Graco E-Flo User manual

Installation
E-Flo®4-Ball
Piston Pumps
Durable, energy efficient piston pumps for high volume paint circulation applications.
For professional use only.
See page 3 for model information, including maximum working pressure. See page 5 for approvals.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti8317c
E-Flo 4000 Pump Shown
311592Z
EN

Related Manuals
2311592Z
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E-Flo 4-Ball Piston Pumps . . . . . . . . . . . . . . . . . 3
Maximum Working Pressure and Pump
Operational Limits . . . . . . . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Components . . . . . . . . . . . . . . . . . . . . . . . . 8
Hazardous Area . . . . . . . . . . . . . . . . . . . . . . . . . 8
Non-Hazardous Area . . . . . . . . . . . . . . . . . . . . . 8
System Wiring Schematics . . . . . . . . . . . . . . . . . . 10
Power Supply Requirements . . . . . . . . . . . . . . . . 13
Power Disconnect Switch . . . . . . . . . . . . . . . . . 13
Hazardous Area Cabling and Conduit
Requirements (Explosion Proof) . . . . . . . . . 13
Increased Safety (European) . . . . . . . . . . . . . . 13
16D612 Power Module . . . . . . . . . . . . . . . . . . . 13
Pressure Transducer Grounding
Requirements . . . . . . . . . . . . . . . . . . . . . . . 14
IS Field Wiring Grounding Requirements . . . . . 14
Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Environmental Conditions . . . . . . . . . . . . . . . . . 15
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15H884 Floor Stand . . . . . . . . . . . . . . . . . . . . . 15
Connect Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . 15
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electric Motor Specifications . . . . . . . . . . . . . . . 16
Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install the Motor . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Noise Filter . . . . . . . . . . . . . . . . . . . . . . 19
Variable Frequency Drive Accessory (VFD) . . . . 20
VFD Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20
VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ACS Module (Optional) . . . . . . . . . . . . . . . . . . . . . 20
ACS Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ethernet Interface (optional) . . . . . . . . . . . . . . . . . 20
Local Control Box (optional accessory) . . . . . . . 21
Pneumatic Back Pressure Regulator (optional) . 22
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 28
Related Manuals
Manual Description
311593 E-Flo Operation Manual
311594 E-Flo Repair-Parts Manual
311595 Pneumatic Back Pressure Regulator
311596 Variable Frequency Drive Instructions
311603 Sensor Circuit Option
3A0539 4-Ball Lowers
3A0006 ACS Module

Models
311592Z 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. EP2160represents electric
power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), 2000 cc
MaxLife lower (6), and no stand installed (0). To order replacement parts, see
the Repair-Parts manual 311594.
Maximum Working Pressure and Pump Operational Limits
E-Flo 1500: 425 psi (2.93 MPa, 29.3 bar) Maximum Working Pressure
E-Flo 2000: 460 psi (3.22 MPa, 32.2 bar) Maximum Working Pressure
E-Flo 3000: 330 psi (2.31 MPa, 23.1 bar) Maximum Working Pressure
E-Flo 4000: 250 psi (1.75 MPa, 17.5 bar) Maximum Working Pressure
See Technical Data, page 26, for pump operational limits.
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 Stand Option
E (electric) P (pump) 0 No motor 0 No circuit
installed
1 1000 cc Chrome 0 No stand
installed
1 230/400V, 5
HP, ATEX
1 Circuit installed 2 1500 cc Chrome 1 Stand
installed
2 230/460V, 5
HP, UL/CSA
3 2000 cc Chrome
3 230/400V, 3
HP, ATEX
41000 cc MaxLife®
4 230/460V, 3
HP, UL/CSA
5 1500 cc MaxLife
6 2000 cc MaxLife
7 750 cc Chrome
8 750 cc MaxLife

Models
4311592Z

Approvals
311592Z 5
Approvals
The E-Flo Pump meets requirements of the following approval agencies.
Refer to the individual components for other specific hazardous location listings.
Component Part No. Approvals
Mechanical Pump
Motor
ATEX
EP1XXX
EP3XXX
UL/CSA
EP2XXX
EP4XXX
IS Sensor Circuit EPX1XX
Ex h T3 Gb
Ex de IIC T4 - CESI 05 ATEX 110X
Class I, Group D, Class II, Group F and G, Division 1,
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
6311592Z
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, 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.
WARNINGWARNINGWARNING
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.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
vapors. To help prevent fire and explosion:
• Clean plastic parts only in a well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment 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 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 manufac-
turer’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.

