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.

26

Installation

1

2

CPM Rate

3

4

5 x10 CPM Multiplier
6 Program Mode
7 Test Mode
8 Remote Run Test

24 VDC, 6W max.

SW1

DIp Switch

25

24 VDC, 6W max.

24 VDC, 6W max.

2

1

24 VDC, 6W max.

Micro Processor

+

Remote Run
Input

–

Air Supply

+

Valve Signal

–

Output

+

Solenoid

–

Valve #1

+

Solenoid

–

Valve #2

160 mA or 80 mA

Fuse

Transformer

J2

J1

Terminal

Block

L

N

Power
(120 VAC

or

240 VAC)

L

N

GRND

Fig. 2

The Remote Run input is an external switch input. A
switch connected to this input should be a potential
free contact.

The Air Supply Line Valve Signal is a 24 VDC output
signal. This signal drives the external 6W solenoid
valve (Graco Part No. 115605), which controls the
main air supply (required for pumps larger than the
Husky 205).

J3

Solenoid Valve #1 and #2 Signals (24 VDC output
signals) are pre-connected to the air valves on the
right side of the CycleFlo.

Power Connections

Connect Line (L), Neutral (N), and Ground (GND) as
shown in Fig. 2. Ground wire must be attached to the
ground stud and fastened down with the nut provided.

309003 7

Setup and Programming

An 8-position DIP switch (SW1) (see Fig. 1 for loca­tion) is used to set the cycle rate and cycles multiplier.
It is also used to invoke the various test modes.

Before the CycleFlo can be put into operation, the
parameters in Fig. 3 must be programmed for each
particular application.

OFF ON

1
2
3
4

5
6
7

8

SW1

Fig. 3

CPM Rate
See Fig. 4

x10 Cycles Multiplier
Program Mode
Test Mode

Remote Run Test

Cycles Per Minute (CPM) Rate

The pump cycle rate is adjustable to accommodate
different pump sizes, varying product viscosity, and
product delivery speed. The pump cycle rate is mea­sured in cycles per minute (CPM), which is the number
of times the pump performs a pump cycle in one
minute. One pump cycle consists of a momentary
pressurization of each one of the two diaphragms.

The CPM Rate Table in Fig. 4 shows the settings for
the first four switches of SW1 and the resulting CPM
rate.

SW1 CPM Rate Table

10

CPM

152520

30

35

40

45

625088

75

100

125

150

1
2
3
4

Presets

The CycleFlo has 32 programmable presets to easily
switch between amounts of fluid delivered by the pump
during a RUN cycle. Each preset is programmed with
the number of times the pump will be cycled. Use the
Y and B buttons on the front panel to step through
the presets. The PRESET display will indicate the
selected PRESET program number and the CYCLES
display will show the associated number of pump
cycles.

NOTE: SW1–5 is the x10 Cycle Multiplier. If SW1–5 is
in the ON position, the actual number of pump cycles
will be 10 times that of the CYCLES display.

To change the number of cycles associated with a
programmed preset, do the following:

1. Place the CycleFlo into Program Mode by moving

SW1–6 to ON. The PRESET display will blink to
indicate that the Program Mode is active.

2. Use the BY buttons to select the PRESET to be

changed.

3. Press and hold the RUN button, then use the B

and Y buttons to adjust the 100’s digit of the
CYCLES display.

4. Press and hold the RESET button, then use the B

and Y buttons to adjust the 10’s digit of the
CYCLES display.

5. Press and hold the PRIME button, then use the B

and Y buttons to adjust the 1’s digit of the
CYCLES display.

6. Once the correct number of cycles is displayed,

use the B and Y buttons to move to another
PRESET and then back to the current one to verify
that the new cycle count was stored correctly.

200

NOTE: Either the B or Y button must be pressed for

the new cycle count to be programmed into the Cycle­Flo’s memory.

7. Repeat for the next PRESET, as needed.

Fig. 4

8 309003

Denotes Switch is ON

8. When finished, switch SW1–6 to the OFF position

to place the CycleFlo into Normal Operating mode.

Operation

Priming the Pump

A priming feature allows for the temporary operation of
the pump for priming purposes. The pump cycle rate
during priming is controlled by the 8-position DIP
switch (SW1).

