Gear Meter System
Contents
1. Component Identification 970175 Bottom Inlet Service Meter c 4 Lae i L 48005 2 6 Fic 1 ti11238a ti11236a Gear Meter Control Panel Gear Meter Junction Box Material Inlet Material Outlet Applicator Air Valve Gear Meter gt 312744B Gear Pump Electric Motor Gear Reducer Breather Fill Port Drain Port Component Identification Electrical Control Unit AE V AJ AH 17117 11 60 17154 Pans 55125 2 AJ AK AL AM AN AP AQ AR AS AT AU AV Emergency Stop Button Start Button Fault Reset Button Manual Mode Dispense Button Power Indicator Light Control Active Light Motor Active Light Over Pressure Fault Light Material Outlet Pressure Below Minimum Light Motor On Off Switch Speed Signal Input POT ANALOG Switch Dispense MANUAL ROBOT Tachometer Display Pressure Display Main Sealer Disconnect Lever2. 48 312744B Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable 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 regulations R3 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 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 For complete information about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement par
3. Gear Meter Systems Horizontal Bottom Inlet Top Inlet Horizontal Inlet Gear Service Service Inlet Service Meter with Ref Meter Meter Meter Heated Hose No Part No Description 970175 970176 970177 970194 1 617517 CONTROL electrical see v v page 33 2 C59755 KIT installation 1 ft disp v v v hose C59758 KIT 1 ft urethane heated v dispense hose 3 PUMP gear pump assem 918477 918465 918473 918473 bly See page 31 See page 27 See page 29 See page 29 4 918490 KIT repair v v v v 5 918539 APPLICATOR ball seat v v v 3 4 port 42 1 6 156172 FITTING union swivel v v v v 7 C20487 FITTING nipple hex v v v 8 15B919 MODULE isolation valve v 9 FITTING swivel v 11 C59555 CONTROL 4 zone con v troller 12 C07738 CABLE jumper 14 soc to v 14 pin 312744B 25 Parts 26 312744B Part 918465 Inlet Gear Pump Parts SIDE VIEW FRONT VIEW 102 103 104 134 154 132 153 105 106 117 133 137 101 132 153 108 109 c 118 165 139 143 140 141 E 138 139 B 142 119 110 111 120 121 a 122 123 124 See Detail A E 150 151 144 a 125 a 115 116
4. Alarms Function Value trAC no dISP no LAtC 1 no ASN 1 input AL 1 1000 HyS 1 1 Act 1 hi LAtC 2 no ASN 2 input AL 2 5000 HyS 2 1 Act 2 hi 15 Setup Potentiometer Settings The Speed Signal Input Selector Switch SS135 AM determines how the gear motor speed is set SS135 can be set to POT or ANALOG POT The speed is based on the physical settings of one of the potentiometers Each potentiometer POT 1 POT 4 can scale the motor speed between the minimum and maximum motor speed Therefore each potentiometer can be set to a unique speed and can be called upon by activating the corresponding pin on connector R52 Only one sig nal pin K L or M of connector R52 should be activated at a time ANALOG The speed of the gear motor is deter mined by the analog voltage signal that is supplied by the robot controller and the setting on the ANALOG SPAN potentiometer POT 1 The POT 1 potentiometer can be used to set the speed of the Gear Meter motor while in MANUAL or ROBOT dispense mode This is the only potentiometer that can control the gear meter speed when the Dispense Mode Switch SS169 AN is set to MANUAL When Dispense Mode Switch SS169 AN is set to ROBOT POT 1 is the default potentiometer if no other active signals are detected on pins K M of connector R52 2 4 In addition to POT 1 potentiometers POT 2
5. 224 Front of Electrical Control Panel 2 x 4 WIRE DUCT 516 111241 1 517 Inside Electrical Control Panel n P See Wiring Schematics on page 35 Partai 55125 55135 158 PBI132 55169 169 ti11239a 312744B 33 Parts Part No 617517 Electrical Control Ref No Part No Description Qty 515 196165 BOARD dc motor drive 1 516A 15F279 LABEL 1 517A 196548 LABEL 1 Replacement Danger and Warning labels tags and cards are available at no cost 34 312744B Wiring Schematics Part No 617517 Electrical Control 617517 u o o 100 FU100 FRS R 10 1L 101 5 60HZ 8 5 L3 102 P 105 1 104 m 105 CRM113 106 9999 120 VAC 16 GREE tos 108 19822 109 0109 TYP E FNA10 110 amp PUMP J BOX 1401 40135 1 111 o 112 START EMERGENCY EMERGENCY 9151 1131 1152 P6071 STOP 0 2 4155 2 lt 2 PB 131 1152 PB1133 114 A 115 116 117 118 SPEED SIGNAL INPUT POT ANALOG 1131 1361 312744B
6. 42 DEVICE ID SUCKET TERMINAL No DEVICE ID PIN CLUTCH BRAKE SOLENOID SOL202 WHT SPEED SENSOR BLK BLK SCL3 1 GREEN GND SCLS B RED 2024 3CL3 3 1083 R50 12 gt WHITE OPEN DISPENSE VALVE 501206 SCL1 3 GREEN GND E SCLi 2 RED 2062 R50 7 SCL1 1 50 12 1083 WHITE DUTLET PRESSURE XDR A N 2521 R176 A gt RED gt 1 1 m Pod 1 1 1 XDR D 2541 R176 B BLACK E XDR E Y SHIELD R176 C gt XDR F SENSOR AMPLIFIER R50 18 RED 3102 O SHIELD R50 19 gt DC MOTOR 3032 R50 14 gt 3052 R50 15 GND R50 3 Eu gt EMERGENCY STOP 1133 50 2 oT o O gt 1132 R50 1 gt MOTOR ACTIVE R50 4 1251 1101 850 12 850 6 312744 Wiring Schematics Gear Meter Junction Box 1083 1083 IN 1101 2024 1s 2521 i 2541 3032 ni 3058 1541 3052 1583 1621 3121 2 SPARE SEED GND 10 TOTAL 14 TOTAL 43 312744B Accessories Accessories Windshield Nozzles Part No Description C51172 End Cut Windshield Nozzle Fluid Filters C58997 Module Filter Part No Description 518779 ADAPTER pipe female 515216 HOUSING filter 210658 VALVE ball 116586 O RING 515222 ELEMENT filter 970126 Header Assembly Filter Part No Description 210658 VALVE ball 617122 FRAME header stand 102814 G
