Graco E-Flo Installation Manual

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Page 1

Installation - Parts

E-Flo

iQ Dispense

333586F

System

For dispensing and metering sealants, adhesives, and other medium to high viscosity fluids. For professional use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

See page 4 for system component information.

Important Safety Instructions

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

Page 2

Contents

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

Dispense System Configurator . . . . . . . . . . . . . . . . 4

Dispense System Components. . . . . . . . . . . . . . . . 5

iQ Ram Supply Units . . . . . . . . . . . . . . . . . . . . . . 5

iQ Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . 6

Hose Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Dispense System Pressure . . . . . . . . . . . . . . . . . . . 7

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

Dispense System Component Identification . . . . 11

Single Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Tandem Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Supply Unit Component Identification . . . . . . . . . 13

iQ Ram Supply Unit . . . . . . . . . . . . . . . . . . . . . . 13

Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . 14

Integrated Air Controls (AG) . . . . . . . . . . . . . . . 15

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 15

Advanced Display Module (ADM) . . . . . . . . . . . 16

Platen (AD) Component Identification . . . . . . . . 17

Electric Driver Communication Connections . . . 18

Installing Tandem. . . . . . . . . . . . . . . . . . . . . . . . 20

Power Junction Box and Heat Control Box

Connections. . . . . . . . . . . . . . . . . . . . . . . . . 22

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Requirements . . . . . . . . . . . . . . . . . . . . . 25

Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . 25

Attach Drum Stops . . . . . . . . . . . . . . . . . . . . . . . 27

Install Vented Oil Cap Before Using Equipment. 28

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Air Line Connections . . . . . . . . . . . . . . . . . . . . . 29

Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . . . 29

Electrical Connections . . . . . . . . . . . . . . . . . . . . 31

Heat Connections (Hoses and Accessories) . . . 33

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Hose Care Guidelines . . . . . . . . . . . . . . . . . . . . . . 36

Flush Before Using Equipment . . . . . . . . . . . . . 36

Check Resistance (Heated Systems) . . . . . . . . . . 37

Check Sensor Resistance . . . . . . . . . . . . . . . . . 37

Check Heater Resistance . . . . . . . . . . . . . . . . . 37

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 39

Shutdown and Care of the Pump . . . . . . . . . . . . . 41

Change Drums . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Driver Maintenance . . . . . . . . . . . . . . . . . . . . . . 43

Platen Maintenance . . . . . . . . . . . . . . . . . . . . . . 44

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 45

End of Product Life . . . . . . . . . . . . . . . . . . . . . . . 45

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Supply Systems Troubleshooting . . . . . . . . . . . . 46

Heat Control Box Troubleshooting . . . . . . . . . . . 47

Platen Valve Kit Troubleshooting . . . . . . . . . . . . 47

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Disconnect Pump from Platen . . . . . . . . . . . . . . 48

Connect Platen . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Remove Wipers . . . . . . . . . . . . . . . . . . . . . . . . . 50

Install Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Remove Displacement Pump. . . . . . . . . . . . . . . 50

Install Displacement Pump . . . . . . . . . . . . . . . . . 52

Remove Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Install Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Ram Supply Unit Repair. . . . . . . . . . . . . . . . . . . 55

Replace Heat Control Box Electrical Component(s)

Replace Fuses in Harness (25R652) . . . . . . . . . 60

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

D200s 6.5 in. Ram Supply Units. . . . . . . . . . . . . 61

D200 3 in. Ram Supply Units . . . . . . . . . . . . . . . 63

D60 3 in. Ram Supply Units . . . . . . . . . . . . . . . . 65

D200, D200s Pump Mounts for 55 Gallon (200 Liter)

Platen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

D60 Pump Mount for 5 Gallon (20 Liter) Platen . 68 D200s Pump Mounts for 16 Gallon (60 Liter)

Platens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Power Junction Box . . . . . . . . . . . . . . . . . . . . . . 70

Heat Control Box, 25R454 . . . . . . . . . . . . . . . . . 72

Cable Track, 26A935 . . . . . . . . . . . . . . . . . . . . . 73

55 Gallon Platen . . . . . . . . . . . . . . . . . . . . . . . . . 74

20 Liter (5 Gallon) Platens . . . . . . . . . . . . . . . . . 75

60 Liter (16 Gallon) Platens . . . . . . . . . . . . . . . . 77

Tandem Block, 25R848, 25R849 . . . . . . . . . . . . 79

2 333586F

Page 3

Related Manuals

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 80

System Kits and Accessories . . . . . . . . . . . . . . . 80

Drum Kits and Accessories . . . . . . . . . . . . . . . . 81

CAN Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

I/O Integration Cable . . . . . . . . . . . . . . . . . . . . . 82

Integration Extension Cables . . . . . . . . . . . . . . . 82

Platen/Pump Heat Harness . . . . . . . . . . . . . . . . 82

Pressure Transducer Cables . . . . . . . . . . . . . . . 82

Solenoid Cables . . . . . . . . . . . . . . . . . . . . . . . . . 82

Heat Extension Cables . . . . . . . . . . . . . . . . . . . . 82

Cable Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Fitting Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Tandem Fitting Kits . . . . . . . . . . . . . . . . . . . . . . 83

Additional Accessories . . . . . . . . . . . . . . . . . . . . 83

Check-Mate 200 CS Pump Heater Kit, 25R450 . 84

Platen Heater Kit, 25R451 . . . . . . . . . . . . . . . . . 85

Communication Gateway Module (CGM) Kits . . 86

Platen Valve Kit, 25R452 . . . . . . . . . . . . . . . . . . 88

Platen Valve Kit, 25R453 . . . . . . . . . . . . . . . . . . 90

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Pump Performance . . . . . . . . . . . . . . . . . . . . . . . . . 95

E-Flo iQ Dispense System Performance Chart . 96

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Technical Specifications . . . . . . . . . . . . . . . . . . . 102

California Proposition 65 . . . . . . . . . . . . . . . . . . . 103

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 104

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 104

Related Manuals

Related Manuals in English:

Manual in

English

333587 E-Flo iQ Supply System Operation

312375

312468

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

334048 EPDM Hose Wiper Kit Instructions - Parts

3A6321

3A6482

333585 iQ Dispense Valves, Instructions-Parts

3A1244 Graco Control Architecture Module

3A4241

Description

Check-Mate Instructions-Parts

200 cc Check-Mate Displacement Pump Repair Parts

Enclosed Wetcup Recirculation Kit Instructions - Parts

ADM Token In-System Programming Instructions

APD20 Advanced Precision Driver Instructions

Hot Melt/Warm Melt Heated Hose Instructions

Displacement Pumps

333586F 3

Page 4

Dispense System Configurator

The E-Flo iQ dispense system provides the flexibility to configure a complete system to meet your specific needs. This includes offering multiple combinations of the following components:

• iQ Ram Supply Units

• iQ Dispense Valves

• Hoses and connectors

For dispense system component information, see Dispense System Components on page 5.

First,

Second

and

Third

Digit

EQC

E-Flo iQ

System

Fourth

Digit

Revision

Fifth Digit Sixth Digit

Seventh

Digit

Platen

Single or

Tandem

S Single H Heated Y Yes T Tan-

dem

Heat

Option

A Ambient

Valve

Option

Eighth Digit

Ram Supply Unit Options

Size

A 3 in.

B 3 in.

C 3 in.

D 3 in.

F 3 in.

G 3 in.

H 3 in.

J 3 in.

K 6.5 in.

M 6.5 in.

N 6.5 in.

P 6.5 in.

R 6.5 in.

T 6.5 in.

Drum

Size

20 L

(5 Gal) CS EPDM

20 L

(5 Gal) CS

20 L

(5 Gal) CM EPDM

20 L

(5 Gal) CM

200 L

(55 Gal) CS EPDM

200 L

(55 Gal) CS

200 L

(55 Gal) CM EPDM

200 L

(55 Gal) CM

200 L

(55 Gal) CS EPDM

200 L

(55 Gal) CS

200 L

(55 Gal) CM EPDM

200 L

(55 Gal) CM 60 L (16

Gal) CS PTFE

60 L (16

Gal) CS PTFE

Pump

Material

Seal

Material

Neo-

prene

Neo-

prene

Neo-

prene

Neo-

prene

Neo-

prene

Neo-

prene

Ninth Digit

Fieldbus

Option

A Ether-

Net/IP

B PROF-

INET

C PROFI-

BUS

D Devi-

ceNet

N None

Digits Ten

through

Seventeen

Hose

Options for

Tandem

Hoses (Dig-

its 10-13)

and Supply

Hoses (Dig-

its 14-17)

(See Hose

Options on

page 6)

Digits

Eighteen

through

Twenty Seven

Valve Options

(See the iQ

Dispense

Valves Instruc-

tions - Parts

manual for

valve model

options)

KEY:

CS = Carbon Steel Severe Duty

CM = Carbon Steel MaxLife

4 333586F

Page 5

Dispense System Components

NOTE: The Heated option for the E-Flo iQ system is for warm melt applications with a maximum temperature of 70° C

(158° F).

iQ Ram Supply Units

Check the identification plate (ID) on the back of the ram post near the Power Junction Box (AJ) for the seven-digit part number of the iQ ram supply unit. Use the following matrix to define the construction of the unit, based on the seven digits.

For example, Part No. EZC2421 represents an electric supply unit (EZ), a carbon steel Check-Mate 200 Severe Duty dis-

placement pump (C2), a 3 in. ram (4), a 5-gallon platen with a neoprene seal (2), and an Advanced Display Module (ADM) (2).

The digits in the following matrix do not correspond to the reference numbers in the Parts drawings and lists.

EZ C2 4

First

and

Second

Digit

(Electric

Supply

System)

Third and Fourth Digit Fifth Digit

Check-Mate Pump Options Ram Options

Pump

Size

Material

C1 200cc CS Ambient

C2 200cc CS Heated

C3 200cc CM Ambient

C4 200cc CM Heated

Heated/

Ambient

≤70° C

≤70° C 4 D60 3 in.

Name Size

1 D60 3 in.

2 D200 3 in.

3 D200s 6.5 in.

5 D200 3 in.

6 D200s 6.5 in.

Drum

Size Style

20 L

(5 Gal) Ambient 1

200 L

(55

Gal) Ambient 2

200 L

(55

Gal) Ambient 3 20 L

200 L

(55

Gal)

200 L

(55

Gal)

Heated

≤70° C 4

Heated

≤70° C 5

Heated

≤70° C 6

(5 Gal)

Sixth Digit

Platen and Seal Options

Platen

Size

(5 Gal) CST/AL Neoprene

(5 Gal) CST/AL EPDM

200 L

Platen

Material

20 L

(55

Gal) AL Neoprene

(55

Gal) AL Neoprene

(55

Gal) AL EPDM

(55

Gal) AL EPDM 60 L

(16

Gal) CST/AL 60 L

(16

Gal) CST/AL

Material Wiper

Seventh

Digit

Interface

Options

Seal

PTFE

Coated

Nitrile PTFE

Coated

Nitrile

Single

Double

Single

Heated/

Ambient Interface

Ring Ambient 2ADM

Ring

Ring Ambient

Ring

Ring Ambient

Ring

Ring Ambient

Ring

Flat Ambient

Flat Heated

Heated

≤70° C 4 No ADM

Heated

≤70° C

Heated

≤70° C

Heated

≤70° C

KEY:

CS = Carbon Steel Severe Duty CM = Carbon Steel MaxLife CST/AL = Carbon Steel/Aluminum AL = Aluminum

333586F 5

Page 6

Dispense System Components

iQ Dispense Valves

Check the identification plate on the valve for the ten-digit part number of the iQ dispense valve. Use the following matrix to define the construction of the valve, based on the ten digits. For example, Part No. V25AB060BA represents a valve (V) with 1/4” NPT inlet ports (25), NPT tip size (A), ball/seat type (B), 60 mm outlet block length (060), solenoid (B), with no heat (A).

First Digit

Second and

Third Digit

Fourth Digit Fifth Digit

Size Tip Size Type

Sixth, Seventh,

and Eighth Digit

Outlet Block

Length

Ninth Digit Tenth Digit

Action Heat

Valve

1/4 in. NPT

A 1/4 in. NPT B Ball/Seat 000 NA B

Mounted

A None

Solenoid

60 mm

C 0.6 mm S Snuff-Back 060

D 1.0 mm T Tip Seal 200

200 mm

*Remote Solenoid

Block

Heated

≤

70° C

F 1.3 mm

G 1.7 mm

* Remote solenoid supplied by customer.

NOTE: Refer to the iQ Dispense Valves Instructions-Parts manual for additional information about iQ Dispense Valves. See Related Manuals on page 3.

Hose Options

Working

Pressure

Temperature

Rating

4000 psi (28

MPa, 276 bar)

at -65° F - 400°

F (101° C - 204°

Part No. JIC Dash Size Length Heat

04 19M404 -10 (5/8 in, 15.9 mm) 6 ft Heated

05 19M405 -10 (5/8 in, 15.9 mm) 10 ft Heated

06 19M406 -10 (5/8 in, 15.9 mm) 15 ft Heated

07 19M407 -10 (5/8 in, 15.9 mm) 20 ft Heated

08 19M408 -10 (5/8 in, 15.9 mm) 25 ft Heated

11 19M411 -12 (3/4 in, 19.0 mm) 6 ft Heated

12 19M412 -12 (3/4 in, 19.0 mm) 10 ft Heated

13 19M413 -12 (3/4 in, 19.0 mm) 15 ft Heated

14 19M414 -12 (3/4 in, 19.0 mm) 20 ft Heated

15 19M415 -12 (3/4 in, 19.0 mm) 25 ft Heated

16 19M416 -16 (1 in, 25.4 mm) 6 ft Heated

17 19M417 -16 (1 in, 25.4 mm) 10 ft Heated

18 19M418 -16 (1 in, 25.4 mm) 15 ft Heated

19 19M419 -16 (1 in, 25.4 mm) 20 ft Heated

20 19M420 -16 (1 in, 25.4 mm) 25 ft Heated

Working

Pressure

Temperature

Rating

4000 psi (28

MPa, 276 bar)

at -65° F - 212°

F (-54° C - 100°

3000 psi (21

MPa, 207 bar)

at 213° F - 400°

F (101° C - 204°

Part No. JIC Dash Size Length Heat

65 17K265 -10 (5/8 in, 15.9 mm) 6 ft Ambient

66 17K266 -10 (5/8 in, 15.9 mm) 10 ft Ambient

67 17K267 -10 (5/8 in, 15.9 mm) 15 ft Ambient

68 17K268 -10 (5/8 in, 15.9 mm) 20 ft Ambient

69 17K269 -10 (5/8 in, 15.9 mm) 25 ft Ambient

72 17K272 -12 (3/4 in, 19.0 mm) 6 ft Ambient

73 17K273 -12 (3/4 in, 19.0 mm) 10 ft Ambient

74 17K274 -12 (3/4 in, 19.0 mm) 15 ft Ambient

75 17K275 -12 (3/4 in, 19.0 mm) 20 ft Ambient

76 17K276 -12 (3/4 in, 19.0 mm) 25 ft Ambient

77 17K277 -16 (1 in, 25.4 mm) 6 ft Ambient

78 17K278 -16 (1 in, 25.4 mm) 10 ft Ambient

79 17K279 -16 (1 in, 25.4 mm) 15 ft Ambient

80 17K280 -16 (1 in, 25.4 mm) 20 ft Ambient

81 17K281 -16 (1 in, 25.4 mm) 25 ft Ambient

00 No Hose N/A N/A N/A

6 333586F

Page 7

Dispense 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

Dispense System Pressure

Check-Mate

200CS/CM

4,000 290 29.0 3,905 269 26.9

333586F 7

Page 8

Warnings

DANGER

WARNING

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.

