Gusmer-Decker RC Polyurethane Processing Equipment

Transcription

1 Operation - Maintenance Gusmer-Decker RC Polyurethane Processing Equipment G ENG For dispensing controlled ratio shots of resin and isocyanate. For professional use only. Not approved for use in European explosive atmosphere locations psi (21 MPa, 207 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this and all supplied manuals. Save these instructions. See page 4 for product configuration information. ti11588b Shown without Hoses

2 Contents Models...3 Related Manuals...3 Product Configurator...4 Warnings...7 Isocyanate Hazard...9 Material Self-ignition...9 Moisture Sensitivity of Isocyanates...9 Keep Components A and B Separate...9 Foam Resins with 245 fa Blowing Agents...9 Changing Materials...9 Component Identification...11 Typical Installation...11 Main System Parts List...11 System Schematic...12 Main Panel...15 Human Machine Interface (HMI) Screens MixHead Hydraulic Unit...32 Tanks...34 Pumpline...36 Temperature Control...37 Other Components...38 Optional Variable Frequency Drive...39 Setup...41 MixHead Hoses...42 MixHead Hydraulic Unit Hoses...43 Connecting Electrical Cord...44 Day Tanks...45 Hydraulic System...45 Optional Boom...45 Optional Press or Simple Interface Manual Mode Pouring with Press Interface Automatic Mode Pouring with Press Interface. 47 Pouring using Press Interface Signals New Machine Maintenance...48 Start-Up...49 MixHead Hydraulic Unit Motor...49 Pumpline...50 Pouring Operation...51 Low and High Pressure Circulation...51 Pour Pendant...51 Manual Mode...51 Automatic Mode...52 Pouring Requirements...52 Beginning the Pour...52 Night Mode Operation...53 Starting Night Mode...53 Requirements for Continuing Night Mode...53 Shutdown...54 Overnight/Weekend...54 Long-Term Shutdown...54 Settings...56 Calibrate Mode...56 Temperature Control...56 Pouring Settings...58 MixHead Settings...59 Chemical Flow Settings...60 Day Tank Settings...61 Flow Measurement Controls...62 Pressure Relief Procedure...66 Air Pressure Relief...66 Hydraulic Pressure Relief...66 Chemical Line Pressure Relief...66 Maintenance...68 Schedule...68 Purge Air from Metering Pump...68 Drain the Water Separator...68 Check Desiccant...68 Replace Desiccant...68 Check/Replace Metering Pump Inlet Filter...69 Check the Accumulator Pre-Charge...69 Pre-Charge the Accumulator...70 Check Tightness of all Clamps and Fittings Check Hoses for Wear...70 Check, Adjust Automatic Unloading Valve Pressure Limits...70 Check Hydraulic Fluid and Filter...71 Replace Hydraulic Fluid and Filter...71 Replace the PLC battery...71 Empty the Day Tank...71 Troubleshooting...74 Alarm Status Screen...74 Alarm History Screen...75 Alarms List...75 Troubleshooting Chart...78 Technical Data...80 Dimensions...81 Graco Ohio Standard Warranty...82 Graco Ohio Information G

3 Models Models Model Voltage Amps RC-20 RC-40 RC-100 See Connecting Electrical Cord, page 44, for cord specifications. Related Manuals Frequency (Hz) Phase Maximum Working Pressure, psi (MPa, bar) (21, 207) (21, 207) or (21, 207) (21, 207) (21, 207) or (21, 207) (21, 207) (21, 207) or (21, 207) Gusmer-Decker RC Manuals Part Description Gusmer-Decker RC Operation Gusmer-Decker RC Repair and Parts Gusmer-Decker RC Electrical Diagrams MixHead Manuals Part Description S-Head Operation and Maintenance L-Head Operation and Maintenance Auto-Fill Manuals Part Description Husky 1040 Air-Operated Diaphragm Pumps Feed Pump Kits T2 2:1 Ratio Transfer Pump Flow Meter Manuals Part Description Volumetric Fluid Flow Meter (Part G only) Ball Seat Applicator Manual Part Description Ball Seat Applicator Air Regulator Manual Part Description Low Volume Air Regulators G 3

4 Product Configurator Product Configurator This system can be ordered with many different options as shown in the configurator below. RC-C-A-B-C-D-E-F- G -H- I -J-K-L-M-N-O-P-Q- R -S-TU-VW-XY-AA-AB CSA Approval Poly Needle/Orifice Kit for MixHead #2 Iso Needle/Orifice Kit for MixHead #2 Poly Needle/Orifice Kit for MIxHead #1 Iso Needle/Orifice Kit for MixHead #1 MixHead #2 Dual Switching Station with Hose Package and Pour Pendant Auto-Fill Poly Tank Agitation Iso Tank Agitation Volumetric Flow Meters Heating System Stand Alone Chiller Pour Pendant MixHead #1 Hose Kit MixHead #1 Day Tanks Iso/Poly Pumpline Variable Frequency Drive Kits Poly Lube Kit Poly Pumpline Iso Lube Kit Iso Pumpline Voltage/Fuse Package Base Unit Module Configurator Series Level The following table applies to the RC configurations and indicates all of the options available for each letter shown above. Code A Base Unit Module 2 Base, 20 lb/min (151 grams/sec) 3 Base, 40 lb/min (302 grams/sec) 4 Base, 100lb/min (756 grams/sec) Code B Voltage/Fuse Package A RC 20/40 230V 3PH B RC 20/ V 3PH C RC 20/ V 3PH E RC V 3PH F RC V 3PH G RC V 3PH Code C Iso Pumpline 1 5 hp, 900 rpm, 5 cc 2 5 hp, 1800 rpm, 5 cc 3 15 hp, 1800 rpm, 12 cc 4 5hp,MAGdrive,900rpm,5cc 5 5 hp, MAG drive, 1800 rpm, 5 cc 6 15 hp, MAG drive, 1800 rpm, 12 cc Code D Iso Lube Kit N None A Static Lube Kit B Seal Flush Kit Code E Poly Pumpline 1 5 hp, 900 rpm, 5 cc 2 5 hp, 1800 rpm, 5 cc 3 15 hp, 1800 rpm, 12 cc 4 5hp,MAGdrive,900rpm,5cc 5 5 hp, MAG drive, 1800 rpm, 5 cc 6 15 hp, MAG drive, 1800 rpm, 12 cc Code F N A B Code G None Static Lube Kit Seal Flush Kit 1 5 cc 230V VFD Kit 2 5 cc V VFD Kit 3 12 cc 230V VFD Kit 4 12 cc V VFD Kit 5 Contactor Kit - No VFD Poly Lube Kit Iso/Poly Pumpline Variable Frequency Drive Kits G

