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Graco 3A2894F User's Manual
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2. 3A2894F USB Kit 24R936 Allows the user to monitor and download information of the machine status Accessories and Kits Catalyst B Hoses Allows the user to balance material pressure in the cata lyst B line by changing the hose diameter Part Description 16W047 HOSE assy 3 32 x60 6k nylon 16V531 HOSE assy 1 8 x60 6k nylon 16V219 HOSE assy 1 4 x60 5k ss braid 16V220 HOSE assy 3 8 60 5k ss braid 16V221 HOSE assy 1 2 x60 5k ss braid Restrictor Kit 24R804 Allows the user to balance material pressure in the cata lyst B line by changing the pin size Ref Part Description 101 16V360 HOUSING restrictor 1 4npt 102 16V356 PIN restrictor 41 0 094 in Ref Part Description 103 16V359 PIN restrictor 2 0 098 in 201 15V628 10 1 Nightcap 104 16V357 PIN restrictor 3 0 102 in 202 15K688 Retaining Nut 105 124961 FITTING O4jic 1 4npt 203 24P850 10 1 Ratio Check 204 256793 Assembly Tool 3A2894F 61 Accessories and Kits Caster Kit 24T091 Includes four casters 62 Mixer Elements for MD2 10 mm Mixer Elements Ref Part Description 001 127160 MIXER assy 10mm x 12 element 24T250 MIXER assy 10mm x 12 element 25 count 24 251 MIXER assy 10mm x 12 e
3. To avoid personal injury or machine damage adjust all air regulators counter clockwise prior to turning the main air on a C 34 Load material Ram Perform the Change Drums procedure in the Air Powered Ram manual Pressure Pot Perform Filling the Tank proce dure in the 5 10 and 15 Gallon Pressure Tanks manual An agitator is recommended for urethane applications utilizing a pressure pot Set the agitator to 25 50 rpm Calibration Check Assembly Only Close the d Open the base A main air slider valve To avoid personal injury or machine damage do not exceed 25 psi on the base A material until a steady flow of material has been established Set the base A air motor regulators to 10 psi 70 kPa 0 7 bar f i2 feo Set the fluid regulator adjustment to 40 psi 280 kPa 2 8 bar g Place the base A hose end into a waste con tainer 3A2894F Setup h Activate on the DM Deactivate on the DM Toyo vs 04 1213 0832 1 i Open the base A air motor slider valve m Close the base A air motor slider valve gt I j Increase the base A air motor regulator as n Repeat steps a through m for the catalyst B required to have material flow out of the hose hose Refer to Integrated Air Controls page 18 for visual clarity NOTE Activate
4. 18 Fluid Control Module FCM 20 Installation 22 Grounding scescretosekreu yeas eb ed 32 Setup 2a mas il 33 Startup cocer up ea ae 42 Base 44 Pressure Relief Procedure 46 Shutdown 48 Calibration Check 49 Maintenance 52 Adjust Packing Nuts 52 Filters an ae aan 52 SealS ia ern kann 52 DM Battery Replacement and Screen Cleaning 53 Software Update Procedure 54 0 55 Mechanical and Electrical 55 Display Module 58 2 Accessories and 60 Light Tower 24R824 60 Low Level Sensors 24R935 S100 and P100 only 60 USB Kit 24R936 61 MD2 Nose Pieces 61 Catalyst B 61 Restrictor Kit 24R804 61 Caster Kit 24 091 62 Mixer Elements for MD2 62 Appendix A DM Icons Overview 64 Setup Screen Icons 64 Run Screen Icons 65 Appendix B DM Setup Screens Overview 66 Appendix C DM Run Screens Overview 68 Appendix
5. PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 3A2894F Important Isocyanate ISO Information erty damage ids containing such solvents plier for compatibility PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or prop e Donotuse 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or flu e other fluids may contain chemicals that can react with aluminum Contact your material sup Important Isocyanate ISO Information Isocyanates ISO are catalysts used in some two component materials Isocyanate Conditions 15 t PDE Keep Components A and B Separate Spraying or dispensing materials containing isocya nates creates potentially harmful mists vapors and atomized particulates Read material manufacturers warnings and material MSDS to know specific hazards and precautions related to is
6. d4O LNHS NYH AH WH 00 DISd 08 NND SAN 3 115 NV Td oze 698 896 196 995 395 95 595 595 195 095 655 sse 186 956 sse 55 ese ese ose 875 lve ove sre bye eve eve Lee Ove 855 gee 61 3A2894F 74 Schematics 184 001 3NIVA AL33VS 104 SYNSS3ud 1 E HOLON HIV A1 YOLVINDSY ddOdnHS 10 3un SS3ud E 33199 3unss3ud 1 ddOdnHs WALSAS 184 0007 418408 uiv AT IN31SAS 184 0006 184 SZ A134dVS BON Nese vor 5 HOLON HIV AI YOLOW NND SIHL 313130 NND ILIVWNENd d ET 001 00 19 1 i 1 260721 IMYA HOLWIND3SY AVES AH 200 YOLWINDAY 154 98 x 3NIVA 134 5 8 5 Sd 0009 15906 YOLOWHIV AH 164 0006 iSd 8 Holvinodu 6 0 001 H 917 21 ASNVHXA AANO SAWA 134 5 V 5 3jdjOinHS NIVIN
7. LNOHH FINGOW WS IOHLNOO CINTA 1007 SS3NHVH inen o FT n 4 A E t Jd gt s lt lt gt p lt lt dnd HIV AH gt D G lt lt 2 viens lt z y gt I lt lt 4 2221 14554511 9 E gqvwad Nid S ZIN Nid S ZIW Nid S ZIW 3LVd NO 9N7 OL 2 zeinor gt LSLAQE NO su gt onm OL N71 OL 60 91 883 191 oar Wy 86021 awa 897821 189 6821 anana em AKRAKRAIAAAAA 960 91 SS3NHVH Greet Greet 00 cy YN z WOO NvO 1 WOO NYO MO CARTA 1ndino espozi NANI e6rsve 5 3 Avidsia OL A gast 96091 SS3NUVH SSANHYH als er an Sale 457 ANNOYS OL 26091 SS3NuVH OHH 1 i Sees d 177 88804 016021 SZIMS OL TWIG 13S 918395 ONY 9189 SANIHOVW 3AIHINSAOd Za OL WIG 136 2184 8 53 HOS vhs OL WIG 136 ANY S3NIHOVIN HOS HOLIMS 104138 WO4 Sn 86812 1 3A2894F 72 Schematics
8. 3A2894F 71 Schematics 10072415 9NIH33NION3 33S 314 TVOINHOAL AON3OV 03 44 AVW LNAWN909 SIH lL3 30 AONSOV 0 c GEKA 210091 SS3NHVH gt e gt vad aww 2 9 Niasz n Nid SZI We 299821 ngo Nid v 9A SSINYVH 966921 Sr NDS SS3NuVH NOILdO JAI41NSATOd Ws ran 71019 NSS3NuvH 1 p 18682 AT S EN Iu gt 9 8 gt gt Sak gt gt gt gt gt rz Ir 3992 gt 9 2 4 gt 9 gt gt gt xd gt ND gt gt 6 8 gt 6 gt gt 2 gt 23 gt gt gt 1 0 n 46 060821 065901 SS3NUVH aav Schematics 8 641 AA AAA anainn srez llsrez de SS3NHVH 2102 NYO 1 WOO NYO WX10S 138 1 2 9 lt z gt gt 2 lt gt 1 I lt 244522 Nid t Nid
9. YOLVINDSY GINS AH O 026108 4 5 HOLON YOLOW HIV AH lt lt 3 SH3QNI1AO Wd AH NYH AH 3unss3ud WVH AH 001 2 lt 1 001 NOILdO INVHLIUNA1Od DISd 08 LNV Id 029 69v 89v 419v Sov vov 55212 eov Lop 09 857 497 99 ssp 12 12 esp 29 8vv Loy 9 ery 042 ovv 6ev Lev ser ver zer ocv 82 Lev ger Sev ver ocv 6v zv 917 Si 1232 ely ev Hv 80v 107 90v Sov vov eov Lov 75 3A2894F Dimensions mensions D DL D BK 997202 T ANS 27 5 5100 Shown o 0 5 um ENSE 5 m EIE lt 3A2894F 76 Technical Data Technical Data ExactaBlend AGP Advanced Glazing Proportioner US Metric Maximum fluid working pressure MD2 or Ultra lite with flexible hose mixer Installed 3000 psi 21 MPa 207 bar Maximum amperage Maximum fluid working pressure 4000 psi 28 MPa 276 bar Ultra lite with Tri core mixer Installed Incoming Air pressure required 80 100 psi
