Instructions Delta Rim 140 3A0863A ENG For professional use only. Not for use in explosive atmospheres. 2800 psi (19.3 MPa, 193 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.
Contents Warnings................................. 3 Important Two-Component Material Information. 6 Isocyanate Conditions..................... 6 Material Self-ignition...................... 6 Keep Components A and B Separate......... 6 Moisture Sensitivity of Isocyanates........... 6 Foam Resins with 245 fa Blowing Agents...... 6 Changing Materials....................... 7 Introduction............................... 8 Low Pressure Recirculation................ 8 High Pressure Recirculation................ 8 Pouring................................ 8 Definitions................................ 9 Machine Controls......................... 10 Main Electric Console.................... 10 Pour Pendant.......................... 12 Main Menu............................... 13 Status Screen............................. 14 Curative Flow Rate (C), Resin Flow Rate (R), and Ratio indicators...................... 14 Control Screens........................... 15 Control Screen #1....................... 15 Control Screen #2....................... 15 Temperature Control....................... 16 Resin Temperature Control................ 16 Setup Screen............................. 17 Alarm History............................. 18 Alarm Status............................. 19 Startup.................................. 20 Shutdown................................ 21 Emergency Stop........................ 21 Lockout Procedure...................... 21 Operation................................ 22 Mix head Hydraulic Unit Operation.......... 22 Curative and Resin Metering Material Pump Operation.......................... 23 Pump Mode............................ 23 Preparation for Pouring.................... 24 Required Inputs for Pouring............... 24 Adjusting Pressures....................... 25 Curative and Resin K Factor Entry and Calculation............................ 26 Pouring Control........................... 27 Manual Mode Pouring.................... 27 Automatic Mode Pouring (Single Mix Head machine)........................... 27 Steps of Pouring (Single Mix Head Machine).. 27 Summary of Alarms........................ 28 Troubleshooting........................... 30 Graco Standard Warranty................... 36 2 3A0863A
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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. WARNING ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock. Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment. Connect only to grounded power source. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: Use equipment only in well ventilated area. Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). Keep work area free of debris, including solvent, rags and gasoline. Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. Ground all equipment in the work area. See Grounding instructions. Use only grounded hoses. Hold gun firmly to side of grounded pail when triggering into pail. If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. Keep a working fire extinguisher in the work area. 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 MSDSs to know the specific hazards of the fluids you are using. Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air. Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. 3A0863A 3
Warnings WARNING 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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to: Protective eyewear, and hearing protection. Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer. + SKIN INJECTION HAZARD High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. Do not point dispensing device at anyone or at any part of the body. Do not put your hand over the fluid outlet. Do not stop or deflect leaks with your hand, body, glove, or rag. Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment. Tighten all fluid connections before operating the equipment. Check hoses and couplings daily. Replace worn or damaged parts immediately. MOVING PARTS HAZARD Moving parts can pinch, cut 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 and disconnect all power sources. 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 from distributor or retailer. Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use. Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only. Do not alter or modify equipment. Use equipment only for its intended purpose. Call your distributor for information. Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not kink or over bend hoses or use hoses to pull equipment. Keep children and animals away from work area. Comply with all applicable safety regulations. 4 3A0863A
Warnings WARNING THERMAL EXPANSION HAZARD Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury. Open a valve to relieve the fluid expansion during heating. Replace hoses proactively at regular intervals based on your operating conditions. SUCTION HAZARD Powerful suction could cause serious injury. Never place hands near the pump fluid inlet when pump is operating or pressurized. RECOIL HAZARD Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured. 3A0863A 5
Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Spraying or dispensing 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. Keep Components A and B Separate Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment s wetted parts, never interchange component A (isocyanate) and component B (resin) parts. 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. NOTE: NOTE: 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 206995. 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. Foam Resins with 245 fa Blowing Agents Some 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. 6 3A0863A
Important Two-Component Material Information Changing Materials When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. Always clean the fluid inlet strainers after flushing. Check with your material manufacturer for chemical compatibility. Most materials use ISO on the A side, but some use ISO on the B side. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side. 3A0863A 7
Introduction Introduction The metering system operates on the principle of positive displacement pumping of Resin (shown as R on the HMI touch screens) and Curative (shown as C on the HMI touch screens) raw materials through an impingement mixing, mechanically self-cleaning Mix Head designed with a recirculation path to tank. Two types of positive displacement pumping are available. The Delta Rim type machine utili9zes axial piston pumps that directly handle the Resin and Curative raw materials. The operator interface (HMI) provides a setup selection to allow selection of Delta Rim or operation depending on which type of machine the control system is connected to. The HMI also allows the following operation: Low Pressure Recirculation In low-pressure recirculation the seat valves open and bypass flow from the metering pump directly to the return lines and back to the tanks. Pouring When initiating a shot, the pour piston is withdrawn hydraulically and closes the recirculation path in the mix head. The injection ports open instantaneously to the mixing chamber and high-pressure impingement mixing takes place. If using the standard pendant for pour control, the pour is terminated by releasing the pendant Pour Start pushbutton (Manual Mode pouring) or after a preset period of time elapses (Auto Mode pouring). If using the optional press interface, then pour control depends on several factors detailed later in this manual. After each pour, the mixing chamber mechanically purges itself of residual material. The cleaning action differs depending on the mix head type as follows: On the S-Head, the pouring piston cleans the mixing chamber by passing through the discharge nozzle as it moves to its closed position. High Pressure Recirculation In high-pressure recirculation mode the seat valves, which normally allow most of the pumped flow to return to the tank, close and the metering pumps are transitioned to high-pressure by sending all pump flow through the injection nozzle orifice within the mix head. The metering unit allows use of one or two mix heads. When two mix heads are installed, it is necessary to block flow to one mix head whenever using the other mix head. This is done either with manual valves or with an optional switching station having actuated valves. 8 3A0863A
Definitions Definitions The following special terms are used throughout this manual: BUTTON: refers to the touch sensitive areas of the HMI that appear as rectangular shapes and that allow integration with the machine PLC controller. It is also referred to as an indicator. HMI (Human Machine Interface): Refers to the touch screen type operator interface on the front of the control panel. Except for energizing control power and emergency stops, all machine control is accomplished by using the screens on the HMI. DELTARIM: Refers to a metering unit that utilizes motor driven pumps called metering hydraulic pumps that deliver high pressure hydraulic oil to reciprocating material pumps. The reciprocating material pumps actually pump the Curative and Resin chemicals at high pressure through the mix head. S-Head: Mix head style (Straight Head) that does not include a cleanout piston. 3A0863A 9
Machine Controls Machine Controls Main Electric Console There are areas within the controls panels with system power active, use caution when working within the control panel. Mix Head On/Off Switch Audible Alarm Main Power Indicator Emergency Stop Control Power button/indicator Touch Screen, HMI Main Power Indicator: Illuminates when power is applied to the main electrical feed Control Power button/indicator: Provides power for the electrical circuitry in the console. Illuminates when power is ON. Main Power Disconnect Switch: This switch disconnects main feed power to the machine control system, and allows access to the control panel. Audio Alarm: Activates when a fault condition occurs. Emergency Stop button: When pressed, all power is removed from the material pumps. Power is still applied to the control system when the Emergency Stop is pressed. 10 3A0863A
