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Graco 3A0294G User's Manual

1. 80 3A0294G Parts Kit 262371 continued m m E l ES N 1 w j Q S S AN 0 DY OSS Q O Oo S CO LF lt R Fa Sa AG V sh Te cui M E NEA 2 81 3A0294G Parts Kit 262371 Parts Ref 2 3 3a 3bA 3c Das 5b 6x 7 8x 9x 10 11 12k 13x 14 17 18 19 20 21 22k 23 24 25 26 27 28 29 30 31 32 33 34 82 Part 262408 262412 189285 15V954 262410 262539 262416 16G294 121226 151859 15X619 15Y051 122030 121806 124273 122622 240404 16E067 110782 24A032 15V719 16G589 100016 101682 277 590 259383 121255 103473 164856 16G410 15M669 111457 16F562 Description Qty BRACKET subassembly LCM 1 VALVE includes 3a 3c 1 SOLENOID air motor 1 includes o ring and screws LABEL caution LABEL valve shutoff air control COVER front electronics KIT module LCM display includes 5a and 5b MODULE LCM display bare TOKEN software CABLE CAN male female 0 4m CABLE assembly DB25 10 ft CABLE pigtail linear sensor
2. 7 LA r 262375 3A0294 41a FIG 96 Install Air Lines Air Valve b Runthe air lines between the adapter bracket and connect them to the top port and bottom port of the solenoid valve assembly as shown See FIG 96 and FIG 97 Top Port Bottom Port ko m Fic 97 Install Air Lines Solenoid Valve c Zip tie both air lines to the pump tie rod 3A0294G Installation 14 Install the electronics subassembly cover 4 hand 15 Install the power supply cord 14 tighten the screws to secure an ES lt 1 PSST ff M S3 p Mm Xd mm m C gt E ERN 7 a Ks SG CY GA Nae ge Cr dd ANS bo u 4 r 262375 3A0294 43a Fic 98 Install Cover Install Power Lo Supply Cord r 262375 3A0294 43a Fic 99 Install Power Supply Cord 16 Turn on air supply to the system 3A0294G 49 Setup Setup Zw cd va NOTE For setup procedures specific your supply sys tem or pump assembly refer to the Supply Systems Operation manual or your specific pump package instructions parts
3. 59 b 57 49 90 3A0294G Kit 262375 Parts Ref c N bade 5b 6a 6b 6c 6d 6e 6 6g 7 8x 9x 10 11x 12x 13x 14 15 16 19 20 21 22k 23 24 25 26 27 28 29 30 31 32 33 34x 35 36 Part 262420 262424 262539 262416 16G294 C59752 111530 111337 100615 C19405 C20365 16F609 121226 151859 15X619 15Y051 122030 121806 124273 15G747 122622 287839 15F772 108014 113500 119700 118605 120730 107257 120143 16E792 100016 101682 160327 119992 157785 C12509 100101 3A0294G Description BRACKET subassembly LCM COVER electronics KIT module LCM display includes 5a and 5b MODULE LCM display bare TOKEN software VALVE subassembly includes 6a 6g VALVE pneumatic 3 way MUFFLER FITTING tee street BUSHING hex steel FITTING connector male FITTING tee air PLUG seal 1 4 tube CABLE CAN male female 0 4m CABLE assembly DB25 10 ft CABLE pigtail linear motor sensor M12 CABLE M12 8 pin female male CABLE GCA solenoid extension M12 5P CABLE solenoid CONNECTOR splitter MAGNET linear sensor CORD power LABEL identification SENSOR assembly ADAPTER lift ring 1 9 16 sst O RING ADHESIVE anaerobic SENSOR reed switch O RING SCREW ma
4. Installation Install Power Supply Cord FiG 48 Install Power Supply Cord 16 Open the air shutoff valves on the air control assem bly 29 Installation Install Kit 262373 1 Close both shutoff valves on the air control panel Shutoff Valve Ecc Fic 49 Close Shutoff Valves 2 Install the electronics subassembly 1 to the back of the bracket on the ram post using four screws 29 and washers 28 Ll Gr P E e 29 28 r 262373 3A0294 28a FiG 50 Install Electronics Assembly 30 3 Install display bracket subassembly 2 to the bot tom of the air motor using two screws 30 and two washers 31 30 r 262373 3A0294 29a Fic 51 Install Display Bracket 4 Install the air valve subassembly 3 a Usetwo wrenches to remove the air hose elbow fitting and pressure gauge from the air controls Air Hose Elbow Fitting Label Pressure po Gauge 3 FiG 52 Air Controls b Remove the air motor slider valve label
5. Install mm D Power Supply Cord E r 262370 3A0294 24a FiG 31 Install Power Supply Cord 14 Open the air shutoff valves on the air control assem bly 23 Installation Install Kit 262371 3 Install the electronics subassembly 1 to the side of the power supply bracket using four screws 28 1 Close both shutoff valves on the air control panel Also secure the bracket to the bottom of the air con trol bracket using two screws 24 and two lock washers 23 J Shutoff Valve 23 1 24 Shutoff Valve Bcc l jer i FIG 32 Close Shutoff Valves WE e NA Q 2 Installthe power supply bracket 27 to the ram post using four screws 24 and lock washers 23 r_262371_3A0294_29a lt Fic 34 Install Electronics Assembly 4 Install the light tower bracket 26 to the top air con trols bracket using three screws 24 and lock wash ers 23 r 262371 3A0294 30a SS D lt lt A n ay NO i 94 S H A 9 o x 8 T CC q NEUE ui c 9 e 24 r 262371 3A0294 28a E FIG 33 Install Power Supply Bracket
6. lt 1 i FIG 101 Connect to ir Inlet 9 Connect air supply and electrical cable to the dis pense valve and solenoid valve See the dispense valve manual for instructions 10 Flush and or prime before using See Prime Purge page 52 for instructions 3A0294G Pressure Relief Procedure A amp V Trapped air can cause the pump to cycle unexpectedly which could result in serious injury from splashing or moving parts 1 Lock the gun valve trigger 2 Change to manual mode in the run screen See Change Operation Mode page 62 3 Shut off the air supply to the system 4 Shut off the air valve by pressing the Air On Off soft key on the display module 5 Close the manual air valve 6 Unlock the gun valve trigger 7 Hold a metal part of the gun valve firmly to the side of a grounded metal pail and press or step on the foot switch 8 Lock the gun valve trigger 9 Open the material line drain valve and the pump bleeder valve Have a container ready to catch the drainage Drain Purge Valve FiG 102 Drain Materia 3A0294G Pressure Relief Procedure Leave the pump bleeder valve open until you are ready to spray dispense again If you suspect that the spray tip nozzle or hose is completely clogged or that pressure has not been fully reli
7. 27 28 SSS r 262370 3A0294 20a FiG 75 Install Pressure Sensor 8 Install cables Reference the cable identification table on the next page and FiG 77 for a diagram of cable connections Drum Low 1 Start Stop 2 Shot Status Light Tower Solenoid Pressure Extension Sensor Cable Extension Cable Not Used Air Motor Changeover Cable id SE 09 LCM Cable FIG 76 Breakout Module Connections 39 Installation 262374 Cable Identification a Power Cable 122487 a mE 60 1524 r m Pigtail 160580 LS1 RS1 5203203 8 Motor cable E 118 p Tom Air Solenoid Extension 122030 Y1 20 508 r u o Ai oo lenoid LET pa 40 3A0294G Installation e9 c81n 9Ide2 WOT Ajddns age NVO sd 4asn q peijddns A PA esuedsiq s u Jy Isa 1 sn Aq p li ddns 9 qe UOIsU91x3 9AJ EA piou os Josueg INSS ld 9 qe2 1osuegs eunssaJg 9 qe5 uoisue x4 piougjos 4 YN T N O 8IGeD plous os Iz npolN noye ig 9 QEO 1010 N AV LINV pps uy jeuondo U91MS 1004 TA uy j
8. r 262373 3A0294 before linear ey t5 RE FiG 56 Remove Lift Ring Adapter and O rings c Place the linear sensor magnet 13 on the installation tool 27 and then insert the magnet down into the top of the motor shaft d Apply the supplied adhesive to the linear sensor assembly 18 threads Install the linear sensor torque to 30 36 ft lbs 40 6 48 8 Nem See FIG 57 31 Installation 32 e Place the o ring 20 on the lift ring adapter 19 and apply the supplied adhesive to the threads See FIG 57 Lift Ring r 262373 3A0294 after linear Route the linear sensor cable through the lift ring adapter Install the lift ring adapter torque to 30 36 ft lbs 40 6 48 8 Nem See FIG 57 Route the linear sensor cable through the hole on the lift ring adapter Apply the supplied adhesive to the lift ring threads Install the lift ring torque to 30 36 ft lbs 40 6 48 8 Nem See FIG 57 Remove the screw on the valve cover to remove the cover See FIG 58 j Install the reed switch sensor 22 Secure with the 1 in 25 mm screw 24 and o ring 23 pro vided See FIG 58 Screw Cover ssh II FIG 58 Install Reed Switch Sensor k Connect the strain relief guide 26 to the reed switch sensor Use a wrench to tighten the 1 2 in
9. 102 Tips for Better Accuracy 102 Appendix C Breakout Module 258999 Connections 103 Appendix D Y Adapter 124273 Connections 105 ACCeSSOLGS 11 59 weg ERI huku SE eed a ma 106 DIMENSIONS uyu u L uu akhu u Re e RN 106 Technical Data 106 Graco Standard Warranty 108 Graco Information 108 3A0294G Related Manuals Related Manuals Manuals are available at www graco com Component manuals in U S English LLL NEN 313526 Supply Systems Operation 313527 Supply Systems Repair Parts 312376 Check Mate Pump Packages Instructions Parts 312375 Check Mate Displacement Pumps Instructions Parts 311827 Dura Flo Displacement Pumps 145cc 180cc 220cc 290cc Instruc tions Parts 311825 Dura Flo Displacement Pumps 430cc 580cc Instructions Parts 311828 Dura Flo Pump Packages 145cc 180cc 220cc 290cc Instructions Parts 311826 Dura Flo Pump Packages 430cc 580cc Instructions Parts 312796 NXT Air Motor Mxxxxx models Instructions Parts 311238 NXT Air Motor Nxxxxx models Instructions Parts 3A1161 Foot Switch Kit Instructions Parts 3A1162 Changeover Solenoid Kits Instructions Parts 3A0294G 3 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion po
10. 24 3A0294G 5 Loosen two screws on the top air controls bracket Install the display module bracket 2 using two screws 24 and lock washers 23 to secure it to the air controls bracket r_262371_3A0294 31a 6 Install the air valve subassembly 3 a Use two wrenches to remove the air hose elbow fitting and pressure gauge from the air controls Air Hose Elbow Fitting Label Pressure Gauge FiG 37 Air Control Assembly b Remove the air motor slider valve label See FIG 15 3A0294G Fic 38 Install Air Va r 262370 3A0294 34a FiG 39 Install Elbow Fitting Installation Loosely install the air valve assembly 3 Grease the o ring included with the air valve assembly Install the o ring and then finish installing the air valve assembly Secure with Screw Slider Valve Label r 262370 3A0294 11a Ive Assembly 8 Install the new air motor slider valve label that is included with the air valve assembly See FIG 37 Coat the gauge fitting with PTFE tape and then reinstall Use a wrench to tighten See FIG 37 Coat the elbow fitting with PTFE tape Reinstall the fitting and air hose on the back of the new air valve assembly Use two wrenches to tighten 7 Snap the display 5 into the display bracket 25 Installation 8 Install the
11. ye Il TT ca S r_262373_3A0294_41a FIG 64 Install Electronics Cover 36 12 Install the power supply cord 14 J Install Power Supply Cord r 262373 3A0294 42a FiG 65 Install Power Supply Cord 13 Open the air shutoff valves on the air control assem bly 3A0294G Install Kit 262374 1 Close both shutoff valves on the air control panel 1 Shutoff Valve Shutoff Valve Bt FIG 66 Close Shutoff Valves 2 Install the electronics subassembly 1 to the back of the bracket on the ram post using four screws 23 and washers 22 L o R o 9 Q o oe 9 23 22 r 262373 3A0294 28a FiG 67 Install Electronics Assembly 3A0294G Installation 3 Install display bracket subassembly 2 to the bot tom of the air motor using two screws 25 and two washers 24 i 24 Yu H YN 25 FiG 68 Install Display Bracket r 262374_3A0294_66a LL 4 I
12. 9 qe2 UdIIMS peeu 1osueg 1eaur e qe2 JOJOW JI V 14 jeuondo YOUMS 1004 ui Jo 31989 WO x aasn Aq poaljddns 9A EA esuedsiq 1asn Aq peiddns A A piou josS 2a X aN 91GeD UOISUS8 Xy Plous OS l I m i i J ye M E T im D a z i E T E i 1 it um 1 I i i r s edt llE Hu m ays z N 1 7 gat gt i NI En J H i i ice N i E d ty a F al 5 fase m mo j j L L L L EET d i a a Sy 9 qe5 Plous os npolN 3noxeaJg E DD 9 Goad Cant Gis pa Cera 1 jeuondo Uy 1eydepy A MOJ 31uBr1 14 euondo uinJp mo 1T 12 de 9 qe5 Plous os Fic 46 Cable Connections D200 with Small NXT 3A0294G 28 12 Secure cables to the air hose using zip ties Tighten all zip ties and then cut off the excess 13 Bundle the cables and zip tie them close to the elec tronics bracket 1 so that they will fit under the elec tronics subassembly cover 4 14 Install the electronics subassembly cover Install the back cover first and hand tighten the screws to secure Then install the front cover hand tighten the screws to secure 4 Front 4 Back E r 262371 3A0294 39a 950 XO FiG 47 Install Covers 3A0294G 15 Install the power supply cord 13 r 262371 3A0294 40a
13. Ad OM am D J jt QUE 9A EA JIV E m quiessy 9 ge5 plous os AV H npolN noye ig qQEO 1010 N AIV dt 14 jeuondo gt J9MOL 4617 dung iei 15 jeuondo MN 9 qe2 uos 1osueg Jeour unJp M07 Iq plousjos 154 jeuondo ae YOUMS 100 _ Jeydepy A Dap aare 47 FIG 93 Cable Connections Wall Mount or Floor Stand Pumps with Large NXT 3A0294G Installation 11 Install the pressure sensor on the pump bleed port a Use a wrench to remove the pressure valve Pressure Valve FIG 94 Remove Pressure Valve b Apply the supplied sealant to the adapter 42 the manifold 43 and the pressure valve Install all three in the order listed i k k vd Pressure L B Q Valve 43 FiG 95 Install Pressure Sensor c Disconnect pressure sensor at PT1 d Install the o ring 45 and pressure sensor 44 See FIG 95 12 Bundle the cables and zip tie them close to the elec tronics bracket 1 so that they will fit under the elec tronics subassembly cover 4 48 13 Install the air lines 34 a Connect the air lines to the valve subassembly 6 as shown Plugged o0 AS ME
