Graco saniforce 2150 Instruction Manual

Operation
SaniForce®2150,3000,4000,
Electric-OperatedDiaphragm
Pump3A5132K
EN
2–Inch, 2–Inch,
2–Inch,3–Inch, 3–Inch, 3–Inch,and and and4–Inch 4–Inch 4–Inchpumps pumps pumpswith with withelectric electric electricdrive drive drivefor for for󰘱uid 󰘱uid 󰘱uidtransfer transfer transferapplications. applications. applications.
Not Not
Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardouslocations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.See See See
Approvals Approvals
Approvalspage page pagefor for formore more moreinformation. information. information.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinyour
Repair/Partsmanual.Save Save
Savethese these theseinstructions. instructions. instructions.
ForMaximumWorkingPressure,see
TechnicalDatasheets
Seepage7forapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.
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Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................6
OrderingInformation...........................................8
Installation..........................................................9
GeneralInformation.....................................9
TightenClampsBeforeFirstUse..................9
TipstoReduceCavitation.............................9
Mountthe2150TPump................................12
Mountthe2150HS/3-A/PH,3000HS,
4000HSPump................................13
GroundTheSystem.....................................14
AirLine........................................................15
FluidOutletLine...........................................15
ElectricalConnections..................................16
LeakSensorWiring......................................18
CompressorWiring......................................19
Operation...........................................................20
InitialCon󰘰guration(ACwithVFD)................20
SanitizethePumpBeforeFirstUse...............20
TransferModeVs.LowPulsation
Mode.............................................20
StartandAdjustthePump............................20
PressureReliefProcedure............................21
PumpShutdown..........................................21
VFDOperation...................................................22
VFDControlPanel.......................................22
AdjusttheSpeed.........................................22
Maintenance......................................................23
MaintenanceSchedule.................................23
Lubrication...................................................23
TightenConnections....................................23
FlushingandStorage...................................23
PerformanceData..............................................24
Dimensions(2150TPump)..................................36
Dimensions(2150HS/3-A/PHPumps)..................39
Dimensions(3000HSFlapperPump)...................41
Dimensions(4000HSFlapperPump)...................43
TechnicalData...................................................45
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A5133SaniForce™2150,3000,4000,Electric-OperatedDiaphragmPump,Repair/Parts
23A5132K
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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.
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,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.
3A5132K3
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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.
43A5132K
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Warnings
WARNING
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalData Data Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand
solventmanufacturer’sSafetyDataSheet(SDS)andrecommendations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)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.
3A5132K5
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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:2150TE,A04AS1 2150TE,A04AS1
2150TE,A04AS1- - -3SSPTPTPT 3SSPTPTPT 3SSPTPTPT
2150 2150
2150T T
