Graco SaniForce 1040e User manual

Operation
SaniForce® SaniForce®
SaniForce®1040e 1040e 1040eElectric Electric Electric- - -Operated Operated Operated
Diaphragm Diaphragm
DiaphragmPump Pump Pump3A3167P
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
hazardous(classi󰘰ed) (classi󰘰ed) (classi󰘰ed)locations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.See See Seeapprovals approvals approvalspage page pagefor for formore more moreinformation. information. information.For For For
professional professional
professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualbeforeusingthe
equipment.Save Save
Savethese these theseinstructions. instructions. instructions.
Formaximumoperatingpressures,
seethePerformanceChartsonpages
50–55.
Seepages6–8formodelinformation,
includingapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrixforFG
Pumps..................................................6
Con󰘰gurationNumberMatrixforHSandPH
Pumps..................................................7
Approvals...........................................................8
OrderingInformation...........................................8
CartSystems...............................................9
Overview............................................................10
Installation..........................................................11
GeneralInformation.....................................11
TipstoReduceCavitation.............................11
MountthePump..........................................13
Grounding...................................................14
AirLine........................................................16
FluidSuctionandOutletLines......................16
LeakSensor................................................17
ElectricalConnections(ACModels).....................18
WireConnectionsattheVariable
FrequencyDrive(VFD)...................18
WireConnectionsattheMotor......................18
WireConnectionsattheATEXMotor............19
WireConnectionsattheExplosionproof
Motor.............................................19
LeakSensorWiring(ACModels)..................20
ElectricalConnections(BLDCModels).................21
ConnectCables...........................................21
WiringTips..................................................22
BLDCMotorWiring......................................23
ControllerWiring..........................................24
LeakSensorWiring(BLDCModels)..............25
PLCWiring..................................................25
CompressorWiring.............................................26
CartWiring.........................................................27
Operation...........................................................28
InitialCon󰘰guration(ACwithVFD)................28
InitialCon󰘰guration(BLDCwithGraco
MotorControl)................................28
SanitizethePumpBeforeFirstUse...............28
TransferModevs.LowPulsation
Mode.............................................28
StartandAdjustthePump............................29
FlowCalibrationProcedure...........................29
BatchCalibrationProcedure.........................30
PressureReliefProcedure............................30
PumpShutdown..........................................30
GracoMotorControlOperation(BLDC
Models)................................................31
Display........................................................31
GracoMotorControlSoftware
Overview........................................32
OperationModes.........................................35
Maintenance......................................................42
MaintenanceSchedule.................................42
Lubrication...................................................42
TightenConnections....................................42
CleantheGracoMotorControl.....................42
UpgradeGracoMotorControl
Software........................................42
FlushingandStorage...................................43
TroubleshootingtheGracoMotorControl.............44
DiagnosticInformation..................................45
PowerLineVoltageSurges..........................46
TestPowerLinewithMultimeter...................46
Events.........................................................47
PerformanceCharts............................................50
Dimensions........................................................56
TechnicalSpeci󰘰cations......................................61
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A3168SaniForce1040eElectric-OperatedDiaphragmPump,Repair/Parts
23A3167P

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
DANGER
SEVERE SEVERE
SEVEREELECTRIC ELECTRIC ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentcanbepoweredbymorethan240V.Contactwiththisvoltagewill
causedeathorseriousinjury.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesand
beforeservicingequipment.
•Thisequipmentmustbegrounded.Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocal
codesandregulations.
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolvent,inwork work
workarea area areacanigniteorexplode.Solvent󰘱owingthrough
theequipmentcancausestaticsparking.Tohelpprevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygrounded󰘱uidlines.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
3A3167P3

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.
•Checklines,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestSafetyDataSheet(SDS)from
distributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Route󰘱uidlinesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhot
surfaces.
•Donotkinkoroverbend󰘱uidlinesoruse󰘱uidlinestopullequipment.
•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.
43A3167P

Warnings
WARNING
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinglines,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacelinesproactivelyatregularintervalsbasedonyouroperatingconditions.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰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.
3A3167P5

