SN8044 RC. Operation - Maintenance E. For dispensing controlled ratio shots of resin and isocyanate. Not for use in explosive atmospheres.

Transcription

1 Operation - Maintenance SN8044 RC E For dispensing controlled ratio shots of resin and isocyanate. Not for use in explosive atmospheres psi (20.6 MPa, 206 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this and all supplied manuals. Save these instructions. ti11588b Machine shown may be different from your machine

2 Contents Models...3 RelatedManuals...3 Warnings...4 Isocyanate Hazard...6 Material Self-ignition...6 Moisture Sensitivity of Isocyanates...6 Keep Components A and B Separate...6 Foam Resins with 245 fa Blowing Agents...6 Changing Materials...6 Component Identification...8 System Schematic...8 Main Panel...11 Human Machine Interface (HMI) Screens Tanks...26 Setup...27 Connecting Electrical Cord...28 Day Tanks...29 Robot Interface...29 BlockingValve...29 New Machine Maintenance...30 Start-Up...31 Pumpline...31 Pouring Operation...32 Low and High Pressure Circulation...32 Pouring Requirements...32 Beginning the Pour...32 Night Mode Operation...33 Starting Night Mode...33 Requirements for Continuing Night Mode...33 Shutdown...34 Overnight/Weekend...34 Long-Term Shutdown...34 Settings...35 Temperature Control...35 Heated Hose and Power Control System...37 PouringSettings...37 MixHead Settings...38 Chemical Flow Settings...38 DayTankSettings...39 Flow Measurement Controls...40 Pressure Relief Procedure...43 Air Pressure Relief...43 Chemical Line Pressure Relief...43 Maintenance...44 Schedule...44 Purge Air from Metering Pump...44 Drain the Water Separator...44 Check Desiccant...44 Replace Desiccant...44 Check/Replace Metering Pump Inlet Filter...45 Check Tightness of all Clamps and Fittings Check Hoses for Wear...45 Replace the PLC battery...45 Empty the Day Tank...46 Troubleshooting...47 AlarmStatusScreen...47 AlarmHistoryScreen...48 AlarmsList...48 Troubleshooting Chart...50 Dimensions...51 TechnicalData...53 Graco Ohio Standard Warranty...54 GracoOhioInformation E

3 Models Models Frequency Maximum Working Pressure, Model Voltage Amps (Hz) Phase psi (MPa, bar) SN (20.6, 206) See Connecting Electrical Cord, page 28, for cord specifications. Related Manuals Assembly Drawings Manual Part Description U80752 Assembly Drawings Manual Pumpline Manuals Part Description 3A0019 Z-Series Chemical Pumps Instructions - Parts 3A0020 Horizontal Hydraulic Driver Repair - Parts Heated Hose Manuals Part Description Heated Hose Manual Power-Lock Splice Kit Auto-Fill Manuals Part Description Husky 1040 Air-Operated Diaphragm Pumps Feed Pump Kits Regulator Manuals Part Description Low Volume Air Regulators High Pressure Regulator E 3

4 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 E

5 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 E 5

6 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 ISOontheBside. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side E

7 Changing Materials E 7

8 Component Identification Component Identification System Schematic NITROGEN SUPPLY SCFM TANK BLEED RELIEF NITROGEN BLANKET SHUTOFF BLEED SHUTOFF AGITATOR ASSY M GR TANK PRESS GAUGE PSI PRESS REGULATOR SAFETY RELIEF VALVE 1/2" HOSE BLOCKING VALVE TANK FLUID LEVEL SIGHT GAUGE X LEVEL SENSORS 20 GAL TANK INLET LOW PRESS SWITCH SET TO 10 PSI X TANK OUTLET BALL VALVE METERING PUMP INLET FILTER 1" HOSE TANK DRAIN VALVE 1/2" HOSE PRESSURE TRANSDUCER PSI AIR SUPPLY SCFM X NITROGEN BLANKET SHUTOFF TANK PRESS GAUGE PSI TANK BLEED RELIEF BLEED SHUTOFF AGITATOR ASSY M GR PRESS REGULATOR SAFETY RELIEF VALVE 1/2" HOSE TANK FLUID LEVEL SIGHT GAUGE X LEVEL SENSORS 1/2" HOSE TANK OUTLET BALL VALVE 20 GAL TANK METERING PUMP INLET FILTER 1" HOSE INLET LOW PRESS SWITCH SET TO 10 PSI ADJUSTABLE PRESS RELIEF SET TO 3000 PSI INITIALLY MIXHEAD HIGH PRESS SWITCH SET TO 3200 PSI TANK DRAIN VALVE T/C M MIXHEAD HIGH PRESS SWITCH SET TO 1500 PSI 1/2" HOSE Pump Motor E

