Graco L20c, 255650, 24C824, 257613, 257612 Instructions - Parts Manual

...
Instructions-Parts
Air Controls
Integrated and 2-Button Interlock Air Controls for use with Supply Systems. For professional use only.
Important Safety Instructions
See page 2 for Model information.
Integrated Air Controls
L20c Air Controls
312374H
EN
r_257302_312376_2e
ti10438a

Contents

Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Integrated Air Controls . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replace Director Valve . . . . . . . . . . . . . . . . . . . . 4
Replace Air Motor Regulator . . . . . . . . . . . . . . . . 4
Replace Ram Air Regulator . . . . . . . . . . . . . . . . 5
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-Button Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Attach Roller Switch and Actuator . . . . . . . . . . . 6
Attach 2-Button Interlock Assembly . . . . . . . . . . 7

Models

L20c Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Replace Air Motor Regulator . . . . . . . . . . . . . . . . 9
Replace Air Motor Shutoff Valve and Ram Shutoff
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove Blowoff Push Button . . . . . . . . . . . . . . . 9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
L20c Air Controls, 257613 . . . . . . . . . . . . . . . . . 10
Integrated Air Controls . . . . . . . . . . . . . . . . . . . . 11
Integrated Air Controls . . . . . . . . . . . . . . . . . . . . 12
2-Button Interlock Kit . . . . . . . . . . . . . . . . . . . . . 13
Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . 14
Integrated Air Control Module . . . . . . . . . . . . . . 14
Integrated Air Control Module with Optional
2-Button Interlock . . . . . . . . . . . . . . . . . . . . 15
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 16
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air Controls
Model
No. Description
255650
24C824
257612
257613
Integrated Air Controls for D60, D200, and
D200s
Integrated Air Controls for D200 and D200s
(Ram only, no pump control)
Air Controls, For S20 3 in., 5 Gallon (20 Liter)
Supply Systems
Air Controls, For L20c 3 in., 5 Gallon (20
Liter) Supply Systems
2-Button Interlock
Model
No. Description
257615
255719
255720
Two-Button Interlock, For D60 3 in., 16 Gallon (60 Liter) Supply Systems
Two-Button Interlock, For D200 3 in., 55 Gallon (200 Liter) Supply Systems
Two-Button Interlock, For D200s 6.5 in., 55 Gallon (200 Liter) Supply Systems
Maximum
Regulated
Working
Pressure
psi (MPa, bar) Air Inlet Size
150 (0.69, 6.9) 3/4 npt(f) 255719
150 (0.69, 6.9) 3/4 npt(f) 255719
150 (0.69, 6.9) 1/2 npt(f) NA
100 (0.7, 7) 1/2 npsm(f) 255615
Compatible
2-Button Interlock
Model
255720
255720
2 312374H

Integrated Air Controls

Integrated Air Controls
255650 (shown)
To reduce the risk of serious injury whenever you are instructed to relieve the pressure, follow the Pressure
Relief Procedure.

Pressure Relief Procedure

1. Close the air motor slider valve (E) and the main air slider valve (F).
2. Set the ram director valve to DOWN. The ram will slowly drop.
3. Jog the director valve up and down to bleed air from ram cylinders.

Disassembly

1. For Supply Systems with Shrouds: Remove shrouds. Loosen six captive screws (A) and disas­semble shrouds (B) from supply system.
C
D
r_289105_312375_2a
IG
. 2
F
255650 (shown)
E
1
F
E
B
B
255650 (shown)
A
r_289105_312375_a
F
IG
. 1
2. Disconnect all hoses and tubing from existing air control.
3. Remove four screws (C) from the mounting bracket (D) and remove the integrated air controls from the supply system.
C
D
r_289105_312375_3a
IG
. 3
F
If you are not replacing the manifold (1), you may prefer to remove the bracket from the ram and leave it attached to the integrated air controls because the screws are easier to reach. See F
1
F
IG
. 4.
312374H 3
Integrated Air Controls
r_289105_312375_4a
F
IG
. 4

Replace Director Valve

Numbers in parentheses refer to FIG. 5.
1. Relieve pressure.
2. Remove screws (4a) and take off director valve.
3. Remove spring (4c), valve plate (4d), and o-ring (4b)
.
4g
4f
4e
4b
4d
4c
4
4a
ti10952a
FIG. 5