10. DM Error Codes 70 Schematics eL LAW WR 72 76 Technical Data 77 Graco Standard Warranty 78 Graco Information 78 3A2894F Related Related Manuals Manuals Manuals are available at www graco com Component manuals below are in English System Manuals 332452 ExactaBlend AGP Advanced Glazing Proportioner Parts 332453 ExactaBlend AGP Advanced Glazing Proportioner Accessory Kits Kit Instructions Ram Manuals 3A0233 Air Powered Ram Instructions Parts Pump Manuals 312375 Check Mate Displacement Pumps Instructions Parts Air Motor Manuals 3A1211 SaniForce Air Motors Instructions Parts 311238 9 Air Motor Instructions Parts 333007 ExactaBlend AGP Air Motor Instructions Parts Displacement Pump Manuals 309577 Displacement Pump Repair Parts Dispense Valve Manuals 312185 MD2 Valve Instructions Parts 308253 Ultra lite Pistol Grip Flo Gun Instructions Parts Flow Meter Manuals 308778 Volumetric Fluid Flow Meter Instructions Parts 309834 Helical Gear Fluid Flow Meters Instructions Parts Fluid Filters Manuals 307273 Fluid Outlet Filter Instructions Parts List Fluid Regulators Manuals 307517 Mastic Fluid Regulators Instructions Parts List 308647 Fl
11. INS O 1 781 01 SS3NHVH 992 92 692 292 192 092 652 852 442 952 992 vse 8682 252 ose 6vc 8vc Lye ore sve ere eve lye ove 855 Lee 962 Sec eez eec 623 822 422 922 Sec voc 882 022 612 Ble Lie 92 Sic vic ele Hec ole 602 802 402 902 902 voc 8082 202 Loc 73 3A2894F Schematics WX SBELZL ENDEL KE HOLOW HIY AT 95622 NadO NXI0S ke H ii 035012 i WSISASISd 0007 HOJ 16408 HIV AT WALSAS ISd 0006 4 184 SZ SATA 134 5 HON x HOLON 1 gt 04 d3 MW3aNr1AO AT N ASO LNHS 00 WWE AT NND HOS SIH1 313730 H NND 9 ama 1 260 21 INVA 6 HOW INDY WIS IVIN AH 1 1 ISd 68 3AWAAISAVS 4 20 001 4 a 72 CD U 72 022108 WALSAS 184 0007 HO 184 06 YOLOW AH WA
12. Secure the electrical lines to the boom using electrical tape or zip ties NOTE Securing the ground cable to the fluid plate is required for the proper grounding of the machine NOTE S100 and U100 models are shown below For P100 models the V P is located on the catalyst air con trols Refer to Integrated Air Controls page 18 Label 102 Label 103 CAN Cable Ground Cable 5100 Shown 2894 Installation 12 Assemble the Base A Mate rial Whip Hose Tighten all fittings to prevent leaking m WW Dispense AV 27 Installation 13 Assemble the Catalyst B Material Whip Hose Refer to PKE 2863 found at http graco custhelp com app answers detail a_id 2863 or by utilizing the QR code below for recommended hose size configurations pin sizes and calibration numbers Tighten all fittings to prevent leaking NOTE Refer to Restrictor Kit 24R804 page 61 for purchase Restrictor pin size is for typical applications and are for reference only It may be necessary to install other pins or configurations to obtain balanced pressures 1 0 094 in 2 4 mm 2 0 098 2 5 3 0 102 in 2 6 mm NOTE Refer to Catalyst B Hoses page 61 for additional hose sizes available a Select the fluid plate to restrictor housing hose c Select the restrictor housing to dispense valve Install the adapter hose Install the restrictor housing to dispens
13. 0 6 0 7 MPa 6 0 7 0 bar Maximum operating temperature 120 F 50 C Voltage range 90 264 VAC 50 60 Hz 1 phase 4 Sound pressure 82 dB A Wetted parts Inlet Outlet Sizes Zinc plated carbon steel aluminum ram plate nitrile rubber wipers chrome stainless steel UHMW polyethylene PTFE nylon Buna N Fluid outlet base 1 2 npt f Fluid outlet catalyst 1 4 npt f Air inlet size 3 4 npt f Weight All models 865 Ib 392 kg Notes pressure and fluid type Startup pressures and displacement per cycle may vary based on suction condition discharge head air Sound pressure measured 3 3 feet 1 meter from equipment Refer to specific component manual for more details 3A2894F 77 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 an
14. Alarm Alarm 100 Low Ratio Alarm Alarm L1C1 D Check Pump A Drum Deviation EHDO R Purge Timer Expired Record Only E9DO R System not ok for dispense Record Only ELMO R System Power On Record Only EMMO R System Power Off Record Only ENB6 R Begin Flowmeter Calibration Pump A Record Only ENA6 R Begin Flowmeter Calibration Pump B Record Only ENB7 R End Flowmeter Calibration Pump A Record Only ENA7 R End Flowmeter Calibration Pump B Record Only ENB8 R Abort Flowmeter Calibration Pump A Record Only ENA8 R Abort Flowmeter Calibration Pump B Record Only EGC6 R Enter Purge Prime Screen Record Only EGB9 R Purge On Pump A Record Only EGBA R Purge Off Pump A Record Only EGA9 R Purge On Pump B Record Only EGAA R Purge Off Pump B Record Only EGC7 R Exit Purge Prime Screen Record Only ECCX R Ratio Changed Record Only EADX R Start Dispense Record Only EBDX R End Dispense Record Only CUCX V Duplicate Node Found Advisory CACX A FCM Missing Alarm CAUX A USB Disconnected Alarm ECB3 R Pump A K factor Changed Record Only ECA3 R Pump B k factor Changed Record Only ECDC R Gel Timer Changed Record Only ECFB R Pressure Transducer Installed Record Only EQUO R USB Logs Downloaded Record Only EQUO D No Configuration Deviation EQU8 D Disk Removed Too Early Deviation R9CX A Insufficient Restriction Unbalanced Pressures Alarm 70 3A2894F Appendix D DM Error Codes
15. Flow Meters Fluid Regulator Calibration Check Assembly Fluid Control Module FCM Material Pressure Gauges Catalyst B Filter Fluid Regulator Adjustment Controls the pressure to the base A fluid regulator Pressure Pot U100 only Air Motor U100 only Displacement Pump U100 only Dosing Valve P100 only 440171 Refer to specific component manual for more detailed information 3A2894F Component Identification U100 Models Fic 2 0100 Models NOTE Refer to key found on page 10 11 3A2894F Component Identification P100 Models RER SSL RAIN EN NS Fic 3 U100 Models NOTE Refer to key found on page 10 3A2894F 12 Component Identification 3A2894F 13 Component Identification Display Module DM User Interface c3 a Q BG BD
16. atmosphere Never store ISO in an open container Keep the ISO pump wet cup or reservoir if installed filled with appropriate lubricant The lubricant creates a barrier between the ISO and the atmosphere e Use only moisture proof hoses compatible with ISO e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use Always lubricate threaded parts with an appropri ate lubricant when reassembling NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature Changing Materials NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime When changing materials flush the equipment multiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemi cal compatibility 3A2894F Important Isocyanate ISO Information Component Identification Component Identification S100 Models Ne ur Fic 1 100 Models Key A Display Module DM B Boom Ram Base Chemical Ram Catalyst Chemical E Dispense Valve F Integrated Air Controls G Electrical Enclosure 10
17. 2 Purge Timer Counter Visual indicator to show the user the remaining idle time before another shot needs to be taken The timer will begin to flash when expired Base A Pump Select Icon will appear white when not acti vated black when activated Catalyst B Pump Select Icon will appear white when not acti vated black when activated Error Number Event Number Date Time Error Event Code Navigate to Totalizer Screen 3A2894F Appendix A DM Icons Overview 65 Appendix B DM Setup Screens Overview Appendix B DM Setup Screens Overview If the DM is showing a Run screen press to access the Setup screens which have a black header 0302473 1 T0100 FI E D WE Screen 1 This screen allows the user to set the purge timer lock the ratio setpoint toggle if low level sensors are installed and to toggle if an Ultra lite with Tri core mixer is installed on a P100 machine S100 and U100 Models 02 26 14 i Bo Pal 5 9 66 Screen 2 This screen allows the user to calibrate the machine See Calibrate the machine page 38 for more details 51050000 51060000 35 00 xo on S 12 04 12 Screen 3 This screen allows the user to format and set the current date and time reset the password adjust the backlight timer and toggle sound silent opera