CongurationNumberMatrixforFGPumps
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrixfor for forFG FG FGPumps Pumps Pumps
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Whenyoureceiveyourpump,recordthe9character
partnumberfoundontheshippingbox(e.g.,
SP1B.0014):
_____________
Alsorecordthecon󰘰gurationnumberonthepumpID
platetoassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1040FG 1040FG
1040FG- - -EA04AS13SSPTPOPT21 EA04AS13SSPTPOPT21 EA04AS13SSPTPOPT21
1040 1040
1040FG FG FGE E
EA A A04A 04A
04AS13 S13 S13SS SS SSPT PT
PTPO PO
POPT PT
PT21 21
21
Pump
Model
Wetted
Section
Material
DriveCenter
Section
Material
GearBox
andMotor
Fluid
Coversand
Manifolds
SeatsBallsDiaphragmsManifold
O-rings
Certi󰘰ca-
tion
Pump Pump
PumpWetted Wetted
WettedSection Section Section
Material Material
Material
Drive 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
04AStandardACInductionMotorwith
Gearbox
S S
SStainlessSteel04B 04B 04BBrushlessDCMotor
04E 04E
04ENEMA56CGearbox‡
04F 04F
04FIEC90B5FlangeGearbox‡
04G 04G
04GNomotor,Nogearbox
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
Gaskets Gaskets
Gaskets
Certi󰘰cation Certi󰘰cation
Certi󰘰cation
S13 S13
S13TriClamp,
FGSS SS
SS316Stainless
SteelCW CW
CWPolychloro-
prene
Weighted
PO PO
POPTFE/EPDM
OvermoldPT PT
PTPTFE21 21
21EN10204
type2.1
S14 S14
S14DIN,FGPT PT
PTPTFEPT PT PTPTFE/EPDM
2-PieceEP EP
EPEPDM31 31
31EN10204
type3.1
SP SP
SPSantopreneSP SP SPSantoprene
63A3167P

CongurationNumberMatrixforHSandPHPumps
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrixfor for forHS HS HSand and andPH PH PHPumps Pumps Pumps
Checktheidenti󰘰cationplate(ID)fortheCon󰘰guration
Numberofyourpump.Usethefollowingmatrixtode󰘰ne
thecomponentsofyourpump.
Whenyoureceiveyourpump,recordthe9characterpart
numberfoundontheshippingbox(e.g.,SP1B.0014):
_____________
Alsorecordthecon󰘰gurationnumberonthepumpIDplate
toassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1040HS.ES04ASSASSPTPOPT21 1040HS.ES04ASSASSPTPOPT21
1040HS.ES04ASSASSPTPOPT21
1040 1040
1040HS HS HSE E
ES S
S04A 04A 04ASSA SSA SSASS SS SSPT PT
PTPO PO
POPT PT
PT21 21
21
Pump
Model
Wetted
Section
Material
DriveCenter
Section
Material
GearBox
andMotor
Fluid
Coversand
Manifolds
SeatsBallsDiaphragmsManifold
Gaskets
Certi󰘰ca-
tion
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
1040HS HS HSHighSanitationE E
EElectricS S
SStainlessSteel04A 04A 04AStandardACInductionMotor
withGearbox
PH PH
PHPharmaceutical04B 04B
04BBrushlessDCMotor
04E 04E
04ENEMA56CGearbox‡
04F 04F
04FIEC90B5FlangeGearbox‡
04G 04G
04GNomotor,Nogearbox
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
Gaskets Gaskets
Gaskets
Certi󰘰cation Certi󰘰cation
Certi󰘰cation
SSA SSA
SSATriClamp,
HSorPHSS SS
SS316Stainless
SteelBN BN
BNBuna-NBN BN BNBuna-NBN BN BNBuna-N21 21
21EN
10204
type2.1
SSB SSB
SSBDIN,HSor
PHCW CW
CWPolychloro-
prene
Weighted
PO PO
POPTFE/EPDM
OvermoldEP EP
EPEPDM31 31
31EN
10204
type3.1
FK FK
FKFKMPS PS
PSPTFE2-Piece
Santoprene
PT PT
PTPTFESP SP
SPSantoprene
SP SP
SPSantoprene
3A3167P7

