Servo PR70 Controls. For professional use only. Not approved to European explosive atmospheres requirements.

Transcription

1 Operation Servo PR70 Controls 3A0262B ENG For professional use only. Not approved to European explosive atmospheres requirements. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

2 Contents Safety Precautions... 3 Machine Features... 4 Startup Screen... 5 Main Menu Screen... 6 Main Screen... 7 Timer/Counter Screen... 9 Servo Screen Level 1 Control Screen Level 2 Control Screen Math Check Screen Input / Output Screen Totalizer Screen Machine Status Screen Shot Size 1-5 Screen Shot Size 6-10 Screen Adjusting the Limit Switches Dry Run Priming the Hoses Ratio Check Phasing the Pumps Daily Operations Shut Down Periodic Maintenance Troubleshooting Graco Ohio Standard Warranty Graco Ohio Information A0262B 2

3 Safety Precautions This manual provides installation, operation, and maintenance instructions for Graco Ohio Inc. meter, mix, and dispense machines. Read this manual before you install and operate your machine. Use your machine only as directed. Safety Terms within our manuals Cautions are given where failure to observe the instruction could result in damage to the equipment, associated equipment, and/or process. Warnings are given where failure to observe the instruction could result in injury or death to people. Some examples follow. Caution Snuff-back can be monitored with DV MODE in AUTO, but must be adjusted with DV MODE in OPEN WARNING Make sure EMERGENCY STOP is locked in before manually aligning the ratio block to the ratio beam. Safety Labeling on our machinery All our machines carry the following safety labels wherever necessary: Danger Labels indicate an imminently hazardous situation, which, if not avoided, could result in death or serious injury. Warning Labels indicate potentially hazardous situations which, if not avoided, could result in death or serious injury. Caution Labels indicate an unsafe practice that may result in moderate or minor injury. Notice Labels state a company policy. Some examples are: DANGER DO NOT OPERATE THIS MACHINE WITH GUARD(S) DETACHED WARNING UNPLUG MACHINE BEFORE OPENING ENCLOSURE NOTICE OVERCURRENT PROTECTION PROVIDED AT MACHINE SUPPLY TERMINALS CAUTION CAUTION WEAR EAR PROTECTION WEAR EYE PROTECTION 3A0262B 3

4 Compact Twinflow CTF Machine: Machine Features CONTROL POWER Switch Provides power for the electrical circuitry in the console. OFF: ON: Electrical power is not applied to the electrical circuitry and the internal green lamp is dimmed. Electrical power is applied to the electrical circuitry and the internal green lamp is illuminated. EMERGENCY STOP Button When the EMERGENCY STOP button is pressed and released, all power is removed from the machine. The pumps will immediately stop in place. The dispense valve will close. Touch Panel The Touch Panel is used to control all machine functions. See the following sections for operation of the different screens. Foot Switch The foot switch is used to initiate a pump cycle when operating in the Shot Mode. Throughout this manual the foot switch will be referred to as the START device. When the Shot Mode button is pressed and the START device is pressed and released, the machine will cycle once then stop and wait for the next start signal. 3A0262B 4

5 Startup Screen This screen appears on Startup Servo Ready indicator This indicator will be displayed when the servo drive is ready to dispense material. Home button This allows the servo drive to move to the home position. This position is when the piston is at the entrance of the metering tube (which is set by the HOME Switch). NOTE: This is the position where the dispense valve is to open. Operator Control Mode button: In this mode, pressing the START DEVICE will allow the machine to take multiple or partial strokes to allow the operator to control the amount of material to be dispensed. (When the START device is pressed and held the piston will extend allowing material to be dispensed until the START DEVICE is released when the piston will stop at its current position. If the START DEVICE is pressed and the held the machine will run continuously.) Shot Mode button: The machine will cycle full the number of times displayed in the CYCLE COUNTER box when the start device is pressed and released. The machine will cycle continuously when the start device is pressed and held. To Start the machine do the following: 1. When the Servo Ready indicator is illuminated, select the HOME button. 2. When the servo drive is in the Home position, select either the SHOT button or OPERATOR CONTROL button depending on the application desired. 3. Press the MAIN button to continue. 3A0262B 5

