Instructions-Parts E E E - - - Flo® Flo® DC DC 2000, 2000, 3000, 3000, and Flo® 2000, 3000, 3A3453H 4000 Circulation Circulation Pumps Pumps 4000 4000 Circulation Pumps Electric drive drive piston piston pumps pumps for for high high volume volume paint paint circulation circulation applications.
Models Models Models Models The part part number number for for your your equipment equipment is is is printed printed on on the the equipment equipment identification identification label label (L). (L). The The part part number number includes includes part number your...
Warnings Warnings 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.
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Warnings WARNING WARNING WARNING PRESSURIZED EQUIPMENT EQUIPMENT HAZARD HAZARD PRESSURIZED PRESSURIZED EQUIPMENT HAZARD Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. • Follow the Pressure Pressure Pressure Relief Relief Procedure Relief Procedure when you stop spraying/dispensing and before cleaning,...
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Warnings WARNING WARNING WARNING BURN BURN HAZARD BURN HAZARD HAZARD Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns: • Do not touch hot fluid or equipment. PERSONAL PERSONAL PROTECTIVE PERSONAL PROTECTIVE EQUIPMENT PROTECTIVE EQUIPMENT EQUIPMENT...
Installation Installation Installation Installation 2. Install the inlet manifold (3). Place gaskets (15) over the inlet ports and attach manifold (3) using clamps (7). 3. Install the outlet manifold. Place gaskets (15) over the outlet ports and attach manifold (3) Installation of this equipment involves potentially using clamps (7).
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Installation NOTICE NOTICE NOTICE When lifting the full assembly use the lift rings on both motors. Failure to use both lift rings will cause the pump to become unbalanced, make it difficult to move, and could result in damage to the assembly. Figure 2 Mount the Pump, with Sealed Bellows Lower 3A3453H...
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Installation Figure 3 Mount the Pump, with Open Wet Cup Lower 3A3453H...
Installation Install the the Control Control Module Module Connect the the Control Control Module Module Install Install Control Module Connect Connect Control Module 1. Shut off and lock out power to the motor. 1. If still on, shut off and lock out power to the motor. 2.
Installation Power Supply Supply Requirements Requirements Power Power Supply Requirements Hazardous Area Area Cabling Cabling and and Conduit Conduit Hazardous Hazardous Area Cabling Conduit Requirements Requirements Requirements Explosion Proof Proof Explosion Explosion Proof All electrical wiring in the hazardous area must be encased in Class I, Division I, Group D approved Improper wiring may cause electric shock or other explosion-proof conduit.
Installation Connect the the Supply Supply Wiring Wiring Connect Connect Supply Wiring NOTE: NOTE: NOTE: For ECxJxx 3 Phase models, see manual 2. Install a start/stop control (C) in the electrical 3A4409 for warnings and wiring installation supply line (A), within easy reach of the instructions.
Installation Power Supply Supply Connections Connections Power Power Supply Connections Each Each Each motor motor connected motor connected connected to to to its its its own own power power power drop drop drop Lock Out Lock Out Motor 2 Motor 1 Two motors motors connected motors...
Before using the equipment, open the fill cap (P) and same ground point. Different ground points add Graco Part No. 16W645 ISO 220 silicone-free (unequal potential) may cause current to flow synthetic gear oil. Check the oil level in the sight glass through component cables, causing incorrect (K).
Operation Operation Operation Operation Startup Startup Startup Control Control Module Control Module Module Overview Overview Overview To operate the pump, follow the Startup instructions The Control Module provides the interface for users for the Advanced motor in the Motor manual. to enter selections and view information related to setup and operation.
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Operation Control Control Module Control Module Screens Module Screens Screens Control Control Module Control Module Keys Module Keys Keys The Control Module has two sets of screens: Run and Setup. For detailed information see Run Screens, page 25, and Setup Screens, page Press to toggle between the Run screens and the Setup screens.
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Operation Table Table Table 4 4 4 Module Module Module Keys Keys Keys Membrane Keys Keys Softkeys Membrane Membrane Keys Softkeys Softkeys Enter Screen. Highlight data that can be edited. Also changes the function of the Up/Down arrows so they move between Press to toggle between Run screens data fields on the screen, rather than between screens.