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.

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.

8 333586F

Page 9

Warnings

WARNING

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.

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.

333586F 9

Page 10

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 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.

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.

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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 333586F

Page 11

Dispense System Component Identification

*Circular Electrical Connection

*Square Electrical Connection

*Circular Electrical Connection

*Square Electrical Connection

Dispense System Component Identification

Single Ram

NOTE: FIG. 1 shows a typical E-Flo iQ dispense system

installation with a single iQ ram supply unit, hoses, connectors, and an iQ dispense valve. Some installations may require only one hose depending on the needs of the system.

FIG. 1: Single E-Flo iQ Dispense System

Key:

A iQ Ram Supply Unit B iQ Dispense Valve C Supply Hose 1 D Supply Hose 2 E Ram Supply System to Supply Hose 1 Fitting

F Supply Hose 1 to Supply Hose 2 Fitting G Supply Hose 2 to Swivel Fitting H Swivel Fitting J Swivel to Valve Fitting

* Applies to heated hoses only.

333586F 11

Page 12

Dispense System Component Identification

*Circular Electrical Connection

*Square Electrical Connection

*Circular Electrical Connection

*Square Electrical Connection

*Circular Electrical Connection

Tandem Ram

Tandem E-Flo iQ Dispense Systems consist of two rams connected using a 3-way block with ball valves, and are controlled by a single ADM.Tandem E-Flo iQ Dispense Systems operate identically to Single E-Flo iQ Dispense Systems, with the added benefit of dispensing from the second ram when the first drum is empty.

NOTE: F

. 2 shows a typical E-Flo iQ dispense system installation with a tandem iQ ram supply unit, hoses, connectors, and an iQ dispense valve. Some installations may not require Supply Hose 2 (D) to iQ Dispense Valve (B) depending on the needs of the system.

FIG. 2: Tandem E-Flo iQ Dispense System

Key:

A iQ Ram Supply Unit 1 B iQ Dispense Valve C Supply Hose 1 D Supply Hose 2 E Tandem Block to Supply Hose 1 Fitting F Supply Hose 1 to Supply Hose 2 Fitting G Supply Hose 2 to Swivel Fitting H Swivel Fitting J Swivel to Valve Fitting K iQ Ram Supply Unit 2

L Tandem Hose 1 M Tandem Hose 2 N Ram Supply Unit 1 to Tandem Hose 1 Fitting P Ram Supply Unit 2 to Tandem Hose 2 Fitting R Tandem Block S Ball Valve

* Applies to heated hoses only.

12 333586F

Page 13

Supply Unit Component Identification

Lift Locations

Ambient System

Heated System

*AX

*ZA

Supply Unit Component Identification

iQ Ram Supply Unit

D200 3 in. Dual Post

NOTICE

Always lift the iQ Ram Supply Unit at the proper lift locations (see F

. 3). Do not lift in any other way.

Failure to lift at the proper lift locations can result in damage to the Supply System.

FIG. 3: iQ Ram Supply Unit

Key:

AA Ram Assembly AB Electric Driver AC Displacement Pump AD Platen (see F AE Fluid Check Valve AF Advanced Display Module (ADM) AG Integrated Air Controls (see F AH Platen Bleed Port AJ Power Junction Box AK Power Junction Box Switch AL Platen Lift Rod AM Pump Bleed Valve AN Wet Cup

333586F 13

. 7)

. 5)

AR Air Line (not supplied) AS Air Line Drain Valve (not supplied) AT Air Filter (not supplied) AU Bleed Type Air Shutoff Valve (required) (not supplied) AV Level Sensors AW Outlet Pressure Transducer AX *Heat Control Box AY Platen Valve Kit (optional) AZ Disconnect Switch (see Power Disconnect on page 14) ZA *Pump Heater ZB Recirculation Hose ZC Pump Relief Valve

* Parts on heated systems only.

Page 14

Supply Unit Component Identification

Heated System

Ambient System

Power Disconnect

Every E-Flo iQ Dispense System has a red and yellow Disconnect Switch which shuts off power to the entire system. The location of the switch is different for ambient and heated systems. See F

On ambient systems, the Disconnect Switch (AZ) is located on the Power Junction Box (AJ).

On heated systems, the Disconnect Switch (AZ) is located on the Heat Control Box (AX). Heated systems also have a red and black Power junction Box Switch (AK) located on the Power Junction Box (AJ). The Power Junction Box Switch (AK) removes power to everything EXCEPT heat. The Disconnect Switch (AZ) removes power to the entire system, including heat.

. 4.

. 4. Power Disconnect

14 333586F

Page 15

Supply Unit Component Identification

1/4 NPT Plug

Integrated Air Controls (AG)

The integrated air controls include:

• Main Air Slider Valve (BA): turns the air on and off

to the iQ Ram Supply Unit. When closed, the valve relieves all air pressure downstream.

• Ram Air Regulator (BB): controls the Ram Assem-

bly up and down pressure and the blowoff pressure.

• Ram Director Valve (BC): controls the Ram

Assembly direction.

• Exhaust Port with Muffler (BD)

• Blowoff Button (BE): turns the air on and off to

push the Platen (AD) out of an empty drum.

Air Line Accessories

See FIG. 3.

• Air Line Drain Valve (AS) (not supplied): removes

condensed water from air line.

• Air Line Filter (AT) (not supplied): removes harmful dirt and moisture from the compressed air sup-

ply.

• Second Bleed-type Air Valve (AU) (required) (not

supplied): isolates the Air Line accessories for ser-

vicing. Locate upstream from all other Air Line accessories.

. 5. Integrated Air Controls

333586F 15

Page 16

Supply Unit Component Identification

Advanced Display Module (ADM)

Front and Rear Views

FIG. 6: ADM Component Identification

Key: CA Startup/Shutdown

Starts up or shuts down the system. Toggles between Active and Inactive system.

CB System Status Indicator LED CC Pump Soft Stop

Stops all pump processes and disables the pump. Also stops all heating processes and disables the heat. This is not a safety or emergency stop.

CD Soft Keys

Defined by the icon on the screen next to the soft key. Performs the specific operation for that icon when pressed.

CE Cancel

Cancels a selection or number entry while in the process of entering a number or making a selection. Cancels the pump processes. Exits a screen without saving changes.

CF Enter

Select to update a field, accept a selection or value, acknowledge an event, enter a screen, and toggle selected items.

CG Lock/Setup

Toggles between Run screens and the iQ Menu.

CH Directional Keypad

Navigate within a screen or to a new screen.

CJ Numeric Keypad

Input numeric values.

CK Part Number Identification Label CL USB Interface CM CAN Cable Connection

Power and communication.

CN Module Status LEDs

Visual indicators to show the status of the ADM.

CP Token Access Cover

Access cover for blue software token.

CR Battery Access Cover CS Light Tower Connection

NOTE: If using a tandem system, the ADM is only

included with the iQ Ram Supply Unit 1 (A).

16 333586F

Page 17

Platen (AD) Component Identification

Ambient

Heated

Supply Unit Component Identification

. 7

Key:

EA Plate EB Wiper EC Heater Cover ED Cap Screws EF Bleed Stick EG Bleed Port EH Air Assist Body Check Valve EJ Wiper Plate (under wiper)

333586F 17

EK O-ring Seal (not shown) EL Platen Valve Port EM Platen Valve Cap

Page 18

Supply Unit Component Identification

Port 1

Port 2

Port 4

Port 6

Port 3

Port 5

Port 3 Connection

Port 4 Connection

Pump Solenoid Valve (M8 4 pin)

Power Junction Box Port C3 (M12 5 pin)

Power Junction Box Port C4 (M12 8 pin)

Dispense Valve Solenoid (M8 4 pin)

Electric Driver Communication Connections

Single Ram

. 8

Key:

Port 1 Connects to port C1 on the Power Junction Box. Port 2 Connects to port C2 on the Power Junction Box. Port 3 Connects to port C3 on the Power Junction Box

(M12 5 pin), and to the pump solenoid valve (M8 4 pin).

Port 4 Connects to port C4 on the Power Junction Box

(M12 8 pin), and to the dispense valve solenoid (M8

4 pin). Port 5 Connects to the pump pressure transducer. Port 6 Connects to the valve pressure transducer.

18 333586F

Page 19

Tandem Ram

Port 1

Port 4

Port 6

Port 3

Port 5

Port 3 Connection

Port 4 Connection

Pump Solenoid Valve (M8 4 pin)

Power Junction Box Port C3 (M12 5 pin)

Tandem Block discrete Robot connection Splitter

Tandem Block dispense valve Solenoid Splitter (M8 4 pin)

Tandem Block

To Robot Controller

To Dispense Valve Solenoid

To Driver Port 6

To Power Junction Box Port C4 (Robot Controller Splitter M12 8 pin)

To Power Junction Box Port C4 (Solenoid Splitter M8 4 pin)

Pressure Transducer

Port 2

Supply Unit Component Identification

FIG. 9

333586F 19

Page 20

Supply Unit Component Identification

ADM

Cable from Tandem Kit

Splitter from Tandem Block

Installing Tandem

1. Remove cable from port C1 on ram 1 and plug into female end of splitter. Splitter is included in tandem kit.

2. Install 0.4 m cable (121226) included in tandem kit from male end of splitter to part C1 on ram 1.

3. Install 5.0 m cable (124003) included in the tandem kit, from male end of splitter and connect to part C1 of ram 2.

4. Use zip ties included in kit to secure cables to ram frame. See F

NOTE: Ram 1 includes ADM, ram 2 has no ADM.

. 10 for cable routing.

. 10: Communication Connections

Key:

Port 1 Connects to port C1 on the Power Junction Box. Port 2 Connects to port C2 on the Power Junction Box. Port 3 Connects to port C3 on the Power Junction Box (M12 5 pin), and to the platen valve solenoid (M8 4 pin). Port 4 Connects to port C4 on the Power Junction Box, and to the Tandem Block (R) solenoid splitter (M8 4 pin). Port 5 Connects to the pump pressure transducer. Port 6 Connects to the valve pressure transducer splitter on the Tandem Block (R).

20 333586F

Page 21

Low Level Sensor Kit, 25R439

NOTE: The Low Level Sensor Kit is an optional accessory for Single Ram Systems, and a required accessory for Tandem Ram Systems.

To install the Low Level Sensor:

1. Turn the Disconnect Switch (AZ) OFF.

2. Disconnect cable from the empty level sensor (EL).

3. Mount the low level sensor (LL) on the mounting bracket.

4. Connect the splitter cable (SP) to the previously disconnected cable.

5. Connect the splitter cable (SP) lead labeled EMPTY to the empty level sensor (EL).

6. Connect the splitter cable (SP) lead labeled LOW to the low level sensor (LL).

Supply Unit Component Identification

7. Raise/lower the low level sensor (LL) to the desired position to activate the sensor.

8. See the E-Flo iQ Supply System Operation manual to set up the low level sensor.

333586F 21

Page 22

Supply Unit Component Identification

Ambient

Heated

AMZ

Power Junction Box and Heat Control Box Connections

Single Ram

FIG. 11

Key:

C1 GCA CAN Port (to ADM) C2 GCA CAN Port (to CGM) C3 Low and Empty Level Sensor Input C4 Discrete Integration Cable

22 333586F

C5 Heated Hose/Accessory Connec-

tion C6 Heated Pump Connection C7 Heated Platen Connection

AK Power Junction Box Switch AZ Disconnect Switch AMZ Auto Multi-Zone

Page 23

Tandem Ram

Ambient

Heated

AMZ

Supply Unit Component Identification

FIG. 12

iQ Ram Supply Unit 1

Key:

C1 GCA CAN Port (to ADM splitter cable on Tandem Block

(R) using the supplied CAN cable (124003)) C2 GCA CAN Port (to CGM) C3 Low and Empty Level Sensor Input

C4 Discrete Integration Cable (to robot splitter cable on tan-

dem block)

C5 Port 1, Port 2, Port 3: Heated Hose/Accessory Connec-

tion C6 (Port 4) Pump C7 (Port 5) Platen AK Power Junction Box Switch (same as Single Ram on

page 22) AZ Disconnect Switch (same as Single Ram on page 22) AMZ Auto Multi-Zone

iQ Ram Supply Unit 2

Key:

C1 GCA CAN Port (to ADM splitter cable on Tandem Block

C2 GCA CAN Port (to CGM) C3 Low and Empty Level Sensor Input

C4 Discrete Integration Cable (to robot splitter cable on TanC5 Port 1, Port 2, Port 3: Heated Hose/Accessory Connec-

C6 (Port 4) Pump C7 (Port 5) Platen AK Power Junction Box Switch (same as Single Ram on

AZ Disconnect Switch (same as Single Ram on page 22) AMZ Auto Multi-Zone

(R) using the supplied CAN cable (124003))

dem Block (R))

tion

page 22)

333586F 23

Page 24

Installation

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

tions.

The E-Flo iQ Dispense System is shipped in five to six containers:

1. iQ Ram Supply Unit that includes the fully assembled ram, electric driver, and pump.

2. iQ Dispense Valve

3. Hoses (shipped in one or two containers depending on the number of hoses used)

4. Fittings

5. Cables and a pressure transducer

The E-Flo iQ Tandem Dispense System is shipped in ten to eleven containers:

1. iQ Ram Supply Unit that includes the fully assembled ram, electric driver, and pump.

2. Second iQ Ram Supply Unit that includes the fully assembled ram, electric driver, and pump.

3. iQ Dispense Valve

4. Hoses (shipped in three or four containers depending on the number of hoses used)

5. Fittings

6. Tandem fittings

7. Cables and a pressure transducer

8. Tandem Kit

Location

Remove the iQ Ram Supply Unit from its crate. Attach a lifting sling at the proper lift locations (see F of the pallet using a crane or a forklift.

To properly locate and anchor the iQ Ram Supply Unit (A), see Dimensions on page 93.

NOTICE

Always lift the iQ Ram Supply Unit at the proper lift locations (see F Failure to lift at the proper lift locations can result in damage to the system.

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

Position the Ram Assembly (AA) so the Driver (AB), Power Junction Box Switch (AK) and/or Disconnect Switch (AZ), Integrated Air Controls (AG), and ADM (AF) are easily accessible. Ensure that there is enough space overhead for the Ram Assembly to raise fully.

Use the holes in the Ram Assembly base as a guide and drill holes for 1/2 in. (13 mm) anchors.

Ensure that the Ram Assembly base is level in all direc-

tions. 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 Assembly from tipping.

. 3). Do not lift in any other way.

. 3). Lift off

NOTE: Additional items including CGM and accessories may be shipped in additional containers.

This section describes how to install and set up the E-Flo iQ system and make all the necessary component connections.

24 333586F

Page 25

Installation

LQ

LQ

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.

Ram Assembly: the iQ Ram Supply Unit is grounded through the incoming power cord. See Connect Power on page 25.

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 the manufacturer’s recommen-

dations.

Power Requirements

Each iQ Ram Supply Unit requires a dedicated circuit protected with a circuit breaker.

For Ambient Systems:

Voltage Phase Hz Current

200-240 VAC 1 50/60 20 A

For Heated Systems:

Voltage Phase Hz Current

200-240 VAC 1 50/60 60 A 200-240 VAC 3 50/60 38 A 380-420 VAC 3 (YN) 50/60 38 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.

Dispense valve: see the iQ Dispense Valves Instruc-

tions-Parts manual for grounding information.

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 sur-

face, 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.

Ambient Systems

1. Turn the Disconnect Switch (AZ) OFF.

2. 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 F

FIG. 13: Power Cord

3. Remove the six screws holding the cover of the Power Junction Box (AJ), then remove the Power Junction Box cover.

. 13.

