GRACO D60, D200, D200S Instruction manual
Installation - Parts
E-Flo® SP
Supply Systems
3A6331G
EN
For transferring or dispensing sealants, adhesives, or other medium to high viscosity fluids. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
D60 3 inch dual post
20 liter (5 gallon), 30 liter (8 gallon),
60 liter (16 gallon) sizes
150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure
D200 3 inch dual post
200 liter (55 gallon) size
150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure
D200S 6.5 inch dual post
200 liter (55 gallon) size
125 psi (0.9 MPa, 9 bar) Maximum Air Inlet Pressure
See page 4 for model information, including maximum working pressure and approvals.
The Graco Control Architecture Electric Components are Listed in Intertek’s Directory of Listed Products.
Important Safety Instructions
Read all warnings and instructions in this manual and in related manuals before using the equipment. Save all instructions.
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tandem Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Identification . . . . . . . . . . . . . . . . . . . 11
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 11
Integrated Air Control Module . . . . . . . . . . . . . . 12
Integrated Air Line Accessories . . . . . . . . . . . . . 12
Advanced Display Module (ADM) . . . . . . . . . . . 13
Platen Component Identification . . . . . . . . . . . . 14
Junction Box Connections . . . . . . . . . . . . . . . . . 15
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Requirements . . . . . . . . . . . . . . . . . . . . . 17
Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . 17
Attach Drum Stops. . . . . . . . . . . . . . . . . . . . . . . 18
Fluid Hose and Air Line Connections. . . . . . . . . 18
Install Vented Oil Cap Before Using Equipment. 18
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 20
Start and Adjust the Ram. . . . . . . . . . . . . . . . . . 21
Start and Adjust the Pump . . . . . . . . . . . . . . . . . 21
Pressure Relief Procedure. . . . . . . . . . . . . . . . . . . 22
Shutdown and Care of the Pump . . . . . . . . . . . . . 23
Change Drums. . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Driver Maintenance . . . . . . . . . . . . . . . . . . . . . . 24
Platen Maintenance . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disconnect Pump from Platen . . . . . . . . . . . . . . 30
Connect Platen . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remove Wipers . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remove Displacement Pump. . . . . . . . . . . . . . . 31
Install Displacement Pump . . . . . . . . . . . . . . . . 32
Remove Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Supply Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 34
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
D200s 6.5 in. Supply Units . . . . . . . . . . . . . . . . . 38 D200 3 in. Supply Units . . . . . . . . . . . . . . . . . . . 40 D60 3 in. Supply Units . . . . . . . . . . . . . . . . . . . . 42
D200s and D200 Pump Mounts for 55 Gallon (200 Liter) Platen . . . . . . . . . . . . . . . . . . . . . . . . . 44
D60 Pump Mount 257624 for 5 Gallon (20 Liter) Platen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Cable Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 55 Gallon Platen . . . . . . . . . . . . . . . . . . . . . . . . . 49
20 Liter (5 Gallon), 30 Liter (8 Gallon), and 60 Liter (16 Gallon) Platens . . . . . . . . . . . . . . . . . . . 50
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 55
Drum Roller Kits for D200 and D200S Supply Units, 255627 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Drum Position Clamp Set for D200 Supply Units, 206537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Drum Position Clamp for D200S Supply Units . . 55 Enclosed Wet Cup Recirculation Kit. . . . . . . . . . 55 200 Liter (55 Gallon) Platen Cover Kits, 255691 55 Light Tower Kit, 255468 . . . . . . . . . . . . . . . . . . . 55 ADM Kit, 25E437 . . . . . . . . . . . . . . . . . . . . . . . . 55 CAN Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 I/O Cable, 122029 . . . . . . . . . . . . . . . . . . . . . . . 55 Communication Gateway Module (CGM) Kits . . 56 Low Level Sensor Kit, 25E447 . . . . . . . . . . . . . . 58 Tandem Connection Kit, 25E595 . . . . . . . . . . . . 59
Tandem Depressurization/Recirculation Kit, 25E618 (carbon steel), 25E619 (stainless steel). . . . 60
Tandem Fluid Filter Kit, 25E620 . . . . . . . . . . . . . 64
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Pump Performance . . . . . . . . . . . . . . . . . . . . . . . . . 69
E-Flo SP Performance Charts . . . . . . . . . . . . . . 70
Technical Specifications . . . . . . . . . . . . . . . . . . . . 76 California Proposition 65 . . . . . . . . . . . . . . . . . . . . 77
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 78
Graco Information 78
2 |
3A6331G |
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3A6331G |
3 |
Models
Models
Check the identification plate (ID) for the 7-digit part number of the supply system. Use the following matrix to define the construction of the supply system, based on the seven digits. For example, Part No. EMC1121 represents an electric supply system (EM), a carbon steel Check-Mate 100 Severe Duty displacement pump with an electric driver (C1), a 3 in. dual post ram with integrated air controls (1), a 5-gallon platen with a nitrile seal (2), and 240 VAC power (1).
