The Tandem Supply System Operation manual is available in the following languages. See the following chart
for specific languages and corresponding part numbers.
Check the identification plate (ID) for the 6-digit part number of your tandem system. Use the following matrix to define the construction of your system, based on
the six digits. For example, Tandem Part No. TC2414 represents a Check-Mate
tandem system (TC), pump (24), crossover option (1), and platen/ram option (4).
Systems with the TD as the first and second digits are Dura-Flo tandem systems.
Some configurations in the following matrix cannot be built. See the
Product Selection Guide for available systems.
ID
To order replacement parts, see Parts section in manual 312400. The digits in
the matrix do not correspond to the Ref. Nos. in the Parts drawings and lists.
Table 3: Dura-Flo Pump Identification Code/Part No. Index
Pump Part No.
Pump
Code
(see manual
311828)
NXT 2200/DF 145SS
A1P31LSS
A2P31LSM
A3P31HSS
A4P31HSM
NXT 3400/DF 145SS
11P46LSS
12P46LSM
13P46HSS
14P46HSM
NXT 3400/DF 180SS
15P40LSS
16P40LSM
17P40HSS
18P40HSM
NXT 3400/DF 220SS
21P30LSS
22P30LSM
23P30HSS
24P30HSM
NXT 6500/DF 220SS
2AP57LSS
2BP57LSM
2CP57HSS
2DP57HSM
NXT 6500/DF 290SS
31P45LSS
32P45LSM
33P45HSS
34P45HSM
Premier/DF 290SS
3LP67LSS
3MP67LSM
3RP67HSS
3SP67HSM
Pump Part No.
Pump
Code
(see manual
311826)
NXT 3400/DF 430CS
41P15LCS
42P15LCM
43P15HCS
44P15HCM
NXT 3400/DF 430SS
45P15LSS
46P15LSM
47P15HSS
48P15HSM
NXT 6500/DF 430CS
49P32LCS
4AP32LCM
4BP32HCS
4CP32HCM
NXT 6500/DF 430SS
4FP32LSS
4GP32LSM
4HP32HSS
4JP32HSM
Premier/DF 430
4LP44LSS
4MP44LSM
4RP44LCS
4SP44LCM
NXT 3400/DF 580CS
51P12LCS
52P12LCM
53P12HCS
54P12HCM
NXT 3400/DF 580SS
55P12LSS
56P12LSM
57P12HSS
58P12HSM
Pump Part No.
Pump
Code
(see manual
311826)
NXT 6500/DF 580CS
59P22LCS
5AP22LCM
5BP22HCS
5CP22HCM
NXT 6500/DF 580SS
5FP22LSS
5GP22LSM
5HP22HSS
5JP22HSM
Premier/DF 580CS
5LP34LSS
5MP34LSM
5RP34LCS
5SP34LCM
Pump Part No.
Pump
Code
(see manual
311833)
NXT 3400/DF 1000CS
O1P06LCS
O2P06LCM
O3P06HCS
O4P06HCM
NXT 3400/DF 1000SS
O5P06LSS
O6P06LSM
O7P06HSS
O8P06HSM
NXT 6500/DF 1000CS
O9P10LCS
0AP10LCM
0BP10HCS
0CP10HCM
NXT 6500/DF 1000SS
0FP10LSS
0GP10LSM
0HP10HSS
0JP10HSM
Premier/DF 1000
0LNR
0MNR
0RNR
0SNR
6312395D
Warnings
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 symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Do not point gun at anyone or at any part of the body.
•Do not put your hand over the spray tip.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Do not spray without tip guard and trigger guard installed.
•Engage trigger lock when not spraying.
•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
•Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•Use equipment only in well ventilated area.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•Ground all equipment in the work area. See Grounding instructions.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail.
•If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
•Keep a working fire extinguisher in the work area.
312395D7
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 Data in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•Do not alter or modify equipment.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
•Turn off and disconnect power cord before servicing equipment.
•Use only grounded electrical outlets.
•Use only 3-wire extension cords.
•Ensure ground prongs are intact on sprayer and extension cords.
•Do not expose to rain. Store indoors.
SPLATTER HAZARD
During blowoff of platen splatter may occur.
•Use minimum drum removal air pressure.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•Read MSDS’s to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
•Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
•Protective eyewear
•Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
•Hearing protection
8312395D
Overview
Overview
System Description
Each tandem supply system consists of two air-powered
rams. Each ram drives a Check-Mate pump and a platen
into a drum of material. The pump removes material
from the drum and pushes it through a supply hose to a
customer-supplied header. Material flows through the
header to individual dispense drops.