7. can be used to set the speed of the Gear Meter motor when a robot controller is connected Each potentiometer rep resents a speed setting that can be saved and called upon by the robot controller These settings can only be accessed via an external signal from a robot controller on pins K M of connector R52 ANALOG SPAN This potentiometer can be used to scale the analog input voltage from the robot controller This potentiome ter should be set to 500 when programming the robot 16 Adjust Gear Motor Speed 1 Turn Main Sealer Disconnect Lever AR off 2 Open the Gear Meter Control Panel A door and locate the potentiometers See Part No 617517 Electrical Control on page 35 3 Slide the lever beneath the potentiometer to the left and adjust the value 4 Turn each potentiometer knob to increase or decrease the motor speed 5 Slide the lever to the right to lock the potentiometer Calibrate Flowrate 1 See Startup on page 17 2 Chart the flowrate for each analog VDC set point and determine the desired flowrate 3 VDC setpoints need to be programmed into the robot if dispensing in ROBOT mode Pressure Relief mA 1 Turn off air supply to supply unit 2 Turn off gear pump at gear meter control panel A using Motor On Off switch 55125 AL 3 Set Dispense Mode Switch 55169 AN to MAN UAL and push Manual Mode Dispense Button PB169 AD Flushing Re
8. 918465 918473 918477 CP 128 228 328 131 231 331 CR 145 245 345 Clutch housing guard screws CR Fic 11 8 Secure electric motor CQ to hoist 9 Remove four black socket head cap screws that connect the module brake unit and the module drive unit 10 Pull the electric motor CQ and the module drive unit of the clutch assembly away from the module brake unit lay on worksurface CAUTION The Modular Drive Unit ball bearing is loose fitting by design Do not allow the ball bearing to fall off the Modular Drive Unit 11 22 Disconnect the module drive unit and the electric motor CQ See the Baldor Electric Company Intergral Horse power D C Motor Installation and Operation user manual MN605 for detailed repair proce dures Install Electric Motor 1 Connect electric motor CQ and the module drive unit of the clutch assembly Install electric motor CQ and module drive unit to the module brake unit with four black socket head cap screws Tighten fitting CR on top of speed sensor motor adapter CP See 11 Connect A1 A2 and ground wires in the wire box on the electric motor Install clutch housing guard and connect black air hoses The motor must turn counterclockwise Reverse A1 and A2 wires if necessary Remove Brake Clutch See Remove Electric Motor Remove four bolts and lockwashers from the gear reducer adapter Discon
9. 40 4 5 5 1085 MAIN PANEL POWER FOR SEALANT INTERFACE 120V 852 IS COM ROBOT DISPENSE SIGNAL SEALER READY SEALER IN CYCLE SEALER MAINTENANCE REQUIRED SELECT SPEED 2 SELECT SPEED 3 SELECT SPEED 4 ANALOG SPEED b COMMAND INPUT MAIN PANEL GROUND TO PUMP J BOX AIR ON TO ACTIVE SUPPLY PUMP 12 TO PUMP TO PUMP J BOX 312744B Wiring Schematics Part No 617517 Electrical Control 4 9 318 2 000 3NIS 3SN 9v6 0138 lyd Z ANY 9 3 2 1 04 2760 38 NY SWALI Q310N L 08d LE 9 95 064 9c 9 9 v 0Gd 9 9I C 0Gd 9 I 09d I 9 0 0Sd 9 62 044 6c 9 87 0Sd 82 9I LT 09d 42 9 92 064 9 9 GZ 0Gd Gz aay 94 vZ 0Gd 9 2 08 ec 9 ZZ 0Gd zz 02 12 08 43 oz OZ 0Sd 02 6 oc Zoe 8 8 02 sole cv oz MAS 9 290 SI 4i zeoe vi aay 94 0Sd 3LIHM 801 9 vcoc 9 0 0Sd 9 6 6 9 8 0Sd 8 aay 9 2902 4 9 9 9 g 0Sd 6 1921 v N3349 9 9 2 9 80105 DMY OTIM v 3 8CvOCd Cilv ZgCX 3NIS 30V
10. At any time Emergency Stop Buttons PB1132 or PB1133 AA may be pushed to stop dispensing opera tions 1 Turn Motor Selector Switch 55125 AL off The Motor Active Lights LT129 and LT131 AH will turn off indicating that the motor is inactive 2 Turn Main Sealer Disconnect Lever AR off The Power Indicator Light LT111 AE will turn off 17 Maintenance Maintenance Vi CAUTION Urethane material should not be exposed to atmo sphere Use grease or petroleum jelly to seal off ure thane material in components from atmosphere Reference the following manuals for detailed mainte nance and repair procedures of the Gear Meter compo nents listed below These manuals are not provided by Graco Part Manual Gear Pump 35 Kawasaki Gear Pump Technical Bulletin No 703M Gear Reducer 19 SEW EURODRIVE Gearmotors and Gear Reducers Operating Instructions 01 805 52 US Electric Motor 31 Baldor Electric Company Intergral Horsepower D C Motor Installation and Operation User Manual MN605 Brake Clutch 25 Nexen Air Champ Products User Manual FORM NO L 20134 F 0200 Pressure Display Red Lion Controls Model IMP Instruction Manual 18 312744B Troubleshooting Troubleshooting Problem Cause Solution Supply pumps are off Overpressure condition Open the dispense gun and disen gage the drive system Depress Fault Reset Button PB158 AC to reset Pressing the Manual Mo
11. Connect input and output fluid hoses to gear pump CJ Remove Electric Motor 1 Relieve Pressure See Pressure Relief on page 16 2 Turn motor selector switch 55125 AL off 17129 and LT131 AH will turn off indicating that the motor is inactive Fic 9 Gear Pump Outlet Flange 3 Turn power off with Main Sealer Disconnect Lever 7 Carefully pull away from the gear reducer the gear The Power Indicator Light LT111 AE will turn pump CJ gear spacer CD and half of coupling off 118 218 318 attached to pump Lay on a clean worksurface See FIG 8 4 Open wire box on the electric motor and disconnect A1 A2 and ground wires See FIG 10 8 Remove three screws 101 201 301 from the bot tom of gear spacer CD See FIG 8 9 Install bypass manifold 104 204 304 or spare gear pump CJ See FIG 8 It is recommended that you have an extra gear pump on hand to continue operating the gear meter system while the gear pump is repaired See Kawasaki Gear Pump Technical Bulletin No 703M for detailed gear pump repair proce dures Fic 10 312744B 21 Repair Remove two screws from clutch housing guards remove guards Disconnect black air hoses from the clutch assembly See 11 Open the wire box on the speed sensor motor adapter CP Disconnect the white red and black wires See FIG 11 Loosen fitting CR at top of speed sensor motor adapter CP See 11
