Graco 309301G User's Manual
Contents
1. ti1361a FiG 5 ProDispense System Typical Installation Install the Fluid Supplies For maintenance and safety you must install VAN e a fluid shutoff valve between each fluid supply line and the ProDispense fluid panel e ableed type air shutoff valve on the air supply line to the fluid supplies The ProDispense fluid panels can be supplied by pressure tanks pail or drum pumps or cen tral recirculating lines The fluid supply must be free of pressure spikes commonly caused by a pump stroke changeover If necessary install pressure regulators or a surge tank on the fluid supply out lets Note that this will also reduce the fluid supply pressure 309301G 15 16 Installation Mount the Fluid Panel s Mount the fluid panel s on a flat sturdy surface Install 1 4 or M6 fasteners in the four 0 28 mounting holes C1 and secure the fluid panel C to the mounting surface Connect a ground wire G as instructed on page 20 13 4 315 mm gt 12 4 340 mm P ti1357a FIG 6 Connect the Air and Fluid Lines Fluid Panel 244599 and 244600 Connect the fluid supply line 11 to the 1 2 npt f meter inlet See Fic 5 Connect a fluid dis pense line 12 to the2. Faulty cable s Replace cable s Blown fuse s Replace fuse s 36 309301G Service Service Removing and Installing Controller A Wear a grounding strap when replacing any of the controller boards to avoid shorting them out N ME 309301G Check with your Graco distributor periodically to see if circuit board or software updates are available To remove controller 1 Turn off controller power switch 2 Disconnect meter F solenoid E and power P cables and ground wire G from the bottom of the controller B See Fia 13 ae Noy ng L i al G 00 B UN OUT B 3B O O O Es A Ga W sl a TI1438a 3 Loosen the four screws A1 and carefully remove the controller cover A See Fic 14 4 Disconnect cable connectors A2 A3 from the display board 5 Remove the four bolts B1 and remove the control box B 37 Service To install controller 6 Secure controller B to the mounting surface with four bolts B1 7 Plug two connectors A2 A3 into the display board See Fia 14 8 Install controller cover A and secure it with four screws A1 9 Reconnect ground wire G and power P meter F and solenoid E cables to the con troller See FIG 13 O FIG 14 309301G Service Replacing Display Board
3. Connect fluid lines to the meter and dispense valve Connect air line to the solenoid 309301G Service 12 Load fluid at low pressure and check for leaks Tighten fittings as needed 9 tit411a FIG 23 309301G 51 ALY 52 Service Servicing Fluid Panel 246838 Replacing Solenoid or Dispense Valve 1 If necessary purge ProDispense system page 35 2 Relieve pressure page 24 and turn off controller power switch 3 Follow steps 3 5 on page 43 to disconnect meter and solenoid cables from the terminal block 4 Disconnect fluid lines from the meter and dispense valve Disconnect air line from the solenoid 5 Remove dispense valve and solenoid assembly from the fluid panel Remove fittings from old components and reinstall in new components as needed 6 If replacing dispense valve 19 a Place flats of the solenoid 3 in a vice b Unscrew dispense valve 19 from the solenoid 3 c Screw new dispense valve into connector C 7 If replacing solenoid 3 a Place flats of the solenoid 3 in a vice and unscrew dispense valve b Screw new solenoid 3 into connector B 8 Follow steps 8 10 on page 45 to connect meter and solenoid cables to the terminal block 9 Connect fluid lines to the meter and dispense valve Connect air line to the solenoid 10 Load fluid at low pressure and check for leaks Tighten fittings as needed 309301G Service O
4. 1 Turn on the power The ProDispense system startup screen will display while the system is starting then the Run screen page 30 or System Setup screen page 26 will appear depending on the mode of operation the system is in For an explanation of operation modes see page 11 FloSync v EEN Startup screen GRACO ProDispense Rev X XX Software revision 2 If this is the initial startup change to Setup Mode page 25 and complete the setup pro cedures 3 Change to the Dispense Mode Run screen if you are not there already page 29 4 Make sure the dispense lines run into the proper reservoir 5 Load the fluids page 34 309301G 23 Pressure Relief Procedure Pressure Relief Procedure T Shutdown 24 checking or servicing the equipment or installing or cleaning a dispense valve nozzle T Follow this procedure to relieve pressure in the fluid panel and dispense line before cleaning Follow the additional instructions in brackets if a dispense valve is installed on the SN dispense line 1 Dispense 2 Switch ON i 3 4 Dispense 5 7 7 Switch AUTO Shut off the fluid supply to the ProDispense fluid panel Follow the Pressure Relief Proce dure for the fluid supply system Place the dispense line or direct the dispense valve into a waste container To begin dispensing turn the Operator Station dispense switch to ON and trigger the dispense valve When fl
5. 6 aa Operation Keys use to operate the ProDispense system functions Start press to start the current recipe dispense Stop press to stop the current process Clear press to clear an entry in an input field Print press to print a report G0 10 309301G 3 DISPENSE AUTO ON N y DISPENSE START d 309301G Stop button Dispense switch Start button Overview Power Switch A On Off O On side of controller Operation Mode Switch B and Key C The position of the switch B determines which mode of operation you are in Dispense Mode 8 or Setup Mode A key C supplied with the ProDispense system is inserted into the switch and turned to change operation modes The key cannot be removed while the system is in Setup Mode Dispense Mode is used to dispense a recipe fluid check fluid totals and to view the alarms log Setup Mode is used to configure the system fluid and recipe parameters and to cali brate the meters Remote Operator Stations A cable connects the operator station to the fluid panel junction box A separate operator sta tion is needed for each fluid panel installed on the system The dispense switch can be set to dispense automatically AUTO or manually ON If set to AUTO the fluid panel will dispense when a recipe or fluid dispense is selected with the controller and the start button is pressed either on the controller or the ope
6. To exit Setup Mode Turn the key to Dispense Mode The Run screen appears Refer to page 30 309301G 25 Setup Mode System Setup Screen Use system setup to enter the date time language to display dispense mode means of rec System ipe selection and station number SYSTEM SETUP Day Month Year Dispense Mode 1 Fluid Station Hour Minute 2 Recipe Recipe Selection Language 1 User Interface 1 English 2 Spanish 3 German 4 French 5 Japanese 2 Network Station Number Fluids System Recipes Meters 26 To setup the system 1 N Type the current date day 1 31 es month 1 12 fe year 2000 2099 fa Type the current time hour 0 23 a minute 0 59 as The ProDispense clock is a 24 hour clock The date and time are used for date time stamps on alarms and reports 3 Type the desired language number 1 5 a N 4 Type the number for the desired dispense mode Power must be cycled before the language change will take affect 1 2 aj Fluid Station use this mode to select individual fluid stations when dispensing Recipe use this mode to select a recipe when dis pensing Dispensing by recipe will signal all fluid sta tions included in the recipe to dispense simultaneously Type the number for the desired recipe selection 1 2 a User Interface use to select recipes from the EasyKey pad Network use to select rec