When one drum is emptied the system performs an
automatic crossover, shutting off the air supply to the
pump on the empty ram and activating the pump on the
full ram.
Keep clear of the inactive ram, as automatic crossover
may occur unexpectedly. To repair or adjust the ram,
first follow all steps of the Pressure Relief Procedure
on page 19.
Ram Installation
Install the rams as explained in manual 312371, supplied. See also F
over systems) and F
crossover systems).
IG. 2 on page 11 (for pneumatic cross-
IG. 3 on page 14 (for electronic
Grounding
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
Pump: use ground wire and clamp (supplied). Loosen
grounding lug locknut and washer. Insert ground wire
end into lug slot and tighten locknut securely. Connect
ground clamp to a true earth ground.
Air and fluid hoses: use only electrically conductive
hoses with a maximum of 500 ft. (150 m) combined
hose length to ensure grounding continuity. Check electrical resistance of hoses. If total resistance to ground
exceeds 29 megohms, replace hose immediately.
Air compressor: follow manufacturer’s recommendations.
Dispense valve: ground through connection to a prop-
erly grounded fluid hose and pump.
Fluid supply container: follow local code.
Fluid Filter Kit Installation
Solvent pails used when flushing: follow local code. Some systems include a fluid filter kit. See Fluid Filter
Kit Dimensions on page 32. Ensure that the fluid filter
stand base is level in all directions. If necessary, level
the base using metal shims. Secure the base to the floor
using anchors that are long enough to prevent the filter
stand from tipping.
312395D9
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive sur-
face, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the dispense
valve firmly to the side of a grounded metal pail, then
trigger the valve.
Overview
Integrated Air Controls
The integrated air controls include:
•Main air slider valve (BA): turns air on and off to
the system. When closed, the valve relieves pressure downstream.
BF
•Ram air regulator (BB): controls ram up and down
pressure and blowoff pressure.
•Ram director valve (BC): controls ram direction.
•Exhaust port with muffler (BD)
•Air motor regulator (BE): controls air pressure to
motor.
•Air motor slider valve (BF): turns air on and off to
the air motor. When closed, the valve relieves air
trapped between it and the air motor. Push the valve
in to shutoff.
•Blowoff button (BG): turns air on and off to push
the platen out of an empty drum.
The air solenoid (Y, FIG. 3), the air motor slider
valve (BF), and the main air slider valve (BA) must
be open for air to flow to the air motor.
•Air relief valve (not visible, attached to ram air reg-
ulator): automatically relieves excessive pressure to
the pump.
BE
BG
BA
F
IG. 1. Integrated Air Controls
BD
BC
BB
TI10438A
System Components
(Pneumatic Crossover)
FIG. 2. shows a pneumatic crossover system. Refer to
manual 312371 (supplied) for ram installation and operating instructions. The pneumatic crossover operates as
follows:
During system operation, as the ram approaches the
drum bottom, the top of the ram contacts the limit switch
(E). The limit switch shuts off air to the air motor via a
solenoid valve (Y), which stops air flow to one motor and
starts air flow to the other air motor. This allows continuous material flow and changing of material drums.
The position of the limit switch (E) on the ram determines when the air motor is turned off. Start by positioning the limit switch to trip when the ram platen (D) is 1 in.
(25 mm) from the bottom of the drum. During operation
the position may be adjusted as desired.
The bypass valve (L) allows you to prime the inactive
pump after a drum change. Open the valve to prime the
pump. Close the valve when priming is complete, and
during normal operation.
ARam A
BRam B
CPump (Ram A and B)
DPlaten (Ram A and B)
ELimit Switch (Ram A and B)
HIntegrated Air Controls (Ram A and B); see page 10
LBypass Valve (Ram A and B)
SFluid Line (not supplied)
TMain Air Line (not supplied)
UAir Line Drain Valve (not supplied)
VAir Filter (not supplied)
W Bleed-Type Air Shutoff Valve (not supplied)
YSolenoid Valve (Ram A and B)
B
C
D
TI11160A
312395D11
Overview
255468 Light Tower Accessory
Order the 255468 Light Tower Accessory as a diagnostic indicator for tandem supply systems. Refer to Light
Tower Kit manual for installation instructions. See Table
4 for a description of light tower signals.
Table 4: Light Tower Signals
SignalDescription
Green on onlySystem is powered up and there
are no error conditions present.
