Graco SaniForce Instruction Manual

Operation
SaniForce® Drum Unloader (SDU)
System 3A5402B
EN
Forusewithh
ygienic bulk supply of medium to high viscosity product. For professional use only. Only
select models are approved for use in explosive atmospheres or hazardous locations. See Configuration
Matrix on page 6 for more information.
Important Safety Instructions
Read all warnings and instructions in this and other system manuals.
Save all instructions.
Maximum Working Air Pressure: 100
psi (0.69 MPa, 6.9 bar)
Maximum Working Fluid Pressure: See
Technical Data table.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Related Manuals ................................................ 2
Warnings ........................................................... 3
Configuration Matrix............................................ 6
Installation.......................................................... 8
General Information ..................................... 8
Choosing a Location for the SDU .................. 8
Unpacking the SDU...................................... 8
Control Panel (Exposed)............................... 10
Control Panel (Enclosed Pneumatic) ............. 11
Control Panel (Electro-Pneumatic) ................ 12
Line Accessories.......................................... 13
Grounding ................................................... 13
AC Power.................................................... 14
Fluid Outlet Line........................................... 14
Manual Ram Lock ........................................ 15
Install a Platen Inflatable Seal....................... 15
Adjust Drum Stops ....................................... 16
System Setup (Pneumatic Control)................ 16
System Setup (Electro-pneumatic
Control).......................................... 16
Operation........................................................... 17
Ram Pressure Relief Procedure.................... 17
Pump Pressure Relief Procedure .................. 17
Clean the Pump Before First Use.................. 17
Start and Adjust Ram ................................... 18
Start and Adjust the Pump............................ 19
Change Drum .............................................. 21
Emergency Stop .......................................... 21
Pump Shutdown .......................................... 21
Maintenance ...................................................... 22
Lubrication................................................... 22
Cleaning the Platen...................................... 22
Cleaning the Pump Lower ............................ 23
Flushing and Storage ................................... 23
Electro-pneumatic Control Panel Display
Screens................................................ 24
Startup Screen............................................. 26
Automatic Screen......................................... 27
Manual Screen ............................................ 29
Recipe Screens ........................................... 31
Event Log.................................................... 39
Job Log ....................................................... 42
System Configuration Screen ....................... 43
Feedback Control Settings Screens .............. 45
About .......................................................... 48
I/O Status Screen......................................... 49
Dimensions ........................................................ 50
Schematic (exposed control) ............................... 51
Schematic (enclosed control)............................... 52
Schematic (electo-pneumatic control) .................. 53
Kits and Accessories........................................... 58
Technical Data ................................................... 59
Related Manuals
Manual Number Title
3A5798 SaniForce 5:1 Sanitary Pumps, Instructions and Parts
3A5564 SaniForce 6:1 Sanitary Pumps, Instructions and Parts
3A5799 SaniForce 12:1 Sanitary Pumps, Instructions and Parts
3A6781 SaniForce 1590 High Sanitation Diaphragm Pump, Repair and Parts
3A6782 SaniForce High Sanitation Diaphragm Pumps, Models 2150, 3150, 4150, Repair
and Parts
3A5800 SaniForce Air Controls, Exposed pneumatic control, Instructions and Parts
3A6101 Enclosed Manual Controls, Repair/Parts
3A6102 Electro-pneumatic Controls, Instructions–Parts
3A5404 SaniForce Drum Unloader (SDU) System, Repair/Parts
23A5402B

Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer backtothese
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. 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 or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint
or solvent flowing through the equipment can cause static sparking. 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• 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.
•Useon
ly grounded hoses.
•Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
Static charge may build up on plastic parts during cleaning and could discharge and ignite
flammable vapors. To help prevent fire and explosion:
• Clean plastic parts only in well ventilated area.
• Do not clean with a dry cloth.
3A5402B 3

Warnings
WARNING
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 and disconnect all power sources.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components willpierce
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 dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
43A5402B

Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request Safety Data Sheet (SDS) from distributor or retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which youareusingit.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
•Keepchil
dren and animals away from work area.
• Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyesoronskin,
inhaled, or swallowed.
•ReadSa
fety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.
•Storeh
azardous fluid in approved containers, and dispose of it according to applicable
guidelines.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. Duringblowoffof
platen, splatter may occur.
• Use minimum air pressure when removing platen from container.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment
includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
3A5402B 5

Configuration Matrix
Configuration Matrix
Check the identification plate (ID) for the Configuration Number of your pump. Use the following matrix to
define the components of your system.
Sample Configuration Number: SDU A01AAA1AA0C21
SDU A01 AA A 1AA 0C21
Sanitary
Drum
Unloader
Frame Pump Platen Seal
Style
Seal
Material
Controls Acces-
sories
Wash Bin Certifica-
tion
NOTE: Some combinations are not possible. Please check with your local supplier.
Sanitary Drum
Unloader
Frame Pump Platen Seal Style
SDU AStainless Steel 01 5:1 Double Ball A20” Conical,
inflatable AInflatable
BCarbon Steel 02 5:1 Priming
Piston B21.25” Conical,
static BStatic
03 6:1 Double Ball
04 6:1 Priming
Piston
05 12:1 Priming
Piston
06 1590HS-
P.SSFKEO‡
07 1590HS-
P.SSPFPO‡
08 1590HS-
P.SSPTPS‡
09 1590HS-
P.SSSPSP‡
11 2150HS-
P.SSFKEO‡
12 2150HS-
P.SSPTPO‡
13 2150HS-
P.SSPTPS‡
14 2150HS-
P.SSSPSP‡
16 3150HS-
P.FL—EO‡
17 3150HS-
P.FL—PO‡
18 3150HS-
P.FL—PS‡
19 3150HS-
P.FL—SP‡
‡Diaphragm pump, identified in size (e.g., 1590), high sanitation (HS), pneumatic (P), seat material (SS or
FLapper), ball material (— for flapper), and diaphragm material.
63A5402B

