Graco E-Flo SP User manual

3A6931A
EN
Instructions
E-Flo®SP Air to Electric
Conversion Kits
For converting NXT®3400 air motor pump and supply systems to electric driver systems
for use with single-component sealant and adhesive materials. For professional use only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
Important Safety Instructions
Read all warnings and instructions in this
manual and in all related manuals before
using the equipment. Save all
instructions.

Related Manuals
23A6931A
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure. . . . . . . . . . . . . . . . . . 9
Air to Electric Pump Conversion Kits . . . . . . . . . . 9
Air to Electric D60 Ram Conversion Kits . . . . . . 12
Air to Electric D200 Ram Conversion Kits . . . . . 16
Air to Electric D200s Ram Conversion Kits . . . . 19
Connect Power to an Electric Ram System . . . . 23
Pump ADM Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Ram ADM Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Standalone Pump Transformer Kit. . . . . . . . . . . 25
Ram Transformer Kits . . . . . . . . . . . . . . . . . . . . 26
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air to Electric Pump Conversion Kits, 25P277-7930
Air to Electric D60 Ram Conversion Kits, 25P280-82
32
Air to Electric D200 Ram Conversion Kits,
25P283-85 . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air to Electric D200s Ram Conversion Kits,
25P286-88 . . . . . . . . . . . . . . . . . . . . . . . . . . 38
E-Flo SP Pump ADM Kit, 25E439 . . . . . . . . . . . 40
E-Flo SP Ram ADM Kit, 25E437 . . . . . . . . . . . . 41
E-Flo SP Pump Transformer Kit, 25E268. . . . . . 42
E-Flo SP Ram Transformer Kit, 25E203 . . . . . . 43
E-Flo SP Ram Transformer Kit, 25E202 . . . . . . 44
Transformer Mounting Hole Diagram . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Related Manuals
Component Manuals in U.S. English
:
Manual Description
3A6586 E-Flo SP Electric Pumps Installation-Parts
3A6331 E-Flo SP Supply Systems Installation-Parts
3A6724 E-Flo SP Software Instructions
3A6482 APD20 Driver Instructions-Parts
313526 Supply Systems Operation
313527 Supply Systems Repair-Parts
312376 Check-Mate®Pump Packages Instructions-Parts
311828 Dura-Flo®Pumps Instructions-Parts
312375 Check-Mate 100cc, 200cc, 250cc, 500cc CS/CM/SS/SM Lower Instruc-
tions-Parts List
311762 Dura-Flo 145cc, 180cc, 220cc, 290cc CS Lower Instructions-Parts List
311827 Dura-Flo 145cc, 180cc, 220cc, 290cc SS Lower Instructions-Parts List
311825 Dura-Flo 430cc CS/SS/SM Lower Instructions-Parts List
3A6321 ADM Token In-System Programming
3A1244 Graco Control Architecture™Module Programming
311619 Pump Mounting Kits
307971 Floor Stand Accessory

Kits
3A6931A 3
Kits
NOTE: Select a kit based on the type of NXT 3400 air motor system you are using as well as the ram and pump
lower size, where applicable. For the pump lower size, CM is Check-Mate and DF is Dura-Flo.
Kit No. Description Pump Lower Size Ram Size Air Motor
Size
Pump System
To Convert a Pump-only System
25P277 KIT, pump, convert, small, relief, 240V CM100 N/A NXT 3400
25P278 KIT, pump, convert, small, no relief, 240V CM200, CM250, DF115,
DF145, DF180, DF220, DF290 N/A NXT 3400
25P279 KIT, pump, convert, large, no relief, 240V CM500, DF430 N/A NXT 3400
Ram System
To Convert a D60 Ram System
25P280 KIT, ram, convert, D60, small, relief, 240V CM100 D60 NXT 3400
25P281 KIT, ram, convert, D60, small, no relief, 240V CM200, CM250, DF115,
DF145, DF180, DF220, DF290 D60 NXT 3400
25P282 KIT, ram, convert, D60, large, no relief, 240V CM500, DF430 D60 NXT 3400
To Convert a D200 Ram System
25P283 KIT, ram, convert, D200, small, relief, 240V CM100 D200 NXT 3400
25P284 KIT, ram, convert, D200, small, no relief, 240V CM200, CM250, DF115,
DF145, DF180, DF220, DF290 D200 NXT 3400
25P285 KIT, ram, convert, D200, large, no relief, 240V CM500, DF430 D200 NXT 3400
To Convert a D200s Ram System
25P286 KIT, ram, convert, D200s, small, relief, 240V CM100 D200s NXT 3400
25P287 KIT, ram, convert, D200s, small, no relief, 240V CM200, CM250, DF115,
DF145, DF180, DF220, DF290 D200s NXT 3400
25P288 KIT, ram, convert, D200s, large, no relief, 240V CM500, DF430 D200s NXT 3400
Add an ADM
To an Electric Pump System
25E439 KIT, pump, ADM All N/A N/A
To an Electric Ram System
25E437 KIT, ram, ADM All All N/A
Add a 480 V Transformer
To an Electric Pump System
25E268 KIT, pump, 480V All N/A N/A
To an Electric Ram System
25E203 KIT, ram, D60, D200, 480V All D60, D200 N/A
25E202 KIT, ram, D200S, 480V All D200S N/A