TE E EA A A04 04
04A A
AS1 S1
S1- - -3 3 3SS SS SSPT PT
PTPT PT PTPT PT PT
Pump
Model
Wetted
Section
DriveCenter
Section
Gear
Boxand
Compressor
MotorFluidCoversand
Manifolds
SeatsBalls
orChe-
cks
DiaphragmsManifold
Seals
Certi󰘰ca-
tion
Pump Pump
PumpWetted Wetted
WettedSection Section SectionDrive Drive
DriveType Type TypeCenter Center
CenterSection Section Section
Material Material
Material
Gearbox Gearbox
Gearboxand and and
Compressor Compressor
Compressor
Motor Motor
Motor
2150 2150
2150T T
TFoodGradeE E EElectricA A
AAluminum94 94
94NoGearboxor
CompressorA A
AStandard
InductionMotor
3000 3000
3000HS HS HSHighSanitationS S SStainlessSteel04 04 04HighSpeedGear
RatioC C
CATEXInduction
Motor
4000 4000
40003A 3A 3A3ACerti󰘰ed05 05 05HighSpeed
GearRatio/120V
Compressor
D D
DFlameproof
InductionMotor
PH PH
PHPharmaceutical06 06
06HighSpeed
GearRatio/240V
Compressor
G G
GNoMotor
14 14
14MidSpeedGear
Ratio
15 15
15MidSpeed
GearRatio/120V
Compressor
16 16
16MidSpeed
GearRatio/240V
Compressor
24 24
24LowSpeedGear
Ratio
25 25
25LowSpeed
GearRatio/120V
Compressor
26 26
26LowSpeed
GearRatio/240V
Compressor
63A5132K
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CongurationNumberMatrix
Fluid Fluid
FluidCovers Covers Coversand and and
Manifolds Manifolds
Manifolds
Seat Seat
SeatMaterial Material MaterialBall Ball Ballor or orCheck Check Check
Material Material
Material
Diaphragm Diaphragm
DiaphragmMaterial Material MaterialManifold Manifold
Manifold
Seals Seals
Seals
Certi󰘰cation Certi󰘰cation
Certi󰘰cation
S1 S1
S1- - -3 3 3Stainless
steel,
TriClamp
FL FL
FL316
Stainless
Steel
Flapper
— —
—Flapper,check,
StainlessSteelEO EO
EOEPDM
OvermoldedEP EP
EPEPDMblanknocerti󰘰cation
S1 S1
S1- - -4 4 4Stainless
steel,DINSS SS
SS316
Stainless
Steel
BN BN
BNBuna-NFK FK FKFKM
FluoroelastomerPT PT
PTPTFE21 21
21EN10204
type2.1
S– S–
S–Stainless
steel,no
manifolds
CW CW
CWPolychloro-
prene
Weighted
PS PS
PSPTFE/Santo-
prene
2–Piece
31 31
31EN10204
type3.1
SSA SSA
SSAStainless
Steel,
Tri-Clamp
(HS/3-A/
PH)
FK FK
FKFKMFluoroe-
lastomerPT PT
PTPTFE/EPDM
2–Piece
SSB SSB
SSBStainless
Steel,DIN
(HS/3-
A/PH)
PT PT
PTPTFESP SP
SPSanto-
prene/EPDM
2–Piece
SP SP
SPSantoprene
Approvals Approvals
Approvals
✦PumpswithmotorcodeCarecerti󰘰edto:
II2GExdhIIBT3Gb
✚PumpswithmotorcodeGarecerti󰘰edto:
II2GExhIIBT3Gb
★MotorscodedDarecerti󰘰edto:
ClassI,Div1,GroupD,T3B
ClassII,Div1,GroupF&G,T3B
BallmaterialscodedPTanddiaphragm
materialscodedPTarecerti󰘰edto:
EC1935
AllModels(exceptgearboxandcompressor
codes05,15,and25,ormotorcodeD)are
certi󰘰edto:
3A5132K7
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OrderingInformation
Ordering Ordering
OrderingInformation Information Information
To To
ToFind Find FindYour Your YourNearest Nearest NearestDistributor Distributor Distributor
Visitwww.graco.com
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. . .SearchforSelector Selector Selector.
To To
ToOrder Order OrderReplacement Replacement ReplacementParts Parts Parts
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
83A5132K
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Installation
Installation Installation
Installation
Installationofthisequipmentinvolvespotentially
hazardousprocedures.Onlytrainedandquali󰘰ed
personnelwhohavereadandwhounderstand
theinformationinthismanualshouldinstallthis
equipment.
•Allelectricalwiringmustbedonebyaquali󰘰ed
electricianandcomplywithalllocalcodesand
regulations
General General
GeneralInformation Information Information
TheTypicalInstallationshownisonlyaguidefor
selectingandinstallingsystemcomponents.Contact
yourGracodistributorforassistanceinplanninga
systemtosuityourneeds.AlwaysuseGenuine
GracoPartsandaccessories.Besureallaccessories
areadequatelysizedandpressureratedtomeetthe
system’srequirements.
Referencelettersinthetext,forexample(A),referto
thecalloutsinthe󰘰gures.
Tighten Tighten
TightenClamps Clamps ClampsBefore Before BeforeFirst First FirstUse Use Use
Afteryouunpackthepump,andbeforeyouuseit
forthe󰘰rsttime,checkallclampsandtightenas
necessary.
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.
