Uni-Drum Supply System - · PDF fileThe Uni-Drum supply system evacuates 1000 liter ......

Uni-Drum Right Hand Supply Unit

Instructions--Parts List

Uni-Drum Supply SystemBulk Supply System for 1000 Liter (264 Gallon) Magnadrums.For professional use only. Not for use in explosive atmospheres.

Maximum Outlet Pressure: 3400 psi (234 bar, 23.4 MPa)

Maximum Fluid Flow: 9.2 gpm (34.6 liters/min at 60 cycles/min)

The Uni-Drum supply system evacuates 1000 liter (264 gallon) magnadrums or other tote drums ofthe same size and capacity. The Uni-Drum pumps and transfers flowable and highly viscous materialssuch as sealant, adhesives, and sound deadeners from bulk drums with maximum efficiency.

The Uni-Drum is built to work with other high pressure equipment to optimize material use.

Important Safety InstructionsRead all warnings and instructions in this manual.Save these instructions.

Uni-Drum Left Hand Supply Unit

Model: U81832 (LH), U81833 (RH)

332499BEN

2 332499

Related Publications

Product Form#

Stainless Steel Dura-Flo� Pump 2400 with Premier� Air Motor 308152

Air Filters, Lubricators, and Kits 308169

Premier� Air Motor 308213

Dura-Flo� Lowers 311825

DV Series Dispense Valves 3A1792

Dura-Flo and Premier are trademarks of Graco, Inc.

332499 3

Table of Contents

Related Publications 2. . . . . . . . . . . . . . . . . . . . . . . . . .

Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Uncrating the System 7. . . . . . . . . . . . . . . . . . . . . . . . .

Overview 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Overview 7. . . . . . . . . . . . . . . . . . . . . . . .Operation Overview 7. . . . . . . . . . . . . . . . . . . . . . . . .

General Description 8. . . . . . . . . . . . . . . . . . . . . . . . . . .System Components 8. . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Layout Panel 10. . . . . . . . . . . . . . . . . . . .Junction Box Panel 10. . . . . . . . . . . . . . . . . . . . . . . .

Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparing the Site 11. . . . . . . . . . . . . . . . . . . . . . . . . .Selecting a Location for the Uni-Drum 11. . . . . . . .Preparing to Install the System 11. . . . . . . . . . . . . .Installing the Uni-Drum 12. . . . . . . . . . . . . . . . . . . . .Connecting Power to the Junction Box 13. . . . . . . .Grounding the System 15. . . . . . . . . . . . . . . . . . . . . .Checking the Resistance Between thePumps and the True Earth Ground 15. . . . . . . . . . .Connecting Air Supply Lines to the Uni-Drum 16. .Connecting Output Hose to the Pumps 17. . . . . . .

Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prepare the Operator 18. . . . . . . . . . . . . . . . . . . . . . .Overview 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Junction Box Panel Switches and Indicators 19. . .Pneumatic Layout Panel Switchesand Indicators 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flushing the System Before Initial Use 23. . . . . . . .Adjusting the Lid Holder Before Initial Use 23. . . . .Initial System Startup Procedure 24. . . . . . . . . . . . .Daily System Startup 29. . . . . . . . . . . . . . . . . . . . . . .System Shutdown 29. . . . . . . . . . . . . . . . . . . . . . . . .Emergency Stop 29. . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Relief Procedure 30. . . . . . . . . . . . . . . . . .Fluid Pressure Relief Procedure 30. . . . . . . . . . . . .Pneumatic Pressure Relief Procedure 32. . . . . . . .Preventive Maintenance Schedule 32. . . . . . . . . . .Changing Empty Drums 33. . . . . . . . . . . . . . . . . . . .

Ram Assembly Troubleshooting 36. . . . . . . . . . . . . .

Pump Troubleshooting 37. . . . . . . . . . . . . . . . . . . . . . .

Air Motor Troubleshooting 38. . . . . . . . . . . . . . . . . . . .

Junction Box Panel Troubleshooting 39. . . . . . . . . .

Pneumatic Layout Panel Troubleshooting 39. . . . .

Routine Maintenance 40. . . . . . . . . . . . . . . . . . . . . . . . .Flushing the System 40. . . . . . . . . . . . . . . . . . . . . . .Cleaning the System 40. . . . . . . . . . . . . . . . . . . . . . .Wiper Lubrication 40. . . . . . . . . . . . . . . . . . . . . . . . . .

Junction Box Panel Service 41. . . . . . . . . . . . . . . . . . .Indicator Light and PushbuttonSwitch Removal 41. . . . . . . . . . . . . . . . . . . . . . . . . . .Indicator Light and PushbuttonSwitch Replacement 41. . . . . . . . . . . . . . . . . . . . . . .Light Bulb Removal 41. . . . . . . . . . . . . . . . . . . . . . . .Light Bulb Replacement 41. . . . . . . . . . . . . . . . . . . .Fuse Removal 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuse Replacement 43. . . . . . . . . . . . . . . . . . . . . . . . .Surge Suppressor Removal 44. . . . . . . . . . . . . . . . .Surge Suppressor Replacement 44. . . . . . . . . . . . .

PLC Interface Accessory Kit Service 45. . . . . . . . . . .Valve Assembly Bank Replacement 45. . . . . . . . . .Pressure Switch Assembly Replacement 45. . . . . .

Pneumatic Layout Panel Service 47. . . . . . . . . . . . . .Filter/Element Replacement 47. . . . . . . . . . . . . . . . .

Ram Assembly Service 49. . . . . . . . . . . . . . . . . . . . . . .Piston Rod Seal Service 49. . . . . . . . . . . . . . . . . . . .Ram Piston Service 50. . . . . . . . . . . . . . . . . . . . . . . .Low/Empty Limit Switch ReplacementDepressurization Valve (Ball Seat Applicator) 51.Repair Procedure 52. . . . . . . . . . . . . . . . . . . . . . . . . .Servicing the Pumps 52. . . . . . . . . . . . . . . . . . . . . . .Replacing Wipers 53. . . . . . . . . . . . . . . . . . . . . . . . . .Pump Removal 54. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241839 Low/Empty Limit Kit 55. . . . . . . . . . . . . . . . .243488 Proximity Switch Accessory Kit 56. . . . . . .

Recommended Spare Parts 57. . . . . . . . . . . . . . . . . . .Spare Parts List 57. . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Diagram 58. . . . . . . . . . . . . . . . . . . . . . . . . . . .Junction Box Panel 58. . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Diagram 57. . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Layout Panel 57. . . . . . . . . . . . . . . . . . . .

Technical Data 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 62. . . . . . . . . . . . . . . . . . . . .

Graco Information 62. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 332499

SymbolsWarning Symbol

WARNING

This symbol alerts you to the possibility of serious inju-ry or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage toor destruction of equipment if you do not follow the in-structions.

WARNING

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

� This equipment is for professional use only.

� Read all instruction manuals, tags, and labels before operating the equipment.

� Use the equipment only for its intended purpose. If you are uncertain about usage, call your Gracodistributor.

� Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

� Check equipment daily. Repair or replace worn or damaged parts immediately.

� Do not exceed the maximum working pressure stated on the equipment or in the Technical Datafor your equipment. Do not exceed the maximum working pressure of the lowest rated componentin your system.

� Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

� Do not kink or overbend hoses or use hoses to pull equipment.

� Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not exposeGraco hoses to temperatures above 180�F (82�C) or below --40�F (--40�C).

� Wear hearing protection when operating this equipment.

� Do not lift pressurized equipment.

� Do not lift the equipment by the air motor lift ring if the total weight of the equipment exceeds 550 lb(250 kg).

� Comply with all applicable local, state, and national fire, electrical, and safety regulations.

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WARNINGSKIN INJECTION HAZARD

Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and causeextremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skincan also cause serious injury.

� Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediatesurgical treatment.

� Do not point the gun at anyone or at any part of the body.

� Do not put your hand or fingers over the spray tip.

� Do not stop or deflect leaks with your hand, body, glove or rag.

� Do not “blow back” fluid; this is not an air spray system.

� Always have the tip guard and the trigger guard on the gun when spraying.

� Check the gun diffuser operation weekly. Refer to the gun manual.

� Be sure the gun trigger safety operates before spraying.

� Lock the gun trigger safety when you stop spraying.

� Follow the Pressure Relief Procedure on page 30 whenever you: are instructed to relieve pres-sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.

� Tighten all fluid connections before operating the equipment.

� Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.Permanently coupled hoses cannot be repaired; replace the entire hose.

� Use only Graco approved hoses. Do not remove any spring guard that is used to help protect thehose from rupture caused by kinks or bends near the couplings.

MOVING PARTS HAZARD

Moving parts, such as the pump rod, follower plate and ram assembly, can pinch or amputate yourfingers.

� Keep clear of all moving parts when starting or operating the pump.

� Keep your hands away from the follower plate and the lip of the drum while the ram is operating.

� Keep your hands away from the ram frame while the ram is operating.

� Before servicing the equipment, follow the Pressure Relief Procedure on page 30 to prevent theequipment from starting unexpectedly.

6 332499

WARNINGFIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition andresult in a fire or explosion and serious injury.

� Ground the equipment and the container where the material is deposited. Refer to Grounding theSystem on page 15.

� If there is any static sparking or you feel an electric shock while using this equipment, stop thepumps immediately. Do not use the equipment until you identify and correct the problem.

� Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluidbeing sprayed.

� Keep the spray area free of debris, including solvent, rags, and gasoline.

� Electrically disconnect all equipment in the spray area.

� Extinguish all open flames or pilot lights in the spray area.

� Do not smoke in the spray area.

� Do not turn on or off any light switch in the spray area while operating or if fumes are present.

� Do not operate a gasoline engine in the spray area.

� Keep a fire extinguisher in the work area.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,inhaled, or swallowed.

� Know the specific hazards of the fluid you are using.

� Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,state and national guidelines.

� Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid andsolvent manufacturer.

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Uncrating the System

The Uni-Drum supply system was carefully packagedfor shipment by Graco. When the system arrives,perform the following procedure to uncrate the system.

WARNINGEQUIPMENT MOVING HAZARDRemoving the unit off the pallet without followingthe uncrating procedure will damage the equip-ment.

To uncrate the system, do the following:

1. Inspect the crate carefully for shipping damage.Contact the carrier promptly if damage is discov-ered.

2. Remove the plywood sides and top of the crate.

3. Inspect the contents carefully. There should not beany loose or damaged parts.

4. Compare the packing slip against all items in-cluded in the crate. Report any shortages or otherinspection problems immediately.

