Graco 309028ZAR, Uni-Drum Supply System Instructions

Instructions–Parts List
Uni-Drum™ Supply System
309028ZAR
Bulk Supply System for 300 Gallon (1200 Liter) Magnadrums.
The Uni-Drum supply system evacuates 300 gallon (1200 liter) magnadrums or other tote drums of
the same size and capacity. The Uni-Drum pumps and transfers flowable and highly viscous materials such as
sealant, adhesives, and sound deadeners from bulk drums with maximum efficiency.
The Uni-Drum is built to work with other high pressure equipment to optimize material use.
For professional use only.
Not for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for List of Models, Maximum Outlet Pressure, and
Maximum Fluid Flow. See page 4 for Table of Contents.
Uni-Drum Left Hand Supply Unit
Uni-Drum Right Hand Supply Unit
PROVEN QUALITY. LEADING TECHNOLOGY.
EN
List of Models
List of Models
The Uni-Drum supply units listed below are covered in this manual. For specific pump information, refer to the chart
in Servicing the Pumps on page 54.
Pump
Ratio
Max. Outlet Pressure
Max. Fluid Flow
@ 60 cpm
246981 (Left Hand)
XL 10000™, SST, silicone nitride, ceramic
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
246982 (Right Hand)
XL 10000™, SST, silicone nitride, ceramic
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
248306 (Left Hand)
XL 10000™, SST, silicone nitride
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
248307 (Right Hand)
XL 10000™, SST, silicone nitride
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
249339 (Left Hand)
XL 10000™, SST, silicone nitride (24V)
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
249340 (Right Hand)
XL 10000™, SST, silicone nitride (24V)
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
232729 (Left Hand)
XL 10000™, carbon steel
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308147
232730 (Right Hand)
XL 10000™, carbon steel
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308147
232839 (Left Hand)
XL 10000™, stainless steel
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
232840 (Right Hand)
XL 10000™, stainless steel
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
246921 (Left Hand)
XL 10000™, stainless steel
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
246922 (Right Hand)
XL 10000™, stainless steel
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
253676 (Left Hand)
XL 10000™, stainless steel
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
253677 (Right Hand)
XL 10000™, stainless steel
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
*258910 (Left Hand)
XL 10000™, stainless steel (24V)
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
*258911 (Right Hand)
XL 10000™, stainless steel (24V)
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308148
249152 (Left Hand)
XL 10000™, stainless steel
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
249153 (Right Hand)
XL 10000™, stainless steel
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
*234972 (Left Hand)
XL 10000™, stainless steel
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
*234973 (Right Hand)
XL 10000™, stainless steel
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
*258956 (Left Hand)
XL 10000™, stainless steel (24V)
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
*258957 (Right Hand)
XL 10000™, stainless steel (24V)
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
249341 (Left Hand)
XL 10000™, stainless steel (24V)
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
249342 (Right Hand)
XL 10000™, stainless steel (24V)
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
255666 (Left Hand)
XL 10000™, carbon steel (24V)
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm 26 lpm)
308147
255665 (Right Hand)
XL 10000™, carbon steel (24V)
47:1
4500 psi (31.0 MPa, 310 bar)
6.9 gpm (26 lpm)
308147
24H017 (Left Hand)
XL 10000™, carbon steel (24V)
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308151
24H016 (Right Hand)
XL 10000™, carbon steel (24V)
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308151
24U642 (Left Hand)
XL 10000™, stainless steel (24V)
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
24U643 (Right Hand)
XL 10000™, stainless steel (24V)
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
†*25N914 (Left Hand)
XL 10000™, stainless steel
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
†*25N915 (Right Hand) XL 10000™, stainless steel
35:1
3400 psi (23.1 MPa, 231 bar)
9.2 gpm (34.8 lpm)
308152
Supply Unit Part No.
*
Pump
Manual
For LASD applications, sst fittings are outlet.
† Models are for conveyors by others (unit does not have guides or end stops). The end user is responsible for
mounting drum clamps and drum in position sensor.
309028ZAP
2
Related Publications
Related Publications
Product
Form#
Carbon Steel Dura-Flo™ Pump 1800 with XL 10000™ Air Motor
308147
Carbon Steel Dura-Flo™ Pump 2400 with XL 10000™ Air Motor
308151
Stainless Steel Dura-Flo™ Pump 1800 with XL 10000™ Air Motor
308148
Stainless Steel Dura-Flo™ Pump 2400 with XL 10000™ Air Motor
308152
XL 10000™ Air Motor
334644
DV Series Dispense Valves
3A1792
Dura-Flo™ and XL 10000™ are trademarks of Graco, Inc.
3
309028ZAP
Table of Contents
Table of Contents
List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . 3
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Uncrating the System . . . . . . . . . . . . . . . . . . . . . . . 8
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation Overview . . . . . . . . . . . . . . . . . . . . . . 8
Operation Overview . . . . . . . . . . . . . . . . . . . . . . 8
General Description . . . . . . . . . . . . . . . . . . . . . . . . 9
System Components . . . . . . . . . . . . . . . . . . . . . . 9
Pneumatic Layout Panel (G) . . . . . . . . . . . . . . . 13
Junction Box Panel (H) . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preparing the Site . . . . . . . . . . . . . . . . . . . . . . . 14
Selecting a Location for the Uni-Drum . . . . . . . 14
Preparing to Install the System . . . . . . . . . . . . . 14
Installing the Uni-Drum . . . . . . . . . . . . . . . . . . . 15
Installing Drum Clamps (25N914 and 25N915 only)
15
Installing Drum In Position Switch (25N914 and
25N915 only) . . . . . . . . . . . . . . . . . . . . . . . 15
Connecting Power to the Junction Box . . . . . . . 16
Grounding the System . . . . . . . . . . . . . . . . . . . 18
Checking the Resistance Between the Pumps and
the True Earth Ground . . . . . . . . . . . . . . . . 18
Connecting the Air Supply Lines to the Uni-Drum 19
Connecting Output Hose to the Pumps . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Prepare the Operator . . . . . . . . . . . . . . . . . . . . 21
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Junction Box Panel Switches and Indicators . . 22
Pneumatic Layout Panel Switches and Indicators
24
Flushing the System Before Initial Use . . . . . . . 26
Adjusting the Lid Holder Before Initial Use . . . . 26
Initial System Startup Procedure . . . . . . . . . . . 27
Daily System Startup . . . . . . . . . . . . . . . . . . . . 32
System Shutdown . . . . . . . . . . . . . . . . . . . . . . . 32
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . 32
Stopping the System . . . . . . . . . . . . . . . . . . . . . 32
Restarting the System . . . . . . . . . . . . . . . . . . . . 32
Pressure Relief Procedures . . . . . . . . . . . . . . . 33
Fluid Pressure Relief Procedure . . . . . . . . . . . . 33
Pneumatic Pressure Relief Procedure . . . . . . . 34
Preventive Maintenance Schedule . . . . . . . . . . 35
Changing Empty Drums . . . . . . . . . . . . . . . . . . 35
309028ZAP
Ram Assembly Troubleshooting . . . . . . . . . . . . . 37
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . 38
Air Motor Troubleshooting . . . . . . . . . . . . . . . . . . 39
Junction Box Panel Troubleshooting . . . . . . . . . 40
Pneumatic Layout Panel Troubleshooting . . . . . 40
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . 41
Flushing the System . . . . . . . . . . . . . . . . . . . . . 41
Cleaning the System . . . . . . . . . . . . . . . . . . . . . 41
Wiper Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 41
Junction Box Panel Service . . . . . . . . . . . . . . . . . 42
Indicator Light and Pushbutton Switch Removal 42
Indicator Light and Pushbutton Switch Replacement
42
Light Bulb Removal . . . . . . . . . . . . . . . . . . . . . . 42
Light Bulb Replacement . . . . . . . . . . . . . . . . . . 42
Fuse Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . 44
Surge Suppressor Removal . . . . . . . . . . . . . . . . . 45
Surge Suppressor Removal . . . . . . . . . . . . . . . 45
Surge Suppressor Replacement . . . . . . . . . . . . 45
PLC Interface Accessory Kit Service . . . . . . . . . . 46
Valve Assembly Bank Replacement . . . . . . . . . 46
Pressure Switch Assembly Replacement . . . . . 47
Pneumatic Layout Panel Service . . . . . . . . . . . . . 49
Filter/Element Replacement . . . . . . . . . . . . . . . 49
Ram Assembly Service . . . . . . . . . . . . . . . . . . . . . 51
Piston Rod Seal Service (Fig. 20) . . . . . . . . . . . 51
Ram Piston Service (Fig. 21) . . . . . . . . . . . . . . . 52
Low/Empty Limit Switch Replacement . . . . . . . 53
Depressurization Valve (Ball Seat Applicator)
Repair Procedure . . . . . . . . . . . . . . . . . . . . 54
Replacing Wipers (Fig. 23) . . . . . . . . . . . . . . . . 55
Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 56
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Recommended Spare Parts . . . . . . . . . . . . . . . . . 87
Spare Parts for Pump and Air Motor . . . . . . . . . 87
See appropriate manual listed on page 3. . . . . . 87
Spare Parts for 47:1 and 35:1 Uni-Drum Supply
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 88
Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . . 89
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 94
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 94
4
Symbols
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
5
•
This equipment is for professional use only.
•
Read all instruction manuals, tags, and labels before operating the equipment.
•
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
•
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
•
Check equipment daily. Repair or replace worn or damaged parts immediately.
•
Do not exceed the maximum working pressure stated on the equipment or in the Technical Data for
your equipment. Do not exceed the maximum working pressure of the lowest rated component in
your system.
•
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
•
Do not kink or overbend hoses or use hoses to pull equipment.
•
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180°F (82°C) or below –40°F (–40°C).
•
Wear hearing protection when operating this equipment.
•
Do not lift pressurized equipment.
•
Do not lift the equipment by the air motor lift ring if the total weight of the equipment exceeds 550 lb
(250 kg).
•
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
309028ZAP
Symbols
WARNING
SKIN INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can
also cause serious injury.
•
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgical
treatment.
•
Do not point the gun at anyone or at any part of the body.
•
Do not put your hand or fingers over the spray tip.
•
Do not stop or deflect leaks with your hand, body, glove or rag.
•
Do not “blow back” fluid; this is not an air spray system.
•
Always have the tip guard and the trigger guard on the gun when spraying.
•
Check the gun diffuser operation weekly. Refer to the gun manual.
•
Be sure the gun trigger safety operates before spraying.
•
Lock the gun trigger safety when you stop spraying.
•
Follow the Pressure Relief Procedures on page 33 whenever you: are instructed to relieve
pressure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
•
Tighten all fluid connections before operating the equipment.
•
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
•
Use only Graco approved hoses. Do not remove any spring guard that is used to help protect the
hose from rupture caused by kinks or bends near the couplings.
MOVING PARTS HAZARD
Moving parts, such as the pump rod, follower plate and ram assembly, can pinch or amputate your
fingers.
309028ZAP
•
Keep clear of all moving parts when starting or operating the pump.
•
Keep your hands away from the follower plate and the lip of the drum while the ram is operating.
•
Keep your hands away from the ram frame while the ram is operating.
•
Before servicing the equipment, follow the Pressure Relief Procedures on page 33 to prevent the
equipment from starting unexpectedly.
6
Symbols
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result
in a fire or explosion and serious injury.
•
Ground the equipment and the container where the material is deposited. Refer to Grounding the
System on page 18.
•
If there is any static sparking or you feel an electric shock while using this equipment, stop the
pumps immediately. Do not use the equipment until you identify and correct the problem.
•
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being
sprayed.
•
Keep the spray area free of debris, including solvent, rags, and gasoline.
•
Electrically disconnect all equipment in the spray area.
•
Extinguish all open flames or pilot lights in the spray area.
•
Do not smoke in the spray area.
•
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
•
Do not operate a gasoline engine in the spray area.
•
Keep a fire extinguisher in the work area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
7
•
Know the specific hazards of the fluid you are using.
•
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
•
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
309028ZAP
Uncrating the System
Uncrating the System
The Uni-Drum supply system was carefully packaged for
shipment by Graco. When the system arrives, perform
the following procedure to uncrate the system.
WARNING
To uncrate the system, do the following:
1. Inspect the crate carefully for shipping damage.
Contact the carrier promptly if damage is
discovered.
2. Remove the plywood sides and top of the crate.
EQUIPMENT MOVING HAZARD
Removing the unit off the pallet without following the
uncrating procedure will damage the equipment.
3. Inspect the contents carefully. There should not be
any loose or damaged parts.
4. Compare the packing slip against all items included
in the crate. Report any shortages or other
inspection problems immediately.
5. Remove the band straps that hold the Uni-Drum to
the pallet.
NOTE: The Uni-Drum is ready for installation. Before
installing the system, read the “General Description”
section to become familiar with the system components.
Overview
Installation Overview
Operation Overview
The location of the Uni-Drum should allow for easy
loading and unloading of the 300 gallon (1200 liter)
magnadrum or other tote drums with either a forklift
truck or pallet-jack hand truck.
The Uni-Drum is a supply system that evacuates fluids
from a 300 gallon (1200 liter) magnadrum or other tote
drums.
The Uni-Drum supply system must be leveled and
mounted on a horizontal floor. An unleveled condition
can keep the Uni-Drum from operating properly.
Anchor the frame’s four foot pads securely to the floor.
The anchor bolts should be sized with sufficient safety
factor to withstand the downward force of the follower
plate and other objects that can push the frame off the
floor.
Each Uni-Drum includes two Graco air motors and
displacement pumps, a ram assembly with a follower
plate, a pneumatic layout panel that controls the air
components and a junction box panel that connects with
an electrical controller (supplied by the customer).
In short, the operator places the magnadrum inside the
frame with the follower plate placed directly on top of the
material. Locally, the system can be operated using
pneumatic layout panel. Remotely, the system can be
operated using signals through the junction box panel.
Two displacement pumps evacuate material out of each
magnadrum. After removing the empty drum from the
system, the operator repeats the evacuation process
when another drum is ready for evacuation.
309028ZAP
8
General Description
General Description
System Components
A general description of the Uni-Drum supply system
helps the installers and operators become familiar with
the system components. Contact your Graco distributor
for help in choosing accessories to suit your particular
needs.
Before you install the system you should be familiar with
the parts described in the following paragraphs.
•
Uni-Drum System (A) is usually setup to alternate
the material supply operation between the left hand
(LH) and right hand (RH) supply units, which is
accomplished using a combination of robotic
software programming (provided by others) and
manual operators. Drum changeovers occur after
the follower plate has reached its preset low limit
level in the drum. Alternating between supply units
eliminates the downtime that is usually expended
unloading an empty drum and reloading a full drum.
Fig. 1 shows the typical Uni-Drum supply system
equipped with XL 10000™ air motors. The following list
identifies the Uni-Drum system components:
–
Ref.
Description
–
A
Left hand (LH) supply unit
B
Right hand (RH) supply unit
C
Dura-Flo™ 1800 pumps with XL 10000™
air motors (2 units)
D
Ram assembly and follower plate
E
Main air inlet
F
3/8 npt air filter
G
Pneumatic layout panel
H
Junction box panel
J
Drum lid holders
N
Drum clamps (installed by end user)
P
Drum in position switch (installed by end
user)
9
LH pump supply unit (A) accommodates one
300 gallon (1200 liter) drum. The LH supply unit
has a local pneumatic layout panel and junction
box panel.
RH pump supply unit (B) accommodates one
300 gallon (1200 liter) drum. The RH supply unit
has a local pneumatic layout panel and junction
box panel.
309028ZAP
General Description
E
E
G
G
H
H
C
C
H
H
J
F
F
D
D
A - Left Hand Unit
B - Right Hand Unit
Left Hand Models
246981
248306
249339
253676
258910
249152
249341
234972
258956
Right Hand Models
246982
248307
249340
253677
258911
249153
249342
234973
258957
Fig. 1
309028ZAP
10
General Description
E
E
G
G
H
H
C
C
H
H
F
J
F
D
D
A - Left Hand Unit
B - Right Hand Unit
Left Hand Models
232729
232839
246921
255666
24H017
24U642
Right Hand Models
232730
232840
246922
255665
24H016
24U643
Fig. 2
11
309028ZAP
General Description
E
E
G
G
H
H
P
C
C
G
H
H
H
F
F
N
K
N
D
D
K
A - Left Hand Unit
B - Right Hand Unit
Fig. 3
Left Hand Models
25N914
309028ZAP
Right Hand Models
25N915
12
General Description
System Components (continued)
•
NOTE: The paragraphs that follow describe the
components for the LH pump supply unit only. The
descriptions are the same for the RH pump supply unit.
