Graco 3A0261H User's Manual
Contents
1. Ref Part Description Quantity 3 00022 COVER connector 15 45deg 1 4 81 0360 11 SCREW jack connector dsub type a 2 5 B2050001 NUT allen 4 40 alloy 2 6 297331 SCREW cap 4x1 4 2 18 81 0378 2 25 STRAP ground ring 10 16ga 1 19 100166 NUT full hex 1 20 96 0005 2 99 WASHER lock ext 10 1 21 84 0130 25 11 LABEL prot earth grnd 375x 375 1 24 127629 VALVE solenoid 4 way 3 position 24V 1 25 82 0217 A 11 MUFFLER air 1 8 2 26 127632 SCREW socket head 4 40x1 00 2 27 94 0705 1 96 FITTING elbow swivel 1 4 tube 3 28 17 412 WASHER split 4 2 24E847 Electrical socket schematic 5 lt gt gt 2 0 T 2 7 2 0 0 a gt Q Q Q A N 4 21 N 0 5 9 gt 5 5 1 82 83 a a l 5 28 11 5 8 933 x 2 25 Gor a 5 N WO 2 5 NOM e 2 a 0261 122899 5 24 847 Valve Connection Kits 13 Setup Setup Motor Driven 1 Connect Dispense Valve I O Start Options and Motor logic cables If level controls are installed connect Level Controls logic cables Feed system and main logic control system must use separate air supplies2. woo 3901 Gg 1 24 38 esi YaWOLSND Nee INOQ 353451 1 6 4 YIWOLSND 9 OCS L 1 1 03345 3215 LOHS 0 1 1 9 03345 3215 LOHS lt L 03345 3215 LOHS g 03345 IZIS LOHS L 03345 IZIS LOHS 0 03445 3215 10 5 0 0 13345 3215 1 0 0 0 G3TIOWLNOD 33425 HINOL 9 3215 LOHS 35 14 1 1 sn 51 430 0 123155 YIWOLSND 22 1 318 1 1 31891335 2 2 8 en 93 5 LSND 9 131891335 8 Z 118 44 55 LSND 13181335 Stree 8 1 8 33 55 1502 LEY v2 2 8 9 avoy 1500 INON 2 09 LYVIS bgp 2 8 19 15 LSND wa 9 INON Sty INON ou INON su 9 9901 02 2 gt gt 3901 _ INON 09 607 9 ud ud 9 9 NO omy zz N A 9 5 2 out lt ior 24 6 9312902 1412 BES 4 9 6 4 901 0 lt 8 2
3. U A 2 Adjust customer supplied air pressure regulator to 80 psi 0 6 MPa 6 bar 3 Perform Setup procedure for dispense valve and feed system components See Related Manuals on page 3 14 Adjust Amplifier The amplifier should be adjusted if e Debris or vibration changed the distance axis between the sensor and metering block 13 Replacing the sensor 1 Navigate to the Motor Status screen 2 Ensure the metering rod connection block 13 is aligned with the sensor 3 Ifthe display shows for the sensor switch being adjusted increase the amplifier intensity adjustment screw until the sensor switch display changes to 1 4 Repeat for each sensor switch installed on assem bly 3A0261H Startup NOTE See HMI Operation starting on page 16 for detailed HMI instructions 1 Press the Control Power On button 2 Navigate to the Metering Valve Control screen 3 Press the Retract button NOTE On Motor Driven models when there is an Emergency Stop condition or the system power is lost the shot selection resets to 0 The operator must then select a shot 4 Navigate to the Supervisor screen 5 Press the Valve Type selection button to select your configuration 6 Navigate to the Shot Size screen 7 Select a shot number 8 Navigate to the Metering Valve Control screen 9 Press the Shot button to select Shot Mode 10 Verify air pressure is
4. OL 5 LDINNOD 11401 11 5012 1 9500 18 ISN 1 999 ole 888888 ZOE 9 006 Tt pat Lasu MNO 35 3A0261H we ISNJASIA YIWOLSMD Oo wD C aSNadsIG WNS dy waWOLSND 887 INON 33101512 330 sa YIWOLSND 39314 whee waWOLsnD 2 8 2 97 9 5 2 INON 7 w onze 99 INVA sO 22 9 10045 97 9 E 975 60099 35012 ud ud INYA 10045 79 6 val OV 95 8 2 amvaaionnos eS oI SLNdLNO 214 ewe an SPURL 38 ISNW ISN 33101512 4 51041010 Schematics LON
5. Perform Pressure Relief Procedure before perform ing any troubleshooting procedure Problem Cause Solution Dispense valve stalling and no mate rial being dispensed despite ade quate input pressure Blocked needle Check needle for cured material replace mixer as required Flow control valve closed Open Dispense valve not discharging nor mal or full volume Low material level in reservoirs Fill material reservoirs and prime the machine Air in material tanks Fill reservoirs and prime machine Material leaks past spool valves Spool valve worn or damaged Replace the spool valve and sleeve Material leaks around needle while dispensing Cured material in needle Check mixer for cured material replace needle The horn beeps after each shot Dispense is longer than the dispense limit timer Check mixer for cured material The horn beeps continuously If the low level sensors on the system may be low on material Check level screen for low level con dition if low level condition is present fill tank with material 34 3A0261H Schematics Schematics OL 13 5 LOINNOD w020 DANZ 5 JANYA 53108834 81 ISN 310 LL SOLDW 9S00 18 ISN 9 8 9 8 i
6. INCLUDED WITH BASE VALVE BLU BRN BLK BLU 15 PIN D SUB CONNECTOR PG 2 CONNECTION TO VALVE CONTROLS gt 0 0 9 2 gt gt 2 O O 2 0 lt 1 1 5 9 ga 5 a lt lt 20 92 w m z m 5 alz lt 5 a 8 2 0 1 12 13 14 lt 15 3A0261H HOOK UP FOR U81377 SWITCH INCLUDED WITH BASE VALVE LS CSV LS OSV Valve Connection Kits ti22897a 5_24E845e Q BRN BLU BRN BLU BLU SOL CSV AN L D may have been supplied in top hole If so move to the NOTE PX HOME must be below PX UP appropriate location as shown 24E846 1053 Dispense Valve with Added Up Validation Actuation Kit Valve Connection Kits AMP HOME 16 14 15 A b LS OSV 0 4 572 7 YD N 172 N SOL OSV LS CS