5 Product Configurator Code H Day Tanks, 20 gal (75.7 L) A B C D E F G H Mild Steel, with 40 mesh, standard Mild Steel, with 40 mesh, placite Mild Steel, with 60 mesh, standard Mild Steel, with 60 mesh, placite Mild Steel, with 80 mesh, standard Mild Steel, with 80 mesh, placite Mild Steel, with 100 mesh, standard Mild Steel, with 100 mesh, placite Code I MixHead #1 N None 1 L-Head 5/8 with Calibration Orifice Kit 2 L-Head 6/10 with Calibration Orifice Kit 3 L-Head 10/14 with Calibration Orifice Kit 4 L-Head 13/20 with Calibration Orifice Kit 5 L-Head 16/25 with Calibration Orifice Kit 6 S-Head with Calibration Orifice Kit 7 S-Head with Calibration Orifice Kit 9 S-Head L/S with Calibration Orifice Kit A Code J N A B C D E F G H Code K N Code L N B C D F G H S-Head L/S with Calibration Orifice Kit None MixHead #1 Hose Kit L-Head Hose Kit, 15 ft, with Boom S-Head Hose Kit, 15 ft, with Boom L-Head Hose Kit, 15 ft, without Boom S-Head Hose Kit, 15 ft, without Boom L-Head Hose Kit, 25 ft, without Boom S-Head Hose Kit, 25 ft, without Boom L-Head Hose Kit, 40 ft, without Boom S-Head Hose Kit, 40 ft, without Boom Pour Pendant Standard Pour Pendant, 20 meter cable (included in Base Unit Module, Code A) Stand Alone Chiller None 1PH, 230V, 1 ton 1PH, 230V, 2 ton 3PH, 230V, 3 ton 3PH, 460V/2.5 ton, 400V/2.0 ton 3PH, 460V/3.5 ton, 400V/3.0 ton 3PH, 460V/5.0 ton, 400V/4.5 ton Code M Heating System N None 1 Heater Assembly, Iso & Poly Code N N A B C Code O Volumetric Flow Meters None Set of 2 with controls, 20 lb/min (151 grams/sec) or 40 lb/min (302 grams/sec), gpm ( lpm) Set of 2 with controls, 20 lb/min (151 grams/sec) or 40 lb/min (302 grams/sec), gpm ( lpm) Set of 2 with controls, 100 lb/min (756 grams/sec) Iso Tank Agitation N None 1 Agitator pre-wire kit, no motor 2 Fixed speed agitator, V 3 Variable Speed Agitator, 230V, iso 4 Variable Speed Agitator, V, iso Code P Poly Tank Agitation N None 1 Agitator pre-wire kit, no motor 2 Fixed speed agitator, V 3 Variable Speed Agitator, 230V, poly 4 Variable Speed Agitator, V, poly Code Q N A B C Code R Auto-Fill None Auto-Fill controls, no pumps Auto-Fill controls with two (2) diaphragm pumps Auto-Fill controls with two (2) 2:1 stick pumps Dual Switching Station with Hose Package and Pour Pendant N None 1 Dual Switching Station for 2nd L-Head, 15 ft 2 Dual Switching Station for 2nd S-Head, 15 ft 3 Dual Switching Station for 2nd L-Head, 25 ft 4 Dual Switching Station for 2nd S-Head, 25 ft 5 Dual Switching Station for 2nd L-Head, 40 ft 6 Dual Switching Station for 2nd S-Head, 40 ft G 5

6 Product Configurator Code S MixHead #2 N None 1 L-Head 5/8 with Calibration Orifice Kit 2 L-Head 6/10 with Calibration Orifice Kit 3 L-Head 10/14 with Calibration Orifice Kit 4 L-Head 13/20 with Calibration Orifice Kit 5 L-Head 16/25 with Calibration Orifice Kit 6 S-Head with Calibration Orifice Kit 7 S-Head with Calibration Orifice Kit 9 S-Head L/S with Calibration Orifice Kit A Codes TU, VW, XY, AA S-Head L/S with Calibration Orifice Kit NN None 00 Calibration Orifice 0A B D E G H J K L M A B C D E G J L M N P Q S 1.90 Needle/Orifice Size Kits; Orifice Size (mm) 2A E F A C F G A C F A F G A F A 7.00 Code AB NC CA Needle/Orifice Size Kits (continued) CSA Approval No CSA Approval Required CSA Approval Required G

7 Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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. DANGER HIGH VOLTAGE ELECTRIC SHOCK HAZARD Contact with high voltage equipment and improper grounding, setup, or usage of the system can cause death or serious injury. Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment. This equipment must be grounded. Connect only to grounded power source. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. WARNING TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. Read MSDS s to know the specific hazards of the fluids you are using. Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. Always wear impervious gloves when spraying or cleaning equipment. 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 Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection SKIN INJECTION HAZARD High-pressure fluid from dispense valve, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. Do not point dispense valve at anyone or at any part of the body. Do not put your hand over the end of the dispense nozzle. Do not stop or deflect leaks with your hand, body, glove, or rag. Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. PRESSURIZED EQUIPMENT HAZARD Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. Tighten all fluid connections before operating the equipment. Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately G 7

8 Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: Use and clean equipment only in well ventilated area. Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). Keep work area free of debris, including solvent, rags and gasoline. Do not plug or unplug power cords or turn lights on or off when flammable fumes are present. Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions. Use only Graco grounded hoses. Check gun resistance daily. If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from system. Keep a working fire extinguisher in the work area. PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. Do not operate the unit when fatigued or under the influence of drugs or alcohol. Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer s warnings. For complete information about your material, request MSDS forms from distributor or retailer. Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer 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. MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts. Keep clear of moving parts. Do not operate equipment with protective guards or covers removed. Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply. BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely G

9 Isocyanate Hazard Isocyanate Hazard Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area. To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area. Material Self-ignition Some materials may become self-igniting if applied too thickly. Read material manufacturer s warnings and material MSDS. Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts. The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature. To prevent exposing ISO to moisture: Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container. Keep the ISO lube pump reservoir (if installed) filled with Graco Throat Seal Liquid (TSL), Part The lubricant creates a barrier between the ISO and the atmosphere. Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system. Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use. Never use solvent on one side if it has been contaminated from the other side. Always lubricate threaded parts with ISO pump oil or grease when reassembling. Keep Components A and B Separate CAUTION To prevent cross-contamination of the equipment s wetted parts, never interchange component A (isocyanate) and component B (resin) parts. Foam Resins with 245 fa Blowing Agents New foam blowing agents will froth at temperatures above 90 F (33 C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system. Changing Materials When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. Always clean the fluid inlet strainers after flushing. Check with your material manufacturer for chemical compatibility. Most materials use ISO on the A side, but some use ISO on the B side. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side G 9

10 Changing Materials G

11 Component Identification Component Identification Typical Installation ti11590b ti11591b FIG. 1 Main System Parts List Ref Description 101 Base Unit 102 Iso Pumpline 103 Poly Pumpline 104 Tanks 105 MixHead Ref Description 106 Temperature Control System 107 Volumetric Flow Meters (optional) 108 Poly Tank Agitator (optional) 109 Boom 110 Main Panel 111 MixHead Hydraulic Unit G 11

12 Component Identification System Schematic A B C D G

13 Component Identification A B C D G 13

14 Component Identification G

15 Component Identification Main Panel AH AJ AK AD AA AE AF 1 AG 1 Only installed if the machine has a variable speed agitator for that chemical. AB AK FIG. 2 1 AC ti11592b Key: AA Alarm Horn AB Main Power Indicator AC Iso Agitator Speed Control Turn-Dial AD Human Machine Interface (HMI) AE Emergency Stop Safety Emergency Stop There is one Emergency Stop located at the main electric console and one Emergency Stop at the end of each installed pour pendant; see FIG. 2 and FIG. 23. Pushing any Emergency Stop will turn off control power and stop all motors. The Emergency Stops stay in position when hit, so before control power can be turned on they must be reset by twisting and pulling out. AF Control Power Push-button/Indicator AG Poly Agitator Speed Control Turn-Dial AH Main Power Lockout Bar AJ Main Power Switch AK Main Panel Vents Lockout A lockout has been provided to lock the main power off and to lock the main panel door closed. To lockout the machine, first turn the machine off by turning the main handle to the off position. Then, while wiggling the power handle, pull out the horizontal black bar on the handle. While holding the bar in the out position, insert a padlock through the open area in the bar and lock G 15

16 Component Identification Human Machine Interface (HMI) Screens When main power is turned on, the HMI will automatically turn on. Main Menu Screen BC BA BS BB BD 4 BE 3 BF BG BH 6 BJ BK BL BM BN BP BR Screen is only accessible when logged in as one of the Supervisor usernames. If not logged in this button will appear as a key image, noting that screen access is password protected. Flow Control button is only visible if Flow Meters are installed. Shown on all screens. When two MixHeads are installed, the Last Shot Data will have two columns of information. Button is used to gain access to the Options Select screen where machine configuration is entered. This screen is only accessible to Graco personnel. Screen is only accessible if temperature control or auto-fill is installed. FIG. 3 Key: BA Set System Clock BB Login/Logout BC Current Alarm Status BD Last Shot Data BE Screen Access buttons section BF Main Menu screen access BG Status screen access BH Machine Control screen access BJ Tank Control screen access BK Pour Time Editor screen access BL Setup screen access BM Flow Control screen access BN Scaling screen access BP Alarm HIstory screen access BR Alarm Status screen access BS Display System Info Last Shot Data The control system records the actual shot time after the shot has occurred. The control system also captures the flow rates and ratio for the last shot. The flow rate is captured shortly after the shot begins G