Replace Air Motor Regulator

Numbers in parentheses refer to Parts, page 11. Air motor regulator not included with 24C824 integrated air controls.
1. Relieve pressure.
2. Disconnect air motor hosing and fittings.
3. Remove two screws (9) and take off the shutoff valve (3) at top of module. If your supply system has an air solenoid, it can remain attached to the shutoff valve.
Note the orientation of the director valve plate when you remove it. The opening should be on the oppo­site side (left) of the lever.
4. Remove and discard pin (4g) and four valve seats (4e) with o-rings (4f).
5. Insert new valve seats (4e) with o-rings (4f) and new pin.
6. Insert new director valve plate (4d, see Note above) spring (4c), and o-ring (4b).
7. Attach new director valve with screws (4a). Tighten screws until snug.
4. Remove two screws (9) and take off the air motor regulator (6).
5. Attach new regulator to manifold. Orient so the gauge lines up with the gauge on the ram air regula­tor and the direction of flow arrow points up. Tighten screws until snug. Recommend using thread locker Loctite 220 or equivalent.
6. Reattach shutoff valve (3) at top of regulator. Make sure that o-ring (5) is in place on valve (3).
4 312374H

Replace Ram Air Regulator

Numbers in parentheses refer to Parts, page 10.
1. Relieve pressure.
2. Remove four screws (7a) and take off the ram air regulator (7).
3. Replace o-rings (7b) on back side of regulator.
4. Attach new air regulator to manifold. Use index pin for correct orientation. Tighten screws until snug.

Reassembly

1. Using four screws, attach the integrated air controls to the mounting bracket. See F
2. Attach the ram up, ram down, and blowoff air lines as shown in Figure F
255650 (shown)
IG
. 6.
IG
. 2.
Integrated Air Controls
Not included with 24C824
}
Ram up
Blowoff Auxiliary air supply port
ti10778a
IG
. 6
F
3. Attach all other hoses and replace shrouds.
Ram down
312374H 5

2-Button Interlock

2-Button Interlock
To reduce the risk of serious injury whenever you are instructed to relieve the pressure, follow the Pressure
Relief Procedure, page 3.

Attach Roller Switch and Actuator

1. Attach roller switch (133) to bracket (132). Position roller switch to far back position on the bracket and leave mounting screws (144) loose.
2. Attach bracket (132) to ram with screws (105) and washers (106). Leave screws loose. See F F
IG
. 8.
IG
. 7 and
3. Raise platen to top of drum.
4. Attach actuator bracket.
a.
For D200 and D200s supply systems
actuator bracket (138) near bottom of lift rod so it engages the roller switch when the platen reaches the top of the drum.
139
140
: Attach
F
IG
. 7: D200 and D200s Bracket
105
106
132
150
ti10844a
144
133
144
133
105
132
106
138
ti10848a
IG
. 9
F
b. For D60 supply systems: Loosen one screw
(151a) and remove one screw (152b). Align actuator rod (151) on piston rod so it touches the air motor mounting bracket. Tighten actua­tor rod to piston rod with four screws (140).
151b
151a
151
138
139
152
153
ti10847a
r_289105_312375_5a
IG
. 8: D60 Bracket
F
6 312374H
F
IG
. 10
140
r_289105_312375_5a
5. Tighten actuator bracket to rod using 4 screws (140) and bracket clamps (139).
6. Adjust the roller switch (133) out so it contacts actu­ator bracket (138), then tighten screws (144).
7. Tighten bracket (132) to ram with screws (105) and washers (106).
8. Connect main air (S1) to port (S1) on roller switch (133) with 15 in. of tubing (146).
9. Connect switch signal air (S2) to port (S2) on roller switch (133) with 15 in. of tubing (146).
10.
For D60 supply systems
: Install two fittings (150)
into (S1) and (S2).
S2
S1
2-Button Interlock
130
145
ti10843a
FIG. 12
133
ti10844a2
F
IG
. 11:

