Aerobotix RC50. Identification - Instructions A SN8023

Transcription

1 Identification - Instructions Aerobotix RC A For dispensing controlled ratio shots of resin and isocyanate in Class 1, Division 1, Group D atmospheres. SN psi (21 MPa, 206 bar) Maximum Fluid Working Pressure 80 psi (550 kpa, 5.5 bar) Maximum Air Inlet Pressure Important Safety Instructions Read all warnings and instructions in this manual and all supplied manuals. Save these instructions. See Related Manuals on page 3. ti14337a Main Control Panel, Module Applicator Group, and Tempered Water Units Not Shown

2 Contents Related Manuals Graco Manuals Non-Graco Manuals Warnings Isocyanate Hazard Material Self-ignition Moisture Sensitivity of Isocyanates Keep Components A and B Separate Foam Resins with 245 fa Blowing Agents Changing Materials Component Identification Installation General Info Location Electrical Requirements Grounding Check Resistance Startup Pumpline Operation Human Machine Interface (HMI) Screens Tanks Pumpline Temperature Control Other Components Variable Frequency Drive Setup Day Tanks Dispense Gun Hoses Optional Robot Interface New Machine Maintenance Pouring Operation Low and High Pressure Circulation Pouring Requirements Beginning the Pour Night Mode Operation Starting Night Mode Requirements for Continuing Night Mode Shutdown Overnight/Weekend Long-Term Shutdown Settings Temperature Control Pouring Settings MixHead Settings Chemical Flow Settings Day Tank Settings Flow Measurement Controls Pressure Relief Procedure Air Pressure Relief Chemical Line Pressure Relief Maintenance Schedule Purge Air from Metering Pump Drain the Water Separator Check/Replace Metering Pump Inlet Filter Check Tightness of all Clamps and Fittings Check Hoses for Wear Replace the PLC battery Empty the Day Tank Troubleshooting Alarm Status Screen Alarm History Screen Alarms List Troubleshooting Chart Recommended Spare Parts Technical Data Graco Ohio Standard Warranty Graco Ohio Information A

3 Related Manuals Related Manuals Graco Manuals These manuals can be found at Sub-Component Manuals Relates Manual No. to Part Description U80756 All Assembly Drawings Manual High Pressure Fluid Regulators Instructions and Parts High Pressure Fluid Heater VISCON HP Instructions /4 in. NPT Fluid Port Ball Seat Applicator Instructions and Parts Model GX-7 Gun Operation and Service Non-Graco Manuals Intrinsically Safe Barriers Agitators Flow Meters Pressure Transducers Thermocouples Safety Relays Solenoid Valves Magnetic Couplings Filters Flow Meter Cable Heat Exchanger Level Sensors Motors Pump and Motor Assembly A 3

4 Warnings Warnings For complete warnings, see supplied manuals. See Related Manuals on page 3. 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. ARC FLASH HAZARD An arc flash can shock, burn or cause death. An arc flash in explosive atmospheres can cause an explosion. Do not install the Main Control Panel, which is not intrinsically safe, in a hazardous area, as defined in Article 500 of the National Electrical Code (USA) or your local electrical code. 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 equipment only in well ventilated area. Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). Keep work area free of debris, including solvent, rags and gasoline. Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. Ground all equipment in the work area. See Grounding instructions. Use only grounded hoses. Hold gun firmly to side of grounded pail when triggering into pail. If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. Keep a working fire extinguisher in the work area A