•
•
•
3/8 in. npt air filter (F) filters air to the pneumatic
layout panel. The 5 micron filter removes particles,
such as dust, moisture, foreign matter and other
contaminants from the compressed air.
Pneumatic Layout Panel (G)
The pneumatic layout panel includes the following
system components. For more information, refer to the
Pneumatic Diagram on page 89.
•
–
–
The two Dura-Flo™ 1800 Pumps (C) have XL
10000™ air motors. The pumps evacuate material
from the drum.
The follower plate (D) is connected to the ram
assembly and is designed to apply an even amount
of pressure to the material in the drum. With the
follower plate in its raised position, the operator
moves a drum inside the frame. The follower plate is
lowered directly on top of the material in the drum.
When pressure is applied to the follower plate, the
material is pumped out of the drum through hoses,
which are attached to the pump outlet ports. When
the drum is empty, the operator raises the follower
plate, removes the empty drum. The process is
repeated when another drum is ready to be
unloaded.
Main Air Inlet Valve (at E) is used to open or shutoff
the air supply to the entire supply unit.
The Ram Position Switch performs the following
three functions:
–
Place the switch in the RAISE position to raise
the follower plate.
Place the switch in the HOLD position to hold
the follower plate in the current position.
Place the switch in the LOWER position to
lower the follower plate.
Junction Box Panel (H)
The junction box panel includes the following system
components. For additional information, refer to the
Electrical Diagram on page 88.
•
System Pressurized lamp is lit when air pressure is
supplied to the system; the lamp is extinguished
when the air supply is depressurized. This occurs
after the Pump On button has been pushed and the
pumps turned on.
•
Pump Active lamp is lit when the air supply is turned
on to the pumps; the lamp is extinguished when the
pumps are inactive, thus turned off. This is activated
by the Pump On pushbutton.
•
Air Pressure On lamp is lit when air pressure to the
system is turned on; the lamp is extinguished when
air pressure to the system is shutoff.
•
Ram Ready lamp is lit when the drum is in position;
the lamp is extinguished when the drum is not in
position.
•
Pump Ready lamp is lit when the pumps are primed
and ready for operation; the lamp is extinguished
when the pumps are not ready for operation.
•
Prime Pump pushbutton turns on the pumps, for
priming. When the pumps are primed, the Pump
Ready lamp turns on. The switch is not used when the
Pump Ready lamp is lit. The Pump Active light will
blink.
•
Pump Reset pushbutton resets the pumps to an active
state. When the pumps are reset, the Pump Active
lamp turns off. The switch is not used when the Pump
Active lamp is lit. The Pump Ready light is on.
•
Pump On pushbutton turns the pumps on and off.
When the pumps are turned on, the Pump Active
lamp also turns on. When the pumps are turned off,
the Pump Active lamp also turns off.
•
Pump No. 1 Air Regulator controls pump speed and
outlet pressure for pump no. 1 by adjusting the air
pressure to the pump.
•
Pump No. 1 Pressure Gauge displays the amount of
air pressure supplied to pump no. 1.
•
Pump No. 2 Air Regulator controls pump speed and
outlet pressure for pump no. 2 by adjusting the air
pressure to the pump.
•
Pump No. 2 Pressure Gauge displays the amount of
air pressure supplied to pump no. 2.
•
Follower Vent Open Valve switch is activated to
open the vent to relieve container pressure.
•
Ram Up pushbutton turns on air pressure to raise
the follower plate.
Bulk Supply Depressurization button opens the
depressurization valve to lower the fluid pressure.
•
Auto Mode On/Off switch puts the system into or out
of automatic operation.
•
13
309028ZAP
Installation
Installation
The installation procedures in this section are intended to
serve as a guide for installing the Uni-Drum system. If
you need more information, contact your Graco
distributor.
NOTE: When raising and lowering the follower plate, be
sure that the unit is unobstructed overhead to avoid
interference with other objects.
The installation procedure includes:
•
Preparing the site
•
Selecting a location for the Uni-Drum
•
Preparing to install the Uni-Drum
•
Installing the Uni-Drum
•
Connecting power to the junction box
•
Grounding the system
•
•
Checking resistance between the junction box and
the true earth ground
Connecting air supply lines to Uni-Drum
Preparing the Site
Ensure that you have an adequate compressed air supply.
Refer to the applicable instruction manual listed in Related
Publications on page 3 to find the air consumption of your
pump. Approximately 450 cfm at 80 psi is required to
operate the pumps at the maximum rate.
Selecting a Location for the Uni-Drum
Refer toTechnical Data on page 90 for ram mounting
and clearance dimensions.
When selecting a location for the Uni-Drum, keep the
following in mind:
1. There should be sufficient space for installing,
servicing, and using the equipment.
• Select an accessible location for the system.
There must be sufficient space around the
system for maintenance.
• Select a convenient location for the equipment.
Check that there is sufficient overhead clearance
for the pump and ram when the ram is in the fully
raised position. Make sure the air regulators for
the pumps and follower plate are fully accessible.
• Make sure the air source for the PLC control
panel and shutoff valves are fully accessible.
• Make sure there is easy and safe access to an
appropriate pneumatic source. Graco
recommends a minimum of 3 feet (0.91 m) of
open space in front of the control panel.
2. Make sure that you will be able to level the base of
the ram using metal shims.
Preparing to Install the System
Before installing the system:
• See component manuals for specific data on
component requirements. Data presented here
pertains to the system only.
• Have all system and subassembly documentation
available during installation.
• Be sure that all non-Graco supplied hoses are
adequately sized and pressure-rated to meet the
system requirements.
Keep the site clear of any obstacles or debris that could
interfere with the installer’s and operator’s movement.
309028ZAP
14
Installation
Installing the Uni-Drum
To install the Uni-Drum, follow the procedure below.
Refer to Technical Data on page 90 for ram mounting
and clearance dimensions.
1. Using equipment such as a forklift or handtruck,
move the Uni-Drum into place on the floor. Remove
the shipping pallet.
2. Level the Uni-Drum, using metal shims.
3. Using the holes in the base as a guide, drill holes for
13 mm (1/2 in.) anchors.
WARNING
EQUIPMENT MISUSE HAZARD
The Uni-Drum system is shipped with
every major component already
attached and weighs approx.
3950 lb (1792 kg). The Uni-Drum system should
never be moved or lifted by one person. To prevent
equipment damage or personal injury, engage an
adequate number of personnel and use a forklift,
hand truck, and sup- port devices, such as a hoist
when moving and installing the Uni-Drum system.
4. Bolt the Uni-Drum to the floor using anchors that are
long enough to prevent the unit from tipping. Refer
to page 86 for more information.
Installing Drum Clamps (25N914 and
25N915 only)
Two drum clamps are provided with the system to be
installed prior to system operation. The clamps hold the
drum in place while removing the follower plate. The end
user must locate and install the clamps in a manner that
will hold the drum to the frame evenly.
CAUTION
Be sure to use as many people as needed when
the frame is being lifted or moved. Exercise care
to avoid jarring, dropping, or tilting the frame while
it is being moved to its installed location to prevent
injury or property damage.
Installing Drum In Position Switch (25N914
and 25N915 only)
A Drum In Position Switch is provided with the system to
be installed prior to system operation. The Drum In
Position Switch indicates that the drum is loaded. The
end user must locate and install the switch in a location
that will indicate the drum is in position. Connect the
switch as shown below to the pneumatic control box.
Connect to
“Drum in position
signal”
15
Connect to
”Drum in position
supply port”
309028ZAP
Installation
Connecting Power to the Junction Box
Perform the following procedure to connect the power to
the junction box panel.
To connect the junction box panel to the electrical
source, do the following:
WARNING
WARNING
ELECTRIC SHOCK HAZARD
Do not connect the junction box panel to a
power source unless you are a trained
electrician. Failure to follow standard
procedures or to observe the necessary precautions
could result in serious bodily injury or equipment
damage.
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury. Have only qualified electricians access the
control assembly.
1. Shut off system power at the main circuit breaker.
2. Remove the cover from the junction box panel.
CAUTION
If power and grounding connections are not done
properly, the equipment may be damaged and the
warranty will be voided.
NOTE: Have a qualified electrician connect the junction
box to a grounded electrical source that has the following
required service ratings:
Description
Voltage:
Hz:
Phase:
Circuit Breaker
309028ZAP
Requirements
120 Vac
24 Vdc
50/60
-
1
-
5 Amp
5 Amp
3. Locate the PLC power terminals KS102 and KS100
on the terminal strip inside the junction box panel.
See Fig. 3. For more information, refer to Electrical
Diagram on page 88.
4. Using the upper wire duct on the left-hand side of
the junction box panel, string two 14 AWG wires
inside the box from the electrical power source.
5. Connect the two 14 AWG wires to power terminals
KS102 (L1, hot) and KS100 (L2, neutral) in the
junction box panel.
6. Seal the area where wires entered the junction box
panel.
7. Replace the cover on the junction box panel.
16
Installation
ISOLATION BLOCKS
(KNIFE SWITCH DISC.
KS100
1001
1002
KS102
1021
1022
Ground Lug
Enclosure (2) TOTAL
Type
1492 -WKD3TP
Terminals
Strain Relief
Fuse Blocks
Terminals
SPARE
SPARE
Wire Way SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
FU136
FU143
SUP136
SUP144
1541
1511
1481
1431
1411
1361
1341
1291
1271
1241
1221
1191
1171
1141
1121
1081
1001
TI0205b
1001
1001
1023
1003
(31) TOTAL
Type 0290.011.25
ENTRELEC
Fig. 4
17
309028ZAP
Installation
Grounding the System
5. Object being sprayed: follow your local code.
6. Fluid supply drum: follow your local code.
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read the
section FIRE AND EXPLOSION
HAZARD on page 7.
1. Pump: use a ground wire and clamp. See Fig. 4.
Verify that the ground screw (GS) is attached and
tightened securely to the air motor. Connect the
clamp (U) of the static ground cable (H) to a true
earth ground. For a ground wire and clamp, order
Part No. 244524.
7. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the pail
on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding
continuity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail, then
trigger the gun.
Checking the Resistance Between the
Pumps and the True Earth Ground
Have a qualified electrician check the resistance
between each pump and the true earth ground. If the
resistance is greater than 1.0 ohms, a different ground
site may be required. Do not operate the system until the
problem is corrected.
8
NOTE: Use a meter that is capable of measuring
resistance at this level.
WLD
*6
Fig. 5
2. Air and fluid hoses: Use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s
recommendations.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock the resistance between the
supply unit components and true earth
ground must be less than 1.0 ohms
4. Spray gun or dispensing valve: ground through
connection to a properly grounded fluid hose and
pump.
309028ZAP
18
Installation
Connecting the Air Supply Lines to the Uni-Drum
Perform the following procedure to connect the input
air supply lines to the Uni-Drum system.
NOTE: Have a qualified technician connect both supply
units to an air supply source that has the following
required ratings:
Connecting Air Supply Lines to the Supply Units
To connect the main air supply line to the LH and RH
supply units, do the following:
Description
Inlet Port Size:
Air Volume:
WARNING
1 in. npt(f)
450 cfm (maximum)
Input Air:
To reduce the risk of overpressurizing your system,
which could result in component rupture and cause
serious injury, never exceed the specified maximum
incoming air pressure to the pumps (see the
Technical Data on page 90).
Requirements
80 psi (5.5 bar, 0.55 MPa)
1. Check the air supply to ensure that it is properly
sized and pressure-rated for this system.
2. Connect the air supply line to the 1 in. npt main air
inlet
Main Air Inlet
Main Air Shutoff Valve
Air Line to Pneumatic Panel
Pilot Valve
Pump Air Manifold
AirLIne Lubricator
Main Air Filter
Ti20917a
Air Line to Pump Air Manifold
TI0204
Air Supply Lines to Pumps
Fig. 6
19
309028ZAP
Installation
Connecting Output Hose to the Pumps
This procedure describes how to connect the fluid
output hoses to the two pumps. It is the customer’s
responsibility to have the fluid supply hose already
installed and ready for connection to the pumps.
NOTE: For more information about the pumps, see
Related Publications on page 3 for the pump
instruction manuals.
NOTE: The fluid supply hose must move freely without
kinking when the pumps move up and down.
Check the fluid supply hose to ensure it is properly sized
and pressure-rated for this system. Use only electrically
conductive hoses. The fluid supply hose should have
spring guards on both ends. Connect the fluid supply
hose to the fluid manifold outlet.
CAUTION
There must be a minimum of 10 feet (3 m) of fluid
supply hose on the outlet to prevent damage to
the unit.
Fluid Supply Hose
Fluid Outlet
Fluid Manifold
TI0139
Fig. 7
309028ZAP
20
Operation
Operation
The operation procedures include:
System Startup
•
Prepare the operator
•
Overview
There are a series of steps that must be followed in
sequential order to startup the system.
•
Junction box panel switches and indicators
System Operation
•
Pneumatic layout panel switches and indicators
•
Initial system startup procedure
Depending upon the system setup, at any time during
operation, the operator can:
•
Daily system startup
•
System shutdown
•
Operation modes for the pumps
•
•
Stop the pumps and relieve ram pressure at the LH
supply unit.
•
Stop the pumps and relieve ram pressure at the RH
supply unit.
Pressure relief procedure
•
Shutdown the system.
•
Air motor icing
•
Preventive maintenance schedule
•
System operation procedures
At the supply unit, the follower plate must be raised to
load the drum into the supply unit. The follower plate is
lowered by the operator directly into the drum. The
pumps are turned on, the follower plate is pressurized,
and material is pumped from the drum through the outlet
ports on the pumps via a supply hose to one or more
targeted applications.
Prepare the Operator
All persons who operate the equipment must be trained
in the safe, efficient operation of all system components
as well as the proper handling of all fluids. All operators
must thoroughly read all instruction manuals, tags, and
labels before operating the equipment.
Overview
The Uni-Drum supply system uses two air driven
reciprocating pumps on the LH supply unit and two air
driven reciprocating pumps on the RH supply unit. Each
supply unit pumps material from a 300 gallon (1200 liter)
drum.
General Functional Description
The LH and RH supply units can operate at the same
time or as independent units. Generally, the Uni-Drum
system is setup to operate as redundant units. This
means that the RH unit is held in reserve on standby
until the drum underneath the LH unit has been emptied, and vice versa.
Operating a redundant system allows the operator to
maintain a continuous supply of material without
interruption. The operator is afforded sufficient time to
replace an empty drum at one supply unit while the
drum at the other supply unit is being emptied.
21
Supply Unit Operation
The Uni-Drum supply system can be setup to alternate
between the LH and RH supply units. This dual supply
system setup (controlled by others) virtually eliminates
material replenishment downtime.
The Uni-Drum supply system allows the operator to load
the material drum into the RH supply unit while the LH
supply unit drum is being emptied. When the supply unit
changeover occurs, the operator unloads the empty
drum at the LH supply unit while the RH supply unit
drum is being emptied. The cycle is repeated as many
times as needed.
System Shutdown
For system shutdown, the operator turns off the pumps
and depressurizes the system. Depending upon the
type of material, the operator may choose to raise the
follower plate from the drum or keep the follower plate
lowered in the drum to prevent the material from being
contaminated. Some materials will harden or congeal
when exposed to air or used past their shelf life. Material
should be kept covered when it is not being used and
uncovered when it is ready to use.
309028ZAP
Operation
Junction Box Panel Switches and Indicators
Use the table and Fig. 7 when operating the switches and reading the indicator on the junction box panel.
Button/Switch
What it Does
• Primes both displacement pumps with material, making the
pumps ready to operate.
PRIME PUMP pushbutton
PUMP RESET pushbutton
• Lights PUMP READY light.
• Restarts the pumps after the pumps were turned off.
PUMP ON pushbutton
• Lights PUMP ACTIVE light
• Activates the pumps.
Bulk Supply Depressurization
pushbutton
• Deactivates the pumps.
• Opens the depressurization valve to lower the fluid supply
pressure.
AUTO MODE ON/OFF switch
Indicator
Indicator
Light is
SYSTEM
PRESSURIZED light
ON
OFF
PUMP ACTIVE light
ON
OFF
AIR PRESSURE ON
light
RAM READY light
ON
OFF
ON
OFF
PUMP READY light
ON
OFF
309028ZAP
• Places fluid dispensing system into Automatic or
Manual mode.
Meaning
System is pressurized.
System is depressurized.
Pumps are active; air is available to the pumps.
Pumps are inactive; air is unavailable to the pumps.
Air pressure is available to the pumps for use.