18. 8 and 10 for visual clarity of hose 33 Nem clamp placement b Install the fluid regulators if removed for installa A tion Resin Hose Clamp 8 Calibration check only 2894 23 Installation 7 Calibration Check Only 8 Route and Connect the Install the Calibration Check Base A Material Hoses Assembly and Material Tubes onto the Boom Assembly a Tighten all fittings to prevent leaking b Tighten all hose clamps to secure material lines a Tighten all fittings to prevent leaking b Tighten all hose clamps to secure material lines Ne NOTE For additional assembly details refer to the ExactaBlend AGP Advanced Glazing Proportioner Accessories Instructions manual 100 Shown 24 3A2894F Installation 9 P100 Only Install the Dosing Valve a Tighten all fittings to prevent leaking b Install the air supply from the catalyst integrated air controls c Connect the solenoid cable from port 3 of the FCM Refer to Fluid Control Module FCM page 20 Allow enough length for lifting the ram e 3A2894F 25 Installation 10 Route and Connect the Cata lyst B Material Hose a Tighten all fittings to prevent leaking b Tighten all hose clamps to secure material lines U100 Shown P100 Shown 26 100 Shown 3A2894F 11 Route and Connect the Air Hoses and Electrical Lines
19. BF E 8 EC BC Fic 4 DM Component Identification Front Key BA System Enable Disable BG Increase Decrease Field Selection Enables disables the system When the system is Increase or decrease the selected value Navigate to disabled dispense operation is disabled another field BB Soft Keys Defined by application using the DM BC Cancel Cancel a selection or number entry while in the process of entering a number or making a selection BD Enter Acknowledge changing a value or making a selection BE Lock Setup Toggle between run and setup screens If setup screens are password protected button toggles between run and password entry screen BF Field Selection Navigate to another field when the DM is in setup mode These buttons have no function when the DM is in run mode 14 3A2894F Component Identification Fic 5 DM Component Identification Rear BH BJ BK BL Model Number Identification tag for the DM CAN Cable Connections Electrical connection for power and communication to other GCA devices Module Status LEDs Visual indicators to show the status of the DM Green Solid Power provided Green Off No power Yellow Flashing Communication with other GCA devices occurring Red Solid Bad DM or machine is in critical status Red Flashing Wrong program uploaded Token Battery Access Cover Access cover for token and battery 3A2894F 15 Component Identifica
20. LSAS 164 0006 184 92 SAWAALSAvS HOLWinoau r 1 44O LNHS x YOLOW HIY HOLON HIV AH Sx Bo 001 mm x 340 1nHS Wv AH oor c3 mm d LT l H nva 3unssaud AH i 4 dWnd NYH AH NIN DISd 08 NOILdO ACISINSAIOd NV Td Mali 620 21 HOLVINDSH Isasg 1 7 x SAIWAALSAVS C Hoy 1n93H AT Iz aa UC vu WALSAS 184 0009 15906 uiv AT WALSAS ISd 0006 ISd SZ BAWAALsays HOLON HOLOW HIV AI CH eT 00 4dO LNHS Wve 1 001 H if A NMOG dh 1 aunsssuawvu H NND SIHL 313730 NND OLLVWNANd So ama 860181 INVA AVE HOIW INDY HOLWINOTY ISa 58 x 3 WAAISAVS Lp HOLWINOAY AIMA AH m T P Ti e 078105 HOLOW AH WALSAS ISd 0009 HOS ISd 06 WALSAS ISd 000 54 SZ SATA AL33VS 3dO4nHs HOLON HIV HOLON HIV AH HOlvIn93H PW n 5 AH
21. OTE For U100 systems the catalyst bleed valve is located on the pump outlet filter 48 3A2894F Calibration Check Calibration Check Perform the calibration check procedure to verify the cal 5 MD2 Only Install the calibration nozzle onto the ibration of the flow meters are correct dispense applicator 1 Perform Base Purge page 44 2 Navigate to the Home screen 052413 Ordo 1 5 EM a 5 6 Open the catalyst B ball valve located near the dis pense applicator 3 Activate 3 on the DM a 047243 0831 1 o l 1 0 00 1 og min VIP 2 0001 5 3 0001 4 Remove the static mixer 3A2894F 49 Calibration Check 7 Calibration Check Assembly O nly Dispense 9 Hold a metal part of the gun firmly to a grounded material into a waste container at the calibration metal pail Trigger the gun until the Display Module check assembly to verify the V P is at the correct value NOTE A restrictor pin for the catalys housing may be required to obtain 5 psi 35 kPa 0 3 bar or above for he V P shown on the DM shown on the DM shows OK t B restrictor 3 9 001 041203 G 1 0 AB 1 0 00 1 og min 2 001 F 041213 oes 1 AEQ 0 3 0001 F 2 0001 s 10 Place two separate containers on two separate 8 Disengage the trigger lock 50 scales and zero the sca
22. Setup Operation G ExactaBlend AGP Advanced Glazing For dispensing two component silicone polysulfide and urethane materials For professional use only Not approved for use in explosive atmospheres or hazardous locations See page 4 for model information including maximum working pressure and approvals Important Safety Instructions Read all warnings and instructions in this manual Save these instructions PROVEN QUALITY LEADING TECHNOLOGY Contents Contents Contents 2 eier 2 Related Manuals 3 Models 2 22 9 14 4 Base Machines 4 ci dare eek ram 5 Dispense Valves 5 Warnings 2 9 x ces cena eet RR ers 6 Important Isocyanate ISO Information 8 Isocyanate Conditions 8 Material Self ignition 8 Keep Components A and B Separate 8 Moisture Sensitivity of Isocyanates 9 Changing Materials 9 Component Identification 10 S100 Models 10 U100 Models 11 P100 Models 12 Display Module 14 User Interface 14 Electrical Enclosure 17 Integrated Air Controls
23. TE The screen below shows only the catalyst B pump selected oan 10341 10 screen or to toggle an option e Shows the current state of the machine okay not okay 68 3A2894F Appendix C DM Run Screens Overview Alarm Log Calibration Check This screen displays the last 70 errors that have This screen displays the ratio after a calibration check occurred dispense NOTE Production material cannot be dispensed from this screen opan 0831 1 808 O l 11 0 00 1 og min Cs 2 0001 Ld 3 0001 Press or to show other errors Totalizer This screen displays the total amount of material in kilo grams dispensed for each pump 03 2403 1245 1 10 Tu 0 00 kg 0 00 kg Information This screen displays diagnostic information useful in troubleshooting 11 10 FLO B FLG gi min 39 T FLO 0 min 3A2894F 69 Appendix D DM Error Codes Appendix D DM Error Codes Error Code Error Name Error Type 0000 0 No Active Errors Alarm 00 Unrecognized Error Alarm F6A3 A Pump A Check Flow Meter Alarm F6B3 A Pump B Check Flow Meter Alarm F5D0 A Machine has not been calibrated Alarm F9D4 A System Flow Rate is too Low Alarm F9D5 A System Flow Rate is too High Alarm R4D0 A High Ratio
24. Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure e off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only e Do not alter or modify equipment Alterations modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it 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 TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDSs to know the specific hazards of the fluids you are using e Route exhaust away from work area If diaphragm ruptures fluid may be exhausted into the air Store hazardous fluid in approved containers and dispose of it according to applicable guidelines