14. 60W ENCLOSURE LCM breakout box SWITCH power 115 250V SCREW self tapping COVER power FUSE 250V 1 2A LABEL caution GROMMET SCHREW grounding WASHER lock ENCLOSURE power supply SCREW mach pan head SCREW countersunk 6 32 x 0 38 SEALANT pipe sst amp The bare display module does not have SmartWare software already installed Use the software upgrade token 5b to install the SmartWare software before using Not shown cards are available at no cost Replacement Danger and Warning labels tags and Reference cable identification table and cable con nection diagram page 40 and page 41 3A0294G Parts Kit 262375 lt pos pen T gt gt m ya i V WS V Ned P Q S d c 5 le E MEL ud 5S eo AT zo d um uL Los qns fM NS et A Apply thread sealant to threads 89 3A0294G Parts Kit 262375 continued Inside the back of the NXT air motor 26 27 x MUSS
15. Shot Volume Yellow Shot volume is less than the Increase the advisory setpoint on Less than Advi Solid advisory setpoint Setup screen 11 Increase shot sory Setpoint consistency by decreasing speed and valve shutoff time and increasing material back pressure Shot Volume Yellow Shot volume is greater than the Increase the advisory setpoint on Greater than Solid advisory setpoint Setup screen 11 Increase shot Advisory Set consistency by decreasing speed and valve shutoff time and increasing material back pressure Inconsistent Yellow A possible inconsistent shot Request a larger shot ae Solid caused by a shot volume less Verify that shot volume variation than overshoot is okay L2 Drum Low Yellow Drum low empty sensor has Replace empty drum with a full AE Solid tripped drum Maintenance Yellow Maintenance counter has Volume specified by setpoint has Counter Solid expired Maintenance counter passed since last reset has counted down to O from set point 3A0294G 69 Shutdown Shutdown e NOTICE Never leave water or water base material in pump overnight If you are pumping water base material 9 Change to manual mode in the run screen See flush with water first then with a rust inhibitor such Change Operation Mode page 62 as mineral spirits solvent or white spirit Relieve pressure but leave rust inhibitor in pump to protect parts from corrosion 4 Turn th
16. H N M Platen Bleed Port N Platen R Ram S Air Valve Assembly T Pressure Sensor Assembly U Linear Sensor Assembly Included in SmartWare kits e e e is Lo E ee m F F s 3A0294G Component Identification cont SmartWare Kit for Wall Mount Pumps FIG 4 Component Identification Key A Lift Ring B Air Motor C Display Module D Air Controls E Air Solenoid under shroud F Power Supply under shroud G Power Switch within shroud H Displacement Pump J Wet Cup 3A0294G Component Identification SmartWare Kit for Floor Mount Pumps d LA hes gt if ed Tc TA T E F G Fluid Outlet Fluid Inlet Floor Mount Stand Pressure Sensor Assembly Valve Assembly lt Ur A Included in SmartWare kits Component Identification User Interface Fic 5 Display Module NOTICE To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails Table 1 Display Module Button Functions Select between Run and Setup modes Start the present operation mode Possible operation modes shot mode sequence mode manual mode and park mode Arrows Up Down Navigate up or down within a screen or to a new screen Soft K
17. Reference cable identification table and cable con nection diagram page 27 and page 28 3A0294G Parts Kit 262373 Inside the back of the NXT air motor 83 3A0294G Parts Kit 262373 continued 40 47 52 41 53 42 lt gt 49 42 3A0294G 84 Kit 262373 Parts Ref 2 3 3a 3bA 3c 5a 5b 6 7 8x 9x 10 11x 12x 13 14 15 18 19 20 21 22 23 24 25 26 2f 28 29 30 31 32x 33 34 35 37k 38 Part 262430 262432 189285 15V954 262424 262539 262416 16G294 122487 151859 15X619 15Y051 122030 121806 124273 15G747 122622 287839 15F772 108014 113500 119700 118605 120730 107257 120143 16E792 100016 101682 100133 121293 103473 164856 16G410 15M669 16F562 111457 3A0294G Description BRACKET subassembly Icm
18. 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 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 contr
19. volume from this screen There are three alarm possibilities Icon Function Description Advisory Advisories do not require atten tion therefore the system con tinues running and N displays next to the operation mode field Deviation Deviations require attention but not immediately therefore the system continues running and M displays next to the oper ation mode field Alarm Alarms require immediate atten tion therefore the system dis ables and the Information screen automatically displays 3A0294G Appendix A User Interface Display The information screen is accessed by pressing either from the run screen Current Error Icon Alarm or Advisory Current Drum Volume Overshoot Icon Current Error Code Average Overshoot Largest Deviation from Average Overshoot 101 Appendix B Tips Appendix B Tips Calibration Procedure Performing the calibration procedure is not necessary for the system to work However performing the proce dure will increase shot accuracy depending on the changeover characteristics of your supply system Each pump and material combination may have unique changeover characteristics volume pumped during the changeover Performing the calibration procedure will calibrate your particular SmartWare kit to more accu rately count the material dispensed during the change over portion of the pump stroke 102 Tips for Better Accuracy Repe
20. 59 Set System Parameters Calibrate The actual weight volume of material dispensed may vary slightly from the displayed weight volume Use the following procedure to calibrate the system as needed Calibration values can be set manually However it is recommended to run the calibration procedure when needed 1 Navigate to setup screen 10 so 2 Press lt gt to start the overshoot calibration pro cess The icons will display ci m 5 Release the start button or foot switch The hour glass icon is updated and the shot mode icon will display 000 0 000 0 deepens Remove any excess material from the dispense valve if necessary Empty the container if necessary Set the scale to Zero Press I 7 to dispense a shot into the container When the shot completes the shot icon will disap pear and the first digit of the weight field will be high lighted et 000 0 amp 4 000 0 J E o 000 0 3 Place a container that is at least as large as the pump volume under the dispense valve 4 Hold down E or the foot switch to run the sys tem The manual mode icon will flash The pump will go through the first changeover stop to measure the overshoot then complete the second changeover and stop 60 3A0294G 9 Remove any excess material from the dispense valve if necessary Include this material in the weight of the shot 10 Weigh the shot on the scale 1
21. COVER power FUSE 250V 1 2A LABEL caution GROMMET SCHREW grounding WASHER lock ENCLOSURE power supply SCREW mach pan head SCREW countersunk 6 32 x 0 38 SEALANT pipe sst amp The bare display module does not have SmartWare software already installed Use the software upgrade token 5b to install the SmartWare software before using Not shown A Heplacement Danger and Warning labels tags and cards are available at no cost Reference cable identification table and cable con nection diagram page 34 and page 35 85 Parts Kit 262374 QO 4 Ua 3A0294G 86 Parts Kit 262374 continued 46 87 43 47 9 34 Se Se 35 x l 38 ee TT b Lf KS S 3A0294G Parts Kit 262374 Parts Ref 2 3 3a 3bA 3c Das 5b 6x 7 8x 9x 10 11 12 13 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 88 Part 262430 262432 1892
22. drum alarm occurs When L2 is enabled the low drum advisory is enabled and RE displays The advisory icon ae displays if a low drum advisory occurs 3A0294G Set Pump Runaway Error 1 Navigate to setup screen 7 Ttg nin BOE i GEB 052 gal f Ht 052 gal E 2 Press rl to access fields to make changes 3 Press to navigate to the pump runaway cycle rate field 4 Press and to increment or decre ment to the desired cycle rate Graco recommends setting the cycle rate to 60 or less Choose a value that is just above the maximum cycle rate of the application 5 Press ull to save the set cycle rate 6 Press N to exit edit mode 3A0294G Set System Parameters Set Maintenance Parameters Set the amounts of material moved through the pump and dosing valve that will result in a maintenance advi sory or alarm 1 Navigate to setup screen 8 601000 000000 Total Volume Dispensed Maintenance Setpoint z 2 Press to access fields to make changes 3 Press to navigate to the maintenance setpoint field 4 Press and to increment or decre ment to the desired amount of material that will result in an advisory when the total volume dis pensed exceeds the maintenance setpoint 5 Press del to save this amount 6 Ifan advisory occurs press to navigate to the total volume dispensed field Clear the field to reset the advisory LN 7 Press N to exit edit mode
23. fields to make changes 3 Press to navigate to the pump selection field 4 Press to scroll through the pump options 5 Press qi to select the correct pump size for the system 6 Press N to exit edit mode 3A0294G Set System Parameters Enable Disable Pump Functions See Setup Screen 5 Enable Disable Pump Func tions page 96 for a description of each pump function 1 Navigate to setup screen 5 z 2 Press to access fields to make changes 3 Press to navigate to each pump func tion field 4 Press al to enable or disable each pump func tion LUN 5 Press N to exit edit mode 57 Set System Parameters Enable Disable Errors See page 92 for an explanation of each error function 1 Navigate to setup screen 6 2 Press to access fields to make changes 3 Press to navigate to each error field 4 Press ail to enable or disable each error code 5 Press to exit edit mode 58 Set Low Empty Drum Error Follow the Enable Disable Errors steps to set either the empty drum alarm or low drum advisory Refer to the Errors section on page 66 for more infor mation on alarms and advisories and how to clear an alarm or advisory The low empty drum error code L1 is used for the empty drum alarm Li and error code L2 is used for the low drum advisory ak When L1 is enabled the drum empty alarm is enabled and an displays The alarm icon a displays if an empty
24. linear sensor 17 a Remove the lift ring or plug b Insert magnet and magnet holder into the top of the motor shaft using the magnet installation tool c Install the linear sensor assembly into the top plate of the air motor 17 Magnet Holder ti18237a Fic 40 Install Linear Sensor 9 Install the reed switch assembly 20 a Remove the air line to the motor b Adjust the air fitting to make room for the reed switch 20 c Install the reed switch 20 into the air valve as shown in FIG 41 and secure with the screw 21 26 NOTE For air motor models MO7xxx M12xxx and M18xxx which have the large mufflers remove the muf fler before installing the reed switch Reinstall the muf fler after the reed switch in installed a N X NX S 20 lt M 21 N a KZ S k x S EN Yo Tif Muffler b IG Se ro FIG 41 Install Reed Switch 10 Install the pressure sensor on the pump bleed port a Use a wrench to remove the pressure valve e e P e 1 Pressure Valve W f r 262370 3A0294 19a D e N lt i J FiG 42 Remove Pressure Valve b Apply the supplied sealant to the adapter 30 the manifold 31 and the pressure valve Install all three in the order listed See FIG 43 c Disconnect pressure sensor at PT1 3A0294G Install
25. of the motor shaft using the magnet installation tool Install the linear sensor assembly into the top plate of the air motor 17 Magnet Holder ti18237a Fic 72 Install Linear Sensor 6 Install the reed switch assembly 19 a Remove the air line to the motor Adjust the air fitting to make room for the reed switch 19 Install the reed switch into the air valve as shown in FIG 41 and secure with the screw 20 3A0294G NOTE For air motor models MO7xxx M12xxx and M18xxx which have the large mufflers remove the muf fler before installing the reed switch Reinstall the muf fler after the reed switch is installed G S 2n zi C 19 d N N 20 xil Muffler Fic 73 Install Reed Switch 7 Install the pressure sensor on the pump bleed port a Use a wrench to remove the pressure valve Pressure Valve yy r 262370 3A0294 19a SB N AN aue J Fic 74 Remove Pressure Valve b Apply the supplied sealant to the adapter 27 the manifold 28 and the pressure valve Install all three in the order listed See FIG 75 c Disconnect pressure sensor at PT1 3A0294G Installation d Install the o ring 33 and pressure sensor 29 use zip ties 26 to secure the cable to the ram and air hose 33 q D Pressure gt Vave i4
