Graco SaniForce STU Series Operation

Tote unloader

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Operation

SaniForce® Tote Unloader (STU)

For use

use with

with food

food grade

grade bulk

For

use

with

food

grade

select

select models

select

models

models are

are approved

are

approved for

approved

Matrix

Matrix on

on page

page 6 6 6 for

page

for more

for

more information.

Important

Important Safety

Important

Safety

Safety Instructions

Read all warnings and instructions in this manual and all related

manuals. Save

Save all all all instructions.

Save

For Maximum Working Air and Fluid

Pressures, see Models on page 8.

bulk supply

supply of of of medium

medium to to to high

bulk

supply

medium

for use

for

use in in in explosive

use

explosive atmospheres

explosive

information.

Instructions

instructions.

PROVEN QUALITY. LEADING TECHNOLOGY.

high viscosity

viscosity product.

product. For

high

viscosity

product.

atmospheres or or or hazardous

atmospheres

hazardous locations.

hazardous

3A5416E

For professional

professional use

use only.

only. Only

For

professional

use

only.

locations. See

locations.

See Configuration

See

Configuration

Only

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Summary of Contents for Graco SaniForce STU Series

Page 1 Operation 3A5416E SaniForce® Tote Unloader (STU) For use use with with food food grade grade bulk bulk supply supply of of of medium medium to to to high high viscosity viscosity product. product. For For professional professional use use only. only.
Page 2: Table Of Contents
Contents Contents Contents Related Manuals ..........2 Start and Adjust the Pump ......26 Change the Tote .......... 26 Warnings ............3 Emergency Stop .......... 28 Configuration Matrix..........6 Pump Shutdown .......... 28 System Shutdown ........28 Models............... 8 Flushing and Storage ........28 Overview............
Page 3: Warnings
Warnings 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 SKIN SKIN INJECTION SKIN INJECTION INJECTION HAZARD HAZARD HAZARD High-pressure fluid from dispensing device, 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 immediate surgical surgical treatment.
Page 5 Warnings WARNING EQUIPMENT EQUIPMENT EQUIPMENT MISUSE MISUSE HAZARD MISUSE HAZARD 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 Matrix Configuration Configuration Matrix Check the identification plate (ID) for the Configuration Number of your system. Use the following matrix to define the components of your system. STU A01AAA1AA1C21 A01AAA1AA1C21 A01AAA1AA1C21 Sample Configuration Configuration Number: Number: Sample Sample Configuration...
Page 7 Configuration Matrix Seal Seal Material Seal Material Material Controls Controls Controls Accessories Accessories Accessories Wash Wash Wash Kit Certification Certification Certification A A A Polychloro- 1 1 1 Enclosed 0 0 0 None EN 10204 type 2.1 Bag Clamp Kit prene (White) Pneumatic B B B...
Page 8: Models
Models Models Models Models Pump Pump Pump Max Pump Pump Pump Air Air Inlet Inlet Inlet Max Working Working Fluid Working Fluid Fluid Max System System System Air Max Control Control Control Air Air Inlet Inlet Inlet Option Pressure PSI PSI (MPa, (MPa, Pressure PSI...
Page 9: Overview
Overview Overview Overview Overview System Components Components System System Components Fig. 1 Typical components 1 1 1 - - - A A A Stainless Stainless Steel Stainless Steel Steel Frame: Frame: supports all of the system components. Frame: 1 1 1 - - - B B B Sanitary Sanitary Pumps: Sanitary...
Page 10 Overview 1 1 1 - - - C C C Air Cylinders: Cylinders: raises and lowers the pumps and the ram plate in and out of the material container. Cylinders: 1 1 1 - - - D D D Ram Plate: Plate: Plate: applies an even amount of pressure to the material in the tote.
Page 11: Before Installing
Before Installing Before Installing Installing Before Before Installing Palletized STU 3A5416E...
Page 12: Uncrate The Equipment
11. Attach the rigid air line between the cylinder air 4. Compare the packing slip against items inside distribution manifold, down air pressure fitting the crate. Immediately call your Graco distributor (EE), and the pilot valve tee (EE1). about any shortages or damage.
Page 13: Select A Location
• Provides easy and safe access to the air supply shutoff valves and the control panel. Graco • Use a forklift or hand truck and support devices, recommends a minimum of 3 ft (0.91 m) of open such as a hoist, and have an adequate number of space in front of the panel.
Page 14: Installation
