Graco 3A0264A Crossover Transfer Pump Package, PD44 Control Box, Maintenance Owner's Manual

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Graco 3A0264A Crossover Transfer Pump Package, PD44 Control Box, Maintenance Owner's Manual | Manualzz

Maintenance

Crossover Transfer

Pump Package

3A0264A

For use with bulk supply of medium to high viscosity sealant and adhesive materials. Not for use in explosive atmospheres.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

A

15W776

  

POWER

ON OFF

AUTO

PUMP1 PUMP2

PUMP #1 LOW

A

PUMP #2 LOW

A

84/2088/11

2

Related Manuals

Contents

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

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

Component Identification . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Dual Transfer Pump Controller Operation . . . . . . 10

Dispensing Operation . . . . . . . . . . . . . . . . . . . . . . 11

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 12

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Optional Customer Outputs . . . . . . . . . . . . . . . . . 12

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

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

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Graco Ohio Standard Warranty . . . . . . . . . . . . . . 14

Graco Ohio Information . . . . . . . . . . . . . . . . . . . . 14

Related Manuals

Feed System Manuals

312376 Check-Mate Pump Packages

Instructions-Parts

313526 Check-Mate Ram Packages Operation

308167 Low Volume Air Regulators

307517 Mastic Fluid Regulators

3A0264A

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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

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 MSDS’s 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 impervious gloves when spraying or cleaning equipment.

• If this equipment is used with isocyanate material, see additional information on isocyanates in Isocyanate Conditions Section of this manual.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

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.

• If there is static sparking or you feel a shock, stop operation immediately.

Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

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

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors.

3A0264A 3

Warnings

4

WARNING

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying 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.

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.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• 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.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage. See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s warnings.

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 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.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

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.

3A0264A

Warnings

WARNING

SPLATTER HAZARD

Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen, splatter may occur.

• Use minimum air pressure when removing platen from drum.

BURN 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.

3A0264A 5

Component Identification

Component Identification

L I I A

Q A

K H J P, R, T

S

15W776

  

POWER

ON OFF

AUTO

PUMP1 PUMP2

PUMP #1 LOW

A

PUMP #2 LOW

A

84/2088/11

M

D

E

B

O

C

F

N

G

Key:

A Control Power Switch

B Power Input

C Transfer Pump #1 Level Sensor

D Transfer Pump #2 Level Sensor

E Main Air Inlet

F Material Outlet

G System Pressure Regulator/Gauge

H Pump #1/Auto/Pump #2 Control

Switch

I Pump #1 Low Light

J Pump #2 Low Light

K Material Low Light

L Ram/Pump #1

M Ram/Pump #2

N Material Regulator (behind stand)

O Ram #1 Reg/Gauge

P Ram #2 Reg/Gauge (Behind Control

Box)

Q Pump #1 Reg/Gauge

R Pump #2 Reg/Gauge (Behind Control

Box)

S Ram #1 Director Valve

T Ram #2 (Behind Control Box)

F IG . 1: Micrometer and LRT PD44 Control Box

6 3A0264A

Grounding

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current.

Grounding plug units: this product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Hard-wired units: the grounding wire must be used. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Air and fluid hoses: use only electrically conductive hoses.

Fluid supply container: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts grounding continuity.

Grounding

3A0264A 7

8

Setup

Setup

1.

Connect air supply to main air inlet. Air supply must include a shut-off/bleed valve that bleeds pressure past the shut-off/bleed valve and an air-water separator/filter.

2.

Adjust each desired Ram regulator to the appropriate pressure.

3.

Switch each desired Ram director valve to the UP position.

4.

Place each desired material container under the pump.

5.

Switch each desired Ram director valve to the

DOWN position.

6.

Adjust each desired pump regulator to the appropriate pressure.

7.

Adjust material regulator to the appropriate pressure.

8.

Plug in power input to a receptacle.

3A0264A

Startup

1.

Energize the control logic box by turning the control power switch to the ON position.

2.

Place the pump #1/Auto/Pump #2 switch to the desired location.

NOTE:

Pump #1 Switch Location (manual mode): When this position is selected the only material output will be from

Station #1.

Auto Switch Location (auto mode): When this position is selected the material output will be from either

Station #1 or #2 as long as neither is in a Low Level condition.

Pump #2 Switch Location (manual mode): When this position is selected the only material output will be from

Station #2.

Startup

3A0264A 9

Dual Transfer Pump Controller Operation

Dual Transfer Pump Controller Operation

Other Indicators

PUMP #1 indicator

When this indicator is activated, the material level of transfer pump #1 reached the low-level limit switch.

When this indicator is illuminated, the transfer pump will be disabled.

PUMP #2 indicator

When this indicator is activated, the material level of transfer pump #2 reached the low-level limit switch.

When this indicator is illuminated, the transfer pump will be disabled.

