Graco G3000 Manual de operación

Instructions-Parts

Volumetric Fluid Flow

Meter 308778Y

For precise metering of plural component fluids or solvents (depending on model).

For professional use only.

See page 3 for model information, including maximum working pressure.

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

TI11579a

G3000, G3000A, and G3000HR

G250 and G250HR

TI13038a

TI14674b

S3000 Solvent Meter

Intrinsically Safe for Hazardous Locations (Class I; Division

1; Group D) when used with an approved barrier only.

0359

3151640

Class I, Div 1, Group D,

T3 (Ta = 0° - 60°C)

Ex ia IIA T3

0°C<Ta<60°C Ga

ITS12ATEX27565X

II 1 G

2308778Y

Contents

Meter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Low Pressure Fluid Meters . . . . . . . . . . . . . . . . . 3

High Pressure Fluid Meters . . . . . . . . . . . . . . . . 3

High Pressure Solvent Meter . . . . . . . . . . . . . . . 3

Meter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

G3000 Fluid Meter Kits . . . . . . . . . . . . . . . . . . . . 3

Solvent Meter Kit . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Dust and Foreign Matter . . . . . . . . . . . . . . . . . . . 7

Installing the Flow Meter . . . . . . . . . . . . . . . . . . . 7

Intrinsically Safe Installation Requirements . . . . 8

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Meter Cables and Adaptor . . . . . . . . . . . . . . . . . 9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pressure Relief Procedure . . . . . . . . . . . . . . . . 10

Flow Meter Function . . . . . . . . . . . . . . . . . . . . . 10

Recommended Usage . . . . . . . . . . . . . . . . . . . 10

Flow Volume Range . . . . . . . . . . . . . . . . . . . . . 10

Checking the Meter Accuracy . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Residue Build-up on the Meter Gears . . . . . . . . 12

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cleaning or Servicing the Meter Chamber . . . . 13

Replacing the Electronic Sensor . . . . . . . . . . . . 13

Cleaning or Servicing the Solvent Meter . . . . . . 14

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Flow Meter Kits, for ProMix

2KS Wall Fluid Panel . . . . . . . . . . . . . . . . . 15

Bare Meter Assemblies . . . . . . . . . . . . . . . . . . . 16

Solvent Meter Assembly . . . . . . . . . . . . . . . . . . 18

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pressure Drop Curve . . . . . . . . . . . . . . . . . . . . . . . 23

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 24

Meter Models

308778Y 3

Meter Models

Low Pressure Fluid Meters

300 psi (2.1 MPa, 21 bar) Maximum Fluid Working Pressure

High Pressure Fluid Meters

4000 psi (28 MPa, 280 bar) Maximum Fluid Working Pressure

High Pressure Solvent Meter

3000 psi (21 MPa, 210 bar) Maximum Fluid Working Pressure

Meter Kits

G3000 Fluid Meter Kits

For use with ProMix 2KS Wall Fluid Panel. Kits include

meter, cable, fluid tube, check valve, mounting bracket

and hardware.

Solvent Meter Kit

For use with ProMix 2KS Wall Fluid Panel. Kit includes

meter, cable, fluid hose, check valve, fittings, mounting

bracket and hardware.

Meter Part No. Series Model Flow Range

249426 B G250 0.02 to 1.0 gpm (75 to 3800 cc/min)

249427 B G250HR 0.01 to 0.5 gpm (38 to 1900 cc/min)

Meter Part No. Series Model Flow Range

289813 B G3000 0.02 to 1.0 gpm (75 to 3800 cc/min)

289814 B G3000HR 0.01 to 0.5 gpm (38 to 1900 cc/min)

26A119 A G3000A 0.02 to 1.0 gpm (75 to 3800 cc/min)

Meter Part No. Series Model Flow Range

258718 B S3000 0.01 to 0.42 gpm (38 to 1600 cc/min)

Kit Part No. Meter

15V804 Part No. 289813 G3000 Meter

15V827 Part No. 289814 G3000HR Meter

826216 Part No. 26A119 G3000A Meter

Kit Part No. Meter

280555 Part No. 258718 S3000 Solvent Meter

Warnings

4308778Y

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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, 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.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. 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 arc).

• 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.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they

are antistatic 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.

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment

will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regula-

tions and the following safety requirements.

• Be sure your installation complies with national, state, and local codes for the installation of electrical

apparatus in a Class I, Group D, Division 1 Hazardous Location, including all of the local safety fire

codes, NFPA 33, NEC 500 and 516, and OSHA 1910.107.

• Equipment that comes in contact with the safety barrier’s intrinsically safe terminals must be rated

for Intrinsic Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove

the unit from the hazardous area when troubleshooting.

• If a printer, computer, or other electrical component is connected, it must be used in conjunction with

a safety barrier.

• Without the safety barrier, the equipment is no longer intrinsically safe and must not be operated in

hazardous locations, as defined in article 500 of the National Electrical Code (USA) or your local

electrical code.