9 Component Identification POLY BACK PRESS VALVE HEATER POLY LOW PRESS RECIR VALVE FLOWMETER GPM POLY SIDE A2 POLY SUPPLY 1/2" HOSE T/C T/C HIGH PRESS GAUGE PSI PRESSURE RELIEF VALVE SET TO 850 PSI X P B T A P B T A P T B A POLY BACK PRESS VALVE BLOCKING VALVE HEATER POLY LOW PRESS RECIR VALVE FLOWMETER GPM ISO SIDE M A2 POLY SUPPLY 1/2" HOSE T/C T/C HIGH PRESS GAUGE PSI E 9

10 Component Identification E

11 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. 1 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. 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 E 11

12 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 BE BF BG BH BJ BK BL BM BN BP BR FIG. 2 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 E

13 Component Identification 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. Login/Logout To gain access to the Scaling Screen, the user must login in as a Maintenance Operator (Password 10). The Factory user name is reserved for Graco factory personnel to set initial parameters on the machine. Logged in as a Default user allows access to all other functions not reserved for the Maintenance/Factory users. The scaling screen will not be accessible to a Default user. 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 E 13

14 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. 5 CC 6 CD CS 3 1 CB 9 CR CL 1 2 CF CG CH CQ CT CU CV CM CN CP 4 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. Shown on all screens. FIG. 3 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 CT Linear Pump Direction CU Hydraulic Pump Motor Speed CV Linear Pump Position E

15 Component Identification 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 E 15

16 Component Identification Manual Control Screen FIG. 4 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. Manual Mode Gun Control 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. 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 in this manual E

17 Component Identification Machine Control Screen DA DG DD DB DE DC DF FIG. 5 Key: DA Low Level Bypass On/Off Control DB Gun Enable DC Iso/Poly Motor Start/Stop DD Iso/Poly Agitator Motor Start/Stop DE Night Mode On/Off DF Flow Information DG Poly Pump Control 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. Poly Pump Mode These buttons control the position and function of the linear poly pump. The retract button retracts the pump rod to prevent build up along the working stroke length. This prolongs seal life and should be used anytime the equipment is shut down for maintenance or an extended period E 17

18 Component Identification Tank Control Screen EA EF EG FIG. 6 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 E

19 Component Identification Temperature Control Screen FIG. 7 Supply Heater Temperature Control These buttons are used to turn temperature control (heaters) 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. The element temperature is the temperature measured by the probe on the heater element. The Iso/Poly temperature is the material temperature measured by the probe diretly upstream of the respective flowmeter. Hose Temperature Control These buttons are used to turn the hose temperature control on or off. The Low Temp and High Temp are the alarm limits for the respective hose temperature set point. The Output percent shows the output of the temperature controller to the heated hose. The Temperature Controller automatically controls the output to the heated hoses. The Output percent displays the output percent of the temperature controller. When the Output percent is 100, the temperature controller is full on heating E 19

20 Component Identification Pour Time Editor Screen FC FA FD FE FF 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 only in the Manual Control screen E