6 Main Menu Screen STARTUP button When the STARTUP button is pressed the Startup screen will appear. See the Startup Screen for more information. MAIN button When the Main button is pressed the Startup screen will appear. See the Main Screen for more information. Timer/Counter button When the Timer/Counter button is pressed the Timer/Counter screen will appear. See the Timer/Counter Screen for more information. SERVO button When the SERVO button is pressed the Servo screen will appear. See the Servo Screen for more information. Input/Output button When the Input/Output button is pressed the Input/Output screen will appear. See the Input/Output Screen for more information. Totalizer button When the Totalizer button is pressed the Totalizer screen will appear. See the Totalizer Screen for more information. Machine Status button When the Machine Status button is pressed the Machine Status screen will appear. See the Machine Status Screen for more information. Shots 1 to 5 button When the Shots 1 to 5 button is pressed the Shots 1 to 5 screen will appear. See Shots 1 to 5 Screen for more information. Shots 6 to 10 button When the Shots 1 to 5 button is pressed the Shots 6 to 10 screen will appear. See Shots 6 to 10 Screen for more information. 3A0262B 6

7 Main Screen Dispense Valve Mode section The following button controls the Twinmixer valve Open: The dispense valve is manually opened during the entire pump cycle. The open position is normally used to prime material hoses or relive line pressure. Closed: The dispense valve is manually closed during the entire pump cycle. The open position is normally used to prime material hoses or relive line pressure. Auto: The dispense valve automatically opens and closes to dispense the preset shot size. Machine Mode section Operator Control Mode: In this mode, pressing the START DEVICE will allow the machines to take multiple or partial strokes to allow the operator to control the amount of material to be dispensed. (When the START device is pressed and held the piston will extend allowing material to be dispensed until the START DEVICE is released, the piston will stop at its current position. If the START DEVICE is pressed and the held the machine will run continuously.) Shot Mode: The machine will cycle the number of times displayed CYCLE COUNTER in the when the start device is pressed and released. The machine will cycle continuously when the start device is pressed and held. Cycle Start button When the CYCLE START button is pressed, the machine will start its programmed cycle (This is also known as a Start Device). Purge Cycle Start button This button when pressed will cycle the machine for the purposes of flushing the dispense valve mixer of gelled material. See the Timer/Counter Screen for more information. Shot Velocity (mm/s) indicator This indicator will display the shot mode flow rate (velocity) in the terms of millimeters of piston stroke per second. O.C. Shot Velocity (mm/s) indicator (Operator Control Velocity) This indicator will display the operator control mode flow rate (velocity) in the terms of millimeters of piston stroke per second. 3A0262B 7

8 Main Screen Select Shot Number button indicator The select shot number button allows the operator select the various shot size previous entered in the Shot screen 1-5 and Shot screen The select shot number displays the current shot size. See Shots 1 to 5 Screen and the Shots 6 to 10 for more information. Servo Ready indicator This indicator will be displayed when the servo drive is ready to dispense material. Servo Busy indicator This indicator will be displayed when the servo drive is currently retracting or currently busy in other operation. The machine is not ready to dispense material at this time. Dispense Complete indicator This indicator will be displayed when the machine has completed dispensing material and is ready to retract for the next shot. 3A0262B 8

9 Timer/Counter Screen Purge Timer OFF button This button disables the purge timer function. Purge Timer ON button This button enables the purge timer function. When the Pump Mode is in the Shot or Operator Control Mode, the purge timer will begin to count up to the time entered (seen in the Enter Purge Time In Seconds indicator), once when this time expires the machine will sound an audio alarm and then cycle dispensing gelled material from the mixer, the timer will reset when cycle is complete. If the machine dispenses material by pressing the start device, the purge time will reset to the preset time. This will continue until the Purge Timer Off button is selected. Cycle Counter Off button This button disables the Cycle Counter function for the machine. Select Cycle Counter On button When this button is selected, the machine will dispense the number of cycles (shots) that was previously entered, which is seen in the Enter Number Of Cycles indicator. Enter Purge In Seconds button/indicator This button will allow the operator to change the time that the machine will purge to be change in seconds. Time Remaining Till Purge indicator This indicator displays the current time that the machine will purge material. Enter Number of Cycles indicator This button will allow the operator to change the cycles that the machine will dispense when in Shot Mode and the Cycle Counter is on. Cycle Complete indicator This indicator displays the remaining number of shot to be dispensed when the cycle count is on. Enter Purge Distance in mm button/indicator This button changes the size of the purge shot in the terms of millimeter of stroke. Enter Purge Speed in mm button/indicator This button changes the flow rate (velocity) of the purge shot in the terms of millimeter of stroke per second. 3A0262B 9