Kits
43A6931A
Pressure Ratings
The APD20 electric driver provides approximately 30% more thrust than an NXT 3400 air motor. The table below
shows the pump working pressure and maximum dynamic pressure using the electric driver. The E-Flo SP Model
column shows the E-Flo model the system will be similar to when the conversion is complete. After converting the
system, follow all warnings and instructions for the E-Flo SP model listed instead of the previous air motor system.
For the pump lower size, CM is Check-Mate and DF is Dura-Flo.
To help prevent serious injury from skin injection, ver-
ify that any components downstream of the pump are
rated to the new, higher pressures shown in the table
below. Replace any components that are not rated to
the higher pressures.
Pump Working (Stall)
Pressure
Max Dynamic (Run)
Pressure
Kit No. Pump
Lower Size psi bar MPa psi bar MPa Ram Size Air Motor Size
E-Flo SP
Model
25P277 CM100 6000 414 41.4 6000 414 41.4 N/A
NXT 3400
EC100XX3
25P278
CM200, 4200 290 29.0 3905 269 26.9 N/A EC200XX3
CM250 3400 234 23.4 3122 215 21.5 N/A EC250XX3
DF115 6000 414 41.4 6000 414 41.4 N/A ED115XX3
DF145 5600 386 38.6 5204 359 35.9 N/A ED145XX3
DF180 4500 310 31.0 4164 287 28.7 N/A ED180XX3
DF220 3700 255 25.5 3470 239 23.9 N/A ED220XX3
DF290 2800 193 19.3 2602 179 17.9 N/A ED290XX3
25P279 CM500 1600 110 11.0 1487 103 10.3 N/A EC500XX3
DF430 1900 131 13.1 1735 120 12.0 N/A ED430XX3
25P280 CM100 6000 414 41.4 6000 414 41.4 D60
NXT3400
EMC11X3
25P281
CM200 4200 290 29.0 3905 269 26.9 D60 EMC51X3
CM250 3400 234 23.4 3122 215 21.5 D60 EMC91X3
DF115 6000 414 41.4 6000 414 41.4 D60 EMD11X3
DF145 5600 386 38.6 5204 359 35.9 D60 EMD21X3
DF180 4500 310 31.0 4164 287 28.7 D60 EMD41X3
DF220 3700 255 25.5 3470 239 23.9 D60 EMD61X3
DF290 2800 193 19.3 2602 179 17.9 D60 EMD81X3
25P282 CM500 1600 110 11.0 1487 103 10.3 D60 EMCD1X3
DF430 1900 131 13.1 1735 120 12.0 D60 EMDA1X3
25P283 CM100 6000 414 41.4 6000 414 41.4 D200 EMC12X3

Kits
3A6931A 5
25P284
CM200 4200 290 29.0 3905 269 26.9 D200
NXT3400
EMC52X3
CM250 3400 234 23.4 3122 215 21.5 D200 EMC92X3
DF115 6000 414 41.4 6000 414 41.4 D200 EMD12X3
DF145 5600 386 38.6 5204 359 35.9 D200 EMD22X3
DF180 4500 310 31.0 4164 287 28.7 D200 EMD42X3
DF220 3700 255 25.5 3470 239 23.9 D200 EMD62X3
DF290 2800 193 19.3 2602 179 17.9 D200 EMD82X3
25P285 CM500 1600 110 11.0 1487 103 10.3 D200 EMCD2X3
DF430 1900 131 13.1 1735 120 12.0 D200 EMDA2X3
25P286 CM100 6000 414 41.4 6000 414 41.4 D200s EMC13X3
25P287
CM200 4200 290 29.0 3905 269 26.9 D200s EMC53X3
CM250 3400 234 23.4 3122 215 21.5 D200s EMC93X3
DF115 6000 414 41.4 6000 414 41.4 D200s EMD13X3
DF145 5600 386 38.6 5204 359 35.9 D200s EMD23X3
DF180 4500 310 31.0 4164 287 28.7 D200s EMD43X3
DF220 3700 255 25.5 3470 239 23.9 D200s EMD63X3
DF290 2800 193 19.3 2602 179 17.9 D200s EMD83X3
25P288 CM500 1600 110 11.0 1487 103 10.3 D200s EMCD3X3
DF430 1900 131 13.1 1735 120 12.0 D200s EMDA3X3
Pump Working (Stall)
Pressure
Max Dynamic (Run)
Pressure
Kit No. Pump
Lower Size psi bar MPa psi bar MPa Ram Size Air Motor Size
E-Flo SP
Model