12. R52 Signals Setup Pin ID Wire ID Color Pin Type Usage Description 1711 Red Power Power for Sealant Interface Power is con nected to this wire when the Dispense Mode Switch 55169 AN is set to robot mode 1083 White Power Power for Sealant Interface Common This wire is not affected by the state of the Dispense Mode Switch 55169 AN This common power line is also connected to ground GND Green Power Ground R52 D Red R52 E Red 1832 Output Sealer in Cycle An active signal is put on this wire when all of the following conditions are true The Dispense Mode Switch 55169 AN is set to Robot Motor Selector Switch 55125 AL 15 set to Outlet pressure is above the minimum pressure set point e Outlet pressure is not above the maxi mum pressure Robot Dispense Signal is active on R52 Y R52 G Red R52 H Red R52 J Red 2261 Input Engage POT 2 Select Speed 2 This signal is activated by closing a dry contact between wire 1711 and wire 2261 at the robot controller An active signal on this wire will set the speed of the motor according to the mechanical setting of POT2 2281 Red Input Engage POT 3 Select Speed 3 This signal is activated by closing a dry contact between wire 1711 and wire 2281
13. Technical Data Technical Data D C Electric Motor Maximum current drive Average current Baldor P N i iac Save med as Air Clutch Assembly Shaft SIZe X es em rx Pei ees Maximum air Nexen P N Gear Reducer Assembly Description SEW Eurodrive Gear Pump Assembly DesctlptlOnz scu ERR Capacity ci weeds Inlet Thread Outlet Thread on Maximum inlet Maximum outlet pressure Maximum Maximum 5 Maximum rotational Recommended fluid Kawasaki P N Wetted parts Electrical Control Enclosure Required Voltage FLA 46 2 HP 1750 RPM 9 3 amps 4 7 amps CDP3585 0 875 in diameter bore and output shaft 50 psi 0 34 MPA 3 44 bar MDB875 Foot mount parallel helical gear reducer c face input 36 84 1 reduction with flexible coupling R87AM145 Inline type high flow precision gear pump 152 cubic in min 1 5 in 11 5 in npt
14. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or c
15. Transformer R53 Analog Robot Interface Connector P50 Meter Interface Cable P176 Transducer Cable PB1132 A AL PB158 AC AA AR ti11239a 312744B Component Identification Gear Meter Junction Box Top View MOTOR SPEED SENSOR 2 Front View PB1133 129 AA AH BD Bottom View XDR SuLeoe 501206 FIG Key BA R176 Connector BE SOL 206 Cable BB R50 Connector BF SOL 202 Cable BC Motor Speed Sensor Connector BD XDR Cable 312744B 7 Component Identification Buttons PB1132 and PB1133 Emergency Stop Buttons AA Engage either of these buttons to stop system operation PB1132 is located on the Gear Meter Control Panel while PB1133 is located on the Gear Meter Junc tion Box PB1131 Start Button AB Engage button to put the system into an ON state when both emergency stop buttons PB1132 amp PB1133 are disengaged and the Main Sealer Disconnect Lever is on The green Control Active Indicator light LT117 AF will illuminate PB158 Fault Reset Button AC Engage button when the system has faulted due to an overpressure condi tion The system will resume normal operation as long as the pressure has gone back down to an acceptable level See Dispense on page 17 for more information PB169 Manual Mode Dispense Button AD Engage
16. b joe 126 127 107 NOS Eo 6 FON EE 150 164 E SN I T 146 147 112 113 gt T 122 114 PA n SS 129 120 166 122 123 163 7 144 155 156 E 157 158 159 122 123 160 Nw 145 149 LL ti11234a ti11403a Detail A To gear reducer To motor side of clutch side of clutch 2 414658 27 312744B Parts Part No 918465 Top Inlet Gear Pump Ref No 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 1357 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 153 154 155 156 157 28 Part 109114 100214 101864 617465 617505 19835 100133 19736 19008 06187 50125 19445 C36183 100731 517458 517456 C19075 100128 C19407 C12509 597151 C52543 C52546 100131 C52559 104472 100020 C52556 617449 517473 517457 617448 C20261 112166 100016 110755 100015 C52545 C20720 20721 20819 158491 110138 20874 06022 07430 517474 19766 Description SCREW cap socket hd WASHER lock SCREW cap socket hd MANIFOLD SPACER gear pump SCREW cap socket head WASHER lock PLUG o ring FRAME SCREW drive MARKER FITTING adapter swivel FILTER BRACKET FITTING elbow streeT MUFFLER WASHER COUPLING jaw type flex GEAR reducer SCREW cap hex hd
17. f 1 5 11 5 in npt m 4267 psi 29 4 MPa 294 19 bar 5689 psi 39 2 MPa 392 24 bar 250 F 121 C 100 000 poise 10 000 Pa s 50 rpm 50 cc rev 3 05 cubic in rev 200 mesh or finer HF50 CM 28 D2 tool steel with tuftride coating 1018 carbon steel fluo roelastomer 480 VAC 3 phase 60 Hz not rated for 50 Hz service 8 3 Amps 312744B Technical Data 312744B 47 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use 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 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 Nor shall Graco be liable for malfunction damage or wear caused by the in
18. stall pressure build up in the gear meter that can result in downstream pressure creep depending on the material viscosity MANUAL Dispense Mode 1 Set 55169 AN to MANUAL 312744B Operation 2 Depress Manual Mode Dispense Button PB169 AD to dispense material This button must be held down to maintain a flow of material ROBOT Dispense Mode 1 Set Dispense Mode Switch 55169 AN to ROBOT 2 Close dry contacts in the robot control panel between wires 1711 and 1712 to dispense e sealer ready signal wire 1813 will be on if the following conditions are present e Motor is on e Pressure is greater than the allowable minimum e Pressure is less than the allowable maximum e sealer in cycle signal wire 1832 will be on if the following conditions are present e Sealer ready is true e Robotic dispense signal is present e The sealer maintenance required signal will be on if the following conditions are present e Motor is not on Material pressure is below minimum Material pressure is above maximum Overpressure Fault The Overpressure Fault Light LT160 AJ illuminates when the pressure transducer detects that the pressure is above a maximum limit An overpressure condition will turn the supply pumps off 1 Open the dispense gun and disengage the drive system 2 Depress the Fault Reset Button PB158 AC to reset the system after the cause for the fault is rectified Shutdown