7. 15 C38163 16 100021 17 112514 18 112512 20 237569 21 116669 22 198426 23 198427 309301G Description PANEL fluid dispense BLOCK solenoid mount VALVE solenoid METER pulse water SCREW cap 1 4 20 UNC 2A x 1 75 WASHER plain 0 281 ID NUT lock hex 1 4 20 UNC 3B CLAMP ground WASHER tab 5 3 mm ID WASHER lock 10 NUT lock hex M5 x 0 8 JUNCTION BOX electrical SCREW cap hex hd 10 24 UNC 2A x 0 375 WASHER lock star 10 SCREW cap hex hd 1 4 20 UNC 2A x1 FERRULE wire AWG 18 not shown FERRULE wire AWG 26 22 not shown WIRE ASSY 25 ft 7 6 m OPERATOR STATION remote HARNESS wire HARNESS wire 2d k LO M M M M a k A k M OM AAR mk 13 7 8 16 Parts 65 Part No 244601 Fluid Panel Ref Part 1 116421 2 156971 3 116463 4 239716 6 112173 7 181256 8 110249 9 104029 10 104582 11 100718 12 105332 13 244660 14 101577 15 C38163 16 156823 17 112514 18 112512 19 205612 20 105468 21 110755 22 244661 23 164749 24 164111 25 237569 26 116669 27 198426 28 198427 66 9 10 11 12 25 Description PANEL fluid dispense NIPPLE short 1 4 18 npt VALVE solenoid METER gear G3000 see Manual 308778 for parts MUFFLER 1 4 18 npt NEEDLE fluid ADAPTER male 90 elbow 1 4 18 npt CLAMP ground WASHER tab 5 3 mm ID WASHER lock 10 NUT lock hex M5 x 0 8 JUNCTION BOX electrical SCREW
8. RIA RE OE EE BULONG a ia pam a Met aal LRT e 35 Emergency Stop re saa ER N OO EE eS UA aw eesti Oe ah 35 Troubleshooting sic tie s s Ks K K K R K K R RR Oke RRR eee a ee ee NG WE N 36 ServlEe a Ka AK reac Send Oa Gn ER WYE a de aC E e te 37 Removing and Installing Controller 0 2 0 0 tetas 37 2 309301G Replacing Display Board paga ped Ada es tad da Pewee bebe GAB Pg RR beds 39 Replacing Display apang ED piped PAN NA AGA A GP ad Mag E eG AA eae AA 40 Replacing Membrane ma a NABAL Chie teehee a Leeks dR Sided A a oo BNG 40 Replacing Main Board is Ee ES ee eee 41 Replacing Power Supply eee 42 Replacing Fluid Panel Junction BOX o oooocococo eee eee 43 Servicing Fluid Panel 244599 0 ee een eee eee nets 46 Servicing Fluid Panel 244600 0 ES eee eee eee tenes 48 Servicing Fluid Panel 244601 and 246837 ES ES eee teen eens 50 Servicing Fluid Panel 246838 renere ng bade eae a ada dae bbe bk eee eed be RR deed 52 Servicing Fluid Panel 246839 0 0 ene eee eens 54 Wiring Charts beet hele meals HBD OR ET OE e KANA ANA DIG 56 la AA ER si aad EE ER AA 62 PAFENO 244561 Controller io is RR ghee A PR ae Ws eae a ata Bien R Ral Kg h 62 Part No 244599 Fluid Panel 2 ESE EE ee a es ee ete ee ee eens 64 Part No 244600 Fluid Panel coco Gma PANA ALENA RA AD EE ad bw raia Wad wae 65 Part No 244601 Fluid Panel ESE EE ee es ee ee se ee ee se ee ee ke ee 66 Part No 246837 Flu
9. This alarm occurs when the current actual dispense is either less than target tolerance or greater than target tolerance Dispense Timeout Alarm The controller stops an active dispense and initiates this alarm when the current dispense is not finished by the end of the Timeout Timeout is a value entered during Fluid Setup page 27 Invalid K factor Alarm This alarm occurs if the meter K factor is set to zero 00 000 Memory Failure Alarm This alarm occurs when the memory has been replaced but not programmed or when the memory has become corrupt SN See page 36 for alarm troubleshooting information 33 Operation Procedures Operation Procedures T la for Wear eye protection whenever you are dispensing fluid Follow the additional instructions in brackets if a dispense valve is installed on the dispense line Loading Fluid Lines Follow this procedure to load the fluid lines and purge out any air 1 Place the dispense line or direct the dispense valve into a waste container 1 To begin loading fluid turn the Operator Station dispense switch to ON and trigger the dispense valve 2 Continue dispensing until all air is purged from the fluid line and fluid flows steadily from the valve 3 Turn the dispense switch to AUTO to stop dispensing Manual Dispense 1 Place the dispense line or direct the dispense valve into the reservoir JI Hi 2 To begin dispensing turn the Operator Station dispense swi
10. cap hex hd 10 24 UNC 2A x 0 375 WASHER lock star 10 UNION swivel 1 4 18 npt FERRULE wire AWG 18 not shown FERRULE wire AWG 26 22 not shown VALVE dispense automatic see Manual 306715 for parts SCREW cap hex hd M6 x 12 WASHER 0 281 ID CABLE G3000 meter not shown TIP valve WASHER 0 465 ID WIRE ASSY 25 ft 7 6 m OPERATOR STATION remote HARNESS wire HARNESS wire Baa ti1324b 2 lt k k Ss k k a PON k GO M MMM HH o AH k mk mk mk mk k k mk 8 16 Parts 7 19 23 24 309301G Part No 246837 Fluid Panel Ref Part 1 116421 2 156971 3 116463 4 244292 6 112173 7 181256 8 110249 9 104029 10 104582 11 100718 12 105332 13 244660 14 101577 15 C38163 16 156823 17 112514 18 112512 19 205612 20 105468 21 110755 22 244661 23 164749 24 164111 25 237569 26 116669 27 198426 28 198427 309301G 9 10 11 12 25 Description PANEL fluid dispense NIPPLE short 1 4 18 npt VALVE solenoid METER gear G3000 HR see Manual 308778 for parts MUFFLER 1 4 18 npt NEEDLE fluid ADAPTER male 90 elbow 1 4 18 npt CLAMP ground WASHER tab 5 3 mm ID WASHER lock 10 NUT lock hex M5 x 0 8 JUNCTION BOX electrical SCREW cap hex hd 10 24 UNC 2A x 0 375 WASHER lock star 10 UNION swivel 1 4 18 npt FERRULE wire AWG 18 not shown FERRULE wire AWG 26 22 not shown VALVE dispense automatic se
11. sure spray from dispense valves hoses or ruptured components can inject fluid into your body and cause an extremely serious injury including the need for amputation Splashing fluid in the eyes or on the skin can also cause a serious injury The following precautions should be taken for high pressure fluid dispensing LOW PRESSURE FLUID HAZARD Fluid Panel 244600 is for low pressure use only see page 4 Fluid coming from the dispense valves leaks or ruptured components can splash in the eyes or on the skin and cause serious injury The following precautions should be taken for either high or low pressure fluid dispensing WARNING A WARNING Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate surgi cal treatment Do not place a rag over the end of the nozzle and blow back fluid to clear the nozzle Follow the additional precautions under LOW PRESSURE FLUID HAZARD Wear protective eyewear Do not put your hand or fingers over the valve nozzle or hose Do not point the dispense valve or hose at anyone or at any part of the body Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure on page 24 before cleaning checking or servicing the equipment or installing or cleaning the dispense valve nozzle Tighten all fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn damag
12. 1 2 npt f solenoid outlet Connect the other end to the dispense valve 9 Fluid Panel 244601 and 246837 Connect an air supply line 8 to the 1 4 npt f solenoid valve port The air supply must be fil tered to 10 micron to lengthen solenoid valve life Connect the fluid supply line 11 to the 1 4 npt f meter inlet Connect a fluid dispense line 12 to the 3 8 npt m outlet of the dispense valve on the fluid panel Connect the other end to the dispense valve 9 309301G 309301G Installation Fluid Panel 246838 Connect an air supply line 8 to the 1 4 npt f solenoid valve port The air supply must be fil tered to 10 micron to lengthen solenoid valve life Connect the fluid supply line 11 to the meter inlet Connect a fluid dispense line 12 to the 3 8 npt m outlet of the dispense valve on the fluid panel Connect the other end to the dis pense valve 9 Fluid Panel 246839 Connect an air supply line 8 to the 1 4 npt f solenoid valve port The air supply must be fil tered to 10 micron to lengthen solenoid valve life Connect the fluid supply line 11 to the 3 4 npt f meter inlet Connect a fluid dispense line 12 to the 3 8 npt m outlet of the dispense valve on the fluid panel Connect the other end to the dispense valve 9 Install the Remote Operator Station Mount the operator station D in a convenient location for the operator Secure it with No 10 or M5 fasteners t