Machine Controls Main Power Disconnect HMI Numeric Keypad When a button requiring a numeric input is pressed, a numeric keypad is displayed. The allowable input range is shown above the number 7 on the keypad. 3A0863A 11
Machine Controls Pour Pendant Start Button Operating in Manual Mode: Press and hold to pour, release to stop pouring Operating in Auto Mode: Press and release, the shot will automatically stop when the preset time has expired. Stop button Press and release to stop an automatic shot before the preset time has expired. 12 3A0863A
Main Menu Main Menu The main menu screen permits selection of each of the screens indicated in the picture above by pressing the buttons located on the touch screen. Each screen is discussed in the sections that follow. 3A0863A 13
Status Screen Status Screen The Status screen shows information for the mix head and it shows machine status information.the machine mode can be changed from this screen. Curative Flow Rate (C), Resin Flow Rate (R), and Ratio indicators The Status screen includes several rectangular shaped indicators that show machine operation status (indicators show green when the named condition is true) as follow: Mix head Pour Ready Indicator: highlighted when all conditions are met, except pressing the pour start push-button) that are required for beginning a pour. Mix head In Cycle Indicator: highlighted when a pour has been started and the controls are in the stages of pouring operation as discussed later in the pouring control section. Mix head Pouring indicator: shows highlighted when the control system has commanded a pour. 14 3A0863A
Control Screens Control Screens Control Screen #1 Control Screen #2 Manual, Calibrate, and Auto Mode Selection The Status Screen permits selection of Manual, Calibrate, or Auto Modes. Mode selection has no conditions; the selection can be changed at any time. The control system will always power-up in the manual mode. The purpose of each mode is: NOTE: Curative/Resin metering pumps can only be turned ON when the hydraulic pump is running. However, turning OFF the hydraulic pump while both pumps are running will also turn OFF the metering pumps. Manual Mode: enables starting of the motors and different types of pour control depending on options installed. Provided all conditions for operation are met, permit pouring for as long as button is pressed. With the Metering pump ON the material circulates from the Day Tanks through the system and back to the same tanks. Calibrate Mode: If one of both metering pumps are running, and then Calibrate Mode is selected then the bypass valves will close and the metering unit will be placed into high-pressure recirculation or the purpose of adjusting mix head orifices. use to adjust high pressures. Selecting the Calibrate Button actuates a pneumatic bypass valve allowing material to flow through the Mix head orifices thus allowing calibration of the high pressures. NOTE: The machine will default to Mix head #1 if two Mix heads are installed. Auto Mode: Selected when operator wants to pour with a pre-selected time from the pendant. The Machine Control screen permits starting of the metering unit motors and selection of several modes of operation. The controls system will always power-up in Manual Mode. Motors can be started or stopped in either manual or auto modes. Curative and Resin Start/Stop Motor Button: The Start/Stop Motor buttons on the Machine Control Screen manually control he Metering Material Pumps. The Status indicator displays the state of the motor. Pump Mode NORMAL button: This enables the curative pump to dispense material into material system. RETRACT button: The curative pumps will immediately retract and remain in the resting (retracted) position. OFF button: When this button is selected the metering pump is inoperative. 3A0863A 15
Temperature Control Temperature Control Resin Temperature Control Temp Cont On/Off button These button turn the temperature control ON or OFF. The displays below the buttons indicate Permitted and On or Not Permitted and Off. The heat indicator displays green when the system is heating and Red when it is not heating. The Cool indicator displays green when the system is cooling and Red when it is not cooling. Setpoint Button Press Setpoint to enter the desired chemical temperature in the tank. Enter a value between 50 and 250. 16 3A0863A
Setup Screen Setup Screen NOTE: This screen is for qualified technicians only. Curative and Resin Specific Gravity: This button when selected permits the entry of the chemical s specific gravity. This entry is required so that the flowrate can be displayed as a mass rate. Pressure Build-up Time: Refers to the amount of time the Metering Unit must remain above the Curative and Resin Low-Pressure Switch setting before pouring may commence. The intention of the pressure build-up time is to allow the pressure to level off after it rises above the Low Pour Pressure Switch settings. Enter the Pressure Build-Up Time through the Setup Screen. Pressure Hold Time: Refers to the amount of time that the Metering Unit will stay in high-pressure after completing a pour. Enter the Pressure Hold Time through the Setup Screen. 3A0863A 17
