Graco SaniForce STU Instruction Manual

Operation
SaniForce® SaniForce®
SaniForce®Tote Tote ToteUnloader Unloader Unloader(STU) (STU) (STU)3A5416L
EN
For For
Foruse use usewith with withfood food foodgrade grade gradebulk bulk bulksupply supply supplyof of ofmedium medium mediumto to tohigh high highviscosity viscosity viscosityproduct. product. product.For For Forprofessional professional professional
use use
useonly. only. only.Only Only Onlyselect select selectmodels models modelsare are areapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardous
locations. locations.
locations.See See SeeConguration Conguration CongurationMatrix Matrix Matrixon on onpage page page6 6 6for for formore more moreinformation. information. information.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandall
relatedmanuals.Save Save
Saveall all allinstructions. instructions. instructions.
ForMaximumWorkingAirandFluid
Pressures,seeModelsonpage8.
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Contents Contents
Contents
RelatedManuals............................................3
Warnings.......................................................4
CongurationMatrix......................................7
Models...........................................................8
Overview........................................................9
SystemComponents................................9
BeforeInstalling.............................................11
UncratetheEquipment............................12
SelectaLocation.....................................13
MovetheFrametotheSelected
Location......................................13
Installation....................................................14
GeneralInformation................................14
GroundtheSystem..................................14
ACPower.................................................15
FluidOutletLines....................................15
SafetyLatch...................................................16
InstallLockoutExtension.........................16
SafetyLatchLockout................................16
EngagingtheSafetyLatch........................16
DisengagingtheSafetyLatch...................16
ControlsandConnections..............................17
ControlPanel(Pneumatic)........................17
ControlPanel(Electro-Pneumatic)...........22
Operation......................................................24
PressureReliefProcedure........................25
CleanthePumpBeforeFirstUse..............25
AdjustToteGuides..................................26
LoadingtheTote.....................................26
StartandAdjustthePump.......................28
ChangetheTote......................................29
EmergencyStop.......................................30
PumpShutdown......................................30
SystemShutdown....................................30
FlushingandStorage...............................30
Maintenance..................................................31
Lubrication..............................................31
CleaningtheRamPlate............................31
CleaningthePumpLower........................31
Electro-pneumaticControlPanelDisplay
Screens.............................................32
StartupScreen.........................................34
AutomaticScreen....................................35
ManualScreen.........................................38
RecipeScreens........................................40
EventLog................................................48
JobLog....................................................52
SystemCongurationScreen...................54
FeedbackControlScreen.........................56
Network..................................................59
Ethernet/IP..............................................60
About......................................................66
I/OStatusScreen.....................................67
ImportandExportwithUSB...........................68
SettingsParameters.................................68
Dimensions...................................................72
WashBin.................................................72
Schematic(pneumaticcontrol).......................74
Schematic(electo-pneumaticcontrol)............75
TechnicalData...............................................80
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RelatedManuals
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A5417SaniForceSanitaryToteUnloader(STU),Repair
3A5798SaniForce5:1SanitaryPumps,InstructionsandParts
3A5799SaniForce12:1SanitaryPumps,InstructionsandParts
3A5999SaniForceHighSanitationDiaphragmPumps,InstructionsandParts
3A6781SaniForce1590HighSanitationDiaphragmPump,RepairandParts
3A6779SaniForceHighSanitationDiaphragmPumps,Model3250,Operation
3A6783SaniForceHighSanitationDiaphragmPumps,Model3250,RepairandParts
3A1211SaniForceAirMotors,InstructionsandParts
3A6101EnclosedManualControls,Repair/Parts
3A6102Electro-pneumaticControls,Instructions-Parts
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Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthis
equipment.Theexclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbols
refertoprocedure-specicrisks.Whenthesesymbolsappearinthebodyofthismanualoron
warninglabels,referbacktotheseWarnings.Product-specichazardsymbolsandwarningsnot
coveredinthissectionmayappearthroughoutthebodyofthismanualwhereapplicable.