NOTE: NOTE:
NOTE:Ifthe󰘱uidinletpressuretothepumpis
morethan25%oftheoutletworkingpressure,
theballcheckvalveswillnotclosefastenough,
resultingininef󰘰cientpumpoperation.Excessive
inlet󰘱uidpressurealsowillshortendiaphragm
life.Approximately3-5psi(0.02-0.03MPA,
0.21-0.34bar)shouldbeadequateformost
materials.
3.Reduceliquidvelocity:Slowthecyclicrateof
thepump.
Pumpedliquidviscosityisalsoveryimportantbut
normallyiscontrolledbyfactorsthatareprocess
dependentandcannotbechangedtoreduce
cavitation.Viscousliquidsaremoredif󰘰culttopump
andmorepronetocavitation.
Gracorecommendstakingalltheabovefactors
intoaccountinsystemdesign.Tomaintainpump
ef󰘰ciency,operatethepumpatthelowestspeedand
pressuresettingneededtoachievetherequired󰘱ow.
Gracodistributorscansupplysitespeci󰘰c
suggestionstoimprovepumpperformanceand
reduceoperatingcosts.
3A5132K9
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Installation
Figure1TypicalInstallationforpumpswithouta
compressor
System System
SystemComponents Components ComponentsAccessories/Components Accessories/Components Accessories/ComponentsNot Not NotSupplied Supplied Supplied
BFluidinletportA*PowercordtoVFD
CFluidoutletportF*Grounded,󰘱exibleairsupplyline
DMountingfeetGBleed-typemasterairvalve
EAirinletportHAir󰘰lter/regulatorassembly
PPumpGroundJMasterairvalve(foraccessories)
RCentersectionregulatorK*Grounded,󰘱exible󰘱uidsupplyline
LFluiddrainvalve(mayberequiredforyour
pumpinstallation)
MFluidshutoffvalve
N*Grounded,󰘱exible󰘱uidoutletline
*Required.Suppliedbycustomer.
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Installation
Figure2Typicalinstallationofapumpwith
compressor
System System
SystemComponents Components ComponentsAccessories/Components Accessories/Components Accessories/ComponentsNot Not NotSupplied Supplied Supplied
BFluidinletportA*PowercordtoVFD
CFluidoutletportF*Powercordtocompressor
DMountingfeetK*Grounded,󰘱exible󰘱uidsupplyline
EAirinletportLFluiddrainvalve(mayberequiredforyour
pumpinstallation)
JCentersectionregulatorMFluidshutoffvalve
PPumpGroundN*Grounded,󰘱exible󰘱uidoutletline
*Required.Suppliedbycustomer.
3A5132K11
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Installation
Mount Mount
Mountthe the the2150T 2150T 2150TPump Pump Pump
Toavoidseriousinjuryordeathfromtoxic󰘱uidor
fumes:
•Nevermoveorliftapumpunderpressure.If
dropped,the󰘱uidsectionmayrupture.Always
followthePressureReliefProcedure,page21,
beforemovingorliftingthepump.
•Donotexposepumportheplasticcomponents
todirectsunlightforprolongedperiods.
ProlongedexposuretoUVradiationwilldegrade
naturalpolypropylenecomponentsofthepumps.
NOTICE NOTICE
NOTICE
Thepumpisheavy.Topreventdamagefrom
dropping,alwaysusealifttomovethepump.Do
notusethemanifoldstoliftthepump.Useatleast
twostraps.
1.Allpumpmodelsmustbesecurelymounted
tothe󰘱oor.Priortosecuring,makesurethe
mountingsurfaceis󰘱atandthatthepump
doesn’twobble.
2.Securethepumpwithscrewsthroughthe
mountingfeetandthroughthemountingbracket
orcompressorboxonthegearbox.See
Dimensions(2150TPump),page36.
NOTICE NOTICE
NOTICE
Topreventpumpdamage,usealleight
fasteners.
3.Foreaseofoperationandservice,mountthe
pumpso󰘱uidinletand󰘱uidoutletportsareeasily
accessible.
