Graco E-Flo SP D200S, E-Flo SP D200, E-Flo SP D60, E-Flo SP, E-Flo SP Series Installation And Parts Manual
...
Installation - Parts
®
E-Flo
SP
3A6331C
Supply Systems
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
EN
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
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
55 Gallon Platen . . . . . . . . . . . . . . . . . . . . . . . . . 48
20 Liter (5 Gallon), 30 Liter (8 Gallon), and 60 Liter
(16 Gallon) Platens . . . . . . . . . . . . . . . . . . . 49
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 53
Drum Roller Kits for D200 and D200S Supply Units,
255627 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Drum Position Clamp Set for D200 Supply Units,
206537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Drum Position Clamp for D200S Supply Units . . 53
Enclosed Wet Cup Recirculation Kit . . . . . . . . . . 53
200 Liter (55 Gallon) Platen Cover Kits, 255691 53
Light Tower Kit, 255467 . . . . . . . . . . . . . . . . . . . 53
ADM Kit, 25E437 . . . . . . . . . . . . . . . . . . . . . . . . 53
CAN Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
I/O Cable, 122029 . . . . . . . . . . . . . . . . . . . . . . . 53
Communication Gateway Module (CGM) Kits . . 54
Low Level Sensor Kit, 25E447 . . . . . . . . . . . . . . 56
Tandem Connection Kit, 25E595 . . . . . . . . . . . . 57
Tandem Depressurization/Recirculation Kit, 25E618
(carbon steel), 25E619 (stainless steel). . . . 58
Tandem Fluid Filter Kit, 25E620 . . . . . . . . . . . . . 62
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Pump Performance . . . . . . . . . . . . . . . . . . . . . . . . . 66
E-Flo SP Performance Charts . . . . . . . . . . . . . . 67
Technical Specifications . . . . . . . . . . . . . . . . . . . . 72
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 74
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 3A6331C
Related Manuals
Manual Description
3A6586
3A6724 E-Flo SP Software Instructions
313526 Supply Systems Operation
312375
311827
311825
311717
312889
312467
312468
312469
312470
312374 Air Controls Instructions-Parts
312491 Pump Fluid Purge Kit Instructions - Parts
E-Flo SP Electric Pump Instructions Parts
Check-Mate
Instructions-Parts
Dura-Flo
180cc, 220cc, 290cc) Instructions-Parts
Dura-Flo
580cc) Instructions-Parts
Carbon Steel Displacement Pump
(1000cc) Instructions-Parts
60 cc Check-Mate Displacement Pump
Repair Parts
100 cc Check-Mate Displacement Pump
Repair Parts
200 cc Check-Mate Displacement Pump
Repair Parts
250 cc Check-Mate Displacement Pump
Repair Parts
500 cc Check-Mate Displacement Pump
Repair Parts
®
Displacement Pumps
™
Displacement Pumps (145cc,
™
Displacement Pumps (430cc,
Related Manuals
312492 Drum Roller Kit Instructions
312493 Light Tower Kit Instructions
312494
406681 Platen Cover Kit
334048 EPDM Hose Wiper Kit Instructions - Parts
3A6321
3A6482
Enclosed Wetcup Recirculation Kit
Instructions - Parts
ADM Token In-System Programming
Instructions
APD20 Advanced Precision Driver
Instructions
3A6331C 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 3A6331C
Models
EM C1 1
First
and
Second
Digit
EM
(Electric
Supply
System)
Third and
Fourth
Digit Fifth Digit
Ram Options
Pump
Code
(See Table
1: for 2-digit
Check-Mate
Pump
Code)
(See Table
1: for 2-digit
Dura-Flo
Pump
Code)
Size Style
1 3 in. D60
2 3 in. D200
3 6.5 in. D200s
21
Sixth Digit Seventh Digit
Platen and Seal Options
Drum
Size
20 L
(5 Gal) INT 1 No Platen 1 None 240 VAC
200 L
(55 Gal) INT 2
200 L
(55 Gal) INT 3
Air
Controls
Platen
(5 Gal) F, SW CS Nitrile D60 2 None 480 VAC
(5 Gal) F, SW CS
4