Installation Installation Installation Installation Before operating the pump, ground the system as explained below. • Electro-pneumatic Electro-pneumatic Electro-pneumatic control control control panel: panel: panel: If installed, it is grounded through the grounding conductor of the incoming power wiring. All electrical wiring must be done by a qualified electrician and comply with all local codes and •...
Page 15: Ac Power
Installation AC Power Power Power 3. Connect the equipment to 100–240 VAC, single phase, 50/60 Hz, with a maximum 15 A branch circuit protection and disconnect switch provided AC power is required for an unloader with an by the installer. Use 14 AWG (2.0 mm ) stranded electro-pneumatic control panel.
Page 16: Safety Latch
Safety Latch Safety Latch Latch Safety Latch Latch Lockout Lockout Safety Safety Latch Safety Safety Latch Lockout Lockout/tagout holes have been provided to lock the ram in the raised position. 1. Push the safety latch handle all the way in to align the lockout/tagout holes (Y).
Page 17: Controls And Connections
Controls and Connections Controls and and Connections Connections Controls Controls Connections Control Panel Panel (Pneumatic) (Pneumatic) Control Control Panel (Pneumatic) Part Part No. Part No. 25C578 25C578 25C578 Control Control Control Side Side Side View View View Component Component Component Panel Panel Panel 3A5416E...
Page 18 Controls and Connections Connection Side Side View View Bottom Bottom Bottom View View View Connection Connection Side View NOTE: NOTE: NOTE: When routing hoses for the air motor air the ram moves up and down. Select which hose supply, seal inflation, and air assist (blowoff) through support bracket hole to use for each specified hose the hose support bracket on the side of the frame, by observing where that hose will travel during...
Page 19 Controls and Connections Ref. Symbol Description Ref. Ref. Symbol Symbol Description Description Ram Position Position Position Selector: Selector: Selector: Ram Up Ram moves up. Up speed is regulated by flow control valve FC2. Up pressure is regulated by R4 (V). Ram Hold Hold Hold...
Page 20 Controls and Connections Ref. Symbol Description Ref. Ref. Symbol Symbol Description Description — — — Ram Down Down Regulator Down Regulator Regulator Controls the air pressure supplied to the cylinders for moving downward. — — — Control Panel Panel Air Air Supply Supply Ball Ball Valve*...
Page 21 Controls and Connections Cylinder air distribution manifold Pilot check valve Ram plate Support plate 3A5416E...
Page 22: Control Panel (Electro-Pneumatic)
Control Control Panel (Electro Pneumatic) This panel is UL508A certified and requires using only Listed or Recognized components. Replacing parts with genuine Graco parts is important to Part Part Part No. No. 25D009 25D009 25D009 maintain this certification. See the parts manual for When supplied with 110–240 VAC power and a...
Page 23 Controls and Connections Ref. Symbol Description Ref. Ref. Symbol Symbol Description Description Seal Seal Seal Inflation Inflation Inflation Port Port Port Route hose through the hose block on the side of the frame and through holes in the support plate to the inflation tube (A1) of the inflatable seal. Use the provided 172 inch hose Air Assist Assist Port...
Page 24: Operation
Operation Operation Operation Operation Pressure Pressure Pressure Relief Relief Relief Procedure Procedure Procedure c. Either raise the ram to the top position and engage safety latch (see Engaging the Safety Latch, page 16) or lower Follow the Pressure Relief Procedure all the way down.
Page 25: Adjust Tote Guides
Operation Adjust Tote Tote Guides Guides Adjust Adjust Tote Guides c. Move the tote in front of the frame. d. Remove the lid from the fluid tote to expose NOTE: The following steps require an empty tote. NOTE: NOTE: the fluid bag. If present, open the outer plastic bag and pull it up over the sides of the tote, exposing the aseptic inner bag.
Page 26: Start And Adjust The Pump
Operation Start and and Adjust Adjust the the Pump Pump Start Start Adjust Pump For Electro-pneumatic Electro-pneumatic Control Control Panel: Panel: 2. For Electro-pneumatic Control Panel: a. Connect pump outlet fittings and hose (not supplied). NOTE: Be sure all components are NOTE: NOTE: adequately sized and pressure rated to meet...
Page 27 Operation c. If the ram raises the tote off of the ground, 4. Inspect the ram plate and, if necessary, remove press the air assist (blowoff) button to break any remaining material or material build-up. the vacuum between the ram plate and a.
Page 28: Emergency Stop
Operation Emergency Stop Stop Flushing and and Storage Storage Emergency Emergency Stop Flushing Flushing Storage Manual control systems do not have this feature. The STU electro-pneumatic control box has an emergency stop button (CC) below the display screen. Pressing the emergency stop button will stop the pump but does not depressurize the system.
