Graco SaniForce STU Series Instruction Manual

Operation
SaniForce®ToteUnloader(STU)3A5416E
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 professionaluse use useonly. only. only.Only Only Only
select select
selectmodels models modelsare are areapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardouslocations. locations. locations.See See SeeCon󰘰guration Con󰘰guration Con󰘰guration
Matrix Matrix
Matrixon on onpage page page6 6 6for for formore more moreinformation. information. information.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandallrelated
manuals.Save Save
Saveall all allinstructions. instructions. instructions.
ForMaximumWorkingAirandFluid
Pressures,seeModelsonpage8.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationMatrix............................................6
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............................24
CleanthePumpBeforeFirstUse..................24
AdjustToteGuides......................................25
LoadingtheTote..........................................25
StartandAdjustthePump............................26
ChangetheTote..........................................26
EmergencyStop..........................................28
PumpShutdown..........................................28
SystemShutdown........................................28
FlushingandStorage...................................28
Maintenance......................................................29
Lubrication...................................................29
CleaningtheRamPlate................................29
CleaningthePumpLower............................29
Electro-pneumaticControlPanelDisplay
Screens................................................30
StartupScreen.............................................32
AutomaticScreen.........................................33
ManualScreen............................................35
RecipeScreens...........................................37
EventLog....................................................45
JobLog.......................................................49
SystemCon󰘰gurationScreen.......................51
FeedbackControlScreen.............................53
Network.......................................................56
About..........................................................57
I/OStatusScreen.........................................58
ImportandExportwithUSB................................59
SettingsParameters.....................................59
Dimensions........................................................63
Schematic(pneumaticcontrol)............................64
Schematic(electo-pneumaticcontrol)..................65
TechnicalData...................................................70
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A5417SaniForceSanitaryToteUnloader(STU),Repair
3A5798SaniForce5:1SanitaryPumps,InstructionsandParts
3A5799SaniForce12:1SanitaryPumps,InstructionsandParts
3A5999SaniForceHighSanitationDiaphragmPumps,InstructionsandParts
3A6781SaniForce1590HighSanitationDiaphragmPump,RepairandParts
3A6782SaniForceHighSanitationDiaphragmPumps,Models2150,3150,4150,Repair
andParts
3A1211SaniForceAirMotors,InstructionsandParts
3A6101EnclosedManualControls,Repair/Parts
3A6102Electro-pneumaticControls,Instructions-Parts
23A5416E

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystem
cancauseelectricshock.
•Turnoffandremovepowerbeforedisconnectinganycablesandbeforeservicingor
installingequipment.Forcart-mountedmodels,unplugthepowercord.Forallother
units,disconnectpoweratthemainswitch.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocal
codesandregulations.
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.
Paintorsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent
󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen
󰘱ammablefumesarepresent.
•Useonlygroundedhoses.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
3A5416E3

Warnings
WARNING
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromdispensingdevice,hoseleaks,orrupturedcomponentswillpierce
skin.Thismaylooklikejustacut,butitisaseriousinjurythatcanresultinamputation.
Get Get
Getimmediate immediate immediatesurgical surgical surgicaltreatment. treatment. treatment.
•Donotpointdispensingdeviceatanyoneoratanypartofthebody.
•Donotputyourhandoverthe󰘱uidoutlet.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinchoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
43A5416E

Warnings
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Data Data
Datainallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.For
completeinformationaboutyourmaterial,requestSafetyDataSheet(SDS)from
distributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentis
notinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywith
genuinemanufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouare
usingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhot
surfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventserious
injury,includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Protective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
3A5416E5

CongurationMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)fortheCon󰘰gurationNumberofyoursystem.Usethefollowingmatrixto
de󰘰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
(BinType)
Seal
Type
Seal
Material
ControlsAccessoriesWashKitCerti󰘰cation
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,
ExtendedLegs02 02
025:1PrimingPiston
2pumps
B B
B43.9x39.9
(Buckhorn315)
03 03
0312:1PrimingPiston,2
pumpsC C
C55.5x42
(Goodpack)
04 04
045:1DoubleBall,4pumpsD D
D43.375x35.625
(TNT)
05 05
055:1PrimingPiston,4pumpsE E
E43.5x40.375
(Arena)
06 06
0612:1PrimingPiston,4
pumpsF F
F41.32x38.9
(Ceva/Pallecon)
07 07
072150HSBallCheck,2
pumpsG G
G43.125x36.375
(SpaceKraft)
08 08
083150HSFlapperCheck,
EO,AODD,2pumps
09 09
093150HSFlapperCheck,
PO,AODD,2pumps
10 10
103150HSFlapperCheck,
PS,AODD,2pumps
11 11
113150HSFlapperCheck,
SP,AODD,2pumps
63A5416E

CongurationMatrix
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
AABagClampKit0 0
0NoneC21 C21 C21EN10204type2.1
B B
BEPDM
(Black)2 2
2*Electro-
pneumaticAB AB
ABAcepticLiner
ClampKit1 1
1PolyTankKitC31 C31 C31EN10204type3.1
*NotATEX.Notintendedforuseinexplosiveorhazardousenvironments.
Allmodelsarerated:
andareFDA-compliant.
ATEXmodelswithpistonpumps
arerated:II2GD
ExhIIAT4GbX
ExhIIIBT100°CDbX
ATEXmodelswithdiaphragm
pumpsarerated:II2GD
ExhIIA82°C...160°CGbX
ExhIIIBT135°CDb
Electro-pneumaticcontrolpanel
componentapproval:
ConformstoULSTD508A
Certi󰘰edtoCSASTDC22.2No.14
3A5416E7

Models
Models Models
Models
Pump Pump
Pump
Option Option
Option
Max 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)
01
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)
07
08
120(0.84,8.4)120(0.84,8.4)150(4.2)
100(0.69,6.9)
09
10
11
83A5416E

Overview
Overview Overview
Overview
System System
SystemComponents Components Components
Fig.1Typicalcomponents
1 1
1- - -A A AStainless Stainless StainlessSteel Steel SteelFrame: Frame: Frame:supportsallofthesystemcomponents.
1 1
1- - -B B BSanitary Sanitary SanitaryPumps: Pumps: Pumps:pumpmaterialfromthetotetothetargetapplication.
3A5416E9

Overview
1 1
1- - -C C CAir Air AirCylinders: Cylinders: Cylinders:raisesandlowersthepumpsandtheramplateinandoutofthematerialcontainer.
1 1
1- - -D D DRam Ram RamPlate: Plate: Plate:appliesanevenamountofpressuretothematerialinthetote.Whentheramplate
sealisin󰘱ated,itcreatesaseal.Theramplatepressesdownonthematerialinthetotetoassist
thepumpsindeliveringthematerial.
1 1
1- - -E E EControl Control ControlPanel: Panel: Panel:containspneumaticcontrolstoregulatetheairpressuretopumpairmotors,ram,
andramplatesealinorderto:
•controlpumpairmotorpressure
•controlpumpspeedcontrol
•controlramupanddownpressureandspeed
•controlsealpressure
•turnthepumpsonoroff
•in󰘱ateorde󰘱atetheramplateseal
•raiseorlowertheramplate
•controlramplateblowoffair
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󰘱atestocreateasealbetweentheramplateandinsidesurfaceoftote.
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.
103A5416E

BeforeInstalling
Before Before
BeforeInstalling Installing Installing
PalletizedSTU
3A5416E11