(5 Gal) F, DW CS Nitrile D60 4 ADM 480 VAC
5
(5 Gal) F, DW CS
6
(5 Gal) F, SW SS
200 L
7
(55 Gal) DR
200 L
8
(55 Gal) DR AL EPDM
200 L
9
(55 Gal) DR AL Neoprene
200 L
A
(55 Gal) DR AL
Size
20 L
20 L
20 L
20 L
20 L
Platen
Style
Platen
Material
PTFE
Coated
AL EPDM
Seal
Material
Polyure-
thane D60 3 ADM 240 VAC
Polyure-
thane D60
PTFE
coated D60
EPDM
Hose
Ram
Compati-
bility Interface Power
D200,
D200s
D200,
D200s
D200,
D200s
D200,
D200s
Interface and Power
Options
KEY:
INT = Integrated air controls SW = Single wiper CS = Carbon Steel Severe Duty
F = Flat DW = Double wiper SS = Stainless Steel Severe Duty SM = Stainless Steel MaxLife
DR = Dual o-ring AL = Aluminum
CM = Carbon Steel MaxLife
Table 1: Pump Code Index
Pump
Code Part No. Pump Type
Pump
Size
Pump
Material
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
Pump
Code Part No. Pump Type
CG EC500SM1 Check-Mate 500cc SM
D1 EC115CS1 Dura-Flo 115cc CS
D2 EC145CS1 Dura-Flo 145cc CS
D3 EC145SS1 Dura-Flo 145cc SS
D4 EC180CS1 Dura-Flo 180cc CS
D5 EC180SS1 Dura-Flo 180cc SS
D6 EC220CS1 Dura-Flo 220cc CS
D7 EC220SS1 Dura-Flo 220cc SS
D8 EC290CS1 Dura-Flo 290cc CS
D9 EC290SS1 Dura-Flo 290cc SS
DA EC430CS1 Dura-Flo 430cc CS
DB EC430SS1 Dura-Flo 430cc SS
DC EC430SM1 Dura-Flo 430cc SM
NOTE: See the E-Flo SP Electric Pump Instructions-Parts
manual for a complete parts list.
Pump
Size
Pump
Material
®
3A6331C 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.
Pump Working (Stall) Pressure Max Dynamic (Run) Pressure
Lower Size psi bar MPa psi bar MPa
100CS/CM/SS/SM
200CS/CM/SS/SM
250CS/CM/SS/SM
500CS/CM/SS/SM
Check-Mate
145SS
180SS
220SS
290SS
430CS/SS/SM
115CS
Dura-Flow
145CS
180CS
220CS
290CS
6,000 414 41.4 6,000 414 41.4
4,200 290 29.0 3,905 269 26.9
3,400 234 23.4 3,122 215 21.5
1,600 110 11.0 1,487 103 10.3
5,600 386 38.6 5,204 359 35.9
4,500 310 31.0 4,164 287 28.7
3,700 255 25.5 3,470 239 23.9
2,800 193 19.3 2,602 179 17.9
1,900 131 13.1 1,735 120 12.0
6,000 414 41.4 6,000 414 41.4
5,600 386 38.6 5,204 359 35.9
4,500 310 31.0 4,164 287 28.7
3,700 255 25.5 3,472 239 23.9
2,800 193 19.3 2,602 179 17.9
Flow Rate Table
Lower Size
100CS/CM/SS/SM
200CS/CM/SS/SM
250CS/CM/SS/SM
500CS/CM/SS/SM
Check-Mate
145SS
180SS
220SS
290SS
430CS/SS/SM
115CS
Dura-Flow
145CS
180CS
220CS
290CS
Flow Rate
(cc/min)
2,500 0.66 1 in. NPT female
5,000 1.32 1 in. NPT female
6,250 1.65 1 in. NPT female
12,500 3.30 1-1/2 in. NPT female
3,625 0.96 1 in. NPT female
4,500 1.19 1 in. NPT female
5,500 1.45 1 in. NPT female
7,250 1.92 1 in. NPT female
10,750 2.84 1-1/2 in. NPT female
2,875 0.76 1 in. NPT female
3,625 0.96 1 in. NPT female
4,500 1.19 1 in. NPT female
5,500 1.45 1 in. NPT female
7,250 1.92 1 in. NPT female
Flow Rate
(gpm)
Outlet Fitting Size
6 3A6331C
Tandem Ram
Models
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
5. Purchase hoses for the system.
- For Check-Mate Pumps:
Pump Lower
Size
100cc 6000 psi
200cc 4200 psi
250cc 3400 psi
500cc 1600 psi
- For Dura-Flo Pumps:
Pump Lower
Size
115cc 6000 psi
145cc 5600 psi
180cc 4500 psi
220cc 3700 psi
290cc 2800 psi
430cc 1900 psi
Max. Pressure
Rating
Max. Pressure
Rating
- 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.
3A6331C 7
Warnings
DANGER
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.
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.
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 3A6331C
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.
3A6331C 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 3A6331C
Component Identification
T
D
EMC1223 Model
Shown
G
A
M
B
R
S
V
U
J
P
N
W
K
E
X
C
F
Lift Locations
Y
Z
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.