5 Warnings WARNING INTRINSIC SAFETY Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements. Be sure your installation complies with national, state, and local codes for the installation of electrical apparatus in a Class I, Division 1, Group D Hazardous Location, including all of the local safety fire codes, NFPA 33, NEC 500 and 516, and OSHA Equipment that comes in contact with the safety barrier s intrinsically safe terminals must be rated for Intrinsic Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting. The equipment in the hazardous area is intrinsically safe or explosion proof when no external electrical components are connected to it. If any other electrical component is connected, it must be used in conjunction with a safety barrier. Without the safety barrier, the equipment is no longer intrinsically safe and must not be operated in hazardous locations, as defined in article 500 of the National Electrical Code (USA) or your local electrical code. Do not install the Main Control Panel, which is not intrinsically safe, in a hazardous area, as defined in Article 500 of the National Electrical Code (USA) or your local electrical code. Ground the intrinsically safe power supply. A voltage limiting safety barrier must be properly grounded to be effective. For proper grounding, use the ground wire provided (or a 12 gauge minimum ground wire), and the barrier s ground must be within 1 ohm of true earth ground. Do not operate the safety barrier module with the cover removed. SKIN INJECTION HAZARD High-pressure fluid from dispense device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. Do not point dispense device at anyone or at any part of the body. Do not put your hand over the dispense outlet. Do not stop or deflect leaks with your hand, body, glove, or rag. Follow Pressure Relief Procedure in this manual, when you stop dispensing and before cleaning, checking, or servicing equipment. 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 A 5

6 Warnings WARNING 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. Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use. Check equipment daily. Repair or replace worn or damaged parts immediately with genuine 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. 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. 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. 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 A

7 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 NOTICE 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 A 7

8 Component Identification Component Identification NOTE: See print U50166 for Module Applicator Group identification. See Assembly Drawings manual U80756 for further Graco-component identification. See non-graco component manuals for further non-graco component identification. AA AB AD AC AE POLY Side AG AH AF ti14337a ISO Side Key: AA Heat Exchangers AB Pressure Gauges AC Volumetric Flow Meters AD Machine Junction Box AE Iso Pumpline AF Poly Pumpline AG Poly Heater AH Poly Filter FIG. 1: RC50 Base - Front View A

9 Component Identification AJ AP AK ISO Side ti14338a AL AM AN POLY Side Key: AJ Poly Tank Agitator AK Poly Tank AL Iso Tank AM Iso Filter AN Iso Heater AP Iso Tank Agitator FIG. 2: RC50 Base - Rear View A 9

10 Component Identification DF 1 2 DA DE DB DC DD 1 DF DG Replacement Danger and Warning labels, tags and cards are available at no cost. Approved for Class 1, Division 1, Group D atmospheres. UL508A approved. Key: DA Intrinsically Safe Barrier DB Main Power On Light DC Control Power On Button DD Emergency Stop Button DE Main Disconnect Switch DF Warning Labels DG Main Control Panel FIG. 3: Main Control Panel A

11 Installation Installation General Info Be sure all accessories are adequately sized and pressure-rated to meet system requirements. Location Substitution of components may impair intrinsic safety. For installation, maintenance or operation instructions, read instruction manuals. Do not install equipment that is approved only for non-hazardous locations in a hazardous area. Main Control Panel: Install in the non-hazardous area. RC50 Base: Install according to requirements for Intrinsically Safe Installation (FIG. 4). Remote Tempered Water Units: Install in the non-hazardous area. NOTE: For an Intrinsically Safe Installation, the RC50 base may be located inside or outside the hazardous location. Install according to appropriate electrical codes. IMPORTANT: Do not substitute or modify system components as this may impair intrinsic safety. NOTE: Refer to FIG. 4 on page 12 for hazardous location equipment requirements. Refer to U80645 and U80762 prints for component orientation. Non-intrinsically safe terminals (power rail) must not be connected to any device which uses or generates more than 250 VRMS or DC unless it has been determined that the voltage has been adequately isolated. The installation must meet the requirements of the National Electric Code, NFPA 70, Article 504 Resp., Article 505 and ANSI/ISA Multiple earthing of components is allowed only if high integrity equipotential system is realized between the points of bonding. Do not operate system with safety barrier cover removed A 11