Air pressure is not available to the pumps for use.
Follower plate is ready for use.
Follower plate is not ready for use.
Pumps are primed and ready to use.
Pumps are not ready to use.
22
Operation
Junction Box Panel Switches and Indicators (continued)
BULK SUPPLY
DEPRESSURIZATION
PUMP
RREADY
RAM
READY
PRIME
PUMP
AIR PRESS
ON
PUMP
ACTIVE
SYSTEM
PRESSURIZED
PUMP
RESET
LOCAL
REMOTE
PUMP
ON
REMOTE
MODE
195320 and 119773 Panel Shown
Fig. 8
23
309028ZAP
Operation
Pneumatic Layout Panel Switches and Indicators
Use the table and Fig. 8 when operating the switches and reading the indicators on the pneumatic layout panel.
Button/Switch/Gauge
What it Does
A
PUMP NO. 1 PRESSURE Air Gauge
Indicates the air outlet pressure setting from pump no. 1.
B
PUMP NO. 2 PRESSURE Air Gauge
Indicates the air outlet pressure setting from pump no. 2.
C
PUMP NO. 1 REGULATOR Control Knob
Controls pump speed and outlet pressure by adjusting
the air pressure to pump no. 1.
D
FOLLOWER VENT Directional Valve
Opens and closes the vent that relieves air pressure
from the follower plate assembly.
E
PUMP NO. 2 REGULATOR Control Knob
Controls pump speed and outlet pressure by adjusting
the air pressure to pump no. 2.
F
RAM UP Pushbutton
Raises the follower plate.
Ref
G
RAM POSITION
Switch
RAISE
Allows the follower plate to raise.
HOLD
Holds the follower plate in the current position.
LOWER
H
Panel Air Inlet Valve
309028ZAP
Lowers the follower plate.
Opens air supply line to the pneumatic layout panel.
24
Operation
B
A
B
E
FOLLOWER VENT
AUTO OPEN
C
G
F
H
24K172 Panel Shown
TI0202
Fig. 9
25
309028ZAP
Operation
Flushing the System Before Initial Use
Flushing the system before its initial use can prevent
material contamination, which may cause the material to
fail or perform poorly.
CAUTION
Flush the system before performing the initial
material loading procedure. The system was
factory-tested using a light soluble oil, a soybean
oil, or some other oil as tagged. Flush the system
to avoid contaminating the material that has been
designated for initial material loading.
To flush the system, perform the following procedure:
1. Select the material for the initial material load.
2. Verify whether the factory-test oil and the initial
material load are compatible:
a.
b.
If the two substances are compatible, omit the
remaining steps in this procedure and perform
the Initial System Startup Procedure on
page 27.
If the two substances are incompatible,
perform the remaining steps in this procedure
to flush the system.
WARNING
Use fluids and solvents that are chemically
compatible with the equipment wetted parts. See the
Technical Data sections of all the equipment
manuals. Always read the material manufacturer’s
literature before using fluid or solvent in this pump.
3. Select a drum containing a compatible material that
can dissolve, clean, and eliminate the factory test oil
from the system. If necessary, check with the
material supplier for a recommended flush material.
4. Before flushing, be sure the entire system and
flushing drums are properly grounded. Refer to
Grounding the System, on page 18.
5. Perform steps 9 through 15 of the Initial System
Startup Procedure on page 27 to load the drum
containing the solvent.
6. Run the flush material through the system for
approximately 1 to 2 minutes.
7. Remove the drum containing the flush material.
Adjusting the Lid Holder Before Initial Use
1. Adjust the lower lid holder channel as low as it will
go on the side of the ram post. The channel should
be 1 in. (25 mm) higher from the floor in the front
compared to the back.
2. Loosen the upper lid holder channel. place the lid in
the center of the lower channel. Lower the upper
channel until it contacts the lid. Tilt the rear of the
upper channel down 1/2 to 1 in. (13 to 25 mm) and
tighten all bolts.
3. The lid should roll in and out from the front and not
roll out the rear.
309028ZAP
26
Operation
Initial System Startup Procedure
WARNING
PRESSURIZED FLUID HAZARD
To reduce the risk of serious bodily injury,
such as fluid injection or splashing fluid in
the eyes or on the skin, always wear eye
protection and protective clothing when
installing, operating, or servicing this
dispensing system.
MOVING PARTS HAZARD
Moving equipment parts can cause
personal injury, including severing of
hands or fingers. Make sure all personnel
are clear of moving parts before operating
the equipment
CAUTION
The use of a non-compatible lubricant can cause
material contamination or inadequate performance.
Use only a lubricant compatible with the material to be
pumped. Check with the material supplier for a
recommended lubricant.
To help avoid damage to equipment, do not use a
drum of material that has been dented or otherwise
damaged; damage to the follower plate wiper may
result.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce risk of injury or equipment
damage.
Settings for Initial System Startup
The initial system startup procedure contains the
checklist of settings, adjustments, and procedural steps
that must be completed before the system is ready for
daily operation.
NOTE: Complete the startup procedure for the LH
supply unit first. Then, repeat the startup procedure for
the RH supply unit.
Perform the initial system startup procedure as follows:
1. Check all material hoses and fittings to ensure
tightness and to prevent any material leakage.
2. Check all system air lines. Make sure that all routing
of air lines will not interfere with any moving
components within the system.
3. Fill the packing nut/wet cup on both pumps 1/3 full
with Graco throat seal liquid (p/n 206995). Refer to
instruction manual 308147 or 308148 for details.
4. Open the main air shut off valve, making air
pressure available to the unit. See Fig. 5.
5. At the pneumatic layout panel (H), open the panel
air inlet valve, making air pressure available to the
pneumatic layout panel. See Fig. 5 and Fig. 8.
6. Adjust both pump main air regulators to 0 psi.
7. Follower Vent switch should be in AUTO position.
8. Set the RAM POSITION switch to RAISE.
9. Press the RAM UP valve switch to raise the follower
plate above the height of the material drum to be
used.
10. Set the RAM POSITION switch to HOLD.
• Make sure all material hose connections
are secure.
• Do not pressurize the system until you
have verified the system is ready and it
is safe to do so.
27
309028ZAP
Operation
Load Material
11. Roll a drum into the supply unit under the elevated
follower plate.
21. Close the bleed-type air valve and pump bleeder
valve.
22. Repeat these steps for Pump No. 2.
NOTE: Whenever a drum change is required, remove
the cover from the drum of new material by holding it
level and lifting it straight up. Tipping the cover may
allow accumulated dirt to spill into the drum, which may
result in damage to the material and equipment.
NOTE:
•
If the pump does not prime properly, which may
occur with heavier, high viscosity fluids, increase
the air pressure to the ram.
12. IMPORTANT: Lubricate the follower plate wiper
with a lubricant that is compatible with the material
to be pumped. Check with your material supplier for
compatibility.
•
If fluid is forced out around the top wiper, ram
pressure is too high; decrease the air pressure to
the ram.
•
Ram pressure adjustments may be carried out
using the dual regulator inside the pneumatic
panel, where the upper regulator knob controls the
downward pressure of the ram, and the lower
regulator knob controls the upward pressure of the
ram.
NOTE: Before lowering the follower plate assembly into
the drum, make sure that nothing is between the
follower plate and the drum, or between the ram tie bar
and the top of the ram posts.
13. Remove bleed sticks at the base of each pump.
14. Lower the follower plate as follows:
a. Set the Ram Position selector to LOWER.
b. Lower the follower plate until the material is
evident in the bleedstick ports.
c.
Set the Ram Position selector to HOLD.
d. Replace the bleedsticks.
e. Set the Ram Position selector to LOWER.
15. Close both pump #1 and pump #2 inlet valves
(located on top of air motor).
16. To prime the pump, press the PRIME PUMP button.
17. Set the pump air pressure to 30 psi.
23. After closing the bleed valve, return Pump No. 1 and
2 regulator to its normal pump pressure setting.
24. Open the air motor ball valves.
25. Open the ball valve in the outlet manifold from
Pump No. 1 and 2.
26. Remove the waste containers, clean up any spilled
material, and dispose of the waste material
properly.
27. Press the PUMP RESET button to restore the
system to operation.
28. Check that the following indicators are lit:
•
SYSTEM PRESSURIZED
•
AIR PRESS. ON
•
RAM READY
•
PUMP READY
18. Check that the AIR PRESS. ON indicator is lit.
19. Use a catch device to bleed the pump. Slowly open
Pump No. 1 bleeder valve. Back off the adjustment
screw several turns; do not remove the screw.
20. Slowly open the bleed-type air valve to the air
motor. Allow the pump to cycle slowly until all air
escapes and material flows free of air from the
bleeder valve.
309028ZAP
28
Operation
Adjusting the Pump Regulators
NOTE: Both pumps must operate at the same cycles
per minute rate to prevent the occurrence of uneven
drum evacuation.
NOTE: For the maximum air input pressure for each
pump see the appropriate manual as indicated on the
chart on page 2).
29. Run the system under normal conditions. Adjust the
PUMP NO. 1 REGULATOR to the desired setting as
follows:
a.
b.
Turn the knob clockwise to increase air
pressure or counterclockwise to decrease air
pressure (see Fig. 8).
Check the air gauge to verify the air pressure
setting.
30. Repeat step 29 to adjust the air regulator for the
PUMP NO. 2 REGULATOR.
Adjusting the Ram-Up and Ram-Down Regulators
31. At the pneumatic layout panel (see Fig. 7), open the
hinged cover.
32. Set the RAM POSITION switch to RAISE and push
the RAM UP pushbutton. Verify that the follower
plate (5) elevates at the desired speed. If not, do the
following:
a. Adjust the RAM –UP REGULATOR. Turn the
knob clockwise to increase the amount of air
pressure. Check the air gauge to verify that air
pressure was increased. See Fig. 8.
b. Verify that regulator R3 is set to 5 to 10 psi
(.035 to .07 MPa, 0.35 to 0.7 bar).
CAUTION
Improper setting of the Regulator R3 while the
selector is in the HOLD position, can cause the
plate to drop and operator injury. Failure to
adjust the Regulator R3 properly can cause
the platen to exit the drum at a high rate of
speed, risking damage to the machine.
c.
Repeat step 32.a until the ram raises at the
desired speed.
33. Set the RAM POSITION switch to DOWN while
observing the air gauge inside the panel.
34. Adjust the RAM – DOWN REGULATOR to 50 psi
(0.34 MPa, 3.4 bar) as follows (see Fig. 8):
a.
Turn the knob clockwise to increase air
pressure or counterclockwise to decrease air
pressure.
b.
Check the air gauge to verify the air pressure
setting.
35. Close and secure the hinged cover.
Preventing Pump Cavitation
NOTE: Cavitation occurs when the pump cylinder did
not fully load with material on the upstroke, and a cavity
forms in the material after the pump changes to the
downstroke. Perform step 36 when there is pump
cavitation. If cavitation is not occurring, omit step 36 and
proceed to step 37.
36. To prevent cavitation from occurring, perform the
following steps:
a. Press the PRIME PUMP switch to prime the
pumps and fill the material passages.
b. Verify that the PUMP READY light turns on.
c.
Lower the air motor air pressure until cavitation
stops.
d. Increase the ram down pressure.
29
309028ZAP
Operation
Regulator R3
Ram Up
Regulator
Ram Down
Regulator
9327A
Fig. 10
309028ZAP
30
Operation
b. Verify that the follower plate lowers to the limit set
point: a level between 1 -4 in. (25.4 -101.6 mm)
from the bottom of the drum.
Adjusting the Low Limit Switch
NOTE: When the low limit switch is activated, the
pumps are normally turned off automatically by a
customer-supplied control, and a second set of pumps
begin pumping.
c.
37. Adjust the low limit switch as follows:
Adjust the low limit switch to activate at the level
defined in step 37.b See Fig. 10.
a. At the junction box panel (see Fig. 7), set the
RAM POSITION switch to LOWER, allowing the
follower plate to activate the lower limit switch.
Limit Switches
1 to 4 in. (25.4 to 101.6 mm)
Pin 1
Pin 3
Pin 5
Pin 2
Pin 4
TI0200
Fig. 11
31
309028ZAP
Operation
Daily System Startup
This procedure is normally provided by the integrator.
System Shutdown
This procedure is normally provided by the integrator.
Restarting the System
2. To restart the system, do the following:
a.
Open the main air shut off valve to the supply
unit (see Fig. 11).
b.
At the junction box panel, press the PUMP
RESET switch which restarts the pumps after
the pumps were turned off (refer to Fig. 7).
Emergency Stop
When an emergency stop is required, do the following:
Stopping the System
Main Air
Shut off
Valve
1. To stop the system, close the main air shut off valve
(see Fig. 11) to the supply unit.
Ti20917a
Fig. 12
309028ZAP
32
Operation
Pressure Relief Procedures
At the pneumatic layout panel, do the following:
These procedures describe how to relieve pressure
from the system.
1. Close the main air shut off valve (B). See Fig. 12.
Fluid Pressure Relief Procedure
2. Open any downstream fluid valves, such as the ball
seat applicators on the ram assemblies, that may be
part of the system.
This procedure describes how to relieve pressure on the
follower plate and in the pumps. Use this procedure
whenever you shutoff the pumps and before checking or
adjusting any part of the system.
WARNING
MOVING PARTS HAZARD
Follow the Pressure Relief Procedures
below before checking or repairing the
follower plate or any other part of the
system and when shutting down the system. Keep
hands and fingers away from the follower plate,
pump inlets, and the drum when raising or lowering
the follower plate to reduce the risk of pinching or
amputating hands or fingers.
3. Press the depressurization button on the electrical
panel.
4. After the pressure is relieved from the follower plate,
raise the follower plate by setting the RAM
POSITION switch to the RAISE position.
NOTE: In order to fully relieve system pressure,
including ram cylinders, the steps in the pneumatic
pressure relief procedure must be performed.
During operation, also keep hands and fingers away
from limit switches to reduce the risk of pinching or
amputating hands or fingers.
WARNING
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. Material under
high pressure can be injected through the skin and
cause serious injury. To reduce the risk of an injury from
injection, splashing fluid, moving parts, follow the
Pressure Relief Procedures whenever you:
•
are instructed to relieve the pressure
•
stop dispensing material
•
check or service any of the system equipment
•
install or clean the follower plate wipers.
33
309028ZAP
Operation
Pneumatic Pressure Relief Procedure
This procedure describes how to relieve pressure on the
pneumatic panel and cylinders. Use this procedure
whenever you perform ram assembly service on the
piston rod seal or the ram piston.
WARNING
MOVING PARTS HAZARD
Follow the Pressure Relief Procedure
below before checking or repairing the
follower plate or any other part of the
system and when shutting down the system. Keep
hands and fingers away from the follower plate, pump
inlets, and the drum when raising or lowering the
follower plate to reduce the risk of pinching or
amputating hands or fingers.
6. After the air pressure has been relieved, remove the
RAM DOWN air line running from the top of the
pneumatic control box to the ram cross bar (G).
7. Close the main air inlet on header (B).
8. Leave the drain cock open and the RAM DOWN
airline removed until service is complete.
9. After service is complete, close drain cocks and
make all pneumatic connections. Perform the
Adjusting the Ram-Up and Ram-Down
Regulators procedure, page 29.
B
G
During operation, also keep hands and fingers away
from limit switches to reduce the risk of pinching or
amputating hands or fingers.
E
A
WARNING
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. Material under
high pressure can be injected through the skin and
cause serious injury. To reduce the risk of an injury from
injection, splashing fluid, moving parts, follow the
Pressure Relief Procedure whenever you:
•
are instructed to relieve the pressure
•
stop dispensing material
•
check or service any of the system equipment
•
install or clean the follower plate wipers.
1. Follow Fluid Pressure Relief Procedure, page 33.
2. Fully lower the ram by setting the RAM POSITION
switch (A) to LOWER. Leave switch in LOWER
position.
3. Open the door on the pneumatic control box (E).
4. Adjust the air pressure to 0 PSI for the RAM DOWN
regulator. Refer to the gauge on the Ram Down
Regulator (Fig. 11) and R3 Regulator to verify the
ram has been depressurized.
5. Slowly open the drain cock located on the bottom of
the air cylinders (D).
309028ZAP
D
Fig. 13
Fig. 14
34
Operation
Preventive Maintenance Schedule
The operating conditions of your particular system
determine how often maintenance is required. Establish
a preventive maintenance schedule by recording when
and what kind of maintenance is needed, and then
determine a regular schedule for checking your system.
