Graco 313528H Operation Manual
Operation
TI10865A
D200 Rams with Electronic
Crossover Shown
Tandem Supply
313528H
Systems
For use with non-heated bulk supply of medium to high viscosity sealants and adhesive
materials. For professional use only.
Not for use in explosive atmospheres.
125 psi (0.9 MPa, 9 bar) Maximum Air Inlet Pressure - S20 3 in. rams
150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure - D60 and D200 3 in. rams
125 psi (0.9 MPa, 9 bar) Maximum Air Inlet Pressure - D200S 6.5 in. rams
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
EN
US Patent Pending
The Graco Control Architecture Electric Components are Listed in Intertek’s Directory of Listed Products.
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System Description . . . . . . . . . . . . . . . . . . . . . . 10
Ram Installation and Setup . . . . . . . . . . . . . . . . 10
Fluid Filter Kit Installation . . . . . . . . . . . . . . . . . 10
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Integrated Air Controls . . . . . . . . . . . . . . . . . . . 11
Pneumatic Crossover System Components . . . 12
Electronic Crossover System Components . . . . 14
255468 Light Tower Accessory . . . . . . . . . . . . . 16
Communications Gateway Module . . . . . . . . . . 16
CGM Status LED Signals . . . . . . . . . . . . . . . . . 16
Display Module (Electronic Crossover Systems) 17
Fluid Control Module . . . . . . . . . . . . . . . . . . . . . 21
Electronic Crossover Operation . . . . . . . . . . . . . 22
Pressure Relief Procedure . . . . . . . . . . . . . . . . 22
Flush Before Using Equipment . . . . . . . . . . . . . 22
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Automatic Crossover . . . . . . . . . . . . . . . . . . . . . 25
Manual Crossover . . . . . . . . . . . . . . . . . . . . . . . 25
Recirculate Function . . . . . . . . . . . . . . . . . . . . . 26
Depressurize Function . . . . . . . . . . . . . . . . . . . 26
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diagnose Alarms . . . . . . . . . . . . . . . . . . . . . . . . 28
Clear Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Alarm Codes and Troubleshooting . . . . . . . . . . 28
Appendix A - User Interface Display . . . . . . . . . . 31
Display Overview . . . . . . . . . . . . . . . . . . . . . . . 31
Display Details . . . . . . . . . . . . . . . . . . . . . . . . . 31
Setup Mode Screens . . . . . . . . . . . . . . . . . . . . 33
Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . 38
Fluid Filter Kit Dimensions . . . . . . . . . . . . . . . . . . 43
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
California Proposition 65 . . . . . . . . . . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 46
2 313528H
Related Manuals
Component Manuals in U.S. English:
Manual Description
313529 Tandem Supply Systems Repair-Parts
313526 Supply Systems Operation
313527 Supply Systems Repair-Parts
Check-Mate
312375
tions-Parts
Check-Mate
312376
Instruction-Parts
Dura-Flo
311827
180cc, 220cc, 290cc) Instructions-Parts
Manual
311825
311717
311828
311826
311833
312889
312467
312468
312469
312470
311238
312796
Dura-Flo
580cc) Instructions-Parts Manual
Carbon Steel Displacement Pump (1000cc)
Instructions-Parts Manual
Dura-Flo
220cc, 290cc) Instructions-Parts Manual
Dura-Flo
Instructions-Parts Manual
Two-Ball NXT
Instructions-Parts Manual
60 cc Check-Mate Displacement Pump
Repair Parts Manual
100 cc Check-Mate Displacement Pump
Repair Parts Manual
200 cc Check-Mate Displacement Pump
Repair Parts Manual
250 cc Check-Mate Displacement Pump
Repair Parts Manual
500 cc Check-Mate Displacement Pump
Repair Parts Manual
™
NXT
Instructions-Parts
™
NXT
Instructions-Parts
312374 Air Controls Instructions-Parts
312491 Pump Fluid Purge Kit
®
Displacement Pumps Instruc-
®
Pump Packages
™
Displacement Pumps (145cc,
™
Displacement Pumps (430cc,
™
Pump Packages (145cc, 180cc,
™
Pump Packages (430cc, 580cc)
™
Pump Packages (1000cc)
Air Motor (Nxxxxx models)
Air Motor (Mxxxxx models)
Related Manuals
312492 Drum Roller Kit Instruction
312493 Light Tower Kit Instruction
312864
313138
Communications Gateway Module, Instruc-
tions-Parts
Supply System Communications Gateway
Module Installation Kit, Instructions-Parts
406681 Platen Cover Kit
334048 EPDM Hose Wiper Kit
334644
313528H 3
Xtreme
®
XL Air Motor, Instructions-Parts
Models
ID
TI11157A
Models
Check the identification plate (ID) for the 6-digit part number of your tandem sys-
tem. Use the following matrix to define the construction of your system, based on
the six digits. For example, Tandem Part No. TC2414 represents a Check-Mate
tandem system (TC), pump (24), crossover option (1), and platen/ram option (4).
