Graco E-Flo DC 2000 Instructions And Parts
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Graco E-Flo DC 2000 Instructions And Parts

Graco E-Flo DC 2000 Instructions And Parts

Circulation pumps
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Instructions-Parts
E-Flo® DC 2000, 3000, and
4000 Circulation Pumps
Electric drive piston pumps for high volume paint circulation applications.
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
See Technical Data for Maximum
Working Pressure.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.
334359D
EN

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Summary of Contents for Graco E-Flo DC 2000

  • Page 1 Instructions-Parts E-Flo® DC 2000, 3000, and 334359D 4000 Circulation Pumps Electric drive piston pumps for high volume paint circulation applications. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See Technical Data for Maximum Working Pressure.

  • Page 2: Table Of Contents

    Screen Navigation and Editing ...... 19 Appendix B. Pump Control from a PLC ....60 Initial Setup ..........19 Notes ..............61 Screen Map ..........20 Run Screens..........22 Graco Standard Warranty........62 Setup Screens ..........26 Troubleshooting..........40 334359D...

  • Page 3: Models

    Models Models The part number for your equipment is printed on the equipment identification label (L). The part number includes digits from each of the following categories, depending on the configuration of your equipment. Pump Type Lower Size Motor Lower Mounting (EC) (4, 5, or 6)

  • Page 4: 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.
  • Page 5 Warnings WARNING 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. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
  • Page 6 Warnings WARNING 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.

  • Page 7: Installation

    Installation Installation Mount the Pump Installation of this equipment involves potentially hazardous procedures. Only trained and qualified During installation pumps could slide together personnel who have read and who understand causing a potential pinch hazard. Use caution the information in this manual should install this when installing the pumps.
  • Page 8 Installation Figure 1 Mount the Pump 334359D...

  • Page 9: Install The Control Module

    Installation Install the Control Module Connect the 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. Assemble the bracket kit (6a-6f) and the holder 2.

  • Page 10: Power Supply Requirements

    Installation Power Supply Requirements Hazardous Area Cabling and Conduit Requirements 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. Follow all National, State, serious injury if work is not performed properly.
  • Page 11 Installation Typical Installation NON-HAZARDOUS LOCATION HAZARDOUS LOCATION Electrical Supply (must be sealed conduit Fluid Pressure Gauge approved for use in hazardous locations) Fluid Shutoff Valve Fused Safety Switch, with lock Pump Ground Wire. Two ground terminals Start/Stop Control (must be approved for are provided if local code requires redundant use in hazardous locations) grounding connections.

  • Page 12: Connect The Power Supply

    Installation Connect the Power Supply 2. Install a start/stop control (C) in the electrical supply line (A), within easy reach of the equipment. The start/stop control must be approved for use in hazardous locations. NOTE: The start/stop control can be Improper wiring may cause electric shock or other wired to operate two motors.

  • Page 13: Power Supply Connections

    Installation Power Supply Connections Each motor connected to its own power drop Lock Out Lock Out Motor 2 Motor 1 Two motors connected to a single power drop Lock Out box Motor 2 Motor 1 P1 P2 Tighten all terminal nuts to 25 in-lb (2.8 N•m) maximum. Do not over-torque. Tighten cover screws to 15 ft-lb (20.3 N•m).

  • Page 14: Grounding

    Before using the equipment, open the fill cap (P) and (unequal potential) may cause current to flow add Graco Part No. 16W645 ISO 220 silicone-free through component cables, causing incorrect synthetic gear oil. Check the oil level in the sight glass signals.

  • Page 15: Operation

    Operation Operation Startup Control Module 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. Run the pump at a slow speed until the fluid lines are primed and all air is forced out of the system.
  • Page 16 Operation Control Module Screens Control Module Keys The Control Module has two sets of screens: Run and Setup. For detailed information see Run Screens, page 22, and Setup Screens, page Press to toggle between the Run screens and the Setup screens. The above image shows a view of the control module display and keys.
  • Page 17 Operation Table 2 Module Keys Membrane Keys Softkeys Enter Screen. Highlight data that can be edited. Also changes the function of the Up/Down Press to toggle between Run screens arrows so they move between data fields on and Setup screens. the screen, rather than between screens.