333586F 25

Page 26

Installation

Screws

Ground Lug

Cord Grip

Disconnect Switch Terminal Block

1L1

3L2

5L3

2T1

4T2

6T3

350

ti31214a

FIG. 14: Remove the Power Junction Box Cover

4. Insert the power cord through the cord grip and into the Power Junction Box (AJ).

Heated Systems

1. Turn the Heat Control Box Disconnect Switch (AZ) OFF.

FIG. 17

2. Loosen the screws and remove the cover (350) on the Heat Control Box (AX).

FIG. 15: Power Connection

5. Attach the ground wire to the ground lug inside the Power Junction Box (AJ).

6. Refer to F

. 16 and connect the wires from the

power cord into terminals 4T2 and 6T3 on the Dis-

connect Switch terminal block.

3. Insert the electrical cord through the electrical enclosure strain relief bushing (SR).

4. Attach insulated ferrules to the end of each wire.

5. Connect the ground wire to the ground stud (GS).

6. Connect power wires to the Heat Control Box Dis-

connect Switch (AZ) as shown below.

NOTE: Use a flat-head or Pozidriv screwdriver to tighten the terminals to 7-10 in-lb (0.8-1.1 N•m).

FIG. 16: Disconnect Switch Terminal Block

NOTE: Use a flat-head or Pozidriv screwdriver to tighten

7. Tighten the strain relief bushing (SR) around the electrical cord.

the terminals to 7-10 in-lb (0.8-1.1 N•m).

7. Tighten the cord grip to securely hold the power cord to the Power Junction Box (AJ).

8. Replace the Power Junction Box cover and secure it with the six screws that were removed in step 2.

26 333586F

8. Close the Heat Control Box door (350).

Page 27

Attach Drum Stops

Drum Stops

Capscrews

55 gal (200 L)

30 gal (115 L)

8 gal (30 L)

5 gal (20 L)

D200 and D200s Base D60 Base

8 gal (30 L)

5 gal (20 L)

60 gal (16 L)

16 gal (60 L)

The iQ Ram Supply Units are shipped with drum stops in place to help position the drum on the Ram Assembly (AA). For replacement parts, order Kit 255477. The kit includes 2 each of capscrews, lock washers (not shown), and drum stops.

Installation

FIG. 18: Drum Stop Installation

1. Locate the correct set of mounting holes on the Ram Assembly base. See F

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

. 19.

FIG. 19: Ram Base

333586F 27

Page 28

Installation

Unvented Cap

Vented Cap

Sight Glass

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. Replace this temporary cap 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.

28 333586F

FIG. 20: Unvented and Vented Oil Caps

Page 29

Setup

A, K

E, N, P

Fluid Check Valve

Setup

2. If using a Single iQ Ram Supply System, connect the Ram Supply System to Supply Hose 1 Fitting (E) to the fluid check valve (AE) on the iQ Ram Supply Unit (A).

Remove the iQ Dispense Valve (B) from its packaging. Refer to the iQ Dispense Valves Instructions-Parts manual included with the valve for information about installing the valve. See Related Manuals on page 3.

Air Line Connections

Refer to FIG. 3 on page 13 for a typical installation.

Attach the Air Line (AR) (not supplied) to the bottom of

the Integrated Air Control (AG) at the 3/4 in. NPT con-

nection.

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

Hoses and Fittings

NOTE: A number of options are available for fittings,

hoses, and cables for the E-Flo iQ Dispense System. Yours may differ in appearance from those shown in F

. 1 on page 11 and FIG. 2 on page 12. However, the

steps for making the connections are the same.

3. If using a Tandem iQ Ram Supply System:

a. Connect the Ram Supply Unit 1 to Tandem

Hose 1 Fitting (N) to the fluid check valve (AE) on iQ Ram Supply Unit 1 (A).

b. Connect the Ram Supply Unit 2 to Tandem

Hose 2 Fitting (P) to the fluid check valve (AE) on the iQ Ram Supply Unit 2 (K).

NOTE: The Recirculation Hose (ZB) should not be connected to the to the platen fitting at this time. See the E-Flo iQ Dispense System Operation manual for more information on when to connect the Recirculation Hose (ZB).

See F

. 1 on page 11 and FIG. 2 on page 12 to connect the hoses and fittings to the iQ Ram Supply Unit(s) (A, K) and the Dispense Valve (B).

NOTE: Do not connect any hoses if flushing the pump for the first time. See the E-Flo iQ Dispense System Operation manual for instructions on flushing the pump and connecting hoses.

NOTE: To ensure the best crossover performance with an E-Flo iQ Tandem System, Tandem Hose 1 and Tandem Hose 2 must be the same inner diameter and length.

1. Follow the Pressure Relief Procedure on page 39.

333586F 29

FIG. 21

4. If using a Single iQ Ram Supply System, connect Supply Hose 1 (C) to the Ram Supply System to Supply Hose 1 Fitting (E) as shown in F F

. 22.

5. If using a Tandem iQ Ram Supply System:

a. Connect Tandem Hose 1 (L) to the Ram Supply

Unit 1 to Tandem Hose 1 Fitting (N) as shown in F

. 2 and FIG. 22.

b. Connect Tandem Hose 2 (M) to the Ram

Supply Unit 2 to Tandem Hose 2 Fitting (P) as

shown in F

. 2 and FIG. 22.

. 1 and

Page 30

Setup

E, N, P

L, M, C

c. Connect Tandem Hose 1 (L) and Tandem Hose

2 (M) from the supply system to the Tandem Block (R). See F

. 23.

d. Connect Supply Hose 1 (C) to the Tandem

Block (R). See F

. 23.

FIG. 22

7. Connect the Supply Hose 2 to Swivel Fitting (G) to the Swivel Fitting (H).

FIG. 25

8. Connect the Swivel to Valve Fitting (J) to the Dispense Valve (B) as shown in F

. 26.

FIG. 26

9. Connect the Swivel Fitting (H) to the Dispense Valve (B) at the Swivel to Valve Fitting (J) that was connected in step 8.

FIG. 23

6. If you are using two supply hoses (C and D), use the Supply Hose 1 to Supply Hose 2 Fitting (F) to connect Supply Hose 1 (C) to Supply Hose 2 (D). See F

. 24.

NOTE: If using heated hoses, make sure the electrical connections of each hose are oriented correctly, with the circular electrical connector facing the Ram. See F

. 1 on page 11 for proper hose orientation on the

system.

FIG. 27

FIG. 24

30 333586F

Page 31

Setup

Pressure Transducer Cable Connection (XX).

Discrete Robot Cable Connection (SS).

Dispense Valve solenoid Cable Connection (YY).

M12 8 pin Discrete Robot Splitter (RR).

M8 4 Pin Dispense Valve Solenoid Splitter (TT) to Splitter Attached to Port 4 on Electric Drive (AB) on Ram 1 and Ram 2. Pin

M12 5 Pin Pressure Transducer Splitter Cable (ZZ) to Port 6 on Electric Drive (AB) on Ram 1 and Ram 2..

(NN)

10. If two hoses are used, connect Supply Hose 2 (D) to the Swivel Fitting (H) on the Dispense Valve (B) using the Supply Hose 2 to Swivel Fitting (G). If only one hose is used, connect Supply Hose 1 (C) to the Swivel Fitting (H) on the Dispense Valve (B) using the Supply Hose 2 to Swivel Fitting (G).

FIG. 28

11. Tighten all fittings until secure.

12. Connect the Air Line (AR) (not supplied) to the air fitting (FT) on the dispense valve solenoid. See the iQ Dispense Valves Instructions-Parts manual. See F

. 31.

Electrical Connections

Pressure Transducer

1. If using a Single iQ Ram Supply System, connect the pressure transducer cable (PC) from dispense valve (B) to Port 6 on the Electric Driver (AB). See Electric Driver Communication Connections for Single Rams on page 18.

2. If using a Tandem iQ Ram Supply System:

a. Connect the Pressure Transducer Cable (PC)

from the Dispense Valve (B) to the Tandem Block Valve Pressure Transducer Splitter. See F

. 29.

b. Connect one male end of the M12 5 pin

Pressure Transducer Splitter cable (ZZ) on the Tandem Block (R) to Port 6 on the Electric Driver (AB) on Ram 1. The second male end goes to Port 6 on Ram 2. See Electric Driver

Communication Connections for Tandem Rams on page 19.

FIG. 29

333586F 31

Page 32

Setup

Solenoid Valve

Cable

Dispense Valve Solenoid

3. If using a Single iQ Ram Supply System:

a. Connect the solenoid valve cable (VC) to the

M8 4 pin end of the splitter cable attached to Port 4 on the Electric Driver (AB). See Electric Driver Communication Connections for Single Rams on page 18. See F

b. Connect the 90 degree end of the included M8 4

pin cable (VD) to the dispense valve, and the straight end of the solenoid valve cable to (VC). See F

. 31.

4. If using an iQ Tandem Ram Supply System:

. 31.

a. Connect the dispense valve solenoid cable to

the tandem dispense valve solenoid connector (YY) on tandem block (R).

b. Connect the 90 degree end of the included M8 4

pin cable (15N040) to the dispense valve, and the straight end of the solenoid valve cable to (VC). See F

. 31.

c. Connect one male end of the M8 4 pin splitter

(TT) on the tandem block (R) to the M8 4 pin end of the splitter cable attached to Port 4 on the Electric Driver (AB) for ram 1 and ram 2. See Electric Driver Communication

Connections for Tandem Rams on page 19.

NOTE: Make sure the pins on the solenoid valve cable

are oriented as shown in F

. 30 before the cable is

plugged into the solenoid valve.

FIG. 31

Robot Connection (if used)

5. If using a Single iQ Ram Supply System:

a. Connect the included M12 8 pin 4 meter I/O

integration cable with flying leads (128441) to Port C4 of the power junction box (AJ)

b. Flying leads of the 4 meter I/O integration cable

(128441) connect to robot controller (not included).

6. If using a Tandem iQ Ram Supply System:

a. Connect the included M12 8 pin 4 meter I/O

integration cable with flying leads (128441) to discrete robot cable connector (SS) on tandem block (R).

b. Connect M12 8 pin discrete robot splitter (RR)

to Port C4 of the power junction box (AJ) on ram 1 and ram 2.

c. Flying leads from the 4 meter I/O integration

cable (128441) connect to robot controller (not included).

FIG. 30

NOTE: If the robot controller is located further away

from the unit than the 4 meter I/O integration cable (128441) can reach, an integration extension cable can be used to increase the length. See

32 333586F

Page 33

Setup

Hose 1

Circular electrical connection

Hose 2 *

Circular electrical connection

Square electrical connection

C5 - Port 1

C5 - Port 2

Single system includes:

• Two heated hoses

• One heated valve

Heat Connections (Hoses and Accessories)

1. Connect heated hoses (with circular electrical connectors) to Heat Control Box Ports 1, Port 2 or Port 3 (C5).

2. Connect heated accessories to the square electrical connector end of each heated hose that is used.

Single System Example

Example 1: Single system with two heated

hoses and one heated dispense valve.

• Hose 1 - Circular electrical connection to Port 1 (C5).

• Hose 2 - Circular electrical connectors to Port 2 (C5). *

• Heated valve - Square electrical connections from hose 2 to iQ dispense valve (B). See F

. 32.

. 32

Note: port 4 is always used for heated pump. Port 5 is

always used for heated platen.

* Requires Heat Extension Cables. See page 82.

333586F 33

Page 34

Setup

Tandem system includes:

• Four heated hoses

• One heated tandem block

• One heated valve

C5 - Port 1

C5 - Port 2

C5 - Port 3

Ram 1

Ram 2

Ram 1

Ram 2

Hose 1

Circular electrical connection

Hose 2

Square electrical connection

Hose 3 *

Hose 4 *

Circular electrical connection

Example 2: Tandem system with 4 heated hoses, one heated tandem block and one heated dispense valve.

• Hose 1 - To tandem block from pump 1 - circular electrical connection to Port 1 (C5) of ram 1.

• Hose 2 - To tandem block from pump 2 - circular electrical connector to Port 1 (C5) of ram 2. **

• Hose 3 - From tandem block - circular electrical connector to part 2 (C5) of ram 1 or ram 2. *

• Hose 4 - From hose 3 to extend length of hose circular electrical connector to Port 3 (C5) of ram 1 or ram 2. *

• Heated Valve - Square electrical connection from hose 4 to iQ dispense valve (B).

• Heated Tandem Block - Square electrical connection from hose 1 or hose 2 to heated tandem

block (R). See F

. 33

Note: port 4 is always used for heated pump. Port 5 is

always used for heated platen.

* Requires Heat Extension Cables. See page 82.

** Heat extension cable included in tandem block kit (25R848).

34 333586F

Page 35

Wet Cup

Before starting, fill the Wet Cup (AN) 1/3 full with Graco Throat Seal Liquid (TSL) or a compatible solvent.

Torque the Wet Cup

The Wet Cup (AN) 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 produc-

tion. Maintaining proper Wet Cup torque is important to extending seal life.

Setup

FIG. 34: 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 39.

2. Torque the Wet Cup (AN) 95-115 ft-lbs (128-155 N•m) using the packing nut wrench (supplied) whenever necessary. Do not overtighten the Wet Cup.

333586F 35

Page 36

Hose Care Guidelines

Fluids subjected to heat in confined spaces can create a rapid rise in pressure due to the thermal

expansion. Over-pressurization can result in equip-

ment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses pro actively at regular intervals based on your operating conditions.

NOTE: Pressure check the hose assemblies. Refer to the E-Flo iQ Supply System Operation manual for instructions on priming the system. Check carefully for leaks at the hose connections. If there are leaks, follow the Pressure Relief Procedure on page 39.

Do not use hose to pull the equipment.

Use hose support spring.

Do not clamp, squeeze, or zip tie hose.

Minimum bend radius:

Use 2 wrenches to tighten. Torque to specification:

Do not tape or cover hose.

Do not flex hose when cold.

Do not bend or crimp hose.

Do not twist hose.

Use proper length hose.

Flush Before Using Equipment

The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating the fluid with oil, flush the equipment with a compatible solvent before using the equipment. See the E-Flo iQ Supply System Operation manual for information about flushing the equipment. See Related Manuals on page 3.

36 333586F

Page 37

Check Resistance (Heated Systems)

Check Sensor Resistance

To reduce risk of injury or damage to equipment, conduct these electrical checks with the Power Junction Box Switch (AK) and the Disconnect Switch (AZ) OFF.

NOTE: Instructions for checking sensor resistance applies to heated systems only.

The package includes up to nine heat sensors and controllers for each of the heated zones. To check sensor resistance:

1. Turn the Power Junction Box Switch (AK) and the Disconnect Switch (AZ) OFF.

2. Wait for components to cool down to ambient room temperature 63°-77°F (17°-25°C). Check electrical resistance for the components.

NOTE: Check resistance at ambient room temperature 63°-77°F (17°-25°C).

Check Heater Resistance

To reduce risk of injury or damage to equipment, conduct these electrical checks with the Power Junction Box Switch (AK) and the Disconnect Switch (AZ) OFF.

NOTE: Instructions for checking heater resistance applies to heated systems only.

1. Turn the Power Junction Box Switch (AK) and the Disconnect Switch (AZ) OFF.

2. Make electrical resistance checks for the compo-

nents.

3. Replace any parts whose resistance readings do

not comply with the ranges listed in Table 1: Sen-

sors on page 38.

Circular Hose

AMZ Pins

First Heat Zone A, J Second Heat Zone C, D First RTD G, K Second RTD M, K Earth Ground B

3. Replace any parts whose resistance readings do

not comply with the ranges listed in Table 1: Sen-

sors on page 38.