Attach 2-Button Interlock Assembly

See FIG. 12.
1. Relieve pressure.
2. Remove shrouds. See F
3. Disconnect air lines.
4. Remove integrated air controls from bracket. See Disassembly, page 3.
5. Remove back cover from 2-button interlock assem­bly (130).
6. Position 2-button interlock assembly between air control bracket and air controls. The screws that attach the integrated air controls to the supply sys­tem also attach the 2-button interlock assembly.
IG
. 1.
7. Reattach integrated air controls. See Reassembly, page 5.
8. Insert cap screw (145) through integrated air con­trols into 2-button interlock module. See F
IG
. 12.
312374H 7
2-Button Interlock
See FIG. 13 for steps 9 - 14.
9. Inside 2-button interlock module, disconnect elbow fitting (6) and push fittings (7) from tee fitting (5). Remove plug (8) from auxiliary air supply port on back of integrated air controls. Install tee fitting (5) through into the port and through the opening in the bracket. Reconnect elbow fitting (6) and push fit­tings (7). Reinstall plug (8) at top of tee fitting (5).
10. Connect tubing (147) from ram down fitting on back of air controls to fitting (D1) on right side of bottom pilot valve. See F
IG
. 13.
11. Connect tubing from ram down fitting near top of ram cylinder to fitting (D2) on left side of bottom pilot valve. See F
IG
. 13.
S1
12. Connect tubing (147) from ram up fitting on back of air controls to fitting (U1) on right side of top pilot
IG
valve. See F
. 13
13. Connect tubing from ram up fitting near bottom of ram cylinder to fitting (U2) on left side of top sole­noid.
14. Connect blowoff air (B1) to blowoff air connector on platen.
15. Replace cover on 2-button interlock assembly.
It may be necessary to rearrange tubing so cover will fit back on assembly.
16. Attach all other hoses and replace shrouds.
U2
B1
(blowoff)
U1
D2
D1
7
S2
6
F
IG
. 13
8
5
D1
(ram down)
U1
(ram up)
8 312374H

L20c Air Controls

To reduce the risk of serious injury whenever you are instructed to relieve the pressure, follow the Pressure
Relief Procedure.
L20c Air Controls

Replace Air Motor Shutoff Valve and Ram Shutoff Valve

See parts illustration on page 10.
1. Remove two screws (211) from air motor shutoff valve and two screws (209) from ram shutoff valve.

Pressure Relief Procedure

1. Close the air motor shutoff valve (E) and remove air line from air control coupling (x).
2. Set the elevator director valve to DOWN. The ram will slowly drop.

Disassembly

1. Remove two screws that attach air control panel to elevator.
2. Disconnect all hoses and tubing from existing air control.

Replace Air Motor Regulator

1. Loosen swivel fitting (205) between regulator (206) and air motor shutoff valve (203).
2. Remove nut (218) from front of regulator and pull regulator out of panel (201).
2. Remove valve assemblies from panel.

Remove Blowoff Push Button

See parts illustration on page 10.
1. Hold button in place and remove screw.
2. Remove nut underneath button and push button from panel (201).

Reassembly

1. Replace parts as needed and reassemble them in the reverse order of disassembly.
2. Connect all hoses and tubing.
3. Install air controls on elevator with two screws and lockwashers from kit 257613. See manual 313527.
206
218
205
203
F
IG
. 14
312374H 9
201
r_289105_312375_8a

Parts

Parts

L20c Air Controls, 257613

Front View
218
211
212
209
r_289105_312375_9a
201
215
214
202
203
Back View
205
204
210
213
216
206, 218
207
208
217
219
r_289105_312375_9a2
Ref. Part Description Qty.
201 PANEL 1 202 517313 VALVE, 3 way 1 203 114362 VALVE, ball, air 2 204 FITTING, adapter 1 205 FITTING, 90° swivel 1 206 110318 REGULATOR 1 207 FITTING, tee 1 208 FITTING, line, air 1 209 SCREW, cap; 10-24 x 0.375 in. 2 210 FITTING, elbow 1 211 SCREW, cap; 10-24 x 0.625 in. 2 212 15T500 GAUGE 1 213 FITTING, 90° swivel 1 214 FITTING, elbow 2 215 FITTING, elbow 3 216 FITTING, elbow 1 217 FITTING, swivel 1 218 NUT, regulator 1 219 SAFETY, valve 1
Mounting screws and lockwashers are included with kit 257613. See manual 313527.
10 312374H
Parts

Integrated Air Controls

9
13
9
8
13
5
7b
3
5
1
10
9
Model 255650; D200s, D200, and D60 Model 257612; S20
3
5
6
11
4b
4
4a
7a
7
ti10774a
Ref. Part Description Qty.
1MANIFOLD 1 3 121108 VALVE, shutoff (includes o-rings
and screws)
121793 VALVE, shutoff (includes o-rings and screws)
4 121107 VALVE, director (includes 4a and
4b, plus all parts shown in F
4a SCREW 4 4b O-RING 1 5 121110 O-RING, buna 3
102620 O-RING 3
6 255651 REGULATOR, air motor (includes
regulator, o-ring, and screws)
257614 REGULATOR, air motor (includes regulator, o-ring, and screws)
7 121106 REGULATOR, ram (includes 7a
and 7b)
7a SCREWS 4 7b O-RING 2 8 121109 VALVE, blowoff (includes valve
and push button)
9 121112 SCREW, cap, socket head
1/4-20 x 5/8
121803 SCREW, cap, button head 10-32 x 1/2
10 517449 MUFFLER 1 11 100721 PLUG, pipe, auxiliary air supply 1 13 101689 GAUGE, air pressure, 0-200 psi
(0-1.4 MPa, 0-14 bar)
113911 GAUGE, air pressure, 0-160 psi (0-1.1 MPa, 0-11 bar)
For D200s, D200, and D60 supply systems only.
ForS20 supply systems only.
IG
. 5)
2
2
1
1
1
1
1
6
6
2
2
312374H 11
Parts