7. snadsia H ASDA 50105 5205 4 9 7 601704 a gt 77 60801 gt 37 3A0261H Schematics 38 3A0261H Technical Data Technical Data Maximum Ambient 110 F 43 Maximum Operating 150 F 65 C Electrical Requirements 120 240V 50 60 Hz Fuses Required 5 x 20 mm 10A fast type F 250 VAC Graco part V 21610P Qty 2 Maximum Amperage 10 amps Dimensions HX 20 in x 8 in x 20 in 508 mm x 203 mm x 508 mm Weight we 60 Ib 27 2 kg 3A0261H 39 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations Thi
8. OPEN In this mode the dispense valve is held in the open posi tion allowing material to pass through AUTO In this mode the dispense valve opens automatically whenever the pump is cycled CLOSE In this mode the dispense valve is held closed 3A0261H HMI Operation 19 HMI Operation Shot Size Screen lt 00000000000 ERROR CODE lt 000 Select Shot Size Flow Rate Combination 000 00 0 00 gt 000 00 0 00 000 00 0 00 a 000 00 0 00 5 000 00 0 00 000 00 0 00 7 000 00 0 00 Strokes lt 00000 Stroke lt 000 Erratic operation results if the shot size value entered is not greater than the absolute value of the Shot Size Off set setting For example if the Shot Size Offset setting is 1 a shot size greater than 1 must be entered See Supervisor screen page 28 Select Shot Size Flow Rate Combination Use this to change the selected shot by entering a num ber between 1 and 7 The selected shot size and flow rate is shown in the Shot Size percent section and Flow Rate mm sec section Number of Strokes This displays the number of shots of material when the machine is dispensing For example if the purge shot size is set at 150 Num ber of Strokes displays a 2 and the Amount Per Stroke displays 75 00 Amount Per Stroke This displays the stroke per shot in percent of stroke For example if the purge shot size i
9. 28 Supervisor Help Screen 30 Motor Error Codes Screen 31 Pressure Relief Procedure 32 cence cea ox 32 Customer InputS 33 Maintenance 34 Troubleshooting 34 Schematics 22 6 ie Pee a eet 35 Technical Data 39 Graco Standard Warranty 40 Graco Information 40 2 0261 Related Manuals Related Manuals Component manuals in U S English Part Description 313812 Dispensit 1093 313566 Dispensit 1053 10B 334001 1053 Valve 24V Solenoid Replacement Kit Instructions 334002 1093 Valve 24V Solenoid Replacement Kit Instructions 3A0261H Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable a TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed the eyes or skin inhaled or swallowed e Read 555 to know the specific hazards of the fluids you are using Store hazardous
10. 3 76 26 6 10 min 10 2 X 13 3 Dwell Alarm Timer Always set the dwell alarm timer to a value that will give the user adequate warning that the machine is about to dispense a purge shot This changes the duration that the audible alarm is active prior to the purge shot being initiated To change the Dwell Timer perform the following steps 1 Select the Dwell Timer button A numeric keypad appears 2 Enter the desired Dwell Timer time in seconds Use the 7 button to enter tenths of seconds 3 Press the button The new Dwell Timer time appears in the Dwell Timer field NOTE The current Dwell Timer time is shown by lt 000 0 Purge Shot Size button This button shows the Shot Size volume in percent of stroke This volume is dispensed during the ratio check To change the Purge Shot Size volume perform the following steps 3A0261H HMI Operation 1 Select Purge Shot Size button A numeric keypad appears 2 Enter the desired material shot size volume 3 Press the button The Purge Timer screen appears The new shot size percentage appears in the Purge Shot Size field Number of Strokes During Purge button indicator This displays the number of strokes used during the purge shot For example if the purge shot size is set at 150 Num ber of Strokes During Purge displays 2 and Amount Per Stroke displays 75
11. 5 5 0 lt r 2 2 8 10 4 z lt 2 ee 87 09 EMS FMS 6 lt 92 330339 53 2 5 410 135 ALON 8 lt 4 LINDYID LYOHS A ESR 2 9 gt 9 i NMOGLNHS 9 lt IYNLVYIAWILYIAO NO 51 lt DY 330 NO dls 5 330 330 lt 104 r lt N 4 414 30102 31 359 13539 lt lt w 5991 kayal 2 gt 1 1 092 gt 9 53 1 65 135 310 18 SONVNOS3Y LINY 9 m ar 5 A Se O 9 NOLLONGIY 05 5 OLNY 5 o 87 02 1 Wwa owe E HWH J DINOWYYH PLE 26 O p gt os 8 000 NOLLM10S34 ex 3435 z 67 49 OW ZOL ZSS_ 1 e A
12. al 1 4 1 r gt gt 0 N gt 0 4 N lt 21 21 N gt 59 0 0 7 4 2 22 2 aes 5 2 T lt 2158 52 2 44 gt gt lt lt lt 65 OZ OZ gt m o 5 5 Vv Vv 8 S S O 2 oo ew 2 gt x 2 gt 8 8 5 2 20 02 malala 9 _ 2 6 11 Valve Connection Kits 24E847 1093 Dispense Valve with Added Actuation Kit NOTE PX HOME must be below PX UP PX HOME may have been supplied in top hole If so move to the appropriate location as shown SOL CSV 24 SOL OSV 18 19 20 0 LS CSV LS OSV 12 PG 2 21 PX HOME __ PX DOWN 11 E 26 28 0261
13. 38 45 2 jz 8 8 218 EMINA 11 2018 9 38 45 9 38 45 gt 9 2 2 3 11 02 0 18 02 JHM 34945 5 THM 5 3945 2 E 0138 Li izzo ig 81 v 5 13 1910 18 91 nia 38445 nig 3395 5 S ja gt z ama 916011 OMYL 38 45 z DYO ENZO 9945 2 ESEB 11 2 0 18 38 45 38 45 45 5 8 5 2 225 30102 3703333 2 383438 5 1514 8 YVAN 9 ots ONWH 3384 SZ HZ O90L L8 SZ HZ O90L L8 3004 8715 62 4 1901 18 62 4 1901 18 OL 52 4 0901 18 52 0901 18 9 315 0115 5 oss 339105 3383 31 ASN ALON 1 3104335 50 105 9 5 oi 1 915 50 105 NYS 05 NOWWO3 AS3 10S 9 EL 3 1 cL 1 915 52 105 95 50 51 19 050 le 01 15251 19 N18 oE 6 8 8 LHM N18 0 4 1 6 9 UVLS DOA e 8 5