  • Page 18: Icons

    Operation 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 22, and Setup Screens, page 26, explain what each icon represents. Screen Icons Screen Icons Profile Number...

  • Page 19: Screen Navigation And Editing

    Operation Screen Navigation and Editing Refer to this section if you have questions about Reset Field screen navigation or about how to enter information The reset field is used for totalizers. Press and make selections. reset the field to zero. All Screens When all data is correct, press to exit the screen.

  • Page 20: Screen Map

    Operation Screen Map INITIAL SETUP SETUP AND EDIT PROFILES (Setup Screens 5–14) (Setup Screens 1–4) (Run Screens 1–8) Setup Screen 5, page 32 Setup Screen 1, page 26 Run Screen 1, page 22 Setup Screen 6, page 33 Setup Screen 2, page 28 Run Screen 2, page 23 Setup Screen 7, page 33 Setup Screen 3, page 29...
  • Page 21 Operation INITIAL SETUP SETUP AND EDIT PROFILES (Setup Screens 5–14) (Setup Screens 1–4) (Run Screens 1–8) Setup Screen 12, page 37 Setup Screen 13, page 38 Setup Screen 14, page 39 334359D...

  • Page 22: Run Screens

    Operation Run Screens Run Screen 1 Key The Run screens display current target values and performance for a selected profile. Any alarms will Enter the screen. display in the sidebar at the right of the screen. Select the desired profile (1 to 4), using Screens 5–8 display a log of the last 20 alarms.
  • Page 23 Operation Run Screen 2 Run Screen 2 Key Enter the screen. This screen displays information for controlling an electric agitator via a 4–20 mA signal to a Variable Select this box to enable control output Frequency Drive (VFD). to a VFD. Set the desired speed setpoint for the agitator, from 0 —...
  • Page 24 Operation Run Screen 3 Run Screen 4 This screen displays pressure settings for the active This screen displays fluid flow settings for the active profile. profile. NOTE: Some fields are grayed out, depending on NOTE: Some fields are grayed out, depending on setup selections.
  • Page 25 Operation Run Screen 5 Run Screens 6–9 This screen displays the current pressure readings of Run Screens 6–9 display a log of the last 20 alarms, transducers 1 and 2. Pressure can be displayed as with date and time. psi, bar, or MPa. See Setup Screen 12, page Figure 16 Run Screens 6–9 (Screen 6 shown) Figure 15 Run Screen 5...