21 Component Identification Setup Screen FIG. 9 See Settings section on page 35 for more information. Night Mode On/Off Time See Night Mode Operation on page 33 for more information. Blocking Valve/Gun Close Delay Sets delay time for blocking valve/gun close delay. This is used to offset any delay as the blocking valve or gun wears. The blocking valve delay is the duration of time the blocking valve will wait to close after receiving a pour command. This is to account for the slower opening of the gun. The gun close delay is the delay after the signal is removed before the gun closes. Poly High/Low Pour PSI The poly pump is equipped with a pressure transducer, which monitors the outlet pressure of the poly pump. The poly high/low pressure are the maximum and minimum pressure settings and serve the same function as the pressure switches found on the iso pump. As a mechanical backup, a pressure relief valve is located on the hydraulic power pack limiting the hydraulic pump. It is factory set to 850 psi which allows the poly material pump to build pressure up to 3200 psi E 21

22 Component Identification Flow Control Screen FIG. 10 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. 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. 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 E

23 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. 11: 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 41 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 E 23

24 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. 12: 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 E

25 Component Identification Alarm History and Alarm Status Screens See Troubleshooting section on page 47 for Alarm screens details E 25

26 Component Identification Tanks 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. 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 35. 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 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 44. Air Pressure System The minimum recommended supplied dry air pressure is listed in the table at the beginning of the Settings section on page 35. 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 39 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 35. 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 E

27 Setup Setup Avoid breathing of vapors and contact with Isocyanate as some people have severe allergic reactions. See Isocyanate Hazard on page 6. 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 E 27

28 Setup Connecting Electrical Cord Power cord is not supplied. See following table. Cord Specification Model Voltage Amps AWG SN GND L1 L2 L3 ti3248a All Models: Connect three power leads to L1, L2, and L3. Connect green to ground (GND) E

29 Setup Day Tanks Tanks Connect all hoses and slowly pressurize each tank while checking for any leaks. See Settings section on page 35 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. Robot Interface The following information is the typical sequence of operation for a Robot Dispense Command. 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 Blocking Valve To provide the ability to set the Iso and Polyol dispense rate and pressure, a blocking valve and back-pressure regulator valve are provided. When the signal is sent to dispense and the RC machine is in the proper state, the blocking valve will close and the air solenoid will open to allow the gun to dispense. When the machine is in high-pressure recirculation mode, the pressure can be set with the back-pressure regulator. Since the gun is operated by an air solenoid, a hydraulic power pack is not installed in this machine and will differ from the standard RC machine in this regard. Blocking Valve Low Pressure Circulation Valve 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. High Pressure Regulator NOTE: To prolong the life of the back-pressure valve, remove the regulator handle and fill the cavity with Mesamoll. Verify this monthly, more often depending upon conditions and usage. To provide greater temperature control of the Polyol and Iso materials, a low-pressure re-circulation circuit is provided. This bypasses the regulator and allows the material to be temperature controlled under low pressure E 29

30 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 45 for instructions E

31 Start-Up Start-Up Air in metering pumps must be purged. See Purge Air from Metering Pump on page 44. Manual or Automatic Mode selected (see Pouring Operation, page 32) 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 11 for more information. 1. Purge air from metering pump. See Maintenance section on page 44 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. 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 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 48, for more information. Starting Metering Pump Motors Navigate to the Machine Control screen then turn on the desired material pump motors. 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. 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 E 31

32 Pouring Operation Pouring Operation If all of the above requirements are satisfied, then the MixHead Pour Ready indicator on the Status Screen will be green, see page 14. 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. 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. 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. 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. MainPoweron 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 E

33 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 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. 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 14. Starting Night Mode See FIG. 5 on page 17. 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 E 33

34 Shutdown Shutdown Overnight/Weekend If using Night Mode to circulate chemicals and maintain chemical temperature, see the Night Mode Operation section on page 33. 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 manual mode for 45 minutes. See the manual mode subsection in the Settings section 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 11. 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 E

35 Settings Settings Temperature Switch Pressures 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) Pressure Switch Pressures Settings 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... 10psi(0.068MPa,0.68bar) Day Tank Operating Air Pressure... 40psi(0.27MPa,2.7bar) Supplied Air Pressure psi ( MPa, bar) Day Tank Pressure Relief Valve... 75psi(0.51MPa,5.1bar) Supplied Water Pressure....40psi(2.76bar) Supplied Water Temperature F (18 C) 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. Built into the HMI program there is an absolute high temperature alarm that will shut down the pumps when triggered. 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. 6 on page 18. 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. 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 E 35