NOTE:
Systems with the TD as the first and second digits are Dura-Flo tandem systems.
Some configurations in the following matrix cannot be built. See the Product
Selection Guide for available systems.
To order replacement parts, see Parts section in manual 313529. The digits in
the matrix do not correspond to the Ref. Nos. in the Parts drawings and lists.
TC 24 1 4
First and
Second Digit
TC
(Tandem
System with
Check-Mate
displacement
pump)
TD
(Tandem
System with
Dura-Flo dis-
placement
pump)
Third and
Fourth Digit Fifth Digit Sixth Digit
Crossover Options
Depressurize/
Recirculate Valve
Material
Carbon
Steel SST
Ram Size
n/a
n/a
n/a
n/a
n/a
n/a
S20, D60,
D200,
(3 in.)
D200S,
(6.5 in.)
Pump Code
(See Table 2
for 2-digit
Check-Mate
pump code)
(See Table 3
for 2-digit
Dura-
Flo pump
code)
Electronic
Crossover
1
2
3
4
5
6
7
8
Pneumatic
Crossover
(Smart
Motors
only)
✔✔✔
✔✔✔
✔✔
✔✔
✔✔
✔
(Standard
Motors
only)
✔
✔
Fluid
Filter
Platen/Ram
Options
See Table 1
for Selections
All supply systems with DataTrak and 24 Vdc or 100-240 Vac power supplies are ETL approved.
4 313528H
Table 1: Platen/Ram Options
Sixth
Digit Platen Size Platen Style
Platen Material
Seal Material Ram Size Voltage
2 20 L (5 Gal) Flat, Single Wiper CS Polyurethane S20, 3 in. none
3 20 L (5 Gal) Flat, Single Wiper SST PTFE-Coated Nitrile S20, 3 in none
7 20 L (5 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. none
8 20 L (5 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. 120 Vdc
9 20 L (5 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. 24 Vdc
0 30 L (8 Gal) Flat, Single Wiper SST PTFE-Coated Nitrile D60, 3 in. none
D 30 L (8 Gal) Flat, Single Wiper SST PTFE-Coated Nitrile D60, 3 in. 120 Vdc
E 30 L (8 Gal) Flat, Single Wiper SST PTFE-Coated Nitrile D60, 3 in. 24 Vdc
K 30 L (8 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. none
N 30 L (8 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. 120 Vdc
P 30 L (8 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. 24 Vdc
U 60 L (16 Gal) Flat, Single Wiper SST PTFE-Coated Nitrile D60, 3 in. none
V 60 L (16 Gal) Flat, Single Wiper SST PTFE-Coated Nitrile D60, 3 in. 120 Vdc
W 60 L (16 Gal) Flat, Single Wiper SST PTFE-Coated Nitrile D60, 3 in. 24 Vdc
X 60 L (16 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. none
Y 60 L (16 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. 120 Vdc
Z 60 L (16 Gal) Flat, Dual Wiper CS Polyurethane D60, 3 in. 24 Vdc
4 115L (30 Gal) D Style CS EPDM D200, 3 in. none
1 20 L (5 Gal) Flat, Single Wiper SST PTFE-Coated Nitrile D200, 3 in. none
6 20 L (5 Gal) Flat, Dual Wiper CS Polyurethane D200, 3 in. none
5 30 L (8 Gal) Flat, Dual Wiper CS Polyurethane D200, 3 in. none
A 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200, 3 in. none
B 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200, 3 in. 120 Vdc
C 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200, 3 in. 24 Vdc
F 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200S, 6.5
none
in.