Warnings
63A6931A
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.
DANGER
SEVERE ELECTRIC SHOCK HAZARD
This equipment can be powered by more than 240 V. Contact with this voltage will cause death or
serious injury.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• This equipment must be grounded. Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
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.

Warnings
3A6931A 7
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.
• 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 dispensing device 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.
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-
tions in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete infor-
mation about your material, request Safety Data Sheets (SDSs) from distributor or retailer.
• 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 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.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,
splatter may occur.
• Use minimum air pressure when removing platen from drum.
WARNING

Warnings
83A6931A
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.
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

Installation
3A6931A 9
Installation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
Follow the Pressure Relief Procedure in the manual for
the air motor system you are converting. See Related
Manuals on page 2for the air motor pump and supply
systems manuals.
Air to Electric Pump Conversion
Kits
The air to electric pump conversion kit is available in
three options depending on the pump lower size.
Disassemble the Air Motor Pump
NOTE: Pumps can be mounted various ways in a
system. The following steps describe disassembling an
air motor pump that is mounted in a way that the pump
lower is easily accessible, such as on a wall mount or a
stand. If the pump is floor mounted or mounted in some
other way, you may need to remove the entire pump
from the system before disassembling it.
1. Follow the Pressure Relief Procedure for the
Check-Mate or Dura-Flo air motor pump system you
are using. See Related Manuals on page 2.
2. Remove the main air supply.
3. See Figure 1 and remove the pump coupling, pump
lower, and the three tie rods from the air motor
pump assembly. Refer to the Check-Mate Pump
Packages Instructions-Parts manual or the Dura-Flo
Pumps Instructions-Parts manual. See Related
Manuals on page 2. Save these parts to be used
when installing the kit.
4. Remove the air motor from the system.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure for the system you are using when you
stop spraying and before cleaning, checking, or ser-
vicing the equipment.
Kit Number Pump Lower Size
25P277 CM100
25P278 CM200, CM250, DF115, DF145,
DF180, DF220, DF290
25P279 CM500, DF430
FIG. 1: Air Motor Pump
Pump Coupling
Tie Rods
Pump Lower

Installation
10 3A6931A
Assemble the Electric Pump Conversion
Kit
NOTE: Refer to the Air to Electric Pump Conversion
Kit, 25P277-79 parts on page 30 for correct assembly.
1. Use the shaft adapter (8,9) included in the kit and
connect the electric driver (1) to the pump coupling,
pump lower, and tie rods that were removed from
the air motor pump.
2. Connect the outlet check valve (2) using the adapter
fitting (4,5,6,7 depending on the kit). Apply thread
sealant to the threads of the check valve and the
adapter fitting prior to installation. Figure 2 shows
options for the 100 cc Check-Mate 100 pump and
the 115 cc Dura-Flo pump.
3. The pressure transducer cable from the outlet check
valve plugs into port 6 on the electric driver. See
Figure 3.
4. Use the wire ties (3) to secure the pressure
transducer cable to a tie rod.
5. Mount the electric pump as required for your system
configuration.
Connect Power to the Electric Pump
System
1. Cut power cord wires to the following lengths:
• Ground wire - 6.5 inches (16.5 cm)
• Power wires - 3.0 inches (7.6 cm)
• Add ferrules as necessary. See Figure 4.
2. Remove the four screws to separate the junction
box cover and the disconnect switch from the junc-
tion box on the electric driver.
FIG. 2: Outlet Check Valve Options
FIG. 3: Electric Driver Ports
Dura-Flo 115
Check-Mate 100
Pressure
Transducer Cable
Port 6
All electrical wiring must be done by a qualified elec-
trician and comply with all local codes and regula-
tions.
FIG. 4: Power Cord
FIG. 5: Remove Driver Junction Box Cover
LQ
LQ
Disconnect
Switch

