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Graco SaniForce Operation

Graco SaniForce Operation

Drum unloader sdu system
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Operation
SaniForce® Drum Unloader (SDU)
System
For use with hygienic 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.
3A5402B
EN

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Summary of Contents for Graco SaniForce

  • Page 1 Operation SaniForce® Drum Unloader (SDU) 3A5402B System For use with hygienic 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.

  • Page 2: Table Of Contents

    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...

  • Page 3: Warnings

    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 back to these Warnings.
  • Page 4 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.
  • Page 5 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.

  • Page 6: Configuration Matrix

    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. SDU A01AAA1AA0C21 Sample Configuration Number: Sanitary Frame Pump Platen Seal Seal Controls Acces- Wash Bin Certifica- Drum Style...
  • Page 7 Configuration Matrix Seal Material Controls Accessories‡ Wash Bin Certification Polychloro- Exposed pneumatic, None None EN 10204 type prene SST inflatable EPDM Enclosed pneumatic, Caster kit EN 10204 type SST inflatable Enclosed electro- Drum dolly Ram pneumatic, SST inflatable Exposed pneumatic, SST Ram piston SST static rods...

  • Page 8: Installation

    Before unpacking, examine packing materials for selecting and installing system components. signs of damage. If damaged, take pictures of the damage and contact Graco for directions on how to Reference letters in the text, for example (A), refer to proceed.
  • Page 9 Installation Fig. 1 Typical installation System Components Required Accessories/Components Not Supplied Air cylinders Outlet Line Pressure Relief Valve rated for the expected fluid working pressure Air motor of the pump Displacement pump Fluid Line Platen Air Supply Line Air Line Drain Valve Control Panel Stop Rod Air Filter...

  • Page 10: Control Panel (Exposed)

    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. Main air slider valve Turns air on and off to the system.

  • Page 11: Control Panel (Enclosed Pneumatic)

    Installation Control Panel (Enclosed Pneumatic) When supplied with a continuous supply of air, the control panel can control the SDU functions for manual unloading of drums. Seal control switch Controls when air is applied to the seal. Air motor control switch Turns air on and off to the air motor.

  • Page 12: Control Panel (Electro-Pneumatic)

    SDU functions for automatic, manual, or batch unloading of drums. This panel is UL508A certified and requires using only Listed or Recognized components. Replacing parts with genuine Graco parts is important to maintain this certification. See the parts manual for replacement part numbers. Touch screen display Operator interface for control of the SDU.

  • Page 13: Line Accessories

    Installation Line Accessories • SDU: Attach the ground cables as shown. Attach the clamp end of the grounding wire to a true earth ground. See Fig. 1. • Outlet Line Pressure Relief Valve (R): provides a pressure relief path for the outlet line. Only needed if a valve is used downstream in the outlet line •...

  • Page 14: Ac Power

    Installation AC Power 3. Connect equipment to 100 – 240 VAC, single phase, 50/60 Hz, 15 A service with 14 AWG stranded copper wire. Attach to L1 and L2 on power switch as shown. Torque to 8 in-lbs (0.9 N•m). NOTICE Branch circuit protection and power disconnect to be provided by the installer per local code.

  • Page 15: Manual Ram Lock

    Installation Manual Ram Lock Install a Platen Inflatable Seal This procedure assumes that no inflatable seal is currently installed on the platen and the platen is attached to the drum unloader assembly. If the platen is detached from the pump lower, the inflatable seal can be installed entirely from the top of the platen.

  • Page 16: Adjust Drum Stops

    Installation Adjust Drum Stops 6. Lower the ram assembly partially into the drum and inflate the platen seal (if applicable). 7. Rotate each drum stop to contact the drum and tighten the drum stop bolts. 8. Deflate the platen seal (if applicable), raise the ram assembly, and remove the empty drum.

  • Page 17: Operation

    Operation Operation Ram Pressure Relief Procedure b. Navigate to the System Configuration screen, page Press the Shutdown/Depressurize icon. Follow the Ram Pressure Relief When pressed, a pop-up will appear Procedure whenever you see this indicating the system is depressurizing. symbol. The ram will slowly move to the bottom of its travel.

  • Page 18: Start And Adjust Ram

    Operation Start and Adjust Ram 2. Enclosed pneumatic control panel: a. Open the air supply to the control panel. b. While observing the position of the ram assembly in relation to surrounding obstacles, operate the ram button to the up position to raise the ram assembly to its •...