26. the supplied adhesive to the pipe nipple 10 Install cables Reference the cable identification fitting 32 Screw the fitting into the air control table below and FiG 93 for a diagram of cable con assembly nections b Apply the supplied adhesive to the adapter fit ting 31 and the pipe swivel fitting 33 Screw Light Tower Shot Status Drum Low 1 both fittings onto the valve assembly as shown Start Stop 2 Solenoid Extension Cable Not Used Air Motor Changeover Cable Solenoid r 262375 3A0294 35a 33 32 LCM Cable FIG 91 Install Valve Assembly with air controls FIG 92 Breakout Module Connections 262375 Cable Identification ae Power Cable 121226 uL m um 16 406 4 Motor cable pL Te 29972 ll Solenoid Extension 122030 HE 20 508 I Accessory Kt yell Air Solenoid cue LAY Teton zo som p FuiSoendd v eon Pressure be Exten sion 46 3A0294G Installation bees lit 9 dqe NWOT 9 de5 NYO Ajddns J9MOd aasn Aq perjddns A PA esuedsiq Kejdsiq s u 11y 1asn q paljddns AJLA Diou josS am e qeo2 uoisuejxa3 piouejog
27. through screens Current setup Soft Keys screen number Scroll down through screens l mT E E l LI Ue 205 Enter Exit Screen FIG 6 Setup Mode Screen Components Run Screen in Shot Mode Shown Current Mode Pause Shot Air on shaded Air off not shaded Soft Keys Information specific to current run screen mode Cancel Pump or Dispense Valve Shot Progress Bar Graph Fic 7 Run Mode Screen Components 12 3A0294G Component Identification Setup Mode Screen Structure The following figure demonstrates the flow of the setup mode screens beginning with setup screen 1 For details on each setup screen see Setup Mode Details on page 94 sae eb th 1 G 1 125 L 160203 w u 0 02 003 i oy j DEO cel 1 A 00 0ccH z OZ 1 Ov in fafafa 0000 t o 00000 E 2 900009 CDECDCDIE i X EXP M ChkHat 250 v Ap n DC 2003 000003245 OMEM 000000 0 20000000 EVA 00000 AE OSS i hni JEMIMA Ont 52 aE t 052 sa F 3A0294G 13 Component Identification Run Mode Screen Structure There are only two run mode screens run and information However there are four modes within the run screen shot sequence manual and park The following figure demonstrates the flow of the modes in the run screen begin ning with power up screen 1 For details on each run mode see Run Mode Details on page 100 Power Up Screen GRACO 0 0 Enter screen to dispense a shot Run Screen Sh
28. to select the desired shot 9 Once all shot positions and shot numbers are con LN figured for the shot sequence press to exit edit mode 55 Set System Parameters Set Password NOTE When the password is 00000 the setup screens can be accessed without entering a password 1 Navigate to setup screen 4 B E UE UE G a D0000 v Ki ChkHat 250 2 Press to access fields to make changes 3 Press to navigate to the first password field 4 Press and to increment or decre ment to the desired digits of the password 5 Press 4l to enter the password 6 Press to navigate to the next password field Follow steps 4 5 to enter and confirm the password 7 Press to exit edit mode 56 Disable Password To disable the password follow Set Password page 56 to change the password to 00000 Reset Password If the password is forgotten it can be reset without los ing the current settings or shot data 1 Disconnect power to the user interface 2 Reconnect power to the user interface 3 When the power up screen appears immediately press and hold both the top soft key and the for six seconds The password automatically resets to 00000 4 Follow the Set Password page 56 instructions to set the password if desired 3A0294G Select Pump 1 2 Press Navigate to setup screen 4 if necessary t 5 00000 1 Cheat 250 T ZA z to access
29. 0 0 00047 amps Digital Output Schematic Connect external load between Digital Output and Ground 24 Volt Rl Om Closed 51 1 KOhm Mff pen 3A0294G 75 Electrical Schematics Digital Input Schematic The SmartWare shot dispense kit uses low side switches for all digital inputs The input is off when nothing is con nected between the input pin and the ground pin The input is on when the ground pin is connected to the input pin Digital Input Schematic Connect external switch between Digital Input and Gound State External Switch RA Om Closed 249 EOhm Off Open 24 Volt 76 3A0294G Parts Parts Kits 262370 and 262372 30 77 OW A AX R par AB UD E i 36 3A0294G Parts Kits 262370 and 262372 continued Inside the back of the NXT air motor 25 26 x MUSS 78 3A0294G Kit 262370 and 262372 Parts Ref 2 3 3a 3bA 3c 5a 5b 6 7 8x 9x 10 11x 12x 1
30. 1 Press and to enter the shot weight in the weight field 12 Set the scale to zero 13 Perform steps 1 6 three more times After you have entered the fourth shot weight in the weight field the material delta top and bottom fields calibration values will automatically update and the specific weight G on setup screen 1 will update The calibration procedure is now complete 3A0294G Set System Parameters Set Shot Accuracy Errors Use this screen to set the shot volume deviation from the shot setpoint that will cause an advisory or alarm NOTE If either the advisory field or alarm field is set to zero the error is disabled 1 Navigate to setup screen 11 s 1 BOO cc 4 A 00 0 cc E v 2 Press to access fields to make changes 3 Press to navigate to the advisory field 4 Press li to enter the advisory field 5 Press p and to set the value in the advisory field 6 Press ei to enter the value 7 Follow steps 4 through 7 for the alarm field x 8 Press N to exit edit mode 61 Operation Operation NOTE The shot dispense kit controller modifies pump packages and supply systems However the operation procedures from the pump packages instructions parts manuals and the Supply Systems Operation manual still apply Startup 1 Refer to your Supply System Operation manual or pump package instruction parts manual for system startup instructions 2 Turn on the
31. 3 14 15 18 19 20 21x 22 23 24 25 26 2f 28 29 30 31 32 33 34 35 36 Part 262408 262412 189285 15V954 262410 262539 262416 16G294 121226 151859 15X619 15Y051 122030 121806 124273 15G747 122622 287839 15F772 108014 113500 119700 118605 120730 107257 120143 16E792 100016 101682 277590 277592 259383 15R108 157785 121255 103473 164856 3A0294G Description BRACKET subassembly LCM VALVE includes 3a 3c SOLENOID air motor includes o ring and screws LABEL caution LABEL valve shutoff air control COVER front electronics KIT module LCM display includes 5a and 5b MODULE LCM display bare TOKEN software CABLE CAN male female 0 4m CABLE assembly DB25 10 ft CABLE pigtail linear motor sen sor M12 CABLE M12 8 pin female male CABLE GCA solenoid extension M12 5P CABLE solenoid CONNECTOR splitter MAGNET linear sensor CORD power LABEL identification SENSOR assembly ADAPTER lift ring 1 9 16 sst O RING ADHESIVE anaerobic SENSOR reed switch O RING SCREW machined hex washer head 1 4 20 x 1 in 25 mm SCREW thd forming hex washer head 1 4 20 x 1 2 in 13 mm GUIDE strain relief TOOL magnet install WASHER lock SCREW socket head cap COVER rear Kit 262370 only Kit 262372 only BRACKET light tower Kit 262370 only Kit 262372 only FITTING swivel BRACKET power supply SCREW count
32. 3850 Pressure Diferential Analog npu 2 Pressure Power vol J o 3 Pressure Ground Shield Analog Shot Active Connector 8 Grey Pin Description M8 Connector 4 pin Female Shot Active 5 volts or Not Active 0 volts 4 Analog Output Phoenix Contact Part Number 1694376 Shot Active Power 5 volt Shot Active Ground 3 Shield Analog 2 Air Motor Connector 9 Grey Pin Description PinNumber M12 Connector 8 pin Female A code Motor Top Reed Switch Digital Input Phoenix Contact Part Number 1542774 Motor Bottom Reed Switch Digital Input j A Reed Switch Ground Linear Sensor Analog Input Linear Sensor Power 5 volt 6 Linear Sensor Ground 7 US LR j 104 3A0294G Appendix D Y Adapter 124273 Connections Appendix D Y Adapter 124273 Connections The Y adapter is used when two components are connected to the same connector on the breakout module The branch connectors labeled 1 and 2 have identical pinouts and are combined in the trunk connector The following table provides descriptions and pins of all connectors used on the Y adapter Branch Connector 1 Black Pin Description PinNumber M12 Connector 5 pin Female A code Digital Input or Output Aq Used for Drum Low Input and Solenoid Air Output Not Used Shield Digital Branch Connector 2 Silver Pin Description M12 Connector 5 pin Female A code Digital Input or Output ee Used for Start Stop Input and Solenoid Fluid Not Used Out
33. 3A0294G 3 O ring ied Slider Valve d gt Label i IT ia Ls Loosely install the air valve assembly 3 Grease the o ring included with the air valve assembly Install the o ring and then finish installing the air valve assembly Secure with the two screws that are included with the air valve assembly L Screw r 262373 3A0294 31a FiG 53 Install Air Valve Assembly d Install the new air motor slider valve label that is included with the air valve assembly Coat the gauge fitting and elbow fitting with PTFE tape and then reinstall Use a wrench to tighten Install the fitting and air hose on the back of the new air valve assembly Use two wrenches to tighten Fitting Z j 5 Air Hose a DN SN fe T 262373 3A0294 32a Nus AN FiG 54 Install Fitting and Air Hose 3A0294G Installation 5 Snap the display 5 into the display bracket See FIG 51 Install the linear sensor assembly 18 and the reed switch sensor 22 a Remove the air motor top cover using a flat head screwdriver ti8218b Fic 55 Remove Air Motor Cover b Use a wrench to remove the air motor lift ring Then remove the lift ring adapter and both o rings Discard the adapter and both o rings
34. 5 NUT TRIM edge protection 0 19 ft SEALANT pipe sst Qty N O m FSB m L L N nwo BR Oo NY 0 2 NO amp The bare display module does not have SmartWare software already installed Use the software upgrade token 5b to install the SmartWare software before using Not shown cards are available at no cost Reference cable identification table and cable con nection diagram page 46 and page 47 Replacement Danger and Warning labels tags and 91 Parts 92 3A0294G Appendix A User Interface Display Appendix A User Interface Display Display Overview The display is divided into two main functions Setup mode and Run mode Setup Mode Functions Setup mode functions enable users to e set units of measurement displayed on screen program shot size program shot sequence e set system password modify pump configurations e enable disable pump functions e enable disable error codes e set pump runaway set drum size e view or modify system and maintenance totalizers e view or clear shot totalizers view error totalizers e and perform calibration Run Mode Functions Run mode functions enable users to e change run mode between shot sequence manual and park e set shot number record shot volume or time e switch air valve on and off view shot progress e dispens
35. 5 2 O v 50 0 cc 0 0 cc 3 Press li to enter the field 4 Press to scroll through the available shot sequences NOTE All defined sequences A E can be selected from the run screen Any sequences that are not defined can not be selected from the run screen Sequences are defined in Setup Mode see Define Shot Sequence on page 55 5 Press di to select the desired shot sequence 3A0294G 6 Dispense the shot sequence See Dispense a Shot page 65 The actual volume dispensed will display under the desired dispense volume kup i m 350 0 cc 189 7 cc 7 Follow steps 2 through 6 to select and dispense another shot sequence 8 When you are finished selecting and dispensing N shot sequences press to exit edit mode 3A0294G Operation Dispense a Shot 1 Ensure the air is on 2 Follow Select a Shot Number page 64 or Selecta Shot Sequence page 64 3 Press I or step on the foot switch purchase separately to begin dispensing The shot progress bar will display on the screen during the shot 1 100 0 cc 39 l cc Target Shot Size Actual Amount Dispensed Pause or Cancel a Shot When a shot is in progress press i i I step on the foot switch to pause the shot Press c to cancel the shot When the system is paused press 74 or the foot switch to continue dispensing NOTE The dispense will automatically stop once the target shot size has been di
36. 6 Theory of Operation 7 Component Identification 8 User Interface llle 10 Grounding uer eem eave doe ess 15 InistalldllOn icd ao T a we CE 16 LOCAHOM inea oe CA oes OE pana uu Sura 16 Install Kits 262370 and 262372 16 Install Kit 262371 24 Stall NIE 262979 sic eth wk RR EO a RA 30 Install Kit 262374 37 riStall KIE262975 vererien bee rat 43 SOLD P rp 50 Enter Password 50 SEUD PUIMND 2 x53 8 Dog pRuE SCORE E eee 50 Pressure Relief Procedure 51 Prime Pulrge 223 elated EIE SG rises 52 Set System Parameters 53 Set Units and Specific Gravity 53 Define Shot Size 54 Define Shot Sequence 55 oet Password 0s seem des 56 Select Pump su su a z usu as ys Sa eee ee eee 57 Enable Disable Pump Functions 57 Enable Disable Errors 58 Set Low Empty Drum Error 58 Set Pump Runaway Error 59 Set Maintenance Parameters 59 COND AUC iu dic mom deo Os an Rr Rode 60 Set Shot Accuracy Errors 61 Operation s s sees eia I tax erba s 62 SAMUS oou Je b OPE IR AUR awe UA OE ase E 62 Change Operation Mode 62 Select a Shot Number 64 Select a Shot Sequence 64 Dis