BeforeInstalling
Uncrate Uncrate
Uncratethe the theEquipment Equipment Equipment
NOTICE NOTICE
NOTICE
MovingtheSaniForceSTUoffthepalletwithout
followingthisuncratingprocedurecandamage
equipment.
UncratetheSTUasfollows:
1.Inspectthecrateforshippingdamage.Contact
thecarrierifdamaged.
2.Removeplywoodtopandsidesofcrate.
3.Checkthecontentsforlooseordamagedparts.
4.Comparethepackingslipagainstitemsinside
thecrate.ImmediatelycallyourGracodistributor
aboutanyshortagesordamage.
5.Removeallbandstraps.
6.Removetheclevispinsholdingthereargateand
removethegate.
7.Removetheboltsholdingtheframepartsand
movetheframepartstotheinstallationlocation.
NOTE: NOTE:
NOTE:Usesanitaryanti-sieze(provided)onall
threadedjointstopreventgalling.
NOTE: NOTE:
NOTE:Wheninstalling,thecrossbar(1-R)must
beorientedwiththesafetylatchbracketfacing
thelegassemblywhichdoesn’tcontainthe
controlpanel.Thisorientationisalsonecessary
toallowproperinstallationoftherigidairlinefrom
thepilotcheckvalve(1–J)totheairmanifold
locatedonthecrossbarbetweentheaircylinders.
8.InstallaprovidedPTFEgasketontopofeach
frameatthelocationwherethecrossbarwillbe
mounted(FG).Useaforkliftoroverheadcrane
tomovetheaircylinderandpumpassemblyinto
placeonthetopoftheframeassembly.Attach
thecrossbartothelegassemblyusingthebolts
provided.
NOTE: NOTE:
NOTE:Airpressuremustbeprovidedtoraise
theaircylindercentershaftsenoughtoallowthe
safetylatchtobedisengaged.Donotforcethe
safetylatchtodisengage.Itmaybenecessary
toinstallthissafetylatchextensionrodatalater
time.
9.Disengagethesafetylatch(1-S).Ontheleg
assemblywithoutthecontrolboxmountedonit,
inserttheendofthesafetylatchextensionrod
throughtheholeclosesttotheverticalcenter
legandthenthroughtheD-shapedholeonthe
safetylatch.Installthelockingnutonthesafety
latchextensionrod.
10.Installthereargateandclevispinsontheframe.
11.Attachtherigidairlinebetweenthecylinderair
distributionmanifold,downairpressure󰘰tting
(EE),andthepilotvalvetee(EE1).
12.Installeachairmotorexhausthosetothetopof
theclosestmuf󰘱ertube.
13.Attachindependentairlinestothetwocontrol
boxinletvalves.
NOTE: NOTE:
NOTE:Separateairinletsareprovidedtoprevent
lossofpneumaticvalvecontrolshouldpumps
consumehighvolumesofair.Useindependent
airsupplies.
14.Attachoutputtubingtothepumpoutputpiping.
NOTE: NOTE:
NOTE:Useonlyappropriatepressure-rated
components.
123A5416E

BeforeInstalling
Select Select
Selecta a aLocation Location Location
WhenselectingalocationfortheSTUassembly,
makesurethelocation:
•Isclosetowherethe󰘱uidisbeingdeliveredto
minimizebackpressureandmaximize󰘱owrate.
•Providesenoughroomaroundtheequipmentfor
maintenance.
•Doesnotinterferewithopeningthecontrolpanel
doororframedoor(ononeorbothsides).
•Providesenoughroomontherightand/orleftside
oftheSaniForceSTUtoeasilyloadandunload
󰘱uidtoteswithaforkliftorpalletjackhandtruck.
•Provideseasyandsafeaccesstotheairsupply
shutoffvalvesandthecontrolpanel.Graco
recommendsaminimumof3ft(0.91m)ofopen
spaceinfrontofthepanel.
•Providesenoughoverheadclearance(10ft,2.7m
recommended)forinstallingandservicingtheSTU.
•Hasa󰘱at,level󰘱oororlevelpads.
Move Move
Movethe the theFrame Frame Frameto to tothe the theSelected Selected Selected
Location Location
Location
Theframeisshippedwithseveralmajor
componentsattachedandweighsabout1500lb
(680kg).Toavoidinjuryandequipmentdamage,
followinstructionsbelow.
TheSTUmustbe󰘰rmlyattachedtothe󰘱oor.The
STUiscapableofexertingdownwardforceof2220
lbf(9.9kN)whichcouldcausetheSTUtoliftoffof
the󰘱oorduringoperation.
•Useaforkliftorhandtruckandsupportdevices,
suchasahoist,andhaveanadequatenumberof
personneltomovetheframetotheinstallationsite.
•Avoidjarringortiltingtheframewhilemovingit.
•Whenthefullyassembledunithasbeenmovedto
theinstallationlocation:
–Markthelocationofthemountingfootholeson
the󰘱oor.
–Movetheframeoutofpositionbyrotatingitto
theside.
–Drillanchormountingholesandinsertanchors
atallmarkedfootholelocations.
–Rotatetheframebackintopositionandinstall
framemountingboltsthroughtheframefeet.
3A5416E13