10 Servo Screen Home button This allows the servo drive to move to the home position. This is when the piston is at the entrance of the metering tube (which is set by the HOME Switch). NOTE: This is the position where the dispense valve is to open. Retract button This allows the servo drive to move to the retract position. Extend button This allows the servo drive to move to the full extend position. WARNING: Make sure that the ratio check valves are open or the dispense valve is open prior to selecting this button. Homing Velocity (mm/sec) button/indicator This button changes the speed (velocity) when the machine is moving to the Home position in the terms of millimeter of stroke per second. Operator Control Velocity (mm/sec) button/indicator This button changes the flow rate (velocity) when the machine is dispensing material in the terms of millimeter of stroke per second when operating in the Operator Control Mode. Reload Velocity (mm/sec) button/indicator This button changes the speed (velocity) when the machine is moving to the Reload position in the terms of millimeter of stroke per second. RESET (RESET IN PROGRESS) button This button reset the servo drive. Current Position (mm) indicator This indicator displays the current position of the servo drive. 3A0262B 10

11 Servo Screen Servo Not Ready indicator This indicator will be displayed when the servo drive is currently retracting or currently busy in other operation. The machine is not ready to dispense material at this time. Servo Not Busy indicator This indicator will be displayed when the servo drive is idle. Disp. Not Complete indicator (Dispense Not Complete) This indicator is illuminated when the machine is currently dispensing. More button When the More button is pressed the Math Check Information Screen will appear. See the Math Check Information Screen for more information. NOTE: If the A TANK STATUS and the B TANK STATUS indicator both display 'LEVELS NOT ACTIVE' then the level control feature is not installed on this machine. Press the Main button to exit from this screen. NOTE: The Level 1 screen will appear with any change of state of any tank material level sensor (If equipped). The Level 1 screen will also appear during any Auto-Fill fault condition. For example: If the Pump mode screen is displayed on the touch screen and a level sensor changes state (e.g. Material low or material high) the Level 1 screen will be displayed and the Pump mode screen will disappear. 3A0262B 11

12 Level 1 Control Screen A TANK STATUS indicator This indicator gives information on the A component tank filling process, the messages possible that this indicator can display are: MATERIAL HIGH MATERIAL LOW FILLING MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE A FILL FAULT B TANK STATUS indicator This indicator gives information on the B component tank filling process, the possible messages that this indicator can display are: MATERIAL HIGH MATERIAL LOW FILLING MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE B FILL FAULT For more information on the Tank Status Indicator Messages, see the Tank Fill Message table in this manual. 3A0262B 12

13 Level 1 continued NOTE: The START FILL A, START FILL B and the STOP FILL buttons will be inoperative if the high level automatic tank refilling feature was not purchased with this machine. START FILL A button When this button is pressed the A tank component pneumatic ball valve will open and fill the A component tank until the material level reaches the high level proximity switch on the A component tank or until the fill timer expires. START FILL B button When this button is pressed the B tank component pneumatic ball valve will open and fill the B component tank until the material level reaches the high level proximity switch on the B component tank or until the fill timer expires. STOP FILL button This button will close the pneumatic ball valve for both A and B component material tank. Silence Alarm button This button will silence the audio alarm when pressed. 3A0262B 13