  • Page 19: Start And Adjust The Pump

    Operation Start and Adjust the Pump 2. For Enclosed Pneumatic Control Panel: a. Connect pump outlet fittings and hose (not supplied). NOTE: Be sure all components are adequately sized and pressure rated to meet the system’s requirements. Keep hands and fingers away from the platen, b.
  • Page 20 Operation 3. For Electro-pneumatic Control Panel: a. Connect pump outlet fittings and hose (not supplied). NOTE: Be sure all components are adequately sized and pressure rated to meet the system’s requirements. b. Be sure the pump is set to pause. Set the ram down air pressure to 10 psi (0.06 MPa, 0.6 bar).

  • Page 21: Change Drum

    Operation Change Drum 4. Inspect platen and, if necessary, remove any remaining material or material build-up. a. Perform pump pressure relief. See Pump Pressure Relief Procedure, page b. Use a tool to remove material build-up. 5. To empty another drum, perform the steps of Excessive air pressure in the material drum could Start and Adjust Ram, page cause the drum to rupture, causing serious injury.

  • Page 22: Maintenance

    Maintenance Maintenance Lubrication 5. Remove the clamp at the large flange connection where the platen attaches to the pump lower and remove the platen mounting clamps where the The pump is lubricated at the factory. It is designed platen attaches to the platen support rods. to require no further lubrication for the life of the packings.

  • Page 23: Cleaning The Pump Lower

    Maintenance Cleaning the Pump Lower 7. Raise the ram assembly to lift the air motor off of the pump lower. Stop raising the ram when the air motor clears the pump lower. 8. Slide the platen and pump lower out from under the air motor.

  • Page 24: Electro-Pneumatic Control Panel Display Screens

    Electro-pneumatic Control Panel Display Screens Electro-pneumatic Control Panel Display Screens When the system is powered up, the Automatic run screen is displayed. The first time the unloader system is powered up, it will be necessary to perform system setup. See System Configuration Screen, page The display screen is a touch screen.
  • Page 25 Electro-pneumatic Control Panel Display Screens Specialty key definitions Description Exit Exit the keyboard or keypad. If the entry has not been saved, any displayed entry shown in the top field of the keyboard or keypad is lost. Backspace Erase the last character of the displayed entry in the top field of the keyboard or keypad. This key will erase one character each time it is pressed.

  • Page 26: Startup Screen

    Electro-pneumatic Control Panel Display Screens Startup Screen When the power ON/OFF switch is turned ON, the display shows the startup screen while the system prepares the system for operation. 3A5402B...

  • Page 27: Automatic Screen

    Electro-pneumatic Control Panel Display Screens Automatic Screen Feedback enabled Feedback disabled NOTES: of the drum. If the platen is not below the rim of the drum when the start button is released, ram • To prime a full drum for automatic operation, press movement ceases.
  • Page 28 Electro-pneumatic Control Panel Display Screens Icon / Field Description Begin drum unloading at the current state of the recipe. If the recipe was stopped before completing, the drum unloading resumes at the point where the unloading was stopped. Stop drum unloading. If the recipe is not complete, the drum unloading status is retained so that the recipe can be completed.

  • Page 29: Manual Screen

    Electro-pneumatic Control Panel Display Screens Manual Screen NOTES: • These buttons are disabled while the automatic sequence is operating. • Recipes which are locked will disable the pressure boxes from editing on this screen. Icon/Field Description Indicates that this is the manual operation screen and it is currently active. Unit of measurement Defined by the value selected in the Pressure Units field on the System Settings screen.
  • Page 30 Electro-pneumatic Control Panel Display Screens Icon/Field Description Seal Control Seal Inflate Press to inflate the platen seal. Stop seal action Stop inflating or deflating the seal. To resume, press the desired seal action button, inflate or deflate. Seal Deflate Press to deflate the platen seal. Batch Information Current Job Details of the current batch.

