Graco 311163ZAC User Manual

Instructions-Parts List

Model BESE1A Shown

ti16236a

™

SaniForce

311163ZAC

Bin Evacuation System

For use with 300 gallon (1135 liter) bags in bin containers. For professional use only. Not approved to European Explosive Atmosphere requirements.

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

Important Safety Instructions Read all warnings and instructions in this

manual. Save these instructions.

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

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

Basic Operation of SaniForce BES . . . . . . . . . . . . . . . . 7

System Components (Manual Control) . . . . . . . . . . . . . 8

System Components (Electronic Control) . . . . . . . . . . . 9

Before Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Anchoring Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installing Air Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 11

Connecting Pump Output Hoses . . . . . . . . . . . . . . . .13

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Checking Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 14

Prepare the Operator . . . . . . . . . . . . . . . . . . . . . . . . .14

Manual Stop (all models) . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Disengaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Manual Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Part No. 15E523 Manual Control . . . . . . . . . . . . . . . . 16

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 17

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Setting Air Pressures . . . . . . . . . . . . . . . . . . . . . . . . . 17

Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . 19

Connecting Pneumatic Control Panel Air Lines . . . . . 19

Installing Electronic Control Panel . . . . . . . . . . . . . . . 20

Part No. 15H145 and 15J902

Electronic Control Panel . . . . . . . . . . . . . . . . . . .21

Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setting Air Pressures . . . . . . . . . . . . . . . . . . . . . . . . . 23

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 24

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

System Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Air Motor Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 28

Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Cleaning Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Cleaning Ram Plate and Seal . . . . . . . . . . . . . . . . . . .29

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Replacing Cylinder Bearing (All Models) . . . . . . . . . . 31

Replacing Ram Plate Seal or Corner Seals

(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Replacing Proximity Switch

(Electronic Control Models Only) . . . . . . . . . . . . . 33

Electronic Control Panel Service

(Electronic Control Models Only) . . . . . . . . . . . . . 33

SaniForce BES Pump Matrices . . . . . . . . . . . . . . . . . . . . 34

3150 AODD Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Available Configurations* . . . . . . . . . . . . . . . . . . . . . . 34

Piston Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Available Configurations* . . . . . . . . . . . . . . . . . . . . . . 35

SaniForce BES Common Parts . . . . . . . . . . . . . . . . . . . . 36

SaniForce BES Common Parts (BESA7A shown) . . . 37

Pump Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Models 24G560 and 24G968, 5:1 SaniForce

Double Ball Pump Module (2 Pumps) . . . . . . . . . 38

Model 24P829, 5:1 SaniForce Priming Piston

Pump Module (2 Pumps) . . . . . . . . . . . . . . . . . . . 39

Model 24G561, 5:1 SaniForce Double Ball

Pump Module (4 Pumps) . . . . . . . . . . . . . . . . . . . 40

Model 24P815, 6:1 SaniForce Priming Piston

Pump Module (2 Pumps) . . . . . . . . . . . . . . . . . . . 41

Model 249488, 24E441, and 24C125 3150 SaniForce

Ball Check Pump Module (2 Pumps) . . . . . . . . . . 42

Model 249489 3150 SaniForce Flapper Check Pump

Module (2 Pumps) . . . . . . . . . . . . . . . . . . . . . . . . 43

Model 24G564 and 24G969 12:1 SaniForce Priming

Piston Pump Module (2 Pumps). . . . . . . . . . . . . . 44

Part No. 24G566 and 24G970 12:1 SaniForce Priming

Piston Pump Module (4 Pumps) . . . . . . . . . . . . . 45

Inflatable Seal, Plate, Frames, and Controls . . . . . . . . . 46

Part No. 15E523, 2 Pump Manual Control Panel . . . . 47

Part No. 15E523, 2 Pump Manual Control Panel,

Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . 48

Part No. 15M343, 4 Pump Manual Control Panel . . . . 49

Part No. 15M343, 4 Pump Manual Control Panel,

Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . 50

Part No. 949949, 2 Pump Pneumatic Control Panel . . 51 Part No. 949949, 2 Pump Pneumatic Control Panel . . 52 Part No. 570193, 4 Pump Pneumatic Control Panel . . 53 Part No. 570193, 4 Pump Pneumatic Control Panel . . 54 Common Parts for 570193 and 949949 Pneumatic

Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Common Parts for 570193 and 949949 Pneumatic

Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Part No. 949949 Pneumatic Control Panel,

Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . 57

Part No. 570193 Pneumatic Control Panel,

Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . 58

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

BES3xx, BES4xx, and BES8xx . . . . . . . . . . . . . . . . . 62

BESAxx, BESBxx, BESCxx, BESDxx, BESExx, and

BESFxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 64

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2 311163ZAC

Models

Maximum Working

Fluid Pressure, BES Part No.,

BESA7A, 410 (2.8, 28.3) 24G742 2 5:1 SaniForce Pump Electronic, Micrologix (2) BESA7F 410 (2.8, 28.3) 24G742 2 5:1 SaniForce Pump Electronic Contrologix (2) BESB7B 410 (2.8, 28.3) 24G742 4 5:1 SaniForce Pump Electronic, Micrologix (4)

BES3A1 120 (0.84, 8.4) 248273 2

BES3P1 120 (0.84, 8.4) 248273 2

BES4A1 120 (0.84, 8.4) 248274 2 BESE1A 1450 (10.1, 100.4) 24F625 2 12:1 SaniForce Pump Electronic, Micrologix (2) BESF6B 1450 (10.1, 100.4) 24F625 4 12:1 SaniForce Pump Electronic, Micrologix (4) BESF7B 1450 (10.1, 100.4) 24F625 4 12:1 SaniForce Pump Electronic, Micrologix (4) BESF9B 1450 (10.1, 100.4) 24F625 4 12:1 SaniForce Pump Electronic, Micrologix (4) BESA4C 410 (2.8, 28.3) 24G742 2 5:1 SaniForce Pump Manual (2) BESA7C 410 (2.8, 28.3) 24G742 2 5:1 SaniForce Pump Manual (2) BESAAC 410 (2.8, 28.3) 24G742 2 5:1 SaniForce Pump Manual (2) BESB7D 410 (2.8, 28.3) 24G742 4 5:1 SaniForce Pump Manual (4) BESCCC 410 (2.8, 28.3) 24P829 2 5:1 SaniForce Pump Manual (2)

BES3F3 120 (0.84, 8.4) 24E440 2

BES3P3 120 (0.84, 8.4) 248273 2

BES4P3 120 (0.84, 8.4) 248274 2

BES8B3 120 (0.84, 8.4) 24C124 2 BESDBC 650 (4.5, 44.8) 24F942 2 6:1 SaniForce Pump Manual (2) BESE1C 1450 (10.1, 100.4) 24F625 2 12:1 SaniForce Pump Manual (2) BESE5C 1450 (10.1, 100.4) 24F625 2 12:1 SaniForce Pump Manual (2) BESE7C 1450 (10.1, 100.4) 24F625 2 12:1 SaniForce Pump Manual (2) BESEAC 1450 (10.1, 100.4) 24D658 2 12:1 SaniForce Pump Manual (2) BESF6D 1450 (10.1, 100.4) 24F625 4 12:1 SaniForce Pump Manual (4) BESF7D 1450 (10.1, 100.4) 24F625 4 12:1 SaniForce Pump Manual (4) BESF9D 1450 (10.1, 100.4) 24F625 4 12:1 SaniForce Pump Manual (4)

per pump

psi (MPa, bar)

Pump Part No.

