Graco 248785 Operation manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001
310766E
Instructions - Parts List
Pump Function
Module System
Single I/O module intended for remote control of tandem bulk pump unloaders,
including pump run-away, depressurization, and material filter differential pressure.
Part No. 248785
Pump Function Module System
4875 psi (33.6 MPa, 336 bar) Maximum Working Pressure
Part No. 234957
Optional Pump Control Module Kit
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
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123456 897121110 13 14 15 22 23 24 2725 26 2928 30 31 32 3433 35
Other Required
Instruction Manuals
• 306934
• 306861
• 307375
• 308027
• 308167
• 308168
• 308351
• 309348

Manual Conventions
2310766E
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Information . . . . . . . . . . . . . . . . . . . . . 5
Optional Pump Control Module Description . . . . 5
Component Description . . . . . . . . . . . . . . . . . . . . . 6
Supply Unit Features . . . . . . . . . . . . . . . . . . . . . . 6
Control Stand Features . . . . . . . . . . . . . . . . . . . . 6
Optional Pump Control Module Features . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . 7
Pump Function Module System Operation . . . . . . 8
Manual Pressure Relief Procedure . . . . . . . . . . . 8
Differential Pressure Switch . . . . . . . . . . . . . . . . 8
Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Optional Pump Control Module Kit Installation . 10
Optional Pump Control Module Kit Operation . . 12
Screen Displays . . . . . . . . . . . . . . . . . . . . . . . . . 12
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . 13
Shut Down Procedure . . . . . . . . . . . . . . . . . . . . 13
Pump Function Module Interconnect Diagram . . 14
Pump Function Module Wiring Diagram . . . . . . . 15
Optional Pump Control Module Kit Electrical
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
(continued on page 17) . . . . . . . . . . . . . . . . . . . 16
Optional Pump Control Module Kit Electrical
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Part No. 248785, Pump Function Mod System . 18
Part No. 234957, Optional Pump Control Mod . 19
Part No. 234956, Optional Pump Control Cable 19
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 20
Manual Conventions
Note
WARNING
WARNING: a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Warnings in the instructions usually include a symbol
indicating the hazard. Read the general Warnings
section for additional safety information.
Hazard Symbol
CAUTION
CAUTION: a potentially hazardous situation which, if
not avoided, may result in property damage or
destruction of equipment.
Additional helpful information.

Warnings
310766E 3
Warnings
The following warnings include general safety information for this equipment. More specific warnings are included in
the text where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground equipment and conductive objects in work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a fire extinguisher in the work area.
INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Comply with all applicable safety regulations.

Warnings
4310766E
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regu-
lations.
WARNING

Component Information
310766E 5
Component Information
This manual provides information only for the Pump
Function Module System and the Optional Pump Con-
trol Module Kit. Specific information concerning
safety, setup, operation, maintenance and repair is
contained in other instruction manuals supplied
with the Ram System. Please refer to them for
detailed information.
Pump Function Module System
Description
Each air-powered ram pushes a follower plate into a
drum of material, while the pump removes material from
the drum and pushes it through a supply hose to a cus-
tomer-supplied header. Material flows through the
header to individual dispense drops.
The Pump Function Module System monitors and con-
trols system functions and outputs a signal from the
module system through the cell communications cable
to the controlling equipment. The standard information
sent from the Pump Function Module Control Sys-
tem through the communications cable must be
interpreted by the monitoring/controlling system
(cell controller) being used that is supplied by oth-
ers. An optional controlling system (234597) can be
ordered through Graco.
Optional Pump Control Module
Description
The Optional Pump Control Module interprets the stan-
dard information signal sent by the Pump Function Mod-
ule System through the Optional Pump Control Cable.
The Optional Pump Control Module displays system
data, such as pump status, input/output status, and
depressurization status; and allows remote control of
the tandem bulk pump unloader system. An Optional
Pump Control Cable (234596) is also available.
WARNING
A main air bleed valve and pump air bleed valve are
included with the equipment. These items help reduce
the risk of serious injury, including fluid injection and
splashing of fluid in the eyes or on the skin, and injury
from moving parts if you are adjusting or repairing the
pump.
The main air bleed valve shuts off and relieves the air
to the pump and ram. The ram will hold pressure if the
ram director valve is in the horizontal (neutral) position.
To relieve air pressure in the ram, close the main air
bleed valve and move the director valve to DOWN. The
ram will slowly drop.
The pump air bleed valve relieves air trapped between
it and the pump after the air is shut off. Trapped air can
cause the pump to cycle unexpectedly. Locate the
valve close to the pump.
The fluid drain valve assists in relieving fluid pressure
in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be suffi-
cient.

