Volume Verification and Batch Control Meter

Transcription

1 Instructions Parts List Volume Verification and Batch Control Meter B Ambient Module (C59617) Temperature Conditioned Module (C59607) Heated Module (C59608) Read warnings and instructions. See page 2 for table of contents.

2 Table of Contents Warnings Operation Unpacking and Repacking Troubleshooting Unpacking the Product Troubleshooting Information Repair and Repacking the Product Technical Data Overview Graco Standard Warranty Installation Graco Information Related Manuals Fluid Flow Meter Mastic Regulator

3 Warnings Warning Symbol WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. Caution Symbol CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions. INSTRUCTIONS EQUIPMENT MISUSE HAZARD WARNING Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in serious injury. This equipment is for professional use only. Read all instruction manuals, warnings, tags, and labels before operating the equipment. Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco distributor. Do not alter or modify this equipment. Use only genuine Graco parts and accessories. Check the equipment daily. Repair or replace worn or damaged parts immediately. Do not exceed the maximum fluid working pressure of 3500 psi (241 bar, 24.1 MPa) to the dispenser or manifold. Never exceed the recommended working pressure or the maximum air inlet pressure stated on your pump or in the Technical Data on page 24. Be sure that all spray/dispensing equipment and accessories are rated to withstand the maximum working pressure of the pump. Do not exceed the maximum working pressure of any component or accessory used in the system. Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco standard hoses to temperatures above 180F (82C) or below 40F ( 40C). Do not use the hoses to pull the equipment. Use only fluids and solvents that are compatible with the equipment wetted parts. See the Technical Data sections of all the equipment manuals. Read the fluid manufacturer s warnings. Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and solvent manufacturers. Comply with all applicable local, state and national fire, electrical and other safety regulations

4 INJECTION HAZARD WARNING Spray from the applicator, hose leaks, or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury. Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medical attention. Do not point the applicator at anyone or at any part of the body. Do not put hand or fingers over the front of the applicator. Do not stop or deflect fluid leaks with your hand, body, glove, or rag. Follow the pressure relief procedure recommended by the system integrator whenever you are instructed to: relieve pressure; stop dispensing; clean, check, or service the equipment; or install or clean a nozzle. Tighten all the fluid connections before operating the equipment. Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose. Always wear eye protection and protective clothing when installing, operating, or servicing this dispensing equipment. Do not remove or modify any part of the applicator; this can cause a malfunction and result in serious bodily injury. Use extreme caution when cleaning or changing nozzles. If the nozzle clogs while applying material, Always follow the pressure relief procedure recommended by the system integrator, then remove the nozzle to clean it. Never wipe off build-up around the nozzle or inlet cap until pressure is fully relieved

5 WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in fire or explosion and serious injury. Ground the equipment, the object being sprayed, and all other electrically conductive objects in the dispense area. Proper grounding dissipates static electricity generated in the equipment. See Grounding the Electrical Control on page 13. Do not use this equipment with flammable liquids. Keep the dispense area free of debris, including solvent, rags, and gasoline. If there is any static sparking or you feel an electric shock while using the equipment, stop dispensing immediately. Do not use the equipment until you have identified and corrected the problem. Be sure all electrical work is performed by a qualified electrician only. Have any checks, installation, or service to electrical equipment performed by a qualified electrician only. Be sure all electrical equipment is installed and operated in compliance with applicable codes. Be sure power is disconnected when servicing and repairing equipment. Before operating the equipment, extinguish all open flames or pilot lights in the dispense area. Do not smoke in the dispensing area. Keep liquids away from the electrical components Disconnect electrical power at the main switch before servicing the equipment. TOXIC FLUID HAZARD Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled. Provide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed. Know the specific hazards of the fluid you are using. Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines. Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer. Avoid exposure to heated material fumes