13. 3 81 mm 4 position CONNECTOR plug 3 81 mm 10 position CONNECTOR plug 3 81 mm 13 position SCREW ground CLAMP grounding Qty 4 1 4 4 3 3 1 1 1 2 1 1 3 1 1 1 we Parts 63 Part No 244599 Fluid Panel Ref Part 1 116421 2 197576 3 110025 4 238618 5 158491 6 102313 7 110755 8 102040 9 104029 10 104582 11 100718 12 105332 13 244660 14 101577 15 C38163 16 100021 17 112514 18 112512 20 237569 21 116669 22 198426 23 198427 64 9 10 11 12 20 Description PANEL fluid dispense BLOCK solenoid mount VALVE solenoid METER electronic pulse see Manual 308245 for parts FITTING nipple 1 2 14 npt SCREW cap 1 4 20 UNC 2A x 1 75 WASHER plain 0 281 ID NUT lock hex 1 4 20 UNC 3B CLAMP ground WASHER tab 5 3 mm ID WASHER lock 10 NUT lock hex M5 x 0 8 JUNCTION BOX electrical SCREW cap hex hd 10 24 UNC 2A x 0 375 WASHER lock star 10 SCREW cap hex hd 1 4 20 UNC 2A x 1 FERRULE wire AWG 18 not shown FERRULE wire AWG 26 22 not shown WIRE ASSY 25 ft 7 6 m OPERATOR STATION remote HARNESS wire HARNESS wire Qty 4 CNM M MM k H H H k M OM HH o Parts 7 8 16 309301G Part No 244600 Fluid Panel Ref Part 1 116421 2 197576 3 110025 4 513891 6 102313 7 110755 8 102040 9 104029 10 104582 11 100718 12 105332 13 244660 14 101577
14. C D E E G H l J 309301G Overview 246837 246838 246839 Controller Solenoid Connection Controller Meter Connection Operator Station Connection Junction Box Fluid Inlet Meter Solenoid Fluid Outlet Air Inlet Fluid Valve K e T GOH DOD E FIG 4 309301G 13 Installation Installation N Were Do not install or service this equipment unless you are trained and qualified Do not install the ProDispense controller fluid panels or remote operator station in a hazardous location 14 e Fic 5 is not an actual system design Contact your Graco distributor for assistance in designing your system e See detailed installation instructions beginning on page 18 Be sure all accessories are adequately sized and pressure rated to meet the system requirements Be sure mounted surfaces and fasteners can support the weight of the equipment hose tubing and cable attachments and fluid Key for FIG 5 ProDispense Controller with EasyKey Pad Remote Operator Station Oil Lubricant Fluid Panel 244599 Water Antifreeze Fluid Panel 244600 Grease Paint Fluid Panel 244601 Fluid Supply Pump Fluid Supply Air Supply Line 9 Dispense Valve 10 Ground Wire to true earth ground 11 Fluid Supply Line 12 Fluid Dispense Line 13 Fluid Shutoff Valve 14 Bleed type Air Shutoff Valve 15 Optional Printer DN GOD OP DN 309301G Installation
15. MEG Turn off controller power switch 2 Remove controller cover A See page 37 steps 1 4 3 Unplug keypad D ribbon cable from the display board Note position of cable in connec tor Arrow indicates pin 1 reconnect with pin 1 engaged 4 Remove four nuts C1 from the board See FiG 15 5 Disconnect ground wire 6 Unplug three fiber optic connectors C3 from the diodes then remove display board F 7 Install parts in reverse order of disassembly e If replacing software chip use a chip puller to remove it N e Spacers G must be used in correct positions to protect the display and board D FIG 15 309301G 39 40 N Service Replacing Display 1 Follow steps 1 through 6 in the procedure for replacing the display board 2 Remove the display C See FiG 15 3 Install the parts in reverse order of disassembly Make sure the keypad ribbon cable does not interfere with the display e Spacers G must be used in correct positions to protect the display and board Replacing Membrane 1 Follow steps 1 6 in the procedure for replacing the display board page 39 2 Remove display C See FIG 15 3 Peel the membrane D off the controller cover 4 Remove adhesive liner from the new membrane Align the membrane with recessed area on the panel A and press it into place 5 Install parts in reverse order of disassembly SN Spacers G must be used in correct positions to protect the displ
16. is reached 31 Dispense Mode Fluid Totals Screen Press the left or right arrow key to select Totals The Fluid Totals screen shows how much of each of the fluids has been dispensed overall Two totals are shown Grand totals are tracked from the time the system is first started up and they are not resettable Resettable totals show the total amount of each fluid dispensed since the last reset Totals FLUID TOTALS Fluid Resettable Grand 1 00005 1 Itr 00312 1 Itr 2 00005 2 Itr 00582 8 Itr 3 00004 8 Itr 00468 2 Itr Press ENTER and CLEAR to reset totals Last Reset Date 23 04 01 Time 07 35 Run Totals Alarms Y Clear Print 32 Press Print E key to print Fluid Totals Report Press Clear and Enter keys simultaneously to reset all resettable totals aa A All resettable totals are reset when Clear and Enter are pressed Fluid totals cannot be reset individually 309301G Dispense Mode Alarms Alarm History Screen Press the left EJ or right E arrow key to select Alarms This screen summarizes the last five alarms that have occurred ALARMS ad Date Time Description Recipe Fluid Press Print 8 key to print an Alarms Report 03 09 9 39 Invalid K factor 10 1 03 08 14 32 Out of Tolerance 0 1 03 05 15 01 Timeout 6 2 03 05 8 12 Out of Tolerance 6 2 03 02 10 59 Invalid K factor 0 3 Run Totals Alarms 309301G Print Out of Tolerance Alarm
17. the solenoid 309301G Service 12 Load fluid at low pressure and check for leaks Tighten fittings as needed 9 tit411a FIG 25 309301G 55 56 Wiring Charts Service Control Box Wiring Chart Connection Connector Pin Wire Harness Internal Wiring 198556 Main PCB to 7 pin bulkhead 1A 198556 Main PCB to 7 pin Bulkhead 2A Fuse 1 PWR SW 1A Color black Function Fuse 2 PWR SW 2A black PWR SW 1 P Supply L black PWR SW 2 P Supply N black GND TB P Supply G green yellow P Supply G P Supply green yellow P Supply J7 3 P Supply Fuse 3 blue ground Fuse 3 J7 4 J7 4 J7 1 jumper J7 1 terminal block 24 VDC power J9 9 J9 10 jumper J10 1 J10 2 jumper J10 2 J10 3 jumper J10 3 J10 4 terminal block jumper 24 VDC power J9 5 stop PB J9 6 J6 2 start PB solenoid J6 1 ground ring terminal terminal block ground 24 VDC power J9 3 stop PB J9 4 start PB J6 4 solenoid J6 3 ground ring terminal ground 309301G Service Control Box Wiring Chart ti Wire Harness gonna bak Color Function Connector Pin terminal block 24 VDC power J9 1 stop PB 198556 Main PCB to 7 pin J9 2 start PB bulkhead 3A J6 6 sole
18. value field that can be edited on the controller screen e Acircled number O in a screen diagram relates a field on the screen to a step in a proce dure Numbers and letters in parentheses in the text such as A or 7 refer to reference num bers and letters in the figures e When you need to press a key during a procedure the key is indicated by an icon as shown in the following example Press Start to begin the dispense WARNING A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Improper grounding poor ventilation open flames or sparks can cause a hazardous condition and result in fire explosion or electric shock Installation and service of electrical components must be completed by a qualified electrician Do not install the ProDispense controller fluid panels or remote operator station in a hazardous location Ground the equipment See Ground the System page 20 If there is any static sparking while using equipment stop dispensing immediately Identify and correct the problem Provide fresh air ventilation to avoid buildup of flammable fumes Eliminate all ignition sources such as cigarettes Avoid spilling fluids onto electrical components Turn off the ProDispense controller power switch before servicing equipment TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin inhaled or swallowed Always wear protective eyewe
19. 01 fluid panels 244599 Fluid panel oil 244600 Fluid panel water 246837 246839 244601 Fluid panel grease Connection Connector Pin T Block 1 Color orange T Block 2 white T Block 3 black T Block 4 blue T Block 7 red ground green yellow Function 197573 6 pin bulkhead operator station T Block 1 T Block 2 orange white T Block 3 red T Block 4 T Block 5 blue black ring terminal green yellow 197574 7 pin bulkhead A cable connection T Block 9 red T Block 10 T Block 11 black T Block 12 white T Block 13 G Y 8 shield 197575 4 pin bulkhead B cable connection meter wires solenoid wires meter wires red black white green shield solenoid wires meter wires black black solenoid wires 59 60 Fluid Panel Wiring Chart Service Harness 246838 Fluid Panel Grease Connection Connector Pin Pole Accessories Wiring Chart Function solenoid wires Harness 197458 5 ft 1 52 m 198669 50 ft 15 24 m Printer Cable Connection Color Function Connector Pin shield 3 clear 5 black 4 a jumper Field Wiring Chart Output Harness Connection Connector Pin Color Function ground General Alarm 24 VDC groun