19. there is a good connection between the ground in the Gear Meter Junction Box B and the ground of the Gear Meter Control Panel A 3 Connect cable P176 from the Gear Meter Control Panel A to the Gear Meter Junction Box B 4 Connect cable 4CL3 from the Gear Meter Control Panel A to the Supply Pump Junction Box 10 Robot Connections Two connectors are available for external robot control ler I O signals The R52 connector is available for dis crete communication signals while the R53 connector is available for an analog speed input See R53 Connec tor on page 14 R52 Connector The input and output signals on R52 use a 120 VAC interface Three types of signals are available from this connector Output Output signals are driven by the Gear Meter Control Panel and provide feedback to the robot control ler An output signal is a 120 VAC signal as referenced between the wire corresponding to the desired output and wire 1083 Input Input signals originate from an external robot controller and can command the Gear Meter to dis pense or change speeds Input signals must be of the dry contact type between wire 1711 and the wire corre sponding to the desired input Power 120 VAC power signals are provided on R52 Table 1 R52 Signals on page 11 identifies available R52 signals and provides a brief description of each sig nal The Pin ID correlates to that shown in FIG 5 on page 13 312744B Table 1
20. 1101 T1051 1KVA 16 WHITE TYP lt P50 6 GS CR 2 LT131 NAZ 1083 1085 Wiring Schematics 480 240 VAC 115 12 BLK POWER ON GROUND CONNECTED MASTER RELAY 108 115 ACTIVATE MOTOR DRIVE BOARD 108 108 CONTROL ACTIVE EED SIGNAL INPUT TO OTOR DRIVE BOARD 181 183 202 212 RELEASES DCMC AND PTFB INHIBIT 304 308 313 yo R_ACTIVE REMOTE MOTOR ACTIVE COUPLE ANALOG 512 515 52 35 Wiring Schematics Part No 617517 Electrical Control TLET PRESSU 152 1 amp 8 9 AS UN 1000 PR 154 Ee 155 156 157 DISENGAGE CLUTCH ENGAGE BRAKE 162 202 206 158 159 160 OVER PRESSURE FAULT 161 162 NOT OVERPRESSURE 158 181 187 PRESSURE DISPLAY DISPENSE 168 MANUAL ROBOT 169 61131 oa 1 NP CRIT DISPENSE MANUAL DISPENSE 55169 169 202 212 206 170 o gt 174 170 1 95170 170 2 1712 DISPENSE ROBOT 8 65 204 208 52 R52 Y ROBOT DISPENSE SIGNAL 4 8 8 9 PUMP ACTIVATION ROBOT MODE 214 172 173 174 175 176 177 178 179 R52 B ou D 1813 1813 SEALER 1083 CR152 CR162 180 181 SEALER CYCLE CR171 R52 T 1831 SEALER MAINT REQUIRED 189 SS169 36 312744B Part 617517 Electrical Control 205 206 207 208 209 210 211 212 213
21. 213 214 222 255 266 226 227 207 267 242 210 211 oon 248 246 21 247 5 222 223 244 245 249 240 241 254 231 See Detail A diede ti11461a Detail A To gear reducer To motor side of clutch side of clutch 250 251 229 230 216 ti11462a 312744B 29 Parts Part No 918473 Horizontal Inlet Gear Pump Ref No 201 202 203 204 205 206 207 208 209 210 211 212 213 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 2357 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 253 254 255 256 257 258 30 Part 109114 100214 101864 617465 617505 19837 100133 19736 19008 06187 C32390 100731 517458 517456 C19075 100128 C19407 C12509 C19391 C52543 C52546 100131 C52559 104472 100020 C52556 617449 517473 517457 617448 C20261 112166 100016 110755 100015 C52545 C20720 20721 20819 158491 110138 20874 06022 07430 100643 50125 517474 19766 Description SCREW cap socket hd WASHER lock SCREW cap socket hd MANIFOLD SPACER gear pump SCREW cap socket hd WASHER lock PLUG o ring FRAME gear pump SCREW drive MARKER FITTING adapter swivel FILTER BRACKET J Box FILTER vent breather WASHER COUPLING jaw type flex GEAR reducer SCREW cap hex hd WASHER lock FITTING connector male TUBE nylon rnd FITTING elbow
22. 214 215 216 217 218 219 230 251 252 233 250 251 252 253 254 255 312744 120 VAC 120 VAC Wiring Schematics SOL202 ee u 2023 DISENGAGE BRAKE 9 ENGAGE CLUTCH ut 2 xr 501206 7 OPEN DISPENSE 5 11 2 5CL1 1 bCL1 3 SOL220 amp SOL224 IN J BOX 617498 40L3 2 40135 35 SUPPLY puis PRESSURE 2242 BELDEN 9501 OR EQUIV PRESSURE TRANSDUCER 37 Wiring Schematics Part No 617517 Electrical Control Md 009 OL Od 5 901VNV 135 co AMOLOV 108 ___ 5 ann 318vl ONULAS ayog 00 od 90 HOLIMS HOWL oF vy soena 312744B 38 Wiring Schematics Part No 617517 Electrical Control METER JUNCTION BOX EMERGENCY T 5 PB1133 MOTOR ACTIVE DISENGAGE BRAKE ENGAGE CLUTCH SOL206 5CL1 1 5CL1 2 6CLI 3 OPEN DISPENSE GUN 50 14 3032 D C MOTOR 2HP 1750 RPM 0 180V ARM PERM MAGNET 145TC FACE TEFC 4 7 RMS 9 3 SPEED SENSOR SPEED SENSOR AMPLIFIER 312744B 39 Wiring Schematics Part No 617517 Electrical Control DISCRETE COMMUNICATION SEALANT ROBOT 120VAC 0 10 VDC FROM ROBOT SUPPLY PUMP JUNCTION BOX REF 617498
23. 4M31NI YILIN LMVHO Nid 31415 9338An1 MJA 39v4 13 18 792 9 222 v 50105 3H 4009 HLON31 056 1 001 7506 6 M S 1S01 V90 46 ON3HdAV 3dAL 9714 assy 318 2 YAONGSNVYL LYVHS Nid Y 80 ama 7414 4 32Y18 LOLL L 80102 Ti Nid MO 9 6010005 318 2 04 M 3104 v SQNIH 3SNOND 3dAL 30V M31NI SdAnd 14405 LNVHO Nid x LON a 3339 LON 2 anig 9018 a ania 1018 30705 T T Nid HION31 3n 8 9 9 dS Svi VZOI 46 TON3HdMV 3dAL 594 10805 39Y4X3LNI DOWNY LNVHO Nid 6 zGu 6 3 90 9 p zau 2 29 2 q ZGH q 0 ZGH Z Su 7 298 x aaa M ZSH 2 128 1 65 29 5 0 04 d GH d N 1022 1852 1 1922 294 9 29 9 2581 3 3 29 3 3349 2 801 8 Y 0705 OT 33M 3 9181 ZO0dZ vV 3NIS 294 30VN3LNI 10803 Nid 41 312744B Wiring Schematics Gear Meter Junction Box