6 Unpacking and Repacking Unpacking the Product The Volume Verification and Batch Control Meter (VVM) was carefully packaged for shipment by Graco. When the package arrives, perform the following procedure to unpack the units: 1. Inspect the shipping box carefully for shipping damage. Contact the carrier promptly if damage is discovered. 2. Unseal the box and inspect the contents carefully. There should not be any loose or damaged parts. 3. Compare the packing slip against all items included in the box. Any shortages or other inspection problems should be reported immediately. 4. Store the box and packing materials in a safe place for future use. Graco recommends that all packing materials be saved in case the unit needs to be shipped again. Repair and Repacking the Product When the VVM requires service, it is the purchaser s responsibility to have the unit repaired. As an option, the purchaser can have the unit repaired by an authorized Graco distributor. For additional information, read the following subsections. On-site Service The VVM components are customarily serviced by the purchaser or an authorized Graco technician. When service is required, follow the Service procedures in this manual. Service by an Authorized Graco Distributor The VVM can be serviced by an authorized Graco distributor after completing a Return Goods Authorization (RGA) form. The purchaser must re-package and ship the VVM to the Graco distributor. When repacking the Regulator/Meter with Control Module, perform the following steps: 1. Retrieve the original box and packing materials for shipment. 2. Place the VVM and any loose or damaged parts in the same bag and box used in the original shipment. Fill the box with filler material to minimize the possibility of damage. 3. Seal the box tightly to protect its contents and prevent shipping damage. 4. Insure your shipment for the proper replacement value of its contents. 5. Ship the VVM freight prepaid to your authorized Graco distributor for service

7 Overview Ambient, Temperature Conditioned, or Heated Regulator/Meter with Control Module Capabilities The ambient regulator/meter with electrical control dispenses precise volumes of sealant and adhesives in a variety of applications. The ambient regulator/meter with electrical control consists of a fluid flow meter, carrier frequency pulse amplifier (sensor), and control module. Fig. 2 Fluid Flow The mastic regulator (Figure 1) regulates fluid pressure and dampens pressure surges. The fluid flow meter contains two cycloid shaped screw spindles which mesh and rotate inside a cylindrical housing. The fluid flow meter housing has two overlapping holes in the form of a figure 8, which forms the measuring chamber. Fig. 3 Fig. 1 The medium flows in axial direction, rotating the spindles. The medium is forced along the measuring chamber bores by the profile of the spindles without pulsation and with minimum leakage. The carrier frequency pulse amplifier, or sensor, (Figure 2) inductively detects the gear teeth tips of the spindle pair through the housing via a pole wheel. This process allows measurement without the pickup coming in contact with the fluid. The displacement of the spindles is proportional to the volume flow over a very high range. The signal from the carrier frequency pulse amplifier is sent to the electrical control (Figure 3). The meter assembly shown in Figure 2 is the model used at the time of this printing. Your assembly may look somewhat different but will function exactly the same. The electrical control includes the enclosure containing power, sensing, and control electronics for the regulator/meter. It is designed to work with other equipment usually supplied by the integrator to monitor, and if desired, control the volume of material through the system. Temperature Conditioned and Heated Modules The temperature conditioned and heated regulator/meter modules provide the user with the ability to process materials that need to be temperature-stabilized. The temperature conditioned module allows the user to either increase or decrease fluid temperature of the system relative to the ambient temperature. The heated module allows the user to supply only heat to the system. Setup and operation of the temperature conditioned and heated modules will be addressed by the overall applied system or the system integrator

8 Overview Batch Control Mode In Batch Control mode, a customer-supplied start signal and solenoid valve opens the system dispense valve and the minimum volume dispensed signal is used to shut the valve off once a preset volume of material has been dispensed. Monitor Mode In Monitor mode, a customer supplied signal opens and closes the system dispense valve. The control compares the actual volume dispensed to preset high and low limits and outputs Volume within limits and volume fault outputs via the interface. Interfaces The control interfaces with the other system components via an interface cable. The control comes supplied with a labeled, 25, seven conductor cable. These strands are labeled with terminal numbers which correspond to the following signals shown in Fig. 4: Additionally, the control can be wired with optional cable C59015 for RS485 connection directly to the BC106 batch controller. This connection allows for remote interrogation, changing, and reset of count values, high/low limits and scale factors. For details of the communication format and command descriptions refer to the BC106 manual included with the unit. Fig

