Operation and Maintenance
PR70
™
2 Component
Liquid Dispensing Systems
PR70 All Models
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
100 PSI (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
For Dispensing Multi-part Sealants and Adhesives.
Not Designed for Use in Explosive Atmospheres.
Important Safety
Instructions
Read all warnings and
instructions in this manual.
312393J
EN
Contents
Contents .................................................... 2
PR70 Accessories .................................................. 3
Tank Level Sensing and Velocity Change (“ ”)
Options (C6) .........................................................19
Supplied Manuals ..................................... 4
Password Setup / Clearing (C5) ............. 20
Related Manuals ....................................... 4
Setting/Clearing an Administrative Password:..........20
Warnings ................................................... 5
Setting/Clearing a Maintenance ONLY Password:21
Installation ................................................. 7
Resetting Passwords ...........................................21
General Information ............................................... 7
Miscellaneous Machine Features .......... 22
Unpacking .............................................................. 7
HMI Hibernate Mode ............................................22
Locate and Install the PR70 ................................... 7
HMI Startup Animation Sequence ........................22
Machine Setup ....................................................... 7
HMI Demo Mode Operation .................................22
Component Identification ........................ 8
Pressure Relief Procedure ..................... 23
HMI Control and Indicators ...................... 9
Standby/Shutdown Procedure ............... 23
HMI Main Run Screen .......................................... 10
Error Codes ............................................. 23
Run Screen Operation ............................ 10
Error Code Table ..................................... 24
Machine Mode Selection...................................... 10
ICON Descriptions .................................. 26
Machine Operation: Shot Mode .......................... 10
Maintenance ............................................ 28
Machine Operation: Operator Mode ................... 10
Shot Number Selection ........................................ 10
Machine Disable Mode (“
Software Upgrades, Run Token ............. 28
Run Token ............................................................28
”red) .......... 11
Troubleshooting...................................... 29
Setup Screens ......................................... 11
Repair ....................................................... 30
Entering the Setup Screens ................................. 11
Major Mechanical Assemblies, and Attachments 30
Setup Screens with Passwords Enabled ............. 11
Base Frame Assembly .........................................31
Machine Priming ..................................... 13
Air Cylinder Assemblies, and Rebuild Kits ...........32
Machine Calibration................................ 13
Drive Block Assembly ..........................................35
Piston Position Calibration (C1) ........................... 13
Pump Assemblies and Rebuild Kits .....................35
Phasing (C2) ........................................................ 14
Piston Cylinders or Metering Tubes .....................38
Open Dispense Valve (ODV) Setting (C3)........... 14
Hose Assemblies .................................................41
Machine Calibration Shots (C4) ........................... 15
Miscellaneous Mechanical Assemblies................43
Shot Size Definition (M2) ........................ 16
Wiring Diagrams ..................................... 46
Ratio Checks ........................................... 16
Technical Data......................................... 48
Miscellaneous Machine Setups ............. 17
Dimensions.............................................. 49
Manual Control Options (M1) ............................... 17
Graco Ohio Standard Warranty ............. 50
Purge Timer / Alarm Settings (M2) ...................... 17
Graco Information ................................... 50
Cycle Counter and Silent Mode Control (M3) ......... 18
Date and Time Settings (M4) ............................... 19
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Models
PR70 Accessories
Mixer and Shroud Options
LC0063
Mixer, 3/16 (6.5 mm) x 32, 10 Mixers with shroud
LC0081
Mixer, 3/8 (9.8 mm) combo, 50 Mixers
LC0057
Mixer, ¼ (6.5 mm) x 24, 10 Mixers with shroud
LC0083
Mixer, 1/4 (6.5 mm) x 24 Luer Lock, 50 Mixers
LC0058
Mixer, 3/8 (9.8 mm) x 24, 10 Mixers with shroud
LC0082
Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 50 Mixers
LC0059
Mixer, 3/8 (9.8 mm) x 36, 10 Mixers with shroud
LC0084
Mixer, 3/16 (4.8 mm) x 32, 250 Mixers
LC0060
Mixer, 3/8 (9.8 mm) Combo, 10 Mixers with shroud
LC0085
Mixer, 1/4 (6.5 mm) x 24, 250 Mixers
LC0061
Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 10 Mixers with shroud
LC0086
Mixer, 3/8 (9.8 mm) x 24, 250 Mixers
LC0062
Mixer, ¼ (6.5 mm) x 24 Luer Lock, 10 Mixers with shroud
LC0087
Mixer, 3/8 (9.8 mm) x 36, 250 Mixers
LC0077
Mixer, 3/16 (4.8 mm) x 32, 50 Mixers
LC0088
Mixer, 3/8 (9.8 mm) combo, 250 Mixers
LC0078
Mixer, ¼ (6.5 mm) x 24, 50 Mixers
LC0089
Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 250 Mixers
LC0079
Mixer, 3/8 (9.8 mm) x 24, 50 Mixers
LC0090
Mixer, ¼ (6.5 mm) x 24 Luer Lock, 250 Mixers
LC0080
Mixer, 3/8 (9.8 mm) x 36, 50 Mixers
MD2, Soft Seat rebuild, needle and nose
MD2, convert Soft Seat nose to Hard Seat (Hard
Seat rebuild), needle and nose
MD2 Valve Kits
255217
MDS2, kit rebuild, air cylinder
255219
255218
MD2, kit rebuild, back-end of wet section (no needle or seat)
255220
Other Accessories
LC0097
Desiccant Dryer, 3/8” NPT with adapter and cartridge
LC0100
Vacuum Transfer Pump, 240V, down to 25 Torr
LC0098
Desiccant Dryer refill cartridge
LC0091
3.0” Air Cylinder rebuild kit
LC0095
Nitrogen Kit for 30L and 60L tank, 1 tank
LC0092
4.5” Air Cylinder rebuild kit
LC0096
Nitrogen Kit for 30L and 60L tank, 2 tanks
LC0093
Check Valve rebuild kit
LC0008
Cord, I/O interface and footswitch part
LC0094
Rear Pump Seal rebuild kit
LC0099
Vacuum Transfer Pump, 120V, down to 25 Torr
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Manuals
Supplied Manuals
The following manuals will be supplied with the
PR70.
Refer to these documents for detailed machine
information.
PR70 Operation
Part
Description
312393
Manual, Operation & Maintenance
PR70
PR70 Feed System
Part
Description
312394
Manual, Tank/Feed System, PR70
Dispense Valve, MD2
Part
Description
312185
Manual, Dispense Valve, MD2
* Heat Control Module(s)
Part
Description
312413
Manual, Heat Control, Tank/Hoses
Related Manuals
The following manuals are for accessories to be used
with the PR70 machine.
*
PR70 Operation
Part
Description
312393
Manual, Operation & Maintenance PR70
PR70 Feed System
Description
Part
312394
Manual, Tank/Feed System, PR70
Dispense Valve, MD2
Part
Description
312185
Manual, Dispense Valve, MD2
Heat Control Module(s)
Part
Description
312413
Manual, Heat Control, Tank/Hoses
The Heat Control Module manual is not provided for machines that do not have a Heated Tank and/or Hose
component.
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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.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
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.
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.
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.
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Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• 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.
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
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Installation
Installation
General Information
Accessories are available from Graco. Make certain all
accessories are adequately sized and pressure-rated to
meet your system needs.
Figures 2 thru 4 are only a guide for identifying system
components and for assisting in installation. Contact
your Graco distributor or Graco Ohio Customer Service
for assistance in designing a system to suit your
particular needs.
Unpacking
1. Inspect the shipping container carefully for damage.
Contact the carrier promptly if there is damage.
2. Open the box and inspect the contents carefully.
There should not be any loose or damaged parts in
the container.
