Graco 309028ZAC - Uni-Drum Supply System Instructions

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Instructions–Parts List

Uni-Drum

Supply System

309028ZAC

EN

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 3 for Table of Contents.

Uni-Drum Left Hand Supply Unit

Ti4624a

Uni-Drum Right Hand Supply Unit

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 51.

Max. Outlet Pressure Pump Manual Supply Unit Part

No.

232840

(Right Hand)

246921

(Left Hand)

246922

(Right Hand)

253676

(Left Hand)

253677

(Right Hand)

*258910

(Left Hand)

*258911

(Right Hand)

249152

(Left Hand)

249153

(Right Hand)

* 234972 (Left

Hand)

* 234973 (Right

Hand)

*258956

(Left Hand)

246981

(Left Hand)

246982

(Right Hand)

248306

(Left Hand)

248307

(Right Hand)

249339

(Left Hand)

249340

(Right Hand)

232729

(Left Hand)

232730

(Right Hand)

232839

(Left Hand)

*258957

(Right Hand)

249341

(Left Hand)

249342

(Right Hand)

255666

(Left Hand)

255665

(Right Hand)

24H017

(Left Hand)

Pump Ratio

Premier, SST, silicone nitride, ceramic

Premier, SST, silicone nitride, ceramic

45:1

45:1

Premier, SST, silicone nitride 45:1

Premier, SST, silicone nitride 45:1

Premier, SST, silicone nitride

(24V)

Premier, SST, silicone nitride

(24V)

Premier, carbon steel

Premier, carbon steel

Premier, stainless steel

Premier, stainless steel

Premier, stainless steel

Premier, stainless steel

Premier, stainless steel

Premier, stainless steel

Premier, stainless steel

(24V)

Premier, stainless steel

(24V)

Premier, stainless steel

Premier, stainless steel

Premier, stainless steel

Premier, stainless steel

45:1

45:1

45:1

45:1

45:1

45:1

45:1

45:1

45:1

45:1

45:1

45:1

34:1

34:1

34:1

34:1

Premier, stainless steel

(24V)

Premier, stainless steel

(24V)

Premier, stainless steel

(24V)

Premier, stainless steel

(24V)

34:1

34:1

34:1

34:1

Premier, carbon steel (24V) 45:1

Premier, carbon steel (24V) 45:1

Premier, carbon steel (24V) 34:1

24H016

(Right Hand)

Premier, carbon steel (24V) 34:1

*For LASD applications, sst fittings are outlet.

4500 psi

(31.0 MPa, 310 bar)

4500 psi

(31.0 MPa, 310 bar)

4500 psi

(31.0 MPa, 310 bar)

4500 psi

(31.0 MPa, 310 bar)

4500 psi

(31.0 MPa, 310 bar)

4500 psi

(31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

3400 psi (23.1 MPa, 231 bar)

3400 psi (23.1 MPa, 231 bar)

3400 psi (23.1 MPa, 231 bar)

3400 psi (23.1 MPa, 231 bar)

3400 psi (23.1 MPa, 231 bar)

3400 psi (23.1 MPa, 231 bar)

3400 psi (23.1 MPa, 231 bar)

3400 psi (23.1 MPa, 231 bar)

4500 psi (31.0 MPa, 310 bar)

4500 psi (31.0 MPa, 310 bar)

3400 psi (23.1 MPa, 231 bar)

3400 psi (23.1 MPa, 231 bar)

Max. Fluid Flow

@ 60 cpm

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

6.9 gpm (26 lpm)

9.2 gpm (34.8 lpm)

9.2 gpm (34.8 lpm)

9.2 gpm (34.8 lpm)

9.2 gpm (34.8 lpm)

9.2 gpm (34.8 lpm)

9.2 gpm (34.8 lpm)

9.2 gpm (34.8 lpm)

9.2 gpm (34.8 lpm)

6.9 gpm 26 lpm)

6.9 gpm (26 lpm)

9.2 gpm (34.8 lpm)

9.2 gpm (34.8 lpm)

308148

308148

308148

308148

308148

308148

308147

308147

308148

308148

308148

308148

308148

308148

308148

308148

308152

308152

308152

308152

308152

308152

308152

308152

308147

308147

308151

308151

2 309028

List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Uncrating the System . . . . . . . . . . . . . . . . . . . . . . . . . 7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Overview . . . . . . . . . . . . . . . . . . . . . . . .

7

7

Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Components . . . . . . . . . . . . . . . . . . . . . . . .

8

8

Pneumatic Layout Panel

Junction Box Panel

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

11

11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing the Site . . . . . . . . . . . . . . . . . . . . . . . . . .

12

12

Selecting a Location for the Uni-Drum

Preparing to Install the System

. . . . . . . .

. . . . . . . . . . . . . .

12

12

Installing the Uni-Drum . . . . . . . . . . . . . . . . . . . . . 13

Connecting Power to the Junction Box

Grounding the System

. . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

14

16

Checking the Resistance Between the

Pumps and the True Earth Ground . . . . . . . . . . . 16

Connecting Air Supply Lines to the Uni-Drum . . 17

Connecting Output Hose to the Pumps . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Operator . . . . . . . . . . . . . . . . . . . . . . .

19

19

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Junction Box Panel Switches and Indicators . . .

19

20

Pneumatic Layout Panel Switches and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Flushing the System Before Initial Use . . . . . . . . 24

Adjusting the Lid Holder Before Initial Use

Initial System Startup Procedure

. . . . .

. . . . . . . . . . . . .

24

25

Daily System Startup

System Shutdown

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

30

30

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

30

31

Preventive Maintenance Schedule

Changing Empty Drums

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

31

32

Ram Assembly Troubleshooting . . . . . . . . . . . . . . 35

Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 36

Air Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . 37

Junction Box Panel Troubleshooting . . . . . . . . . . 38

Pneumatic Layout Panel Troubleshooting . . . . . 38

Routine Maintenance

Flushing the System

. . . . . . . . . . . . . . . . . . . . . . . . . 39

. . . . . . . . . . . . . . . . . . . . . . . 39

Cleaning the System

Wiper Lubrication

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

39

39

Table of Contents

Junction Box Panel Service . . . . . . . . . . . . . . . . . . .

Indicator Light and Pushbutton

40

S witch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .

Indicator Light and Pushbutton

40

S witch Replacement

Light Bulb Removal

. . . . . . . . . . . . . . . . . . . . . . . 40

. . . . . . . . . . . . . . . . . . . . . . . . 40

Light Bulb Replacement

Fuse Removal

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

42

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . .

Surge Suppressor Removal . . . . . . . . . . . . . . . . .

42

43

Surge Suppressor Replacement . . . . . . . . . . . . . 43

PLC Interface Accessory Kit Service

Valve Assembly Bank Replacement

. . . . . . . . . . . 44

. . . . . . . . . . 44

Pressure Switch Assembly Replacement . . . . . . 44

Pneumatic Layout Panel Service

Filter/Element Replacement

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

46

46

Ram Assembly Service . . . . . . . . . . . . . . . . . . . . . . .

Piston Rod Seal Service . . . . . . . . . . . . . . . . . . . .

48

48

Ram Piston Service . . . . . . . . . . . . . . . . . . . . . . . .

Low/Empty Limit Switch Replacement

49

Depressurization Valve (Ball Seat Applicator) . 50

Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Servicing the Pumps

Replacing Wipers

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

51

52

Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

System Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Uni-Drum Supply Units –

54

Left Hand and Right Hand 34:1 and 45:1

Left Hand and Right Hand 45:1

. . . . .

. . . . . . . . . . . . . .

54

58

241840 Depressurization Kit . . . . . . . . . . . . . . . . .

241837 Pneumatic Accessory Kit . . . . . . . . . . . .

60

61

241839 Low/Empty Limit Kit . . . . . . . . . . . . . . . . . 62

241891, 243510 Follower Plate Assembly

243488 Proximity Switch Accessory Kit

. . . . .

. . . . . . .

64

63

195319 PLC Pneumatic Layout Panel

241838 PLC Interface Accessory Kit

. . . . . . . . 66

. . . . . . . . . 69

195320 Junction Box Panel

233041 Follower Plate

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

70

72

241902 Elevator Assembly . . . . . . . . . . . . . . . . . . 73

Recommended Spare Parts

Spare Parts List

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

74

74

Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Junction Box Panel . . . . . . . . . . . . . . . . . . . . . . . .

75

75

Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Layout Panel . . . . . . . . . . . . . . . . . . . .

76

76

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . 82

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . 84

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

309028 3

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

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.

4 309028

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 Procedure on page 31 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.

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 Procedure on page 31 to prevent the equipment from starting unexpectedly.

309028 5

6 309028

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 16.

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.

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.

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

EQUIPMENT MOVING HAZARD

Removing the unit off the pallet without following the uncrating procedure will damage the equipment.

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.

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.

Installation 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 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.

Overview

Operation Overview

The Uni-Drum is a supply system that evacuates fluids from a 300 gallon (1200 liter) magnadrum or other tote drums.