Installation
3A6931A 11
NOTE: Inside the junction box, power wires to the driver
are connected to terminals 3L2 and 5L3 on the discon-
nect block. Refer to Figure 6 for the terminal locations.
3. Insert the power cord through the cord grip and into
the driver junction box.
4. Refer to Figure 6 and connect the wires from the
power cord into terminals 4T2 and 6T3. Each wire
can be connected to either terminal.
5. Attach the ground wire to one of the two ground ter-
minals inside the junction box as shown in Figure 7.
NOTE: Do not attach the ground wire to the grounding
lug locknut located by the wiring cord grip on the outside
of the electric driver. The lug locknut should only be
used for other grounding purposes if needed.
6. Place the power wires into the open area on either
side of the disconnect block as space permits.
7. Reinstall the driver junction box cover and discon-
nect switch using the four screws removed in step 2.
8. Tighten the cord grip to securely hold the power
cord in the driver junction box.
9. Place the identification label (16,17) included in the
kit on the electric driver as shown in Figure 9.
FIG. 6: Terminal Connections
FIG. 7: Connect Driver Junction Box Power
/
/
/
7
7
7
Incoming
Power
Power to
Driver
Disconnect
Block
For clarity, power wires to
the driver are not shown
Cord Grip
NOTICE
If wires get pinched when the screws are tightened,
damage will occur. Make sure all wires are routed
correctly before installation.
FIG. 8: Tighten Cord Grip
FIG. 9: Apply Label to Electric Driver
PARTNO. SERIES
SERIALNO.
MAXFLUID WPR
MPa
bar
PSI
V
PH
A
HZ
Seewww.graco.com/patents
ArtworkNo.
294966Rev. D
16,17

Installation
12 3A6931A
10. Verify all components downstream of the pump are
rated to the new, higher pressure. Replace any
components that are not rated to the higher
pressures.
NOTE: Converting the pump from air to electric changes
the operation of the pump system. Follow the E-Flo SP
Electric Pumps Installation-Parts manual and the E-Flo
SP Software Instructions for complete warnings and
instructions for the system going forward. See Related
Manuals on page 2.
Air to Electric D60 Ram
Conversion Kits
The air to electric D60 ram conversion kit is available in
three options depending on the pump lower size.
Disassemble the Air Motor Ram
1. Follow the Pressure Relief Procedure for the air
motor pump and ram system you are using. See
Related Manuals on page 2.
2. Remove the main air supply from the air controls.
3. See Figure 10 and remove the pump coupling,
pump lower, and three tie rods from the air motor
supply system. Save these parts to be used when
installing the kit. Refer to the Supply Systems
Operation manual and the Supply Systems
Repair-Parts manual. See Related Manuals on
page 2.
4. Remove the air motor supply hose and fittings from
the top of the air controls.
5. On the air controls, disconnect the air motor shutoff
and control sections together by removing the two
screws underneath the air motor control as shown in
Figure 10. Lift the two sections to remove them.
Remove the o-ring from around the hole in the top of
the air controls.
6. Remove the air motor from the ram.
Assemble the Electric D60 Ram Conversion
Kit
NOTE: Refer to the Air to Electric D60 Ram
Conversion Kit, 25P280-82 parts on page 32 for
correct assembly.
1. Refer to Figure 11 on page 13 and remove the hex
nut from the mounting plate. Place the cable track
bracket (119) on the mounting plate and replace the
hex nut.
This conversion results in increased pressure to the
system. To help prevent serious injury from skin injec-
tion, all components downstream of the pump must
be rated to the new, higher maximum pressures. See
the Pressure Ratings table on page 4.
Kit Number Pump Lower Size
25P280 CM100
25P281 CM200, CM250, DF115, DF145,
DF180, DF220, DF290
25P282 CM500, DF430
FIG. 10: D60 with Air Motor
All electrical wiring must be done by a qualified elec-
trician and comply with all local codes and regula-
tions.
Air Motor
Air Motor
Air Supply
Fittings
Pump
Coupling
Tie Rods
Pump
Lower
Air Motor
Shutoff/
Control