3. Compare the packing slip against all the items in
the box. Report any shortage or other inspection
problems immediately.
4. Remove the PR70 system components from the
container. Do not lift the machine by the tanks.
Locate and Install the PR70
1. Locate a bench top or equivalent location to
mechanically mount the PR70 dispensing machine.
Verify the location has access to compressed air,
AC power and is well ventilated.
2. Place the PR70 onto the designated location. Allow
to the machine to rest on the rubber feet provided.
3. Turn the Shield Locking Screws clockwise on both
sides to remove the PR70 protective shield.
4. Attach the PR70 frame to the selected location by
installing fasteners (not provided with unit) thru the
4 mounting holes. Refer to Figure 1 for mounting
hole dimensions.
Machine Setup
Avoid contact with electrical inter-connects, when connecting electric
power to the machine. Read all manufacturer’s warning and material
MSDS to know the specific hazards of the material used.
1. Connect a compressed airline to the input air in the
back of the machine.
2. Load material into the on-board or off-board tanks
feeding the machine.
3. Using the power cord provided, connect AC power
(100-240V, 50/60 Hz, single-phase) to the machine.
Figure 1: Mounting Hole Dimensions for Installing the PR70 Machine (dimensions in inches/mm)
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Component Identification
Component Identification
Key:
A Dispense Valve (DV)
B HMI (Human Machine Interface)
C Static Mixer
D Shield Locking Screw
E Power Switch
F Air Filter
G Customer Input Receptacle
H Protective Shield
I
Air Pressure Regulator
J Ball Valve (Optional)
K A and B Tanks (Onboard,
Polyethylene versions illustrated).
Figure 2: Typical PR70 (Back View, without Hoses)
Key:
A Pump Assembly
B Solenoid Valves
C Air Cylinder Assembly
D DC Power Supply
E Fluid Control Module (FCM)
Figure 3: PR70 Back View with Shield, Tanks, DV and HMI Removed.
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Component Identification
Key:
A Drive Block
B Hydracheck (optional)
C Check Valve
D Cylinder (Metering Tube)
E Rear Bearing
F Phase Adjustment Screw/Locking
Nut
G Mounting Hole in Base Frame
Figure 4: PR70 Top View with Shield, Tanks, DV and HMI Removed.
HMI Control and Indicators
Figure 5: PR70 HMI Controls
Key:
A
B, D
C
E
F
G-J
K
L
M
Screen, Display Area
Up and Down Keys
Up and Down Key LED
Enter Key LED
Enter Key
Soft Keys 1 thru 4 (Left to Right).
Shot Mode ICON
Shot Mode LED
Mode Select Key
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N
O
P
Q
R
S
T
U
Operator Mode ICON
Operator Mode LED
Red Stop or Cancel Key (used to stop machine
operation)
Lock Key (used to enter and exit setup screens)
Green Go Key (used to request a shot)
Display area
Diagnostic LED’s
HMI Rear Access Panel (used to access clock
battery and for reprogramming the HMI).
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Run Screens
HMI Main Run Screen
Figure 6: Typical PR70 Main Run Screen (Shot and Operator Modes) Respectively)
Key:
A
Shot Number Field (“x” in Operator Mode)
B
Shot Size Field (“XXXXXX” in Operator Mode)
C
Shot weight/mass unit of measure (Grams).
D
Tank Fill Status Indicators
E
Pistons Status Field
F
G
H
I
J
K
Cycle Counter
DV status Field
Purge Timer status Field
Error code status Field
Current Date Field (DD-MM-YY)
Current Time Field (24 Hr. Format)
Run Screen Operation
3. To cancel the shot, press
Read all manufacturer’s warning and material MSDS to know the
specific hazards of the material used.
Machine Mode Selection
To dispense material, one of the following 2 modes
must be selected;
•
Shot mode dispenses a predetermined amount
of material when the machine receives a “Go”
command.
•
Operator mode dispenses material as long as
the machine is receiving a “Go” command.
To select Shot mode:
.
Machine Operation: Operator Mode
1. Place the item or part to be filled below the
dispense valve static mixer.
2. Press and hold
(green) or the footswitch to start
the shot. The machine will continue to dispense
until the
(green) or the footswitch is released.
The pistons will not retract unless they are almost fully
extended. They will automatically retract after 4
minutes. The machine will beep to signal that it is about
to retract. To manually retract the machine, press
Shot Number Selection
1. Press
until
.
2. Press
to accept or
to cancel.
To select Operator mode:
In Shot mode, up to 5 predefined shot sizes may be
selected. To select a shot:
1. When the machine is idle (not dispensing a shot)
press
3. Press
until
.
4. Press
to accept or
to cancel.
2. Press
or
to select the new shot size.
to accept, or
to cancel.
Machine Operation: Shot Mode
1. Place the item or part to be filled below the
dispense valve static mixer
2. Press
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(green) or the footswitch to start the shot.
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.
Disable Mode, Entering Set-up Screens
Machine Disable Mode (“
”red)
2. To enter the calibration screens, press
. To
enter the maintenance screens, press
. Refer
to Figure 9 for a screen navigation diagram.
Setup Screens with Passwords Enabled
Figure 6: Typical Run Screen when Machine in
“Disable” Mode
1. From the Run screen press
. If a password has
been programmed, the Password Entry Screen
(Figure 8) will be displayed.
1. At any time and from any screen, to immediately
disable all machine motion, press
(red).
2. If activated, the purge timer will be disabled
3. To resume operation, the machine must be put
back into an operating mode as described in the
Machine Mode Selection section.
Figure 8: Password Entry Screen
4. If activated, the purge timer will not restart until a
shot is taken.
2. Enter the 6 digit password by pressing the
corresponding soft keys, G-J in Figure 5.
Setup Screens
3. After the 6th digit has been entered, press
Before the machine will operate properly, it must be
calibrated and shot size information must be entered.
Entering the Setup Screens
1. From the Run screen press
. If no password
has been programmed into the HMI, the
Programming Mode Selection Screen (Figure 7)
will be displayed.
4. If the correct password has been entered, the
Programming Mode Selection Screen will be
displayed. Refer to Figure 9 for a screen navigation
diagram.
5. If the incorrect password has been entered, the
password entry will need to be repeated until the
correct 6-digit sequence is entered.
6. To abort the password entry, press
.
Figure 7: Programming Mode Selection Screen
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Screen Layout
Figure 9: PR70 Screen Navigation Diagram
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Priming and Calibration
Machine Priming
Before the machine can be properly calibrated with
material, it will need to be primed.
Be careful not to pinch fingers when manually moving the machine
drive block.
Piston Position Calibration (C1)
Read all manufacturer’s warning and material MSDS to know the
specific hazards of the material used.
From the Run Screen press
then press
following screen will be displayed.
. The
This step should be executed the 1st time the machine
is setup, and may not need to be re-executed unless
the position sensor, an electronic component or a piston
has been replaced.
From the Run Screen press
then press
following screen will be displayed.
. The
Figure 11: Piston Position Calibration Screen (C1)
Figure 10: Maintenance Screen for Priming (M1)
Key:
A Full Retract ICON
B Full Extend ICON
C Change Dispense Valve Mode
= Always Open
= Always Closed
= Opens at Cylinder Entrance (Automatic)
D Current Piston Position
E Current Dispense Valve Mode
F Screen Number (C1)
G
&
keys will navigate to adjacent screens.
1. Place a waste container under the dispense valve
to capture any dispensed material.
2. Press
until the upper ICON is
3. Press
to extend the piston fully.
4. Press
to retract the piston fully.
.
5. Repeat steps 3 and 4 until both materials dispense
from the valve without air.
6. Press
twice to return to the Run screen.
Machine Calibration
Before the machine will accurately dispense, it must
be calibrated.