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.

309028 7

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.

D

E

F

G

H

J

Fig. 1 shows the typical Uni-Drum supply system equipped with Premier air motors. The following list identifies the Uni-Drum system components:

Ref.

Description

A

B

C

Left hand (LH) supply unit

Right hand (RH) supply unit

Dura-Flo 1800 pumps with Premier air motors (2 units)

Ram assembly and follower plate

Main air inlet

3/8 npt air filter

Pneumatic layout panel

Junction box panel

Drum lid holders

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.

– 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.

8 309028

General Description

H

H

F

D

C

E

G

J

Ti4625a

Fig. 1

TI0137

A – Left Hand Unit

Left Hand Models

246981

248306

249339

Ti4624a B – Right Hand Unit

Right Hand Models

246982

248307

249340

E

G

H

C

H

F

D

309028 9

General Description

E

G

H

F

D

H

C

Fig. 2

A – Left Hand Unit

Left Hand Models

246981

248306

249339

232729

232839

246921

253676

249152

234972

249341

258910

258956

255666

24H017

J

B – Right Hand Unit

Right Hand Models

246982

248307

249340

232730

232840

246922

253677

249153

234973

249342

258911

258957

255665

24H016

E

G

H

F

D

H

C

TI013

10 309028

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.

The two Dura-Flo 1800 Pumps (C) have Premier 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.

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 76.

Main Air Inlet Valve (at E) is used to open or shutoff the air supply to the entire supply unit.

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.

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 75.

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.

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.

309028 11

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.

Selecting a Location for the Uni-Drum

Refer to Technical Data on page 78 for ram mounting and clearance dimensions.

When selecting a location for the Uni-Drum, keep the following in mind:

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

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.

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

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 the Site

Ensure that you have an adequate compressed air supply. Refer to the applicable instruction manual listed in Related Publications on page 82 to find the air consumption of your pump. Approximately 450 cfm at

80 psi is required to operate the pumps at the maximum rate.

Keep the site clear of any obstacles or debris that could interfere with the installer’s and operator’s movement.

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.

12 309028

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.

Installation

Installing the Uni-Drum

To install the Uni-Drum, follow the procedure below.

Refer to Technical Data on page 78 for ram mounting and clearance dimensions.

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 support devices, such as a hoist when moving and installing the Uni-Drum system.

3.

Using the holes in the base as a guide, drill holes for 13 mm (1/2 in.) anchors.

4.

Bolt the Uni-Drum to the floor using anchors that are long enough to prevent the unit from tipping.

Refer to page 78 for more information.

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.

309028 13

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

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.

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 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.

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 75 .

NOTE: Have a qualified electrician connect the junction box to a grounded electrical source that has the following required service ratings:

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.

Description

Voltage:

Hz:

Phase:

Circuit Breaker

Requirements

120 Vac 24 Vdc

50/60 –

1

5 Amp

5 Amp

6.

Seal the area where wires entered the junction box panel.

7.

Replace the cover on the junction box panel.

14 309028

Installation

Connecting Power to the Junction Box

(continued)

Strain Relief

Fuse Blocks Terminals

ISOLATION BLOCKS

(KNIFE SWITCH DISC.

Ground Lug

KS100 1001

1002

Enclosure

KS102 1021

1022

(2) TOTAL

Type

1492–WKD3TP

Wire Way

TI0205b

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. 3

309028 15

Installation

5.

Object being sprayed: follow your local code.

Grounding the System

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 6.

1.

Pump: use a ground wire and clamp. See Fig. 4.

Loosen the grounding lug locknut (W) and washer

(X). Insert one end of a 12 ga (1.5 mm ) minimum ground wire (Y) into the slot in lug (Z) and tighten the locknut securely. Connect the other end of the wire to a true earth ground. For a ground wire and clamp, order Part No. 237569.

Z

Y

6.

Fluid supply drum: follow your local code.

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 the each pump and the true earth ground.

The resistance must be less than 29 megohms. If the resistance is greater than 0.25 ohms, a different ground site may be required. Do not operate the system until the problem is corrected.

X

W

0720

Fig. 4

2.

Air and fluid hoses: Use only electrically conductive hoses.

3.

Air compressor: follow manufacturer’s recommendations.

4.

Spray gun or dispensing valve: ground through connection to a properly grounded fluid hose and pump.

NOTE: Use a meter that is capable of measuring resistance at this level.

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 0.25

ohms.

16 309028

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:

Input Air:

Requirements

1 in. npt(f)

450 cfm (maximum)

80 psi (5.5 bar, 0.55 MPa)

WARNING

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 78).

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

Pump Air Manifold

Pilot Valve

AirLIne Lubricator

Air Line to Pump Air Manifold

TI0198

Main Air Filter

TI0204

Air Supply Lines to Pumps

Fig. 5

309028 17

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 82 for the pump instruction manuals.

CAUTION

There must be a minimum of 10 feet (3 m) of fluid supply hose on the outlet to prevent damage to the unit.

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.

Fluid Supply Hose

Fluid Outlet

Fluid Manifold

TI0139

Fig. 6

18 309028

Operation

The operation procedures include:

Prepare the operator

Overview

Junction box panel switches and indicators

Pneumatic layout panel switches and indicators

Initial system startup procedure

Daily system startup

System shutdown

Operation modes for the pumps

Pressure relief procedure

Air motor icing

Preventive maintenance schedule

System operation procedures

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.

System Startup

There are a series of steps that must be followed in sequential order to startup the system.

System Operation

Depending upon the system setup, at any time during operation, the operator can:

Stop the pumps and relieve ram pressure at the LH supply unit.

Stop the pumps and relieve ram pressure at the RH supply unit.

Shutdown the system.

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.

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.

309028 19

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

PRIME PUMP pushbutton

PUMP RESET pushbutton

PUMP ON pushbutton

Bulk Supply Depressurization pushbutton

AUTO MODE ON/OFF switch

What it Does

Primes both displacement pumps with material, making the pumps ready to operate.

Lights PUMP READY light.

Restarts the pumps after the pumps were turned off.

Lights PUMP ACTIVE light

Activates the pumps.

Deactivates the pumps.

Opens the depressurization valve to lower the fluid supply pressure.

Places fluid dispensing system into Automatic or Manual mode.

Indicator

SYSTEM

PUMP ACTIVE light

AIR PRESSURE ON

RAM READY light

PUMP READY light

Indicator

Light is

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

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.

20 309028

Operation

Junction Box Panel Switches and Indicators

(continued)

Fig. 7

195320 and 119773 Panel Shown

TI0203

309028 21

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.

Ref Button/Switch/Gauge

A PUMP NO. 1 PRESSURE Air Gauge

B PUMP NO. 2 PRESSURE Air Gauge

What it Does

Indicates the air outlet pressure setting from pump no. 1.

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

G RAM POSITION RAISE

Raises the follower plate.

Allows the follower plate to raise.

H Air Inlet Valve

HOLD

LOWER

Holds the follower plate in the current position.

Lowers the follower plate.

Opens air supply line to the unit.

22 309028

Fig. 8

D

A

F

C

Operation

FOLLOWER VENT

AUTO OPEN

B

E

G

H

195319 Panel Shown

TI0202

309028 23

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.

If the two substances are compatible, omit the remaining steps in this procedure and perform the Initial System Startup Procedure on page 25.

b.

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 factorytest 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

Ground the System , on page 16.

5.

Perform steps 8 through 14 of the Initial System

Startup Procedure on page 25 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.

24 309028

Initial System Startup Procedure

Operation

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.

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.

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.

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.

At the pneumatic layout panel, open the main air inlet valve at the LH supply unit, making air pressure available to the unit. See Fig. 5.

5.

Adjust both pump main air regulators to 0 psi.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce risk of injury or equipment damage:

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.

6.

Follower Vent switch should be in AUTO position.

7.

Set the RAM POSITION switch to RAISE.

8.

Press the RAM UP valve switch to raise the follower plate above the height of the material drum to be used.

9.

Set the RAM POSITION switch to HOLD.

309028 25

Operation

Initial System Startup Procedure

(continued)

Load Material

10. Roll a drum into the supply unit under the elevated follower plate.

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.

11.

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.

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.

12. Remove bleed sticks at the base of each pump.

13. 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.

14. Close both pump #1 and pump #2 inlet valves (located on top of air motor).

15. To prime the pump, press the PRIME PUMP button.

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.

22. After closing the bleed valve, return Pump No. 1 and 2 regulator to its normal pump pressure setting.

23. Open the air motor ball valves.

24. Open the ball valve in the outlet manifold from

Pump No. 1 and 2.

25. Remove the waste containers, clean up any spilled material, and dispose of the waste material properly.

16. Set the pump air pressure to 30 psi.

26. Press the PUMP RESET button to restore the system to operation.

17. Check that the AIR PRESS. ON indicator is lit.

27. Check that the following indicators are 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.

SYSTEM PRESSURIZED

AIR PRESS. ON

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.