Installation
3A6931A 13
2. Using the top mounting bracket (109), attach the
ram junction box (108) to the ram using two screws
(114) and washers (113) as shown in Figure 11.
3. Attach the bottom mounting brackets (110, 111) with
four screws (115), nuts (116) and washers (113) as
shown in Figure 11.
4. Disconnect the wires from the disconnect block (A).
5. Remove and discard the driver junction box cover
(C) and the disconnect switch (B) from the driver.
See Figure 12.
6. Remove and discard the extrusion (D), then remove
and discard the plug (E).
7. Remove the cord grip and save it for reuse.
8. Install the electric driver (101) with the four screws
(132) and washers (133) included in the kit.
9. Install the cord grip that was removed in step 7 into
the driver junction box where the plug was removed.
See Figure 14 on page 14.
10. The power cable from the ram junction box (108) is
routed through the cable track. Run it through the
cord grip and connect it using the supplied
connectors. Connect the ground wire to one of the
two green ground terminals inside the driver
junction box.
FIG. 11: Attach Ram Junction Box to the D60
NOTICE
Do not over-torque the ram junction box mounting
brackets. Over-torquing can damage the cylinder.
119
113,114
113,115,116
111
110
109
Hex Nut
108
FIG. 12: Remove Driver Junction Box
FIG. 13: Install D60 Electric Driver
A
D
C
B
ECord Grip
132,133
101

Installation
14 3A6931A
11. Install the new driver junction box cover using the
four screws. The cover and screws are included with
the cable track assembly.
12. Connect the cable track connections as shown in
Figure 15.
a. Connect the two CAN connectors to ports 1 and
2.
b. Connect the 5 pin connector to port 3.
c. Connect the 8 pin connector to port 4.
NOTE: Use Figure 3 on page 10 for further reference.
13. Use the shaft adapter included in the kit and
connect the electric driver to the pump coupling,
pump lower, and tie rods that were removed from
the air motor pump. Refer to the E-Flo SP Supply
Systems Installation-Parts manual. See Related
Manuals on page 2.
14. Connect the outlet check valve (102) using the
adapter fitting (104) included in the kit. Apply thread
sealant to the threads of the check valve and the
adapter fitting prior to installation. See Figure 16.
15. The pressure transducer cable from the outlet check
valve plugs into port 6 on the electric driver. Use
Figure 3 on page 10 for reference.
16. Use the wire ties (103) included in the kit to secure
the pressure transducer cable to a tie rod.
17. Mount the assembled ADM mounting brackets with
four screws (114) and washers (113) as shown in
Figure 17.
18. Plug the air line hole in the top of the air controls
with the supplied plug (134) as shown in Figure 17.
FIG. 14: D60 Driver Junction Box Cover
FIG. 15: D60 Cable Track Connections
Cord Grip
Cover
Screws
FIG. 16: D60 Outlet Check Valve Installation
FIG. 17: D60 ADM Mounting Bracket
104
102
134
113,114