Alarm History Alarm History This screen provides a history of previously cleared alarms. 18 3A0863A
Alarm Status Alarm Status Alarm Status Screen indicates alarm conditions by way of a display that is visible in the alarm display section near the top of most of the HMI screens. A new alarm condition will cause an alarm beeper on the control panel to sound. The new alarm message will immediately appear in the alarm display section. Pressing the Alarm Silence button, which is one of the default screen buttons, can silence the alarm beeper. Latched Alarms in the PLC controller and must be silenced, cleared, and reset or unlatched. Clearing means correcting the alarm condition. Before the alarm can be reset the alarm condition must be both silenced and cleared in the PLC controller. Press the default screen button labeled Alarm Status to reach the Alarm Silence and Alarm Reset buttons. Press the Alarm Reset button to reset. 3A0863A 19
Startup Startup 1. Check that the Curative and Resin chemical tanks are pressurized to approximately 30 to 40 psi on the existing truck. 2. Check that all ball valves are in the open position on the existing truck. 3. Purge air from Curative and Resin Chemical Pumps using the ball valve located at the top of each pump. 4. Turn on the Main Panel Power (3-Phase) by positioning the Disconnect Switch Handle on the front of the control panel to the On position. A white Main Power ON light indicates that the main panel power is ON. 5. Once the Main Panel Power is ON, turn on the Metering Unit Control Power by pressing the green Control Power pushbutton. The green light within the button indicates that Control Power is ON. NOTE: If control power fails to run ON check if either of the Emergency Stop buttons has been activated. If so, reset the button by twisting it clockwise and pulling out. Press the Control Power pushbutton to restore control power. 6. Use the Machine Control screen to turn on the hydraulic motor. 7. Use the Machine Control screen to turn on the Curative and Resin motor. 8. Use the Status screen to place the unit in Calibrate mode. 9. Turn the Mix head switch to the ON position. 10. Use the Status Screen to place the unit in Auto Mode. 11. Begin operation. 20 3A0863A
Shutdown Shutdown 1. Turn the Mix head switch to the OFF position. 2. Use the Machine Control screen to turn OFF the Curative and Resin motor. 3. Use the Machine Control screen to turn OFF the Hydraulic Motor. 4. Turn the Main Disconnect Switch to the OFF position to turn off main panel power. The white Main Power light will go out, indicating that Main Panel Power is OFF. Emergency Stop If the machine must be stopped immediately, press the Emergency Stop button. When it is ok to restart the machine, twist the Emergency Stop clockwise and pull out to reset. Lockout Procedure The Main Power Disconnect switch on the control panel may be locked in the OFF position. Place a safety lock through the disconnect switch handle to lockout the machine in accordance with lockout procedures in effect at the equipment location. 3A0863A 21
Operation Operation The left column indicates Last Shot usage. The center Column indicates current shot usage. The right column indicates Life Cycle usage. Mix head Hydraulic Unit Operation Before running the Mix head Hydraulic Unit, check the tank level, filter cleanliness, and accumulator pre-charge. Control power for the metering unit must be ON. Unit will not operate with alarms present, reset any active alarms. Starting the Mix head Hydraulic Pump Press the hydraulic indicating button on the Machine Control screen to start or stop the motor. Mix head Hydraulic Unit Alarms Mix head Hydraulic Motor Overload Alarm: This alarm stops the hydraulic pump motor immediately. If this alarm occurs, the alarm must be reset (and the overload button on the start must be reset) before the motor can be started). Mix head Hydraulic High-Pressure Alarm: This alarm stops the Mix Head hydraulic pump. This alarm occurs if hydraulic pressure rises above the setpoint on the mix head hydraulic high-pressure. Mix Head Hydraulic Low-Pressure Alarm: This alarm stops the Curative and Resin pumps and stops any pouring operation that is in progress. This alarm occurs if hydraulic pressure drops below the setpoint on the mix head hydraulic low-pressure switch. This alarm protects the mix head from crossover that could occur if hydraulic pressure dropped too low to shut the mix head. Mix head Hydraulic Tank High Temp Warning Alarm: This alarm warns of excessive hydraulic oil temperature. 22 3A0863A