5. Remove the band straps that hold the Uni-Drum tothe pallet.

NOTE: The Uni-Drum is ready for installation. Beforeinstalling the system, read the “General Description”section to become familiar with the system compo-nents.

OverviewInstallation Overview

The location of the Uni-Drum should allow for easyloading and unloading of the 1000 liter (264 gallon)magnadrum or other tote drums with either a forklifttruck or pallet-jack hand truck.

The Uni-Drum supply system must be leveled andmounted on a horizontal floor. An unleveled conditioncan keep the Uni-Drum from operating properly.

Anchor the frame’s four foot pads securely to the floor.The anchor bolts should be sized with sufficient safetyfactor to withstand the downward force of the followerplate and other objects that can push the frame off thefloor.

Operation Overview

The Uni-Drum is a supply system that evacuates fluidsfrom a 1000 liter (264 gallon) magnadrum or other totedrums.

Each Uni-Drum includes two Graco air motors and dis-placement pumps, a ram assembly with a followerplate, a pneumatic layout panel that controls the aircomponents and a junction box panel that connectswith an electrical controller (supplied by the customer).

In short, the operator places the magnadrum inside theframe with the follower plate placed directly on top ofthe material. Locally, the system can be operated us-ing pneumatic layout panel. Remotely, the system canbe operated using signals through the junction boxpanel.

Two displacement pumps evacuate material out ofeach magnadrum. After removing the empty drumfrom the system, the operator repeats the evacuationprocess when another drum is ready for evacuation.

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General DescriptionSystem Components

A general description of the Uni-Drum supply systemhelps the installers and operators become familiar withthe system components. Contact your Graco distribu-tor for help in choosing accessories to suit your partic-ular needs.

Before you install the system you should be familiarwith the parts described in the following paragraphs.

Fig. 1 shows the typical Uni-Drum supply systemequipped with Premier� air motors. The following listidentifies the Uni-Drum system components:

Ref. Description

A Left hand (LH) supply unit

B Right hand (RH) supply unit

C Pumps and air motor

D Follower plate

E Main air inlet

F 1/2 npt air filter

G Pneumatic layout panel

H Junction box panelJ Drum lid holders

� Uni-Drum System (A) is usually setup to alternatethe material supply operation between the left hand(LH) and right hand (RH) supply units, which isaccomplished using a combination of robotic soft-ware programming (provided by others) and manu-al operators. Drum changeovers occur after thefollower plate has reached its preset low limit levelin the drum. Alternating between supply unitseliminates the downtime that is usually expendedunloading an empty drum and reloading a full drum.

-- LH pump supply unit (A) accommodates one1000 liter (264 gallon) drum. The LH supplyunit has a local pneumatic layout panel andjunction box panel.

-- RH pump supply unit (B) accommodates one1000 liter (264 gallon) drum. The RH supplyunit has a local pneumatic layout panel andjunction box panel.

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General Description

Fig. 1A -- Left Hand Unit

Left Hand Models

U81832

B -- Right Hand Unit

Right Hand Models

U81833

CC

DD

E E

FF

GG

H H

HH

J

TI20915a

10 332499

General DescriptionSystem Components (continued)

NOTE: The paragraphs that follow describe the com-ponents for the LH pump supply unit only. The descrip-tions are the same for the RH pump supply unit.

� The pumps evacuate material from the drum.

� The follower plate (D) is connected to the ramassembly and is designed to apply an even amountof pressure to the material in the drum. With thefollower plate in its raised position, the operatormoves a drum inside the frame. The follower plateis lowered directly on top of the material in thedrum. When pressure is applied to the followerplate, the material is pumped out of the drumthrough hoses, which are attached to the pumpoutlet ports. When the drum is empty, the operatorraises the follower plate, removes the empty drum.The process is repeated when another drum isready to be unloaded.

� 1/2 in. npt air filter (F) filters air to the pneumaticlayout panel. The 20 micron filter removes particles,such as dust, moisture, foreign matter and othercontaminants from the compressed air.

Pneumatic Layout Panel (G)

The pneumatic layout panel includes the followingsystem components. For more information, refer to thePneumatic Diagram on page NO TAG.

� Main Air Inlet Valve (at E) is used to open or shutoffthe air supply to the entire supply unit.

� Pump No. 1 Air Regulator controls pump speed andoutlet pressure for pump no. 1 by adjusting the airpressure to the pump.

� Pump No. 1 Pressure Gauge displays the amountof air pressure supplied to pump no. 1.

� Pump No. 2 Air Regulator controls pump speed andoutlet pressure for pump no. 2 by adjusting the airpressure to the pump.

� Pump No. 2 Pressure Gauge displays the amountof air pressure supplied to pump no. 2.

� Blow off pushbutton turns on air pressure to assistraising the follower plate.

� Blow--off regulator adjusts air pressure to blow--offvalves.

� Blow--off pressure gauge displays the amount of airpressure supplied to the blow--off valve.

� The Ram Position Switch performs the followingthree functions:

-- Place the switch in the RAISE position to raisethe follower plate.

-- Place the switch in the HOLD position to holdthe follower plate in the current position.

-- Place the switch in the LOWER position tolower the follower plate.

Junction Box Panel (H)

The junction box panel includes the following systemcomponents. For additional information, refer to theElectrical Diagram on page 58.

� System Pressurized lamp is lit when air pressure issupplied to the system; the lamp is extinguishedwhen the air supply is depressurized. This occursafter the Pump On button has been pushed and thepumps turned on.

� Pump Active lamp is lit when the air supply isturned on to the pumps; the lamp is extinguishedwhen the pumps are inactive, thus turned off. Thisis activated by the Pump On pushbutton.

� Air Pressure On lamp is lit when air pressure to thesystem is turned on; the lamp is extinguished whenair pressure to the system is shutoff.

� Ram Ready lamp is lit when the drum is in position;the lamp is extinguished when the drum is not inposition.

� Pump Ready lamp is lit when the pumps are primedand ready for operation; the lamp is extinguishedwhen the pumps are not ready for operation.

� Prime Pump pushbutton turns on the pumps, forpriming. When the pumps are primed, the PumpReady lamp turns on. The switch is not used whenthe Pump Ready lamp is lit. The Pump Active lightwill blink.

� Pump Reset pushbutton resets the pumps to anactive state. When the pumps are reset, the PumpActive lamp turns off. The switch is not used whenthe Pump Active lamp is lit. The Pump Ready lightis on.

� Pump On pushbutton turns the pumps on and off.When the pumps are turned on, the Pump Activelamp also turns on. When the pumps are turned off,the Pump Active lamp also turns off.

� Bulk Supply Depressurization button opens thedepressurization valve to lower the fluid pressure.

� Auto Mode On/Off switch puts the system into orout of automatic operation.

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Installation

The installation procedures in this section are intendedto serve as a guide for installing the Uni-Drum system.If you need more information, contact your Gracodistributor.

NOTE: When raising and lowering the follower plate,be sure that the unit is unobstructed overhead to avoidinterference with other objects.

The installation procedure includes:

� Preparing the site

� Selecting a location for the Uni-Drum

� Preparing to install the Uni-Drum

� Installing the Uni-Drum

� Connecting power to the junction box

� Grounding the system

� Checking resistance between the junction box andthe true earth ground

� Connecting air supply lines to Uni-Drum

Preparing the Site

Ensure that you have an adequate compressed airsupply. Refer to the applicable instruction manual listedin Related Publications on page 2 to find the airconsumption of your pump.

Keep the site clear of any obstacles or debris thatcould interfere with the installer’s and operator’s move-ment.

Selecting a Location for the Uni-Drum

Refer to Technical Data on page NO TAG for rammounting and clearance dimensions.

When selecting a location for the Uni-Drum, keep thefollowing in mind:

1. There should be sufficient space for installing,servicing, and using the equipment.

� Select an accessible location for the system.There must be sufficient space around thesystem for maintenance.

� Select a convenient location for the equipment.Check that there is sufficient overhead clear-ance for the pump and ram when the ram is inthe fully raised position. Make sure the airregulators for the pumps and follower plate arefully accessible.

� Make sure the air source for the PLC controlpanel and shutoff valves are fully accessible.

� Make sure there is easy and safe access to anappropriate pneumatic source. Graco recom-mends a minimum of 3 feet (0.91 m) of openspace in front of the control panel.

2. Make sure that you will be able to level the base ofthe ram using metal shims.

Preparing to Install the System

Before installing the system:

� See component manuals for specific data on com-ponent requirements. Data presented here pertainsto the system only.

� Have all system and subassembly documentationavailable during installation.

� Be sure that all non-Graco supplied hoses areadequately sized and pressure-rated to meet thesystem requirements.

12 332499

InstallationInstalling the Uni-Drum

To install the Uni-Drum, follow the procedure below.Refer to Technical Data on page NO TAG for rammounting and clearance dimensions.

1. Using equipment such as a forklift or handtruck,move the Uni-Drum into place on the floor. Re-move the shipping pallet.

2. Level the Uni-Drum, using metal shims.

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

4. Bolt the Uni-Drum to the floor using anchors thatare long enough to prevent the unit from tipping.Refer to page NO TAG for more information.

WARNINGEQUIPMENT MISUSE HAZARDThe Uni-Drum system is shipped withevery major component already attachedand weighs approx. 3950 lb (1792 kg).

The Uni-Drum system should never be moved orlifted by one person. To prevent equipment damageor personal injury, engage an adequate number ofpersonnel and use a forklift, hand truck, and sup-port devices, such as a hoist when moving andinstalling the Uni-Drum system.

CAUTIONBe sure to use as many people as needed when theframe is being lifted or moved. Exercise care to avoidjarring, dropping, or tilting the frame while it is beingmoved to its installed location to prevent injury orproperty damage.

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Installation

Connecting Power to the Junction Box

Perform the following procedure to connect the powerto the junction box panel.

WARNINGELECTRIC SHOCK HAZARDDo not connect the junction box panel toa power source unless you are a trainedelectrician. Failure to follow standard

procedures or to observe the necessary precau-tions could result in serious bodily injury or equip-ment damage.

CAUTIONIf power and grounding connections are not doneproperly, the equipment may be damaged and thewarranty will be voided.

NOTE: Have a qualified electrician connect the junc-tion box to a grounded electrical source that has thefollowing required service ratings:

Description Requirements

Voltage: 120 Vac 24 Vdc

Hz: 50/60 --

Phase: 1 --

Circuit Breaker 5 Amp 5 Amp

To connect the junction box panel to the electricalsource, do the following:

WARNINGELECTROCUTION HAZARDInstalling and servicing this equipmentrequires access to parts which couldcause an electric shock or other serious

injury. Have only qualified electricians access thecontrol assembly.