Component Description
6310766E
Component Description
Before you install the system, you should be familiar
with the parts discussed in the following paragraphs.
Supply Unit Features
Pump (1) - supplies power for rams.
Air Bleed Lockout Valve (2) - shuts off and relieves the
air to the pump and ram.
Air Motor Solenoid (3) - turns air on to the pump from
the cell controller.
Pump Air On Pressure Switch (4) - pressure switch
that verifies there is pressure to the pumps.
Empty Level Limit Switch (5) - indicates when a low
material level has been reached and sends a signal
back to the cell controller. This switch is adjustable.
Depressurization Valve/Solenoid (6) - relieves mate-
rial pressure in the system through the cell controller
which controls the on and off solenoid.
Level Indicator (7) - visual indicator of the remaining
material in the drum.
Pump Stroke Detector Proximity Switch (8) - sends
pump stroke signal count back to cell controller.
Material Check Valve (9) - prevents back flow from one
ram system to the other.
Control Stand Features
Standard Interface Cable Electrical Connection (10) -
electrical connection to cell controller.
Filter Module (11) - filters out foreign objects from fluid.
Filter Plugged Detector (12) - pressure switch across
the filter sends a signal to the cell controller indicating
when the filter is plugged. This switch is adjustable.
Fault Beacon (13) - illuminates when there is a fault in
the system.
Material Isolation Ball Valves (14) - shuts off material
flow to one ram unit. This is used when maintenance is
required for only one unit of the system.
Supply Hoses (15) - provides drum material to pump
control.
Electrical Cables (16) - controls each ram to pump
function control monitor.
Pump Function Module (17) - The Pump Function
Module monitors and controls system functions and out-
puts a signal from the module system through the cell
communications cable to the controlling equipment.
Optional Pump Control Module
Features
Pump Control Box (18) - houses the terminal block and
panel view display and controls.
Pump Control Panel View (19) - displays system infor-
mation and houses programmable controls.
Pump Control Cable (20) - connects the optional pump
control module to the tandem bulk pump unloader.
Reference numbers in parentheses in the text
refer to the callouts in FIG. 1.

Component Identification
310766E 7
Component Identification
Key:
1 Pump
2 Air Bleed Lock Out Valve
3 Air Motor Solenoid
4 Pump Air On Pressure Switch
5 Empty Level Limit Switch
6 Depressurization Valve/Solenoid
7 Level Indicator
8 Pump Stroke Detector Proximity Switch
9 Material Check Valve
10 Standard Interface Cable Electrical Connection
11 Filter Module
12 Filter Plugged Detector
13 Fault Beacon
14 Material Isolation Ball Valves
15 Supply Hoses
16 Electrical Cables
17 Pump Function Module
18 Pump Control Box (optional)
19 Pump Control Panel View (optional)
20 Pump Control Cable (optional)
FIG. 1
1
1
Supply Unit A Supply Unit B
Filter/Pump Control Stand
Material Out
Material In
Cell Communications Cable to PFlo Control Box
22
33
4
4
5
5
66
77
88
99
10 10
11
12
13
14
15
15
16 16
14
A
BB
C
C
DD
17
19
18
20