25. ail a_id 2823 or by utilizing the QR code below for software version NOTE When the screen turns on the following screen history will appear 00 08 00 00 1 Turn the power switch to OFF 2 Remove the DM from the bracket 3 Remove the token access panel Icon Description Update successful Update unsuccessful B Update complete no changes necessary ks Update was successful complete but one or more GCA modules did not have a CAN boot loader so the software was not updated in that module E 7 Remove the token Fic 12 Remove Access Cover 8 Replace the token access panel 4 Insert and press software upgrade token Token 9 Press to continue part no 16V853 firmly into the slot 5 Install the DM onto the bracket 54 3A2894F Troubleshooting Troubleshooting 1 Follow Pressure Relief Procedure page 46 before checking or repairing a dispense valve 2 Check all possible problems and causes before disassembling the dispense valve Mechanical and Electrical PROBLEM CAUSE SOLUTION Dispense Applicator No flow of catalyst B Clogged gun nose Clean or replace the gun nose Clogged injector housing Ultra lite Clean or replace the injector housing only Clogged restrictor housing Clean or replace the restrictor housing and pin Ball valve is closed Open the ball valve V P is
26. al 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 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 judic
27. ating in housing Use a fitting behind the restrictor hous ing with an inner diameter that will not allow the pin to back out 56 3A2894F Troubleshooting PROBLEM CAUSE SOLUTION Pump Abnormal pump pressures dur ing operation Pump moves during stall Worn or damaged packings Replace the packings Bad check valves Malfunctioning check valves Clean or replace the check valves Clean or replace the check valves Pump does not run No air supply to the pump Turn on the air or increase the air pres sure Catalyst B ball valve is closed Open the ball valve Clogged mixer Replace or clean the mixer Ultra lite has cured material in it Clean or replace Clogged restrictor Clean or replace the restrictor 3A2894F 57 Troubleshooting Display Module CODE PROBLEM CAUSE SOLUTION F6A3 A Base Flow Meter Error Flow meter signal is not detected Check the base flow meter cable Flow meter is clogged Replace sensor Flow rate is too low Clean the flow meter F6B3 A Catalyst Flow Meter Error Flow meter signal is not detected Check the catalyst flow meter cable Flow meter is clogged Replace sensor Flow rate is too low Clean out the flow meter Increase system flow rate 5 libration nce has not n Perform Calibration procedure or Den Machin
28. atio set point Ratio setpoint will not be able to be adjusted when activated Icon shown represents that it is not locked 4 E Audible Alarm Allow the machine to sound an alarm when an error occurs Download Depth Low Level Sensor Option Toggle if a low level sensor is installed or not installed on the machine Icon shown represents not installed Base A Pump 000 Set how many hours of data the system will download Log Intervals O i0 s Set the time interval that the system will record the machine status Display Module Catalyst B Pump T Advanced Fluid Control Module Weight System units are in grams QO Flow Meter Shows the calibration fac tor K after calibration has been performed 95 5 9 Ultra Lite Tri core Mixer P100 Model Only Toggle if an ultra lite tri core mixer is installed on a P100 machine Start Calibration lt Confirmation 64 3A2894F Run Screen Icons Icon Description gt Return to Home Screen m Navigate to Purge Prime Screen Navigate to Alarm Log Screen Navigate to Information Screen u z Calibration Check Changes the machine status to not okay in order to perform the calibra tion check procedure 2 Calibration Reset Clears all data and resets all sam ples to 0 gx 04 5
29. ation Component Connection Reference from FCM S100 Model Shown Fic 11 Component Connection Reference from FCM 21 3A2894F Installation Installation NOTICE To avoid flow meter malfunction do not use PTFE tape on NPT threads Only apply pipe sealant Loc tite 565 or equivalent to all NPT threads when installing 1 Locate the Machine Base 2 Assemble the Hose Clamps Locate the machine on a level surface Refer to Dimen and Swivel Assembly onto sions page 76 for space requirements the Boom Base a Torque the swivel assembly fasteners to 24 ft lb 33 Nem b Hand tighten all hose clamps NOTE Refer to steps 8 and 10 for visual clarity of hose clamp placement Swivel 8100 Shown Assembly Calibration Check only 22 3A2894F Installation 3 Install the Boom Base onto 5 Install the Front Boom Arm the Machine Base onto the Boom Base Slide the boom base into the machine base mast Torque all fasteners to 24 ft lb 33 Nem 3 Places 6 Install the Fluid Plate onto the Front Boom Arm Injury may occur if the fluid plate is lifted by only one 4 Assemble the Hose Clamps person Use a hoist multiple people or remove the onto the Front Boom Arm fluid regulators prior to installation Hand tighten all hose clamps a Torque the fluid plate fasteners to 24 ft lb NOTE Refer to steps
30. c shock Grounding provides an escape wire for the electric current Machine Grounded through customer supplied power cord Fluid supply container follow local code Solvent pails used when flushing follow local code Use only conductive metal pails placed on a grounded surface Do not place the pail on a nonconductive sur face such as paper or cardboard which interrupts grounding continuity To maintain grounding continuity when flushing or relieving pressure hold metal part of the gun dispense valve firmly to the side of a grounded metal pail then trigger the gun valve 3A2894F Setup A To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails When software is updated on the DM the software is The DM will display an error message when initialization then automatically updated on all connected GCA com is complete This error occurs because the machine has ponents A status screen is shown while the software is updating to indicate the progress When the status bar is not been calibrated Press to acknowledge the error and continue with the setup procedure complete press to continue When the main electrical power is turned on the splash screen will be displayed until communication and initial ization is complete GRACO 3A2894F 33 Setup 1 Purge Material Lines
31. check assembly 07 Pa 0 5 pc b Activate both on the DM 042 10 34 1 2 3A2894F 37 Setup f Dispense the material into the waste container 4 Calibrate the machine until both the base A and catalyst B material lines have been purged and are free of air Perform the following procedure during initial setup of the machine if the flow meters were replaced or if the machine needs to be recalibrated a Engage the trigger lock b Open the base A and catalyst B air motor slider valves h Clean the nozzles of the calibration check assembly and install the JIC caps lt i AND on the DM N c Setthe base A and catalyst B air motor regu lators 12 04 72 70 34 MD2 or Ultra lite with flexible hose 70 psi 480 kPa 4 8 bar Ultra lite with Tri core 85 psi 586 kPa 5 9 bar 38 3A2894F d the fluid regulator adjustment to 40 psi 280 kPa 2 8 bar e Place two separate containers on two separate scales and zero the scales These containers will be used in step j NOTE Weight units of the scales are to be set as grams f Navigate to setup Screen 2 NOTE Screen 2 is already shown if this procedure is performed during the initial setup of the machine Screen 2 Recalibration 20472 1037 REDI 5 0000 00 g 5 0000 00 g 3 00 300 00 3000 im A Scre