1. Shut off system power at the main circuit breaker.

2. Remove the cover from the junction box panel.

3. Locate the PLC power terminals KS102 andKS100 on the terminal strip inside the junction boxpanel. See Fig. 2. For more information, refer toElectrical Diagram on page 58 .

4. Using the upper wire duct on the left-hand side ofthe junction box panel, string two 14 AWG wiresinside the box from the electrical power source.

5. Connect the two 14 AWG wires to power terminalsKS102 (L1, hot) and KS100 (L2, neutral) in thejunction box panel.

6. Seal the area where wires entered the junction boxpanel.

7. Replace the cover on the junction box panel.

14 332499

InstallationConnecting Power to the Junction Box (continued)

Fig. 2

Terminals

SPARESPARESPARESPARESPARESPARESPARESPARESPARESPAREFU136FU143SUP136SUP144154115111481143114111361134112911271124112211191117111411121108110011001100110231003(31) TOTALType 0290.011.25ENTRELEC

ISOLATION BLOCKS

(KNIFE SWITCH DISC.

KS100 10011002

KS102 10211022

(2) TOTALType1492--WKD3TP

Strain Relief

Fuse Blocks Terminals

Wire Way

Enclosure

Ground Lug

TI0205b

332499 15

Installation

Grounding the System

WARNINGFIRE AND EXPLOSION HAZARDBefore operating the pump, ground thesystem as explained below. Also readthe section FIRE AND EXPLOSIONHAZARD on page 6.

1. Pump: use a ground wire and clamp. See Fig. 3.Loosen the grounding lug locknut (W) and washer(X). Insert one end of a 12 ga (1.5 mm�) minimumground wire (Y) into the slot in lug (Z) and tightenthe locknut securely. Connect the other end of thewire to a true earth ground. For a ground wire andclamp, order Part No. 237569.

W

Y

X

Z

Fig. 30720

2. Air and fluid hoses: Use only electrically conduc-tive hoses.

3. Air compressor: follow manufacturer’s recommen-dations.

4. Spray gun or dispensing valve: ground throughconnection to a properly grounded fluid hose andpump.

5. Object being sprayed: follow your local code.

6. Fluid supply drum: follow your local code.

7. Solvent pails used when flushing: follow your localcode. Use only metal pails, which are conductive,placed on a grounded surface. Do not place thepail on a nonconductive surface, such as paper orcardboard, which interrupts the grounding continu-ity.

8. To maintain grounding continuity when flushing orrelieving pressure, hold a metal part of the spraygun firmly to the side of a grounded metal pail,then trigger the gun.

Checking the Resistance Between the

Pumps and the True Earth Ground

Have a qualified electrician check the resistancebetween each pump and the true earth ground. Theresistance must be less than 1.0 ohm. If the resistanceis greater than 1.0 ohm, a different ground site may berequired. Do not operate the system until the problemis corrected.

NOTE: Use a meter that is capable of measuringresistance at this level.

WARNINGFIRE, EXPLOSION, AND ELECTRICSHOCK HAZARDTo reduce the risk of fire, explosion, orelectric shock the resistance betweenthe supply unit components and trueearth ground must be less than 1.0 ohm.

16 332499

InstallationConnecting the Air Supply Lines to the Uni-Drum

Perform the following procedure to connect the inputair supply lines to the Uni-Drum system.

Connecting Air Supply Lines to the Supply Units

To connect the main air supply line to the LH and RHsupply units, do the following:

WARNINGTo reduce the risk of overpressurizing your system,which could result in component rupture and causeserious injury, never exceed the specified maxi-mum incoming air pressure to the pumps (see theTechnical Data on page NO TAG).

NOTE: Have a qualified technician connect bothsupply units to an air supply source that has the follow-ing required ratings:

Description Requirements

Inlet Port Size: 1 in. npt(f)

Air Volume: 450 cfm (maximum)

Input Air: 80 psi (5.5 bar, 0.55 MPa)

1. Check the air supply to ensure that it is properlysized and pressure-rated for this system.

2. Connect the air supply line to the 1 in. npt main airinlet.

Fig. 4

Main Air Inlet

Main Air Shutoff Valve

Air Line to Pneumatic Panel

Main Air Filter

Air Line to Pump Air Manifold

Pump Air Manifold

Pilot Valve

AirLIne Lubricator

Air Supply Lines to Pumps

TI0204

Ti20917a

332499 17

InstallationConnecting Output Hose to the Pumps

This procedure describes how to connect the fluidoutput hoses to the two pumps. It is the customer’sresponsibility to have the fluid supply hose alreadyinstalled and ready for connection to the pumps.

NOTE: For more information about the pumps, seeRelated Publications on page 2 for the pump in-struction manuals.

CAUTIONThere must be a minimum of 10 feet (3 m) of fluidsupply hose on the outlet to prevent damage to theunit.

NOTE: The fluid supply hose must move freely withoutkinking when the pumps move up and down.

Check the fluid supply hose to ensure it is properlysized and pressure-rated for this system. Use onlyelectrically conductive hoses. The fluid supply hoseshould have spring guards on both ends. Connect thefluid supply hose to the fluid manifold outlet.

Fig. 5

Fluid Manifold

Fluid Outlet

Fluid Supply Hose

TI0139

18 332499

Operation

The operation procedures include:

� Prepare the operator

� Overview

� Junction box panel switches and indicators

� Pneumatic layout panel switches and indicators

� Initial system startup procedure

� Daily system startup

� System shutdown

� Operation modes for the pumps

� Pressure relief procedure

� Air motor icing

� Preventive maintenance schedule

� System operation procedures

Prepare the Operator

All persons who operate the equipment must betrained in the safe, efficient operation of all systemcomponents as well as the proper handling of all fluids.All operators must thoroughly read all instructionmanuals, tags, and labels before operating the equip-ment.

Overview

The Uni-Drum supply system uses two air drivenreciprocating pumps on the LH supply unit and two airdriven reciprocating pumps on the RH supply unit.Each supply unit pumps material from a 1000 liter(264 gallon) drum.

General Functional Description

The LH and RH supply units can operate at the sametime or as independent units. Generally, the Uni-Drumsystem is setup to operate as redundant units. Thismeans that the RH unit is held in reserve on standbyuntil the drum underneath the LH unit has been emp-tied, and vice versa.

Operating a redundant system allows the operator tomaintain a continuous supply of material withoutinterruption. The operator is afforded sufficient time toreplace an empty drum at one supply unit while thedrum at the other supply unit is being emptied.

System Startup

There are a series of steps that must be followed insequential order to startup the system.

System Operation

Depending upon the system setup, at any time duringoperation, the operator can:

� Stop the pumps and relieve ram pressure at the LHsupply unit.

� Stop the pumps and relieve ram pressure at the RHsupply unit.

� Shutdown the system.

At the supply unit, the follower plate must be raised toload the drum into the supply unit. The follower plate islowered by the operator directly into the drum. Thepumps are turned on, the follower plate is pressurized,and material is pumped from the drum through theoutlet ports on the pumps via a supply hose to one ormore targeted applications.

Supply Unit Operation

The Uni-Drum supply system can be setup to alternatebetween the LH and RH supply units. This dual supplysystem setup (controlled by others) virtually eliminatesmaterial replenishment downtime.

The Uni-Drum supply system allows the operator toload the material drum into the RH supply unit whilethe LH supply unit drum is being emptied. When thesupply unit changeover occurs, the operator unloadsthe empty drum at the LH supply unit while the RHsupply unit drum is being emptied. The cycle is re-peated as many times as needed.

System Shutdown

For system shutdown, the operator turns off the pumpsand depressurizes the system. Depending upon thetype of material, the operator may choose to raise thefollower plate from the drum or keep the follower platelowered in the drum to prevent the material from beingcontaminated. Some materials will harden or congealwhen exposed to air or used past their shelf life. Mate-rial should be kept covered when it is not being usedand uncovered when it is ready to use.

332499 19

Operation

Junction Box Panel Switches and Indicators

Use the table and Fig. 6 when operating the switches and reading the indicator on the junction box panel.

Button/Switch What it Does

PRIME PUMP pushbutton � Primes both displacement pumps with material, making thepumps ready to operate.

� Lights PUMP READY light.

PUMP RESET pushbutton � Restarts the pumps after the pumps were turned off.

� Lights PUMP ACTIVE light

PUMP ON pushbutton � Activates the pumps.

� Deactivates the pumps.

Bulk Supply Depressurizationpushbutton

� Opens the depressurization valve to lower the fluid supplypressure.

AUTO MODE ON/OFF switch � Places fluid dispensing system into Automatic or Manualmode.

Indicator IndicatorLight is

Meaning

SYSTEMPRESSURIZED light

ON System is pressurized.SYSTEMPRESSURIZED light OFF System is depressurized.

PUMP ACTIVE light ON Pumps are active; air is available to the pumps.PUMP ACTIVE light

OFF Pumps are inactive; air is unavailable to the pumps.

AIR PRESSURE ONlight

ON Air pressure is available to the pumps for use.AIR PRESSURE ONlight OFF Air pressure is not available to the pumps for use.

RAM READY light ON Follower plate is ready for use.RAM READY light

OFF Follower plate is not ready for use.

PUMP READY light ON Pumps are primed and ready to use.PUMP READY light

OFF Pumps are not ready to use.

20 332499

Operation

Junction Box Panel Switches and Indicators (continued)

Fig. 6

195320 and 119773 Panel Shown

TI0203

332499 21

Operation

Pneumatic Layout Panel Switches and Indicators

Use the table and Fig. 7 when operating the switches and reading the indicators on the pneumatic layout panel.

Ref Button/Switch/Gauge What it Does

A PUMP NO. 1 PRESSURE Air Gauge Indicates the air outlet pressure setting from pump no. 1.

B PUMP NO. 2 PRESSURE Air Gauge Indicates the air outlet pressure setting from pump no. 2.

C PUMP NO. 1 REGULATOR Control Knob Controls pump speed and outlet pressure by adjustingthe air pressure to pump no. 1.

D BLOW--OFF REGULATOR Control Knob Adjusts air pressure to blow--off valves.

E PUMP NO. 2 REGULATOR Control Knob Controls pump speed and outlet pressure by adjustingthe air pressure to pump no. 2.

F BLOW--OFF PUSH Button Turns on air pressure to assist raising the follower plate.

G RAM POSITIONSwitch

RAISE Allows the follower plate to raise.G RAM POSITIONSwitch HOLD Holds the follower plate in the current position.

LOWER Lowers the follower plate.

H Panel Air Inlet Valve Opens air supply line to the pneumatic layout panel.