Connector

333586F 37

Page 38

Check Resistance (Heated Systems)

Table 1: Sensors

Port Zone Component

1 Heated Hose 100 G, K See hose manual See hose manual

2 Heated Accessory 1 100 M, K See accessory manual

3 Heated Hose 100 G, K See hose manual See hose manual

4 Heated Accessory 2 100 M, K See accessory manual

5 Heated Hose 100 G, K See hose manual See hose manual

6 Heated Accessory 3 100 M, K See accessory manual

7 Not Used NA NA NA NA 8 Pump 1000 M, K 37 C, D

5 gallon platen 100 M, K 80 C, D

55 gallon platen 1000 M, K 15

RTD Range

(Ohms)

RTD Pin

Numbers

Heater Element

Resistance (Ohms)

Heater Pin

Numbers

See accessory manual

C, D (#1) A, J (#2)

38 333586F

Page 39

Pressure Relief Procedure

Pump Pressures

Valve Pressure

Pump Pressure

Valve Pressure

Single Unit Run Screen

Tandem Unit Run Screen

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 Pro-

cedure when you stop spraying and before cleaning, checking, or servicing the equipment.

NOTE: The ADM must be in Local control mode to depressurize the system. See the See the E-Flo iQ Supply System Operation manual.

NOTE: For iQ Tandem Ram Supply Systems, make sure both Ball Valves (S) on the Tandem Block are open to ensure pressure is fully relieved.

soft key to open the iQ Dispense Valve (B) allowing the system to depressurize.

FIG. 35: Tandem Block Ball Valves

NOTE: To relieve pressure for the entire E-Flo iQ

Dispense System, follow steps 1 through 12. To relieve pressure for the fluid side only, leaving air on to the ram cylinder follow steps 1 through 9.

1. Ensure the control mode is set to Local. See Con-

trol Modes in the E-Flo iQ Supply System Opera-

tion manual.

2. At the ADM (AF) Run screen, press the soft

key for Valve Depressurization. Then press the

333586F 39

3. The current pump pressure and current dispense valve pressure show the progress of the depressurization on the Run screen.

4. When all of the pressure has been relieved in the

system, press the soft key to close the iQ Dispense Valve (B).

5. Press the soft key to exit the valve depressurization mode.

NOTE: If using a tandem system, perform steps 6-12 on both units.

6. If using an ambient system, turn the Disconnect Switch (AZ) OFF. If using a heated system, turn the

Page 40

Pressure Relief Procedure

Open

Power Junction Box Switch (AK) and the Disconnect Switch (AZ) OFF.

7. Open the Pump Bleed Valve (AM). Have a container ready to catch the drainage.

8. Leave the Pump Bleed Valve (AM) open until ready to dispense again.

9. If you suspect the dispense valve is clogged or that pressure has not been fully relieved:

a. VERY SLOWLY loosen the hose end coupling to

relieve pressure gradually.

b. Loosen the coupling completely.

c. Clear the obstruction in the tip/nozzle of the

valve.

10. Close the Main Air Slider Valve (BA).

FIG. 36: Air Control for Pressure Relief

11. Set the Ram Director Valve (BC) to DOWN. The Ram (AA) will slowly drop.

12. Once the Ram (AA) is completely down, jog the Ram Director Valve (BC) up and down to bleed air from the Ram (AA) cylinders.

40 333586F

Page 41

Shutdown and Care of the Pump

Change Drums

Shutdown and Care of the Pump

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.

1. Follow the Pressure Relief Procedure on page 39.

2. Set the Ram Director Valve (BC) to DOWN, and lower the Ram (AA) to the desired position for shutdown. If using a tandem system, perform this step on both units.

3. Set the Ram Director Valve (BC) to neutral.

4. 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 iQ Supply System Operation manual for information about jogging the Pump. See Related Manuals on page 3.

5. Always flush the Pump before the fluid dries on the displacement rod. See the E-Flo iQ Supply System Operation manual for steps to flush the pump.

Keep hands away from the pump inlet to prevent serious injury from moving parts.

If the Platen (AD) does not come out of the pail easily when the Pump is being raised, the air assist tube (AT) or check valve (416) may be plugged. A plugged valve prevents air from reaching the underside of the plate to assist in raising it from the pail. See F

1. Turn off power to the Electric Driver (AB):

a. If using an ambient Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF. See F

. 37.

b. If using a heated Single Ram Supply System,

turn the black Power Junction Box Switch (AK) OFF. See F

c. If using an ambient Tandem Ram Supply

System, turn the red Power Junction Box Switch (AK) OFF on the Ram Supply Unit that requires a drum change only. See F

d. If using a heated Tandem Ram Supply System,

turn the black Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires a drum change only. See F

. 37.

. 40 on page 44.

. 37.

333586F 41

Page 42

Shutdown and Care of the Pump

Heated System

Ambient System

2. Set the Ram Air Regulator (BB) to 0 psi.

3. Set the Ram Director Valve (BC) to UP.

4. Slowly increase the pressure on the Ram Air Regulator until the Platen (AD) starts to raise, and immediately press and hold the Blowoff Button (BE)

until the Platen is completely out of the drum.

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.

5. Release the Blowoff Button (BE) and allow the Ram to rise to its full height.

. 38. Integrated Air Controls

6. Remove the empty drum.

. 37. Power Disconnect

42 333586F

Page 43

Maintenance

Fill Cap

Sight Glass

Bearing Pre-loads

Oil Drain Plug

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 pre-

ventative 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

See FIG. 39 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 (AB) is not run-

ning. 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.

1. Follow the Pressure Relief Procedure on page 39.

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

3. Remove the oil drain plug. See F of the drain plug. Allow all oil to drain from the Driver (AB).

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.

. 39 for the location

FIG. 39: 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.

333586F 43

Page 44

Maintenance

TI10613A

55 Gallon Platen

5 Gallon Platen

Platen Maintenance

1. Follow the steps to Change Drums on page 41.

2. Follow the Pressure Relief Procedure on page 39.

3. Refer to parts illustration on page 75 and remove the platen check valve (449) as shown.

4. Clear air assist tube (AT) in Platen (AD).

5. Clean all parts of the platen check valve (449) and replace if necessary.

6. Remove Bleed Stick (EF) from Platen (AD). Push Bleed Stick through Bleed Relieve Ports (EG) to remove material residue.

Remove and Reinstall Wipers

Remove Platen Wipers

NOTE: Five gallon Platens have a single Wiper that

must be removed, and 55 gallon Platens have a top and bottom Wiper that must be removed.

1. Follow the Pressure Relief Procedure on page 39.

2. If using an ambient system, turn the Disconnect Switch (AZ) OFF. If using a heated system, turn the Power Junction Box Switch (AK) and the Disconnect Switch (AZ) OFF.

3. To replace worn or damaged Wipers (EB), raise Platen up out of drum. Remove drum from base. Wipe fluid off of Platen.

4. Cut the Wiper(s) (EB) with knife and remove from Platen. See F

. 41.

FIG. 40

FIG. 41

44 333586F

Page 45

Maintenance

TI10614A

55 Gallon Platen

5 Gallon Platen

Reinstall Platen Wipers

NOTE: Five gallon Platens have a single Wiper that

must be reinstalled, and 55 gallon Platens have a top and bottom Wiper that must be reinstalled.

1. Using a wooden or plastic tool to prevent damage to the Wiper (EB), clean all material from the seal grooves.

2. Working from the bottom, angle one Wiper (EB) over the back of the Platen (AD). See F

3. Insert the Wiper (EB) in the top groove and run the front of the Wiper into the groove.

4. If using a 55 gallon Platen, insert the second Wiper (EB) in the lower groove and run the front of the Wiper into the groove.

5. Lubricate the outside of the Wiper with lubricant compatible with the material being pumped. Check with the material supplier.

. 42.

Recycling and Disposal

End of Product Life

At the end of the product’s useful life, dismantle and recycle it in a responsible manner.

• Perform the Pressure Relief Procedure.

• Drain and dispose of fluids according to applicable regulations. Refer to the material manufacturer’s Safety Data Sheet.

• Remove motors, batteries, circuit boards, LCDs (liquid crystal displays), and other electronic components. Recycle according to applicable regulations.

• Do not dispose of batteries or electronic components with household or commercial waste.

. 42

• Deliver remaining product to a recycling facility.

333586F 45

Page 46

Troubleshooting

2. Check all possible problems and causes before disassembling the Ram, Pump, or Platen.

NOTE: Refer to Supply Unit Operation manual for descriptions of ADM diagnostic codes.

NOTE: Refer to your Pump package manual for Pump

1. Follow Pressure Relief Procedure, page 39,

before checking or repairing the Ram, Pump, or Platen.

Supply Systems Troubleshooting

Problem Cause Solution

System will not turn ON. No power to unit. Check main power breaker is turned

Ram will not raise or lower. Closed air valve or clogged air line. Open, clear.

Not enough air pressure. Increase.

Worn or damaged piston. Replace. See Ram Supply Unit

Hand valve closed or clogged. Open, clear.

Ram raises and lowers too fast. Air pressure is too high. Decrease.

Air leaks around cylinder rod. Worn rod seal. Replace. See Ram Supply Unit

Fluid squeezes past ram plate wip-

ers.

Pump will not prime properly or pumps air.

Air assist valve will not hold drum down or push plate up.

Air pressure too high. Decrease.

Worn or damaged wipers. Replace. See Remove and Rein-

Not enough pressure. Increase pressure setting.

Worn or damaged piston. Replace. See Pump manual.

Hand valve closed or clogged. Open, clear. See Platen Mainte-

Hand valve is dirty, worn, or dam-

aged.

Closed air valve or clogged air line. Open, clear. See Platen Mainte-

Not enough air pressure. Increase.

Valve passage clogged. Clean. See Platen Maintenance on

troubleshooting.

ON.

Check power cord is connected.

Repair on page 55.

stall Wipers on page 44.

nance on page 44.

Clean, service.

nance on page 44.

page 44.

46 333586F

Page 47

Troubleshooting

Heat Control Box Troubleshooting

Problem Cause Solution

System does not heat. Blown fuse. Replace fuse.

Over-temperature switch tripped. Measure over-temperature switch

resistance. It should read close to 0 ohms when at room temperature. If open, replace over-temperature switch.

Cable to over-temperature switch is off or broken.

Electrical short. Check jumpers.

Disconnect switched OFF. Check disconnects.

Slow warm-up time. Low incoming voltage. Verify incoming voltage is 200V L-N

Insufficient power supplied to sys-

tem.

Zone Types set up incorrectly. Ensure Zone Types are set up cor-

Open heater. Verify resistance of heaters. See

Check connection of cable to over-temperature switch both to main board and to switch. If connection is good, look for a break in the wire.

Check resistances on heater rods and RTDs.

Check cable connections.

or 240V L-C.

Connect system to a power supply

capable of maximum power per sys-

tem specification. All changes must

be performed by a qualified electri-

cian.

rectly in the ADM.

Check Heater Resistance on page

37.

Platen Valve Kit Troubleshooting

Problem Cause Solution

Material leak. Loose fitting connection. Ensure fittings are tight. See Parts

on page 61 for part identification.

Improper fitting used. Replace fitting. See Parts on page

61 for part identification.

System does not depressurize as expected.

Valve does not open or close as expected.

333586F 47

Clogged hose or fittings. Flush or replace clogged pieces.

Failed solenoid actuation. Replace solenoid.

Solenoid mufflers plugged. Replace solenoid mufflers.

No air to solenoid. Re-establish air supply to solenoid.

Page 48

Repair

TI10422A

426

425

427

428

Heated Platen

Ambient Platen

428

426

427

Repair

Disconnect Pump from Platen

The Pump is mounted to the Platens by different mount-

ing kits. See the Repair Kits on page 81.

55 Gallon Platen

1. Follow the Pressure Relief Procedure on page 39.

2. Turn off power to the ram:

a. If using an ambient Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

b. If using a heated Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

c. If using an ambient Tandem Ram Supply

System, turn the red Disconnect Switch (AZ)

3. Remove four hex screws (426), four clamps (427),

4. Carefully pull Pump away to prevent damage to

OFF on the Ram Supply Unit that requires repair only.

d. If using a heated Tandem Ram Supply System,

turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

and washers (425).

Pump inlet and remove o-ring (428).

FIG. 43: 55 Gallon Mounting Kit

48 333586F

Page 49

20, 30, and 60 Liter Platen

463

462

463

462

Ambient Platen

Heated Platen

1. Follow the Pressure Relief Procedure on page 39.

2. Turn off power to the ram:

a. If using an ambient Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

b. If using a heated Single Ram Supply System, turn

the red Disconnect Switch (AZ) OFF.

c. If using an ambient Tandem Ram Supply System,

turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

d. If using a heated Tandem Ram Supply System,

turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

3. Loosen two 5/16 in. screws (462) from Platen (AD).

Repair

4. Carefully pull Pump away to prevent damage to Pump inlet. If using a Pump with an intake adapter, remove screws (472), adapter (471), and o-rings (463) from Pump inlet.

. 44: 20 liter mounting kit

333586F 49

Page 50

Repair

Connect Platen

55 Gallon Platen

1. Place o-ring (428) from mounting kit on the Platen (AD). If attached to plate, place Displacement Pump (AC) onto Platen (AD). See F

2. Secure Pump’s intake flange to plate with screws (426), washers (425), and clamps (427) included in mounting kit 255392.

20 Liter Platen

NOTE: Before installing the 20, 30, or 60 liter Platen to a

Pump with an intake adapter, install adapter and o-ring from mounting kit using the two set screws. See F

1. Place o-ring (463) from mounting kit on Pump intake. Loosen the Pump intake flange screws (462) and carefully lower Pump onto o-ring (463) and Platen.

2. Secure Pump’s intake flange to plate with screws (462).

. 43.

. 44.

Remove Displacement Pump

The procedure for removing the Displacement Pump (AC) depends on which Driver (AB) and Platen (AD) the unit uses. Find your Ram Assembly (AA), Driver (AB), and Platen (AD) below to remove the Displacement Pump (AC). Refer to your Displacement Pump manual to repair the Displacement Pump.

If the Driver does not require servicing, leave it attached to its mounting. If the Driver does need to be removed, see Remove Driver on page 52.

D200 3 in. and D200s 6.5 in. Ram Supply Units

1. Follow the Pressure Relief Procedure on page 39.

2. Turn off power to the ram:

a. If using an ambient Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

Remove Wipers

See Remove and Reinstall Wipers on page 44.

Install Wipers

See Remove and Reinstall Wipers on page 44.

b. If using a heated Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

c. If using an ambient Tandem Ram Supply

System, turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

d. If using a heated Tandem Ram Supply System,

turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

3. See Disconnect Displacement Pump in your

Pump package manual.

4. Open the Main Air Slider Valve (BA).

50 333586F

Page 51

Repair

106

105

107

105a

5. Raise the Driver (AB):

a. Loosen nut (105a) under Ram bar and thread it

down the threaded rod (106) to the lift ring adapter (107) holding the Driver (AB). Use wrench on nut (105) on top of Ram bar to raise Driver (AB).

7. Use two people to lift out the Displacement Pump (AC).

. 45

b. For Driver (AB) with smaller Platens (AD) and

all ram supply units: See procedure for D60 3

in. Dual Post Ram Supply Units on page 51.

6. See Disconnect Pump from Platen on page 48 to

disconnect the Platen (AD) from the Displacement Pump (AC).