24. AUGE press fluid 118854 VALVE ball high pressure 521975 FITTING union pipe 518779 ADAPTER pipe female 518741 BUSHING C20490 FITTING nipple hex 515216 HOUSING filter 516715 ELEMENT filter 100840 FITTING elbow street 116586 O RING 44 Qty Qty o gt Repair Kits Gear Pump Repair Kits Part No Description 241403 SHAFT gear 248253 SEAL 108357 O RING 241404 Hard Metal Repair Kit Description Qty SHAFT gear SHAFT gear SEAL DRIVE GEAR DRIVEN GEAR SPACER KRaAaS RS Qty 312744B Dimensions Model 970175 Gear Meter 617517 Electrical Control 312744B n 1717 is E 24 5 o CIH ponsa T0321 uu PD166 rm D A B 1 11243 Part No Width Height Depth Gear Meter 970175 970176 26 in 660 mm 59 in 1498 mm 23 in 584 mm 970177 970194 Electrical Control 617517 38 in 965 mm 64 in 1626 mm 12 in 305 mm Dimensions ti11239a 45
25. CLUTCH brake STUD threaded NUT full hex ADAPTER motor speed sensor SCREW cap WASHER lock MOTOR D C SCREW FLANGE TRANSDUCER PUMP hi flo precision gear FLANGE O RING SCREW cap socket hd WASHER lock WASHER plain NUT hex mscr JUNCTION BOX GUARD coupling FITTING flex conduit 3 ft FITTING flex conduit FITTING conduit tee FITTING nipple CONNECTOR conduit straight PACKING o ring conduit sealing VALVE CONNECTOR sealed WASHER lock SCREW cap socket hd BRACKET PACKING SCREW machine binding RING 9 lt Ol H DAH H NH H NH H HWMDHAHAPFHAHPHANANAAHHANNH HAO HA HPP Ref No 259 260 261 262 264 265 266 267 Part No 157021 C07501 100284 513421 100166 C20004 Description WIRE copper electrical WASHER lock int WIRE copper electrical NUT hex mscr WIRE 3 cond 18 gauge BRACKET FRL mounting full hex SCREW cap Qty ON 1 See Repair Kits on page 44 for Gear Pump repair parts purchase separately 312744B Parts Part No 918477 Bottom Inlet Gear Pump SIDE VIEW FRONT VIEW 331 349 345 322 323 362 309 344 315 316 m 340 341 345 326 327 307 325 See 344 355 Detail A 56 357 358 359 342 360 312 313 314 322 343 310 311 338 339 306 317 308 305 332 353 dd 333 337 334 354 Ho
26. Instructions Parts gt GRACO 312744B Gear Meter System Bi For continuous bead dispense control For professional use only Not approved for explosive atmospheres 970175 Bottom Inlet Gear Meter 970176 Top Inlet Gear Meter 970177 Horizontal Inlet Gear Meter 970194 Heated Hose Horizontal Inlet Gear Meter 918465 918473 918477 Gear Pump 617517 Electrical Control 5000 psi 34 47 MPa 344 bar Maximum Working Pressure Important Safety Instructions e Read all warnings and instructions in this manual Save these instructions 5 8 ollo 0101610 516 q y 9 i Gera 9 ee SR Se lt lt 0c 89 ti11243a LLL ti11239a PROVEN QUALITY LEADING TECHNOLOGY Contents Warnings eta es 3 Component Identification 5 Gear Meter System 5 Electrical Control Unit 6 Gear Meter Junction 7 Buttons kars ree 8 Lights PESE Ia ES 8 Swilcli s ates SERRE ipee 8 Displays OERS e NER 8 Communic
27. O al ti11463a ti11464a 302 303 304 304 Detail A To gear reducer To motor side of clutch side of clutch 329 331 350 351 d11465a 312744B 31 Parts Part No 918477 Bottom Inlet Gear Pump Ref No 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 3357 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 353 354 355 356 32 Part No 109114 100214 101864 617465 617505 C19835 100133 C19736 C19008 C06187 C50125 C19445 C36183 100731 517458 517456 C19075 100128 C19407 C12509 C19391 C52543 C52546 100131 C52559 104472 100020 C52556 617449 517473 517457 617448 C20261 112166 100016 110755 100015 C52545 C20720 20721 20819 158491 110138 20874 06022 07430 517474 19766 Description SCREW cap socket hd WASHER lock SCREW cap socket hd MANIFOLD SPACER gear pump SCREW cap socket hd WASHER lock PLUG o ring FRAME SCREW drive MARKER FITTING adapter swivel FILTER BRACKET FITTING elbow street MUFFLER WASHER COUPLING jaw type flex GEAR reducer SCREW cap hex hd WASHER lock FITTING connector male TUBE nylon rnd 6 ft FITTING elbow CLUTCH brake STUD threaded NUT full hex ADAPTER motor speed sensor SCREW cap WASHER lock MOTOR D C SCREW FLANGE T
28. RANSDUCER PUMP hi flo precision gear FLANGE O RING SCREW cap socket hd WASHER lock WASHER plain NUT hex mscr JUNCTION BOX GUARD coupling FITTING flex conduit 5 ft FITTING flex conduit FITTING conduit tee FITTING nipple CONNECTOR conduit straight PACKING o ring conduit sealing VALVE CONNECTOR sealed WASHER lock PACKING SCREW machine binding RING 9 lt 00 00 Ref No 357 358 359 360 362 Part No 157021 C07501 100284 513421 Description WIRE copper electrical WASHER lock WIRE copper electrical NUT hex mscr WIRE 3 cond 18 gauge Qty 1 See Repair Kits on page 44 for Gear Pump repair parts purchase separately 312744B Parts Part No 617517 Electrical Control 3 x 4 WIRE DUCT Sj 3 x 4 WIRE DUCT 2 x 4 WIRE DUCT 480 VOLTS T1051 2 x 4 WIRE DUCT 2 x 4 WIRE DUCT TERMINALS 1KVA TRANSFORMER POTENTIOMETER LAYOUT POTI POT2 ANALOG 2 x 4 WIRE DUCT
29. WASHER lock FITTING connector male TUBE nylon rnd 7 ft FITTING elbow CLUTCH brake STUD threaded NUT full hex ADAPTER motor speed sensor SCREW cap WASHER lock MOTOR D C SCREW FLANGE TRANSDUCER PUMP hi flo precision gear FLANGE O RING SCREW cap socket hd WASHER lock WASHER plain NUT hex mscr JUNCTION BOX GUARD coupling FITTING flex conduit 5 ft FITTING flex conduit FITTING conduit tee FITTING nipple CONNECTOR conduit straight PACKING o ring conduit sealing VALVE CONNECTOR sealed WASHER lock PACKING SCREW machine binding RING WIRE copper electrical 9 lt gt gt 5 gt Ref No 158 159 160 163 164 165 166 Part No 157021 C07501 100284 C20365 C07431 103345 C20004 Description Qty WASHER lock WIRE copper electrical NUT hex mscr FITTING tee air CONNECTOR sealed SCREW cap socket hd SCREW cap 5 1 See Repair Kits on page 44 Gear Pump repair parts purchase separately 312744B Parts Part No 918473 Horizontal Inlet Gear Pump SIDE VIEW TOP VIEW 202 203 204 234 256 236 237 232 253 206 217 233 237 232 253 243 208 238 239 218 244 245 257 258 259 260 222 223 224 265 225 212