J BLOW--OFF PRESSURE air gauge Indicates the air blow--off pressure setting.

22 332499

Operation

Fig. 7

AB

C

DE

F

G

H

24R995 Panel Shown

J

332499 23

Operation

Flushing the System Before Initial Use

Flushing the system before its initial use can preventmaterial contamination, which may cause the materialto fail or perform poorly.

CAUTIONFlush the system before performing the initialmaterial loading procedure. The system was facto-ry-tested using a light soluble oil, a soybean oil, orsome other oil as tagged. Flush the system to avoidcontaminating the material that has been designatedfor initial material loading.

To flush the system, perform the following procedure:

1. Select the material for the initial material load.

2. Verify whether the factory-test oil and the initialmaterial load are compatible:

a. If the two substances are compatible, omit theremaining steps in this procedure and performthe Initial System Startup Procedure onpage 24.

b. If the two substances are incompatible, per-form the remaining steps in this procedure toflush the system.

WARNINGUse fluids and solvents that are chemically compat-ible with the equipment wetted parts. See theTechnical Data sections of all the equipmentmanuals. Always read the material manufacturer’sliterature before using fluid or solvent in this pump.

3. Select a drum containing a compatible materialthat can dissolve, clean, and eliminate the factory-test oil from the system. If necessary, check withthe material supplier for a recommended flush ma-terial.

4. Before flushing, be sure the entire system andflushing drums are properly grounded. Refer toGround the System, on page 15.

5. Perform steps NO TAG through 13 of the InitialSystem Startup Procedure on page 24 to loadthe drum containing the solvent.

6. Run the flush material through the system forapproximately 1 to 2 minutes.

7. Remove the drum containing the flush material.

Adjusting the Lid Holder Before Initial Use

1. Adjust the lower lid holder channel as low as it willgo on the side of the ram post. The channel shouldbe 1 in. (25 mm) higher from the floor in the frontcompared to the back.

2. Loosen the upper lid holder channel. place the lidin the center of the lower channel. Lower the upperchannel until it contacts the lid. Tilt the rear of theupper channel down 1/2 to 1 in. (13 to 25 mm) andtighten all bolts.

3. The lid should roll in and out from the front and notroll out the rear.

24 332499

Operation

Initial System Startup Procedure

WARNINGPRESSURIZED FLUID HAZARDTo reduce the risk of serious bodily inju-ry, such as fluid injection or splashingfluid in the eyes or on the skin, alwayswear eye protection and protective cloth-ing when installing, operating, or servic-ing this dispensing system.

MOVING PARTS HAZARDMoving equipment parts can cause per-sonal injury, including severing of handsor fingers. Make sure all personnel areclear of moving parts before operatingthe equipment.

CAUTIONThe use of a non-compatible lubricant can causematerial contamination or inadequate perfor-mance. Use only a lubricant compatible with the ma-terial to be pumped. Check with the material supplierfor a recommended lubricant.

To help avoid damage to equipment, do not use adrum of material that has been dented or otherwisedamaged; damage to the follower plate wiper mayresult.

WARNINGPRESSURIZED EQUIPMENT HAZARDTo reduce risk of injury or equipmentdamage:

� Make sure all material hose connec-tions are secure.

� Do not pressurize the system untilyou have verified the system is readyand it is safe to do so.

Settings for Initial System Startup

The initial system startup procedure contains thechecklist of settings, adjustments, and proceduralsteps that must be completed before the system isready for daily operation.

NOTE: Complete the startup procedure for the LHsupply unit first. Then, repeat the startup procedure forthe RH supply unit.

Perform the initial system startup procedure as follows:

1. Check all material hoses and fittings to ensuretightness and to prevent any material leakage.

2. Check all system air lines. Make sure that all rout-ing of air lines will not interfere with any movingcomponents within the system.

3. Fill the packing nut/wet cup on both pumps 1/3 fullwith Graco throat seal liquid (p/n 206995). Refer toinstruction manual 308147 or 308148 for details.

4. Open the main air shut off valve, making air pres-sure available to the unit. See Fig 4.

5. At the pneumatic layout panel, open the panel airinlet valve at the LH supply unit, making air pres-sure available to the unit. See Fig. 7.

6. Adjust both pump main air regulators to 0 psi.

7. Set the RAM POSITION switch to RAISE andimmediately press and hold the BLOW--OFFbutton until the follower is completely out of thedrum. Use minimum amount of air pressure neces-sary to push the follower out of the drum.

8. Set the RAM POSITION switch to HOLD.

332499 25

Operation

Initial System Startup Procedure (continued)

Load Material

9. Roll a drum into the supply unit under the elevatedfollower plate.

NOTE: Whenever a drum change is required, removethe cover from the drum of new material by holding itlevel and lifting it straight up. Tipping the cover mayallow accumulated dirt to spill into the drum, whichmay result in damage to the material and equipment.

10. IMPORTANT: Lubricate the follower plate wiperwith a lubricant that is compatible with the materialto be pumped. Check with your material supplierfor compatibility.

NOTE: Before lowering the follower plate assemblyinto the drum, make sure that nothing is between thefollower plate and the drum, or between the ram tie barand the top of the ram posts.

11. Remove bleed sticks at the base of each pump.

12. Lower the follower plate as follows:

a. Set the Ram Position selector to LOWER.

b. Lower the follower plate until the material isevident in the bleedstick ports.

c. Set the Ram Position selector to HOLD.

d. Replace the bleedsticks.

e. Set the Ram Position selector to LOWER.

13. Close both pump #1 and pump #2 inlet valves (lo-cated on top of air motor).

14. To prime the pump, press the PRIME PUMPbutton.

15. Set the pump air pressure to 30 psi.

16. Check that the AIR PRESS. ON indicator is lit.

17. Use a catch device to bleed the pump. Slowlyopen Pump No. 1 bleeder valve. Back off theadjustment screw several turns; do not remove thescrew.

18. Slowly open the bleed-type air valve to the airmotor. Allow the pump to cycle slowly until all airescapes and material flows free of air from thebleeder valve.

19. Close the bleed-type air valve and pump bleedervalve.

20. Repeat these steps for Pump No. 2.

NOTE:

� If the pump does not prime properly, which mayoccur with heavier, high viscosity fluids, increasethe air pressure to the ram.

� If fluid is forced out around the top wiper, rampressure is too high; decrease the air pressure tothe ram.

� Ram pressure adjustments may be carried outusing the dual regulator inside the pneumaticpanel, where the upper regulator knob controls thedownward pressure of the ram, and the lowerregulator knob controls the upward pressure of theram.

21. After closing the bleed valve, return Pump No. 1and 2 regulator to its normal pump pressure set-ting.

22. Open the air motor ball valves.

23. Open the ball valve in the outlet manifold fromPump No. 1 and 2.

24. Remove the waste containers, clean up any spilledmaterial, and dispose of the waste material proper-ly.

25. Press the PUMP RESET button to restore thesystem to operation.

26. Check that the following indicators are lit:

� SYSTEM PRESSURIZED

� AIR PRESS. ON

� RAM READY

� PUMP READY

26 332499

Operation


Adjusting the Pump Regulators

NOTE: Both pumps must operate at the same cyclesper minute rate to prevent the occurrence of unevendrum evacuation.

NOTE: For the maximum air input pressure for eachpump see the appropriate manual as indicated on thechart on page NO TAG).

27. Run the system under normal conditions. Adjustthe PUMP NO. 1 REGULATOR to the desiredsetting as follows:

a. Turn the knob clockwise to increase air pres-sure or counterclockwise to decrease air pres-sure (see Fig. 7).

b. Check the air gauge to verify the air pressuresetting.

28. Repeat step 27 to adjust the air regulator for thePUMP NO. 2 REGULATOR.

Adjusting the Ram-Up and Ram-Down Regulators

29. At the pneumatic layout panel (see Fig. 6), openthe hinged cover.

30. Set the RAM POSITION switch to RAISE andpush the RAM UP pushbutton. Verify that thefollower plate (5) elevates at the desired speed. Ifnot, do the following:

a. Adjust the RAM--UP REGULATOR. Turn theknob clockwise to increase the amount of airpressure. Check the air gauge to verify that airpressure was increased. See Fig. 7.

b. Verify that regulator R3 is set to 5 to 10 psi(.035 to .07 MPa, 0.35 to 0.7 bar).

CAUTIONImproper setting of the Regulator R3 while theselector is in the HOLD position, can cause theplate to drop and operator injury.

c. Repeat step 30.a until the ram raises at thedesired speed.

31. Set the RAM POSITION switch to DOWN whileobserving the air gauge inside the panel.

32. Adjust the RAM--DOWN REGULATOR to 50 psi(0.34 MPa, 3.4 bar) as follows (see Fig. 7):

a. Turn the knob clockwise to increase air pres-sure or counterclockwise to decrease air pres-sure.

b. Check the air gauge to verify the air pressuresetting.

33. Close and secure the hinged cover.

Preventing Pump Cavitation

NOTE: Cavitation occurs when the pump cylinder didnot fully load with material on the upstroke, and acavity forms in the material after the pump changes tothe downstroke. Perform step 34 when there is pumpcavitation. If cavitation is not occurring, omit step 34and proceed to step 35.

34. To prevent cavitation from occurring, perform thefollowing steps:

a. Press the PRIME PUMP switch to prime thepumps and fill the material passages.

b. Verify that the PUMP READY light turns on.

c. Lower the air motor air pressure until cavitationstops.

d. Increase the ram down pressure.

332499 27

Operation

Fig. 8

RamDownRegulator

Ram UpRegulator

Regulator R3

9327A

Ram Pressure RegulatorSet to 80 psi (550 kPa,5.5 bar)

28 332499

Operation


Adjusting the Low Limit Switch

NOTE: When the low limit switch is activated, thepumps are normally turned off automatically by acustomer-supplied control, and a second set of pumpsbegin pumping.

35. Adjust the low limit switch as follows:

a. At the junction box panel (see Fig. 6), set theRAM POSITION switch to LOWER, allowingthe follower plate to activate the lower limitswitch.

b. Verify that the follower plate lowers to the limitset point: a level between 1--4 in. (25.4--101.6mm) from the bottom of the drum.

c. Adjust the low limit switch to activate at thelevel defined in step 35.b See Fig. 9.

Fig. 9

TI0200

1 to 4 in. (25.4 to 101.6 mm)

Limit Switches

Pin 1

Pin 3

Pin 5

Pin 2

Pin 4

332499 29

Operation

Daily System Startup

This procedure is normally provided by the integrator.

System Shutdown

This procedure is normally provided by the integrator.

