GRACO D60, D200, D200S Instruction manual

Installation - Parts

E-Flo

3A6331G

Supply Systems

For transferring or dispensing sealants, adhesives, or other medium to high viscosity fluids. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

D60 3 inch dual post

20 liter (5 gallon), 30 liter (8 gallon), 60 liter (16 gallon) sizes

150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure

D200 3 inch dual post

200 liter (55 gallon) size

150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure

D200S 6.5 inch dual post

200 liter (55 gallon) size

125 psi (0.9 MPa, 9 bar) Maximum Air Inlet Pressure

See page 4 for model information, including maximum working pressure and approvals.

The Graco Control Architecture Electric Components are Listed in Intertek’s Directory of Listed Products.

Important Safety Instructions

Read all warnings and instructions in this manual and in related manuals before using the equipment. Save all instructions.

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 6

Tandem Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Identification . . . . . . . . . . . . . . . . . . . 11

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 11

Integrated Air Control Module . . . . . . . . . . . . . . 12

Integrated Air Line Accessories . . . . . . . . . . . . . 12

Advanced Display Module (ADM) . . . . . . . . . . . 13

Platen Component Identification . . . . . . . . . . . . 14

Junction Box Connections . . . . . . . . . . . . . . . . . 15

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power Requirements . . . . . . . . . . . . . . . . . . . . . 17

Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . 17

Attach Drum Stops. . . . . . . . . . . . . . . . . . . . . . . 18

Fluid Hose and Air Line Connections. . . . . . . . . 18

Install Vented Oil Cap Before Using Equipment. 18

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 20

Start and Adjust the Ram. . . . . . . . . . . . . . . . . . 21

Start and Adjust the Pump . . . . . . . . . . . . . . . . . 21

Pressure Relief Procedure. . . . . . . . . . . . . . . . . . . 22

Shutdown and Care of the Pump . . . . . . . . . . . . . 23

Change Drums. . . . . . . . . . . . . . . . . . . . . . . . . . 23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Driver Maintenance . . . . . . . . . . . . . . . . . . . . . . 24

Platen Maintenance . . . . . . . . . . . . . . . . . . . . . . 25

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Disconnect Pump from Platen . . . . . . . . . . . . . . 30

Connect Platen . . . . . . . . . . . . . . . . . . . . . . . . . 31

Remove Wipers . . . . . . . . . . . . . . . . . . . . . . . . . 31

Install Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Remove Displacement Pump. . . . . . . . . . . . . . . 31

Install Displacement Pump . . . . . . . . . . . . . . . . 32

Remove Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Install Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Supply Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 34

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

D200s 6.5 in. Supply Units . . . . . . . . . . . . . . . . . 38

D200 3 in. Supply Units . . . . . . . . . . . . . . . . . . . 40

D60 3 in. Supply Units . . . . . . . . . . . . . . . . . . . . 42

D200s and D200 Pump Mounts for 55 Gallon (200

Liter) Platen . . . . . . . . . . . . . . . . . . . . . . . . . 44

D60 Pump Mount 257624 for 5 Gallon (20 Liter)

Platen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Cable Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

55 Gallon Platen . . . . . . . . . . . . . . . . . . . . . . . . . 49

20 Liter (5 Gallon), 30 Liter (8 Gallon), and 60 Liter

(16 Gallon) Platens . . . . . . . . . . . . . . . . . . . 50

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 55

Drum Roller Kits for D200 and D200S Supply Units,

255627 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Drum Position Clamp Set for D200 Supply Units,

206537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Drum Position Clamp for D200S Supply Units . . 55