Changing Empty Drums
NOTE: After the automatic pump crossover has taken
place, immediately replace the empty drum with a new,
full drum. If both Uni-Drums become empty at the same
time:
NOTE:
•
Material will stop being delivered to the dispenser
•
Air may enter the supply hose or pipe header
•
Pump runaway could occur, resulting in damage to
the pumps.
Drum Changing Procedure
To remove an empty drum and load a new, full drum:
1. Verify that the two front and rear drum clamps are
engaged on the Uni-Drum ram base.
2. Check that the pump air is turned off. On the
junction box panel the PUMP ACTIVE and PUMP
READY indicators are not lit.
3. Check that the RAM UP air regulator is set to 60 psi
(maximum).
4. Close the two ball valves at the outlet manifold at
the rear of the Uni-Drums.
5. To raise the follower plate:
a. Set the RAM POSITION control to RAISE, then
wait 5 seconds.
NOTE: If RAM UP button is pushed within 5 seconds,
the vent valves may open before the pressure under the
follower plate is relieved causing the material to bleed
past the vents.
b. Push and hold the RAM UP button as the
follower plate slowly rises.
6. With the ram raised and the RAM POSITION control
set to RAISE, pull the drum clamps back and
remove the empty drum, using a suitable lifting
device.
WARNING
MOVING PARTS HAZARD
Use a long-handled flat-bladed ice scraper
if it is necessary to scrape the bottom of the
follower plate. Do not put your hands
between the plate and the drum.
7. IMPORTANT: Being careful not to damage the
follower plate wipers, wipe or scrape any material
buildup from the follower plate and wipers, and
properly dispose of the waste material.
NOTE: When you open a new drum, take care to
remove the cover by holding it level. Tipping the cover
may allow accumulated dirt to spill into the material,
which can damage the equipment. Also check that the
drum is not damaged or dented.
8. Remove the cover from the new drum and remove
any other packing from the drum, exposing the
material. Make sure there are no foreign objects on
the surface of the material.
9. Position the new drum, using a suitable lifting
device, under the raised follower plate. Check that
the RAM READY indicator is lit.
10. IMPORTANT: Lubricate the follower plate wipers
with a lubricant approved by the material
manufacturer.
11. Push the two front and rear drum clamps forward
until engaged.
WARNING
PRESSURIZED FLUID HAZARD
To reduce the risk of serious bodily injury,
such as fluid injection or splashing fluid in
the eyes or on the skin, always wear eye
protection and protective clothing when
installing, operating, or servicing this
dispensing system.
MOVING PARTS HAZARD
Moving equipment parts can cause personal
injury, including severing of hands or fingers.
Make sure all personnel are clear of moving
parts before operating the equipment.
35
309028ZAP
Operation
CAUTION
The use of a non-compatible lubricant can cause
material contamination or inadequate
performance. Use only a lubricant compatible with
the material to be pumped. Check with the material
supplier for a recommended lubricant.
To help avoid damage to equipment, do not use
a drum of material that has been dented or
otherwise damaged; damage to the follower plate
wiper may result.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce risk of injury or equipment
damage:
19. Slowly open the bleed-type air valve to the air
motor. Allow the pump to cycle slowly until all air
escapes and material flows free of air from the
bleeder valve.
20. Close the bleed-type air valve and pump bleeder
valve.
21. Repeat these steps for Pump No. 2.
NOTE:
•
If the pump does not prime properly, which may
occur with heavier, high viscosity fluids, increase
the air pressure to the ram.
•
If fluid is forced out around the top wiper, ram
pressure is too high; decrease the air pressure to
the ram.
•
Ram pressure adjustments may be carried out
using the dual regulator inside the pneumatic
panel, where the upper regulator knob controls the
downward pressure of the ram, and the lower
regulator knob controls the upward pressure of the
ram.
• Make sure all material hose connections
are secure.
• Do not pressurize the system until you
have verified the system is ready and it is
safe to do so.
12. Remove the bleed sticks from the follower plate.
22. After closing the bleed valve, return Pump No. 1 and
2 regulator to its normal pump pressure setting.
NOTE: Before lowering the ram into the drum, make
certain that nothing is between the follower plate and
the drum, or between the ram tie bar and the top of the
ram posts.
23. Open the air motor ball valves.
13. Lower the follower plate as follows:
a. Set the Ram Position selector to LOWER.
25. Remove the waste containers, clean up any spilled
material, and dispose of the waste material
properly.
b. Lower the follower plate until the material is
evident in the bleedstick ports.
26. Press the PUMP RESET button to restore the
system to operation.
c.
Set the Ram Position selector to HOLD
d. Replace the bleedsticks.
24. Open the ball valve in the outlet manifold from
Pump No. 1 and 2.
27. Check that the following indicators are lit:
e. Set the Ram Position selector to LOWER.
•
SYSTEM PRESSURIZED
14. Close both pump #1 and pump #2 inlet valves
(located on top of the air motor).
•
AIR PRESS. ON
•
RAM READY
•
PUMP READY
15. To prime the pump, press the PRIME PUMP button.
16. Set the pump air pressure to 30 psi.
17. Check that the AIR PRESS. ON indicator is lit.
18. Use a catch device to bleed the pump. Slowly open
Pump No. 1 bleeder valve. Back off the adjustment
screw several turns; do not remove the screw.
309028ZAP
36
Ram Assembly Troubleshooting
Ram Assembly Troubleshooting
Problem
Cause(s)
Solution(s)
Ram won’t raise or lower
Closed main air valve or clogged air line Open air valve, clear air line
Not enough air pressure
Increase ram pressure
Worn or damaged piston
Replace piston. See procedure on
page 52.
Ram air pressure too high
Decrease ram air pressure
Fluid squeezes past follower plate Ram air pressure too high
wipers
Worn or damaged wipers
Decrease ram air pressure
Ram raises or lowers too fast
Pump won’t prime properly, or
pumps air
37
Replace wipers. See procedure on
page 55.
Not enough ram air pressure
Increase ram pressure
Worn or damaged ram piston
Replace ram piston. See procedure
on page 52.
Bent drum has stopped follower plate
Replace drum
309028ZAP
Pump Troubleshooting
Pump Troubleshooting
For additional information about the displacement pump, refer to Related Publications on page 3 to find the
applicable instruction manual.
Problem
Cause(s)
Rapid downstroke or upstroke
(pump cavitation)
Air is trapped in pump.
Solution(s)
Bleed air from the pump using this
procedure:
1. Place a waste container under the
pump bleed port.
2. Press the PRIME PUMP button to
turn on air to the pump.
3. Allow material to flow from the bleed
port until it is air-free.
4. Release the PRIME PUMP button to
shut off air to the pump. Close the
bleed port.
5. Turn air on to the pump and set the
pump air regulator for normal
operation.
Downstroke: Lower check in pump Rebuild and replace pump, as necessary.
is worn.
Material leaks around pump outlet
Upstroke: Upper check in pump is
worn.
Outlet fitting is loose.
Tighten outlet fitting.
Material leaks around bleed port
Bleed port fitting is loose.
Tighten bleed port fitting.
Pump won’t move up or down
Problem with air motor.
See Air Motor Troubleshooting chart
on page 39.
Foreign object lodged in pump.
Remove object and rebuild pump
assembly.
WARNING
To reduce the risk of serious injury
whenever you are instructed to relieve
pressure, always follow the Pressure
Relief Procedures (page 33).
Before attempting to dislodge a foreign
object:
1. Relieve system pressure.
2. Remove the pump from the air motor.
Wet-cup leaks
309028ZAP
Worn throat packings.
Tighten wetcup. Replace throat packings.
38
Air Motor Troubleshooting
Air Motor Troubleshooting
For additional information about the air motor, refer to Related Publications on page 3 to find the applicable
instruction manual.
Problem
Cause(s)
Solution(s)
Air motor will not shift directions,
stalled in DOWN position
Main air valve spool is dirty or damaged Clean/rebuild main air valve.
Air motor will not shift directions,
stalled in UP position
Air motor stalled halfway between
the top and bottom
Air continually exhausting around
air motor shaft.
Air motor shaft seal is damaged
Replace air motor shaft seal.
Air continually exhausting around
the air valve/slide valve
Air valve/slide valve gasket is damaged
Replace the valve gasket.
Air continually exhausting from
muffler while the motor is idle
Internal seal damage
Rebuild air motor.
Oil leaking from exhaust port
Too much lubricant mixed in with the air Reduce lubricant supply.
supply
Frost build-up on muffler
Air motor operating at high pressure, or
high cycle rate
39
Reduce pressure, cycle rate, or duty
cycle of the air motor.
309028ZAP
Junction Box Panel Troubleshooting
Junction Box Panel Troubleshooting
Problem
Cause(s)
Power from PLC control panel is
The knife switch disconnect contacts
ON, but no indicator lights are lit at (KS100 and KS102) are open.
junction box panel.
One or more fuses blown.
Voltage limit to circuits in junction box
panel was exceeded.
Solution(s)
Check the PLC power connections at
customer’s site.
Replace the blown fuse(s). Check
FU136 and FU143 located inside the
knife switch disconnect blocks.
Check the surge suppressors
SUP136 and SUP144. Replace if
required. Reset power to unit.
Pneumatic Layout Panel Troubleshooting
Problem
Cause(s)
Solution(s)
Ram will not move up or down.
Main air valve on box is not open.
Open valve.
Ram will not move up.
Air supply to unit is not on.
Turn on air supply.
Direction valve is not in the UP position. Set direction valve to the UP
position.
RAM UP button is not pushed.
Push RAM UP button.
Resistance in drum is too great.
Turn air pressure up to 60 psi. The
ram may take a few minutes to
withdraw from the container.
Insufficient lubrication of the follower
plate seal.
After the plate has been removed
from the container, clean the seal
Pumps will not operate.
Air regulator is set too low.
Increase air pressure setting.
Vent valve will not open.
FOLLOWER VENT switch is not in
AUTO position.
Put FOLLOWER VENT switch in
AUTO position.
309028ZAP
40
Routine Maintenance
Routine Maintenance
Flushing the System
Cleaning the System
CAUTION
Flush the pump:
•
Before the first use
•
When changing material or fluid part number or
brand
•
Before fluid can dry or settle out in a dormant pump
(check the shelf life or pot life of catalyzed fluids)
•
Before storing the pump.
Flush with a fluid that is compatible with the fluid you are
pumping and with the wetted parts in your system. Check
with your fluid manufacturer or supplier for
recommended flushing fluids and flushing frequency.
WARNING
FIRE AND EXPLOSION HAZARD
Before flushing, read the section FIRE AND
EXPLOSION HAZARD on page 7. Be sure
the entire system and flushing pails are
properly grounded. Refer to Grounding the
System on page 18.
To flush the system, perform the following procedure:
1. Place a drum of compatible flush material under the
follower plate.
2. Run the pumps and circulate the flush material
through the system for approximately 1 to 2 minutes
or until the solution is clean.
3. Remove the drum containing the flush material from
under the follower plate.
4. Return the system to current readiness condition.
Cleaning the system after using it can prevent
material contamination, which may cause the
material to fail or perform poorly. Do not load new
material into a contaminated system.
Clean the system to avoid untimely equipment
malfunctions and to ensure that system
components operate efficiently
To clean the system, perform the following procedure:
WARNING
MOVING PARTS HAZARD
Use a long-handled flat-bladed ice scraper if
it is necessary to scrape the bottom of the
follower plate. Do not put your hands
between the plate and the drum.
1. IMPORTANT: Being careful not to damage the
follower plate wipers, wipe or scrape any material
buildup from the follower plate and wipers, and
properly dispose of the waste material.
2. Apply a generous amount of lubricant to the follower
plate wipers.
3. To clean vent valve:
a. Put FOLLOWER VENT switch to ON position.
This opens valve to allow you to clean out dried
material.
b. When vent is clean, put switch to AUTO
position.
4. Return the system to current readiness condition.
Wiper Lubrication
It is extremely important that the follower plate wipers be
thoroughly lubricated between drum changes. The
follower plate may stick without lubrication.
41
309028ZAP
Junction Box Panel Service
Junction Box Panel Service
This part of the manual provides information about the
following junction box panel components:
4. Verify that the replaced component operates
correctly.
•
Indicator light and pushbutton switch replacement
•
Light bulb replacement
•
Fuse replacement
Light Bulb Removal
•
Surge suppressor replacement
Remove the light bulb as follows:
NOTE: Refer to Junction Box Parts on page 82 while
servicing the junction box panel.
Indicator Light and Pushbutton Switch
Removal
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could cause
an electric shock or other serious injury.
Have only qualified electricians access the control
assembly.
1. Shut off power to the junction box panel.
2. At the junction box panel, remove the cover from the
junction box panel.
3. Disconnect the lead wires from the terminals on the
switch. For wiring information, refer to the Electrical
Diagram on page 88. If necessary, label the wires
to facilitate reconnection after replacing the
component.
4. Loosen two screws which clamp the fixture to the
cover. Rotate and remove the outer ring on the
defective component counterclockwise to remove
the light lens or switch. Separate the parts and
remove them from the cover.
Indicator Light and Pushbutton Switch
Replacement
5. Return the system to current readiness condition.
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could cause
an electric shock or other serious injury.
Have only qualified electricians access the control
assembly.
1. Shut off power to the junction box panel.
2. Unscrew and remove the indicator light lens.
3. Gently press and rotate the bulb counterclockwise,
1/4 of a turn, unlocking the bulb from its socket.
Remove the bulb from the socket.
Light Bulb Replacement
Replace the light bulb as follows:
1. Insert the light bulb in the socket.
2. Gently press and rotate the bulb clockwise, 1/4 of a
turn to lock the bulb in its socket.
3. Replace the lens.
4. Reapply power to the junction box panel.
5. Verify that the light bulb operates correctly.
6. Return the system to current readiness condition.
1. Reverse steps 2 through 4 in the previous
paragraph.
2. For wiring information, refer to the Electrical
Diagram on page 88.
3. Reapply power to the junction box panel.
309028ZAP
42
Junction Box Panel Service
KS100
1001
1002
KS102
1021
1022
Ground Lug
Enclosure
Wire Way
TI0205b
Ground
Fuses
Terminals
Surge Suppressors
(2) TOTAL
Type
1492 -WKD3TP
Terminals
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
FU136
FU143
SUP136
SUP144
1541
1511
1481
1431
1411
1361
1341
1291
1271
1241
1221
1191
1171
1141
1121
1081
1001
1001
1001
1023
1003
(31) TOTAL
Type 0290.011.25
ENTRELEC
Fig. 15
43
309028ZAP
Junction Box Panel Service
Fuse Removal
Fuse Replacement
Remove the fuse as follows:
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could cause
an electric shock or other serious injury.
Have only qualified electricians access the control
assembly.
Replace the fuse as follows:
NOTE: Check the new fuse to ensure that it matches
the amp rating of the failed fuse.
1. Press both ends of the new fuse evenly into place in
the fuse holder. See Fig. 14.
2. Reinstall the cover on the junction box panel.
1. Shut off power to the junction box panel.
3. Reapply power to the junction box panel.
2. At the junction box panel, remove the cover from the
junction box panel.
4. Verify that the fuse operates correctly.
3. Locate the failed fuse on the terminal strip.
Reference Fig. 14 for the fuse terminal
identification.
5. Return the system to current readiness condition.
4. Carefully remove the fuse from the fuse holder.
309028ZAP
44
Surge Suppressor Removal
Surge Suppressor Removal
Surge Suppressor Removal
Remove the surge suppressor as follows:
4. Remove the two screws and surge suppressor from
the terminal strip.
Surge Suppressor Replacement
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could cause
an electric shock or other serious injury.
Have only qualified electricians access the control
assembly.
Replace the surge suppressor as follows:
1. Install the new surge suppressor into place on the
terminal strip using the two screws. See Fig. 14.
2. Reinstall the cover on the junction box panel.
1. Shut off power to the junction box panel.
3. Reapply power to the junction box panel.
2. At the junction box panel, remove the cover off the
junction box panel.
4. Verify that the fuse operates correctly.
3. Locate the failed surge suppressor on the terminal
strip. Reference Fig. 14 for the surge suppressor
terminal identification.
5. Return the system to current readiness condition.
Pressure Switch
Solenoid Valve
T10196
Fig. 16
45
309028ZAP
PLC Interface Accessory Kit Service
PLC Interface Accessory Kit Service
This part of the manual provides information about the
following PLC interface accessory kit components:
•
Valve assembly bank replacement
•
Pressure switch assembly replacement
Valve Assembly Bank Replacement
Remove the valve assembly bank that is mounted below
the junction box panel as follows:
NOTE: The valve assembly bank has two solenoids
(SOL139 and SOL147) that are used as switches to
control pump operation. SOL139 depressurizes the
pumps. If the output is high (open), pumps will
depressurize. SOL147 turns air on to the pumps.