17 Component Identification Login/Logout To gain access to certain screens, the user must be logged in with an appropriate username and password. There are two levels of passwords for customers and one for Graco personnel. Logging in as any of the Maintenance usernames will allow access to the Pump Calibration screen. Logging in as any of the Supervisor usernames will allow the user to change the default setting of the MixHead cleanout piston to normally open or normally closed, as well as the ability to change the screen language, temperature units, passwords, and access to the Temperature Log/Gain and Scaling screens. The Factory user names are for Graco personnel only. Setting the System Clock To adjust the system clock, first turn on main power and then control power. When the HMI finishes loading the Main Menu screen, select Set System Clock. Then select each date and time button in the PanelView Clock/Calendar screen to enter the current information. There will be a short delay between hitting the return arrow and the new information being displayed on the PanelView screen. Enter the hour item as the 24-hour time. For example, 1 PM is entered as 13. The machine will automatically convert the time in the upper left corner of the screen to display the appropriate AM/PM time. Key Icon When a screen is not accessible to the current user, the text in the screen access button on the bottom of the screen will be replaced with a key icon. To access a screen that is currently inaccessible, log in as the appropriate username then press the desired screen access button G 17

18 Component Identification Status Screen In the figure below, only the Iso side has been labeled. The items on the Poly side are the same as those on the Iso side. 1 CB 5 CC 6 CD CS 8 CQ CE 3 9 CR 3 CE CL 1 2 CF CG CH CM 7 1 CJ CN CP 7 7 A CK FIG A 4 Status is indicated by a red background and the word OFF or a green background and the word ON The path the fluid follows is indicated by these lines. When the line is gray, no fluid is in that section. When it is colored, there is fluid passing through that section. The color indicates whether the chemical is being cooled. Blue is cooling, gray is not cooling. Red indicates heating, black indicates no action. The approximate current fluid level is shown on the screen. Gray indicates no action, red for iso or blue for poly indicates refilling. Also shown on the Machine Control screen. Only if MAG drive is installed for that chemical. Shown on all screens. CA Shown only if Flow Meters are installed. Key: CA Heater CB Agitator Status CC Tank Level CD Auto-Fill CE Heat Exchanger CF Metering Pump Motor CG Fluid Flow CH Circulation Valve CJ MixHead Hydraulic Unit Status CK Flowrate (grams per second) CL MixHead Piston Position Rectangles CM Calibrate mode CN Automatic mode CP Manual mode CQ MAG drive temperature CR Fault Status CS Night Mode Status G

19 Component Identification Manual, Automatic, Calibrate Modes With control power on, any of these three modes can be selected. When a certain mode is selected, the related button will turn green. System Status Indicators The status of all system conditions is shown. This includes various temperatures and pressures throughout the system. The relative position of these sensors is shown schematically on the screen. Other system indicators include motor status, tank level, temperature control and, if installed, auto-fill status. MixHead Status Indicators The Status Screen includes several indicators that show machine operation status. MixHead Pour Ready Indicator shows green when all requirements are made for beginning a pour besides pressing the start button. MixHead In Cycle Indicator shows green when a pour has been started and the controls are in the stages of a pouring operation MixHead Pouring Indicator Shows green when the control system has commanded a pour. This occurs regardless of whether the MixHead is turned on or off. Cleaning Piston Open Indicator top rectangle of the three shown green when the cleaning piston is open Cleaning Piston Closed Indicator middle rectangle of the three shown green when the cleaning piston is closed Material Piston Open indicator bottom rectangle of the three shown green when the material piston is open G 19

20 Component Identification Machine Control Screen 1 DD 1 DD 2 DA DE DB DC DD 3 DF Buttons shown only if the machine has an agitator installed for that chemical. Only shown when low level option is enabled. Shown only if Flow Meters are installed. FIG. 5 Key: DA Low Level Bypass On/Off Control DB MixHead Hydraulic Motor Start/Stop DC MixHead Control screen access DD Iso/Poly Agitator Motor Start/Stop DE Night Mode On/Off DF Flow Information Motors Start and Stop Buttons These buttons control whether a specific motor is running and the current status of each motor will be displayed below each set of buttons. The Iso and Poly metering pump motors cannot be started when the MixHead Hydraulic Motor is off. This protects from fluid spill that could occur if chemicals were to flow through the MixHead without the material piston held shut by hydraulic pressure. System Outlet Conditions Data The data along the bottom of the screen for flow, ratio, and temperature display the machine's outlet conditions G

21 Component Identification MixHead Control Screen SA SB 1 SH SC SD SE SF 2 SG MixHead #2 section of screen only shown if second MIxHead is installed. Only shown if L-Head is installed. Only shown if logged in as one of the Supervisor usernames. FIG. 6 Key: SA MixHead Off SB MixHead On SC Current pendant channel selected SD Preset time for current channel SE Cleanout piston normally closed selection SF Cleanout piston normally open selection SG Current default status of cleanout piston SH MixHead #2 section Normally Open/Closed The cleanout piston default state is determined by whether normally open or normally closed is selected on the MixHead Control screen. Normally open means that when the machine is not pouring the cleanout piston will be open and normally closed is the opposite G 21

22 Component Identification Tank Control Screen 2 2 EH EC ED EE EB 1 EF 1 EA 1 EG 3 FIG Buttons only shown if Auto-Fill is installed. Only shown if Temperature Control is installed. Button only shown if temperature control or auto-fill is installed. Key: EA Auto-Fill On/Off EB Ideal Temperature Setpoint EC Temperature Control On/Off ED High Temperature Alarm Setpoint EE Low Temperature Alarm Setpoint EF Fail to Fill Alarm Delay EG Fill Delay EH Actual Temperature Iso, Poly Temperature Control The temperature control portion of the screen is identical for Iso and Poly streams. The heading above each area displays the current chemical temperature. Temperature Control On/Off and Indicators These buttons are used to turn temperature control on or off. When a metering pump motor is on and the associated temperature control is on the indicator below will indicate ON and when it is off it will indicate OFF. When temperature control is on but the associated metering pump motor is off, the indicator below will show Permitted. If the temperature control is off for any reason, the indicator will display not permitted to show that the temperature control will not turn on when the metering pump motor is turned on G

23 Component Identification Pour Time Editor Screen 1 FB FA FC FD FE FF Shown only if machine is set-up to use Press Interface Shown only if a second MixHead is installed. Press button to select which MixHead timers to edit. FIG. 8 Key: FA Preset Pour Timers, seconds duration FB Press Interface Automatic Mode Pour Time FC First Group FD Previous Group FE Next Group FF Last Group The Pour Time Editor screen allows entry of a pour time preset for each of the 99 available channels. To access different groups of presets, push the First Group, Prev Group, Next Group, and Last Group buttons. To change a particular pour time preset, select that button and enter the new time. TIMER # is the channel number shown on the status screen. The selected channel, or timer, can be changed using only the pour pendant, if installed G 23

24 Component Identification Setup Screen GC 2 GG GB 2 GH GA 1 GE GF 1 GD 1 2 Only shown if L-Head installed. Only shown if logged in as one of the Supervisor username. FIG. 9 Key: GA Pressure Build Time GB Night Mode On/Off Time GC Iso, Poly Specify Gravity GD Cleanout Delay setting GE Cleanout Extend Time setting GF Pressure Hold Time GG Screen Setup screen access GH Password Setup screen access See Settings section on page 56 for more information. Night Mode On/Off Time See Night Mode Operation on page 53 for more information G

25 Component Identification Screen Setup Screen This screen is accessible from the Setup screen but only when logged in as one of the Supervisor usernames. TA TB TC FIG. 10 Key: TA Language Selection TB Temperature Units Selection TC Current Temperature Units Selection Language Selection To select a language press and hold the desired language button for about three seconds. The text on all of the screens will slowly change to the new language within about 30 seconds. Temperature Units Selection To have temperature information displayed in Celsius or Fahrenheit, press the appropriate button G 25

26 Component Identification Password Setup Screen This screen is accessible from the Setup screen but only when logged in as one of the Supervisor usernames. UA UB FIG. 11 Key: UA Username UB Password Usernames To change a username, select a username and type the new name. Regardless of the names for each user, the top four names listed will have Maintenance level access and the bottom three will have Supervisor level access. Changing Passwords To change one of the existing passwords, touch the password and enter the new password in the new window G