Enclosed Wet Cup Recirculation Kit. . . . . . . . . . 55

200 Liter (55 Gallon) Platen Cover Kits, 255691 55

Light Tower Kit, 255468 . . . . . . . . . . . . . . . . . . . 55

ADM Kit, 25E437 . . . . . . . . . . . . . . . . . . . . . . . . 55

CAN Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

I/O Cable, 122029 . . . . . . . . . . . . . . . . . . . . . . . 55

Communication Gateway Module (CGM) Kits . . 56

Low Level Sensor Kit, 25E447 . . . . . . . . . . . . . . 58

Tandem Connection Kit, 25E595 . . . . . . . . . . . . 59

Tandem Depressurization/Recirculation Kit, 25E618

(carbon steel), 25E619 (stainless steel). . . . 60

Tandem Fluid Filter Kit, 25E620 . . . . . . . . . . . . . 64

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Pump Performance . . . . . . . . . . . . . . . . . . . . . . . . . 69

E-Flo SP Performance Charts . . . . . . . . . . . . . . 70

Technical Specifications . . . . . . . . . . . . . . . . . . . . 76

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 77

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 78

Graco Information 78

2 3A6331G

Related Manuals

Manual Description

3A6586

3A6724 E-Flo SP Software Instructions

313526 Supply Systems Operation

E-Flo SP Electric Pump Instructions Parts

Related Manuals

312375

311827

311825

311717

312889

312467

312468

312469

312470

312374 Air Controls Instructions-Parts

312491 Pump Fluid Purge Kit Instructions - Parts

312492 Drum Roller Kit Instructions

312493 Light Tower Kit Instructions

312494

406681 Platen Cover Kit

Check-Mate® Displacement Pumps Instructions-Parts

™

Dura-Flo 180cc, 220cc, 290cc) Instructions-Parts

Dura-Flo 580cc) Instructions-Parts

Carbon Steel Displacement Pump (1000cc) Instructions-Parts

60 cc Check-Mate Displacement Pump Repair Parts

100 cc Check-Mate Displacement Pump Repair Parts

200 cc Check-Mate Displacement Pump Repair Parts

250 cc Check-Mate Displacement Pump Repair Parts

500 cc Check-Mate Displacement Pump Repair Parts

Enclosed Wetcup Recirculation Kit Instructions - Parts

Displacement Pumps (145cc,

™

Displacement Pumps (430cc,

334048 EPDM Hose Wiper Kit Instructions - Parts

3A6321

3A6482

3A6331G 3

ADM Token In-System Programming Instructions

APD20 Advanced Precision Driver Instructions

Models

Check the identification plate (ID) for the 7-digit part number of the supply system. Use the following matrix to define the construction of the supply system, based on the seven digits. For example, Part No. EMC1121 represents an electric supply system (EM), a carbon steel Check-Mate 100 Severe Duty displacement pump with an electric driver (C1), a 3 in. dual post ram with integrated air controls (1), a 5-gallon platen with a nitrile seal (2), and 240 VAC power

(1).

NOTICE

To prevent damage to DataTrak soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

NOTE: Systems with the EMD as the first and second digits are Dura-Flo supply systems.

The digits in the matrix on the next page do not correspond to the Ref. Nos. in the Parts drawings and lists.

4 3A6331G

Models

EM C1 1

First

and

Second

Digit

(Electric

Supply

System)

Third and

Fourth

Digit Fifth Digit

Ram Options

Pump

Code

(See Table 1: for 2-digit Check-Mate

Pump

Code)

(See Table 1: for 2-digit

Dura-Flo

Pump

Code)

Size Style

1 3 in. D60

2 3 in. D200

3 6.5 in. D200s

Sixth Digit Seventh Digit

Platen and Seal Options

Drum

Size

20 L

(5 Gal) INT 1 No Platen 1 None 240 VAC

200 L

(55 Gal) INT 2

200 L

(55 Gal) INT 3

Air

Controls

Platen

(5 Gal) F, SW CS Nitrile D60 2 None 480 VAC

(5 Gal) F, SW CS

(5 Gal) F, DW CS Nitrile D60 4 ADM 480 VAC

(5 Gal) F, DW CS

(5 Gal) F, SW SS

200 L

(55 Gal) DR

200 L

(55 Gal) DR AL EPDM

200 L

(55 Gal) DR AL Neoprene

200 L

(55 Gal) DR AL

Size

20 L

Platen

Style

Platen

Material

PTFE

Coated

AL EPDM

Seal

Material

Polyure-

thane D60 3 ADM 240 VAC

Polyure-

thane D60 PTFE

coated D60

EPDM

Hose

Ram

Compati-

bility Interface Power

D200,

D200s

D200,

D200s

D200,

D200s

D200,

D200s

Interface and Power

Options

KEY: INT = Integrated air controls SW = Single wiper CS = Carbon Steel Severe Duty

