Graco 311603K, Sensor Circuit Option for E-Flo 4-Ball Piston Pump Instruction

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Graco 311603K, Sensor Circuit Option for E-Flo 4-Ball Piston Pump Instruction | Manualzz

Instructions

Sensor Circuit

Option Kit

To upgrade E-Flo

®

4-Ball Piston Pumps to include the sensor circuit option.

For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual and in E-Flo Repair-Parts manual 311594. Save these instructions.

24J305 Series B Sensor Circuit Option Kit

For E-Flo Pumps, Series D and later, and for use with the ACS E-Flo control module. Includes circuit board, pressure transducer, TDC sensor, motor position sensor, and 2-sensor conduit.

15J755 Series B Sensor Circuit Option/Service

Replacement Kit

For E-Flo Pumps, Series C and earlier. Includes circuit board, pressure transducer, TDC sensor, and 1-sensor conduit.

For use with the Graco CT VFD. Includes the current revision application module

The following hazardous location listings apply to the sensor circuit (item 25) only.

311603K

EN

293140l

E-Flo Pump with Sensor Circuit

Option installed.

ti8317c

2

Pressure Relief Procedure

Pressure Relief

Procedure

Kit Parts

Sensor Circuit Kit 24J305 Series B

For E-Flo Pumps, Series D and later

Includes items 12-42, 44a, 46-80

Sensor Circuit Kit 15J755 Series B

For E-Flo Pumps, Series C and earlier

Includes items 12-43, 44b, 58, 74a-77

System pressure can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

1.

Set START/STOP switch to STOP.

2.

Push in SECURE DISABLE switch.

3.

Open the back pressure regulator and all fluid drain valves in the system, having a waste container ready to catch drainage. Leave open until you are ready to pressurize system again.

4.

Check that pressure gauges on fluid supply and return lines read zero. If gauges do not read zero, determine cause and carefully relieve pressure by

VERY SLOWLY loosening a fitting. Clear obstruction before pressurizing system again.

Ref.

No.

Part No. Description

12*

25

116719 SCREW, 8-32 hex washer head n/a SENSOR CIRCUIT; includes items

25a-25c

25a* n/a

25b* n/a

PRESSURE TRANSDUCER

TDC SENSOR

25c* n/a

32* n/a

33*

35* n/a n/a

36*

41*

CIRCUIT BOARD

COVER, side opposite motor

GASKET, circuit board

CONNECTOR, strain relief, 45° n/a LABEL, calibration

111316 O-RING; chemically resistant fluoroelastomer

42*

43* n/a n/a

44a* n/a

44b* n/a

46*

58*

16J588 TERMINAL BLOCK; Kit 24J305 only n/a SPACER; brass

74a* 16J487 BUSHING, strain relief; steel

76* 16G496 FERRITE; for pressure transducer leadwires

77*

78*

ADAPTER, transducer

NUT, transducer; Kit 15J755 only

CONDUIT, 2-sensor; Kit 24J305 only

CONDUIT, 1-sensor; Kit 15J755 only

79*

80*

123375 FERRITE; for IS circuit field wiring n/a ADAPTER, position sensor; Kit

24J305 only n/a SLEEVE, position sensor; Kit 24J305 only

16K088 POSITION SENSOR; Kit 24J305 only

Qty

14

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

Parts designated n/a are not available separately.

311603K

Installation

Installation

Disassembly

1.

Jog the motor to bring the lower on the side opposite from the motor to the bottom of its stroke.

2.

Relieve pressure, page 2.

3.

Shut off electrical power to the unit.

4.

See F IG . 1. Remove two screws (12) and the cover

(32).

5.

See F

IG

. 3, page 4. Remove six screws (12), the circuit board cover (B), and the gasket (33). Discard the old gasket.

12*

32*

12*

Install the Kit

NOTE: Parts included in the Sensor Circuit Kit are marked with an asterisk, for example (12*). Use all the new parts in the kit. Kit 24J305 Series B (for Series D and later pumps) includes parts for the position sensor which are not included in Kit 15J755 Series B. These differences are noted in the text and illustrations.

1.

See F

IG

. 3. Unscrew the plug from the TDC port (C) and clean old sealant from the port. Apply pipe sealant and screw the TDC sensor (25b*) into the port.

Torque to 66-78 in-lb (7.4-8.8 N•m).