37. 85 15V954 262424 262539 262416 16G294 122487 151859 15Y051 122030 121806 124273 122622 24C404 16E067 110782 24A032 15V719 16G589 100016 101682 100133 121293 103473 164856 16G410 15M669 16F562 111457 Description BRACKET subassembly LCM VALVE includes 3a 3c SOLENOID air motor includes o ring and screws LABEL caution LABEL valve shutoff air control COVER front electronics KIT module LCM display includes 5a and 5b MODULE LCM display bare TOKEN software CABLE CAN male female 1 5m CABLE assembly DB25 10ft CABLE M12 8 PIN female male CABLE GCA solenoid extension M12 5P CABLE solenoid CONNECTOR splitter CORD power LABEL identification KIT linear sensor BUSHING O RING SWITCH reed assy SCREW pan head 8 32 x 1 50 CABLE linear sensor and reed switch WASHER lock SCREW socket head cap WASHER lock SCREW socket head cap STRAP tie wire ADAPTER MANIFOLD pressure transducer SENSOR pressure fluid outlet CABLE pressure sensor exten sion M12 male female 2m reverse key O RING Qty 1 1 1 a m D LL LL N O N NS Ref 33 34 35 36 37 38 39A 40 41 43 44 46 47 48 Part 15M293 258999 121254 101845 255634 121262 196548 112738 111593 100272 256979 117683 121255 119400 Description POWER SUPPLY 24Vdc 2 5 A
38. Drum Size Setup screen 7 enables users to set the pump runaway cycle rate drum size and drum fill volume Refer to the following table for more information Pump Runaway Cycle Rate Set the pump runaway cycle rate which if surpassed will issue a pump runaway error Graco recommends setting the cycle rate to 60 or less Choose a value that is just above the maximum cycle rate of the appli cation Drum Size Enter the size of the material supply drum ES min DB EE Drum Fill Volume Enter the exact volume of the material in the supply drum If unknown contact the supplier for the exact volume This value is used to determine the remaining volume in the supply drum HEt min BOE i GEB 052 gal f Ht 052 gal E 3A0294G Appendix A User Interface Display Setup Screen 8 Grand Batch and Maintenance Totalizer Setup screen 8 enables users to view the grand and batch totals for the pump This screen also enables users to set maintenance setpoint amount for the pump and dosing valve The units of measurement are displayed in the corner and in the units of measurement selected in the Setup Units screen Grand and Batch Totalizers The grand totalizer tracks and displays the amount of material the system has dispensed during its lifetime The batch totalizer tracks and displays the amount of material since the last user reset Maintenance Totalizers Set the amounts of material moved through the pum
39. Instructions Parts gt g GRACO SmartWare Shot Dispense Kit Accurate metered dispensing kit for one component materials Kits are compatible with Check Mate pumps and Dura Flo pumps both alone and as part of a supply system For professional use only Not approved for use in European explosive atmosphere locations Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Kit 262370 for D200 and D60 For D200 3 inch dual post ram with NXT 2200 and larger air motors For D60 3 inch dual post ram with NXT2200 and larger air motors Kit 262371 for D200 For D200 3 inch dual post ram with NXT1800 and smaller air motors Kit 262372 for D200S For D200S 6 inch dual post ram with NXT2200 and larger air motors 1 Kit 262373 for S20 LLL For S20 3 inch single post ram NXT2200 and larger air motors ER 2 Kit 262374 for S20 For S20 3 inch single post ram with NXT1800 and smaller air motors Kit 262375 for pumps For wall mount or floor stand pump with NXT2200 and larger air motors Kit 262370 Shown C PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Warnings s 2e deme nda recie P EAE Rea 4 System Description 6 Typical Applications 6 COmbpalbllily zz 2 524 ed aeree he ev ees 6 Critical System Parameters
40. M12 CABLE M12 8 PIN F M CABLE GCA solenoid extension M12 5P CABLE solenoid CONNECTOR splitter CORD power LABEL identification KIT linear sensor BUSHING O RING SWITCH reed assy SCREW pan head 8 32 x 1 50 CABLE linear sensor and reed WASHER lock SCREW socket head cap COVER rear BRACKET light tower BRACKET power supply SCREW countersunk 6 32 x 0 38 STRAP tie wire 1 ADAPTER MANIFOLD pressure transducer SENSOR pressure fluid outlet O RING CABLE pressure sensor exten sion M12 male female 2m reverse key a m L WO olo C JA m m m m m m m o m LL Ref 35 36 37 38 39 40 42 43 44 45 46 47 48A 49 Part 15M293 258999 101845 255634 112738 111593 100272 121070 121255 255636 121254 121261 196548 119400 Description POWER SUPPLY 24Vqc 2 5 A 1 60W ENCLOSURE LCM breakout box SCREW self tapping COVER power GROMMET SCREW grounding WASHER lock SCREW mach 8x1 0 375 SCREW countersunk 6 32 x 0 38 BRACKET mounting right side SWITCH power 115 250V FUSE 250V 1 2A LABEL caution SEALANT pipe sst amp The bare display module does not have SmartWare software already installed Use the software upgrade token 5b to install the SmartWare software before using Not shown cards are available at no cost Replacement Danger and Warning labels tags and
41. VALVE includes 3a 3c SOLENOID air motor includes o ring and screws LABEL caution LABEL valve shutoff air control COVER electronics KIT module LCM display includes 5a and 5b MODULE LCM display bare TOKEN software CABLE CAN male female 1 5m CABLE assembly DB25 10 ft CABLE pigtail linear motor sen sor M12 CABLE M12 8 pin female male CABLE GCA solenoid extension M12 5P CABLE solenoid CONNECTOR splitter MAGNET linear sensor CORD power LABEL identification SENSOR assembly ADAPTER lift ring 1 9 16 sst O RING ADHESIVE anaerobic SENSOR reed switch O RING SCREW machined hex washer head SCREW thd forming hex washer head GUIDE strain relief TOOL magnet install WASHER lock SCREW socket head cap WASHER lock SCREW socket head cap STRAP tie wire ADAPTER MANIFOLD pressure transducer SENSOR pressure fluid outlet CABLE pressure sensor exten sion M12 male female 2m reverse key O RING Qty 1 1 1 a m L m L LL LL jN SON ETE E Gods ERE Ref 39 40 41 42 43 44 45A 46 47 49 50 52 53 54 Part 15M293 258999 121254 101845 255634 121262 196548 112738 111593 100272 256979 117683 121255 119400 Parts Description POWER SUPPLY 24Vqc 2 5 A 60W ENCLOSURE LCM breakout box SWITCH power 115 250V SCREW self tapping
42. a FiG 11 Install Power Supply Bracket 3A0294G 3 Install the electronics subassembly 1 to the side of the power supply bracket using four screws 34 Also secure the bracket to the bottom of the air con trol bracket using two screws 29 and two lock washers 28 r 262370 3A0294 7a FiG 12 Install Electronics Assembly 5 4 Install the light tower bracket 31 to the top air con trols bracket using three screws 29 and lock wash ers 28 r 262370 3A0294 8a O le lE fF L8 z lt Fic 13 Install Light Tower Bracket 3A0294G Installation 5 Loosen two screws on the top air controls bracket Install the display module bracket 2 using two screws 29 and lock washers 28 to secure it to the air controls bracket r_262370_3A0294_9a Bracket Fic 14 Install Display odu 6 Install the air valve subassembly 3 a Use two wrenches to remove the air hose elbow fitting and pressure gauge from the air controls Air Hose Elbow Fitting Label Pressure p Gauge gt D Cl 3 FiG 15 Air Control Assembly b Remove the air motor slider valve label See FIG 15 17 Instal
43. a supply system or a pump system into a dosing system The kits enable you to dose a pre set amount of single component material without using flowmeters or gear meters in the fluid stream Instead a sensor tracks the pump position so that the pump acts like a flowmeter The amount dispensed is based on the pump size Typical Applications e Cartridge fill e Potting e Encapsulating e Mold making e Batching or kitting Compatibility SmartWare shot dispense kits are compatible with J series NXT2200 and larger air motors and D series NXT1800 and smaller air motors Critical System Parameters If any of the following parameters are below the recom mended value see Appendix B Tips page 102 for tips for better accuracy Percentage shot size pump size Oom BEHER Percentage overshoot shot size function of valve time and pump speed MEM Air motor pressure PSI Pump Speed CPM Ma 3A0294G Theory of Operation SmartWare shot dispense kits do not use flowmeters in the material path to measure the volume pumped Instead the kit measures the volume pumped by using the following calculation See Fic 1 for a graphical rep resentation Area of the pump piston x distance traveled measured by the linear sensor volume pumped Distance Area Volume pumped Area x Distance FIG 1 Volume Pumped When the system receives the start signal the dispense valve opens O
44. act 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 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 For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call 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 3A0294 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revis
45. atable dispense components Use a high qual ity and highly repeatability dispense valve and sole noid Always use the greatest air pressure available to actuate the dispense valve Faster valve Use the smallest dispense valve that will work for your flow rate and pressure A small dispense valve will open and close faster which will reduce overshoot see page 92 for overshoot val ues Use a large enough solenoid and large enough air lines to maximize the air flow which will increase the speed of the dispense valve Slower pump speeds Decrease the pump speed to decrease overshoot and increase accuracy If pumping higher viscosity materials with a DuraFlo pump install a spring loaded ball check at the pump inlet Doing so will provide more consistent pumping through the top and bottom changeovers Use the smallest diameter and shortest length outlet hose possible to minimize the amount of material between the pump and the dispense point Minimize the material temperature swings to help prevent changes in material properties that will affect accuracy 3A0294G Appendix C Breakout Module 258999 Connections Appendix C Breakout Module 258999 Connections The following table provides descriptions and pins of all connectors used on the breakout module These can be used if the components are being wired directly to the breakout module See Appendix D Y Adapter 124273 Connec tions page 105 if the component is bein
46. ation Install cables Reference the table below and FIG d Install the o ring 83 and pressure sensor 32 11 46 for a diagram of cable connections use zip ties 35 to secure the cable to the ram and air hose Drum Low 1 I Light T 32 on ees Shot Stats Start Stop 2 33 DK ln eo d D solenoid Pressure Extension Sensor Pressure U R ure p icy Cable Extension Valve Cable Not Used Air Motor 31 Sii net Changeover S cw SAS SUDDEN Solenoid LCM Cable r 262370 3A0294 20a Fic 44 Breakout Module Connections FIG 43 Install Pressure Sensor r 262371 3A0294 75a 20 lt q D NE 2 MESS z vi 6 H Connect Cable FIG 45 Connect l ihear Sensor Reed Switch Cable 262371 Cable Identification Length Description Labels relative to graphic in NE NA Connectors Power Power Cabe 121226 _ Noe 7 n 122080 Accessory Kit k RR NES SE pon Fluid Solenoid m NE 3A0294G 27 Installation EGCc8LN 9 qe5 NYO Ajddns J9MOd LSd ajgen uoisu 1lx3 Josueg inss id e qeo2 1osueg eJnsseJd
47. bense a SNOl 3 c ed ac aca tae s 65 Pause or Cancel a Shot 65 OES acero AP s ooo AP e otl rd lit codex 66 Errors with Light Tower 66 Clear ENOS s ape dox a B del kun E d dos Us 66 EI OPFCOUGS iu Loa dum eoe b aad aqa ad 67 Sh tdOWD zo L puquy E eee tetas RR 70 Maintenance 71 Preventive Maintenance Schedule 71 Pump Maintenance 71 Supply System Maintenance 71 Cleaning Procedure 71 Upgrade Display Software 72 Clean User Interface Display 72 Troubleshooting 73 HeDall 3 dc 6 ara ert oe wes ee hee Se amu k asua 74 Replace Display 74 Electrical Schematics 75 Digital Output Schematic 75 Digital Input Schematic 76 Parts uc cater ares aan eve CE c edd etr cr a ea 77 Kits 262370 and 262372 77 KL 2629 1 dieto tino ee Ar She ba aaa ied 80 Kil 26294 9 S suu smua db od Ed Rot gend 83 Ki 2623742 gas catus aha be Matias std 86 Kik 262375 Pm 89 Appendix A User Interface Display 93 Display Overview 93 Display Details 93 Setup Mode Details 94 Run Mode Details 100 Appendix Tips 102 Calibration Procedure