F = Flat DW = Double wiper SS = Stainless Steel Severe Duty SM = Stainless Steel MaxLife DR = Dual o-ring AL = Aluminum

CM = Carbon Steel MaxLife

Table 1: Pump Code Index

Pump

Code Part No. Pump Type

Pump

Size

Pump

Material

C1 EC100CS1 Check-Mate 100cc CS C2 EC100CM1 Check-Mate 100cc CM C3 EC100SS1 Check-Mate 100cc SS C4 EC100SM1 Check-Mate 100cc SM C5 EC200CS1 Check-Mate 200cc CS C6 EC200CM1 Check-Mate 200cc CM C7 EC200SS1 Check-Mate 200cc SS C8 EC200SM1 Check-Mate 200cc SM

C9 EC250CS1 Check-Mate 250cc CS CA EC250CM1 Check-Mate 250cc CM CB EC250SS1 Check-Mate 250cc SS CC EC250SM1 Check-Mate 250cc SM CD EC500CS1 Check-Mate 500cc CS CE EC500CM1 Check-Mate 500cc CM

CF EC500SS1 Check-Mate 500cc SS

Pump

Code Part No. Pump Type

CG EC500SM1 Check-Mate 500cc SM

D1 ED115CS1 Dura-Flo 115cc CS D2 ED145CS1 Dura-Flo 145cc CS D3 ED145SS1 Dura-Flo 145cc SS D4 ED180CS1 Dura-Flo 180cc CS D5 ED180SS1 Dura-Flo 180cc SS D6 ED220CS1 Dura-Flo 220cc CS D7 ED220SS1 Dura-Flo 220cc SS D8 ED290CS1 Dura-Flo 290cc CS

D9 ED290SS1 Dura-Flo 290cc SS DA ED430CS1 Dura-Flo 430cc CS DB ED430SS1 Dura-Flo 430cc SS DC ED430SM1 Dura-Flo 430cc SM

NOTE: See the E-Flo SP Electric Pump Instructions-Parts

manual for a complete parts list.

Pump

Size

Pump

Material

3A6331G 5

Models

System Pressure

Due to factors such as the dispensing system design, the material being pumped, and the flow rate, the dynamic pressure will not reach the rated working (stall) pressure of the system.

Pump Working (Stall) Pressure Max Dynamic (Run) Pressure

Lower Size psi bar MPa psi bar MPa

100CS/CM/SS/SM 200CS/CM/SS/SM 250CS/CM/SS/SM 500CS/CM/SS/SM

Check-Mate

145SS 180SS 220SS 290SS 430CS/SS/SM 115CS

Dura-Flow

145CS 180CS 220CS 290CS

6,000 414 41.4 6,000 414 41.4 4,200 290 29.0 3,905 269 26.9 3,400 234 23.4 3,122 215 21.5 1,600 110 11.0 1,487 103 10.3 5,600 386 38.6 5,204 359 35.9 4,500 310 31.0 4,164 287 28.7 3,700 255 25.5 3,470 239 23.9 2,800 193 19.3 2,602 179 17.9 1,900 131 13.1 1,735 120 12.0 6,000 414 41.4 6,000 414 41.4 5,600 386 38.6 5,204 359 35.9 4,500 310 31.0 4,164 287 28.7 3,700 255 25.5 3,472 239 23.9 2,800 193 19.3 2,602 179 17.9