RAM READY

PUMP READY

26 309028

Operation

Initial System Startup Procedure

(continued)

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).

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.

28. Run the system under normal conditions. Adjust the PUMP NO. 1 REGULATOR to the desired setting as follows: a.

Turn the knob clockwise to increase air pressure or counterclockwise to decrease air pressure (see Fig. 8).

b.

Check the air gauge to verify the air pressure setting.

29. Repeat step 28 to adjust the air regulator for the

PUMP NO. 2 REGULATOR.

Adjusting the Ram-Up and Ram-Down Regulators

30. At the pneumatic layout panel (see Fig. 7), open the hinged cover.

31. 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.

c.

Repeat step 31.a until the ram raises at the desired speed.

32. Set the RAM POSITION switch to DOWN while observing the air gauge inside the panel.

33. 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.

34. 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 35 when there is pump cavitation. If cavitation is not occurring, omit step 35 and proceed to step 36.

35. 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.

309028 27

Ram Down

Regulator

Operation

Regulator R3

Ram Up

Regulator

9327A

Fig. 9

28 309028

Operation

Initial System Startup Procedure

(continued)

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.

36. Adjust the low limit switch as follows: 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.

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.

c.

Adjust the low limit switch to activate at the level defined in step 36.b See Fig. 10.

Limit Switches

1 to 4 in. (25.4 to 101.6 mm)

Pin 1

Pin 3

Pin 5

Pin 2

Pin 4

TI0200

Fig. 10

309028 29

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 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

1.

To stop the system, close the main air inlet supply

(see Fig. 11) to the supply unit.

Main Air Inlet

Main Air Valve

TI0198

Fig. 11

30 309028

Operation

Pressure Relief Procedure

This procedure describes how to relieve pressure from the system. Use this procedure whenever you shutoff the pumps and before checking or adjusting any part of the system, to reduce the risk of serious injury.

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.

During operation, also keep hands and fingers away from limit switches to reduce the risk of pinching or amputating hands or fingers.

To relieve pressure on the follower plate and in the pumps, perform the following procedure:

At the pneumatic layout panel, do the following:

1.

Close the main air inlet valve (see Fig. 11).

2.

Open any downstream fluid valves, such as the ball seat applicators on the ram assemblies, that may be part of the system.

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.

Ball Seat

Applicator

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.

TI0195

Fig. 12

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.

309028 31

Operation

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:

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.

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:

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.

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).

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.

4.

Close the two ball valves at the outlet manifold at the rear of the Uni-Drums.

5.

To raise the follower plate:

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.

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.

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.

32 309028

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:

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.

Operation

12. Remove the bleed sticks from the follower plate.

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.

13. 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.

14. Close both pump #1 and pump #2 inlet valves (located on top of the air motor).

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.

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.

309028 33

Operation

22. After closing the bleed valve, return Pump No. 1 and 2 regulator to its normal pump pressure setting.

26. Press the PUMP RESET button to restore the system to operation.

27. Check that the following indicators are lit:

23. Open the air motor ball valves.

SYSTEM PRESSURIZED

24. Open the ball valve in the outlet manifold from

Pump No. 1 and 2.

AIR PRESS. ON

25. Remove the waste containers, clean up any spilled material, and dispose of the waste material properly.

RAM READY

PUMP READY

34 309028

Ram Assembly Troubleshooting

Problem

Ram won’t raise or lower

Ram raises or lowers too fast

Fluid squeezes past follower plate

Pump won’t prime properly, or

Cause(s) Solution(s)

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 49.

Ram air pressure too high

Ram air pressure too high

Worn or damaged wipers

Not enough ram air pressure

Worn or damaged ram piston

Decrease ram air pressure

Decrease ram air pressure

Replace wipers. See procedure on page 52.

Increase ram pressure

Bent drum has stopped follower plate

Replace ram piston. See procedure on page 49.

Replace drum

309028 35

Pump Troubleshooting

For additional information about the displacement pump, refer to Related Publications on page 82 to find the applicable instruction manual.

Problem

Rapid downstroke or upstroke

(pump cavitation)

Cause(s)

Air is trapped in pump.

Solution(s)

Bleed air from the pump using this procedure:

Downstroke: Lower check in pump is worn.

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.

Rebuild and replace pump, as necessary.

Upstroke: Upper check in pump is worn.

Material leaks around pump outlet Outlet fitting is loose.

Material leaks around bleed port Bleed port fitting is loose.

Pump won’t move up or down Problem with air motor.

Foreign object lodged in pump.

Tighten outlet fitting.

Tighten bleed port fitting.

See Air Motor Troubleshooting chart on page 37.

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 Procedure (page 31).

Before attempting to dislodge a foreign object:

Wet-cup leaks Worn throat packings.

1.

Relieve system pressure.

2.

Remove the pump from the air motor.

Tighten wet-cup. Replace throat packings.

36 309028

Air Motor Troubleshooting

For additional information about the air motor, refer to Related Publications on page 82 to find the applicable instruction manual.

Problem

Air motor will not shift directions, stalled in DOWN position

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 continually exhausting around the air valve/slide valve

Air continually exhausting from muffler while the motor is idle

Oil leaking from exhaust port

Frost build-up on muffler

Cause(s) Solution(s)

Main air valve spool is dirty or damaged Clean/rebuild main air valve.

Air motor shaft seal is damaged Replace air motor shaft seal.

Air valve/slide valve gasket is damaged Replace the valve gasket.

Internal seal damage

Too much lubricant mixed in with the air supply

Air motor operating at high pressure, or high cycle rate

Rebuild air motor.

Reduce lubricant supply.

Reduce pressure, cycle rate, or duty cycle of the air motor.

309028 37

Junction Box Panel Troubleshooting

Problem

Power from PLC control panel is j i b l

Cause(s)

The knife switch disconnect contacts

(KS100 and KS102) are open.

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

Ram will not move up or down.

Ram will not move up.

Pumps will not operate.

Vent valve will not open.

Cause(s)

Main air valve on box is not open.

Solution(s)

Open valve.

Air supply to unit is not on.

Direction valve is not in the UP position.

Turn on air supply.

Set direction valve to the UP position.

RAM UP button is not pushed.

Resistance in drum is too great.

Insufficient lubrication of the follower plate seal.

Air regulator is set too low.

FOLLOWER VENT switch is not in

AUTO position.

Push RAM UP button.

Turn air pressure up to 60 psi. The ram may take a few minutes to withdraw from the container.

After the plate has been removed from the container, clean the seal and thoroughly lubricate.

Increase air pressure setting.

Put FOLLOWER VENT switch in

AUTO position.

38 309028

Flushing the System

Flush the pump:

Before the first use

Routine Maintenance

Cleaning the System

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)

CAUTION

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:

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

6. Be sure the entire system and flushing pails are properly grounded. Refer to

Grounding on page 16.

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.

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.

309028 39

Junction Box Panel Service

This part of the manual provides information about the following junction box panel components:

Indicator light and pushbutton switch replacement

Light bulb replacement

Fuse replacement

Surge suppressor replacement

NOTE: Refer to Junction Box Parts on page 71 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.

4.

Verify that the replaced component operates correctly.

5.

Return the system to current readiness condition.

Light Bulb Removal

Remove the light bulb 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.

1.

Shut off power to the junction box panel.

2.

Unscrew and remove the indicator light lens.

1.

Shut off power to the junction box panel.

2.

At the junction box panel, remove the cover from the junction box panel.

3.

Gently press and rotate the bulb counterclockwise,

1/4-in. of a turn, unlocking the bulb from its socket.

Remove the bulb from the socket.

3.

Disconnect the lead wires from the terminals on the switch. For wiring information, refer to the

Electrical Diagram on page 75. If necessary, label the wires to facilitate reconnection after replacing the component.

Light Bulb Replacement

Replace the light bulb as follows:

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

1.

Reverse steps 2 through 4 in the previous paragraph.

2.

For wiring information, refer to the Electrical

Diagram on page 75.

3.

Reapply power to the junction box panel.

1.

Insert the light bulb in the socket.

2.

Gently press and rotate the bulb clockwise, 1/4-in.

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.

40 309028

Fig. 13

Junction Box Panel Service

Ground Fuses Terminals Surge Suppressors

Ground Lug

KS100 1001

1002

Enclosure

KS102 1021

1022

(2) TOTAL

Type

1492–WKD3TP

Wire Way

TI0205b

Terminals

1481

1431

1411

1361

1341

1291

1271

1241

1221

1191

1171

1141

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

FU136

FU143

SUP136

SUP144

1541

1511

1121

1081

1001

1001

1001

1023

1003

(31) TOTAL

Type 0290.011.25

ENTRELEC

309028 41

Junction Box Panel Service

Fuse Removal

Remove the fuse as follows:

Fuse Replacement

Replace 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.

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. 13.

2.

Reinstall the cover on the junction box panel.

1.

Shut off power to the junction box panel.

2.

At the junction box panel, remove the cover from the junction box panel.

3.

Locate the failed fuse on the terminal strip. Reference Fig. 13 for the fuse terminal identification.

