SAMES KREMLIN Magna-Ram User manual

USER MANUAL
Magna-Ram
300 Gallon
Elevator and Controls

Version B June, 2020 2 MagnaRam-SK
SAMES KREMLIN, Inc.
45001 Five Mile Road
Plymouth, MI 48170
[phone]
http://www.sames-kremlin.com
Parts Ordering
Phone: [phone]
Fax: [phone]
Email: [email protected]
Technical Suppor
t
Phone: [phone]
24 Hour Hotline: [phone]
Email: [email protected]
S
ervice
Phone: [phone]
24 Hour Hotline: [phone]
Email: [email protected]
Training
Phone: [phone]
Email: [email protected]
All communication or reproduction of this document, in any form whatsoever and all use or communication
of its contents is forbidden without express written authorization from SAMES KREMLIN, Inc.
The descriptions and characteristics mentioned in this document are subject to change without prior
notice.
© SAMES KREMLIN, Inc. 2020
Member of EXEL Industries

Version B June, 2020 3 MagnaRam-SK
Table of Contents
1Safety..................................................................................................................................................... 6
1.1Introduction..................................................................................................................................... 6
1.2General Safety Instructions ............................................................................................................ 7
1.3Pictograms...................................................................................................................................... 7
1.4Pressure Hazards........................................................................................................................... 8
1.5High Pressure Injection Hazards .................................................................................................... 8
1.6Fire - Explosion - Sparks - Static Electricity Hazards ..................................................................... 8
1.7Toxic Product Hazards ................................................................................................................... 9
1.8Lockout Energy Sources................................................................................................................. 9
1.9Heavy Equipment ........................................................................................................................... 9
1.10Equipment Requirements ............................................................................................................. 10
1.10.1Pumps ................................................................................................................................... 10
1.10.2Hoses .................................................................................................................................... 10
1.10.3Commercial Products ............................................................................................................ 10
1.11General Electrostatic Systems...................................................................................................... 11
1.11.1Manual Electrostatic Systems ............................................................................................... 12
2Magna-Ram ......................................................................................................................................... 13
2.1Complete Magna-Ram with double ball pumps. ........................................................................... 14
2.1.1Double Ball Pumps................................................................................................................ 15
3Specifications....................................................................................................................................... 16
3.1Frame Dimensions........................................................................................................................ 16
3.2Ram Retracted. ............................................................................................................................ 17
3.3Ram Extended.............................................................................................................................. 17
3.4Load Height .................................................................................................................................. 18
4Installation............................................................................................................................................ 19
4.1Locate MagnaRam. ...................................................................................................................... 19
4.2Grounding the pump..................................................................................................................... 19
4.3Install Air Supply Hose.................................................................................................................. 20
4.4Install Material Hose. .................................................................................................................... 21
4.5Pneumatic Single Pneumatics...................................................................................................... 22
4.5.1Single MagnaRam pneumatics – No Crossover.................................................................... 22
4.5.2Dual Magna-Ram – With Automatic Crossover..................................................................... 23
5Preventative Maintenance ................................................................................................................... 24
6Operation: ............................................................................................................................................ 25