Page 29: Maintenance
Maintenance Maintenance Maintenance Maintenance Lubrication Cleaning the the Pump Pump Lower Lower Lubrication Lubrication Cleaning Cleaning Pump Lower The pump is lubricated at the factory. It is designed to require no further lubrication for the life of the packings. There is no need to add an inline lubricator under normal operating conditions.
Page 30: Electro-Pneumatic Control Panel Display Screens
Electro-pneumatic Control Panel Display Screens Electro - - - pneumatic pneumatic Control Control Panel Panel Display Display Screens Screens Electro 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.
Page 31 Electro-pneumatic Control Panel Display Screens Specialty key key definitions definitions Specialty Specialty definitions Description Description Description Exit Exit 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 Backspace Backspace...
Page 32: Startup Screen
Electro-pneumatic Control Panel Display Screens Startup Screen Screen Startup 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. 3A5416E...
Page 33: Automatic Screen
Electro-pneumatic Control Panel Display Screens Automatic Screen Screen Automatic Automatic Screen Feedback enabled Feedback disabled NOTES: NOTES: NOTES: of the tote. If the ram plate is not below the rim of the tote when the start button is released, ram •...
Page 34 Electro-pneumatic Control Panel Display Screens Icon / / / Field Field Description Icon Icon Field Description Description AUTO AUTO AUTO SEQUENCE SEQUENCE SEQUENCE Current Current Recipe Current Recipe Recipe Name of the recipe selected for unloading this tote. Click in this field to display the recipe selection screen.
Page 35: Manual Screen
Electro-pneumatic Control Panel Display Screens Manual Screen Screen Manual Manual Screen NOTES: NOTES: NOTES: • These buttons are disabled while the automatic sequence is operating. • Locked recipes disable editing for the pressure boxes on this screen. Icon/Field Icon/Field Icon/Field Description Description Description...
Page 36 Electro-pneumatic Control Panel Display Screens Icon/Field Description Icon/Field Icon/Field Description Description Seal Seal Control Seal Control Control Seal Seal Seal Inflate Inflate Inflate Press to inflate the ram plate seal. Stop Stop Stop seal seal seal action action action Stop inflating or deflating the seal. To resume, press the desired seal action button: inflate or deflate.
Page 37: Recipe Screens
Electro-pneumatic Control Panel Display Screens Recipe Screens Screens Recipe Recipe Screens NOTES: NOTES: 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 STU will be has been evacuated, so the system settings must operated manually, it is not necessary to define all be completed before any recipes are defined.
Page 38 Electro-pneumatic Control Panel Display Screens Material Material Material Recipe Recipe Screen Recipe Screen Screen Material Recipes can be exported to a USB device and viewed or edited on a PC, then imported back into the system. See Import and Export with USB, page Icon/Field Icon/Field Icon/Field...
Page 39 Electro-pneumatic Control Panel Display Screens Material Material Material Recipe Recipe Recipe Edit Edit Screen Edit Screen Screen When creating a new recipe from scratch, default pressure settings are shown. These pressures are good starting points, but most pressure settings will have to be varied to obtain optimal performance for the specific application.
Page 40 Electro-pneumatic Control Panel Display Screens Icon/Field Description Icon/Field Icon/Field Description Description Default Default Batch Default Batch Size Batch Size 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 41 Electro-pneumatic Control Panel Display Screens Material Material Material Recipe Recipe Recipe Timers Timers Timers Screen Screen Screen Icon/Field Icon/Field Icon/Field Description Description Description Press to complete the fields of this recipe with the values assigned to another recipe. The copied values will overwrite any defined values in this recipe. After copying, individual fields can be modified to differentiate this recipe from the one copied.
Page 42 Electro-pneumatic Control Panel Display Screens Container Container Container Recipe Recipe Recipe Screen Screen Screen Icon/Field Description Icon/Field Icon/Field Description Description Recipe Recipe Recipe # # # A numeric list of all available Container Recipes can be exported to a recipes. A maximum of 100 (0–99) USB device and viewed or edited on a PC, recipes can be defined.
