Graco SaniForce 1040e Instruction Manual

Operation
SaniForce®1040e
Electric-OperatedDiaphragm
Pump3A3167N
EN
For For
For󰘱uid 󰘱uid 󰘱uidtransfer transfer transferin in inindoor indoor indoorsanitary sanitary sanitaryapplications. applications. applications.Not Not Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or or
hazardous hazardous
hazardouslocations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.See See Seeapprovals approvals approvalspage page pagefor for formore more moreinformation. information. information.For For Forprofessional professional professional
use use
useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanual.Save Save
Savethese these these
instructions. instructions.
instructions.
Formaximumoperatingpressures,
seethePerformanceChartsonpages
49–53.
Seepages6and7formodel
information,includingapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.
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Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................6
OrderingInformation...........................................8
CartSystems...............................................9
Overview............................................................10
Installation..........................................................11
GeneralInformation.....................................11
TipstoReduceCavitation.............................11
MountthePump..........................................13
Grounding...................................................14
AirLine........................................................16
FluidSupplyLine.........................................16
FluidOutletLine...........................................16
LeakSensor................................................16
ElectricalConnections(ACModels).....................17
WireConnectionsattheVariable
FrequencyDrive(VFD)...................17
WireConnectionsattheMotor......................17
WireConnectionsattheATEXMotor............18
WireConnectionsattheExplosionproof
Motor.............................................18
LeakSensorWiring(ACModels)..................19
ElectricalConnections(BLDCModels).................20
ConnectCables...........................................20
WiringTips..................................................21
BLDCMotorWiring......................................22
ControllerWiring..........................................23
LeakSensorWiring(BLDCModels)..............24
PLCWiring..................................................24
CompressorWiring.............................................25
CartWiring.........................................................26
Operation...........................................................27
InitialCon󰘰guration(ACwithVFD)................27
InitialCon󰘰guration(BLDCwithGraco
MotorControl)................................27
SanitizethePumpBeforeFirstUse...............27
TransferModeVs.LowPulsation
Mode.............................................27
StartandAdjustthePump............................28
FlowCalibrationProcedure...........................28
BatchCalibrationProcedure.........................29
PressureReliefProcedure............................29
PumpShutdown..........................................29
GracoMotorControlOperation(BLDC
Models)................................................30
Display........................................................30
GracoMotorControlSoftware
Overview........................................31
OperationModes.........................................34
Maintenance......................................................41
MaintenanceSchedule.................................41
Lubrication...................................................41
TightenConnections....................................41
CleantheGracoMotorControl.....................41
UpgradeGracoMotorControl
Software........................................41
FlushingandStorage...................................42
TroubleshootingtheGracoMotorControl.............43
DiagnosticInformation..................................44
PowerLineVoltageSurges..........................45
TestPowerLinewithMultimeter...................45
Events.........................................................46
PerformanceCharts............................................49
Dimensions........................................................56
TechnicalData...................................................61
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A3168SaniForce1040eElectric-OperatedDiaphragmPump,Repair/Parts
23A3167N
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Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffandremovepowerbeforedisconnectinganycablesandbeforeservicingorinstalling
equipment.Forcart-mountedmodels,unplugthepowercord.Forallotherunits,disconnect
poweratthemainswitch.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
•Wait󰘰veminutesforcapacitordischargebeforeopeningequipment.
•Forcart-mountedmodels,useonly3-wireextensioncords.
•Forcart-mountedmodels,ensuregroundprongsareintactonanypowerandextensioncords.
•Forcart-mountedmodels,donotexposetorain.Storeindoors.
•Donotexposecompressorboxtowashdownspray.
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
3A3167N3
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Warnings
WARNING
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
PRESSURIZED PRESSURIZED
PRESSURIZEDALUMINUM ALUMINUM ALUMINUMPARTS PARTS PARTSHAZARD HAZARD HAZARD
Useof󰘱uidsthatareincompatiblewithaluminuminpressurizedequipmentcancauseserious
chemicalreactionandequipmentrupture.Failuretofollowthiswarningcanresultindeath,
seriousinjury,orpropertydamage.