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could cause
an electric shock or other serious injury.
Have only qualified electricians access the control
assembly.
1. Shut off power to the junction box panel.
Valve Assembly Removal
2. At the junction box panel, remove the cover off the
junction box panel.
309028ZAP
3. Locate the valve assembly (203) that is attached to the
mounting plate (201) below the junction box panel
(217). See Fig. 15.
4. Disconnect the two cables (216) from the terminal strip
inside the junction box panel (217) for the valve
assembly (203) bank. For wiring information, refer to
the Electrical Diagram on page 88.
5. Remove four cap screws (205), the lock washers
(206), and the valve assembly (203) from the
mounting plate (201).
Valve Assembly Replacement
6. Install the new valve assembly (203) on the mounting
plate (201) using the four cap screws (205) and lock
washers (206). See Fig. 15.
7. Reconnect the two cables (216) on the terminal strip
inside the junction box panel (217) for the valve
assembly (203) bank. For wiring information, refer to
the Electrical Diagram on page 88.
8. Reinstall the cover on the junction box panel.
9. Reapply power to the junction box panel.
10. Perform the Daily System Startup procedure on
page 32 at the applicable supply unit (LH or RH).
11. Verify that the valve assembly (203) bank operates
correctly.
12. Return the system to current readiness condition.
46
PLC Interface Accessory Kit Service
Pressure Switch Assembly Replacement
Remove the pressure switch assembly that is mounted
below the junction box panel as follows:
NOTE: The pressure switch (PS108) turns air pressure
on the system.
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could cause
an electric shock or other serious injury.
Have only qualified electricians access the control
assembly.
1. Shut off power to the junction box panel.
Switch Removal
2. Remove the cover from the junction box panel.
3. Locate the pressure switch assembly (202) that is
attached to the mounting plate (201) below the
junction box panel (217). See Fig. 15.
4. Disconnect the 5-pin cord (211) from the pressure
switch assembly (202). For wiring information, refer to
the Electrical Diagram on page 88.
5. Disconnect the end of the lead wire from the pressure
switch assembly (202). Leave the other end of the
lead wire connected to the valve assembly bank (203).
6. Remove the two cap screws, the lock washers, and
the pressure switch assembly (202) from the mounting
plate (201).
Switch Replacement
To replace the switch, follow the switch removal steps in
reverse order.
47
309028ZAP
PLC Interface Accessory Kit Service
Junction Box Panel
Mounting Plate
Valve Assembly
Pressure Switch
Assembly
Screw, Washer
90° Elbow
Elbow
Tube Muffler
Fitting
TI0208
Fig. 17
309028ZAP
48
Pneumatic Layout Panel Service
Pneumatic Layout Panel Service
The pneumatic layout panel service procedures include:
•
WARNING
Filter/element replacement
Filter/Element Replacement
Listed below are the filters used with the ram assembly
on the Uni-Drum supply system.
•
The air filter between the air supply source and both
air motors. See Fig.17.
•
The air filter between the air supply source and the
pneumatic layout panel. See Fig. 18.
To replace an air filter/element, do the following:
1. At the pneumatic layout panel, do the following:
a.
Press the PUMP AIR OFF to shutoff the air
supply at both pumps.
b.
Close the main air inlet valve.
c.
Turn the shutoff valve under the panel to the
off position.
2. At the junction box panel, do the following:
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedures on page 33.
3. Relieve the pressure.
4. At the junction box panel, verify that the SYSTEM
PRESSURIZED and RAM READY lights turn off.
Filter Removal
5. Turn the air filter counterclockwise to unscrew the
filter from its mounting.
Filter/Element Replacement
6. Replace the old air filter element with a new filter
element.
7. Clean the sight glass, if necessary. Reinstall the
sight glass back on its threaded mounting. Tighten
the sight glass.
a.
Press the PUMP OFF switch, turning off air to
both pumps (see Fig. 7).
8. Perform the Daily System Startup procedure on
page 32.
b.
Verify that the PUMP ACTIVE and AIR
PRESS ON lights turn off.
9. Check for air leakage around the filter.
10. Return the system to current readiness condition
Main Air
Filter
Ti20917a
Pneumatic
Panel Air
Filter
Fig. 18
Fig. 19
49
309028ZAP
Pneumatic Layout Panel Service
FOLLOWER VENT
AUTO OPEN
TI0202
Fig. 20
309028ZAP
50
Ram Assembly Service
Ram Assembly Service
Piston Rod Seal Service (Fig. 20)
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedures on page 33.
1. Relieve the air pressure. Follow the Pneumatic
Pressure Relief Procedure on page 34.
2. Remove the four nuts and lockwashers holding the
tie bar to the rods. Remove the tie bar.
3. Remove the guide sleeve retaining ring by gripping
the ring tab with a pair of pliers and rotating the ring
out of its groove.
4. Remove the guide sleeve by sliding it off of the rod.
Four 1/4 in. -20 holes are provided to ease removal
of the guide sleeve.
WARNING
Ring, Seal Guard
Sleeve
Ring
O-ring
O-ring
7056A
Refer to Repair Kit 918110.
Fig. 21
Do not use pressurized air to remove the guide
sleeve or piston. Failure to follow this instruction may
result in personal injury.
5. Inspect the parts for wear or damage. Replace as
necessary.
6. Install new O-rings and seal guard. Lubricate the
packings with O-ring lubricant.
7. Slide the guide sleeve onto the rod and push it into
the cylinder. Replace the retaining ring by feeding it
around the guide sleeve groove.
8. Reinstall the tie bar using the nuts and lockwashers.
Torque to 40 ft-lb (54 N•m).
51
309028ZAP
Ram Assembly Service
Ram Piston Service (Fig. 21)
WARNING
6. Install new O-ring seals on the piston rod and the
piston. Lubricate the piston and seals. Reinstall the
piston and retaining ring.
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedures on page 33.
7. Carefully insert the piston into the cylinder and push
the rod straight down into the cylinder. Add 3
ounces of lubricant to each cylinder after inserting
the piston.
1. Relieve the air pressure. Follow the Pneumatic
Pressure Relief Procedure on page 34.
8. Slide the guide sleeve onto the piston rod. Reinstall
the retaining ring and tie bar, as explained under
Piston Rod Seal Service (Fig. 20).
2. Remove the tie bar as explained under Piston Rod
Seal Service (Fig. 20).
3. Remove the guide sleeve and slide it off of the
piston rod.
Ring
O-ring
WARNING
Do not use pressurized air to remove the guide
sleeve or piston. Failure to follow this instruction may
result in personal injury.
4. Carefully pull the piston rod straight up out of the
cylinder. If the rod is cocked to one side, the piston
or inside surfaces of the cylinder could be damaged.
5. Carefully lay the piston and rod down so the rod will
not be damaged or bent. Remove the lower piston
retaining ring. Slide the piston off the piston rod.
309028ZAP
O-ring
Band
Piston
Ring
7056A
Fig. 22
52
Ram Assembly Service
NOTE: The first limit switch closes when the follower
plate reaches the preset low limit level in the drum. The
second limit switch closes when the follower plate
reaches the preset empty level in the drum. Both limit
switches provide inputs to the PLC interface.
The ram assembly service procedures include:
•
Low/Empty limit switch replacement
•
Ball seat applicator repair procedure
•
Servicing the pumps
Switch Removal
3. Between the two limit switches (305), locate the
faulty switch. See Fig. 22.
Low/Empty Limit Switch Replacement
To replace the lower limit switch, do the following:
4. Disconnect the wiring (301) for the limit switch at its
power source. For reference, use the wiring
diagram shown in Fig. 22.
1. Perform the System Shutdown procedure
provided by the integrator at the applicable supply unit
(LH or RH).
5. Mark the surface on the ram limit bracket using a
felt-tipped pen to ensure that the new lower limit
switch is installed in the same spot.
WARNING
6. Measure the distance from the mounting bracket
(306) to the outer diameter of the limit switch roller
to ensure that the new roller is installed in the same
position.
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could cause
an electric shock or other serious injury.
Have only qualified electricians access the control
assembly.
7. Remove three cap screws (302), the lock washers
(303), the plain washers (304), and the limit switch
(305) from the limit bracket (306). See Fig. 22.
2. Shut off power to the junction box panel.
NOTE: When raising and lowering the follower plate, be
sure that the unit is unobstructed overhead to avoid
interference with other objects.
301
302, 303, 304
Pin 1
305
Pin 3
Pin 5
306
Pin 2
Pin 4
307, 308
309, 310
311
TI0200
Fig. 23
53
309028ZAP
Ram Assembly Service
Switch Replacement
8. Install the new limit switch (305) on the limit bracket
(306) using the three cap screws (302), lock washers
(303), and plain washers (304). See Fig. 22.
9. Reconnect the wiring (301) for the limit switch at its
power source. For reference, use the wiring diagram
shown in Fig. 22.
10. Make sure that the limit switch roller is positioned in
the same location per the measurement in step 6.
See Fig. 22.
11. Reinstall the cover on the junction box panel.
Depressurization Valve (Ball Seat
Applicator) Repair Procedure
Refer to instruction manual 3A1792 for the ball seat
applicator (V1M350) service procedures and parts
information.
Servicing the Pumps
When the pumps and air motors require service, refer to
the applicable instruction manual, listed below, for
detailed information.
12. Reapply power to the junction box panel.
13. Perform the Daily System Startup procedure
provided by the integrator at the applicable supply
unit (LH or RH).
14. Verify that the limit switch operates correctly.
Form
308147
308148
15. Return the system to current readiness condition.
308213
309028ZAP
Description
Carbon Steel Dura-Flo™
Pump 1800 with XL
10000™ Air Motor
Stainless Steel Dura-Flo™
Pump 1800 with XL 10000™
Air Motor
XL 10000™ Air Motor
P/N
237555
241957
24X856
54
Ram Assembly Service
Replacing Wipers (Fig. 23)
1. Perform the System Shutdown procedure provided
by the integrator.
2. To replace worn or damaged wipers (412), raise the
follower plate up out of the drum. Remove the drum
from the base. Wipe the fluid off the follower plate.
Refer to the Changing Empty Drums procedure on
page 35.
3. Separate the wiper joint (A) and bend back the
strapping (413a) covering the clamp setscrew
(413c). See Detail A of Fig. 23. Loosen the
setscrew, pull the end of the strapping through the
clamp (413b) and remove the wiper.
4. Slide the strapping (413a) through the new wiper
(412). Slide the clamp (413b) onto the new
strapping and bend the strapping back
approximately 3 in. (76 mm). Insert the strapping
through the clamp a second time. See Detail B of
Fig. 23.
5. Install the wipers on the follower plate. Position the
wipers so that their joints (A) are 180° apart.
NOTE: You will need the special banding tool (C) shown
in Detail C of Fig. 23 to tighten the strapping. Order Part
No. 168092 Banding Tool.
6. Grip the strapping (413a) with the tool (C) as shown.
With your thumb on the gripper lever (E), turn the
tool handle (F) clockwise to apply tension.
NOTE: Be careful not to pull the cutting handle (D) until
you are ready to cut the strapping in step 8.
7. Continue turning the tool handle until you see the
strapping stop moving through the clamp (413b).
Stop turning the handle.
8. Tighten the setscrew (B) with a wrench (G). Pull the
cutting handle (D) to cut. Remove the tool (C). Bend
the strapping back over the clamp (413b).
9. Pound the wiper all the way around with a rubber
1
Detail A
413c
412
Detail B
413a
413b
02949
H
412
A
2
413b
413a
02946
413b
413c
Detail C
G
E
1
Slide the clamp onto the
strapping and bend the strapping
back approximately 3 in. (76 mm).
2
Turn clockwise to apply tension.
3
Cut the strapping and bend it
back over the clamp.
C
D
2
F
413a
05712
Fig. 24
55
309028ZAP
Ram Assembly Service
Pump Removal
•
Air motor exhaust kit
(Refer to System Parts Diagram; page 57.)
•
Pump proximity switch kit
•
Pump grounding wire
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedures on page 33.
1. Relieve the air pressure from the air motors and ram
assembly to be serviced.
2. Move the RAM POSITION switch to HOLD.
3. Close the pump outlet ball valves and relieve the
fluid pressure from the pumps at the pump bleed
valve on the ram assembly to be serviced.
4. Using an overhead lifting device, attach and secure
a chain capable of lifting the weight of the pump
assembly to the eye at the top of the air motor.
NOTE: For effective pump removal, the lifting point
must be directly above the pump and capable of moving
sideways. The lifting action should be the “chain fall”
type that allows a slow upward and downward
movement.
NOTE: Check the Technical Data page in the separate
pump manual to find the weight of the pump being
serviced. For example, Graco XL 10000™ 45:1 SST
Pump (24Y208) weighs 236 lb (106 kg) per Form
308148.
5. Detach the air hose from the air motor.
6. Detach the fluid supply hose at the pump outlet.
NOTE: When loosening the pump and the air motor
fasteners in steps and below, ensure the chain slack is
taken up to prevent the pump assembly from falling.
7. On the follower plate adapter, loosen and rotate or
remove four lugs and hex bolts holding the flange of
the pump lower.
8. On the underside of the air motor, remove the bolts
securing the air motor to the motor support
brackets. It may be necessary to move or remove
some brackets for effective pump removal.
9. Detach any other connections to the pump
assembly to ensure the pump is free of attachments
before removal. Possible connections include:
309028ZAP
NOTE: When lifting the pump in step below, ensure the
lifting chain does not damage the air controls mounted
at the top of the ram cross-members.
10. Using a “chain fall” style lifting device, slowly pull the
pump upward a few inches until the base of the
pump clears the pump mounting adapter and the air
motor clears the support brackets.
11. Pull the pump assembly out of the ram assembly
and guide the pump assembly downward to the
floor, placing the base of the pump on a wood
surface and taking care not to damage the seal area
of the pump inlet housing.
12. Remove the gasket and o-ring (items 32 and 33)
from the pump adapter. They should be discarded
and replaced when the pump is reinstalled.
13. Clean excess and hardened material from the pump
adapter on the follower plate.
14. Ensure that material is not rising through the pump
adapter in the follower plate. If material is flowing
upward, move the RAM POSITION switch to RAISE
until the flow stops, then move the switch back to
HOLD.
15. Move the pump assembly to a suitable work area
and repair the pump using the appropriate Graco
Instruction Manual.
Pump Installation
(Refer to System Parts Diagram; page 57.)
1. When the pump is serviced and tested and ready to
be replaced in the Uni-Drum Ram, perform the
steps of the Pump Removal procedure in reverse
order.
2. It is recommended that the pump be tagged with the
type and date of repair and the name of the
technician who performed the repair.
3. Before returning the reassembled pump to
production use, it must be primed with material and
air removed from the material. Follow the Pump
Instruction Form and the pump material bleeding
procedure from the Changing Empty Drums
section on page 35.
56
Parts
Parts
246981, 248306, 249339, 253676, 258910 - 47:1 Left Hand Supply Unit
246982, 248307, 249340, 253677, 258911 - 47:1 Right Hand Supply Unit
249152, 249341, 234972, 258956 - 35:1 Left Hand Supply Unit
249153, 249342, 234973, 258957 - 35:1 Right Hand Supply Unit
121
67, 72
See detail F
119
68
26
66
26
46
70
71
76
7
30
15
46
26
60
99, 100
27
97
93, 94
16
101
98
14
35, 48
38
17
13
47
3
4
9, 41, 48, 49
Detail F
117
49, 31
6
1
5, 9, 49
80
33
52
57
309028ZAP
Parts
123 112 111
122
110
96
95
73, 115
87
86
14, 73, 74
113
114
24
19
116
10
20
53
25
See detail C
10
Detail C
309028ZAP
58
Parts
Ref
Part
No.
No.
Description
1
3
4
5
6
7
8
9
10
11
12
13
241902
C58306
C58361
C20450
196073
15D133
517272
100132
C12509
195319
158585
24Y227
ELEVATOR, assembly 300 gallon
Description
Qty
1 No.
No.
PLATE, adjuster
2 29
C12039
HOSE, air
1
BRACKET, support
2 30
C19032
UNION, swivel
3
U-BOLT
4 31
111803
SCREW, cap, hex
8
CLAMP
109495
O-RING
8 33
2
CLAMP, support
4 34
115438
VALVE, ball
1
CLAMP, support
109570
WASHER
2 35
8
WASHER, flat
12 36
214656
HOSE, coupled, 10 ft.