9 Controls A D B BC106 The BC106 front panel allows the user to enter parameters to control the operation of the system. The system high and low limits and the scale factor may vary greatly depending upon the application and are commonly changed as needed via the front panel. The scale factor is a multiplier, which in conjunction with the scale multiplier, converts the raw signal from the meter into the desired units for display. As they are the most commonly changed parameters, each can be accessed by a single button on the front panel, SF for scale factor, P1 for low limit and P2 for high limit. C Fig. 5 The front panel of the control includes: A Volume Fault Indicator (Red) B Volume Within Limits Indicator (Green) C Fault Reset Button D BC106 front panel Factory Presets Timer Relay The timer relay TR 120 is located inside the control box and is used to define the end of a batch or shot. The timer allows for interruptions in the dispensing cycle of up to 10 seconds without an end of batch signal by counting when pulses from the flowmeter cease and delaying the logical end of batch until the preset time has past. In general, this time delay should be set.2 seconds longer than any skip duration in the dispense cycle. The unit comes from the factory set for operation. Presets as shipped: Code Button Value Parameter status 43 1 A is active, B is inhibited 44 1 Count pulse at on to off transition 45 1 Count multiplier set to one decimal location 52 3 At reset, start monitoring counts 53.1 Output #1 time delay 54 1 Output #2 stop at reset 55.1 Output #2 time delay 61 3 Process and batch output reset to zero with button 62 1 Process counter reset to zero and tracking disabled 63 1 Batch counter reset to zero 64 3 Batch output termination reset at start Batch output time delay 66 4 Presets, scale factor and reset available at front panel P1 1 Minimum number of cc for an acceptable batch/shot P2 3 Number cc at which to declare oversized batch/shot SF.2850 Scale factor of flowmeter with particular material for readout in cc. NOTE: The presets listed above are set by Graco and do not correspond to the control manufacturers factory presets listed on page 6 of the BC106 manual

10 Overview Additionally, there are 8 dip switches on the back of the BC106 controller that are set as shown in Fig. 6. Fig. 6 NOTE: If the unit is in an electrical noise free environment, the contact of control relay CR138 on line 112 (see schematic) may be shorted and the #5 dip switch placed in the up position. This will allow post dispense monitoring of any component downstream of the flowmeter for leaks. If a leak is detected then the high alarm fault will be activated. Initial set up When the controls have been integrated into the entire dispense system it, verify that the scale factor (SF) setting is appropriate for the material being dispensed. To do this: 1. Weigh an empty container (use a scale that reads grams to simplify additional calculations) and dispense material into the container. 2. To determine the net weight of the material, weigh the container of material and subtract the weight of the empty container. 3. If the displayed output does not correspond to the actual output adjust the SF until the display is accurate. a. To adjust SF if the desired readout display is weight in grams (gm): new SF = original SF X (net weight displayed reading) b. To adjust SF if the desired readout display is volume in cubic centimeters (cc): new SF = original SF X (cc displayed reading) 4. Repeat adjustment as necessary until display is accurate. Once a dispense cycle has been set up for the system, timer relay TR120 should be adjusted to.2 sec greater than the longest skip duration in the dispense cycle and the high and low limits set

11 Overview Reading the Regulator/Meter with Control Assembly Controls and Indicators Tables 1 and 2 describe the controls and indicators on the regulator/meter with control assembly. See Figure 5 for an illustration of the controls and indicators. Table 1. Control Assembly Controls Button P1 P2 SF RESET What it Does Controls the volume. Target volume for an acceptable batch/shot in batch control mode Minimum volume for an acceptable shot in monitor mode Controls the volume. Target volume at which to declare a high volume alarm in batch control mode Maximum volume for an acceptable shot in monitor mode Scale factor of flowmeter with a particular material When the unit senses a fault, the RESET button must be pressed before monitoring will continue. Table 2 describes the indicators on the electrical control assembly. Table 2. Control Assembly Panel Indicators Indicator Light Indicator Meaning Light is Red ON Volume fault exists Green ON Volume within limit