36 Settings 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. 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. 12 on page 24. This screen is accessed from the Scaling screen, see FIG. 11 on page 23. 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 E

37 Settings 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. If you have a true RMS AC current meter, you can check one of the hose cables for 45 amps AC +/- 2 amps while the green signal light and orange current limit light are both steadily on. The Hose Heat Output percent on the Temperature Control Screen should read 100%. Heated Hose and Power Control System Please refer to the included heated hose manual, , for safety and warning instructions regarding the installed heated hoses. The Hose Power Control System automatically maintains an optimum power setting for hose heat systems based upon the temperature value inputted by the operator in the software. The system eliminates the need for manual adjustment of transformer tap settings or manual hose heat power control. The transformers and controllers are located inside the two side cabinets mounted to the main electrical enclosure. When troubleshooting the system, input a temperature that is higher than the current hose temperature to turn the hose heaters on. Referencing the following image, ensure the green signal light above terminal #4 is on. Also verify that the orange current limit light above terminal #5 is on. As the hose reaches the commanded temperature, the orange current limit light will flicker off slowly, followed by the green light. Pouring Settings Iso, Poly Specific Gravity Chemical specific gravities are entered from the Setup screen, see FIG. 9 on page 21. 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. 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 20 then select that channel on the Manual Control screen. Press the Start button on the Manual Control screen. 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 E 37

38 Settings Pressure Build Time Pressure Build Time is set using the Setup screen, see FIG. 9 on page 21. 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 21. 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 17. 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. 11 on page 23 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. 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. Chemical Flow Settings 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, using the back pressure regulator valves. See Setup Screen on page 21 and Machine Control Screen on page 17 for details about changing the following settings E

39 Settings Main and Control Power on Night Mode must be off Appropriate Metering Pump Motors must be on When the preceding requirements are met: 1. Select manual mode and high pressure override to put the machine into high-pressure circulation. 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. 2. When the chemical line pressures are within 200 psi, turn off the high pressure override. Adjusting Metering Pump Motor RPM 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. 10 on page Stop incoming air by closing the day tank incoming air valve. 2. Open day tank manual vent valve (MB). 3. Allow the day tank charge pressure to bleed to 5 psi (0.034 MPa, 0.34 bar). 4. Close the day tank manual vent valve (MB). 5. Open day tank incoming air valve (MK). 6. Adjust pressure regulator (MC) fully clockwise. 7. Set day tank pressure by turning pressure regulator. See the table at the beginning of the Settings section on page 35 for recommended setting. 8. Adjust the pressure regulator counter-clockwise until it just starts to exhaust. 9. From this point, adjust the pressure regulator clockwise one half-turn. 10. Lock valve knob in place. 1. Navigate to the Flow Control screen. 2. Under the Flow Control heading, select Manual mode. 3. Under Manual Mode Setpoints, type in the desired metering pump motor percent for each motor. Day Tank Settings Adjusting Day Tank Air Pressure Tank fumes will discharge when opening the day tank manual vent valve. CAUTION Do not allow the pressure to drop below 5 psi as this may introduce moist air to the system. This is especially important during periods of extended shutdown. See Moisture Sensitivity of Isocyanates, page E 39

40 Settings Flow Measurement Controls Adjusting Flowrate. Ensure the chemical specific gravities are accurate and calibrate the flowrate accuracy before adjusting the flowrate. See Calibrating Machine-Calculated Mass Flow on page 41. With Variable Frequency Drive and with Flow Meters If a Variable Frequency Drive is installed then the Flow Control screen will be available. This screen can used to automatically adjust metering pump motor rpm so that the flow rate remains constant. 1. Turn on MixHead and Metering Pump Motors. 2. Select calibrate mode. 3. Navigate to the flow control screen. 4. Select Automatic from the Flow Control screen to select Automatic mode. 5. Type in the desired grams per second and ratio. The speed of each metering pump motor speed will continually adjust to achieve the input flowrate and ratio. 6. If necessary, balance the chemical line pressures by slowly adjusting each orifice on the MixHead with a hex key until the pressure remains constant for at least five seconds E