Approvals
Approvals Approvals
Approvals
Approvals Approvals
Approvals
Allmodelsareapprovedto:
*DiaphragmmaterialscodedPO,PT,or
PScombinedwithballmaterialscodedPT
complywith:
EC1935/2004
‡Pumpswithcode04Eor04Fareapproved
to:
II2G
ExhIIBT3Gb
DiaphragmmaterialscodedPTorPS
combinedwithballmaterialscodedPT
complywith:
ClassVI
All󰘱uidcontactmaterialsareFDAcompliant
andmeettheUnitedStatesCodeofFederal
Regulations(CFR).
*EC1935/2004compliantpumpsmaybesubjecttoindividualnationalprovisionsinadditiontothose
speci󰘰edintheECregulation.Itistheusersresponsibilitytoknowandfollowlocallaws.
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.
83A3167P

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.
3A3167P9

Overview
Overview Overview
Overview
Theproductlineofferselectric-powereddiaphragmpumpsinawiderangeofmodels.Thissectionshows
thebasicstructureofavailablemodels.
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
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.
103A3167P

Installation
Installation Installation
Installation
General General
GeneralInformation Information Information
ATypicalInstallationshowninFigure1.Itisonlya
guideforselectingandinstallingsystemcomponents.
ContactyourGracodistributorforassistancein
planningasystemtosuityourneeds.Alwaysuse
GenuineGracoPartsandAccessories.Besureall
accessoriesareadequatelysizedandpressurerated
tomeetthesystem’srequirements.
Referencelettersinthetext,forexample(A),referto
thecalloutsinthe󰘰gureslocatednearthereference.
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
lines.Rememberthat󰘰ttingsaddfriction
lengthtothelines.Reducethenumberof
󰘰ttingstoreducethefrictionlength.
c.Increasethediameterofthesuctionlines.
d.Ensuretheinlet󰘱uidpressuredoesnot
exceed25%oftheoutletworkingpressure.
e.IncreasetheNetPositiveSuctionHead
(NPSH).SeePerformanceCharts,page50.
3.Reduceliquidvelocity:Slowthecyclicrateof
thepump.
Pumpedliquidviscosityisalsoveryimportantbut
normallyiscontrolledbyfactorsthatareprocess
dependentandcannotbechangedtoreduce
cavitation.Viscousliquidsaremoredif󰘰culttopump
andmorepronetocavitation.
Gracorecommendstakingalloftheabovefactors
intoaccountinsystemdesign.Tomaintainpump
ef󰘰ciency,supplyonlyenoughpowertothepumpto
achievetherequired󰘱ow.
Gracodistributorscansupplysite-speci󰘰c
suggestionstoimprovepumpperformanceand
reduceoperatingcosts.
3A3167P11

Installation
Graco Graco
GracoMotor Motor MotorControl Control ControlComponent Component ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
KEY: KEY:
KEY:
AConduitHoles
BDisplayControlPanel
CMountingTabs
DWarningLabel
123A3167P

Installation
Mount Mount
Mountthe the thePump Pump Pump
Thepumpmaybeveryheavy(see
TechnicalSpeci󰘰cations,page61,forspeci󰘰c
weights).Ifthepumpmustbemoved,followthe
PressureReliefProcedure,page30,andhavetwo
peopleliftthepumpbygraspingtheoutletmanifold
securely,oruseappropriateliftingequipment.
Neverhaveonepersonmoveorliftthepump.
1.Ensurethatthemountingsurfaceisleveland
cansupporttheweightofthepump,lines,and
accessories,aswellasthestresscausedduring
operation.
2.Forallmountings,besurethepumpissecured
withscrewsthroughthemountingbracketonthe
gearbox.SeeDimensions,page56.
NOTE: NOTE:
NOTE:Foreaseofoperationandservice,mount
thepumpsotheairvalvecover,airinlet,and
󰘱uidinletandoutletportsareeasilyaccessible.
NOTICE NOTICE
NOTICE
Topreventpumpdamage,useallfour
fastenersinallfourmountingholestoattach
thebrackettothemountinglocation.Donot
usethefeetontheinletmanifoldformounting.
3.Cart Cart
CartMounting: Mounting: Mounting:Forallmodels,CartMounting
Kit24Y923isavailable.Foravailable
pre-con󰘰guredcartandpumpsystems,see
CartSystems,page9.
NOTICE NOTICE
NOTICE
Topreventunstableloadingduetoanoffset
centerofgravity,liftthecartbyusingstraps
attachedatmultiplepointsonthecartrather
thanattemptingtoliftthepumpandcartusing
onlythepumpliftring.
3A3167P13