12 Installation NON-HAZARDOUS LOCATION ONLY HAZARDOUS (CLASSIFIED) LOCATION CLASS I, DIV I, GROUP D ISO Tempered Water Unit ISO Agitator ISO Agitator POLY Heater POLY Tempered Water Unit X-P SO X-P SO X-P SO X-P SO Robot Control Cabinet X-P SO X-P SO X-P SO X-P SO ISO Metering Pump POLY Metering Pump ISO Heater Main Control Panel Safety Barrier 460 VAC Supply Voltage X-P SO Intrinsically Safe Wiring through Barriers Machine Frame Panel Robot Base All conduits must be rigid metal conduit X-P SO = Explosion Proof Seal-Off NOTES: 1. All intrinsically safe conduits/wires/cables are to enter the main control panel on the safety barrier side of the main control panel. This wiring must not come near or in contact with any non-intrinsically safe wiring. 2. Any replacement of intrinsically safe barriers must be an identical replacement to maintain intrinsically safe circuit rating. 3. The non-intrinsically safe terminals (power rail) must not be connected to any device which uses or generates more than 250 Vrms or d.c. unless it has been determined that the voltage has been adequately isolated. 4. The installation must meet the requirements of the National Electric Code, NFPA 70, Article 504 Resp., Article 505 and ANSI/ISA Multiple earthing of components is allowed only if high integrity equipotential system is realized between the points of bonding. 6. Do not operate system with safety barrier cover removed. WARNING: Substitution of components may impair intrinsic safety. For installation, maintenance or operation instructions, see instruction manual. FIG. 4: Intrinsically Safe Installation A

13 Installation Electrical Requirements All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations. Enclose all cables routed in high traffic areas in conduit to prevent damage from materials, solvent, and traffic. NOTE: All components are electrically tested at the factory. The system operates with 89 amps, 60 Hz, 3 Phase, 460 volts input power. All conduits must be installed by a qualified electrician per U80638 print. Connect Main Power 1. Connect power to line side of Main Disconnect Switch (DE). 2. Ground the Main Control Panel to a true earth ground. See Grounding, page 14. Connect Main Control Panel to Main Junction Box See U80638 schematic. Connect Main Control Panel to Pumpline Motors, Agitator Motors, and Heaters See U80638 conduit schedule and chart A 13

14 Installation Grounding Do not run wires around the Intrinsically Safe Barrier (DA) instead of through the barrier as this will impair intrinsic safety. See FIG. 3 on page 10. See grounding procedure and related warnings in supplied manuals. See Related Manuals on page 3. For Intrinsic Safety The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit. Ground wires from the pumps must be connected to the same true earth ground. See FIG. 5, page 15. Ground the system as described here and in the individual component manuals. A ground wire and clamp, part number , is available from Graco. Module Applicator Group Connect a ground wire to a true earth ground. Air and Fluid Hoses Use grounded hoses only. Check Resistance To ensure proper grounding, resistance between components and true earth ground must be less than 1ohm. Have a qualified electrician check resistance between each component and true earth ground. If resistance is greater than 1 ohm, a different ground site may be required. Do not operate the system until the problem is corrected. Main Control Panel Connect a ground wire to a true earth ground. Machine Junction Box Connect a ground wire to a true earth ground. Flow Meters The Volumetric Flow Meters (AC)are grounded through the power cable connection to the Machine Junction Box (AD). Heaters Connect a ground wire to a true earth ground through main control panel. See U80638 schematic. Pumpline Motors Connect a ground wire to a true earth ground through main control panel. See U80638 schematic. Agitator Motors Connect a ground wire to a true earth ground through main control panel. See U80638 schematic A

15 Installation NON-HAZARDOUS LOCATION ONLY HAZARDOUS (CLASSIFIED) LOCATION CLASS I, DIV I, GROUP D Main Control Panel RC50 Base Iso Tempered Water Unit Poly Tempered Water Unit NOTE: Assemblies not shown to scale Module Applicator Group (not all items shown) ti14339a NOTE: See U80638 control schematic. FIG. 5: Grounding A 15

