Graco 233035 Instructions-Parts List Manual
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Graco 233035 Instructions-Parts List Manual

Graco 233035 Instructions-Parts List Manual

200 liter (55 gallon) drum size warm melt supply units
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Contents
INSTRUCTIONS-PARTS LIST
Parts
INSTRUCTIONS
200 Liter (55 Gallon) Drum Size,
165 mm (6.5") Dual Post Air-Powered Ram
Warm Melt Supply Units
480V Heated Supply Unit, Triumphr Pump with
Stainless Steel Check-Matet 800 Chrome Free Displacement Pump
1100 psi (8 MPa, 79 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
160_F (71_C) Maximum Operating Temperature
Part No. 233035
Module Supply Unit with Smooth Bottom Plate
Refer to page 2 for the Table of Contents.
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
GRACO INC. P.O. BOX 1441
ECOPYRIGHT 2000, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
First choice when
quality counts.t
MINNEAPOLIS, MN 55440–1441
309113
Rev. A

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  • Page 1 Part No. 233035 Module Supply Unit with Smooth Bottom Plate Refer to page 2 for the Table of Contents. GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 ECOPYRIGHT 2000, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    ..Model C32434, Pump Mounting Kit ... Graco Factory P, I, and D Settings ... Model C32451, Vent Hood Kit .

  • Page 3: Symbols

    D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 82° C (180° F) or below -40° C (-40° F). D Do not use the hoses to pull the equipment.
  • Page 4 WARNING HOT SURFACE AND FLUID HAZARD Heated fluid can cause severe burns and can cause equipment surfaces to become very hot. D Wear protective gloves and clothing when operating this equipment in a heated system. D Do not touch the metal heat sink when the surface is hot. D Allow the equipment to cool thoroughly before servicing.
  • Page 5 WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor air ventilation, open flames or sparks can cause a hazardous condition and result in fire or explosion and serious injury. D Ground the equipment and the object being sprayed, and all other electrically conductive ob- jects in dispense area.
  • Page 6 WARNING MOVING PARTS HAZARD Moving parts, such as the ram follower plate/pump inlet can pinch fingers. D Do not operate the equipment with the guard removed. D Keep clear of all moving parts when starting or operating the equipment. D Keep hands and fingers away from the priming piston during operation and whenever the pump is charged with air.
  • Page 7 Typical Installation Air Line Filter 10 Follower Rod Lock-out Master Air Valve (bleed-type) (required) 100 Ram Module Main Air Line Supply 106 Pump Assembly Electrical Control Panel 107 Wipers Air Line Lubricator 109 Heated Follower Plate Assembly Pump Mounting Bracket 110 Ram Hand Valve G Hose Hanger Drum Vent...

  • Page 8: Typical Installation

    Accessories section on page 65. NOTE: For more information about converting the ram FIRE HAZARD from air to hydraulic operation, contact your Graco dis- Only use hoses that have a maximum tributor. wattage less than or equal to 1250 Selecting a Location for the Ram watts.
  • Page 9 Typical Installation 3-Regulator Air Control Module TI0111 Fig. 2 309113...
  • Page 10 Typical Installation Air Line Modules D Ram Air Regulator controls the air pressure to the ram. There are separate air regulators to control the ram pressure in the up and down directions. WARNING D Ram Air Supply Inlet (C) connects the ram air to PRESSURIZED FLUID HAZARD AND the air manifold.

  • Page 11: Installation

    Installation Electrically Connect Hoses to the The installation procedure includes: Electrical Control Panel D locating and installing the ram D electrically connecting hoses to the electrical con- WARNING trol panel D grounding the system FIRE HAZARD Only use hoses that have a maximum D connecting the electrical control panel to a power wattage less than or equal to 1250 source...

  • Page 12: Ground The System

    Installation Ground The System To reduce the risk of static sparking, ground the pump, object being sprayed, and all other spraying/dispensing equipment used or located in the spraying/dispensing Ground the supply unit as instructed here and in the area. Check your local electrical code for detailed individual component manuals.

  • Page 13: Connecting The Electrical Control Panel To A Power Source

    Installation Connecting the Electrical Control Panel to Have a trained electrician connect the electrical control panel (Fig. 4) to a grounded electrical source that has a Power Source the required service ratings: The electrical control panel (Fig. 4) comes already attached and wired to the ram, however before the CAUTION supply unit becomes functional, you must connect the...