•Donotuse1,1,1-trichloroethane,methylenechloride,otherhalogenatedhydrocarbon
solventsor󰘱uidscontainingsuchsolvents.
•Donotusechlorinebleach.
•Manyother󰘱uidsmaycontainchemicalsthatcanreactwithaluminum.Contactyourmaterial
supplierforcompatibility.
43A3167N
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Warnings
WARNING
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSDStoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
3A3167N5
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CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1040FGE 1040FGE
1040FGE- - -A04AS13SSPTPOPT A04AS13SSPTPOPT A04AS13SSPTPOPT
1040 1040
1040FG FG FGE E
EA A A04A 04A
04AS13 S13 S13SS SS SSPT PT
PTPO PO
POPT PT
PT
Pump
Model
WettedSection
Material
DriveCenterSection
Material
GearBox
andMotor
FluidCovers
andManifolds
SeatsBallsDiaphragmsManifold
O-Rings
Pump Pump
PumpWetted Wetted
WettedSection Section SectionMaterial Material MaterialDrive Drive
DriveType Type TypeCenter Center
CenterSection Section SectionMaterial Material MaterialMotor Motor Motorand and andGearbox Gearbox Gearbox
1040 1040
1040FG FG FGFoodGradeE E
EElectricA A
AAluminum04A 04A
04AStandardACInductionMotor
withGearbox
HS HS
HSHighSanitationS S
SStainlessSteel04B 04B 04BBrushlessDCMotor
PH PH
PHPharmaceutical04E 04E
04ENEMA56CGearbox‡
04F 04F
04FIEC90B5FlangeGearbox‡
05C 05C
05CBrushlessDCMotor(con󰘰gured
forcart-mountedsystems)
Fluid Fluid
FluidCovers Covers Coversand and and
Manifolds Manifolds
Manifolds
Seat Seat
SeatMaterial Material MaterialBall Ball
BallMaterial Material MaterialDiaphragm Diaphragm DiaphragmMaterial Material MaterialManifold Manifold
Manifold
O O
O- - -Rings Rings Rings
S13 S13
S13TriClamp,FGSS SS SS316Stainless
SteelCW CW
CWPolychloroprene
WeightedPO PO
POPTFE/EPDM
OvermoldPT PT
PTPTFE
S14 S14
S14DIN,FGPT PT
PTPTFEPT PT PTPTFE/EPDM
2–PieceEP EP
EPEPDM
SSA SSA
SSATriClamp,HS
orPHSP SP
SPSantopreneSP SP SPSantoprene
SSB SSB
SSBDIN,HSorPH
Approvals Approvals
Approvals
AllModelsarecerti󰘰edto:
ModelswhichdonotcontainSantoprene*:
63A3167N
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CongurationNumberMatrix
Approvals Approvals
Approvals
II2GExhIIBT3Gb
‡Pumpswithcode04Eor04Farecerti󰘰edto:ATEXT-coderatingisdependentonthetemperatureof
the󰘱uidbeingpumped.Fluidtemperatureislimitedbythe
materialsofthepumpinteriorwettedparts.SeeTechnical
Dataforthemaximum󰘱uidoperatingtemperatureforyour
speci󰘰cpumpmodel.
*EC1935/2004compliantpumpsmaybesubjecttoindividualnationalprovisionsinadditiontothose
speci󰘰edintheECregulation.Itistheusersresponsibilitytoknowandfollowlocallaws.
3A3167N7
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OrderingInformation
Ordering Ordering
OrderingInformation Information Information
To To
ToFind Find FindYour Your YourNearest Nearest NearestDistributor Distributor Distributor
1.Visitwww.graco.com.
2.ClickonWhere Where
Whereto to toBuy Buy BuyandusetheDistributor Distributor DistributorLocator. Locator. Locator.