20. 104029 10 104582 11 100718 12 105332 13 244660 14 101577 15 C38163 16 156823 17 112514 18 112512 19 205612 20 117028 21 115226 22 198578 23 164749 24 164111 25 237569 26 116669 27 198426 28 198427 29 193715 309301G 9 10 11 12 25 Description PANEL fluid dispense NIPPLE short 1 4 18 npt VALVE solenoid METER heli gear amb with sensor see manual 309834 for parts MUFFLER 1 4 18 npt NEEDLE fluid ADAPTER male 90 elbow 1 4 18 npt CLAMP ground WASHER tab 5 3 mm ID WASHER lock 10 NUT lock hex M5 x 0 8 JUNCTION BOX electrical SCREW cap hex hd 10 24 UNC 2A x 0 375 WASHER lock star 10 UNION swivel 1 4 18 npt FERRULE wire AWG 18 not shown FERRULE wire AWG 26 22 not shown VALVE dispense automatic see Manual 306715 for parts SCREW cap hex hd M6 x 16 WASHER M6 CABLE G3000 meter not shown TIP valve WASHER 0 465 ID WIRE ASSY 25 ft 7 6 m OPERATOR STATION remote HARNESS wire HARNESS wire FITTING union swivel k k ss ssa MM k GO M MMM HAH AH AH kk mk k k mk mk mk Parts 69 Notes 70 Notes 309301G Technical Data Power Requirements Electrical Pneumatic Model 244601 only Number of fluids Totalizers 4 los ee NANG No of Recipes Cable Lengths Meter Sig
21. 2 npt m 0 2 1 gpm 0 76 3 8 Ipm 20 5000 cps 3 on dispenses over 12 cc 0 119 cc pulse 3000 psi 21 MPa 207 bar 120 psi 0 8 MPa 8 bar 1 4 npt f 3 8 npt m 71 246837 Grease Paint Flow rate oo o oooooo Viscosity range ACCUIACY wi iia ika K K ml nG Resolution EE Ee Maximum Working Pressure Maximum Air Pressure Fluid inlet Fluid outlet Air inlet amd PAA e aoe 246838 Meter less flow meter supplied by user Flow rate o ooo oooooo Viscosity range AGCCUIAGCY naw PA ED R ie EY Resolution EE Es Maximum Working Pressure Maximum Air Pressure Fluid inlet Fluid outlet A fee tek he NG 246839 Grease Paint Sealants Flow rate o oo ooooooo Viscosity range ACCUrACY a Resolution EE Maximum Working Pressure Maximum Air Pressure Fluid inlet Fluid outlet Airinlet o o o o oooooo 72 Technical Data 01 5 gpm 038 1 9 Ipm 20 3000 cps 1 5 on dispenses over 12 cc 061 cc pulse 3000 psi 21 MPa 207 bar 120 psi 0 8 MPa 8 bar 1 4 npt f 3000 psi 21 MPa 207bar 120 psi 0 8 MPa 8 bar TBD User supplied 1 4 npt f 1 4 npt f 013 6 gpm 05 22 Ipm 30 1 000 000 cps 5 on dispenses over 12 cc 0 286 cc p
22. E 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 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 indi
23. FIG 24 53 309301G ALY 54 Service Servicing Fluid Panel 246839 Replacing Fluid Meter Solenoid or Dispense Valve 1 If necessary purge ProDispense system page 35 Relieve pressure page 24 and turn off controller power switch Follow steps 3 5 on page 43 to disconnect meter and solenoid cables from the terminal block Disconnect fluid lines from the meter and dispense valve Disconnect air line from the solenoid Remove screw 20 and washer 21 from the meter 4 Remove meter dispense valve and solenoid assembly from the fluid panel Remove fittings from old components and reinstall in new components as needed 6 If replacing meter 4 a Place flats of the solenoid 3 in a vice and unscrew the meter 4 b Screw new meter into connector A If replacing dispense valve 19 a Place flats of the solenoid 3 in a vice and unscrew the meter 4 b Unscrew dispense valve 19 from the solenoid 3 c Screw new dispense valve into connector C d Screw the meter into the connector A If replacing solenoid 3 a Place flats of the solenoid 3 in a vice and unscrew dispense valve and meter assembly b Screw new solenoid 3 into connector B Secure the assembly to the fluid panel with screw 20 and washer 21 Follow steps 8 10 on page 45 to connect meter and solenoid cables to the terminal block Connect fluid lines to the meter and dispense valve Connect air line to
24. Instructions Parts 7 GRACO ProDispense 3093016 ENG Used to meter and dispense paints coatings solvents water and lubrication fluids For Professional Use Only Not for use in explosive atmospheres Part No 244561 Electronic Preset Dispense System Important Safety Instructions A Read all warnings and instructions in this manual Save these instructions See page 4 for maximum working fluid pressure and system component information ARTERT ER CE W Conforms to ANSI UL standard 3121 1 CAN CSA C22 2 No 1010 1 92 HO03 PROVEN QUALITY LEADING TECHNOLOGY Contents ProDispense System Components 00 cee RE RR RR eee RR RR RA RR RR ee 4 COnventlons ES TE EE AT aaa ewan EG 5 WARNING x AE se roo Ke N Ee RR OR eed DAN N Se Ee oe ee ee a a 6 OVGIVIGW 3 2 ase da deel ie AR DE jos JA RE Ge PR ee wei oie a 8 How the ProDispense System Works 02 ee ek ee ee tees 8 Main Components ss es EE SE ah aan aia oe eG li ose PAD ER EE AS gere EE oen se XE 9 Installation da AA AA A A hei NR RR alee BANA NADA GARENA 14 Install the Fluid Supplies Es EE HE wn EE amp a SON dahon Be a nhan dos 15 Mountthie Fluid Panel 8 ss Ka naawa pa RE RE NG BEG SS MEE SR DER ERG RE BE da bb DD REEDE NG gen bee NG 16 Connect the Air and Fluid Lines R STR EE E ee ee ee ke ee ek ee ke ee ek ee A ds ee 16 Install the Remote Operator Station EE EE EG Ee Se ee ee ee Ge ee de ee Gee ee eke ek ed ee de 17
25. Mount the Controller soii sie Babe BE EE RR ANDA MAA ED fe ER mode ae BE RR GER ogi ee 18 Connect the Cables and Power Cord 19 Groundtie Systerf ss SEE Re a N oe Pa ESE RR RLE ete Ea enue 20 Check the Resistance oi tusu HTS EE E RRR R T R RR R ee E RRR HNR N ee KE RR ke ds ee 20 Connect a Printer optional EE EE EE ee tte tet eee ee 21 Connect to a PC or Alarm optional teen eens 21 Before Beginning Operation EE Ee tenet eens 22 Slap eine es Se EE AA ER Gok ee aes 23 Pressure Relief Procedure sist ss ii eee a we eee en eS N 24 Shutdown ooo orc ve aa E Ad 24 Setup Mode sere ered EES rete GG Poe iG SEN ARA AA RARA ae PRN 25 Screen Navigation vi N etna aod tas Pad a RE EO eae eee 25 System Setup Screen eee eee ee 26 Fluid Setup Screen Seios VEER ED a WE ieee EE ed a ii 27 Recipe Setup Screen e eens 28 Calibrate Meter Screen 28 Dispense MOOG soen KERSE SE BOE AE NA eres NAKA AA AAA AAA 29 Screen Navigation ts pu ana EE A aE nG A ANN Soe KA 29 RUN Screen ii AE EE ea Ree OO RE ee 30 MEER TE N ee eee 32 Alarm History Screen e Reg Ke es se R R E ne a dee eke dee de ed N 33 Operation Procedures c ie ab see SR nisi EER DS EN ENE EEE KIS EA Ee ER RR ER eae 34 Loading Fluid Lin curras BEERS ee eas te ME EE NG OR we Ral Rd aoe ee ee ee ee es 34 Manual Diepens 320 ca paws oes HE ORDER Ramee ewan Ba aed vada ahem LINA 34 Automatic Dispense rs cave a am Ml eh eA eae ee Oe Peedi dated bA wd 34 Purging
26. Water eel 20 6 1 m station cable extension 198456 is available FIG 1 ProDispense Controller The controller is used to setup the ProDispense system fluids and recipes calibrate the meters and select a recipe or preset a dispense The controller totalizers enable you to view fluid dispense information and print the following reports Alarm history report Totals report Configuration Setup report Fluid Setup report Recipe Setup report Run report Display and EasyKey Pad The EasyKey pad is the operator interface for the ProDispense system The keypad con sists of number keys enter key scrolling arrow keys and operation start stop clear and print keys The graphic LCD screen displays system status setup information and operation options that can be selected using the keypad 309301G 9 Overview Number Keys Previous Field Display 4 5 6 Next Field Scrolling Keys 7 8 9 Previous Screen y Next Screen 9000 lalo Start Stop Clear Print Enter Key Operation Keys FIG 2 Number Keys type in setup or operation data Enter Key press to accept and enter data If you press a scrolling key without pressing Enter the cursor will move to the next field and the information you typed will reset back to the previous data Scrolling Keys press the up or down arrows to move between fields on the screen Use the left or right arrows to move between screens