• Do not install equipment approved only for a non-hazardous location in a hazardous area. See the

ID label for the intrinsic safety rating for the flow meter sensor.

• Ground the intrinsically safe power supply. A voltage limiting safety barrier must be properly

grounded to be effective. For proper grounding, use the ground wire provided (or a 12 gauge mini-

mum ground wire), and the barrier’s ground must be within 1 ohm of true earth ground.

• Do not operate the safety barrier module with the cover removed.

• Never use the flow meter with an electrostatic gun isolation stand.

Warnings

308778Y 5

SPECIAL CONDITIONS FOR SAFE USE

Equipment must comply with the following conditions to avoid a hazardous condition which can cause

fire, explosion, or electric shock:

• Sensor housing is of aluminum construction. Precautions must be taken to avoid impacts or contact

with moving parts.

SKIN INJECTION HAZARD

High-pressure fluid from gun, 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 spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying 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.

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 Relief Procedure when you stop spraying/dispensing and before cleaning,

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Warnings

6308778Y

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 Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information

about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• 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 manu-

facturer’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.

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 MSDSs 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.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

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. This 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.

Installation

308778Y 7

Installation

Dust and Foreign Matter

Avoid having dust or foreign matter enter the flow meter

by taking the following precautions:

• Thoroughly flush the fluid supply lines before install-

ing the flow meter.

• When installing fittings, make sure that no sealing

tape overlaps into the inside of the pipe.

• Install a 100 mesh fluid filter upstream of the flow

meter.

Installing the Flow Meter

NOTE: You must assemble the meter sensor to the

meter body before connecting the cable to the sensor for

the meter to function properly.

• Flow volume can only be measured at the location

where the flow meter is installed.

• The Fluid Flow Meters are intrinsically safe for Haz-

ardous (Classified) Locations, when installed with

an intrinsically safe power device and wiring:

Class I, Div I, Group D, T3 (US and Canada)

Class I, Zone I Group IIA T3 (ATEX only)

TA = 0°C to 60°C

Refer to ANSI standards ISA-RP12.6, NEC Article

504 and the Canadian Electrical Code Appendix F.

• Do not use more than 200 ft. (61 m) of cable.

• Refer to FIG. 1 to locate and install the flow meter,

connectors, and fluid shutoff valves. Install a check

valve to prevent backflow. The arrows on the flow

meter and check valve show the direction of fluid

flow.

• The shutoff valves allow you to isolate the meter for

service.

• Refer to Dimensions on page 20 and Technical

Data on page 22 for dimension, inlet/outlet size,

temperature and other specifications.

Improper wiring can cause fire and explosion, electric

shock, or other serious injury.

• Disconnect power source before installing.

• All electrical equipment must only be installed by

a qualified electrician.

• Understand and follow your local code and safety

regulations for hazardous location wiring of intrin-

sically safe circuits.

FIG. 1: Typical Installation

Cable

(see Table 1 on page 9

for available cables)

Electronic Sensor

Flow Meter

Fluid Line

Fluid Shutoff Valve

on outlet side

Ground Sheath

Check Valve

Fluid Shutoff Valve

on inlet side

7379A

Installation

8308778Y

Intrinsically Safe Installation

Requirements

See FIG. 2.

1. The non-intrinsically safe terminals must not be con-

nected to any device which uses or generates more

than 250 Vrms or dc unless it has been determined

that the voltage has been adequately isolated.

2. The installation must meet the requirements of the

National Electric Code, Canadian Electrical Code

Part I, NFPA 70, Article 504 Resp., Article 505 and

ANSI/ISA 12.06.01.

3. Multiple earthing of components is allowed only if

high integrity equipotential system is realized

between the points of bonding.

4. Do not operate system with safety barrier cover

removed.

5. For ATEX, install per EN 60079-14 and applicable

local and national codes.

6. Cable used to connect sensor and safety barrier

must take capacitance and inductance into account.

The maximum capacitance of the barrier is to be

greater than the cable capacitance plus the sensor

capacitance (Ci). The maximum inductance of the

barrier is to be greater than the cable inductance

plus the sensor inductance (Li).

Find cable capacitance and inductance by:

a. Using the most exacting electrical parameters

provided by the cable manufacturer.

b. Using the electrical parameters determined by

measurement of a sample.

7. Product meets 500 Vac isolation test between the

intrinsically safe circuits and earth ground.

FIG. 2. Intrinsically Safe Installation

NON-HAZARDOUS LOCATION ONLY HAZARDOUS (CLASSIFIED) LOCATION

CLASS I, DIV I, GROUP D, T3 (US AND CANADA)

CLASS I, ZONE I GROUP IIA T3 (ATEX ONLY)

TA = 0°C TO 60°C

Safety

Barrier

Flow Meter Body

G3000

G3000HR

G250

G250HR

S3000

G3000A

250 VAC Maximum

Supply Voltage

Power 10-30 Vdc (Red), Ref. to Common

Sensor - 24W650

24W651

Ground

(Grounded thru meter

mounting bracket to

system ground.)