Installation
3A6931A 15
19. Install the empty level sensor.
a. Attach the actuator bracket (127) onto the ram
air cylinder shaft as shown in Figure 18.
b. Install the level sensor bracket (128) using two
screws (114) and washers (113).
c. Attach the level sensor (129) onto the level
sensor bracket (128) as shown in Figure 18.
d. Connect one end of the harness (130) to the
level sensor. Connect the other end of the
harness to the bulk head connection labeled C3
on the ram junction box (108).
e. Use four wire ties (131) to secure the harness.
20. Verify all components downstream of the pump are
rated to the new, higher pressure. Replace any
components that are not rated to the higher
pressures.
NOTE: Converting from air to electric changes the
operation of the ram supply system. Follow the E-Flo SP
Supply Systems Installation-Parts manual and the E-Flo
SP Software Instructions for complete warnings and
instructions for the system going forward. See Related
Manuals on page 2.
21. The identification label (137,138) included in the kit
needs to be applied on the rear side of the ram
cylinder where the original identification label is
located below the ram junction box mounting
bracket as shown in Figure 19.
NOTE: When you are applying the new label, you must
leave the part number, serial number, and series
showing on the original label. The rest of the original
identification label needs to be covered by the new one
to allow for updated pressure and electrical information.
22. Carefully place the new identification label over the
original one so they line up as shown in Figure 20.
FIG. 18: D60 Empty Level Sensor
This conversion results in increased pressure to the
system. To help prevent serious injury from skin injec-
tion, all components downstream of the pump must
be rated to the new, higher maximum pressures. See
the Pressure Ratings table on page 4.
113,114
127 128
129 130 131 108
C3
FIG. 19: D60 Identification Label Location
FIG. 20: Apply Identification Label on D60
137,138
Original
Label
PART NO. SERIAL NO. SERIES
MAX AIR WPR
MPa bar PSI
MAX FLUID WPR
MAX TEMP
ºC
WEIGHT
kg
MADE IN
MPa bar PSI
lbºF
BAR CODE TO BE INSERTED HERE
GRACO.COM / PATENTS Artwork No. 291841 Rev. E
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CMXXXX XXXXX XXXX
GRACO
INC
.
P.
O
. Box 1441
Mi
nnea
p
o
li
s
,
M
N
MADE
IN
PART NO. SERIES SERIAL NO.
VOLTS
PHASE
AMPS
HZ
MAX FLUID WPR
MPa
bar
PSI
Read instruction manual.
Artwork No. 29A057 Rev. A
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CUSTOMER MUST SUPPLY
BRANCH CIRCUIT PROTECTION
See www.graco.com/patents
MAX AIR WPR
MPa
bar
PSI
EMYYYYY YYYY YYYYY
R
PS
I
M
P
M
P
º
F
CO
DE
E
T
T
TO
O
O
B
BE
E
E
I
N
NS
ER
T
S
ERIE
S
PART NO. SERIAL NO. SERIES
MAX AIR WPR
MPa bar PSI
MAX FLUID WPR
MAX TEMP
ºC
WEIGHT
kg
MADE IN
MPa bar PSI
lbºF
BAR CODE TO BE INSERTED HERE
GRACO.COM / PATENTS Artwork No. 291841 Rev. E
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CMXXXX XXXXX XXXX
PART NO. SERIES SERIAL NO.
VOLTS
PHASE
AMPS
HZ
MAX FLUID WPR
MPa
bar
PSI
Read instruction manual.
Artwork No. 29A057 Rev. A
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CUSTOMER MUST SUPPLY
BRANCH CIRCUIT PROTECTION
See www.graco.com/patents
MAX AIR WPR
MPa
bar
PSI
EMYYYYY YYYY YYYYY
Original
Label
New
Label
Correct Label Alignment
New
Label

Installation
16 3A6931A
23. Refer to Connect Power to an Electric Ram
System on page 23 to connect power to the ram
junction box.
Air to Electric D200 Ram
Conversion Kits
The air to electric D200 ram conversion kit is available in
three options depending on the pump lower size.
Disassemble the Air Motor Ram
1. Follow the Pressure Relief Procedure for the air
motor pump and ram system you are using. See
Related Manuals on page 2.
2. Remove the main air supply from the air controls.
3. See Figure 21 and remove the pump coupling,
pump lower, and three tie rods from the air motor
supply system. Save these parts to be used when
installing the kit. Refer to the Supply Systems
Operation manual and the Supply Systems
Repair-Parts manual. See Related Manuals on
page 2.
4. Remove the air motor supply hose and fittings from
the top of the air controls.
5. On the air controls, disconnect the air motor shutoff
and control sections together by removing the two
screws underneath the air motor control as shown in
Figure 21. Lift the two sections to remove them.
Remove the o-ring from around the hole in the top of
the air controls.
6. Remove the air motor from the ram.
Assemble the Electric D200 Ram
Conversion Kit
NOTE: Refer to the Air to Electric D200 Ram
Conversion Kit, 25P283-85 parts on page 35 for
correct assembly.
1. Refer to Figure 22 and remove the hex nut from the
ram’s cross beam. Place the cable track bracket
(219) on the cross beam with the track on the rear of
the beam and replace the hex nut.
Kit
Number Pump Lower Size
25P283 CM100
25P284 CM200, CM250, DF115, DF145,
DF180, DF220, DF290
25P285 CM500, DF430
FIG. 21: D200 with Air Motor
Air Motor
Air Motor
Air Supply
Fittings
Pump
Coupling
Tie Rods
Pump
Lower
Air Motor
Shutoff/
Control
All electrical wiring must be done by a qualified elec-
trician and comply with all local codes and regula-
tions.
FIG. 22: D200 Cable Track and Ram Junction Box
219
213,214
213,215,216
210
211
209
Hex Nut
208