14. 1 NOWWOD 20A X19 NY9 9 38745 14 335 IWOH Xd 19 034 91 3845 g ved My DOA IHM 8 38 45 z ANNOYS OL HIV 31084 NOWWOD 9 1 ama Buds 40102 PENON aovsn Nid PANNON ess g 335 LON ZL 6 TVNOIS SIYIM YIMOd YIM LON OG LL TWNIWYAL OL OMAA 1 03123 38 1318 2 01 9 YOLDINNOD OOOOOOO 5 TIY 6 OY 134 015 OLYASIY E AA GNIS LNIYd ON 72 none 254 Td NLS YOLDNANOD 1901 18 2 5 33105 TIY ONISNL aaa 1901 3 1231084 WWNYALXA 1Y 11 92 0610 98 138 1 14 1 1 91 8 X 9118 AVE 1 52 0 0901 18 DNIGNNOYD WVZ S2 b L9OL L8 4 lt 2 0901 18 lt 22 ors 50 105 3301512 33101512 lt 310 H 310 35019 89 avona NYD 35012 5 1 74 INVA INVA 10045 001 10045 Tio SWIL en 78 EEN
15. The Error Code button is shown on every screen See the Main screen for definition Metering Control cope 0000 Retract Horne Start Cycle Di Valve Extend 0115 Start button lt When the Start button is pressed the machine starts the cycle for the selected Pump Mode Pump Mode NOTE The metering rods must be retracted prior to changing any setting under Pump Mode See Retract Piston page 15 Retract Mode The air cylinder and pumps immediately retract and remain in the retracted position This is used for mainte nance purposes only 18 Shot Size Extend Mode lt The air cylinder and pumps immediately extend and remain in the extended position This position must be selected when the pump is idle for a long period of time Shot Mode The machine cycles the number of times displayed in the Cycle Counter field when the start device is pressed and released The machine cycles continuously when the start device is pressed and held Continuous Operator Control Mode In this mode the machine to dispense while the start device is pressed When the start device is released the metering rods retract to the home position 3A0261H DV Valve Mode B amp This mode actuates an optional dispense valve
16. cycle 26 Dispense Complete This displays 1 if the metering rods are reloaded with material or at the end of the dispense cycle and dis plays 0 the metering tube is loaded with material and ready to dispense Contrast button This button increases the contrast of the screen Contrast button This button decreases the contrast of the screen These fields display the programs downloaded into the PLC and HMI 3A0261H Motor Status Screen NOTE A 1 indicates that the button is in the posi tion A 0 indicates that the button is in the OFF posi tion HMI Operation NOTE The Error Code button is shown on every screen See the Main screen for definition page 17 Motor Status 8 lt 00000000000 ot Mode Step lt 7 lt lt Home lt Switch ower To navigate to the Motor Status screen press the Motor Status button on the Status screen CSV Switch Closed Spool Valve Switch This displays 1 when the spool valve is in the closed or reload position OSV Switch Open Spool Valve Switch This displays 1 when the spool valve is in the open or dispense position Home Switch Home Limit Switch This displays 1 when the metering valve rod home switch is activated Upper Switch Upper Over Limit Switch Extend This displays 1 when the metering valve rod upper over trave
17. Metering Valve Control D Shot Size Flow Rate Level 1 Control lt gt Level 2 Control Purge Timer Status lt gt Motor Status lt Motor Error Codes Supervisor lt gt Supervisor Help FIG 2 3A0261H Main Screen NOTE The Error Code button is shown on every screen on the Motor Driven model Liquid Control 7 GRACO Metering Valve Shot Size Level Control Flow Rate Control Superson Timer Screen Access Buttons All buttons on the main screen except for the Password and Error Code buttons open a new specified screen For example pressing the Status button opens the Status screen Password The password button enables the user to changes values in certain screens To access the password press the Password Access button shown as 0000 When the keyboard appears enter 5810 then press the Enter key Error Code NOTE The Error Code button is shown on every screen On all screens that it is shown the Error Code button resets the error seen in the error string shown as lt 0000000000 and the error code number shown as lt 000 See the Motor Error Codes screen for more information page 31 3A0261H lt 00000000000 ERROR CODE lt 000 HMI Operation 17 HMI Operation Metering Valve Control Screen NOTE A 1 indicates that the button is in the ON posi tion A 0 indicates that the button is in the OFF posi tion NOTE
18. error string shown as lt 0000000000 and the error code number shown as lt 000 See the Motor Error Code screen for more information page 31 Reload Setup Only one of the three Reload Setup Options can be enabled at any given time Reload After Each Shot button In this mode the metering rods retract after every shot This is the default system setup Reload After Multiple Shots button In this mode the metering rods retract only when the metering rods are about to reach the end of the stroke This feature is only available when in Operator Control mode 28 1 indicates that the button is in the ON posi 3000000000000 Reload After Each Shot 1 Reload After ee Mutiple Shots 1 Manual Reload wi Cust Signal f SEESE 2044 1093 1053 2 1053 1 4 Speed ETE mm sec 00 00 00 ERROR 0000 Valve Type For example if the selected shot size is 30 of the metering rods stroke three shots will be taken 90 of the stroke then the metering rods will retract The rods retract after three shots because it cannot do another shot without going over 100 stroke If the selected shot size is greater than 50 of the metering rods stroke the metering rods will retract after every shot Manual Reload W Customer Signal button In this mode the customer must send a signal to reload the valve before the lower s
