Graco E-Flo Plus User manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2007, Graco Inc. is registered to I.S. EN ISO 9001
311592 rev. B
Installation
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

2311592B
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
System Components . . . . . . . . . . . . . . . . . . . . . . . . 6
Hazardous Area . . . . . . . . . . . . . . . . . . . . . . . . . 6
Non-Hazardous Area . . . . . . . . . . . . . . . . . . . . . 6
System Wiring Schematics . . . . . . . . . . . . . . . . . . . 8
Power Supply Requirements . . . . . . . . . . . . . . . . 10
Power Disconnect Switch . . . . . . . . . . . . . . . . . 10
Hazardous Area Cabling and Conduit Requirements
(Explosion Proof) . . . . . . . . . . . . . . . . . . . . 10
Increased Safety (European) . . . . . . . . . . . . . . 10
288036 Power Module . . . . . . . . . . . . . . . . . . . 10
Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Environmental Conditions . . . . . . . . . . . . . . . . . 11
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
15H884 Floor Stand . . . . . . . . . . . . . . . . . . . . . 11
Connect Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . 11
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electric Motor Specifications . . . . . . . . . . . . . . . 12
Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install the Motor . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Noise Filter . . . . . . . . . . . . . . . . . . . . . . 14
Variable Frequency Drive Accessory (VFD) . . . . 15
VFD Installation . . . . . . . . . . . . . . . . . . . . . . . . . 15
VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ethernet Interface (optional) . . . . . . . . . . . . . . . 15
120373 Local Control Box (optional accessory) . 16
Pneumatic Back Pressure Regulator (optional) . 17
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 20

Models
311592B 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 the Repair-Parts manual 311594.
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 21, for pump operational limits.
Approvals
The E-Flo Plus Pump meets requirements of the follow-
ing 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 0 None
assigned
1 230/400V ATEX 1 Circuit installed 2 1500 cc
2 230/460V
UL/CSA
3 2000 cc
4 1000 cc Maxlife
5 1500 cc Maxlife
6 2000 cc Maxlife
II2G EExdIIA T3
Manual Description
311593 E-Flo Plus Operation Manual
311594 E-Flo Plus Repair-Parts Manual
311595 Pneumatic Back Pressure Regulator
311596 Variable Frequency Drive Instructions
311603 Sensor Circuit Option

Warnings
4311592B
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
311592B 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

System Components
6311592B
System Components
FIG. 1 illustrates a typical North American system instal-
lation, showing the major system components. Also see
the wiring schematic in FIG. 2 and FIG. 3.
Hazardous Area
See FIG. 1. The following system components are
approved for use in a hazardous area:
• E-Flo Plus Electric Circulation Pump
• Sensor Control Circuit (option). See intrinsic safety
installation requirements below.
Sensor Circuit Wetted Parts
Pressure transducer: 17-4 PH stainless steel
• Explosion-Proof Electric Motor
• Local Control Box (accessory)
• Pneumatic Back Pressure Regulator (accessory)
All other components shown in FIG. 1 must be installed
in a non-hazardous area.
Non-Hazardous Area
See FIG. 1. Install the following components in a
non-hazardous area:
• System Power Disconnect Switch
• Electrical Noise Filter (accessory)
• Variable Frequency Drive (accessory)
• Power Module (accessory)
• 3-Way Pneumatic Solenoid Valve (accessory)
Do not install equipment approved only for non-haz-
ardous locations in a hazardous area.

System Components
311592B 7
Key:
AE-Flo Plus 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. 1: Typical Installation
ti8651a
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

System Wiring Schematics
8311592B
System Wiring Schematics
FIG. 2 shows components that must be installed in a
non-hazardous location.
FIG. 3 shows components approved for installation in a
hazardous location.
FIG. 2: System Wiring Schematic, Non-Hazardous Location Only

System Wiring Schematics
311592B 9
FIG. 3: System Wiring Schematic, Hazardous Location
SEE DETAIL
BELOW
SEE ABOVE

Power Supply Requirements
10 311592B
Power Supply Requirements
See TABLE 1 for power supply requirements. The system
requires a dedicated circuit protected with a 20 A circuit
breaker.
Power Disconnect Switch
See FIG. 1 on page 7. Install a power disconnect switch
(E) in the non-hazardous area. This switch must shut off
and lock-out all electric power to the system.
Hazardous Area Cabling and
Conduit Requirements
(Explosion Proof)
All electrical wiring in the hazardous area must be
encased in Class I, Division I, Group C and D approved
explosion-proof conduit.
Wire passages from the hazardous to the non-hazard-
ous area must be secured by explosion-proof seal fit-
tings (L).
Increased Safety (European)
Use appropriate cables, connectors, and cable glands
rated for ATEX II 2 G. Follow all National and Local elec-
tric codes.
288036 Power Module
The 288036 Power Module transforms the high voltage
power supply to a 24 Vdc input for the pump sensor cir-
cuit. See manual 311608 for further information.
See FIG. 1 on page 7. Install the power module (G) in
the non-hazardous area.
See FIG. 2 Electrical Schematic for module wiring con-
nections.
Improper wiring may cause electric shock or other
serious injury if work is not performed properly. Have
a qualified electrician perform any electrical work. Be
sure your installation complies with all National, State
and Local safety and fire codes.
Table 1: Power Supply Specifications
Voltage Phase Hz
Minimum Circuit
Breaker Size
230/400V 3 50/60 20 A/15 A
230/460V 3 50/60 20 A/15 A
Table 2: Cabling Specifications
Connection Points Wire Size,
AWG (mm2)
Maximum
Length
ft (m)
VFD to Motor 14 (2.5) 330 (100)
Motor Overtempera-
ture Switch to VFD
18 (0.75) 330 (100)
Local Control Box to
VFD
16 (1.5) 330 (100)