27 Component Identification Flow Control Screen This screen is only available if Flow Meters are installed. HB HA HK HM HL HJ HP HC HH HD 1 2 HN HE HF HG Only shown if logged in as one of the Maintenance or Supervisor usernames. Only shown if Variable Frequency Drives are installed. Only shown if second MixHead is installed. FIG. 12 Key: HA Manual Flow Control HB Automatic Flow Control HC Total Flow Rate Warning/Shutdown Tolerance (percent) HD Flow Ratio Warning/Shutdown Tolerance (percent) HE Iso Flow (grams per second) HF Total Flow (grams per second) HG Poly Flow (grams per second) Manual Flow Control Enables use of the Manual Mode Motor Percent Setpoints. When in Manual mode, motor speed remains constant. Automatic Flow Control Enables use of the Automatic Mode Setpoints and machine will continually adjust motor speeds to meet setpoints. HH Flow Ratio HJ Manual Mode Poly Motor RPM Setpoint HK Manual Mode Iso Motor RPM Setpoint HL Automatic Mode Ratio Setpoint (Poly divided by Iso) HM Automatic Mode Total Flow Setpoint (grams per second) HN Pump Calibration screen access HP MixHead #2 Flow Control section Flow Rate/Ratio Warning/Shutdown Tolerance Allowable error in flow rate/ratio when automatic mode is enabled for flow control. When outside the warning range, an alarm will be displayed. When outside the shutdown range, the MixHead will not shoot G 27

28 Component Identification Pump Calibration Screen This screen is accessible from the Flow Control screen but only if logged in as one of the Maintenance or Supervisor usernames and Variable Frequency Drives are installed. VA VB VD VC VE VF VG FIG. 13 Key: VA MixHead Number selection VB Iso Hi Speed Calibration Setpoint Percent VC Iso Low Speed Calibration Setpoint Percent VD Poly High Speed Calibration Setpoint Percent VE Poly Low Speed Calibration Setpoint Percent VF Start Calibration VG Stop Calibration High/Low Speed Calibration Percent This is the high and low calibration speeds that will be used when the Start Calibration button is pressed. Start/Stop Calibration Pressing the Start Calibration button will calibrate the motor speed to the flow rate input on the Flow Control screen. The motors will spin at high speed for one minute then at low speed for one minute. If at any time the calibration needs to stop, press the Stop Calibration button or hit the Emergency Stop G

29 Component Identification Scaling Screen This screen is only accessible when logged in as one of the Supervisor usernames. JK JA JB JJ JL JC JD JE JG JH JF FIG. 14: This screen is for qualified technicians only and is password protected. Key: JA Current K Factor Value JB Test Shot Actual Weight (grams) JC Iso Calibration Shot start button JD Poly Calibration Shot start button JE Calibration Shot stop button JF Temperature Log/Gains screen access JG Flowrate Filter On/Off JH Last Shot Data JJ Calculate New K Factor button JK Flow Meter Reading (grams per second) JL Test Flowrate (grams per second) See Calibrating Machine-Calculated Mass Flow on page 64 for more information. Flowrate Filter The flowrate input and display may be filtered to provide a more stable display of flow rate by turning the filter ON. Instantaneous flow rate changes are displayed with the filter turned off G 29

30 Component Identification Temperature Log/Gains Screen This screen is accessible from the Scaling screen. KM KL KK KA KJ KB KC KD KE KF KG KH FIG. 15: This screen is for qualified technicians only and is password protected. Key: KA Up Scale KB Down Scale KC Pen KD Move Left KE Home KF End KG Pause KH Move Right KJ Poly Heat Gain KK Poly Cool Gain KL Iso Heat Gain KM Iso Cool Gain See Temperature Gains section on page G

31 Component Identification Alarm History and Alarm Status Screens See Troubleshooting section on page 74 for Alarm screens details G 31

32 Component Identification MixHead Hydraulic Unit LB LA LC LD LE LF LG LH LJ LK ti11593b FIG. 16: MixHead Hydraulic Unit Key: LA Accumulator LB Motor LC Hydraulic Fluid Filter Gauge LD Hydraulic Filter Cap LE Automatic Unloading Valve LF Hydraulic Pressure Gauge LG Directional Valves LH Manual Unloading Valve LJ Hydraulic Tank Fluid Level Sight Gauge LK Hydraulic Tank The MixHead hydraulic unit is designed to operate the MixHead pistons at a sufficient pressure to overcome sticking and at a sufficient speed to ensure proper mixing. It is the accumulator that actually opens the Mix- Head while the power pack recharges the accumulator. Because of this a sufficient time for recharging must be allowed between each discharge of the accumulator. A minimum of 5 seconds between shots is recommended. To protect against mechanical failure of the hydraulic unit components, an electric over pressure switch is installed in the pressure line, see table at the beginning of the Settings section on page 56 for switch setting. This limit switch will shut down the hydraulic motor and be accompanied by alarms. In this event, the cleaning piston maintains its position. The accumulator pre-charge automatically positions the MixHead material piston G

33 Component Identification There is also a low-pressure switch and a temperature limit switch in the hydraulic reservoir, see table at the beginning of the Settings section on page 56 for switch settings. The more frequent the shots the more heat generated by the system. This limit switch will shut down the hydraulic motor and trigger an alarm. The component that controls the high and low hydraulic pressure limits is the automatic unloading valve. This dual acting valve has two separate settings: one to define the upper operating pressure limit and the other to define the lower operating pressure limit. When the accumulator is charged to the maximum limit, the automatic unloading valve diverts pump flow to the circulation line. During this circulation, pressure is maintained in the accumulator by a check valve in the unloading valve. When the accumulator is below the upper limit, the unloading valve automatically directs flow to recharge the accumulator. See table at the beginning of the Settings section on page 56 for factory automatic unloading valve settings. A low-pressure switch is also provided to prevent failures in the event the hydraulic pressure is not sufficient to open the MixHead. When tripped, this limit switch will prevent the MixHead from opening and will trigger an alarm. See table at the beginning of the Settings section on page 56 for switch setting. The success of any hydraulic system is dependent on the quality and maintenance of the hydraulic fluid. A return line filter is provided to maintain the fluid and assure the reliable operation of the unloading and directional valves. See Maintenance section on page 68. Directional Valve (if L-Head installed) The directional valve controls the directional movement of the cleaning piston and material piston in the L-Head. If electricity is interrupted by a power failure, fault or an Emergency Stop, the cleaning piston will remain open or closed. The material piston will default to closed position G 33

34 Component Identification Tanks MB MC MC MK MB MD MA ME ME MF MG MJ FIG. 17 ML MJ MH ti11594b Key: MA Tank MB Pressure Relief and Manual Vent Valve MC Pressure Gauge and Regulator MD Level Sensor ME Metering Pump Inlet Filter MF Desiccant Dryer MG Water Separator MH Tank Fluid Level Sight Gauge MJ Tank Outlet Ball Valve MK Day Tank Incoming Air Valve ML Tank Drain Ball Valve CAUTION Relieving tank pressure may introduce moist air into the system causing crystallization and damage to the machine. The pumps must never be run dry. If the metering pump is not properly supplied with fluid and pressure during operation, cavitation will result. This will damage the pump and will lead to an off ratio condition. To ensure proper supply of material to the MixHead, the machine includes temperature conditioned and pressurized day tanks. Temperature conditioning is accomplished by circulating the chemicals through a heat exchanger and optional heater in the return line to tank. The operator-selected temperature is maintained by the program G

35 Component Identification To assure adequate chemical pressure at the inlet to the metering pump, the tank must be pressurized with dry air to the specification listed in the table at the beginning of the Settings section on page 56. The fluid level in the tank must be manually maintained between 60% to 90% full to assure proper temperature and aeration control, unless the optional Auto-Fill system is installed. A tank fluid level sight gauge (MH) is also provided. Should the pressure in a tank rise excessively while the tank is refilling, an operator adjustable pressure relief valve is provided to assist the regulator in bleeding the pressure. The recommended set point for this valve is listed in the table at the beginning of the Settings section on page 56. Level Sensor A sensitivity adjustment is provided for the level sensors to compensate for various liquid properties. Turn clockwise to increase sensitivity and counterclockwise to decrease sensitivity. Metering Pump Inlet Filter CAUTION The metering pump inlet filter prevents particulate matter from damaging the precision metering pumps. The filter element is a basket type and should it become clogged, it will cause cavitation of the pump resulting in damage to the pump. Therefore, it is necessary that the filter be properly serviced at all times. See Maintenance section on page 68. Air Pressure System The minimum recommended supplied dry air pressure is listed in the table at the beginning of the Settings section on page 56. The air supplied to the machine must be dry. To remove excess moisture and particulate matter from the shop air, a water separator is provided. For the day tanks only, a desiccant air dryer is provided to charge the day tanks. To prevent contamination of the air system by a reaction of the iso fumes with the poly fumes, the systems are isolated by means of separate check valves. Adjust Day Tank Settings See Day Tank Settings section on page 61 for more information G 35