NOTE: TDC sensor nuts are locked in place to ensure correct positioning. Do not adjust.

2.

Connect the TDC cable (25b*) to J2 on the circuit board (25c*).

3.

Install the circuit board (25c*) using four screws

(12*).

4.

Screw the 45° conductive strain relief (35*) tightly into the housing.

5.

See F IG . 2. Install the black o-ring (41*) and the brass spacer (58*) on the transducer (25a*). Thread the transducer’s cable (25a*) through the adapter

(42*), conduit (44*), and conductive strain relief

(35*).

NOTE: On Kit 24J305 Series B, thread the transducer cable through the short length of the 2-sensor conduit

(44a*).

F IG . 1. Remove Cover ti8317c

P

7 Torque to 15-20 ft-lb (21-27 N•m).

F IG . 2. Pressure Transducer

44*

M*

7

42*

7

58*

25a*

41* ti8721b

311603K 3

Installation

6.

Connect the transducer’s cable to J1 on the circuit board (25c*). Install the ferrite (76*) around the transducer leadwires. See F

IG

. 3.

7.

See F

IG

. 2. At the pump outlet manifold, remove the plug from the transducer port (P). Insert the transducer into the port. Torque the adapter (42*) first, then the conduit nut (M) to 15-20 ft-lb (21-27 N•m).

NOTE: The conduit nut (M) is included with the conduit

(44a*) on Kit 24J305 Series B. It is a separate part (43*) in Kit 15J755 Series B.

74a*

25b* 12*

*25c

25b*

25a*

*76

76*

*25a

35*

C 25c* 33* B ti8725b

36* ti17640a

*35

3

B

G

N

Position Sensor Circuit is used on Kit 24J305 only.

-

-

-

,66(1625

&,5&8,7

%2$5'

-

%51

%/8

-

%51

%/8

5('

*51

:+7

%/.

326,7,21

6(1625

7'&

1$085

6(1625

35(6685(

75$16'8&(5

)(55,7(

*

5 Land shield drain and foil to conductive strain relief.

ti17644a

F IG . 3. Circuit Board and Sensor Circuit Wiring Connections

*44 ti16890b

Pressure Transducer Grounding Schematic

3 Tighten nut (N) securely to ensure that the shield and drain wire (G) has firm metal-to-metal contact between the nut and bushing (B).

4 311603K

Installation

8.

See F

IG

. 3. Ensure that the conductive strain relief

(74a*) is screwed tightly into the housing. Units with a sensor circuit must use the conductive strain relief to ensure proper grounding of the IS field wire.

9.

See F

IG

. 4. Thread the IS field wire and shield through the conductive strain relief (74a*) and connect to J2 and J3 on the circuit board (25c*). See

F

IG

. 3 and the Electrical Schematic in the E-Flo

Repair-Parts Manual 311594.

10. See F

IG

. 4. Tighten the nut (N) on the conductive strain relief (74a*) securely. Install the ferrite (77*) on the field wire (F), not more than 2 in. (51 mm) from the bottom of the conductive strain relief. Install ground wire (G) to grounding screw in junction box.

F

IG

74a

N

B

Not more than

2 in. (51 mm)

77

. 4. IS Circuit Field Wire

F

G ti16891b

NOTE:

Steps 11 through 14 apply only to Kit 24J305

Series B for use with Series D and later pumps. If you are installing Kit 15J755 Series B on a Series C or ear-

lier pump, go to step 15.

11. Mount the position sensor in the port on the underside of the gear housing, on the opposite side of the housing from the circuit board. See F

IG

. 5. Apply thread lubricant to the adapter (78*) and screw the adapter into the port. Torque to 75-80 ft-lb (102-108

N•m).

12. Install the position sensor (80*) into the adapter

(78*) and secure with the sleeve (79*).

NOTE: The Position Sensor nuts are locked in place to ensure correct positioning. Do not adjust.

13. Thread the position sensor wires through the long length of the 2-sensor conduit (44a*) into the circuit board cavity. Connect a terminal block (46*) to each wire. Reconnect the IS circuit field wires to the terminal blocks. See F

IG

. 5 and the Electrical Schematic in the E-Flo Repair-Parts Manual 311594.

14. Secure the conduit (44a*) to the position sensor sleeve (79*) with the nut (M). Torque to 15-20 ft-lb

(21-27 N•m). Continue with step 15.