14 Indication MATERIAL HIGH Level 1 continued Tank Status Indicator Messages Cause This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the 'A' or B component tank material level reaches the high level proximity switch (If equipped with high level proximity switch). MATERIAL LOW FILLING MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE FILL FAULT This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the 'A' or B component tank material level reaches the low level proximity switch (If equipped with low level proximity switch). This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the 'A' or B component tank material is currently refilling in the tank refilling process. (If equipped with tank refilling.) This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the 'A' or B component tank material level is between the high and the low level proximity switch (If equipped with low level and high level proximity switch). This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the machine senses a high material level and a low material of the 'A' or B component tank simultaneously. (If equipped with low level and high level proximity switch). This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the high or low level proximity switches are not installed for the tank that the TANK STATUS indicator that is being displayed. This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the tank material is currently refilling and the tank material level does not reach the high level proximity switch within the time previously entered into the FILL TIMER button seen in the LEVEL2 CONTROL screen. NOTE: In the LEVEL 1 CONTROL Screen if the A TANK STATUS and the B TANK STATUS indicators both displays 'LEVELS NOT ACTIVE' then the level control feature is not installed on this machine. Press the Main button to exit from this screen. NOTE: The 1 indicates that the button is in the ON position the 0 indicates that the button is in the OFF position. 3A0262B 14

15 Level 2 Control Screen LOW LEVEL SHUTDOWN button When this button displays 1 or active condition and the material level of either the A component tank or the B component tank reaches the low level sensor, the machine will shutdown. To recover, refill the component tank with material pass the low level sensor. When the button is pressed to display 0 the machine shutdown feature will be disabled. ENGAGE ALARM button When this button displays 1 or active condition and the material level of either the A component tank or the B component tank reaches the low level sensor and audio alarm will be activated. ENGAGE AUTO FILL button When this button displays 1 or active condition the automatic filling function is activated. NOTE: If the automatic refilling option has not been purchased the Fill Timer button will be inoperative. Fill Timer button/indicator This changes the time that the FILL TIMER FAULT message is displayed to the corresponding A TANK STATUS or B TANK STATUS indicator seen in the LEVEL 1 CONTROL screen. If the material level reaches the material component tank high level proximity switch before the fill time previously entered, then the TANK HIGH LEVEL message will be displayed in the TANK STATUS indicator and the fill timer will be reset. If the timer expires before reaching the high level switch, then the FILL TIMER FAULT will appear in the Level1 Control Screen To change the Fill Timer: 1. Select the Fill Timer button (shown as =0000.0) a numeric keypad should appear. 2. Enter in the Fill Timer time in 10 th of seconds as required. (If 10 were entered, the fill time will be 1 second.) 3. Press the button. 4. The new Fill Timer time should appear in the Fill Timer indicator. NOTE: The accumulated or the current time of the Fill Timer lower indicator is shown by this indicator will count up to the previous preset time. 3A0262B 15

16 Level 2 continued NOTE: In the LEVEL 1 CONTROL Screen if the A TANK STATUS and the B TANK STATUS indicators both displays 'LEVELS NOT ACTIVE' then the level control feature is not installed on this machine. Press the Main button to exit from this screen. NOTE: If the automatic refilling option has not been purchased the Shutdown Timer button will be inoperative. Shutdown Timer button/indicator If the material level is lower then the material component tank low level proximity switch past the preset time the machine will shutdown. To change the Shutdown Timer: 1. Select the Shutdown Timer button (shown as =0000.0) a numeric keypad should appear. 2. Enter in the Shutdown Timer time in 10 th of seconds as required. (If 10 were entered, the Shutdown time will be 1 second.) 3. Press the button. 4. The new Shutdown Timer time should appear in the Shutdown Timer indicator. NOTE: The accumulated or the current time of the Shutdown Timer lower indicator is shown by this indicator will count up to the previous preset time. Clear Fill Fault button This button when pressed will clear the FILL TIMER FAULT message that is displayed in the corresponding A TANK STATUS or B TANK STATUS indicator seen in the LEVEL 1 CONTROL screen. Silence Alarm button: This button will silence the low level audio alarm when pressed. The audio alarm will also be silenced when the material can be filled above the high level proximity switch on both tanks. 3A0262B 16

17 Math Check Screen This screen is used for advance trouble shooting purposes only. Call Graco Ohio Inc. for more information. 3A0262B 17