Installation
Installation Installation
Installation
Allelectricalwiringmustbedonebyaquali󰘰ed
electricianandcomplywithalllocalcodesand
regulations.
General General
GeneralInformation Information Information
Referencelettersinthetext—forexample,(A)—refer
tothecalloutsinthe󰘰gures.
TheSTUSystemconsistsofstationarypartsand
partsattachedtotheaircylindercentershafts.The
parts,suchasthepumpsandplate,attachedto
theaircylindercentershaftswillraiseandlower
(move)duringnormaloperation.Thesemovingparts
comprisetheram.
Installationwillinvolveattachingairlines
betweenvarioussystemcomponents.Referto
ControlsandConnections,page17fordetails
regardingthoseairlineconnectionsfromthecontrol
panel.
Ground Ground
Groundthe the theSystem System System
Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricalshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
Beforeoperatingthepump,groundthesystemas
explainedbelow.
•Electro-pneumatic Electro-pneumatic
Electro-pneumaticcontrol control controlpanel: panel: panel:Ifinstalled,itis
groundedthroughthegroundingconductorofthe
incomingpowerwiring.
•Pump: Pump:
Pump:Thepumpsaregroundedbythemetal
componentsbeingattachedtotheSTU.
•Air Air
Airand and and󰘱uid 󰘱uid 󰘱uidhoses: hoses: hoses:Useonlygroundedhoseswith
amaximumof500ft(150m)combinedhoselength
toensuregroundingcontinuity.Checkelectrical
resistanceofhoses.Iftotalresistancetoground
exceeds29megohms,replacehoseimmediately.
•Dispense Dispense
Dispensevalve: valve: valve:groundthroughconnectiontoa
properlygrounded󰘱uidhoseandpump.
•Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followlocalcode.
•Solvent Solvent
Solventcontainers containers containersused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:Follow
localcode.Useonlyconductivemetalcontainers,
placedonagroundedsurface.Donotplacethe
containeronanon-conductivesurface,suchas
paperorcardboard,whichinterruptsgrounding
continuity.
•STU: STU:
STU:Ifusingtheelectro-pneumaticcontrolpanel,
theSTUisgroundedbythegroundwireinthe
electricalconnectiontothepanel.Ifusingthe
pneumaticcontrolpanel,theusermustattacha
groundwirebetweentheSTUandearthground.
Groundwire237686isavailableseparately.
Checkyoursystemelectricalcontinuityafterthe
initialinstallation,andthensetuparegularschedule
forcheckingcontinuitytobesurepropergrounding
ismaintained.Theresistanceshouldnotexceed1
ohm.
143A5416E

Installation
AC AC
ACPower Power Power
ACpowerisrequiredforanunloaderwithan
electro-pneumaticcontrolpanel.
Allelectricalwiringmustbedonebyaquali󰘰ed
electricianandcomplywithalllocalcodesand
regulations.
1.Routewirestothecontrolpanelthroughelectrical
conduit.Attachtheconduitusingtheholeonthe
bottomright-handsideofenclosurewithatype
4Xratedconduithub.
2.Attachthepowersystemgroundwiretothe
chassisgroundlug(asshown)withaminimum
14AWG(2.0mm2)strandedcopperwire.Torque
to35in-lbs(3.95N•m).
3.Connecttheequipmentto100–240VAC,single
phase,50/60Hz,withamaximum15Abranch
circuitprotectionanddisconnectswitchprovided
bytheinstaller.Use14AWG(2.0mm2)stranded
copperwireandattachtoL1andL2onthepower
switchasshown.Torqueto8in-lbs(0.9N•m).
Fluid Fluid
FluidOutlet Outlet OutletLines Lines Lines
NOTICE NOTICE
NOTICE
Topreventdamagetoequipment,besureall
componentsareadequatelysizedandpressure
ratedtomeetthesystem’srequirements.Referto
thepumpmanualforoutputpressure.
1.Connectdesiredpumpoutlet󰘰ttings(not
supplied)tothe󰘱uidoutletport(1-F)ofeach
pump.
2.Connectagrounded,󰘱exible󰘱uidhose(not
supplied)toeithertheuser-supplied󰘰ttingsor
the󰘱uidoutletport(1-F).
3A5416E15