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthe
systemcancauseelectricshock.
•Turnoffandremovepowerbeforedisconnectinganycablesandbeforeservicing
orinstallingequipment.Forcart-mountedmodels,unplugthepowercord.For
allotherunits,disconnectpoweratthemainswitch.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaqualiedelectricianandcomplywithall
localcodesandregulations.
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteor
explode.Paintorsolventowingthroughtheequipmentcancausestaticsparking.
Tohelppreventreandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectric
lamps,andplasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroff
whenammablefumesarepresent.
•Useonlygroundedhoses.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donot
useequipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworkingreextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischarge
andigniteammablevapors.Tohelppreventreandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
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Warnings
WARNING
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressureuidfromdispensingdevice,hoseleaks,orrupturedcomponents
willpierceskin.Thismaylooklikejustacut,butitisaseriousinjurythatcan
resultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgicaltreatment. treatment. treatment.
•Donotpointdispensingdeviceatanyoneoratanypartofthebody.
•Donotputyourhandovertheuidoutlet.
•Donotstopordeectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingand
beforecleaning,checking,orservicingequipment.
•Tightenalluidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinchoramputatengersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,
orservicingequipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnect
allpowersources.
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Warnings
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorundertheinuenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthe
lowestratedsystemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Useuidsandsolventsthatarecompatiblewithequipmentwettedparts.See
Technical Technical
TechnicalData Data Datainallequipmentmanuals.Readuidandsolventmanufacturer’s
warnings.Forcompleteinformationaboutyourmaterial,requestSafetyData
Sheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipment
isnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediately
withgenuinemanufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodicationsmayvoidagency
approvalsandcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhich
youareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorfor
information.
•Routehosesandcablesawayfromtrafcareas,sharpedges,movingparts,
andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxicuidsorfumescancauseseriousinjuryordeathifsplashedintheeyesor
onskin,inhaled,orswallowed.
•ReadSafetyDataSheets(SDSs)toknowthespecichazardsoftheuidsyou
areusing.
•Storehazardousuidinapprovedcontainers,anddisposeofitaccordingto
applicableguidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelpprevent
seriousinjury,includingeyeinjury,hearingloss,inhalationoftoxicfumes,and
burns.Protectiveequipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbytheuidand
solventmanufacturer.
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CongurationMatrix
Conguration Conguration
CongurationMatrix Matrix Matrix
Checktheidenticationplate(ID)fortheCongurationNumberofyoursystem.Usethefollowing
matrixtodenethecomponentsofyoursystem.
Sample Sample
SampleConguration Conguration CongurationNumber: Number: Number:STU STU
STUA01AAA1AA1C21 A01AAA1AA1C21 A01AAA1AA1C21
STU STU
STUA A
A01 01
01A A
AA A AA A A1 1 1AA AA AA0 0
0C21 C21 C21
Sanitary
Tote
Unloader
FramePumpPlateSize
(Bin
Type)
Seal
Type
Seal
Mate-
rial
ControlsAccessoriesWashKitCertica-
tion
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplier.
