Graco E-Flo 4000 Bedienungsanleitung

3A3385B

Operation

E-Flo®4-Ball

Pumps

with Sealed or Open Wet Cup Lowers

Piston pumps for high-volume paint circulation applications.

For professional use only.

See page 3 for model information, including maximum working pressure. See page 4 for approvals.

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

ti27591a

E-Flo 4000 Pump Shown

ti27597a

Related Manuals

23A3385B

Contents

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

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

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

Maximum Working Pressure and Pump

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

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ground the System . . . . . . . . . . . . . . . . . . . . . . . . . 9

Controls and Indicators . . . . . . . . . . . . . . . . . . . . 10

Variable Frequency Drive (VFD) . . . . . . . . . . . . 10

Local Control Box . . . . . . . . . . . . . . . . . . . . . . . 10

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fill Gear Reducer Reservoir with Oil . . . . . . . . . 11

Flush Before Using Equipment . . . . . . . . . . . . . 11

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Procedure . . . . . . . . . . . . . . . . 12

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Motor Speed and Flow Chart . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Preventive Maintenance Schedule . . . . . . . . . . 14

Check Gear Reducer Oil Level . . . . . . . . . . . . . 14

Gear Box and Drive Lubrication . . . . . . . . . . . . 14

Clean the Slider Cylinder Collectors . . . . . . . . . 15

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 16

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 18

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 18

Related Manuals

Manual Description

311592 E-Flo Installation Manual

3A3386 E-Flo Repair Manual

311595 Pneumatic Back Pressure Regulator

311596 Variable Frequency Drive Instructions

311603 Sensor Circuit Option

333022 Sealed 4-Ball Lowers

3A3452 4-Ball Lowers with Open Wet Cup

Models

3A3385B 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. EP21D0represents electric

power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), 1000 cc

lower with an open wet cup (D), and no stand installed (0). To order replace-

ment parts, see Manual 3A3386.

Maximum Working Pressure and Pump Operational Limits

EPxxGx and EPxxHx: 425 psi (2.93 MPa, 29.3 bar) Maximum Working Pressure

EPxxAx and EPxxDx: 460 psi (3.22 MPa, 32.2 bar) Maximum Working Pressure

EPxxBx and EPxxEx: 330 psi (2.31 MPa, 23.1 bar) Maximum Working Pressure

EPxxCx and EPxxFx: 250 psi (1.75 MPa, 17.5 bar) Maximum Working Pressure

See Performance Charts, page 16, for pressure and flow limits.

EP 2 1 D 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) 0No motor 0No circuit

installed

A1000cc Sealed 0No stand

installed

1230/400V, 5 HP,

ATEX

1Circuit installed B1500cc Sealed 1Stand

installed

2230/460V, 5 HP,

UL/CSA

C2000cc Sealed

3230/400V, 3 HP,

ATEX

D1000cc Open Wet Cup

4230/460V, 3 HP,

UL/CSA

E1500cc Open Wet Cup

F2000cc Open Wet Cup

G750cc Sealed

H750cc Open Wet Cup

ti8912a

Approvals

43A3385B

Approvals

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

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

Component Description Approvals

Mechanical

Pump

Motor

ATEX

(for pump Models

EP1XXX and

EP3XXX)

UL/CSA

(for pump Models

EP2XXX and

EP4XXX)

IS Sensor

Circuit

(for pump Models

EPX1XX)

Ex h IIB T3 Gb

Ex de IIC T4 Gb - CESI 05 ATEX 110X

Class I, Div. 1, Group D, Class II, Div. 1, Group F and G, T3B

Hazardous Locations

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

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

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

Warnings

3A3385B 5

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 or on warning labels, 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.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or sol-

vent flowing through the equipment can cause static sparking. 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 sparking).

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

• Never spray or flush solvent at high pressure.

• 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.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they

are anti-static or conductive.

•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-

tric shock.

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

or installing 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 equipment, leaks, or ruptured components can splash in the eyes or on skin and cause

serious injury.

• Follow the Pressure Relief Procedure when you stop spraying/dispensing 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.

Warnings

63A3385B

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

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

ponent. See Technical Data in all equipment manuals.

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

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

about your material, request Safety Data Sheet (SDS) 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. Alterations or modifications may void agency approvals and create

safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• 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.

MOVING PARTS HAZARD

Moving parts can pinch, cut 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 and disconnect all power sources.

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 Safety Data Sheet (SDS) 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.

BURN HAZARD

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

burns:

• Do not touch hot fluid or equipment.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including

eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not

limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

Overview

3A3385B 7

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)

ti27597a

FIG. 2. Cutaway Showing Offset Stroke Positions

ti8321a

Overview

83A3385B

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

ti27599a

Hazardous AreaNon-Hazardous Area

Hazardous

Area

Entrance

Hazardous AreaNon-Hazardous Area

ABZAC

Ground the System

3A3385B 9

Ground the System

Ground the following equipment:

•Pump: use ground screw (GS) to attach a ground

wire (Z) to the pump. Tighten the screw securely.

Connect the other end of the ground wire to a true

earth ground.

•Variable frequency drive: grounded through proper

connection to power source.

•Local control box: follow your local code.

•Fluid supply container: follow your local code.

•Solvent pails used when flushing: follow your local

code. Use only metal pails, which are conductive,

placed on a grounded surface. Do not place pail on

a non-conductive surface, such as paper, plastic, or

cardboard, which interrupts grounding continuity.

•To maintain grounding continuity when flushing or

relieving pressure: Hold metal part of the spray gun

or valve firmly to the side of a grounded metal pail,

then trigger the gun or open the valve.

The equipment must be grounded to reduce the

risk of static sparking and electric shock. Electric or

static sparking can cause fumes to ignite or

explode. Improper grounding can cause electric

shock. Grounding provides an escape wire for the

electric current.

FIG. 4. Oil Fill

ti9230a

Controls and Indicators

10 3A3385B

Controls and Indicators

Variable Frequency Drive (VFD)

Use a variable frequency drive (VFD) accessory to pro-

vide motor drive control to the pump. Graco supplies

accessory 240V and 480V VFDs that optimize pump

performance. See manual 311596.

Local Control Box

The local control box contains five controls. See FIG. 5.

Secure/Disable Switch

• Push in to secure.

• Pull out to disable.

Start/Stop Switch

• Set to START to start pump.

• Set to STOP to stop pump.

Alarm Reset Button

Press to clear an alarm.

Local/Remote Switch

• Set to LOCAL to control pump using local control

box.

• Set to REMOTE to control pump from a PC in a

remote location.

Jog Button

Press to enter jog mode.

FIG. 5: Local Control Box

120991 ATEX Control Box

120373 UL/CSA Control Box

TI10719A

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