41 Settings Calibrating Machine-Calculated Mass Flow Parts/Tools Required 5 Gallon Bucket to catch spilled material 5 Gallon Bucket to weigh dispensed material Avoid breathing of vapors and contact with Isocyanate as some people have severe allergic reactions. See Isocyanate Hazard on page 6. This section applies only to systems with Flow Meters. Scaling screen access is required for calibration. The Scaling screen can only be accessed when logged in using a specific username and password which is controlled by the owner of the machine. Before performing this procedure, ensure you can access the Scaling screen. To log in, navigate to the Main Menu screen, select Login and type in the appropriate username and password. The following procedure describes how to adjust the mass flowrate calculated by the machine. To calculate the mass flowrate, the machine uses the chemical specific gravities entered on the Setup screen, the volumetric flow measured by the flow meters, and the K-Factor inputs for each chemical. The flow meters are calibrated at the factory and will never need to be calibrated unless harmful materials pass through them, such as solvents or materials including abrasives, which are strongly discouraged for use in the machine. While this procedure adjust the K-Factor, its purpose is to fine-tune the calculated specific gravity of each chemical used. Because of this, it is very important to have accurate chemical specific gravities entered on the Setup. The specific gravities entered on the HMI at the factory are for mesamoll which is used to test the machine before shipment. The specific gravities will need to be updated every time new chemicals are used. Before performing this procedure, verify the specific gravities entered on the HMI are accurate for the chemicals currently in each tank. See Iso, Poly Specific Gravity on page 37. Weighing scale to measure weight of empty and filled bucket Relieve Pressure 1. Turn off all motors. 2. Turn the main panel power handle to the off position and lockout. 3. Relieve air pressure, hydraulic fluid pressure, and chemical line pressure. See Pressure Relief Procedure on page 43. Execute Calibration Shot 4. Unlock the main power handle and turn on. 5. Turn on control power. 6. Turn on MixHead. 7. Turn on the metering pump motor for the chemical to be calibrated, which will have the one open orifice at the MixHead. 8. Turn on Automatic Mode. 9. Log in to gain access to the Scaling screen. 10. Measure the weight of the clean, dry, and empty calibration bucket in grams. Record this measurement or tare the scale. 11. Place the calibration bucket in an appropriate location to catch the dispensed material. Because this procedure is for fine-tuning, having even a small amount of material splash out of the bucket will affect the calibration effectiveness. The bucket should be held at an angle to prevent material splashing. 12. Navigate to the Scaling screen and under Single Stream Calibration Shots press the button labeled as the chemical to be calibrated. 13. Press the pour start button. A shot lasting the preset time for the channel selected on the pour pendant will begin E 41

42 Settings Adjust K-Factor as Necessary 14. Remove the calibration bucket, weigh, and calculate the dispensed material weight. 15. On the scaling screen the weight of the shot calculated by the machine will be shown. If this matches the weight of material dispensed then the machine is accurately calculating the flowrate for that chemical. If so, move to step If the displayed weight does not match the weight of the dispensed material, touch the Test Shot Act Weight (gm) and enter the exact weight in grams of the dispensed material. 17. Record the current K-Factor and then hit the Calculate New K-Factor. This will change the K-Factor so the machine will accurately calculate dispensed weight. Repeat to Test New K-Factor 18. Repeat the procedure as desired to test flow measurement accuracy with new K-Factor. Repeat for other Chemical Line 19. Repeat the calibration procedure as necessary with the other chemical line E

