Graco G-JR Operation manual

3A8109A

Instructions-Parts

G-JR Chemical

Injection Pump

Electric pump for injecting chemicals at well sites. For professional use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

Not recommended for use with chemicals outside of the pH range of 4-9.

See page 2 for model information, including maximum

working pressure.

Important Safety Instructions

Read all warnings and instructions in this

manual and in the Harrier®EZ-JR

manual before using the equipment.

Save these instructions.

23A8109A

Contents

Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification . . . . . . . . . . . . . . . . . . . . 5

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Flush Before Using Equipment . . . . . . . . . . . . . . 6

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 7

Choosing an Installation Location . . . . . . . . . . . . 8

Fluid Connections . . . . . . . . . . . . . . . . . . . . . . . . 8

Motor Electrical Connections . . . . . . . . . . . . . . . . 9

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

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

Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 10

Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 11

Calibrate Chemical Dosage . . . . . . . . . . . . . . . . 11

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Remove G-JR Pump . . . . . . . . . . . . . . . . . . . . . 13

Replace Fluid Module . . . . . . . . . . . . . . . . . . . . 14

Replace Gear Assembly . . . . . . . . . . . . . . . . . . 15

Replace Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Reinstall G-JR Pump . . . . . . . . . . . . . . . . . . . . . 15

Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

G-JR Chemical Injection Pump . . . . . . . . . . . . . 16

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . 17

Technical Specifications . . . . . . . . . . . . . . . . . . . . 19

California Proposition 65. . . . . . . . . . . . . . . . . . . . 19

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20

Related Manuals

Models

Manual No. Description

334993 Harrier EZ-JR Injection Pump Controller

Part No. Voltage Maximum Working Pressure

psi (MPa, bar)

25T650 12 VDC 2000 (13.7, 137)

25T651 120 VAC

Warnings

3A8109A 3

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 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.

WARNING

FIRE AND EXPLOSION HAZARD

When flammable fluids are present in the work area be aware that flammable fumes can ignite or

explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources, such as cigarettes and portable electric lamps.

• Ground all equipment in the work area.

• Keep work area free of debris, including rags and spilled or open containers of solvent.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Use only grounded hoses.

•Stopoperationimmediatelyifstaticsparkingoccurs oryoufeel ashock.Donotuseequipmentuntil

you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 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 andbefore cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings before each use. Replace worn or damaged parts immediately.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-

tric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing

or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and

regulations.

Warnings

43A8109A

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.

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 Sheet (SDS) to know the specific hazards of the fluids you are using.

• Store hazardous fluids 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,protectiveclothing, and gloves as recommended by the fluid and solvent manufacturers.

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 com-

ponent. See Technical Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-

tions in all equipment manuals. Read fluid and solvent manufacturers’ warnings. For complete infor-

mation about your material, request Safety Data Sheet (SDS) from material supplier or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Checkequipmentregularly.Repair or replace wornor damagedpartsimmediatelywithgenuineman-

ufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations ormodifications 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.

WARNING

Component Identification

3A8109A 5

Component Identification

Key:

Access the Harrier controller (3) and other components

inside the enclosure (1) by removing the lid (7) and

pump cover (4).

FIG. 1 G-JR Pump Components

1Enclosure

2 G-JR Pump Module

3 Harrier EZ-JR Controller

4 Pump Cover

6Base

7 Lid (included with Enclosure)

H Pump Inlet

J Pump Outlet

M Priming Port Plug

FIG. 2 Access to Enclosure Components

Installation

63A8109A

Installation

Grounding

Pump: grounded through Motor Electrical Connec-

tions on page 9.

Fluid lines: use only electrically conductive lines.

Fluid supply container: follow local codes and regula-

tions.

Accessories

Install the following required accessories in the order

shown in Typical Installation, page 7, using adapters

as necessary. These required accessories must be sup-

plied and installed by the customer before use.

•Fluid Filter (Y-Strainer) (included in K): with a 60

mesh (250 micron) stainless steel element to filter

particles from the fluid before it reaches the pump.

•Fluid Shutoff Valves (L): shuts off fluid flow.

•Pressure Relief Valve (D): overpressure protec-

tion.