Installation
3A6931A 17
2. Using the mounting bracket (209), attach the ram
junction box (208) to the ram using two screws (214)
and washers (213) as shown in Figure 22 on page
16.
3. Attach the mounting brackets (210, 211) with four
screws (215), nuts (216), and washers (213).
4. Disconnect the wires from the disconnect block (A).
5. Remove and discard the driver junction box cover
(C) and the disconnect switch (B) from the driver.
See Figure 23.
6. Remove and discard the extrusion (D), then remove
and discard the plug (E).
7. Remove the cord grip and save it for reuse.
8. Install the electric driver (201) using the same
hardware that was used with the air motor.
9. Install the cord grip that was removed in step 7 into
the driver junction box where the plug was removed.
See Figure 24.
10. The power cable from the ram junction box (208) is
routed through the cable track. Run it through the
cord grip and connect it using the supplied
connectors. Connect the ground wire to one of the
two green ground terminals inside the driver
junction box.
11. Install the new driver junction box cover using the
four screws. The cover and screws are included with
the cable track assembly.
12. Connect the cable track connections as shown in
Figure 25.
a. Connect the two CAN connectors to ports 1 and
2.
b. Connect the 5 pin connector to port 3.
c. Connect the 8 pin connector to port 4.
NOTE: Use Figure 3 on page 10 for further reference.
13. Use the shaft adapter included in the kit and
connect the electric driver to the pump coupling,
pump lower, and tie rods that were removed from
the air motor pump. Refer to the E-Flo SP Supply
Systems Installation-Parts manual. See Related
Manuals on page 2.
NOTICE
Do not over-torque the ram junction box mounting
brackets. Over-torquing can damage the cylinder.
FIG. 23: Remove Driver Junction Box
A
D
C
B
E
Cord Grip
FIG. 24: D200 Driver Junction Box Cover
FIG. 25: D200 Cable Track Connections
Cord Grip
Cover
Screws

Installation
18 3A6931A
14. Connect the outlet check valve (202) using the
adapter fitting (204) included in the kit. Apply thread
sealant to the threads of the check valve and the
adapter fitting prior to installation. See Figure 26.
15. The pressure transducer cable from the outlet check
valve plugs into port 6 on the electric driver. See
Figure 3 on page 10 for reference.
16. Use the wire ties (203) included in the kit to secure
the pressure transducer cable to a tie rod.
17. Mount the assembled ADM mounting bracket with
four screws (214) and washers (213) as shown in
Figure 27.
18. Plug the air line hole in the top of the air controls
with the supplied plug (134) as shown in Figure 27.
19. Install the empty level sensor.
a. Attach the actuator bracket (227) onto the ram
air cylinder shaft as shown in Figure 28.
b. Install the level sensor bracket (228) using two
screws (214) and washers (213).
c. Attach the level sensor (229) onto the level
sensor bracket (228) as shown in Figure 28.
d. Connect one end of the harness (230) to the
level sensor. Connect the other end of the
harness to the bulk head connection labeled C3
on the ram junction box (208).
e. Use four wire ties (231) to secure the harness.
20. Verify all components downstream of the pump are
rated to the new, higher pressure. Replace any
components that are not rated to the higher
pressures.
NOTE: Converting from air to electric changes the
operation of the ram supply system. Follow the E-Flo SP
Supply Systems Installation-Parts manual and the E-Flo
SP Software Instructions for complete warnings and
instructions for the system going forward. See Related
Manuals on page 2.
FIG. 26: D200 Outlet Check Valve Installation
FIG. 27: D200 ADM Mounting Bracket
202 204
234
213,214
FIG. 28: D200 Empty Level Sensor
This conversion results in increased pressure to the
system. To help prevent serious injury from skin injec-
tion, all components downstream of the pump must
be rated to the new, higher maximum pressures. See
the Pressure Ratings table on page 4.
213,214
227 228
229 230 231 208
C3