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6.1Unloading Material........................................................................................................................ 25
6.2Loading Material. .......................................................................................................................... 26
6.2.1MagnaRam Drum Safety Concerns....................................................................................... 27
7The Magna-Ram consists of seven major components....................................................................... 28
7.1The Pumps Packages................................................................................................................... 29
7.2Magna-Ram Elevator (Ram). 62-3147-01 (RH) / 62-3147-02 (LH) .............................................. 29
7.2.1Elevator 62-3147-0x components.......................................................................................... 30
7.2.2Upper Frame and follower Assembly. ................................................................................... 31
7.2.3Elevator Guide Bushing assembly 62-3009-03. .................................................................... 32
7.2.4Elevator Piston Assembly 62-3009-02 .................................................................................. 33
7.2.5Removing/ Installing the Elevator Piston Assembly. ............................................................. 34
7.2.6Elevator Control Tubing 65-3224-01 ..................................................................................... 35
7.3Barrel Clamps 62-3035-00............................................................................................................ 36
7.4Safety Ram Up Lockout 62-3065-01 ............................................................................................ 37
7.5Operation and Lock-out Sticker and tags. .................................................................................... 38
7.6Control Box Components ............................................................................................................. 39
7.6.1Control Box Inside components............................................................................................. 40
7.6.2Control Box Top .................................................................................................................... 41
7.6.3Control Box 65-3290-00 Operation........................................................................................ 42
7.6.4Control Box Door Layout ....................................................................................................... 43
7.6.5Control Box Subplate Layout................................................................................................. 44
7.6.6Control Box Back Layout....................................................................................................... 45
7.6.7Control Box Part Numbers..................................................................................................... 46
7.7Empty Drum Switch 62-3263-01................................................................................................... 47
7.8Control Box/Lock-Out Bracket 62-3228-01................................................................................... 48
7.9Upper Frame Pneumatic Assembly 65-3225-01........................................................................... 49
7.9.1Upper Frame Pneumatic Connections .................................................................................. 50
7.9.2Upper Frame Pneumatic Assembly....................................................................................... 50
7.9.3Pneumatics Shown assembled to upper frame. .................................................................... 51
7.10Pump Air Supply Kit 65-3223-01. ................................................................................................. 52
7.11Pump Air Supply Kit 65-3223-02. ................................................................................................. 53
7.12Utility Routing Assembly............................................................................................................... 54
7.12.1Pilot Supply Bracket layout.................................................................................................... 55
7.12.2Utility Routing Assembly Installed. ........................................................................................ 55
7.12.3Utility Brackets Tube Connections......................................................................................... 56
7.13Magna-Ram Follower Plate. 62-3241-01...................................................................................... 57
7.13.1Follower Plate Assembly 62-3241-01.................................................................................... 58

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7.13.2Powered Vents 668-160-205 (Standard)............................................................................... 59
7.13.3Gravity Vents 668-160-206 (Optional)................................................................................... 60
7.14Outlet Porting................................................................................................................................ 61
7.14.162-3220-01 Material Outlet-Steel. ......................................................................................... 62
7.14.262-3220-02 Material Outlet-Steel. ......................................................................................... 63
7.14.362-3220-03 Material Outlet-Plated. ....................................................................................... 64
7.14.462-3220-04 Material Outlet-Plated. ....................................................................................... 65
7.15Side Port Check Valve 62-3213-01 – 1-1/4NPTF......................................................................... 66
7.16Side Port Check Valve 62-3213-02 – 1-1/4NPT - Plated.............................................................. 67
7.17Pump Installation Assembly 62-3244-01 (105mm)....................................................................... 68
7.18Pump Installation Assembly 62-3244-03 (80mm)......................................................................... 69
7.19Depressurization Kit 65-3056-04 .................................................................................................. 70
7.19.1Depressurization Components: ............................................................................................. 71
7.20105-034N Depressurization Vavle................................................................................................ 72
7.20.1105-034N Depressurization Valve componants .................................................................... 73
7.20.2Depressurization Valve Dis-Assembly................................................................................... 74
7.20.3105-034N Depressurization Valve Assembly ........................................................................ 75
8Trouble Shooting ................................................................................................................................. 76
8.1Trouble Shooting Air Motor........................................................................................................... 77
8.2Trouble Shooting MagnaRam Fluid Section................................................................................. 78
9Recommended Spare Parts ................................................................................................................ 79
10Control Drawings 45-0538-00 .......................................................................................................... 80