  • Page 26: Setup Screens

    Operation Setup Screens Setup Screen 1 Key Use the Setup screens to set control parameters for the motor. See Enter the screen. Screen Navigation and Editing, page 19, for Profile selection — See Step 1. information on how to make selections and enter data.
  • Page 27 Operation 1. Select the desired profile (1 to 4), using the pull-down menu. Figure 19 Select Mode (Pressure Mode Shown) 3. If the system is equipped with a back pressure regulator (BPR) kit (P/N 24V001), set the target Figure 18 Select Profile Number air pressure to the BPR from 0 to 100 percent (approximately 1 to 100 psi).
  • Page 28 Operation Setup Screen 2 Use this screen to set the maximum, target, and 1. Select the desired profile (1 to 4), using the minimum fluid pressure for a selected profile. In pull-down menu. pressure mode, you will set a target fluid pressure. 2.
  • Page 29 Operation Setup Screen 3 Use this screen to set your flow rate settings for a 1. For systems with multiple pumps and one selected profile. In pressure mode, you will set a display, select the desired pump (1 to 8), using maximum flow rate.
  • Page 30 Operation Setup Screen 4 Setup Screen 4 Key Use this screen to specify how the system will respond if the pump begins to operate outside of Enter the screen to set or change the pressure and flow settings established on Setup preferences.
  • Page 31 Operation Pressure Mode Examples Flow Mode Examples • Runaway Control: The user may choose to set the • Runaway Control: The user may choose to set maximum flow to Alarm. If the flow rate exceeds the minimum pressure to Alarm. If a hose bursts, the maximum entered on Setup Screen 3, an Alarm the pump will not change speed, but the back pressure will fall.
  • Page 32 Operation Setup Screen 5 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.
  • Page 33 Operation Setup Screen 6 Setup Screen 7 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. The screen also displays the current cycle count.
  • Page 34 Operation Setup Screens 8 and 9 Use these screens to set up the pressure transducers. The screens are identical, except Screen 8 is for transducer 1 and Screen 9 is for transducer 2. Selecting a transducer and checking the pressure control checkbox activates closed loop pressure control.
  • Page 35 Operation Setup Screen 10 This screen is auto-populated with the serial numbers and software versions for each motor. In this system there is a ‘parent’ motor and a ‘child’ motor. The ‘parent’ motor controls itself to the active profile setpoints while the ‘child’ follows. The first serial number listed on this screen corresponds to Figure 38 Setup Screens 10 the ‘parent’...
  • Page 36 Operation Setup Screen 11 Use this screen to set your modbus preferences. Figure 41 Set Modbus Node ID Figure 39 Setup Screen 11 Setup Screen 11 Key Enter the screen. Control location. Select local remote control from the dropdown Figure 42 Set Baud Rate (Bits Per Second) options.
  • Page 37 Operation Setup Screen 12 Use this screen to set the desired units for pressure, totals, and flow. Figure 44 Select Desired Pressure Units Figure 43 Setup Screen 12 Setup Screen 12 Key Select desired pressure units (psi, bar, or MPa) Figure 45 Select Desired Volume Units Select desired volume units (liters or gallons)
  • Page 38 Operation Setup Screen 13 Use this screen to set your date format, date, and time. Figure 48 Select the Date Format Figure 47 Setup Screen 13 Setup Screen 13 Key Enter the screen to set or change preferences. Select your preferred date format from Figure 49 Set the Date the dropdown menu.
  • Page 39 Operation Setup Screen 14 Use this screen to enter a password that will be required to access the Setup screens. This screen also displays the software version. Figure 53 Set the Password Figure 52 Setup Screen 14 Setup Screen 14 Key Enter the screen to set the password.

  • Page 40: Troubleshooting

    Troubleshooting Troubleshooting NOTE: Check all possible remedies before disassembling the pump. NOTE: The LED on the motor will blink if an error is detected. See Error Code Troubleshooting in the motor manual for further information. Problem Cause Solution Pump output low on both strokes. Inadequate power supply.

  • Page 41: Notes

    Notes Notes 334359D...

  • Page 42: Error Code Troubleshooting

    Error Code Troubleshooting Error Code Troubleshooting Error codes can take three forms: NOTE: In the error codes listed below, an “X” means the code is associated with the display only. • Alarm : alerts you to the alarm cause and shuts NOTE: In the error codes listed below, a “_”...
  • Page 43 Voltage supplied to motor is too high. Advanced WCW_ Advanced Alarm E-Flo DC 2000, 3000, and 4000 circulation pump system key token (blue) is missing; install in token slot under back panel on side of display. WMC_ Basic and 4–5 Alarm Internal software error.

  • Page 44: Performance Charts

    Performance Charts Performance Charts Key to Performance Charts To find the fluid pressure (psi/bar/MPa) at a specific fluid flow (gpm/lpm) and percentage of maximum NOTE: The charts show the motor operating at force: 100%, 70%, and 40% of maximum force. These 1.
  • Page 45 Performance Charts Table 4 . Models EC5xxx and EC22xx 3000 cc (2x 1500 cc lower, 2 HP motor, 2800 lb maximum force) CYCLES PER MINUTE (per pump) (21.0, 2.10) (17.5, 1.75) (14.0, 1.40) FLUID PRESSURE: (10.5, 1.05) psi (bar, MPa) (7.0, 0.70) (3.5, 0.35) (7.6)

  • Page 46: Repair

    5. Flush and test the pump before reinstalling 7. There are no user-serviceable parts in the it in the system. Connect hoses and flush motor. Contact your Graco representative for the pump. While it is pressurized, check for assistance. smooth operation and leaks. Adjust or repair as necessary before reinstalling in the system.