Qty. Pump Controls Approvals

3150 SaniForce Pump, Ball Check Electronic, Micrologix (2)

3150 SaniForce Pump, Flapper Check Electronic, Micrologix (2)

3150 SaniForce Pump, 3A Ball Check Manual (2)

3150 SaniForcePump, Ball Check Manual (2)

3150 SaniForce Pump, Flapper Check Manual (2)

3150 SaniForce Pump, 3A Ball Check Manual (2)

Models

311163ZAC 3

Models

Material Certification

Reference: SaniForce Product Family

Issue Date: September 14, 2011

All fluid contact materials in the SaniForce product family are FDA-Compliant and meet the United States Code of Federal Regulations (CFR) Title 21, Section 177 or are of a corrosion resistant grade Stainless Steel. This includes the below product groups:

1. SaniForce 1040, 1590, 2150 Air-Operated Double Diaphragm Pumps

2. SaniForce 1590, 3150 HS Air-0perated Double Diaphragm Pumps

3. SaniForce 1590, 3150 HS 3-A Certified Air-Operated Double Diaphragm Pumps

4. SaniForce 5:1, 6:1 and 12:1 Air-Operated Piston Pumps

5. SaniForce Diaphragm Pump and Piston Pump Drum Unloaders

6. SaniForce Diaphragm Pump and Piston Pump Bin Evacuation Systems

Bradley A. Byron Quality Manager Graco Inc.

4 311163ZAC

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

Warning

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

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

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

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

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

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

• Connect only to grounded power source.

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

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

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

• Do not put your hand over the fluid outlet.

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

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

• Tighten all fluid connections before operating the equipment.

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

311163ZAC 5

Warnings

Warning

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

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

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

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

and follow the Pressure Relief Procedure when equipment is not in use.

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

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

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

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

6 311163ZAC

Overview

Operation Overview

The SaniForce BES evacuates fluids from a 300 gallon (1135 liter) bag in a plywood box, IBC, or collapsible bin.

The SaniForce BES consists of a frame, two or four Graco pumps, ram plate with an inflatable seal, ram air cylinder, and a manual or electronic control panel.

Basic Operation of SaniForce BES

1. The operator places the bin inside the frame.

2. Using the control panel, the operator lowers the ram plate on top of the material.

3. The operator aligns and centers the bin with the ram plate.

4. The operator inflates the ram plate seal, applies down pressure to the ram plate, and turns on the pumps.

5. The pumps evacuate the material out of the bin.

6. The operator stops the pumps, deflates the seal, and raises the ram plate out of the bin.

7. The empty bin is removed, another bin is put in place, and the SaniForce BES is ready to repeat the process.

311163ZAC 7

Overview

AIR IN

PUMP 1

PUMP 2

RAM UP

RAM DOWN

Bottom View of Manual Control Panel (B)

Seal

Ram Up

Ram Down

Pump 2

Pump 1

Air In

System Components (Manual Control)

See FIG. 1.

A Stainless Steel Frame: supports the cardboard or

collapsible bin.

B Manual Control Panel: contains pneumatic

controls to regulate the air pressure to pump air motors, ram, and ram plate seal in order to control:

• pump air motor pressure

• pump speed control

• ram up and down pressure

• seal pressure

• turn the pumps on or off

• inflate or deflate the ram plate seal

• raise or lower the ram plate

C Air Shutoff Valve: shuts off air to the pneumatic

control panel (B).

D Sanitary Pumps: pump material from the bin to the

target application.

E Air Cylinder: raises and lowers the pumps and the

ram plate in and out of the material container.

F Ram Plate: applies an even amount of pressure to

the material in the bin. When the ram plate seal is inflated, it creates a seal. The ram plate presses down on the material in the bin to assist the pumps in delivering the material.

FIG. 1: Typical Installation (Manual Control; BES3P3 shown)

8 311163ZAC

System Components (Electronic Control)

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TOP VIEW

Seal

Ram Up

Ram Down

Pump 2

Pump 1

TI16216a TI16217a TI16218a

Overview

See FIG. 2.

A Stainless Steel Frame: supports the cardboard or

collapsible bin.

B Pneumatic Control Panel: contains pneumatic

controls to regulate the air pressure to pump air motors, ram, and ram plate seal in order to control:

• pump air motor pressure

• pump speed control

• ram up and down pressure

• seal pressure

C Electronic Control Panel: is connected to the

pneumatic control panel with the 24 VDC cable supplied. The panel uses 110 VAC input (20 amp circuit). If a flow meter is used, it must also be connected. The electronic control panel sends signals to:

• turn the pumps on or off

• inflate or deflate the ram plate seal

• raise or lower the ram plate

• turn off the air supply to the ram plate so the

ram can slowly lower into the bin

D Sanitary Pumps: pump material from the bin to the

target application.