30. all to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 312744 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2007 Graco Inc is registered to ISO 9001 WWW graco com Revised 03 2010
31. alog Speed Command Input 0 10 VDC From Robot Connect to the wire of a 0 10 VDC analog controller The speed of the motor directly correlates to this voltage where 0 volts com mands the slowest possible speed and 10 volts commands the fastest possible speed B 3105 Blue Analog Speed Command Input 0 10 VDC From Robot Connected to the wire 0 10 VDC ana log controller Do Not Wire Do Not Connect D GND Green Ground E Do Not Wire Do Not Connect FiG 6 depicts the pin out of the R53 receptacle Amphe nol type 97 3102A 14S 5P Fic 6 R53 Pin Out Receptacle ti11388a 14 312744B Set Pressure Display Pressure Display PD166 AQ shows the outlet pres sure The pressure display is factory programmed with default over pressure and minimum outlet pressure val ues 1 Press the Down arrow key on PD166 AQ and verify that the display is set to Input and not Total ized This will display the outlet pressure value not a totalized sum The optimum values vary from system to system based on variables such as hose length and mate rial viscosity The best settings for a particular appli cation may be found empirically Graco Set Values Programming of the pressure display is divided into modular steps Use the up and down arrows beneath the display to navigate the set up menu and change the function values The P button is used to select a pro grammi
32. at the robot controller An active signal on this wire will set the speed of the motor according to the mechanical setting of POTS 2301 Red Input Engage POT 4 Select Speed 4 This signal is activated by closing a dry contact between wire 1711 and wire 2301 at the robot controller An active signal on this wire will set the speed of the motor according to the mechanical setting of POT4 R52 N Red 312744B 11 Setup Pin ID Wire ID Color Pin Type Usage Description P R52 P Red Q R52 Q Red R R52 R Red 5 52 5 Red T 1831 Red Output Sealer Maintenance Required An active signal is put on this wire when the Dispense Mode Switch SS169 AN is set to ROBOT and one or more of the following conditions is true Motor Selector Switch 55125 AL 15 set to Off e Outlet pressure is not above the mini mum pressure of set point e Outlet pressure is above the maximum pressure U 1831 Red Output Sealer Ready An active signal is put on this wire when all of the following conditions are true The Dispense Mode Switch 55169 is set to ROBOT e Motor Selector Switch 55125 AL is set to On e Outlet pressure is above the minimum pressure set point e Outlet pressure is not above the maxi mum pressure V R52 V Red W R52 W Red X R52 X Red Y 1712 Red Input Robot Dis
33. ations Diagram 9 Setup ous Leere es e 10 Connections 10 emp 14 Set Pressure 15 Potentiometer Settings 16 Adjust Gear Motor Speed 16 Calibrate Flowrate 16 Pressure Relief 16 FIUSNING A wee ees 16 Operation 2222 2 22 17 s a 17 Dispense 17 Shutdown b res EE ERES TAA 17 2 Maintenance 18 Troubleshooting 19 soisessa romed I ete ete ees 20 Remove Gear Pump 20 Install Gear Pump 21 Remove Electric Motor 21 Install Electric Motor 22 Remove Brake Clutch 22 Install Brake Clutch 22 cto ae ia cee eee 23 Wiring Schematics 35 AccessorieS 44 Windshield Nozzles 44 Fluid Filters 44 Repair KIIS 2 cee eee tite IRR 44 Gear Pump Repair Kits 44 DIMENSIONS 2 45 Technical Data 46 Graco Standard Warranty 48 Graco Information
34. button to open the dispense gun when selector switch 55169 is set to MANUAL Lights LT111 Power Indicator Light AE This white indica tor light is illuminated when there is power to the system and the Main Sealer Disconnect Lever AR is on The states of the emergency stop buttons PB1132 and PB1133 do not affect this light LT117 Control Active AF This green indicator light illuminates after the Start Button PB1131 has success fully put the system into the on state and remains lit until either of the emergency stop buttons PB1132 and PB1133 have been pressed or the Main Sealer Discon nect Lever AR has been turned off LT131 AND LT129 Motor Active AH These amber indicator lights illuminate when the motor is on SS125 is set to LT131 is located on the Gear Meter Con trol Panel while LT129 is located on the Gear Meter Junction Box LT160 Over Pressure Fault AJ This red indicator light is illuminated when the outlet pressure transducer detects that the pressure is above a maximum limit When this condition occurs the motor disconnects from the gear pump via a clutch To program the over pres sure set point see Set Pressure Display on page 15 LT154 Material Outlet Pressure Below Minimum AK This red indicator light is illuminated when the pressure transducer detects that the pressure is below a set point To program the minimum pressure set point see Set Pressure Display on pag
35. compatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS
36. de Dispense Button PB169 AD does not dis pense material System is in ROBOT mode Turn Dispense Mode Switch SS169 AN to MANUAL mode The man ual dispense button does not have an effect on the system while SS169 AN is set to ROBOT Gear motor does not respond to ana log speed control mode System is in POT speed mode The Speed Signal Input Selector Switch SS135 AM must be manu ally set to ANALOG in order for an analog signal to drive the motor con trol board ANALOG SPAN potentiometer is set to 0 Increase the ANALOG SPAN potenti ometer setting It is recommended that this potentiometer be set to 50 when programming the robot control ler The potentiometer proportionally weights the analog signal 312744B 19 Repair Repair 75 Each figure the repair section includes identifica tion table Use the two letters in the left column of the table to identify a reference number used in one of the three gear pump parts lists Remove Gear Pump 1 Relieve pressure See Pressure Relief on page 16 2 Turn power off with Main Sealer Disconnect Lever AR The Power Indicator Light LT111 AE will turn off 3 Disconnect input and output fluid hoses from gear pump CJ CAUTION Urethane material should not be exposed to atmo sphere Use grease or petroleum jelly to seal off ure thane material in co