48. bles users to enable and disable Setup screen 5 enables users to enable and disable specific error codes that will be issued if an alarm advi functions that directly relate to pump activity Disabling sory or deviation is detected in the system See Errors functions in this screen will prevent them from being page 66 for an explanation of each error code Refer to used in run mode Refer to the following table for more the following table for more information information Diving Up Deviation Air Pressure After Shot Indicates the pump is cavitating during the Check the box to have the air pressure bottom changeover remain on after a shot completes Or Diving Down Deviation uncheck the box to have the air pressure Indicates the pump is cavitating during the turn off after a shot completes top changeover Shot Switch Tap Mode Empty Drum Alarm Change shot switch mode There are two If checked the empty drum alarm is modes turn switch on and off tap mode ka enabled or turn switch on and hold hold mode Tap If unchecked the empty drum advisory is mode is enabled when field is checked enabled Hold mode is enabled when field is not Pump Runaway Error checked kx Enable or disable pump runaway error Shot Editing Enables shot key on display and the edit ing of the shot number or operation mode Changeover Solenoid If checked the changeover solenoid func tion is enabled 96 3A0294G Setup Screen 7 Setup Pump Runaway and
49. chined hex washer head SCREW thd forming hex washer head GUIDE strain relief TOOL magnet install WASHER lock SCREW socket head cap FITTING union adapter 90 deg FITTING pipe nipple 3 4 x 3 4 npt FITTING swivel TUBE nylon round 10 ft BRACKET assembly adapter SCREW cap hex head L 1 ll oo m m L L m L ll OO O Ref 37 38 39 40 41x 42 43 44 45 46 46a 46b 46c 46d 46e 47 48 49 50 51 52 53A 54 55 57 58 59 60 61 62 64 65 Part 100731 101566 100133 103473 164856 16G410 15M669 111457 198446 C19405 112698 C06061 100403 15M293 258999 121254 101845 255634 121261 196548 112738 111593 100272 256979 117683 121255 116798 C27076 114225 119400 Parts Description WASHER NUT lock BRACKET controls mount WASHER lock STRAP tie wire ADAPTER MANIFOLD pressure transducer SENSOR pressure fluid outlet O RING VALVE subassembly includes 46a 466 VALVE dispense closer FITTING connector male ELBOW male swivel MUFFLER PLUG pipe POWER SUPPLY 24 Vdc 2 5 A 60W MODULE LCM breakout box SWITCH power 115 250V SCREW self tapping COVER power FUSE 250V 1 2A LABEL caution GROMMET SCREW grounding WASHER lock ENCLOSURE power supply SCREW machined pan head SCREW countersunk 6 32 x 0 38 SCREW machined pan head 4 x 1 2
50. ctive 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 TI1102 2 TI1102 1 FiG 9 To maintain grounding continuity when flushing or relieving pressure hold metal part of the dispense valve firmly to the side of a grounded metal pail then trigger the valve 15 Installation Installation i ts AO The procedures in this section are specific to each shot dispense kit Follow only the installation instructions for your particular kit For supply system or pump assembly installation instructions refer to the Supply Systems Operation manual or your pump packages instructions parts man ual Location NOTE SmartWare Shot Dispense kits are not approved for use in explosive atmospheres Follow the location guidelines and instructions provided in the Supply Systems Operation manual or your pump packages instructions parts manual before installing the shot dispense kit 16 Install Kits 262370 and 262372 1 Close both shutoff valves on the air control panel r Shutoff e Ys Uto Vave Ox D FIG 10 Close Shutoff Valves 2 Install the power supply bracket 33 to the ram post using four screws 29 and lock washers 28 b OL CSF 7 a Ss e 33 r_262370_3A0294_6
51. e material shots e clear errors e and fill material drum 3A0294G Display Details Power Up Screen The following screen appears when the display module is powered up It remains on while the display module runs through initialization and establishes communica tion with other components in the system GRACO Soft Keys Icons to the left of the soft keys indicate which mode or action is associated with each soft key Soft keys that do not have an icon to the left of them are not active in the current screen Enter Exit Screens In screens that have editable fields press Uh to access the fields and make changes When changes are complete press E to exit edit mode Navigation within Screens Press mE to open drop down menus and select data to edit Also press to enter changes or make a selection Press to navigate to a new screen and to navigate up and down within a screen Also press to move between fields within a drop down menu and to increment or decrement numbers within a field 93 Appendix A User Interface Display Setup Mode Details Setup mode screens enable users to view or modify system configuration data Users can set units set shot sizes program shot sequences set the password select specific pump sizes adjust pump configuration setup errors and view totalizers Setup Screen 1 Units Setup screen 1 enables users to set units of measure ment that will display on ot
52. e reed switch sensor 22 Remove the air motor top cover using a flat head screwdriver tia218b b Usea wrench to remove the air motor lift ring Then remove the lift ring adapter and both o rings Discard the adapter and both o rings r 262373 3A0294 before linear Fic 85 Remove Lift Ring Adapter and O rings Place the linear sensor magnet 13 on the installation tool 27 and then insert the magnet down into the top of the motor shaft Apply the supplied adhesive to the linear sensor assembly 18 threads Install the linear sensor torque to 30 36 ft lbs 40 6 48 8 Nem See FIG 86 Place the new o ring 20 on the lift ring adapter 19 and apply the supplied adhesive to the threads See FIG 86 Lift Ring r 262373 3A0294 after linear Install Linear Sensor Route the linear sensor cable through the lift ring adapter Install the lift ring adapter torque to 30 36 ft lbs 40 6 48 8 Nem See FIG 86 Route the linear sensor cable through the hole on the lift ring adapter Apply the supplied adhesive to the lift ring Install the lift ring torque to 30 36 ft lbs 40 6 48 8 Nem See FIG 86 Remove the screw on the valve cover to remove the cover See FIG 87 3A0294G Installation j Install the reed switch sensor 23 Secure with n Remove the plug in the air motor cover Route the 1 in 255 mm screw 25 and o ring 24 the linear sens
53. e regulator adjustment knob counterclock wise to the lowest possible fluid pressure 6 Hold a metal part of the gun valve firmly to the side of a grounded metal pail and press I or step on the foot switch purchase separately until clean 1 Follow the Pressure Relief Procedure on page 51 solvent dispenses 2 Remove the spray tip and tip guard from gun or 7 Follow the Pressure Relief Procedure on page 51 remove the nozzle from the dispense valve again 3 Place siphon tube in grounded metal pail containing cleaning fluid Fic 104 70 3A0294G Maintenance A O V To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 51 Preventive Maintenance Schedule The operating conditions of your particular system determine how often maintenance is required Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed and then determine a regular schedule for checking your system Pump Maintenance Wet Cup Check the wet cup daily Keep it 2 3 full with Graco Throat Seal Liquid TSL or compatible solvent Corrosion Protection Always flush the pump before the material dries on the displacement rod Never leave water or water based material in the pump overnight First flush with water or a compatible solvent then with mineral spirits solvent or white spiri
54. ed 26 April 2013
55. ed solenoid Replace damaged solenoid wires Plug in disconnected solenoid Replace damaged solenoid wires 67 Errors Alarms continued Piston Red Solid Piston traveled less than one Verify dispense valve is not stuck q Inch in ten seconds Verify adequate air pressure to Drum Empty Red Solid Drum empty sensor tripped diis empty drum with a full LU peas prea sari Persas Hed Solid Pressure sensor is discon Heconnect pressure sensor ug eM Damaged pressure sensor wires Replace pressure sensor mmm LU d _ Check air solenoid wiring and air connection Replace or repair if necessary Check dispense valve air con nection Replace or repair if nec essary WJ Air Red Solid Air solenoid is disconnected Plug in disconnected air sole s Solenoid noid Damaged air solenoid wires air solenoid wires Replace air solenoid air solenoid Red Solid S UR solenoid is disconnected viden NN in disconnected fluid sole Solenoid noid Damaged fluid solenoid wires fluid solenoid wires Replace fluid solenoid fluid solenoid Invalid Pump Red Solid a pump setup Select a valid pump in the avais icis NN Screens 68 3A0294G Errors Deviations Diving Up Red Flash Pump leaking during up stroke Replace worn piston valve or 2 ing packings Diving Down Red Flash Pump leaking during down Replace worn intake valve or E ing stroke priming rod seal mmm Le _ Advisories
56. ensing 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 4 3A0294G 3A0294G Warnings 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 from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn 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 manufacturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Houte hoses and cables away from traffic a
57. ersunk 6 32 x 0 38 STRAP tie wire ADAPTER Qty 1 1 1 m L L m L G jN 1 1 4 1 Ref 37 38 40 41 42 43 44 45 46 47 49 50 51 52 53 54 55A 65 66 Part 16G410 15M669 16F562 111457 15M293 258999 101845 255634 112738 111593 100272 121070 121255 255636 121254 121261 196548 255616 119400 Parts Description MANIFOLD pressure transducer SENSOR pressure fluid outlet CABLE pressure sensor exten sion M12 male female reverse key O RING POWER SUPPLY 24Vdc 2 5 A 60W ENCLOSURE LCM breakout box SCREW self tapping COVER power GROMMET SCREW grounding WASHER lock SCREW mach 8x1 0 375 SCHREW countersunk 6 32 x 0 38 BRACKET mounting right side SWITCH power 115 250V FUSE 250V 1 2A LABEL caution KIT bleed valve short 262370 only shipped loose SEALANT pipe sst Qty JN N AA DN oO The bare display module does not have SmartWare software already installed Use the software upgrade token 5b to install the SmartWare software before using Not shown A Replacement Danger and Warning labels tags and cards are available at no cost Reference cable identification table and cable con nection diagram page 21 and page 22 79 Parts Kit 262371
58. esuedsig SOUl JlV ajgen uoisuelx3 Josueg eunssaJg aasn Ag peijddns 9A EA PIOUZIOS i lqe uoisuejx3 piou los A3 qeo Josueg eJnsseJg amp U9IIMS Ge PER I qwoassy f Ok 99 NS ey lt lt Tq rr Ae 9AJBA JV 9 ge5 DIOU OS AV X npolN jnoyeoig Lld SN DN e qe2 JOJO JI V A euondo 1M euondo E Gay LST YOHMS 1003 E I iamos 48r 1eydepv A HE Q jeuondo ES dund JOSU9S JEe9UI uinJp M07 9 qe plous OS 3A0294G FiG 29 Cable Connections D200S D200 and D60 with Large NXT 22 10 Secure cables to the air hose using zip ties Tighten all zip ties and then cut off the excess 11 Bundle the cables and zip tie them close to the elec tronics bracket 1 so that they will fit under the elec tronics subassembly cover 4 12 Install the electronics subassembly cover Install the back cover first and hand tighten the screws to secure Then install the front cover hand tighten the screws to secure 4 Back r 262370 3A0294 23a FIG 30 Install Covers 3A0294G Installation 13 Install the power supply cord 14
59. euondo d amo 1uBr Jeydepy A eBid 154 jeuondo unJp MO qeo uoisuejx3 piouejos 9 qe2 Josues Jeaur Fic 77 Cable Connections S20 with Small NXT 41 3A0294G Installation 10 11 Route all cables out the top of the electrical enclo sure Make sure there is enough slack to extend ram to full height Secure cables to the air hose using zip ties Tighten all zip ties and then cut off the excess Bundle the excess cable length and zip tie them close to the electronics bracket 1 so that they will fit under the electronics subassembly cover 4 Install the electronics subassembly cover Install the back cover first and hand tighten the screws to secure Then install the cover and hand tighten the screws to secure 12 Install the power supply cord 12 a g Install Power Supply Cord r 262373 3A0294 42a FiG 79 Install Power Supply Cord 42 13 Open the air shutoff valves on the air control assem bly 3A0294G Installation Install Kit 262375 4 Install the electronics subassembly 1 to the side of the adapter bracket using four screws 30 and 1 Shut off the air supply to the system washers 29 2 Floor stand kit only Install the control mount bracket 39 to the pump using
60. eved after following the previous steps very slowly loosen the tip guard retaining nut hose end coupling and relieve pressure gradually then loosen completely Now clear the tip nozzle or hose 51 Prime Purge Prime Purge Age 52 K FiG 103 Flush with Solven Follow Pressure Relief Procedure on page 51 Priming only replace pail of material if necessary Remove the spray tip and tip guard from gun or remove the nozzle from the dispense valve Flushing only If desired remove built in fluid filter present on some models Reinstall filter cap after removing fluid filter Place pump in material if priming or solvent if flushing Turn air regulator to O psi Open the manual shutoff valve s Perform a manual purge a Change to manual mode in the run screen See Change Operation Mode page 62 b Place a drain tube in a grounded waste pail Open drain purge valve slightly by rotating counterclockwise Drain Purge Valve c Increase pressure on the air regulator until the pump begins to move Run the pump until no air is released from the drain purge valve or until clean solvent flows from the drain tube Close drain purge valve by rotating clockwise The pump will stall 9 Prime or purge hose and gun valve a f necessary change to manual mode in the run screen See Change Operation Mode page 62 b Hold a metal part of the gun valve firmly to the s