Operation Curative and Resin Metering Material Pump Operation IMPORTANT: Since the mix head valves are hydraulically operated, the control system requires that the Mix head Hydraulic Pump be running before starting to meter material pumps. A chemical spill or a crossover could occur if chemical flow passed through a head with a partly open pour piston. Before running the curative or resin metering material pumps, check tank levels, open all ball valves blocking normal chemical flow, and set blanket pressure on each tank. The following instructions apply to both curative and resin systems unless otherwise indicated. Pump Mode Pump Mode can be selected from the Control Screen. The available modes are Normal, Off, and Retracted. The control system will always turn on with the Pump Mode set to Off. In Normal mode, a chemical pump will be allowed to pump material through the chemical lines provided that it s associated metering hydraulic pump is running. It is possible to run both or either chemical pump for all purposes except pouring. Selecting Pump Mode Off stops all reciprocating material pump motion. Selecting Retract mode forces the pumps to move to their retracted positions. In order to RUN the metering material pumps, control power for the metering unit must be on and the Mix Head Hydraulic unit must be running. In order the START the metering material pumps, Manual or Auto Mode must be selected and pump mode must be set to OFF. Starting a material pump in Calibrate Mode is not possible, but it will remain running if Calibrate Mode is selected after the Metering Material Pump is started. Press the Start/Stop Motor buttons on the Machine Control screen to Start/Stop the motor. Metering Material Pump Alarms Curative/Resin Pump Motor Overload Alarm: This alarm causes an immediate stop of the pump motor. if the motor overload alarm has occurred, the alarm must be reset) and the overload button on the starter must be reset) before the motor can be started. Curative/Resin Metering high-pressure Alarm: These alarms occur any time the metering pressures reaches the setpoint on the high-pressure switch at the metering material pump discharge. The high-pressure switch safely shuts down the metering material pump. Both the Curative and the Resin pumps stop when high-pressure alarm occurs regardless of which pump has the alarm condition. 3A0863A 23
Preparation for Pouring Preparation for Pouring Required Inputs for Pouring Curative and Resin Specific Gravity: Enter a value between 0.01 and 9.99. Pressure Build-up Time: Enter a value between 0.0 and 327.67 Pressure Hold Time: Enter a value between 0.00 and 327.67. 24 3A0863A
Adjusting Pressures Adjusting Pressures In order to adjust the mix head orifices in Calibrate Mode, the following conditions must be met: No alarms may be active At least one metering material pump must be running Calibrate Mode must be selected When these conditions are met, the metering unit will be placed into high-pressure recirculation for adjusting mix head orifices. 3A0863A 25
Curative and Resin K Factor Entry and Calculation Curative and Resin K Factor Entry and Calculation If an approximate K factor is known from other data or an existing machine, enter that value into the screen. Otherwise, make an educated guess. Execute a shot of at least 20 lb and weigh the liquid. Compare the weight of the shot with the setpoint weight. If identical, the existing K factor is correct. If different, divide the actual weight of the shot by the setpoint weight and multiple the ratio by the previous K factor to obtain a new K factor. Continue this process until the actual shot weight matched the setpoint weight. 26 3A0863A
Pouring Control Pouring Control Steps of Pouring (Single Mix Head Machine) The following conditions must be met for a pour to be initiated: Manual or Auto Mode must be selected Mix head Hydraulic Pump running Curative Metering Material Pump running Resin Metering Material Pump running If all of the above conditions are satisfied, then the Mix head Pour Ready indicator on the Status screen will be ON. Manual Mode Pouring Single Mix Head Standard Machine Mix head #1 Pendant with Normal Interface If a pour is started by pressing the pour start pushbutton on the pendant while in manual mode, then the pour will continue for as long as the pushbutton is held down. Automatic Mode Pouring (Single Mix Head machine) Mix head #1 Pendant with Normal Interface If a pour is started by pressing the pour start pushbutton on the pendant while in Auto mode then the pour will last until the predefined time elapses. The pour start button does not need to be held down to complete the pour. The timed pour can be stopped early by pressing the pour stop pushbutton. Pressure Build-up Time After the metering unit is placed into high-pressure (valves close as needed to force all metering pump output through the mix head orifices) but before a pour is allowed to begin, the pressure on both materials must rise to the setting on the low pour pressure switches at each chemical pump discharge. Programmed time delays (the data entered Pressure Build-Up Time ) begin after each stream reaches the required