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Key:
A Full Extend position number from last calibration
B Full Extend Command ICON
C Full Retract position number from last calibration
D Full Retract Command ICON
E Cylinder Entrance position from last calibration
F Cylinder Entrance Command ICON
H Current Piston Position Field
I Screen Number (C1)
J
&
keys will navigate to adjacent screens.
1. Place a waste container under the dispense valve
to capture any dispensed material.
2. With air pressure applied to the machine, press
.
3. The piston should fully extend and a number
between 3600 to 3900 should appear for ‘H’
4. Press
to accept the number or
current number.
5. Press
to keep the
.
6. The piston should fully retract and a number
between 1250 to 1600 should appear for ‘H’.
7. Press
to accept the number or
current number.
to keep the
8. Decrease the air pressure by adjusting the machine
air pressure regulator to a minimal value (i.e. ~ 10 20 psi).
9. Press
.
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Priming and Calibration
10. The machine pistons should extend slowly until they
encounter the cylinder entrance and a number
between 2000 to 2400 should appear for ‘H’.
11. If the pistons do not move, manually move the
piston by pulling on the machine drive block, until
mechanical resistance is encountered at the
cylinder entrance.
12. Press
to accept the number or
current number.
to keep the
13. Adjust the Air Pressure Regulator back to a
reasonable value for proper machine operation.
14. Press
twice to return to the Run screen.
Phasing (C2)
Remove any static mixer attached to the dispense
valve, and replace it with a ratio check nozzle. Place a
waste container under the valve to capture any
dispensed material.
press
(from the extend to retract motion) by pressing
keys. Pressing
or
will decrease the phasing
shot. Pressing
will increase the phasing shot. A
“+” value indicates that the piston will reverse beyond
the cylinder entrance. A “-“ value indicates the piston
will reverse prior to reaching the cylinder entrance.
2. Press
(green) or the footswitch.
3. During the shot execution, visually monitor the 2
materials exiting the ratio check nozzle. If the
timing of the 2 materials exiting the nozzle cannot
be properly observed, press
then repeat step 2.
or
accordingly,
4. If the A side material exits the ratio nozzle before
To enable the machine to dispense the correct ratio of
material from the A and B tanks and to mix properly,
both materials will need to enter the static mixer at the
same time. Phasing shots will need to be executed to
visually verify that the 2 materials are exiting the
dispense valve at the same time.
From the Run screen, press
1. Select the location where the piston will reverse
, then press
, and then
once. The following will screen will be displayed.
the B side material (“
”), turn the B piston
Phase Adjustment Screw/ Locking nut and shaft
counterclockwise to move the B piston forward, as
ICON. Slight adjustments in
indicated on the
the piston shaft will be significant. Adjustments of a
quarter turn are typical.
5. If the B side material exits the ratio nozzle before
the A side material (“
”), turn the A piston
Phase Adjustment Screw/ Locking nut and shaft
counterclockwise to move the A piston forward, as
indicated on the
ICON.
6. Repeat step 2 until both materials exit the ratio
”).
check nozzle at the same time (“
7. Press
twice to return to the Run screen.
Open Dispense Valve (ODV) Setting (C3)
Figure 12: Phasing Calibration Screen (C2)
Key:
A A material leads B ICON
B Adjust B side Forward ICON
C B material leads A ICON
D Adjust A side Forward ICON
E A and B Exit the Same Time ICON
F Do NO Mechanical Adjustment ICON
G Phase Shot Request ICON
I Screen Number (C2)
J
&
keys will navigate to adjacent screens.
K Decrease Phase Shot Percentage Amount ICON
L Current Phase Shot Percentage Amount
M Increase Phase Shot Percentage Amount ICON
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The next step in the calibration process is to determine
the proper position to open the Dispense Valve (DV)
during the shot.
Advancing or increasing the opening position (in millimeters) will build more pressure in the material hoses
prior to the dispense valve opening. If the Dispense
Valve opens too late in the shot, a surge of material
can occur or the piston could stall. If the Dispense
Valve opens to early in the shot, material “drooling” at
the beginning of the dispense cycle could occur.
From the Run screen, press
press
, then press
, and then
2 times. The following screen will be displayed.
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Priming and Calibration
From the Run screen, press
, then press
, then press
3 times. The following screen will be displayed.
Figure 13: Open Dispense Valve (ODV) Screen (C3)
Key:
A Current ODV Adjustment (in mm from the cylinder
entrance).
B Adjust ODV value Option ICON.
C Relative ODV Position ICON with respect to
cylinder entrance (This ICON will move right or
left at +/- mm transition).
D Cylinder Entrance ICON (stationary).
I Screen Number (C3)
J
&
keys will navigate to adjacent screens.
1. To adjust the ODV position with respect to the
cylinder entrance, press
Figure 14: Stroke Calibration (CAL) Screen (C4)
Key:
A Short Shot Column ICON
B Last/Current Short Shot weight (mass) entry.
C Long Shot Column ICON
D Last/Current Long Shot weight (mass) entry.
E Grams (Weight or Mass unit used)
F Short Shot ICON
G Long Shot ICON
I Screen Number (C4)
J
.
&
keys will navigate to adjacent screens.
2. Press
to increase the value or
to decrease
the value. Values of – 5.0 mm to + 5.0 mm are
allowed.
1. Press
3. Press
to accept the value or
to retain the
previous value. The default value from the factory
is – 1.0 mm.
2. Place the empty container below the static mixer,
4. Press
and discard the contents of the material
3. Press
dispensed
twice to return to the Run screen.
Machine Calibration Shots (C4)
to arm the machine to take a short CAL
shots. The icon will be highlighted (“
”). Press
to de-arm the machine.
and press
(green) or the footswitch.
4. Repeat the previous 2 steps until the static mixer is
filled with material. Verify the material dispensed
from the mixer is mixed properly.
5. Place a container on a scale and tare (zero) it.
Read all manufacturer’s warning and material MSDS to know the
specific hazards of the material used.
Calibration shots are necessary to program the
machine to properly dispense the correct amount of
material. Several short CAL shots (“
long CAL shots (“
”) and several
”) are required.
Remove the ratio check nozzle, install the static mixer
intended to be used, and adjust the air pressure to the
level intended for use during normal operation.
The air pressure must be set to operating
conditions for this step. Significant changes
in air pressure could adversely affect shot
accuracy.
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6. Place the tared container below the static mixer,
and press
7. Press
(green) or the footswitch.
to erase existing average weight data.
8. Place the container with the dispensed material on
the tared scale.
9. Enter the mass in grams into the HMI, by pressing
or
accordingly.
to accept the number. The number
10. Press
entered will be transferred to the right of the
average icon (“ ”).
11. Repeat steps 5 through 10, skipping step 7, several
times. Each additional shot weight will be averaged
in the row with the previous shots.
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Priming and Calibration
12. Press
to arm the machine to take a long CAL
shots. The icon will be highlighted (“
”). Press
to de-arm the machine.
I
J
Screen Number (M2).
&
keys will navigate to adjacent screens.
1. Press
. The following screen will be displayed:
13. Place a container on a scale and tare (zero) it.
14. Place the tared container below the static mixer,
and press
15. Press
(green) or the footswitch.
to erase existing average weight data.
16. Place the container with the dispensed material on
the tared scale.
17. Enter the mass in grams into the HMI, by pressing
or
accordingly.
18. Press
to accept the number. The number
entered will be transferred to the right of the
average icon (“ ”).
19. Repeat steps 13 through 18, skipping step 15,
several times. Each additional shot weight will be
averaged in the row with the previous shots.
Figure 16: M2 Shot Definition Screen
2. Press
or
to select a shot number to define.
3. Press
or
to enter the shot size.
The shot size (in grams) must be greater
than the Short CAL Shot size from the
previous C4 calibration screen.