To To
ToSpecify Specify Specifythe the theCon󰘰guration Con󰘰guration Con󰘰gurationof of ofa a aNew New NewPump Pump Pump
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
OR OR
OR
UsetheOnline Online
OnlineDiaphragm Diaphragm DiaphragmPump Pump PumpSelector Selector SelectorTool Tool Toolat at atwww.graco.com www.graco.com www.graco.com. . .GototheProcess Process ProcessEquipment Equipment EquipmentPage. Page. Page.
To To
ToOrder Order OrderReplacement Replacement ReplacementParts Parts Parts
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
83A3167N
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OrderingInformation
Cart Cart
CartSystems Systems Systems
Cartsystemsincludeastainlesssteelwashdowncart,aBLDCmotor,compressor,aircontrol,andGraco
motorcontroller.Twocompressorinputpowerlevelsareavailable.Seetablebelowforavailablesystems.
Cart Cart
CartSystem System SystemReplacement Replacement
Replacement
Pump Pump
Pump†
Pump Pump
PumpCon󰘰guration Con󰘰guration Con󰘰gurationCompressor Compressor Compressorkit kit kitVoltage Voltage Voltage
25A67225A8791040TE-S05CS13SSPTPOPT120V
25A70325A8801040TE-S05CS13SSPTPTPT120V
25A70425A8811040TE-S05CS13SSSPSPPT120V
25A70525A8821040TE-S05CS13SSCWSPEP120V
25A70625A8791040TE-S05CS13SSPTPOPT240V
25A70725A8801040TE-S05CS13SSPTPTPT240V
25A70825A8811040TE-S05CS13SSSPSPPT240V
25A70925A8821040TE-S05CS13SSCWSPEP240V
†Pumpsarereplacementpumpsforcartedsystemsonly.Thesepumpsarenotsuppliedwith󰘱oor
mountingbracketsoraircontrols.
3A3167N9
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Overview
Overview Overview
Overview
Theproductlineofferselectric-powereddiaphragmpumpsinawiderangeofmodels.Thissectionshowsthe
basicstructureofavailablemodels.Fluidsectionoptionsaretoonumeroustoinclude.Themanymanifold,
seat,ball,anddiaphragmoptionsareavailableonawidevarietyofthesemodels.
Food Food
FoodGrade Grade GradePump Pump PumpModels Models Models
Center Center
Center
Section Section
Section
Motor Motor
MotorType Type TypeController Controller
ControllerGearbox Gearbox GearboxCompressor Compressor CompressorApproval Approval
Approval
Options Options
Options
Cart Cart
Cart
Yes-120VNoneNo*
Yes-240VNo*AC
VFD—notincluded.
VFDKits16K911(240V)
and16K912(480V)are
available.
Yes–part
ofmotor
No†CENo*
Yes-120VNoneYes
Yes-240VYesBrushless
DC
GracoMotorControl–
includedNEMA
No†CENo*
NEMA
Aluminum
or
Stainless
Steel
NoneNoneIECNoneATEX&CENo*
*CartKit24Y923isavailable.
†CompressorKits24Y921(120V)and24Y922(240V)areavailable
High High
HighSanitation Sanitation Sanitationor or orPharmaceutical Pharmaceutical PharmaceuticalPump Pump PumpModels Models Models
Center Center
CenterSection Section SectionMotor Motor
Motor
Type Type
Type
Controller Controller
ControllerGearbox Gearbox GearboxCompressor Compressor CompressorApproval Approval
Approval
Options Options
Options
Cart Cart
Cart
AC
VFD—notincluded.
VFDKits16K911(240V)
and16K912(480V)are
available.
Yes–
partof
motor
Brushless
DC
GracoMotorControl–
includedNEMA
No†CE
NEMA
Aluminumor
StainlessSteel
NoneNoneIECNoneATEX&CE
No*
*CartKit24Y923isavailable.
†CompressorKits24Y921(120V)and24Y922(240V)areavailable
Key Key
KeyPoints: Points: Points:
•PumpsareavailablewithanACorBrushless
DC(BLDC)motor,orwithjustagearbox(for
applicationswhereamotorisalreadyavailable).