Operation Icons Icons Icons As you move through the screens, you will notice that most information is communicated using icons rather than words to simplify global communication. The detailed screen descriptions in Run Screens, page 25, and Setup Screens, page 28, explain what each icon represents.
Operation Screen Navigation Navigation and and Editing Editing Screen Screen Navigation Editing Refer to this section if you have questions about Reset Reset Field Reset Field Field screen navigation or about how to enter information and make selections. The reset field is used for totalizers. Press reset the field to zero.
Operation Run Screens Screens Screens Run Screen Screen 1 1 1 Screen This screen displays information for a selected The Run screens display current target values and profile. A box around an icon indicates which mode performance for a selected profile. Any alarms will the profile is running (pressure or flow).
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Operation Run Screen Screen Screen 2 2 2 Run Screen Screen 3 3 3 Screen This screen displays information for controlling an This screen displays pressure settings for the active electric agitator using the supervisor to pass on pump and profile. the control set point to a Variable Frequency Drive NOTE: Some fields are grayed out, depending on NOTE:...
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Operation Run Screen Screen 4 4 4 Run Screen Screen 5 5 5 Screen Screen This screen displays fluid flow settings for the active This screen displays the current pressure readings of profile. transducers 1 and 2. Pressure can be displayed as psi, bar, or MPa.
Operation Setup Screens Screens Setup Setup Screens Use the Setup screens to set control Setup Screen Screen 1 1 1 Key Setup Setup Screen parameters for the motor. See Profile selection — See Step 1. Screen Navigation and Editing, page 21, for information on how to make selections and enter Select the operating mode...
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Operation Figure 19 Select Mode (Pressure Mode Shown) Figure 20 Set Back Pressure Regulator 3. If the system is equipped with a back pressure regulator (BPR) kit (P/N 24V001), set the target air pressure to the BPR from 0 to 100 percent (approximately 1 to 100 psi).
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Operation Setup Screen Screen 2 2 2 Setup Setup Screen Use this screen to set the maximum, target, and NOTE: NOTE: If closed loop pressure is enabled, the NOTE: minimum fluid pressure for a selected profile. In pressure will be displayed as a pressure value pressure mode, you will set a target fluid pressure.
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Operation Setup Screen Screen 3 3 3 Setup Setup Screen Use this screen to set your flow rate settings for a 1. Select the desired profile (1 to 4), using the selected profile. In pressure mode, you will set a pull-down menu.
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Operation Setup Setup Screen Setup Screen Screen 4 4 4 Use this screen to specify how the system will Setup Screen Screen 4 4 4 Key Setup Setup Screen respond if the pump begins to operate outside of To enable the pressure alarm: the pressure and flow settings established on Setup Sceren 2 and Setup Screen 3.
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Operation Flow Flow Mode Flow Mode Examples Mode Examples Examples • Runaway Runaway Control: Runaway Control: The user may choose to set Control: the minimum pressure to Alarm. If a hose bursts, the pump will not change speed, but the back pressure will fall.
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Operation Setup Screen Screen 5 5 5 Setup Setup Screen Use this screen to set the lower pump size (cc) of the system. The default is blank; select the correct lower size. This screen also activates jog mode, allowing you to position the motor/pump shaft for connection or disconnection.
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Operation Setup Screen Screen 6 6 6 Setup Screen Screen 7 7 7 Setup Setup Screen Setup Setup Screen Use this screen to view the grand totalizer value and Use this screen to set the desired maintenance set or reset the batch totalizer. interval (in cycles) for each pump.
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Operation Setup Screen Screen 8 8 8 Setup Setup Screen Use this screen to set up the pressure for transducer 1. Selecting a transducer and checking the pressure control checkbox activates closed loop pressure control. Figure 39 Closed Loop Pressure Enable Figure 37 Setup Screen 8 Setup Setup...
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Operation Setup Screen Screen 9 9 9 Setup Screen Screen 10 Setup Setup Screen Setup Setup Screen Use this screen to set up the pressure for transducer Use this screen to specify how the system responds if the system pressure begins to operate outside of the system settings.