19. 97 ag ud 9 ma 6 ud ud so lt see 6 450 5407 2 ag SA INON ATaWASSY 384 30 335 4 eet LON 4Y __ _ ict asNadsia NOLLISOd 1 2 94 354349 10045 Gira Te avora NOLLISOd 2 94 2 4 90733 10045 586 3 mame lt lt 0 5 589 if 0 154 54 Lod WNOIS LUVAS 00 NOLLNAT 9 4 SLNANI 19 15 LSND 1274 38 wood Danve 0261 36 Schematics GUVISIG 1510 u9 380914 999 4 95955999995 39995 Buds 5 ie 8 8 ENZA 4
20. Amount Per Stroke This displays the percent of the stroke used during a shot For example if the shot size is set at 150 Number of Strokes During Purge displays 2 and Amount Per Stroke displays 75 25 HMI Operation Status Screen NOTE A 1 indicates that the button is in the ON posi tion A 0 indicates that the button is in the OFF posi tion NOTE The Error Code button is shown on every screen See the Main screen for definition page 17 Status Screen PLC Maintenance Totalizer Cycle Totalizer 0000000000 of Times Maintenance Totalizer has been Reset 00000 Reset Maintenance Totalizer 000000000000 0000000000 Motor Status Dispense Dispense Ready Complete Maintenance Totalizer This counter increments each time the machine cycles Press the Reset Maintenance Totalizer button to reset This counter is used for maintenance purposes Of Times Maintenance Totalizer has been Reset This counter increments each time the Reset Mainte nance Totalizer button is pressed Reset Maintenance Totalizer button This button resets the Maintenance Totalizer Cycle Totalizer This counter increments each time the machine cycles Dispense Ready This displays 1 if the metering rods are loaded with material and ready to dispense It displays 0 if the metering tube is reloading or at the end of the dispense
21. Power Switch Tank Level Controls Connection Touch Panel J B Tank Level Controls Connection D Alarm Speaker L Dispense Valve I O Connection Power Input Motor Connection Fic 1 Motor Driven Control Box Power input fuse holder 81 0365 3 11 can be set to either 115V or 230V To determine what voltage it is currently set to look at the port and read what is showing through the cover window To switch voltage open the fuse holder cover with a small screwdriver pull the fuse holder out flip the fuse holder 180 push the fuse holder back in and snap the fuse holder cover back into place NOTE Fuse part number V 21610P 120 V power cord part number 81 1051 1 11 240 V power cord part number 121054 6 3A0261H Grounding A This product must be grounded In the event of an elec trical short circuit grounding reduces the risk of electric shock by providing an escape wire for the electric cur rent Grounding plug units this product is equipped with a cord having a grounding wire with an appropriate grounding plug The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances Hard wired units the grounding wire must be used All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Air and fluid hoses use only electrically conductive hoses Fluid supply con
22. Setup Operation gt GRACO 1 053 1 093 3A0261H Control Box EN Patented meter and dispense system for precise one component micro dispensing Not for use in explosive atmospheres Important Safety Instructions Read all warnings and instructions in this manual Save these instructions CONTROL POWER 5 8 PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 WarningS 4 Component Identification 6 Control 6 Grounding 7 amp Lee oaks 7 Valve Connection 8 eee ete vane ded 14 Motor Driven 14 Adjust Amplifier 14 Startup eet de 15 Dispensing Operation 15 HMI Operation 16 Screen Navigation Diagrams 16 Main Screen 17 Metering Valve Control Screen 18 Shot Size Screen 20 Level 1 Control Screen 21 Level 2 Control Screen 22 Purge Timer Screen 24 Status Screen 26 Motor Status Screen 27 Supervisor Screen
23. V 3A0261H 10 Valve Connection Kits Ref Part Description Quantity 1 96 0098 99 SCREW socket head 10 24x1 50 2 2 16 798 PLATE mounting 1053 15 1 3 00022 COVER connector dsub 15 45deg 1 4 81 0360 11 SCREW jack connector dsub type 2 5 B2050001 NUT allen 4 40 alloy 2 6 297331 SCREW cap 4x1 4 2 14 81 1265 11 BRACKET end 2 15 297639 SCREW button head 2 16 81 0283 DIN 11 RAIL din 0 01 17 0200075 CABLE prox photo 1 18 81 0378 2 25 STRAP ground ring 10 16ga 1 19 100166 NUT full hex 1 20 96 0005 2 99 WASHER lock ext 10 1 21 84 0130 25 11 LABEL prot earth grnd 375x 375 1 22 16D050 AMPLIFIER 1chan photo pnp 24vdc 1 23 94 0740 A 99 FITTING elbow swivel 1 4tubex10 32 2 24 127629 VALVE solenoid 4 way 3 position 24V 1 25 82 0217 A 11 MUFFLER air 1 8 NPT 2 26 127632 SCREW socket head 4 40x1 00 2 27 94 0705 1 96 FITTING elbow swivel 1 4 tube 3 28 17 412 WASHER split 4 2 24E846 Electrical socket schematic 3A0261H N 5 gt gt gt gt i T gt Pall 9 92 zal T T 1 532 Q Q 2 x