Version B June, 2020 6 MagnaRam-SK
1 Safety
1.1 Introduction
SAMES KREMLIN, Inc. is not and does not represent itself as an expert in safety systems, safety
equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of
the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the
workplace.
The appropriate level of safety for your application and installation can best be determined by safety
system professionals. It is therefore, recommended that each customer consult with such professionals to
provide a workplace that allows for the safe application, use, and operation of SAMES KREMLIN, Inc.
equipment.
As the owner, employer, or user of a paint or dispensing system, it is your responsibility to arrange for the
training of the operator to recognize and respond to known hazards associated with the equipment.
Additionally, personnel need to be aware of recommended operating procedures for your site-specific
application and installation.
It is therefore, recommended that all personnel who intend to operate, program, repair, or otherwise use
the SAMES KREMLIN, Inc. system or components be trained in an approved SAMES KREMLIN, Inc.
training course and become familiar with the proper operation of the system.
All persons involved with electrostatic or non-electrostatic finishing operations should carefully read and
fully understand this booklet and other applicable safety publications, particularly NFPA No.33. It is very
important that both equipment operators and supervisory personnel be fully aware of the requirements for
safe electrostatic finishing system operation.
The following guidelines are provided to emphasize the importance of safety in the workplace.
Other nationally recognized authorities which issue relevant safety standards are listed below.
Reference Standards:
NATIONAL FIRE PROTECTION ASSOCIATION
60 BATTERYMARCH PARK
BOSTON, MASSACHUSETTS 02110
NFPA NO. 33 Spray Applications
NFPA NO. 63 Explosion Prevention NFPA NO. 70 National Electric Codes
NFPA NO. 77 Static Electricity NFPA NO. 86A Ovens and Furnaces
NFPA NO. 91 Blower and Exhaust Systems NFPA NO. 654 Dust Explosions in Industrial Plants
Reference Advisory/Regulatory Safety Authorities:
NFPA National Fire Protection Association NEMA National Electrical Manufacturers
Association NIOSH National Institutes of Occupational
Safety and Health OSHA Occupational Safety and Health
FM Factory Mutual UL Underwriters Laboratories
IRI Industrial Risk Insurance AIA American Insurance Association
Local Authorities Insurance Carriers
Safety

Version B June, 2020 7 MagnaRam-SK
1.2 General Safety Instructions
Only trained and certified personnel should attempt to operate any equipment. (To acquire
necessary training, please contact the training center in Plymouth Michigan at 734-979-0100).
Supervisors must ensure that personnel are properly trained in the safe usage of all equipment as well as
proper procedures which are outlined in system manuals for parts and accessories. All materials provided
to the user address safety advisories, label markings, pictograms and warnings. All users of SAMES
KREMLIN, Inc. products should be safety trained and certified before operating any equipment. Improper
use of system equipment may result in injury. This equipment is for professional use only. Equipment
should be used only for what it has been designed for. Never modify or alter any component of the
system. All parts and accessories supplied should be routinely inspected. Always replace defective or
worn parts whenever necessary.
Never exceed the equipment’s maximum recommended operating pressure.
Always comply with local and state regulations concerning safety, fire and electrical codes. Use only
materials which are intended to be used with the design of the equipment. Ensure solvents being used are
also compatible with the components internal design. (Always refer to the material safety data sheet
supplied by the manufacturer).
1.3 Pictograms

Version B June, 2020 8 MagnaRam-SK
1.4 Pressure Hazards
Current legislation requires that an air relief shut off valve is mounted on the supply circuit
of the pump motor as to bleed residual air pressure when closing the circuitry. Without
this precaution, the motors residual air pressure may allow the pump to generate
excessive pressure which may result in injury. Therefore, always ensure that a material
drain valve is mounted in series of the material delivery circuit.
1.5 High Pressure Injection Hazards
When working with high pressure application equipment, special care is required. Fluid
lines may burst from excessive pressures. This increases the risk of a material injection
wound under the skin.
•Seek immediate medical attention should a material injection wound occur. Failure to
do so could lead to serious, long lasting health issues.
•Never point the applicator nozzle toward another individual. Additionally, refrain from
ever placing any extremities in front of the dispensing tip.
•Always follow the proper system shut down procedure and depressurize the air and
fluid circuits before attempting to carry out any work. This includes collecting of fluids,
cleaning, troubleshooting and preventative maintenance procedures.
•Whenever possible, always ensure the high-pressure applicator trigger is in the
locked position when not in use.
1.6 Fire - Explosion - Sparks - Static Electricity Hazards
A poor earth ground connection, inadequate ventilation, sparks and static electricity may
trigger a fire or explosion. In order to avoid these potential risks when using or servicing
equipment, the following safety procedures should always be adhered to;
•Ensure a good earth ground connection and grounding of all parts to be handled by
personnel. Use proper care with solvents and rags.
•Provide adequate ventilation.
•Stress good housekeeping measures to keep the worksite free and clear of any debris
that may be a source of ignition. This might include waste or reclaimed solvent and
paints, chemicals, paper and spent material drums.
•Identify any equipment failures which could cause a spark.
•Avoid using volatile application materials which may cause the formation of flammable
gas.
•Verify that all material drums and paint totes are covered with secure lids and retain
grounding straps.