G 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200S, 6.5
120 Vdc
in.
H 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200S, 6.5
24 Vdc
in.
J 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200, 3 in. none
L 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200, 3 in. 120 Vdc
M 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200, 3 in. 24 Vdc
R 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200S, 6.5
none
in.
S 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200S, 6.5
120 Vdc
in.
T 200 L (55 Gal) Dual O-ring PTFE-Coated AL EPDM D200S, 6.5
24 Vdc
in.
Models
313528H 5
Models
Pump
Code
Pump Part No.
(see manual
312376)
NXT 200/CM 60
4A P05LCS
4B P05LCM
4C P05LSS
4F P05LSM
NXT 400/CM 60
6A P11LCS
6B P11LCM
6C P11LSS
6F P11LSM
6G P11RCS
6H P11RCM
6J P11RSS
6K P11RSM
61 P11SCS
62 P11SCM
63 P11SSS
64 P11SSM
NXT 700/CM 60
7A P20LCS
7B P20LCM
7C P20LSS
7F P20LSM
7G P20RCS
7H P20RCM
7J P20RSS
7K P20RSM
71 P20SCS
72 P20SCM
73 P20SSS
74 P20SSM
NXT 1200/CM 60
8A P38LCS
8B P38LCM
8C P38LSS
8F P38LSM
8G P38RCS
8H P38RCM
8J P38RSS
8K P38RSM
81 P38SCS
82 P38SCM
83 P38SSS
84 P38SSM
NXT 1800/CM 60
9A P61LCS
9B P61LCM
9C P61LSS
9F P61LSM
9G P61RCS
9H P61RCM
9J P61RSS
9K P61RSM
91 P61SCS
92 P61SCM
93 P61SSS
94 P61SSM
NXT 2200/CM 100
11 P40LCS
12 P40LCM
1F P40LSS
1G P40LSM
13 P40RCS
14 P40RCM
1H P40RSS
1J P40RSM
10 P40SSS
1A P40SSM
19 P40SCS
NXT 3400/CM 100
15 P63LCS
16 P63LCM
1T P63LSS
1U P63LSM
17 P63RCS
18 P63RCM
1W P63RSS
1Y P63RSM
1B P63SSS
1C P63SSM
Pump
Code
Pump Part No.
(see manual
312376)
NXT 2200/CM 200
21 P23LCS
22 P23LCM
23 P23RCS
24 P23RCM
25 P23LSS
26 P23LSM
27 P23RSS
28 P23RSM
NXT 3400/CM 200
29 P36LCS
2A P36LCM
2B P36RCS
2C P36RCM
2F P36LSS
2G P36LSM
2H P36RSS
2J P36RSM
NXT 6500/CM 200
2L P68LCS
2M P68LCM
2R P68RCS
2S P68RCM
2T P68LSS
2U P68LSM
2W P68RSS
2Y P68RSM
20 P68SCS
NXT 3400/CM 250
31 P29LCS
32 P29LCM
33 P29RCS
34 P29RCM
35 P29LSS
36 P29LSM
37 P29RSS
38 P29RSM
Pump
Code
Pump Part No.
(see manual
312376)
NXT 6500/CM 250
39 P55LCS
3A P55LCM
3B P55RCS
3C P55RCM
3F P55LSS
3G P55LSM
3H P55RSS
3J P55RSM
Xtreme XL/CM 250
3L P85LCS
3M P85LCM
3R P85LSS
3S P85LSM
NXT 3400/CM 500
51 P14LCS
52 P14LCM
53 P14RCS
54 P14RCM
55 P14LSS
56 P14LSM
57 P14RSS
58 P14RSM
NXT 6500/CM 500
59 P26LCS
5A P26LCM
5B P26RCS
5C P26RCM
5F P26LSS
5G P26LSM
5H P26RSS
5J P26RSM
Xtreme XL/CM 500
5L P42LCS
5M P42LCM
5R P42LSS
5S P42LSM
No Pump
NN
Pump
Code
Pump Part No.
(see manual
312376)
Table 2: Check-Mate Pump Identification Code/Part No. Index
6 313528H
Pump
Code
Pump Part No.