Sanitary Sanitary
Sanitary
Tote Tote
Tote
Unloader Unloader
Unloader
Frame Frame
FramePump Pump PumpPlate Plate
PlateSize Size Size
(Bin (Bin
(BinType) Type) Type)
Seal Seal
SealType Type Type
STU STU
STUA A
AStainless
Steel,Footed01 01
015:1DoubleBall
2pumpsA A
A44.375x40.375
(plywood)A A
AInatable
B B
BStainless
Steel,
Extended
Legs
02 02
025:1PrimingPiston
2pumps
B B
B43.9x39.9
(Buckhorn315)
(Schoeller315)
0 0
0None
03 03
0312:1PrimingPiston,2
pumpsC C
C55.5x42
(Goodpack)
04 04
045:1DoubleBall,4pumpsD D
D43.375x35.625
(TNT)
05 05
055:1PrimingPiston,4
pumpsE E
E43.5x40.375
(Arena)
06 06
0612:1PrimingPiston,4
pumpsF F
F41.32x38.9
(Ceva/Pallecon)
07 07
07
3250HSBallCheck,
P.SSPTPO,AODD,2
pumps
J J
J43.9x39.9
(Citadel)
12 12
12
3250HSBallCheck,
P.SSFKEO,AODD,2
pumps
0 0
0None
13 13
13
3250HSBallCheck,
P.SSPTPS,AODD,2
pumps
14 14
14
3250HSBallCheck,
P.SSSPSP,AODD,2
pumps
Seal Seal
SealMaterial Material MaterialControls Controls ControlsAccessories Accessories
AccessoriesWash Wash
WashKit Kit KitCertication Certication
Certication
A A
APolychloro-
prene
(White)
1 1
1Enclosed
PneumaticAA AA
AABagClamp
Kit0 0
0NoneC21 C21 C21EN10204type2.1
B B
BEPDM(Black)2 2
2*Electro-
pneumaticAB AB
ABAcepticLiner
ClampKit1 1
1PolyTankKitC31 C31
C31EN10204type3.1
0 0
0None
*NotATEX.Notintendedforuseinexplosiveorhazardousenvironments.
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Models
Approvals Approvals
Approvals
Allmodelsarerated:
andareFDA-compliant.
ATEXmodelswithpiston
pumpsarerated:II2GD
ExhIIAT4GbX
ExhIIIBT100°CDbX
ATEXmodelswithdiaphragm
pumpsarerated:II2GD
ExhIIA82°C...160°CGbX
ExhIIIBT135°CDb
Electro-pneumaticcontrol
panelcomponentapproval:
ConformstoULSTD508A
CertiedtoCSASTDC22.2No.14
Models Models
Models
Pump Pump
Pump
Option Option
OptionMax Max
MaxPump Pump PumpAir Air AirInlet Inlet Inlet
Pressure Pressure
PressurePSI PSI PSI(MPa, (MPa, (MPa,
bar) bar)
bar)
Max Max
MaxWorking Working WorkingFluid Fluid Fluid
Pressure Pressure
PressurePSI PSI PSI(MPa, (MPa, (MPa,bar) bar) bar)
Max Max
MaxSystem System SystemAir Air Air
Consumption Consumption
Consumptionscfm scfm scfm
(m (m
(m3 3
3/min) /min)
/min)
Max Max
MaxControl Control ControlAir Air AirInlet Inlet Inlet
Pressure Pressure
PressurePSI PSI PSI(MPa, (MPa, (MPa,
bar) bar)
bar)
01100(0.69,6.9)
02
80(0.55,5.5)410(2.83,28.3)140(3.9)
03100(0.69,6.9)1450(10.0,100)240(6.8)
04
05
80(0.55,5.5)410(2.83,28.3)140(3.9)
06100(0.69,6.9)1450(10.0,100)240(6.8)
07100(0.69,6.9)100(0.69,6.9)225(6.3)
12
13
14
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Overview
Overview Overview
Overview
System System
SystemComponents Components Components
Fig.1Typicalcomponents
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Overview
1 1
1- - -A A AStainless Stainless
StainlessSteel Steel SteelFrame: Frame: Frame:supportsallofthesystemcomponents.
1 1
1- - -B B BSanitary Sanitary
SanitaryPumps: Pumps: Pumps:pumpmaterialfromthetotetothetargetapplication.
1 1
1- - -C C CAir Air
AirCylinders: Cylinders: Cylinders:raisesandlowersthepumpsandtheramplateinandoutofthe
materialcontainer.
1 1
1- - -D D DRam Ram
RamPlate: Plate: Plate:appliesanevenamountofpressuretothematerialinthetote.When
theramplatesealisinated,itcreatesaseal.Theramplatepressesdownonthe
materialinthetotetoassistthepumpsindeliveringthematerial.