NOTICE
To prevent damage to DataTrak soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.
NOTE: Systems with the EMD as the first and second digits are Dura-Flo supply systems.
The digits in the matrix on the next page do not correspond to the Ref. Nos. in the Parts drawings and lists.
4 |
3A6331G |
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EM |
C1 |
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2 |
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First |
Third and |
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and |
Fourth |
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Fifth Digit |
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Sixth Digit |
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Seventh Digit |
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Second |
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Interface and Power |
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Ram Options |
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Platen and Seal Options |
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Options |
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Ram |
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Pump |
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Drum |
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Air |
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Platen |
Platen |
Platen |
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Seal |
Compati- |
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Code |
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Size |
Style |
Size |
Controls |
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Size |
Style |
Material |
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bility |
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Power |
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EM |
(See Table |
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1 |
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20 L |
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1 |
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1 |
None |
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240 VAC |
(Electric |
1: for 2-digit |
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3 in. |
D60 |
(5 Gal) |
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INT |
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No Platen |
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Supply |
Check-Mate |
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200 L |
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20 L |
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System) |
Pump |
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2 |
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3 in. |
D200 |
(55 Gal) |
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INT |
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2 |
(5 Gal) |
F, SW |
CS |
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Nitrile |
D60 |
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2 |
None |
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480 VAC |
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Code) |
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3 |
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200 L |
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3 |
20 L |
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Polyure- |
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3 |
ADM |
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240 VAC |
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6.5 in. |
D200s |
(55 Gal) |
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INT |
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(5 Gal) |
F, SW |
CS |
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thane |
D60 |
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4 |
20 L |
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4 |
ADM |
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480 VAC |
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(5 Gal) |
F, DW |
CS |
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Nitrile |
D60 |
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5 |
20 L |
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Polyure- |
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(5 Gal) |
F, DW |
CS |
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thane |
D60 |
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(See Table |
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6 |
20 L |
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PTFE |
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(5 Gal) |
F, SW |
SS |
coated |
D60 |
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1: for 2-digit |
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PTFE |
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Dura-Flo |
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200 L |
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Coated |
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D200, |
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Pump |
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7 |
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(55 Gal) |
DR |
AL |
EPDM |
D200s |
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Code) |
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8 |
200 L |
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D200, |
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(55 Gal) |
DR |
AL |
EPDM |
D200s |
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9 |
200 L |
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D200, |
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(55 Gal) |
DR |
AL |
Neoprene |
D200s |
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A |
200 L |
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EPDM |
D200, |
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(55 Gal) |
DR |
AL |
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Hose |
D200s |
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KEY: |
