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
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.
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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.
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