Pump Function Module System Operation
8310766E
Pump Function Module System Operation
Manual Pressure Relief
Procedure
1. Relieve system pressure to which Graco module
supply units are attached. (See manual 308027).
2. Close dispenser ball valves (A). Disconnect ball
valves from system. See FIG. 1.
3. Close pump air bleed valve (B).
4. Shut off main air bleed valve (C) required in your
system. Set ram director valve to DOWN. Ram will
slowly drop.
5. Open the drain valve (required in your system)
and/or the pump bleeder valve (D). Have a container
ready to catch the drainage.
6. Leave the drain valve open until you are ready to
spray/dispense again.
7. Repeat procedure for each ram.
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
Differential Pressure Switch
The differential pressure switch measure the fluid pres-
sure difference between the inbound and outbound side
of the filter. The pump function module system is
shipped from the factory with the differential pressure
set at 100 PSI.
Adjusting the Differential Pressure
1. Enter the set up mode by pressing button (F). Set
point 1 (SP1) will display. See FIG. 2.
2. To display the current psi value press and release
button (E). The actual psi value is the number
displayed times 10. See FIG. 3.
Automatic pressure relief is actuated by the cell
controller.
WARNING
Follow Manual Pressure Relief Procedure (auto-
matic pressure relief is actuated by the cell con-
troller) when you stop spraying and before cleaning,
checking, servicing, or transporting equipment. Read
warnings, page 3.
WARNING
Read warnings, page 3.
FIG. 2
FIG. 3
bar
MPa
PSI X10
OUT 2
OUT 1
rP 1
bar
MPa
PSI X10
OUT 2
OUT 1
0
bar
MPa
PSI X10
OUT 2
OUT 1
10
bar
MPa
PSI X10
OUT 2
OUT 1
SP 1
E
F
bar
MPa
PSI X10
OUT 2
OUT 1
rP 1
bar
MPa
PSI X10
OUT 2
OUT 1
0
bar
MPa
PSI X10
OUT 2
OUT 1
10
Actual pressure is 100 psi
(psi number displayed x 10)
E
F

Pump Function Module System Operation
310766E 9
3. To change the psi value press and hold button (E).
The display will blink and after several seconds the
value will increase slowly at first and then at a faster
rate. Release the button when the desired psi value
has been reached. See FIG. 3.
Differential Pressure Reset Point
The differential pressure reset point is the psi value
where the output shuts off. It automatically is set to one
number below the psi value for set point one (SP1). To
change the reset point to a different value:
1. Enter the set up mode by pressing button (F). Set
point 1 (SP1) will display. See FIG. 4.
2. Press button (F) again to display the reset point
(rP1).
3. Press and release button (E) to display the current
pressure reset point. The actual psi value is the
number displayed times 10.
4. To change the reset point press and hold button (E)
until the desired psi number appears.
Filter Change
The filter needs to be cleaned on a regular basis or
when it becomes plugged.
1. Drain the filter (11) using the drain valve (H). See
FIG. 5.
2. Remove the filter cover (G) and clean the screen
located within.
3. Replace the filter, screen, and filter cover (G). Be
sure to lubricate threads when assembling.
4. Close the drain valve (H).
If you go past the desired number keep going to
recycle through the numbers.
FIG. 4
bar
MPa
PSI X10
OUT 2
OUT 1
rP 1
E
F
WARNING
Follow Manual Pressure Relief Procedure (auto-
matic pressure relief is actuated by the cell con-
troller) when you stop spraying and before cleaning,
checking, servicing, or transporting equipment. Read
warnings, page 3.
FIG. 5
H
G

Optional Pump Control Module Kit Installation
10 310766E
Optional Pump Control Module Kit Installation
1. Mount the pump control box (18) near the tandem
bulk pump unloaders. To function correctly the pump
control box must be located within 20 ft of the pump
function module (17). See FIG. 1.
2. Install the terminal blocks (202) by snapping it into
place in the dinrail of the PrecisionFlo control box.
See FIG. 6 and FIG. 7.
3. Wire the cell communication cable to the terminal
block by connecting the four tagged wires (1, 2, 3,
and 4). See FIG. 8.
The length of the Optional Pump Control Cable
(234956) to connect the pump control box and
the pump function module is 20 ft.
FIG. 6
202
FIG. 7
FIG. 8
1
23
4