12 Installation Suggested Tools and Materials To install the electrical control, we suggest these tools and materials: Standard open end wrench set Multi meter Mounting hardware [(8)1/4 20X1 bolts and (8)1/4 20 nuts Attaching hardware (air lines, material hoses and wire) Thread sealant Electrical Control Installation To install the electrical control: Prepare to install the electrical control. Mount the electrical control. Ground the control (electrically). Connect electrical control to the flowmeter. Connect electrical control to the interface. Check resistance between the electrical control and a true earth ground. Connect electrical control to a power source. WARNING ELECTROCUTION HAZARD Installing and servicing this equipment requires access to parts which could cause an electric shock or other serious injury. Have only qualified electricians access the control assembly. Preparing to Install the Electrical Control Before installing the electrical control: See component manuals for specific data on component requirements. Data presented here pertains to the regulator/meter with control assembly only. Have all applicable documentation available during installation. Use only the Graco electrical control assembly with the regulator/meter. Mounting the Electrical Control 1. Select a location to mount the electrical control. Keep the following in mind: Allow sufficient space for mounting and using the equipment: Mount the electrical control approximately 48 to 67 (1.2 to 1.7 m) above the floor. Make sure all cables reach components without strain. Make sure there is sufficient space for repair, maintenance, and operation of the regulator/ meter with control. The National Electrical Code requires 3 feet (91.4 cm) of open space in front of the control assembly. Make sure there is sufficient clearance around the control assembly for running fluid lines and cables to other components. Make sure there is easy and safe access to an appropriate electrical power source. 2. Secure the electrical control using four 1/4 bolts through the two.44 diameter holes and two slots in the mounting flanges. See Fig. 7 for the mounting hole spacing of the electrical control

13 Installation.44 holes slots Fig. 7 Grounding the Electrical Control WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD To reduce the risk of fire, explosion, or electric shock: The regulator/meter with control assembly must be electrically connected to a true earth ground; the ground in the electrical system may not be sufficient. All wires used for grounding must be 8 AWG (8.36 mm 2 ) minimum. A qualified electrician must complete all grounding and wiring connections. Refer to your local code for the requirements for a true earth ground in your area. Also read and follow the warnings on pages 3 through. CAUTION If power and grounding connections are not done properly, the equipment may be damaged and the warranty will be voided. Connect a ground wire from the GND terminal in the electrical control (shown in wiring diagram on pages 20 and 21) to a true earth ground

14 Installation Checking Resistance Between the Electrical Control and the True Earth Ground WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD To reduce the risk of fire, explosion, or electric shock, the resistance between the supply unit components and true earth ground must be less than 0.25 ohms. Have a qualified electrician check the resistance between each system component and the true earth ground. The resistance must be less than 0.25 ohms. If the resistance is greater than 0.25 ohms, a different ground site may be required. Do not operate the regulator/meter with control module until the problem is corrected. Connecting the Electrical Control to a Power Source Perform the following procedure to connect the electrical control to a power source. Have a qualified electrician connect the control to a grounded electrical source that has the following required service ratings: Description Requirements Vac: 120 Hz: 50/60 Phase: 1 Full Load Amps:.3 at 120 Vac NOTE: Power to the electrical control must be supplied from a source with a lockable-off disconnect switch, or by use of a cord with a plug-and-socket connection to the source of power. To connect the electrical control to the electrical source: 1. Shut off system power at the main circuit breaker. 2. Locate the 120 vac, 3 amp power cable on the bottom of the electrical control. See Fig Connect electrical power to the control assembly. WARNING ELECTRIC SHOCK HAZARD Do not connect the control to a power source unless you are a trained electrician. Failure to follow standard procedures or to observe the necessary precautions could result in serious bodily injury or equipment damage. CAUTION If power and grounding connections are not done properly, the equipment may be damaged and the warranty will be voided. Fig. 8 Flow Meter Interface Power Cable