Page 43 Electro-pneumatic Control Panel Display Screens Container Container Container Recipe Recipe Edit Recipe Edit Screen Edit Screen Screen An empty tote is required for defining the container recipe. Icon/Field Icon/Field Icon/Field Description Description Description Recipe Name Name Recipe Recipe Name User-defined alphanumeric field, 19 characters maximum. Lock Lock Lock...
Page 44 Electro-pneumatic Control Panel Display Screens Icon/Field Description Icon/Field Icon/Field Description Description Ram Jog Press and hold to lower the ram assembly. Releasing the button will stop lowering the ram. Ram Down Down 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 45: Event Log
Electro-pneumatic Control Panel Display Screens Event Log Event Event Icon/Field Description Icon/Field Icon/Field Description Description All Events Events Events Select this field and choose a Events are Alarms, Deviations, Advisories, and selection to filter the event list to a Records detected by the system. They are logged single event type.
Page 46 Electro-pneumatic Control Panel Display Screens ELECTRIC SHOCK SHOCK HAZARD HAZARD ELECTRIC 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.
Page 47 Alarm Software Error WX00 Unexpected state detected in the Acknowledge the alarm. If the alarm is software triggered regularly, contact Graco Alarm X20AO2622 analog WMCA X20AO2622 module reports an Check X20AO2622 module and wiring. output module error error Verify that the modules are installed in the proper locations*.
Page 48 Electro-pneumatic Control Panel Display Screens Event Error Event Event Error Error Type Type Type Event Event Description Event Description Description Code Code Code Cause Cause Cause Deviation USB operation failed WXU0 A USB import or export command check that the USB device is fully was not able to be completed: an inserted into the USB ports on the back unspecified error occurred during...
Page 49: Job Log
Electro-pneumatic Control Panel Display Screens Job Log Icon/Field Description Icon/Field Icon/Field Description Description Move up the list. Momentarily The Job Log screen displays a historical log of press to move up one entry. Press jobs completed by the system. Pressing the Job and hold to continuously move up Complete button on the Automatic or Manual run the list until releasing the icon or...
Page 50 Electro-pneumatic Control Panel Display Screens A Job Log contains the following information: • Job Number • Job Name • Amount Dispensed • Target Amount for batching • Recipe Number used for the job • Name of recipe used for the job •...
Page 51: System Configuration Screen
Electro-pneumatic Control Panel Display Screens System Configuration Configuration Screen Screen System System Configuration Screen The system configuration screen defines the STU parameters. The system settings can be exported to a USB device and viewed or edited on a PC, then imported back into the system. See Import and Export with USB, page Icon/Field Icon/Field...
Page 52 Electro-pneumatic Control Panel Display Screens Icon/Field Description Icon/Field Icon/Field Description Description Lock Lock Lock If a password has been set, press the Lock button to immediately lock all settings from being edited. Enter the password to unlock the settings. The system will automatically lock after two minutes if a password is set and the user leaves the settings menu without pressing Lock.
Page 53: Feedback Control Screen
Electro-pneumatic Control Panel Display Screens Feedback Control Control Screen Screen Feedback Feedback Control Screen 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 scale feedback Selecting pulse feedback Icon/Field...
Page 54 Electro-pneumatic Control Panel Display Screens Icon/Field Description Icon/Field Icon/Field Description Description Aux 1 1 1 Input Input 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.
Page 55 Electro-pneumatic Control Panel Display Screens Setting Setting Setting K K K - - - Factor Factor Factor Setting Setting Scale Setting Scale Feedback Scale Feedback Feedback In order for a batching cycle to accurately measure In order for a batching cycle to accurately measure product, the K-Factor must be appropriately set and product, the 4 mA Mass and 20 mA Mass settings for the system outlet fluid lines fully loaded.
Page 56: Network
The Network page is used to configure the STU for network communication. Currently, the only functionality enabled via a network connection is access to a viewable-only virtual network computing (VNC) server. Contact Graco Customer Support for information regarding Network Communication Protocols. To access the view-only VNC connection, connect...
Page 57: About