  • Page 14: Check The Resistance Between The Supply Unit And The True Earth Ground

    Installation Check the Resistance Between the Supply Sensor Resistance Checks Unit and the True Earth Ground WARNING ELECTROCUTION HAZARD WARNING To reduce risk of injury or damage to FIRE, EXPLOSION, AND ELECTRIC equipment, conduct these electrical SHOCK HAZARD checks with the main disconnect OFF. To reduce the risk of fire, explosion, or electric shock the resistance between The supply unit includes six heat sensors and control-...
  • Page 15 Installation Heater Resistance Checks 1. Make sure the power is off and that the disconnect switch is in the OFF position. WARNING 2. Make electrical resistance checks for the compo- nents. Refer to Schematics on page NO TAG for ELECTROCUTION HAZARD wiring diagram information.

  • Page 16: Functions Of The Red Lion Control

    Installation Functions of the Red Lion Control Updating/Changing Red Lion Control The Red Lion control monitors the built–in pulse stream output from the Triumpht electric motor and Settings interrupts the torque control voltage setting from the The Red Lion control settings can be read and torque control potentiometer mounted on the system changed through the RJ11 connection on the side of control panel.
  • Page 17 Installation The settings, when the control was shipped from Graco, are: 309113...
  • Page 18 Installation 309113...
  • Page 19 Installation 309113...
  • Page 20 Installation 309113...

  • Page 21: Overview Of The Temperature Controller Settings

    Installation Overview of the Temperature Controller Settings The basic program settings for each temperature controller satisfy most application needs. These settings are pre- set at the factory, but can be changed. The input type, temperature scale, and over temperature alarm point are the critical controller settings that you must check before doing an auto-tune or using any controller in normal op- eration.

  • Page 22: Setting Temperature Controllers

    Installation Setting Temperature Controllers Table 1 describes the operation indicators for the E5CK temperature controller. WARNING Table 1. Operation Indicators Indicator Description HOT MATERIAL AND EQUIPMENT HAZARD Display 1 Displays the process value or pa- rameter symbols. This supply unit is rated for operation at 206_C (400_F) maximum.

  • Page 23: First Steps - Programming Tip

    Installation First Steps – Programming Tip 3. Go to the next procedure to check the three critical controller settings. Perform the following procedures to program each controller without the heating zone turned on. Checking Critical Controller Settings NOTE: Refer to Figure 6, Table 1, and Table 2 for The critical controller settings must be checked before user information about the E5CK controller.
  • Page 24 Installation Checking the Temperature Scale Setting 2. To check the alarm value 1 function, perform the following steps: To check the temperature scale setting, perform the following procedure: a. Change from the function mode to the level mode using the mode key (X). 1.

  • Page 25: Auto Tuning The Controllers

    Installation Auto Tuning the Controllers 6. Repeat steps 1 through 5 to change the set point for the other five controllers. After the critical controller settings have been checked, complete the following procedures: 7. Go to the next procedure to perform the auto tune process.
  • Page 26 Installation NOTE: The auto tune type 2 process can take from 5 6. Using the down arrow key (Y), change display 2 to show the auto tune OFF function, as shown in minutes to 2 hours to complete. Fig. 16. 9.

  • Page 27: Recording The Site P, I, And D Settings

    11. Keep the recorded settings in a safe place for later Hose reference, in case a programmed controller fails. The auto-tune process is complete. As an option, go Manifold to the next procedure: Graco Factory P, I, and D Compensator settings. 309113...

  • Page 28: Graco Factory P, I, And D Settings

    2. Press arrow key (Z) to set the function to the Stop mode (See Fig. 22). Verify that the stop light turns Compare the P, I, and D settings that you recorded for your site with the Graco factory P, I, and D settings for standard control panels. LEVEL...

  • Page 29: Flushing The System

    When the follower plate is above the height of system. If necessary, check with Graco or the ma- the material drum to be used, move the ram terial supplier for a recommended solvent.

  • Page 30: Initial Material Loading

    Otherwise For information about specific air pressure settings, hot material will leak out of the opening. refer to the Graco system documentation. 6. Place a material waste container under the dis- pense gun. 7. Turn the Triumph power on at the control panel and Slowly adjust the pump speed control.

  • Page 31: Operation

    Operation Pressure Relief Procedure To relieve pressure in the supply unit, perform the following procedure: This procedure describes how to relieve pressure for the supply unit. Use this procedure whenever you shut 1. Lock the gun/valve trigger safety. off the dispenser/sprayer and before checking or 2.