20. Press
to de-arm the cal shot.
4. Press
to accept the value or
previous value.
21. Press
twice to return to the Run screen.
5. Repeat the previous 2 steps for other shot sizes as
required.
to retain the
Shot Size Definition (M2)
6. Press
to exit the Shot Definition screen.
To dispense in Shot Mode, one or more, up to 5, shot
sizes need to be entered. This step is not required for
Operator mode.
7. Press
twice to return to the Run screen.
From the Run screen, press
press
, then press
Ratio Checks
, and then
once. The following screen will be displayed.
Read all manufacturer’s warning and material MSDS to know the
specific hazards of the material used.
This is a procedure to verify the weight ratio between
the 2 materials. This is easiest to do with two scales.
1. From the Run screen, put the machine in Shot
”). See page 13.
mode (“
2. Verify that the machine is properly calibrated and
phased as outlined in the calibration section.
Figure 15: Shot Size and Purge Timer Screen (M2)
A
B
C
D
E
F
G
Key:
Shot Number
Shot Size (in grams).
Purge Timer Setting (Turned OFF in Figure 15).
Purge Timer Alarm Setting.
Define Shot ICON
Set Purge Timer ICON
Purge Timer Warning ICON.
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3. Remove any static mixer attached to the dispense
valve and replace it with a ratio check nozzle.
Place a waste container under the valve to capture
any dispensed material.
4. Select a shot size between the Short and Long CAL
shot sizes previously done, by pressing
and
or
to accept.
5. Place the empty container below the Ratio Check
Nozzle and the footswitch. Discard this shot.
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Priming and Calibration
6. Place an empty container on a scale, and tare
(zero) the scale. Repeat the process with a 2nd
container on a 2nd scale.
7. Place both containers under the ratio check nozzle,
positioned so one container captures material A,
and the 2nd container captures material B.
9. After the material is dispensed, place each
container on the same scale, and measure the net
mass of each of the materials. Record the mass of
both the A and B materials.
10. Divide the A material mass by the B material mass
to obtain the material ratio being dispensed.
8. Press the footswitch.
Miscellaneous Machine Setups
The following sections outline how to configure various
optional settings.
Manual Control Options (M1)
The user can control the machine’s piston position and
displacement valve operation manually the M1 screen.
From the Run Screen press
then press
following screen will be displayed.
. The
Manual DV Control:
1. To change the DV operation press the third blue
key from the left.
2. When the Current Dispense Valve Mode (E in
Figure 17) is
, the valve will open and stay open
regardless of the piston position.
3. When the Current Dispense Valve Mode is
, the
valve will close and stay closed regardless of the
piston position.
4. When the Current Dispense Valve Mode is
, the
valve will be in automatic mode, opening when the
pump gets to the cylinder entrance and closing
when it gets to the end of the cylinder.
5. Press
twice to return to the Run screen.
Purge Timer / Alarm Settings (M2)
Figure 17: Maintenance Screen (M1)
Key:
A Full Retract ICON
B Full Extend ICON
C Change Dispense Valve Mode
When activate, the Purge Timer will automatically
dispense a shot if the machine is idle (not dispensing
material) for a programmed duration of time. This
prevents the mixed material from hardening in the
static mixer. To set the Purge Timer;
From the Run screen, press
press
, then press
, and then
once. The following screen will be displayed.
= Always Open
= Always Closed
= Opens at Cylinder Entrance (Automatic)
D Current Piston Position
E Current Dispense Valve Mode
F Screen Number (C1)
G
&
keys will navigate to adjacent screens.
Manual Piston Control:
Figure 18: M2 after Purge Timer Selection
1. Press
to extend the piston.
1. Press
2. Press
to retract the piston.
2. Press
or
to enter the purge timer value.
This idle time allowed before the machine will
automatically dispense a shot to clear the mixer.
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.
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Miscellaneous Machine Setups
3. Press
to accept the value or
previous value.
to retain the
From the Run screen, press
press
, then press
, and then
2 times. The following screen will be displayed.
Figure 19: M2 after Purge Shot Size Prompt
4. Press
or
to enter the purge shot size (in
grams). Enter a number with at least as much
volume as the mixer.
5. Press
to accept the value or
previous value.
6. Press
to retain the
twice to return to the Run screen.
Activating the purge timer automatically activates the
. This is the amount of time before
purge alarm
the purge timer reaches zero that the machine will
sound a warning beep to signaling that it is about to
take a purge shot. To change the Purge Alarm value;
From the Run screen, press
press
, then press
, and then
once. The following screen will be displayed.
Figure 21: M3 Cycle Counter and Silent Mode Control
Key:
A Total Pump Cycle Counter Value (Not Resettable)
B Resettable Cycle Counter Value
C Current Silent Mode State ICON
Silent Mode Off
Silent Mode On
D Reset Cycle Counter ICON
E Toggle Silent Mode ICON.
I Screen Number (M3)
J
&
1. Press
keys will navigate to adjacent screens.
.
2. Press
to accept the value or
previous value.
3. Press
to retain the
twice to return to the Run screen.
Silent Mode Operation:
The default setting is
, Silent Mode Off, where audio
feedback is provided when a valid key (1 short tone), or
an invalid key (3 short tones) is pressed.
Figure 20: M2 after Purge Alarm Selection
1. Press
.
2. Press
or
to enter the purge alarm duration
(in seconds). The minimum value is 2 seconds,
and a maximum of 59 seconds or the value of the
purge timer if the timer is more than 59 seconds.
3. Press
to accept the value or
previous value.
4. Press
to retain the
twice to return to the Run screen.
In
, Silent Mode On, audio feedback is not provided.
Silent Mode On has no effect on the audio sounds
provided for the purge timer alarm, an error code, or
when power is initially applied to the machine.
To toggle or change the silent mode:
From the Run screen, press
, then press
then press
2 times. Screen M3, see Figure 21, will
be displayed.
1. Press
or
.
Cycle Counter and Silent Mode Control (M3)
2. Press
to accept the change or
previous setting.
Resetting the Cycle Counter:
3. Press
to retain the
twice to return to the Run screen.
The cycle counter shown on the Run screen, see Figure
6, shows the number of pump cycles since the last time
the cycle counter was reset. To reset the cycle counter:
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, and
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Miscellaneous Machine Setups
Date and Time Settings (M4)
1. Press
. The M4 screen will appear as follows.
At the bottom right corner of the Run screen the date is
shown in DD-MM-YY format and the time is shown in
HH:MM, 24 hour format. The formats cannot be changed.
To set the current date:
From the Run screen, press
press
, then press
, and then
3 times. The following screen will be displayed.
Figure 25: M4 after Time Set Selection
2. Press
and
to enter the hour (0 - 23).
to accept the change or
3. Press
previous setting.
4. Press
Figure 23: M4 Screen for Setting the Date and Time
Key:
A Current Date (DD-MM-YY)
B Current Time (HH:MM, 24 Hour Format)
C Current Software Revision
Dsp = Display Module
FCM = Fluid Control Module
D Date Set ICON
E Time Set ICON.
I Screen Number (M4)
J
&
1. Press
keys will navigate to adjacent screens.
. The M4 screen will appear as follows.
Figure 24: M4 Screen after Date Set Selection
3. Press
and
to enter the year.
4. Press
to accept the change or
previous setting.
5. Press
and
and
9. Press
to retain the
to enter the day.
to accept the change or
8. Press
previous setting.
to enter the minutes (0 - 59).
5. Press
to accept the change or
previous setting.
6. Press
to retain the
twice to return to the Run screen.
Tank Level Sensing and Velocity Change
(“ ”) Options (C6)
If tank level sensors are installed into the system, an
alarm is generated when a tank is almost empty. If the
feature is turned ON, a Tank A low (“
”), a Tank B
low (“ ”), or a both tanks are low (“
generated if the condition exists.
