Graco 333391B User Manual

Instructions

Dyna-Star

HP and

HF Pump AC to DC

333391B

Conversion Kit

Kit to convert an AC Power Source to a DC Power Source. For use with the Electric Dyna-Star HP and HF Pump only. Not approved for outdoor use. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

Part No.: 77X524

Important Safety Instructions

Read all warnings and instructions in this manual and in the Dyna-Star HP and HF Pump instruction manual. Save all instructions.

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Dyna-Star Pump Current Control Adjustment . . . . . . . . . . . . . 4

Enclosure Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Controller Cord Grip Installation . . . . . . . . . . . . . . . . . . . 5

Pressure Switch Cord Grip . . . . . . . . . . . . . . . . . . . . . . . 5

Electric Dyna-Star Cord Grip . . . . . . . . . . . . . . . . . . . . . 6

Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GLC2200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GLC2200 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installing Enclosure to Mounting Surface . . . . . . . . . . . . . . . . 7

Fuse Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Connecting Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Configuration and Wiring . . . . . . . . . . . . . . . . . . 9

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Dyna-Star Pump Connections . . . . . . . . . . . . . . . . . . . . 9

Controller Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 10

LEVER-NUTS

Installing Power Cord Clamp . . . . . . . . . . . . . . . . . . . . 10

Installing Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Kit 77X524 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Enclosure Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Kit 77X524 Inside Enclosure Parts . . . . . . . . . . . . . . . . . . . . 14

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Enclosure Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . 15

Cord Grip/Cable Gland Dimensions . . . . . . . . . . . . . . . . . . . 16

Bottom View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Warnings

WARNINGWARNINGWARNING

WARNING

Warnings

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

ELECTRIC SHOCK HAZARD

This equipment must be grounded. 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 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.

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 from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure in you pump manual when equip- ment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’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.

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. This protective equipment includes but is not limited to:

• Protective eye wear, and hearing protection.

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

2 333391B

Typical Installation

A AC to DC Kit Enclosure B Dyna-Star Pump* C Fluid Drum* D GLC2200* (24N468) E GLC2200 Connector F Cable Gland Kit (77X533) G Pressure Switch Connection (Optional) H Power Cord - 9 feet (2.7 meters) J GLC2200* (wall installation) K Electric Dyna-Star Power Cord and Cable Kits* (77X527, 77X528) L GLC2200 Cable* (24P686)

*User supplied

333391B 3

Installation

116

120

119

116

120

119

Installation

Dyna-Star Pump Current Control Adjustment

NOTE: The Dyna-Star Pump is designed to draw 40 Current Amps. The AC to DC conversion kit is only designed for 20 Current Amps. The current control must be adjusted on the Dyna-Star Motor Control Board for 20 Current Amps. The Dyna-Star pump will not run efficiently if this adjustment is not made.

1. Disconnect power to Dyna-Star pump.

2. On Dyna-Star pump, remove screws (116) from motor control box cover (120) and remove cover and gasket (119) (F

IG. 1).

value to the setting shown in F

IG. 2.

FIG. 1

3. Turn current control potentiometer knob counter-clockwise to decrease the Amp setting

FIG. 2

4. Replace motor control board gasket (119) and cover (120) with screws (116) (F pinch any wires. Tighten bolts securely. Torque to 17 - 19 ft lbs (23 - 25 N.m).

FIG. 3

IG. 3) being careful not to

4 333391B

Installation

12a

Enclosure Preparation

• Select a flat surface near the Dyna-Star pump to install the Enclosure (1).

• Enclosure Mounting Dimensions are provided on page 15 of this manual. They are provided for reference only and to use as a guide for pre-drilling holes.

• 3 cord grips are included in the kit.

• 2 cord grips (12) are used for controller inter-

face and pressure switch.

• 1 cord grip (10) is used for power to the

Dyna-Star pump.

• Determine the location on the Enclosure box (1)

that best suits your application and add holes in the box accordingly.

Controller Cord Grip Installation

• Cord Grip (12) (included in the kit) will accommodate a cable with an outside diameter of 0.230 in. -

0.395 in. (5.8 mm - 10.0 mm). If the outside diameter of your controller cord is not within this range, an appropriately sized cord grip must be used.

Enclosure (1) as shown in F sion nut and torque to 5.5 ft. lbs (7.5 N.m).

FIG. 4

IG. 4. Tighten compres-

Pressure Switch Cord Grip (Optional)

• Cord Grip (12) (included in the kit) will accommodate a cable with an outside diameter of 0.230 in. -

0.395 in. (5.8 mm - 10.0 mm). If the outside diameter of your pressure switch cord is not within this range, an appropriately sized cord grip must be used.