  • Page 32: Raising And Lowering The Ram

    Operation Raising and Lowering the Ram Daily Start-up Procedure The ram hand valve on the ram air control has 3 WARNING positions (Fig. 23): PRESSURIZED FLUID HAZARD CAUTION To reduce the risk of serious bodily inju- ry, such as fluid injection or splashing fluid in the eyes or on the skin, ALWAYS An empty drum clamp can interfere with up and wear eye protection and protective cloth-...

  • Page 33: Changing Empty Drum

    Operation WARNING CAUTION MOVING PARTS HAZARD Do not raise the ram and remove the follower plate from the empty drum unless the supply Moving equipment parts can cause per- unit is at full operating temperature. Drum sonal injury, including severing of hands or fingers.

  • Page 34: Shutdown

    Operation Changing Empty Drums 9. Bleed the air from the material pump that was (continued) introduced during the drum change: 6. Place the new drum in the ram: a. Place a waste container under the pump bleed a. Remove the cover from a drum of appropriate port.

  • Page 35: Emergency Stop

    Operation Emergency Stop 2. Stop the pump by soff the Triumph power on the control panel. 1. On the electrical control panel (Fig. 24): 3. To stop the ram from moving (Fig. 25): a. Turn the CONTROL ON (V) switch to OFF. a.

  • Page 36: Reading The Electrical Control Panel Indicators

    Operation Reading the Electrical Control Panel Indicators Use the table and Fig. 26 below to read the indicators on the electrical control panel. Light# Indicator: Indicator Meaning: Light is: Power On/ Power is on and ground is connected. Ground Connected Power is off and/or ground is disconnected.

  • Page 37: Reading The Temperature Controllers

    Operation Reading the Temperature Controllers To reset the ground fault interrupt, have a qualified electrician: Refer to Controller Reference Information on page 22, which includes Figure 6, Table 1, and Table 2, to read about the E5CK temperature controller. 1. Turn OFF the electrical disconnect on the electrical Temperature Out of Range control panel.

  • Page 38: Flushing Safety

    Operation Flushing Safety WARNING Use fluids and solvents that are chemically compat- ible with the equipment wetted parts. See the Technical Data sections of all the equipment manuals. Always read the material manufacturer’s literature before using fluid or solvent in this pump. 1.

  • Page 39: Ram Troubleshooting

    Ram Troubleshooting Problem Cause(s) Solution(s) Ram won’t raise or lower Closed main air valve or clogged air line Open air valve, clear air line Not enough air pressure Increase ram pressure Worn or damaged piston Replace piston. See procedure in Form #310523.

  • Page 40: Heated Pump Troubleshooting

    Heated Pump Troubleshooting For additional information about the Check-Mate 800 Displacement Pump, see Form# 308352. For more informa- tion about the Therm-O-Flow Pump Module, see Form# 310530. Problem Cause(s) Solution(s) Rapid down stroke or up stroke Material not heated to proper Check and adjust temperature set point.

  • Page 41: Air Motor Troubleshooting

    SOLUTION Motor does not run Power source is shut off. Turn power source on. Defective electronic control module. Contact your Graco distributor for proper service. Power wires hooked up incorrectly. Refer to page NO TAG for proper installation. Motor has shut off because pump speed...
  • Page 42 Electrical Control Panel Troubleshooting For more information, see the electrical control panel documentation. Problem Cause(s) Solution(s) Disconnect is ON, but no indica- The ground fault interrupt has been Reset the ground fault interrupt. tor lights are lit activated See procedure on page 37. One or more fuses has (have) been Replace the blown fuse(s) blown...

  • Page 43: Service

    Service Inspection Frequency 2. Using the ram hand valve lever on the air control (Fig. 23), move the ram to the DOWN position. Periodically (once a month), inspect the ram guide sleeves, rods and cylinders for wear or damage, Ram UP replace all worn parts.

  • Page 44: Removing A Material Drum From The Supply Unit

    Empty Drum on page 33. the procedure on page 47. For information about replacing wires that connect the follower to the pump, 2. To remove or install the wipers, stretch them over see Form# 310530, or contact your Graco distributor. the heated platen. 309113...
  • Page 45 Service Replacing Heat Sensors 7. Loosen the cord grip (100), located under the junc- tion box. Perform the following procedure to replace a sensor: 8. Remove the junction box’s cover. WARNING 9. Disconnect the 2 sensor wires from the junction box.

  • Page 46: Pump Removal And Replacement

    Service Pump Removal and Replacement 7. Bleed off excess material and pressure in the system by opening the dispense gun and catching For information about servicing the Check-Matet 800 the material in a waste container. Displacement Pump, see Form# 308352. For informa- tion about servicing the Thermo-O-Flow Pump Module, 8.