(see manual
311828)
NXT 2200/DF 145SS
A1 P31LSS
NXT 3400/DF 145SS
B1 P46LSS
NXT 3400/DF 180SS
B5 P41LSS
NXT 3400/DF 220SS
C1 P30LSS
NXT 6500/DF 220SS
CA P57LSS
Xtreme XL/DF 290SS
DL P67LSS
Pump
Code
Pump Part No.
(see manual
311826)
NXT 3400/DF 430SS
E5 P15LSS
E6 P15LSM
NXT 6500/DF 430SS
EF P32LSS
EG P32LSM
Xtreme XL/DF 430
EL P47LSS
EM P47LSM
ES P47LCM
ET P47LCS
NXT 3400/DF 580SS
F5 P12LSS
F6 P12LSM
Pump
Code
Pump Part No.
(see manual
311826)
NXT 6500/DF 580CS
F9 P22LCS
NXT 6500/DF 580SS
FF P22LSS
FG P22LSM
Xtreme XL/DF 580CS
FL P35LSS
FM P35LSM
FT P35LCS
Pump
Code
Pump Part No.
(see manual
311833)
NXT 6500/DF 1000CS
G9 P10LCS
Table 3: Dura-Flo Pump Identification Code/Part No. Index
Models
313528H 7
Warnings
WARNING
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
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.
8 313528H
Warnings
WARNINGWARNINGWARNING
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 forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’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.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
SPLATTER HAZARD
During blowoff of platen splatter may occur.
• Use minimum drum removal air pressure.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
313528H 9
Overview
pressure sensor cable
#1#2
outlet
inlet
splitter
#7
Overview
System Description
Each tandem supply system consists of two air-powered
rams; both of which are always the same size. Each ram
drives a Check-Mate pump and a platen into a drum of
material. The pump removes material from the drum
and pushes it through a supply hose to a customer-supplied header. Material flows through the header to indi-
vidual dispense drops.
When one drum is emptied the system performs an
automatic crossover, shutting off the air supply to the
pump on the empty ram and activating the pump on the
full ram.
Keep clear of the inactive ram, as automatic crossover
may occur unexpectedly. To repair or adjust the ram,
first follow all steps of the Pressure Relief Procedure
on page 22.
Ram Installation and Setup
Fluid Filter Kit Installation
Some systems include a fluid filter kit. See Appendix A
- User Interface Display on page 31. Ensure that the
fluid filter stand base is level in all directions. If neces-
sary, level the base using metal shims. Secure the base
to the floor using anchors that are long enough to pre-
vent the filter stand from tipping.
1. Connect pressure sensor cable from the fluid filter
kit to port 7 of the fluid control module.
2. Connect male side of the splitter to the other end of
the pressure sensor cable.
3. Connect end of splitter cable labeled #1 to the pres-
sure sensor on the outlet side of the filter.
4. Connect end of splitter cable labeled #2 to the pres-
sure sensor on the inlet side of the filter.
1. Install and set up individual rams as explained in
manual 313526 (supplied).
NOTE:
See F
IG
. 2 on page 13 (for pneumatic crossover sys-
tems) and F
over systems) for examples.
2. Connect pneumatic line (AC) or CAN cable (X)
between rams.
IG
. 3 on page 15 (for electronic cross-
10 313528H
Overview
BA
BB
BC
BG
BE
BF
TI10438A
BD
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 ground wire and clamp (supplied). Loosen
grounding lug locknut and washer. Insert ground wire
end into lug slot and tighten locknut securely. Connect
ground clamp to a true earth ground.
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 elec-
trical resistance of hoses. If total resistance to ground
exceeds 29 megohms, replace hose immediately.
Air compressor: follow manufacturer’s recommenda-
tions.
• Exhaust port with muffler (BD)
• Air motor regulator (BE): Controls air pressure to
motor.
• Air motor slider valve (BF): turns air on and off to
the air motor. When closed, the valve relieves air
trapped between it and the air motor. Push the valve
in to shutoff. Remote DataTrak: The air solenoid
(Y, F
IG
. 2), the air motor slider valve (BF), and the
main air slider valve (BA) must be open for air to
flow. (See Remote DataTrak Setup section in Sup-
ply Systems operation manual 313526.)
• Blowoff button (BG): turns air on and off to push
the platen out of an empty drum.
Dispense valve: ground through connection to a prop-
erly grounded fluid hose and pump.