18 Input / Output Screen This screen gives the status of the various input and outputs of the PLC. See the electrical logic drawings for information. 3A0262B 18

19 Totalizer Screen Resetable Totalizer indicator This counter will increment 1 count for each time the machine cycles. The totalizer is resetable to 0 counts by pressing the Reset button. This counter is used for maintenance purposes. Non-Resetable Totalizer indicator () This counter will increment 1 count when the machine makes 1 cycle. This indicator is not resetable. Reset button This button resets the Maintenance Totalizer indicator. 3A0262B 19

20 Machine Status Screen Audio Alarm button This button silences the audio alarm. Servo Not Ready indicator This indicator will be displayed when the servo drive is currently retracting or currently busy in other operation. The machine is not ready to dispense material at this time. Servo Not Busy indicator This indicator will be displayed when the servo drive is idle. Dispense Not Complete indicator This indicator is illuminated when the machine is currently dispensing. Current Position (mm) indicator This indicator displays the current position of the servo drive. 3A0262B 20

21 Shot Size 1-5 Screen Shot Size Push to Select button This button allows the operator to choose one of the five preprogrammed shot sizes and flow rate seen in the SHOT SIZE (mm) section and Velocity (mm/s) section. SHOT SIZE (percent) section Shot Size 1 Shot Size 5 buttons These indicators allow the operator to change 5 different shot sizes in the terms of millimeter of stroke. Once the shot sizes are programmed the shot sizes can be selected using the Shot Size Push to Select button. Velocity (mm/sec) section (Flow Rate) Velocity 1 Velocity 5 buttons These indicators allow the operator to change 5 different flow rates (Velocity) in the terms of millimeters per second (mm s / second). Once the flow rates are programmed the flow rate can be selected using the SELECT SHOT SIZE/FLOW RATE COMBINATION button. 3A0262B 21

22 Shot Size 6-10 Screen Shot Size Push to Select button This button allows the operator to choose one of the five preprogrammed shot sizes and flow rate seen in the SHOT SIZE (mm) section and Velocity (mm/s) section. SHOT SIZE (percent) section Shot Size 6 Shot Size 10 buttons These indicators allow the operator to change 5 different shot sizes in the terms of millimeter of stroke. Once the shot sizes are programmed the shot sizes can be selected using the Shot Size Push to Select button. Velocity (mm/sec) section (Flow Rate) Velocity 6 Velocity 10 buttons These indicators allow the operator to change 5 different flow rates (Velocity) in the terms of millimeters per second (mm s / second). Once the flow rates are programmed the flow rate can be selected using the SELECT SHOT SIZE/FLOW RATE COMBINATION button. 3A0262B 22

23 Adjusting the Limit Switches The over travel limit switch are factory adjusted, when tripped, they will stop the servo motor from going into an extreme over travel condition. The home adjustment switch allows set the piston at the beginning of the dispense tube. Do not adjust the Retract or Extend limit switches. To adjust the HOME position switch do the following: 1. Loosen the screw securing the home limit switch. Open the dispense valve. 2. From the Servo screen press the RETRACT Button, the machine moves to the retract position. 3. Press the HOME button, and watch for material dispensing from the dispense valve. 4. The home limit switch is set properly when the piston is at the point of the metering tubes material entrance, very little material will be dispensed (the amount of the material will not be enough to drip from the ratio check nozzles if not a small surge or bump of material may be seen.). Readjust the HOME limit switch and repeat steps 1 and 3 until there is no to very little to no material (as previously mentioned) when the machine is moves from retract to home position. NOTE: Both ratio checks must dispense material at the same time. If one ratio check dispenses material prior to the other, then, see the Phasing section in this manual for more information. The center position on the HOME switch scale is the approximate HOME position. 3A0262B 23

24 Dry Run A Dry Run demonstrates the machine s controls and dispensing steps. It also verifies that the machine is working correctly before loading material. 1. From the Servo screen, do the following. 2. Press the RETRACT button. 3. Set the SHOT SIZE for a large shot. See adjusting the Shot Size. 4. From the Main Screen press the SHOT button. 5. Press and release the start device (START CYCLE button or foot switch). Machine takes one cycle and stops. 6. Press and hold the start device. Machine cycles continuously. 7. Press the Release the Start Device. The machine stops. 3A0262B 24