  • Page 47: Separating The Pump From The Air Motor

    D when you reinsert the collar couplings into the coupling nut the large flanges point upwards D you re-apply RTV sealant to the pump shrouds before re-assembling them For more information, see Form# 310530, or call your Graco distributor. 309113...

  • Page 48: Removing The E5Ck Temperature Controller

    Service Removing the E5CK Temperature a. If applicable, remove the snap pin that secures the terminal cover on the E5CK controller. Controller Remove the terminal cover (Fig. 33). To remove the E5CK temperature controller, which replaces the E5CS controller, perform the following procedure: WARNING TERMINAL...

  • Page 49: Installing The E5Ck Temperature Controller

    Service Installing the E5CK Temperature Controller To install the E5CK controller, which replaces the E5CS controller, perform the following procedure: The E5CK temperature controller is part of Tempera- ture Controller Kit, P/N 918579. NOTE: Before inserting the replacement E5CK con- 7986A troller into the panel, make sure the gasket is Fig.
  • Page 50 Notes 309113...

  • Page 51: For 480 Vac Supply Units - Schematic

    Service For 480 VAC Supply Units – Schematic To Ram Junction Box 1391 1401 1321 1331 1791 1841 Fig. 38 309113...

  • Page 52: Parts

    Parts Model 233035, (480 VAC) 165 mm (6.5”) Ram, 19:1 Senator, Heated Check-Mate 800, smooth bottom plate Plate is smooth on the bottom. 2, 3, 4, 5 113, 114 7, 3, 2 8, 9, 10 TI0111 Specifications Model Volts Full Load Amps Pump: 60 Cycles/Min.
  • Page 53 Parts Model 233035, (480 VAC) 165 mm (6.5”) Ram, 11:1 Triumph Motor, Heated Check-Mate 800, smooth bottom plate Part Description Qty. Part Description Qty. 195977 Frame, electrical control mounting 243445 MODULE, ram, 11:1 Triumph; includes items 101–116 C19185 Nut, hex 3/8”–16...

  • Page 54: Model 243448 Pump Module

    Parts Part No. 243448 Heated Pump, Series A, 11:1 Ratio, with Triumph Electric Motor Ref. Part No. Description Qty. 243452 MOTOR, Triumph See 309126 for parts 195982 ROD, tie; 265 mm (10.43”) shoulder to shoulder 106166 NUT, hex; M16 x 2.0 186925 NUT, coupling 184129...

  • Page 55: Model 243450 Therm-O-Flow Pump Module

    Parts Model 243450, Therm-O-Flow Pump Module, 200 liter (55 gal.) 480 V AC Part Description Qty. Part Description Qty. 243451 Pump, hot melt 200 liter (55 gal.) C20487 Nipple, hex 3/4 npt 242053 Heater, band pump lower 600 watts C32200 Terminal, ring for #10 stud C32255 Sensor, RTD...

  • Page 56: Model 243451 Displacement Pump

    Parts Model 243451, Series A Displacement Pump (refer to manual 308352 for service instructions) 9405A 309113...
  • Page 57 Parts Model 243451, Series A Chrome Free Displacement Pump (refer to manual 308352 for service instructions) Part Part Description Description 195984 ROD, displacement; stainless steel 195983 ROD, priming piston; stainless steel 236582 PACKING NUT/WET-CUP; 195581 CYLINDER, intake; stainless steel stainless steel 276378 PISTON, priming;...

  • Page 58: Model 243471, Ram Air Control Module

    Parts Model 243471, Ram Air Control Module Part Description Part Description C06021 Valve, lockout 1/2 npt C19019 Union, swivel 1/2 npt C11033 Filter, air C11037 Insert, pipe port 1/2 npt C11039 Connector, air interface C11034 Lubricator C11029 Regulator, air C11040 Insert, ported 1/4 npt C36260 Gauge, pressure 160 psi...
  • Page 59 Parts Model 243471, Air Control Module 180, 80, 380 TI0110 309113...

  • Page 60: Model C32434, Pump Mounting Kit

    Parts Model C32434, Pump Mounting Kit Part Description Qty. Part Description Qty. C32402 Rod, follower hot C19206 Washer, lock for 3/4 195974 Plate, motor mounting C19187 Nut, hex 3/4–10 unc 100672 Screw, set 3/8–16 unc x 1 40 50 7570B 309113...