Fluid supply container: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive sur-
face, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the dispense
valve firmly to the side of a grounded metal pail, then
trigger the valve.
Integrated Air Controls
The integrated air controls include:
• Main air slider valve (BA): turns air on and off to
the system. When closed, the valve relieves pres-
sure downstream.
• Ram air regulator (BB): controls ram up and down
pressure and blowoff pressure.
• Ram director valve (BC): controls ram direction.
FIG. 1. Integrated Air Controls
Air Line Accessories
See FIG. 2.
• Air line drain valve (U)
• Air line filter (V): removes harmful dirt and mois-
ture from compressed air supply.
• Second bleed-type air valve (W): isolates air line
accessories and supply system for servicing. Locate
upstream from all other air line accessories.
• Air relief valve (attached to ram air regulator, not
visible): automatically relieves excessive pressure.
313528H 11
Overview
Pneumatic Crossover System Components
NOTE:
D200, D60, and S20 sizes are used in pneumatic
crossover systems.
IG
. 2. shows a pneumatic crossover system. Refer to
F
manual 313526 (supplied) for ram installation and oper-
ating instructions. The pneumatic crossover operates as
follows:
During system operation, as the ram approaches the
drum bottom, the top of the ram contacts the limit switch
(E). The limit switch shuts off air to the air motor via a
solenoid valve (Y), which stops air flow to one motor and
starts air flow to the other air motor. This allows continu-
ous material flow and changing of material drums.
The position of the limit switch (E) on the ram determines when the air motor is turned off. Start by position-
ing the limit switch to trip when the ram platen (D) is 1 in.
(25 mm) from the bottom of the drum. During operation
the position may be adjusted as desired.
The bypass valve (L) allows you to prime the inactive
pump after a drum change. Open the valve to prime the
pump. Close the valve when priming is complete, and
during normal operation.
12 313528H
Overview
A
B
D
L
T
H
V
E
C
TI11160A
C
D
E
U
H
Y
S
W
L
S
T
U
V
Y
W
D200 Rams Shown
AA
AB
AC
E
S20 Ram Shown
H
Y
L
FIG. 2: Component Identification, Pneumatic Crossover
Key to FIG. 2:
ARam A
BRam B
C Pump (Ram A and B)
D Platen (Ram A and B)
E Limit Switch (Ram A and B)
H Integrated Air Controls (Ram A and B); see page 11
L Bypass Valve (Ram A and B)
S Fluid Line (not supplied)
313528H 13
T Main Air Line (not supplied)
U Air Line Drain Valve (not supplied)
V Air Filter (not supplied)
W Bleed-Type Air Shutoff Valve (not supplied)
Y Solenoid Valve (Ram A and B)
AA Cable from Ram A to Limit Switch A
AB Cable from Ram A to Limit Switch B
AC Main Crossover Cable; from Ram A to Solenoid B
Overview
Electronic Crossover System Components
NOTE:
D200 and D60 sizes are used in electronic crossover
systems. See F
you should be familiar with the following compo-
nents.
NOTE:
Reference numbers and letters in parentheses in the
text refer to the callouts in the figures.
Both rams (A and B) include a Check-Mate Pump (C),
platen (D), integrated air controls (H), drum empty sen-
sor (E), and fluid control module (G).
Only Ram A includes the display module (F) and power
supply box (K).
Drum empty sensor (E). Signals drum empty condition.
Display module (F). Mounted on Ram A only. Provides
Run Mode status screens, Setup screens, and control
keys.
Fluid control module (G). See page 21.
IG
. 3. Before you install the system,
Integrated air controls (H). See page 11.
Power supply box (K).
Air motor solenoid (Y). Solenoid is on when system is on
and in Run Mode, Recirculate Mode, or Prime Mode.
Solenoid is off when system is shut off or when in
Depressurize Mode, or the ram is in an Inactive Ready
Mode. Turns on in Recirculate Mode. The solenoid LED
will illuminate when the solenoid is on.
Depressurize/recirculate fluid valve (Z). Depressurizes
system when Depressurize Mode is active. Recirculates
fluid when Recirculate Mode is active.
To depressurize the system, press the Depressurize
key on the display module and select Yes when
asked if you want to depressurize the system. Follow
the Pressure Relief Procedure on page 22. Shutting
off power or removing power from the system will not
depressurize the system.
14 313528H
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