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

System Wiring Schematics
311592Z 11
FIG. 3: System Wiring Schematic, Hazardous Location
IS SENSOR
CIRCUIT
BOARD
(249639)
1
2
J2
1
2
3
4
5
TDC
NAMUR
SENSOR
(15H984)
J1
PRESSURE
TRANSDUCER
(120371)
3
4
J2
1
2
3
J3
LOCAL CONTROL
(120373)
HAZARDOUS AREA
COM
TRIP RESET
RUN/STOP
LOCAL/REMOTE
JOG
SECURE DISABLE
24V (+)
GRN/YLW - 14 GA ALPHA WIRE P/N: V16014/EQUIV.
BLK - 14 GA ALPHA WIRE P/N: V16014/EQUIV.
BLK - 14 GA ALPHA WIRE P/N: V16014/EQUIV.
BLK - 14 GA ALPHA WIRE P/N: V16014/EQUIV.
BLU - 18 GA MTW WIRE
BLU - 18 GA MTW WIRE
GREEN
RED
BLACK
POSITION SENSOR
(16K088)
SEE SHEET 1 DETAIL
BLACK
6
SEE DETAIL
B, page 12
IS Control Drawing 288110
SEE DETAIL A,
page 12
Alpha Wire P/N M16107LW/equiv.
6

System Wiring Schematics
12 311592Z
FIG. 4: System Wiring Schematic, Hazardous Location Detail Views
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IS SENSOR
CIRCUIT
BOARD
(249639)
1
2
J2
1
2
3
4
5
TDC
NAMUR
SENSOR
(15H984)
J1
+ (BRN)
- (BLU)
(RED)
(GRN)
(WHT)
(BLK)
PRESSURE
TRANSDUCER
(120371)
3
4
J2
1
2
3
J3
BARRIER
(16A630)
ALL SWITCHES
"ON" POSITION 1
BARRIER
(16A633)
1
3
1
2
3
4
GREEN
RED
BLACK
FERRITE
(16G496)
BELDEN 8777 OR EQUIV.
WITH FERRITE (123375)
POSITION SENSOR
(16K088)
(16J588)
INSTALLED ON PUMP ASSEMBLY
INSTALLED IN E-FLO JUNCTION BOX ONLY
+(BRN) -(BLU)
BLACK
5
2
DETAIL A
DETAIL B
HAZARDOUS (CLASSIFIED) LOCATION
CLASS I, DIV. 1, GROUP C & D, T3 (FM ONLY)
GROUP II, CATEGORY 2 - ZONE 1, GAS (ATEX ONLY)
CLASS I, DIV. 1, GROUP C & D T3 (CANADA)
IS Control Drawing 288110
NON-HAZARDOUS
AREA
1 The installation must meet the requirements of the National Electric Code,
Canadian Electrical Code Part I, Article 504, NFPA 70, and ANSI/ISA 12.06.01.
Individually shielded cables needed to ensure separation of sensor and
transducer circuits.
The voltage (Vmax or Ui), current (Imax or Ii), and power (Pi) must be equal to or
greater than the voltage (Voc, Uo, or Vt), current (Isc, Io, or It), and power (Po or
Pt) levels, which can be delivered by the associated apparatus. In addition, the
maximum unprotected capacitance (Ci) and inductance (Li) of the intrinsically
safe apparatus, including interconnecting wiring, must be less than the
capacitance (Ca) and inductance (La) which can be safely connected to the
associated apparatus.
Land shield drain and foil to conductive strain relief.
2
3
5
SEE PAGE 11
3
HAZARDOUS AREA

Power Supply Requirements
311592Z 13
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 9. 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 non-intrisically safe 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.
16D612 Power Module
The 16D612 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 9. 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)