16 Startup Startup See startup instructions and related warnings in supplied manuals. See Related Manuals on page Go through the Pre-Operation Checklist in the following table. 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. See FIG. 3 on page 10 for more information. 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. Checklist System Grounded Verify all grounding connections were made. See Grounding, page 14. All connections are tight and correct Verify all electrical, fluid, air, and system connections are tight and installed according to the supplied schematics. Air supply valves are open Verify all incoming air ball valves are open. Fluid supply valves are open Verify all fluid supply valves are open. 7. Verify all alarm and shutdown setpoints are set. See Settings, page 45. Pumpline 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 54. Manual or Automatic Mode selected (see Pouring Operation, page 42) Requirements for Operation The machine operates at high pressure and high voltage. Be careful during operation and always wear the appropriate protective gear. 2. Purge air from metering pump. See Maintenance section on page 54 for procedure. 3. Turn on main power by turning the power handle so it points to ON. See FIG. 3 on page 10 for more information. 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. 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 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. See Alarms List, page 59, for more information. Starting Metering Pump Motors Navigate to the Machine Control screen, and turn on the material pump motors A

17 Operation Operation 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 1 BT BE 2 3 BF BG BH BJ BK BL BM BN BP BR Screen is only accessible when logged in as one of the Maintenance usernames. If not logged in this button will not be accessible. Shown on all screens. Must be logged in as Operator, Maintenance, or Factory for screens to have functionality. FIG. 6 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 BT Shot Count Reset A 17

18 Operation Last Shot Data The control system records the actual shot time after the shot has occurred for each dispense gun. The control system also captures the flow rates, ratios, temperatures, and pressures for the last shot. The flow rate is captured shortly after the shot begins. A running count of the number of shots taken is tracked and can be returned to zero by pressing the reset button. Login/Logout When logged in as a default user, only the Main Menu screen is accessible. The user must log in as an Operator (Password 20) to gain access to all screens except for the Scaling screen. To gain access to the Scaling screen, the user must log in as a Maintenance user (Password 10). The Factory user name is reserved for Graco factory personnel to set initial parameters on the machine. 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 A

19 Operation 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 3 9 CR CE CL 1 2 CF CG CH CQ CM CN CP CA CK 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. Only shown when Night Mode is activated. 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. Shown on all screens. FIG. 7 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 CK Flowrate (grams per second) CL MixHead Piston Position Rectangles CM Manual Control CN Automatic mode CP Manual mode CQ MAG drive temperature CR Fault Status CS Night Mode Status A 19

20 Operation Manual, Automatic Modes With control power on, either of these 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 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. Manual Control Manual Control allows the operator to dispense material without a remote (robot) signal. See Manual Control Screen on page 21 for more information A

21 Operation Manual Control Screen DA DE 1 DD DB DC 1 Only active when service mode has been selected. Key: DA Visual Indicators: PLC Inputs DB Visual Indicators: PLC Outputs DC Temperature/Flow Information DD Visual Indicator of Active Gun DE Service Mode Control FIG. 8 Service Mode Service mode allows the operator to open the gun for service under no load. The Open/Close Service Mode Gun Control buttons will not be active unless the Service Mode button is pressed. The Service Mode button shuts both pumps down to eliminate the chance of material being dispensed while the gun is being serviced.note: The gun may still dispense material because of the pressure on the day tanks. Ensure that the gun is also in service mode to prevent this from occurring. Automatic Mode Status The Automatic Mode Status section is a visual status indicator for the communication between the RC machine and the Robot. The machine must be in Auto Mode for the indicators to function. If the RC machine receives a signal from the robot while in Manual mode, the indicator will show the signal, but the signal will be ignored. For further detail on this interface, refer to the Robot Interface section found in this manual. Manual Mode Gun Control The Manual Mode Gun Control allows the operator to dispense material manually from the HMI. The material will dispense for the duration of time assigned to the channel set. The time duration can be set for each channel under the Pour Time Editor A 21

22 Operation Machine Control Screen DA DD DD DB DE DD DF FIG. 9 Key: DA Low Level Bypass On/Off Control DB Gun Enable 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. System Outlet Conditions Data The data along the bottom of the screen for flow, ratio, pressure, and temperature display the machine's outlet conditions A