Electro-pneumatic Control Panel Display Screens About About About The About screen displays the STU software information. Icon/Field Icon/Field Icon/Field Description Description Description Removes all user-defined data. This includes locked recipes and passwords, system configuration data, pressure settings, etc. 3A5416E...
Page 58: I/O Status Screen
Electro-pneumatic Control Panel Display Screens I/O Status Status Screen Screen Status Screen Icon / / / Field Field Active Conditions Conditions Icon Icon Field Active Active Conditions Digital Digital Digital Outputs Outputs Outputs Available settings: (blue) Asserted (yellow) Not Asserted Pump fast Pump slow, pump fast Ram up...
Page 59: Import And Export With Usb
Import and Export with USB Import and and Export Export with with USB Import Import Export with Settings Parameters Parameters Settings Settings Parameters When modifying some elements for import, the Settings file requires use of numerical values to represent desired values. The allowable values for To reduce the risk of injury due to electric shock, all fields are detailed in the following table: remove power to the control panel before entering...
Page 60 Import and Export with USB Parameter Value Value Meaning Meaning Parameter Value Value Meaning Meaning Parameter Parameter Value Value Value Value Meaning Parameter Parameter Value Value Value Value Meaning Name Name Name Name Name Name Timezone (UTC -05:00) Bogotá, Timezone (UTC +01:00) Brussels, Lima, Quito Copenhagen, Madrid,...
Page 61 Import and Export with USB Parameter Value Value Meaning Meaning Parameter Value Value Meaning Meaning Parameter Parameter Value Value Value Value Meaning Parameter Parameter Value Value Value Value Meaning Name Name Name Name Name Name Timezone (UTC +05:30) Chennai, Timezone (UTC +10:00) Canberra, Calcutta, Bombay, New Melbourne, Sydney...
Page 62 Import and Export with USB Parameter Value Value Meaning Meaning Parameter Value Value Meaning Meaning Parameter Parameter Value Value Value Value Meaning Parameter Parameter Value Value Value Value Meaning Name Name Name Name Name Name Mass Pounds AUX1/2 None Units Input Kilograms Pump Start/Stop...
Page 63: Dimensions
Dimensions Dimensions Dimensions Dimensions K in. (cm) Lowest Highest (cm) (cm) (cm) (cm) in. (cm) (cm) (cm) (cm) in. (cm) Position Position 59.5 117.3 64.6 48.6 49 max. 76.5 6 (15.2) 3.2 (8.1) 50.8 (129) (151) (298) (164) (123) (124.5) (178) (194) (137)
Page 64: Schematic (Pneumatic Control)
Schematic (pneumatic control) Schematic (pneumatic (pneumatic control) control) Schematic Schematic (pneumatic control) 3A5416E...
Page 65: Schematic (Electo-Pneumatic Control)
E-ST OP 1060 1070 LINE+ 108CP 24 V DC 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...
Page 66 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 WHITE 1560 BLUE 1570 BLUE 1580 BLACK 1590 BLACK 1600 SEAL AIR PRESSURE BROWN 1610 PUMP AIR PRESSURE BROWN 1620...
Page 67 Schematic (electo-pneumatic control) FROM L I NE FRO M L INE FRO M L INE 1061 1060 1061 BASE- X2 0BM11 BASE- X2 0BM11 TERM INAL BLOCK- X20TB12 TERM INAL BLOCK- X20TB12 MODUL E - X20DO8322 MODULE- X20AO2622 BLACK-2 BLACK-1 2020 1061 2270...
Page 68 Schematic (electo-pneumatic control) FROM LINE All components marked Optional are not provided 1060 1061 with the control panel and must be provided by the installer. BASE- X2 0BM11 TERM INAL BLOCK- X20TB12 MODUL E - X20CM8281 All fittings and connections emerge from the bottom of the control panel.
Page 69 SR1 (SOME MODELS) REMOTE PUMP MANIFOLD PRESSUR E RELIEF V AL VE 85 PSI PRESSURE SENSOR PUMP 1/2" TUBE PUMP PUMPS 3 (R) 1/2" TUBE PUMP PUMPS 2 (A ) PUMPS PUMPS 1/2" TUBE PUMP RAM DOW N (CONNECT TUBING TO CYLINDER ASSEMBL Y CYLINDE R TOP) UP SPEED...
Page 70: Technical Data
Technical Data Technical Data Data Technical Technical Data SaniForce SaniForce STU SaniForce Metric Metric Metric Maximum working fluid pressure See pump manual Compressed air requirement 60–100 psi 0.41–0.7 MPa, 4.1–7 bar Pressure ratio See pump manual Air consumption See pump manual. Multiply by number of pumps Flow rate @ 60 cpm See pump manual.
Page 71 California Proposition 65 Fluid Temperature Temperature Range Range Fluid Fluid Temperature Range NOTICE NOTICE NOTICE Temperature limits are based on mechanical stress only. Certain chemicals will further limit the fluid temperature range. Stay within the temperature range of the most-restricted wetted component. Operating at a fluid temperature that is too high or too low for the components of your pump may cause equipment damage.
Page 72 With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

Graco SaniForce STU Series Operation

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