SafetyLatch
Safety Safety
SafetyLatch Latch Latch
Theoverallsystemweighsabout2400–3400lb.
(1089–1542kg).Topreventbeingtrappedunder
theramplate,alwayssetthemanualsafetylatchto
theEngagepositionwhenworkingundertheplate.
Install Install
InstallLockout Lockout LockoutExtension Extension Extension
Asafetylatchlockoutextensionrod(W)isprovided
foruseonthesafetylatch.Installationofthe
extensionrodrequiresthesafetylatchtobe
disengaged.
1.Disengagethesafetylatch.SeeDisengaging Disengaging
Disengagingthe the the
Safety Safety
SafetyLatch Latch Latch.
2.UsetheRamJogicontolowertheramplateto
itslowestposition.
3.FollowthePressureReliefProcedure,page24.
4.Insertthesafetylatchextensionrod(W)through
thebracket(X).Withthepolymerinsertnut
provided,attachtheextensionrodtothesafety
latchattheD-shapedholeonthelatch.
Safety Safety
SafetyLatch Latch LatchLockout Lockout Lockout
Lockout/tagoutholeshavebeenprovidedtolockthe
ramintheraisedposition.
1.Pushthesafetylatchhandleallthewayinto
alignthelockout/tagoutholes(Y).
2.Insertapadlockthroughtheholeandlockin
place.
Engaging Engaging
Engagingthe the theSafety Safety SafetyLatch Latch Latch
1.Usingtherampositionselector,raiseramuntilit
stopsatthemaximumheight.
NOTE: NOTE:
NOTE:Thesafetylatchmustalignwiththe
groovesinthecylindercenterrodstomove.
2.Pushthesafetylatchhandleinthedirection
showntoengagewiththegrooveinthecylinder
rod(shownengaged).
Disengaging Disengaging
Disengagingthe the theSafety Safety SafetyLatch Latch Latch
1.Usingtherampositioncontrolpanelselector,
makesuretheplateisraisedallthewayup(not
restingonthesafetylatch).
2.Pullthesafetylatchhandleallthewayoutto
disengagethegrooveinthecylinderrod.
163A5416E

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
3A5416E17

ControlsandConnections
Connection Connection
ConnectionSide Side SideView View ViewBottom Bottom
BottomView View View
NOTE: NOTE:
NOTE:Whenroutinghosesfortheairmotorair
supply,sealin󰘱ation,andairassist(blowoff)through
thehosesupportbracketonthesideoftheframe,
mostofthelengthsofeachhosemustbeableto
movefreelyabovethehosesupportbracketas
therammovesupanddown.Selectwhichhose
supportbracketholetouseforeachspeci󰘰edhose
byobservingwherethathosewilltravelduring
movement.
183A5416E