1
TUBE, nylon
64 ft. 37
C19381
ELBOW, tube, (m)
1
PANEL, pneumatic layout
054139
TUBE, nylon
4
1 38
NIPPLE
2 39
C19200
WASHER
4
PUMP, 47:1 stainless steel
1 40
C19124
SCREW, cap, hex
4
41
(248306, 248307, 249339, 249340,
C19126
SCREW, cap, hex
4
42
253676, 253677 only)
517254
CLIP, tube
3
PUMP, 47:1 stainless steel
1 43
110299
RIVET, blind
3
44
(246981, 248982, 258910, 258911 only)
106149
FILTER, air, 1/2 npt
1
PUMP, 35:1 stainless steel
521975
UNION, pipe
1 45
2
(249152, 249153, 249341, 249342,
234963
UNION, pipe (234972, 234973,
2
234972, 234973, 258956, 258957 only)
253676, 253677, 258910, 258911,
U-BOLT
6
258956, 258957 only)
NUT, lock
6 46
118854
VALVE, ball
4
TUBE, coiled
2 47
24Y228
PUMP, 47:1 stainless steel
1
BRACKET, mounting
2
(248306, 248307, 249339, 249340,
COUPLING, reducing
253676, 253677 only)
2
TEE, pipe
24Y227
PUMP, 47:1 stainless steel
2
1
NIPPLE, reducing, hex
3
(246981, 248982, 258910, 258911 only)
VALVE, check 1/2 in.
1
24Y206
PUMP, 35:1 stainless steel
1
UNION, swivel
3
(249152, 249153, 249341, 249342,
ELBOW, street
2
234972, 234973, 258956, 258957 only)
ELBOW, street (234972, 234973,
2 48
100307
NUT, hex
12
49
253676, 253677, 258910, 258911,
100133
WASHER, lock
20
50
258956, 258957 nly)
617200
BRACKET, support
1
COVER, left
1 52
112698
SWIVEL, elbow (m)
4
SCREW, socket head, flat
12 53
196084
COVER, right
1
NIPPLE, hex
7 54
C52751
PLATE, limit switch
1
NIPPLE, hex (234972, 234973,
7 55
C19810
SCREW, cap
2
56
253676, 253677, 258910, 258911,
195454
BRACKET, limit
1
57
258956, 258957 only)
C19197
WASHER
4
VALVE, check
2 58
C19204
WASHER, lock
4
59
VALVE, check (234972, 234973,
C20003
SCREW, cap
4
2
253676, 253677, 258910, 258911,
Continued on next page.
258956, 258957 only)
24Y228
24Y192
14
15
16
17
18
19
20
21
22
23
C51238
101566
517288
241844
C38457
106464
C20463
C57799
C19019
C38324
119900
24
25
26
196085
C20811
C20490
119893
27
246929
234960
59
Qty
Ref
Part
309028ZAP
Parts
Ref
No.
Part
No.
60
61
62
63
64
65
66
C07431
104227
C19138
100016
100018
C07560
15D140
15G091
67
C19491
119901
68
69
V1M350
C20485
114373
70
156172
15G092
71
234558
234962
72
C19661
119896
73
74
76
C19213
C19185
234428
234961
77
243255
24V775
309028ZAP
Description
CONNECTOR, sealed
NUT, lock
SCREW, cap, hex
WASHER, lock
WASHER, lock spring
SWITCH, limit, with arm
MANIFOLD, three-way
(249341, 249342, 249152, 249153,
248306, 248307, 249339, 249340,
246981, 246982 only)
MANIFOLD, three-way
(234972, 234973, 258910, 258911,
258956, 258957, 253676, 253677 only)
TEE, fitting, 1-1/4 npt(f)
TEE, fitting, 1-1/4 npt(f)
(234972, 234973, 258910, 258911,
258956, 258957, 253676, 253677 only)
APPLICATOR, ball seat, 1/2 in.
NIPPLE, hex
NIPPLE, hex (234972, 234973,
253676, 253677, 258910, 258911,
258956, 258957, 253676, 253677 only)
COUPLING, hex pipe
COUPLING, hex pipe
(234972, 234973, 253676, 253677,
258910, 258911, 258956, 258957 only)
HOSE, coupled
HOSE, coupled (234972, 234973,
253676, 253677, 258910, 258911,
258956, 258957 only)
FITTING, 1-1/4 x 1/2 in.
FITTING, 1-1/4 x 1/2 in.
(234972, 234973, 253676, 253677,
258910, 258911, 258956, 258957 only)
WASHER, lock
NUT, jam hex
HOSE, coupled
HOSE, coupled (234972, 234973,
253676, 253677, 258910, 258911,
258956, 258957 only)
KIT, accessory, PLC interface
(246981, 246982, 248306,
248307, 249152, 249153, 234972,
234973, 253676, 253677 only)
KIT, accessory, PLC interface
(249339, 249340, 249341,
249342, 258910, 258911, 258956,
258957 only)
Ref
Qty No.
2
2
2
6
2
2
1
1
1
1
1
1
3
1
1
1
1
1
1
10
4
2
2
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
107
108
109
110
111
112
113
114
115
116
117
118
1 119
120
121
122
1
123
124
130
Part
No.
114158
195356
158555
113332
112859
501014
104172
113532
617202
617337
C19800
617338
517455
C56572
196510
119417
516102
114508
233041
617180
101535
101533
617204
100549
C20461
515147
115419
214849
517290
C19438
16U204
114112
113093
C20378
100469
502526
246994
120163
Description
ADAPTER, fitting
KIT, accessory
NIPPLE, reducing
VALVE, ball
FILTER, air
ACTUATOR, air
FITTING, 1/8NPT x 1/4 tube
FITTING, elbow, female
MANIFOLD, air bracket
COLLAR, clamp
SCREW, cap, socket head
BRACKET, mounting
SWITCH
CABLE
COUPLING, housing
SCREW
CLAMP, pipe
NIPPLE
PLATE, ram, Neoprene
ROD, connecting
NUT
WASHER, spring lock
CARRIAGE, weldment, 300 gallon
ELBOW, street
NIPPLE, reducing, hex
REGULATOR, air, 1/2p
ADAPTER, fitting
LUBRICATOR
HOSE
ELBOW, fitting, 90°
TUBE, unidrum, air inlet
CONNECTOR, fitting (f)
CONNECTOR, pipe
BRANCH, fitting
SCREW, cap, hex
VALVE, air three-way
VALVE, pressure, bleed
KIT, safety, lockout (not shown)
(234972, 234973,
253676, 253677 only)
C20487
NIPPLE, hex, 3/4-14 npt
206996
FLUID, TSL, 1 gal
617569
FITTING, reducer, plug-in
15D936
FITTING, male connector,
1/2 npt x 5/8-12
16U212
CLAMP, 1.25 in. OD pipe
94/0398/99 FITTING, 90°, 1” NPT
103347
VALVE, safety, 100 psi
Qty
1
1
2
2
1
2
4
4
1
4
4
2
2
2
2
2
1
1
4
8
8
1
2
2
2
2
2
2
2
1
1
2
2
2
2
2
1
1
1
1
2
2
1
2
2
60
Parts
24U642 - 35:1 Left Hand Supply Unit
24U643 - 35:1 Right Hand Supply Unit
See detail A
See detail F
120
124
46
17, 35, 48
71
125 126 5
14
9, 41
48, 49
60
76
27
18, 23, 26, 45
2
105
99, 100
101
5, 9, 49
117
13
47
3
4
1
15
6, 31, 49
98
33
61
52
97
309028ZAP
Parts
D
D
detail B
detail F
Section D-D
See detail B
detail A
309028ZAP
62
Parts
Ref
No.
Part
No.
Description
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
241902
C58306
C58361
C20450
196073
15D133
517272
100132
C12509
195319
158585
24Y192
C51238
101566
517288
241844
119899
106464
C20463
C57799
C19019
119900
196085
C20811
119893
234960
ELEVATOR, assembly 300 gallon
PLATE, adjuster
BRACKET, support
U-BOLT
CLAMP
CLAMP, support
CLAMP, support
WASHER, flat
TUBE, nylon
PANEL, pneumatic layout
NIPPLE
PUMP, 35:1 stainless steel
U-BOLT
NUT, lock
TUBE, coiled
BRACKET, mounting
COUPLING, reducing, sst
TEE, pipe
NIPPLE, reducing, hex
VALVE, check 1/2 in.
UNION, swivel
ELBOW, street, sst
COVER, left
SCREW, socket head, flat
NIPPLE, hex, sst
VALVE, check, sst
Ref
Qty No.
29
1 30
2 31
2 33
4 34
8 35
4 36
2 37
12 38
64 ft. 39
1 40
2 41
1 42
6 43
6 44
2 45
2 46
2 47
2 48
3 49
1 50
3 52
2 53
1 54
12 55
7 56
2 57
58
59
Part
No.
C12039
C19032
111803
109495
115438
109570
214656
C19381
054139
C19200
C19124
C19126
517254
110299
106149
234963
118854
24Y206
100307
100133
617200
112698
196084
C52751
C19810
195454
C19197
C19204
C20003
Description
HOSE, air
UNION, swivel
SCREW, cap, hex
O-RING
VALVE, ball
WASHER
HOSE, coupled, 10 ft.
ELBOW, tube, (m)
TUBE, nylon
WASHER
SCREW, cap, hex
SCREW, cap, hex
CLIP, tube
RIVET, blind
FILTER, air, 1/2 npt
UNION, pipe, sst
VALVE, ball
PUMP, 35:1 stainless steel
NUT, hex
WASHER, lock
BRACKET, support
SWIVEL, elbow (m)
COVER, right
PLATE, limit switch
SCREW, cap
BRACKET, limit
WASHER
WASHER, lock
SCREW, cap
Qty
1
3
8
2
1
8
1
1
4
4
4
4
3
3
1
2
4
1
12
20
1
4
1
1
2
1
4
4
4
Continued on next page.
63
309028ZAP
Parts
Ref
No.
Part
No.
Description
60
61
62
63
64
65
66
67
68
69
71
72
73
76
77
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
C07431
104227
C19138
100016
100018
C07560
94/0398/99
119901
V1M350
114373
24U667
127119
C19213
24U666
24V775
114158
195356
158555
113332
112859
501014
104172
113532
617202
617337
C19800
617338
517455
C56572
196510
CONNECTOR, sealed
NUT, lock
SCREW, cap, hex
WASHER, lock
WASHER, lock spring
SWITCH, limit, with arm
FITTING, 90°, 1” NPT
TEE, fitting, 1-1/4 npt(f), sst
APPLICATOR, ball seat, 3/4 in.
NIPPLE, hex, sst
HOSE, coupled, sst
BUSHING, reducing, sst
WASHER, lock
HOSE, coupled, sst
KIT, accessory, PLC interface
ADAPTER, fitting
KIT, accessory
NIPPLE, reducing
VALVE, ball
FILTER, air
ACTUATOR, air
FITTING, 1/8NPT x 1/4 tube
FITTING, elbow, female
MANIFOLD, air bracket
COLLAR, clamp
SCREW, cap, socket head
BRACKET, mounting
SWITCH
CABLE
COUPLING, housing
309028ZAP
Qty
2
2
2
6
2
2
2
1
1
3
1
1
10
2
1
1
1
2
2
1
2
4
4
1
4
4
2
2
2
2
94
95
96
97
98
99
100
101
102
103
104
107
108
109
110
111
112
113
114
115
116
117
118
120
121
122
119417
516102
114508
233041
617180
101535
101533
617204
100549
C20461
515147
115419
214849
517290
C19438
16U204
114112
113093
C20378
100469
502526
246994
190724
206996
617569
15D936
123
124
125
126
127
130
16U212
617203
517284
C20449
16F241
103347
SCREW
CLAMP, pipe
NIPPLE
PLATE, ram, Neoprene
ROD, connecting
NUT
WASHER, spring lock
CARRIAGE, weldment, 300 gallon
ELBOW, street
NIPPLE, reducing, hex
REGULATOR, air, 1/2p
ADAPTER, fitting
LUBRICATOR
HOSE
ELBOW, fitting, 90°
TUBE, unidrum, air inlet
CONNECTOR, fitting (f)
CONNECTOR, pipe
BRANCH, fitting
SCREW, cap, hex
VALVE, air three-way
VALVE, pressure, bleed
NIPPLE, hex, sst
FLUID, TSL, 1 gal
FITTING, reducer, plug-in
FITTING, male connector,
1/2 npt x 5/8-12
CLAMP, 1.25 in. OD pipe
BAR, support
MANIFOLD, y-pipe
BOLT, U
FITTING, adapter
VALVE, safety, 100 psi
2
1
1
4
8
8
1
2
2
2
2
2
2
2
1
1
2
2
2
2
2
1
1
1
2
2
1
1
1
2
1
2
64
Parts
232729, 47:1 Left Hand Supply Unit, with carbon steel pump
232839, 47:1 Left Hand Supply Unit, with stainless steel and ceramic pump
232730, 47:1 Right Hand Supply Unit, with carbon steel pump (shown)
232840, 47:1 Right Hand Supply Unit, with stainless steel and ceramic pump
246921, 47:1 Right Hand Supply Unit, with stainless steel pump
246922, 47:1 Left Hand Supply Unit, with stainless steel pump
255666, 47:1 Left Hand Supply Unit, with carbon steel pump
255665, 47:1 Right Hand Supply Unit, with carbon steel pump
R
GRACO
BULK SUPPLY
DEPRESSURIZATION
LT100
LT101
G
G
LT104
G
PB200
LT102
G
LT103
G
PB201
OFF
PB202
ON
B
B
A
BE
P
P
AE
AE
BE
65
A
AUTO MODE
309028ZAP
Parts
Ref
No.
Part
No.
1
241902
2
241891
243510
3
4
5
6
7
C58360
C58361
C20450
196073
241837
8
9
10
11
12
13
C19126
100132
101566
100307
158585
24Y211
24Y221
24Y225
14
15
C51238
241838
24V775
16
241840
17
19
241844
106464
Description
ELEVATOR, assembly 300 gallon;
see page 82
FOLLOWER PLATE ASSY;
(232729, 232839, 246921, 255666
only)
see page 73
(232730, 232840, 246922, 255665
only)
PLATE, adjuster, Uni-Drum
BRACKET, pump support
U-BOLT
CLAMP
KIT, accessory, pneumatic;
see page 69
SCREW, cap hex head
WASHER, flat
NUT, lock
NUT, hex; 3/8-16
NIPPLE
PUMP, 47:1; carbon steel;
(232729, 232730, 255665,
255666 only; see manual 308147)
PUMP, 47:1; stainless steel and
ceramic
(232839, 232840 only;
see manual 308148)
PUMP, 47:1; stainless steel;
(246921, 246922 only;
see manual 308148)
U-BOLT; 6 in. tube x 1/2-13un
KIT, accessory, PLC interface;
see page 78
(232729, 232730, 232839,
232840 only)
KIT, accessory, PLC interface;
see page 78
(255665, 255666 only)
KIT, accessory, depressurization;
see page 68
BRACKET, mounting
TEE, pipe; 1 in. npt
Ref
Qty No.
1 20
21
1 22
24
25
26
29
30
2 31
2 32
4 33
8 34
1 35
36
4 39
16 40
6 41
12 42
1 43
2 44
45
46
2 47
2
4
1
49
50
1 52
53
54*
1 56
Part
No.
C20463
C57799
C19019
196085
C20811
C20490
C12039
C19032
111803
184086
109495
115438
109570
214656
243488
100133
C38457
521850
C38324
233058
521975
118854
24Y212
Description
NIPPLE, fitting hex reducing; 1 in.
VALVE, check; 1/2 npt (fbe)
FITTING, union, swivel
COVER, left
SCREW, socket, flat head
FITTING, nipple, hex
HOSE, air; 1 in. ID
SWIVEL, adapter, union
SCREW, cap, hex head
GASKET
O-RING
VALVE, ball; 1 in. locking
WASHER, plain
HOSE; 1/2 in ID; 10 ft long
KIT, accessory; see page 71
LOCKWASHER, spring; 3/8 in.
COUPLING, reducing
VALVE, check
ELBOW, street
HOSE, coupled
UNION, pipe
VALVE, ball
PUMP, 47:1; carbon steel;
(232729, 232730, 255665,
255666 only; see manual 308147)
24Y222
PUMP, 47:1; stainless steel and
ceramic;
(232839, 232840 only;
see manual 308148)
24Y226
PUMP, 47:1; stainless steel;
(246922, 246921 only;
see manual 308148)
101535
NUT, hex; 7/8 in.
101533
LOCKWASHER, spring; 7/8 in.