Pressing the PRIME button on the front panel will start
the pump cycling while the button is held. Once
primed, release the button to stop pump operation.

Front Panel Operation

The B and Y buttons (see Fig. 5) select the desired
PRESET pump cycle. The pump cycle count for each
PRESET is displayed in the CYCLES display.

B Decrease Y Increase

Cycles

Preset

Pressing the RUN button on the front panel starts the
pump cycling for the number of cycles indicated by the
CYCLES display. The CYCLES display will count down
from its current count every time the pump performs a
complete cycle (both diaphragms alternately acti­vated). When all cycles have been performed, the
pump will stop and the CYCLES display will automati­cally be reset to the full cycle count for the current
PRESET. The unit is then ready for another dispense
cycle.

Pressing the RESET button during a RUN operation
stops the pumping cycle. The CYCLES display will
blink to indicate that the RUN mode was interrupted.
Once in this mode, there are two possible actions:
pressing the RUN button will resume the pump cycling
where it was interrupted or pressing the RESET button
again will reset the CYCLES to the full count for the
current PRESET.

Remote Operation

The B and Y buttons select the desired PRESET
number of pump cycles. Pump cycles for each PRE­SET are displayed in the CYCLES display.

Closing the REMOTE RUN contact starts the pump
cycling for the number of cycles indicated by the
CYCLES display. The CYCLES display will count down
from its current count every time the pump performs a
complete cycle (both the diaphragms alternately acti­vated). When all cycles have been performed, the
pump will stop and the CYCLES display will automati­cally be reset to the full cycle count for the current
RESET.

Run

Emergency Stop

Fig. 5

Reset

Prime

9408B

Opening the REMOTE RUN contact stops the pump
cycling. The CYCLES display will blink to indicate that
the RUN mode was interrupted. Once in this mode,
there are two possible actions: closing the REMOTE
RUN contact again will resume the pump cycling
where it was interrupted or pressing the RESET button
on the front panel will reset the CYCLES to the full
count for the current PRESET.

When all cycles have been performed, the pump will
stop and the CYCLES display will show 000 until the
REMOTE RUN contact is opened. The CYCLES
display will then automatically be reset to the full cycle
count for the current PRESET.

309003 9

Troubleshooting

p

The following is a list of possible problems and their causes. The CycleFlo also has a built-in self-test mode that
allows dynamic testing of all components.

Troubleshooting Guide

Problem

No operation at all

LED display shows incomplete
digits

Front panel button(s) don’t work

Pump won’t operate when RUN
button is pressed

Pump won’t operate (cycles count
down and valve driver LED’s
blink)

Pump won’t operate (CYCLES
count down but no valve driver
LED’s)

Cause Solution

Blown fuse. Check fuse and replace with 250 V

1/4A type.
Emergency Stop switch OFF. Press switch.
Poor ribbon cable connection. Turn power off and unplug then re-

plug ribbon cable on main board and

display board.
Damaged display board. Replace board.
Poor ribbon cable connection. Turn power off and unplug then re-

plug ribbon cable on main board and

display board.
Loose mounting screw. Make sure mounting screws on dis-

play board are securely tightened.
Damaged display board. Replace board.
Incorrect operating mode. Make sure SW1–6, 7, 8 are all in the

OFF position.
No or low air supply. Check air supply to make sure there

is sufficient pressure and air avail-

able.
Bad solenoid wire connections. Turn off power and check wire con-

nections from solenoid valve #1 and

#2 to make sure they are all con-

nected and seated properly.
Bad solenoid valve(s). Turn off air supply and listen for

“clicking” on solenoid valves; replace

valves if no “clicking” is audible.
Bad valve drivers on main board. Replace main board.

10 309003

Self-Test Mode

CAUTION

During this test, the solenoid valves may be acti­vated. This will activate a connected pump. To
prevent inadvertent pumping, disconnect the air
supply to the solenoid valves or remove the air lines
to the pump.

TEST MODE (SW1–7)

The CycleFlo has a built-in test program that allows for
dynamic testing of all internal and external compo­nents.

Once activated, the self-test mode will do the following
continuously until the test mode is de-activated:

D All display digits count from 0–9 in unison. This is

used to determine if any of the displays are faulty.
Replace the display board if segments of the dis­play fail to activate during the self-test.