43 Pressure Relief Procedure Pressure Relief Procedure Chemical Line Pressure Relief 1. Turn off and lockout main power. See Lockout section on page 11 for procedure. Before performing system maintenance, system pressure must be relieved. Air Pressure Relief CAUTION Relieving air pressure in the machine means that the supplied dry air will be replaced by moist, room air. Do not leave the machine exposed to moist air for more than 30 minutes. When the metering pump motors are turned off, all chemical line pressure is relieved except for the pressure coming from the tank blanket air pressure. 2. Relieve tank air pressure. See Air Pressure Relief procedure. 3. Ensure there is no pressure in the chemical lines by looking at the pressure gauges mounted above the main panel. If the machine must be left without air pressure for more than 30 minutes, the day tanks must be emptied and thoroughly flushed. See Long-Term Shutdown on page Turn off and lockout main power. See Lockout section on page 11 for procedure. 2. Close day tank incoming air supply valve. See Tanks section on page Disconnect air supply hose from water separator (MG). See Tanks section on page Bleed air pressure from system by opening the pressure relief valve (MB) on top of each day tank. See Tanks section on page Ensure there is no air pressure in the tanks by looking at the pressure gauges mounted on the tanks E 43

44 Maintenance Maintenance Schedule Procedure Purge Air from Metering Pump Drain the Water Separator Check Desiccant Check Metering Pump Inlet Filter Check Tightness of all Clamps and Fittings Check Hoses for Wear Replace PLC battery Empty the Day Tanks Frequency Daily before use Daily Daily Weekly Monthly Monthly As Needed As Needed Purge Air from Metering Pump 1. Place a small bucket under valve opening. 2. Open the bleed valve on the metering pump case slowly. 3. Keep valve open until a steady stream of fluid, with no air or bubbles, is released from the bleed valve. 4. Close the bleed valve. Check Desiccant When desiccant is new, it will be blue. Over time, the desiccant will fade to pink. Replace the desiccant before it is completely pink. The speed at which the desiccant is used will vary depending on the amount of moisture in the incoming air supply. Replace Desiccant Drain the Water Separator This procedure is performed with the system pressurized. 1. Pressurize the air system. 2. If desired, place container underneath water separator to catch expelled water. 3. Depress purge valve. 4. Release valve when all traces of water are gone. Relieve air pressure. See Pressure Relief Procedure on page Disconnect the air supply. 2. Remove the desiccant bowl and service with fresh desiccant. 3. Replace the bowl and bowl guard. Do not pressurize the air system without the bowl guard in place. The bowl could burst under pressure. 4. Reconnect the air supply E

45 Maintenance Check/Replace Metering Pump Inlet Filter 7. Ensure that the element is properly seated in the bowl and replace the cap. 8. Hand tighten the clamp. 9. Open the tank ball valve and check for leaks. Always relieve day tank pressure and close the tank bleed valve to prevent fluid flow to the metering pump inlet filter. Failure to do this can lead to getting sprayed with chemical when opening the filter. CAUTION Do not open the metering pump inlet filter cap immediately before leaving the machine at rest for a long period of time. This will introduce moist air to the chemical and may cause the chemical to react and not mix properly when dispensed. This procedure requires exposing the chemicals to moist air. Have all necessary tools and parts nearby to minimize the amount of time the chemicals are exposed to the moist air. See assembly drawings manual for filter and o-ring part numbers. One indication that the metering pump inlet filter requires service is the low inlet pressure alarms when there is adequate day tank pressure and fluid volume in the tanks. To Remove/Inspect the Filter 1. Turn the main power handle to the off position and lockout. 2. Relieve day tank pressure. Make sure the tank air pressure gauges read zero pressure. 3. Close day tank ball valve to prevent flow from the tank to the pump inlet filter. 4. Remove filter cap and visually inspect the filter element for particles. To Replace the Filter 5. Replace the element and o-ring as required. 6. Liberally coat the o-ring and surrounding surfaces with a moisture free grease. 10. Apply day tank pressure. 11. Remove lock on main power. 12. Turn on main power and then control power. 13. Start motors and run for at least 60 minutes to circulate the material that has been exposed to moist air. Check Tightness of all Clamps and Fittings 1. Turn off main power and lock out. 2. Wait until all parts are cool to the touch. 3. Walk around the machine and inspect for loose clamps and fittings. 4. Tighten clamps and fittings as necessary. Check Hoses for Wear Look for wear on all hoses where they come into contact with anything. Over time, rubbing may wear down the hose and increase the chance for a hose rupturing. Replace all hoses with noticeable wear. Replace the PLC battery This procedure requires entering the main panel where the main power is routed. To avoid serious injury or death, disconnect main power source at the wall using breaker or by unplugging the machine. If a PLC Battery Low alarm is triggered, the battery will need to be replaced. 1. Turn off main power. 2. If necessary, unlock the main panel door. 3. Open the main panel door E 45