Mounting Mounting
Mountinga a apump pump pumpwithout without withouta a aGearmotor Gearmotor Gearmotor
ApumpwithoutaGracogearboxandmotorwill
requireamountingplatformtoprovidesupport
forthecustomer-suppliedmotorandgearbox
andprovidealignmentwiththepumpalignment
housing(116)anddriveshaft(112)withoutputting
strainonthemountingplatformorpump.See
Dimensions(2150TPump),page36forassistance
infabricatingamountingplatform.
REF REF
REFDESCRIPTION DESCRIPTION
DESCRIPTIONDIMENSION DIMENSION DIMENSION
AGearboxcouplerboreand
keyway
35mm/10
mmkeyway
BFlangepilotdiameter110mm
CBoltcirclediameter130mm
DMountingholethreadsizeM8x1.25
Tospecifyanon-Gracogearbox,refertothe󰘰gure
andtableabove.
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Installation
Mount Mount
Mountthe the the2150 2150 2150HS/3 HS/3 HS/3- - -A/PH, A/PH, A/PH,3000HS, 3000HS, 3000HS,4000HS 4000HS 4000HSPump Pump Pump
Toavoidseriousinjuryordeathfromtoxic󰘱uidor
fumes:
•Nevermoveorliftapumpunderpressure.If
dropped,the󰘱uidsectionmayrupture.Always
followthePressureReliefProcedure,page21,
beforemovingorliftingthepump.
NOTICE NOTICE
NOTICE
Thepumpisheavy.Topreventdamagefrom
dropping,alwaysusealifttomovethepump.Do
notusethemanifoldstoliftthepump.Useatleast
twostraps.
1.Allpumpmodelsmustbesecurelymounted
tothe󰘱oor.Priortosecuring,make
surethemountingsurfaceis󰘱atandthat
thepumpbasedoesn’twobble.See
Dimensions(2150HS/3-A/PHPumps),page39,
Dimensions(3000HSFlapperPump),page41,
orDimensions(4000HSFlapperPump),page43,
asappropriate.
NOTICE NOTICE
NOTICE
Topreventpumpdamage,useallfasteners.
2.Securethepumpwithscrewsthroughthe
mountingbracket.
3.Foreaseofoperationandservice,mountthe
pumpso󰘱uidinletand󰘱uidoutletportsareeasily
accessible.
4.Attachthepumpbasetothemountingsurface.
3A5132K13
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Installation
Ground Ground
GroundThe The TheSystem System System
Theequipmentmustbegroundedtoreducethe
riskofstaticsparking.Staticsparkingcancause
fumestoigniteorexplode.Impropergrounding
cancauseelectricshock.Groundingprovidesan
escapewirefortheelectricalcurrent.
•Always Always
Alwaysgroundtheentire󰘱uidsystemas
describedbelow.
•Followyourlocalcodesandregulations.
Beforeoperatingthepump,groundthesystemas
explainedbelow.
•Pump: Pump:
Pump:Allpumpshaveagroundscrew.Loosen
thegroundingscrew.Insertoneendofa12–gauge
minimumgroundwirebehindthegroundscrew
andtightenthescrewsecurely.Connecttheclamp
endofthegroundingwiretoatrueearthground.A
groundwireandclamp,Part238909,isavailable
fromGraco.
•Motor: Motor:
Motor:Motorshaveagroundscrewintheelectrical
box.Useittogroundthemotortothecontroller.
•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:Groundthevariablefrequencydrivethrough
aproperconnectiontoapowersource.Referto
theVFDmanualforgroundinginstructions.
Checkyoursystemelectricalcontinuityafterthe
initialinstallation,andthensetuparegularschedule
forcheckingcontinuitytobesurepropergrounding
ismaintained.Theresistanceshouldnotexceed1
ohm.
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Installation
Air Air
AirLine Line Line
Models Models
Modelsthat that thatInclude Include Includea a aCompressor: Compressor: Compressor:
Anairlineisalreadyconnectedfromthecompressor
tothepumpairinlet.