15. See F IG . 3 or F IG . 5. Tighten the nut (N) on the conductive strain relief (35) securely to ensure that the shield and drain wire (G) has firm metal-to-metal contact between the nut and bushing (B).

16. See F

IG

. 3. Install the new gasket (33*), the cover

(B), and six screws (12*).

17. Attach the label (36*) to the cover (B).

18. Calibrate the transducer, entering the calibration information found on the new label (36*):

• For systems using the Graco ACS Module, see the ACS manual 3A0006.

For non-ACS systems, see page 7.

19. See F

IG

. 1. Reinstall the cover (32*) with two screws

(12*).

311603K 5

Installation

46*

28 (Ref)

1 (Ref)

78

80

79

44 (Ref)

Position Sensor Parts and Location ti17643a

-

-

-

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&,5&8,7

%2$5'

)(55,7(

*

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%/8

-

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%/8

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*51

:+7

%/.

ti17644a

*76

326,7,21

6(1625

7'&

1$085

6(1625

35(6685(

75$16'8&(5

Connect Field

Wires here

*35

3

B

G

N

Position

Sensor

Wires

*44a ti16890b

Position Sensor Wires and Terminals

3 Tighten nut (N) securely to ensure that the shield and drain wire (G) has firm metal-to-metal contact between the nut and bushing (B).

F IG . 5. Position Sensor

6 311603K

Pressure Sensor Calibration Information (non-ACS systems)

Pressure Sensor

Calibration Information

(non-ACS systems)

NOTE: To calibrate the transducer in systems using the

Graco ACS Module, see the ACS manual 3A0006.

Pressure sensor information ( Pr 20.34, 20.35, and

20.36) for your system must be keyed into the Variable Frequency Drive before system start-up.

To prevent accidental change of pressure sensor calibration parameters, they are locked by Pr 20.16

. To enter calibration parameters, perform the following steps: a.

Set Pr 20.16

to 777, to unlock pressure sensor parameters.

b.

Enter calibration parameters Pr 20.34

, 20.35

, and 20.36

.

c.

Set Pr 20.16

to 0 to lock pressure sensor parameters.

Calibration Parameters from the label:

Pr 20.34 – Zero Calibration

Pr 20.35

– Calibration Pressure

Pr 20.36

– High Calibration

Pressure Transducer

Calibration Procedure

(non-ACS systems)

E-Flo pressure sensor must be calibrated against an instrument grade High Precision Pressure Transducer, which should be installed near the E-Flo pressure sensor.

1.

Ensure that the High Precision Pressure Transducer calibration is up to date.

2.

Set Pr 20.16

to 777, to unlock pressure sensor parameters.

3.

Calibrate Low Pressure Point as follows: a.

Ensure that system is not pressurized. Calibration instrument pressure reading should be 0 psi. b.

Use Keypad to navigate to Pr 20.33

; monitor its reading for 5 – 10 seconds to determine its average value. Make a record of it.

c.

Navigate to Pr 20.34

and enter the recorded average value of Pr 20.33

.

4.

Calibrate the High Pressure Point as follows: a.

Pressurize the system to 250 – 275 psi.

Do not exceed pressure rating of the system! If system is rated to a pressure lower then 250 psi, use maximum allowable rated pressure. Refer to Operation

Manual 311593.

b.

Keep the system pressurized and ensure that pressure does not fluctuate. c.

Take a pressure reading from the calibration instrument and make a record of it.

d.

Navigate to Pr 20.35

and enter the recorded system pressure.

e.

Navigate to Pr 20.33

; monitor its reading for

5-10 seconds to determine its average value.

Make a record of it.

f.

Navigate to Pr 20.36

and enter the recorded value of Pr 20.33

.

5.

Set Pr 20.16

to 0 to lock pressure sensor parameters.

6.

Verify pressure calibration.

a.

Relieve system pressure.

b.

Navigate to Pr 20.31

and verify that its reading is within the range of 0-3 psi.

c.

Pressurize the system to about 100 psi. Verify that reading of Pr 20.31

is within +/- 2.5 psi of the system pressure.

d.

Pressurize system to about 250 psi. Verify that reading of Pr 20.31

is within +/- 2.5 psi of the system pressure.

311603K 7

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. 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.

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. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original instructions.

This manual contains English. MM 311603

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2007, Graco Inc. is registered to ISO 9001 www.graco.com

Revision K, April 2014

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