Warnings
311592Z 7
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.
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 swal-
lowed.
• 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.
WARNINGWARNINGWARNING
WARNING

System Components
8311592Z
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 Electric Circulation Pump
• Explosion-Proof Electric Motor
• Local Control Box (accessory)
• Pneumatic Back Pressure Regulator (accessory)
• Sensor Control Circuit (option). See intrinsic safety
installation requirements below.
Schedule of Limitations
ATEX:
1. After the installation of the Electric Circulation
Pump Control into an enclosure the creepage
and clearance distances shall meet the require-
ments of 6.4 (Table 4) of EN50020.
2. After the installation of the Electric Circulation
Pump Control into an enclosure the assembly
shall be capable of withstanding an r.m.s. a.c.
test voltage of twice the voltage of the intrinsi-
cally safe circuit or 500 V, whichever is the
greater.
Sensor Circuit Wetted Parts
Pressure transducer: 17-4 PH stainless steel
NOTE: 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.
293140l

System Components
311592Z 9
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. 1: Typical Installation
ti8651c
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
10 311592Z
System Wiring Schematics
For use with Variable Frequency Drive (VFD) Accesory
FIG. 2 shows components that must be installed in a
non-hazardous location.
FIG. 3 shows components approved for installation in a
hazardous location, and FIG. 4 shows detail views of
hazardous location components.
FIG. 2: System Wiring Schematic, Non-Hazardous Location Only
VARIABLE FREQUENCY DRIVE
200/230 VAC - (120361)
400/460 VAC - (120362)
ETHERNET
TCP/IP
MODULE
(120368)
APPLICATIONS
LITE
MODULE
(120367)
41
42
OPEN
OPEN
1
2
3
4
5
6
7
8
9
10
11
COM
EXTERNAL 24 VDC
COM
INTERNAL 10 VDC
DIFF. ANALOG INPUT (+)
DIFF. ANALOG INPUT (-)
ANALOG IN #2
MOTOR THERMISTOR
OPEN
OPEN
COM
BARRIER
(16A630)
ALL SWITCHES
"ON" POSITION 1
I.S.
ACTIVE
BARRIER
(16A633)
15
14
7
8
15
14
9
1
3
1
2
3
4
PE L1 L2 L3 UVWGND
NON-HAZARDOUS AREA
BREAKING
RESISTOR
200/230 VAC - (120363)
400/460 VAC - (120364)
24 VDC
POWER
SUPPLY
(120369)
EXPLOSION
PROOF SEAL
FITTING
RFI FILTER
200/230 VAC - (120365)
400/460 VAC - (120366)
PE L2 L3
L1
LINE POWER (IN)
3 , 60 Hz, 230/460 VAC
3 , 50 Hz, 200/400 VAC
EXPLOSION PROOF CONDUIT BETWEEN MOTOR
JUNCTION BOX AND EXPLOSION PROOF SEAL FITTING.
CLASS I, DIV. I, GROUP C & D APPROVED.
L1 L2 L3
PE
21
22
23
24
25
26
27
28
29
30
31
COM
INTERNAL 24 VDC
OPEN
TDC SENSOR
TRIP RESET
BPR SOLENOID
RUN/STOP
LOCAL REMOTE
JOG
OPEN
SECURE DISABLE
25
26
27
28
29
31
22
TERMINAL
BLOCKS
25
26
27
28
29
31
22
BPR
SOLENOID
A
A
A
A
1
1
1
1
1
1
1
1
24V (+)
COM (-)
COM (-)
EXPLOSION
PROOF SEAL
FITTING
L3
L2
L1
PE
+ -
TRANSFORMER
(400/460 VOLT
SYSTEMS ONLY)
H1
H2
H3
H4
X1
XF
X2
L
N
L3
L2
L1
SUPPLY
GRND
TERMINAL
BLOCKS
EXPLOSION PROOF CONDUIT BETWEEN LOCAL
CONTROL BOX AND EXPLOSION PROOF SEAL FITTING.
CLASS I, DIV. I, GROUP C & D APPROVED.
FUSE 1
FUSE 2
FUSE 3
TRIP RESET
RUN/STOP
LOCAL REMOTE
JOG
SECURE DISABLE
24V (+)
GND
3
2
1
COM
TERMINAL BLOCKS
1
1
1
2
2
3
3
3
4
4
4
4
4
12 Gauge Alpha Wire P/N V16012/equiv.
16 Gauge MTW Wire.
Blue/White 16 Gauge MTW Wire.
Blue 16 Gauge MTW Wire.
1
2
3
4
NON-HAZARDOUS AREA
IS Control Drawing 288110