  • Page 31: Recipe Screens

    Electro-pneumatic Control Panel Display Screens Recipe Screens NOTES: • Recipes may use feedback from external devices Recipes define preset settings for unloader operation to determine when a specific measure of product when unloading defined products. If the SDU will has been evacuated, so the system settings must be operated manually, it is not necessary to define be completed before any recipes are defined.
  • Page 32 Electro-pneumatic Control Panel Display Screens Material Recipe Screen Icon/Field Description Recipe # A numeric list of all available recipes. A maximum of 100 (0–99) recipes can be defined. Recipe Name User defined alphanumeric name. The maximum number of characters allowed, including spaces is 19.
  • Page 33 Electro-pneumatic Control Panel Display Screens Material Recipe Edit Screen When creating a new recipe from scratch, default pressure settings will be pre-filled in. These pressures are offered as good starting points but most will have to be varied to obtain optimal performance for the specific application.
  • Page 34 Electro-pneumatic Control Panel Display Screens Icon/Field Description Default Batch Size Select a value that is indicative of the normal size of a batch of the product being evacuated. The value can be larger than the contents of the container. In this case, one or more container changes may be required to complete the batch.
  • Page 35 Electro-pneumatic Control Panel Display Screens Material Recipe Timers Screen Icon/Field Description Press to complete the fields of this recipe with the values assigned to another recipe. After copying, individual fields can be modified to differentiate this recipe from the one copied. The copied values will overwrite any defined values in this recipe.
  • Page 36 Electro-pneumatic Control Panel Display Screens Container Recipe Screen Icon/Field Description Container Recipe # A numeric list of all available recipes. A maximum of 20 (0–19) recipes can be defined. Container Recipe User defined alphanumeric name. The maximum number of characters allowed, including spaces is 19.
  • Page 37 Electro-pneumatic Control Panel Display Screens Container Recipe Edit Screen An empty drum will be required for defining the container recipe. Icon/Field Description Recipe Name User defined alphanumeric field, 19 characters maximum Recipe Locked When locked, the password defined on the System Settings page must be entered to edit the selected recipe.
  • Page 38 Electro-pneumatic Control Panel Display Screens Icon/Field Description Ram Jog Press and hold to lower the ram assembly. Releasing the button will stop lowering the ram. Ram Down Momentarily press to lower the ram to the lowest position. The ram will continue lowering until the ram has reached the bottom of its travel unless manually stopped.

  • Page 39: Event Log

    Electro-pneumatic Control Panel Display Screens Event Log Events are Alarms, Deviations, Advisories, and Records detected by the system. They are logged to assist in troubleshooting the system. Alarms will cause the unloader to cease operation when they are detected. A user will need to clear the alarm and restart the unloader.
  • Page 40 Electro-pneumatic Control Panel Display Screens ELECTRIC SHOCK HAZARD To reduce the risk of electric shock when accessing the electrical enclosure while power is present: • All electrical work must be done by a qualified electrician. • Wear appropriate personal protective equipment. Event Error Type...
  • Page 41 Alarm WX00 Unexpected state detected in the Software Error Acknowledge the alarm. If the alarm is software triggered regularly, contact Graco Alarm Check X20AO2622 module and wiring. X20AO2622 analog WMCA X20AO2622 module reports an Verify that the modules are installed in...

  • Page 42: Job Log

    Electro-pneumatic Control Panel Display Screens Job Log This screen will show the latest completed jobs, but user interaction is not currently available. 3A5402B...

  • Page 43: System Configuration Screen

    Electro-pneumatic Control Panel Display Screens System Configuration Screen The system configuration screen defines the SDU parameters. Icon Description Import USB: Import the system settings from a flash drive. Export USB: Export the system settings to the flash drive. I/O Status: Press to view the I/O Status screen. Shutdown/Depressurize: Press to vent pressure from the system.
  • Page 44 Electro-pneumatic Control Panel Display Screens Field Description Language Select the desired language. Date Format Select the desired date format. Date Enter the current date. Time Enter the current time. Password Enter the desired password to be used to access the control box display screens.

  • Page 45: Feedback Control Settings Screens

    Electro-pneumatic Control Panel Display Screens Feedback Control Settings Screens No Feedback 3A5402B...
  • Page 46 Electro-pneumatic Control Panel Display Screens Feedback Control To reduce the risk of injury due to electric shock, remove power to the control panel before entering the control panel to make connections for measurement devices. Selecting pulse feedback Selecting scale feedback Icon/Field Description Feedback Type...
  • Page 47 Electro-pneumatic Control Panel Display Screens Icon/Field Description Aux 1 Input CM8281–11 Input Voltage Asserted: >16 VDC. Not Asserted: <5 VDC Select input type: • None: Not monitored • Start/Stop: When running the Automatic Sequence and the System Loaded status is set, the pumps will only run if Asserted. The signal is ignored when running the prime and empty sequences.