  • Page 47: Reassemble The Coupling Adapter And Tie Rods To The Motor

    Repair Reassemble the Coupling Adapter and Tie Rods to the Motor NOTE: Use this procedure only if the coupling 2. Screw the coupling adapter (16) into the motor adapter (16) and tie rods (9) have been disassembled shaft and torque to 90–100 ft-lb (122–135 N•m). from the motor, to ensure proper alignment of the 3.

  • Page 48: Parts

    Parts Parts Pump Assembly Models, page 3 for an explanation of the pump part number. 334359D...
  • Page 49 Parts Part Description Pump Matrix, page 50 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 TUBE, manifold, long Pump Matrix, page 50 PUMP, displacement;...

  • Page 50: Pump Matrix

    Parts Pump Matrix Pump Pump Motor Lower Pump Part No. Series (Ref 1, Qty. 2) (Ref 4, Qty. 2) EC4921 EM0025 24F426 EC4931 EM0025 24F427 EC5921 EM0025 24F434 EC5931 EM0025 24F435 EM0025 24F441 EC6921 EC6931 EM0025 24F442 EC4021 EM0026 24F426 EC4031 EM0026 24F427...

  • Page 51: 24P822 Control Module Kit

    Parts 24P822 Control Module Kit Part Description Part Description 24P821 DISPLAY KIT, control — — — BRACKET, control module; includes module — — — BRACKET, mounting item 1a; see manual 332013 for approvals — — — LOCKWASHER, information about the external tooth;...

  • Page 52: Accessories

    Accessories Accessories Back Pressure Regulators Control Module Part Description Part Description 288117 Pneumatic BPR (20 gpm, 300 psi max 16P912 25 ft (8m) CAN cable fluid pressure, 1–1/4 npt) 24X089 Pressure Transducer 288311 Pneumatic BPR (20 gpm, 300 psi max 16V103 Transducer Extension Cable fluid pressure, 1–1/2 npt)

  • Page 53: Dimensions

    Dimensions Dimensions 58.00 in. (1473 mm) 17.00 in. (432 mm) 45.50 in. (1156 mm) 19.88 in. (505 mm) 334359D...

  • Page 54: Mounting Hole Patterns

    Mounting Hole Patterns Mounting Hole Patterns Dimension Measurement 19.88 in. (505 mm) 14.50 in. (368 mm) 16.88 in. (429 mm) 17.00 in. (432 mm) 334359D...

  • Page 55: Technical Specifications

    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...

  • Page 56: Appendix A - Modbus Variable Map

    Appendix A - Modbus Variable Map Appendix A - Modbus Variable Map To communicate through fiber optics with the E-Flo Table 3 shows the registers needed for basic DC Control Module, reference the appropriate operation, monitoring, and alarm control features. hardware as shown in manual 332356.
  • Page 57 Appendix A - Modbus Variable Map NOTE: See Error Code Troubleshooting, page 42, for a description of each alarm. Table 7 Alarm Bits 404112 - Pump Alarms Word 1 Event Type Event Code Event Name Deviation T3D_ Over Temperature Alarm P6D_ Pressure Transducer Missing Deviation...
  • Page 58 Appendix A - Modbus Variable Map 404114 - Display Alarms Word 1 Event Type Event Code Event Name Deviation P6C_ Pressure Transducer Missing others Reserved 404115 - Display Alarms Word 2 Event Type Event Code Event Name Alarm CAG_ Modbus Communication Alarm CAC_ CAN Communication Display...
  • Page 59 Appendix A - Modbus Variable Map Table 9 Units Unit Type Selectable Units Units Register Converting registers to Register value for 1 unit values unit Pressure Percent Pressure = Register 1 = 1% Pressure Pressure 403208 = 0 Pressure = Register 1 = 1 psi 403208 = 1 Pressure = Register/10 10 = 1.0 Bar...

  • Page 60: Appendix B. Pump Control From A Plc

    Appendix B. Pump Control from a PLC Appendix B. Pump Control from a PLC 5. Monitor alarms and deviations: Read register This guide shows how to use the information in Appendix A to control a pump remotely from a PLC. 404112 to 404115.

  • Page 61: Notes

    Notes Notes 334359D...

  • Page 62: Graco Standard Warranty

    Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts.

This manual is also suitable for:

E-flo dc 3000E-flo dc 4000

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