Yellow flashingA low priority error exists.
Yellow onA medium priority error exists.
Red flashingA high priority error exists.
Red onThe system is shut down due to
error conditions.
Communications Gateway
Module
The Communications Gateway Module (CGM) provides
a control link between Graco Control Architecture based
systems and a selected fieldbus. This provides the
means for remote monitoring and control by external
automation systems.
Data provided by the CGM to the fieldbus depends on
which Graco Control Architecture based system and
fieldbus are connected. A data map supplied on a map
token is defined for this pairing. Once the data map has
been loaded into the CGM, it is stored internally, and the
map token is no longer required for operation.
Module Status LED Signals
SignalDescription
Green onSystem is powered up
YellowInternal communication in progress
Red
Solid
*Red
(5 flashes)
*Red
(7 flashes)
*The red LED (F) will flash a code, pause, then repeat.
See for diagnositc information in CGM manual 312864.
NOTE:
Verify that you are using the correct token for your system and reinstall token. If fails, order new token.
CGM hardware failure
CGM hardware failure
Data map load failure
Incorrect data map for fieldbus type
No data map loaded
12312395D
Overview
System Components (Electronic
Crossover)
See FIG. 3. Before you install the system, you should be
familiar with the following components.
Reference numbers and letters in parentheses in
the text refer to the callouts in the figures.
Both rams (A and B) include a Check-Mate Pump (C),
platen (D), integrated air controls (H), drum empty sensor (E), and fluid control module (G).
Only Ram A includes the display module (F) and power
supply box (K).
•Display module (F). Mounted on Ram A only. Provides Run Mode status screens, Setup screens, and
control keys.
•Fluid control module (G). See page 18.
•Integrated air controls (H). See page 10.
•Power supply box (K).
•Air motor solenoid (Y). Solenoid is on when system
is on and in Run Mode, Recirculate Mode, or Prime
Mode. Solenoid is off when system is shut off or
when in Depressurize Mode, or the ram is in an
Inactive Ready Mode. Turns on in Recirculate Mode.
The solenoid LED will illuminate when the solenoid
is on.
•Depressurize/recirculate fluid valve (Z). Depressurizes system when Depressurize Mode is active.
Recirculates fluid when Recirculate Mode is active.
To depressurize the system, press the Depressurize
key on the display module and select Yes when
asked if you want to depressurize the system. Follow
the Pressure Relief Procedure on page 19. Shutting
off power or removing power from the system will not
depressurize the system.
ARam A
BRam B
CPump (Ram A and B)
DPlaten (Ram A and B)
EDrum Empty Sensor (partially hidden; Ram A and B)
FDisplay Module (Ram A only)
GFluid Control Module (behind rear shroud, Ram A and B)
HIntegrated Air Controls (Ram A and B); see page 10
JFluid Filter and Stand
KPower Supply Box (behind shroud, Ram A only)
XCAN Communication Cable
YAir Motor Solenoid (Ram A and B)
ZDepressurize/Recirculate Fluid Valve (Ram A and B)
C
14312395D
Display Module (Electronic Crossover Systems)
FIG. 4: Display Module (see Table 5 for Module Key Functions)
Overview
Table 5: Display Module Key Functions (see FIG. 4)
KeyFunction
System On/OffPress to toggle the system ON and OFF.
•When ON, the active ram is pressurized and the air motor solenoid is ON. The active ram
is indicated by a highlighted letter (A or B) on the display. The hose graphic is darkened on
the active ram when the system is ON.
•When OFF, the air motor solenoids are OFF.
CAUTION: Turning the system OFF relieves pressure from the pump motor. It does not
depressurize the fluid pressure. Follow the Pressure Relief Procedure, page 19.
NOTE: The ram up/down and blowoff air is independent of the electronic controls and can be
operated anytime the main air slider valve is open and air pressure is available.
CancelCancels current action or window.
SetupPress to enter Setup Mode, or to exit Setup Mode and return to the Run screens.
•Setup changes can be made while system is operating.
•Password is required if enabled.
EnterOpens drop down menus on Setup fields.
Press to enter changes and to select an action.
Arrows Left/RightUse to move between tabs in a screen or to highlight digits.
Arrows Up/DownUse to increase or decrease a value, and move between screens or between fields.
312395D15
Overview
Table 5: Display Module Key Functions (see F
IG. 4)
KeyFunction
DepressurizeUse to relieve fluid pressure from the pump outlet to below the platen on the currently active
ram. This function is not available with all models; see page 4.
