Graco 309003E User Manual

Instructions – Parts List

CycleFlo™ Pneumatic

309003E

Pump Controller

Controls pump speed, run time, and quantity of product delivered, for precise
batching, metering, and dosing of fluids at high or low pressures and flow rates.

Not for use in explosive atmospheres.

Part No. 195264 (120 VAC)
Part No. 196706 (240 VAC)

120 psi (0.8 MPa, 8 bar) Maximum Air Inlet Pressure

D Integrated Air Valves with Silenced Exhaust
D 32 Batch Presets
D 1–999 Pump Cycles per Batch Preset
D x10 Cycle Multiplier for High Volume Applications (10–9990 Cycles)
D 16 Pump Cycle Rates (10–200 CPM)
D Easy Field Programming
D Self-Test Function for Easy Troubleshooting
D Standard 120 or 240 VAC Power

ENG

Important Safety Instructions

Read all warnings and instructions in this
manual. Save these instructions.

9408B

Table of Contents

Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Connections 6. . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 6. . . . . . . . . . . . . . . . . . . . . . . .

Setup and Programming 8. . . . . . . . . . . . . . . . . . . . . . . .

Cycles Per Minute (CPM) Rate 8. . . . . . . . . . . . . . . . .

Presets 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming the Pump 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Panel Operation 9. . . . . . . . . . . . . . . . . . . . . . . .

Remote Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self-Test Mode 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Installation Diagrams 13. . . . . . . . . . . . . . . . . . . .

Specifications 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Information 17. . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

2 309003

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious
injury or death if you do not follow the corresponding
instructions.

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

INSTRUCTIONS

D This equipment is for professional use only.

D Read all instruction manuals, warnings, tags, and labels before operating the equipment.

D Use equipment only for its intended purpose. If you are uncertain about usage, call your Graco

distributor.

D Other than for installation purposes, do not alter or modify this equipment. Use only genuine

Graco parts and accessories.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated system component.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not

expose Graco hoses to temperatures above 82° C (180° F) or below -40° C (-40° F).

D Do not lift pressurized equipment.

D Comply with all applicable local, state and national fire, electrical, and other safety regulations.

309003 3

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in fire or explosion and other serious injury.

D Ground the pumping equipment. Proper grounding dissipates static electricity.

D This equipment is not intended for intrinsically safe areas.

D Keep the dispense area free of debris, including solvent, rags, and gasoline.
D If there is any static sparking or you feel an electric shock while using the equipment, stop op-

erating immediately. Do not use the equipment until you have identified and corrected the
problem.

D Make sure all electrical work is performed by a qualified electrician.

D Have any checks, installation, or service to electrical equipment performed by a qualified electri-

cian only.

D Make sure all electrical equipment is installed and operated in compliance with local and appli-

cable codes.

D Make sure power is disconnected when servicing and repairing equipment.

D Keep liquids away from the electrical components.

D Disconnect electrical power at the main switch before servicing equipment.

D Never exceed maximum wattage of the supply unit.

4 309003

General Description

The CycleFlo is a pneumatic pump controller that
allows precise control over the amount of product that
is delivered by the pump, as well as the pump speed.
The CycleFlo achieves this by operating the pump for
a preset number of cycles and then halting the pump­ing cycle. Up to 32 different batch sizes may be pro­grammed into the memory of the CycleFlo for easy
delivery of different product volumes.

A batch may be initiated either from the front panel
RUN button or via a remote switch. Such a remote
switch may be connected to the trigger of a dispensing
valve so that the pump only pumps when the operator
depresses the valve trigger. Using the remote input,
the pumping cycle may also be initiated by some other
piece of equipment such as a timer or a pH controller.
The CycleFlo will halt the pumping cycle once the
preset volume of product has been dispensed.

The CycleFlo also features an adjustable pumping
rate. This allows the CycleFlo to be used with different
pump types and also to tailor the pump cycle to deliver
fluids with a variety of flow characteristics.

309003 5

Installation

Pneumatic Connections

The integrated air valves (solenoids #1 and #2), lo­cated on the right side of the CycleFlo enclosure, have
a common air inlet (1/4 in. npt) port at the bottom and
two outlet ports (1/8 in. npt to 1/4 in. elbow tube fitting)
towards the front of the unit. The exhaust is silenced
with a muffler.

Fig. 1

The A and B outlet ports are to be connected to the A
and B ports, respectively, on the Huskyt 205, or to
the two air valve control ports located on the air motors
of pumps larger than the Husky 205. The unit comes
equipped with 1/4 in. OD push-in tube fittings installed
in the A and B ports.

On pumps larger than the Husky 205, a three-way
solenoid valve (Graco Part No. 115605 or equivalent)
should be installed on the main air supply to the pump.
This ensures that pressure is not generated by the
pump when the controller is not operating. The air
supply valve signal output on the CycleFlo controller is
designed to control this valve.

An access hole with a strain relief installed has been
provided for the external power connection. Due to the
unique requirements of each installation, access holes
have not been provided for other optional external
wiring connections. Access holes will need to be added
for the external Air Supply Valve Signal and/or Remote
Run options. Have a qualified electrician determine the
proper strain relief, wire type, and wire size for your
particular application. When positioning or adding
access holes, be careful not to damage any internal
components. Failure to use the proper strain relief,
wire type, and wire size can cause damage to internal
components or personal injury.

The 24 Volt DC Air Supply Valve Signal output is used
to control a three-way valve (Graco Part No. 115605 or
equivalent) on the main air supply of pumps larger than
the Husky 205. This ensures that pressure is not
generated by the pump when the controller is not
operating. Failure to use this valve can cause damage
to the unit and possible personal injury.

WARNING

Failure to use the recommended valve can cause
damage to the unit and possible personal injury.
Follow the pressure relief procedure in the pump
manual before moving or servicing the pump.

The CycleFlo requires 120/240 VAC, 50/60 Hz to
operate. The power input is fuse-protected with a 160
mA fuse for 120 Volt service and an 80 mA fuse for
240 Volt service (see Fig. 2).

Electrical Connections

WARNING

FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD

To reduce the risk of fire, explosion, or
electric shock:

D The power source conduit is not an

adequate ground for the system. The
unit must be grounded to a true earth
ground.

D A qualified electrician must complete

all grounding and wiring connections
and check the resistance.

D Refer to your local code for the requirements for

a “true earth ground” in your area.

6 309003

WARNING

When replacing the fuse, make sure to replace it
only with one of equivalent rating. Failure to do so
may cause damage to the unit and possible per­sonal injury.

Connect power to the unit as described. Always have a
qualified electrician perform wiring connections. Con­nect Line (L) and Neutral (N) wires to the terminal
block as shown in Fig. 2. The Ground wire (GND) must
be attached to the #10–32 ground stud. A crimp-on
ground wire lug comes attached to the ground stud.
Remove the lug and attach to the ground wire. Re­place the lug assembly back onto the stud and fasten
down with the kepsnut provided.