Graco 248785 Operation manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

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.

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

Supply Unit A Supply Unit B

Filter/Pump Control Stand

Material Out

Material In

Cell Communications Cable to PFlo Control Box

10 10

16 16

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

bar

MPa

PSI X10

OUT 2

OUT 1

bar

MPa

PSI X10

OUT 2

OUT 1

SP 1

bar

MPa

PSI X10

OUT 2

OUT 1

rP 1

bar

MPa

PSI X10

OUT 2

OUT 1

bar

MPa

PSI X10

OUT 2

OUT 1

Actual pressure is 100 psi

(psi number displayed x 10)

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

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

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

This manual suits for next models

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