If system is pressurized, press key.
•Display reads “Depressurize system?”
•Select Yes or No. Key LED turns on in Depressurize Mode. Depressurizing the active ram will depressurize both rams.
NOTE: If additional user-supplied check valves have been added to the system, only the active
ram will be depressurized. You must do a manual crossover and select depressurize again to
depressurize both rams. See Crossover section of this table on page 17.
If system is depressurized, press key.
•Display reads “Pressurize system?”
•Select Yes or No. Key LED turns off in Pressurize Mode.
Pump Prime•Activates the air solenoid on the inactive ram, allowing you to purge air and prime the
pump.
•Clears the Pump Not Primed warning or alarm (depending on setup selection).
•Resets the drum volume remaining to the drum fill volume setpoint.
Press key when in Run Mode.
•Display reads “Prime the inactive ram?”
•Select Yes to prime. Key LED turns on. One minute before expiration of the prime time
counter the LED begins to blink. Key LED turns off when counter expires.
Press key when in Prime Mode to exit Prime Mode or to reset counter to the prime time.
•Display reads “Exit Prime Mode?”
•Select Yes to exit Prime Mode. Key LED turns on. One minute before expiration of the
prime time counter the LED begins to blink. Key LED turns off when counter expires.
•Select No. Display reads “Reset the Prime Time Counter?” Select Yes to reset. Select No
to not reset.
RecirculateRecirculate Mode pumps fluid from the drum, through the pump, and back into the drum on the
currently active ram. This function is not available with all models; see page 4.
Set motor air regulator to 30 psi (0.2 MPa, 2.1 bar) before pressing Recirculate key.
If system is not in Recirculate Mode, press key.
•Display reads “Turn recirculation on?”
•Select Yes or No. Key LED turns on in Recirculate Mode. Adjust motor air regulator to
obtain desired flow rate.
If system is in Recirculate Mode, press key.
•Display reads “Turn recirculation off?”
•Select Yes or No. Key LED turns off upon exiting Recirculate Mode.
16312395D
Overview
Table 5: Display Module Key Functions (see F
IG. 4)
KeyFunction
CrossoverCrossover key transitions the active ram to inactive, and inactive ram to active.
NOTE: If an alarm is present on the inactive ram, crossover will not be successful. Manual
crossover is disabled in single ram operation.
Press key.
•Display reads “Initiate a crossover?”
•Select Yes or No.
If Crossover error exists, press key to clear Crossover error.
•Display reads “Clear crossover alarm?”
•Select Yes or No.
312395D17
Overview
Fluid Control Module
Table 6: Fluid Control Module Sensor Connections
ConnectionRamSensor Description
1not usednot used
2not usednot used
3Ram AFluid pressure at filter inlet.
4Ram AFluid pressure at filter outlet.
5Ram A and Ram BSignal harness: air motor solenoid (white), light tower (green),
drum low (yellow), drum empty (black)
6Ram A and Ram BFluid depressurize/recirculate solenoid.
7Ram A and Ram BAir motor sensors.
CAN communication
cable 1
CAN communication
cable 2
Ram A (F
IG. 5, top view) From Ram A Fluid Control Module to Display Module.
Ram A and B (F
bottom view)
IG. 5,
15 ft (4.57 m) from Ram A Fluid Control Module to Ram B Fluid
Control Module.
Ram A, Top ViewRam B, Top View
CAN Cable 1
3
45
TI10866ATI10867A
5
Bottom View, Both Rams
CAN Cable 2
TI10868A
67
FIG. 5: Fluid Control Module Sensor Connections
18312395D
Electronic Crossover Operation
Electronic Crossover Operation
These instructions are for the display module functions used on tandem systems. For basic ram and
pump operation, refer to the component manuals
supplied.
Pressure Relief Procedure
1. Lock the gun/valve trigger.
2. Press the System On/Off key . If system is
On, display will read: “Turn the system off?” Select
Yes to turn off. See F
IG. 6.
If you suspect that the spray tip/nozzle or hose is completely clogged, or that pressure has not been fully
relieved after following the steps above, very slowly
loosen the tip guard retaining nut or hose end coupling
and relieve pressure gradually, then loosen completely.
Now clear the tip/nozzle or hose.
Flush Before Using Equipment
The pump was tested with lightweight oil, which is left in
the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the pump with a compatible
solvent before use. See your pump manual for flushing
directions.