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Operation Setup Setup Screen Setup Screen 11 Screen Setup Setup Screen Setup Screen 12 Screen This screen is auto-populated with the serial numbers Use this screen to set your modbus preferences. and software versions for each motor. In this system there is a parent motor and a child motor.
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Operation Setup Screen Screen 13 Setup Setup Screen Select this box to enable the tank to automatically fill. You can then set the Use this screen to configure and control the tank fill fill levels. feature and Intelligent Paint Kitchen peripherals. When the tank level reaches this NOTE: The alert trigger time varies based on how far NOTE:...
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Operation Setup Setup Screen Setup Screen Screen 14 Use this screen to monitor, set up, and control the Intelligent Paint Kitchen peripherals. For more information, see the Set Up Peripherals section of the Intelligent Paint Kitchen manual 3A4030. NOTE: NOTE: NOTE: The second field varies, depending on the menu selection in the first field.
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Operation Setup Screen Screen 15 Setup Screen Screen 17 Setup Setup Screen Setup Setup Screen Use this screen to set up the input scaling (radar level Use this screen to enable or disable the run/stop sensor) for 4–20mA devices and turn on the current switch and auto restart.
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Operation Setup Screen Screen 18 Setup Setup Screen Use this screen to set the units for pressure, totals, and flow. Figure 55 Select Desired Pressure Units Figure 54 Setup Screen 18 Setup Setup Screen Setup Screen Screen 18 18 Key Select the pressure units: Figure 56 Select Desired Volume Units •...
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Operation Setup Screen Screen 19 Setup Screen Screen 20 Setup Setup Screen Setup Setup Screen Use this screen to set your date format, date, time, Use this screen to enter a password that will be or force a restart of the system when updating the required to access the Setup screens.
Maintenance Maintenance Maintenance Maintenance Flushing Flushing Flushing See the motor manual for required motor maintenance procedures. Preventive Maintenance Maintenance Schedule Schedule Preventive Preventive Maintenance Schedule The operating conditions of your particular system To avoid fire and explosion, always ground determine how often maintenance is required. equipment and waste container.
Troubleshooting Troubleshooting Troubleshooting Troubleshooting NOTE: NOTE: NOTE: Check all possible remedies before disassembling the pump. NOTE: The LED on the motor will blink if an error is detected. See Error Error Code Code Troubleshooting Troubleshooting in the motor NOTE: NOTE: Error Code Troubleshooting...
Error Code Troubleshooting Error Code Code Troubleshooting Troubleshooting Error Error Code Troubleshooting Error codes can take three forms: NOTE: NOTE: In the error codes listed below, an “X” means NOTE: the code is associated with the display only. • Alarm : alerts you to the alarm cause and shuts NOTE: NOTE: In the error codes listed below, a “_”...
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Error Code Troubleshooting Display Display Display Applicable Applicable Applicable Blink Blink Blink Alarm Alarm Alarm or or or Description Description Description Code Code Code Motor Motor Motor Code Code Code Deviation Deviation Deviation EBC_ Advanced None Advisory Run/Stop switch in Stop position (closed). EBC_ EBC_ ELI_...
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Error Code Troubleshooting Display Applicable Blink Alarm or or or Description Display Display Applicable Applicable Blink Blink Alarm Alarm Description Description Code Code Code Motor Motor Motor Code Code Code Deviation Deviation Deviation P5DX P5DX P5DX Advanced None Deviation More than one pump is assigned to a transducer. The assignment for that transducer is automatically cleared under this condition.
(6). Separate the motor (3) and lower (7). 6. To repair the lower, see the lower manual. 7. There are no user-serviceable parts in the motor. Contact your Graco representative for assistance. 6. Insert the collars (18) into the coupling nut (17).
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Repair 8. Models Models Models with with Sealed with Sealed Sealed Lowers: Lowers: Lowers: Install the shields (10) by engaging the bottom lips with the groove in the top plate. Snap the two shields together. 9. Remove the plugs and reconnect the inlet and outlet manifolds (3).