• Cord Grip (12) is used for installing the Pressure Switch Wiring Harness in the Enclosure (1).

• Cord Grip (12) (included in kit) is used for installing the GLC2200 Wiring Harness (24P314) in the Enclosure (1).

• For your convenience and reference, Mounting Dimensions are provided on page 16 of this manual. Install the cord grip in a location that is the most efficient for your installation location.

1. Determine the best path for the wiring cable between the controller and Enclosure (1).

2. Use a 3/4 inch (19 mm) drill bit to create the hole to install Cord Grip (12) in the Enclosure (1).

NOTE: If a different sized cord grip is used an appropriately sized drill bit must be used to create the installation hole.

3. Deburr the hole to remove sharp edges.

4. Install cord grip through drilled hole in Enclosure (1). Install lock nut on the inside of the Enclosure, over threaded end of cord grip. Tighten nut securely to hold cord grip in place. Torque nut to 5.9 ft. lbs (8 N.m).

5. Feed the end of the controller wiring harness (c) through the cord grip and into the inside of the

• For your convenience and reference, Mounting Dimensions are provided on page 16 of this manual. Install the cord grip in a location that is the most efficient for your installation location.

1. Determine the best path for the wiring cable between the Dyna-Star Pump and the Enclosure (1).

2. Use a 3/4 inch (19 mm) drill bit to create the hole to install Cord Grip (12) in the Enclosure (1).

NOTE: If a different sized cord grip is used an appropriately sized drill bit must be used to create the installation hole.

3. Deburr the hole to remove sharp edges.

5. Feed the wires through the cord grip and into the inside of the Enclosure (1). Tighten compression nut and torque to 5.5 ft. lbs (7.5 N.m).

333391B 5

Installation

Electric Dyna-Star Cord Grip

• Cord Grip(10) (included in the kit) will accommodate a cable with an outside diameter of 0.350 in. - 0.63 in. (9 mm - 16 mm). If the outside diameter of your pump cable is not within this range, an appropriately sized cord grip must be used.

• Cord Grip (10) included in kit) is used for installing the Dyna-Star pump cord (77X528) in the Enclosure (1).

• For your convenience and reference, Mounting Dimensions are provided on page 16 of this manual. Install the Cable Gland (10) in a location that is most efficient for your installation location.

1. Determine the best path for the wiring cable between the Dyna-Star Pump and the Enclosure (1).

2. Use a 1 inch (25 mm) drill bit to create a hole to install the Cable Gland Kit (10).

NOTE: If a different sized cord grip is used an appropriately sized drill bit must be used to create the installation hole.

3. Deburr the hole to remove sharp edges.

Controller Installation

NOTE:

• The following instructions are specifically written for installing a Graco GLC2200 Controller. These instructions may be modified or may be unnecessary if you are using a different type of controller or a PLC with your system.

• For your convenience, Controller Mounting Dimensions for a Graco GLC2200 are provided on page 15 of this manual. They are provided for reference only. Install the Controller in a location that is the most efficient for your installation location.

GLC2200

Graco recommends installing the GLC2200 directly to the side of the Enclosure (1). If that type of installation is not feasible for your location, it can also be mounted securely to a flat surface as close as possible to the Enclosure (see Typical Installation option J, page 3).

NOTE: The GLC2200 wiring harness cord is 5 feet long.

• If the GLC2200 is installed to the side of the Enclosure (1) the wiring harness cord must be trimmed to remove the excess length.

4. Install cable gland in drilled hole in Enclosure (1). Install lock nut (11) on the inside of the enclosure, over threaded end of cable gland. Tighten nut securely to hold cable gland in place. Torque nut to

5.1 ft. lbs (7 N.m).

5. Feed the end of the pump wiring harness (e) through the cable gland and into the inside of the Enclosure (1) as shown in F sion nut and torque to 3.7 ft. lbs (5 N.m).

FIG. 5

IG. 5. Tighten compres-

• If the GLC2200 is not mounted directly onto the side of the Enclosure (1), be sure the mounting location selected is close enough to the Enclosure to allow sufficient cord length between the GLC2200 and the connection points inside the Enclosure.

• Always pre-drill mounting holes in the Enclosure (1) or your installation location.

Before drilling the mounting holes:

• Use the mounting hole dimensions provided in

the GLC2200 instruction manual as a guide to pre-drill mounting holes

or,

• Mark the location of the two mounting holes by

positioning the GLC2200 Controller on the installation location. Mark the location of each mounting hole with a pencil.

6 333391B

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