Startup
1. On both ram A and B, turn on the main air slider
valve (BA). Set the ram director valve (BC) to the
down position. The ram will slowly drop.
2. Turn on the air motor slider valve (BF) on both ram A
and B.
FIG. 6: System Function Screen
3. Turn off the air motor slider valve (BF) on both ram A
and B.
4. On both ram A and B, turn off the main air slider
valve (BA). Set the ram director valve (BC) to the
down position. The ram will slowly drop.
5. Unlock the gun/valve trigger.
6. Hold a metal part of the gun/valve firmly to the side
of a grounded metal pail, and trigger the gun/valve
to relieve pressure.
7. Lock the gun/valve trigger.
8. On both ram A and B, open the drain valve and/or
the pump bleed port. Have a container ready to
catch the drainage.
9. Leave the pump bleed port open until you are ready
to dispense again.
BF
BE
BC
BA
BB
TI10438A
FIG. 7. Integrated Air Controls
312395D19
Electronic Crossover Operation
3. Turn on the power on/off switch at the back of the
power supply box on ram A. The Splash screen will
appear. See F
IG. 8: Splash Screen
F
IG. 8.
4. Verify that “No Active Error” displays in the lower left
corner of the screen. If an error is displayed, refer to
the Troubleshooting section of manual 312400.
5. Press the System On/Off key . If system is
Off, display will read: “Turn the system on?” Select
Yes to turn on.
6. See F
IG. 9. The Home Run screen displays which
ram (A or B) is active and how much volume is
remaining in each drum. The fluid line is shown filled
indicating the system is on.
7. The air motor solenoid LED will illuminate.
2. Press the Pump Prime key . The display
prompts the operator to confirm. See F
IG. 10. Select
Yes to begin prime.
F
IG. 10: Prime Function Screen
3. The LED on the keypad will turn on. When the prime
timer is less than 1 minute, the LED will begin flashing. When the timer expires the LED and the air
motor solenoid will turn off.
4. To exit Prime Mode before the timer expires, press
the Pump Prime key . The display prompts the
operator to confirm. See F
IG. 11. Select Yes to exit
prime.
To extend the prime time counter, select No in F
IG.
11. Display will read “Reset the Prime Time Counter?” See F
IG. 12. Select Yes to reset.
Active ram is
highlighted
Fluid line shown filled
when system is ON
Current
screen
IG. 9: Home Run Screen
F
Priming
1. To prime the inactive ram, first ensure that the sys-
tem is on and in Run Mode; see Startup, page 19.
F
IG. 11: Exit Prime Mode Screen
F
IG. 12: Reset Prime Time Counter
20312395D
Electronic Crossover Operation
Automatic Crossover
Keep clear of the inactive ram, as automatic crossover
may occur unexpectedly. To repair or adjust the ram,
first follow all steps of the Pressure Relief Procedure
on page 19.
The automatic crossover feature allows continuous flow
and prevents system shutdown. If the active ram
encounters a pump runaway, drum empty, or air solenoid disconnected alarm it will attempt an automatic
crossover to the inactive ram.
The system will generate a crossover error if the active
ram attempts an automatic crossover while the inactive
ram has a pump runaway, drum empty, air solenoid disconnected, or not primed alarm.
Manual Crossover
If the active ram has a pump runaway error, drum
empty error, or air motor solenoid disconnected
error, the system will attempt an automatic crossover.
F
IG. 13: Crossover Function Screen
Recirculate Function
Use Recirculate Mode to pump fluid from the drum,
through the pump, and back into the drum on the currently active ram.
To enter Recirculate Mode, set motor air regulator to 30
In Run Mode, press the Crossover key . The dis-
play prompts the operator to confirm. See F
Press the Crossover key to initiate a manual crossover
to the inactive ram, provided the following conditions are
met:
•inactive ram is not in the drum empty error condition.
•air motor solenoid disconnected error does not
exist.
•pump runaway and not primed alarms do not exist.
IG. 13.
psi (0.2 MPa, 2.1 bar). Press the Recirculate key .
The display prompts the operator to confirm. Adjust
motor air regulator to obtain desired flow rate. See F
14.
To exit Recirculate Mode, press the Recirculate key. The
display prompts the operator to confirm.
You must exit Recirculate Mode before depressurizing or initiating a crossover.
While in Recirculate Mode, the inactive ram cannot
be primed.
IG.