32. e Base purging prevents mixed material within the dispense applicator from cur ing The machine will remain pressurized and electri cally connected 1 Navigate to the Purge Prime screen NOTE Verify both pumps are activate oat 10241 0 2 Close the catalyst B ball valve located near the dispense applicator 3 Dispense material into a waste container until only the base A chemical is present 4 Engage the trigger lock 44 3A2894F Base Purge 3A2894F 45 Pressure Relief Procedure Pressure Relief MD2 Proced a Remove the static mixer 162 8 This equipment stays pressurized until pressure is A44 n t PA manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Procedure when you stop dispensing and before cleaning checking or servicing the equipment 1 If electrical power is supplied to the machine perform Base Purge page 44 b Open the catalyst B ball valve located near the dispense applicator If electrical power is not supplied to the machine continue to the next step 2 100 and P100 Close the base and catalyst B air motor slider valves U100 Close the base A air motor slider valve and the supply ball valve on the pressure pot Bleed
33. e valve hose to the restrictor pin assembly or union b Select the restrictor pin or union U100 with MD2 Install the union to the fluid plate to restrictor housing hose If utilizing the d U100 with MD2 If utilizing the restrictor pin restrictor pin assembly the restrictor pin assem assembly replace the swivel union found on the bly will be installed in step d MD2 with the restrictor pin assembly All other Configurations Install the restrictor pin assembly or union to the fluid plate to restrictor housing hose p Note the orientation of gt and housing 28 3A2894F 14 Connect the Catalyst B and Base A Material Whip Hoses to the Fluid Plate Damage to the moisture lok hoses may result in moisture sensitive material to cure within the hose To avoid machine damage avoid damaging the protec tive coating on the moisture lok hoses a Tighten all fittings to prevent leaking bas Catalyst Base b Slide protective sleeve over base and catalyst hoses 3A2894F Installation c MD2 Tape sleeve 8 in 20 cm behind the high volume fitting to allow adequate movement of the gun handle d Pullthe other end of the protective sleeve tightly and secure with electrical tape 29 Installation 15 MD2 Only Connect the Air Fitting and Route the Air Hose a Remove the plug located on the catalyst B integrated air control lt 2 5100 S
34. e not calibrated 2 2 AERA 2 calibration values F9D4 A System Flow Rate too Low Tale do 0 TOW TOL accurate Increase the system flow rate measurement by flow meters Reduce the restriction in the catalyst flow path F9D5 A System Flow Rate too High Decrease the system flow rate measurement Increase the restriction in the cata lyst flow path R4D0 A High Ratio Alarm Ratio is too high Re calibrate the machine Catalyst material line is plugged Check the material supply The flow for the base is too high The flow could be turned down or a and the flow for the catalyst is too larger size hose could be used for low the catalyst Adjusted flowrate between dis Run until machine status states penses 100 Low Ratio Alarm Ratio is too low Re calibrate the machine Base flow rate is too low Check the material supply Adjusted flowrate between dis penses ncrease the base flow rate Run until machine status states Insufficient Restrictions The restrictor pin is missing or Install a restrictor pin of the correct Boe Unbalanced Pressure under sized size Hoses are not sized to properly Size the hoses so that the pressures balance the pressures are balanced heck Pump B ta Check drum base or catalyst mate Drm NERIS Fw level Oros rial level and replace if 20 Check the drum level sensor cable N A Purge Timer Expired Gel timer has expired Use machine Normal operation Di
35. ek check and tighten throat seals on the pumps and dosing valve 3A2894F Maintenance DM Battery Replacement and Screen Cleaning Battery Replacement 3 Remove the old battery and replace with a new CR2032 battery A lithium battery maintains the DM clock when power is not connected 4 Properly dispose the old lithium battery according to local codes To replace the battery 5 Replace rear access panel 1 Disconnect power to the DM 6 Connect the power to the DM and reset the clock NOTE This can be done by removing the CAN cable through Screen 3 Refer to Appendix B DM from the bottom of the DM Setup Screens Overview for more detail 2 Remove rear access panel Cleaning Use any alcohol based household cleaner such as glass cleaner to clean the DM Spray on the rag then wipe DM Do not directly spray the DM Replaceable screen protectors 15M483 are available 2894 53 Maintenance Software Update Procedure 6 Turn the power switch to ON When software is updated on the DM the software is then automatically updated on all connected GCA com A status is shown while software is updating to indi ponents A status screen is shown while the software is cate progress To prevent corrupting the software updating to indicate the progress load do not remove token until the status screen dis appears Refer to PKE 2823 found at http graco custhelp com app answers det
36. en 2 Initial Calibration 032413 07451 20000 00 g 20000 00 g gt 00 0000 00 0000 Li LI 3A2894F Setup g Activate to signal the machine of the fol lowing calibration shot h MD2 Install the calibration nozzle onto the dis pense applicator Disengage the trigger lock 39 Setup Dispense the chemicals into two separate con tainers MD2 Chemical will be dispensed through the applicator Ultra lite Chemical will be dispensed through the calibration check assembly k Continue to dispense the chemical into the con tainers until both status bars are complete NOTE If the light tower is installed a green light will be illuminated when the status bars are complete 2 EYES Tr 5 0000 00 g fa 0000 00 g gt gt 005000 49 005000 LI E 40 Weigh both containers separately and input the values of both chemicals into setup Screen 2 NOTE To change a value in a desired field perform the following Press or to highlight the desired field to be changed e Press to activate the desired field or to activate deactivate an option e Press or to change the value of the selected field Press to set the value NOTE Weight units are in grams 10 3 1 HAF o Tu 20000 00 g 5110000 00 3 00 0000 85 00 0000 02115113 3A2894F S
37. erify calibration check assembly outlets are clear and unob Weekly structed Check desiccant Weekly Check restrictor housing and pin assembly to prevent crystalliza Weekly tion U100 Check iso lube bottle for Daily discoloration Perform Shutdown and install Daily nightcap Adjust packing nuts When TSL has seeped through the packing nut Adjust Packing Nuts NOTE There must be no pressure when adjusting the packing nuts Air pressure in the feed tanks is too much 1 Follow Pressure Relief Procedure page 46 including relieving air pressure in the tanks 2 Fill metering pump packing nuts with throat seal liq uid TSL 3 After TSL is added torque metering pump packing nuts to 50 ft lb 67 5 Nem Follow instructions in Xtreme Lowers manual 311762 4 Fill dosing valve packing nut with throat seal liquid TSL 52 5 After TSL is added tighten dosing valve packing nuts 1 4 turn after nut contacts packings about 145 155 16 18 Nem A TSL Filters Once a week check clean and replace if needed the following filters e S100 and U100 Models Catalyst pump outlet filter comes with a 60 mesh fil ter Two pack 60 mesh filter replacement kit 224459 is available e P100 Models Catalyst pump outlet filter comes with a 30 mesh fil ter Two pack 30 mesh filter replacement kit 224458 is available Seals Once a we