Integrated Air Controls

1
10
8
13
5
7b
3
9
7
11
4b
7a
ti10774a
4a
Model 24C824; D200s and D200
Ref. Part Description Qty.
1MANIFOLD 1 3 121108 VALVE, shutoff (includes o-rings
and screws)
4 121107 VALVE, director (includes 4a and
IG
4
4a SCREW 4 4b O-RING 1 5 121110 O-RING, buna 3 7 121106 REGULATOR, ram (includes 7a
7a SCREWS 4 7b O-RING 2 8 121109 VALVE, blowoff (includes valve
9 121112 SCREW, cap, socket head
10 517449 MUFFLER 1 11 100721 PLUG, pipe, auxiliary air supply 1 13 101689 GAUGE, air pressure, 0-200 psi
4b, plus all parts shown in F
and 7b)
and push button)
1/4-20 x 5/8
(0-1.4 MPa, 0-14 bar)
. 5)
2
1
1
1
2
1
12 312374H
Parts

2-Button Interlock Kit

Model 255719
(For D200 3-in., 55 gallon (200 liter) supply systems with NXT 2200, 3400 and 6500 Air Motors only)
Model 255720
(For D200s 6.5-in., 55 gallon (200 liter) supply systems with NXT 2200, 3400 and 6500 Air Motors only)
Model 257615
(For D60 3-in., 16 gallon (60 liter) supply systems)
Ref. Part Description Qty.
105 SCREW, cap, 1/4-20 x 5/8 2 106 WASHER, lock, 1/4 2 130 AIR CONTROL, 2-button interlock 1 132 BRACKET, switch, mounting 1
BRACKET, switch, mounting 1 133 VALVE, roller operated 1 135 WASHER, no. 8 2 136 WASHER, lock, no. 8 2 137 NUT, hex, 8-32 2 138 BRACKET, actuator 1 139 BRACKET, actuator, mounting 2 140 SCREW, cap, 1/4-20 x 1 1/4 4
SCREW, cap, 8/32 x 1 4 144 SCREW, panhead, 8-32 x 1 1/2 2 145 SCREW, cap, 1/4-20 x 2 1/2 1 146 TUBING, nylon, 5/32 in. (not shown) 30 147 TUBING, nylon, 1/4 in. (not shown 30 150 ELBOW, 90°; 5/32 tube x 5/32 OD 2 151 ACTUATOR, weldment 1 152 WASHER, plain- 4 153 NUT, hex; 8/32 4
144
133
105
106
132
135 136
137
1
Flip mounting bracket 132 on D60 supply systems.
ti10844a1
130
145
1
ti10843a1
For D60 2-button interlock kit 257615 only.
Actuator Bracket (138) for 255719 and 255720
Actuator Bracket (138) for 257615
151
139
138
140
138
139
152
153
ti10848a
140
312374H 13
r_289105_312375_5a

Pneumatic Schematic

Pneumatic Schematic

Integrated Air Control Module

INTEGRATED AIR CONTROL MODULE
Pump Pressure
Regulator
Air Motor
Shutoff
MAIN
AIR IN
Air Pressure
Relief Valve
Ram Pressure
Regulator
Ram Directional
Control Valve
UP
DOWN
Pump Air
Motor
Ram Down
Blow Off
Valve
Platen
Ram Up
14 312374H
Pneumatic Schematic

Integrated Air Control Module with Optional 2-Button Interlock

INTEGRATED AIR CONTROL MODULE
Pump Pressure
Regulator
Air Motor
Shutoff
MAIN
AIR IN
Air Pressure
Relief Valve
Ram Interlock
Roller Valve
Ram Pressure
Regulator
OPTIONAL 2-BUTTON INTERLOCK
Ram Directional
Control Valve
UP
DOWN
Pump Air
Motor
Blow Off
Valve
Platen
Ram Down Pilot
Interlock Valve
Ram Down
Ram Up Pilot Interlock Valve
Interlock
Ram Up
Push buttons
P S
A
Synchronous Input Safety Valve
B
312374H 15

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER,
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
contact your Graco distributor or call to identify the nearest distributor.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions.
International Offices: Belgium, China, Japan, Korea
This manual contains English. MM 312374
Graco Headquarters: Minneapolis
www.graco.com
Revision H, September 2014
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