Emergency Stop

When an emergency stop is required, do the following:

Stopping the System

1. To stop the system, close the main air shut offvalve (see Fig. 10) to the supply unit.

Restarting the System

2. To restart the system, do the following:

a. Open the main air valve to the supply unit (seeFig. 10).

b. At the junction box panel, press the PUMPRESET switch which restarts the pumps afterthe pumps were turned off (refer to Fig. 6).

Fig. 10

Main Air ShutOff Valve

Ti20917a

30 332499

Operation

Pressure Relief Procedures

These procedures describe how to relieve pressurefrom the system.

Fluid Pressure Relief Procedure

This procedure describes how to relieve pressure onthe follower plate and in the pumps. Use this proce-dure whenever you shutoff the pumps and beforechecking or adjusting any part of the system, to reducethe risk of serious injury.

WARNINGMOVING PARTS HAZARDFollow the Pressure Relief Procedurebelow before checking or repairing thefollower plate or any other part of the

system and when shutting down the system. Keephands and fingers away from the follower plate,pump inlets, and the drum when raising or loweringthe follower plate to reduce the risk of pinching oramputating hands or fingers.

During operation, also keep hands and fingersaway from limit switches to reduce the risk ofpinching or amputating hands or fingers.

WARNINGSKIN INJECTION HAZARDThe system pressure must be manuallyrelieved to prevent the system fromstarting or spraying accidentally. Material

under high pressure can be injected through theskin and cause serious injury. To reduce the risk ofan injury from injection, splashing fluid, movingparts, follow the Pressure Relief Procedurewhenever you:

� are instructed to relieve the pressure

� stop dispensing material

� check or service any of the system equipment

� install or clean the follower plate wipers.

At the pneumatic layout panel, do the following:

1. Close the main air inlet valve (B).

2. Open any downstream fluid valves, such as theball seat applicators on the ram assemblies, thatmay be part of the system.

3. Press the depressurization button on the electricalpanel.

Fig. 11Ti20918a

Ball SeatApplicator

NOTE: In order to fully relieve system pressure, in-cluding ram cylinders, the steps in the pneumaticpressure relief procedure must be performed.

332499 31

Operation

Pneumatic Pressure Relief Procedure

This procedure describes how to relieve pressure onthe pneumatic panel and cylinders. Use this procedurewhenever you perform ram assembly service on thepiston rod seal or the ram piston.

WARNINGMOVING PARTS HAZARDFollow the Pressure Relief Procedurebelow before checking or repairing thefollower plate or any other part of the

system and when shutting down the system. Keephands and fingers away from the follower plate,pump inlets, and the drum when raising or loweringthe follower plate to reduce the risk of pinching oramputating hands or fingers.

During operation, also keep hands and fingersaway from limit switches to reduce the risk ofpinching or amputating hands or fingers.

WARNINGSKIN INJECTION HAZARDThe system pressure must be manuallyrelieved to prevent the system fromstarting or spraying accidentally. Material

under high pressure can be injected through theskin and cause serious injury. To reduce the risk ofan injury from injection, splashing fluid, movingparts, follow the Pressure Relief Procedurewhenever you:

� are instructed to relieve the pressure

� stop dispensing material

� check or service any of the system equipment

� install or clean the follower plate wipers.

1. Follow Fluid Pressure Relief Procedure, page30.

2. Fully lower the ram by setting the RAM POSITIONswitch (A) to LOWER. Leave switch in the LOWERposition.

3. Open the door on the pneumatic control box (E).

4. Adjust the air pressure to 0 PSI for the RAMDOWN regulator. Refer to the gauge on the RamDown Regulator (Fig. 8) and R3 Regulator to verifythe ram has been depressurized.

5. Slowly open the drain cock located on the bottomof the air cylinders (D).

6. After the air pressure has been relieved, removethe RAM DOWN air line running from the top ofthe pneumatic control box to the ram cross bar(G).

7. Close the main air inlet on header (B).

8. Leave the drain cock open and the RAM DOWNairline removed until service is complete.

9. After service is complete, close drain cocks andmake all pneumatic connections. Perform the Ad-justing the Ram-Up and Ram-Down Regulatorsprocedure, page 26.

Fig. 12

B

G

E

A

D

Fig. 13

RamDownRegulator

RegulatorR3

32 332499

Operation

Preventive Maintenance Schedule

The operating conditions of your particular systemdetermine how often maintenance is required. Estab-lish a preventive maintenance schedule by recordingwhen and what kind of maintenance is needed, andthen determine a regular schedule for checking yoursystem.

332499 33

Operation

Changing Empty Drums

NOTE: After the automatic pump crossover has takenplace, immediately replace the empty drum with a new,full drum. If both Uni-Drums become empty at thesame time:

� Material will stop being delivered to the dispenser

� Air may enter the supply hose or pipe header

� Pump runaway could occur, resulting in damage tothe pumps.

Drum Changing Procedure

To remove an empty drum and load a new, full drum:

1. Check that the pump air is turned off. On thejunction box panel the PUMP ACTIVE and PUMPREADY indicators are not lit.

2. Check that the RAM UP air regulator is set to 60psi (maximum).

3. Close the two ball valves at the outlet manifold atthe rear of the Uni-Drums.

4. To raise the follower plate:

a. Set the RAM POSITION CONTROL to RAISEand immediately press and hold the BLOW--OFF AIR button until the follower plate iscompletely out of the drum. Use minimumamount of air pressure necessary to push thefollower out of the drum.

NOTE: If drum begins to lift from the frame, increasethe blow--off pressure.

5. With the ram raised and the RAM POSITIONcontrol set to RAISE, remove the empty drum,using a suitable lifting device.

WARNINGMOVING PARTS HAZARDUse a long-handled flat-bladed icescraper if it is necessary to scrape thebottom of the follower plate. Do not putyour hands between the plate and thedrum.

6. IMPORTANT: Being careful not to damage thefollower plate wipers, wipe or scrape any materialbuildup from the follower plate and wipers, andproperly dispose of the waste material.

NOTE: When you open a new drum, take care toremove the cover by holding it level. Tipping the covermay allow accumulated dirt to spill into the material,which can damage the equipment. Also check that thedrum is not damaged or dented.

7. Remove the cover from the new drum and removeany other packing from the drum, exposing thematerial. Make sure there are no foreign objectson the surface of the material.

8. Position the new drum, using a suitable liftingdevice, under the raised follower plate. Check thatthe RAM READY indicator is lit.

9. IMPORTANT: Lubricate the follower plate wiperswith a lubricant approved by the material manufac-turer.

34 332499

Operation

WARNINGPRESSURIZED FLUID HAZARDTo reduce the risk of serious bodily inju-ry, such as fluid injection or splashingfluid in the eyes or on the skin, alwayswear eye protection and protective cloth-ing when installing, operating, or servic-ing this dispensing system.

MOVING PARTS HAZARDMoving equipment parts can cause per-sonal injury, including severing of handsor fingers. Make sure all personnel areclear of moving parts before operatingthe equipment.

CAUTIONThe use of a non-compatible lubricant can causematerial contamination or inadequate perfor-mance. Use only a lubricant compatible with the ma-terial to be pumped. Check with the material supplierfor a recommended lubricant.

To help avoid damage to equipment, do not use adrum of material that has been dented or otherwisedamaged; damage to the follower plate wiper mayresult.

WARNINGPRESSURIZED EQUIPMENT HAZARDTo reduce risk of injury or equipmentdamage:

� Make sure all material hose connec-tions are secure.

� Do not pressurize the system untilyou have verified the system is readyand it is safe to do so.

10. Remove the bleed sticks from the follower plate.

NOTE: Before lowering the ram into the drum, makecertain that nothing is between the follower plate andthe drum, or between the ram tie bar and the top of theram posts.

11. Lower the follower plate as follows:

a. Set the Ram Position selector to LOWER.

b. Lower the follower plate until the material isevident in the bleedstick ports.

c. Set the Ram Position selector to HOLD.

d. Replace the bleedsticks.

e. Set the Ram Position selector to LOWER.

12. Close both pump #1 and pump #2 inlet valves (lo-cated on top of the air motor).

13. To prime the pump, press the PRIME PUMPbutton.

14. Set the pump air pressure to 30 psi.

15. Check that the AIR PRESS. ON indicator is lit.

16. Use a catch device to bleed the pump. Slowlyopen Pump No. 1 bleeder valve. Back off theadjustment screw several turns; do not remove thescrew.

17. Slowly open the bleed-type air valve to the airmotor. Allow the pump to cycle slowly until all airescapes and material flows free of air from thebleeder valve.

18. Close the bleed-type air valve and pump bleedervalve.

19. Repeat these steps for Pump No. 2.

NOTE:

� If the pump does not prime properly, which mayoccur with heavier, high viscosity fluids, increasethe air pressure to the ram.

� If fluid is forced out around the top wiper, rampressure is too high; decrease the air pressure tothe ram.

� Ram pressure adjustments may be carried outusing the dual regulator inside the pneumaticpanel, where the upper regulator knob controls thedownward pressure of the ram, and the lowerregulator knob controls the upward pressure of theram.

332499 35

Operation

20. After closing the bleed valve, return Pump No. 1and 2 regulator to its normal pump pressure set-ting.

21. Open the air motor ball valves.

22. Open the ball valve in the outlet manifold fromPump No. 1 and 2.

23. Remove the waste containers, clean up any spilledmaterial, and dispose of the waste material proper-ly.

24. Press the PUMP RESET button to restore thesystem to operation.

25. Check that the following indicators are lit:

� SYSTEM PRESSURIZED

� AIR PRESS. ON

� RAM READY

� PUMP READY

36 332499

Ram Assembly Troubleshooting

Problem Cause(s) Solution(s)

Ram won’t raise or lower Closed main air valve or clogged air line Open air valve, clear air lineRam won’t raise or lower

Not enough air pressure Increase ram pressure

Worn or damaged piston Replace piston. See procedure onpage 50.

Ram raises or lowers too fast Ram air pressure too high Decrease ram air pressure

Fluid squeezes past follower platewipers

Ram air pressure too high Decrease ram air pressureFluid squeezes past follower platewipers Worn or damaged wipers Replace wipers. See procedure on

page 53.

Pump won’t prime properly, orpumps air

Not enough ram air pressure Increase ram pressurePump won’t prime properly, orpumps air Worn or damaged ram piston Replace ram piston. See procedure

on page 50.

Bent drum has stopped follower plate Replace drum

Drum lifts off of frame when rais-ing ram

Blow--off pressure too low Increase blow--off pressure

332499 37

Pump TroubleshootingFor additional information about the displacement pump, refer to Related Publications on page 2 to find theapplicable instruction manual.