F
IG. 14: Enter Recirculate Mode
312395D21
Electronic Crossover Operation
Depressurize Function
Use the Depressurize function to relieve fluid pressure
from the pump outlet to below the platen on the currently
active ram.
In Run Mode, press the Depressurize key . The
display prompts the operator to confirm depressurize or
pressurize (depending on current system status). See
F
IG. 15.
F
IG. 15: Depressurize Function Screen
Shutdown
CAUTION
Turning the system OFF relieves pressure from the
pump motor. It does not depressurize the fluid pressure. Follow the Pressure Relief Procedure, page
19.
The ram up/down and blowoff air is independent of
the electronic controls and can be operated anytime the main air slider valve is open and air pressure is available.
Follow the Pressure Relief Procedure, page 19.
22312395D
Setup Screens
Setup Screens
Password Screen
In Run Mode, press the Setup key . If the password
is not set to 0000, the Password screen will appear. See
F
IG. 16. Enter the password to continue in Setup Mode.
To set the password, see Advanced Setup Screen
4, page 27.
F
IG. 16: Password Screen
Setup Screen 1
Table 7: System Setup Parameters
ParameterUnitsRange
Operating Mode Tandem/Ram
A/Ram B
Not Primed
Event
Prime TimeMinutes1 - 9
Pump Runaway
Limit
Warning/AlarmSelect as desired
Cycles per Minute
Select as desired
0 - 99 (Default is
60; 00 disables)
This screen allows you to change system setup parame-
ters. Use the Enter key to access pull-down
menus. See F
IG. 17: Setup Screen 1
F
IG. 17 and Table 7.
312395D23
Setup Screens
Maintenance Setup Screen 1
This screen allows you to change system maintenance
intervals. See F
This screen allows you to change platen seal maintenance intervals. See F
Table 8: Maintenance Setup Parameters
ParameterUnitsRange
Ram Maintenance (A and B)
Rebuild Pump (A
and B)
Rebuild Air Motor
(A and B)
Rebuild Platen
Seals (A and B)
IG. 19 and Table 8.
User Settable;
see Advanced Setup Screen 1,
page 26
User Settable;
see Advanced Setup Screen 1,
page 26
User Settable;
see Advanced Setup Screen 1,
page 26
Drums0 - 9999
0 - 999
(0 disables)
0 - 999
(0 disables)
0 - 99999
(0 disables)
(0 disables)
24312395D
Setup Screens
Hardware Setup Screen 1
This screen allows you to specify if a fluid filter monitor
is installed, and set the high and low limits for the pressure drop across the filter. See F
see Status Screen 2, page 29, for additional details.
Monitor the filter pressure readings through the normal
range of flow with a clean filter to establish the initial limit
settings.
Set the low limit to detect a filter element collapse
or a missing element.
Set the high limit to detect a clogged filter.
IG. 20 and Table 9. Also
Hardware Setup Screen 2
This screen allows you to specify if a fluid solenoid is
installed. The fluid solenoid controls the depressurize/recirculate valve. See F
FIG. 21: Hardware Setup Screen 2
IG. 21.
Hardware Setup Screen 3
This screen allows you to specify if a drum low sensor is
installed. See F
IG. 22.
F
IG. 20: Hardware Setup Screen 1
Table 9: Fluid Filter Monitor Setup Parameters
ParameterUnitsRange
Filter ModeDisabled Moni-
tor warning
Filter Monitor
Low Limit
Filter Monitor
High Limit
User Settable;
see Advanced Setup Screen 1,
page 26
User Settable;
see Advanced Setup Screen 1,
page 26
Select as desired
0 - 1000
0 - 5000
IG. 22: Hardware Setup Screen 3
F
312395D25
Setup Screens
Advanced Setup Screen 1
This screen allows you to set units displayed on other
screens. Use the Enter key to access pull-down
menus. See F
IG. 23: Advanced Setup Screen 1
F
Parameter UnitsRange
LanguageEnglish, Spanish,
Volu me
Unit
Pressure
Unit
Maintenance Unit
IG. 23 and Table 10.
Table 10: Advanced Setup Screen 1
Select as desired
French, German,
Japanese, Chinese,
Korean, Portuguese
cycles/gal. (US),
gal. (UK), oz (US),
oz (UK), liters/cc
This screen allows you to set pump size (in cc/cycle),
drum size (in gal. or liters), and drum fill volume (in gal.
or liters). Drum fill volume is the amount of material in a
new drum. It is used to calculate the volume of material
remaining during operation. See F
These values must be entered accurately for the
volume remaining estimates on the Home Run
screen to be accurate.