TOWER LIGHT indicator

POWER Switch

ON position

Enables power to the Transfer Pump Controller.

OFF position

Disables power to the Transfer Pump Controller.

PUMP CROSS OVER switch

PUMP 1 Switch position

When this position is selected, the dispense valve will feed from transfer PUMP #1 only. The material ball valve will stall out PUMP #2.

AUTO Switch position

When this position is select the dispense valve will feed from transfer PUMP #1 until the transfer PUMP#1 material level reaches the LOW LEVEL proximity switch, at this time transfer PUMP #2 will feed the dispense valves.

Note: The material ball valve will stall out the opposite pump.

PUMP 2 Switch position

When this position is selected, the dispense valve will feed from transfer PUMP #2 only. The material ball valve will stall out PUMP #1.

When this light is illuminated and flashing, the material levels of transfer pump #1 and transfer pump #2 are both at the low level condition, both transfer pumps will be disable and the PUMP #1 and the PUMP #2 indicators will be illuminated. If one of the transfer pumps where to be at the low level, the light will be illuminated.

NOTE: When the setting the low level sensor on the material rams, the low level sensors should be activated when the material rams are a ½ inch above the bottom of the pail or a transfer pump motor can be running for a prolong period when the pail is out of material.

10 3A0264A

Dispensing Operation

Dispense Continuously

To dispense continuously, place the Pump

#1/Auto/Pump #2 switch to the Auto location.

NOTE:

As a result the material output will be from either Station

#1 or #2 as long as neither is in a Low Level condition.

If Station #1 is in a Low Level condition the Material Low indicator will illuminate. Pump #1 indicator will illuminate and the Transfer Pump #1 will be disabled.

If Station #2 is in a Low Level condition the Material Low indicator will illuminate. Pump #2 indicator will illuminate and the Transfer Pump #2 will be disabled.

If both Station #1 and Station #2 are in a Low Level condition then Pump #1 and Pump #2 indicator will illuminate, the Material Low indicator will illuminate and flash, the customer signal on the PLC activates, and both transfer pumps will be disabled.

Dispense Pump #1 Only (manual mode)

To dispense pump #1 only, place the Pump

#1/Auto/Pump #2 switch to the Pump #1 location.

NOTE:

As a result the material output will only be from Station

#1. Once Station #1 is in a Low Level condition, the

Pump #1 indicator and Material Low Light indicator will illuminate and the Transfer Pump #1 will be disabled.

Dispense Pump #2 Only (manual mode)

To dispense pump #2 only, place the Pump

#1/Auto/Pump #2 switch to the Pump #2 location.

NOTE:

As a result the material output will only be from Station

#2. Once Station #2 is in a Low Level condition, the

Pump #2 indicator and Material Low Light indicator will illuminate and the Transfer Pump #2 will be disabled.

3A0264A

Dispensing Operation

11

Pressure Relief Procedure

Pressure Relief

Procedure

1.

Turn main air supply shut-off/bleed valve to the off position. This will bleed air from the system.

2.

Perform feed system pressure relief procedure. See

Related Manuals on page 2.

Maintenance

NOTE: If material is leaking, see

Troubleshooting

on

page 12.

See Related Manuals on page 2 for dispense valve and

feed system maintenance schedule and procedures.

Air-Water Separator/Filter

Drain water once a shift or as necessary.

Troubleshooting

Shutdown

Perform

Pressure Relief Procedure

before performing any troubleshooting procedure.

1.

Perform

Pressure Relief Procedure .

2.

De-energize the control logic box by turning the control power switch to the OFF position.

See Related Manuals on page 2

Schematics

Schematics are included in the assembly drawings manual.

Optional Customer

Outputs

Material Low Level Condition: If either or both

Pump #1 and Pump #2 are in a Low Level condition,

PLC 0/O will be activated.

12 3A0264A

Technical Data

Maximum Ambient Temperature. . . . . . . . . . . . . . . . . . . . 110°F (43°C)

Maximum Operating Temp . . . . . . . . . . . . . . . . . . . . . . . . 150°F (65°C)

Maximum Air Working Pressure . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Supplied Air Requirements. . . . . . . . . . . . . . . . . . . . . . . . 1 to 3 cfm at 80 psi to 100 psi

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 120V, 60 Hz

Fuses Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm x 40 mm, Part Number 81/0033-2/11

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height:

Total Open: 6 ft

Total Closed: 4 ft 8 in.

Length: 3 ft 8 in.

Width: 2 ft 3 in.

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 lb (249.5 kg)

Technical Data

3A0264A 13

Graco Ohio 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 Ohio Information

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

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

Toll Free: 1-800-746-1334 or Fax: 330-966-3006

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.

This manual contains English. MM 3A0264

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO OHIO INC. 8400 PORT JACKSON AVE NW, NORTH CANTON, OH 44720

Copyright 2009, Graco Ohio Inc. is registered to ISO 9001 www.graco.com

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