36 Component Identification Pumpline NF NE NE NC ND ti11595b NB NA 12 cc Pump and MAG Dive Shown FIG. 18 Key: NA Pump Turn-Dial NB Metering Pump NC Metering Pump Air Purge Valve ND Metering Pump Motor NE Pressure Switches NF Relief Valve Both pumps are protected on the inlet side by a basket filter and a low-pressure switch. Day tank pressure below the setting of the Metering Pump Low Inlet Pressure switch will cause a warning alert and the affected metering pump motor will shutdown. See the table at the beginning of the Settings section on page 56 for switch setting. The pumps are protected on the outlet side by a mechanical relief valve and a pressure switch, see the table at the beginning of the Settings section on page 56 for settings. Should this pressure be exceeded, and the affected metering pump motor will automatically stop and will be accompanied by alarms. A minimum pressure switch is also provided to protect the MixHead from chemical crossover. All pressure switches and relief valves are factory set and should not be adjusted G

37 Component Identification Temperature Control PB PC PE PA PB PA Shown with MixHead Hydraulic Unit, Tanks, and Pumplines removed PD ti11596c FIG. 19 PA Heater PB Heat Exchanger PC Supplied Water Inlet PD Supplied Water Outlet PE Water Solenoid Valve Heat Exchanger The heat exchanger (PB) cools the chemical in the outlet line before moving to the MixHead. The heat exchanger is controlled by the HMI and will open and close the water inlet valves as necessary to maintain the desired fluid temperatures. Optional Stand Alone Chiller A separate, stand alone water chiller may be purchased to improve the efficiency of the heat exchanger. The function of the chiller is to cool the inlet water flowing to the heat exchanger thus cooling the material faster. Optional Heater The optional heater (PA) heats the material to the desired temperature before moving to the MixHead. Over-Temperature Switches For operation information, see Temperature Control section on page 56. For factory settings, see the table at the beginning of the Settings section on page G 37

38 Component Identification Other Components QA QA QB QC QB FIG. 20 QC QE QD ti11597b Key: QA Chemical Line Pressure Gauge QB Circulation Valve QC Flow Meter QD Air Control Valve Assembly QE Circulation Valve Override screw Circulation Valve A pneumatically operated Circulation Valve (QB) allows low pressure operation at startup and between shots. It transfers flow from the outlet of the heaters to the circulation loop and directly back to the day tanks which bypasses circulation through the MixHead. Circulation Valve Override For fault analysis or setup, a circulation valve override screw (QE) is provided on the air control valve to manually open and close the circulation valves. Turn to operate G

39 Component Identification Optional Variable Frequency Drive The variable frequency drive enables control of the metering pump motor rpm as well as advanced flow control from the HMI. See Adjusting Metering Pump Motor RPM (if VFD is installed) on page 60 and Calibrating Machine-Calculated Mass Flow on page 64 for more information on Variable Frequency Drive operation G 39

40 Component Identification G

41 Setup Setup Avoid breathing of vapors and contact with Isocyanate as some people have severe allergic reactions. See Isocyanate Hazard on page 9. The machine is assembled on a heavy-duty steel frame that accepts all the major operating components. The machine will arrive from the factory pre-assembled, completely tested and ready for installation. If the unit includes a boom, the unit will come fully assembled with the boom detached. Setting the unit in place, providing electric service to the main electric console, connecting the air supply, servicing the hydraulic and day tanks, connecting the hoses and gun, and, if included, installing the boom is required. Prior to installing the machine, check for any damage that may have occurred during transit. If any damage is found, notify Graco immediately. The machine is to be installed on a flat surface in an area that permits easy access to all areas of the machine for maintenance and operation. The metering unit was plumbed, wired and tested at the factory. For transporting purposes, the unit was drained of all fluids and the chemical hoses were detached. The machine has been designed to prevent the accidental connection of chemical hoses to the wrong source. The Iso pressure hose is color coded red for pressure and red/white for return. The Poly pressure hose is color-coded blue for pressure and blue/white for return G 41

42 Setup MixHead Hoses SB SC SD SA FIG. 21: MixHead Hose Setup ti11597b Key: SA Poly Return to Tank SB Poly Pressure SC Iso Pressure SD Iso Return to Tank G

43 Setup MixHead Hydraulic Unit Hoses TC TD 1 TA 1 TB 1 Only installed if an L-Head is installed. ti11598b FIG. 22: MixHead Hydraulic Unit Hose Setup Key: TA L-Head Cleaning Piston Pressure to Open TB L-Head Cleaning Piston Pressure to Close TC MixHead Material Piston Pressure to Open TD MixHead Material Piston Pressure to Close G 43

44 Setup Connecting Electrical Cord Power cord is not supplied. See following table. Model Voltage Amps Cord Specification AWG (mm 2 ) (5.3) RC (5.3) (13.3) (5.3) RC (5.3) (13.3) (21.2) RC (21.2) (42.4) GND L1 L2 L3 ti3248a All Models: Connect three power leads to L1, L2, and L3. Connect green to ground (GND) G

45 Setup Day Tanks Tanks Connect all hoses and slowly pressurize each tank while checking for any leaks. See Settings section on page 56 for suggested pressure procedure. Chemical Feed System Each day tank has an inlet port on the back, where the chemical feed line gets connected. Each tank has an auto-fill air solenoid valve located on the center column between the two tanks. Air lines need to be run from these air solenoid valves to the proper feed pump. Hydraulic System Fill the hydraulic fluid reservoir with approved hydraulic oil. See Maintenance on page 68 for procedure and the table at the beginning of the Settings section on page 56 for reservoir capacity. Charge the accumulator. See Maintenance section on page 68 for procedure. Fully close manual unloading valve. See Component Identification section on page 11 for location. The hydraulic unit is fully tested at the factory and drained of all hydraulic fluid prior to shipment. Before operating, service with hydraulic fluid as recommended in Maintenance section. Optional Boom The boom comes detached and will need to be installed before use. See manual for assembly instructions G 45

46 Setup Optional Press or Simple Interface This machine is capable of being controlled by an external machine using three interface options: Press, Simple, and Normal. Normal interface is the default interface and does not require any additional setup. When Simple or Press interface is selected, the machine is able to utilize advanced interactivity with a Press. The machine also responds differently to the buttons on the pour pendant, as outlined in this section. Setup Refer to manual for an electrical schematic that shows electrical hook-ups needed to install a Press Interface. A press interlock arrangement as basic as a limit switch to close contact only when the press is fully closed and ready for a pour (the Press Pour Request contact) A limit switch to close contact only when the press is fully open and finished with it s cycle (the Press Cycle Complete contact) An arrangement with the two items above can use the metering unit s Ready signal to know when the metering unit is ready for a pour request. It can also use the metering unit s Pour Complete signal to know when the pour is finished so the press can finish it s cycle. Simple Interface Configuration If the metering unit is configured with the Simple interface instead of Press interface, then only the Metering Unit Pour Complete interlock contact is available. This only sends a signal to notify the press that the pour is complete. Signals From the Metering Unit Metering Unit Ready Contact This contact is closed as long as all of the metering unit s pour permissives are met, see Pouring Requirements section on page 52. Pour requests are ignored unless this contact is closed. Once a pour request has been received and a pour has been started, the metering unit will not accept a second pour request until the needed Press Cycle Complete signal is received. The Pour Request signal from the press must also have been turned Off since the last Pour Request was sent to the metering unit. These requirements provide the anti-repeat feature needed to prevent multiple pours into the same press or mold. Metering Unit Pour Complete Contact The closing of this contact means that a pour was started and has stopped (the pour may have been stopped prematurely or may have poured to completion). This contact closes for one second when the pour stops. If the L-Head is installed, which comes with a Cleanout Piston, then the closing of the Pour Complete contact is delayed until the cleanout motion is finished. This signal should be used to start the press cure timer and to reset the pour start signal which must remain true or On for the pour to continue to completion. Signals To the Metering Unit Press Pour Request Contact The transition of this contact from open to closed initiates the pour request. This contact then acts as a pour permissive (it must be held on during the pour sequence). If the contact opens during the pour sequence, the pour will be canceled (or stopped short if already started). Normally the press control system holds the pour request signal true or On until the Pour Complete signal is received from the metering unit. This signal provides the press with the means to request a pour and also to stop a pour. Press Cycle Complete Contact Once a pour is requested and the pour has been started, another pour cannot be started until the Press Cycle Complete signal is received. Press Cycle Complete usually means the cure timer has expired and the press is opened. The duration of this signal s contact closure should be at least one second. Once a pour has been started, the metering unit will not start another pour until both of the following events have occurred: G