F
IG. 24: Advanced Setup Screen 2
Table 11: Advanced Setup Screen 2
ParameterUnitsRange
Pump Size (A and B) cc/cycle_ _ _
Drum Size (A and B)User Settable; see
Advanced Setup
Screen 1, page 26
Drum Fill Volume
(A and B)
User Settable; see
Advanced Setup
Screen 1, page 26
IG. 24 and Table 11.
(100,
200, 250,
or 500)
1 - 9999
1 - 9999
26312395D
Setup Screens
Advanced Setup Screen 3
This screen allows you to set the date and time. See
F
This screen contains software part number and version
information for system components. See F
FIG. 27: Advanced Setup Screen 5
IG. 27.
Advanced Setup Screen 4
This screen allows you to set the password and screen
saver time, and adjust the contrast. See F
Table 13.
F
IG. 26: Advanced Setup Screen 4
Table 13: Advanced Setup Screen 4
ParameterUnitsRange
PasswordDigits0 - 9999;
0000 = no password
Screen SaverMinutes1 - 9
Adjust ContrastSliding
Scale
Scale is 0 - 100, but no
numbers are displayed
IG. 26 and
312395D27
Run Screens
Run Screens
The Run screens display information related to system
operation. See F
lighted. Use the left/right arrow keys to move to the next
tab.
IG. 28. The current screen is high-
Home Run Screen
The Home Run screen displays which ram (A or B) is
active and how much volume is remaining in each drum.
The fluid line is shown filled, indicating the system is on.
This screen also displays the flow rate of the active ram.
Active ram is
highlighted
Current
screen
Fluid line shown filled
when system is ON
Icon
FIG. 29: Home Run Screen with Recirculate Icon
IG. 28: Home Run Screen
F
See F
IG. 29. The Home Run screen will display the
appropriate icon if the system is:
•depressurized
•in Recirculate Mode
•or if the inactive ram is in Prime Mode
28312395D
Run Screens
Status Screens
Use the left/right arrow keys to move to the Status
screens.
There are three Status screens. Use the up/down arrow
keys to navigate among the three screens.
Status Screen 1
This screen displays primary system status information
and pump diagnostic codes describing any error conditions detected. See F
F
IG. 30: Status Screen 1
IG. 30 and Table 14.
Drum Empty alarms cannot be cleared by the operator;
they are cleared when the condition is corrected.
To clear an alarm, navigate to the alarm, press Enter
key then confirm on the screen. See F
IG. 31.
•Pump Runaway must always be cleared by the
operator, after the condition has been corrected.
•Not Primed can be either an alarm or a warning,
and may or may not be cleared by the operator (if
the inactive ram enters Prime Mode, the warning/alarm will automatically clear).
FIG. 31: Confirm Clearing Alarm
Table 14: Error Codes
CodeDescription
E1Pump diving up.
E2Pump diving down.
E5Air motor position sensor error.
Status Screen 2
This screen displays the fluid filter inlet pressure, outlet
pressure, and the pressure drop across the filter. See
F
IG. 32.
F
IG. 32: Status Screen 2
•Filter Pressure Drop Low Warning will appear if the
pressure drop is below the setpoint for 10 consecutive pump cycles.
•Filter Pressure Drop High Warning will appear if the
pressure drop is above the setpoint for 10 consecutive pump cycles.
•To clear a warning, navigate to the warning, press
Enter key then confirm on the screen.
312395D29
Run Screens
Status Screen 3
This screen displays the job totals and grand totals. See
F
IG. 33.
F
IG. 33: Status Screen 3
To reset a job total for a single ram (A or B), navigate to
the value, press Enter key , and confirm. See F
34.
If you select and reset Total, A and B totals will also be
reset.
IG.
Maintenance Screen 1
This screen displays the number of maintenance units
remaining before preventive maintenance is due for the
ram, pump, and air motor. See F
FIG. 35: Maintenance Screen 1
To reset the counter to its user-settable value, navigate
to the counter, press Enter key , and confirm. See
IG. 36.
F
IG. 35.
Grand totals are not resettable.
F
IG. 34: Reset Job Totals
Maintenance Screens
Use the left/right arrow keys to move to the Maintenance
screens. There are two Maintenance screens. Use the
up/down arrow keys to navigate between the screens.
The maintenance screens enable you to establish a preventive maintenance schedule based on the equipment’s application and repair history.