  • Page 48: About

    Electro-pneumatic Control Panel Display Screens About The about screen displays the SDU software information. Icon/Field Description Removes all user-defined data. This includes locked recipes and passwords, system configuration data, pressure settings, etc. 3A5402B...

  • Page 49: I/O Status Screen

    Electro-pneumatic Control Panel Display Screens I/O Status Screen Icon / Field Active Conditions Digital Outputs Available settings: (blue) Asserted (yellow) Not asserted Pump fast Pump slow, pump fast Ram up Ram jog, ram down Seal inflate Air assist Seal deflate Aux 1 Auxiliary 1 output Auxiliary 2 output...

  • Page 50: Dimensions

    Dimensions Dimensions In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In (cm) In. (cm) 116 (295) 76.2 (194) 21.0 (53.3) 25.0 (63.5) 44.0 (112) 48.0 (127) 27.5 (700) 57.5 (146) 3A5402B...

  • Page 51: Schematic (Exposed Control)

    Schematic (exposed control) Schematic (exposed control) 3A5402B...

  • Page 52: Schematic (Enclosed Control)

    Schematic (enclosed control) Schematic (enclosed control) 3A5402B...

  • Page 53: Schematic (Electo-Pneumatic Control)

    107PB E-STOP 1060 1070 LINE+ 108CP 24 VDC CIRCUIT PROTECTOR 2.0 AMP 1090 24 VDC LOAD+ I/O POWER LINE 125 1061 1060 GRACO HMI 4PPC70.070M-20F001 RDY/F OPS1 OPS2 OPS3 OPS4 OPS5 POWERLINK OP2 OP1 1060 1060 1150 1060 1090 1090...
  • Page 54 Schematic (electo-pneumatic control) BASE- X20BM11 TERMINAL BLOCK- X20TB12 MODULE- X20DS438A 1520 BLACK 1530 BLACK 1540 LASER SENSOR BROWN 1550 SHOP AIR PRESSURE BROWN NOT USED 1560 WHITE BLUE 1570 BLUE 1580 BLACK 1600 SEAL AIR PRESSURE BROWN 1620 BLUE 3A5402B...
  • Page 55 Schematic (electo-pneumatic control) FROM LINE FROM LINE FROM LINE 1061 1060 1061 BASE- X20BM11 BASE- X20BM11 TERMINAL BLOCK- X20TB12 TERMINAL BLOCK- X20TB12 MODULE- X20DO8322 MODULE- X20AO2622 BLACK-2 2270 2020 BLACK-1 1061 WHITE PUMP FAST SOLENOID VALVE 1060 BROWN 1060 BROWN 1060 BLACK-2 BLACK-1 WHITE 2280...
  • Page 56 Schematic (electo-pneumatic control) FROM LINE 1060 1061 BASE- X20BM11 TERMINAL BLOCK- X20TB12 MODULE- X20CM8281 24 VDC OPTIONAL 3.3 mA DIGITAL INPUT 1 24 VDC OPTIONAL 3.3 mA DIGITAL INPUT 2 OPTIONAL 24 VDC 3.3 mA PULSE COUNTER INPUT OPTIONAL 24 VDC 500 mA DIGITAL OUTPUT 1...
  • Page 57 Schematic (electo-pneumatic control) RV2 (SOME MODELS) PRESSURE RELIEF VALVE 85/100/130 PSI PUMP 1/2" TUBE 1/2" TUBE PUMP 2 (A) FREE FLOW 3/8" TUBE PUMP CIRCUIT EXHAUST RAM DOWN UP SPEED (CONNECT TUBING TO 3/8" TUBE CYLINDER TOP) FREE FLOW RAM UP 3/8"...

  • Page 58: Kits And Accessories

    Kits and Accessories Kits and Accessories Caster Kit (Accessory code AB) Stainless Steel Piston Rods (Accessory code AE) Provides added corrosion protection. Kit includes: • 2 dollies, each with 2 swivel casters • Mounting hardware Kit contains: Drum Dolly (Accessory code AC) •...

  • Page 59: Technical Data

    Technical Data Technical Data Metric Maximum fluid working pressure 5:1 pump 410 psi 2.9 MPa, 28.7 bar 6:1 pump 650 psi 4.5 MPa, 44.8 bar 12:1 pump 1200 psi 8.3 MPa, 83 bar 1:1 diaphragm pumps 120 psi 0.8 MPa, 8 bar Maximum system air inlet pressure 100 psi 0.69 MPa, 6.9 bar...
  • Page 60 Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts.

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