Flow Rate Table

Lower Size

100CS/CM/SS/SM 200CS/CM/SS/SM 250CS/CM/SS/SM 500CS/CM/SS/SM

Check-Mate

145SS 180SS 220SS 290SS 430CS/SS/SM 115CS

Dura-Flow

145CS 180CS 220CS 290CS

Flow Rate

(cc/min)

2,500 0.66 1 in. NPT female 5,000 1.32 1 in. NPT female 6,250 1.65 1 in. NPT female

12,500 3.30 1-1/2 in. NPT female

3,625 0.96 1 in. NPT female 4,500 1.19 1 in. NPT female 5,500 1.45 1 in. NPT female 7,250 1.92 1 in. NPT female

10,750 2.84 1-1/2 in. NPT female

2,875 0.76 1 in. NPT female 3,625 0.96 1 in. NPT female 4,500 1.19 1 in. NPT female 5,500 1.45 1 in. NPT female 7,250 1.92 1 in. NPT female

Flow Rate

(gpm) Outlet Fitting Size

6 3A6331G

Tandem Ram

Models

How to Buy

1. Configure Tandem Ram “A” - E-Flo SP Ram with an ADM (Quantity 1 per Tandem System).

- Example: EMC1283 – D200 Ram, Electric

Pump with Check-Mate 100 CS Lower, 200L EPDM Platen, 240V, with ADM.

2. Configure Tandem Ram “B” - E-Flo SP Ram without an ADM (Quantity 1 per Tandem System).

- Example: EMC1281 – D200 Ram, Electric

Pump with Check-Mate 100 CS Lower, 200L EPDM Platen, 240V, without ADM.

3. Purchase Tandem Connection Kit, 25E595 (Quantity 1 per Tandem System).

4. Purchase Accessories.

- Depressurization/Recirculation Kit (Quantity 1

per Ram)

25E618: for Carbon Steel Pump Lowers 25E619: for Stainless Steel Pump Lowers

5. Purchase hoses for the system.

- For Check-Mate Pumps:

Pump Lower

Size

100cc 6000 psi 200cc 4200 psi 250cc 3400 psi 500cc 1600 psi

- For Dura-Flo Pumps:

Pump Lower

Size

115cc 6000 psi 145cc 5600 psi 180cc 4500 psi 220cc 3700 psi 290cc 2800 psi 430cc 1900 psi

Max. Pressure

Rating

Max. Pressure

Rating

- Fluid Filter Kit, 25E620 (Quantity 1 per Tandem

System)

- Extension Cables for Fluid Filter Monitoring

Pressure Transducers (Quantity 1 per Ram)

124943: 1 meter 122497: 2 meters 124409: 3 meters 17H363: 7.5 meters 17H364: 16 meters

- Low Level Sensor Kit, 25E447 (Quantity 1 per

Ram)

NOTE: Rams come with Empty Level Sensors already installed.

3A6331G 7

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 or on warning labels, 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.

DANGER

SEVERE ELECTRIC SHOCK HAZARD

This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.

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

• This equipment must be grounded. Connect only to grounded power source.

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

WARNING

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.

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.

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure and disconnect all power sources.

8 3A6331G

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. 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 sparking).

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

• Never spray or flush solvent at high pressure.

• 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.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are anti-static or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheets (SDSs) from distributor or retailer.

• 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. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• 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.

SPLATTER HAZARD

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

• Use minimum air pressure when removing platen from drum.

3A6331G 9

Warnings

WARNING

TOXIC FLUID OR FUMES HAZARD

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

• Read Safety Data Sheets (SDSs) 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

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective 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.

10 3A6331G

Component Identification

Typical Installation

D200 3 in. and D200s 6.5 in. Dual Post

EMC1223 Model Shown

Lift Locations

NOTICE

Always lift the supply system at the proper lift locations (see FIG. 1). Do not lift in any other way. Failure to lift at the proper lift locations can result in damage to the supply system.