47 Setup The Pour Request signal from the press must have been turned Off since the last Pour Request was sent to the metering unit The Press Cycle Complete signal must have been received by the metering unit Operation Sequence Preparation for pouring To start the sequence, the operator must place the metering unit in the correct state. Automatic mode should be entered, alarms cleared and reset, and the appropriate pumps started. If all metering unit permissives are met, then the Metering Unit Ready contact should be On (closed). The metering unit must have received a Pour Complete signal and the press s Pour Start signal must have been turned Off since the last pour. If the above requirements are met, then the metering unit will respond to a pour request. Pouring When the Pour Request contact closes, the metering unit control system begins it s pouring procedure. If a single metering unit is equipped with two MixHeads and is servicing two presses, then the Pour Request must remain closed until the metering unit finishes servicing the other press. Additionally, the Pour Request contact must remain closed while the metering unit is pouring the requesting press. If the Pour Request signal opens before the pour is started, the pour will be canceled. If the Pour Request signal opens while the pour is in progress, the pour will be stopped short. Manual Mode Pouring with Press Interface The press interface is not intended Manual Mode pouring. If the machine is in Manual Mode and a pour is started by pressing the pour start push-button on the pendant, then a timed pour will be performed for the preset duration for the channel number selected on the pour pendant thumb-switches. The pour start button does not need to be held down to complete the pour and the timed pour can be stopped early by pressing the pour stop button on the pendant. Automatic Mode Pouring with Press Interface The press interface signals are used for Automatic Mode pouring. When in Automatic Mode, the pour time will be determined by the time value entered in the Press Interface Automatic Mode Pour Time button on the Pour Time Editor screen, see FIG. 8 on page 23. Pouring using Press Interface Signals The machine and Press will interact as defined in the Optional Press or Simple Interface section on page 46. After Pouring After the pour stops (whether timed to completion or stopped short), the metering unit will signal the end of the pour by closing the Pour Complete contact for one (1) second. The press can then begin it s cure timer and proceed through it s automatic cycle. The metering unit will not allow another pour into that same press until after the press s Cycle Complete (press open) signal has been received and the Pour Request signal from the press has been turned Off G 47

48 New Machine Maintenance New Machine Maintenance Metering Pump Inlet Filter During the first week of operating a new machine, the filter should be inspected every other day. If the element is dirty, clean it with solvent or replace it with a new one as required. See Check/Replace Metering Pump Inlet Filter on page 69 for instructions G

49 Start-Up Start-Up Close the manual unloading valve by turning all the way clockwise Requirements for Operation The machine operates at high pressure and high voltage. Be careful during operation and always wear the appropriate protective gear. See Main Panel section on page 15 for more information. 1. Purge air from metering pump. See Maintenance section on page 68 for procedure. 2. If the machine is locked-out, remove the lock and push the black bar back into the power handle. 3. Turn on main power by turning the power handle so it points to ON. 4. When the HMI reaches the main menu screen, general settings can be changed. If an Emergency Stop has been pressed, it will need to be rotated and pulled out to be reset before control power can be turned on. 5. Turn on the control power by hitting the green push-button on the main panel. The button will be lit when control power is on. 6. Navigate to the Machine Control screen and turn on the MixHead Hydraulic Motor. Before turning on the pump motors, make sure there is sufficient chemical in both day tanks and that the day tank air pressure is at the suggested setting. See Settings section on page Turn on the pump motors. MixHead Hydraulic Unit Motor Before Turning on the MixHead Hydraulic Unit Motor If any of the following requirements are not met, the MixHead Hydraulic Unit will stop and/or not be permitted to start. Control power on Night Mode off MixHead Hydraulic Unit High-Pressure alarm inactive MixHead Hydraulic Unit Motor Overload alarm inactive The overload relays on the motor starter must be manually reset before the motor can be restarted after an overload. Starting the MixHead Hydraulic Unit Motor If any electrical work has been done on this machine, the rotational direction of the Hydraulic motor should be checked. This is indicated by the rotational arrow and must be maintained at all times. If the rotation is incorrect, change any two of the power leads on the main terminal strip. CAUTION Do not attempt to change rotation by entering the motor junction box. This will void the warranty. If the hydraulic fluid has recently been replaced, check the sight gauge to ensure the reservoir has been properly refilled. The hydraulic system must not be operated dry. To start the MixHead Hydraulic Motor, ensure main power and control power are on and navigate to the Machine Control screen on the HMI and select the Mix- Head Hydraulic Motor button, see FIG. 5 on page 20. Check hydraulic fluid level using the sight gauge Open all valves blocking normal oil flow G 49

50 Start-Up Pumpline The MixHead Hydraulic Motor must be running before starting the Iso and Poly metering pump motors. See Alarms List, page 75, for more information. Starting Metering Pump Motors Navigate to the Machine Control screen, and turn on the MixHead Hydraulic Motor, then turn on the desired material pump motors. Before starting the Metering Pump Motors Tank levels should be checked All ball valves blocking normal chemical flow should be opened Blanket pressure on each tank should be set Air in metering pumps must be purged. See Purge Air from Metering Pump on page 68. MixHead Hydraulic Motor on Manual or Automatic Mode selected (see Pouring Operation, page 51) The metering pump motors cannot be started in Calibrate Mode but will remain running if Calibrate Mode is selected after the metering pump motors are started. Requirements for Operation If any of the below requirements are not met, the iso and poly metering pump motors will stop and/or not be permitted to start. Control Power on Night Mode off MixHead Hydraulic Motor on MixHead Hydraulic Low Pressure alarm inactive Iso and Poly Metering Pump Overload alarm inactive Iso and Poly Metering Pump Inlet Low-Pressure alarm inactive Iso and Poly High-Pressure alarms inactive Iso and Poly Tank Low-Level alarms inactive G

51 Pouring Operation Pouring Operation Low and High Pressure Circulation When the metering pump motors are first turned on, the machine will enter low pressure circulation. After that the machine will stay in or return to low pressure circulation if the following conditions are met. A pour has not occurred since the metering pump motors were started If the preset High Pressure Hold Time has elapsed since the last pour occurred and calibrate mode has not been selected. When any of the following conditions are met, the machine will be in high pressure circulation. Calibrate mode is selected The pour start button has been pressed but Pressure-Build Time has not yet elapsed A pour has finished but High Pressure Hold Time has not yet elapsed Pour Pendant Channel Emergency Stop If an Automatic mode shot needs to stop before the preset time has elapsed, push the Stop button on the pendant. To stop the pour but keep motors running, hit one of the Emergency Stops. If you wish to perform long shots without specific durations, program one of the channels to have a very long duration, then hit the stop whenever the needed amount has been poured. This will minimize wear on the Start button. On L-Head models, pushing the Cleaning Piston button on the pour pendant will activate the cleaning piston. Each push of the cleaning piston button will move the piston from the open to the closed position or from the closed to the open position. The cleaning piston is used to clear the pouring nozzle of accumulated material. Pendant Channel The channel number is the number selected on the pendant and can be anything from 00 to 99. The channel number refers to the preset timer number discussed in the Pour Time Editor Screen section, page 23. All channels from 01 to 99 can be used for pouring, provided the preset timer on the Pour Time Editor screen is not set to zero seconds. If channel 00 is selected on the pour pendant, nothing will occur when the start button is pushed. Start Stop Cleaning Piston Manual Mode In manual mode, a pour occurs when the pour initiation button is pressed and held and stops when the button is released. If a pour pendant is attached to the machine, then the pour initiation button is the start push-button on the pendant. FIG. 23: Pour Pendant When in Manual Mode, press and hold the Start button until the desired amount of product has been dispensed, then release the Start button. When in Automatic Mode, select the desired channel using the pour pendant, then press and release the Start button to make a shot for the preset amount of time G 51