37. e 15 Switches 55125 Motor ON OFF AL In the off state the motor and the supply pump will be off In the on state the motor will turn on The system will not dispense however until a dispense signal is present and the pres sure is within an acceptable range 55135 Speed Signal Input POT ANALOG This selector switch determines how the motor speed is set Mode the motor speed is determined by the settings on the potentiometers POT 1 ANALOG Mode the voltage present on wires 3131 and 3105 pins A and B of connector R53 deter mines the motor speed See Potentiometer Settings on page 16 for descrip tions of each potentiometer 55169 Dispense MANUAL ROBOT AN This selector switch determines how the dispense signal is issued to the system e MANUAL the dispense push button PB169 con trols the dispense signal e ROBOT the robot dispense signal on wires 1711 and 1083 pins A and B of connector R52 control the dispense state e The output control signals Sealer in Cycle Sealer Ready and Sealer Maintenance Required are only valid when SS169 is set to ROBOT Displays TD321 Tachometer Display AP This digital display shows the current speed RPM of the gear motor PD166 Pressure Display AQ This digital display shows the current output pressure as measured by the pressure sensor near the material ou
38. enoid Cable This cable runs between the Gear Meter Junction Box and the Dispense Gun SOL206 SOL 202 Solenoid Cable This cable runs between the Gear Meter Junction Box and the Brake Clutch SOL202 XDR Transducer Cable This cable runs between the Gear Meter Junction Box and the Pressure Transducer Setup Setup n e Supply hoses are not included with the Gear Meter We recommend 1 1 5 in ID hose with nylon or PTFE core and SST overbraid for 5000 psi 34 47 MPa 344 bar High pressure fluid filters should be used between the supply unit and the gear meter inlet See Fluid Filters on page 44 Connections Power The system requires 480 VAC 3 phase 60 Hz line volt age with ground The system is not approved for use with 50 Hz line voltage All electrical wiring must be per formed by a qualified electrician and comply with all local codes and regulations 1 Wire each phase to a separate terminal on Main Sealer Disconnect DISC100 AR 2 You must connect ground to the Gear Meter Control Panel A The ground wire must be connected to the ground bar above DISC100 System Cables 1 Connect P50 cable from the Gear Meter Control Panel A to the Gear Meter Junction Box B Cable P50 provides ground to the gear meter See page 41 for a detailed pin out Use only cables supplied by Graco or cables that meet the requirements shown in the wiring sche matic on page 41 2 Verify that
39. fer to material manufacturer for recommended flush ing compound CAUTION Urethane material should not be exposed to atmo sphere Use grease or petroleum jelly to seal off ure thane material in components from atmosphere 312744B Operation Startup 1 Main Sealer Disconnect Lever AR The Power Indicator Light LT111 AE should illuminate indicating that power is on and that ground is con nected 2 Depress Start button PB1131 AB The Control Active Light LT117 AF should illuminate 3 Turn Motor Selector Switch 55125 AL on Motor Active Lights LT129 and LT131 AH should illuminate 4 Set the Dispense Mode Switch 55169 AN to MANUAL or ROBOT dispense mode 5 Select speed with the Speed Signal Input Selector Switch SS135 AM a POT Mode See Potentiometer Settings on page 16 b Analog Mode the motor speed is controlled by a 0 10 VDC signal applied to wires 3131 and 3105 common It is suggested that ANALOG SPAN potentiometer be set to 500 to allow eas ier adjustment when reprogramming the robot output speed signal Dispense Once the system has been setup the system is ready to dispense Pump activation is controlled by a pushbutton or a robotic dispense signal The supply pump is only acti vated when dispensing occurs in order to prevent large pressure increases downstream of the gear meter This helps prevent
40. mponents from atmosphere 4 Remove four screws CA lockwashers CB and coupling guard See 7 918465 918473 918477 CA 138 238 338 CB 139 239 339 143 243 343 Fic 7 Coupling Guard 5 Remove four screws CE and lockwashers CG from gear pump spacer CD See FiG 8 918465 918473 918477 CD 105 205 305 CE 106 206 306 CF 109 209 309 CG 117 217 317 CH 133 233 333 CJ 135 235 335 CK 136 236 336 CL 137 237 337 Fic 8 Gear Pump 20 312744B Repair 6 Remove four screws CM lockwashers CN and Install Gear Pump two o rings CL from the inlet flange CK and outlet flange CH Check the o rings for damage and 1 Connect gear pump CJ to gear spacer with three replace as necessary See FIG 8 and FIG 9 screws 101 201 301 2 Carefully lower and align the gear pump and gear 918465 918473 918477 reducer coupling parts together Ensure coupling CM 132 232 332 118 218 318 is connected CN 153 253 353 3 Connect gear pump CJ and spacer CD to frame CF with screws CE and lockwashers CG See FIG 8 CH 4 Install inlet flange CK and outlet flange CH two o rings CL four lockwashers CN and screws CM See FiG 9 CM CN 5 Install coupling guard CC four lockwashers CB and screws CA See FIG 7 on page 20 6
