Graco C59519 Operation manual

310295

Revision A

First choice when

quality counts.

INSTRUCTIONS-PARTS LIST

INSTRUCTIONS

This manual contains important

warnings and information.

READ AND KEEP FOR REFERENCE.

3” RAM

Electric Crossover Kit

250 psi (1.7 MPa, 17.2 bar) Maximum Air Inlet Pressure

Part No. C59519, Series A

Electric Crossover Kit

Table of Contents

Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Identification and Function 4. . . . . . . . . . . .

Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty 12. . . . . . . . . . . . . . . . . . . . . .

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

Graco Inc. is registered to I.S. EN ISO 9001

2 310295

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

instructions.

WARNINGS

INSTRUCTIONS

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

This equipment is for professional use only.

Read all instruction manuals, tags, and labels before operating the equipment.

Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

Check equipment daily. Repair or replace worn or damaged parts immediately.

Do not exceed the maximum working pressure stated on the equipment or in the Technical Data

for your equipment. Do not exceed the maximum working pressure of the lowest rated component

in your system.

Use fluids and solvents which are compatible with the equipment wetted parts. Refer to Technical

Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

Wear hearing protection when operating this equipment.

Comply with all applicable local, state, and national fire, electrical, and safety regulations.

310295 3

WARNINGS

MOVING PARTS HAZARD

Moving parts, such as the ram plate/pump inlet can pinch fingers.

Do not operate the equipment with the guard removed.

Keep clear of all moving parts when starting or operating the equipment.

Keep hands and fingers away from the priming piston during operation and whenever the pump is

charged with air.

Keep clear of the ram plate, pump fluid inlet, and lip of the fluid container when raising or lowering

the ram.

Before checking or servicing the ram or pump, follow the Pressure Relief Procedure in the ram or

pump manual.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,

inhaled, or swallowed.

Know the specific hazards of the fluid you are using.

Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,

state and national guidelines.

Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and

solvent manufacturer.

Avoid exposure to heated material fumes.

Provide adequate ventilation.

FIRE, EXPLOSION AND ELECTRIC SHOCK HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and

result in fire, explosion, or electricshock and other serious injury.

Ground the equipment, the object being dispensed, and all other electrically conductive objects in

the dispense area. Proper grounding dissipates static electricity generated in the equipment. See

Ground the System in your system manual.

Do not use this equipment with flammable liquids.

Keep the dispense area free of debris, including solvent, rags, and gasoline.

If there is any static sparking while using the equipment, stop dispensing immediately. Identify

and correct the problem.

Make sure all electrical work is performed by a qualified electrician only.

Make sure all electrical equipment is installed and operated in compliance with applicable codes.

Make sure power is disconnected when servicing and repairing equipment.

Have any checks, installation, or service to electrical equipment performed by a qualified electrician

only.

4 310295

Component Identification and Function

Fig. 1

KEY

A3–Way Solenoid Valve (2)

BEmpty Level Kit (2) CLimitSwitch(2)

DUnloaderCross–overPanel

8584A

BA B

Supply Unit A Supply Unit B

NOTE: Viewed from the

loading direction.

CL3 CL1 CL4 CL2

310295 5

Installation

Prepare the Site

NOTE: Always use Genuine Graco Parts and Acces-

sories, available from your Graco distributor. If you

supply your own accessories, be sure they are ade-

quately sized and pressure rated for your system.

NOTE: Letters and numbers in parenthesis refer to the

callouts and the parts list on page 10.

Bring a compressed air supply line from the air com-

pressor to the pump location. Be sure all air hoses are

properly sized and pressure-rated for your system.

Use only electrically conductive hoses. The air hose

should have a 3/4 npsm(m) thread.

Before installing any air line components, blow out the

air lines to remove scale and other debris. Use pipe

compound or tape sparingly and only on male threads.

Install a bleed-type shutoff valve in the air line up-

stream from all other air line components, to isolate

them for servicing.

Electrical Service

Electrical power to the crossover is supplied by a

power cord.