Installation
Grounding Grounding
Grounding
Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
•Always Always
Alwaysgroundtheentire󰘱uidsystemas
describedbelow.
•Followyourlocalcodesandregulations.
Beforeoperatingthepump,groundthesystemas
explainedbelow.
•Pump: Pump:
Pump:Loosenthegroundingscrew(R).Insertone
endofa12-gauge(2mm2)orthickergroundwire
behindthegroundscrewandtightenthescrew
securely.Connecttheclampendofthegrounding
wiretoatrueearthground.Toorderagroundwire
andclamp,orderpartnumber238909.
•Motor: Motor:
Motor:ACandBLDCmotorshaveagroundscrew
intheelectricalbox.Useittogroundthemotorto
thecontroller.
•Air Air
Airand and andFluid Fluid FluidLines: Lines: Lines:Useonlyconductivelineswith
amaximumof500ft(150m)combinedlinelength
toensuregroundingcontinuity.Checkelectrical
resistanceoflines.Iftotalresistancetoground
exceeds29megohms,replacelineimmediately.
•Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followlocalcodesand
regulations.
•Pails Pails
Pailsfor for forsolvents solvents solventsand and andsanitizing sanitizing sanitizingsolution solution solutionused used usedwhen when when
󰘱ushing: 󰘱ushing:
󰘱ushing:Followlocalcodesandregulations.Use
onlyconductivemetalpails,placedonagrounded
surface.Donotplacethepailonanonconductive
surface,suchaspaperorcardboard,which
interruptsgroundingcontinuity.
•VFD: VFD:
VFD:Groundthevariablefrequencydrive(VFD)
throughaproperconnectiontotheelectrical
system.RefertotheVFDmanualforgrounding
instructions.
•Graco Graco
GracoMotor Motor MotorControl: Control: Control:Groundthrougha
properconnectiontoapowersource.See
ControllerWiring,page24.
Checkyoursystemgroundcontinuityaftertheinitial
installation,andthensetuparegularschedulefor
checkingcontinuitytobesurepropergroundingis
maintained.Theresistancetoearthgroundshould
notexceed1ohm.
143A3167P

Installation
Figure1TypicalInstallation(ACPumpShown)
System System
SystemComponents Components ComponentsAccessories/Components Accessories/Components Accessories/ComponentsNot Not NotSupplied Supplied Supplied
APowercordtoVFDFGrounded,󰘱exibleairsupplyline
BFluidinletportGBleed-typemasterairvalve
CFluidoutletportHAirregulator(required,notsupplied)
DMountingfeetJMasterairvalve(foraccessories)
EAirinletvalveKFlexible󰘱uidsuctionline
UAirregulatorLFluiddrainvalve(mayberequiredforyourpump
installation,notsupplied)
MFluidshutoffvalve(required,notsupplied)
NFlexible󰘱uidoutletline
PGroundwireandclamp(required,notsupplied)
RAirline󰘰lter
TAirpressuregauge(required,notsupplied)
3A3167P15