Parts Parts Parts Parts Pump Assembly Assembly Pump Pump Assembly Models, page 3 , for an explanation of the pump part number. Models Models Models ECxx41, ECxx41, ECxx41, with with with Sealed Sealed Sealed 4–Ball 4–Ball Lower 4–Ball Lower Lower 3A3453H...
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Parts Models, page 3 , for an explanation of the pump part number. Models Models Models ECxx61, ECxx61, ECxx61, with with Open with Open Open Wet Wet Cup Cup 4–Ball 4–Ball Lower 4–Ball Lower Lower 3A3453H...
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Parts Models, page 3 , for an explanation of the pump part number. Models Models Models EC8J41, EC8J41, with EC8J41, with with Sealed Sealed Sealed 4–Ball 4–Ball Plus 4–Ball Plus Lower Plus Lower Lower 3A3453H...
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Parts Part Part Part Description Description Description Pump Matrix, page 55 MOTOR; see motor manual; includes items 1a and 1b 1a� 16M130 LABEL, warning 16W645 OIL, gear, synthetic; ISO 220 silicone-free; 1 quart (0.95 liter); not shown 16W212 BRACKET, stand 16W211 MANIFOLD, inlet and outlet PUMP, displacement;...
Parts 24P822 Control Control Module Module Kit 24P822 24P822 Control Module Part Description Part Description Part Part Description Description Part Part Description Description — — — 24P821 DISPLAY KIT, control BRACKET, control module; includes module — — — item 1a; see manual BRACKET, mounting 332013 for approvals —...
Accessories Accessories Accessories Accessories Back Pressure Pressure Regulators Regulators Control Module Module Back Back Pressure Regulators Control Control Module Part Part Part Description Description Description Part Part Part Description Description Description 288117 16P912 Pneumatic BPR (20 gpm, 300 psi max 25 ft (8m) CAN cable fluid pressure, 1–1/4 npt) 24X089...
Dimensions Dimensions Dimensions Dimensions Pump with with Sealed Sealed 4–Ball 4–Ball Lower Lower Pump with with Sealed Sealed 4–Ball 4–Ball Plus Plus Lower Lower Pump Pump with Sealed 4–Ball Lower Pump Pump with Sealed 4–Ball Plus Lower Pumps Pumps Pumps A A A B B B C C C...
Mounting Hole Patterns Mounting Mounting Hole Mounting Hole Patterns Hole Patterns Patterns A A A 19.88 in. (505 mm) B B B 14.50 in. (368 mm) C C C 16.88 in. (429 mm) D D D 17.00 in. (432 mm) E E E Hole size .59 in.
Appendix A - Modbus Variable Map Appendix A A A - - - Modbus Modbus Variable Variable Map Appendix Appendix Modbus Variable To communicate through fiber optics with the E-Flo Table 4 shows the registers needed for basic DC Control Module, reference the appropriate operation, monitoring, and alarm control features.
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Appendix A - Modbus Variable Map Modbus Modbus Modbus Variable Variable Variable Register Register Register Size Notes/Units Notes/Units Notes/Units Size Size Register Register Register Access Access Access 404119 16 Bit Run/Stop Switch State Read Only 0 = Switch closed (Stop state), 1 = Switch open (Run state) Extended Modbus Variables The registers shown in this section are intended for advanced integration solutions, where the user desires full...
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Appendix A - Modbus Variable Map Modbus Variable Register Size Notes/Units Modbus Modbus Variable Variable Register Register Size Size Notes/Units Notes/Units Register Register Register Access Access Access Integration Setup Block This section contains system-level control variables that may need to be monitored or controlled on occasion (infrequently).
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Appendix A - Modbus Variable Map Modbus Modbus Modbus Variable Variable Variable Register Register Register Size Notes/Units Notes/Units Notes/Units Size Size Register Register Register Access Access Access Intelligent Paint Kitchen Registers 406100 0 - 60 Secs Counter Read Only 406101 Pump Status Bits Read Only bit 0 = Pump trying to move...