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INT = Integrated air controls |
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SW = Single wiper |
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CS = Carbon Steel Severe Duty |
CM = Carbon Steel MaxLife® |
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F = Flat |
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DW = Double wiper |
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SS = Stainless Steel Severe Duty |
SM = Stainless Steel MaxLife |
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DR = Dual o-ring |
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AL = Aluminum |
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Table 1: Pump Code Index
Pump |
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Pump |
Pump |
Code |
Part No. |
Pump Type |
Size |
Material |
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C1 |
EC100CS1 |
Check-Mate |
100cc |
CS |
C2 |
EC100CM1 |
Check-Mate |
100cc |
CM |
C3 |
EC100SS1 |
Check-Mate |
100cc |
SS |
C4 |
EC100SM1 |
Check-Mate |
100cc |
SM |
C5 |
EC200CS1 |
Check-Mate |
200cc |
CS |
C6 |
EC200CM1 |
Check-Mate |
200cc |
CM |
C7 |
EC200SS1 |
Check-Mate |
200cc |
SS |
C8 |
EC200SM1 |
Check-Mate |
200cc |
SM |
C9 |
EC250CS1 |
Check-Mate |
250cc |
CS |
CA |
EC250CM1 |
Check-Mate |
250cc |
CM |
CB |
EC250SS1 |
Check-Mate |
250cc |
SS |
CC |
EC250SM1 |
Check-Mate |
250cc |
SM |
CD |
EC500CS1 |
Check-Mate |
500cc |
CS |
CE |
EC500CM1 |
Check-Mate |
500cc |
CM |
CF |
EC500SS1 |
Check-Mate |
500cc |
SS |
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Pump |
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Pump |
Pump |
Code |
Part No. |
Pump Type |
Size |
Material |
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CG |
EC500SM1 |
Check-Mate |
500cc |
SM |
D1 |
ED115CS1 |
Dura-Flo |
115cc |
CS |
D2 |
ED145CS1 |
Dura-Flo |
145cc |
CS |
D3 |
ED145SS1 |
Dura-Flo |
145cc |
SS |
D4 |
ED180CS1 |
Dura-Flo |
180cc |
CS |
D5 |
ED180SS1 |
Dura-Flo |
180cc |
SS |
D6 |
ED220CS1 |
Dura-Flo |
220cc |
CS |
D7 |
ED220SS1 |
Dura-Flo |
220cc |
SS |
D8 |
ED290CS1 |
Dura-Flo |
290cc |
CS |
D9 |
ED290SS1 |
Dura-Flo |
290cc |
SS |
DA |
ED430CS1 |
Dura-Flo |
430cc |
CS |
DB |
ED430SS1 |
Dura-Flo |
430cc |
SS |
DC |
ED430SM1 |
Dura-Flo |
430cc |
SM |
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NOTE: See the E-Flo SP Electric Pump Instructions-Parts manual for a complete parts list.
3A6331G |
5 |
Models
System Pressure
Due to factors such as the dispensing system design, the material being pumped, and the flow rate, the dynamic pressure will not reach the rated working (stall) pressure of the system.
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Pump Working (Stall) Pressure |
Max Dynamic (Run) Pressure |
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Lower Size |
psi |
bar |
MPa |
psi |
bar |
MPa |
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100CS/CM/SS/SM |
6,000 |
414 |
41.4 |
6,000 |
414 |
41.4 |
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200CS/CM/SS/SM |
4,200 |
290 |
29.0 |
3,905 |
269 |
26.9 |
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250CS/CM/SS/SM |
3,400 |
234 |
23.4 |
3,122 |
215 |
21.5 |
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500CS/CM/SS/SM |
1,600 |
110 |
11.0 |
1,487 |
103 |
10.3 |
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145SS |
5,600 |
386 |
38.6 |
5,204 |
359 |
35.9 |
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180SS |
4,500 |
310 |
31.0 |
4,164 |
287 |
28.7 |
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220SS |
3,700 |
255 |
25.5 |
3,470 |
239 |
23.9 |
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| <![if ! IE]> <![endif]>Flow |
290SS |
2,800 |
193 |
19.3 |
2,602 |
179 |
17.9 |
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430CS/SS/SM |
1,900 |
131 |
13.1 |
1,735 |
120 |
12.0 |
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115CS |
6,000 |
414 |
41.4 |
6,000 |
414 |
41.4 |
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145CS |
5,600 |
386 |
38.6 |
5,204 |
359 |
35.9 |
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180CS |
4,500 |
310 |
31.0 |
4,164 |
287 |
28.7 |
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220CS |
3,700 |
255 |
25.5 |
3,472 |
239 |
23.9 |
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290CS |
2,800 |
193 |
19.3 |
2,602 |
179 |
17.9 |
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Flow Rate Table
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Flow Rate |
Flow Rate |
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Lower Size |
(cc/min) |
(gpm) |
Outlet Fitting Size |
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| <![if ! IE]> <![endif]>Mate |
100CS/CM/SS/SM |
2,500 |
0.66 |
1 in. NPT female |
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200CS/CM/SS/SM |
5,000 |
1.32 |
1 in. NPT female |
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250CS/CM/SS/SM |
6,250 |
1.65 |
1 in. NPT female |
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500CS/CM/SS/SM |
12,500 |
3.30 |
1-1/2 in. NPT female |
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145SS |
3,625 |
0.96 |
1 in. NPT female |
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180SS |
4,500 |
1.19 |
1 in. NPT female |
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220SS |
5,500 |
1.45 |
1 in. NPT female |
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| <![if ! IE]> <![endif]>Flow |
290SS |
7,250 |
1.92 |
1 in. NPT female |
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430CS/SS/SM |
10,750 |
2.84 |
1-1/2 in. NPT female |
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115CS |
2,875 |
0.76 |
1 in. NPT female |
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145CS |
3,625 |
0.96 |
1 in. NPT female |
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180CS |
4,500 |
1.19 |
1 in. NPT female |
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220CS |
5,500 |
1.45 |
1 in. NPT female |
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290CS |
7,250 |
1.92 |
1 in. NPT female |
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6 |
3A6331G |
Tandem Ram
How to Buy
1.Configure Tandem Ram “A” - E-Flo SP Ram with an ADM (Quantity 1 per Tandem System).