52 Pouring Operation Automatic Mode In automatic mode with a pour pendant attached, a pour is initiated by pushing and releasing the pendant start button. The duration of the pour is determined by the preset time for the selected channel number. If the pour needs to be stopped before the preset time has elapsed, hit one of the Emergency Stop buttons, or the stop button on the Pour Pendant. See Pour Time Editor Screen, page 23, for information on preset timers. Pouring Requirements The following requirements must be met in order for a pour to occur. Main Power on Control Power on Night Mode off Manual or Automatic Mode selected MixHead Hydraulic Pump on MixHead on MixHead Hydraulic Low-Pressure Alarm inactive Iso and Poly Metering Pump Motors on Pendant Channel selected with desired preset pour time If Pendant Channel 00 or any channel with a pour time of 0.00 seconds is selected, a pour will not occur. Iso and Poly Fail To Build Pour Pressure Alarm inactive Iso and Poly Low Pour Pressure Alarm inactive Iso and Poly Tank Low Level Alarms inactive If all of the above requirements are satisfied, then the MixHead Pour Ready indicator on the Status Screen will be green, see page 18. Beginning the Pour After both streams reach the required pour pressure and the preset pressure build time elapses, the MixHead is commanded to open and the pour occurs G

53 Night Mode Operation Night Mode Operation CAUTION Night mode enables machine operation when personnel are not present. If the machine encounters a problem during Night mode, such as a hose rupture or electrical problem, property damage may result. Night Mode is used to maintain chemical temperature and to circulate the chemicals in low-pressure circulation during periods when the machine is not is use, such as at night or over a weekend. At specified intervals Night Mode cycles the pumps on and off. If installed, the temperature control may also be cycled on and off. During Night Mode, the agitators may be turned on or off when desired but will not cycle on or off with the on-time and off-time periods. To run agitators, simply turn them on as usual either before or after beginning Night Mode. When Night Mode is turned on, the period of time known as off-time begins. The machine stays at rest for the specified amount of time, which will be displayed on the screen and counted down until the time has elapsed. When the specified duration for off-time has elapsed, the period known as on-time begins. During on-time, the Iso and Poly Pumps and MixHead Hydraulic Unit are on. If installed, the Temperature Control will also be activated. Just as in off-time, the amount of time remaining will be displayed on the screen. When on-time has elapsed, the pumps are turned off and off-time begins. This sequence of going from off-time to on-time and back will continue until Night Mode is turned off. To see how the night mode information is displayed, see Status Screen, page 18. Starting Night Mode See FIG. 5 on page 20. A small Ready indicator is located just under the words Night Mode on the Machine Control Screen. The Ready indicator on the Machine Control Screen will show green when all requirements for turning Night Mode on have been satisfied. If the Ready indicator is not green, then Night Mode cannot be turned on. The following requirements must be met to start night mode. Main and Control power on MixHead Hydraulic Motor turned off Iso Pump turned off Poly Pump turned off Once Night Mode is on, the previous items cannot be started until Night Mode is turned off. Requirements for Continuing Night Mode If any of the following requirements are not met, night mode will stop. Control power on Manual mode selected MixHead Hydraulic Unit Motor Overload alarm inactive MixHead Hydraulic Unit High Temperature alarm inactive MixHead Hydraulic Unit High-Pressure alarm inactive MixHead Hydraulic Unit Low-Pressure alarm inactive MixHead #1 Pour Piston Failure alarm inactive Iso and Poly Pump Motor Overload alarms inactive Iso and Poly Metering System Inlet Low-Pressure alarms inactive Iso and Poly High-Pressure alarms inactive Iso and Poly Tank Low-Level alarms inactive If an L-Head is installed the following requirements must also be met MixHead Pour Piston Failure alarm inactive MixHead Cleanout Piston Failure alarm inactive G 53

54 Shutdown Shutdown Overnight/Weekend If using Night Mode to circulate chemicals and maintain chemical temperature, see the Night Mode Operation section on page 53. Otherwise, follow these steps. CAUTION Do not disconnect or relieve tank pressure. Dry air pressure must be maintained at all times. 1. Turn off all motors using the Machine Control screen. 2. Turn off main power and lockout. See Lockout on page Remove lock on main power. 10. Turn on main power and control power. 11. Run the system in calibrate mode for 45 minutes. See Calibrate Mode on page Repeat steps 3 through 11 until the machine is thoroughly flushed. 13. Turn off all motors using the Machine Control screen. 14. Turn off main power and lockout. See Lockout on page 15. Long-Term Shutdown The system must be completely flushed before long-term shutdown to prevent chemical crystallization within the MixHead, metering pumps, tanks, and chemical lines. 1. Turn off all motors by using the Machine Control screen. 2. Turn off main power and lockout. See Lockout on page Empty both day tanks completely. See Empty the Day Tank on page Empty metering pump inlet filter by unscrewing drain plug. 5. Empty metering pumps by unscrewing drain plug on bottom of pump. 6. Using a bucket to catch spilled material, remove lowest hose from heat exchanger. This will empty the heat exchanger and heater, and all chemical lines above. 7. Tighten metering pump drain plug and reattach heat exchanger hose. 8. Fill each tank 1/2 full with mesamoll G

55 Shutdown G 55

56 Settings Settings Temperature Switch Pressures Pressure Switch Pressures Settings MAGdrive F (76.7 C) Chemical Absolute High Temperature F (82.2 C) Heater F (82.2 C) MixHead Hydraulic Unit...160ºF (71.1 C) Max Metering Pump Outlet psi (22.0 MPa, 220 bar) Min Metering Pump Outlet (in high pressure mode) psi (10.3 MPa, 103 bar) Min Metering Pump Inlet psi(0.068 MPa, 0.68 bar) Max Hydraulic Fluid psi (19.3 MPa, 193 bar) Min Hydraulic Fluid psi (10.3 MPa, 103 bar) Day Tank Operating Air Pressure psi(0.27 MPa, 2.7 bar) Supplied Air Pressure psi ( MPa, bar) Day Tank Pressure Relief Valve psi(0.51 MPa, 5.1 bar) Supplied Water Pressure...40 psi(2.76 bar) Supplied Water Temperature...65 F (18 C) Automatic Unloading Valve Upper Limit psi (16.5 MPa, 165 bar) Automatic Unloading Valve Lower Limit psi (14.4 MPa, 144 bar) Accumulator Pre-Charge psi ( MPa, bar) Calibrate Mode Some settings will require running the machine in Calibrate mode to adjust. Calibrate mode puts the machine into high pressure circulation and is used most commonly to adjust the chemical line pressures or flowrate. With the MixHead motor and metering pump motors on, select Calibrate mode from the Machine Control or Status screen. To remove the machine from calibrate mode, select manual or automatic mode, or hit one of the Emergency Stops. Temperature Control The high and low temperature setpoints on the HMI are used to alert the operator of an out-of-limit condition. When these alarms are triggered, the pumps will still function and pouring will not be stopped. There is a mechanical heater switch that will shut off power to the heater if the chemical temperature goes above the setting. The pumps will continue to run if the heater is shut off so that the chemical can be cooled by flowing through the Heat Exchanger. If a MAG drive motor is installed, a MAG drive over-temperature alarm is provided to prevent motor overheating. See table at beginning of this section for alarm setting. Temperature Control On/Off CAUTION The temperature control should always be turned on when the machine is turned on unless there is a specific reason not to. With the temperature control turned off, the chemical temperature will slowly heat up until it eventually triggers one of the over-temperature alarms. If the MAG drive over-temperature alarm caused the shutdown, the machine will not be able to be started until the machine has cooled to significantly below the over-temperature setting. Temperature Control is turned on/off from the Tank Control screen, see FIG. 7 on page 22. With Temperature Control turned on, the heat exchanger and heater will work to maintain each chemical temperature to the input temperature setpoint. The heat exchanger works to cool the fluid with water from the inlet. Water inlet valves control cooling by cycling open and closed as necessary. The heater works to heat the material by exposing the chemical to heated rods that are turned on and off as necessary. Built into the HMI program there is an absolute high temperature alarm that will shut down the pumps when triggered G