pour pressure. The Curative pressure buildup timer starts when the Curative stream reaches its set pressure and the Resin pressure buildup timer starts when the Resin stream reaches its set pressure. When both pressure build-up timers have timed out, a timed pour can occur. The pressure build-up time period is intended to allow the pressure to level off after it rises above the low pour pressure switch setting. NOTE: The curative and resin pressure buildup times are not reset at the end of a pour. They are only reset when the pressure drops back below the low-pressure switch settings. As a result, a new pour started before the machine goes out of high-pressure can begin pouring as soon as the pour pushbutton is pressed. Beginning the Pour After both streams reach the required pour pressure and the pressure build-up time ends, the mix head is directed to open the pour occurs. After the Pour - High Pressure Hold Time After a shot has a occurred, the metering unit remains in high-pressure for a period of time. 3A0863A 27
Summary of Alarms Summary of Alarms Any alarm that will stop Mix head Hydraulic unit or metering pump operation will stop a pour. The following additional alarms are generated during manual and automatic operation of the metering unit. Curative/Resin Fail to Build Pour Pressure in Time Alarm This alarm can occur during the pressure build-up portion of manual pouring or automatic pouring. 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, buildup time is allowed before this alarm will occur). Once a pour begins, this alarm is ignored but a similar alarm (the Low Pour Pressure Alarm described below) can occur in its place. Curative/Resin Low Pour Pressure Alarm If the chemical pressure at the discharge of the metering pump drops below the setting for the Low Pour Pressure Switch, the Low Pour Pressure Alarm can occur during a pour while the mix head is open. This alarm will stop the pour. Improper orifice adjustment is a possible cause. Curative/Resin High-pressure Alarm The High-pressure Alarm can occur any time that the pressure at the pump discharge rises above the setting on the high-pressure switch at the pump discharge. This alarm stops both the Curative and Resin pumps and stops any pour that is in progress. Curative/Resin Pump Motor Overload Alarm This alarm causes an immediate stop of the pump motor. If the motor overload alarm has occurred, the alarm must and the overload button on the starter must be reset. Mix head Hydraulic Motor Overload Alarm This alarm causes an immediate stop of the hydraulic pump motor. If the motor overload alarm has occurred, the alarm must be reset (and the overload button on the starter must be reset) before the motor can be started. Mix head Hydraulic High-pressure Alarm This alarm stops the mix head hydraulic pump. This alarm occurs if hydraulic pressure rises above the set point on the mix head hydraulic high-pressure switch. This is a safety high-pressure shutdown. 28 3A0863A
Summary of Alarms Mix head Hydraulic Low-pressure Alarm This alarm stops both the Curative and Resin pumps and stops any pouring operation that is in progress. This alarm occurs if hydraulic pressure drops below the set point on the mix head hydraulic low-pressure switch. This alarm protects the mix head from crossover that occurs if hydraulic pressure dropped too low to shut the mix head. PLC Battery Low Alarm The PLC battery life is nearly expired and the battery should be replaced as soon as possible. 3A0863A 29
Troubleshooting Troubleshooting Symptom Description Corrective Action Curative and resin fail to build pour pressure Indicates pressure are below set minimum, which will not let machine pour 1. Check needle adjustment at Mix head 2. Check flow rate 3. Make sure correct orifice is installed 4. Check pressure switches Curative and resin low pressure during pour Curative and resin high pressure Curative and resin over-temperature indicates pressures are below set minimum during a pour Indicates pressures are above maximum setting before or during pour Indicates high temperature in the corresponding heater 5. Check wiring to pressure switches 1. Check the needle adjustments at Mix head 2. Check flow rates 3. Make sure correct orifice is installed 4. Check pressure switches 5. Check wiring to pressure switches 1. Check the needle adjustments at Mix head 2. Check orifice for debris 3. Make sure all valves are open on return side including seat valve. 4. Make sure hoses are not crosses at Mix head. 5. Check pressure switches. 6. Check wiring to pressure switches. 1. Verify adequate water in system. 2. Shorted heating element. 3. Incorrect settings on controller. 30 3A0863A