Using Using
UsingYour Your YourOwn Own OwnCompressor: Compressor: Compressor:
Installagrounded,󰘱exibleairhosefromthe
compressortothepumpairinlet(E).
Using Using
UsingShop Shop ShopAir: Air: Air:
1.Installanair󰘰lter/regulatorassembly(H).The
󰘱uidstallpressurewillbethesameasthesetting
oftheairregulator.The󰘰lterremovesharmful
dirtandmoisturefromthecompressedairsupply.
Trappedaircancausethepumptocycle
unexpectedly,whichcouldresultinserious
injuryfromsplashing.
2.Locateamasterairvalve(J)upstreamfromthe
regulator(H).Useittoisolatethesystemduring
cleaningandrepair.
3.Locateableed-typemasterairvalve(G)closeto
thepumpanduseittorelievetrappedair.Be
surethevalveiseasilyaccessiblefromthepump
andlocateddownstreamfromtheregulator(H).
4.Installagrounded,󰘱exibleairhose(F)between
theaccessoriesandthepumpairinlet.
Fluid Fluid
FluidOutlet Outlet OutletLine Line Line
1.Use󰘱exible,grounded󰘱uidhoses.
2.Forbestsealingresults,useastandardtri-clamp
orDINstylesanitarygasketofa󰘱exiblematerial
suchasEPDM,Buna-N,󰘱uoroelastomer,or
silicon.
3.Installa󰘱uiddrainvalve(L)nearthe󰘱uidoutlet.
4.Installashutoffvalve(M)inthe󰘱uidoutletline.
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Installation
Electrical Electrical
ElectricalConnections Connections Connections
Allelectricalwiringmustbecompletedbya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
Wire Wire
WireConnections Connections Connectionsat at atthe the theMotor Motor Motor
(Motor (Motor
(MotorCode Code CodeA) A) A)
NOTE: NOTE:
NOTE:Followtheinstructionsinthemotor
manufacturer’smanual.Useamotorstarterwith
overloadprotection.Wiresize,fusesize,andother
electricaldevicesmustcomplywithalllocalcodes
andregulations.
ThemotormustbewiredtotheVFD.Installthe
wiringatthemotorasfollows:
1.Remove4boltstoopenthemotor’selectrical
box.
2.Installastrainreliefinoneoftheportsatthe
bottomofthejunctionbox.
3.Connectthegreengroundwiretotheground
screw.
4.For For
For230 230 230V V Vmotors: motors: motors:Bridgeasshown,then
connectL1toT1,L2toT2,andL3toT3.
T4 T5 T6
L2 L3L1
T7 T8 T9
T1 T2 T3
Figure3WireConnectionsfora230VMotor
5.For For
For460 460 460V V Vmotors: motors: motors:Bridgeasshown,then
connectL1toT1,L2toT2,andL3toT3.
T4 T5 T6
L2 L3L1
T7 T8 T9
T1 T2 T3
Figure4WireConnectionsfora460VMotor
6.Closethemotorelectricalbox.Torquethebolts
to20in-lb(2.2N•m).
Wire Wire
WireConnections Connections Connectionsat at atthe the theATEX ATEX ATEXMotor Motor Motor
(Motor (Motor
(MotorCode Code CodeC) C) C)
Installthewiringatthemotorasfollows:
1.Openthemotor’selectricalbox.
2.Installwiringsystemwithproperconnectionsto
themotorelectricalbox.
3.Connectthegreengroundwiretotheground
screw.
4.For For
For400V 400V 400VWiring: Wiring: Wiring:Bridgeasshown,thenconnect
wireL1toU1,L2toV1,andL3toW1.
W2 U2 V2
L2 L3L1
U1 V1 W1
Figure5Connectionsfor400VWiring
5.For For
For230V 230V 230VWiring: Wiring: Wiring:ConnectwireL1toU1,L2to
V1,andL3toW1.Bridgeasshown.
W2 U2 V2
L2 L3L1
U1 V1 W1
Figure6Connectionsfor230VWiring
6.Torqueterminalsto20in-lb(2.3N•m).
7.Closethemotorelectricalbox.Torquethe
screwsto20in-lb(2.3N•m).