24. creen This screen describes the various reload and shot options in the Supervisor screen To get to the Setup Help screen press the Help button on the Supervisor screen oad Wi Customer Signal Multiple shots can be spool valve after each Shift Spool t Shifts valve only when the metering v cor Back 30 3A0261H HMI Operation Motor Error Codes Screen These screens give descriptions of the motor error codes io he Error Codes Description error Aborted by user Configuration error Call LCC For Technical Help Illegal command Call LCC For Technical Help Aborted due to no valid configuration Aborted due to no user power Aborted due to no defined reference point Aborted due to STOP input active Aborted due to UPPER LIMIT input ac Aborted due to LOWER INPUT input acti Aborted due to problem executing motion No profile block configured for specified profile Error 3A0261H Error Codes Description Illegal operation mode Operation mode not supported for this command Illegal number of steps in profile block Illegal dir on change Illegal distance RPS trigger occurred before target speed reached i region width Speed out of range cient distance to perform desired speed change 5 at Power Up Back 31 Pressure Relief Procedure Pressure Relief Shutdown Pr r ocedure WA D 1 Turn main air supply shut off b
25. e Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations gt PLASTIC PARTS CLEANING SOLVENT HAZARD Use only compatible water based solvents to clean plastic structural or pressure containing parts Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage See Technical Data in this and all other equipment instruction manuals Read fluid and solvent manufacturer s warnings BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment 3A0261H Component Identification Component Identification Control Boxes CONTROL Pt AUDIO ALARM J Key Emergency Stop Start Options Connection Control
26. en if A Tank Status and Tank Status both display Levels Not Active then the level control feature is not installed on this machine Press the Main button to exit from this screen Level2 Control Screen 000 0 000 0 lt 000 0 lt 000 0 Clear Fill Fault Silence Alarm Low Level Shutdown button When this button displays 1 and the material level of either the A component tank or the B component tank goes below the low level sensor the machine shuts down To recover refill the component tank with material to above the low level sensor When 0 is displayed the low level shutdown feature is disabled Alarm Engage button When this button displays 1 and the material level of either the A component tank or the B component tank goes below the low level sensor the audible alarm is activated Auto Fill Engage button When this button displays 1 the automatic filling func tion is activated 22 Low Level Shutdown Alarm Engage Auto Fill Engage Level 1 lt Clear Fill Fault button This button clears the Fill Timer Fault message dis played in the corresponding A Tank Status or B Tank Status field in the Level 1 Control screen Silence Alarm button Press this button to silence the low fluid level audible alarm The audible alarm will be activated again when the low level condition reoccurs 3A0261H Shutdown Timer button
27. fluid in approved containers and dispose of it according to applicable guidelines e Always wear impervious gloves when spraying or cleaning equipment e If this equipment is used with isocyanate material see additional information on isocyanates Iso cyanate Conditions Section of this manual 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 inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 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 e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc e Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present 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 sparki
28. g for hardware location and wiring information 24E845 1053 Dispense Valve with Added Up and Down Validation Actuation Kit NOTE PX HOME must be below PX UP PX HOME may have been supplied in top hole If so move to the appropriate location as shown SOL CSV 14 15 16 AMP HOME AMP U 2 PX HOME PX U 8 3A0261H Ref Part Description Quantity 1 96 0098 99 SCREW socket head 10 24x1 50 2 2 16 798 PLATE mounting 1053 dsub 15 1 3 00022 COVER connector 15 45deg 1 4 81 0360 11 SCREW jack connector dsub type a 2 5 B2050001 NUT allen 4 40 alloy 2 6 297331 SCREW cap 4x1 4 2 14 81 1265 11 BRACKET end 2 15 297639 SCREW cap button head 2 16 81 0283 DIN 11 RAIL din 0 01 17 20200075 CABLE prox photo 2 18 81 0378 2 25 STRAP ground ring 10 16ga 1 19 100166 NUT full hex 1 20 96 0005 2 99 WASHER lock ext 10 1 21 84 0130 25 11 LABEL prot earth grnd 375x 375 1 22 16D050 AMPLIFIER 1chan photo pnp 24vdc 2 23 94 0740 A 99 FITTING elbow swivel 1 4tubex10 32 2 24 127629 VALVE solenoid 4 way 3 position 24V 1 25 82 0217 A 11 MUFFLER air 1 8 2 26 127632 SCREW socket head 4 40x1 00 2 27 94 0705 1 96 FITTING elbow swivel 1 4 tube 3 28 17A412 WASHER split 4 2 24E845 Electrical socket schematic PX H
29. gt owa ova 8 111 554 9 9 8 8 YOLOW NG omy zz S JOULNOD a Lad 8 4 al 9 2015 T a De 8 AN nz 91 A ELED 8 1 2 826 154 TO U om N A AZI G y 55 45 11 5 7 9 8 2 4 ra 7 7 2 92 8S 95 6 2 N 1 C W zs 1 15 4 gt tld V 5 5 ESOL YOA DYA 1 UL T 5 SY TANVd XV 135 1 38 OL JOVIIOA ION gt OL ANY CTAIHS 1318 2 YOLOW 41815 9 TSM 09 05 DVA OSZ OL AOZ 1934 01 38 015 94 OL 13 4 318 2 5 Sy iss YOLDINNOD 403415 13 4 NO 6 8 SNid oft 12 0 5 YOLDINNOD 40 Z 1 SNId E T