-Example: EMC1283 – D200 Ram, Electric Pump with Check-Mate 100 CS Lower, 200L EPDM Platen, 240V, with ADM.
2.Configure Tandem Ram “B” - E-Flo SP Ram without an ADM (Quantity 1 per Tandem System).
-Example: EMC1281 – D200 Ram, Electric Pump with Check-Mate 100 CS Lower, 200L EPDM Platen, 240V, without ADM.
3.Purchase Tandem Connection Kit, 25E595 (Quantity 1 per Tandem System).
4.Purchase Accessories.
-Depressurization/Recirculation Kit (Quantity 1 per Ram)
25E618: for Carbon Steel Pump Lowers
25E619: for Stainless Steel Pump Lowers
-Fluid Filter Kit, 25E620 (Quantity 1 per Tandem System)
-Extension Cables for Fluid Filter Monitoring Pressure Transducers (Quantity 1 per Ram)
124943: 1 meter
122497: 2 meters
124409: 3 meters
17H363: 7.5 meters
17H364: 16 meters
-Low Level Sensor Kit, 25E447 (Quantity 1 per Ram)
NOTE: Rams come with Empty Level Sensors already installed.
Models
5.Purchase hoses for the system. - For Check-Mate Pumps:
Pump Lower |
Max. Pressure |
Size |
Rating |
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100cc |
6000 psi |
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200cc |
4200 psi |
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250cc |
3400 psi |
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500cc |
1600 psi |
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-For Dura-Flo Pumps:
Pump Lower |
Max. Pressure |
Size |
Rating |
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115cc |
6000 psi |
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145cc |
5600 psi |
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180cc |
4500 psi |
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220cc |
3700 psi |
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290cc |
2800 psi |
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430cc |
1900 psi |
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3A6331G |
7 |
Warnings
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.
DANGER
SEVERE ELECTRIC SHOCK HAZARD
This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.
•Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.
•This equipment must be grounded. Connect only to grounded power source.
•All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Do not point dispensing device at anyone or at any part of the body.
•Do not put your hand over the fluid outlet.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.
•Tighten all fluid connections before operating the equipment.
•Check hoses and couplings daily. Replace worn or damaged parts immediately.
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.
•Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
8 |
3A6331G |
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent 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.
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 Specifications in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheets (SDSs) from distributor or retailer.
•Turn off all equipment and follow the Pressure Relief Procedure when equipment 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.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen, splatter may occur.
•Use minimum air pressure when removing platen from drum.
3A6331G |
9 |
Warnings
WARNING
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 Sheets (SDSs) 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.
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.
10 |
3A6331G |
Component Identification
Component Identification
Typical Installation
D200 3 in. and D200s 6.5 in. Dual Post
EMC1223 Model
Shown
U
E
Lift Locations
A
K
M
B 
S
Y
C 
J 
D 
NOTICE
Always lift the supply system at the proper lift locations (see FIG. 1). Do not lift in any other way. Failure to lift at the proper lift locations can result in damage to the supply system.
W
V
X
F
G
T
NOTE: The Outlet Pressure Relief Valve is used on Check-Mate 100cc pumps only. See the E-Flo SP Electric Pump Instructions-Parts manual for a complete parts list.