15 Operation Adjusting the Regulator Outlet Pressure WARNING To reduce the risk of serious injury, never remove the adjusting screw or diaphragm housing when the valve is under pressure. Adjust the pump air pressure and the regulator pressure for the best spray/dispense combination. For the optimum performance, the inbound fluid pressure should be at least 600 psi (4.1 MPa, 41 bar) above the regulated outlet fluid pressure at maximum desired flowrate. NOTE: When using a fluid pressure gauge in the regulator outlet, partially relieve pressure by triggering the gun before reducing the regulator pressure. This helps ensure a correct gauge reading. Table 3 shows the approximate air pressure needed to regulate the air-operated regulator to a given fluid outlet pressure. Table 3. Fluid Pressure to Air Pressure Chart Air Pressure Regulated Fluid Outlet Pressure psi bar kpa psi bar MPa The Volume Verification Meter (VVM) is designed as a modular component of larger dispense systems. See the system manual, provided by the integrator, for VVM operation in relation to the system. Pressure Relief Procedure This assembly is intended to be used as part of a larger system. Consult your integrator for system pressure relief

16 Troubleshooting Some solutions require disassembling the dispense valve. Always relieve system pressure before performing these procedures. WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the pressure relief procedure recommended by the system integrator. Troubleshooting Information Table 4 provides troubleshooting information. For other troubleshooting situations, call your Graco distributor. Table 4. Troubleshooting Problem Causes Solutions Regulator/Meter with Control Module Clogged nozzle. Change nozzle inoperable. No material being dispen- sed. (NOTE: When a fault occurs, No material or pressure. Check fluid delivery system the RESET button must be Fault in dispense valve. For applicator: Refer to manual: pressed before monitoring will continue.) C Gun does not shut off in batch control mode. Volume Low fault or Fault condition before dispense cycle is complete. Improper control settings. Time set too short. Check status of all control parameters, including high/ low limits and scale factor. Reset as necessary. Adjust timer TR120. Inaccurate volume display Scale factor/multiplier incorrect Adjust scale factor and scale multiplier as necessary. Volume High fault Leaky dispense valve Check dispense valve for leaks. Valve control error Check for proper function external valve controls

17 Preventive Maintenance Schedule Table 5 shows the preventive maintenance schedule for the Regulator/Meter with Control Module. Repair technicians must conform to the prescribed maintenance intervals to prevent malfunctions and unscheduled production interruptions. For components or procedures that are not listed in the table, call your Graco distributor. Table 5. Preventive Maintenance Schedule Schedule Component Description Reference Weekly Inspect cables and hoses Inspect the dispense valve for signs of leakage 3 to 6 months Service the dispense valve using repair kit

18 Parts Part No. C58985, Control Meter 1 2 TI0699 Ref. No. Part No. Description Qty. 1 C58985 CONTROL, electrical 1 (See component manuals included with enclosure) 2 C59592 REGULATOR/METER, Ambient 1 (Shown) (See manual ) C59552 REGULATOR/METER, Temperature Controlled (T/C) (See manual ) C59554 REGULATOR/METER, Heated (See manual )

19 Wiring Diagrams

20 Wiring Diagrams

21 Wiring Diagrams

22 Dimensions Part No. C58985, Electrical Control Assembly

23 Dimensions Part No. C59592, Ambient Regulator, Meter Module 9.00 In Out TI

24 Technical Data Unit Description Specification Flow Meter Measuring Capacity 0.1 to 11 Gallons per minute Supply Voltage 7 to 29 VDC Current Requirement <4 ma Max. Operating Pressure 4,150 PSI Fittings 3/4 14 NPT(f) Operating Temp. Range FLUID 0 deg C to +150 deg C (32 deg F to deg F) AMBIENT 20 deg. C to +80 deg. C Output Signal Hz PULSE Weight 14 lbs. (X kg) Electrical Assembly Control Input power Approx.Weight 120 Vac, 1/60Hz,.3FLA 25 lbs. (11.4 kg) Performance Envelope Flowrate Shot size (volume) Repeatability/accuracy 1.0 cc/second, minimum 10 cc (minimum per application) 5% (after calibration)

25 Notes

26 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées. Graco Information TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you: Toll Free. All information, illustrations and specifications in this document are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice Sales Offices: Minneapolis, Detroit International Offices: Belgium, Korea, Hong Kong, Japan GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN PRINTED IN U.S.A /2000 Revised 04/2003