61. eys Soft keys activate the mode or action represented by the icon next to each soft key See Table 2 for soft key icons and actions Top Soft Key Turn air solenoid on off pause shot continue shot edit data accept edited data or move right within a number field Bottom Soft Key Enter a screen exit a screen cancel a shot or cancel edited data 10 3A0294G Component Identification Table 2 Display Soft Key Icons Enter Screen In screens that have editable fields press to access the fields and make changes La In screens that have editable fields press to exit edit mode In screens that have editable fields press to make data selections or to enter changes In screens that have editable fields press to move to the right while in a field Cancel a selection or edited data Returns to the original data Cancel a shot when the shot is active Reset the selected field or value kj HEE Pause Continue Pause the shot that is currently active Continue the shot that is currently active Ku Turn the air valve on and off Start the automatic calibration process 3A0294G 11 Component Identification User Interface Display For details regarding the user interface display see page 92 Display Screen Components The following figures call out the navigational status and general informational components of each display screen Setup fields spe cific to current setup screen Scroll up
62. g connected to the Y adapter 124273 before connecting to the breakout module Light Tower Connector 2 Blue Pin Description M12 Connector 5 pin Female A code Lamp 1 Yellow Digital Output Po A Phoenix Contact Part Number 1542761 Lamp 2 Red Digital Output Digital Output Power 24 volt Digital Output Ground Shield Digital Solenoid Air Fluid Connector 3 Red Pin Description PinNumber M12 Connector 5 pin Female A code Solenoid Air Digital Output 0 0 4 Phoenix Contact Part Number 1542761 Solenoid Fluid Digital Output 0 Digital Output Power 24 volt j 03 Digital Output Ground o 3 Shield Digital Solenoid Air Fluid Connector 4 Green Pin Description M12 Connector 5 pin Female A code Solenoid Changeover Kit Top Digital Output Phoenix Contact Part Number 1542761 Solenoid Changeover Kit Bottom Digital Output Digital Output Power 24 volt HENNE SENE Digital Output Ground AM MN Shield Digital 3A0294G 103 Appendix C Breakout Module 258999 Connections Prox Start Stop Connector 5 Grey Pin Description Pin Number M12 Connector 5 pin Female A code Drum Low Digital Input Phoenix Contact Part Number 1542761 Start Stop Digital Input Digital Input Power 24 volt Digital Input Ground Shield Digital Pressure Connector 6 Blue Pin Description Mi2Connedor 5 pin Female Bcode Pressure Differential AnalogInput 4 Phoenix Contact Part Number 154
63. gs d Place the linear sensor magnet 13 on the installation tool 27 and then insert the magnet down into the top of the motor shaft Apply the supplied adhesive to the linear sensor assembly 18 threads Install the linear sensor torque to 30 36 ft lbs 40 6 48 8 Nem See FIG Place the new o ring 20 on the lift ring adapter 19 and apply the supplied adhesive to the threads See FIG 21 r 262373 3A0294 after linear FiG 21 Install Linear Sensor Installation g Route the linear sensor cable through the lift ring adapter Install the lift ring adapter torque to 30 36 ft lbs 40 6 48 8 Nem See FIG 21 h Route the linear sensor cable through the hole on the lift ring adapter i Apply the supplied adhesive to the lift ring threads Install the lift ring torque to 30 36 ft lbs 40 6 48 8 Nem See FIG 21 j Remove the screw on the valve cover to remove the cover See FIG 22 k Install the reed switch sensor 22 Secure with the 1 in 25 mm screw 24 and o ring 23 pro vided See FiG 22 22 e r 262370 3A0294 16a FiG 22 Install Reed Switch Sensor 19 Installation l Connect the strain relief guide 26 to the reed p D200 systems only reconnect the air motor switch sensor Use a wrench to tighten the Install threaded rod through center ho
64. have completed the sequence will start over at the first shot Manual Mode Manual mode runs the pump when 4 is pressed or when the dispense valve is triggered Use manual mode to determine how much material is needed to fill a con tainer prime the system flush the system or verify sys tem operation NOTE All errors are ignored in this mode 3A0294G 63 Operation Select a Shot Number Shots are defined in setup screen 2 See Define Shot Size page 54 for instructions 1 Change operation mode to shot if necessary See Change Operation Mode page 62 for instructions 2 Press to navigate to the shot number field 2 3 Press ee to enter the shot number field 4 Press to increment or decrement to the desired shot number 5 Press el to select the desired shot number 6 Dispense the shot See Dispense a Shot page 65 The actual volume dispensed will display under the desired dispense volume 7 Follow steps 2 through 6 to select and dispense another shot 8 When you are finished selecting and dispensing shots press to exit edit mode 64 Select a Shot Sequence Sequences are defined in setup screen 3 See Define Shot Sequence page 55 for instructions 1 Change operation mode to sequence if necessary See Change Operation Mode page 62 for instruc tions 2 Press to navigate to the current mode field which should be set to shot sequence Sn 2
65. hen calibrating the pump e amp t 000 0 1 eS Y000 IPEA si 0000 0 3A0294G Appendix A User Interface Display Setup Screen 11 Shot Accuracy Errors Setup screen 11 enables users to set the shot volume difference from the shot setpoint that will cause an advi sory or alarm Refer to the following table for more infor mation Advisory If the final shot volume is greater or less than the shot setpoint by the value entered in this field an advisory is generated Alarm i If the final shot volume is greater or less than the shot setpoint by the value entered in this field an alarm is generated NOTE If either the advisory field or alarm field is set to zero the error is disabled BOO cc 41 00 0 cc E 3A0294G 99 Appendix A User Interface Display Run Mode Details Run mode enables users to perform material shots adjust shot number view shot volume time monitor pump movement and view shot time Users can access the Information screen from the run screen which enables them to clear errors and fill material drums The system always starts with the run screen See Operation page 62 for instructions on using the Run screen Operation Modes Users can perform material shots using one of three operation modes Shot Sequence or Manual Mode Function Shot Mode Enables users to repeatedly dispense 1 of 25 shots Sequence Mode Enables users to dispense a sequence of s
66. her screens This screen also uses the specific gravity of the material being dispensed to convert units Additionally this screen displays the software number and version Refer to the following table for more information Units of Measure Select units of measurement for material volume or material weight Specific Gravity The system uses the material s specific gravity that is entered in the field to convert volume units cc to weight units grams The weight units will display on other screens if the Shot Weight field on the Shot Size screen is enabled Ials Ib j 1 se 1 125 H l 16c202 u 0 02 003 94 Setup Screen 2 Shot Size Setup screen 2 enables users to program up to 25 shots 1 25 Each shot number can be defined so that the system will dispense the predetermined quantity of material when the shot number is selected and a shot is initiated Refer to the following table for more informa tion Set Volume Weight Select shot number Set weight volume of specific material for the shot Weight units are displayed when the Shot Weight icon is checked Volume units are displayed when the Shot Weight icon is unchecked Shot Weight Configure system to use shot weight if checked or shot volume if unchecked Shot Time Displays shot time if checked or shot vol ume weight if unchecked 3A0294G Setup Screen 3 Shot Sequence Setup screen 3 enables users to program up to f
67. hots As more are noticeably less accurate within this area for the compensa shots take place in this area accu tion factor to be accurate racy will improve 3A0294G 73 Repair Repair WA wo The shot dispense kits do not include any repairable parts They include only replacement parts Therefore see the Installation section that is specific to your kit for instructions on replacing kit parts Also use the Electri cal Schematics section page 75 as a reference For system specific repair procedures refer to your Sup ply Systems Repair Parts manual or pump package instructions parts manual Replace Display NOTE Order Kit 262539 for replacement To avoid damaging circuit board wear a grounding strap 1 Disconnect power 2 Pull display out of bracket clips to remove it 3 Disconnect both CAN cables 4 Replace with new display Reconnect both CAN cables 5 Load the correct display software for the system Follow the steps in Upgrade Display Software on page 72 74 3A0294G Electrical Schematics Electrical Schematics Digital Output Schematic The SmartWare shot dispense kit uses high side switches for all digital outputs When they are on the module power supply voltage is switched to the output pin When they are off the power supply voltage goes through a pull up resis tor that limits the current to a maximum of the supply voltage divided by 51100 24 5110
68. hots in a specified order Manual Mode Enables users to manually dispense shots Park Mode Runs pump to bottom of the stroke and then disables the system Air Valve On Off Press the Air On Off button to turn the air valve on and off If the Air Pressure After Shot field is checked on the screen 5 Enable Disable Pump Functions screen the air will remain on after the shot When the air valve is on the Current Mode box displays a black background and white icon And when the air valve is off the Current Mode box displays a white back ground and black icon Fluid Valve On Off When the fluid valve is on during a shot the Actual Shot Volume or Time starts at zero and increments the pump icon displays pump movement and the Progress Bar Graph starts incrementing NOTE The progress bar graph is only displayed during a shot Run Screen in Shot Mode Shown Current Mode Shot Number Shot Volume or Weight Target user selects Actual Shot Time or Volume user selects 100 Pump Air On Off Enter Screen Progress Bar Graph 3A0294G Information Screen This screen displays the present alarm or advisory along with the current error icon and error code The information screen also displays the current volume of material in the drum This screen also displays the aver age overshoot and the largest deviation from the aver age overshoot Users can clear alarms or advisories and reset the drum
69. ide of a grounded metal pail c Press I and hold or step on the foot switch purchase separately until all air in the hose is purged 10 If priming the system is now ready to dispense go to Dispense a Shot page 65 If flushing follow the Operation on page 62 leave the solvent in and store the equipment 3A0294G Set System Parameters NOTE Refer to Appendix B Tips page 102 for setup guidelines and tips Set Units and Specific Gravity 1 Navigate to setup screen 1 t gaius T im bi 1 sc 1 125 H l e 160203 uU D 2 005 Z to access fields to make changes 3 Press to navigate to the units of mea sure fields 2 Press 4 Press qi to open the first drop down box Press to select the desired units 5 Press li to save selection 6 Press to navigate to the next drop down box and perform the same two steps 3A0294G T Set System Parameters Press to navigate to the specific gravity SG field NOTE If the specific gravity is unknown use the cali bration routine to enter it automatically See Calibrate on page 60 for calibration instructions Press and to increment or decre ment to the specific gravity of the material being dis pensed Press il to save the selection LUN Press N to exit edit mode 53 Set System Parameters Define Shot Size Up to 25 shots 1 25 can be defined in the setup shot screen To define a shot si
70. int 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 throughout the body of this manual where applicable 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 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 power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area 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 Do not point disp