4.

Carefully remove the fuse from the fuse holder.

3.

Reapply power to the junction box panel.

4.

Verify that the fuse operates correctly.

5.

Return the system to current readiness condition.

42 309028

Junction Box Panel Service

Surge Suppressor Removal

Remove the surge suppressor as follows:

Surge Suppressor Replacement

Replace the surge suppressor 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.

1.

Shut off power to the junction box panel.

2.

At the junction box panel, remove the cover off the junction box panel.

3.

Locate the failed surge suppressor on the terminal strip. Reference Fig. 13 for the surge suppressor terminal identification.

4.

Remove the two screws and surge suppressor from the terminal strip.

1.

Install the new surge suppressor into place on the terminal strip using the two screws. See Fig. 13.

2.

Reinstall the cover on the junction box panel.

3.

Reapply power to the junction box panel.

4.

Verify that the new surge suppressor operates correctly.

5.

Return the system to current readiness condition.

Fig. 14

Pressure Switch

Solenoid Valve

T10196

309028 43

PLC Interface Accessory Kit Service

8.

Reinstall the cover on the junction box panel.

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.

9.

Reapply power to the junction box panel.

10. Perform the Daily System Startup procedure on page 30 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.

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.

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.

1.

Shut off power to the junction box panel.

3.

Locate the valve assembly (203) that is attached to the mounting plate (201) below the junction box panel (217). See Fig. 14.

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. 14.

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 75.

5.

Remove four cap screws (205), the lock washers

(206), and the valve assembly (203) from the mounting plate (201).

4.

Disconnect the 5-pin cord (211) from the pressure switch assembly (202). For wiring information, refer to the Electrical Diagram on page 75.

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. 14.

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 75.

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.

44 309028

PLC Interface Accessory Kit Service

Junction Box Panel

Fig. 15

Mounting Plate

Pressure

Switch

Assembly

90

°

Elbow

Tube

Fitting

Elbow

Muffler

Valve

Assembly

Screw,

Washer

TI0208

309028 45

Pneumatic Layout Panel Service

The pneumatic layout panel service procedures include:

Filter/element replacement

Filter/Element Replacement

Listed below are the filters used with the ram assembly on the Uni-Drum supply system.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 31.

The air filter between the air supply source and both air motors. See Fig. .

The air filter between the air supply source and the pneumatic layout panel. See Fig. 17.

To replace an air filter/element, do the following:

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.

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: a.

Press the PUMP OFF switch, turning off air to both pumps (see Fig. 7).

b.

Verify that the PUMP ACTIVE and AIR

PRESS ON lights turn off.

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.

8.

Perform the Daily System Startup procedure on page 30.

9.

Check for air leakage around the filter.

10. Return the system to current readiness condition.

Fig. 16

46 309028

Main

Air Filter

TI0198

Fig. 17

Pneumatic

Panel

Air Filter

TI0201

Pneumatic Layout Panel Service

Filter/Element Replacement

(continued)

FOLLOWER VENT

AUTO OPEN

Fig. 18

TI0202

309028 47

Ram Assembly Service

Piston Rod Seal Service (Fig. 19)

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 31.

1.

Relieve the air pressure.

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.

Ring, Seal Guard

Sleeve

Ring

O-ring

O-ring

Refer to Repair Kit 918110.

Fig. 19

WARNING

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).

7056A

48 309028

Ram Assembly Service

Ram Piston Service (Fig. 20)

6.

Install new O-ring seals on the piston rod and the piston. Lubricate the piston and seals. Reinstall the piston and retaining ring.

WARNING

To reduce the risk of serious injury, whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 31.

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.

2.

Remove the tie bar as explained under Piston

Rod Seal Service.

8.

Slide the guide sleeve onto the piston rod. Reinstall the retaining ring and tie bar, as explained under Piston Rod Seal Service.

3.

Remove the guide sleeve and slide it off of the piston rod.

Ring

WARNING

Do not use pressurized air to remove the guide sleeve or piston. Failure to follow this instruction may result in personal injury.

O-ring

O-ring

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.

Fig. 20

Band

Piston

Ring

7056A

309028 49

Ram Assembly Service

The ram assembly service procedures include:

Low/Empty limit switch replacement

Ball seat applicator repair procedure

Servicing the pumps

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.

Low/Empty Limit Switch Replacement

To replace the lower limit switch, do the following:

1.

Perform the System Shutdown procedure provided by the integrator at the applicable supply unit

(LH or RH).

Switch Removal

3.

Between the two limit switches (305), locate the faulty switch. See Fig. 21.

4.

Disconnect the wiring (301) for the limit switch at its power source. For reference, use the wiring diagram shown in Fig. 21.

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.

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.

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.

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

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. 21.

302, 303, 304

305

306

Pin 1

Pin 3

Pin 5

Pin 2

Pin 4

307, 308

309, 310

311

TI0200

Fig. 21

50 309028

Ram Assembly Service

Low/Empty Limit Switch Replacement

(continued)

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.

21.

9.

Reconnect the wiring (301) for the limit switch at its power source. For reference, use the wiring diagram shown in Fig. 21.

10. Make sure that the limit switch roller is positioned in the same location per the measurement in step

6. See Fig. 21.

11. Reinstall the cover on the junction box panel.

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.

15. Return the system to current readiness condition.

Depressurization Valve (Ball Seat

Applicator) Repair Procedure

Refer to instruction manual 310550 for the ball seat applicator (918537) 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.

Form Description

308147 Carbon Steel Dura-Flo

Pump 1800 with Premier

Air Motor

308148 Stainless Steel Dura-Flo

Pump 1800 with Premier

Air Motor

308213 Premier Air Motor

P/N

237555

241957

222800

309028 51

Ram Assembly Service

Replacing Wipers (Fig. 22)

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 Drum Changing procedure on page 32.

NOTE: You will need the special banding tool (C) shown in Detail C of Fig. 22 to tighten the strapping.

Order Part No. 168092 Banding Tool.

6.

Grip the strapping (413) 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.

3.

Separate the wiper joint (A) and bend back the strapping (413) covering the clamp setscrew (415).

See Detail A of Fig. 22. Loosen the setscrew, pull the end of the strapping through the clamp (414) and remove the wiper.

7.

Continue turning the tool handle until you see the strapping stop moving through the clamp (414).

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 (414).

4.

Slide the strapping (413) through the new wiper

(412). Slide the clamp (414) 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. 22.

5.

Install the wipers on the follower plate. Position the wipers so that their joints (A) are 180 apart.

9.

Pound the wiper all the way around with a rubber mallet until the joints (A) are butted tightly together.

10. Return the system to current readiness condition.

Refer to the Drum Changing procedure on page

32.

1

Detail A

412 414

415

413

Detail B

02949

Detail C

A

1

2

E

Slide the clamp onto the strapping and bend the strapping back approximately 3 in. (76 mm).

Turn clockwise to apply tension.

3 Cut the strapping and bend it back over the clamp.

Fig. 22

52 309028

2 F

412 H 3 414 413

02946

414

415

G

D

C

413 05712

Pump Assembly Service

Pump Removal

(Refer to System Parts Diagram; page 54.)

Air motor exhaust kit

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 Procedure on page 31.

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.

1.

Relieve the air pressure from the air motors and ram assembly to be serviced.

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.

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.

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.

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 Premier 45:1 SST Pump

(222939) weighs 240 lb (109 kg) per Form 308148.

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.

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 .

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 54.)

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.

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:

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 Drum Changing Procedure on page 32 .

309028 53

Parts

246981, 248306, 249339, 253676, 258910, and 255666 45:1 Left Hand Supply Unit

246982, 248307, 249340, 253677, 258911, and 255665 45:1 Right Hand Supply Unit

249152, 249341, 234972, 258956, and 24H017 34:1 Left Hand Supply Unit

249153, 249342, 234973, 258957, and 24H016 34:1 Right Hand Supply Unit

29 34 12 30 19 12 83 12 30

62, 64

65 61 57, 58, 59

20

21

22

36

37

39, 40, 73

56

55, 63

54

67, 72 69

32

See detail F

11

26

66

26

46

68

69

70

71

50

69, 44, 22

76

7

23

45

10

77

42, 43

26

60 28

18

38

10

15

93, 94

116

107

84

Detail F

97

97

46

16

26

38

27

13

9, 41, 48, 49

117

49, 31

6

52

99, 100

101

98

14

35, 48

17

47

3

4

1

5, 9, 49

80

33

54 309028

Parts

246981, 248306, 249339, 253676, 258910, and 255666 45:1 Left Hand Supply Unit

246982, 248307, 249340, 253677, 258911, and 255665 45:1 Right Hand Supply Unit

249152, 349341, 234972, 258956, and 24H017 34:1 Left Hand Supply Unit

249153, 349342, 234973, 258957, and 24H016 34:1 Right Hand Supply Unit

112 111 96 95

8

110

73, 115

87

86

14, 73, 74

103

104

32 108

102

109

113

114

24

19 20 53 25

81

82

10 See detail C

10

90

92 91 63, 89

88

93

116

10

Detail C

ti4546a

309028 55

Parts

246981, 248306, 249339, 253676, 258910, and 255666 45:1 Left Hand Supply Unit

246982, 248307, 249340, 253677, 258911, and 255665 45:1 Right Hand Supply Unit

Ref

No.