Configuration Matrix
Seal Material Controls Accessories‡Wash Bin Certification
APolychloro-
prene 1Exposed pneumatic, SST inflatable AA None 0None C21 EN 10204 type 2.1
BEPDM 2Enclosed pneumatic,
SST inflatable AB Caster kit C31 EN 10204 type 3.1
3* Enclosed electro-
pneumatic, SST
inflatable
AC Drum dolly Ram
5Exposed pneumatic,
SST static AE SST Ram piston
rods
6Exposed pneumatic,
carbon steel, inflatable
7Exposed pneumatic,
carbon steel, static
* Not ATEX. Not intended for use in explosive or hazardous environments.
‡ For accessory descriptions, see Kits and Accessories, page 58.
All models are rated and are FDA compliant.
Diaphragm materials
coded EO, PO or PS
combined with flapper or
PT ball checks are certified
to:
EC 1935
ATEX models with piston
pumps are rated II 2 GD
Ex h IIA T4 Gb X
Ex h IIIB T100°CDbX
ATEX models with
diaphragm pumps are
rated
II 2 GD
Ex h IIA 82°C...160°CGbX
Ex h IIIB T135°CDb
Electro-pneumatic control
panel component approval
Conforms to UL STD 508A
Certified to CSA STD C22.2 No. 14
3A5402B 7

Installation
Installation
All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations
General Information
The Typical Installation shown is only a guide for
selecting and installing system components.
Reference letters in the text, for example (A), refer to
the callouts in the figures.
The SDU consists of parts which are stationary and
parts attached to the air cylinder center shafts. The
parts, such as the pump and platen, attached to
the air cylinder center shafts will raise and lower
(move) during normal operation. These moving parts
comprise the ram.
Performing different steps in the operation of the
SDU will require use of the controls located on the
control panel. Refer to the table under the illustration
that corresponds with the control panel installed
on the SDU for the use of those controls. Learn
what each control does before using the SDU in a
production situation.
Choosing a Location for the SDU
1. Choose a location for the SDU so the air controls
are easily accessible. Ensure that there is
enough space overhead for the ram to rise fully
and the control box cover can be opened without
interference. See Dimensions, page 50.
2. Make sure the surface is flat and that the SDU
doesn’t wobble.
NOTE: If the SDU is being located in a permanent
location, use the four holes in the baseplate as a
guide to locate where to drill holes for mounting
hardware.
3. For ease of operation and service, locate the
SDU so the fluid outlet port is easily accessible.
Unpacking the SDU
Before unpacking, examine packing materials for
signs of damage. If damaged, take pictures of the
damage and contact Graco for directions on how to
proceed.
1. Remove packing materials and mounting bolts
from the base.
2. Attach a hoisting strap around the upper end of
each air cylinder, below the crossbar. Ensure
that air hoses or laser sensor are not damaged
by the straps.
3. Use a forklift or overhead hoist to lift the SDU off
the shipping pallet.
NOTE: If using casters on a pneumatic unit,
attach at this time.
4. Place the SDU at the desired location.
5. Permanently mount the electro-pneumatic unit.
83A5402B

Installation
Fig. 1 Typical installation
System Components Required Accessories/Components Not Supplied
A Air cylinders
BAirmotor
R* Outlet Line Pressure Relief Valve rated
for the expected fluid working pressure
of the pump
CDisplacement pump SFluidLine
DPlaten T Air Supply Line
EControl Panel U Air Line Drain Valve
FStop Rod VAi
r Filter
GPl
aten Support Rods WBleed Type Air Shutoff Valve
HDrum Stops XLaser Sensor (Electro-pneumatic units
only)
JGround Cable Kit * Only required if a valve or dispenser is downstream
in the outlet line.
3A5402B 9

Installation
Control Panel (Exposed)
When supplied with a continuous supply of air, the
control panel can control the SDU functions for
manual unloading of drums.
NOTE: An SDU that uses a static seal will not have
inflatable seal components on the control panel.
AA Main air slider valve Turnsaironandofftothesystem. Whenclosed,thevalverelieves
pressure downstream.
AB Ram air regulator Controls ram up and down pressure and air assist pressure.
AC Ram air pressure gauge Displays the air pressure used to raise and lower the ram.
AD Ram director valve Controls ram direction.
AE Air motor regulator Controls air pressure to the motor.
AF air motor pressure gauge Displays the air pressure used to drive the air motor.
AG Air assist button Turns air on and off to push the platen out of an empty drum.
AH Air motor slider valve Turns air on and off to the air motor. When closed, the valve relieves
air trapped between it and the air motor. Push the valve to shutoff.
AJ Seal air pressure regulator Controls the air pressure used to inflate the seal.
AK Seal air pressure gauge Displays the air pressure used to inflate the seal.
AL Seal inflate switch Controls when air is applied to the seal.
AM Pressure relief valve Prevents overpressurization of the seal.
10 3A5402B