•Gracorecommendstheuseofamotorsoft
starteroraVFD(PN16K911or16K912)inthe
electricalcircuitforallinstallations.Seethe
motormanufacturer’srecommendationsforproper
installationwhenusingeitherofthesecomponents.
Inallcases,makesureallproductsareinstalledin
accordancewithlocalcodesandregulations.
•BLDCmotorsarecontrolledbytheGracoMotor
Controlthatissuppliedwiththepump.
103A3167N
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Installation
Installation Installation
Installation
General General
GeneralInformation Information Information
TheTypicalInstallationshownisonlyaguide
forselectingandinstallingsystemcomponents.
ContactyourGracodistributorforassistancein
planningasystemtosuityourneeds.Alwaysuse
GenuineGracoPartsandAccessories.Besureall
accessoriesareadequatelysizedandpressurerated
tomeetthesystem’srequirements.
Referencelettersinthetext,forexample(A),referto
thecalloutsinthe󰘰gureslocatednearthereference.
Ifacalloutisona󰘰gurelocatedelsewhereinthe
manual,thereferencewillindicatewheretolook
withinthemanual.
Pumpswithaluminumcentersectionsmayexhibit
fadingorsignsofcorrosiondependingoncleaning
solutionsused.
Tips Tips
Tipsto to toReduce Reduce ReduceCavitation Cavitation Cavitation
Cavitationinadoublediaphragmpumpisthe
formationandcollapseofbubblesinthepumped
liquid.Frequentorexcessivecavitationcancause
seriousdamage,includingpittingandearlywearof
󰘱uidchambers,balls,andseats.Itmayresultin
reducedef󰘰ciencyofthepump.Cavitationdamage
andreducedef󰘰ciencybothresultinincreased
operatingcosts.
Cavitationdependsonthevaporpressureofthe
pumpedliquid,thesystemsuctionpressure,andthe
velocitypressure.Itcanbereducedbychangingany
ofthesefactors.
1.Reducevaporpressure:Decreasethe
temperatureofthepumpedliquid.
2.Increasesuctionpressure:
a.Lowertheinstalledpositionofthepump
relativetotheliquidlevelinthesupply.
b.Reducethefrictionlengthofthesuction
piping.Rememberthat󰘰ttingsaddfriction
lengthtothepiping.Reducethenumberof
󰘰ttingstoreducethefrictionlength.
c.Increasethesizeofthesuctionpiping.
d.IncreasetheNetPositiveSuctionHead
(NPSH).SeePerformanceCharts,page49.
NOTE: NOTE:
NOTE:Besuretheinlet󰘱uidpressuredoesnot
exceed25%oftheoutletworkingpressure.
3.Reduceliquidvelocity:Slowthecyclicrateof
thepump.
Pumpedliquidviscosityisalsoveryimportantbut
normallyiscontrolledbyfactorsthatareprocess
dependentandcannotbechangedtoreduce
cavitation.Viscousliquidsaremoredif󰘰culttopump
andmorepronetocavitation.
Gracorecommendstakingalloftheabovefactors
intoaccountinsystemdesign.Tomaintainpump
ef󰘰ciency,supplyonlyenoughpowertothepumpto
achievetherequired󰘱ow.
Gracodistributorscansupplysitespeci󰘰c
suggestionstoimprovepumpperformanceand
reduceoperatingcosts.
3A3167N11
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Installation
Graco Graco
GracoMotor Motor MotorControl Control ControlComponent Component ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
KEY: KEY:
KEY:
AConduitHoles
BDisplayControlPanel
CMountingTabs
DWarningLabel
123A3167N
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Installation
Mount Mount
Mountthe the thePump Pump Pump
Toavoidseriousinjuryordeathfromtoxic󰘱uidor
fumes:
•Nevermoveorliftapumpunderpressure.If
dropped,the󰘱uidsectionmayrupture.Always
followthePressureReliefProcedure,page29,
beforemovingorliftingthepump.
NOTICE NOTICE
NOTICE
Thepumpisheavy.Topreventdamagefrom
dropping,alwaysuse2peopleoralifttomovethe
pump.Donotusethemanifoldstoliftthepump.