D Each of the five front panel buttons activates a

decimal point on the LED displays. Replace the
display board if a button fails to activate a decimal
point.

Position SW1–7 to the ON position to activate the
self-test mode. Position SW1–7 to the OFF position to
de-activate the self-test mode.

REMOTE RUN TEST (SW1–8)

Position SW1–8 (the REMOTE RUN test) to the ON
position to activate the AIR SUPPLY VALVE signal and
cycle the solenoid valves at the CPM rate set by
SW1–1, 2, 3, 4. The Remote Run Test (SW1–8) per­forms the same function as closing the Remote Run
Switch input, and therefore, is used to test the func­tionality of the Remote Run Switch input. Follow the
Troubleshooting Guide on page 10 if either fails to
operate.

309003 11

Parts

Display
Board

Enclosure

Ribbon Cable

Main Board

Air
Valve

Parts

Part No. Description

195264 CycleFlo Pneumatic Pump Controller Unit (120 VAC)
196706 CycleFlo Pneumatic Pump Controller Unit (240 VAC)
––––– Enclosure
––––– Emblem (not shown – located on front of unit) (120 VAC)
––––– Emblem (not shown – located on front of unit) (240 VAC)
115381 Main Board (120 VAC)
116111 Main Board (240 VAC)
115380 Display Board
115382 Ribbon Cable
115383 Air Valve (NOTE: two valves are required per controller)

Optional Accessories

Part No. Description

102518 Cord Set, Electrical
115988 Tube, Nylon, 50 ft
115605 Valve, Solenoid, 24 VDC, 6W

––––– Not sold separately.

12 309003

Typical Installation Diagrams

A

120 or 240 VAC

CycleFlo

Remote Run Input

Diaphragm Pump
(Husky 205 shown)

PH Controller, Flow
Controller, Timer, etc.
Sends on/off signal to
CycleFlo Controller

Controller

Compressed Air In

9409

309003 13

Typical Installation Diagrams

CycleFlo Controller

Chemical Injector

Flow Controller sends
on/off signal to the
CycleFlo Controllers*

Flow
Sensors*

Remote Run Input

In

Solenoid
Valve #1

CycleFlo
Controller

Solenoid
Valve #2

Husky 1040
Metering Pump

120 or 240 VAC

Air Supply Valve Signal (24 VDC)

Compressed Air

Air Supply
Solenoid Valve

Out

Inline
Mixers*

*Provided by others

14 309003

Typical Installation Diagrams

CycleFlo Controller

Water Neutralization

CycleFlo
Controller

Flow
Sensor*

Remote Run Input

Flow
Meter

Chemical
Injector

Husky 1040

In

Remote Pump

Solenoid
Valve #1

Solenoid
Valve #2

120 or 240 VAC

Air Supply Valve Signal (24 VDC)

Compressed Air In

Air Supply
Solenoid Valve

Out

*Sends on/off signal to CycleFlo Controller

Husky 1040–3275
Transfer Pump

309003 15

Typical Installation Diagrams

CycleFlo Controller

Water Treatment

Air Supply
Solenoid Valve

Air Supply Valve

Cooling Coils*

Signal (24 VDC)

120 or
240 VAC

Compressed Air In

CycleFlo
Controller

Remote Run Input

Corrosion
Inhibitor
Chemicals

* Provided by others

In

Solenoid
Valve #1

Solenoid
Valve #2

Out

Husky 1040
Metering Pump

PH Controller –
sends on/off signal to
CycleFlo Controller*

Centrifugal Pump*
(water circulating)

16 309003

Specifications

Power Requirements:

120 VAC, 50/60 Hz, 160 mA
240 VAC, 50/60 Hz, 80 mA

Air Supply:

120 psi (0.8 MPa, 8 bar) Maximum

Mounting Information

4 in.

(102 mm)

8 7/8 in.

(225 mm)

9438A

309003 17

Graco Standard Warranty

Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor­dance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub­stitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais­sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor, or call to identify the distributor closest to you:

Phone: [phone] or Toll Free: 1–800–328–0211 Fax: [phone]

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

This manual contains English. MM 309003

International Offices: Belgium, China, Japan, Korea

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

18 309003

Graco Headquarters: Minneapolis

Copyright 1999, Graco Inc. is registered to ISO 9001

www.graco.com

Revised 09/2009