”) error will be
The machine also measures the piston velocity and
will generate an alarm if the piston velocity has
changed significantly since the machine was last
calibrated. A significant change is piston velocity,
usually caused by a change in air pressure, can
degrade shot size accuracy.
The user has the capability to turn the
feature OFF
by selecting a level of 0%, or ON by selecting
levels
of 20%, 40% or 60%. For instance, if 40% is selected,
and the piston velocity changes by + or – 40%, an error
code will be generated after the corresponding shot to
inform the operator of the situation. If the velocity
increases above the selected level, a
error will be
generated, and if the velocity decreases below the
to enter the month.
6. Press
to accept the change or
previous setting.
7. Press
to retain the
and
to retain the
to retain the
twice to return to the Run screen.
selected level a
error will be generated.
The
feature is automatically disabled when the
machine is in Operator mode, or when the machine is
executing a purge shot.
From the Run screen, press
, then press
, then press
5 times. The following screen will be displayed.
To set the current time:
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Miscellaneous Machine Setups
E
I
J
Change
Level ICON
Screen Number (C6)
&
keys will navigate to adjacent screens.
To turn the Tank Level Sensors On/Off:
1. Press
Figure 26: Tank Level and
B Current
.
2. Press
to accept the change or
previous setting.
(C6)
3. Press
Key:
A Current Tank Level Mode
= OFF,
or
to retain the
twice to return to the Run screen.
To turn the Velocity Change On/Off:
1. Press
= ON
level
.
= OFF
to accept the change or
2. Press
previous setting.
= 20% change before warning
3. Press
to retain the
twice to return to the Run screen.
= 40% change before warning
= 60% change before warning
D Turn ON / OFF Tank Level Sensing ICON
Password Setup / Clearing (C5)
The machine has the capability to limit access to the
Maintenance and Calibration screens. The password
option can be configured into 1 of the following 3
possibilities:
a. No Password (default configuration, when machine
shipped): All users can access all setup screens to
configure the system.
b. One password (“
”): Allows access to both the
maintenance and calibration screens (
c.
+
).
Two passwords:. One password allows access to
both the calibration and maintenance screen (
+
=
). The second password only allows
access to the maintenance screens (
=
).
To alter the password configuration:
From the Run screen, press
press
, then press
, and then
4 times. The following screen will be displayed.
Figure 29: C5 Screen with at least 1 Password
Configured
Key:
A Administrative Password ICON
B Access Indicator for Administrative Password
D Entry Status (Only filled after password change).
E Maintenance ONLY Password ICON
F Access Indicator for Maintenance ONLY Password
G Administrative Password Set/Clear ICON
H Maintenance ONLY Password Set/Clear ICON
I Screen Number (C5)
J
&
Setting/Clearing an Administrative Password:
1. Press
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keys will navigate to adjacent screens.
. The following screen will appear.
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Password Setting/Clearing
3. Press
to accept.
4. Re-enter the same 6-digit number.
5. Press
Figure 30: Administrative Password Entry with NO
Previous Password Stored
6. If both 6-digit passwords match, the C5 screen will
be displayed, and an “OK” after the second row of
symbols. If the 2 numbers do not match, the
process will need to be repeated.
7. Press
If a previous Administrative password has
been entered, the number at the top of the
screen is the existing password. A zero
indicates no Administrative password.
To clear the password, enter “000000”.
to accept.
twice to return to the Run screen.
With a Maintenance ONLY password, after the user
enters the password from the Password Entry screen,
the following screen will be displayed.
2. Enter a 6-digit sequence, by pressing the
corresponding soft keys, G-J in Figure 5. After the
6th key entry, the enter LED will blink.
3. Press
to accept.
4. Re-enter the same 6-digit number.
5. Press
to accept.
6. If both 6-digit passwords match, the C5 screen will
be displayed, and an “OK” after the first row of
symbols. If the 2 numbers do not match, the
process will need to be repeated.
7. Press
twice to return to the Run screen.
Setting/Clearing a Maintenance ONLY
Password:
1. Press
. The following screen will appear.
Figure 32: Mode Selection Screen after
Maintenance ONLY Password Entry
Resetting Passwords
If for whatever reason, the passwords for the machine
are not known, the passwords can be reset.
To reset all the passwords to 000000:
1. Temporarily remove power to the HMI.
2. Re-apply power to the HMI.
3. Immediately after the completion of the startup
sequence ( , , , , , ….), press and hold
the second soft key for at least 6 seconds.
If the press and hold does not start
immediately after the animation sequence, or
the press and hold is interrupted, the
procedure will need to be restarted at step 1.
4. After 6 seconds, the HMI will generate a single tone
indicating that the passwords have been cleared.
Figure 31: Maintenance ONLY Password Entry with
NO Previous Password Stored
5. New passwords may be entered by following the
steps in Password Setup / Clearing.
If a previous Maintenance Only password
has been entered, the number at the top of
the screen is the existing password. A zero
indicates no Administrative password.
To clear the password, enter “000000”.
2. Enter a 6-digit sequence, by pressing the
corresponding soft keys, G-J in Figure 5. After the
6th key entry, the enter LED will blink.
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Hibernate and Demo Modes
If the press and hold does not start
immediately after the animation sequence,
or the press and hold is interrupted, the
previous and this step may need to be
repeated.
Miscellaneous Machine Features
HMI Hibernate Mode
To help preserve the life of the HMI backlight, the
HMI will enter a Hibernate mode after the machine
has remained idle for an extended period of time.
To exit Hibernate mode, the user simply needs to
activate a HMI key or the machine footswitch.
When in Hibernate mode, the HMI LCD backlight
will be turned OFF, and the enter LED will blink at a
slow duty cycle (1 part ON, 8 parts OFF).
4. After 6 seconds, the HMI will generate a single
tone and the Demo Mode ON or OFF state will
be changed.
5. When in Demo Mode, a “D” will remain on the
bottom left-hand corner of the Run screen, as
indicated in the following figure.
If the machine performs a purge shot when the HMI
is hibernating, the HMI will remain in Hibernate mode.
HMI Startup Animation Sequence
When power is applied to the machine, the
electronics need time to initialize communication.
An “Hour Glass” animation sequence is generated
( , , , , , ….). Attempts to use the
machine during the startup period will be rejected.
Figure 33: Typical Run Screen in Demo Mode
6. To switch the HMI out of Demo Mode, repeat the
previous steps.
HMI Demo Mode Operation
Limitations of Demo Mode Simulation
The machine HMI is equipped with a demonstration
mode. When in “Demo Mode”, the HMI will not send
any requests to the Fluid Control Module and the
machine will not operate. The HMI will simulate
normal operation and provide audio feedback to the
user. All Demo Mode Maintenance and Calibration
screens are identical to screens provided in normal
mode operation.
Even though Demo Mode provides a good training
simulation for the user, it does have limitations when
compared to the HMI operating in normal mode.
•
On the Run screen, all the shot mode shots are
simulated as single piston stroke shots
regardless of the shot size and calibration
numbers entered.
Demo Mode can be used as a training tool for the
user. The user simply has to connect the HMI unit to
a separate power supply module, and the HMI will
operate normally without the machine attached.
•
The run screen animation sequence of the piston
movement is not as gradual as in real operation.
•
On the Run screen, during Operator mode
operation, a stalled piston condition is not
simulated.
•
The piston cycle counter is not stored for use
after power interruption, so if power is cycled to
the HMI, the cycle count will be reset.
•
The piston position numbers provided on the C1
screen are simulated.
•
All error codes will be NOT be generated, except
a stuck key error (E11) if the condition exists.