71. ive sequences A E Each sequence can have up to 14 steps and each step can be one of the possible 25 shots programmed from the Shot Size setup screen If any sequence contains either an undefined shot or one of the positions is undefined no material will be dispensed when that shot is taken Refer to the following table for more information a Set Shot A n Set number of shots for each step in the sequence Shot Sequence Select shot sequence letter A E RE Shot Volume 222 21 The shot volume box displays the volume of the selected highlighted shot number Shot sequence screen shown with shot number selected which also displays the shot volume box 2222 2 1 F 5 00 2 09 9 00 13 10 00 a a seo 12 08 5 RE 6 00O 1 3 00 re OD 14 00 3A0294G Appendix A User Interface Display Setup Screen 4 Password and Pump Setup screen 4 enables users to set a password and select the pump size used by the specific system Refer to the following table for more information Password The setup screens can be protected by a password to restrict their accessibility See Set Password page 56 for more informa tion and instructions for setting a password Pump Select pump used on the system B E UE UE CO DDDDD E v TY Ehkhat 250 95 Appendix A User Interface Display Setup Screen 5 Enable Disable Pump Setup Screen 6 Enable Disable Errors Functions Setup screen 6 ena
72. lation c Loosely install the air valve assembly 3 7 Install the linear sensor assembly 18 and the reed Grease the o ring included with the air valve switch sensor 22 e i SMS Mr AN diat a D200 systems only disconnect the air motor SHANI Mese tr Meli SE SKS yes HESS WI Loosen nut below crossbar Use wrench to hold SCrew thread adapter in place and loosen threaded rod above crossbar with another wrench Rod N Nut Slider Valve Plate Thread eo r 262370 3A0294 11a Adapter FIG 16 Install Air Valve Assembly f Lift Ring d Installthe new air motor slider valve label that is Adapter included with the air valve assembly See FIG 15 ti10649a e Coatthe gauge fitting with PTFE tape and then reinstall Use a wrench to tighten See FIG 15 FIG 18 Disconnect Air Motor b Remove the air motor top cover using a flat f Coat the swivel fitting 32 with PTFE tape head screwdriver Install the fitting and air hose on the back of the new air valve assembly Use two wrenches to tighten tia218b Fic 19 Remove Air Motor Cover FiG 17 Install Swivel Fitting 18 3A0294G Use a wrench to remove the air motor lift ring Then remove the lift ring adapter and both o rings Discard the adapter and both o rings r 262373 3A0294 before linear FIG 20 Remove Lift Ring Adapter and O rin
73. lay with any alcohol based household cleaner such as glass cleaner 7 Allow enough time for solvent to dry before using system 71 Maintenance Upgrade Display Software NOTICE To avoid damaging circuit board wear a grounding strap 1 Disconnect power 2 Pull display out of bracket clips to remove it 3 Remove screw and then access cover Pa om Access Cover Indicator Light Token r 26416 3a0294 token explode Fic 105 Upgrade Display Software 4 Insert and press token firmly into slot NOTE There is no preferred orientation of token 5 Turn power on 6 Thered indicator light will flash until new software is completely loaded 7 Turn power off 8 Remove token 9 Reassemble access cover and screw 10 Snap display back into bracket and reconnect power 72 Clean User Interface Display Use any alcohol based household cleaner such as glass cleaner to clean the display 3A0294G Troubleshooting Troubleshooting ML w e NOTE Troubleshooting covered in this manual is spe 1 Follow the Operation page 62 cific to the shot dispense kits Refer to your Supply Sys tems Repair Parts manual or pump packages 2 Disconnect all power to the supply system or pump instructions parts manual for system specific trouble package before repairing shooting For air motor or pump troubleshooting ques tions refer to your NXT air motor instruction parts manual or
74. le Identification Length Description Labels to graphic in E E Pgal 1 16G589 LS1RSI RS1 1 52 1320 8 8 c S Ligen 122080 20 508 121 Extension 34 3A0294G Installation EvEC8 Lit 9 dqe NWOT 9 de5 NYO Ajddns JOMOd 4asn Aq paijddns 9A EA osuedsiq SOU JV ajgen uoisu x3 JOSU8S eunssaJg 4asn q pei ddns AJLA Diou joS ajgen uoisua x3 piou joS e qeo 1osueg eJnsseJg rr Ir ki o EA N E SN 9 qe5 plous os npolN noye ig e qe2 100 JI V 14 jeuondo To SI YOUMS 1004 y jeuondo p Jamo 4 7 e qeo dung Josue PU Heaters 15 pita WNJp mo J93depy A 1 12 ajgen uoisua1 x3 piou joS FiG 63 Cable Connections S20 with Large NXT 35 3A0294G Installation 10 11 Secure cables to the air hose using zip ties Tighten all zip ties and then cut off the excess Bundle the cables and zip tie them close to the elec tronics subassembly bracket 1 so that they will fit under the electronics subassembly cover 4 Install the electronics subassembly cover hand tighten the screws to secure T ie
75. le in the 1 4 20 x 1 2 in screw 25 on the strain relief crossbar Install lock washers and nuts onto guide and to secure it to the top plate of the air threaded rod both above and below crossbar motor Use wrench to hold lift ring adapter and tighten threaded rod into lift ring adapter using another wrench Tighten nut below crossbar to 25 ft lb 25 34 Nem maximum Tighten nut above crossbar Nr 2 to lock motor in place 26 Fic 23 Install Strain Relief Guide m Use a zip tie to secure the reed switch sensor UE Nut cable n Reinstall the valve cover and tighten the nut Lift Ring See FIG 22 Adapter o Remove the plug in the air motor cover Route the linear sensor cables through the hole in the back of the cover Snap the air motor cover back ti11169a Fic 25 Reconnect Air Motor into place 8 Install the pressure sensor on the pump bleed port g D60 rams only If pump bleed valve is longer than the supplied replace it with the supplied bleed valve Ug J 65 a Use a wrench to remove the pressure valve HH yas I 0 o B Pressure Valve Y B Tier js r 262370 3A0294 17a FiG 24 Reinstall Air Motor Cover i r 262370 3A0294 19a AR R FIG 26 Remove Pressure Valve 20 3A0294G b Apply the supplied sealant to the adapter 36 the manifold 37 and the pressure va
76. lume Greater than Error Setpoint Shot volume is greater than the error setpoint Pump Runaway Pump is running faster than set exhausted material supply Pump Cavitation Red Solid Red Solid half a stroke because of exhausted material supply Red Solid Linear sensor is not connected or it is reading outside maximum values Red Solid Multiple up strokes without a down stroke or multiple down strokes without an up stroke Red Solid Red Solid DJ Linear Sensor Reed Switch caused by damaged or discon nected reed switch Top Solenoid is disconnected Changeover Solenoid DL Bottom Solenoid is disconnected Changeover Solenoid 1 14117 aa mw vis s 3A0294G runaway limit because of high air pressure high material output or Pump is diving down more than a Errors Increase the error setpoint on Setup screen 11 Increase shot consistency by decreasing speed and valve shutoff time and increasing material back pressure Increase the error setpoint on Setup screen 11 Increase shot consistency by decreasing speed and valve shutoff time and increasing material back pressure Decrease air pressure Decrease material output Replace material supply drum Replace material supply drum Check linear sensor wiring and replace if necessary Check linear sensor and replace if necessary Reconnect reed switch wiring Replace reed switch Plug in disconnect
77. lve Install all three in the order listed See FIG 27 c Disconnect sensor cable at PT1 Install the o ring 41 and pressure sensor 38 use zip ties 35 to secure the cable to the ram and air hose 41 Bw Pressure Tha Valve BS a 38 2x M HIT 36 37 K CM r 262370 3A0294 20a Fic 27 Install Pressure Sensor Installation 9 Install cables Reference FIG 29 for a diagram of cable connections and Drum Low 1 Shot Status Light Tower Start Stop 2 Solenoid Pressure Cable Extension Cable Not Used Air Motor Changeover Cable id i LCM Cable FiG 28 Breakout Module Connections 262370 and 262372 Cable Identification rd Power 00 121 121226 Pigtail 1 LI 9 rayos FE Solenoid Extension Y1 yellow 20 508 122030 Accessory Kit Bro Y2 orange 20 508 Air Solenoid A yellow 20 508 121806 Fluid ESTO 2 yellow 20 508 3A0294G Noe 16 4064 406 4 LS1 RS1 KASPI 8 AM1 118 LA 2 21 Installation EGCEC8 LH 8IGFD NWOT 9 qe5 NYO 1asn Ag peijddns 9A 6A
78. manual Enter Password If a password is enabled the password entry screen automatically opens when you change to setup mode Enter the password to access setup mode Setup Pump 1 Follow the Installation guidelines on page 16 2 Follow the Installation procedure for your particular shot dispense kit The procedures start on page 16 3 Fill displacement pump wet cup 2 3 full with Graco Throat Seal Liquid TSL M U m Wet Cup P Fic 100 Fill Wet Cup 4 Attach electrically conductive fluid hose to pump outlet and tighten 5 Attach other end of electrically conductive fluid hose to dispense valve and tighten 6 Shut off the air valve by pressing the Air On Off soft key on the display module 7 Back off the air regulators to their full counterclock wise position and close all shutoff valves for the rams 50 8 Connect the air line from the air source to the sys tem air inlet See Fic 101 Refer to your specific pump manual to determine the correct air supply flow requirements Connect an air supply hose that is capable of meeting the required flow to the air motor air inlet NOTE Quick disconnects restrict flow for NXT2200 and larger air motors NXT2200 and Larger Air Motors Air Inlet NXT1800 and Smaller Air Motors Air Inlet 74
79. nce the correct distance is traveled which equates to the desired shot volume the dispense valve closes and the pump stalls 3A0294G Theory of Operation Just like a car does not stop the instant you push on the brake the SmartWare kit pump does not stop pumping the instant it receives a stop signal Therefore during the time it takes for the dispense valve to physically close fluid is still being pumped the volume pumped during this time is called the overshoot volume See FIG 2 for a a graphical representation Overshoot Volume Stop Position Stop Signal Start Signal FIG 2 Overshoot Volume The SmartWare kit automatically compensates for over shoot by taking previous shots into consideration and then sending the stop signal early The pressure transducer compensates for pump travel during changeovers Since only a few shots end ina changeover this compensation will take longer than the basic overshoot compensation Component Identification Component Identification SmartWare Kit for D200 and D60 Rams T FIG 3 Component Identification Key Lift Ring Air Motor Display Module Air Controls Air Solenoid under shroud Power Supply under shroud Power Switch within shroud Displacement Pump Wet Cup Fluid Outlet Fluid Inlet E F G SmartWare Kit for S20 Rams M T
80. nstall the air valve subassembly 8 a Use two wrenches to remove the air hose elbow fitting and pressure gauge from the air controls Air Hose Elbow Fitting Label Pressure po Gauge x gt FIG 69 Air Valve b Remove the air motor slider valve label 37 Installation r 262374 3A0294 68a 38 3 li y O ring Bm Te Slider Valve Label er Loosely install the air valve assembly 3 Remove air pressure gauge if necessary Grease the o ring included with the air valve assembly Install the o ring and then finish installing the air valve assembly Secure with the two screws that are included with the air valve assembly Screw Install the new air motor slider valve label that is included with the air valve assembly If removed coat the gauge fitting and elbow fit ting with PTFE tape and then reinstall Use a wrench to tighten Install the fitting and air hose on the back of the new air valve assembly Use two wrenches to tighten Fitting rl r 262374 3A0294 69a itting 5 Install the linear sensor 17 a Remove the lift ring or plug Insert magnet holder and magnet into the top
81. or cables through the hole in the provided back of the cover Snap the air motor cover back into place A FIG 87 Install Reed Switch Sensor Fic 89 Remove Plug I k Connect the strain relief guide 27 to the reed 8 Without integrated air controls only Install valve switch sensor Use a wrench to tighten the 1 2 subassembly 6 and fittings ui aii S9 Obie stat bid s anes a Apply the supplied adhesive to the adapter fit secure it to the top plate of the air motor ting 31 Screw the fitting into bottom of the air valve so that the fitting points away from the dis play module 26 7 9 b Apply the supplied adhesive to the pipe nipple fitting 32 and the pipe swivel fitting 33 Screw both fittings onto the valve assembly as shown 27 FiG 88 Install Strain Relief Guide l Use a zip tie to secure the reed switch sensor cable m Reinstall the valve cover and tighten the nut eee aoe s 32 31 Fic 90 Install Valve Assembly without air controls c Screw entire assembly onto the adapter fitting Use two wrenches to tighten 3A0294G 45 Installation 9 With integrated air controls only Install valve c Screw the entire assembly onto the pipe nipple assembly 6 and fittings fitting Use two wrenches to tighten a Apply
82. 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 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