Installation
3A6931A 19
21. The identification label (237,238) included in the kit
needs to be applied on the rear side of the ram
cylinder where the original identification label is
located below the ram junction box mounting
bracket as shown in Figure 29.
NOTE: When you are applying the new label, you must
leave the part number, serial number, and series
showing on the original label. The rest of the original
identification label needs to be covered by the new one
to allow for updated pressure and electrical information.
22. Carefully place the new identification label over the
original one so they line up as shown in Figure 30.
23. Refer to Connect Power to an Electric Ram
System on page 23 to connect power to the ram
junction box.
Air to Electric D200s Ram
Conversion Kits
The air to electric D200s ram conversion kit is available
in three options depending on the pump lower size.
Disassemble the Air Motor Ram
1. Follow the Pressure Relief Procedure for the air
motor pump and ram system you are using. See
Related Manuals on page 2.
2. Remove the main air supply for the air controls.
FIG. 29: D200 Identification Label Location
FIG. 30: Apply Identification Label on D200
237,238
Original
Label
PART NO. SERIAL NO. SERIES
MAX AIR WPR
MPa bar PSI
MAX FLUID WPR
MAX TEMP
ºC
WEIGHT
kg
MADE IN
MPa bar PSI
lbºF
BAR CODE TO BE INSERTED HERE
GRACO.COM / PATENTS Artwork No. 291841 Rev. E
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CMXXXX XXXXX XXXX
GRACO
INC
.
P.
O
. Box 1441
Mi
nnea
p
o
li
s
,
M
N
MADE
IN
PART NO. SERIES SERIAL NO.
VOLTS
PHASE
AMPS
HZ
MAX FLUID WPR
MPa
bar
PSI
Read instruction manual.
Artwork No. 29A057 Rev. A
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CUSTOMER MUST SUPPLY
BRANCH CIRCUIT PROTECTION
See www.graco.com/patents
MAX AIR WPR
MPa
bar
PSI
EMYYYYY YYYY YYYYY
R
PS
I
M
P
M
P
º
F
CO
DE
E
T
T
TO
O
O
B
BE
E
E
I
N
NS
ER
T
S
ERIE
S
PART NO. SERIAL NO. SERIES
MAX AIR WPR
MPa bar PSI
MAX FLUID WPR
MAX TEMP
ºC
WEIGHT
kg
MADE IN
MPa bar PSI
lbºF
BAR CODE TO BE INSERTED HERE
GRACO.COM / PATENTS Artwork No. 291841 Rev. E
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CMXXXX XXXXX XXXX
PART NO. SERIES SERIAL NO.
VOLTS
PHASE
AMPS
HZ
MAX FLUID WPR
MPa
bar
PSI
Read instruction manual.
Artwork No. 29A057 Rev. A
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CUSTOMER MUST SUPPLY
BRANCH CIRCUIT PROTECTION
See www.graco.com/patents
MAX AIR WPR
MPa
bar
PSI
EMYYYYY YYYY YYYYY
Original
Label
New
Label
Correct Label Alignment
New
Label
Kit
Number Pump Lower Size
25P286 CM100
25P287 CM200, CM250, DF115, DF145,
DF180, DF220, DF290
25P288 CM500, DF430
FIG. 31: D200s with Air Motor
Air Motor
Air Motor
Air Supply
Fittings
Pump
Coupling
Tie
Rods
Pump
Lower
Air Motor
Shutoff/
Control

Installation
20 3A6931A
3. See Figure 31 on page 19 and remove the pump
coupling, pump lower, and three tie rods from the air
motor supply system. Save these parts to be used
when installing the kit. Refer to the Supply Systems
Operation manual and the Supply Systems
Repair-Parts manual. See Related Manuals on
page 2.
4. Remove the air motor supply hose and fittings from
the top of the air controls.
5. On the air controls, disconnect the air motor shutoff
and control sections together by removing the two
screws underneath the air motor control as shown in
Figure 31 on page 19. Lift the two sections to
remove them. Remove the o-ring from around the
hole in the top of the air controls.
6. Remove the air motor from the ram.
Assemble the Electric D200s Ram
Conversion Kit
NOTE: Refer to the Air to Electric D200s Ram
Conversion Kit, 25P286-88 parts on page 38 for
correct assembly.
1. Refer to Figure 32 and remove the hex nut from the
ram’s cross beam. Place the cable track bracket
(311) on the cross beam with the track on the rear of
the beam and replace the hex nut.
2. Attach the ram junction box (308) to the ram using
three screws (310) and washers (309) as shown in
Figure 33.
3. Disconnect the wires from the disconnect block (A).
4. Remove and discard the driver junction box cover
(C) and the disconnect switch (B) from the driver.
See Figure 34.
5. Remove and discard the extrusion (D), then remove
and discard the plug (E).
6. Remove the cord grip and save it for reuse.
7. Install the electric driver (301) using the same
hardware that was used with the air motor.
8. Install the cord grip that was removed in step 6 in
the driver junction box where the plug was removed.
See Figure 35 on page 21.
All electrical wiring must be done by a qualified elec-
trician and comply with all local codes and regula-
tions.
FIG. 32: D200s Cable Track Installation
Hex Nut
311
FIG. 33: D200s Ram Junction Box Installation
FIG. 34: Remove Driver Junction Box
309,310
A
D
C
B
E
Cord Grip