27. ar gloves clothing and respirator as recommended by the fluid and solvent manufacturer Know the specific hazards of the fluid you are using Store hazardous fluid in an approved container Dispose of hazardous fluid according to all local state and national guidelines EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury This equipment is for professional use only Read all instruction manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are not sure call your Graco distributor Do not alter or modify this equipment Check equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure stated on the equipment or in the Technical Data page 71 Use fluids and solvents which are compatible with the equipment wetted parts Refer to the Techni cal Data in all equipment manuals and the fluid manufacturer warnings Route hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 E 40 C Comply with all applicable local state and national fire electrical and safety regulations 309301G HIGH PRESSURE FLUID HAZARD SKIN INJECTION HAZARD Fluid Panels 244599 and 244601 can be operated at very high fluid pressure see page 4 High pres
28. ay and board 309301G Service Replacing Main Board X Jy 1 Turn off controller power switch ZN fr Remove controller cover See page 37 steps 1 4 Unplug all wire connectors G from the main board H See FIG 16 Squeeze release clips and pull the main board H away from the din rail J ao fF 9 M Install parts in reverse order of disassembly NY If replacing software chip use a chip puller to remove it TI1441A FIG 16 309301G 41 42 AL Service Replacing Power Supply 1 Turn off controller power switch 2 Remove controller cover See page 37 steps 1 4 3 Unplug all wire connectors from the power supply 4 Pull the tab up with a screw driver and remove the power supply from the din rail See FIG 17 5 Install parts in reverse order of disassembly TI1455a FiG 17 309301G Service Replacing Fluid Panel Junction Box X Jy 1 Turn off controller power switch ZN ft 2 Disconnect three cables C from the junction box J See FIG 18 3 Remove four screws K and remove junction box cover L 4 Disconnect meter and solenoid wires M from the terminal block 5 Loosen two strain relief connectors N to pull out the wires NG manas FIG 18 309301G 43 44 ti1404a Fig 19 6 Remove the two screws P and remove the junction box J See FIG 19 7 Secure the new junction box with t
29. ct meter and solenoid cables to the terminal block 10 Connect fluid lines to the meter and solenoid 11 Load fluid at low pressure and check for leaks Tighten fittings as needed 309301G 309301G Fic 21 Service 47 Service Servicing Fluid Panel 244600 Replacing Fluid Meter or Solenoid 1 If necessary purge ProDispense system page 35 Bag X Jy 2 Relieve pressure page 24 and turn off controller power switch DM fc 3 Follow steps 3 5 on page 43 to disconnect meter cable from the terminal block If replac ing the solenoid also disconnect solenoid cable 4 If replacing meter 4 a Disconnect fluid line from the meter Loosen two nuts A holding the meter and remove meter See FIG 22 b Secure new meter 4 with the nuts A Continue with step 6 5 If replacing solenoid 3 a Disconnect fluid lines from meter and solenoid b Remove two bolts 6 and washers 7 from the solenoid 3 and remove solenoid and meter assembly See FIG 22 c Place flats of the solenoid 3 in a vice and unscrew the meter 4 d Secure new solenoid 3 to the meter with the nut A e Secure meter and solenoid assembly to the fluid panel with solenoid washers 7 and bolts 6 6 Follow steps 8 10 on page 45 to connect meter cable and solenoid cable if it was discon nected to the terminal block 7 Connect fluid line s 8 Load fluid at low pressure and check for leaks Tighten
30. d Fluid 1 Alarm 24 VDC ground Fluid 2 Alarm 24 VDC ground Fluid 3 Alarm 24 VDC Modbus B Modbus A ground 309301G Service Notes 309301G 61 Parts Part No 244561 Controller Ref Part 3 197386 4 116368 4a 116370 5 116320 12 196975 13 244952 16 197835 18 245222 18a 197431 18b 116371 18c 197281 18d 198573 62 Description LABEL power switch SWITCH key 2 position includes item 4a e KEY PACKAGE 2 duplicate keys SWITCH power POWER SUPPLY 24 VDC BOARD circuit main control HARNESS wire COVER ASSEMBLY electrical section includes items 18a 18h e COVER enclosure e SPACER 0 151 ID e SWITCH membrane e DISPLAY graphic lt mk Dk mk mk k mk mk k k T Parts 309301G Ref Part 18e 116374 18f 244407 18g 103181 18h 100072 19 198556 20 198557 22 194741 24 116726 31 114835 32 120614 33 197827 46 116772 47 116773 48 116774 49 116343 50 222011 Item 18 Cover Assembly Part No 245222 309301G Description e SPACER 0 14 ID e BOARD circuit display e WASHER lock external 6 e NUT hex 6 32 UNC 2B WIRE HARNESS solenoid WIRE HARNESS meter LABEL warning not shown WIRE HARNESS printer FUSE time lag 4 A 250 V FUSE time lag 1 6 A 250 V WIRE HARNESS CONNECTOR plug
31. d connector B on the first fluid panel 3 Repeat the cable connection for each of the fluid panels installed in the system 2A to A 2B to B etc A knockout marked is provided for a customer supplied power input P cable with strain relief or for wire conduit oO O LIN OUT J 18 28 38 DOO LE A J UA 2A 3A pnl i P a Er TI1438a FIG 10 309301G 19 Installation Ground the System N WO8 The system must be properly grounded Follow the instructions here and on page 6 ProDispense Controller Connect a ground wire G1 to the grounding lug H1 on the bottom of the controller Connect the other end of the ground wire to a true earth ground Fluid Panels Connect a ground wire G to the grounding lug H on the junction box bracket Connect the other end of the ground wire to a true earth ground b ap TI439a Fic 11 Feed Pumps or Pressure Pots See your separate pump or pressure pot manual Air and Fluid Hoses Use only grounded hose Fluid Supply Container Ground the container according to your local code Solvent Pails Used when Purging Ground pails according to your local code Use conductive metal pails placed on a grounded surface Do not place pails on nonconductive surfaces such as paper or cardboard Check the Resistance A W
32. e Manual 306715 for parts SCREW cap hex hd M6 x 12 WASHER 0 281 ID CABLE G3000 meter not shown TIP valve WASHER 0 465 ID WIRE ASSY 25 ft 7 6 m OPERATOR STATION remote HARNESS wire HARNESS wire k sss a M M k CLO M MM M HH H AH k k k k k k k mk Parts 7 19 23 24 67 Part No 246838 Fluid Panel Pi Ref Part 1 116421 3 116463 6 112173 7 181256 8 110249 9 104029 10 104582 11 100718 12 105332 13 244660 14 101577 15 C38163 16 156823 17 112514 18 112512 19 205612 22 244661 23 164749 24 164111 25 237569 26 116669 27 198426 28 198427 68 Description PANEL fluid dispense VALVE solenoid MUFFLER 1 4 18 npt NEEDLE fluid ADAPTER male 90 elbow 1 4 18 npt CLAMP ground WASHER tab 5 3 mm ID WASHER lock 10 NUT lock hex M5 x 0 8 JUNCTION BOX electrical SCREW cap hex hd 10 24 UNC 2A x 0 375 WASHER lock star 10 UNION swivel 1 4 18 npt FERRULE wire AWG 18 not shown FERRULE wire AWG 26 22 not shown VALVE dispense automatic see Manual 306715 for parts CABLE G3000 meter not shown TIP valve WASHER 0 465 ID WIRE ASSY 25 ft 7 6 m OPERATOR STATION remote HARNESS wire HARNESS wire O rd som k k L M M MM k SS O Parts 309301G Part No 246839 Fluid Panel L Ref Part 1 116421 2 15B556 3 116463 4 246190 6 112173 7 181256 8 110249 9
33. ed or loose parts immediately 309301G Overview Overview How the ProDispense System Works Usage The ProDispense system enables you to accurately dispense preset amounts of up to three different fluids or to manually dispense fluid as desired The fluid meters provide accurate fluid flow readings to the controller Controller totalizers use the meter flow readings to calculate fluid volume and usage and display the information on the screen The controller can store the parameters for up to 250 recipe dispenses Fluid Supply The ProDispense system can dispense fluids supplied from pressure tanks or feed pumps Each fluid is supplied separately to the ProDispense fluid panels Choice of Recipe Dispense or Fluid Dispense You can choose Fluid Dispense mode to individually enter a fluid preset volume and dispense the fluid Or you can choose Recipe Dispense mode to dispense a preset recipe A recipe allows you to select or set up to three preset fluid volumes simultaneously Regardless of which dispense mode you choose a dispense tolerance must be entered for each fluid The controller monitors the Target and Actual dispense values and reports an error if the tolerance is not maintained 8 309301G Overview Main Components ProDispense Controller with display and EasyKey pad Remote Operator Station 10 3 05 m station cable standard 50 15 24 m meter amp solenoid cables Grease Paint