Useatleastonestraporliftringonthepump.
1.Forallmountings,besurethepumpissecured
withscrewsthroughthemountingbracketonthe
gearbox.SeeDimensions,page56.
NOTICE NOTICE
NOTICE
Topreventpumpdamage,useallfour
fastenerstoattachthebrackettothemounting
location.Donotusethefeetontheinlet
manifoldformounting.
2.Makesurethesurfaceis󰘱atandthatthepump
doesn’twobble.
3.ForBLDCmodels,securelymounttheGraco
MotorControlusingtheprovidedmountingtabs.
4.Foreaseofoperationandservice,mountthe
pumpso󰘱uidinletand󰘱uidoutletportsareeasily
accessible.
5.Cart Cart
CartMounting: Mounting: Mounting:Forallmodels,CartMounting
Kit24Y923isavailable.Foravailable
pre-con󰘰guredcartandpumpsystems,see
CartSystems,page9.
NOTICE NOTICE
NOTICE
Topreventunstableloadingduetoanoffset
centerofgravity,liftthecartbyusingstraps
attachedatmultiplepointsonthecartrather
thanattemptingtoliftthepumpandcartusing
onlythepumpliftring.
3A3167N13
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Installation
Grounding Grounding
Grounding
Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
•Always Always
Alwaysgroundtheentire󰘱uidsystemas
describedbelow.
•Followyourlocal󰘰recodes.
Beforeoperatingthepump,groundthesystemas
explainedbelow.
•Pump: Pump:
Pump:Loosenthegroundingscrew(R).Insertone
endofa12–gaugeminimumgroundwirebehind
thegroundscrewandtightenthescrewsecurely.
Connecttheclampendofthegroundingwiretoa
trueearthground.Agroundwireandclamp,Part
238909,isavailablefromGraco.
•Motor: Motor:
Motor:ACandBLDCmotorshaveagroundscrew
intheelectricalbox.Useittogroundthemotorto
thecontroller.
•Air Air
AirLine Line Lineand and andFluid Fluid Fluidhoses: hoses: hoses:Useonlygrounded
hoseswithamaximumof500ft(150m)combined
hoselengthtoensuregroundingcontinuity.Check
electricalresistanceofhoses.Iftotalresistance
togroundexceeds29megohms,replacehose
immediately.
•Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followlocalcode.
•Solvent Solvent
Solventpails pails pailsused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:Followlocal
code.Useonlyconductivemetalpails,placed
onagroundedsurface.Donotplacethepail
onanonconductivesurface,suchaspaperor
cardboard,whichinterruptsgroundingcontinuity.
•VFD: VFD:
VFD:Groundthevariablefrequencydrive(VFD)
throughaproperconnectiontotheelectrical
system.RefertotheVFDmanualforgrounding
instructions.
•Graco Graco
GracoMotor Motor MotorControl: Control: Control:Groundthrougha
properconnectiontoapowersource.See
ControllerWiring,page23.
Checkyoursystemgroundcontinuityaftertheinitial
installation,andthensetuparegularschedulefor
checkingcontinuitytobesurepropergroundingis
maintained.Theresistancetoearthgroundshould
notexceed1ohm.
143A3167N
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Installation
Figure1TypicalInstallation(ACPumpShown)
System System
SystemComponents Components ComponentsAccessories/Components Accessories/Components Accessories/ComponentsNot Not NotSupplied Supplied Supplied
APowercordtoVFDFGrounded,󰘱exibleairsupplyhose
BFluidinletportGBleed-typemasterairvalve
CFluidoutletportHAir󰘰lter/regulatorassembly
DMountingfeetJMasterairvalve(foraccessories)
EAirinletvalveKGrounded,󰘱exible󰘱uidsupplyhose
LFluiddrainvalve(mayberequiredforyourpump
installation)
MFluidshutoffvalve
NGrounded,󰘱exible󰘱uidoutlethose
PGroundwireandclamp(required)
3A3167N15
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Installation
Air Air
AirLine Line Line
If If
Ifusing using usinga a aGraco Graco GracoCompressor Compressor CompressorKit: Kit: Kit:
Anairlineisprovidedinthekitwhichmustbe
installedbetweenthecompressorandthepumpair
inlet.