Rapid downstroke or upstroke(pump cavitation)

Air is trapped in pump. Bleed air from the pump using this pro-cedure:

1. Place a waste container under thepump bleed port.

2. Press the PRIME PUMP button toturn on air to the pump.

3. Allow material to flow from the bleedport until it is air-free.

4. Release the PRIME PUMP button toshut off air to the pump. Close thebleed port.

5. Turn air on to the pump and set thepump air regulator for normal opera-tion.

Downstroke: Lower check in pumpis worn.

Upstroke: Upper check in pump isworn.

Rebuild and replace pump, as neces-sary.

Material leaks around pump outlet Outlet fitting is loose. Tighten outlet fitting.

Material leaks around bleed port Bleed port fitting is loose. Tighten bleed port fitting.

Pump won’t move up or down Problem with air motor. See Air Motor Troubleshooting chart onpage 38.

Foreign object lodged in pump. Remove object and rebuild pumpassembly.

WARNINGTo reduce the risk of serious injurywhenever you are instructed to relievepressure, always follow the PressureRelief Procedure (page 30).

Before attempting to dislodge a foreignobject:

1. Relieve system pressure.

2. Remove the pump from the airmotor.

Wet-cup leaks Worn throat packings. Tighten wet-cup. Replace throat pack-ings.

38 332499

Air Motor TroubleshootingFor additional information about the air motor, refer to Related Publications on page 2 to find the applicableinstruction manual.


Air motor will not shift directions,stalled in DOWN position

Main air valve spool is dirty or damaged Clean/rebuild main air valve.

Air motor will not shift directions,stalled in UP position

Air motor stalled halfway betweenthe top and bottom

Air continually exhausting aroundair motor shaft.

Air motor shaft seal is damaged Replace air motor shaft seal.

Air continually exhausting aroundthe air valve/slide valve

Air valve/slide valve gasket is damaged Replace the valve gasket.

Air continually exhausting frommuffler while the motor is idle

Internal seal damage Rebuild air motor.

Oil leaking from exhaust port Too much lubricant mixed in with the airsupply

Reduce lubricant supply.

Frost build-up on muffler Air motor operating at high pressure, orhigh cycle rate

Reduce pressure, cycle rate, orduty cycle of the air motor.

332499 39

Junction Box Panel Troubleshooting


Power from PLC control panel isON, but no indicator lights are litat junction box panel.

The knife switch disconnect contacts(KS100 and KS102) are open.

Check the PLC power connectionsat customer’s site.ON, but no indicator lights are lit

at junction box panel. One or more fuses blown. Replace the blown fuse(s). CheckFU136 and FU143 located insidethe knife switch disconnect blocks.

Voltage limit to circuits in junction boxpanel was exceeded.

Check the surge suppressorsSUP136 and SUP144. Replace ifrequired. Reset power to unit.

Pneumatic Layout Panel Troubleshooting


Ram will not move up or down. Main air valve on box is not open.

Air supply to unit is not on.

Open valve.

Turn on air supply.

Ram will not move up. Direction valve is not in the UP position.

RAM UP button is not pushed.

BLOW--OFF button is not pushed.

Resistance in drum is too great.

Insufficient lubrication of the followerplate seal.

BLOW--OFF pressure too low

Set direction valve to the UP posi-tion.

Push RAM UP button.

Push BLOW--OFF button.

Turn air pressure up to 60 psi. Theram may take a few minutes towithdraw from the container.

After the plate has been removedfrom the container, clean the sealand thoroughly lubricate.

Increase BLOW--OFF pressure.

Pumps will not operate. Air regulator is set too low. Increase air pressure setting.

Vent valve will not open. FOLLOWER VENT switch is not inAUTO position.

Put FOLLOWER VENT switch inAUTO position.

Drum lifts off of frame when rais-ing ram.

BLOW--OFF pressure too low

BLOW--OFF button not pushed

Increase BLOW--OFF pressure

Push BLOW--OFF button

40 332499

Routine MaintenanceFlushing the System

Flush the pump:

� Before the first use

� When changing material or fluid part number orbrand

� Before fluid can dry or settle out in a dormant pump(check the shelf life or pot life of catalyzed fluids)

� Before storing the pump.

Flush with a fluid that is compatible with the fluid youare pumping and with the wetted parts in your system.Check with your fluid manufacturer or supplier forrecommended flushing fluids and flushing frequency.

WARNINGFIRE AND EXPLOSION HAZARDBefore flushing, read the section FIREAND EXPLOSION HAZARD on page6. Be sure the entire system and flush-ing pails are properly grounded. Refer toGrounding on page 15.

To flush the system, perform the following procedure:

1. Place a drum of compatible flush material underthe follower plate.

2. Run the pumps and circulate the flush materialthrough the system for approximately 1 to 2 min-utes or until the solution is clean.

3. Remove the drum containing the flush materialfrom under the follower plate.

4. Return the system to current readiness condition.

Cleaning the System

CAUTIONCleaning the system after using it can prevent mate-rial contamination, which may cause the material tofail or perform poorly. Do not load new material into acontaminated system.

Clean the system to avoid untimely equipment mal-functions and to ensure that system componentsoperate efficiently.

To clean the system, perform the following procedure:

WARNINGMOVING PARTS HAZARDUse a long-handled flat-bladed icescraper if it is necessary to scrape thebottom of the follower plate. Do not putyour hands between the plate and thedrum.

1. IMPORTANT: Being careful not to damage thefollower plate wipers, wipe or scrape any materialbuildup from the follower plate and wipers, andproperly dispose of the waste material.

2. Apply a generous amount of lubricant to the follow-er plate wipers.


Wiper Lubrication

It is extremely important that the follower plate wipersbe thoroughly lubricated between drum changes. Thefollower plate may stick without lubrication.

332499 41

Junction Box Panel ServiceThis part of the manual provides information about thefollowing junction box panel components:

� Indicator light and pushbutton switch replacement

� Light bulb replacement

� Fuse replacement

� Surge suppressor replacement

NOTE: Refer to Junction Box Parts on pageNO TAG while servicing the junction box panel.

Indicator Light and Pushbutton Switch

Removal



1. Shut off power to the junction box panel.

2. At the junction box panel, remove the cover fromthe junction box panel.

3. Disconnect the lead wires from the terminals onthe switch. For wiring information, refer to theElectrical Diagram on page 58. If necessary, labelthe wires to facilitate reconnection after replacingthe component.

4. Loosen two screws which clamp the fixture to thecover. Rotate and remove the outer ring on thedefective component counterclockwise to removethe light lens or switch. Separate the parts andremove them from the cover.

Indicator Light and Pushbutton Switch

Replacement

1. Reverse steps 2 through 4 in the previous para-graph.

2. For wiring information, refer to the ElectricalDiagram on page 58.

3. Reapply power to the junction box panel.

4. Verify that the replaced component operatescorrectly.


Light Bulb Removal

Remove the light bulb as follows:




2. Unscrew and remove the indicator light lens.

3. Gently press and rotate the bulb counterclockwise,1/4-in. of a turn, unlocking the bulb from its socket.Remove the bulb from the socket.

Light Bulb Replacement

Replace the light bulb as follows:

1. Insert the light bulb in the socket.

2. Gently press and rotate the bulb clockwise, 1/4-in.of a turn to lock the bulb in its socket.

3. Replace the lens.


5. Verify that the light bulb operates correctly.


42 332499

Junction Box Panel Service

Fig. 14

Terminals

SPARESPARESPARESPARESPARESPARESPARESPARESPARESPAREFU136FU143SUP136SUP144154115111481143114111361134112911271124112211191117111411121108110011001100110231003(31) TOTALType 0290.011.25ENTRELEC

KS100 10011002

KS102 10211022

(2) TOTALType1492--WKD3TP

Fuses Terminals

Wire Way

Enclosure

Ground Lug

TI0205b

Ground Surge Suppressors

332499 43

Junction Box Panel ServiceFuse Removal

Remove the fuse as follows:




2. At the junction box panel, remove the cover fromthe junction box panel.

3. Locate the failed fuse on the terminal strip. Refer-ence Fig. 14 for the fuse terminal identification.

4. Carefully remove the fuse from the fuse holder.

Fuse Replacement

Replace the fuse as follows:

NOTE: Check the new fuse to ensure that it matchesthe amp rating of the failed fuse.

1. Press both ends of the new fuse evenly into placein the fuse holder. See Fig. 14.

2. Reinstall the cover on the junction box panel.


4. Verify that the fuse operates correctly.


44 332499

Junction Box Panel Service

Surge Suppressor Removal

Remove the surge suppressor as follows:




2. At the junction box panel, remove the cover off thejunction box panel.

3. Locate the failed surge suppressor on the terminalstrip. Reference Fig. 14 for the surge suppressorterminal identification.

4. Remove the two screws and surge suppressorfrom the terminal strip.

Surge Suppressor Replacement

Replace the surge suppressor as follows:

1. Install the new surge suppressor into place on theterminal strip using the two screws. See Fig. 14.



4. Verify that the new surge suppressor operatescorrectly.


Fig. 15

T10196

Pressure Switch

Solenoid Valve

332499 45

PLC Interface Accessory Kit ServiceThis part of the manual provides information about thefollowing PLC interface accessory kit components:

� Valve assembly bank replacement

� Pressure switch assembly replacement

Valve Assembly Bank Replacement

Remove the valve assembly bank that is mountedbelow the junction box panel as follows:

NOTE: The valve assembly bank has two solenoids(SOL139 and SOL147) that are used as switches tocontrol pump operation. SOL139 depressurizes thepumps. If the output is high (open), pumps will depres-surize. SOL147 turns air on to the pumps.




Valve Assembly Removal

2. At the junction box panel, remove the cover off thejunction box panel.

3. Locate the valve assembly (203) that is attachedto the mounting plate (201) below the junction boxpanel (217). See Fig. 15.

4. Disconnect the two cables (216) from the terminalstrip inside the junction box panel (217) for thevalve assembly (203) bank. For wiring information,refer to the Electrical Diagram on page 58.

5. Remove four cap screws (205), the lock washers(206), and the valve assembly (203) from themounting plate (201).

Valve Assembly Replacement

6. Install the new valve assembly (203) on the mount-ing plate (201) using the four cap screws (205) andlock washers (206). See Fig. 15.

7. Reconnect the two cables (216) on the terminalstrip inside the junction box panel (217) for thevalve assembly (203) bank. For wiring information,refer to the Electrical Diagram on page 58.