34. ere To reduce the risk of fire explosion or electric shock the resistance between the ProBatch components and true earth ground must be less than 1 ohm 20 Have a qualified electrician check the resistance between each ProDispense component and true earth ground If the resistance is 1 ohm or greater a different ground site may be required Do not operate the system until the problem has been corrected 309301G Installation Connect a Printer optional Connect the 5 ft 1 52 m printer cable provided with printer kit 239873 between the printer and controller printer connector marked amp See Fic 5 page 15 SN Accessory Printer Cable 198669 50 ft 15 24 m long is available Do not use longer cables Connect to a PC or Alarm optional The ProDispense system can be connected to a PC via Modbus RTU network protocol 6 and or audible alarms 7 as shown in FIG 12 Refer to field wiring chart page 60 Follow instructions on page 26 to setup modbus station number and recipe selection Contact your Graco distributor for Modbus address mapping list FiG 12 309301G 21 22 Before Beginning Operation e Check all fluid and air connections for correctness and tightness e Follow the Startup procedure on page 23 Installation 309301G Startup Startup Follow this procedure to start the ProDispense system for the first time initial startup or after the system has been shut down
35. fittings as needed 48 309301G Service a FIG 22 309301G 49 ALY 50 Service Servicing Fluid Panel 244601 and 246837 Replacing Fluid Meter Solenoid or Dispense Valve 1 If necessary purge ProDispense system page 35 Relieve pressure page 24 and turn off controller power switch Follow steps 3 5 on page 43 to disconnect meter and solenoid cables from the terminal block Disconnect fluid lines from the meter and dispense valve Disconnect air line from the solenoid Remove screw 20 and washer 21 from the meter 4 Remove meter dispense valve and solenoid assembly from the fluid panel Remove fittings from old components and reinstall in new components as needed 6 If replacing meter 4 a Place flats of the solenoid 3 in a vice and unscrew the meter 4 b Screw new meter into connector A If replacing dispense valve 19 a Place flats of the solenoid 3 in a vice and unscrew the meter 4 b Unscrew dispense valve 19 from the solenoid 3 c Screw new dispense valve into connector C d Screw the meter into the connector A If replacing solenoid 3 a Place flats of the solenoid 3 in a vice and unscrew dispense valve and meter assembly b Screw new solenoid 3 into connector B Secure the assembly to the fluid panel with screw 20 and washer 21 Follow steps 8 10 on page 45 to connect meter and solenoid cables to the terminal block
36. he two screws P Service 309301G Service 8 Connect meter and solenoid wires M to the terminal block Connect as shown for the specific fluid panel in Fic 20 WN 00 66 98 88 y j FIG 20 9 Tighten two strain relief connectors N See FIG 18 10 Secure the cover L with four screws K 11 Reconnect three cables C 309301G 45 ALY 46 Service Servicing Fluid Panel 244599 Replacing Fluid Meter or Solenoid 1 8 9 If necessary purge ProDispense system page 35 Relieve pressure page 24 and turn off controller power switch Follow steps 3 5 on page 43 to disconnect meter and solenoid cables from the terminal block Disconnect fluid lines from the meter and solenoid Remove two bolts 6 and washers 7 from the solenoid 3 and remove solenoid and meter assembly See FiG 21 Place flats of the solenoid 3 in a vice and unscrew the meter 4 Install new meter or solenoid Secure the assembly to the fluid panel with solenoid washers 7 and bolts 6 Follow steps 8 10 on page 45 to conne
37. hrough the four 0 22 mounting holes D1 Connect the cable D2 to the fluid panel junction box connector marked C 20 ft 6 1 m station cable extension 198456 is available L tit45ta FiG 7 17 Installation Mount the Controller Mount the controller on a flat sturdy surface as instructed below 1 Loosen the four screws A1 disconnect the two cables A2 A3 and remove the control ler cover A 2 Install 0 44 or M11 fasteners in the four 0 51 mounting knockouts B1 and secure the controller B to the mounting surface 3 Reconnect the cables A2 A3 4 Install the controller cover A and secure it with the screws A1 TI1436a FIG 8 17 38 l 441 mm gt 14 5 __ 368 mm P c o 4 a NG A Ka o O 8 5 216 mm 11 3 287 mm Ce id T FIG 9 18 309301G Installation Connect the Cables and Power Cord On the bottom of the controller there are meter and solenoid cable connectors for three Fluid panels The row of connectors marked 1A 2A and 3A are for solenoid cable connections The row of connectors marked 1B 2B and 3B are for meter cable connections Connect the cables as instructed below 1 Connect the solenoid cable E between controller connector 1A and connector A on the first fluid panel 2 Connect the meter cable F between controller connector 1B an
38. id Panel is eds casa RR Rede Nee tee det Ep Be Gale eee Re Ee Re 67 Part No 246838 Fluid Panel ike 535g ct ER SEE EES EES eee EER K A SE N NA d ATK EE ER ERG ER Ed de 68 PartNo 246839 Fluid Panel se A abies athe ar R A wk EER aed AMING NS Rais 69 NOTES so a is EE tn ee EL ws Be EE Re Ee EED Ge EE AD da 70 Technical Data sit sede salas BR De R N 71 Accessories and KIS ER RS tebe dads ORE RR RE ER EDE a RE RR RO T EER 73 Graco Standard Warranty oes de aa ee ea pa a de N Ed Ee a Ee ME eg We de 74 Graco Information ses aa AS bee DEL OEE a NLA 74 309301G 3 ProDispense System Components ProDispense System Components Follow the instructions in this manual 809301 and refer to the component manuals for addi tional warning operation service and parts information See the table below for e maximum working pressure of the fluid panels e component part numbers and manual numbers e parts list page numbers Fluid Panels Part No 244599 244600 244601 Oil Lubricant Water Antifreeze Grease Paint Maximum Working Pressure 1500 psi 10 MPa 103 bar 250 psi 1 7 MPa 17 bar 3000 psi 21 MPa 207 bar Fluid Meter Part No 238618 513891 239716 Manual No 308245 308778 Dispense Valve Part No 205612 Manual No 306715 Parts List Page No 64 66 Fluid Panels Part No 246837 246838 246839 Grease Paint Meterless Sealants Maximum Working Pressure 3000 psi 21 MPa 207 bar 3000 psi 21 MPa 207 bar 3000 psi 21 MPa 207 bar Fluid Mete
39. iner minimum 300 cc by turning the Operator Station dispense switch to ON and triggering the dispense valve 2 Stop dispensing by releasing the dispense valve trigger and turning the dispense switch to AUTO 3 The amount the controller detected was dispensed appears on the screen in the Dispensed column If the value in the column differs from the measured amount in the container enter the measured value in cc in the Actual column If nothing is entered in the Actual column the K fac tor remains unchanged N 4 The controller will calculate the meter K factor and display the new value in the K factor column 5 Repeat the process for each of your fluid panels 309301G Dispense Mode Dispense Mode Screen Navigation Dispense Mode is used to dispense a fluid or recipe check fluid dispense totals and view l the alarms log Dispense Mode RECIPE DISPENSE ID r Recipe Dispense screen Fluid 1 Fluid 2 Fluid 3 Idle Idle Idle Target 005 00 Itr 050 00 Itr 010 10 Itr Actual 5 00 Itr 51 00 Itr 10 00 Itr Tolerance 5 5 5 Difference 0 2 1 Run Totals Alarms 3 screen selections l current screen The name of the screen that is currently displayed is highlighted The Operator Station dispense switch must be set to AUTO to dispense using the controller Press the left or right arrow keys on the keypad to move through the screens Press the up or down arrow keys to move th