38. etup m Press to signal the machine that the cali 5 Set the Display Module DM praon procedure 15 complete Perform the following tasks to fully setup the DM Refer automatically calculate the K factor of both to Appendix A DM Icons Overview page 64 for clar materials ity n Engage the trigger lock a Define general system settings See Screen 3 page 66 o MD2 Remove the calibration nozzle and install a static mixer on the dispense valve b Define specific system settings See Screen 1 page 66 p Navigate to the Home screen c P100 with Ultra Lite Tri core Mixer Select the 85 psi 5 9 bar option box See Screen 1 page 66 3A2894F 41 Startup Startu p 3 Turn the power on at the electrical enclosure va 2 Do not operate machine without all covers and shrouds in place 1 Engage the trigger lock 2 Install the static mixer or nozzle onto the dispense applicator See specific applicator manual for details 4 Open the base A and catalyst B main air slider valves NOTE Cutting more than two outlet steps on the static mixer may increase the chance of the mixing elements being pushed out of the static mixer NOTE If using the mixer element kit 24T035 assemble the sleeve onto the MD2 dispense applicator prior to fas tening the 1 4 NPT outlet adapter Hand tighten the 1 4 NPT outlet adapter 5 Open the base A a
39. hown 0100 Shown 100 Shown b Install the air fitting if required Use sealant on the threads and tighten to prevent leaking 5100 Shown 0100 Shown P100 Shown c Route the air line beside the other air hoses that were routed in step 11 30 3A2894F 16 Ultra lite Tri core Only Replace the Relief Valve on Both Integrated Air Controls Replace the standard relief valve found on both the base A and catalyst B integrated air controls with the relief valve for the Ultra lite Tri core dispense valve 5 0100 Shown 3A2894F Installation 17 U100 Models Only Locate and Connect the Pressure Pot a Locate the pressure pot on the machine base b Connectthe chemical line from the pressure pot to the fluid filter inlet using fitting provided c Connectthe air line from the Base A Inte grated Air Controls to the pressure pot 31 Installation 18 Install Accessories Refer to the ExactaBlend AGP Advanced Glazing Pro portioner Accessory Kits manual for details 19 Connect Air to the Machine NOTE Air inlet port size is 3 4 npt f 20 Connect Electrical Power to Machine Connect the power cord to the electrical enclosure 32 Grounding The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electri
40. iaires 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 call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 746 1334 Fax 330 966 3006 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 For patent information see www graco com patents Original instructions This manual contains English MM 3A2894 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2013 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised July 2014
41. lement 50 count 002 16V841 SLEEVE mixer no front thread 003 24T035 SLEEVE mixer thread x 1 4 NPT outlet 1 2 in Mixer Elements Ref Part Description 001 512288 MIXER assy 1 2 x 24 element 512289 MIXER assy 1 2 x 30 element 512286 MIXER assy 1 2 x 36 element 002 16T001 SLEEVE mixer 24 element 16T002 SLEEVE mixer 30 element 16T003 SLEEVE mixer 36 element 3A2894F Accessories and Kits 3A2894F 63 Appendix A DM Icons Overview Appendix A DM Icons Overview Setup Screen Icons Icon Description Icon Description Return to Home Screen HB Calendar Date Set the date format and cur rent date Left Navigation Navigates to the previous Screen Set the current time in 24 hour format Right Navigation Navigates to the next screen 2 05 min Set Purge Timer Allow the machine to remind the operator to take a shot before the chemical hardens in the gun Timer starts once a dispense is complete 0000 Password Set a password to lock sys tem settings Password 0000 disables the lock Backlight Time Set how long the screen will illuminate when idle before darkening Entering 0 dis ables the timer A B2O Lock Ratio Setpoint Lock the current r
42. les These containers will be used in step 11 NOTE Weight units of the scales are to be set as grams 3A2894F 11 Dispense the chemicals into two separate contain ers MD2 Chemical will be dispensed through the appli cator Ultra lite Chemical will be dispensed through the calibration check assembly 12 Continue to dispense the chemical into the contain ers until a 400 gram shot has been dispensed NOTE A value will be shown on the DM when a dis pense is complete This is the value the machine was running at based on the flow meter values B min 1 8311 2 0001 ME 3 0001 3A2894F 041203 083 1 0 13 15 16 Calibration Check Weigh both containers separately and calculate the ratio A B of the two chemicals Compare the ratio calculated from the weighed con tainers with the ratio shown on the DM If the ratio comparison is acceptable acti vates on the DM or repeat steps 10 through 14 twice if more verification is required Press to clear all values if more than three samples are required If the ratio comparison is unacceptable perform Calibrate the machine page 38 51 Maintenance Maintenance 9 a ui 9 4 6 Task Schedule Refer to specific component man As Required ual for more detailed information Check catalyst B filter assembly Weekly to prevent crystallization V
43. liter machine An agitator is recommended for urethane applica tions utilizing a pressure pot Set the agitator to 25 50 rpm 4 3A2894F Base Hose in cm Catalyst Hose 1 in cm Catalyst Hose 2 in cm Hose Kits Hose Kit Reference Part No No 24R832 1 24R833 2 24R834 3 24T092 4 24T093 5 24T094 6 240253 7 5 8 x 120 1 6 x 305 1 8 x 60 0 3 x 152 1 8 x 60 0 3 x 152 1 4 x 60 0 6 x 152 1 8 x 60 0 3 x 152 1 4 x 60 0 6 x 152 1 4 x 60 0 6 x 152 1 8 x 60 0 3 x 152 1 4 x 60 0 6 x 152 3 32 x 60 0 2 x 152 1 2 x 60 1 3 x 152 YS _ Hy 3 8 x 60 1 0 x 152 3 8 x 60 1 0 x 152 3 32 x 60 0 2 x 152 3 32 x 60 0 2 x 152 Dispense Valves Part No Description 24P217 MD2 dispense valve with handle 24P223 Ultra lite 6000 with 36 element flexible hose mixer 24P221 Ultra lite 6000 with 36 element Tri core mixer 3A2894F Models 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 symbols refer to procedure specific risks When these symbols appear in the body of this manual refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear thro