20

21

22

23

14

15

16

17

18

19

1

3

4

7

8

5

6

9

10

11

12

13

249152, 249341, 234972, 258956, and 24H017 34:1 Left Hand Supply Unit

249153, 249342, 234973, 258957, and 24H016 34:1 Right Hand Supply Unit

24

25

26

27

Part

No.

233460

C51238

101566

517288

241844

C38457

106464

C20463

C57799

C19019

C38324

119900

241902

C58306

C58361

C20450

196073

15D133

517272

100132

C12509

195319

158585

246989

248992

233127

249157

196085

C20811

C20490

119893

246929

234960

Description Qty

ELEVATOR, assembly 300 gallon

PLATE, adjuster

BRACKET, support

U–BOLT

CLAMP

CLAMP, support

CLAMP, support

WASHER, flat

TUBE, nylon

PANEL, pneumatic layout

12

64 ft.

1

4

2

4

8

1

2

2

3

1

NIPPLE

PUMP, 45:1 stainless steel

(Models 248306, 248307, 249339,

249340, 253676, and 253677 only)

PUMP, 45:1 stainless steel

(Models 246981 and 248982 only)

PUMP, 45:1 carbon steel

(Models 232729, 232730, 255665, and 255666 only)

PUMP, 34:1 stainless steel

(Models 249152, 249153, 249341,

249342, 234972, and 234973 only)

PUMP, 34:1 carbon steel

1

1

1

1

(Models 24H017 and 24H016 only)

U–BOLT

NUT, lock

TUBE, coiled

BRACKET, mounting

COUPLING, reducing

TEE, pipe

NIPPLE, reducing, hex

VALVE, check 1/2 in.

UNION, swivel

ELBOW, street

ELBOW, street (234972, 234973,

253676, 253677, 258910, 258911,

258956, and 258957only)

COVER, left

SCREW, socket head, flat

NIPPLE, hex

NIPPLE, hex (234972, 234973,

253676, 253677, 258910, 258911,

258956, and 258957only)

VALVE, check

VALVE, check (234972, 234973,

253676, 253677, 258910, 258911,

258956, and 258957only) 2

2

1

12

7

7

2

3

2

3

1

2

2

6

6

2

2

33

34

35

36

37

38

39

Ref

No.

28

29

30

31

32

40

41

42

43

44

45

Part

No.

C19254

C12039

C19032

111803

C19391

109495

115438

109570

214656

C19381

C12194

C19200

C19124

C19126

517254

110299

106149

521975

234963

46

47

118854

246990

246991

233128

249158

233461

48

49

50

52

53

54

55

56

57

58

59

100307

100133

617200

112698

196084

C52751

C19810

195454

C19197

C19204

C20003

Continued on next page.

Description

PLUG, pipe, plug, 1/4 in.

HOSE, air

UNION, swivel

SCREW, cap, hex

ELBOW

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

UNION, pipe (234972, 234973,

253676, 253677, 258910, 258911,

258956, and 258957only)

VALVE, ball

PUMP, 45:1 stainless steel

(Models 248306, 248307, 249339,

249340, 253676, 253677, 258910,

258911, 258956, and 258957 only)

PUMP, 45:1 stainless steel

(Models 246981, 248982, 258910,

258911, 258956, and 258957 only)

PUMP, 45:1, carbon steel

(Models 232729, 232730, 255665, and 255666 only)

PUMP, 34:1 stainless steel

(Models 249152, 249153, 249341,

249342, 234972, 234973, 258910,

258911, 258956, and 258957 only)

PUMP, 34:1 carbon steel

(Models 24H017 and 24H016 only)

NUT, hex

WASHER, lock

BRACKET, support

SWIVEL, elbow (m)

COVER, right

PLATE, limit switch

SCREW, cap

BRACKET, limit

WASHER

WASHER, lock

SCREW, cap

1

4

4

8

1

2

1

Qty

2

1

2

8

4

3

3

4

4

1

2

1

1

1

1

12

20

1

1

4

4

1

2

4

1

4

2

4

1

56 309028

Parts

(Continued from previous page)

246981, 248306, 249339, 253676, 258910, and 255666 45:1 Left Hand Supply Unit

246982, 248307, 249340, 253677, 258911, and 255665 45:1 Right Hand Supply Unit

249152, 249341, 234972, 258956, and 24H017 34:1 Left Hand Supply Unit

249153, 249342, 234973, 258957, and 24H016 34:1 Right Hand Supply Unit

Ref

No.

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

76

77

79

Part

No.

C07431

104227

C19138

100016

100018

C07560

15D140

15G091

C19491

119901

918537

C20485

114373

158566

15G092

234558

234962

C19660

119896

C19213

C19185

234428

234961

234255

249343

114158

Description

CONNECTOR, sealed

NUT, lock

SCREW, cap, hex

WASHER, lock

WASHER, lock spring

SWITCH, limit, with arm

MANIFOLD, three–way

MANIFOLD, three–way

(234972, 234973, 258910, 258911,

258956, and 258957 only)

TEE, fitting, 1–1/4 npt(f)

TEE, fitting, 1–1/4 npt(f)

(234972, 234973, 258910, 258911,

258956, and 258957 only)

APPLICATOR, ball seat, 1/2 in.

NIPPLE, hex

NIPPLE, hex (234972, 234973,

253676, 253677, 258910, 258911,

258956, and 258957 only)

COUPLING, hex pipe

COUPLING, hex pipe

(234972, 234973 only)

HOSE, coupled

HOSE, coupled (234972, 234973,

253676, and 253677 only)

FITTING, 1–1/4 x 1/2 in.

FITTING, 1–1/4 x 1/2 in.

(234972, 234973 only)

WASHER, lock

NUT, jam hex

HOSE, coupled

HOSE, coupled (234972, 234973,

253676, 253677, 258910, 258911,

258956, and 258957 only)

KIT, accessory, PLC interface

(Models 246981, 246982, 248306,

248307, 249152, 249153, 234972,

234973, 253676, and 253677 only)

KIT, accessory, PLC interface

(Models 249339, 249340, 249341,

249342,258910, 258911, 258956, and 258957 only)

ADAPTER, fitting

Qty

2

6

2

2

2

2

1

1

1

1

10

4

2

1

1

3

1

1

1

1

1

2

1

1

1

3

Part

No.

C20461

515147

115419

214849

517290

C19438

C19630

114112

113093

C20378

100469

502526

246994

120163

195356

158555

113332

617338

517455

C56572

196510

119417

516102

114508

233041

617180

101535

101533

617204

100549

Ref

No.

111

112

113

114

115

116

117

103

104

107

108

109

110

118

94

95

96

97

98

99

100

80

81

82

90

91

92

93

101

102

Description Qty

KIT, accessory

NIPPLE, reducing

VALVE, ball

BRACKET, mounting

SWITCH 2

CABLE 2

COUPLING, housing 2

2

2

1

2

SCREW

CLAMP, pipe

NIPPLE

PLATE, ram, Neoprene

ROD, connecting

NUT

WASHER, spring lock

CARRIAGE, weldment, 300 gallon

ELBOW, street

2

2

8

8

1

1

4

2

1

NIPPLE, reducing, hex

REGULATOR, air, 1/2p

ADAPTER, fitting

LUBRICATOR

HOSE

ELBOW, fitting, 90

NIPPLE, fitting, 1npt

CONNECTOR, fitting (f)

CONNECTOR, pipe

BRANCH, fitting

SCREW, cap, hex

VALVE, air three–way

VALVE, pressure, bleed

KIT, safety, lockout (not shown)

(Models 234972, 234973,

253676, and 253677 only) 1

2

2

1

2

2

1

2

2

2

2

2

2

2

309028 57

Parts

232729, 45:1 Left Hand Supply Unit, with carbon steel pump

232839, 45:1 Left Hand Supply Unit, with stainless steel and ceramic pump

232730, 45:1 Right Hand Supply Unit, with carbon steel pump (shown)

232840, 45:1 Right Hand Supply Unit, with stainless steel and ceramic pump

246921, 45:1 Right Hand Supply Unit, with stainless steel pump

246922, 45:1 Left Hand Supply Unit, with stainless steel pump

255666, 45:1 Left Hand Supply Unit, with carbon steel pump

255665, 45:1 Right Hand Supply Unit, with carbon steel pump

49, 50

2

1

35, 17, 14

13

3

47

7

8, 9, 11, 40

4

5, 9, 40, 11

39

10

15

16

46

26

45

24, 25 52

TI0141c

6, 31, 40

12

53, 25

29

34

30

19

TI0141

32, 33

20

21

22

36

26 41

44

43

42

58 309028

TI0195

12

TI0198

14

15

16

17

19

20

21

System Parts

232729, 45:1 Left Hand Supply Unit, with carbon steel pump

232839, 45:1 Left Hand Supply Unit, with stainless steel and ceramic pump

232730, 45:1 Right Hand Supply Unit, with carbon steel pump (shown)

232840, 45:1 Right Hand Supply Unit, with stainless steel and ceramic pump

246921, 45:1 Right Hand Supply Unit, with stainless steel pump

246922, 45:1 Left Hand Supply Unit, with stainless steel pump

255666, 45:1 Left Hand Supply Unit, with carbon steel pump

255665, 45:1 Right Hand Supply Unit, with carbon steel pump

1

2

Ref

No.