112698
ELBOW, swivel; 1/8 npt
196084
COVER, right
103347
VALVE, safety, 100 psi
94/0398/99 FITTING, 90°, 1” NPT
Qty
1
1
2
1
12
2
1
3
8
2
1
1
8
2
2
20
2
2
2
2
2
2
1
1
1
4
4
4
1
2
2
2
1
* Not Shown
309028ZAP
66
Parts
Ref
No.
Part
No.
Description
Qty
The following items are for 255665, 255666,
only. Items are not shown.
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
77
78
79
80
81
67
C07431
104227
C07560
100018
C19138
100016
C19810
195454
C19197
C19204
C20003
C52751
104172
501014
502526
115419
C19185
C19213
114158
C12509
195356
CONNECTOR, sealed
NUT, lock
SWITCH, limit with arm
WASHER, lock, spring
SCREW, cap, hex head
WASHER, lock
SCREW, cap, socket head
BRACKET, limit
WASHER, plain
WASHER, lock #10
SCREW, cap, socket head
PLATE, limit switch
FITTING, limit switch
ACTUATOR, air
VALVE, air, 3-way
FITTING, adapter
NUT, jam, hex
WASHER, lock
FITTING, adapter, Y
TUBE, nylon
KIT, accessory
2
2
2
2
2
6
2
1
4
4
4
1
4
2
2
2
4
4
1
12 ft
1
309028ZAP
Parts
25N914 - 35:1 Left Hand Supply Unit
25N915 - 35:1 Right Hand Supply Unit
19
30
34
12
122
83
12
62,64
65
61
57,58,59
29
119
68
56
124
72
85
55,63
54
20
21
22
36
37
116
39,40,73
11
69
50
44
7
107
84
117
10
22
15
80 †
121
99,100
60
101
16
93,94
98
14
35,48
17
97
47
38
13
3
4
126,30
1
9,41,48,49
†
5,9,49
49,31
6
10
52
†
† The end user must locate and install these parts (see
Installation on page 14).
309028ZAP
68
Parts
123
73,115
114
111
122
96 95
110
93
87
116
88
86
63,89
91
90
14,73,74
79
92
113
71
67,72
26
26
66
46
26
112 24
10 10
103 104
127 19
20 127 53 25
32 108
102
109
8
46
76
81 82
76
46
26
46
27
23
45
26
27
23
45
26
18
69
26
18
309028ZAP
Parts
Ref
Part
No.
No.
Description
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
29
30
31
33
34
35
36
37
38
39
40
41
44
45
24M558
C58306
C58361
C20450
196073
15D133
517272
100132
C12509
195319
158585
24Y192
C51238
101566
517288
241844
119899
106464
C20463
C57799
C19019
119900
196085
C20811
119893
234960
C12039
C19032
111803
109495
115438
109570
214656
C19381
054139
C19200
C19124
C19126
106149
234963
ELEVATOR, assembly 300 gallon
PLATE, adjuster
BRACKET, support
U-BOLT
CLAMP
CLAMP, support
CLAMP, support
WASHER, flat
TUBE, nylon
PANEL, pneumatic layout
NIPPLE
PUMP, 35:1 stainless steel
U-BOLT
NUT, lock
TUBE, coiled
BRACKET, mounting
COUPLING, reducing
TEE, pipe
NIPPLE, reducing, hex
VALVE, check 1/2 in.
UNION, swivel
ELBOW, street
COVER, left
SCREW, socket head, flat
NIPPLE, hex
VALVE, check
HOSE, air
UNION, swivel
SCREW, cap, hex
O-RING
VALVE, ball
WASHER
HOSE, coupled, 10 ft.
ELBOW, tube, (m)
TUBE, nylon
WASHER
SCREW, cap, hex
SCREW, cap, hex
FILTER, air, 1/2 npt
UNION, pipe
Qty
1
2
2
4
8
4
2
12
64 ft.
1
2
1
6
6
2
2
2
2
3
1
3
2
1
12
7
2
1
3
8
2
1
8
1
1
4
4
4
4
1
Ref
No.
46
47
48
49
50
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
71
72
73
74
76
77
79
80
81
82
83
84
85
86
Part
No.
118854
24Y206
100307
100133
617200
112698
196084
C52751
C19810
195454
C19197
C19204
C20003
C07431
104227
C19138
100016
100018
C07560
15G091
C19491
V1M350
114375
234558
127119
C19213
C19185
234961
243255
114158
195356
158555
113332
112859
501014
104172
113532
Description
VALVE, ball
PUMP, 35:1 stainless steel
NUT, hex
WASHER, lock
BRACKET, support
SWIVEL, elbow (m)
COVER, right
PLATE, limit switch
SCREW, cap
BRACKET, limit
WASHER
WASHER, lock
SCREW, cap
CONNECTOR, sealed
NUT, lock
SCREW, cap, hex
WASHER, lock
WASHER, lock spring
SWITCH, limit, with arm
MANIFOLD, three-way
TEE, fitting, 1-1/4 npt(f)
APPLICATOR, ball seat, 1/2 in.
NIPPLE, hex
HOSE, coupled
FITTING, 1-1/4 x 1/2 in.
WASHER, lock
NUT, jam hex
HOSE, coupled
KIT, accessory, PLC interface
ADAPTER, fitting
KIT, accessory
NIPPLE, reducing
VALVE, ball
FILTER, air
ACTUATOR, air
FITTING, 1/8NPT x 1/4 tube
FITTING, elbow, female
Qty
4
1
12
20
1
4
1
1
2
1
4
4
4
2
2
2
6
2
2
1
1
1
1
1
1
10
4
2
1
1
1
2
2
1
2
4
4
2
Continued on next page.
309028ZAP
70
Parts
Ref
No.
Part
No.
87 617202
88 617337
89 C19800
90 617338
91 517455
92 C56572
93 18A185
94 119417
95 516102
96 114508
97 233041
98 617180
99 101535
100 101533
101 617204
102 100549
103 C20461
104 515147
71
Ref
Qty No.
Description
MANIFOLD, air bracket
COLLAR, clamp
SCREW, cap, socket head
BRACKET, mounting
SWITCH
CABLE
COUPLING, housing
SCREW
CLAMP, pipe
NIPPLE
PLATE, ram, Neoprene
ROD, connecting
NUT
WASHER, spring lock
CARRIAGE, weldment, 300 gallon
ELBOW, street
NIPPLE, reducing, hex
REGULATOR, air, 1/2p
1
4
4
2
2
2
2
2
1
1
4
8
8
1
2
2
2
2
Part
No.
107
108
109
110
112
113
114
115
116
117
118
119
120
121
122
115419
214849
517290
C19438
114112
113093
C20378
100469
502526
246994
120163
190724
206996
617569
15D936
124
127
16F241
103347
Description
Qty
ADAPTER, fitting
LUBRICATOR
HOSE
ELBOW, fitting, 90°
CONNECTOR, fitting (f)
CONNECTOR, pipe
BRANCH, fitting
SCREW, cap, hex
VALVE, air three-way
VALVE, pressure, bleed
KIT, safety, lockout (not shown)
NIPPLE, hex, 3/4-14 npt
FLUID, TSL, 1 gal
FITTING, reducer, plug-in
FITTING, male connector,
1/2 npt x 5/8-12
FITTING, adapter, 12jic x 3/4 NPT
VALVE, safety, 100 psi
2
2
2
1
2
2
2
2
2
1
1
1
1
2
2
2
2
309028ZAP
Parts
Part No. 241840, Depressurization Kit
Ref
No.
Part
No.
16c
V1M350
16d
16e
16f
C20490
C19661
C19491
309028ZAP
Description
APPLICATOR, ball seat;
see 3A1792 for parts
NIPPLE
BUSHING
TEE
Ref
Qty No.
1 16g
16h
1 16k
1 16m
1 16r
Part
No.
Description
617569
236425
157129
C20487
156172
FITTING, reducer, plug-in
HOSE
NIPPLE
NIPPLE, hex
FITTING, union, swivel
Qty
2
1
1
1
1
72
Parts
Part No. 241837, Pneumatic Accessory Kit
Ref
Part
No.
No.
Description
7a
7b
7c
7d
7e
7f
7g
7h
C12509
C12509
C12509
C12509
517272
C20378
517288
24K172
7j
7k
7m
C19381
C12194
C12509
TUBE; nylon
TUBE; nylon
TUBE; nylon
TUBE; nylon
CLAMP, support
FITTING, Y-branch
TUBE; 1/4 in.
PANEL, pneumatic layout;
see page 75
CONNECTOR; 1/2 npt x 1/2 in.
TUBE; 1/2 in.
TUBE; nylon
73
Ref
Qty No.
248 in.
200 in.
23 in.
31 in.
2
2
2
1
7n
7p
7r
7s
7t
7u
7v
7w
7x
tube 1 7y
8 in. 7z
120 in.
Part
No.
Description
Qty
C12194
C19399
C19200
C19124
C19213
517254
110299
106149
C20485
C19019
617200
40 in.
TUBE; 1/2 in.
1
CONNECTOR; 1/2 npt x 1/2 in. tube
4
WASHER, plain
4
SCREW, cap, hex hd
4
WASHER, lock
3
CLIP, tube
3
RIVET
1
FILTER, air; 1/2 npt
1
FITTING; 1/2 npt
1
UNION, swivel
1
SUPPORT, bracket
309028ZAP
Parts
Part No. 241839, Low/Empty Limit Kit (For Uni-Drum Use)
Ref
No.
Part
No.
Description
301
302
303
304
305
306
C07431
C20003
C19204
C19197
C07560
195454
CONNECTOR, sealed
CAPSCREW, socket head
WASHER, lock #10 bolt
WASHER, plain
SWITCH, limit
BRACKET, limit, low-level, Uni-Drum
309028ZAP
Ref
Qty No.
2
4
4
4
2
1
307
308
309
310
311
312
Part
No.
Description
C19810
100016
112166
100018
C52751
104227
CAPSCREW, socket head
WASHER, spring lock; 1/4 in.
SCREW, cap, hex head
LOCKWASHER, spring; 1/2 in.
PLATE, limit switch
NUT, lock
Qty
2
2
2
2
1
2
74
Parts
Part No. 243488 Proximity Switch Accessory Kit
Ref
No.
Part
No.
601
602
603
604
617337
100016
C19800
617338
75
Description
COLLAR, clamp
WASHER, lock; 1/4 in.
SCREW, socket hd; 1/4-20 x 1/2 in.
BRACKET, proximity switch
mounting
Ref
Qty No.
2 605
2 606
2 611
1 612
Part
No.
Description
517455
C56572
196510
119417
SWITCH, proximity; 18 mm
CABLE, proximity; 2 m long
HOUSING, coupling nut
SCREW, cup point set; 1/4-20
Qty
1
1
1
1
309028ZAP
Parts
Part Nos. 241891 and 243510, Follower Plate Assembly
309028ZAP
76
Parts
Part Nos. 241891 and 243510, Follower Plate Assembly
Ref
No.
Part
No.
Description
603
604
605
609
610
611
612
613
614
615
616
620
621
622
623
624
625
626
516102
114508
617203
233041
617180
C20450
101535
101533
617204
C20449
517284
100549
C20461
515147
C19391
106464
C20463
214849
CLAMP, pipe
NIPPLE
BAR, support
PLATE, follower; see page 81
ROD, connecting
U-BOLT
NUT, hex
LOCKWASHER, spring; 7/8 in.
CARRIAGE
U-BOLT; 3/8-16
DISCHARGE MANIFOLD
ELBOW, street
NIPPLE, reducing
REGULATOR
ELBOW
TEE
NIPPLE, reducing
LUBRICATOR, air line
77
Ref
Qty No.
2
1
1
1
4
2
4
4
1
2
1
2
2
2
2
1
2
2
Part
No.
627
631
632
633
634
635
517290
C19438
16U204
114112
113093
C20378
636
637
638
639
640
641
642
643
644
645
100469
C19213
617202
113532
15D936
158585
112859
113332
158555
16U212
Description
HOSE
ELBOW; 1 in. npt
TUBE, unidrum, air inlet
CONNECTOR, female
CONNECTOR, pipe
FITTING, tube, Y-branch;
1/4 npt (m) x 1/4 OD tube
SCREW, cap, hex hd
WASHER, lock
MANIFOLD, air
ELBOW; 1/4 npt
FITTING, male connector
NIPPLE
FILTER, air; 1 in. npt
VALVE, ball
NIPPLE, reducing
CLAMP, 1.25 in. OD, pipe
Qty
2
1
1
6
4
2
2
2
1
4
2
1
1
2
2
1
309028ZAP
Parts
24K172, PLC Pneumatic Layout Panel
309028ZAP
78
Parts
Ref No. Graco Part No. Description
105
106
109
110
115
117
155
125502
125504
125505
125506
125452
517313
24J876
FITTING, PLUG, HEX, MUFFLER
VALVE, PNEUMATIC, 3 POSITION
NUT, PNEUMATIC, REGULATOR, PLAST
VALVE, PNEUMATIC, REGULATOR
GAUGE, PRESSURE, AIR, PANEL MOUNT
VALVE, 3 WAY, BUTTON, PALM
SWITCH, PNEUMATIC, ASSEMBLY
109a
112a
112b
114a
139a
145a
153a
154a
125505
517412
127379
125507
125501
125458
125511
115793
PNEUMATIC PANEL ASSEMBLY
NUT, PNEUMATIC, REGULATOR, PLAST
REGULATOR, VALVE, DUAL, 4 WAY
GAUGE, PRESSURE, AIR, 0-160 PSI
VALVE, PNEUMATIC, REGULATOR
VALVE, PNEUMATIC, CHECK, PUSH IN
SWITCH, PNEUMATIC, LOGIC
GAUGE, PRESSURE, AIR
VALVE, PILOT, 4-WAY DUAL AIR
101b
102b
121265
125409
TIMER CONTROL VALVE
VALVE, REMOTE, AIR ACTUATED
VALVE, FLOW CONTROLLER
79
Qty
1
1
2
2
2
1
1
1
1
2
1
1
1
1
2
1
1
309028ZAP
Parts
TIMER CONTROL VALVE
(SIDE OF ENCLOSURE)
309028ZAP
80
Parts
241838 and 24V775, PLC Interface Accessory Kit
Ref
No.
Part
No.
201
202
195330
C55568
119776
203
115440
119777
204
205
206
207
209
210
211
212
213
214
81
597151
96/0340/99
96/04321/99
596936
100016
517449
C07434
C19407
103219
C19391
Description
Ref
Qty No.
PLATE, mounting
SWITCH, pressure; 1/4 in. npt
(241838 only)
SWITCH, pressure; 1/4 in. npt
(24V775 only)
VALVE, assembly
(241838 only)
1 215
1 216
217
1
VALVE, assembly
(24V775 only)
ELBOW, male
SCREW, S.H.C.; CS PL #6-32x 5/8
WASHER, lock; CS PL #6
1
SCREW, S.H.C.; 1/4-20 x 1.5
WASHER, lock; CS PL 1/4
MUFFLER
CORD, 5-pin; 6 ft long
FITTING, tube; 1/4T x 1/8P
PLUG, pipe; 1/8 npt
ELBOW, 90 degree, tube; 1/4P x 1/4
1
3
4
4
2
2
2
1
2
1
T1
218
219
220
221
222
223
224
225
226
227
228
229
230
Part
No.
C19254
127366
195320
119773
C51238
C19185
C19213
502526
501014
104172
115419
195356
241839
C07435
114158
100157
C12509
Description
Qty
PLUG, pipe; 1/4 npt
CABLE, 2
PANEL, junction box;
(241838 only) see page 79
PANEL, junction box;
(24V755 only) see page 76
U-BOLT; 6 in. x 3/8-16 (not
shown)
JAM NUT (not shown)
WASHER, lock; 3/8 (not shown)
VALVE, air
ACTUATOR, air
FITTING, tube
FITTING, adapter
KIT, accessory
KIT, low/empty limit;
CORD, 5-pin; 12 ft long
FITTING, adapter, Y
SCREW; 10-32 X 0.38
TUBE; 1/4 in.; nylon
2
2
1
1
2
4
4
2
2
4
2
1
1
3
1
4
144 in.
309028ZAP
Parts
Part No. 195320 and 119773, Junction Box Panel
309028ZAP
82
Parts
Ref No.
290
280
270
260
250
240
230
220
210
200
190
180
170
160
Symbol
PB
SS
FU
DISC
FU
SUP
PB
PB
LT
LT
150
LT
LT
140
LT
LT
130
LT
LT
120
110
100
90
80
70
60
50
40
30
20
10
83
Description
Remark
U.L. File No.