F
IG. 36: Confirm Maintenance Counter Reset
Maintenance Screen 2
This screen displays the number of maintenance units
remaining before preventive maintenance is due on the
platen seals. See F
IG. 37.
If a maintenance interval is set to 0, the display will be a
series of dashes.
30312395D
F
IG. 37: Maintenance Screen 2
Run Screens
Report Screens
Use the left/right arrow keys to move to the Report
screens.
The Report screens display a chronological list of the
most recent 15 errors. Use the up/down arrow keys to
scroll through the three Report screens. See F
Table 15 lists the possible Error Conditions.
F
IG. 38: Report Screen
Table 15: Error Conditions
Alarms
A - Alarm 1Pump Runaway
B - Alarm 1Pump Runaway
A - Alarm 2Drum Empty
B - Alarm 2Drum Empty
A - Alarm 3Not Primed
B - Alarm 3Not Primed
A - Alarm 4Air Solenoid Disconnected
B - Alarm 4Air Solenoid Disconnected
A - Alarm 5Reed Switch Error
B - Alarm 5Reed Switch Error
A - Alarm 6Communication Error - Ram A
Not Found
B - Alarm 6Communication Error - Ram B
Not Found
Alarm 7Crossover Error
IG. 38.
Table 15: Error Conditions
Warnings
A - Warning 1Not Primed
B - Warning 1Not Primed
A - Warning 2Drum Low
B - Warning 2Drum Low
A - Warning 3Pump Diving Up
B - Warning 3Pump Diving Up
A - Warning 4Pump Diving Down
B - Warning 4Pump Diving Down
A - Warning 5Ram Maintenance Due
B - Warning 5Ram Maintenance Due
A - Warning 6Ram Maintenance Reset
B - Warning 6Ram Maintenance Reset
A - Warning 7Rebuild Air Motor
B - Warning 7Rebuild Air Motor
A - Warning 8Air Motor Maintenance Reset
B - Warning 8Air Motor Maintenance Reset
A - Warning 9Rebuild Platen Seals
B - Warning 9Rebuild Platen Seals
A - Warning 10Platen Seals Maintenance Reset
B - Warning 10Platen Seals Maintenance Reset
A - Warning 11Rebuild Pump
B - Warning 11Rebuild Pump
A - Warning 12Pump Maintenance Reset
B - Warning 12Pump Maintenance Reset
A - Warning 13Fluid Solenoid Disconnected
B - Warning 13Fluid Solenoid Disconnected
Warning 14Filter Pressure Drop Low
Warning 15Filter Pressure Drop High
312395D31
Fluid Filter Kit Dimensions
Fluid Filter Kit Dimensions
Refer to the supplied manuals, page 3, for dimensions of the rams, pumps, and other components.
F
G
A
Key
A52.25 in. (1327 mm)
B11 in. (279 mm)
C14 in. (356 mm)
D17 in. (432 mm)
E14. in. (356 mm)
F (fluid inlets)1 in. npt(f)
G (fluid outlet)1 in. npt(f)
Filter Element Mesh Sizes
Part No.Mesh
51521960
51522050
51522140
51522230 (standard)
B
C
32312395D
E
D
TI11158A
Fluid Filter Kit Dimensions
312395D33
Fluid Filter Kit Dimensions
34312395D
Technical Data
Technical Data
See the supplied component manuals, page 3, for
complete component technical data.
Maximum air inlet pressure3 in. rams: 150 psi (1.0 MPa, 10 bar)
Maximum fluid working pressure5000 psi (35 MPa, 350 bar) or the maximum working pressure of the pump, if
less than 5000 psi (35 MPa, 350 bar).
For Check-Mate displacement pumps, see manual 312376.
For Dura-Flo displacement pumps, see manuals 311717, 311825, 311826,
311827, 311828, 311833.
Maximum flowSee pump manuals.
External power supply requirements Vac systems: 100-240 Vac, 50/60 Hz, single-phase, 1.2 A maximum draw
Vdc systems: 24 Vdc, 1.2 A maximum draw
Ambient operating temperature
range
Sound dataSee applicable air motor manual, page 3.
Wetted partsFor Check-Mate displacement pumps, see manual 312375.
32-120°F (0-49°C)
For Dura-Flo displacement pumps, see manuals 311717, 311825, 311827.
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
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
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 reserves the right to make changes at any time without notice.
This manual contains English. MM 312395
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
www.graco.com
9/2007, Rev. 10/2008
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