Flush Before Using Equipment

The equipment was tested with lightweight oil, which is

left in the fluid passages to protect parts. To avoid con-

taminating your fluid with oil, flush the equipment with a

compatible solvent before using the equipment. See

Flush the Equipment, page 10.

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.

Installation

3A8109A 7

Typical Installation

FIG. 3 is an example of an installation with a G-JR

chemical injection pump. Your installation may differ

from what is shown here. The G-JR pump (A) is the only

component in FIG. 3 supplied by Graco. All other com-

ponents are supplied by customer.

Key:

A G-JR pump

B Power Source

CTank

D Pressure Relief Valve (Required)

E Inlet Line

F Outlet Line

G Pressure Relief Line

H Pump Inlet

J Pump Outlet, 1/4 in. npt

K Manifold Assembly (includes y-strainer)

L Fluid Shutoff Valve (outlet) (Required)

M Priming Port Plug

FIG. 3 Typical Installation

Installation

83A8109A

Choosing an Installation

Location

1. Select a location that will adequately support the

weight of the pump, as well as all plumbing and

electrical connections.

2. Always mount the pump upright.

3. Mount the pump above the top rim of the contain-

ment tank, if used, to prevent submersion.

4. If you have a mounting configuration that requires

installation in a manner different than depicted in

FIG. 3, please contact your Graco distributor.

Fluid Connections

1. Remove and discard the caps on the Pump Inlet (H)

and Outlet (J). See FIG. 1 on page 5.

2. Connect a 1/4 npt(f) fluid line from the fluid source to

the Pump Inlet (H).

3. Install a Pressure Relief Valve (D) on the outlet side

of the pump. See FIG. 3 on page 7.

NOTE: A Pressure Relief Valve (D) is available from

Graco (see Kits and Accessories on page 18) and can

be connected back to the tank ordirectly to the inlet side

of the pump.

4. Set the Pressure Relief Valve (D) at or below the

maximum working pressure of the pump.

5. Connect a 1/4 npt(f) Outlet Line (F) from the Pump

Outlet (J) to the injection point.

To reduce the risk of skin injection and damage to the

pump in the event of an outlet line blockage, ensure the

pressure relief valve (D) is set at or below the maxi-

mum working pressure of the pump.

Installation

3A8109A 9

Motor Electrical Connections

NOTE: Over-current protection is provided, for both AC

and DC models, within the enclosure (1).

The AC and DC models both havepre-wired controllers.

The power sources and connections differ as follows:

•For AC models (25T651), simply plug the power

cord (18) into a standard 115 VAC receptacle. See

FIG. 4.

•For DC models (25T650), connect red wire on the

controller (15) to the red wire on the power supply

(13), and the black wire on the pump (2) to the black

wire of the power supply (13).

To reduce the risk of electrical shock;

• All electrical wiring must be done by a qualified

electrician and complywith all local codes andreg-

ulations.

• Installthepump with a dedicated meansto discon-

nect the main power to the pump.

NOTICE

To avoid potential damage to equipment, verify that all

system valves are open before connecting power to

the pumps.

FIG. 4 AC Power Source

Operation

10 3A8109A

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

NOTE: Always discharge fluid into an approved con-

tainer or location.

1. Disconnect electrical power to the pump.

2. Shut off the inlet and outlet lines using the Fluid

Shutoff Valves (L). See FIG. 3 on page 7.

3. Slowly loosen the pump outlet (J) fitting to relieve

downstream fluid pressure. See FIG. 1 on page 5.

4. Disconnect and cap the Inlet (E) and Outlet (F)

Lines.

Flush the Equipment

• Check fittings for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid

being dispensed and the equipment’s wetted parts.

1. Perform the Pressure Relief Procedure.

2. Connect the Pump Inlet (H) to the flushing fluid sup-

ply source. See FIG. 1 on page 5.

3. Connect the Pump Outlet (J) to a waste reservoir.

4. Run the pump until the dispensed fluid is predomi-

nately flushing fluid.

5. Perform the Pressure Relief Procedure.

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from

pressurized fluid, such as skin injection and splashing

fluid, follow the Pressure Relief Procedure when

you stop dispensing and before cleaning, checking, or

servicing the equipment.

To avoid fire andexplosion, always ground equipment

and waste container. To avoid static sparking and

injury from splashing, always flush at the lowest pos-

sible pressure.

This manual suits for next models

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