10. Perform the Daily System Startup procedure onpage 29 at the applicable supply unit (LH or RH).

11. Verify that the valve assembly (203) bank operatescorrectly.


Pressure Switch Assembly Replacement

Remove the pressure switch assembly that is mountedbelow the junction box panel as follows:

NOTE: The pressure switch (PS108) turns air pres-sure on the system.




Switch Removal

2. Remove the cover from the junction box panel.

3. Locate the pressure switch assembly (202) that isattached to the mounting plate (201) below thejunction box panel (217). See Fig. 15.

4. Disconnect the 5-pin cord (211) from the pressureswitch assembly (202). For wiring information,refer to the Electrical Diagram on page 58.

5. Disconnect the end of the lead wire from thepressure switch assembly (202). Leave the otherend of the lead wire connected to the valve assem-bly bank (203).

6. Remove the two cap screws, the lock washers,and the pressure switch assembly (202) from themounting plate (201).

Switch Replacement

To replace the switch, follow the switch removal stepsin reverse order.

46 332499

PLC Interface Accessory Kit Service

Fig. 16

TI0208

Junction Box Panel

Mounting Plate

PressureSwitchAssembly

90° Elbow

Muffler

ValveAssembly

Elbow

Screw,Washer

TubeFitting

332499 47

Pneumatic Layout Panel ServiceThe pneumatic layout panel service procedures in-clude:

� Filter/element replacement

Filter/Element Replacement

Listed below are the filters used with the ram assemblyon the Uni-Drum supply system.

� The air filter between the air supply source andboth air motors. See Fig. .

� The air filter between the air supply source and thepneumatic layout panel. See Fig. 18.

To replace an air filter/element, do the following:

1. At the pneumatic layout panel, do the following:

a. Press the PUMP AIR OFF to shutoff the airsupply at both pumps.

b. Close the main air inlet valve.

c. Turn the shutoff valve under the panel to theoff position.

2. At the junction box panel, do the following:

a. Press the PUMP OFF switch, turning off air toboth pumps (see Fig. 6).

b. Verify that the PUMP ACTIVE and AIRPRESS ON lights turn off.

Fig. 17

MainAir Filter

Ti20917a

WARNINGTo reduce the risk of serious injury whenever youare instructed to relieve pressure, always follow thePressure Relief Procedure on page 30.

3. Relieve the pressure.

4. At the junction box panel, verify that the SYSTEMPRESSURIZED and RAM READY lights turn off.

Filter Removal

5. Turn the air filter counterclockwise to unscrew thefilter from its mounting.

Filter/Element Replacement

6. Replace the old air filter element with a new filterelement.

7. Clean the sight glass, if necessary. Reinstall thesight glass back on its threaded mounting. Tightenthe sight glass.

8. Perform the Daily System Startup procedure onpage 29.

9. Check for air leakage around the filter.


Fig. 18

PneumaticPanelAir Filter

Ti20919a

48 332499

Pneumatic Layout Panel Service

Filter/Element Replacement (continued)

Fig. 19

332499 49

Ram Assembly ServicePiston Rod Seal Service (Fig. 20)

WARNINGTo reduce the risk of serious injury whenever youare instructed to relieve pressure, always follow thePressure Relief Procedure on page 30.

1. Relieve the air pressure. Follow the PneumaticPressure Relief Procedure on page 31.

2. Remove the four nuts and lockwashers holding thetie bar to the rods. Remove the tie bar.

3. Remove the guide sleeve retaining ring by grippingthe ring tab with a pair of pliers and rotating thering out of its groove.

4. Remove the guide sleeve by sliding it off of therod. Four 1/4 in.--20 holes are provided to easeremoval of the guide sleeve.

WARNINGDo not use pressurized air to remove the guidesleeve or piston. Failure to follow this instructionmay result in personal injury.

5. Inspect the parts for wear or damage. Replace asnecessary.

6. Install new O-rings and seal guard. Lubricate thepackings with O-ring lubricant.

7. Slide the guide sleeve onto the rod and push it intothe cylinder. Replace the retaining ring by feedingit around the guide sleeve groove.

8. Reinstall the tie bar using the nuts and lockwash-ers. Torque to 40 ft--lb (54 N�m).

7056A

Fig. 20

Ring, Seal Guard

Sleeve

Ring

O-ring

O-ring

Refer to Repair Kit 918110.

50 332499

Ram Assembly ServiceRam Piston Service (Fig. 21)

WARNINGTo reduce the risk of serious injury, whenever youare instructed to relieve pressure, always follow thePressure Relief Procedure on page 30.

1. Relieve the air pressure. Follow the PneumaticPressure Relief Procedure on page 31.

2. Remove the tie bar as explained under PistonRod Seal Service.

3. Remove the guide sleeve and slide it off of thepiston rod.

WARNINGDo not use pressurized air to remove the guidesleeve or piston. Failure to follow this instructionmay result in personal injury.

4. Carefully pull the piston rod straight up out of thecylinder. If the rod is cocked to one side, the pistonor inside surfaces of the cylinder could be dam-aged.

5. Carefully lay the piston and rod down so the rodwill not be damaged or bent. Remove the lowerpiston retaining ring. Slide the piston off the pistonrod.

6. Install new O-ring seals on the piston rod and thepiston. Lubricate the piston and seals. Reinstall thepiston and retaining ring.

7. Carefully insert the piston into the cylinder andpush the rod straight down into the cylinder. Add3 ounces of lubricant to each cylinder after insert-ing the piston.

8. Slide the guide sleeve onto the piston rod. Rein-stall the retaining ring and tie bar, as explainedunder Piston Rod Seal Service.

7056A

Fig. 21

O-ring

Band

Piston

Ring

O-ring

Ring

332499 51

Ram Assembly ServiceThe ram assembly service procedures include:

� Low/Empty limit switch replacement

� Ball seat applicator repair procedure

� Servicing the pumps

Low/Empty Limit Switch Replacement

To replace the lower limit switch, do the following:

1. Perform the System Shutdown procedure pro-vided by the integrator at the applicable supply unit(LH or RH).




NOTE: When raising and lowering the follower plate,be sure that the unit is unobstructed overhead to avoidinterference with other objects.

NOTE: The first limit switch closes when the followerplate reaches the preset low limit level in the drum.The second limit switch closes when the follower platereaches the preset empty level in the drum. Both limitswitches provide inputs to the PLC interface.

Switch Removal

3. Between the two limit switches (305), locate thefaulty switch. See Fig. 22.

4. Disconnect the wiring (301) for the limit switch atits power source. For reference, use the wiringdiagram shown in Fig. 22.

5. Mark the surface on the ram limit bracket using afelt-tipped pen to ensure that the new lower limitswitch is installed in the same spot.

6. Measure the distance from the mounting bracket(306) to the outer diameter of the limit switch rollerto ensure that the new roller is installed in thesame position.

7. Remove three cap screws (302), the lock washers(303), the plain washers (304), and the limit switch(305) from the limit bracket (306). See Fig. 22.

Fig. 22

301

302, 303, 304

305

306

307, 308309, 310

311

TI0200

Pin 1

Pin 3

Pin 2

Pin 5

Pin 4

52 332499

Ram Assembly ServiceLow/Empty Limit Switch Replacement

(continued)

Switch Replacement

8. Install the new limit switch (305) on the limit brack-et (306) using the three cap screws (302), lockwashers (303), and plain washers (304). See Fig.22.

9. Reconnect the wiring (301) for the limit switch atits power source. For reference, use the wiringdiagram shown in Fig. 22.

10. Make sure that the limit switch roller is positionedin the same location per the measurement in step6. See Fig. 22.



13. Perform the Daily System Startup procedureprovided by the integrator at the applicable supplyunit (LH or RH).

14. Verify that the limit switch operates correctly.


Depressurization Valve (Ball Seat

Applicator) Repair Procedure

Refer to instruction manual 3A1792 for the ball seatapplicator (V1M350) service procedures and partsinformation.

Servicing the Pumps

When the pumps and air motors require service, referto the applicable instruction manual, listed below, fordetailed information.

Form Description P/N

308152 Stainless Steel Dura-Flo�Pump 2400 with Premier�Air Motor

249991

308213 Premier� Air Motor 222800

332499 53

Ram Assembly ServiceReplacing Wipers (Fig. 23)

1. Perform the System Shutdown procedure pro-vided by the integrator.

2. To replace worn or damaged wipers (412), raisethe follower plate up out of the drum. Remove thedrum from the base. Wipe the fluid off the followerplate. Refer to the Drum Changing procedure onpage 33.

3. Separate the wiper joint (A) and bend back thestrapping (413) covering the clamp setscrew (415).See Detail A of Fig. 23. Loosen the setscrew, pullthe end of the strapping through the clamp (414)and remove the wiper.

4. Slide the strapping (413) through the new wiper(412). Slide the clamp (414) onto the new strap-ping and bend the strapping back approximately 3in. (76 mm). Insert the strapping through the clampa second time. See Detail B of Fig. 23.

5. Install the wipers on the follower plate. Position thewipers so that their joints (A) are 180� apart.

NOTE: You will need the special banding tool (C)shown in Detail C of Fig. 23 to tighten the strapping.Order Part No. 168092 Banding Tool.

6. Grip the strapping (413) with the tool (C) asshown. With your thumb on the gripper lever (E),turn the tool handle (F) clockwise to apply tension.

NOTE: Be careful not to pull the cutting handle (D)until you are ready to cut the strapping in step 8.

7. Continue turning the tool handle until you see thestrapping stop moving through the clamp (414).Stop turning the handle.

8. Tighten the setscrew (B) with a wrench (G). Pullthe cutting handle (D) to cut. Remove the tool (C).Bend the strapping back over the clamp (414).

9. Pound the wiper all the way around with a rubbermallet until the joints (A) are butted tightly together.

10. Return the system to current readiness condition.Refer to the Drum Changing procedure on page33.

05712

Fig. 23

1

3

2

0294602949

Detail A Detail B

Detail C

Slide the clamp onto thestrapping and bend the strapping backapproximately 3 in. (76 mm).

Turn clockwise to apply tension.

Cut the strapping and bendit back over the clamp.

E

F

413

D

C

G

415

414

412 414 413A

413

415

414412

1

2

3H

54 332499

Pump Assembly ServicePump Removal

(Refer to System Parts Diagram; page NO TAG.)

WARNINGTo reduce the risk of serious injury, whenever youare instructed to relieve pressure, always follow thePressure Relief Procedure on page 30.

1. Relieve the air pressure from the air motors andram assembly to be serviced.

2. Move the RAM POSITION switch to HOLD.

3. Close the pump outlet ball valves and relieve thefluid pressure from the pumps at the pump bleedvalve on the ram assembly to be serviced.