46 Maintenance 4. Locate the PLC battery, which should be in the HMI on the back of the main panel door. 5. Replace battery. 6. Close main panel door and lock the main panel if necessary. 7. The system clock and date may need to be reset. Empty the Day Tank See the day tank capacity in the table at the beginning of the Settings section on page 35. To avoid a potential mess, always prepare to collect up to the full capacity. 1. Turn the main power handle to the off position and lockout. 2. Close tank air supply valve (MK). 3. Depressurize day tank to approximately 5 psi. 4. Place container to catch tank fluid. 5. Open the tank outlet valve (MJ) and the tank drain valve (ML) and empty tank into the container. 6. Be careful as the last of the tank fluid is released, there will be a semi-uncontrolled spitting of material from the 5 psi charge. 7. Close the tank supply valve and replace the drain plug. If no further maintenance is anticipated, leave the 5 psi charge of dry air on the tank. Otherwise vent the charge to zero pressure. CAUTION If the machine will be left with zero pressure for more than 30 minutes, the day tanks must be emptied and thoroughly flushed to avoid chemical crystallization and machine damage. See Long-Term Shutdown on page E

47 Troubleshooting Troubleshooting See the table at the beginning of the Settings section on page 35 for temperature and pressure alarm settings. Alarm Status Screen RA RB RC FIG. 13 Key: RA Alarm Silence RB Alarm Reset RC Reset Alarm Data Alarm conditions are indicated on the Alarm Status screen which can be selected from the menu bar along the bottom of all screens. A new alarm condition will cause an alarm to sound and the new alarm message will immediately appear in the alarm display section. Pressing the Alarm Silence button will silence the alarm beeper and pressing Alarm Reset will reset the alarm if the fault is absent. Alarms must be silenced, cleared, and reset prior to restarting any motors stopped by the alarm E 47

48 Troubleshooting Alarm History Screen 1 1 Sort button. Push to sort by name or time of alarm. FIG. 14 This screen stores all alarms that have been triggered. See the table at the beginning of the Settings section on page 35 for pressure and temperature switch settings. Alarms List Pouring Alarms If a pouring alarm has been triggered, and the cause is unknown, dry cycling the machine may be helpful in finding the cause. See the MixHead On/Off section on page 38 for more information. Any alarm that will stop the MixHead Hydraulic Unit operation will stop a pour. Iso/Poly Failed To Build Pour Pressure Alarm This alarm occurs during pressure build. A timer in the PLC controller will stop the pour sequence if the metering pump fails to develop minimum pouring pressure within a set time. Typically 15 seconds longer than the pressure build time is allowed before this alarm will occur. Iso/Poly Low Pour Pressure Alarm If the chemical pressure during a pour drops below the setting for the Low Pour Pressure Switch will be tripped and will stop the pour. Improper orifice adjustment is a possible cause E