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1.7 Toxic Product Hazards
Toxic materials and vapors can cause severe injury not only though contact with the
body, but also if they are ingested or inhaled. Therefore, it is imperative that personnel;
•Know the material products and risks they are being exposed to. Properly read all
Material Safety Data Sheets and understand the content.
•Be certified in the handling and disposal of hazardous materials. Additionally, how
materials must be stored in accordance with all regulations.
•Protective clothing should always be worn in compliance with the material
manufacturers' recommendations.
•Depending on the application and chemical safety instructions, safety glasses, gloves,
footwear, protective masks and possible breathing equipment should be worn to
comply with all regulations.
CAUTION!
It is forbidden to use any solvent containing a halogenated hydrocarbon base
material that can come in contact with equipment made from aluminum or zinc. The
non-compliance with the instruction has the capacity to cause explosion hazards
which may result in fatal injuries.
1.8 Lockout Energy Sources
Lock out any source of energy and relieve/discharge any force/voltage/pressure before
performing any maintenance on the system.
•Electrical – Main control panel before working on Temperature Conditioning System
or Electrical service panel. Voltages 480V, 220V, 120V, 24V.
•Material Pressure – Bleed Pump pressure and lockout air supply to pumps before
disconnecting any material hose, filter, pump fluid section, traced water hose and
dispense applicator.
•Air Pressure – Close lockout pneumatic ball valve and bleed and stored air pressure
in the system. NOTE: Air Intensifier outlet must be discharged separately.
•Water Pressure – Turn off TCU and Lockout Main control panel – close water ball
valves at TCU before any maintenance is performed on the water system.
•Oil Recirculation – Turn off air supply to recirculation pump.
1.9 Heavy Equipment
Use proper lifting techniques and/or mechanical lifting aids remove the pumps, meters
and applicators when repairing. Failure to follow instructions may result in personal injury.

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1.10 Equipment Requirements
1.10.1 Pumps
Before carrying out any work, it is important that the user become familiar with all aspects
of the fluid pump. The operator shall understand the equipment and the safety related
issues that are associated with these components. When in operation, always keep ones’
hands away from the moving parts. Before starting up any equipment, please read the
PRESSURE RELIEF instructions. Ensure that any relief or drain valves that have been
incorporated are in proper working condition.
1.10.2 Hoses
•Keep all hosing runs away from moving parts and hot surfaces.
•Never expose product pneumatic or material lines and hoses to temperatures higher
than 60°C / 140° F or lower than 0°C / 32° F.
•Avoid kinking of hoses. Always install pneumatic and material lines with sweeping soft
bends.
•Before production, verify that all fittings are properly fastened as to avoid possible
leaks.
•Routinely check the hoses for kinking and wear/leaks.
•Never exceed the working pressure (WP) indicated by the manufacturer.
1.10.3 Commercial Products
Considering the variety of products that may be used by the consumer, it is an
impossibility to predict with any certainty issues which may arise when mixing non-
compatible coating materials. Negative reactions (from non-compatible materials) can
cause very serious conditions to the user. Therefore, SAMES KREMLIN, Inc. assumes no
liability for:
•Any user equipment not designed to be compatible with a specific chemical
composition of a material coating.
•Risks taken by staff or personnel who have not been properly trained or certified.
•Prior damage to existing equipment. (Pre-existing conditions).
•Overall quality due to improper equipment use.