30. indicator NOTE If the level control option has not been pur chased the Shutdown Timer button is disabled This changes the delay before the Fill Timer Fault mes sage is displayed in the corresponding A Tank Status or B Tank Status field on the Level 1 Control screen If the material level is below the low level sensor for more than the duration of the Shutdown Timer setting the machine shuts down To change the Shutdown Timer setting perform the fol lowing steps 1 Select the Shutdown Timer button Shown as 00000 A numeric keypad appears 2 Enter the desired Shutdown Timer setting in tenths of a second NOTE For example if 15 is entered the shutdown time is 1 5 seconds 3 Press the button The new Shutdown Timer set ting is shown NOTE The current time of the Shutdown Timer is shown by lt 00000 This counts up to the preset time Fill Timer NOTE If the automatic refilling option has not been pur chased the Fill Timer function is disabled This changes the delay before the Fill Timer Fault mes sage is displayed to the corresponding A Tank Status or B Tank Status field in the Level 1 Control screen If the material level reaches the tank high level sensor before the preset fill time elapses the Tank High Level message is displayed in the Tank Status field and the Fill Timer is reset If the preset fill time expires before mate rial reaches the high level senso
31. k is currently refilling in the tank refilling process Material The tank level is between the high and the low Present level sensors Level Sen The machine senses material at the high level sor Fault sensor but not at the low level sensor Levels Not Level sensors are not installed for the tank Active Fill Fault The tank began refilling and the fluid level did not reach the high level sensor within the preset time entered into the Fill Timer button seen in the Level2 Control screen Tank has stopped refilling Silence Alarm button This button silences the audible alarm when pressed 3A0261H 00000000000000000000 Start Fill A Start Fill B button When this button is pressed the transfer pump fills the tank until the material level reaches the high level sen sor on that tank NOTE The Start Fill A Start Fill B and the Stop Fill but tons are inoperable if the high level automatic tank refill ing feature was not purchased with this machine Stop Fill button This button stops the automatic tank refilling process for both the A and B component material tanks 21 HMI Operation Level 2 Control Screen NOTE A 1 indicates that the button is in the ON posi tion A 0 indicates that the button is in the OFF posi tion NOTE The Error Code button is shown on every screen on the Motor Driven PD44 See the Main screen for def inition page 17 NOTE In the Level 1 Control Scre
32. l limit switch is activated The dispense valve is in the most retracted position Lower Switch Lower Over Limit Switch Retract This displays 1 when the metering valve rod lower over travel limit switch is activated The dispense valve is in the most extended position Put the dispense valve in this position when it is idle for a long period of time 3A0261H ERROR CODE lt 000 Step 0 Step lt 0 lt 000000000 lt 000000 00 Motor lt 000000 00 Main Motor Position Steps This gives the motor step position in terms of transducer steps Shot Size This shows the Shot Size volume in percent of stroke Flow Rate mm sec This allows the operator to view the current flow rate in millimeters per second Shot Mode Step This gives the current step in the shot mode program This is used for troubleshooting Reload Mode Step This gives the current step in the reload mode program This is used for troubleshooting Oper Mode Step This gives the current step in the operator mode pro gram This is used for troubleshooting 27 HMI Operation Supervisor Screen NOTE tion A 0 indicates that the button is in the OFF posi tion Supervisor Screen Reload Setup Feed Setup Cartridges Syringes NOTE To change the values on this screen log in as the supervisor See Main Screen page 17 Error Code button This button resets the error in the
33. leed valve to the off 2 Press the Retract button position This will bleed air from the system 1 Go to the Metering Valve Control screen 3 Press the Extend button 2 Perform feed system pressure relief procedure See Related Manuals on page 3 4 Press the Emergency Stop button Ensure every thing is off 3 Perform dispense valve pressure relief procedure 1 See Related Manuals on 3 5 Twist Emergency Stop to reset 6 Perform Pressure Relief Procedure 7 Perform feed system shutdown procedure See Related Manuals on page 3 8 Perform dispense valve shutdown procedure See Related Manuals on page 3 32 3A0261H Customer Inputs Customer Inputs Name Description Customer Start Input When a momentary contact closure is applied to this input the start device is activated Customer Purge Start Input When a momentary contact closure is applied to this input the purge shot is activated Customer SS FR Bit 1 2 3 Input When these inputs are activated in the proper sequence the machine acti vates the Shot Size and Flow Rate Combination seen on the Shot Sizes screen See the machine logic drawings for more information Customer Signal Done Output This output activates for 2 seconds after the dispense cycle is complete Customer Signal Dis pense Ready Output This output is active when the machine is in the Sh