44. nd catalyst B air motor slider gt ARE valves 9 gt A f 872 p JI 42 3A2894F Startup 6 Verify the base A and catalyst B air motor regula NOTE The Home screen will indicate Not OK and the tors are set to the correct pressure light tower if installed will illuminate red until the next step is completed 03 24113 oras 1 MD2 or Ultra lite with flexible hose 70 psi 480 kPa 4 8 bar Ultra lite with Tri core 85 psi 586 kPa 5 9 bar 10 Disengage the trigger lock NOTE If a new static mixer has been installed a base purge is recommended to prevent side walling Perform Base Purge page 44 11 Hold a metal part of the gun firmly to a grounded metal pail Trigger the gun until the Display Module shows OK and the light tower if installed illumi nates green 7 P100 with Ultra Lite Tri core Mixer Verify that the 85 psi 5 9 bar option box is selected Refer to Screen 1 page 66 02 26 14 14411 Bl 255179 8 Verify the ram director valve is set to lower the ram 9 The DM will show a standby screen when power is NOTE Additional dispensing may be required in order to ensure a good mixture first supplied to the machine Press to go to the Home screen GRACO 3A2894F 43 Base Purge Base Purge Base purge results in the purging of the base A chemi cal through the dispense valv
45. ocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Cross contamination can result in cured material in fluid lines which could cause serious injury or damage equipment To prevent cross contamination Never interchange component A and component B wetted parts Never use solvent on one side if it has been con taminated from the other side Material Self ignition Some materials may become self igniting if applied too thick Read material manufacturer s warnings and material MSDS 3A2894F Moisture Sensitivity of Isocyanates Exposure to moisture such as humidity will cause ISO to partially cure forming small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity NOTICE Partially cured ISO will reduce performance and the life of all wetted parts e Always use a sealed container with a desiccant dryer in the vent or a nitrogen
46. off Ensure the power is on Ensure the machine is in dispense mode Ensure V P is turned on when machine enters Purge Prime mode No air to catalyst B pump Turn air on Ensure that there is pressure to the No catalyst ram down pressure catalyst ram and that the control lever is in the down position Tighten packing nut If leak continues replace the packings Dosing valve leaking at rod Loose or worn packings Dosing valve between main housing and outlet housing Bad o ring Replace both o rings on the seat Dosing valve not cycling Bad cable Replace the cable Bad power valve Replace the power valve Dispense NOL OIEPENSE Trigger lock engaged Disengage the trigger lock material No air to MD2 Connect air to the MD2 Turn on the air Clogged mixer Clean or replace Tri core or Flex mixer Ultra lite has cured material in it Clean or replace Dispense Valve will No air to MD2 Connect air to the MD2 material dispense Turn on the air Repair the MD2 Refer to the MD2 for more details Ultra lite seal is worn Replace the seal Bad seal in MD2 3A2894F 55 Troubleshooting PROBLEM CAUSE SOLUTION No material flow Material supply is off Ensure the base A solenoid valve is on and has pressure Ensure the catalyst B V P is on and has pressure Ensure the motor s have air pressure Ensure there is
47. on the DM when prompted and all slider valves refer to the catalyst B air controls oan 1034 1 10 ae 1 Dispense the material into the waste container until the base A material hose is purged and free of air 3A2894F 35 Setup 2 Connect the dispense appli _Ultra lite cator a Connect the base A hose to the base A inlet fitting MD2 a Connect both base A and catalyst B material hoses to the dispense applicator b Activate both Al and on the DM 12 04 2 1034 1 10 b Connect the catalyst B hose to the catalyst inlet fitting c Open the catalyst B ball valve and dispense material into a waste container until the dis pense valve has been purged and is free of air d F DM 08531 1 0 c Open the catalyst B ball valve and dispense material into a waste container until the dis pense valve has been purged and is free of air d Close the catalyst B ball valve and dispense material into a waste container until only base A is present 36 3A2894F Setup 3 Calibration Check Assembly c Place a waste container underneath the calibra Only Purge material lines to tion check assembly the calibration check assem bly a Open the base A and catalyst B air motor s 72 slider valves amp A A I c d Remove the JIC caps from the calibration check x assembly e Open the calibration
48. spense material into a waste con tainer Base purge the machine 58 3A2894F Troubleshooting CODE PROBLEM CAUSE SOLUTION CUCX V Duplicate Node Found Unknown Software Error Cycle the system power Unintended module plugged into Verify that only necessary GCA mod the system ules are plugged into system CACX A FCM Missing FCM unplugged from CAN bus Verify the FCM CAN cable is plugged in Damaged FCM Replace the FCM Damaged FCM Base Replace the FCM base CAUX A USB Disconnected USB unplugged from CAN bus mu Vig USB CAN cable 8 plugged Damaged USB Replace the USB Damaged USB Base Replace the USB base 3A2894F 59 Accessories and Kits Accessories and Kits Light Tower 24R824 Visual and audible indicator of machine status Status Description Red Solid An error has occurred and requires maintenance Red and Green Solid Allows a dispense but notifies the user of an uncleared error e g low level Green Solid Machine is ready to dispense Green Flashing Machine is okay Gel timer has expired 60 Low Level Sensors 24R935 S100 and P100 only Alerts the user when material drums are empty Calibration Check Assembly 24R777 Allows the user to watch the DM while performing the Calibration Check procedure Kit is required for all Ultra lite dispense valve applications
49. sufficient down pres sure and the control lever is in the down position Clogged mixer Replace the static mixer Clean or replace the Tri core or hose mixer Clogged restrictor Clean or replace the restrictor V P won t turn on NOTE The turns off after 30 seconds of no activity It will turn on during dispense or when entering Purge Prime mode Fluid Plate Bad cable Replace the cable Disconnected cable Connect the cable V P reads 0 V P does not match information on the information screen Air supply to V P shut off Air supply is restricted Turn on the air supply to the V P Replace with a minimum 3 4 in ID hose Faulty V P Replace V P V P obtains 85 psi 586 kPa 5 86 bar and then alarms Flow rate is too high Reduce the flow rate Too much restriction in the catalyst B hose Resize the hoses to reduce restriction Flowmeter clogged Clean or replace the flow meter Bad flowmeter Replace the flowmeter Catalyst B air motor pressure is too low Catalyst B air motor pressure is too low Abnormal pressures during oper ation or after dispense Clogged restrictor housing Pressures not balanced Clean or replace restrictor housing and pin Change catalyst hose size Ball seat not seating properly in fluid regulator s Clean or replace ball seat Restrictor pin not se