1 1
1- - -E E EControl Control
ControlPanel: Panel: Panel:containspneumaticcontrolstoregulatetheairpressuretopumpair
motors,ram,andramplatesealinorderto:
•controlpumpairmotorpressure
•controlpumpspeedcontrol
•controlramupanddownpressureandspeed
•controlsealpressure
1 1
1- - -F F FPump Pump
PumpOutput Output OutputLines: Lines: Lines:deliversproductoutputfrompump.
1 1
1- - -G G GSupport Support
SupportPlate: Plate: Plate:providessupportforpumpoutlettubes.
1 1
1- - -H H HRear Rear
RearGate: Gate: Gate:providestotepositioningandaccess.
1 1
1- - -J J JPilot Pilot
PilotCheck Check CheckValve: Valve: Valve:preventsunexpectedcylindermovement.
1 1
1- - -K K KTote Tote
ToteGuides: Guides: Guides:providesalignmentfortote.
1 1
1- - -M M MSeal Seal
SealRetainer Retainer RetainerPlate: Plate: Plate:keepsinatablesealinplace.
1 1
1- - -N N NInatable Inatable
InatableSeal: Seal: Seal:inatestocreateasealbetweentheramplateandinsidesurfaceof
tote.
1 1
1- - -P P PCorner Corner
CornerSeal: Seal: Seal:sealscornersbetweenramplateandinsidecorneroftote.
1 1
1- - -R R RCrossbar: Crossbar:
Crossbar:mainstructuralsupportforcylinder/ramplateassemblies.
1 1
1- - -S S SSafety Safety
SafetyLatch: Latch: Latch:Engagetopreventaccidentalloweringoframplate.
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BeforeInstalling
Before Before
BeforeInstalling Installing Installing
PalletizedSTU
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BeforeInstalling
Uncrate Uncrate
Uncratethe the theEquipment Equipment Equipment
NOTICE NOTICE
NOTICE
MovingtheSaniForceSTUoffthepallet
withoutfollowingthisuncratingprocedure
candamageequipment.
UncratetheSTUasfollows:
1.Inspectthecrateforshippingdamage.
Contactthecarrierifdamaged.
2.Removeplywoodtopandsidesofcrate.
3.Checkthecontentsforlooseordamaged
parts.
4.Comparethepackingslipagainstitems
insidethecrate.ImmediatelycallyourGraco
distributoraboutanyshortagesordamage.
5.Removeallbandstraps.
6.Removetheclevispinsholdingthereargate
andremovethegate.
7.Removetheboltsholdingtheframeparts
andmovetheframepartstotheinstallation
location.
NOTE: NOTE:
NOTE:Usesanitaryanti-sieze(provided)on
allthreadedjointstopreventgalling.
NOTE: NOTE:
NOTE:Wheninstalling,thecrossbar(1-R)
mustbeorientedwiththesafetylatch
bracketfacingthelegassemblywhich
doesn’tcontainthecontrolpanel.This
orientationisalsonecessarytoallowproper
installationoftherigidairlinefromthepilot
checkvalve(1–J)totheairmanifoldlocated
onthecrossbarbetweentheaircylinders.
8.InstallaprovidedPTFEgasketontopofeach
frameatthelocationwherethecrossbarwill
bemounted(FG).Useaforkliftoroverhead
cranetomovetheaircylinderandpump
assemblyintoplaceonthetopoftheframe
assembly.Attachthecrossbartotheleg
assemblyusingtheboltsprovided.
NOTE: NOTE:
NOTE:Airpressuremustbeprovidedto
raisetheaircylindercentershaftsenoughto
allowthesafetylatchtobedisengaged.Do
notforcethesafetylatchtodisengage.It
maybenecessarytoinstallthissafetylatch
extensionrodatalatertime.
9.Disengagethesafetylatch(1-S).Ontheleg
assemblywithoutthecontrolboxmounted
onit,inserttheendofthesafetylatch
extensionrodthroughtheholeclosestto
theverticalcenterlegandthenthroughthe
D-shapedholeonthesafetylatch.Install
thelockingnutonthesafetylatchextension
rod.
10.Installthereargateandclevispinsonthe
frame.