E Air Cylinder: raises and lowers the pumps and the

ram plate in and out of the material container.

F Ram Plate: applies an even amount of pressure to

the material in the bin. When the ram plate seal is inflated, it creates a seal. The ram plate presses down on the material in the bin to assist the pumps in delivering the material.

FIG. 2: Typical Installation (Electronic Control; BESA7A shown)

311163ZAC 9

Before Installing

Uncrating Equipment

NOTICE

Moving the SaniForce BES off the pallet without following this uncrating procedure will damage equipment.

Uncrate the SaniForce BES as follows:

1. Inspect the crate for shipping damage. Contact the carrier if damaged.

2. Remove plywood sides and top of crate.

3. Check the contents for loose or damaged parts.

4. Compare the packing slip against items inside the crate. Immediately call your Graco distributor about any shortages or damage.

5. Remove the band strap holding the cylinder bin to the frame.

6. Remove and unpack the air cylinder bin and pumps (if applicable).

NOTE: See your system component manuals to become familiar with system components and general operation.

• Provides easy and safe access to the air supply shutoff valves and the pneumatic control panel. Graco recommends a minimum of 3 ft (0.91 m) of open space in front of the panel.

• Provides enough overhead clearance (11 ft, 3.4 m recommended) for installing and servicing the air cylinder and connecting air supply lines to the pneumatic control panel.

• Has a flat, level floor.

Moving Frame to Location

The frame is shipped with several major components attached and weighs about 2500 lb. (1134 kg). To avoid injury and equipment damage, follow instructions below. Never have one person move or lift the frame.

• Do not remove the frame from the pallet at this time.

• Use a forklift or hand truck and support devices, such as a hoist, and have an adequate number of personnel to move the frame to the installation site.

Location

When selecting a location, make sure the location:

• Is close to where the fluid is being delivered to minimize back pressure and maximize flow rate.

• Provides enough room around the equipment for maintenance.

• Does not interfere with opening the pneumatic control panel door or frame door (on one or both sides). If the frame is rotated 180°, the frame door will open from left to right or from right to left.

• Provides enough room on the right and/or left side of the SaniForce BES to easily load and unload fluid bins with a forklift or pallet-jack hand truck.

10 311163ZAC

• Avoid jarring or tilting the frame while moving it.

NOTE:

• Ensure there is an adequate compressed air supply. Refer to air motor/pump manual for your pump air consumption. About 250-300 scfm at 100 psi (0.7 MPa, 7 bar) is required to operate the pumps at the maximum rate.

• Have all component manuals available for specific component requirements.

• Ensure that all hoses are properly sized and pressure rated for the system.

Installation

602

TI3116A

Installation

Anchoring Frame

1. Remove bolts holding the frame (602) to the shipping pallet.

The overall system weighs about 2400-3400 lb. (1089-1542 kg). To avoid injury and equipment damage, follow instructions below. Never have one person move or lift the frame.

2. To lift the system, use the top joists on the frame with a forklift. Have an adequate number of personnel to lift or move the unit; avoid jarring or tilting it.

3. Remove the pallet and all remaining shipping supports from underneath the frame.

The four base footings of the frame and the bottom of the bin must be level on the same surface in order for the SaniForce BES to operate properly. If necessary, level the SaniForce BES using sanitary metal shims. Make sure the frame does not wobble.

3. Secure the air cylinder (4) to the frame (602) with the screws (20) and washers (19). See F

4. Install the air motor mounting plate (402), slipping plate over the top and down the length of air cylinder (4).

5. Using tubing (6), connect the cylinder upper air supply line to the upper 1/2 in. elbow (26).

6. Using tubing (6), connect the cylinder lower air supply line to the 1/2 in. lower elbow (26).

IG. 4.

Anchor the four foot pads to the floor. To prevent the frame from being pushed off the floor, the anchor bolts must be long enough to withstand the 5027 lb. (22.36 kN) of downward force that the air cylinder can exert.