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

The electrical wiring shall be performed

only by trained and qualified personnel

to reduce the risk of serious injury and

electric shock.

Observe all local codes and regulations

regarding electrical wiring.

When installing in a flammable atmosphere (hazardous

location) refer to Article 500 of the US National Electric

Code or other applicable agency standards to plan the

work.

The operating voltage is 120VAC. This equipment re-

quires a 50/60 Hz, single-phase, 15 Ampere grounded

power supply.

Application

The electric crossover kit is designed to allow two

drum ram systems to be converted into a continuous–

flow system. It shifts pumping from an online ram

when the drum becomes empty.

Typical Electric Crossover Installation

WARNING

Never leave fingers between the ram plate and the

drum when the ram plate is being operated.

WARNING

Never enter the operating area of the ram , when

the ram is in the top position. When the air pres-

sure is lost or in the case of leaks in the air pres-

sure system, the ram plate may drop.

The typical installation, shown on page 4, Fig. 1 of this

manual, is only a guide. See the system manual for

your application or contact your Graco distributor for

assistance in designing a system to meet your needs.

See your ram manual if installing a new ram or relocat-

ing an existing ram.

6 310295

Installation

Electric Crossover Setup

1. Install cross–over unloader (1) on ram assembly,

using U–bolt (3), washer (4) and nut (5) as shown

in Parts, page 7. Connect air supply.

WARNING

ELECTRIC SHOCK HAZARD

Do not open the electrical control panel,

unless you are a trained professional.

Before opening the control panel, make sure that

all power has been removed from the control panel.

2. Connect electrical connectors to cross–over

unloader (see Fig. 2). Refer to Schematic,

Fig. 3.

Fig. 2

3. Install solenoid valve (7) and connect electrical

connector as shown in Parts, page 8.

4. Install 2 empty level kit assemblies (9) on each

ram assembly, using attaching parts (9e thru 9g),

as shown in Parts, page 9.

5. Connect electrical connector to each empty level

kit assembly (9). Refer to Schematic, Fig. 3.

Fig. 3

6. Adjust limit switch (9c) to trip with the ram plate 1”

from base plate (see Parts, page 9).

310295 7

Parts

Model C59519 Electric Crossover

Includes items 1–13 (See page 10)

8584A

See Sheet 2

4, 5

See Sheet 2

See Sheet 3

10, 11, 12, 13

Sheet 1 of 3

SOL 121 SOL 117 LS 109

Supply Unit #1 Supply Unit #2

8 310295

Parts

Model C59519 Electric Crossover

Includes items 1–13 (See page 10)

Sheet 2 of 3

Air Out to Motor

Air In

Top View

310295 9

Parts

Model C59519 Electric Crossover

Includes items 1–13 (See page 10)

10)

9e, 9f 9g

Sheet 3 of 3

10 310295

Parts

Model C59519 Electric Crossover

Includes items 1–13

Ref Part

No. No. Description Qty

1 C59528 CROSS–OVER, UNLOADER 2

2 617837 PLATE, mounting, J–box 4

3 C24332 U–BOLT, 3/8–16 2

4 107176 WASHER, lock, 3/8 4

5 100307 NUT, hex, 5/8–16 4

6 C06311 MUFFLER, 3/4 NPT 2

7 C06325 VALVE, solenoid, 3/4 NPT 2

8 175013 NIPPLE, hex, 3/4 NPT 2

9 C55333 KIT ASSEMBLY, empty level (includes

items 10 through 16 2

Ref Part

No. No. Description Qty

9a C32111 S LIGHT FIXTURE 1

9b C07451 S CONNECTOR, receptacle 1

9c C07368 S LIMIT SWITCH w/lever 1

9d C55409 S BRACKET, limit switch 1

9e C19192 S NUT, hex, 3/8–16 2

9f C19213 S WASHER, lock 2

9g C24332 S U–BOLT 1

10 C19736 SCREW, drive 8

11 C19107 SCREW, hex hd, 5/16–18 4

12 C19211 WASHER, lock, 5/16 8

13 C19191 NUT, hex, 5/16–18 4

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