8

9

10

11

12

13

5

6

7

3

4

Part

No.

241902

241891

243510

C58360

C58361

C20450

196073

241837

C19126

100132

101566

100307

158585

233127

241957

246923

C51238

241838

241840

241844

106464

C20463

C57799

Description Qty

ELEVATOR, assembly 300 gallon; see page 73

FOLLOWER PLATE ASSY; see page 64

PLATE, adjuster, Uni-Drum

BRACKET, pump support

U-BOLT

CLAMP

KIT, accessory, pneumatic; see page 61

SCREW, cap hex head

WASHER, flat

NUT, lock

NUT, hex; 3/8-16

NIPPLE

PUMP, 45:1; carbon steel; used on Model 232729, 232730,

255665, and 255666 only; see manual 308147

PUMP, 45:1; stainless steel and ceramic; used on Model 232839 only; see manual 308148

PUMP, 45:1; stainless steel; used on Model 246921 only; see manual 308148

U-BOLT; 6 in. tube x 1/2-13un

KIT, accessory, PLC interface; see page 69

KIT, accessory, depressurization; see page 60

BRACKET, mounting

TEE, pipe; 1 in. npt

NIPPLE, fitting hex reducing; 1 in.

VALVE, check; 1/2 npt (fbe)

1

16

6

1

4

12

2

2

2

1

2

4

1

1

1

2

1

1

2

2

4

8

49

50

52

53

Ref

No.

40

41

42

43

44

45

31

32

33

34

35

36

39

46

47

22

24

25

26

29

30

Part

No.

C19019

196085

C20811

C20490

C12039

C19032

111803

184086

109495

115438

109570

214656

243488

100133

C38457

521850

C38324

233058

521975

118854

233128

243689

246924

101535

101533

112698

196084

Description Qty

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 63

LOCKWASHER, spring; 3/8 in.

COUPLING, reducing

VALVE, check

ELBOW, street

HOSE, coupled

UNION, pipe

VALVE, ball

PUMP, 45:1; carbon steel; used on model 232729, 232730,

255665, and 255666 only; see manual 308147

PUMP, 45:1; stainless steel and ceramic; used on model 232839 only;

20

2

2

2

2

2

8

2

2

1

1

8

2

2

1

;

12

2

2

1

1

1

1 see manual 308148

PUMP, 45:1; stainless steel; used on model 246922 only; see manual 308148

NUT, hex; 7/8 in.

LOCKWASHER, spring; 7/8 in.

ELBOW, swivel; 1/8 npt

COVER, right

4

4

1

4

1

309028 59

System Parts

Part No. 241840, Depressurization Kit

Ref

No.

Part

No.

Description

16a

16c

16d

16e

16f

C19254

918537

C20490

C19660

C19491

PLUG, pipe

APPLICATOR, ball seat; see 310550 for parts

NIPPLE

BUSHING

TEE

Qty

2

1

1

1

1

Ref

No.

Part

No.

16g

16h

C19391

215241

16j

16k

156172

157129

16m C20485

16n C19685

Description

ELBOW, swivel

HOSE

UNION

NIPPLE

NIPPLE

BUSHING

16c

16g

16e, 16f, 16m

16d

16a

16m

16j, 16n

16h

Qty

2

1

2

1

2

1

16j, 16k

TI0195

60 309028

System Parts

7a

7b

7c

7d

7e

7f

7g

7h

Part No. 241837, Pneumatic Accessory Kit

Ref

No.

Part

No.

Description Qty

7j

7k

7m

C12509

C12509

C12509

C12509

517272

C20378

517288

195319

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 66

248 in.

200 in.

23 in.

31 in.

2

2

2

1

CONNECTOR; 1/2 npt x 1/2 in. tube 1

TUBE; 1/2 in.

8 in.

TUBE; nylon 120 in.

Ref

No.

7n

7p

7r

7s

7t

7u

7v

7w

7x

7y

7z

Part

No.

C12194

C19399

C19200

C19124

C19213

517254

110299

106149

C20485

C19019

617200

Description Qty

TUBE; 1/2 in.

40 in.

CONNECTOR; 1/2 npt x 1/2 in. tube 1

WASHER, plain

SCREW, cap, hex hd

WASHER, lock

CLIP, tube

RIVET

FILTER, air; 1/2 npt

FITTING; 1/2 npt

UNION, swivel

SUPPORT, bracket

1

1

3

1

1

4

3

4

4

7d 7c

7a 7b 7e 7f

7g

7h

7j

7k

7z

7m

7n

7p

7r, 7s, 7t

7w, 7x, 7y

7u, 7v

TI0201

309028 61

Parts

Part No. 241839, Low/Empty Limit Kit (For Uni-Drum Use)

Ref

No.

Part

No.

Description Qty

Ref

No.

Part

No.

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 2

BRACKET, limit, low-level, Uni-Drum 1

4

4

2

4

307

308

309

310

311

312

C19810

100016

C19138

100018

C52751

104227

Description

CAPSCREW, socket head

WASHER, spring lock; 1/4 in.

SCREW, cap, hex head

LOCKWASHER, spring; 1/2 in.

PLATE, limit switch

NUT, lock

Qty

1

2

2

2

2

2

312

301

302, 303, 304

305

306

307, 308

309, 310

311

TI0200b

62 309028

Parts

Part No. 243488 Proximity Switch Accessory Kit

Ref

No.

Part

No.

Description Qty

Ref

No.

601

602

603

604

617337

100016

C19800

617338

COLLAR, clamp

WASHER, lock; 1/4 in.

SCREW, socket hd; 1/4–20 x 1/2 in.

2

BRACKET, proximity switch mounting 1

2

2

605

606

611

612

Part

No.

517455

C56572

196510

C19363

Description Qty

SWITCH, proximity; 18 mm

CABLE, proximity; 2 m long

HOUSING, coupling nut 1

SCREW, cup point set; 1/4–20 x 1/2 in. 1

1

1

602, 603

604

601

606

605

TI1479A

612

611

TI1479A

309028 63

Parts

Part Nos. 241891 and 243510, Follower Plate Assembly

603 634 633 632 631 604

603

642

641

640

631

636, 637

638

633, 639

635 TI0206

620

621

622

623

625

624

626

627

605

643

644

64 309028

TI0204

609

TI0138

610

611

TI0139

612,

613

614

615

616

Parts

Part Nos. 241891 and 243510, Follower Plate Assembly

Ref

No.

Part

No.

Description Qty

Ref

No.

Part

No.

615

616

620

621

622

623

624

625

603

604

605

609

610

611

612

613

614

516102

114508

617203

233041

617180

C20450

101535

101533

617204

C20449

517284

100549

C20461

515147

C19391

106464

C20463

CLAMP, pipe

NIPPLE

BAR, support

PLATE, follower; see page 72

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

2

2

1

2

2

2

1

2

4

4

1

4

2

1

1

2

1

636

637

638

639

640

641

642

643

644

626

627

631

632

633

634

635

214849

517290

C19438

C19630

114112

113093

C20378

100469

C19213

617202

113532

C19032

158585

112859

113332

158555

Description

LUBRICATOR, air line

HOSE

ELBOW; 1 in. npt

NIPPLE

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

SWIVEL, union

NIPPLE

FILTER, air; 1 in. npt

VALVE, ball

NIPPLE, reducing

Qty

6

4

2

1

2

2

2

1

2

4

1

2

1

2

2

2

309028 65

195319, PLC Pneumatic Layout Panel

129, 130

Parts

129

101

115

110 FOLLOWER VENT

AUTO OPEN

103

115

110

117

106

134

129

143

152

133

119

129, 130

TI0202b

107

133

134

105

66 309028

TI0143b

Parts

195319, PLC Pneumatic Layout Panel

Ref No.

Graco Part No.

Manufacturer Part No.