FIG. 46

D60 3 in. Dual Post Ram Supply Units

1. Follow the Pressure Relief Procedure on page 39.

2. Turn off power to the ram:

a. If using an ambient Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

b. If using a heated Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

c. If using an ambient Tandem Ram Supply

System, turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

d. If using a heated Tandem Ram Supply System,

turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

3. See Disconnect Displacement Pump in your Pump packages manual.

333586F 51

Page 52

Repair

4. See Disconnect Pump from Platen on page 48 to

disconnect the Platen (AD) from the Displacement Pump (AC).

5. Open the Main Air Slider Valve (BA).

6. Raise the Ram Assembly (AA) to lift the Driver (AB) away from the Displacement Pump (AC).

7. Remove Displacement Pump (AC) and service as needed.

Install Displacement Pump

D200 3 in. and D200s 6.5 in. Ram Supply Units

1. Insert Displacement Pump (AC) on Platen (AD). Follow Connect Platen steps on page 50.

2. See Reconnect Displacement Pump in your Pump package manual.

3. Connect Driver (AB):

Remove Driver

To avoid serious injury when installing and removing the Driver, make sure the Driver is supported at all times.

1. Follow the Pressure Relief Procedure on page 39.

2. Turn off power to the Ram:

a. If using an ambient Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

b. If using a heated Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

c. If using an ambient Tandem Ram Supply

System, turn the red Disconnect Switch (AZ) OFF only on the Ram Supply Unit the Driver is being removed from.

a. Use wrench on nut (105) on top of Ram bar to

lower Driver (AB) onto Displacement Pump (AC). See F up and tighten it under Ram bar. Tighten nut (105) below the crossbar to 25 ft-lb (34 N•m) maximum.

. 45 on page 51. Thread nut (105)

D60 3 in. Dual Post Ram Supply Units

1. Raise Ram (AA) to install Displacement Pump (AC) to Platen (AD).

2. Insert Displacement Pump (AC) on Platen (AD). Follow Connect Platen steps on page 50.

3. See Reconnect Displacement Pump in your Pump packages manual.

d. If using a heated Tandem Ram Supply System,

turn the red Disconnect Switch (AZ) OFF only on the Ram Supply Unit the Driver is being removed from.

3. See Disconnect Displacement Pump in your

Pump package manual.

4. Disconnect power from the Driver (AB):

a. Remove the Driver housing cover (HC).

52 333586F

Page 53

Repair

126

125

127

125

Lift Ring

256

255

259

b. Disconnect the wires inside the Driver housing.

See F

. 47: Wires in Driver Housing

. 47.

c. Loosen the cord grip (CG).

d. Remove wires from Driver housing by pulling

them through the cord grip (CG).

e. Disconnect the cables connected to ports 1-6

on the side of the Driver (AB), shown in F

. 49.

5. Disconnect Driver (AB):

a. D200 3 in. and D200s 6.5 in. ram supply units:

Attach a secure hoist to the driver lift ring. Loosen nut (125) below crossbar. Use wrench to hold lift ring adapter (127) in place and loosen threaded rod (126) above crossbar with another

wrench. See F

. 50.

FIG. 50: 55 Gallon Platen

b. D60 3 in. ram supply units: Remove screws

(255) and washers (256) from mounting plate (259). Using a secure hoist, lift the Driver (AB) from the mounting plate (259). See F

. 51.

. 48

. 51: D60 with Ram

. 49

333586F 53

Page 54

Repair

126

125

127

125

124

Install Driver

To avoid serious injury when installing and removing the Driver, make sure the Driver is supported at all times.

D200 3 in. and D200s 6.5 in. Ram Supply Units

55 gallon platen:

1. Using a capable hoist, insert tie rods into the Dis-

placement Pump (AC) and secure the Driver (AB) to the Pump (AC).

a. See Reconnect Displacement Pump in your

Pump package manual.

b. Install threaded rod (126) through center hole in

the crossbar. Install lock washers (124) and nuts (125) onto threaded rod (126), both above and below crossbar. Use wrench to hold lift ring adapter (127) and tighten threaded rod (106) into lift ring adapter (127) using another wrench. See F

. 52.

2. Connect power to the Driver (AB). Follow a-e of step 4 on page 52 in reverse.

3. If using an ambient system, turn the Disconnect Switch (AZ) ON. If using a heated system, turn the Power Junction Box Switch (AK) and the Disconnect Switch (AZ) ON.

D60 3 in. Dual Post Supply Unit

1. Using a secure hoist, attach Driver (AB) to mounting plate (259) with screws (255) and washers (256). See F

. 51 on page 53.

2. See Reconnect Displacement Pump in your Pump package manual.

3. Connect power to the Driver (AB). Follow a-e of step 4 on page 52 in reverse.

c. Tighten nut (125) below crossbar to 25 ft-lb (34

N•m) maximum.

d. Tighten nut (125) above crossbar to lock Driver

(AB) in place.

. 52

54 333586F

Page 55

Repair

TI10784A

134

136

137

135

142

132

133

Ram Supply Unit Repair

To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 39. Do not use pressurized air to remove the guide sleeve or the piston.

D200s 6.5 in. Ram Piston Rods

Always service both cylinders at the same time. When you service the Lift Rod (AL) always install new o-rings in the piston rod seal and Ram piston.

Disassemble Piston Rod Seal

1. Follow the Pressure Relief Procedure on page 39.

2. Turn off power to the ram:

a. If using an ambient Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

8. Remove guide sleeve (135) by sliding it off of rod (132). Four 1/4 in -20 holes are provided to ease removal of the guide sleeve.

9. Inspect parts for wear or damage.

FIG. 53: 6.5 in. Piston Rod Seal

b. If using a heated Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

c. If using an ambient Tandem Ram Supply

System, turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

d. If using a heated Tandem Ram Supply System,

turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

3. Remove the nuts (123) and lockwashers (122) hold-

ing the tie bar (219) to the piston rods (132). See parts illustration on page 61.

4. Remove nuts (303, 305) and washers (302, 304). See parts illustration on page 67.

5. Lift tie bar (219) off of rods.

6. Remove retaining ring (136) by gripping the ring tab with a pair of pliers and rotating the ring out of its groove.

7. Remove snap ring (134) and rod wiper (133).

Assemble Piston Rod Seal

1. Install new o-rings (137,142), rod wiper (133), and

snap ring (134). Lubricate packings with o-ring lubri-

cant.

2. Slide guide sleeve (135) onto rod (132) and push it into cylinder. Replace retaining ring (136) by feeding it around the guide sleeve groove.

3. Reinstall tie bar (219) using nuts (123) and lock-

washers (122). Torque to 40 ft-lb (54 N•m).

4. Reinstall washers (302, 304) and nuts (303, 305).

Disassemble Ram Piston

1. Follow the Pressure Relief Procedure on page 39.

2. Turn off power to the ram:

a. If using an ambient Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

b. If using a heated Single Ram Supply System,

turn the red Disconnect Switch (AZ) OFF.

c. If using an ambient Tandem Ram Supply

System, turn the red Disconnect Switch (AZ)

333586F 55

Page 56

Repair

TI10785A

132

138

139

137

141

140

OFF on the Ram Supply Unit that requires repair only.

d. If using a heated Tandem Ram Supply System,

turn the red Disconnect Switch (AZ) OFF on the Ram Supply Unit that requires repair only.

3. Remove nuts (123) and lockwashers (122) holding the tie bar (219) to the piston rods (132). See page

61.

4. Remove nuts (303, 305) and washers (302, 304). See parts illustration on page 67.

5. Lift tie bar (219) off rods.

6. Remove retaining ring (136) by gripping the ring tab with a pair of pliers and rotating the ring out of its groove.

7. Remove guide sleeve (135) and slide it off piston rod (132).

NOTICE

Do not tilt the piston rod to one side when removing it from the base or when installing it. Such movement can damage the piston or inside surface of the base cylinder.

8. Carefully lay piston (141) and rod (132) down so rod will not be bent. Remove bottom retaining ring (138) and o-ring (139). Remove piston guide band (140). Slide piston (141) off piston rod (132).

Assemble Ram Piston

1. Install new o-rings (139, 137) on piston rod (132) and piston (141). Lubricate the piston (141) and o-rings (139, 137). Reinstall piston (141) and lower

retaining ring (138) onto piston rod (132). Install pis-

ton guide band (140) onto piston (141).

2. Carefully insert piston (141) into cylinder and push rod (132) straight down into cylinder. Add three ounces of lubricant to each cylinder after inserting the piston (141).

3. Slide guide sleeve (135) onto piston rod (132).

4. Install retaining ring (134) and tie bar (219). Perform steps to Disassemble Ram Piston in reverse order.

D200 and D60 3 in. Ram Piston Rods

Always service both cylinders at the same time. When you service the piston rod always install new o-rings in the piston rod seal and Ram piston.

Disassemble Piston Rod Seal and Bearing

1. Follow the Pressure Relief Procedure on page 39.

2. Access piston rod seal and bearing.

a. For D200 3 in. Ram: Remove nuts (125) and

lockwashers (124) holding the tie bar (219) to the piston rods (246). Remove nuts (305) and washers (304). Remove tie bar (219). Refer to parts illustration on page 63.

b. For D60 3 in. Ram: Ensure Ram is in lowest

position. Remove nuts (125) and lockwashers (254) from piston rods (261). Remove entire pump package, including the mounting plate (259) off of the piston rods (261). Secure Pump package so Pump (AC) and Platen (AD) will not fall. See page 68.

3. Remove retaining ring (218).

4. Remove piston rod seal and bearing.

a. Slide end cap (241), pin (238), o-ring (245), and

spring (244) up off of the piston rod (261, 246).

. 54: 6.5 in. Ram Piston

Remove retaining ring (242) and bearing (243) from end cap (241) and remove o-ring (240).

56 333586F

Page 57

Repair

WLD

261,

244

242

243

241

245

218

238

240

D200 and D60 3 in. Rams

246

TI10521A

261, 246

245

247

239

124

125

5. Inspect parts for wear or damage. Replace as nec-

essary.

NOTE: Do not reinstall end cap assembly if the ram piston (247) needs to be removed from the piston rod. See the next page for ram piston repair instructions.

Disassemble Ram Piston

1. Complete steps 1-4 from Disassemble Piston Rod Seal and Bearing to remove the end cap from the

piston rod.

NOTICE

Do not tilt the piston rod to one side when removing it from the base or when installing it. Such movement can damage the piston or inside surface of the base cylinder.

2. Carefully lay piston (247) and rod (261, 246) down so piston rod will not be bent. Remove nut (125), washer (124), piston (247), outer o-ring (245), and inner o-ring (239).

3. Inspect parts for wear or damage. Replace as nec-

essary.

. 55: 3 in. Piston Rod Seal

Assemble Piston Rod Seal and Bearing

See F

. 55 on page 57.

1. Lubricate o-ring (240) and bottom bearing (243).

a. Install o-ring (240), bottom bearing (243), and

retaining ring (242) into end cap (241).

b. Install new o-ring (245) and pin (238) on end

cap (241). Lubricate o-ring (245) and end cap (241).

c. Slide spring (244) and end cap (241) on piston

rod (261, 246).

2. Install retaining ring (218).

3. For D200 3 in Ram: Install tie bar (219), washers (124), and nuts (125).

4. For D60 3 in. Ram: Remount mounting plate (259) and attach nuts (255) and lockwashers (256). Torque to 40 ft-lb (54 N•m).

333586F 57

. 56: 3 in. Ram Piston

Assemble Ram Piston

1. Install new o-rings (245, 239) and lubricate piston (247) and o-rings.

2. Apply medium strength thread sealant. Install piston (247), washer (124), and nut (125) on piston rod (261, 246).

3. Carefully insert piston (247) into cylinder and push piston rod (261, 246) straight down into cylinder.

4. Slide spring (244) and end cap (241) onto piston rod (261, 246).

5. For D200 3 in. Rams: Install retaining ring (218), tie bar (219), washers (124), and nuts (125).

6. For D60 3 in. Rams: Install retaining ring (218) and install mounting plate (259) with nuts (255) and washers (256) with Pump package and Platen.

Page 58

Repair

350

333

AMZ

Replace Heat Control Box Electrical Component(s)

1. Turn the Heat Control Box Disconnect Switch (AZ) OFF.

2. Remove the door (350) on the Heat Control Box

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 the Power Junction Box Switch (AK) and the Disconnect Switch (AZ) OFF before disconnecting any cables and before servicing equipment.

(AX).

3. Use a non-conductive fuse puller tool to remove the blown fuse.

Using an improper tool, such as a screwdriver or pli-

ers may break the fuse or cause damage to board.

NOTICE

Replace Auto Multi-Zone (AMZ) Fuse(s)

NOTE: Fuses FHA and FHB are not replaceable. If FHA

or FHB fuses are blown, order AMZ Replacement Kit, 25R533.

4. Install a new fuse into the empty fuse holder.

5. Install the Heat Control Box door (350).

Replace Auto Multi-Zone (AMZ)

1. Turn the Heat Control Box Disconnect Switch (AZ) OFF.

2. Loosen screws and remove the door (350) on the Heat Control Box (AX).

. 57

NOTICE

To prevent system damage, always use fast acting fuses. Fast acting fuses are required for short-circuit protection.

Fuse Part Identification

F1A-F4B 129346 250VAC, 12.5A, fast acting

FHA-FHB - - - - - 250VAC, 25A

58 333586F

. 58

3. Remove the AMZ:

a. Disconnect the heated electrical connections

from the back of the AMZ.

Page 59

Repair

b. Disconnect the cables from the AMZ on the

inside of the Heat Control Box (AX).

c. Remove the four screws (333) used to mount

the AMZ to the back of the Heat Control Box (AX) and remove the AMZ.

4. Insert the new AMZ:

a. Set the AMZ dial position number 1 on the dial

for single ram systems.

b. Set AMZ dial to position number 2 for ram 2 for

a tandem system. NOTE: Ram 2 does not

include an ADM. .

Replace Advanced Display Module (ADM)

NOTICE

The ADM stores useful lifetime and diagnostic data that will be lost when it is replaced. To keep this data, perform a USB download prior to replacing the ADM.

1. Turn the Heat Control Box Disconnect Switch (AZ) OFF.

2. Disconnect the cable from the bottom of the ADM (AF).

3. Remove the ADM (AF) from the bracket (114). See Parts on page 61.

4. Install the new ADM (AF) into the bracket (114).

5. Connect the cable to the bottom of the new ADM (AF).

Replace Power Supply

NOTE: Instructions for replacing the power supply

applies to heated systems only.

. 59: AMZ Dial Position

c. Mount the AMZ to the back of the Heat Control

Box (AX) using the four screws (333) removed from the original AMZ.

d. Reconnect the cables on the inside of the Heat

Control Box (AX) to the AMZ.

e. Reconnect the heated electrical connections to

the back of the AMZ.

5. Replace the Heat Control Box door (350).

1. Turn the Heat Control Box Disconnect Switch (AZ) OFF.

2. Loosen the screws and remove the door (350) on the Heat Control Box (AX).

3. Disconnect the power supply harness from the AMZ (headers J3 and J21).

4. Remove the power supply (338) from the din rail in the Heat Control Box (AX).

5. Disconnect the power supply harness from the power supply.

6. Mount the new power supply to the din rail in the Heat Control Box (AX).

7. Connect the power supply harness to the AMZ (headers J3 and J21).

8. Close the Heat Control Box door (350).

333586F 59

Page 60

Repair

Open Here

Replace Fuses in Harness (25R652)

The harness comes with fuses installed. Follow these steps to replace a fuse.

1. Turn the Heat Control Box Disconnect Switch (AZ) OFF.

2. Remove the Heat Control Box door (350).

3. Unscrew the spring-loaded fuse holder to open it. The fuse can be easily removed by hand.

. 60

4. Install the new fuse.

5. Reconnect and tighten the fuse holder.

6. Install the Heat Control Box Door (350).

NOTICE

To prevent damage to the AMZ circuit board, use only 5 x 20 mm, 10 Amp AC, fast acting fuses. Fast acting fuses are required for short-circuit protection.