40. ipes from a networked source 6 Type the station number 1 99 a N This number is used for network communications to identify the station Each station must have a unique number 7 Press the right arrow key Bt go to the Fluid Setup screen 309301G Fluids Fluid Setup Screen Setup Mode Use fluid setup to designate the parameters for each fluid you will dispense N Fluid parameters must be set before the fluid can be used in a recipe FLUID SETUP Fluid 1 Fluid 2 Fluid 3 Units of Measure 1 cc 2 0z 3 Qt 4 Ltr 5 Gal Tolerance Timeout Value min K factor cc pulse System Fluids Recipes Meters 309301G To set up the fluids You can have 1 3 fluid panels connected to the ProDis pense controller Setup the fluids for each of your fluid panels as follows 1 Type the number for the desired units of measure 1 5 a Type the dispense tolerance percentage 1 99 a Type the timeout value in minutes 1 99 la If a dispense does not complete by the end of the entered value a Dispense Timeout alarm occurs See page 33 4 Type the fluid meter s K factor cc pulse 6a Fluid Panel Meter Type K factor part no cc pulse 244599 oil lubricant 4 73 244600 water antifreeze 25 244601 grease coating 0 119 246837 grease coating 061 246838 grease coating n a 246839 grease coating 0 286 The K factors in the table a
41. ipment 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 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 PURPOS
42. n Recipe Setup You cannot change it in the Run screen Type a 4 digit ID if desired aa Press the Start button on the Controller or on the Remote Operator Station to begin dispensing the recipe As the fluids dispense their statuses on the screen change from Idle to Dispense and the amounts dis pensed appear in the Actual row Each fluid panel stops dispensing when its individual Target is reached 309301G Status line i FLUID DISPENSE ID Fluid 1 Fluid 2 Fluid 3 Ke ldle Idle Idle Target 005 00 Itr 050 00 Itr 010 10 Itr Actual 5 00 Itr 51 00 Itr 10 00 Itr Tolerance 5 5 5 Difference 0 2 1 Ru Totals Alarms 0008 stop Ma Dispense Cl Switch AUTO 3 START 309301G Dispense Mode Fluid Dispense Fluid Dispense displays in the Run screen if Fluid Sta tion is selected as the Dispense Mode Fluid Dispense allows you to select a fluid panel and the amount to dis pense on an individual basis 1 Place the fluid panel dispense line into the recepta cle Type a 4 digit ID if desired fa In the column for the fluid you want to dispense type the desired amount of fluid in the Target field a gt Press the Start button on the Remote Operator Sta tion to begin dispensing the fluid 5 As the fluid dispenses the status on the screen changes from Idle to Dispense and the amount dis pensed appears in the Actual row 6 The fluid panel stops dispensing when its Target
43. nal Solenoid signal Operator Station Fluid Panels 244599 Oil Lubricant Flow rate o o oooooo Viscosity range ACCUTANE Resolution o o o o oo o Maximum Working Pressure Fluid inlet Fluid outlet 244600 Water Antifreeze Flow rate o oooo ooo Viscosity range ACCUTAC ci ed aNg Resolution o o o o o o Maximum Working Pressure Fluid inlet Fluid outlet 244601 Grease Paint Flow rate Es EE ER Ee a Viscosity range ACCUrACy eee Resolution nnana nananana nna Maximum Working Pressure Maximum Air Pressure Fluid inlet Fluid outlet Air iNlet AA AA ER REN 309301G Technical Data 115 230 VAC 1 6 amp maximum 50 or 60 Hz 85 120 psi 0 59 0 9 MPa 5 9 9 bar at 1 4 cfm maximum filtered to 10 micron 1 3 valves Last dispense Resettable Grand 250 maximum 50 ft 50 ft 10 ft 20 ft 15 24 m 15 24 m 3 05 m 6 10 m available e pe GT 0 25 4 gpm 0 95 15 Ipm 10 wt oil 2 grease 1 2 on dispenses over one gallon 4 73 cc pulse 1500 psi 10 MPa 103 bar 1 2 npt f 1 2 npt f 0 25 4 gpm 0 95 15 lpm 1 20 cps 3 on dispenses over one gallon 25 cc pulse 250 psi 1 7 MPa 17 bar 1
44. noid J6 5 ground ring terminal ground 24 VDC power 198557 ground Main PCB to 4 pin bulkhead 1B E meter signal ring terminal J11 4 24 VDC power i 198557 i J11 5 ground Main PCB to 4 pin bulkhead 2B J11 6 meter signal ring terminal ground J11 1 24 VDC power l 198557 J11 2 ground Main PCB to 4 pin bulkhead 3B J11 3 meter signal ring terminal ground 116726 R ground Main PCB to 3 pin printer bulkhead RS485_B Main board to ground front panel DSRI VCC 197835 J1 1 Swi black key switch Front panel to key switch J1 2 SW2 red key switch 309301G 57 Service Fluid Panel Wiring Chart Connection Harness Connector Pin Color Function orange white 198426 bala Control box to fluid blue panel 1A 2A 3A black red shield 198427 Control box to fluid panel 1B 2B 3B white shield 2POS SW NC 2 orange 2POS SW NO 3 orange Start PB X1 orange Start PB NO 4 brown 2POS SW NO 4 brown 116669 Stop PB NC 1 brown green Remote operator Start PB NO 3 white station Start PB X2 black green Ground Lug green Stop PB NC 2 red F11 Stop PB NC 1 blue F12 Ground Lug shield stop PB NC 2 2POS SW NC 1 blue jumper 309301G 309301G Fluid Panel Wiring Chart Service Harness 244660 Fluid panel junction box Terminal block 5 amp 6 are bridged Terminal block 7 amp 8 are bridged Used for 244599 244600 2446
45. r Part No 244292 246190 Manual No 308778 309834 Dispense Valve Part No 205612 205612 205612 Manual No 306715 306715 306715 Parts List Page No 69 70 71 ProDispense Controller Part No 244561 Parts List Page No 62 Remote Operator Station Part No 116669 4 309301G Conventions Conventions The following conventions are used in this manual to help guide you through the information A N WO8 Warning Symbols The warning symbol alerts you to the possibility of serious injury or death if you do not follow the instructions Symbols such as fire explosion or electric shock hazard shown at left alert you to the spe cific hazard Read the main Warnings on pages 6 7 for detailed information about the hazard indicated A Caution Symbol The caution symbol alerts you to the possibility of equipment or property damage or to opera tion errors if you do not follow the instructions Amount 20 qts Recipe ID 1 Enter the ID number 309301G Note Symbol The note symbol is used to call your attention to additional helpful information e Italicized text in a screen diagram indicates the text may vary according to how the sys tem parameters have been configured For example the units of measure shown in the manual may be qts quarts The units you see on your screen may be pounds kilograms quarts gallons or liters e A shaded box is used to indicate a
46. rator station The dispense will stop when the preset amount is reached or when the stop button is pressed on either the controller or the operator station If set to ON the fluid panel will begin dispensing immediately or when the dispense valve is triggered The dispense is stopped by releasing the trigger or turning the dispense switch to AUTO or pressing the STOP button on the operator station 17 FIG 3 12 Overview Fluid Panels There are six types of fluid panels available 244599 Oil and Lubricant Fluid Panel 244600 Water and Antifreeze Fluid Panel 244601 Grease and Paint Fluid Panel 246837 Grease and Paint Fluid Panel 246838 Meterless Fluid Panel meter supplied by user e 246839 Grease and Paint Fluid Panel There are three cable connections on the fluid panel junction box for connecting e operator station to the solenoid connection e controller to solenoid connection e controller to meter connection Signals from the controller and operator station communicate to the fluid panel s when to start and stop dispensing Signals from the fluid panel s fluid meter communicate to the con troller how much fluid has been dispensed 244599 244600 244601 C T a Controller Solenoid Connection Controller Meter Connection Operator Station Connection Junction Box Fluid Inlet Meter Solenoid Fluid Outlet Air Inlet Fluid Valve Ni A Key A B