P-N 90 DEG. CORD GRIP DB-1090
A-B PB 800T-XD2
A-B PB 800T FX9A1
A-B SS 800T-H2A
BARRIER ENTRELEC 29104221
BUSS FUSS GDC-250 MA 5 X 20 mm
GND ENTRELEC 0290.019.05
ENTRELEC 0290.041.03
ENTRELEC FUSE BLOCK 0115.662.22
A-B SUPPRESSOR 1492-WD4SS
A-B PB #800T-A2D1 (BLACK)
A-B PB #800T-A2D1 (GREEN)
A-B LIGHT WHITE #800T-PT16W
(195320 only)
A-B LIGHT WHITE #800T-QT24W
(119773 only)
A-B LIGHT BLUE #800T-PT16B
(195320 only)
A-B LIGHT BLUE #800T-8T24B
(119773 only)
A-B LIGHT AMBER #800T-PT16A
(195320 only)
A-B LIGHT AMBER #800T-QT24A
(119773 only)
A-B LIGHT GREEN #800T-PT16G
(195320 only)
A-B LIGHT GREEN #800T-QT24G
(119773 only)
A-B JUMPER 0291.103.24
TERMINAL ENTRELEC 0290.011.25
ENTRELEC END BARRIER 0291.041.20
ENTRELEC END ANCHOR 10300226
A-B MOUNTING CHANNEL 1492-N44
T & B SEAL RING 5262
T & B LOCKNUT 141
P-N 90 DEG. CORD GRIP DB-890
TAYLOR DUCT COVER
TAYLOR WIRE DUCT (1.5 X 2)
HOFF PANEL #C-P2016
HOFF ENCLOSURE #C-SD20168
Qty
4
1
1
1
1
K5100, 102
FU136, 143
SUP136, 144
PB119, 122
PB124
LT 148
E160646
E40735
E40735
E40735
E14840-NKCR
LT 148
E14840-NKCR
LT110
E14840-NKCR
LT110
E14840-NKCR
LT 141
E14840-NKCR
LT 141
E14840-NKCR
LT 134, 106
E14840-NKCR
LT 134, 106
E14840-NKCR
E40735
2
4
2
2
2
2
1
1
1
1
1
1
1
2
2
AR
31
1
2
12 in
8
8
4
29 in
29 in
1
1
309028ZAP
Parts
Part No. 233041 Follower Plate
Ref
No.
Part
No.
Description
401
402*
403*
404*
405
406*
407*
408*
409*
410*
411*
412**
413**
233040
115782
196052
196053
517286
115783
196051
100333
100016
112245
115784
617195
068104
PLATE, ram
CYLINDER, air
SPACER
PLATE
PLUNGER
BOLT, hex hd
SPACER
SCREW, cap, hex hd
WASHER, lock; 1/4 in.
O-RING
SCREW, cap, socket hd
WIPER
STRAPPING; steel
Ref
Qty No.
1
2
8
2
2
2
2
8
8
2
8
2
288 in.
Part
No.
Description
Qty
414**
101817
CLAMP, banding
2
415**
115785
SCREW, set
2
416
617230
GASKET
2
417
196072
RING, adapter
2
418
233044
PLUG, vent
2
419
C19843
CAPSCREW
4
420
106115
LOCKWASHER
4
421
102726
PLUG, pipe
2
422
196122
SHIELD
2
423
114269
GROMMET
2
*These items may be purchase separately or in Kit 234958
**These items may be purchased separately or in Wiper Kit,
918241.
DETAIL A
SEE DETAIL A
DETAIL B
SEE DETAIL B
309028ZAP
84
Parts
Part No. 241902 Elevator Assembly
(Ref)
(Ref)
(Ref)
85
309028ZAP
Parts
Ref
No.
Part
No.
Description
501
502
505
506
507*
508
509
510
516
517
518*
519*
520
521
522
523
517269
C12194
114129
617206
C31001
C03043
C20808
617179
100321
C03042
121306
156593
C31000
617176
C20417
C03046
DRAIN COCK
TUBE; 1/2 in.
CONNECTOR, male
FRAME, elevator
WIPER, rod
RING, snap
SCREW, socket, flat-head
PAD, rest
NUT
RING, lock
O-RING
O-RING
SLEEVE
ROD, lift
RING, retaining
PISTON, elevator
309028ZAP
Ref
Qty No.
4
136 in.
8
1
4
4
16
4
6
4
4
4
4
4
8
4
Part
No.
Description
524*
C20280
O-RING
525*
C03047
GUIDE, band
526*
158776
O-RING
527
C19130
SCREW, cap, hex hd
528
100018
WASHER, lock
529
194968
CLAMP
530
517281
PIN, spring
531
C14022
LABEL, warning
532
C14007
LABEL, warning
536
100681
NUT, jam, hex
537
517411
KNOB
538
114111
CONNECTOR, male
539
100361
PLUG, pipe
* These items may be purchased separately or in
Repair Kit 918110
Qty
4
4
4
6
6
2
2
2
4
2
2
1
3
86
Recommended Spare Parts
Recommended Spare Parts
Spare Parts for Pump and Air Motor
See appropriate manual listed on page 3.
Spare Parts for 47:1 and 35:1 Uni-Drum Supply Units
The customer should maintain an inventory of the spare parts (per unit) listed below.
CST
Units
SST
Units
515147 515147
V1M350 V1M350
115440
C55568
C07560
102774
517285
87
115440
C55568
C07560
102774
517285
Description
Qty.
CST
Units
SST
Units
Description
AIR REGULATOR
RECIRCULATING VALVE
KIT, see manual 3A1792
VALVE, solenoid
SWITCH, pressure
SWITCH, limit
LUBRICATOR KIT
AIR CYLINDER
1
2
C20247
517286
C03039
162440
502526
501014
918110
918241
234958
C20247
517286
C03039
162440
502526
501014
918110
918241
234958
O-RING
PLUNGER
UNI-DRUM ELEVATOR KIT
BOWL SEAL
PILOT VALVE
ACTUATOR
AIR CYLINDER KIT
WIPER KIT
FOLLOWER PLATE VENT
VALVE KIT
1
1
1
1
1
Qty.
2
2
2
1
1
1
1
1
1
309028ZAP
309028ZAP
YELLOW
RED
POWER
PLC POWER
CONNECTION
POWER
RAK
CONTROL
NEUTRAL
YELLOW
POWERED FROM PLC CONTROL PANEL
NEUTRAL
WHITE
CYCLE COUNT PUMP 2
PROX. SWITCH
INPUT TO PLC
CYCLE COUNT PUMP 1
PROX. SWITCH
INPUT TO PLC
PUMP ON
INPUT TO PLC
RESET PJMP
INPUT TO PLC
PRIME PUMP
INPUT TO PLC
DRUM EMPTY
INPUT TO PLC INDICATES
DRUM EMPTY
LOW LEVEL
INPUT TO PLC INDICATES
DRUM LOW LEVEL
RAM READY
INPUT TO PLC INDICATES
DRUM IN PLACE
AIR PRESSURE ON
INPUT TO PLC INDICATES AIR
AVAILABLE TO UNLOADER
GREEN
Junction Box Panel
FILE WIRING
LOCAL REMOTE
WIRE ASSIGNED AT REMOTE DEVICE
LOCATED OUTSIDE THIS PANEL.
LEGEND
Electrical Diagram
TI0207
REMOTE MODE
BULK SUPPLY
DEPRESSURIZATION
(NOT ACTIVATED)
PUMP READY
OUTPUT FROM PLC
INDICATES READY
FOR CHANGEOVER
PUMP ACTIVE
OUTPUT FROM PLC TURNS
AIR ON TO PUMPS
PUMP ACTIVE (LIGHT)
OUTPUT FROM PLC
NOTE: IF OUTPUT IS HIGH
(OPEN), PUMPS WILL
DEPRESSURIZE
DEPRESSURIZE PUMP
OUTPUT FROM PLC
SYSTEM PRESSURIZED
OUTPUT FROM PLC
Electrical Diagram
88
89
PUMP #1
REGULATOR
MAIN AIR
FILTER
PUMP #1
PUMP #2
UNIDRUM ASSEMBLY
MAIN AIR ’IN’
PUMP #2
DV - DIRECTIONAL VALAVE
IV - IMPULSE VALVE
SV - SHUTTLE VALVE
R - REGULATOR
I - INDICATOR
GA - GAUGE
LEGEND
LOCATED ON UNIDRUM
RAM PLATE
RAM PLATE
VENT 2
RAM PLATE
VENT 1
PUMP #2
REGULATOR
LOCK-OUT
VALVE
DV9
VENT OPEN
FOLLOWERVENT
BOX VENT
BOX VENT
AUTO OPEN
REGULATOR
DV6
LOWER
DV3
(TOP)
DV2
(BOTTOM)
RAISE
RAM CONTROL
RAM DOWN
CYLINDER EXHAUST
MAIN AIR SUPPLY FOR
SOLENOID VALVES &
SOLENOID PR. SWITCH
VENT CLOSET
RAM UP
SAFETY
A PILOT
DV8
B PILOT
RAM UP
PUMP 2 REMOTE REGULARTOR SIGNAL
PUMP 1 REMOTE REGULARTOR SIGNAL
Pneumatic Diagram
UNIDRUM RAM
DEPRESSURIATION
VALVE
PILOTED
REGULATOR
PUMP2
PILOTED
REGULATOR
PUMP1
SOL
SOL
LOCATED ON
J-BOX PANEL
PRESURE
SWITCH
PS108
Pneumatic Diagram
309028ZAP
Technical Data
Technical Data
Unit
Description
Uni-Drum System Overall dimensions:
248306, 248307,
249339, 249340,
253676, 253677
Supply Units
Compressed air requirement
(LH and RH)
Pumps (1/unit)
24Y228, 24Y227
Main air inlet size
Overall Weight
1 in. npt(f)
Approximately 3950 lb (1792 kg)
Ratio
47:1 fluid to air power ratio
Maximum fluid working pressure
4500 psi (310 bar, 31.0 MPa)
Maximum air input pressure
95 psi (7 bar, 0.7 MPa)
Pump cycles
Recommended pump speed for
continuous operation
8.7 per 1 gal. (3.8 liters)
60 cycles per min
Maximum flow rate
6.9 gpm (26.1 liters/min) at 60 cycles/min
Air motor piston effective area
132.7 in.2 (856 cm2)
Stroke length
4.8 in. (122 mm)
Air motor cylinder inside diameter
Displacement pump effective area
13 in. (330mm)
2.79 in.2 (18 cm2)
Pump operating temperature
Air inlet size
150° F (65.5° C) maximum temperature
1 in. npt(f)
Fluid inlet size
2 in. npt(f)
Fluid outlet size
Wetted components
1-1/2 in. npt(m)
304, 329, and 17-4 PH Grades of stainless steel;
silicone nitride; acetal; Ultra-high molecular weight
polyethylene, and leather
Approx. 234 lbs. (106 kg) per pump
Weight
309028ZAP
Specification
Width: 69 in. (1753 mm)
Depth: 51 in. (1295 mm)
Height (lowered): 85.2 in. (2164 mm)
Height (raised): 141 in. (3581 mm)
80 psi maximum
(5.5 bar, 0.55 MPa)
450 cfm
90
Technical Data
Unit
Description
Uni-Drum System Overall dimensions:
249152, 249153
249341, 249342
234972, 234973
258956, 258957
24U642, 24U643
25N914, 25N915
Specification
Width: 69 in. (1753 mm)
Depth: 51 in. (1295 mm)
Height (lowered): 85.2 in. (2164 mm)
Height (raised): 141 in. (3581 mm)
Supply Units
(LH and RH)
Compressed air requirement
80 psi maximum
(5.5 bar, 0.55 MPa)
450 cfm
Main air inlet size
Overall Weight
1 in. npt(f)
Approximately 3950 lb (1792 kg)
Ratio
35:1 fluid to air power ratio
Maximum fluid working pressure
3400 psi (231 bar, 23.1 MPa)
Maximum air input pressure
95 psi (7 bar, 0.7 MPa)
Pump cycles
Recommended pump speed for
continuous operation
Maximum flow rate
6.5 per 1 gal. (3.8 liters)
60 cycles per min
Air motor piston effective area
132.7 in.2 (856 cm2)
Stroke length
4.8 in. (122 mm)
Air motor cylinder inside diameter
Displacement pump effective area
13in. (330 mm)
3.72 in.2 (24 cm2)
Pump operating temperature
Air inlet size
150° F (65.5° C) maximum temperature
1 in. npt(f)
Fluid inlet size
2 in. npt(f)
Fluid outlet size
Wetted components
1-1/2 in. npt(m)
All Models: 304, 329, and 17-4 PH Grades of stainless
steel; silicone nitride; acetal; Ultra-high molecular
weight polyethylene, and leather
24U642 and 24U643 only: carbon steel
Weight
Approx. 234 lbs. (106 kg) per pump
Pumps (1/unit)
24Y192, 24Y206
91
9.2 gpm (34.6 liters/min) at 60 cycles/min
309028ZAP
Technical Data
Unit
Description
Uni-Drum System Overall dimensions:
232729, 232730,
255665, 255666
Supply Units
(LH and RH)
Pumps (1/unit)
24Y211, 24Y212
309028ZAP
Compressed air requirement
Specification
Width: 69 in. (1753 mm)
Depth: 51 in. (1295 mm)
Height (lowered): 85.2 in. (2164 mm)
Height (raised): 141 in. (3581 mm)
80 psi maximum
(5.5 bar, 0.55 MPa)
450 cfm
Main air inlet size
Overall Weight
1 in. npt(f)
Approximately 3950 lb (1792 kg)
Ratio
47:1 fluid to air power ratio
Maximum fluid working pressure
4500 psi (310 bar, 31.0 MPa)
Maximum air input pressure
95 psi (7 bar, 0.7 MPa)
Pump cycles
Recommended pump speed for
continuous operation
Maximum flow rate
8.7 per 1 gal. (3.8 liters)
60 cycles per min
Air motor piston effective area
132.7 in.2 (856 cm2)
Stroke length
Displacement pump effective area
4.8 in. (122 mm)
2.79 in.2 (18 cm2)
Pump operating temperature
Air inlet size
150° F (65.5° C) maximum temperature
1 in. npt(f)
Fluid inlet size
2 in. npt(f)
Fluid outlet size
Wetted components
1-1/2 in. npt(m)
Carbon steel, chrome, zinc, and electroless nickel
plating; 304, 440 and 17-4 PH Grades of stainless
steel; tungsten carbide; ductile iron; acetal;
PTFE, leather
Weight
Approx. 234 lbs. (106 kg) per pump
6.9 gpm (26.1 liters/min) at 60 cycles/min
92
Technical Data
Unit
Uni-Drum System
232839, 232840,
246921, 246922
Description
Overall dimensions:
Supply Units
(LH and RH)
Compressed air requirement
Pumps (1/unit)
24Y221, 24Y222,
24Y225, 24Y226
Main air inlet size
Overall Weight
1 in. npt(f)
Approximately 3950 lb (1792 kg)
Ratio
47:1 fluid to air power ratio
Maximum fluid working pressure
4500 psi (310 bar, 31.0 MPa)
Maximum air input pressure
95 psi (7 bar, 0.7 MPa)
Pump cycles
Recommended pump speed for
continuous operation
Maximum flow rate
8.7 per 1 gal. (3.8 liters)
60 cycles per min
Air motor piston effective area
132.7 in.2 (856 cm2)
Stroke length
4.8 in. (122 mm)
Air motor cylinder inside diameter
Displacement pump effective area
13 in. (330 mm)
2.79 in.2 (18 cm2)
Pump operating temperature
Air inlet size
150° F (65.5° C) maximum temperature
1 in. npt(f)
Fluid inlet size
2 in. npt(f)
Fluid outlet size
Wetted components
1-1/2 in. npt(m)
304, 329 and 17-4 PH Grades of stainless steel;
tungsten carbide; acetal; PTFE, Ultra-high
molecular weight polyethylene, leather
Approx. 234 lbs. (106 kg) per pump
Weight
93
Specification
Width: 69 in. (1753 mm)
Depth: 51 in. (1295 mm)
Height (lowered): 85.2 in. (2164 mm)
Height (raised): 141 in. (3581 mm)
80 psi maximum
(5.5 bar, 0.55 MPa)
450 cfm
6.9 gpm (26.1 liters/min) at 60 cycles/min
309028ZAP
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
Sealant and Adhesive Dispensing Equipment
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, go to www.graco.com, or call to identify the nearest
distributor.
If calling from the USA: 1-800-746-1334
If calling from outside the USA: 0-1-330-966-3000
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 309028
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2000, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision ZAR, March 2019

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