Installation
Air Air
AirLine Line Line
Ableed-typemasterairvalve(G)isrequiredinthe
systemtorelieveairtrappedbetweenthisvalve
andthepump.Trappedaircancausethepumpto
cycleunexpectedly,whichcouldresultinserious
injury,includingsplashingintheeyesoronthe
skin.SeeFigure1.
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: NOTE:
NOTE:CalloutsarelocatedonFigure1,page15.
1.Installanairregulator(H)andairline󰘰lter(R).
The󰘱uidstallpressurewillbethesameasthe
settingoftheairregulator.The󰘰lterremoves
harmfuldirtandmoisturefromthecompressed
airsupply.
2.Locateableed-typemasterairvalve(G)closeto
thepumpanduseittorelievetrappedair.Be
surethevalveiseasilyaccessiblefromthepump
andlocateddownstreamfromtheregulator.
3.Locatetheothermasterairvalve(J)upstream
fromallairlineaccessoriesanduseittoisolate
themduringcleaningandrepair.
4.Installaconductive,󰘱exibleairline(F)between
theaccessoriesandthe3/8npt(f)pumpairinlet.
Fluid Fluid
FluidSuction Suction Suctionand and andOutlet Outlet OutletLines Lines Lines
Forbestsealingresults,useastandardtri-clampor
DINstylesanitarygasketofa󰘱exiblematerialsuch
asEPDM,Buna-N,󰘱uoroelastomer,orsilicone.
NOTE: NOTE:
NOTE:Compliancewith3Asanitarystandards
requiresDINconnectionstousecertaingaskets.See
CCECoordinationBulletinNumber2011-3.
1.Connect󰘱exible,conductive󰘱uidlines(KandN).
For1040FGpumps,theportis1.5in.(38cm)
sanitaryTri-Clamp󰘱angeor40mmDIN11851.
For1040HSand1040PHpumps,theportis1.0
in.(2.5cm)sanitary󰘱angeor25mmDIN11851.
2.Installa󰘱uiddrainvalve(L)
closetothe󰘱uidoutlet.See
TypicalInstallation(ACPumpShown).
A󰘱uiddrainvalve(L)isrequiredtorelieve
pressureinthe󰘱uidoutletlineifitisplugged.
Thedrainvalvereducestheriskofserious
injury,includingsplashingintheeyesoronthe
skin,whenrelievingpressure.
3.Installa󰘱uidshutoffvalve(M)inthe󰘱uidoutlet
line(N)downstreamfromthe󰘱uiddrainvalve(L).
NOTE: NOTE:
NOTE:Forbestresults,alwaysinstallthepump
ascloseaspossibletothematerialsource.See
theTechnicalSpeci󰘰cations,page61formaximum
suctionlift(wetanddry).
NOTICE NOTICE
NOTICE
Thepumpcanbedamagedif󰘱exible󰘱uidlinesare
notused.Ifhard-plumbed󰘱uidlinesareusedinthe
system,useashortlengthof󰘱exible,conductive
󰘱uidlinetoconnecttothepump.
163A3167P

Installation
Leak Leak
LeakSensor Sensor Sensor
Theoptionalleaksensor(Kit24Y661)ishighly
recommendedtoavoidoperatingthepumpwith
aruptureddiaphragm.Toinstalltheleaksensor,
removeplug123.Installthebushingandleaksensor.
NOTE: NOTE:
NOTE:Thearrowontheleaksensormustpointdown.
SeealsoLeakSensorWiring(ACModels),page20,
orLeakSensorWiring(BLDCModels),page25.
1
Toensureawatertightseal,applyLoctite®425
Assure™threadlockertothreads.
3A3167P17

ElectricalConnections(ACModels)
Electrical Electrical
ElectricalConnections Connections Connections(AC (AC (ACModels) Models) Models)
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
Alwayscheckthemotormanufacturer’smanualfor
thepropertechnicalandinstallationinformation.
Followtheinstructionsinthemotormanufacturer’s
manual.WhenusingaGracoinverterduty-rated
motor,useofaproperly-sizedVFDoramotor
soft-starterisrecommended.Inallcases,wiresize,
fusesize,andotherelectricaldevicesmustcomply
withalllocalcodesandregulations.Themotormust
bewiredtotheVariableFrequencyDrive(VFD)
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).
183A3167P

ElectricalConnections(ACModels)
Wire Wire
WireConnections Connections Connectionsat at atthe the theATEX ATEX ATEXMotor Motor Motor
(ForusewithoptionalATEXmotorkit25C081)
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
(Forusewithoptionalexplosionproofmotorkit
25C082)
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).
3A3167P19

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,page17,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.
203A3167P