ControlsandConnections
Ref. Ref.
Ref.Symbol Symbol SymbolDescription Description
Description
Ram Ram
RamPosition Position PositionSelector: Selector: Selector:
Ram Ram
RamUp Up Up
Rammovesup.Upspeedisregulatedby󰘱owcontrolvalveFC2.Uppressureis
regulatedbyR4(V).
Ram Ram
RamHold Hold Hold
Holdsramatintermediateposition.
A
Ram Ram
RamDown Down Down
Rammovesdownandmaintainsforceagainsttopofproductintote.Downpressureis
regulatedbyR3(J).Downspeedisregulatedby󰘱owcontrolvalveFC1.
B Ram Ram
RamJog Jog Jog
Whilepressed,theramwilltraveldownward.Releasethebuttontostoptheramtravel.
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.Pumpslowspeedcanbe
adjustedusing󰘱owcontrolvalveFC5.
Seal Seal
SealIn󰘱ate In󰘱ate In󰘱ateSelector Selector Selector
Seal Seal
SealIn󰘱ate In󰘱ate In󰘱ate
Sealwillin󰘱ateuntilthepressuresetbyregulatorR1(F)isreached.Pressurewillbe
maintaineduntilSealDe󰘱ateisselected.
Pause/Off Pause/Off
Pause/Off
Sealwillholdcurrentpressure.Venturiwillbeturnedoff.
D
Seal Seal
SealDe󰘱ate De󰘱ate De󰘱ate
Sealwillde󰘱ateuntilempty.Venturiwillaidde󰘱ationandwillremainon.Venturi󰘱ow
ratecanbeadjustedusing󰘱owcontrolvalveFC3.
E Air Air
AirAssist Assist Assist
Whilepressed,willforceairthroughthecheckvalve(BB)tohelpunsticktheramplate
fromthebottomofthetoteortoteliner.
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.
3A5416E19

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.Thisvalvewillsupplyairto
controlvalvepilots,airassist,andthein󰘱atableseal.
NOTE: NOTE:
NOTE:ItisrecommendedthattheControlPanelAirSupplybeseparatefromthe
PumpAirSupplytoavoidthehighairconsumptionofpumpsfromstarvingthecontrol
pilots.Useonlyclean,dryair.
L———Pump Pump
PumpAir Air AirSupply Supply SupplyBall Ball BallValve* Valve* Valve*
Connectaclean,dryairsupplytothisvalveforthepumps.Seethespeci󰘰cpump
instructionmanualforminimumandmaximumpressureand󰘱owrequirements.Use
onlyclean,dryair.
M Air Air
AirAssist Assist AssistPort Port Port
Routehosethroughthehoseblockonthesideoftheframeandthroughholesinthe
supportplatetothecheckvalve(B1)inthecenteroftheramplate.Usetheprovided
172-inchhose.
N
Pump Pump
PumpAir Air AirSupply Supply SupplyPorts Ports Ports(3provided)
Connecttosupplyairtopumpmanifold(FF)ports.Routehosesthroughthehoseblock
onthesideoftheframe.Usethethreeprovided109-inchhoses.Connectthepump
manifold(GG)portstothepumpairmotors.
P
Cylinder Cylinder
CylinderDown Down DownPort Port Port
Connecttothedownpressureport(DD)onthecylinderdistributionmanifoldonthe
topsideofthecrossbar.
R
Cylinder Cylinder
CylinderUp Up UpPort Port Port
Connect1/2in.tubetothepilotcheckvalve,V6–IN(R1)locatedonthesideofthe
frame.
S Pilot Pilot
PilotSignal Signal SignalPort Port Port
Connect3/8in.tubetothepilotport(S1)onthepilotcheckvalve(V6)locatedonthe
sideoftheframe.
T
Seal Seal
SealIn󰘱ation In󰘱ation In󰘱ationPort Port Port
Routethehosethroughthehoseblockonthesideoftheframeandthroughholesin
thesupportplatetothein󰘱ationtube(A1)ofthein󰘱atableseal.Usetheprovided
172-inchhose.
U———Cylinder Cylinder
CylinderExhaust Exhaust ExhaustPort Port Port
Movementoftheramplatewillexhaustreturnsideoftheramcylindersthroughthisport.
V———Pump Pump
PumpPressure Pressure PressureDump Dump DumpPort Port Port
Wheneverpumpsarestopped,theairsupplypressuretothepumpdistributionmanifold
andthepumpairinletsisdumpedthroughthisport.
* Toavoiddamagetothepneumaticcontrolequipmentcausedbyconstructiondebris,dirt,andmetal
fragments,thoroughlycleanoutallairsupplylinesbeforeconnectingtothisequipment.
203A5416E