47. re a starting point You can calibrate the meter as instructed on page 28 5 Repeat steps 1 4 for each additional fluid panel 6 Press the right arrow key Bt go to the Recipe Setup screen 27 Recipes Setup Mode Recipe Setup Screen Use recipe setup to configure your recipes by assigning a recipe number and designating Tar get Amounts for each fluid in the recipe RECIPE Fluid 1 SETUP Fluid 2 Fluid 3 Target Amount ltr ltr ltr Type in O for Target Amount if Fluid is not used in this Recipe To setup the recipes 1 Type a recipe number 1 250 2 Type the Target Amount for each fluid used in the recipe 0 999 99 6a Type in O if a fluid is not used in the recipe The units of measure are set in Fluid Setup page 27 N 3 Press the right arrow key Bi go to the Calibrate Meter screen Calibrate Meter Screen Use this screen to calibrate your fluid panel meters All values are in cubic centimeters cc Follow the additional instructions in brackets if a dispense valve is installed on the Meters dispense line CALIBRATE METER K factor Dispensed Actual cc pulse cc cc Fluid 1 04 730 0 Fluid 2 00 119 0 Fluid 3 25 000 0 1 2 Manually dispense fluid into a calibrated container minimum of 300 cc Type in Actual Value and Press ENTER System Fluids Recipes Meters 28 To calibrate a meter 1 Dispense fluid into a calibrated conta
48. rectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures 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 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax 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 This manual contains English MM 309301 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2001 Graco Inc is registered to ISO 9001 www graco com Revised 11 2009
49. rough data fields on the Run screen 309301G 29 Dispense Mode Use the Run screen to dispense a recipe or individual fluids The Run screen displays either Recipe Dispense or Fluid Dispense depending on which Dispense Mode was selected in In each of the fluid columns under the Fluid panel number is a status line which shows the status of the associated fluid panel The three possible statuses are Alarm controller has detected the fluid panel has an alarm condition To view alarm information press the right arrow key twice to move to Alarm screen Refer to page 33 Recipe Dispense Recipe Dispense displays in the Run screen if Recipe is selected as the Dispense Mode Recipe Dispense is used to dispense a set amount of fluid typically from more than one fluid panel simultaneously 1 Place the dispense lines into the receptacle s you want to dispense into Run Run Screen System setup Idle Dispense and Alarm Status Idle fluid panel is idle not dispensing Dispense fluid panel is dispensing Status line t RECIPE DISPENSE ID i Fluid 1 Fluid 2 Fluid 3 ca Idle Idle Idle Target 005 00 Itr 050 00 Itr 010 10 Itr Actual 5 00 Itr 51 00 Itr 10 00 Itr Tolerance 5 5 5 Difference 0 2 1 ORR as arms O Start DISPENSE 30 Y Dispense Switch AUTO 3 N Set the Operator Station dispense switch to AUTO Type the desired recipe number 1 250 a The Target value is set i
50. ss the STOP button on the Operator Station connected to the Ll STOP fluid panel 35 Troubleshooting Problem Cause Troubleshooting Solution Out of Tolerance Alarm Dispense is under or over tolerance limit set for the fluid Run screen shows tolerance difference for last dispense Use the value to determine whether you should e Increase the tolerance value Model 244601 only increase fluid flow by further opening the dispense valve turn the t handle clockwise e Increase or decrease fluid flow rate of the fluid supply Dispense Timeout Alarm The dispense did not complete within set Dispense Timeout value Check the following Fluid supply container is not empty Fluid supply equipment is not faulty Fluid flow rate is sufficient e Timeout value is too low and needs increase Fluid line is not clogged e Solenoids are operating Model 244601 only solenoid is receiv ing air and dispense valve is open Cables are properly connected e Meters are operating and communicating with controller Dispense valves are operating Service equipment as needed Invalid K factor Alarm Meter K factor is set to zero 00 000 Set valid meter K factor page 27 Memory Failure Alarm The system is not configured Enter setup values page 25 The memory is corrupt Replace flash EPROM No display No power Turn on or reconnect power
51. tch to ON and trigger the dis aa Ispense 7 sie Switch ON pense valve Oy START 3 Turn the dispense switch to AUTO or release the dispense valve trigger to stop dispens ing Automatic Dispense Refer to page 30 for instructions on dispensing a recipe or page 31 to dispense individual fluids 34 309301G Operation Procedures Purging Fluid Follow this procedure to purge the fluid lines 1 Connect the fluid supply line to a solvent supply Set the fluid supply pressure as low as possible to avoid splashing To begin purging the lines direct the fluid outlet into a grounded metal pail turn the Oper ator Station dispense switch to ON and trigger the dispense valve Continue dispensing until fluid lines are clean Turn the dispense switch to AUTO or release the dispense valve trigger to stop dispens ing If you are loading a new material connect the fluid supply line to the new fluid supply and follow the procedure for Loading Fluid Lines Emergency Stop To stop fluid flow at all the fluid panels connected to the RECIPE DISPENSE ISS controller press the Stop button on the controller Fluid 1 Fluid 2 Fluid 3 Idle Idle Idle Target 005 00 Itr 050 00 Itr 010 10 Itr Actual 000 00 Itr 000 00 Itr 000 00 Itr Tolerance 5 5 5 Difference 98 99 97 ORR oa arms Q O DISPENSE AUTO ON o DISPENSE START 309301G To stop fluid flow at an individual fluid panel pre
52. uid stops flowing and pressure is relieved release the dispense valve trigger and turn the dispense switch to AUTO to stop dispensing Repeat the process for each fluid panel as needed Follow this procedure before servicing the equipment and to avoid having fluid dry in the equipment and fluid lines when the equipment is not being operated 1 Purge the system until it is clean page 35 2 Relieve the pressure as instructed above 3 Turn off the ProDispense controller power switch 309301G Setup Mode Screen Navigation D To enter Setup Mode iN You must have the key supplied with the system Insert the key into the switch and turn it to ia Setup Mode gg The System Setup screen appears Setup Mode abort the dispense Do not turn the key to Setup Mode while the ProDispense is dispensing or the system will Day Month Year Hour Minute Language 1 English 2 Spanish 3 German 4 French 5 Japanese SYSTEM SETUP Dispense Mode 1 Fluid Station 2 Recipe Recipe Selection 1 User Interface 2 Network Station Number Recipes Meters System Fluids current screen System Setup Screen 4screen selections The name of the screen that is currently displayed is highlighted Q Press the left or right arrow keys on the keypad to move through the screens O O Press the up or down arrow keys to move through data fields on the screen
53. ulse 3000 psi 21 MPa 207 bar 120 psi 0 8 MPa 8 bar 3 4 npt f 309301G Accessories and Kits Wetted Parts 244599 eink ba bali ea dan ten Oe aluminum carbon steel bronze buna N stainless steel 244600 doc brass stainless steel polyimide polypropylene EPDM o ring aluminum buna N carbon steel MAGO occ 303 400 series and 416 stainless steel Tungsten carbide PTFE carbon steel chrome nylon UHMWPE leather ProDispense and EasyKey are trademarks of Graco Inc Accessories and Kits Part Number Description 239873 Printer kit 514037 Printer paper roll 198669 Printer cable 50 ft 15 24 m 197902 Paint Shield For display screen package of 10 198456 Remote Station Extension Cable 20 ft 6 1 m 245248 Software Upgrade Kit for Main PCB Includes main PCB chip with software upgrade chip extractor and grounding strap 244840 Software Upgrade Kit for Display PCB Includes display PCB chip chip extractor and grounding strap 309301G 73 Graco Standard Warranty Graco warrants all equipment 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 equ
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