60 333586F

Page 61

Parts

Model EZC2661 Shown

Detail A

114

102, 109

103, 113

112

106

107,108

108

107

108

104

101

110

131

115

124

105

126

125

123

122

134

133

134

142

137

135

136

132

116

130

111

138

139

138

141

140

137

131

117

119

118

106

131

121

219

143

144

Detail B

107,108

265

264

262

263

107,108

145

146

NOTE: If using a tandem system, the ADM is only included with the iQ Ram Supply Unit 1 (A).

107

267

D200s 6.5 in. Ram Supply Units

Parts

333586F 61

Page 62

Parts

D200s 6.5 in. Ram Supply Units, EZC2661

Ref. Part Description Qty.

101 102040 NUT 1 102 110755 WASHER, plain 1 103 117017 WASHER 1

104 15V954 LABEL, valve, shutoff, air con-

trol 105 --- LABEL, cross bar 1 106 C12509 TUBE, nylon 15 107 100016 WASHER, lock 15 108 121112 SCREW 15 109 --- SCREW 1 110 --- BRACKET, mounting, painted 1 111 --- RAM, 6.5 in. 1 112 --- BRACKET, pendant pivot,

painted 113 --- FASTENER, knob 2 114 --- BRACKET, mounting, assembly 1 115 24C824 KIT, air control 1 116 --- JUNCTION BOX, ram mounted,

E-drive 117 C19853 SCREW 2 118 C32467 STOP, drum 2 119 C38185 WASHER, lock 2

120✖ --- SEALANT, pipe, sst 1

121 15M531 ROD, follower 2 122 101015 WASHER, lock 2 123 C19187 NUT 2 124 101533 WASHER, spring lock 2 125 101535 NUT 2 126 15J992 ROD, threaded 1

127✖ 15J991 ADAPTER, lift ring 1 128✖ 15J993 RING, lift, plate 1 129✖ --- LUBRICANT, anti-seize 1 130▲ 196548 LABEL, caution 1 131▲ 15J074 LABEL, safety, crush & pinch 3

132 C32401 ROD 2 133* C03043 RING, snap 2 134* C31001 WIPER, rod 2 135 18C233 SLEEVE, guide 2 136* C32409 RING, retaining 2 137* C38132 PACKING, o-ring 4 138* C20417 RING, retaining 4 139* 158776 PACKING, o-ring 2 140* C32408 BAND, guide 2 141 C32405 PISTON, elevator air 2 142* C02073 PACKING, quad ring 2 143 --- RAM, D60, electric driver, heat 1

144▲ 15G303 LABEL, warning, electrical 1

145 --- CONTROL, box, heat 1

146▲ 17J476 LABEL, safety, warning 1

219 167646 BEAM, tie 1

Ref. Part Description Qty.

262 130787 SENSOR, barrel 1 263 123673 HARNESS 1 264 255381 ACTUATOR, sensor,

265 --- BRACKET, lvl sensor, dual,

267 234966 KIT, accessory, hose hanger 1

▲ Replacement safety labels, tags, and cards are

available at no cost.

* Parts included in Ram Supply Units Repair Kit

918432 (purchase separately).

✖ Not shown.

low/empty, painted

D200

62 333586F

Page 63

D200 3 in. Ram Supply Units

Model EZC2561 Shown

Detail A

106

107,108

221

107,108

103,113

102, 109

114

112

107

108

107

108

131

101

115

104

125

124

239

247

245

220

201, 213, 107

116

130

224

225

107, 108

205, 217

226

246

244

241

238

242

243

240

245

218

125

124

219

105

126

125

208

252

106

223

117

119

118

143

144

107,108

Detail B

107,108

265

264

262

263

145

146

NOTE: If using a tandem system, the ADM is only included with the iQ Ram Supply Unit 1 (A).

267

Parts

333586F 63

Page 64

Parts

D200 3 in. Ram Supply Units, EZC2561

Ref. Part Description Qty.

101 102040 NUT 1 102 110755 WASHER, plain 1 103 117017 WASHER 1 104 15V954 LABEL, valve, shutoff, air control 1 105 --- LABEL, cross bar 1 106 C12509 TUBE, nylon 15 107 100016 WASHER, lock 16 108 121112 SCREW 12 109 --- SCREW 1 112 --- BRACKET, pendant pivot, painted 1 113 --- FASTENER, knob 1 114 --- BRACKET, mounting, assembly 1 115 24C824 KIT, air control 1 116 --- JUNCTION BOX, ram mounted,

e-drive 117 C19853 SCREW 2 118 C32467 STOP, drum 2 119 C38185 WASHER, lock 2

120✖ --- SEALANT, pipe, sst 1

124* 101533 WASHER, spring lock 6 125* 101535 NUT, full hex 6 126 15J992 ROD, threaded 1

127✖ 15J991 ADAPTER, lift ring 1 128✖ 15J993 RING, lift, plate 1 129✖ --- LUBRICANT, anti-seize 1 130▲ 196548 LABEL, caution 1 131▲ 15J074 LABEL, safety, crush & pinch 4

143 --- RAM, D60, electric driver, heat

144▲ 15G303 LABEL, warning, electrical 1

145 --- CONTROL, box, heat 1

146▲ 17J476 LABEL, safety, warning 1

201 100014 SCREW 4 205 108050 WASHER, lock, spring 6 208 189559 CAP, end 2 213 100015 NUT 4 217 121518 SCREW 6 218* 127510 RING, retaining, internal 2 219 167646 BEAM, tie 1 220 --- RAM, weldment, 3” 1 221 255296 BRACKET, mounted, painted 1 223 128863 FITTING, elbow 2 224 --- BRACKET, mounting, btm 1 225 --- BRACKET, mounting, acc. box 1 226 --- BRACKET, mounting, ram 1

234✖ --- LUBRICANT, grease 1 235✖ --- LUBRICANT, oil 1 237✖ --- SEALANT, thread, med strength 1

Ref. Part Description Qty.

247 183943 PISTON 1

251✖ C20987 PACKING, o-ring 1

252 167652 ROD, tie ram 2 262 130787 SENSOR, barrel 1 263 123673 HARNESS 1 264 255381 ACTUATOR, sensor, low/empty,

painted

265 --- BRACKET, lvl sensor, dual, D200,

pnt

267 234966 KIT, accessory, hose hanger 1

▲ Replacement safety labels, tags, and cards are

available at no cost.

* Parts included in Ram Supply Units Repair Kit

255687 (purchase separately).

✖ Not shown.

64 333586F

Page 65

D60 3 in. Ram Supply Units

Model EZC2424 Shown

Detail A

107

108

107

108

131

101

115

104

254

125

106

107,108

106

107,108

103,113

102, 109

223

112

254,125

106

223

258

257

117

119

118

259

261

244

218

245

240

243

242

238

241

125

124

239

247

245

266

Detail B

107,108

265

264

262

263

114

221

260

256

255

226

201,107 213

224

130

116

205, 217

225

107,108

143

144

145

146

NOTE: If using a tandem system, the ADM is only included with the iQ Ram Supply Unit 1 (A).

268

Parts

333586F 65

Page 66

Parts

D60 3 in. Ram Supply Units, EZC2424

Ref. Part Description Qty.

101 102040 NUT 1 102 110755 WASHER, plain 1 103 117017 WASHER 1 104 15V954 LABEL, valve, shutoff, air control 1 106 C12509 TUBE, nylon, rnd 2 107 100016 WASHER, lock 18 108 121112 SCREW 14 109 --- SCREW 1 112 --- BRACKET, pendant pivot, painted 1 113 --- FASTENER, knob 1 114 --- BRACKET, mounting, assembly 1 115 24C824 CONTROL, air, ram, hyd driver 1 116 --- JUNCTION BOX, ram mounted,

E-drive 117 C19853 SCREW 2 118 C32467 STOP, drum 2 119 C38185 WASHER, lock 2

120✖ --- SEALANT, pipe, sst 1

124* 101533 WASHER, spring lock 1 125* 101535 NUT 3

130▲ 196548 LABEL, caution 1 131▲ 15J074 LABEL, safety, crush & pinch 4

143 --- RAM, D60, electric driver, heat

144▲ 15G303 LABEL, warning, electrical 1

145 --- CONTROL, box, heat 1

146▲ 17J476 LABEL, safety, warning 1

201 100014 SCREW 4 205 108050 WASHER, lock, spring 6 213 100015 NUT 4 217 121518 SCREW 6 218* 127510 RING, retaining, internal 2 221 255296 BRACKET, mounted, painted 1 223 128863 FITTING, elbow 2 224 --- BRACKET, mounting, btm 1 225 --- BRACKET, mounting, acc. box 1 226 --- BRACKET, mounting, ram 1

234✖ --- LUBRICANT, grease 1 235✖ --- LUBRICANT, oil 1 237✖ --- SEALANT, thread, med strength 1

238* --- BEARING, ram end cap 1 239* 156401 PACKING, o-ring 1 240* 156698 PACKING, o-ring 1 241* 15F453 RETAINER, retaining ring 1 242 15M295 BEARING, ram end cap 1 243 15U979 PIN, spring, straight 1 244* 160138 SPRING, compression 1 245* 160258 PACKING, o-ring, buna-n 2 247 183943 PISTON 1 254 104395 WASHER, lock, tooth, external 2 255 110141 SCREW 4 256 100133 WASHER, lock 4 257 --- RAM, dp, weldment 1 258 16T421 ADAPTER, pipe hex 1 259 --- BRACKET, shelf, D60,

3400/6500, paint 260 --- BRACKET, cable track, D60 ram,

paint 261 --- ROD, piston, dp ram 1

Ref. Part Description Qty.

262 130787 SENSOR, barrel 1 263 123673 HARNESS 1 264 255381 ACTUATOR, sensor, low/empty,

painted

265 --- BRACKET, lvl sensor, dual, D200,

pnt 266 --- TIE, cable 4 268 26B203 BRACKET, hose, spring 1

▲ Replacement safety labels, tags, and cards are

available at no cost.

* Parts included in Ram Supply Units Repair Kit

255687 (purchase separately).

✖ Not shown.

66 333586F

Page 67

D200, D200s Pump Mounts for 55 Gallon (200 Liter) Platen

TI10771A

301

303, 305

302, 304

128

126

127

304

305

Note: See page 61 for kit configuration table.

Parts

Ref. Part Description Qty

301 15M531 ROD, platen 2

--302 101015 WASHER, lock 2 303 C19187 NUT 2 304 101533 WASHER, spring lock 2 305 101535 NUT 2 126 --- ROD, threaded 1 127 15J991 ADAPTER, lift, ring 1 128 15J993 RING, lift, plate 1

333586F 67

Page 68

Parts

308

307

306

309

310

D60 Pump Mount for 5 Gallon (20 Liter) Platen

Ref. Part Description Qty.

306✿--- BRACKET, shelf, NXT3400 and

NXT6500 307 101533 WASHER, spring lock 2 308 101535 NUT 2 309 100133 WASHER, lock 4 310 110141 SCREW 4

68 333586F

Page 69

D200s Pump Mounts for 16 Gallon (60 Liter) Platens

361

362

363

369

370

371

363

377

376

Parts

Ref. Part Description Qty.

361 15M298 ROD, tie bar, shelf 2 362 101533 WASHER, lock 4 363 101535 NUT, hex 4 364 --- BRACKET, shelf 1 365 100133 WASHER, lock 4 366 --- SCREW, cap, hex hd 4 367 --- ROD, threaded 1 368 --- ADAPTER, lift, ring 1 369 --- RING, lift, plate 1

333586F 69

Page 70

Parts

311

205, 217

312

314

313

315

316

130

318

319

321

320

322

Power Junction Box

Ambient Power Junction Box

Ref. Part Description Qty.

205 108050 WASHER, lock, spring 3 217 121518 SCREW 3 311 --- BRACKET, cable track mount,

painted 312 121612 CONNECTOR, thru, M12, mxf 3 313 --- CONNECTOR, thru, M12, mxf, 8

pin 314 --- JUNCTION BOX, assembly,

e-drive, painted 315 120993 NUT 2 316 108787 SCREW 2 317* 16K918 LABEL, power in, branch circuit 1 318 --- COVER, assy, j-box, e-drive, paint 1 319 114185 SCREW 6

Ref. Part Description Qty.

320 123967 KNOB, disconnect, operator 1 321 123970 SWITCH, disconnect, 40A 1 322 121171 GRIP, cord 1

130▲ 196548 LABEL, caution 1

324* --- LABEL, multiple, emc and emd

assy

▲ Replacement safety labels, tags, and cards are

available at no cost.

* Not shown.

70 333586F

Page 71

Heated Power Junction Box

Detail A

Detail B

Detail C

See Detail A

See Detail B

See Detail C

325

315

325

314

325

205

217

326

130

Parts

Ref. Part Description Qty.

205* 108050 WASHER, lock, spring 5 217* 121518 SCREW 5 311† --- BRACKET, cable track mount,

painted 312† 121612 CONNECTOR, thru, M12, mxf 3 313† --- CONNECTOR, thru, M12, mxf, 8

pin 314 --- JUNCTION BOX, assembly,

e-drive, painted 315 120993 NUT 2 316† 108787 SCREW 2 317† 16K918 LABEL, power in, branch circuit 1 318† --- COVER, assy, j-box, e-drive,

paint 319† 114185 SCREW 6 320† 123967 KNOB, disconnect, operator 1

Ref. Part Description Qty.

321† 123970 SWITCH, disconnect, 40A 1

130▲ 196548 LABEL, caution 1

324† --- LABEL, multiple, emc and emd

assy 325* --- CONTROL BOX, heat 1 326* --- BUSHING, snap, nylon, black,

1.125”

* Parts included in kit 25R454.

▲ Replacement safety labels, tags, and cards are

available at no cost.

† Not shown.

333586F 71

Page 72

Parts

333

350

144

335

338

336

332

333

331

322

333

454

320

339

344

343

347

346

349

454

342

345

342

344

343

351

Heat Control Box, 25R454

Ref. Part Description Qty.

331 --- ENCLOSURE, electrical, heat,

painted 332 25R533 MODULE, gca 1 333 116595 SCREW 10 322 121171 GRIP, cord 1 335 --- RAIL, mt 0.5 336 112776 WASHER, plain 2 454 110911 NUT 4 338 126453 POWER SUPPLY, 24V 4 339 --- SWITCH, disconnect, 40A 1 320 123967 KNOB, disconnect, operator 1

144▲ 15G303 LABEL, warning, electrical 1

342 25R652 HARNESS, heat, control 1 343 --- HARNESS, power, heat 1 344 --- HARNESS, 24V, heat 1 345 --- HARNESS, ground, heat 1

Ref. Part Description Qty.

346 121000 CABLE, can, female/female 0.5m 1

347 --- HARNESS, power, incoming 1 441† 111307 WASHER, lock, external 5 348† 16T440 CAP 5 349 --- LABEL, multiple, control, heat 1 350 18B778 COVER, enclosure, electric, heat,

paint

351▲19B283 LABEL, multiple, control, heat 1

▲ Replacement safety labels, tags, and cards are

available at no cost.

† Not shown.

72 333586F

Page 73

Cable Track, 26A935

362

363

361

367

366

365

364

370

368

369

Parts

Ref. Part Description Qty.