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Appendix A - Modbus Variable Map Modbus Variable Register Size Notes/Units Modbus Modbus Variable Variable Register Register Size Size Notes/Units Notes/Units Register Register Register Access Access Access Intelligent Paint Kitchen Registers Setup 406129 Pump 1 Alarms High Word Read Only 406130 Pump 1 Alarms Low Word Read Only...
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Appendix A - Modbus Variable Map Modbus Variable Register Size Notes/Units Modbus Modbus Variable Variable Register Register Size Size Notes/Units Notes/Units Register Register Register Access Access Access Profile Setup Blocks Each profile block is a group of 12 registers. The profile (1–4) is the 4th digit (x) in the register number and corresponds with the actual user profile being defined.
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Appendix A - Modbus Variable Map NOTE: NOTE: NOTE: See Error Code Troubleshooting, page 46, for a description of each alarm. Table Table Table 6 6 6 Alarm Alarm Alarm Bits Bits Bits 404112 - - - Pump Pump Events Events 1 1 1 —...
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Appendix A - Modbus Variable Map — — Reserved — — Reserved Deviation CAD_ CAN Communication Error Pump Deviation E5D_ Encoder Calibration Failed Deviation E5N_ Stroke Calibration Failed Advisory ENDC Encoder/Stroke Range Calibration In Progress Alarm CCC_ Pump Could Not Find Display During Startup Deviation ELI_ Unexpected Hot Board Reset...
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Appendix A - Modbus Variable Map 404114 - - - Display Display Events Events — — — High High Word Word 404114 404114 Display Events High Word Event Type Event Code Event Name Deviation P6CX Pressure Transducer Error Alarm L1AF Primary Tank Freeze Alarm Deviation P3CB...
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Appendix A - Modbus Variable Map Table 7 7 7 Pump Pump Status Status and and Control Control Bits Bits Table Table Pump Status Control Bits 404100 404100 404100 - - - Pump Pump Status Pump Status Bits Status Bits Bits Meaning Reads 1 if the pump is trying to move...
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Appendix A - Modbus Variable Map Table Table Table 8 8 8 Units Units Units Unit Type Type Selectable Units Units Units Register Register Converting registers registers to to to Register value value for for 1 1 1 unit unit Unit Unit Type...
Appendix B - Pump Control from a PLC Appendix B B B - - - Pump Pump Control Control from from a a a PLC Appendix Appendix Pump Control from Monitor alarms alarms and and deviations: deviations: Read register This guide shows how to use the information in 5.
3. Insert and press the token (T) firmly into the slot. NOTE: NOTE: NOTE: Token has no preferred orientation. 4. Supply electrical power to the Graco Control Module. To help prevent fire and explosion, do not 5. The red indicator light (L) will flash while the connect, download, or remove the token unless software is being loaded on the display.
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Return to step 5 for step progression if the update restarts. 10. Remove power from the Graco Control Module by turning off system power. 11. If the token is still inserted, remove from the slot.
Performance Charts Performance Charts Charts Performance Performance Charts Key to to to Performance Performance Charts Charts To find the fluid pressure (psi/bar/MPa) at a specific Performance Charts fluid flow (gpm/lpm) and percentage of maximum NOTE: The charts show the motor operating at NOTE: NOTE: force:...
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Performance Charts Models EC5xxx EC5xxx and and EC22xx EC22xx 3000 3000 cc cc cc (2x (2x 1500 1500 cc cc cc lower, lower, 2 2 2 HP HP motor, motor, 2800 2800 lb lb lb maximum maximum force) force) Models Models EC5xxx EC22xx...
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Performance Charts Models EC8J41 EC8J41 5000cc 5000cc (2x (2x 2500 2500 cc cc cc lower, lower, 2 2 2 HP HP motor, motor, 3500 3500 lb lb lb max max force) force) Models Models EC8J41 5000cc 2500 lower, motor, 3500 force) CYCLES CYCLES PER...
Less than 70 dB(A) Oil capacity (each motor) 1.5 quarts 1.4 liters Oil specification Graco Part No. 16W645 ISO 220 silicone-free synthetic gear oil Weight Pump package (motor, 4000cc lower, Pump package (motor, 4000cc lower, stand, and tie rods): 440 lb stand, and tie rods): 199.6 kg...
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With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.