Graco E-Flo 4000 Bedienungsanleitung

311593R

Operation

E-Flo®4-Ball

Piston Pumps

Durable, energy efficient piston pumps for high volume paint circulation applications.

For professional use only.

See page 3 for model information, including maximum working pressure. See page 5 for approvals.

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

ti8317c

E-Flo 4000 Pump Shown

Related Manuals

2 311593R

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

E-Flo 4-Ball Piston Pumps . . . . . . . . . . . . . . . . . 3

Maximum Working Pressure and

Pump Operational Limits . . . . . . . . . . . . . . . 3

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Ground the System . . . . . . . . . . . . . . . . . . . . . . . . 11

Controls and Indicators . . . . . . . . . . . . . . . . . . . . 12

Variable Frequency Drive (VFD) . . . . . . . . . . . . 12

Local Control Box . . . . . . . . . . . . . . . . . . . . . . . 12

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fill gear reducer reservoir with oil . . . . . . . . . . . 13

Fill TSL Reservoirs . . . . . . . . . . . . . . . . . . . . . . 13

Flush before using equipment . . . . . . . . . . . . . . 13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pressure Relief Procedure . . . . . . . . . . . . . . . . 14

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Preventive Maintenance Schedule . . . . . . . . . . 16

Check Gear Reducer Oil Level . . . . . . . . . . . . . 16

Gear Box and Drive Lubrication . . . . . . . . . . . . 16

Clean the Slider Cylinder Collectors . . . . . . . . . 16

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Changing the TSL . . . . . . . . . . . . . . . . . . . . . . . 17

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 20

Related Manuals

Manual Description

311592 E-Flo Installation Manual

311594 E-Flo Repair-Parts Manual

311595 Pneumatic Back Pressure Regulator

311596 Variable Frequency Drive Instructions

311603 Sensor Circuit Option

3A0539 High-Flo Lowers

Models

311593R 3

Models

E-Flo 4-Ball Piston Pumps

Check your pump’s identification plate (ID) for the 6-digit part number of your

pump. Use the following matrix to define the construction of your pump, based

on the six digits. For example, Pump Part No. E P 2 1 6 0 represents electric

power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), 2000 cc

MaxLife lower (6), and no stand installed (0). To order replacement parts, see

the Repair-Parts manual 311594.

Maximum Working Pressure and Pump Operational Limits

E-Flo 1500: 425 psi (2.93 MPa, 29.3 bar) Maximum Working Pressure

E-Flo 2000: 460 psi (3.22 MPa, 32.2 bar) Maximum Working Pressure

E-Flo 3000: 330 psi (2.31 MPa, 23.1 bar) Maximum Working Pressure

E-Flo 4000: 250 psi (1.75 MPa, 17.5 bar) Maximum Working Pressure

See Technical Data, page 18, for pressure and flow limits.

ti8912a

EP 2 1 6 0

First Digit Second Digit Third Digit Fourth Digit Fifth Digit Sixth Digit

Power

Source Equipment

Style Motor Sensor Circuit Lower Size Stand Option

E (electric) P (pump) 0 No motor 0 No circuit

installed 1 1000 cc Chrome 0 No stand

installed

1 230/400V,5HP,

ATEX 1 Circuit installed 2 1500 cc Chrome 1 Stand

installed

2 230/460V,5HP,

UL/CSA 3 2000 cc Chrome

3 230/400V,3HP,

ATEX 41000 cc MaxLife®

4 230/460V,3HP,

UL/CSA 5 1500 cc MaxLife

6 2000 cc MaxLife

7 750 cc Chrome

8 750 cc MaxLife

Models

4 311593R

Approvals

311593R 5

Approvals

The E-Flo Pump meets requirements of the following approval agencies.

Refer to the individual components for other specific hazardous location listings.

Component Part No. Approvals

Mechanical Pump

Motor

ATEX

EP1XXX

EP3XXX

UL/CSA

EP2XXX

EP4XXX

IS Sensor Circuit EPX1XX

Ex h IIB T3 Gb

Ex de IIC T4 - CESI 05 ATEX 110X

Class I, Group D, Class II, Group F and G, Division 1, T3B

Hazardous Locations

Ex ib IIB Ta = 0°C - 50°C - FM 06 ATEX 0025U

Class 1, Div. 1, Group C & D T3 Hazardous Locations

Ex ib IIB Ta = 0°C - 50°C - KTL 13-KB4BO-0088

Warnings

6 311593R

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When

these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and

warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent

fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable

vapors. To help prevent fire and explosion:

• Clean plastic parts only in a well ventilated area.

• Do not clean with a dry cloth.

• Do not operate electrostatic guns in equipment work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information

about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-

facturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

Warnings

311593R 7

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing

equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and

regulations.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and

cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating

area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic

fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe

burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

WARNING

Overview

8 311593R

Overview

An electric motor (B) provides input to a 75:1 gear

reducer (GR), which drives two fluid pumps (FP). See

FIG. 1. The stroke positions of the two pumps are offset

to achieve consistent flow from the pump assembly. See

FIG. 2.

The optional sensor circuit includes a top dead center

(TDC) sensor which assists software in measuring

motor speed, and a pressure transducer (PT) with circuit

board, which measures fluid pressure at the pump out-

let. The Graco VFD software mimics the effect of a cam-

shaft, constantly adjusting motor speed to keep steady

fluid flow and achieve minimal pressure variation. The

output shaft of the gearbox and the connecting rods

experience the effect of the imaginary camshaft by

speeding up when the pressure drops (pump lower is at

a changeover) and slowing down when pressure

increases (both lowers are pumping).

The VFD can be controlled by a local control box

mounted in the hazardous area, via communication pro-

tocol (such as modbus), or directly from the keypad.

FIG. 3 shows a layout of a typical North American sys-

tem. The pump (A) may be controlled by a local control

box (C) mounted in the hazardous area, a variable fre-

quency drive (D) mounted in the non-hazardous area, or

remotely from a computer (Y). See manual 311592 for

pump and accessory installation information.

FIG. 1. E-Flo Electric Circulation Pump

TDC (behind

cover)

ti8317c

FIG. 2. Cutaway Showing Offset Stroke Positions

ti8321a

Overview

311593R 9

Key:

AE-Flo Electric Circulation Pump

B* Explosion-Proof Electric Motor

C* Local Control Box

D* Variable Frequency Drive (VFD)

E** System Power Disconnect Switch

F* Electrical Noise Filter

G* Power Module

H* VFD/BPR Pneumatic Control Kit

J** Electric Power Cable, VFD to Electric Motor

K** Electric Control Cable, Local Control Box to VFD

L** Explosion-Proof Seal Fittings

M** Electric IS Control Cable, Power Module to Pump Sensor

Circuit

N** Electric Cable, VFD to 3-Way Solenoid Valve (2 meters

provided by Graco)

P* Pump Stand

R** Fluid Inlet Line

S** Fluid Outlet Line

T** Fluid Return Line

U* Pneumatic Back Pressure Regulator

V** Air Supply Lines to 3-Way Solenoid Valve

W** Air Line, Solenoid Valve to Back Pressure Regulator

X** Ethernet Cable, VFD to Computer

Y** Personal Computer

Z** Pump Ground Wire

AA* Explosion-Proof Electric Agitator

AB** Pressure Relief

AC* Fluid Filters

AD* Fluid Line Isolation Valves

*Option available from Graco.

** Supplied by integrator.

FIG. 3: Typical Installation

ti8651c

Hazardous AreaNon-Hazardous Area

Hazardous

Area

Entrance

YAA

Hazardous AreaNon-Hazardous Area

ABZ AC

Overview

10 311593R

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