Graco E-Flo Installation Manual

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.

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

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

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

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

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

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

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

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

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

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

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

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.

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

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

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

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

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

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

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

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

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

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

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

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

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).

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

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

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

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

+ 74 hidden pages