361 C12509 TUBE, nylon, round 14 ft 362 --- CONNECTOR, 2 conductor,

363 --- CORD, power 1 364 121003 CABLE, CAN 2 365 124415 CABLEW, 5 pin 1 366 125183 CABLE, M12, 8 pin 1 367 --- CABLE, track 1 368 25R662 HARNESS, heat, platen, pump,

369 25R663 HARNESS, heat, platen, pump,

370 15N095PKG BRACKET, track, cable, painted 1

* For use with heated D60 rams only.

25R664 HARNESS, heat, platen, pump,

25R665 HARNESS, heat, platen, pump,

leuer lock

10ft

14ft

12ft

16ft

** For use with heated D200 and D200s rams only.

333586F 73

Page 74

Parts

414

417

416

403

408

421

ti20583a

*426

*427

*428

55 Gallon Platen

200 Liter (55 Gallon) Platen, 255663 and 255664

200 Liter (55 Gallon) Platen Parts

Ref. Part Description Qty.

403 257697 HANDLE, bleed assy 1

408◆ 255652 SEAL, wiper, drum, 55 gal., neo-

prene; for 255664 only.

255653 SEAL, wiper, drum, 55 gal., EPDM;

for 255663 and 255662 only. 414 --- PLATE, ram 55 gal. 1 416 122056 VALVE, check, 1/4 1 417 17E556 FITTING, TUBE, quick disconnect 1 421 --- ADAPTER, for 255663, 255664,

426*✠◆ 102637 SCREW, cap 4 427*✠◆ --- CLAMP 4 428*✠◆ 109495 O-RING 1

* Parts included in 255392 Kit (purchase separately).

✠ Parts not included with 255662, 663, and 664.

◆ Parts not included with 25N344.

16W974 ADAPTER, for 255662 only 1

and 25N344

74 333586F

Page 75

20 Liter (5 Gallon) Platens

Ambient

25R536 and 25R537

Heated

25R534 and 25R535

458

457

453

434

454

436

435

434

455

433

432

440

439

442

441

437

453

438

429

450

449

456

452

451

430

447

445

446

444

431

455

448

456

452

451

447

450

449

429

430

447

446

445

444

431

459

460

Parts

FIG. 61: Single and Double Wiper Assemblies

333586F 75

Page 76

Parts

20 Liter (5 Gallon) Platen Parts, Heated (25R534 and 25R535)

Ref. Part Description Qty.

429 --- BASE, platen, heated, recharge 1 430 121829 O-RING, packing 1 431 --- PLATE, btm, 20 30L platen,

warm melt 432 16C499 GASKET, heat transfer, D60,

warm melt 433 --- PLATE, heater, lower, D60 warm

melt 434 25R653 HARNESS, heat, wiper, 5 gallon 1 435 --- PLATE, heater, upper, D60 warm

melt 436 123744 SCREW 4 437 --- FITTING 1 438 --- SWITCH, over-temperature 1 439 103181 WASHER, lock external 2 440 104714 SCREW 2 441 111307 WASHER, lock, external 4 442 111593 SCREW 1 443 --- HARNESS, ground, 14AWG,12"

long 444 17T371 SEAL 1 445 --- PLATE 1

446 25R654 SEAL, drum, wiper, 5 gallon, neo-

prene

25R656 SEAL, drum, wiper, 5 gallon,

EPDM 447 113504 NUT 8 448 100057 SCREW 2 449 122056 VALVE, check 1 450 17E556 FITTING, elbow 90° 1 451 100840 FITTING, elbow, street 1 452 121310 FITTING, connector 1 453 --- COVER, wiper, 5 gallon, heated,

painted 454 110911 NUT 1 455 257697 HANDLE, bleed, SST, assembly 1 456 123140 FITTING 1 457 132371 SCREW 4 458 109482 PACKING, o-ring 1

459▲ 15K616 LABEL, caution 1 460▲ 189930 LABEL, caution 1

20 Liter (5 Gallon) Platen Parts, Ambient (25R536 and 25R537)

Ref. Part Description Qty.

429 --- BASE, platen, heated, recharge 1 430 121829 O-RING, packing 1 431 --- PLATE, btm, 20 30L platen,

warm melt

444 17T371 SEAL 1

445 --- PLATE 1

446 25R654 SEAL, drum, wiper, 5 gallon, neo-

prene

25R656 SEAL, drum, wiper, 5 gallon,

447 113504 NUT 12 448 100057 SCREW 2 449 122056 VALVE, check 1 450 17E556 FITTING, elbow 90° 1 451 100840 FITTING, elbow, street 1 452 121310 FITTING, connector, NPT x JIC 1 455 257697 HANDLE, bleed, SST, assembly 1 456 123140 FITTING, cap, 1/2 JIC, CS 1 458 109482 PACKING, o-ring 1

EPDM

▲ Replacement safety labels, tags, and cards are

available at no cost.

76 333586F

Page 77

60 Liter (16 Gallon) Platens

Ambient

(26B211)

Heated

(26B210)

459

460

447

474

472

473

470

471

469

436

465

450

449

456

452

451

448

432

463

436

464

454

442

441

468

466

447

461

430

462

447

476

469

470

471

472

473

475

452

456

450

449

461

448

462

447

430

451

Parts

FIG. 62: Single and Double Wiper Assemblies

333586F 77

Page 78

Parts

60 Liter (16 Gallon) Platen Parts, Heated (26B210)

Ref. Part Description Qty.

461 --- BASE, platen, heated, recharge 1 430 121829 O-RING, packing 1 462 --- PLATE, bottom, platen 1 432 16C499 GASKET, heat transfer, D60,

warm melt

463 --- PLATE, heater, lower, D60, warm

melt 464 25R653 HARNESS, heat, wiper, 5 gal 1 465 --- PLATE, heater, upper, D60,

warm melt 436 123744 SCREW 4 466 --- FITTING, 1/8” NPT 1 467 15B137 SWITCH, over temperature 1 439 103181 WASHER, lock external 2 440 104714 SCREW 2 441 111307 WASHER, lock, external 4 442 111593 SCREW 1 468 --- STOP, adjust, 1/4” 1 469 257683 WIPER, PE support 1 470 257677 WIPER, main 1 471 257691 WIPPER, support 1 472 257684 SPACER 1 473 257685 CLAMP, retaining 1 447 113504 NUT 16 448 100057 SCREW, cap 2 449 122056 VALVE, check 1 450 17E556 FITTING, elbow 90 deg 1 451 100840 FITTING, elbow, street 1 452 121310 FITTING, connector, NPT x JIC 1 456 123140 FITTING, CAP, 1/2 JIC, cs 1 474 --- COVER, wiper, 60L, heated 1

460▲ 189930 LABEL, caution 1 459▲ 15K616 LABEL, caution 1

454 110911 NUT, hex 1 476 257697 HANDLE, bleed, stainless steel,

assembly 458 109482 PACKING, o-ring 1 477 --- SEALANT, pipe, stainless steel 1 478 --- LUBRICANT, grease 1 479 --- LUBRICANT, grease 1

60 Liter (16 Gallon) Platen Parts, Ambient (26B211)

Ref. Part Description Qty.

461 --- BASE, platen, heated, recharge 1 430 121829 O-RING, packing 1 462 --- PLATE, bottom, platen 1 447 113504 NUT 20

469 257683 WIPER, PE support 1 470 257677 WIPER, main 1

471 257691 WIPPER, support 1 472 257684 SPACER 1 473 257685 CLAMP, retaining 1

448 100057 SCREW, cap 2 449 122056 VALVE, check 1 450 17E556 FITTING, elbow 90 deg 1 451 100840 FITTING, elbow, street 1 452 121310 FITTING, connector, NPT x JIC 1 456 123140 FITTING, CAP, 1/2 JIC, cs 1 475 --- COVER, wiper, 60L 1 476 257697 HANDLE, bleed, sst, assy 1 458 109482 PACKING, o-ring 1 477 --- SEALANT, pipe, sst 1 478 --- LUBRICANT, grease 1 479 --- LUBRICANT, grease 1

▲ Replacement safety labels, tags, and cards are

available at no cost.

78 333586F

Page 79

Tandem Block, 25R848, 25R849

471

472

474

475

477

478

479

480

481

482

483

484

485

486

487, 488

474

472

Parts

Ref. Part Description Qty.

471 --- BLOCK, 3 way, S, 1” NPT 1 472 C38302 FITTING, nipple 2 473* --- SEALANT, pipe, SST 1 474 521477 VALVE, ball, 1” 2 475† 24E413 KIT, heat, pgm, inlet, 25R848

only 476†* --- LUBRICANT, thermal 1 477 --- BRACKET, mounting, cables 1 478 126496 CONNECTOR, thru, M12 1 479 15N045 HARNESS, splitter, M12 1 480 128911 CONNECTOR, thru, M8 1 481 15N047 HARNESS, splitter, M8 1 482 --- CONNECTOR, thru, M12 1 483 15N046 HARNESS, splitter, M12 1 484 127047 SCREW 2

485▲† 189930 LABEL, caution 1

Ref. Part Description Qty.

486▲† 15K616 LABEL, caution 1

487 --- BLANK, label, kit 1 488 --- ARTWORK, identification, block 1 489* 124003 CABLE, can 1 490* 124654 CONNECTOR, splitter 1

491* 25R439 KIT, low level sensor 2 492* 121226 CABLE, can 1 493†* 129300 CABLE, ext, TOF hose 15 ft

▲ Replacement safety labels, tags, and cards are

available at no cost.

† Parts included in 25R848 only.

* Not Shown.

333586F 79

Page 80

Kits and Accessories

Accessories are available from Graco. Make certain all accessories are adequately sized and pressure-rated to meet the system’s requirements.

System Kits and Accessories

Light Tower Kit, 255467

For D200s, D200, and D60 single supply systems.

See the E-Flo iQ Supply System Operation manual for more information.

Low Level Sensor Kit, 25R439

To install the Low Level Sensor:

1. Turn the Disconnect Switch (AZ) OFF.

2. Disconnect cable from the empty level sensor (EL).

3. Mount the low level sensor (LL) on the mounting bracket.

4. Connect the splitter cable (SP) to the previously disconnected cable.

5. Connect the splitter cable (SP) lead labeled EMPTY to the empty level sensor (EL).

6. Connect the splitter cable (SP) lead labeled LOW to the low level sensor (LL).

7. Raise/lower the low level sensor (LL) to the desired position to activate the sensor.

8. See the E-Flo iQ Supply System Operation manual to set up the low level sensor.

200 Liter (55 Gallon) Platen Cover Kits, 255691

See the Platen Cover Kit manual for more information.

ADM Kit, 25R542

Part Description Qty.

--- MODULE, gca, adm 18A921 TOKEN, gca, upgrade, E-Flo iQ

1 1

Enclosed Wet Cup Recirculation Kit

See the Enclosed Wetcup Recirculation Kit manual for more information.

80 333586F

Page 81

Kits and Accessories

551

552

553

554

555

556

557

558

559

560

Tandem Block Stand, 26B177

For use with tandem systems only.

560 117638 SCREW

To install the Tandem Block Stand:

1. Use the holes in the Tandem Block Stand support (551) as a guide and drill holes for 1/2 in. (13 mm) anchors.

2. Secure the support (551) to the floor using 1/2 in. (13 mm) anchors that are long enough to prevent the Tandem Block Stand from tipping.

3. Attach the Tandem Block (R) to the Tandem Block Stand mounting base (553) using the supplied screws (560). The warning labels should be pointing away from the stand so they are visible after attaching the Tandem Block (R).

Drum Kits and Accessories

Drum Roller Kits for D200 and D200S Ram Supply Units, 255627

See the Drum Roller Kit manual for more information.

Drum Position Clamp Set for D200 Ram Supply Units, 206537

Includes two clamps.

Ref. Part Description Qty.

551 --- SUPPORT, stand 552 --- CAP PLUG, vinyl 553 --- BASE, mounting 554 C30021 BOLT, u 555 100023 WASHER, flat 556 100133 WASHER, lock 557 100131 NUT 558 101044 WASHER, plain 559 100018 WASHER, lock, spring

1 1 1 2 4 4 4 4 4

CAN Cables

The following CAN cables and splitter are available for use with E-Flo SP electric pumps.

Part Description Length

121000 CABLE, CAN, female/female 121001 CABLE, CAN, female/female 121002 CABLE, CAN, female/female 121003 CABLE, CAN, female/female 120952 CABLE, CAN, female/female 121201 CABLE, CAN, female/female 121004 CABLE, CAN, female/female 121228 CABLE, CAN, female/female 123341 CABLE, CAN, female/female 121807 CONNECTOR, splitter, male/male

0.5 m

1.0 m

1.5 m

3.0 m

4.0 m

6.0 m

8.0 m

15.0 m

40.0 m

333586F 81

Page 82

Kits and Accessories

I/O Integration Cable

See the E-Flo iQ Supply System Operation manual for setup and pin out information.

Part Description Length

128441 CABLE, GCA, M12-8p

4.0 m

Integration Extension Cables

Part Description Length

132459 16P791

CABLE, F/C, 10m, extenxion CABLE, F/C, 16m, extension

10.0 m

16.1 m

Platen/Pump Heat Harness

Part Description Length

25R662 HARNESS, heat, platen/pump 25R663 HARNESS, heat, platen/pump 25R664 HARNESS, heat, platen/pump 25R665 HARNESS, heat, platen/pump

3.0 m

3.7 m

4.3 m

4.9 m

Heat Extension Cables

Part Description Length

129300 129301

CABLE, ext, TOF hose CABLE, ext, TOF hose

4.6 m

7.6 m

Pressure Transducer Cables

Part Description Length

124943 CABLE, M12, 5 pin 122497 CABLE, M12, 5 pin 124409 CABLE, M12, 5 pin 17H363 CABLE, M12, 5 pin 132457 CABLE, M12, 5 pin 17H364 CABLE, M12, 5 pin

1.0 m

2.0 m

3.0 m

7.5 m

10.0 m

16.1 m

Solenoid Cables

Part Description Length

132458 17H352

CABLE, M8, 4pin CABLE, M8, 4pin

10.0 m

16.1 m

82 333586F

Page 83

Kits and Accessories

Cable Kits

Transducer

Part

Number

25R342 33 ft (10 m) NA 15M669 25R343 33 ft (10 m) 8 ft

25R344 33 ft (10 m) 15 ft

25R345 33 ft (10 m) 25 ft

25R346 53 ft (16 m) NA 15M669 25R347 53 ft (16 m) 15 ft

25R348 53 ft (16 m) 25 ft

and Solenoid

Cable Length

Hose

Cable

Length Transducer

15M669

(2.4 m)

15M669

(4.6 m)

15M669

(7.6 m)

15M669

(4.6 m)

15M669

(7.6 m)

Fitting Kits

Hose Connections

Working

Part Number

25R319 4500 psi (31

25R320 5000 psi (34.5

25R321 4500 psi (31

25R322 4500 psi (31

25R323 5000 psi (34.5

25R324 5000 psi (34.5

25R325 4000 psi (28

25R326 4000 psi (28

Pressure

MPa, 310 bar)

MPa, 345 bar)

MPa, 310 bar)

MPa, 345 bar)

MPa, 276 bar)

Supply Hose 1

10 NA

12 NA

16 NA

10 10

12 12

12 10

16 16

16 12

Supply Hose 2

Tandem Fitting Kits

Hose Connections

Working

Part Number

25R891 4500 psi (31

25R892 5000 psi (34.5

25R893 5000 psi (34.5

Pressure

MPa, 310 bar)

MPa, 345 bar)

Tandem

Hose 1

10 10

12 12

16 16

Additional Accessories

Part Number Description

25R959 KIT, switch, foot

Tandem

Hose 2

333586F 83

Page 84

Kits and Accessories

512, 513

519

517

515

See Detail A

514

509

513

Detail A

508

503, 504, 505

518

516

502, 506

501

511

520

Check-Mate 200 CS Pump Heater Kit, 25R450

. 63: Check-Mate 200 CS Pump Heater Kit, 25R450

Ref. Part Description Qty.