8.ConnectthermostatwiresP1andP2toexternal
overloaddetection.ThermostatisNC(normally
closed).
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Installation
Wire Wire
WireConnections Connections Connectionsat at atthe the theExplosionproof Explosionproof Explosionproof
Motor Motor
Motor(Motor (Motor (MotorCode Code CodeD) D) D)
Installthewiringatthemotorasfollows:
1.Openthemotor’selectricalbox.
2.Installwiringsystemwithproperconnectionsto
themotorelectricalbox.
3.Connectthegreengroundwiretotheground
screw.
4.For For
For460V 460V 460VWiring: Wiring: Wiring:ConnectwireL1toT1,L2to
T2,andL3toT3,andbridgetheotherwires,as
shown.
T1
T2
T3
L1
L2
L3
T4
T7
T5
T8
T6
T9
Figure7Connectionsfor460VWiring
5.For For
For230V 230V 230VWiring: Wiring: Wiring:Bridgethewiresasshown.
Then,connectL1toT1/T7,L2toT2/T8,andL3
toT3/T9.
T1
T7
T2
L1
L2
L3
T8
T3
T9
T4
T5
T6
Figure8Connectionsfor230VWiring
6.ConnectthermostatwiresP1andP2toexternal
overloaddetection.ThermostatisNC(normally
closed).
7.Closethemotorelectricalbox.Torquethe
screwsto20in-lb(2.3N•m).
Wire Wire
WireConnections Connections Connectionsat at atthe the theVariable Variable VariableFrequency Frequency Frequency
Drive Drive
Drive(VFD) (VFD) (VFD)
NOTE: NOTE:
NOTE:FollowtheinstructionsintheVFD
manufacturer’smanual.
InstallthewiringattheVFDasfollows:
1.Connectthewirestothemotor.See
ElectricalConnections,page16.
2.OpentheVFD’selectricalbox.
3.Installstrainreliefsinbothportsatthebottomof
theVFDbox.
4.Connectthegreengroundwiretotheground
screw.
5.Connectthewiresfromthemotorterminalstothe
matchingterminalsintheVFDbox,asshown.
U/T1 V/T2 W/T3 PE
PE
PES
PES
PES
PES
PES
PE
Figure9WireConnectionsfromtheMotortotheVFD
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Installation
Main Main
MainPower Power PowerConnections Connections Connectionsat at atthe the theVFD VFD VFD
Allelectricalwiringmustbecompletedbya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
ConnectthepowersupplywirestotheVFD,as
follows:
1.ConnectthewiringbetweenthemotorandVFD,
asdetailedabove.
2.Connectthegreengroundwireofthepower
supplytothegroundscrew.Thegroundwire
fromthemotorisalsoconnectedtothisscrew.
3.Connectthepowersupplywirestothepower
terminalsintheVFDbox,followingalllocalcodes
andregulations.
4.ClosetheVFDelectricalbox.
Leak Leak
LeakSensor Sensor SensorWiring Wiring Wiring
FollowtheseinstructionstowiretheLeakSensorto
aVFD.
NOTE NOTE
NOTE:Theleaksensorisdesignedtooperateas
anormally-closedcircuit.
1.TurnoffpowertotheVFD.
2.OpentheaccesscoverontheVFD.
3.ForaGracoVFD,performthefollowing:
a.Wireoneleadtoterminal4ontherail.
b.Wireasecondleadtoterminal13Aonthe
rail.
c.Closetheaccesscover.
d.TurnonpowertotheVFD.
e.GotoscreenP121.
f.Changethevalueto21andpresstheMode
button.
4.Foranon-GracoVFD,performthefollowing:
a.Attachthetwoleadstothedetectioncircuit
intheVFD.
NOTE NOTE
NOTE:RefertotheVFDmanualforproper
connectionpoints.
b.Closetheaccesscover.
c.TurnonpowertotheVFD.
d.Con󰘰guretheVFDtomonitortheleaksensor
circuit.
5.RefertotheVFDmanualforinformationonhow
tocon󰘰guretheVFDtogenerateafaultorstop
thepumpwhenaleakisdetected.