Any calibration, passwords, shot sizes, purge timer
settings, or other miscellaneous settings entered
while operating in Demo mode WILL NOT alter any
normal mode settings. Also, the first time Demo
mode is entered, all the calibration & maintenance
screen setups previously described will need to be
repeated.
To configure the HMI into and out of Demo Mode:
1. Temporarily remove power to the HMI.
2. Re-apply power to the HMI.
3. Immediately after the completion of the startup
sequence ( , , , , , ….), press and
hold the first soft key for at least 6 seconds.
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Pressure Relief and Shutdown Procedures, Error Codes
Pressure Relief Procedure
With the machine in an idle state:
1. If the machine pistons are not fully retracted,
retract the pistons by pressing
screen. See Figure 17.
in the M1
2. Manually open the dispense valve by pressing
the third M1 soft key until the “ ” ICON is
shown in the Current DV field. See Figure 17.
Figure 34: Typical Error Code Screen
3. Remove the incoming air pressure by closing the
air inlet valve (item 13 in Figure 54).
Key:
A Error Code Animation Field
Standby/Shutdown Procedure
D Error Code ICON
E Error Code Acknowledgement ICON
If the machine is to remain idle for an extended
period of time, implement the following:
When an error code is generated, the user will need
to acknowledge the condition by pressing the soft key
1. Remove any static mixer installed at the end of
the dispense valve.
under the
2. Place a container below the valve, and activate a
small shot to flush material away from the end of
the valve.
key, the error number
After the user activates the
generated in the Figure 34 example, will be displayed
on the bottom left hand corner of the Run screen,
while the condition is still present.
3. To prevent accidental pump movement, press
B Error Code Number Field
ICON.
(red).
4. With a clean rag, clean the end of the dispense
valve to remove excess material.
5. Install a nightcap at the end of the valve.
Error Codes
When the machine is operating and a fault is
detected, it will report the condition by generating an
error code. Error codes are typically generated
when the machine is idle after dispensing a shot.
When error codes are generated, a screen will be
displayed which contains an animation sequence, the
error code number and an ICON symbol representing
the condition detected. The HMI will also output an
error code tone sequence. The tone sequence
cannot be disabled.
Figure 35: Typical Run Screen with an Active
Error Code Condition
The example E12 number on the main run screen will
remain on the run screen as long as the error
condition exists. If the problem is corrected the
example E12 number will be removed.
If more than 1 error code condition exists for the
machine, the corresponding “EXX” numbers will be
listed on the bottom left corner, separated by
commas.
When errors are generated, the machine will
automatically be disabled and remain in an idle state
until the user acknowledges the condition. Any active
purge timer present prior to error code generation will
be suspended, and will need re-started by requesting
a shot after the error is acknowledged.
The following typical screen is generated when an
error code is generated:
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Error Code Table
Error Code Table
Title
#
Cause, Details
ICON
Stuck Key Error
E11
A key on membrane has been active (pressed) for > 30 seconds continuously.
Replace the HMI. This error code does not require user acknowledgment and
will clear itself automatically if the condition is removed.
Communication
Error
E12
The Display module has lost communication with the Fluid Control Module.
Material dispensing will be disabled if this condition exists. Check
communication cables between the 2 electronic components, or check the
HMI and/or the Fluid Control Module.
This error will be regenerated continuously while the condition exists.
No or Invalid Run
Token Error
E13
The Run Token in the FCM is missing (not installed), or does not have the
correct data.
Piston Stroke
Time-out Error
E21
A piston stroke action has taken > 55 seconds. Typically caused by no/too
little air pressure to the machine or a mechanical interference with the piston
has occurred. Check machine input line pressure.
Less than
Minimum Shot
Requested Error
E23
User has requested a shot < the minimum allowable size entered during
calibration. (< 15% of stoke, N/A in Operator Mode).
Improper
Calibration Error
E24
The calibration done on the machine is invalid, so the requested shot cannot
be executed. For instance, a Large Stroke Calibration Shot mass which is
less than the Short Stroke Calibration Shot mass (C4 screen) will create this
error code. If the wiring to the linear position transducer is reversed this error
will appear. If invalid piston positions are calibrated into the machine (C1
screen) this error will appear.
Delta Velocity
(“V”) Minus Error
E25
The piston velocity is slower than the calibration velocity measured, by the
percentage amount selected by the user (20%, 40% or 60%). If the user
selects 0%, this monitoring or alarm feature is disabled.
If generated, shot size accuracy may be degraded. Typically the problem is
created when the machine pressure regulator is adjusted to different value
from when the machine was calibrated. Another less likely cause could be a
mechanical failure with dispensing (worn piston, etc.). This error will not be
generated for a purge shot or when the machine is in Operator mode.
Delta Velocity
(“V”) Plus Error
E26
The piston velocity is faster than the calibration velocity measured, by the
percentage amount selected by the user (20%, 40% or 60%). If the user
selects 0%, this monitoring or alarm feature is disabled.
If generated, shot size accuracy may be degraded. Typically the problem is
created when the machine pressure regulator is adjusted to different value
from when the machine was calibrated. Another less likely cause could be a
mechanical failure with dispensing (worn piston, etc.). This error will not be
generated for a purge shot, or when the machine is in Operator mode.
Low Material
Level, Tank A
Alarm or Error
E27
Low Material
Level, Tank B
Alarm or Error
E28
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Tank A is low (only generated if tank sensing is enabled). Fill tank A with
material.
Tank level errors will be generated after every shot if the condition still exists.
Tank B is low (only generated if tank sensing is enabled). Fill tank B with
material.
Tank level errors will be generated after every shot if the condition still exists.
24 of 50
Error Code Table
Low Material
E29
Level, Both Tanks
Alarm or Error
Both tanks are low (only generated if tank sensing is enabled). Fill both tanks
with material.
Bad Linear
Position Sensor
There is a fault with the linear position sensor. Check wiring or replace.
E50
Tank level errors will be generated after every shot if the condition still exists.
Table 1: Error Code Table
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ICON Tables
ICON Descriptions
Key
Key Description
Screen
Maintenance and Calibration Screens Enter / Exit.
Shot Mode / Operator Control Mode Selection.
All
Run
Run, C2,
C4
Shot Request (green)
Red Stop or Cancel (Stops Operation Immediately, regardless of Screen).
All
Up (Used to Raise Numerical Entry, Screen Navigation or Shot Selection).
Many
Down (Used to Lower Numerical Entry, Screen Navigation or Shot Selection).
Many
Enter (Used to Accept Entry).
Many
Soft (Changes Function, Depending Upon Screen).
All
Table 2: PR70 HMI ICON Table
ICON
Description
Screen
Calibration Screens.
Maintenance Screens.
Option Abort or Escape.
Many
Piston Full Extend.
C1, M1
Piston Full Retract.
C1, M1
Metering Tube or Cylinder Entrance.
C1
Phasing Shot.
C2
Decrease Phasing Shot.
C2
Increase Phasing Shot.
C2
Open Displacement Valve (DV) Position Adjustment.
C3
Tables 3: PR70 Screen ICON Tables
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ICON Tables
ICON
Description
Screen
Short Stroke Calibration Shot
C4
Long Stroke Calibration Shot
C4
Administrative Password Set/Clear
C5
Maintenance Only Screens Password Set/Clear
C5
Tank Level Sensing ON
C6
Tank Level Sensing OFF
C6
Delta Velocity Set Level (0 = OFF)
C6
Displacement Valve Always Open
M1
Displacement Valve Always Closed
M1
Displacement Valve Automatic Operation
M1
Shot Size Definition
M2
Purge Timer Set/Clear
M2
Purge Shot Size
M2
Purge Alarm Setting
M2
Zero Cycle Counter
M3
Silent Mode ON
M3
Silent Mode OFF
M3
Set Date
M4
Set Time
M4
Tables 4: PR70 Screen ICON Tables (Continued)
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Maintenance, Software Upgrades and Run Token
Maintenance
The following items should be checked daily, once
during a shift, or as required for the application:
•
Air Filter - Check air filter and release any water
circuit water trapped in the base of the filter.