501 121980 HEATER, pump, 725 watt

502 --- HOLDER, rtd, overtemp

503 16K094 SWITCH, overtemp, horizontal

504 103181 WASHER

505 104714 SCREW

506 102273 SCREW

507 C31012 CLAMP

508 25R660

509 --- HARNESS, ground

510 --- HARNESS, heater, pump #1

511 --- HARNESS, heater, pump #2

512 116343 SCREW

HARNESS, heater, pump, rtd, over-

temp

513 111307 WASHER

514 100166 NUT

515 15W706 ENCLOSURE, pump, front

516 25R658 COVER, enclosure, pump, heat

517 --- PLUG

518 110637 SCREW

519

520

▲ Replacement safety labels, tags, and cards are

15J075

▲

17V667 LABEL, safety, warning, amputation

▲

LABEL, safety, hot surface and ener-

gized

available at no cost.

84 333586F

Page 85

Platen Heater Kit, 25R451

Detail A

521

529

528

527

Detail D

Detail B

Detail C

526

525

524

523

522

521

539

521

527

530, 531

521

532

533, 534

536

537

538

535

541

Kits and Accessories

. 64: Platen Heater Kit, 25R451

Ref. Part Description Qty.

521 25R666

522 --- CONDUCTOR, block, heater 523 --- STUD 524 --- WASHER, flat 525 --- WASHER, lock 526 100015 NUT 527 15B137 SWITCH, over temperature 528 103181 WASHER 529 124131 SCREW 530 --- WASHER 531 117026 SCREW

532 ---

533 --- WASHER

333586F 85

HARNESS, heat, wiper, 55 gallon

HARNESS, ground, 14awg, 18” long

2 6 6 6 6

2 2 1 1

534 116343 SCREW 535 --- COVER, platen, heated, rear 536 --- COVER, platen front, assy 537 --- FASTENER, platen, cover 538 --- PLUG 539 100166 NUT 540 --- LUBRICANT, thermal

541▲ 15J075

LABEL, safety, hot surface and energized

▲ Replacement safety labels, tags, and cards are

available at no cost.

1 1 1 2 1 2 1

Page 86

Kits and Accessories

CAN Port 1

CAN Port 2

Communication Gateway Module (CGM) Kits

Installing a CGM Kit

All electrical wiring must be done by a qualified elec-

trician and comply with all local codes and regulations

1. Follow the Pressure Relief Procedure on page 39.

2. Verify the power is off to the system.

3. Install the CGM bracket included with the kit to the ram post bracket with the four 1/4-20 x 0.5 in. screws included in the kit.

4. Remove the access cover from the CGM (DA). Loosen and save the two M5-0.8 x 45 mm x screws (DB), and remove the CGM (DC) from the base

FIG. 65: CGM CAN Connections

(DD). See F

. 66..

CGM Kits

Part Number Description Heat Option

26B169 CGM Kit, EtherNet/IP Heated 26B170 CGM Kit, PROFINET Heated 26B171 CGM Kit, PROFIBUS Heated 26B172 CGM Kit, DeviceNet Heated 26B173 CGM Kit, EtherNet/IP Ambient 26B174 CGM Kit, PROFINET Ambient 26B175 CGM Kit, PROFIBUS Ambient 26B176 CGM Kit, DeviceNet Ambient

FIG. 66: Disassembling the CGM

5. Using the four M4-0.7 x 20 mm mounting screws included in the kit, mount the base (DD) to the CGM bracket.

6. Reattach the CGM (DC) onto the base (DD) with the two screws (DB) that were removed and saved from step 4.

7. Reattach the access cover (DA).

8. Unplug the cable from the ADM and plug the cable back into CGM (DC).

9. Plug 3.0 m cable (121003) included in the CGM kit

86 333586F

from the CGM to the ADM.

Page 87

Kits and Accessories

ADM

Ram post bracket

CGM (DC)

CGM Base (DC)

CGM Bracket

M4-0.7 x 20 mm

M4-0.8 x 45 mm

1/4-20 x 0.5 in.

Fieldbus Connection

. 67

10. connect the Ethernet/IP, DeviceNet, or PROFIBUS cable to the fieldbus connection on the CGM as applicable.

FIG. 68: CGM Fieldbus Connection

11. Connect the other end of the Ethernet/IP, Devi-

ceNet, or PROFIBUS cable to the fieldbus device.

12. Refer to the Graco Control Architecture Module pro-

gramming manual for step-by-step instructions on

how to update the software version of GCA mod-

ules. See Related Manuals on page 3.

13. Refer to the E-Flo iQ Supply System Operation manual for details regarding the feildbus pinout

setup and to perform the setup procedure to config-

ure the feildbus. See Related Manuals on page 3.

333586F 87

Page 88

Kits and Accessories

606

605

601

602

603

604

607

Platen Valve Kit, 25R452

. 69: Platen Valve Kit, 25R452

Ref. Part Description Qty.

601 V25AB000BA

VALVE, 25, npt/b, 000, adj/sol, amb

602 100721 PLUG, pipe 603 --- FITTING, elbow 604 156823 FITTING, union, swivel 605 162449 FITTING, nipple, reducing 606 15R873 FITTING 607 16D270 HOSE, assy 608 --- SEALANT, pipe, sst 609 --- HARNESS, P20 610 054776 TUBE, nylon 611 116197 FITTING, elbow

To install the Platen Valve Kit on a 5 gallon system:

1. Perform the Pressure Relief Procedure on page

39.

1 1 1 1 1 1 1 1

12 ft

2. Disconnect the pressure transducer from port 5 on the Electric Driver (AB).

3. Remove the pressure transducer fitting (TF) and the fitting it is attached to from the Fluid Check Valve (AE).

4. Using thread tape, install the 1/2 NPT tee fitting (606) into the Fluid Check Valve (AE), then reinstall the pressure transducer fitting (TF) into the bottom of the 1/2 NPT tee fitting (606).

5. Using thread tape, install the 1/4 NPT x 1/2 NPT adapter (605) into the 1/2 NPT tee fitting (606). See F

. 69.

6. Install the platen valve (601) onto the 1/4 NPT fitting (606) using the swivel fitting (604), then tighten.

7. Install the recirculation hose (607) onto the platen valve (601) and tighten.

8. Reconnect the pressure transducer to port 5 on the Electric Driver (AB).

88 333586F

Page 89

Kits and Accessories

609

610

609

M8 Connector

M12 Connector

611

610

Solenoid Valve

Cable

NOTE: Do not install the recirculation hose (607) onto

the platen valve fitting (603) until material has been loaded into the platen valve (601). See the E-Flo iQ Operation manual for instructions to load material into the platen and platen valve.

9. Unplug the existing M12 connector from port 3 on the Electric Driver (AB).

10. Connect the harness (609) to port 3 on the Electric Driver (AB).

11. The harness (609) has an M8 connector and an M12 connector. Connect the M12 connector that was originally connected to port 3 on the Electric Driver (AB) to the M12 connector on the harness (609). Connect the M8 4 pin connector to the

solenoid on the platen valve (601).

12. Remove the 1/4 NPT plug from the Integrated Air

Controls (AG). See Integrated Air Controls (AG) on page 15.

13. Insert the elbow fitting (611) into the Integrated Air Controls (AG).

14. Connect the nylon tube (610) to the elbow fitting (611) and the platen valve (601).

. 70

FIG. 71

NOTE: Make sure the pins on the solenoid valve cable

are oriented as shown in F

. 72 before the cable is

plugged into the solenoid valve.

FIG. 72

333586F 89

Page 90

Kits and Accessories

702

701

703

704

705

706

713

711

710

709

708

707

713

Platen Valve Kit, 25R453

FIG. 73: Platen Valve Kit, 25R453

Ref. Part Description Qty.

701 V25AB000BA

VALVE, 25, npt/b, 000, adj/sol, amb

702 100721 PLUG, pipe 703 121310 FITTING, connector 704 156823 FITTING, union, swivel 705 162449 FITTING, nipple 706 15R873 FITTING, tee 707 C20487 FITTING, nipple 708 801787 FITTING, tee 709 100896 FITTING, bushing, pipe

710 17K616 FITTING, nipple

711 123140 FITTING, cap 712 --- SEALANT, pipe, sst

1 1 1 1

713 16D269 HOSE, assy 714 --- HARNESS, P20 715 054776 TUBE, nylon, round 716 116197 FITTING, elbow

1 1 1 1 1 1 1

1 1 1 1

90 333586F

Page 91

Kits and Accessories

714

715

714

M8 Connector

M12 Connector

To install the Platen Valve Kit on a 55 gallon system:

1. Perform the Pressure Relief Procedure on page

39.

2. Disconnect the pressure transducer from port 5 on the Electric Driver (AB).

3. Remove the pressure transducer fitting (TF) and the fitting it is attached to from the Fluid Check Valve (AE).

4. Using thread tape, install the 1/2 NPT tee fitting (706) into the Fluid Check Valve (AE), then reinstall the pressure transducer fitting (TF) into the bottom of the 1/2 NPT tee fitting (706).

5. Using thread tape, install the 1/4 NPT x 1/2 NPT adapter (705) into the 1/2 NPT tee fitting (706). See F

. 69.

12. The harness (714) has an M8 connector and an M12 connector. Connect the M12 connector that was originally connected to port 3 on the Electric Driver (AB) to the M12 connector on the harness (714). Connect the M8 4 pin connector to the

solenoid on the platen valve (701).

6. Install the platen valve (701) onto the 1/4 NPT fitting (706) using the swivel fitting (704), then tighten.

7. Install the recirculation hose (713) onto the platen valve (701) and tighten.

8. Reconnect the pressure transducer to port 5 on the Electric Driver (AB).

9. Remove the Bleed Stick (EF) and Bleed Port (EG), and install the fittings (707, 708, 709, 710, 711) as shown in F

. 73.

NOTE: Do not install the recirculation hose (713) onto the platen valve fitting (703) until material has been loaded into the platen valve (701). See the E-Flo iQ Operation manual for instructions to load material into the platen and platen valve.

10. Unplug the existing M12 connector from port 3 on the Electric Driver (AB).

11. Connect the harness (714) to port 3 on the Electric Driver (AB).

FIG. 74

13. Remove the 1/4 NPT plug from the Integrated Air

Controls (AG). See Integrated Air Controls (AG) on page 15.

14. Insert the elbow fitting (716) into the Integrated Air Controls (AG).

333586F 91

Page 92

Kits and Accessories

716

715

15. Connect the nylon tube (715) to the elbow fitting (716) and the platen valve (701).

. 75

92 333586F

Page 93

Dimensions

D60 3 in. Ram Supply System

D200 3 in. Ram Supply System

D200s 6 in. Ram Supply System

Dimensions

333586F 93

Page 94

Dimensions

Ram Size

in. (mm)

D60 D200 D200s

Total Height (A) 70 (1778) 88 (2235) 96 (2438)

Ram Height (B) 57 (1448) 70 (1778) 69 (1753)

Extended Ram

Height (C)

Base Depth (D) 20 (508) 25 (635) 25 (635)

Machine Width (E) 45 (1143) 52 (1321) 45 (1143)

Mounting Hole

Depth (F)

Mounting Hole

Width (G)

89 (2261) 118 (2997) 125 (3175)

14 (356) 21 (533) 23 (584)

24 (610) 38 (965) 45 (1143)

Ram Weight

lb (kg)

D60 D200 D200s

Ambient 451.6 (204.8) 593.6 (269.3) 869.6 (394.4)

Heated 501.6 (227.5) 643.6 (291.9) 919.6 (417.1)

See the identification plate (ID) for the weight of your Ram Supply Unit.

94 333586F

Page 95

Pump Performance

Calculate Fluid Outlet Pressure

To calculate fluid outlet pressure (psi/MPa/bar) at a specific fluid flow (gpm/lpm) and electrical power, use the following instructions and pump data chart.

1. Refer to the desired flow along the bottom of the chart.

2. Follow the vertical line up to the intersection with the selected fluid outlet pressure curve. Follow left to the scale to read the fluid out pressure.

Calculate Electrical Power

To calculate electrical power at a specific fluid flow (gpm/lpm), use the following instructions and pump data chart.

Pump Performance

1. Refer to the desired flow along the bottom of the chart.

2. Follow the vertical line up to the intersection with the selected electrical power curve. Follow right to the scale to read the fluid out pressure.

3. NOTE: Performance is measured using 10 weight oil. System design and material being pumped may produce different results.

333586F 95

Page 96

Pump Performance

500

1000

1500

2000

2500

3000

750

1500

2250

3000

3750

4500

0.0 0.2 0.4 0.6 0.8 1.0 1.2

1PXFS8BUUT

1SFTTVSFQTJ.1BCBS

(2.3)

'MPXHQNMQN

&'MPJ2XJUI$IFDL.BUFDD1VNQ

(0.0) (0.8) (1.5) (3.0) (3.8) (4.5)

(10.3, 103)

(5.2, 52)

0 (0, 0)

(15.5, 155)

(20.7, 207)

(25.9, 259)

(31.0, 310)

Pressure WŽǁĞƌ

E-Flo iQ Dispense System Performance Chart

NOTE: Performance is measured using 10 weight oil. System design and material being pumped may produce

different results.

96 333586F

Page 97

Wiring Diagrams

333586F 97

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Wiring Diagrams

98 333586F

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Wiring Diagrams

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Page 100

Wiring Diagrams

100 333586F

Graco E-Flo Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Dispense System Configurator

Dispense System Components

iQ Ram Supply Units

iQ Dispense Valves

Hose Options

Dispense System Pressure

Warnings

Dispense System Component Identification

Single Ram

Tandem Ram

Supply Unit Component Identification

iQ Ram Supply Unit

Power Disconnect

Integrated Air Controls (AG)

Air Line Accessories

Advanced Display Module (ADM)

Platen (AD) Component Identification

Electric Driver Communication Connections

Installing Tandem

Power Junction Box and Heat Control Box Connections

Installation

Location

Grounding

Power Requirements

Connect Power

Attach Drum Stops

Install Vented Oil Cap Before Using Equipment.

Setup

Air Line Connections

Hoses and Fittings

Electrical Connections

Heat Connections (Hoses and Accessories)

Wet Cup

Hose Care Guidelines

Flush Before Using Equipment

Check Resistance (Heated Systems)

Check Sensor Resistance

Check Heater Resistance

Pressure Relief Procedure

Shutdown and Care of the Pump

Change Drums

Maintenance

Driver Maintenance

Platen Maintenance

Recycling and Disposal

End of Product Life

Troubleshooting

Supply Systems Troubleshooting

Heat Control Box Troubleshooting

Platen Valve Kit Troubleshooting

Repair

Disconnect Pump from Platen

Connect Platen

Remove Displacement Pump

Remove Wipers

Install Wipers

Install Displacement Pump

Remove Driver

Install Driver

Ram Supply Unit Repair

Replace Heat Control Box Electrical Component(s)

Replace Fuses in Harness (25R652)

Parts

D200s 6.5 in. Ram Supply Units

D200 3 in. Ram Supply Units

D60 3 in. Ram Supply Units

D200, D200s Pump Mounts for 55 Gallon (200 Liter) Platen

D60 Pump Mount for 5 Gallon (20 Liter) Platen

D200s Pump Mounts for 16 Gallon (60 Liter) Platens

Power Junction Box

Heat Control Box, 25R454

Cable Track, 26A935

55 Gallon Platen

20 Liter (5 Gallon) Platens

60 Liter (16 Gallon) Platens