11.Attachtherigidairlinebetweenthecylinder
airdistributionmanifold,downairpressure
tting(EE),andthepilotvalvetee(EE1).
12.Installeachairmotorexhausthosetothe
topoftheclosestmufertube.
13.Attachindependentairlinestothetwo
controlboxinletvalves.
NOTE: NOTE:
NOTE:Separateairinletsareprovidedto
preventlossofpneumaticvalvecontrol
shouldpumpsconsumehighvolumesofair.
Useindependentairsupplies.
14.Attachoutputtubingtothepumpoutput
piping.
NOTE: NOTE:
NOTE:Useonlyappropriatepressure-rated
components.
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BeforeInstalling
Select Select
Selecta a aLocation Location Location
WhenselectingalocationfortheSTUassembly,
makesurethelocation:
•Isclosetowheretheuidisbeingdelivered
tominimizebackpressureandmaximizeow
rate.
•Providesenoughroomaroundtheequipment
formaintenance.
•Doesnotinterferewithopeningthecontrol
paneldoororframedoor(ononeorboth
sides).
•Providesenoughroomontherightand/or
leftsideoftheSaniForceSTUtoeasilyload
andunloaduidtoteswithaforkliftorpallet
jackhandtruck.
•Provideseasyandsafeaccesstotheairsupply
shutoffvalvesandthecontrolpanel.Graco
recommendsaminimumof3ft(0.91m)of
openspaceinfrontofthepanel.
•Providesenoughoverheadclearance(10
ft,2.7mrecommended)forinstallingand
servicingtheSTU.
•Hasaat,leveloororlevelpads.
Move Move
Movethe the theFrame Frame Frameto to tothe the theSelected Selected Selected
Location Location
Location
Theframeisshippedwithseveralmajor
componentsattachedandweighsabout1500
lb(680kg).Toavoidinjuryandequipment
damage,followinstructionsbelow.
TheSTUmustbermlyattachedtotheoor.
TheSTUiscapableofexertingdownward
forceof2220lbf(9.9kN)whichcouldcause
theSTUtoliftoffoftheoorduringoperation.
•Useaforkliftorhandtruckandsupport
devices,suchasahoist,andhaveanadequate
numberofpersonneltomovetheframetothe
installationsite.
•Avoidjarringortiltingtheframewhilemoving
it.
•Whenthefullyassembledunithasbeen
movedtotheinstallationlocation:
–Markthelocationofthemountingfoot
holesontheoor.
–Movetheframeoutofpositionbyrotating
ittotheside.
–Drillanchormountingholesandinsert
anchorsatallmarkedfootholelocations.
–Rotatetheframebackintopositionand
installframemountingboltsthroughthe
framefeet.
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Installation
Installation Installation
Installation
Allelectricalwiringmustbedonebya
qualiedelectricianandcomplywithalllocal
codesandregulations.
General General
GeneralInformation Information Information
Referencelettersinthetext—forexample,
(A)—refertothecalloutsinthegures.
TheSTUSystemconsistsofstationaryparts
andpartsattachedtotheaircylindercenter
shafts.Theparts,suchasthepumpsandplate,
attachedtotheaircylindercentershaftswill
raiseandlower(move)duringnormaloperation.
Thesemovingpartscomprisetheram.
Installationwillinvolveattachingairlines
betweenvarioussystemcomponents.Referto
ControlsandConnections,page17fordetails
regardingthoseairlineconnectionsfromthe
controlpanel.
Ground Ground
Groundthe the theSystem System System
Theequipmentmustbegroundedtoreduce
theriskofstaticsparkingandelectricalshock.
Electricorstaticsparkingcancausefumesto
igniteorexplode.Impropergroundingcan
causeelectricshock.Groundingprovidesan
escapewirefortheelectriccurrent.
Beforeoperatingthepump,groundthesystem
asexplainedbelow.