Use the holes in the four base footings as a guide and drill holes for 1/2 in. (13 mm) bolts. Bolt the frame to the floor with anchors.

Installing Air Cylinder

The air cylinder weighs about 130 lb. (59 kg). To avoid injury and equipment damage, follow instructions below. Never have one person move or lift the frame.

NOTE: All models do not use the same parts. Refer to parts lists for your model, pages 35-45.

1. Using a hoist, lift the air cylinder (4) into position on top of the frame (602). See F

IG. 3.

FIG. 3: Air Cylinder Shaft

7. Loosen but do not remove the screws (18) from the frame (602).

8. Supply air to main air inlet on pneumatic control box.

9. Remove the two band straps that hold the ram plate (502) to the shipping pallet. Do not remove the pallet.

10. Apply sanitary grease (36, supplied) to the cylinder shaft threads to avoid damaging them. Align and screw the air cylinder shaft (A) into the ram plate (502). See F erly, do not force it. Re-check alignment of plate (502).

IG. 3. If the shaft does not thread prop-

2. Lower the air cylinder shaft (A) through the center hole in the frame.

311163ZAC 11

Installation

405, 411

602

408, 409, 410

402

502

404

TI16216a TI16234a

FIG. 4: Air Motor Mounting Plate (BESA7A shown)

11. Uncrate and mount pumps to the ram plate (502), with outlets facing away from pneumatic control panel. Secure pumps to plate using the following gaskets and hardware:

• Part No. BESFxx and BESExx: gasket (415),

screws (406), and washers (407)

• Part No. BESAxx, BESBxx, BESCxx, and

BESDxx: gasket (407), tri-clamp (406)

• Part No. BES3xx and BES4xx: gasket (407),

tri-clamp (406)

• Part No. BES7xx: screws (406), clamps (407),

and gasket (415)

12. For part numbers BES3xx, BES8xx, and BES4xx install the two connecting rods (404) to the ram plates. Secure with screws (405) and washers (411).

13. Install cylinder guide bearings (408) on top of the air motor mounting plate (402), using screws (409) and washers (410).

NOTE: The open arch in the cylinder guide bearings (408) fits around tie rods on the air cylinder (4).

16. On the control panel, switch to the RAM UP position. Raise the ram and set the manual stop latch to Engage position. See page 15. Remove the pallet and any other shipping material.

14. Tighten lock nuts (7).

15. Using tubing (6), connect pneumatic control panel to air motor air inlets.

12 311163ZAC

Connecting Pump Output Hoses

406, 407

TI16216a TI16233a

Installation

NOTE:

• The output hose(s) (supplied by others) should already be installed, with riggings and supports, and ready for connection to the 2 in. tri-clamp (412, supplied on some systems). See F

• Make sure the output hose(s) are sized and pressure-rated for the system. Use only electrically conductive hoses with spring guards on both ends.

• The fluid hoses must move freely, without kinking, when the pumps move up and down.

• The two pump AODD systems do not include a hose, clamps, or gaskets on the outlet side.

IG. 5.

Two Pump System Includes:

BESAxx, BESBxx, BESCxx, BESExx, BESFxx

2 in. (51 mm) tri-clamp sanitary clamps (412) 4 or 6 2 in. (51 mm) tri-clamp sanitary gaskets (413) 4 or 6

BESDxx

1.5 in (38 mm) tri-clamp sanitary clamps (412) 4

1.5 in (38 mm) tri-clamp sanitary gaskets (413) 4

Qty

Four Pump System Includes:

Description Qty

2 in. (51 mm) tri-clamp sanitary clamps (412) 8 or 12 2 in. (51 mm) tri-clamp sanitary gaskets (413) 8 or 12

FIG. 5: Connect pump outlet hoses (BESA7A shown)

311163ZAC 13

Installation

Grounding

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

Pump: use the ground wire and clamp (supplied). There are two styles of grounding connections on pump air motors.

If you have ground screw shown in F

to order part no. 222011 ground wire, ring terminal, and clamp assembly (Y). To install 222011, remove the ground screw (Z) and insert it through the eye of ring terminal (X), then tighten ground screw back into air motor as shown in F a true earth ground.