23 Operation Tank Control Screen EA EF EG FIG. 10 Key: EA Auto-Fill On/Off EF Fail to Fill Alarm Delay EG Fill Delay Iso, Poly Temperature Control The Temperature Control Screen is accessible by pressing the Temperature Control button. See Temperature Control Screen on page A 23

24 Operation Temperature Control Screen FB FD FC FA FE FF 1 1 Press the Temp Gain Setup button to change the temperature gains. FIG. 11 Key: FA Ideal Temperature Setpoint FB High Temperature Alarm Setpoint FC Low Temperature Alarm Setpoint FD Actual Temperatures FE Temperature Log Access FF Temperature Gain Access Heat Exchange and Supply Heater Temperature Control 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. See Temperature Gains on page A

25 Operation Pour Time Editor Screen FC FA FD FE FF FIG. 12 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 only in the Manual Control screen A 25

26 Operation Setup Screen GC GB GE GA GF GD FIG. 13 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 See Settings section on page 45 for more information. Night Mode On/Off Time See Night Mode Operation on page 43 for more information. Blocking Valve/Gun Close Delay See Pouring Settings on page A

27 Operation Flow Control Screen This screen is accessible from the Flow Control screen but only if logged in as one of the Maintenance usernames. HB HA HK HM HL HJ HN HP HR HS HT HD HU HH HE HF HG FIG. 14 Key: HA Manual Flow Control HB Automatic Flow Control 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) HH Flow Ratio HJ Manual Mode Poly Motor RPM Setpoint HK Manual Mode Iso Motor RPM Setpoint HL Automatic Mode Ratio Setpoint (Iso divided by Poly) HM Automatic Mode Total Flow Setpoint (grams per second) HN Iso Hi Speed Calibration Setpoint Percent HP Iso Low Speed Calibration Setpoint Percent HR Poly High Speed Calibration Setpoint Percent HS Poly Low Speed Calibration Setpoint Percent HT Start Calibration HU Stop Calibration A 27

28 Operation 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. 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. 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 A

29 Operation Scaling Screen This screen is only accessible when logged in as one of the Maintenance usernames. JK JA JB JJ JL JC JD JE JG JH JF FIG. 15: 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 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 50 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 A 29

30 Operation Temperature Log Screen This screen is accessible from the Scaling screen. KA KB KC KD KE KF KG KH FIG. 16: 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 A

31 Operation Alarm History and Alarm Status Screens See Troubleshooting section on page 57 for Alarm screens details A 31

32 Operation Tanks MC MK MM MB MH MA MB MD MJ ML ME MF MG ti14338a1 FIG. 17 Key: MA Tank MB Pressure Relief and Manual Vent Valve MC Pressure Gauge and Regulator MD Level Sensor ME Metering Pump Inlet Filter MF Tank Outlet to Pump Ball Valve 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 MM Auto-fill Air Operated Ball Valve A

33 Operation NOTICE 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 dispense gun, the machine includes temperature conditioned and pressurized day tanks. Temperature conditioning is accomplished by circulating the chemicals through a heat exchanger in the inlet supply line and heater in the high pressure supply line. The operator-selected temperature is maintained by the program. 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 45. 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. Metering Pump Inlet Filter NOTICE 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 54. Air Pressure System The minimum recommended supplied dry air pressure is listed in the table at the beginning of the Settings section on page 45. 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 48 for more information. 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 45. 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 A 33

34 Operation Pumpline NG NE NE NH NC ND ti14338a1 FIG. 18 NB NA NF Key: NA Pump Turn-Dial NB Metering Pump NC Metering Pump Air Purge Valve ND Metering Pump Motor NE Pressure Switches NF Relief Valve NG Pressure Transducer NH Inlet Pressure Gauge Both pumps are protected on the inlet side by a basket filter and a low-pressure switch. An inlet pressure gauge also provides a visual indication of the pump inlet pressure. 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 45 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 45 for settings. A pressure transducer provides a digital signal to the PLC to indicate the outlet pressure. Should this pressure be exceeded, the affected metering pump motor will automatically stop and will be accompanied by alarms A