Z
N
R
P
FIG. 1: Typical Installation |
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Key: |
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A |
Ram Assembly |
N |
Platen Lift Rod |
B |
Electric Driver |
P |
Pump Bleed Valve |
C |
Displacement Pump |
R |
Enclosed Wet Cup |
D |
Platen |
S |
Fluid Line (not supplied) |
E |
Cable Track |
T |
Air Line (not supplied) |
F |
Advanced Display Module (ADM) |
U |
Air Line Drain Valve (not supplied) |
G |
Integrated Air Controls (see FIG. 2) |
V |
Air Filter (not supplied) |
J |
Platen Bleed Port |
W |
Bleed Type Air Shutoff Valve (required) (not supplied) |
K |
Power Junction Box |
X |
Level Sensors |
M |
Disconnect Switch |
Y |
Outlet Pressure Transducer |
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Z |
Outlet Pressure Relief Valve (Check-Mate 100 only) |
3A6331G |
11 |
Component Identification
Integrated Air Control Module
D200, D200s, and D60 Models
The integrated air controls include:
•Main air slider valve (AA): turns air on and off to the system. When closed, the valve relieves pressure downstream.
•Ram air regulator (AB): controls ram up and down pressure and blowoff pressure.
•Ram director valve (AC): controls ram direction.
•Exhaust port with muffler (AD)
•Blowoff button (AE): turns air on and off to push the platen out of an empty drum.
AC
AE
AB
AA
FIG. 2. Integrated Air Control Module
Integrated Air Line Accessories
See FIG. 1.
•Air line drain valve (U).
•Air line filter (V): removes harmful dirt and moisture from compressed air supply.
•Second bleed-type air valve (W) (required): isolates air line accessories for servicing. Locate upstream from all other air line accessories.
•Air relief valve (required) (not visible): automatically relieves excessive pressure.
12 |
3A6331G |
Component Identification
Advanced Display Module (ADM)
Front and Rear Views
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BB |
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BC |
BR |
BK |
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BA |
BD |
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BE
BF
BH
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BP |
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BG |
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BL |
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BN |
BM |
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BJ
FIG. 3: ADM Component Identification
Key: |
|
BA Pump Enable |
BG Lock/Setup |
Enables the pump. Toggles between Active and |
Toggle between run and setup screens. |
System Off. |
BH Directional Keypad |
BB Pump Status Indicator Light |
Navigate within a screen or to a new screen. |
BC Pump Soft Stop |
BJ Numeric Keypad |
Stops all pump processes and disables the pump. |
BK Part Number Identification Label |
BD Soft Keys |
BL USB Interface |
Defined by the icon on the screen next to the soft |
BM CAN Cable Connection |
key. |
Power and communication. |
BE Cancel |
BN Module Status LEDs |
Cancel a selection or number entry while in the |
Visual indicators to show the status of the ADM. |
process of entering a number or making a selection. |
BP Token Access Cover |
Cancels the pump processes. |
Access cover for software token. |
BF Enter |
BR Battery Access Cover |
Accept change, acknowledge error, select item, and |
|
toggle selected item. |
|
3A6331G |
13 |
Component Identification
Platen Component Identification
Model 255319, 200 liter (55 gallon)
EF
EA
EG
EH
EB
Model 256742 and 256745, 20 liter (5 gallon)
EF
EA
ED
EH
EC
EB
EJ
FIG. 4
Key:
EA |
Plate |
EB |
Wipers |
EC |
Spacer |
ED |
Cap Screws |
EE |
Clamps (not shown) |
EF |
Bleed Stick |
EG |
Bleed Port |
EH |
Air Assist Body Check Valve |
EJ |
Wiper Plate (under wiper) |
EK |
O-ring Seal (not shown) |
14 |
3A6331G |
Component Identification
Junction Box Connections
C1
C2
C3
C4
FIG. 5
Key:
C1 CGA CAN Port
C2 GCA CAN Port
C3 Low and Empty Level Sensor Input
C4 Fluid Filter Solenoid Input
NOTE: See the E-Flo SP Software Instructions manual for all I/O descriptions.
3A6331G |
15 |
Installation
Installation
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
Location
To properly locate and anchor the supply system, refer to Dimensions on page 67.
NOTICE
Always lift the supply system at the proper lift locations (see FIG. 1). Do not lift in any other way. Failure to lift at the proper lift locations can result in damage to the supply system.
Attach a lifting sling at the proper lift locations. Lift off the pallet using a crane or a forklift.
NOTE: The lift ring on the driver is only to be used for replacing the driver. Do not use it to lift the entire system.