NOTE: The Outlet Pressure Relief Valve is used on Check-Mate 100cc pumps only. See the E-Flo SP Electric Pump Instructions-Parts manual for a complete parts list.

FIG. 1: Typical Installation

Key:

A Ram Assembly B Electric Driver C Displacement Pump D Platen E Cable Track F Advanced Display Module (ADM) G Integrated Air Controls (see F J Platen Bleed Port K Power Junction Box M Disconnect Switch

IG. 2)

N Platen Lift Rod P Pump Bleed Valve R Enclosed Wet Cup S Fluid Line (not supplied) T Air Line (not supplied) U Air Line Drain Valve (not supplied) V Air Filter (not supplied) W Bleed Type Air Shutoff Valve (required) (not supplied) X Level Sensors Y Outlet Pressure Transducer Z Outlet Pressure Relief Valve (Check-Mate 100 only)

3A6331G 11

Component Identification

Integrated Air Control Module

D200, D200s, and D60 Models

The integrated air controls include:

• Main air slider valve (AA): turns air on and off to

the system. When closed, the valve relieves pressure downstream.

• Ram air regulator (AB): controls ram up and down

pressure and blowoff pressure.

• Ram director valve (AC): controls ram direction.

• Exhaust port with muffler (AD)

• Blowoff button (AE): turns air on and off to push

the platen out of an empty drum.

Integrated Air Line Accessories

See FIG. 1.

• 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) (required): iso-

lates air line accessories for servicing. Locate upstream from all other air line accessories.

• Air relief valve (required) (not visible):

automatically relieves excessive pressure.

FIG. 2. Integrated Air Control Module

12 3A6331G

Advanced Display Module (ADM)

Front and Rear Views

Component Identification

FIG. 3: ADM Component Identification

Key: BA Pump Enable

Enables the pump. Toggles between Active and System Off.

BB Pump Status Indicator Light BC Pump Soft Stop

Stops all pump processes and disables the pump.

BD Soft Keys

Defined by the icon on the screen next to the soft key.

BE Cancel

Cancel a selection or number entry while in the process of entering a number or making a selection. Cancels the pump processes.

BF Enter

Accept change, acknowledge error, select item, and toggle selected item.

BG Lock/Setup

Toggle between run and setup screens.

BH Directional Keypad

Navigate within a screen or to a new screen.

BJ Numeric Keypad BK Part Number Identification Label BL USB Interface BM CAN Cable Connection

Power and communication.

BN Module Status LEDs

Visual indicators to show the status of the ADM.

BP Token Access Cover

Access cover for software token.

BR Battery Access Cover

3A6331G 13

Component Identification

Platen Component Identification

Model 255319, 200 liter (55 gallon)

FIG. 4

Model 256742 and 256745, 20 liter (5 gallon)

Key:

EA Plate EB Wipers EC Spacer ED Cap Screws EE Clamps (not shown) EF Bleed Stick EG Bleed Port EH Air Assist Body Check Valve EJ Wiper Plate (under wiper) EK O-ring Seal (not shown)

14 3A6331G

Junction Box Connections

Component Identification

FIG. 5

Key:

C1 CGA CAN Port C2 GCA CAN Port C3 Low and Empty Level Sensor Input C4 Fluid Filter Solenoid Input

NOTE: See the E-Flo SP Software Instructions manual for all I/O descriptions.

3A6331G 15

Installation

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

Location

To properly locate and anchor the supply system, refer to Dimensions on page 67.

NOTICE

Always lift the supply system at the proper lift locations (see FIG. 1). Do not lift in any other way. Failure to lift at the proper lift locations can result in damage to the supply system.

Attach a lifting sling at the proper lift locations. Lift off the pallet using a crane or a forklift.

NOTE: The lift ring on the driver is only to be used for replacing the driver. Do not use it to lift the entire system.

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Electric pump: the pump is grounded through the power cord.

Ram: the ram is grounded through the power cord.

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 the hoses. If the total resistance to ground exceeds 29 megaohms, replace the hose immediately.