NOTE: See Intrinsically Safe Installation Requirements above.

WARNING: Substitution of components may impair intrinsic safety. For installation,

maintenance or operation instructions, see instruction manual.

ADVERTISSEMENT: La substitution de composants peut compromettre la securite

intrinseque.

ATEX CERTIFICATE #ITS12ATEX27565X

SYSTEM ASSEMBLY CERTIFICATE

Ground

System

Common (Black)

Signal 0-30 Vdc (White), Ref. to Common

Cable Shield

Sensor Entity Parameters

(per barrier channel):

Ui/Umax = 30 Vdc

Ii/Imax = 110 mA

Ci = 0.4 microFarads

Li = 0.01 mH

Pi = 0.8 W

24M600

Control Drawing

Installation

308778Y 9

Grounding

1. Ground the flow meter by connecting a grounded

cable to the meter housing or sensor.

Have a qualified electrician check the electrical

grounding continuity between the flow meter sensor

and a true earth ground; remove the cable connec-

tor from the sensor and measure the resistance

from the cable connector Pin 2 to true earth ground.

Refer to FIG. 3.

If the resistance is greater than 25 ohms, check the

cable ground connection. Refer to FIG. 3. Reconnect

the ground sheath or replace the cable. Do not oper-

ate the system until the problem is corrected.

2. Always ground the meter, using one of the following

options:

a. Mount the meter to a grounded conductive sur-

face, or

b. Connect the conductive fluid hose to the meter

inlet and outlet, or

c. Connect a ground wire to the meter's M6

mounting holes.

3. Never use the flow meter with an electrostatic gun

isolation stand.

Meter Cables and Adaptor

See Table 1 for available meter cables or the adaptor for

use with cables with a black plastic connector and a

replacement sensor.

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.

FIG. 3

TI26838a

1+10-30 Vdc Supply (red)

2Ground (black)

3Signal Out (white)

Table 1: Meter Cables

Cable Part No. Length Ferrite Platform

17C743 5 ft (1.52 m) Various

17C910 42 in. (1029 mm) 15D906 ProMix 2KS

17C887 6 ft (1.83 m) Various

17C888 50 ft (15.25 m) Various

17C889 150 ft (45.75 m) Various

24Y434 Adaptor - Not included with cables (see note)

NOTE: These cables have a metal connector, which will only mate with a sensor that

also has a metal connector. Adaptor 24Y434 is required to connect an existing cable

with a plastic connector to a replacement sensor, which has a metal connector.

Adaptor 24Y434 purchased separately.

Operation

10 308778Y

Operation

Pressure Relief Procedure

1. Shut off the fluid supply to the meter.

2. Shut off all electrical power to the fluid system.

3. Follow the Pressure Relief Procedure for your fluid

system dispensing device.

Flow Meter Function

This is a positive displacement, gear flow meter. The

gear flow meter is highly accurate, even with low flow

rates. The fluid flowing through the meter rotates the

gears. The gear tooth is picked up by a sensor device,

which produces an impulse for every gear tooth passing

by.

Recommended Usage

• See the Technical Data on page 22 for fluid and

ambient temperature limits.

• Only use the flow meter with fluids that are compati-

ble with the “Wetted Parts” listed in the Technical

Data.

Flow Volume Range

The G3000v G3000A, and G250 meters flow volume

range is 0.02-1.0 gal./min. (75-3800 cc/min.).

The G3000HR and G250HR meters flow volume range

is 0.01-0.5 gal./min. (38-1900 cc/min.).

The S3000 solvent meter flow volume range is

0.01-0.42 gpm (38-1600 cc/min).

Checking the Meter Accuracy

1. To check the accuracy of the meter, turn your gun

fan and atomizing air off, then trigger the fluid into a

graduated cylinder; dispense at least 500 cc of fluid.

2. Measure the volume of fluid in the beaker in

cubic-centimeters (cc) and read the volume on the

flow meter monitor.

G3000, G3000A, and G250: If the flow meter scale

factor is not between 0.112-0.140 cc/pulse, follow

the cleaning procedure on page 13, then recalibrate

the flow meter.

G3000HR and G250HR: If the flow meter scale fac-

tor is not between 0.05-0.07 cc/pulse, follow the

cleaning procedure on page 13, then recalibrate the

flow meter.

S3000: If the solvent meter scale factor is not

between 0.019-0.022 cc/pulse, follow the cleaning

procedure on page 13, then recalibrate the flow

meter.

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 Pro-

cedure when you stop spraying and before cleaning,

checking, or servicing the equipment.

Do not exceed the maximum working pressure of your

meter or any component or accessory in your system.

NOTICE

The flow meter gears and bearings can be damaged

if they rotate at excessive speeds. To avoid high

speed rotation, open the fluid valve gradually. Do not

over-speed the meter with air or fluid. Do not use

compressed air to rotate flow meter gears. Do not

exceed the meter’s maximum flow rate.

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