If you have ground screw shown in F

grounding lug locknut (W) and washer (X). Insert one end of the 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. Order 237569 ground wire and clamp assembly.

IG. 6. Connect the other end of the wire to

IG. 6, you need

IG. 7, loosen the

Air and fluid hoses: use only electrically conductive

hoses with a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity. Check the electrical resistance of your air and fluid hoses. If the total resistance to ground exceeds 29 megohms, replace the hose immediately.

Air compressor: follow manufacturer’s recommendations.

Dispense valve: ground through connection to a properly grounded fluid hose and pump.

Fluid supply container: follow your local code.

Solvent pails used when flushing: follow your local

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

To maintain grounding continuity when flushing or relieving pressure: hold a metal part of the dispense

valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

Checking Resistance

FIG. 6: Ground Screw

FIG. 7: Ground Screw

Have a qualified electrician check the resistance between each pump and true earth ground. Resistance must be less than 0.25 ohms. If the resistance is greater, a different ground site may be required. Do not operate the system until you correct the problem.

Prepare the Operator

Anyone operating the equipment must be trained to safely operate all system components and properly handle fluids used. Operators must read all instruction manuals, tags, and labels before operating equipment.

14 311163ZAC

Manual Stop (all models)

Engage Position

Disengage Position

Lock Position Move latch until tab snaps into roller grab mounted under frame.

TI16236a

TI17829a

TI17828a

TI15702a

The overall system weighs about 2400-3400 lb. (1089-1542 kg). To avoid injury, always set manual stop latch to Engage position when working under the plate.

Engaging

1. Raise plate until it stops at the top.

Manual Stop (all models)

Lockout

A lockout has been provided to lock the plate in the raised position.

1. Engage the manual stop. See Engaging.

2. Insert a padlock through the hole in the handle and the mating piece on the frame.

NOTE: Follow any national and state lockout/tagout codes and local regulations.

2. Set latch to Engage position. See F

IG. 8.

Disengaging

1. Make sure plate is raised all the way up (not resting on stop).

2. Move latch to Disengage position. See F

IG. 8.

FIG. 8. Manual Stop (BESA7A shown)

311163ZAC 15

Manual Control System

Tee is used on four pump systems only

ti22760

Manual Control System

Part No. 15E523 Manual Control

See FIG. 9.

Ref. Key Switch/Button Name Operation

A Seal Inflate On/Off Switch to ON to inflate ram plate seal.

Switch to OFF to deflate ram plate seal. B Ram Plate Seal Pressure Gauge Displays Ram plate seal pressure. C Ram Plate Seal Regulator Adjust to raise or lower ram plate seal pressure. D Pump On/Off Switch to ON to run the pumps.

Switch to OFF to stop the pumps. E Pump Pressure Gauge Displays current pump pressure. F Pump Pressure Regulator Adjust to raise or lower pump inlet air pressure. G Ram Directional Switch Switch to UP to raise the ram plate.

Switch to DOWN to apply ram pressure to the material.

Switch to NEUTRAL to hold the position of the ram plate. H Ram Up Pressure Gauge Displays Ram Up operation pressure.

J Ram Up Regulator Adjust to raise or lower ram up pressure. K Ram Down Pressure Gauge Displays Ram Down operation pressure. L Ram Down Regulator Adjust to raise or lower ram down pressure.

FIG. 9: Part No. 15E523 Manual Control

16 311163ZAC

Manual Control System

Pressure Relief Procedure

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from injection, splashing or moving parts. Relieve pressure when you stop pumping and before cleaning, checking, or servicing equipment.

1. To turn off the pumps move pump switch to OFF.

2. Shut off the air to the pumps by closing the bleed-type air shutoff valve on the pumps’ air supply line, or disconnect the air line.

3. Open all system fluid drain valves that are downstream of the pumps.

Initial Startup

NOTE: Pump cavitation occurs when the pump cylinder

does not fully load with material on the up stroke and an air pocket forms in the material after the pump changeover. If pump cavitation occurs, increase the ram down air pressure.