34. ng or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem e Keep a working fire extinguisher in the work area ELECTRIC SHOCK HAZARD AN This equipment must be grounded Improper grounding setup or usage of the system can cause elec gt lt 2 tric shock e off and disconnect power cord before servicing equipment e Use only grounded electrical outlets e Use only 3 wire extension cords e Ensure ground prongs are intact on power and extension cords Do not expose to rain Store indoors 4 3A0261H Warnings PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Do not leave the work area while equipment is energized or under pressur
35. ot Mode and the dispense valve is retracted and loaded with material This output deactivates when the dispense valve is dispensing or if the machine is not in the shot mode Customer Signal Time to Purge Output If the Manual Reload W Customer Signal button under the Supervisor screen is selected this output is active when it is time for the machine to take a purge shot NOTE The dispense valve will not perform a purge shot until the start device is activated Customer Signal Open Auxiliary Dispense Valve Output This is to be used only when there is a metering valve feeding an on off type dispense valve This signal is used to open and close the dispense valve Customer Signal Reload Input When in customer reload mode after each shot the dispense Done signal is turned on for 2 seconds During this time the customer can toggle the cus tomer reload signal to reload the system If the timer expires the machines assumes the customer does not want to reload and finishes the sequence then turns on the ready signal and does not allow another reload until after the next shot 3A0261H 33 Maintenance NOTE If material is leaking see Troubleshooting on page 34 See Related Manuals on page 3 for dispense valve and feed system maintenance socket schedule and proce dures Air Water Separator Filter Drain water once a shift or as necessary Troubleshooting
36. r Fill Timer Fault appears in the Level1 Control Screen To change the Fill Timer setting perform the following steps 1 Select the Fill Timer button shown as 00000 A numeric keypad appears 2 Enter in the Fill Timer time in tenths of a second 3A0261H HMI Operation NOTE For example if 15 is entered the Fill Timer set ting is 1 5 seconds 3 Press the 1 button The new Fill Timer setting appears in the Fill Timer field NOTE The current Fill Timer time is shown by lt 00000 This counts up to the preset time 23 HMI Operation Purge Timer Screen NOTE The Error Code button is shown on every screen See the Main screen for definition page 17 Purge Timer Screen SEC lt 00000000000 lt 000 umber Strokes During Purge On Off lt 000 0 Amount Per Stroke lt 00000 Purge Shot lt 000 00 Size Purge Timer On Off Always set the dwell alarm timer to a value that will give the user adequate warning that the machine is about to dispense a purge shot See Dwell Alarm Timer section on page 25 The Purge Timer On Off switch is used to enable dis able the Purge Timer OFF The Purge Timer is disabled ON The Purge Timer is enabled The machine initiates a purge shot when the purge timer expires provided the fluid ball valves are open Shot Mode is selected and no errors exist 24 Enter P
37. s set at 340 Amount Per Stroke displays 85 00 and Number of Strokes During Purge displays a 4 20 Metering Valve Control Shot Size percent Flow Rate mm sec These are the 7 preset Shot Size percent and Flow Rate mm sec values Shot size is in percent of stroke The preset values can be selected using Select Shot Size Flow Rate Combination To edit the preset Shot Size or Flow Rate values log in as the supervisor See Main Screen page 17 Below is the minimum and maximum field allowance for this design Shot Size Minimum 2 5 Maximum 500 0 Flow Rate Minimum 0 50 mm second Maximum 25 00 mm second 3A0261H Level 1 Control Screen NOTE The Error Code button is shown on every screen See the Main screen for definition page 17 NOTE If A Tank Status and B Tank Status both dis play Levels Not then the level control feature is not installed on this machine HMI Operation 1 Control Screen A Tank Status 000000000000 ERROR CODE 9000 00000000000000000000 B Tank Status Alarm Stop Fill A Tank Status Tank Status This displays information about each component tank filling process The following are the possible messages Message Description Material The tank level is at or above the high level sen High sor Material The tank level is below the low level sensor Low Filling The tan
38. s 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 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 for