Air compressor: follow manufacturer’s recommendations.

Dispense valve: ground through connection to a prop-

erly grounded fluid hose and pump.

Position the ram so the driver, disconnect switch, air controls, and ADM are easily accessible. Ensure that there is enough space overhead for the ram to raise fully.

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

Ensure that the ram base is level in all directions. If necessary, level the base using metal shims. Secure the base to the floor using 1/2 in. (13 mm) anchors that are long enough to prevent the ram from tipping.

Fluid supply container: follow local code.

Solvent pails used when flushing: follow local code.

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

16 3A6331G

Installation

Power Requirements

The system requires a dedicated circuit protected with a circuit breaker.

Voltage Phase Hz Current

200-240 VAC 1 50/60 20 A 400-480 VAC 1 50/60 10 A

Connect Power

NOTICE

To avoid equipment damage, route and secure a power cord that is long enough to allow the full range of movement for the ram.

6. Cut power cord wires to the following lengths:

• Ground wire - 6.5 inches (16.5 cm)

• Power wires - 3.0 inches (7.6 cm)

• Add ferrules as necessary. See FIG. 6.

8. Insert the power cord through the cord grip and into the junction box (K).

Ground Stud

Disconnect Switch Terminal Block

Cord Grip

FIG. 8: Power Connection

9. Attach the ground wire to the ground stud inside the junction box (K).

10. Refer to FIG. 9 and connect the wires from the power cord into terminals 4T2 and 6T3 on the disconnect switch terminal block.

LQ

LQ

FIG. 6: Power Cord

7. Remove the six screws holding the cover of the junction box (K), then remove the junction box cover.

Screws

1L1

3L2

5L2

2T1

4T2

6T3

FIG. 9: Disconnect Switch Terminal Block

11. Tighten the cord grip to securely hold the power cord to the junction box (K).

12. Replace the junction box cover and secure it with the six screws that were removed in step 2.

FIG. 7: Remove the Junction Box Cover

3A6331G 17

Installation

Attach Drum Stops

The electric supply systems are shipped with drum stops in place to help position the drum on the ram. For replacement parts, order Kit 255477. The kit includes 2 each of capscrews, lock washers (not shown), and drum stops.

Capscrews

Drum Stops

FIG. 10: Drum Stop Installation

Install Vented Oil Cap Before Using Equipment.

The driver gear-box is shipped from the factory pre-filled with oil. The temporary unvented cap prevents oil leaks during shipment. This temporary cap must be replaced with the vented oil cap supplied with the equipment, before use.

NOTE: Prior to use, check oil level. Oil level should be half way up the sight glass.

Vented Cap

Unvented Cap

1. Locate the correct set of mounting holes on the ram base.

2. Using the capscrews and lock washers, attach the drum stops to the ram base.

Fluid Hose and Air Line Connections

Refer to FIG. 1 on page 11 for a typical installation.

Attach the fluid hose (not supplied) to the Outlet Check Valve (E) connection.

Attach the air line (not supplied) to the bottom of the Integrated Air Control (G) at the 3/4 in. NPT connection.

NOTE: Be sure all components are adequately sized and pressure rated to meet the system’s requirements.

FIG. 11: Unvented and Vented Oil Caps

18 3A6331G

Setup

Wet Cup

Before starting, fill the wet cup (L) 1/3 full with Graco Throat Seal Liquid (TSL) or a compatible solvent.

Torque the Wet Cup

The wet cup is torqued at the factory; however, throat packing seals on Severe Duty pumps may relax over time. Check wet cup torque frequently after initial start-up and periodically after the first week of production. Maintaining proper wet cup torque is important to

extending seal life.

Setup

FIG. 12: Wet Cup

NOTE: MaxLife pumps use a special u-cup throat seal

that is non-adjustable and does not require periodic torquing.

1. Follow the Pressure Relief Procedure on page 22.

2. Torque the wet cup (R) 95-115 ft-lbs (128-155 N•m) using the packing nut wrench (supplied) whenever necessary. Do not overtighten the wet cup. See the table below for torque values.