Using Using
UsingYour Your YourOwn Own OwnCompressor: Compressor: Compressor:
Connecttheairlinefromthecompressortotheinlet
valveonthepneumaticenclosure(28).
Using Using
UsingShop Shop ShopAir: Air: Air:
NOTE:CalloutsarelocatedonFigure1,page15.
1.Installanair󰘰lter/regulatorassembly(H).The
󰘱uidstallpressurewillbethesameasthesetting
oftheairregulator.The󰘰lterremovesharmful
dirtandmoisturefromthecompressedairsupply.
2.Locateableed-typemasterairvalve(G)closeto
thepumpanduseittorelievetrappedair.Be
surethevalveiseasilyaccessiblefromthepump
andlocateddownstreamfromtheregulator.
Trappedaircancausethepumptocycle
unexpectedly,whichcouldresultinserious
injuryfromsplashing.
3.Locateanothermasterairvalve(J)upstream
fromallairlineaccessoriesanduseittoisolate
themduringcleaningandrepair.
4.Installagrounded,󰘱exibleairhose(F)between
theaccessoriesandthe3/8npt(f)pumpairinlet.
Fluid Fluid
FluidSupply Supply SupplyLine Line Line
1.Connectagrounded,󰘱exible󰘱uidhose(See
KonFigure1,page17)tothe󰘱uidinletport.
For1040FGpumps,theportis1.5in.(3.8
cm)sanitary󰘱angeor40mmDIN11851.For
1040HSand1040PHpumps,theportis1.0in.
(2.5cm)sanitary󰘱angeor25mmDIN11851.
2.Iftheinlet󰘱uidpressuretothepumpismore
than25%oftheoutletworkingpressure,theball
checkvalveswillnotclosefastenough,resulting
ininef󰘰cientpumpoperation.Excessiveinlet
󰘱uidpressurealsowillshortendiaphragmlife.
Mostmaterialsshouldrequirenomorethan3psi
(0.02MPa,0.21bar)󰘱uidinletpressure.
3.Formaximumsuctionlift(wetanddry),see
TechnicalData,page61.Forbestresults,always
installthepumpascloseaspossibletothe
materialsource.Minimizesuctionrequirements
tomaximizepumpperformance.
Fluid Fluid
FluidOutlet Outlet OutletLine Line Line
NOTE: NOTE:
NOTE:CalloutsarelocatedonFigure1,page15.
1.Connectagrounded,󰘱exible󰘱uidhose(K)tothe
󰘱uidinletport.For1040FGpumps,theportis1.5
in.(3.8cm)sanitary󰘱angeor40mmDIN11851.
For1040HSand1040PHpumps,theportis1.0
in.(2.5cm)sanitary󰘱angeor25mmDIN11851.
2.Installa󰘱uiddrainvalve(L)nearthe󰘱uidoutlet.
3.Installashutoffvalve(M)inthe󰘱uidoutletline.
Leak Leak
LeakSensor Sensor Sensor
Theoptionalleaksensor(Kit24Y661)ishighly
recommendedtoavoidoperatingthepumpwith
aruptureddiaphragm.Toinstalltheleaksensor,
removeplug123.Installthebushingandleaksensor.
NOTE: NOTE:
NOTE:Thearrowontheleaksensormustpointdown.
SeealsoLeakSensorWiring(ACModels),page19,
orLeakSensorWiring(BLDCModels),page24.
1
Toensureawatertightseal,applyLoctite®425
Assure™threadlockertothreads.
163A3167N
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ElectricalConnections(ACModels)
Electrical Electrical
ElectricalConnections Connections Connections(AC (AC (ACModels) Models) Models)
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
Followtheinstructionsinthemotormanufacturer’s
manual.Wiresize,fusesize,andotherelectrical
devicesmustcomplywithalllocalcodesand
regulations.ThemotormustbewiredtotheVFD.