Position the ram so the driver, disconnect switch, air controls, and ADM are easily accessible. Ensure that there is enough space overhead for the ram to raise fully.
Using the holes in the ram base as a guide, drill holes for 1/2 in. (13 mm) anchors.
Ensure that the ram base is level in all directions. If necessary, level the base using metal shims. Secure the base to the floor using 1/2 in. (13 mm) anchors that are long enough to prevent the ram from tipping.
Grounding
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.
Electric pump: the pump is grounded through the power cord.
Ram: the ram is grounded through the power cord.
Air and fluid hoses: use only electrically conductive hoses with a maximum of 500 ft. (150 m) combined hose length to ensure grounding continuity. Check the electrical resistance of the hoses. If the total resistance to ground exceeds 29 megaohms, replace the hose immediately.
Air compressor: follow manufacturer’s recommendations.
Dispense valve: ground through connection to a properly grounded fluid hose and pump.
Fluid supply container: follow local code.
Solvent pails used when flushing: follow local code. Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity.
To maintain grounding continuity when flushing or relieving pressure: hold a metal part of the dispense valve firmly to the side of a grounded metal pail, then trigger the valve.
16 |
3A6331G |
Power Requirements
The system requires a dedicated circuit protected with a circuit breaker.
Voltage |
Phase |
Hz |
Current |
200-240 VAC |
1 |
50/60 |
20 A |
400-480 VAC |
1 |
50/60 |
10 A |
Connect Power
NOTICE
To avoid equipment damage, route and secure a power cord that is long enough to allow the full range of movement for the ram.
6.Cut power cord wires to the following lengths:
•Ground wire - 6.5 inches (16.5 cm)
•Power wires - 3.0 inches (7.6 cm)
•Add ferrules as necessary. See FIG. 6.
Installation
8.Insert the power cord through the cord grip and into the junction box (K).
Ground Stud
Disconnect Switch
Terminal Block
Cord Grip
FIG. 8: Power Connection
9.Attach the ground wire to the ground stud inside the junction box (K).
10.Refer to FIG. 9 and connect the wires from the power cord into terminals 4T2 and 6T3 on the disconnect switch terminal block.
LQ
LQ
1L1 |
3L2 |
5L2 |
2T1 |
4T2 |
6T3 |
FIG. 6: Power Cord
7.Remove the six screws holding the cover of the junction box (K), then remove the junction box cover.
K
Screws
FIG. 9: Disconnect Switch Terminal Block
11.Tighten the cord grip to securely hold the power cord to the junction box (K).
12.Replace the junction box cover and secure it with the six screws that were removed in step 2.
FIG. 7: Remove the Junction Box Cover
3A6331G |
17 |
Installation
Attach Drum Stops
The electric supply systems are shipped with drum stops in place to help position the drum on the ram. For replacement parts, order Kit 255477. The kit includes 2 each of capscrews, lock washers (not shown), and drum stops.
Install Vented Oil Cap Before
Using Equipment.
The driver gear-box is shipped from the factory pre-filled with oil. The temporary unvented cap prevents oil leaks during shipment. This temporary cap must be replaced with the vented oil cap supplied with the equipment, before use.
NOTE: Prior to use, check oil level. Oil level should be half way up the sight glass.
Capscrews
Drum Stops
FIG. 10: Drum Stop Installation
1.Locate the correct set of mounting holes on the ram base.
2.Using the capscrews and lock washers, attach the drum stops to the ram base.
Fluid Hose and Air Line
Connections
Refer to FIG. 1 on page 11 for a typical installation.
Attach the fluid hose (not supplied) to the Outlet Check Valve (E) connection.
Attach the air line (not supplied) to the bottom of the Integrated Air Control (G) at the 3/4 in. NPT connection.
NOTE: Be sure all components are adequately sized and pressure rated to meet the system’s requirements.
Vented Cap |
Unvented |
|
Cap |
FIG. 11: Unvented and Vented Oil Caps
18 |
3A6331G |
Setup
Setup
Wet Cup
Before starting, fill the wet cup (L) 1/3 full with Graco
Throat Seal Liquid (TSL) or a compatible solvent.
Torque the Wet Cup
The wet cup is torqued at the factory; however, throat packing seals on Severe Duty pumps may relax over time. Check wet cup torque frequently after initial start-up and periodically after the first week of production. Maintaining proper wet cup torque is important to extending seal life.