3A6331G 19

Startup

Letters in parenthesis are used in this section for reference to callouts in the Component Identification section starting on page 11.

Flush the Pump

To avoid fire and explosion, always ground the equipment and the waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.

NOTE: The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent before using the pump.

Always flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary. Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

3. Turn the disconnect switch (M) ON.

4. At the ADM (F), use the ADM’s arrow keys to select the pump you want to flush from the Menu Bar.

NOTE: If multiple pumps are connected together, there can be up to six pumps listed in the Menu Bar.

5. Enter the Edit screen for that pump by pressing the

soft key next to the icon.

6. Press the soft key next to the Pressure Mode icon.

7. Enter 100 psi (0.69 MPa, 6.9 bar) as the pressure.

8. Press the soft key next to the Pump On/Off icon to turn on the pump.

9. Adjust pressure as necessary.

10. Hold a metal part of the dispense valve firmly to the side of a grounded metal pail.

11. Open the dispense valve and flush the system until clear solvent flows from the gun/valve.

NOTE: Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency.

NOTICE

To prevent damage to the pump from rust, never leave water or water-based fluid in a carbon steel pump overnight. If you are pumping a water-based fluid, flush with water first. Then flush with a rust inhibitor, such as mineral spirits. Relieve pressure, but leave the rust inhibitor in the pump to protect parts from corrosion.

NOTE: Refer to the E-Flo SP Software Instructions manual for additional information about using the software features of the ADM. See Related Manuals on page 3.

1. Follow the Pressure Relief Procedure on page 22.

2. Place a pail of compatible solvent in the ram. See

Grounding instructions for solvent pails on page

16.

12. Exit the Edit screen by pressing the soft key next to

the icon.

13. Repeat steps 3 through 11 for each pump you want to flush.

14. Follow the Pressure Relief Procedure on page 22.

15. Remove the solvent pail from the ram.

20 3A6331G

Startup

Start and Adjust the Ram

1. Turn the disconnect switch (M) OFF.

2. Raise the Ram by opening the main air slider valve (AA) and setting the ram air regulator (AB) to 40 psi (0.28 MPa, 2.8 bar).

3. Set the ram director valve handle (AC) to UP and let the ram rise to its full height.

4. Set the ram director valve handle (AC) to neutral.

5. Lubricate the platen wiper (EB) with grease or other lubricant compatible with the fluid you will pump.

6. Put a full drum/pail on the ram base and center it under the platen (D).

7. Remove the drum/pail cover and smooth the surface of the fluid with a straightedge. To prevent air from being trapped under the platen, scoop fluid from the center of the pail to the sides, to make the surface concave.

8. Adjust the drum/pail to be sure it is aligned with the platen, and remove the platen bleed stick to open the platen bleed port.

9. With hands away from the drum/pail and the platen, push down on the ram director valve (AC) handle, and lower the ram until the platen rests on the lip of the drum/pail. Move the ram director valve handle to the horizontal position (neutral).

10. Lower the ram:

a. Set the ram director valve (AC) to DOWN and

continue to lower the ram until fluid appears at the platen bleed port.

b. Set the ram director valve to neutral, replace the

platen bleed stick, and tighten it securely.

Start and Adjust the Pump

1. With the disconnect switch (M) OFF, set the ram air regulator (AB) to about 50 psi (0.35 MPa, 3.5 bar). Set the ram director valve (AC) to DOWN.

2. Turn the driver disconnect switch (M) ON.

3. Start the pump. See the E-Flo SP Software Instructions manual for instructions on operating the system.

D60

Platen Bleed Stick

4. Keep the ram director valve (AC) set to DOWN while the pump is operating.

NOTE: Increase air pressure to the ram if the pump does not prime properly with more viscous fluids. Decrease air pressure if fluid is forced out around the top seal or platen.