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Installation
Compressor Compressor
CompressorWiring Wiring Wiring
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
FollowtheseinstructionstowireGracoCompressor
24Y544(120V)or24Y545(240V).
NOTE: NOTE:
NOTE:Useonlycopperwirewithaninsulationrating
of75°Corhigher.
1.Removethecoverfromthecompressor’s
electricalbox.
2.Installwiringsystemwithproperconnections(i.e.
conduit/󰘰ttings,powercable/cablegrip)tothe
compressorelectricalbox.
3.Connectlinepower(120VACor240VAC,
dependingonyourcompressor)toL1andL2/N.
Connectsupplygroundto
.Useminimum
12AWG(4mm2)wirewhenthesystemis
con󰘰guredfora16Acircuitand14AWG(2.5
mm2)whencon󰘰guredfora12Acircuit.Torque
terminalsto10in-lb(1.2N•m).
4.Reinstallthecoveroftheelectricalbox.Torque
screwsto60in-lb(6.8N•m).
Figure10WireConnectionsattheCompressor
L1
L2
A
KEY KEY
KEY
A A
ATopowersupply
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Operation
Operation Operation
Operation
Initial Initial
InitialCon󰘰guration Con󰘰guration Con󰘰guration(AC (AC (ACwith with withVFD) VFD) VFD)
Con󰘰guretheVFDaccordingtothemotornameplate
information.
Sanitize Sanitize
Sanitizethe the thePump Pump PumpBefore Before BeforeFirst First FirstUse Use Use
Itistheuser’sresponsibilitytoproperlysanitize
thepumpbefore󰘰rstuse.Itisuptotheuser
whetherthiswillincludedisassemblingandcleaning
individualpartsorsimply󰘱ushingpumpwitha
sanitizingsolution.Asnecessary,followthesteps
underStartandAdjustthePump,page20,or
FlushingandStorage,page23.
Transfer Transfer
TransferMode Mode ModeVs. Vs. Vs.Low Low LowPulsation Pulsation Pulsation
Mode Mode
Mode
Whenthecentersectionairpressureisatleast
10psihigherthanthedesiredoutletpressure,the
pumpisinTransferModeandnopulsationdamping
isoccurring.Toreduceoutletpulsation,startby
settingthecentersectionairpressure equal tothe
desiredoutlet󰘱uidpressure.Continuetoadjustthe
centersectionairpressurerelativetotheoutlet󰘱uid
pressure.Lowerrelativecentersectionairpressures
producemorepulsationdamping.Higherrelative
centersectionairpressuresproducebetterpump
ef󰘰ciency.
Start Start
Startand and andAdjust Adjust Adjustthe the thePump Pump Pump
1.Besurethepumpisproperlygrounded.See
GroundTheSystem,page14.
2.Check󰘰ttingstobesuretheyaretight.Usea
compatibleliquidthreadsealantonmalethreads.
Tighten󰘱uidinletand󰘱uidoutlet󰘰ttingssecurely.
3.Placethesuctiontube(ifused)in󰘱uidtobe
pumped.
NOTE: NOTE:
NOTE:If󰘱uidinletpressuretothepumpismore
than25%ofoutletworkingpressure,theball
checkvalveswillnotclosefastenough,resulting
ininef󰘰cientpumpoperation.
NOTICE NOTICE
NOTICE
Excessive󰘱uidinletpressurecanreduce
diaphragmlife.
4.Placetheendofthe󰘱uidhoseintoanappropriate
container.
5.Closethe󰘱uiddrainvalve.
6.Turnthecentersectionairregulatorknobto
matchthedesired󰘱uidstallpressure.Openall
bleed-typemasterairvalves.
7.Ifthe󰘱uidhosehasadispensingdevice,holdit
open.Besureall󰘱uidshutoffvalvesareopen.
8.SetthedesiredfrequencyontheVFD.
9.Pressthestart(run)buttonontheVFD.
10.Ifyouare󰘱ushing,runthepumplongenoughto
thoroughlycleanthepumpandhoses.
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