10. Adjust the seal vacuum pump air regulator to 15 psi (103 kPa, 1.0 bar).

11. Deflate the seal.

12. Press the RAM UP button. If the ram does not raise, increase the ram up air regulator pressure.

13. Verify the seal is completely deflated after the ram plate exits the bin. If it is not, deflate the seal.

14. When adjustments are complete, close the pneumatic control panel door.

15. Follow Unloading the Bin procedure, page 18.

16. The system is now ready for standard operation. See page 17.

When raising or lowering the ram plate, keep hands and body away from ram plate and bin lip.

This procedure takes you through the settings, adjustments, and other steps that must be completed before the system is ready for daily operation.

1. Fill all the pumps packing nut/wet cups 1/3 full with a compatible lubricant if applicable. Refer to your pump manual for details. Do not use Graco Throat Seal Lubricant with a sanitary application.

2. Turn on the air to the pneumatic control panel.

3. Turn SEAL INFLATE to OFF.

4. Open the air shutoff valves for the pneumatic controls and pumps.

5. Open the pneumatic control panel door. Check for air leaks.

6. The equipment was tested with water. Flush the system before loading material. See page 28.

Setting Air Pressures

Each system function has an associated air pressure. Air pressure regulators are located on the pneumatic control panel. Set initial air pressures as shown in the table below. Make adjustments as needed during operation. See F

Ref.

Key

B* SEAL INFLATE 7 (48, 0.5)

H RAM UP 30 (207, 2.1) K RAM DOWN 30 (207, 2.1) E PUMP 50 (345, 3.4)

*A pressure relief regulator is required when a control system other than a Graco control panel is used.

IG. 9.

Function Regulator Setting

psi (kPa, bar)

Max: 15 (103, 1.0)

7. Follow Loading the Bin procedure, page 18.

8. Set the ram down air regulator to 30 psi (207 kPa,

2.1 bar). Adjust as needed.

9. Adjust the pump regulator as needed.

311163ZAC 17

Manual Control System

38*

37*

TI16235a

* Not used with BESCCC.

Standard Operation

Loading the Bin

When raising or lowering the ram plate, keep hands and body away from ram plate and bin lip.

NOTE: When raising and lowering the ram plate, make sure there are no objects obstructing the unit.

1. Open the air shutoff valves for the air controls and pumps.

2. On the control panel, switch to the RAM UP position. If the ram does not elevate, increase the ram up air regulator pressure on the pneumatic control panel.

3. Move the bin in front of the frame.

4. Remove the lid from the fluid bin to expose the fluid bag. If present, open the outer plastic bag and pull it up over the sides of the bin, exposing the aseptic inner bag.

12. Use the ram plate handles to center the ram plate inside the bin. Be careful not to pinch the inflatable seal when it enters the bin.

5. Make sure the bag is taut and secure it in place.

6. Secure the bag sides by using clamps (37) and tubes (38). See F

7. Load the bin of material into the center of the frame. Center the bin with the ram plate.

8. Initial Startup Only: The frame has spring-loaded guides to stabilize the bin. Adjust the guides equally with the screws on all four sides of the bin. Leave enough space between guides and bin to allow for removal of the bin.

9. Make sure the corner seals (21) are in place.

10. Use corners (39) to help guide the plate. See F

10.

11. Switch to the Ram Down position

IG. 10.

FIG. 10

Unloading the Bin

NOTE: When raising and lowering the ram plate, make

sure there are no objects obstructing the unit.

1. Follow the Pressure Relief Procedure, page 17.

2. Ensure seal is deflated and ram is raised.

IG.

3. Unload the bin from the frame.

System Shutdown

Follow the Pressure Relief Procedure, page 17.

Depending on the type of material, it may be best to deflate the seal and raise the ram plate out of the material or keep the ram plate lowered in the bin. Some materials dry and harden when exposed to air. Cover materials when they are not being used.