Power Supply Requirements
14 311592Z
Pressure Transducer Grounding
Requirements
The pressure transducer cable (25a) shield and drain
wire is grounded through metal-to-metal contact with the
transducer conductive strain relief (35). See FIG. 5.
Ensure that the conductive strain relief (35) is screwed
tightly into the housing, to ensure electrical continuity to
the pump housing.
Tighten the nut (N) on the conductive strain relief (35)
securely to ensure that the shield and drain wire (G) has
firm metal-to-metal contact between the nut and bushing
(B). Ensure that the ferrite (76) is attached around the
transducer leadwires, and is located inside the circuit
board compartment.
IS Field Wiring Grounding
Requirements
The IS field wire is grounded through the grounding
screw in the junction box. See FIG. 6.
Ensure that the conductive strain relief (74a) is screwed
tightly into the housing. Units with a sensor circuit must
use the conductive strain relief to ensure proper shield-
ing of the IS field wire.
Thread the IS field wire through the conductive strain
relief (74a) and connect it to J2 and J3 on the circuit
board. See FIG. 6 and the System Wiring Schematics,
page 11.
See FIG. 6. Tighten the nut (N) on the conductive strain
relief (74a) securely. Install the ferrite (77) on the field
wire (F), not more than 2 in. (51 mm) from the bottom of
the conductive strain relief (74a). Install ground wire (G)
to grounding screw in junction box.
FIG. 5. Transducer Cable Grounding
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76
25a
B
G
N
44
Tighten nut (N) securely to
ensure that the shield and
drain wire (G) has firm
metal-to-metal contact
between the nut and
bushing (B).
3
3
35
ti17644a
Land shield drain and foil to conductive strain relief.
5
FIG. 6. IS Circuit Field Wire
ti16891b
F
N
77
B
74a
Not more than
2 in. (51 mm)
G

Pump Location
311592Z 15
Pump Location
Environmental Conditions
See Technical Data, page 26, for recommended ambi-
ent temperature range and environmental conditions.
Clearance
When selecting the location for the pump, keep the fol-
lowing in mind:
• There must be sufficient space on all sides of the
pump for installation, operator access, repair, and
air circulation. See Dimensions, page 23. See
manual 311593 for maintenance requirements.
• Ensure that the mounting surface and mounting
hardware are strong enough to support the weight
of the equipment, fluid, hoses, and stress caused
during operation.
• There must be a pump disable switch within easy
reach of the pump. The Secure Disable switch on
the Local Control Box Accessory provides this func-
tion. See page 21.
15H884 Floor Stand
Floor Stand 15H884 is available as an option. See
406638 for assembly and mounting instructions.
Connect Fluid Lines
See FIG. 7. The fluid manifolds are secured to the
pumps with 1-1/2 in. clamps and sanitary gaskets (CG).
Manifolds can be oriented in either direction. Connect
the fluid line (R) to the manifold (MF) using 2 in. clamps
and sanitary gaskets (SC). Graco recommends a mini-
mum suction tube size of 1-1/4 in. (31.8 mm). Optional
fittings are available. See TABLE 3.
Table 3: Fluid Fittings, Clamps, and Sanitary
Gaskets
Part No. Description
15J423 Converts 2 in. sanitary to 2 in. npt
adapter
15J422 Converts 1-1/2 in. sanitary to 1-1/2 in. npt
adapter
15J639 Converts 2 in. sanitary to 1-1/2 in. sani-
tary reducer adapter
120350 1-1/2 in. Sanitary Clamp
120620 2 in. Sanitary Clamp
120631 2 in. Sanitary Gasket, PTFE
680454 1-1/2 in. Sanitary Gasket, Virgin PTFE
120351 1-1/2 in. Sanitary Gasket, PTFE
encapsulated fluoroelastomer
FIG. 7. Fluid Connection (Pump Inlet, E-Flo 4000
Shown)
ti8744b
R
SC
MF
CG
Use 120351 Gaskets at these locations.
1
1