35 Operation Temperature Control PC PB PA PD PA PE ti14337a1 FIG. 19 PA Heater PB Heat Exchanger PC Supplied Water Inlet PD Supplied Water Outlet PE Thermocouple Heat Exchanger The heat exchanger (PB) cools the chemical in the pump inlet line prior to reaching the pump. The HMI sends a temperature setpoint signal to the tempered water units using the thermocouples (PE) as feedback. The tempered water units open and close a water inlet valve as necessary to maintain the desired fluid temperatures. Tempered Water Unit The stand-alone tempered water units improve the efficiency of the heat exchanger. The function of the tempered water units are to cool or heat the inlet water flowing to the heat exchanger to increase the temperature control on the material. Heater The heater (PA) heats the material to the desired temperature before moving to the dispense gun. Over-Temperature Switches For operation information, see Temperature Control section on page 45. For factory settings, see the table at the beginning of the Settings section on page A 35

36 Operation Other Components QA QA QB QB QC ti14338a1 FIG. 20 Key: QA Chemical Line Pressure Gauge QB Flow Meter QC Air Manifold Circulation Valve A pneumatically operated Circulation Valve (remotely mounted) allows low pressure operation at startup and between shots. It transfers flow from the outlet of the flow meter, through the dispense guns so that flow bypasses the back-pressure regulator A

37 Operation 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 on page 48 and Calibrating Machine-Calculated Mass Flow on page 50 for more information on Variable Frequency Drive operation A 37

38 Setup Setup Avoid breathing of vapors and contact with Isocyanate as some people have severe allergic reactions. See Isocyanate Hazard on page 7. 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. Day Tanks Tanks Connect all hoses and slowly pressurize each tank while checking for any leaks. See Settings section on page 45 for suggested pressure procedure. Chemical Feed System Each day tank has an inlet port on the back, where the chemical feed line gets connected A

39 Setup Dispense Gun Hoses SB SA SC SD ti14338a1 FIG. 21: Dispense Gun Hose Setup Key: SA Poly Return to Tank SB Poly Pressure SC Iso Pressure SD Iso Return to Tank A 39

40 Setup Optional Robot Interface The following information is the typical sequence of operation for a Robot Dispense Command. 1. The Robot System is placed in the proper state for automatic cycle. 2. The RC System is placed in the proper state for automatic cycle (remote mode). 3. The RC System turns on the RC System Ready for Automatic Cycle signal. 4. The Robot System turns on the Robot High Pressure Request signal. 5. The RC System goes into high-pressure recirculation mode and readies itself for dispensing 6. The RC System turns on the RC System Ready for Dispense signal. 7. The Robot System turns on the Robot System Dispense command. 8. The RC System opens the spray gun (begins to dispense) and the RC Dispensing signal is turned on. 9. The Robot System turns off the Robot System Dispense Command signal. 10. The RC System closes the gun (stops dispensing) and turns off the RC System Dispensing signal. 11. At this point in the sequence, the spray process can be repeated by returning to step 7 or the robot can return the RC System machine to low-pressure recirculation mode by turning off the Robot System High-Pressure Request signal A

41 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 54 for instructions A 41

42 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. 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. When any of the following conditions are met, the machine will be in high pressure circulation. 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 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 Iso and Poly Metering Pump Motors on 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 A

43 Night Mode Operation Night Mode Operation NOTICE 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 are on. 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. The following requirements must be met to start night mode. Main and Control power on 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 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 To see how the night mode information is displayed, see Status Screen, page 19. Starting Night Mode See FIG. 9 on page 22. 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 A 43

44 Shutdown Shutdown Overnight/Weekend If using Night Mode to circulate chemicals and maintain chemical temperature, see the Night Mode Operation section on page 43. Otherwise, follow these steps. NOTICE 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. 10. Turn on main power and control power. 11. Run the system in manual mode for 45 minutes. See Manual, Automatic Modes 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. 2. Turn off main power and lockout. 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. 3. 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. 9. Remove lock on main power A