•Electro-pneumatic Electro-pneumatic
Electro-pneumaticcontrol control controlpanel: panel: panel:Ifinstalled,
itisgroundedthroughthegrounding
conductoroftheincomingpowerwiring.
•Pump: Pump:
Pump:Thepumpsaregroundedbythemetal
componentsbeingattachedtotheSTU.
•Air Air
Airand and anduid uid uidhoses: hoses: hoses:Useonlygroundedhoses
withamaximumof500ft(150m)combined
hoselengthtoensuregroundingcontinuity.
Checkelectricalresistanceofhoses.Iftotal
resistancetogroundexceeds29megohms,
replacehoseimmediately.
•Dispense Dispense
Dispensevalve: valve: valve:groundthroughconnectionto
aproperlygroundeduidhoseandpump.
•Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followlocalcode.
•Solvent Solvent
Solventcontainers containers containersused used usedwhen when whenushing: ushing: ushing:
Followlocalcode.Useonlyconductivemetal
containers,placedonagroundedsurface.Do
notplacethecontaineronanon-conductive
surface,suchaspaperorcardboard,which
interruptsgroundingcontinuity.
•STU: STU:
STU:Ifusingtheelectro-pneumaticcontrol
panel,theSTUisgroundedbytheground
wireintheelectricalconnectiontothepanel.
Ifusingthepneumaticcontrolpanel,theuser
mustattachagroundwirebetweentheSTU
andearthground.Groundwire237686is
availableseparately.
Checkyoursystemelectricalcontinuityafter
theinitialinstallation,andthensetuparegular
scheduleforcheckingcontinuitytobesure
propergroundingismaintained.Theresistance
shouldnotexceed1ohm.
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Installation
AC AC
ACPower Power Power
ACpowerisrequiredforanunloaderwithan
electro-pneumaticcontrolpanel.
Allelectricalwiringmustbedonebya
qualiedelectricianandcomplywithalllocal
codesandregulations.
1.Routewirestothecontrolpanelthrough
electricalconduit.Attachtheconduitusing
theholeonthebottomright-handsideof
enclosurewithatype4Xratedconduithub.
2.Attachthepowersystemgroundwireto
thechassisgroundlug(asshown)with
aminimum14AWG(2.0mm2)stranded
copperwire.Torqueto35in-lbs(3.95N•m).
3.Connecttheequipmentto100–240VAC,
singlephase,50/60Hz,withamaximum15
Abranchcircuitprotectionanddisconnect
switchprovidedbytheinstaller.Use14AWG
(2.0mm2)strandedcopperwireandattach
toL1andL2onthepowerswitchasshown.
Torqueto8in-lbs(0.9N•m).
Fluid Fluid
FluidOutlet Outlet OutletLines Lines Lines
NOTICE NOTICE
NOTICE
Topreventdamagetoequipment,be
sureallcomponentsareadequatelysized
andpressureratedtomeetthesystem’s
requirements.Refertothepumpmanualfor
outputpressure.
1.Connectdesiredpumpoutletttings(not
supplied)totheuidoutletport(1-F)of
eachpump.
2.Connectagrounded,exibleuidhose(not
supplied)toeithertheuser-suppliedttings
ortheuidoutletport(1-F).
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SafetyLatch
Safety Safety
SafetyLatch Latch Latch
Theoverallsystemweighsabout2400–3400
lb.(1089–1542kg).Topreventbeingtrapped
undertheramplate,alwayssetthemanual
safetylatchtotheEngagepositionwhen
workingundertheplate.
Install Install
InstallLockout Lockout LockoutExtension Extension Extension
Asafetylatchlockoutextensionrod(W)is
providedforuseonthesafetylatch.Installation
oftheextensionrodrequiresthesafetylatch
tobedisengaged.
1.Disengagethesafetylatch.SeeDisengaging Disengaging
Disengaging
the the
theSafety Safety SafetyLatch Latch Latch.
2.UsetheRamJogicontolowertheramplate
toitslowestposition.
3.FollowthePressureReliefProcedure,page
25.