41. nect the module brake unit of clutch See the Nexen Air Champ Products user manual FORM NO L 20134 F 0200 for detailed repair pro cedures of the brake clutch 125 225 325 Install Brake Clutch 1 2 Install module brake unit of clutch to gear reducer adapter with four bolts and lockwashers See Install Electric Motor 312744B Parts Parts Part No 970175 Bottom Inlet Service Meter Part No 970176 Top Inlet Service Meter Bottom Inlet Service Meter ti11243a 5 6 7 Top Inlet Service Meter ti11245a 312744B 23 Parts Part No 970177 Horizontal Inlet Gear Meter System Part No 970194 Horizontal Inlet Gear Meter System with Heated Hose Horizontal Inlet Gear Meter System 5 6 7 4 2 y ti11244a 15 37 in 390 40 mm pipi 25 26 641 6 mm 11 erac 2 12 Horizontal Inlet Gear Meter System with Heated Hose li ti11246a 24 312744B Part No 970175 970176 970177 970194 Gear Meter Systems Parts
42. ng module or function and to save the function values 1 Press P to enter programming mode The mes sage Pro followed by a number should appear The number identified is the selected Program Mod ule 2 Press the Up or Down arrow keys to scroll the functions in the current program module 3 Press P to select the highlighted function Use the Up or Down arrows to change the value 4 Press P to save the function value The following tables show the functions and Graco set values used Program Modules 1 4 5 7 8 9 are not used See the Red Lion Controls Model IMP Instruc tion Manual not provided by Graco for all of the default programming values and description of all the Program Modules The over pressure set point is controlled by Alarm 2 AL 2 and has a factory default setting of 5000 psi 34 47 MPa 344 bar The under pressure set point is controlled by Alarm 1 AL 1 and has a factory default setting of 1000 psi 6 89 MPa 68 94 bar 312744B Setup Program Module 2 Scaled by Signal Method Function Value dECPNt 0 round 1 SCALE yes dSP 1 0 INP 1 4 00 dSP 1000 INP 2 7 19 Program Module 3 Front Panel Lockout Function Value dSP AL yes Ent AL yes dSPHYS yes ENthYS yes rSt AL yes dSPbUF no rStbUF no SELdSP no RSttOt no tArE no Program Module 6
43. om dispense valve hose leaks 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 e Do not point dispense valve at anyone or at any part of the body e Do not put your hand over the end of the dispense nozzle Do not stop or deflect leaks with your hand body glove or rag Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately Ww MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts Do not operate equipment with protective guards or covers removed e 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 4 312744B Component Identification Gear Meter System
44. pense Signal This signal is activated by closing a dry con tact between wire 1711 and wire 1712 at the robot controller Asserting a signal on this line will do the following e Open dispense gun e If the Motor Selector Switch 55125 AL is set to the supply pumps on will be activated If the motor is on and the supply pres sure is below the maximum limit the brake will be disengaged and the clutch will be engaged R52 Z Red R52 a Red 12 312744B Setup Pin ID Wire ID Color Pin Type Usage Description b R52 b Red R52 c Red d R52 d Red e R52 e Red f R52 f Red g R52 g Red By default POT 1 is engaged only if POT 2 POT 3 and POT 4 are disengaged FiG 5 depicts the pin out of the R52 receptacle nol SINE type A431 2P04 E5 Fic 5 R52 Pin Out Receptacle A No o gt o ti11387a 312744B 13 Setup R53 Connector The R53 connector is available as an analog speed input from a robot controller An acceptable signal from a robot controller is 0 10 VDC signal Table 2 R53 Signals Table 2 R53 Signals identifies the available R53 sig nals and provides a brief description of each signal The Pin ID correlates to the pins identified in FIG 6 Pin ID Wire ID Color Usage Description A 3131 Blue An
45. tlet port This mod ule controls the system s minimum and maximum pres sure limits To program see Set Pressure Display on page 15 312744B Communications Diagram Component Identification SOL206 SOL202 Pressure Dispense Gun Brake Clutch Transducer Gear Meter Control Panel 617517 P50 P176 176 P50 4 4 SOL 206 R50 SOL 206 SOL 202 XDR SOL 202 Gear Meter Junction Box Robot Interface Supply Pump Junction Box Cables R52 Discrete Robot Interface Connector This connector provides a means to connect a cable between the Gear Meter Control Panel and a robot con troller that carries discrete signals This cable carries the following signals e Robot Dispense Signal Sealer Ready e Sealer in Cycle e Sealer Maintenance Required e Select Speed 2 e Select Speed 3 e Select Speed 4 Power R53 Analog Robot Interface Connector This connector provides a means to connect a cable between the Gear Meter Control Panel and a robot con troller that carries an analog speed signal P50 Meter Interface Cable This cable runs between the Gear Meter Control Panel and the Gear Meter Junction Box 312744B P176 Transducer Cable This cable runs between Gear Meter Control Panel and Gear Meter Junction Box 4CL3 Supply Pumps Interface Cable This cable runs between the Main Electrical Control Panel and the Supply Pump Junction Box SOL 206 Sol
46. ts only Do not alter or modify equipment Use equipment only for its intended purpose Call your 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 Keep children and animals away from work area Comply with all applicable safety regulations 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 and clean 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 lights on or off when flammable fumes are present Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions Use only Graco grounded hoses Check gun resistance daily If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Do not flush with gun electrostatics on Do not turn on electrostatics until all solvent is removed from system Keep a working fire extinguisher in the work area 312744B Warnings SKIN INJECTION HAZARD High pressure fluid fr
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