25 Priming the Hoses Priming the Hoses ensures that air-free material is flowing through the material hoses and out the dispense valve outlet. Before proceeding, load the machine with materials. Priming is critical to keep the system working properly. 1. Set the Shot Size as required. See adjusting the Shot Size. 3. From the Main screen. Under PUMP MODE press the SHOT button. 4. At the pump outlets, close the ratio check ball valves. 5. Remove the dispense valve from its mount if necessary. 6. Hold the material hose and dispense valve outlet at a constant incline from the pumps so that air can be pushed out by the material when the machine is cycled. Avoid sags in the hoses! 7. Position a waste container under the outlet to catch dispensed material. Select the start device. 8. While keeping the hoses at a constant incline, cycle the machine slowly until all signs of air have disappeared. Then release the start device. To avoid material spitting, keep flow rate low. 9. Once air-free material is flowing from the outlet, press the RETRACT button. 10. Remount the dispense valve before proceeding. 3A0262B 25

26 Ratio Check The Ratio Check is a simple procedure where individual samples of material are collected, weighed, and compared to the manufacturer s desired outputs. We recommend that you do a ratio check by weight at least once a day, and if the machine is used in production for more than one shift, then once a shift. A ratio check log is included with this binder. Before proceeding, phase the pumps and prime the ratio check valves (if equipped) and material hoses. 1. Put ratio check nose on dispense valve. 2. Weigh six small empty cups and label as A1, A2, and A3. Record on Ratio Check form. 3. Set the shot size to 100%. See Adjusting the Shot Size. 4. From the Main screen press the SHOT button. 5. Place empty cups under the nozzles. 6. Press and release the start device. 7. Repeat steps 5 and 6 with all three sets of labeled cups. Always take a dump shot into a waste container before taking weights. 8. Reweigh all three cups and record results on form. 9. Complete weight calculations. If significantly different, see Troubleshooting section. 3A0262B 26

27 Phasing the Pumps When the machine begins pumping material, both pistons must enter the metering tubes at precisely the same time so that both materials start flowing simultaneously. This will ensure proper mixing and a very repeatable metered ratio. Follow these instructions at initial start-up and after a pump repair. Before proceeding, if your model is equipped with ratio check ball valves, first close the material hose ball valves and then open the ratio check ball valves. 1. From the Main screen select the SHOT button. 2. Open the dispense valve. 3. Remove the pump guard. 4. The pumps are in phase when the material begins to flow from the ratio check nozzle outlets at exactly the same time. 5. Readjust the HOME position switch as required, see Adjusting the Limit Switch section of this manual for more information. If the material from the A pump flows before the material from the B pump, loosen the jam nut and set screw. Then rotate the shaft of the B piston counterclockwise a quarter turn with an open-end wrench positioned on the wrench flats. Cycle the machine again and, as before, sight across both outlet ports. Repeat until both materials flow simultaneously. If the material in the B pump begins to flow before the material in the A pump (overcompensation), rotate the shaft of the B piston clockwise in quarter-turn increments until both materials flow simultaneously. Always retighten the jam nuts and set screws, securing both pump shafts in the phased position. (see the illustration next page) 3A0262B 27

28 Phasing the Pumps Throughout this manual, references to the A pump and B pump are used. The A and B pumps correspond to the particular material originally specified for use in this machine and relate to the corresponding label on the material supply and to the hoses. Any change of resin supplier may cause a need to re-label the supply, pumps, and hoses accordingly. PUMP SHAFT FLATS Adjustment screws and jam nuts 3A0262B 28

29 Daily Operations The following steps illustrate the day-to-day operation of the CTF. Before proceeding, perform all Daily Maintenance listed in the Periodic Maintenance section. Also complete all loading, priming, phasing, and ratio check procedures. 1. Set push the EMERGENCY POWER and press the control power to the ON position (if required). 3. Confirm that the material tanks level is normal. 4. Confirm that the machine maintenance, ratio checks, and calibrations, and have been completed at the required intervals. From the Main screen select the Shot number as required. 5. From the Main screen press the Shot Mode button and press the START CYCLE or foot switch. 3A0262B 29