4.Insertthesafetylatchextensionrod(W)
throughthebracket(X).Withthepolymer
insertnutprovided,attachtheextensionrod
tothesafetylatchattheD-shapedholeon
thelatch.
Safety Safety
SafetyLatch Latch LatchLockout Lockout Lockout
Lockout/tagoutholeshavebeenprovidedto
locktheramintheraisedposition.
1.Pushthesafetylatchhandleallthewayinto
alignthelockout/tagoutholes(Y).
2.Insertapadlockthroughtheholeandlock
inplace.
Engaging Engaging
Engagingthe the theSafety Safety SafetyLatch Latch Latch
1.Usingtherampositionselector,raiseram
untilitstopsatthemaximumheight.
NOTE: NOTE:
NOTE:Thesafetylatchmustalignwiththe
groovesinthecylindercenterrodstomove.
2.Pushthesafetylatchhandleinthedirection
showntoengagewiththegrooveinthe
cylinderrod(shownengaged).
Disengaging Disengaging
Disengagingthe the theSafety Safety SafetyLatch Latch Latch
1.Usingtherampositioncontrolpanel
selector,makesuretheplateisraisedallthe
wayup(notrestingonthesafetylatch).
2.Pullthesafetylatchhandleallthewayoutto
disengagethegrooveinthecylinderrod.
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ControlsandConnections
Controls Controls
Controlsand and andConnections Connections Connections
Control Control
ControlPanel Panel Panel(Pneumatic) (Pneumatic) (Pneumatic)
Part Part
PartNo. No. No.25C578 25C578 25C578
Control Control
ControlSide Side SideView View ViewComponent Component ComponentPanel Panel Panel
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ControlsandConnections
Connection Connection
ConnectionSide Side SideView View ViewBottom Bottom
BottomView View View
NOTE: NOTE:
NOTE:Whenroutinghosesfortheairmotorair
supply,sealination,andairassist(blowoff)
throughthehosesupportbracketontheside
oftheframe,mostofthelengthsofeachhose
mustbeabletomovefreelyabovethehose
supportbracketastherammovesupanddown.
Selectwhichhosesupportbracketholetouse
foreachspeciedhosebyobservingwherethat
hosewilltravelduringmovement.
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ControlsandConnections
Ref. Ref.
Ref.Symbol Symbol
SymbolDescription Description
Description
Ram Ram
RamPosition Position PositionSelector: Selector: Selector:
Ram Ram
RamUp Up Up
Rammovesup.UpspeedisregulatedbyowcontrolvalveFC2.Uppressure
isregulatedbyR4(V).
Ram Ram
RamHold Hold Hold
Holdsramatintermediateposition.
A
Ram Ram
RamDown Down Down
Rammovesdownandmaintainsforceagainsttopofproductintote.Down
pressureisregulatedbyR3(J).Downspeedisregulatedbyowcontrolvalve
FC1.
B
Ram Ram
RamJog Jog Jog
Whilepressed,theramwilltraveldownward.Releasethebuttontostopthe
ramtravel.
Pump Pump
PumpSpeed Speed SpeedSelector: Selector: Selector:
Pump Pump
PumpFast Fast Fast
Maximumairowwillbesuppliedtoallpumpsinthesystem.
Pump Pump
PumpOff Off Off
Pumpswillbeturnedoffandallsupplypressurewillbedumpedtoatmosphere.
C
Pump Pump
PumpSlow Slow Slow
Airowtopumpsisrestrictedtoallowmoreeffectivepriming.Pumpslow
speedcanbeadjustedusingowcontrolvalveFC5.
Seal Seal
SealInate Inate InateSelector Selector Selector
Seal Seal
SealInate Inate Inate
SealwillinateuntilthepressuresetbyregulatorR1(F)isreached.Pressure
willbemaintaineduntilSealDeateisselected.
Pause/Off Pause/Off
Pause/Off
Sealwillholdcurrentpressure.Venturiwillbeturnedoff.
D
Seal Seal
SealDeate Deate Deate
Sealwilldeateuntilempty.Venturiwillaiddeationandwillremainon.