57 Settings Temperature Setpoint The temperature setpoint is the goal temperature for the chemical. The machine will automatically maintain the temperature of the chemical within a reasonable range from the input temperature setpoint based on the current gain settings, see Temperature Gains, page 58. High Temperature Setpoint The high temperature setpoint is the temperature at which the high temperature alarm will be triggered to notify the operator that there is a problem and the machine should be inspected for the cause. This alarm is disabled for the first thirty minutes of operation to allow the chemical temperature to stabilize without unnecessary alarms. The suggested high temperature varies by chemical but should be the highest temperature at which the chemical will react as desired when mixed at the MixHead G 57

58 Settings Low Temperature Setpoint The low temperature setpoint is the temperature at which the low temperature alarm will be triggered to notify the operator that there is a problem and that the machine should be inspected for the cause. The low temperature setpoint should be the lowest temperature at which the chemical will as desired react at the Mix- Head. Temperature Gains CAUTION Adjusting the temperature gains should only be performed by a technician knowledgeable in the operation of this machine. Incorrect adjustment of the temperature gains can lead to overheating, erratic temperature control, and/or poor chemical reaction at the MixHead during pours due to poor temperature control. Gains are shown on the Gains Control screen, see FIG. 15 on page 30. This screen is accessed from the Scaling screen, see FIG. 14 on page 29. Gains control two things: temperature fluctuation from the setpoint and heating time at startup. The default setting for all four Gains is 100. This setting will maintain a reasonable margin for temperature as well as a reasonable time for heating at initial startup. If the temperature gains have been altered and temperature control is not performing as desired, reset all four gains to 100. If the temperatures are not controlled to your desire with the gains set to the default settings of 100, you may be able to adjust the gains to make the machine work better for your application. Things to consider when adjusting the gains: It is recommended that all four gains be set to the same number Higher gains will lead to faster heating at initial startup but will increase the temperature fluctuation If Night mode is used then the chemical temperature is maintained, so higher gains are not needed. Lower gains will lead to smaller temperature margins and slower heating at initial startup CAUTION Lowering the gains can lead to the materials and pumps overheating. Lower chemical flow rates require higher gains to keep the materials from overheating Higher flow rates may accept lower gains without overheating The procedure below will help to find gains that will maintain temperature within a desired margin, but will also effect warm-up time. To adjust the gains, first turn off the chemical pump motors, then navigate to the Scaling screen and select Temp Gains. Ensure that all four gains are shown as 100. If not, set them to the factory setting of 100, turn on the chemical pump motors, and let the chemical temperatures stabilize into a pattern check whether adjustment is needed. If you wish to change the gain settings, turn off the chemical pump motors, and alter the gain settings to get the desired results as suggested in the previous paragraphs. Be aware of the temperatures while waiting for the machine to stabilize into a pattern. If at any time the chemicals begin getting too hot, hit the Emergency Stop and reset the gains to 100. Repeat the procedure until chemical temperatures are maintained as desired. To check initial heating time, once the chemicals have cooled to ambient temperature turn on the pumps and heaters. If it takes too long to heat up, either raise the gains or consider using Night Mode to maintain chemical temperature during down-time. Pouring Settings Iso, Poly Specific Gravity Chemical specific gravities are entered from the Setup screen, see FIG. 9 on page 24. This entry is used to calculate mass flow in grams by multiplying by the volumetric flow measured by the flow meter. It is very important that the chemicals correct specific gravities are entered, to ensure accurate pours G

59 Settings Preset Pour Timers Preset Pour Timers are presets that enable quick execution of pours with specific durations. To execute a pour of a specific length, change one of the preset pour timers on the Pour Time Editor Screen, see page 23, then select that channel on the pour pendant. Select Automatic mode, and then hit the pour start button to execute a shot of the selected channel s preset duration. The channel can be changed at any time and the next shot duration will be based on the preset time for the selected channel. If a channel has a time of 0.00 then no pour will occur, but the pressure will build and hold in the same manner as when a pour does occur. Pressure Build Time Pressure Build Time is set using the Setup screen, see FIG. 9 on page 24. When a pour is initiated the machine will build pressure to get ready to pour. Pressure Build Time gives the machine time to stabilize pressure. Once a pour is initiated the build timer begins and when the build time elapses if the machine has reached high pressure the pour will begin. A new pour that is started before the machine goes out of high-pressure can begin pouring as soon as the pour push-button is pressed. The time the machine stays in high pressure is called High Pressure Hold Time. High Pressure Hold Time High Pressure Hold Time is set using the Setup screen, see FIG. 9 on page 24. This is the time that the metering system will stay in high-pressure after a pour has been completed. This time should be increased if shots are to be performed in rapid succession, so the machine does not return to low pressure circulation. Allowing the machine to exit high pressure circulation between rapid shots will lead to a longer wait between shots. Low Level Bypass On/Off CAUTION Using low level bypass allows the pumps to continue running when an automatic shot is performed and the fluid level in one or both tanks goes below the low level sensor. If your application will ever require performing an automatic shot that will dispense more than four gallons from one of the tanks, be very cautious of fluid level before performing shots. Low Level Bypass is turned on/off from the Machine Control screen, see FIG. 5 on page 20. Having Low Level Bypass on or off determines whether the metering pump motors will continue to run after the fluid level in either or both tanks drops below the low level sensor during an automatic mode shot. During a pour with Low Level Bypass off, when the tank level drops below the low level sensor and that pour stops, the metering pump motors will stop. During a pour with Low Level Bypass on, when the tank level drops below the low level sensor and that pour stops, the metering pump motors will continue to circulate material. Manual mode pours will always stop when fluid level drops below the low level sensor whether low level bypass is on or off. Pours will not be allowed to start when the fluid level in either or both tanks is below the low level sensor. Flow-Rate Display Filter See FIG. 14 on page 29 for more information. MixHead Settings MixHead On/Off The MixHead must be turned on to dispense chemical. When the MixHead is turned off, dry cycling will be enabled but will not occur unless all conditions required for starting a pour are met. Dry cycling is when the machine does everything necessary to do a pour without opening the material piston so that material is not dispensed G 59

60 Settings To dry cycle the machine, execute a pour without turning on the MixHead. The machine will go through the normal cycle for pouring, without dispensing material, and if anything is not running correctly an alarm will be triggered. Dry cycling is useful when an alarm has been triggered and the cause of the alarm needs to be found. In that situation, reset the alarm, attempt to fix the problem, and dry cycle the machine to test whether the problem has been corrected, without wasting any material. Cleanout Delay (if L-Head installed) The delay between the end of a pour and the activation of the cleanout piston. Cleanout Extend Time (if L-Head installed) The amount of time the cleanout piston remains extended when hitting the Cleaning Piston button on the pour pendant. When the preceding requirements are met: 1. Select calibrate mode to put the machine into high-pressure circulation. 2. Using a hex key, adjust the orifice by turning the hand grip on either side of the MixHead very slowly while watching the pressure on the gauges above the main panel. The pressure for the two chemical lines should be within 200 psi to avoid chemical crossover at the MixHead. Chemical crossover will lead to chemicals mixing and curing within the MixHead and will require more frequent MixHead rebuilding. Chemical Flow Settings Hand Grip Adjusting Chemical Line Pressures Having pressure equal between the iso and poly lines is important for proper mixing. The usual guideline for proper mixing is to have the difference in pressures less than a few hundred psi. Whenever the pressures are not equal adjust the chemical line pressures. Before adjusting the MixHead orifices, ensure the following requirements have been met. See Setup Screen on page 24 and Machine Control Screen on page 20 for details about changing the following settings. Main and Control Power on Night Mode must be off MixHead Hydraulic Pump on Appropriate Metering Pump Motors must be on MixHead Hydraulic Low-pressure Alarm must be inactive ti11599b L-Head shown 3. When the chemical line pressures are within 200 psi, select automatic or manual mode to exit Calibrate mode. Adjusting Metering Pump Motor RPM (if VFD is installed) If Variable Frequency Drive is installed then the metering pump motor rpm can be adjusted individually for both metering pump motors. This is done using the Flow Control Screen on the HMI, see FIG. 12 on page Navigate to the Flow Control screen. Hand Grip 2. Under the Flow Control heading, select Manual mode G