50. the air from the pressure pot by opening the manual bleed valve c Disengage the trigger lock d Trigger the gun to relieve pressure into a waste container 46 3A2894F Pressure Relief Procedure f Close the base and catalyst B main air Ultra lite slider valves a Remove the JIC caps from the calibration check assembly b Place a waste container underneath the calibra g If electrical power is not supplied to the machine place a waste container underneath the pump bleed valves Open the pump bleed valves NOTE For U100 systems the catalyst bleed valve is located on the pump outlet filter c Open the calibration check assembly to relieve pressure into a waste container h Clean the nose of the dispense valve or bleed valve i Install the night cap onto the MD2 d Verify the pressure gauges display 0 3A2894F 47 Shutdown e Close the 2 ey Sh utd own wae ad 1 Perform Pressure Relief Procedure page 46 2 Turn the power off at the electrical enclosure f Clean the nozzles of the calibration check assembly and install the JIC caps g Close the base A and catalyst B main air slider valves h If electrical power is not supplied to the machine place a waste container underneath the pump bleed valves Open the pump bleed valves Clean the pump bleed valves once com plete N
51. the Pressure Relief Procedure and disconnect all power sources 3A2894F Warnings gt lt T 11 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 e Use equipment only in well ventilated area e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc e Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present e Ground all equipment in the work area See Grounding instructions e Use only grounded hoses e Hold gun firmly to side of grounded pail when triggering into Do not use pail liners unless they are antistatic or conductive e Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem e Keep a working fire extinguisher in the work area 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 e Use fluids and solvents that are compatible with equipment wetted parts See
52. tion 1245 3 E gunn 000 03043 Dos DE 3A2894F Screen 4 This screen is only displayed when the USB option is installed The screen allows the user to enable down loading of USB logs set log intervals and set how many hours of data to download 03 2415 09 3 S ESSET 9 0 75 Screen 5 This screen is displayed as Screen 4 when the USB option is not installed The screen displays information of part numbers and software versions that are currently found within the system The USB information is only displayed when the USB option is installed 0412713 08 35 5 160599 160245 16 205 VS 101002 Vs 101001 WS 101002 3A2894F Appendix B DM Setup Screens Overview 67 Appendix C DM Run Screens Overview Appendix C DM Run Screens Overview If the DM is showing a Setup screen press to Purge Prime Access the This screen allows the pumps to be run independently NOTE All machine alarms are disabled when this screen is displayed on the DM 140472 10241 0 Home This screen shows the current ratio and allows the user to access other screens Press the corresponding to deactivate or acti 0302473 1 0 08 010 0 1 e Press or to increase or decrease the ratio a a e Press the corresponding amp to access another vate the desired pump for operation NO
53. tion Main Display Components The following figure calls out the navigational status and general informational components of each screen Previous screen Current screen Faults Status Current date and time Next screen E ae 0312443 OCE Selection screen Function display Fic 6 Main Display Components 16 3A2894F Electrical Enclosure Fic 7 Electrical Enclosure Component Identification Key DA Power Switch Turns electrical power on or off DB 24VDC Power Supply Converts input power to 24 VDC 3A2894F 17 Component Identification Integrated Air Controls FiG Base A Side All Models Nu 8 Integrated Air Controls Catalyst B Side S100 Models Key CA CB cc CD CE CF 18 Main Air Slider Valve Turns air on and off to the entire system When closed the valve relieves pressure downstream Ram Air Regulator Controls the ram up and down pressure and blowoff Pressure Ram Director Valve Controls the ram direction Exhaust Port with Muffler Air Motor Regulator Controls the air pressure to the motor Air Motor Slider Valve Turns air on and off to the air motor When closed the valve relieves air trapped between it and the motor Push the valve in to shutoff CG Blowoff Button Turns air on and off to push the platen out of an empty drum CJ Catalyst Air Slider Valve T
54. ughout the body of this manual where applicable N D amp ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause elec tric shock e 0 SKIN INJECTION 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 surgical treatment Turn off and disconnect power cord before servicing equipment Connect only to grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on power and extension cords Do not expose to rain Store indoors Do not point dispensing device at anyone or at any part of the body Do not put your hand over the fluid outlet Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop dispensing and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately V MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow
55. uid Pressure Regulators Instructions Parts List Pressure Pot Manuals 308369 5 10 and 15 Gallon Pressure Tanks Instructions Parts List Heated Platen Manuals 332511 ExactaBlend AGP Advanced Glazing Proportioner Heated Platen Kit Kit Instructions Reference Man uals 3A1244 Graco Control Architecture Module Programming Valve Manuals 313342 Dosing Valve Instructions Parts 3A2894F Models Models Base Machines Chemical Ratio Maximum Working Pressure Part No Industry Description by Weight psi MPa bar 248809 AGP S100 System 55 gallon 5 gallon n 200 liter 20 liter machine with boom Sipang AGP S100 Syst 55 gallon 5 gall ystem 55 gallon 5 gallon 200 liter 20 liter machine 24R811 AGP U100 System 55 gallon 5 gallon 200 liter 20 liter machine with boom 24R812 AGP U100 System 55 gallon 5 gallon MD2 200 liter 20 liter machine 3000 21 207 Urethane AGP U100 System 55 gallon 5 gallon 6 1 to 14 1 Ultra lite with flexible hose mixer 24R813 200 liter 20 liter machine with boom 3000 21 207 and pressure pot Ultra lite with Tri core mixer 4000 28 276 AGP U100 System 55 gallon 5 gallon 24R814 200 liter 20 liter machine with pres sure pot 24R815 AGP P100 System 55 gallon 5 gallon 200 liter 20 liter machine with boom Polysulfide 24R816 AGP P100 System 55 gallon 5 gallon 200 liter 20
56. urns air on and off to the catalyst motor only When closed the valve relieves pressure down stream CK Voltage to Pneumatic Regulator V P Electrically controlled air regulator 3A2894F Component Identification Catalyst B Side Catalyst B Side U100 Models P100 Models 9 Integrated Air Controls NOTE Refer to key found on page 18 3A2894F 19 Component Identification Fluid Control Module FCM aJ A Fic 10 FCM e Key EA EB EC ED EE EF EG 20 Port 1 Air Shut off Valve Controls the air to the base A material regulator Port 1 Low Level Sensors Optional Low level input for the both materials Refer to Accessories and Kits page 60 for more details Includes splitter Port 2 Flow Meters Base A and Catalyst B flow meter input Includes splitter Port 3 Solenoid Valve P100 only To open and close the dosing valve Port 4 Voltage to Pneumatic V P Regulator Controls the air to the catalyst B material regulator Port 5 Audible Light Tower Optional Visual and audible indicator of machine status Refer to Accessories and Kits page 60 for more details Port 6 Not Used Port 7 Not Used EH CAN Connection Supplies power and communication to GCA components 3A2894F Component Identific
57. y 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 incompatibility 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 incident
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