R
FIG. 12: Wet Cup
NOTE: MaxLife pumps use a special u-cup throat seal that is non-adjustable and does not require periodic torquing.
1.Follow the Pressure Relief Procedure on page 22.
2.Torque the wet cup (R) 95-115 ft-lbs (128-155 N•m) using the packing nut wrench (supplied) whenever necessary. Do not overtighten the wet cup. See the table below for torque values.
3A6331G |
19 |
Startup
Startup
Letters in parenthesis are used in this section for reference to callouts in the Component Identification section starting on page 11.
Flush the Pump
To avoid fire and explosion, always ground the equipment and the waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.
NOTE: The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent before using the pump.
Always flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary. Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.
NOTE: Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency.
NOTICE
To prevent damage to the pump from rust, never leave water or water-based fluid in a carbon steel pump overnight. If you are pumping a water-based fluid, flush with water first. Then flush with a rust inhibitor, such as mineral spirits. Relieve pressure, but leave the rust inhibitor in the pump to protect parts from corrosion.
NOTE: Refer to the E-Flo SP Software Instructions manual for additional information about using the software features of the ADM. See Related Manuals on page 3.
1.Follow the Pressure Relief Procedure on page 22.
2.Place a pail of compatible solvent in the ram. See Grounding instructions for solvent pails on page 16.
3.Turn the disconnect switch (M) ON.
4.At the ADM (F), use the ADM’s arrow keys to select the pump you want to flush from the Menu Bar.
NOTE: If multiple pumps are connected together, there can be up to six pumps listed in the Menu Bar.
5.Enter the Edit screen for that pump by pressing the soft key next to the 
icon.
6.Press the soft key next to the Pressure Mode 
icon.
7.Enter 100 psi (0.69 MPa, 6.9 bar) as the pressure.
8.Press the soft key next to the Pump On/Off 
icon to turn on the pump.
9.Adjust pressure as necessary.
10.Hold a metal part of the dispense valve firmly to the side of a grounded metal pail.
11.Open the dispense valve and flush the system until clear solvent flows from the gun/valve.
12.Exit the Edit screen by pressing the soft key next to the 
icon.
13.Repeat steps 3 through 11 for each pump you want to flush.
14.Follow the Pressure Relief Procedure on page 22.
15.Remove the solvent pail from the ram.
20 |
3A6331G |
Start and Adjust the Ram
1.Turn the disconnect switch (M) OFF.
2.Raise the Ram by opening the main air slider valve (AA) and setting the ram air regulator (AB) to 40 psi (0.28 MPa, 2.8 bar).
3.Set the ram director valve handle (AC) to UP and let the ram rise to its full height.
4.Set the ram director valve handle (AC) to neutral.
5.Lubricate the platen wiper (EB) with grease or other lubricant compatible with the fluid you will pump.
6.Put a full drum/pail on the ram base and center it under the platen (D).
7.Remove the drum/pail cover and smooth the surface of the fluid with a straightedge. To prevent air from being trapped under the platen, scoop fluid from the center of the pail to the sides, to make the surface concave.
8.Adjust the drum/pail to be sure it is aligned with the platen, and remove the platen bleed stick to open the platen bleed port.
D60
Platen Bleed Stick
EB 
D200
Platen Bleed Stick 
EB
Startup
9.With hands away from the drum/pail and the platen, push down on the ram director valve (AC) handle, and lower the ram until the platen rests on the lip of the drum/pail. Move the ram director valve handle to the horizontal position (neutral).
10.Lower the ram:
a.Set the ram director valve (AC) to DOWN and continue to lower the ram until fluid appears at the platen bleed port.
b.Set the ram director valve to neutral, replace the platen bleed stick, and tighten it securely.
Start and Adjust the Pump
1.With the disconnect switch (M) OFF, set the ram air regulator (AB) to about 50 psi (0.35 MPa, 3.5 bar). Set the ram director valve (AC) to DOWN.
2.Turn the driver disconnect switch (M) ON.
3.Start the pump. See the E-Flo SP Software Instructions manual for instructions on operating the system.
4.Keep the ram director valve (AC) set to DOWN while the pump is operating.
NOTE: Increase air pressure to the ram if the pump does not prime properly with more viscous fluids. Decrease air pressure if fluid is forced out around the top seal or platen.