Description

101

102

103

104

105

135

136

137

138

139

140

141

127

128

129

130

131

132

133

134

142

143

145

152

153

154

155

156

157

120

121

122

123

124

125

126

113

114

115

116

117

118

119

106

107

108

109

1

1

0

111

112a

112b

195321

517313

C19254

115826

168491

115793

A–20

A–20P16

6522–53–32

BV–4

NVM151–N01–35

SEL–4–RED

6540–08–00

RO5X51P

R35–01C

RO5X51P

6532B–241RA

PR65C–35HA

2543–04–04

R35–02A

CDS–1P–010–B

6800–04–08

6540–53–00

PC125B–8

PCU–156F–2

PCU–500F–2

PCU–250F–2BLK

P6520–53–02

P6520–04–04

6510–08–08

P6520–08–08

P6430–04–02

P6510–04–04

6590–04–00

6800–53–04

6560–53–00

PC68BH–8

6590–08–00

6580–53–00

6520–04–02

P6520–53–04

6950–08–00

PCSCV–6

PC42G–64

6540–04–00

81–540–001

PC121B–8

SAD–1501–0–30

SEL–301–2

AOT

AO–30–4

HOFFMAN ENCLOSURE

HOFFMAN BACK PANEL

CAMOZZI SWL M ELB

UCI MUFFLER

SMC

UCI BALL VALVE

CAMOZZI UNION T

WATTS PANEL NUT

WATTS QUBE REGULATOR

Qty

WATTS PANEL NUT

MAC

MAC

CAMOZZI COUPLING

WATTS QUBE REGULATOR

DYNAMIC FLUID GAUGE

CAMOZZI REDUCER

CAMOZZI UNION T

POLLYCON MALE ELBOW

POLLYCON TUBING

POLLYCON TUBING

POLLYCON TUBING

CAMOZZI SWL M–ELB

CAMOZZI SWLM–ELB

CAMOZZI MALE CON

CAMOZZI SWT M–ELB

CAMOZZI M–BR T–SWL

CAMOZZI MALE CONN

CAMOZZI BULKHEAD

CAMOZZI REDUCER

CAMOZZI UNION Y

POLLYCON BULKHEAD CON

CAMOZZI BULKHEAD

CAMOZZI UNION

CAMOZZI SWL M–ELB

CAMOZZI SWL M–ELB

CAMOZZI DBL UNION

POLLYCON CHECK VALVE

POLLYCON REDUCER

CAMOZZI UNION T

CROUZET ELEMENT

POLLYCON (NOTE: DRILL 0.125 IN. HOLE IN CENTER OF PLUG)

UCI GAUGE

PNEUMADYNE 2 POSITION SELECTOR

PNEUMADYNE MOUNT

PNEUMADYNE VALVE

309028 67

1

3

2

3

2

2

2

5

2

1

1

5

2

4

1

3

1

50 ft

5 ft

20 ft

9

2

3

2

1

2

1

1

2

1

1

1

1

1

1

1

1

2

3

1

1

1

1

3

2

2

1

1

1

1

1

155

156

157

127

123

110

195319, PLC Pneumatic Layout Panel

101 115 113 137 115 113 137

Parts

118

129 130

125

110

103

141

140

135

145

DV8

126

139

126

136 123

104

118

141

130

131

123

117

106

See

Details

Below

118

112

139 114

R3

160

152

141

138 125 133 108 116 128 153

142

9327c

132

124

124

154

TI0142b

123

68 309028

Parts

241838 and 249343, PLC Interface Accessory Kit

Ref

No.

201

202

203

204

205

206

207

209

210

211

212

213

Part

No.

195330

C55568

119776

115440

119777

597151

111714

103739

596936

100016

517449

C07434

C19407

103219

Description

PLATE, mounting

SWITCH, pressure; 1/4 in. npt

(241838 only)

SWITCH, pressure; 1/4 in. npt

(249343 only)

VALVE, assembly

(241838 only)

VALVE, assembly

(249343 only)

ELBOW, male

SCREW, S.H.C.; CS PL #4-40x 5/8

WASHER, lock; CS PL #4

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

Qty

1

1

1

1

1

3

4

4

2

1

2

2

2

1

Ref

No.

214

215

216

217

218

219

220

221

222

223

224

225

226

227

228

229

230

Part

No.

C19391

C19264

C20536

195320

C51238

C19185

C19213

502526

501014

104172

115419

195356

241839

C07435

114158

C19047

C12509

Description Qty

ELBOW, 90 degree, tube; 1/4P x 1/4T 1

PLUG, pipe; 1/4 npt 2

CABLE, 2 cond. 96 in.

PANEL, junction box; see page 70

V-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

2

2

4

4

4

1

2

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

1

4

1

3

144 in.

2

1

223

221

224

B

228

A

230

226

222

223

229

217

203

216

227

201

230 212

225

227

202, 207, 209

214

211

230

215

A

B

205, 206

210

204 213

230

TI0196

309028 69

Parts

Part No. 195320 and 119773, Junction Box Panel

70

10

20

30, 40

80, 90, 100, 120 270

260, 280

110

190, 240

200

TI0205b

70 309028

Parts

Part No. 195320 and 119773, Junction Box Panel

Symbol

150

140

130

50

40

30

20

10

120

110

100

90

80

70

60

Ref No.

240

230

220

210

200

190

180

170

160

290

280

270

260

250

PB

SS

LT

LT

LT

LT

FU

DISC

FU

SUP

PB

PB

LT

LT

LT

LT

Description

P–N 90 DEG. CORD GRIP DB–1090

A–B PB 800T–XD2

A–B PB 800T FX 9A1

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

Remark U.L. File No.

K5100, 102

PB124

LT148

E160646

E40735

FU136, 143 E40735

SUP136, 144 E40735

PB119, 122

E14840-NKCR

LT148 E14840-NKCR

LT110

LT110

E14840-NKCR

E14840-NKCR

LT141

LT141

LT134, 106

LT134, 106

E14840-NKCR

E14840-NKCR

E14840-NKCR

E14840-NKCR

E40735

Qty

1

1

1

4

1

1

1

2

2

AR

31

1

2

12 in.

8

8

4

29 in.

29 in.

1

1

2

2

2

1

1

2

4

2

1

1

1

309028 71

Parts

Part No. 233041 Follower Plate

Ref

No.

Part

No.

Description

401 233040

402* 115782

403* 196052

404* 196053

405 517286

406* 115783

407* 196051

408* 100333

409* 100016

410* 112245

411* 115784

412** 617195

413** 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

Qty

2

288 in.

2

8

2

8

8

2

2

8

2

1

2

Ref

No.

Part

No.

Description Qty

414** 101817

415** 115785

416

417

418

419

420

421

422

617230

196072

233044

C19843

106115

102726

196122

CLAMP, banding

SCREW, set

GASKET

RING, adapter

PLUG, vent

CAPSCREW

LOCKWASHER

PLUG, pipe

SHIELD

423 114269 GROMMET

*These items may be purchase separately or in Kit 234958

**These items may be purchased separately or in Wiper Kit,

918241.

2

4

2

2

2

4

2

2

2

2

414

415

DETAIL B

418

423 422

421

419, 420

417

401

411*

407*

402*

403*

408*

409*

410* 405*

DETAIL A

406*

404*

SEE DETAIL A

413

412

TI0144

416

SEE DETAIL B

72 309028

Parts

Part No. 241902 Elevator Assembly

531

501

502

532

505

538

539

536, 537

516, 527, 528

529

530

509

506

510

507, 508

511 505

(Ref)

517

518

520

519

539 (Ref)

521

522

523

501 (Ref)

526

524

525

9586A

309028 73

Parts

Part No. 241902 Elevator Assembly

Ref

No.

Part

No.

Description

501

502

517269

C12194

505

506

114129

617206

507* C31001

508 C03043

509

510

516

C20808

617179

100321

517 C03042

518* 121306

519* 156593

520 C31000

521

522

523

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

Qty

4

136 in.

16

4

6

4

4

8

1

4

8

4

4

4

4

4

Ref

No.

Part

No.

Description

524* C20280

525* C03047

526* 158776

527 C19130

528

529

100018

194968

530

531

532

517281

C14022

C14007

O-RING

GUIDE, band

O-RING

SCREW, cap, hex hd

WASHER, lock

CLAMP

PIN, spring

LABEL, warning

LABEL, warning

536

537

538

539

100681

517411

114111

100361

NUT, jam, hex

KNOB

CONNECTOR, male

PLUG, pipe

* These items may be purchased separately or in

Repair Kit 918110

Qty

2

2

4

6

2

4

6

4

4

1

3

2

2

Recommended Spare Parts

Spare Parts for 45:1 and 34:1 Uni-Drum Supply Units

The customer should maintain an inventory of the spare parts (per unit) listed below.

CST

Units

SST

Units

Description Qty.

CST

Units

SST

Units

Description Qty.