39. set to 80 psi 5 6 bar 11 Perform feed system startup procedure s See Related Manuals on page 3 12 Perform dispense valve startup procedure See Related Manuals on page 3 3A0261H Startup Dispensing Operation NOTE See HMI Operation on page 16 for detailed HMI instructions The foot switch the Start button and the optional Cus tomer Start Signal can be used to initiate shots These are referred to as start devices Perform a Shot 1 Navigate to the Metering Valve Control screen 2 Press the Retract button 3 Press the Shot button to select Shot Mode 4 Press and release the start device to perform one shot Dispense Continuously The valve dispenses continuously until the end of the stroke is reached 1 Navigate to the Metering Valve Control screen 2 Under Metering Valve Control press the Retract button 3 Press the Continuous button 4 Motor Driven models press and hold the start device to dispense continuously Release the start device to stop dispensing and retract the metering rods Retract Piston 1 Navigate to the Metering Valve Control screen 2 Under Metering Valve Control press the Retract button Extend Piston 1 Navigate to the Metering Valve Control screen 2 Under Metering Valve Control press the Extend but ton 15 HMI Operation HMI Operation Screen Navigation Diagrams Motor Driven Main Screen
40. tainer follow local code Solvent pails used when flushing follow local code Use only conductive metal pails placed on a grounded surface Do not place the pail on a non conductive sur face such as paper or cardboard which interrupts grounding continuity 3A0261H Grounding Kits NOTE 80 2957 1 50 1053 1093 control requires three sensor switches to operate Valve control and connec tion kits are sold separately Some assembly required Part Description 24E845 Connection kit for 1053 models that include 1 switch 24E846 Connection kit for 1053 models that include 2 switches including the following assem blies A2A10007 A2A10008 A2A10009 A2A10010 A2A10011 A2A1001 A2A10015 A2A10016 A2A10018 A2A10019 A2A10020 A2A10200 A2A10300 A2A10301 A2A10302 A2A10303 A2A10304 A2A10305 A2A10306 A2A10307 A2A10308 A2A10309 Connection kit for 1093 models including the following assemblies A2A05401 A2A05402 A2A05403 A2A05404 A2A05405 A2A05406 24 8471 Mounting adapter kit 24V674 may be required for mounting the solenoid to the 1053 valve Mounting side plate 01 2983 97 may be required for mounting the solenoid to the 1093 valve Valve Connection Kits Valve Connection Kits These valve connection kits enable certain valves to be used with this control package Each kit contains the mechanical electrical and pneumatic hardware needed to install the valve See associated drawin
41. th 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 contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction d
42. u pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Toll Free 1 800 746 1334 or Fax 330 966 3006 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original Instructions This manual contains English MM 3A0261 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 Revised August 2014
43. urge Time Button The Enter Purge Time button is shown as 000 0 below the Purge Timer On Off button The Enter Purge Time button allows the operator to set the required time between cycles When the Purge Timer switch is in the ON position and the Pump Mode switch is in the Shot or Operator Control position the purge timer unit counts up to the preset time When it reaches the preset time a purge shot is initiated The timer then automatically resets and continues with the sequence of cycling and resetting It continues until the Purge Timer is turned to the OFF position To change the Purge Timer setting perform the follow ing steps 1 Select Purge Timer button A numeric keypad appears 2 Enter the desired purge time in seconds Use the button to enter tenths of a second 3 Press the button The Purge Timer screen appears The new purge time appears in the Purge Timer button 3A0261H NOTE The current Purge Timer time is shown in the bottom text box below the Purge Timer button Calculating the Purge Timer Setting If the shot size is larger than the mixer volume set the timer for one half the gel time of the material If the shot size is smaller use the following formula to determine the Purge Timer setting Gel Time X Shot Size Timer Setting 2 X Mixer Volume For example with mixer volume 13 3cc shot size 10cc gel time 10 minutes use the following equation 100 cc min
44. witch is activated Otherwise the dispense valve will initiate a shot using the selected shot size and flow rate combination NOTE This can be linked with a PLC input for system integration See the logic drawings for more information Reload Speed mm sec button This allows the operator to change the retract or reload speed in millimeters per second Feed Setup This allows the operator to choose the low level setting for the feed system with tanks or a feed system with car tridge or syringes This inverts the switch function in the PLC logic 3A0261H Valve Type Only one of the three valve type options can be enabled at any given time This feature is enabled at the time of build based on Valve Type and should not be manipu lated Enabling the Valve Type with a 1053 1 in when a 1053 2 or 1093 is used will cause the improper maximum shot size allowed by the mechanics of the valve Enabling the Valve Type with the 1053 2 in when a 1053 1 in will cause the Low Switch to be tripped and will not allow the Valve to cycle Enabling the Valve Type with the 1053 2 1093 is used will cause the improper maximum shot size allowed by the mechanics of the valve Enabling the Valve Type with the 1093 when a 1053 1 in or 1043 2 in is used will cause the Low Switch or PF44 to be tripped and will not allow the Valve to cycle 3A0261H HMI Operation 29 HMI Operation Supervisor Help S
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