83. ot Mode Dispense a Shot 350 0 cc 100 0 cc 5 0 0 cc 39 l cc Information Screen Run Screen Sequence Mode Dispense a Shot Sequence JP n i x i 41 35 FO Enter screen to dispense a shot sequence 14 3A0294G Grounding Awe The equipment must be grounded Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit To reduce the risk of static sparking ground the pump the object being dispensed to and all other dispensing equipment used or located in the dispensing area All electrical wiring must be done by a qualified electrician and comply with local codes and regulations Supply System ground the supply system as instructed in the grounding section of the Supply Sys tems Operation manual Pump use a ground wire and clamp Connect the ground wire to the ground stud on the air motor Con nect ground clamp to a true earth ground Tl8250a FIG 8 Air and fluid hoses use only electrically conductive hoses Air compressor follow manufacturer s recommenda tions Dispense valve ground through connection to a prop erly grounded fluid hose and pump See dispense valve manual for instructions and guidelines Fluid supply container follow local code 3A0294G Grounding Solvent pails used when flushing follow local code Use only condu
84. p and dosing valve that will result in a maintenance advi sory when the Total Volume Dispensed exceeds the Maintenance Setpoint Clearing the Total Volume Dis pensed will clear the advisory Grand Totalizer Batch Totalizer 00003245 00000 0 I 0001000 em ri Total Volume Dispensed Maintenance Setpoint 97 Appendix A User Interface Display Setup Screen 9 Shot and Error Totalizer Setup screen 9 enables users to view the shot and error totals Refer to the following table for more information Shot Totalizer Records and displays the number of times each shot number has occurred Error Totalizer Records and displays the number of times each error type has occurred 1 un FAEERE D D Or Shot and error totalizer screen shown with shot number highlighted which enables the user to clear a shot by then pressing P 9 a 1 0000243 mum I I 7 I Ku El Ez E D ANN ur 98 Setup Screen 10 Calibration Setup screen 10 enables users to start the calibration process for top changeover bottom changeover and shot weight Refer to the following table for more infor mation Material Delta Fields are updated after four shot weights are entered into the Weight box Weight sto Used to enter the weight of the shot I Timer T Displays when the calibration process starts Shot Calibration Hi Displays when calibrating a shot sk 7 Pump Calibration Displays w
85. pump instructions parts manual See Related Manuals page 3 for specific manual numbers Check all possible problems before disassembling any part of the supply system pump package or shot dispense kit Penn Cmm mm Display volume matches pump vol System has not finished compen Dispense more shots Shot volumes ume but is consistently higher than sating for higher overshoot should converge on nominal nominal shot size Display volume matches pump vol System has not finished compen Dispense more shots Shot volumes ume but is consistently lower than sating for lower overshoot should converge on nominal nominal shot size Display volume does not match Changeovers are out of calibration Perform calibration procedure see actual volume pumped Errors page 66 Incorrect pump selected during Chose correct pump and pump size setup in setup screen 4 Shots are consistently inaccurate See Tips for Better Accuracy See Tips for Better Accuracy page 102 page 102 Display shows shot is active when No air supply to the air motor Check air supply to air motor eet PUPON puso HERO male Dispense valve is stuck closed Check the dispense valve to ensure rial is pumped ae It is opening and closing correctly No air supply to dispense valve Check the dispense valve to ensure It is opening and closing correctly Shots that end near a changeover Not enough shots have taken place Continue dispensing s
86. put Power meme E Shield Digital Trunk Connector Silver Pin Description Pin Number M12 Connector 5 pin Male A code Digital Input or Output from Branchi 4 Digital Input or Output from Branch 2 Power EE EN EE me _ 3A0294G 105 Accessories Accessories Changeover Kits 262453 and 262464 Use the changeover kit to increase shot accuracy and eliminate changeovers on shots that are less than 20 of the pump volume There are two changeover kits available For NXT2200 and larger air motors order 262453 For NXT1800 and smaller air motors order 262464 Dimensions For supply system or pump package dimensions refer to the supply system or pump package manual Technical Data Power supply requirements Pressure transducer manifold maximum working fluid pressure Ambient operating temperature range Operating humidity range 106 Foot Switch Kit 262530 The foot switch kit enables the operator to trigger the dispense valve using a foot pedal 100 240 Vac 50 60 Hz single phase 1 2 amps max 7500 psi 52 5 MPa 5 25 bar 32 120 F 0 49 C 0 90 non condensing 3A0294G Technical Data 3A0294G 107 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
87. reas 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 MOVING PARTS HAZARD Moving parts can pinch cut 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 and disconnect all power sources 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 e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury hearing loss inhalation of toxic fumes and burns This 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 System Description System Description SmartWare shot dispense kits contain everything needed to convert
88. screw 25 on the strain relief guide and to secure it to the top plate of the air motor bra 26 Fic 59 Install Strain Relief Guide Use a zip tie to secure the reed switch sensor cable m Reinstall the valve cover and tighten the nut See FIG 58 n Remove round plug and route the linear sensor cable through the opening in the back of the cover Snap the air motor cover back into place 3A0294G 7 Install the pressure sensor on the pump bleed port a Use a wrench to remove the pressure valve Pressure Valve N FiG 60 Remove Pressure Valve b Apply the supplied sealant to the adapter 33 the manifold 34 and the pressure valve Install all three in the order listed See FIG 61 c Disconnect pressure sensor at PT1 d Install the o ring 38 and pressure sensor 35 use zip ties 32 to secure the cable to the ram and air hose 35 Valve FiG 61 Install Pressure Sensor 3A0294G Installation 8 Install cables Reference the cable identification table on the next page and FiG 63 for a diagram of cable connections Shot Status Drum Low 1 Light Tower Start Stop 2 solenoid Pressure Cable Extension Cable Not Used Air Motor Changeover Cable Solenoid LCM Cable Fic 62 Breakout Module Connections 33 Installation 262373 Cab
89. spensed 65 Errors Errors From the Run screen press to navigate to the Information screen The Information screen displays the current alarm or advisory and the amount of remain ing material in the drum a 7 DJ D Ji 1 Alarms indicated by A require immediate attention therefore the system disables and the Information screen automatically displays Deviations indicated by M require attention but not immediately Advisories indicated by Lt do not require attention Therefore if a deviation or advisory occur the system continues run ning and M or EN displays next to the operation mode field Errors with Light Tower If you have a system that uses a light tower errors are indicated by the light tower as well as on the display The following table explains the error type that is associated with the particular light tower LED Light Tower LED Description No LED Yellow Solid An advisory exists Li Hed Flashing A deviation exists Red Solid An alarm exists and the system shuts down A 66 Clear Errors To clear an error 1 Press to access the fields 2 Press to navigate to the error code reset field 3 Highlight the error code Press to clear the error code 4 Press E to exit edit mode 3A0294G Error Codes PPAR gi w o Om Red Solid Shot volume is less than the error setpoint Red Solid Shot Volume Less than Error Setpoint Shot Vo
90. t See Prime Purge page 52 for flushing instructions Relieve the pressure see Operation page 62 but leave the mineral spirits in the pump to protect the parts from corrosion Seals Once a week check and tighten throat seals on pump Be sure to follow the Operation page 62 prior to tight ening seals 3A0294G Maintenance Supply System Maintenance Platen Maintenance If the platen does not come out of the pail easily when the pump is being raised the air assist tube or check valve may be plugged A plugged valve prevents air from reaching the underside of the plate to assist in raising it from the pail See the Supply Systems Repair Parts manual for instructions Adjust Spacers Adjust spacers to be used with tapered pails if neces sary See the Supply Systems Repair Parts manual for instructions Replace Wipers To replace worn or damaged wipers see the Supply Systems Repair Parts manual for instructions Cleaning Procedure WA w 1 Ensure all equipment is grounded See Installation page 16 2 Ensure the area where the system will be cleaned is well ventilated and remove all ignition sources 3 Relieve pressure See Operation page 62 4 Shutdown system and turn off all power See Shut down page 70 5 Clean external surfaces only using a rag soaked in solvent that is compatible with the dispense material and the surfaces being cleaned 6 Clean the disp
91. two screws 36 and wash ers 37 and 40 d 9 ro E 39 e UA J I cm 40 r 262375 3A0294 28a 1 29 30 36 Fic 82 Install Electronics Assembly 5 Install the display bracket 2 to the electronics sub assembly using four screws 30 and washers 29 r 262375 3A0294 26a FiG 80 Install Control Mount Bracket 3 Install the adapter bracket 35 to the wall mount 2 bracket or the control mount bracket using two screws 36 washers 37 and nuts 38 6 EC EC 35 4 c 30 0 cm wl al 29 36 W J r 262375_3A0294_29a 38 37 FIG 83 Install Display Bracket r 262375 3A0294 27a Fic 81 Install Adapter Bracket 3A0294G 43 Installation Fic 84 Remove Air Motor Cover 44 Snap the display 5 into the display bracket Install the linear sensor assembly 18 and th
92. user interface display and wait for the power up screen to complete and the run screen to appear Change Operation Mode There are four operation modes shot mode sequence mode manual mode and park mode This section explains each operation mode See page 92 for more details about the operation modes and the run screens Use the following instructions to change between opera tion modes 1 Press Z to access fields to make changes 2 Press to navigate to the operation mode field de oc 0 0 cc 3 Press ol to enter operation mode field 62 4 Press to scroll through the operation mode choices 5 Press dl to select the desired operation mode LUN 6 Press N to exit edit mode Shot Mode Shot mode dispenses a specific volume or weight of material When the shot completes the user can start another identical shot Shots first need to be defined in setup screen 1 Up to 25 shots can be programmed See Define Shot Size page 54 1 6 95 3A0294G Operation Sequence Mode Park Mode Sequence mode dispenses a sequence of shots in a Park mode dispenses material until the pump reaches specific order Sequences first need to be defined in the bottom of its stroke Then the system will disable setup screen 3 Up to five A E sequences can be pro grammed See Define Shot Sequence page 55 After the first shot in a sequence completes the next shot can start After all of the shots in a sequence
93. ze 1 54 Navigate to setup screen 2 Press 4 Press to navigate to the shot number field Press to scroll through the 25 shot numbers to access fields to make changes Press ei to select the desired shot number Press to navigate to the fluid weight field Press and to increment or decre ment to the desired shot size Press di to accept the shot size Define another shot size a Press to move to the shot number field b Repeatsteps 4 through 8 to define the next shot size LN Press to exit edit mode 3A0294G Define Shot Sequence Up to 5 sequences A E can be programmed Each sequence can have up to 14 shot positions and each shot position can be one of the possible 25 shots NOTE Only shots that are already defined can be added to a shot sequence To edit a shot sequence 1 Navigate to setup screen 3 js r 8 00 z 09 9 00 3 15 10 00 Arrius 5 1 RE amp sll 12 O00 r DO 14 00 v 2 Press z to access the fields 3 Press to navigate to the shot sequence field Press qi to select the field 4 Press to scroll through the shot sequences 5 Press al to select the desired shot sequence 6 Press to navigate to the shot positions 3A0294G Set System Parameters 7 Press qi and to navigate through each shot position and to select shot numbers NOTE When a shot number is selected the shot volume box will display 8 Press di

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