49 Troubleshooting Iso/Poly High-Pressure Alarm The High-Pressure alarm can occur any time the pressure at the pump discharge rises above the setting on the high-pressure switch at the pump discharge. This alarm stops both the Iso and Poly pumps and stops any pour in progress. This may be caused by improper orifice adjustment. Ratio Out Of Tolerance Warning/Shutdown When the dispensing ratio is outside of the tolerance specified on the Flow Control Screen this alarm will be displayed. Flow Rate Out Of Tolerance Warning/Shutdown When the total flow rate is outside of the tolerance specified on the Flow Control Screen this alarm will be displayed. Iso, Poly Metering System Alarms Iso, Poly Pump Motor Overload Alarm This alarm causes an immediate stop of the metering pump motor. If the motor overload alarm has occurred, the overload button on the starter must be reset before the motor can be started. Iso, Poly Metering Pump Inlet Low-Pressure Alarm This alarm is generated any time the inlet pressure at the metering pump drops below the setting of the inlet low-pressure switch. This alarm stops the affected metering pump motor. Possible causes for this alarm: Metering pump inlet filter may be clogged and need to be serviced Day tank pressure is too low Pump inlet valve is closed and need to be opened to allow fluid flow from tank Iso, Poly Metering Pump High-Pressure Alarm Tanks Alarms Iso/Poly Tank Low Level Alarm This alarm will occur when the tank level reaches 10%. This alarm affects the running of the pump fed by the tank and affects pouring depending on whether the Low Level Bypass is turned on or off. Iso/Poly Tank Auto-Fill Failed to Fill This alarm is triggered when the Auto-Fill fails to fill within the time specified on the Tank Control page. This alarm protects from overfilling the tanks in the event one of the top fluid level sensors fail. Iso/Poly Tank Agitator Motor Overload This alarm is triggered when the agitator motor overloads. Temperature Alarms Poly/Iso Heater High Temperature This alarm is triggered when the temperature reaches the heater high temperature switch setting. In this event, the heater will need to cool to the heater switch on-temperature setting. Iso/Poly Low/High Temperature These alarms are triggered when the iso or poly chemical temperature goes outside of the range specified by the high and low temperature setpoints on the Tank Control screen. These alarms will not trigger within the first 30 minutes after startup to allow for chemical temperatures to stabilize. Iso/Poly MAG Drive High Temperature This alarm exists only for machines with MAG drives. The alarm is triggered when the MAG drive temperature reaches the high temperature setting specified in the table at the beginning of the Settings section on page 35. When this alarm is triggered, the metering pump motors will shutdown and will not be able to be started until the temperature drops below the setpoint. This alarm is generated any time the pressure at the metering pump rises above the set point on the high-pressure switch, located at the metering pump discharge. Both the Iso and the Poly pump motors stop when one of them triggers the high pressure switch E 49

50 Troubleshooting Other Alarms PLC Battery Low PLC Battery needs to be replaced. See Maintenance section on page 44. Iso/Poly Absolute High Pressure This alarm is triggered when metering pump outlet pressures exceeds the absolute high pressure setting. Troubleshooting Chart Fault Automatic Action taken by Machine Iso, Poly Heater High Temp Alarm banner Yellow alarm light ON Fault horn ON Heater OFF Iso, Poly Pump High Pressure Alarm banner Red fault light ON Fault horn ON Iso pump OFF Poly pump OFF Iso, Poly Pump Low Pour Pressure or Failure to Build Pressure Alarm banner Red fault light ON Fault horn ON MixHead locked CLOSED Iso Pump Low Inlet Pressure Alarm banner Red fault light ON Fault horn ON Iso pump OFF Tank Low Level Alarm banner Red fault light ON Fault horn ON MixHead locked CLOSED Solution 1. Check high temperature set point 2. Check Power cube 3. Allow heater to cool, reset limit switch ONE TIME ONLY 1. All pressure Iso, Poly valves OPEN 2. Check/clean Iso, Poly jet 3. Check Iso, Poly output 4. Check Iso, Poly temperature 5. Check DIN connector on pressure switch 1. Check air supply pressure 2. Adjust Iso, Poly jet 3. Check Iso, Poly output 4. Check Iso, Poly temperature 5. Check DIN connector on pressure switch 1. Open all metering pump inlet valves 2. Check day tank air pressure 3. Check for clogged inlet basket filter 4. Check DIN connector on pressure switch 1. Check fluid level and add fluid as necessary. Turn Auto-Fill ON if installed. 2. Adjust fluid sensor sensitivity E

51 Dimensions Dimensions E D A C B ti11590b FIG. 15 Key: A Length without Boom: 62 in. (158 cm) B Length with Boom: 134 in. (341 cm) C Width: 67 in. (171 cm) D Height without Boom: 73 in. (185 cm) E Height with Boom: 105 in. (267 cm) E 51