222555

ÁÁÁ

222845 PUMP KIT

ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ

2 102774 102774

ÁÁÁ

LUBRICATOR KIT 1

ÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ

1

ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ

222881 222875

(45:1 models only)

PUMP KIT 2

517285

C20247

517285

C20247

AIR CYLINDER

O-RING 2

ÁÁÁ

(34:1 models only)

ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ

517286 517286 PLUNGER 2

222958 222958 PREMIER AIR MOTOR KIT 2

C03039 C03039

ÁÁÁ

UNI-DRUM ELEVATOR KIT 2

ÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ

222959 222959 AIR VALVE KIT 2

162440 162440 BOWL SEAL 1

ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ 222982 222982 DETENT KIT 2

502526 502526 PILOT VALVE 1

222981 222981

ÁÁÁÁÁÁÁÁÁ

2

ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ

501014

ÁÁÁ ÁÁÁÁÁÁÁÁÁ

501014 ACTUATOR

ÁÁÁ

1

515147 515147 AIR REGULATOR 1

918110 918110

ÁÁÁÁÁÁÁÁÁ ÁÁÁ

AIR CYLINDER KIT 1

ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁ

918537 918538 RECIRCULATING VALVE 2 918241 918241 WIPER KIT 1

ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ KIT

234958 234958 FOLLOWER PLATE VENT 1

115440 115440

ÁÁÁÁÁÁÁÁÁ

1

ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ

VALVE KIT

ÁÁÁ

C55568 C55568 SWITCH, pressure 1

ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁÁÁÁÁÁ

C07560 C07560 SWITCH, limit 1

ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ

74 309028

NOTE: IF OUTPUT IS HIGH (OPEN), PUMPS

309028 75

76 309028

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

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309028 77

Technical Data

Unit

Uni-Drum System

246981, 246982,

258910, 258911

Description

Overall dimensions:

Supply Units

(LH and RH)

Compressed air requirement

Main air inlet size

Overall Weight

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

1 in. npt(f)

Approximately 3950 lb (1792 kg)

Pumps (1/unit)

246991, 246992

Ratio 45:1 fluid to air power ratio

Maximum fluid working pressure 4500 psi (310 bar, 31.0 MPa)

Maximum air input pressure 100 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

Air motor piston effective area

Stroke length

Displacement pump effective area

6.9 gpm (26.1 liters/min) at 60 cycles/min

124 in.

2 (800 cm

2

)

4.75 in. (120 mm)

2.79 in.

2 (18 cm

2

)

Pump operating temperature

Air inlet size

Fluid inlet size

Fluid outlet size

Wetted components

150

°

F (65.5

°

C) maximum temperature

3/4 in. npsm(f)

2 in. npt(f)

1–1/2 in. npt(m)

Weight

Chrome, zinc, and electroless nickel plating; 304, 440 and 17–4 PH Grades of stainless steel; silicone nitride, ceramic, acetal, leather, and UHMWP

Approx. 240 lbs. (109 kg) per pump

78 309028

Technical Data

Unit

Uni-Drum System

248306, 248307,

249339, 249340,

253676, 253677

Supply Units

(LH and RH)

Description

Overall dimensions:

Compressed air requirement

Main air inlet size

Overall Weight

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

1 in. npt(f)

Approximately 3950 lb (1792 kg)

Pumps (1/unit)

246990, 246989

Ratio 45:1 fluid to air power ratio

Maximum fluid working pressure 4500 psi (310 bar, 31.0 MPa)

Maximum air input pressure 100 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

Stroke length

Displacement pump effective area

6.9 gpm (26.1 liters/min) at 60 cycles/min

124 in.

2 (800 cm

2

)

4.75 in. (120 mm)

2.79 in.

2 (18 cm

2

)

Pump operating temperature

Air inlet size

Fluid inlet size

150 ° F (65.5

° C) maximum temperature

3/4 in. npsm(f)

2 in. npt(f)

Fluid outlet size

Wetted components

Weight

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. 240 lbs. (109 kg) per pump

309028 79

Technical Data

Unit

Uni-Drum System

249152, 249153

249341, 249342

234972, 234973

258956, 258957

Supply Units

(LH and RH)

Description

Overall dimensions:

Compressed air requirement

Main air inlet size

Overall Weight

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

1 in. npt(f)

Approximately 3950 lb (1792 kg)

Pumps (1/unit)

249157, 249158

Ratio 34:1 fluid to air power ratio

Maximum fluid working pressure 3400 psi (231 bar, 23.1 MPa)

Maximum air input pressure 100 psi (7 bar, 0.7 MPa)

Pump cycles

Recommended pump speed for continuous operation

Maximum flow rate

Air motor piston effective area

6.5 per 1 gal. (3.8 liters)

60 cycles per min

9.2 gpm (34.6 liters/min) at 60 cycles/min

124 in.

2 (800 cm 2 )

4.75 in. (120 mm)

3.72 in.

2 (24 cm

2

)

Stroke length

Displacement pump effective area

Pump operating temperature

Air inlet size

Fluid inlet size

Fluid outlet size

150 ° F (65.5

2 in. npt(f)

°

3/4 in. npsm(f)

C) maximum temperature

1–1/2 in. npt(m)

Wetted components

Weight

304, 329, and 17–4 PH Grades of stainless steel; silicone nitride; acetal; Ultra-high molecular weight polyethylene, and leather

Approx. 240 lbs. (109 kg) per pump

80 309028

Technical Data

Unit

Uni-Drum System

232729, 232730,

232839, 232840,

246921, 246922,

255665, 255666

Supply Units

(LH and RH)

Description

Overall dimensions:

Compressed air requirement

Main air inlet size

Overall Weight

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

1 in. npt(f)

Approximately 3950 lb (1792 kg)

Pumps (1/unit)

(233127, 233128)

Ratio 45:1 fluid to air power ratio

Maximum fluid working pressure 4500 psi (310 bar, 31.0 MPa)

Maximum air input pressure 100 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

Air motor piston effective area

Stroke length

Displacement pump effective area

6.9 gpm (26.1 liters/min) at 60 cycles/min

124 in.

2 (800 cm

2

)

4.75 in. (120 mm)

2.79 in.

2 (18 cm

2

)

Pump operating temperature

Air inlet size

Fluid inlet size

Fluid outlet size

Wetted components

150

°

F (65.5

°

C) maximum temperature

3/4 in. npsm(f)

2 in. npt(f)

1–1/2 in. npt(m)

Weight

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

Approx. 240 lbs. (109 kg) per pump

309028 81

Technical Data

Unit

Pumps (1/unit)

(241957, 243689,

246923, 246924)

Description

Ratio

Specification

45:1 fluid to air power ratio

Maximum fluid working pressure 4500 psi (310 bar, 31.0 MPa)

Maximum air input pressure 100 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

Air motor piston effective area

Stroke length

Displacement pump effective area

6.9 gpm (26.1 liters/min) at 60 cycles/min

124 in.

2 (800 cm

2

)

4.75 in. (120 mm)

2.79 in.

2 (18 cm

2

)

Pump operating temperature

Air inlet size

Fluid inlet size

Fluid outlet size

Wetted components

150

°

F (65.5

°

C) maximum temperature

3/4 in. npsm(f)

2 in. npt(f)

1–1/2 in. npt(m)

Weight

304, 329 and 17–4 PH Grades of stainless steel; tungsten carbide; acetal; PTFE, Ultra-high molecular weight polyethylene, leather

Approx. 240 lbs. (109 kg) per pump

Related Publications

Product

Carbon Steel Dura-Flo Pump 1800 with Premier Air Motor

Carbon Steel Dura-Flo Pump 2400 with Premier Air Motor

Stainless Steel Dura-Flo Pump 1800 with Premier Air Motor

Stainless Steel Dura-Flo Pump 2400 with Premier Air Motor

Premier Air Motor

60:1, 1/2 in. Fluid Port Ball Seat Applicator

Dura-Flo

and Premier

are trademarks of Graco, Inc.

Form#

308147

308151

308148

308152

308213

310550

82 309028

Unit

Uni-Drum System

24H017, 24H016

Description

Overall dimensions:

Supply Units

(LH and RH)

Main air inlet size

Overall Weight

Technical Data

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

1 in. npt(f)

Approximately 3950 lb (1792 kg)

Pumps (1/unit)

233460, 233461

Ratio 34:1 fluid to air power ratio

Maximum fluid working pressure 3400 psi (231 bar, 23.1 MPa)

Maximum air input pressure 100 psi (7 bar, 0.7 MPa)

Pump cycles 6.5 per 1 gal. (3.8 liters)

60 cycles per min Recommended pump speed for continuous operation

Maximum flow rate

Air motor piston effective area

Stroke length

Displacement pump effective area

Pump operating temperature

Air inlet size

Fluid inlet size

Fluid outlet size

Wetted components

Weight

9.2 gpm (34.6 liters/min) at 60 cycles/min

124 in.

4.75 in. (120 mm)

3.72 in.

150

°

2

2

(800 cm

(24 cm

F (65.5

2 in. npt(f)

°

3/4 in. npsm(f)

2

2

)

)

C) maximum temperature

1–1/2 in. npt(m)

Carbon steel, chrome, zinc, and electroless nickle plating; 304, 440, and 17–4 PH Grades of stainless steel; tungsten carbide; ductile iron, acetal, PTFE, leather

Approx. 240 lbs. (109 kg) per pump

309028 83

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 procedures concernées.

Graco Information

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

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

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

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

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

Original Instructions. This manual contains English. MM 309028

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES

S

P.O. BOX 1441

S

MINNEAPOLIS MN 55440–1441

S

USA

Copyright 2000, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revised 09/2011

84 309028

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