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Pressure Relief Procedure
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever you see this symbol.
This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.
1.At the ADM, enter manual mode by pressing the soft key next to the 
icon.
2.Press the soft key next to the 
icon to stop the pump.
3.Turn the disconnect switch (M) OFF.
AC
AA
FIG. 13: Air Control for Pressure Relief
4.Close the main air slider valve (AA).
5.Set the ram director valve (AC) to DOWN. The ram will slowly drop.
6.Once the ram is completely down, jog the ram director valve up and down to bleed air from the ram cylinders.
7.Hold a metal part of the dispense valve firmly to the side of a grounded metal pail, and open the dispense valve to relieve pressure.
8.Open your system’s fluid line drain valve and open the pump bleed valve (P). Have a container ready to catch the drainage.
9.Leave the pump bleed valve (P) open until ready to dispense again.
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Shutdown and Care of the Pump
Shutdown and Care of the Pump
Change Drums
NOTICE
To prevent damage to the pump from rust, never leave water or water-based fluid in a carbon steel pump overnight. If you are pumping a water-based fluid, flush with water first. Then flush with a rust inhibitor, such as mineral spirits. Relieve pressure, but leave the rust inhibitor in the pump to protect parts from corrosion.
1.Set the ram director valve (AC) to DOWN, and lower the ram to the desired position for shutdown.
2.Set the ram director valve (AC) to neutral.
3.Stop the pump at the bottom of the stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat packings. See the E-Flo SP Software Instructions manual for information about jogging the pump. See Related Manuals on page 3.
4.Always flush the pump before the fluid dries on the displacement rod. Follow steps to Flush the Pump on page 20.
1.Stop the pump.
2.Set the ram director valve (AC) to UP to raise the platen, and immediately press and hold the blowoff air button (AE) until the platen is completely out of the drum. Use the minimum amount of air pressure necessary to push the platen out of the drum.
Excessive air pressure in the material drum could cause the drum to rupture, causing serious injury. The platen must be free to move out of the drum. Never use drum blowoff air with a damaged drum.
3.Release the blowoff air button (AE) and allow the ram to rise to its full height.
4.Remove the empty drum.
5.Inspect the platen and, if necessary, remove any remaining material or material build–up.
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Maintenance
Maintenance
Driver Maintenance
NOTICE
Do not open/remove the gear cover. The gear side is not intended to be serviced. Opening the gear cover may alter the factory set bearing pre-load and may reduce the product life.
Preventative Maintenance Schedule
The operating conditions of your particular system determine how often maintenance is required. Establish a preventative maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.
Change the Oil
NOTE: Change the oil after a break-in period of 200,000 to 300,000 cycles. After the break-in period, change the oil once per year.
1.Follow the Pressure Relief Procedure on page 22.
2.Place a minimum 2 quart (1.9 liter) container under the oil drain port.
3.Remove the oil drain plug. See FIG. 14 for the location of the drain plug. Allow all oil to drain from the driver.
4.Reinstall the oil drain plug. Torque to 18-23 ft-lb (25-30 N•m).
5.Open the fill cap and add Graco Part 16W645 ISO 220 silicone-free synthetic EP gear oil. Check the oil level in the sight glass. Fill until the oil level is near the halfway point of the sight glass. The oil capacity is approximately 1.0 - 1.2 quarts (0.9 - 1.1 liters). Do not overfill.
6.Reinstall the fill cap.
Check Oil Level
Refer to FIG. 14 below. Check the oil level in the sight glass on a regular basis. The oil level should be near the halfway point of the sight glass when the driver is not running. If the oil is low, open the fill cap and add Graco Part No. 16W645 ISO 220 silicone-free synthetic EP gear oil.
The oil capacity is approximately 1.0 - 1.2 quarts (0.9 - 1.1 liters). Do not overfill.
NOTICE
Only use oil with Graco part number 16W645. Any other oil may not lubricate properly and can cause damage to the drive train.
Fill Cap
Bearing Pre-loads
Sight Glass
Oil Drain Plug
FIG. 14: Sight Glass and Oil Fill Cap
Bearing Pre-Load
The bearing pre-loads are factory set and are not user adjustable. Do not adjust the bearing pre-loads. See APD20 Advanced Precision Driver Instructions-Parts manual for maintenance information.
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