D200

Platen Bleed Stick

3A6331G 21

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. At the ADM, enter manual mode by pressing the

soft key next to the icon.

2. Press the soft key next to the icon to stop the pump.

7. Hold a metal part of the dispense valve firmly to the side of a grounded metal pail, and open the dispense valve to relieve pressure.

8. Open your system’s fluid line drain valve and open the pump bleed valve (P). Have a container ready to catch the drainage.

9. Leave the pump bleed valve (P) open until ready to dispense again.

3. Turn the disconnect switch (M) OFF.

FIG. 13: Air Control for Pressure Relief

4. Close the main air slider valve (AA).

5. Set the ram director valve (AC) to DOWN. The ram will slowly drop.

6. Once the ram is completely down, jog the ram director valve up and down to bleed air from the ram cylinders.

22 3A6331G

Shutdown and Care of the Pump

Change Drums

NOTICE

1. Set the ram director valve (AC) to DOWN, and lower the ram to the desired position for shutdown.

2. Set the ram director valve (AC) to neutral.

1. Stop the pump.

2. Set the ram director valve (AC) to UP to raise the platen, and immediately press and hold the blowoff air button (AE) until the platen is completely out of the drum. Use the minimum amount of air pressure

necessary to push the platen out of the drum.

Shutdown and Care of the Pump

3. Stop the pump at the bottom of the stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat packings. See the E-Flo SP Software Instructions manual for information about jogging the pump. See Related Manuals on page 3.

4. Always flush the pump before the fluid dries on the displacement rod. Follow steps to Flush the Pump on page 20.

Excessive air pressure in the material drum could cause the drum to rupture, causing serious injury. The platen must be free to move out of the drum. Never use drum blowoff air with a damaged drum.

3. Release the blowoff air button (AE) and allow the ram to rise to its full height.

4. Remove the empty drum.

5. Inspect the platen and, if necessary, remove any remaining material or material build–up.

3A6331G 23

Maintenance

Driver Maintenance

NOTICE

Do not open/remove the gear cover. The gear side is not intended to be serviced. Opening the gear cover may alter the factory set bearing pre-load and may reduce the product life.

Preventative Maintenance Schedule

The operating conditions of your particular system determine how often maintenance is required. Establish a preventative maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

Change the Oil

NOTE: Change the oil after a break-in period of 200,000

to 300,000 cycles. After the break-in period, change the oil once per year.

Check Oil Level

Refer to FIG. 14 below. Check the oil level in the sight glass on a regular basis. The oil level should be near the halfway point of the sight glass when the driver is not running. If the oil is low, open the fill cap and add Graco Part No. 16W645 ISO 220 silicone-free synthetic EP gear oil.

The oil capacity is approximately 1.0 - 1.2 quarts (0.9 -

1.1 liters). Do not overfill.

NOTICE

Only use oil with Graco part number 16W645. Any other oil may not lubricate properly and can cause damage to the drive train.

Fill Cap

1. Follow the Pressure Relief Procedure on page 22.

2. Place a minimum 2 quart (1.9 liter) container under the oil drain port.

3. Remove the oil drain plug. See FIG. 14 for the loca- tion of the drain plug. Allow all oil to drain from the driver.

4. Reinstall the oil drain plug. Torque to 18-23 ft-lb (25-30 N•m).

5. Open the fill cap and add Graco Part 16W645 ISO 220 silicone-free synthetic EP gear oil. Check the oil level in the sight glass. Fill until the oil level is near the halfway point of the sight glass. The oil capacity is approximately 1.0 - 1.2 quarts (0.9 - 1.1 liters). Do

not overfill.

6. Reinstall the fill cap.

Bearing Pre-loads

Sight Glass

Oil Drain Plug

FIG. 14: Sight Glass and Oil Fill Cap

Bearing Pre-Load

The bearing pre-loads are factory set and are not user adjustable. Do not adjust the bearing pre-loads. See APD20 Advanced Precision Driver Instructions-Parts manual for maintenance information.

24 3A6331G

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