Troubleshooting Symptom Description Corrective Action Mix head motor overload Indicates high amperage 1. Check for loose wiring to motor. 2. Check for blown fuses. 3. Check supply voltage to machine. Mix head hydraulic high pressure Mix head hydraulic low pressure Indicates high pressure in the hydraulic motor. Indicates low pressure in the hydraulic motor 4. Check overload switches on contacts. 1. Check accumulator pressure. 2. Check settings on charging valve. 3. Check for crossed hoses. 4. Check for debris in hydraulic valves. 5. Check pressure switch. 6. Check wiring to pressure switches. 1. Check motor rotation. 2. Check accumulator pressure. 3. Make sure valve on manifold is closed. 4. Check settings on charging valve. 5. Check pressure switches. 6. Check wiring to pressure switch. Mix head motor over-temperature indicates high oil temperature 1. Check oil for cleanliness. 2. Check water supply to heat exchanger if supplied. 3. Check for restriction in lines. Relief valve set too high. 4. Unloading valve set incorrectly. Curative and resin motor overloads Indicates high amperage in motors 1. Check for loose wiring to the motor. 2. Check for blown fuses. 3. Check overload switches on contacts. 3A0863A 31
Troubleshooting Symptom Description Corrective Action Mix head hydraulic pump noisy Excessive noise during operation 1. Intake blocked. 2. Air leaks in suction or shaft seal. Air drawn in through inlet due to low oil level. 3. Entrained air. 4. Fluid viscosity too high. 5. Pump running too fast. 6. Suction filter too small. 7. Loose parts in pump. 8. Worn or damaged parts. No pressure or lack of pressure in mix head hydraulic pump Not building up pressure or losing pressure after a period of time. 9. Foreign matter drawn in pump. 1. Relief valve not working. 2. Broken line. Fluctuation of fluid pressure in mix head hydraulic pump 3. Check that mix head hydraulic accumulator dump valve is fully closed. Pressure varies during operation 1. Air entrapment. 2. Dirt passing through relief valve. No main power No control power No power or insufficient power to machine. No power to machine controls except for PLC panel. 3. Check that mix head hydraulic accumulator dump valve is fully closed. 1. Check main power supply to machine. 2. Check fuses at main fuse panel. 1. Check all emergency stop switches. 2. Check fuses to transformer. 3. If light on switch is on but still no power check wiring master control relay. 32 3A0863A
Troubleshooting Symptom Description Corrective Action PLC screen off 1. Check HMI 24 volt DC power supply. 2. Check screen saver, touch the screen to deactivate the screen saver. Mix head hydraulic motor will not run 3. Check the brightness and contrast settings of the display. 1. Check all emergency stop switches. 2. Check to make sure control power switch is on. 3. Check fuses. 4. Check overload relays. 5. Check wiring to contact and motor. Curative or resin motor will not run 1. Check all emergency stop switches. 2. Check to make sure control power switch is on. 3. Make sure mix head hydraulic motor is running. 4. If motors still do not run check fuses and overload relays. 5. Check wiring to contact and motor. Mix head will not pour 1. Make sure mix head is turned on in PLC or manual switch on older models. 2. Make sure correct mix head is selected. 3. Make sure machine is in automatic or manual mode. Machine will not go into Calibrate mode 4. Make sure correct shot times selected. 1. Make sure air is connected to machine. 2. Check wiring to machine bypass valve. 3A0863A 33
Troubleshooting Symptom Description Corrective Action Curative or resin heaters not working 1. make sure temperature control is selected on PLC. 2. Motors must be running in order for temperature control to work. 3. Check settings on controllers. 4. Check fuses. 5. Check high temperature switches. 6. Check wiring from controllers to solid state relay. Curative or resin encoders not reading 7. Check wiring to heating element. NOTE: Encoder readings only occur in Calibrate mode and during actual pour only. Chemical leak from curative or resin metering pump Drips underneath metering pump or chemical seeping into lube cup. 1. Switch wires from suspected flow meter to good flow meter. If flow reading is given then flow meter is ok. 2. Check wiring to flow meter. 1. Check for debris in or near seals. 2. Seals need to be replaced. 34 3A0863A
Troubleshooting Symptom Description Corrective Action Fluctuation of chemical pressure during calibration or pour time 1. Check orifice size. 2. Check for debris in orifice housing. 3. Check seat valves by placing machine in calibrate mode and shutting ball valve underneath suspected seat valve. If problem disappears, seat valve needs to be replaced. 4. If problem does not disappear check pump pressure relief valve for leakage. Curative or resin metering pump makes noises 5. If relief valve ok then check pump. 1. Check day tank pressures. 2. Check for debris in strainer filter. 3. Verify all valves are open. 4. Check for air in pump. 5. Check low inlet pressure switch. 3A0863A 35
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 to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505 All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 3A0863 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO OHIO INC. 8400 PORT JACKSON AVE, NORTH CANTON, OH 44720 Copyright 2010, Graco Ohio Inc. is registered to ISO 9001 www.graco.com