspect; repair or replace.
Worn gear reducer. Replace.
Pump changes direction or shakes. One leg of 3-phase is lost. Inspect and correct wiring connections on
VFD, motor, and wiring.
PROBLEM CAUSE SOLUTION

ElectricalDiagrams
10 311594B
Electrical Diagrams
FIG. 1 shows components which must be installed in a
non-hazardous location.
FIG. 2 shows components approved for installation in a
hazardous location.
FIG. 1: System Wiring Schematic, Non-Hazardous Location Only