VenturiowratecanbeadjustedusingowcontrolvalveFC3.
E
Air Air
AirAssist Assist Assist
Whilepressed,willforceairthroughthecheckvalve(BB)tohelpunstickthe
ramplatefromthebottomofthetoteortoteliner.
F———Seal Seal
SealRegulator Regulator Regulator
Controlstheairpressuresuppliedtotheinatableseal.
G———Ram Ram
RamUp Up UpRegulator Regulator Regulator
Controlstheairpressuresuppliedtothecylinderformovingupward.
G5———Seal Seal
SealPressure Pressure PressureGauge Gauge Gauge
Indicatesactualsealpressure.
H———Pump Pump
PumpRegulator Regulator Regulator
Controlstheairpressuresuppliedtothepumps.
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ControlsandConnections
Ref. Ref.
Ref.Symbol Symbol
SymbolDescription Description
Description
J———Ram Ram
RamDown Down DownRegulator Regulator Regulator
Controlstheairpressuresuppliedtothecylindersformovingdownward.
K———Control Control
ControlPanel Panel PanelAir Air AirSupply Supply SupplyBall Ball BallValve* Valve* Valve*
Connectaclean,dryairsupplytothisvalveforthecontrols.Thisvalvewill
supplyairtocontrolvalvepilots,airassist,andtheinatableseal.
NOTE: NOTE:
NOTE:ItisrecommendedthattheControlPanelAirSupplybeseparatefrom
thePumpAirSupplytoavoidthehighairconsumptionofpumpsfromstarving
thecontrolpilots.Useonlyclean,dryair.
L———Pump Pump
PumpAir Air AirSupply Supply SupplyBall Ball BallValve* Valve* Valve*
Connectaclean,dryairsupplytothisvalveforthepumps.Seethespecic
pumpinstructionmanualforminimumandmaximumpressureandow
requirements.Useonlyclean,dryair.
M
Air Air
AirAssist Assist AssistPort Port Port
Routehosethroughthehoseblockonthesideoftheframeandthroughholes
inthesupportplatetothecheckvalve(B1)inthecenteroftheramplate.Use
theprovided172-inchhose.
N
Pump Pump
PumpAir Air AirSupply Supply SupplyPorts Ports Ports(3provided)
Connecttosupplyairtopumpmanifold(FF)ports.Routehosesthroughthe
hoseblockonthesideoftheframe.Usethethreeprovided109-inchhoses.
Connectthepumpmanifold(GG)portstothepumpairmotors.
P
Cylinder Cylinder
CylinderDown Down DownPort Port Port
Connecttothedownpressureport(DD)onthecylinderdistributionmanifold
onthetopsideofthecrossbar.
R
Cylinder Cylinder
CylinderUp Up UpPort Port Port
Connect1/2in.tubetothepilotcheckvalve,V6–IN(R1)locatedontheside
oftheframe.
S
Pilot Pilot
PilotSignal Signal SignalPort Port Port
Connect3/8in.tubetothepilotport(S1)onthepilotcheckvalve(V6)located
onthesideoftheframe.
T
Seal Seal
SealInation Ination InationPort Port Port
Routethehosethroughthehoseblockonthesideoftheframeandthrough
holesinthesupportplatetotheinationtube(A1)oftheinatableseal.Use
theprovided172-inchhose.
U———Cylinder Cylinder
CylinderExhaust Exhaust ExhaustPort Port Port
Movementoftheramplatewillexhaustreturnsideoftheramcylinders
throughthisport.
V———Pump Pump
PumpPressure Pressure PressureDump Dump DumpPort Port Port
Wheneverpumpsarestopped,theairsupplypressuretothepumpdistribution
manifoldandthepumpairinletsisdumpedthroughthisport.
* Toavoiddamagetothepneumaticcontrolequipmentcausedbyconstructiondebris,dirt,and
metalfragments,thoroughlycleanoutallairsupplylinesbeforeconnectingtothisequipment.
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