Wire Wire
WireConnections Connections Connectionsat at atthe the theVariable Variable Variable
Frequency Frequency
FrequencyDrive Drive Drive(VFD) (VFD) (VFD)
FollowtheinstructionsintheVFDmanufacturer’s
manual.IfyoupurchasedanoptionalGracoVFD
(PN16K911or16K912),detailedinstallationand
connectioninformationisprovidedinthemanualthat
shipswiththeVFD.
NOTICE NOTICE
NOTICE
Toavoidequipmentdamage,donotplugthe
motordirectlyintoawallsocket.Themotormust
bewiredtoaVFD.
Wire Wire
WireConnections Connections Connectionsat at atthe the theMotor Motor Motor
Installthewiringatthemotorasfollows:
1.Openthemotor’selectricalbox.
2.Installwiringsystemwithproperliquid-tight
connectionsinoneoftheportsatthesideofthe
motorbox.
3.Connectthegreengroundwiretotheground
screw.
4.For For
For480V 480V 480VWiring: Wiring: Wiring:Themotorcomeswiredfor
480V.Ifthisisthevoltageyouwant,theexisting
wiringcanremainasitis.Connectpowerwires
L1toU1,L2toV1andL3toW1,asshown.
W2 U2 V2
L2 L3L1
U1 V1 W1
W3 U3 V3
Figure2Connectionsfor480VWiring
5.For For
For240V 240V 240VWiring: Wiring: Wiring:Movetheblackwire(U3),the
redwire(V3)andthebluewire(W3)asshown.
Usingthebridgessuppliedwiththemotor,bridge
W2,U2,andV2.ThenconnectpowerwiresL1
toU1,L2toV1andL3toW1.
W2 U2 V2
L2 L3L1
U1 V1 W1
U3 V3 W3
Figure3Connectionsfor240VWiring
6.Torqueterminalsto20in-lb(2.3N•m).
7.Closethemotorelectricalbox.Torquethe
screwsto20in-lb(2.3N•m).
3A3167N17
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ElectricalConnections(ACModels)
Wire Wire
WireConnections Connections Connectionsat at atthe the theATEX ATEX ATEXMotor Motor Motor
(Optionalkit25C081)
Installthewiringatthemotorasfollows:
1.Openthemotor’selectricalbox.
2.Installwiringsystemwithproperconnectionsto
themotorelectricalbox.
3.Connectthegreengroundwiretotheground
screw.
4.For For
For480V 480V 480VWiring: Wiring: Wiring:Bridgeasshown,thenconnect
wireL1toU1,L2toV1,andL3toW1.
W2 U2 V2
L2 L3L1
U1 V1 W1
Figure4Connectionsfora480VWiring
5.For For
For240V 240V 240VWiring: Wiring: Wiring:ConnectwireL1toU1,L2to
V1,andL3toW1.Bridgeasshown.
W2 U2 V2
L2 L3L1
U1 V1 W1
Figure5Connectionsfora240VWiring
6.Torqueterminalsto20in-lb(2.3N•m).
7.Closethemotorelectricalbox.Torquethe
screwsto20in-lb(2.3N•m).
Wire Wire
WireConnections Connections Connectionsat at atthe the the
Explosionproof Explosionproof
ExplosionproofMotor Motor Motor
(Optionalkit25C082)
Installthewiringatthemotorasfollows:
1.Openthemotor’selectricalbox.
2.Installwiringsystemwithproperconnectionsto
themotorelectricalbox.
3.Connectthegreengroundwiretotheground
screw.
4.For For
For480V 480V 480VWiring: Wiring: Wiring:ConnectwireL1toT1,L2to
T2,andL3toT3,andbridgetheotherwires,as
shown.
T1
T2
T3
L1
L2
L3
T4
T7
T5
T8
T6
T9
Figure6Connectionsfor480VWiring
5.For For
For240V 240V 240VWiring: Wiring: Wiring:Bridgethewiresasshown.
Then,connectL1toT1/T7,L2toT2/T8,andL3
toT3/T9.