  • Page 61: Model C32451, Vent Hood Kit

    Parts Model C32451, Vent Hood Kit Part Description Qty. Part Description Qty. 517416 Hood, vent Therm–O–Flow 550 C19092 Screw, hex hd., 1/4–20 x 7/8 lg. C32445 Bracket, vent hood middle C19198 Washer, flat 1/4 C32446 Bracket, vent hood side C19209 Washer, lock 1/4 C32444 Bolt, U, square bend C19189 Nut, hex 1/4–20 C19213 Washer, lock 3/8...

  • Page 62: Model 115745 6-Zone Electrical Control Panel

    Parts 6-zone Electrical Control Panel, Model 115745 (480 VAC) TI0112 Spare Parts Part Number Temperature Controller 918579 Solid State Relay (for SSRs 152 – 173) C78082 Timer, Inactivity C78342 For information about other parts, contact your Graco distributor. 309113...

  • Page 63: Model 243472 Heated Follower Plate Kit

    Parts Model 243472, Heated Follower Plate Kit with smooth bottom plate (*Wipers not included) Part Description Qty. Part Description Qty. 243472 Platen, heated 18 k watts, smooth; C19254 Plug, pipe 1/4 npt C32204 O-ring 19.5 i.d. x 0.12 C19258 Plug, pipe 1/2 npt C19213 Washer, lock Φ...
  • Page 64 Parts Model 243472, Heated Follower Plate Kit with smooth bottom plate (*Wipers not included) 1321 1331 7993A *See Accessories section on page 65 for ordering information. 309113...

  • Page 65: Accessories

    Accessories Use Only Genuine Graco Parts and Accessories Description Part No. HEATED 55-GALLON FOLLOWER PLA TE ASSEMBLY 560mm (22”) O.D. Order wiper rings separately Smooth Bottom 918470 55-GALLON HEATED FOLLOWER WIPER RINGS KITS 560mm (22”) O.D. Kit contains upper and lower hoses and clamp...
  • Page 66 Accessories MATERIAL PUMP INACTIVITY KIT 617334 Used to shut down the heaters if there is no pump activity. Contains proximity switch, electronic timer, and the hardware necessary to install it in the supply unit. MATERIAL PUMP THROAT PACKING REBUILD KIT 222786 See Form# 308352 7-DAY TIMER KIT...

  • Page 67: Dimensions

    Dimensions Electrical Control Panel Mounting and Clearance Dimensions 254 mm 493 mm (10”) (19.4”) 945 mm 1189 mm (37.25”) (46.8”) 646 mm (25.4”) Fig. 40 309113...

  • Page 68: Ram Mounting And Clearance Dimensions

    Dimensions Ram Mounting and Clearance Dimensions 48 in. (1168 mm.) 42.0 in. (1067 mm.) 36.9 (937 mm) 29.0 (737 mm) 21.0 in. 25 in. (635 mm.) (533 mm.) 108.2 (2748 mm) 64.0 68.2 (1626 mm) (1732 mm) 16.7 (424 mm) 11.1 (132 mm) (282 mm)

  • Page 69: Technical Data

    SST Check-Mate 800 Displacement Pump 308352 Therm-O-Flow Pump Modules 310530 Triumph Motor 309114 Triumph Reciprocator 309126 Air Operated Blow–Off Valve 306715 CheckMate 800 Pump Service 308352 Check-Mate is a trademark of Graco, Inc. Senator and Therm-O-Flow are registered trademarks of Graco, Inc. 309113...

  • Page 70: Spare Parts And Equipment

    Spare Parts and Equipment Part Number Description 111398 Capacitors 243681 Motor Control Module 242053 Heater Pump (2) 207440 Blow–Off Valve C34079 Heated Vent Valve 165501 ”D” Style Drum Seal C32202 Heated Platen RTD Sensor C32255 Pump RTD Sensor 918579 Omron Temperature Controller E5CK Red Lion Rate Monitor LGPB0000 Spare Seals and Kits C32201...

  • Page 71: Appendix

    Appendix Temperature Controller Settings List Setup, Function Mode Parameter Names Level 0, Function Mode Parameter Names Input type Set point _C/_F selection Run/Stop Parameter initialize Level 1, Function Mode Parameter Names Control output 1 assignment Auto-tuning Execute/Cancel Control output 2 assignment Alarm value 1 Auxiliary control 1 assignment Alarm value 2...

  • Page 72: Graco Standard Warranty

    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 sub- stitution of non–Graco component parts.

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