•
Tanks – Check material levels and refill as
necessary. Verify the material reservoirs are
vented properly.
•
Air Dryer - Check the condition of the desiccant air
dryer, and replace if necessary.
•
Pump Shafts – Clean both pump shafts with
solvent and lubricate with approved lubricant such
as mesamoll or Silicon oil.
•
Dispense Head – Dismantle, clean thoroughly and
re-assemble. Lubricate all parts with a thin coat of
approved lubricant, or silicon oil.
•
Ratio Check – If material ratio is critical for the
application, implement the ratio check procedure as
required.
Software Upgrades, Run Token
When software in the HMI or Fluid Control Module
(FCM) needs updating, a black Graco update token is
used.
4. Insert a black programming token into the slot
provided. Make sure it snaps into place when
inserted.
5. Turn ON the AC power switch.
6. Verify the red LED on the FCM or HMI starts
blinking at a fast steady rate, then the red LED
stops flashing accordingly. Verify the Green LED is
on continuously, and the amber LED blinks every
few seconds.
7. Turn OFF the AC power switch.
8. Remove the programming token from the FCM or
HMI. If the second electronic component needs
updating, insert the token into the other electronic
module. If the FCM was re-programmed, re-insert
the blue run token in the slot provided.
9. If programming a second electronic module, repeat
steps 5 through 8.
10. Re-apply machine power.
11. Go to the M4 screen to verify the new software
revision(s).
Run Token
The PR70 Fluid control module (FCM) contains a blue
run token, installed in the socket provided. It has
identical appearance to the black programming token,
but is blue.
If the token is not installed into the FCM, the machine
will not operate, and an E13 error will be generated on
the display module. Hence, if the FCM software is
updated, it will need to be re-installed at the end of the
re-programming procedure.
Figure 36: Standard Graco Data Token
To transfer an updated software program from the
token to the PR70 HMI or FCM:
1. Turn OFF the AC power switch in the back of the
machine.
2. If updating the Fluid Control Module (FCM), open
the access door to the FCM by loosening the 2
access screws. Remove the Blue Run token from
the FCM.
3. If updating the Human Machine Interface (HMI),
remove the HMI from the mounting bracket and
remove the back cover by removing the 4 screws on
the back of the enclosure.
312393G
28 of 50
Troubleshooting
Troubleshooting
3. Allow the machine to cool, if the machine has a heat
control option.
Before starting any troubleshooting procedures:
1. Relieve pressure (refer to Pressure Relief
Procedure Section).
Try the recommended solutions in the order given for
the each problem to avoid unnecessary repairs. Also
verify all circuit breakers, switches, and controls are
properly set and wiring is correct before assuming there
is a problem.
2. Disconnect AC power to the machine.
PROBLEM
CAUSE
No Power
Fuse Blown
HMI Display Completely Dark
No or incorrect amount of
material dispensed from either
side
Piston stalled (E21 Error)
Loose connection
Bad HMI
Ball Valve Closed
Tank empty
Tank Clogged
Air in material
Check valve malfunction
Piston worn or broken
Input Air Reduced or
removed
Mixer blocked
ODV adjustment too late
Blocked Check valve
Air Cylinder Failure
Significant material leaking
from pump rear seal
Pump Shaft worn
Specific gravity of 1 or more
of the 2 materials has
changed since calibration.
Machine Air pressure has
changed since calibration.
Material dispensed not correct
weight
Machine dispensing off ratio
Pumps drawing material back
from valve hose
312393G
Not enough material in 1 or
more tanks
Mixer has slight obstruction
Check valve malfunction
Piston worn or broken
One tank is empty
Tank Ball valve Closed
Machine out of phase
Check valve malfunction
Piston worn or broken
Check valve stuck open
SOLUTION
Verify rear AC Power switch is ON.
Replace Machine fuses (Refer to “Miscellaneous
Mechanical Assemblies” Section).
Tighten 5 pin cable on HMI.
Replace HMI
Open Tank Ball Valve (if installed).
Fill tank with material
Verify no obstruction in the tank
Prime the machine until the air is removed.
Remove, clean or replace check valve.
Remove and replace piston if worn.
Re-connect input air line to machine. Increase
air pressure regulator adjustment.
Replace static mixer. Incorporate or decrease
purge time amount to prevent mixer blockage.
Re-adjust the ODV setting to occur sooner (C3
screen section).
Remove check valve, clean and replace.
Remove air cylinder and re-install cylinder kit
items if necessary.
Remove pump shaft assembly, and re-install rear
pump re-built kit.
Mix materials in tanks, dispense another shot,
then re-weigh. Re-calibrate if necessary (C4
section).
Re-adjust air pressure regulator to value used
when machine was calibrated, or re-calibrate (C4
% level.
section). Turn ON or decrease
Check tank levels, and fill and prime if
necessary.
Replace static mixer. Re-prime machine.
Remove check valve(s), clean or replace if
necessary.
Remove and replace piston(s) if necessary.
Check tank levels. Add material if necessary.
Open tank ball valve. Re-prime machine.
Re-phase machine (C2 section).
Remove check valve(s), clean or replace if
necessary.
Remove and replace piston(s) if necessary.
Remove check valve(s), clean or replace if
necessary.