T1
T7
T2
L1
L2
L3
T8
T3
T9
T4
T5
T6
Figure7Connectionsfor240VWiring
6.Option: Option:
Option:ConnectthermostatwiresP1andP2to
externaloverloaddetection.ThermostatisNC
(normallyclosed).
7.Closethemotorelectricalbox.Torquethe
screwsto20in-lb(2.3N•m).
183A3167N
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ElectricalConnections(ACModels)
Leak Leak
LeakSensor Sensor SensorWiring Wiring Wiring(AC (AC (ACModels) Models) Models)
FollowtheseinstructionstowiretheoptionalLeak
SensorKit24Y661toaVFD.
NOTE: NOTE:
NOTE:LeakSensorElectricalRatings:
•Voltage:36VDC/30VAC
•Current:0.5A
•Normallyclosed
1.Selectandpurchaseacablefromthefollowing
table,determinedbythecableroutingdistance
betweenthepumpandtheVFD.
Part Part
PartNumber Number NumberCable Cable
CableLength Length Length
17H3899.8ft,3.0m
17H39024.6ft,7.5m
17H39152.5ft,16m
2.SeeLeakSensor,page16,toinstalltheleak
sensor.Connecttheselectedcabletothe
installedleaksensor.
3.TurnoffpowertotheVFD.
4.OpentheaccesscoverontheVFD.
5.ForaGracoVFD,performthefollowing:
a.Wireonelead(blueorblack)toterminal1
ontherail.
b.Wireasecondlead(blueorblack)toterminal
4ontherail.
c.Connectajumperwirebetweenterminals4
and13A.
d.Indivduallyterminatethetworemaining
leads.
e.Closetheaccesscover.
f.TurnonpowertotheVFD.
g.OntheVFDdisplay,gotoscreenP100.
h.Changethevalueto4andpresstheMode
button.
i.GotoscreenP121.
j.Changethevalueto8andpresstheMode
button.
6.Foranon-GracoVFD,performthefollowing:
a.Attachtheblueandblackleadstothe
detectioncircuitintheVFD.
NOTE NOTE
NOTE:RefertotheVFDmanualforproper
connectionpoints.
b.Indivduallyterminatethetworemaining
leads.
c.Closetheaccesscover.
d.TurnonpowertotheVFD.
e.Con󰘰guretheVFDtomonitortheleaksensor
circuit.
3A3167N19
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ElectricalConnections(BLDCModels)
Electrical Electrical
ElectricalConnections Connections Connections(BLDC (BLDC (BLDCModels) Models) Models)
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
Connect Connect
ConnectCables Cables Cables
TheGracoMotorControlprovidesseveral
connectionsforCANcableandsystem-speci󰘰cI/O
devices.Connectaccordingtothefollowingtableto
ensurethatthecablesinyoursystemareconnected
tothecorrectconnectorsontheGracoMotorControl.
NOTE: NOTE:
NOTE:Tomaintainenclosureratinguseapproved
Type4(IP66)󰘰ttingsandensureeitheracableor
plugisattachedtoallM12andM8connectors.
Table Table
Table1 1 1Connector Connector ConnectorInformation Information Information
Graco Graco
GracoMotor Motor MotorControl Control Control
Label Label
LabelIdenti󰘰er Identi󰘰er Identi󰘰erConnector Connector ConnectorType Type TypeConnector Connector ConnectorUse Use Use
1M12,8–position,
Female
Motorpositionandtemperaturefeedback.Connectonlyto
GracoBLDCmotorwithGracocabling.
•121683(9.8ft;3.0m)
•17H349(24.6ft;7.5m)
•17H352(52.5ft;16m)
2(Spare)M12,5–position,
Female,B-Code
Notcurrentlyused.
3and4M8,4–position,
Female
SeeTable2forpinoutandpowerspeci󰘰cations;mustbe
suppliedbyaClass2powersource.
M12,5–position,
Male,A-Code
CANPowerandCommunication.ConnectonlytoGraco
suppliedcablingandmodules.Connecttoamaximum30
VDC,Class2powersource.
203A3167N
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