Electric Motor
16 311592Z
Electric Motor
Electric Motor Specifications
The electric motor must be approved as explosion-proof
for use in a hazardous area. See Approvals, page 5, for
applicable agencies and requirements. All wiring must
meet Local and National electric codes for hazardous
area.
See TABLE 4 for motor specifications. If motor is not pur-
chased with pump, adapter kits are available. See TABLE
5 on page 17.
NOTE: Graco does not support the use of the Graco
VFD CAM mode on motors not supplied by Graco.
Motor Wiring
See the System Wiring Schematics on pages 10 and
11.
Install an explosion-proof seal fitting in the wall separat-
ing the hazardous area from the non-hazardous area.
Use explosion-proof conduit or increased safety protec-
tion concepts to run wires between the motor junction
box and the variable frequency drive (VFD).
Use 14 gauge wire (3 wires plus ground) to connect the
VFD and the motor.
Use 18 gauge wire between pins 8 and 11 on the VFD
and the motor overtemperature switch.
Motor must be wired to rotate fan counter-clockwise
when viewed from fan end of motor. See FIG. 9 or FIG.
10.
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 4: Electric Motor Specifications
Motor Kit
Part No. Voltage Phase
Supply
Frequency Horsepower rpm
Full Load
Torque
255226 230/400V 3 50 Hz 5 1500
(4 pole)
15 ft-lb
(20.3 N•m)
255225 230/460V 3 60 Hz 5 1800
(4 pole)
15 ft-lb
(20.3 N•m)
289552 230/400V 3 50 Hz 3 1500
(4 pole)
9.1 ft-lb
(12.3 N•m)
289551 230/460V 3 60 Hz 3 1800
(4 pole)
9.1 ft-lb
(12.3 N•m)
NOTE: The motor must be rated for use with a VFD. The motor must be able to operate at full
current through the range of 5-50 Hz or 6-60 Hz.

Electric Motor
311592Z 17
Install the Motor
NOTE: A NEMA 182/184 TC Frame is required to mate
with the gear reducer. If the pump is purchased without
a motor, you must order a kit to mate with the gear
reducer. See TABLE 5.
1. Thoroughly clean the input shaft and motor shaft,
removing any debris. This ensures proper clearance
and fit for the coupler.
NOTE: Do not reuse old keys or setscrews. Use only the
parts supplied with the coupler.
2. See FIG. 8. Assemble the key (20) in the input shaft
(105) keyway. Assemble the two setscrews (31) in
the coupler (28), ensuring that they do not encroach
on the keyway or the input shaft bore of the coupler.
3. Slide the coupler into the gear reducer so the key
and input shaft mate with the coupler. Slide on until
coupler bottoms out on the tapered step of the shaft.
4. Tighten setscrews to 66-78 in-lb (7.4-8.8 N•m).
Apply antiseize lubricant (LPS®-04110 or equiva-
lent) to bore of coupling.
NOTE: When installing an IEC 112M/B5 or 100L/B5
Frame electric motor, ensure that the motor adapter
(MA) and screws (MS) are in place before mounting the
motor on the gear reducer. Torque screws to 40-45 ft-lb
(54-61 N•m). See FIG. 10.
NOTE: A faint clicking may be heard while the motor is
running. This is normal and is due to necessary clear-
ances between the coupler (28), motor shaft, and motor
key. If the intensity increases significantly over time, it
could indicate the coupler is wearing and should be
replaced. Do not open the gear reducer. Opening the
gear reducer voids the warranty. The gear reducer is
not field serviceable beyond the maintenance recom-
mended in this manual.
Table 5: Motor Adapter Kits
Kit No. Description
16C487 Coupler Kit for NEMA 182-184 TC Frame
3 or 5 HP motors. Includes 2.25 in. (57.2
mm) key. See manual 311605.
15H880 Coupler Kit for NEMA 182/184 TC Frame
3 or 5 HP motors. Includes 1.75 in. (44.5
mm) key. See manual 311605.
24E453 Mounts IEC 112M/B5 or 100L/B5 Frame 3
or 5 HP motor to gear reducer. See
manual 311605.
NOTE: All kits include the 0.62 in. (15.7 mm) key
(120376). Some kits include an additional motor shaft
key. Measure the length of the motor keyway to
determine the correct key length. Key length should
be at least 90% of keyway length.
NOTICE
Ensure that neither the input key (20) or the end of the
coupler (28) motor shaft bore extend past the end of
the input shaft (105). This could cause the motor shaft
to bottom out on the coupler, causing excessive heat
and bearing damage.
NOTICE
When installing the electric motor, always ensure that
the motor shaft key cannot move out of position. If the
key works loose it could cause excessive heat and
equipment damage.
FIG. 8. Install the Coupler
ti8913b
105
28
20
Apply antiseize lubricant (LPS®-04110 or equivalent)
to bore of coupling (28).
15
15