30 Shut Down 1. From the SHOT FLOW screen, select the RETRACT button, select the OFF button, 2. Press and release the EMERGENCY STOP button. Ensure everything is OFF. 3. Inspect the pump shafts for a material buildup. Clean and lubricate. 3A0262B 30

31 Daily (once a shift or as required) Periodic Maintenance Water Trap Bowl Material Reservoirs Check air circuit water trap valve and release any water, as necessary, through the base outlet. Check material levels and refill as necessary. Ensure that the material reservoirs are vented properly. (Dry Air, Nitrogen, etc.) Air Dryer Pump Shafts Check the condition of the desiccant air dryer. Clean both pump shafts with solvent and lubricate with Mesamoll. Dispense Head Dismantle, clean thoroughly, and reassemble. Lubricate all parts with a thin coat of Mesamoll. *Refer to Daily Operation and Shutdown Sections of the manual, if material is leaking refer to the Troubleshooting Section of this manual. 3A0262B 31

32 Troubleshooting Pumping (after satisfactory startup) Problem Cause Solution Pump stalling and no material being pumped despite adequate input pressure. Blocked mixer. Turn off air supply and remove hoses from mixer. Check hoses for flow. Pumps cycling satisfactorily but total material output dropped off, or one pump output lags behind the other. Pumps not discharging normal or full volume. Pumps not cycling at all or pumps not completely cycling. Pumps drawing material back down from hose. Closed outlet ball valves. Blocked check valve. One pump metering incorrectly. Low material level in reservoirs. Air in material (normally only high viscosity material). Piston worn or broken. Check valve malfunction. Flow controls set differently Air circuit failure. Check valve stuck open. Open ball valves Unlikely to be fully restricted, but possible. Dismantle, clean, and reinstall. Check both outputs from the hoses. If pumps are out of phase or if one pump is not discharging a full shot of material, see next solution. Refill reservoirs. Prime pump and hoses. Reload reservoir with minimum air entrapment. (Ask for technical advice.) See air in hose solution. Remove and inspect suspected piston. Replace if worn, damaged. Remove, clean, and reinstall the check valve. Readjust flow controllers. See Logic Circuit troubleshooting. Remove check valve and clean or replace. 3A0262B 32

33 Troubleshooting Pumping (after satisfactory startup) continued Problem Cause Solution Material continues to flow after pumps stop dispense stroke, or air bubble apparent at some part of the dispense stroke each time. Air in hose. Hose not primed correctly. Air in material entrapped during reservoir refill. Incline hose from check valve to outlet of hose. Avoid sags in hose. Cycle machine until all trapped air is discharged. Reload reservoir with minimum air entrapment. (Ask for technical advice.) Air in material being drawn into pump from behind check valve. Remove check valve and fitting in front of pump. Reinstall with PTFE tape. Air in material being drawn Tighten or seal as necessary. into pump through inlet hoses or coupler. Severe leaks at pump shaft. Pump shaft seals worn. Remove pump packing assembly Pumps remain in extended position and will not return. Roller trip switch faulty. and replace shaft seal set. If roller trip switch has air pressure applied but does not function when checked, replace. Pumps remain at rest in retracted position and do not move when the machine is signaled to start. Pump is out of calibration. Material cured on piston rod. Pump is out of calibration. Recalibrate pump. Clean piston rod, apply Mesamoll. Recalibrate pump. Motionless Mixer (after satisfactory startup) Problem Cause Solution Material leaks past inlet valves of dispense valve, mixing block, or dispense block. Inlet valve O-ring or seals damaged or worn. Replace O-rings or seals. 3A0262B 33

34 Graco Ohio Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set 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 indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Ohio Information For the latest information about Graco products, visit TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Toll Free: or 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. Original instructions. This manual contains English. MM 3A0262 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO OHIO INC PORT JACKSON AVE NW, NORTH CANTON, OH Copyright 2009, Graco Ohio Inc. is registered to ISO Rev 11/2010 3A0262B 34