4. Using an overhead lifting device, attach and se-cure a chain capable of lifting the weight of thepump assembly to the eye at the top of the airmotor.

NOTE: For effective pump removal, the lifting pointmust be directly above the pump and capable ofmoving sideways. The lifting action should be the“chain fall” type that allows a slow upward and down-ward movement.

NOTE: Check the Technical Data page in the separatepump manual to find the weight of the pump beingserviced. For example, Graco Premier 45:1 SST Pump(222939) weighs 240 lb (109 kg) per Form 308148.

5. Detach the air hose from the air motor.

6. Detach the fluid supply hose at the pump outlet.

NOTE: When loosening the pump and the air motorfasteners in steps and below, ensure the chain slackis taken up to prevent the pump assembly from falling.

7. On the follower plate adapter, loosen and rotate orremove four lugs and hex bolts holding the flangeof the pump lower .

8. On the underside of the air motor, remove thebolts securing the air motor to the motor supportbrackets. It may be necessary to move or removesome brackets for effective pump removal.

9. Detach any other connections to the pump as-sembly to ensure the pump is free of attachmentsbefore removal. Possible connections include:

� Air motor exhaust kit

� Pump proximity switch kit

� Pump grounding wire

NOTE: When lifting the pump in step below, ensurethe lifting chain does not damage the air controlsmounted at the top of the ram cross-members.

10. Using a “chain fall” style lifting device, slowly pullthe pump upward a few inches until the base of thepump clears the pump mounting adapter and theair motor clears the support brackets.

11. Pull the pump assembly out of the ram assemblyand guide the pump assembly downward to thefloor, placing the base of the pump on a woodsurface and taking care not to damage the sealarea of the pump inlet housing.

12. Remove the gasket and o-ring (items 32 and 33)from the pump adapter. They should be discardedand replaced when the pump is reinstalled.

13. Clean excess and hardened material from thepump adapter on the follower plate.

14. Ensure that material is not rising through the pumpadapter in the follower plate. If material is flowingupward, move the RAM POSITION switch toRAISE until the flow stops, then move the switchback to HOLD.

15. Move the pump assembly to a suitable work areaand repair the pump using the appropriate GracoInstruction Manual.

Pump Installation(Refer to System Parts Diagram; page NO TAG.)

1. When the pump is serviced and tested and readyto be replaced in the Uni-Drum Ram, perform thesteps of the Pump Removal procedure in reverseorder.

2. It is recommended that the pump be tagged withthe type and date of repair and the name of thetechnician who performed the repair.

3. Before returning the reassembled pump to produc-tion use, it must be primed with material and airremoved from the material. Follow the PumpInstruction Form and the pump material bleedingprocedure from the Drum Changing Procedure onpage 33.

332499 55

System Parts

Part No. 241839, Low/Empty Limit Kit (For Uni-Drum Use)

Ref Part

No. No. Description Qty

Ref Part


301 C07431 CONNECTOR, sealed 2302 C20003 CAPSCREW, socket head 4303 C19204 WASHER, lock #10 bolt 4304 C19197 WASHER, plain 4305 C07560 SWITCH, limit 2306 195454 BRACKET, limit, low-level, Uni-Drum 1

307 C19810 CAPSCREW, socket head 2308 100016 WASHER, spring lock; 1/4 in. 2309 112166 SCREW, cap, hex head 2310 100018 LOCKWASHER, spring; 1/2 in. 2311 C52751 PLATE, limit switch 1312 104227 NUT, lock 2

301

302, 303, 304

305

306

307, 308

309, 310

311

TI0200b

312

56 332499

Parts

Part No. 243488 Proximity Switch Accessory Kit

Ref Part


Ref Part


601 617337 COLLAR, clamp 2602 100016 WASHER, lock; 1/4 in. 2603 C19800 SCREW, socket hd; 1/4--20 x 1/2 in. 2604 617338 BRACKET, proximity switch mounting 1

605 517455 SWITCH, proximity; 18 mm 1606 C56572 CABLE, proximity; 2 m long 1611 196510 HOUSING, coupling nut 1612 119417 SCREW, cup point set; 1/4--20 1

TI1479A

TI1479A

601

602, 603

604

605

606

612

611

627 517290 HOSE 2631 C19438 ELBOW; 1 in. npt 1632 16U204 TUBE, unidrum, air inlet 1633 114112 CONNECTOR, female 6634 113093 CONNECTOR, pipe 4635 C20378 FITTING, tube, Y-branch; 2

1/4 npt(m) x 1/4 OD tube636 100469 SCREW, cap, hex hd 2637 C19213 WASHER, lock 2

638 617202 MANIFOLD, air 1639 113532 ELBOW; 1/4 npt 4640 15D936 FITTING, male connector 2641 158585 NIPPLE 1642 112859 FILTER, air; 1 in. npt 1643 113332 VALVE, ball 2644 158555 NIPPLE, reducing 2645 16U212 CLAMP, 1.25 in. OD, pipe 1

332499 57

Recommended Spare Parts

Spare Parts for 34:1 Uni-Drum Supply Units

The customer should maintain an inventory of the spare parts (per unit) listed below.

SST

Units

Description Qty.

222875 PUMP KIT(34:1 models only)

2

222958 PREMIER AIR MOTOR KIT 2

222959 AIR VALVE KIT 2

222982 DETENT KIT 2

222981 TRIP ROD KIT 2

515147 AIR REGULATOR 1

V1M350 RECIRCULATING VALVE KIT,see manual 3A1792

1

119777 VALVE, solenoid, 24 VDC 1

119776 SWITCH, pressure, 24 VDC 1

C07560 SWITCH, limit 1

SST

Units

Description Qty.

102774 LUBRICATOR KIT 1

502526 PILOT VALVE 1

501014 ACTUATOR 1

918110 AIR CYLINDER KIT, Ram 1

918241 WIPER KIT 1

109495 Pump to Follower, o--ring 2

58 332499

Junction

Box

Panel

Ele

ctr

icalD

iagra

m

TI0

20

7

1511

1541

RE

MO

TE

MO

DE

55154

��

��

��

��

��

332499 59

PneumaticLayoutPanel

PneumaticDiagram

LOCK--OUT

VALVE

DV9

PILOTED

REGULATOR

PUMP2

PILOTED

REGULATOR

PUMP1

DEPRESSURIZATION

VALVE

PRESSURE

SWITCH

PS108

SOL

139

SOL

147

PUMP1REMOTEREGULATORSIGNAL

PUMP2REMOTEREGULATORSIGNAL

RAMUP

UNIDRUMRAM

CYLINDEREXHAUST

BOXVENT

LOCATEDON

J--BOXPANEL

RAMDOWN

PUMP#1

REGULATOR

REGULATOR

PUMP#2

PUMP#1

PUMP#2

FILTER

MAINAIR

(

(

E

J

D

C

K

FG

MAINAIRSUPPLYFOR

SOLENOID

VALVES&

SOLENOID

PR.SWI

TCH

UNIDRUMASSEMBLY

DV--DIRECTIONALVALVE

IV--IMPULSEVALVE

SV--SHUTTLEVALVE

R--REGULATOR

I--INDICATOR

GA--GAUGE

LEGEND

A

A

B C

B

MAINAIR’IN’

(15)

(23)(22)

(BOTTOM)

(TOP)

(1)

(3)

(1)

(20)

LOWER

(1)

DV6

(1)

(17)

RAISE

(1)

R2

(14)

GA2

DV3

(11)

GA1

R1

24

DV2

3 A

1 5

R3

(3)

(32)

(23)

(20)

(19)

(19)

DV8

(22)

(19)

(12)

(12)

(15)

312

DV7

RAM

BLOW--OFF

VENTREGUL

VE

NT

RE

GU

LATOR

X AX32

54 1

(20)

(21)

(22)

(20)

A B

APIL

OT

BPILOT

IN EX(19)

1

A A

P

(25)

R4

GA4

(32)

R5

GA5

(32)

(32)

PIL

OT

ED

RE

GU

LA

TO

R

BL

OW

--O

FF

C

D

LO

CAT

ED

ON

UN

IDR

UM

RA

MP

LAT

E

BL

OW

--O

FF

RE

GU

LA

TO

R

60 332499

332499 61

Technical Data

Unit Description Specification

Uni-Drum SystemU81832, U81833

Overall dimensions: Width: 69 in. (1753 mm)Depth: 51 in. (1295 mm)Height (lowered): 89 in. (2261 mm)Height (raised): 141 in. (3581 mm)

Supply Units(LH and RH)

Compressed air requirement 80 psi maximum(5.5 bar, 0.55 MPa)450 cfm

Main air inlet size 1 in. npt(f)

Overall Weight Approximately 3950 lb (1792 kg)

Pumps (1/unit)249157, 249158

Ratio 34:1 fluid to air power ratio

Maximum fluid working pressure 3400 psi (231 bar, 23.1 MPa)

Maximum air input pressure 100 psi (7 bar, 0.7 MPa)

Pump cycles 6.5 per 1 gal. (3.8 liters)

Recommended pump speed forcontinuous operation

60 cycles per min

Maximum flow rate 9.2 gpm (34.6 liters/min) at 60 cycles/min

Air motor piston effective area 124 in.2 (800 cm2)

Stroke length 4.75 in. (120 mm)

Displacement pump effectivearea

3.72 in.2 (24 cm2)

Pump operating temperature 150° F (65.5° C) maximum temperature

Air inlet size 3/4 in. npsm(f)

Fluid inlet size 2 in. npt(f)

Fluid outlet size 1--1/2 in. npt(m)

Wetted components 303, 304, 316, and 17--4 PH Grades of stainless steel;silicone nitride; acetal; Ultra-high molecular weightpolyethylene, PTFE, and leather

Weight Approx. 240 lbs. (109 kg) per pump

62 332499

Graco Standard WarrantyGraco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from de-fects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, orlimited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of theequipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintainedin 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 byfaulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-stitution of non--Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility ofGraco 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 forverification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. Theequipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does notdisclose any defectin material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, andtransportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUTNOT 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 otherremedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or anyother incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of thedate of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLDBUT 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 mak-ing 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 equipmenthereunder, 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 CUSTOMERSThe parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedingsentered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciairesexécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco InformationFor the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor, or call to identify the nearest distributor:Toll Free 1--800--746--1334 or Fax: 330--966--3006

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.

For patent information, see www.graco.com/patents.

Original Instructions. This manual contains English. MM 332499

Graco Headquarters: MinneapolisInternational Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES �� P.O. BOX 1441 �� MINNEAPOLIS MN 55440--1441 �� USACopyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.comRevised December 2014

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