Component Identification
Typical Installation
D200 3 in. and D200s 6.5 in. Dual Post
NOTICE
Always lift the supply system at the proper lift locations
(see F
IG. 1). Do not lift in any other way. Failure to lift
at the proper lift locations can result in damage to the
supply system.
FIG. 1: Typical Installation
Key:
ARam Assembly
B Electric Driver
C Displacement Pump
DPlaten
ECheck Valve
F Advanced Display Module (ADM)
G Integrated Air Controls (see F
J Platen Bleed Port
K Power Junction Box
M Disconnect Switch
IG. 2)
3A6331C 11
N Platen Lift Rod
P Pump Bleed Valve
R Enclosed Wet Cup
S Fluid Line (not supplied)
T Air Line (not supplied)
U Air Line Drain Valve (not supplied)
V Air Filter (not supplied)
W Bleed Type Air Shutoff Valve (required) (not supplied)
X Level Sensors
Y Outlet Pressure Transducer
Z Outlet Pressure Relief Valve (Check-Mate 100 only)
Component Identification
AA
AB
AC
AE
AD
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.
Integrated Air Line Accessories
See FIG. 1.
• Air line drain valve (U)
• Air line filter (V): removes harmful dirt and mois-
ture from compressed air supply.
• Second bleed-type air valve (W) (required): iso-
lates air line accessories for servicing. Locate
upstream from all other air line accessories.
• Air relief valve (required) (not visible):
automatically relieves excessive pressure.
F
IG. 2. Integrated Air Control Module
12 3A6331C
Advanced Display Module (ADM)
BA
BB
BC
BD
BE
BF
BG
BH
BP
BK
BN
BM
BL
BJ
BR
Front and Rear Views
Component Identification
FIG. 3: ADM Component Identification
Key:
BA Pump Enable
Enables the pump. Toggles between Active and
System Off.
BB Pump Status Indicator Light
BC Pump Soft Stop
Stops all pump processes and disables the pump.
BD Soft Keys
Defined by the icon on the screen next to the soft
key.
BE Cancel
Cancel a selection or number entry while in the
process of entering a number or making a selection.
Cancels the pump processes.
BF Enter
Accept change, acknowledge error, select item, and
toggle selected item.
BG Lock/Setup
Toggle between run and setup screens.
BH Directional Keypad
Navigate within a screen or to a new screen.
BJ Numeric Keypad
BK Part Number Identification Label
BL USB Interface
BM CAN Cable Connection
Power and communication.
BN Module Status LEDs
Visual indicators to show the status of the ADM.
BP Token Access Cover
Access cover for software token.
BR Battery Access Cover
3A6331C 13
Component Identification
ED
EC
EB
EF
Model 256742 and 256745,
20 liter (5 gallon)
Model 255319, 200 liter (55 gallon)
EH
EJ
EB
EF
EG
EH
EA
EA
Platen Component Identification
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 3A6331C
Junction Box Connections
C1
C2
C3
C4
Component Identification
F
IG. 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.
3A6331C 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 64.
NOTICE
Always lift the supply system at the proper lift locations
(see F
IG. 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.
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 prop-
erly grounded fluid hose and pump.
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.
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 3A6331C
Installation
LQ
LQ
Screws
K
Ground Stud
Cord Grip
Disconnect Switch
Terminal Block
1L1
3L2
5L2
2T1
4T2
6T3
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 F
IG. 6.
8. Insert the power cord through the cord grip and into
the junction box (K).
FIG. 8: Power Connection
9. Attach the ground wire to the ground stud inside the
junction box (K).
10. Refer to F
IG. 9 and connect the wires from the power
cord into terminals 4T2 and 6T3 on the disconnect
switch terminal block.
FIG. 6: Power Cord
7. Remove the six screws holding the cover of the junction box (K), then remove the junction box cover.
FIG. 7: Remove the Junction Box Cover
3A6331C 17
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.
Installation
Drum Stops
Capscrews
Unvented
Cap
Vented Cap
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.
FIG. 10: Drum Stop Installation
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.
1. Locate the correct set of mounting holes on the ram
2. Using the capscrews and lock washers, attach the
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.
base.
drum stops to the ram base.
FIG. 11: Unvented and Vented Oil Caps
18 3A6331C
Setup
R
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.
Setup
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.
3A6331C 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.
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.
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.
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 3A6331C
Startup
Platen Bleed Stick
EB
Platen Bleed Stick
EB
D200
D60
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.
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.
3A6331C 21
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.
Pressure Relief Procedure
AA
AC
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.
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.
3. Turn the disconnect switch (M) OFF.
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.
22 3A6331C
Shutdown and Care of the Pump
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.
Shutdown and Care of the Pump
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.
3A6331C 23
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