Electric Motor
18 311592Z
5. See FIG. 9 or FIG. 10. Lift the motor (19) into posi-
tion. Align the key on the motor shaft with the mating
slot of the motor coupler, and the four mounting
holes with the holes in the gear reducer (1). Slide
the motor into place.
6. While one person supports the motor (19), install
the screws (37). Torque to 75-80 ft-lb (102-108
N•m).
FIG. 9. All NEMA 182/184 TC Frame Electric Motors
ti8726b
19
37
31
20
28
31
1
Motor Rotation
(counter-clockwise as viewed from fan end)
FIG. 10. IEC 112M/B5 and 100L/B5 Frame Electric
Motors
19
37
31
20
28
Motor Rotation
(counter-clockwise as viewed from fan end)
MA
MS
1
ti9007b

Electrical Noise Filter
311592Z 19
Electrical Noise Filter
See FIG. 1 on page 9 and FIG. 2 Electrical Schematic on
page 10. Install the electrical noise filter in the non-haz-
ardous area, upstream of the VFD.
Graco supplies accessory noise filters, depending on
your system voltage. See TABLE 6.
Table 6: Electrical Noise Filters
Part No.
Rated
Voltage Amps
Mounting Hole
Diagram
120365 230 Vac 32 FIG. 11
120366 480 Vac 16 FIG. 12
FIG. 11. 120365 Filter Mounting Holes
15.93 in.
404.6 mm
4.92 in.
125.0 mm
0.256 in. (6.5 mm)
diameter mounting holes
1.18 in.
30.0 mm
FIG. 12. 120366 Filter Mounting Holes
16.65 in.
422.9 mm
2.91 in.
73.9 mm
0.217 in.(5.5 mm)
diameter mounting holes

Variable Frequency Drive Accessory (VFD)
20 311592Z
Variable Frequency Drive
Accessory (VFD)
Use a variable frequency drive (VFD) accessory to pro-
vide motor drive control to the pump. Graco supplies
accessory VFDs that optimize pump performance.
Order Part No. 15J753 (200-240 Vac) or 15J754
(380-480 Vac), depending on your system voltage.
See VFD manual 311596 for further information.
VFD Installation
See FIG. 1 on page 9. Install the VFD (D) in the non-haz-
ardous area.
Install an electrical noise filter (F) upstream of the VFD.
See page 19.
VFD Wiring
See FIG. 2 Electrical Schematic on page 10f or VFD wir-
ing connections.
• Connect 14 gauge or larger wires to terminals U, V,
W, and GND on the VFD. See Motor Wiring, page
16.
• Connect 18 gauge wires between pins 8 and 11 on
the VFD and the motor overtemperature switch.
ACS Module (Optional)
The advanced motor control system provides optimal
control of paint circulating systems when used with an
E-Flo pump and a Variable Frequency Drive Accessory.
Order ACS module kit 24H372. The kit includes manual
3A0006.
ACS Wiring
See ACS manual 3A0006 for further information.
Ethernet Interface
(optional)
To operate the system from a personal computer, order
Ethernet Interface Kit 15H885 for the VFD. See FIG. 13.
The kit includes manual 311612.
See FIG. 1 on page 9. Use Category V Ethernet cable
(X) to connect the computer (Y) to the VFD (D).
FIG. 13. Ethernet Interface Module
Ethernet Port