18 311163ZAC

Electronic Control System

Key:

A Pumps 1-4 Air Supply B Control Box Air Supply C Seal Air DRam Down Air ERam Up Air F Pump 1 Air G Pump 2 Air H Pump 3 Air J Pump 4 Air K Exhaust Muffler

CDEFGHJ

ti19841a

Electronic Control System

Connecting Pneumatic Control Panel Air Lines

Air supply to panel must be filtered, dry and capable of delivering a minimum of 100 scfm at 100 psi (0.7 MPa, 7 bar). Refer to the table below and the Pneumatic Diagrams, pages 57 and 58, to make the top and bottom panel connections.

Origin Destination

Ref. Key

C Seal Air Supply Ram Plate Seal Inflates ram plate seal. D Cylinder Upper Air Supply Upper Port On Air Cylinder Applies down force on ram plate when

E Cylinder Lower Air Supply Lower Port On Air Cylinder Applies up force on ram plate when

F Pump 1 Air Supply Pump 1 Supplies air to pump 1.* G Pump 2 Air Supply Pump 2 Supplies air to pump 2.* H Pump 3 Air Supply Pump 3 Supplies air to pump 3.*

J Pump 4 Air Supply Pump 4 Supplies air to pump 4.*

Top Panel Connections Component Connections Function

RAM PRESS is selected.

RAM UP is selected.

Bottom Panel Connections Pneumatic Source Connections

B Air Controls Air Inlet —

1/2 in. npt(f) A Pumps Air Inlet — 1 in. npt(f) Pumps Air Supply Line Supplies input air pressure to pumps. K Exhaust (no air line connection is

needed)

* Pump air valves open when PUMP SLOW or PUMP FAST (SV1 or SV2) are activated.

Air Controls Air Supply Line Supplies air to open and close air

valves.

Air Controls Exhaust Line Connects to a muffler that expels pres-

surized air from system when ram plate is raised or seal deflated.

FIG. 11: Air Control Panel (570193, 4 pump shown)

311163ZAC 19

Electronic Control System

Installing Electronic Control Panel

• Locate the electronic control panel so the operator has an unobstructed view of the SaniForce BES to avoid starting equipment when other personnel could be injured.

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

Mount the electronic control panel in a level, vertical position on a sturdy surface. Make sure there is enough room to open the enclosure door.

Connect 110 VAC (20 amp) power to the POWER IN cable connector. The 110 VAC line must be rigidly piped.

Connect 24 VDC cable between the electronic and pneumatic control panels.

If a flow meter is used, its cable must also be connected to the electronic control panel. Contact the flow meter supplier for installation information.

Discrete Devices 110 VAC Manual Push Buttons

Emergency Stop Power

Manual Selector Switches

Seal Inflate Pump Slow Pump Fast

Digital Inputs 24 VDC

Ram Jog Ram Up Start Stop

High Speed Counter. . . . . Flow meter sensor

Ram Low . . . . . . . . . . . . . Proximity switch 1

Seal Inflate . . . . . . . . . . . . PSI switch 1

Standard Functions

Start . . . . . . . . . . . . . . . . . Initiates pumping cycle*

Stop . . . . . . . . . . . . . . . . . Activates seal deflate**

Seal Inflate . . . . . . . . . . . . Activates seal deflate*

Seal Deflate . . . . . . . . . . . Activates seal deflate*

Ram Up . . . . . . . . . . . . . . Initiates ram up*

Ram Jog. . . . . . . . . . . . . . Activates ram jog*

Ram Press . . . . . . . . . . . . Initiates ram press*

Pump Slow . . . . . . . . . . . . Activates pumps in slow

mode*

Pump Fast . . . . . . . . . . . . Initiates pumps in fast

mode*

Digital Outputs 24 VDC

Pumps 1 and 2 On Slow. . Solenoid 1

Pumps 1 and 2 Fast . . . . . Solenoid 2

Ram Press . . . . . . . . . . . . Solenoid 3

Ram Up Solenoid 4 Ram Jog Solenoid 5 Seal Off (vacuum

pump on) . . . . . . . . . . . . . Solenoid 6

Seal On . . . . . . . . . . . . . . Solenoid 7

Optional Remote Output . Energized during a pump

cycle

* Normally open ** Normally closed

20 311163ZAC

+ 44 hidden pages