29 of 50
Base Frame and Air Cylinder Assemblies
Repair
Major Mechanical Assemblies, and Attachments
Figure 38: PR70 Top View w/o Tanks with Footswitch and HMI Illustrated
Figure 39: PR70 Base Frame to Air Cylinder, Pump and Drive Block Attachments
Key:
Ref
1
2
3
4
P/N
LC0112
120913
120919
LC0110, or
LC0111
312393G
Description
Pump Assembly, PR70
Screw, SHC, M8-1.25 x 25
Nut, Hex, M14
Air Cylinder Assemblies, 3.0” or 4.5”
QTY
1
4
1
Ref
5
6
7
8
P/N
LC0107
121166
LC0109
121167
Description
Drive Block Assembly, PR70
Screw, SHC, M6-1.0 x 40
Base Frame Assembly
Screw, SHC, M8 - 1.25 x 40
QTY
1
4
1
4
30 of 50
Base Frame and Air Cylinder Assemblies
Figure 40: PR70 Power Entry Bracket and Control Bracket Assembly Attachments
Key:
Ref
1
2
P/N
120885
LC0108
Description
Screw, SHC, M5 – 0.8 x 14
Control Bracket Assembly, PR70
QTY
4
1
Ref
3
4
P/N
LC0106
120885
Description
Power Entry Assembly, PR70
Screw, SHC, M5 – 0.8 x 14
QTY
1
2
Base Frame Assembly
Figure 41: PR70 Base Frame Assembly (LC0109)
Key:
Ref
1
2
3
4
P/N
120599
120885
120913
15K788
312393G
Description
PIN, DOWEL, 3/8DIAX1.50LG, SS
SCREW,SHC, M5-0.8X14,MS,E
SCREW,SHC, M8X1.25X25,MS, E
FRAME, BASE, PR70S, MACHINED
QTY
2
2
2
1
Ref
5
6
7
8
P/N
15K796
LC0033
120918
120886
Description
CLAMP
TRANSDUCER ASSY, LINEAR, PR70S
GUIDE, LINEAR
SCREW, SHC,M6-1.0X25,MS,E
31 of 50
QTY
1
1
1
4
Base Frame and Air Cylinder Assemblies
Air Cylinder Assemblies, and Rebuild Kits
Figure 42: PR70 Air Cylinder System and Schematic
312393G
32 of 50
Air Cylinder Assemblies
Figure 43: PR70 Air Cylinder Assemblies, 3.0” & 4.5” Diameters (LC0110 & LC0111)
Key:
(LC0110, 3.0” DIA. Assy., PR70)
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
P/N
107571
114100
120875
120880
120881
120884
120899
120900
120922
120923
120932
121018
121020
121021
121022
15K790
15K791
15K792
15K793
15K795
312393G
Description
ORING, VIT, BAD
SCREW, SHC, M4X0.7X55, MS, E
ORING, VIT, CCE
SCREW, SHC, M8-1.25 X 125, MS, E
BEARING, 1.00ID X 1.252 OD X 1.00LG,
SCREW, SHC, M12-1.75 X 20, MS
VALVE, 4W, 3P, COE, DSSC, ¼ NPT, 24VDC
VALVE, PWR, 4W, SSSR, 1/4NPT, 24VDC
MUFFLER, AIR, ¼ NPT, FLOW CONTROL
ELBOW, SWVL, ¼ TUBE X 10-32, FXM, 90o,
ORING, VIT, JDA
ELBOW, SWVL, 3/8 TUBE X ¼ NPT, FXM, 90o
ELBOW, SWVL, EXT'D, ¼ X ¼ NPT, FXM, 90o
MUFFLER, AIR, ¼ NPT, BRONZE
ELBOW, SWVL, ¼ TUBE X ¼ NPT, FXM, 90o
TUBE, AIR CYL, 3.0 I.D., PR70S
BLOCK, AIR CYL, ROD END, PR70S
BLOCK, AIR CYL, BLIND END, PR70S
PISTON,AIR CYL, 3.0 I.D., PR70S
ROD, PISTON, AIR CYL, PR70S
(LC0111, 4.5” DIA. Assy., PR70)
QTY
1
3
1
4
1
1
1
1
1
1
2
5
1
3
2
1
1
1
1
1
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
P/N
107571
114100
104131
120880
120881
120884
120899
120900
120922
120923
104271
121018
121020
121021
121022
15K789
15K791
15K792
15K794
15K795
Description
ORING,VIT,BAD
SCREW, SHC, M4X0. 7X55,MS,E
ORING,VIT,CDG
SCREW,SHC,M8-1.25X125,MS,E
BEARING, 1.00IDX1.252ODX 1.00LG
SCREW, SHC,M12-1.75X20,MS
VALVE, 4W, 3P,COE, DSSC, 1/4NPT, 24VDC
VALVE,PWR,4W, SSSR, ¼ NPT, 24VDC
MUFFLER,AIR, 1/4NPT, FLOW CONTROL
ELBOW, SWVL, ¼ X 10-32, FXM, 90o, CM/PL
ORING,VIT,JDG
ELBOW,SWVL,3/8TUBEX ¼ NPT, FXM, 90DE
ELBOW, SWVL, EXT'D, ¼ X ¼ NPT, FXM, 90o
MUFFLER,AIR, ¼ NPT, BRONZE
ELBOW, SWVL, ¼ TUBE X ¼ NPT, FXM, 90DE
TUBE, AIR CYL,4.5 I.D.,PR70S
BLOCK, AIR CYL, ROD END, PR70S
BLOCK, AIR CYL, BLIND END, PR70S
PISTON, AIR CYL,4.5 I.D.,PR70S
ROD, PISTON, AIR CYL,PR70S
33 of 50
QTY
1
3
1
4
1
1
1
1
1
1
2
5
1
3
2
1
1
1
1
1
Pump Assembly
To install a new Air Cylinder Kit:
1.
Follow the Pressure Relief Procedure and turn off the
machine.
2.
Disconnect the airline, remove the PR70 Shroud, and
remove the machine power entry assembly (item 3 or
Figure 40) from the machine by removing the 2
attachment screws (4 of Figure 40).
3.
Remove the 2 air valves (items 7 & 8) from the cylinder
end block (18) by removing the 3 attachment screws (2).
4.
Disconnect the air cylinder piston rod (20) from the
machine drive block assembly (item 5 of Figure 39) by
removing all hex nuts (item 3 of Figure 39) from the piston
rod (additional nuts may be installed if the machine has a
Hydracheck option). An open-end wrench will be
required to prevent the rod from turning when the nuts are
removed.
5.
Disconnect the air cylinder from the machine frame base
assembly (item 7 of Figure 39) by removing the 4 screws
(item 8 of figure 39), which attach the cylinder rod end
block (17) to the frame. Access the screw through the 4
holes in the blind end block (18) using a long allen
wrench.
12. Remove the cylinder rod from the rod end block, then
remove the rod o-ring (item 3 of Figure 40) from the rod
end block and replace.
13. Liberally apply Graco high temperature lubricant Grease
(Graco P/N 115982) to the inside of the tube (16), the
outside of the piston (19), all the o-rings and the cylinder
rod (20).
14. Re-assemble the air cylinder. Attach the 2 drive blocks
by reinstalling the 4 long screws (4) finger tight. Then
torque the screws as specified in note
a crisscross pattern.
of Figure 43 in
NOTICE
In the previous step, air cylinder damage may result if
screws are not installed in a crisscross pattern.
15. Air Cylinder damage may result if bolts are not installed in
a crisscross pattern.
16. Reinsert the air cylinder into the back of the machine by
inserting the cylinder rod through the hole in the base
frame and in the drive block.
6.
Remove the air cylinder by pulling on the cylinder from
the back of the machine.
17. Before the cylinder is completely in place, re-connect the
airlines to the cylinder block elbows fittings (12). Verify
the correct airlines are connected (see Figure 43).
7.
With the cylinder partially removed, disconnect the
airlines at the air cylinder elbow fittings (12).
18. Reattach the cylinder to the base frame by reinstalling the
4 screws (item 8 of Figure 39).
8.
On a bench, disassemble the air cylinder by removing the
4 long screws (4), which connect the 2 cylinder blocks.
19. Reattach the cylinder to the drive block by reinstalling the
hex nut (item 3 of Figure 39) to the cylinder rod. Torque
9.
Inspect the cylinder tube (16) and piston (19) to verify no
scratches exists. Replace if necessary.
10. Using a clean dry cloth, remove any existing grease from
the inside of the tube (16), the outside of the piston (19)
and the cylinder rod (20).
11. Remove the 2 cylinder block o-rings (item 2 of Figure 40)
from the blocks and replace. Remove the piston o-ring
and replace (item 1 of Figure 40).
the nut as specified in note
of Figure 39.
20. Reattach the valves to the blind end block by reattaching
the 3 screws (2).
21. Reattach the power entry assembly by reinstalling the 2
attachment screws (item 4 of Figure 40).
22. Reconnect input air into the machine. Operate the
machine accordingly, and verify no air leaks are found.
Recalibrate the machine.
Figure 44: PR70 Air Cylinder Rebuild Kits, 4.5” and 3.0” Diameter Versions (LC0092 & LC0091).
Key:
(LC0092, 4.5” DIA. Rebuild Kit)
Ref
1
2
3
P/N
104131
104271
107571
312393G
Description
ORING, VIT, CDG
ORING, VIT, JDG
ORING, VIT, BAD
(LC0091, 3.0” DIA. Rebuild Kit)
QTY
1
2
1
Ref
1
2
3
P/N
120875
120932
107571
Description
ORING, VIT, CCE
ORING, VIT, JDA
ORING, VIT, BAD
QTY
1
2
1
34 of 50
Pump Assembly
Drive Block Assembly
Figure 45: PR70 Drive Block Assembly (LC0107)
Key:
Ref
1
2
3
P/N
120891
15K801
15K802
Description
SCREW, SHS, M6-1.0 X 8, MS
ROD, ALIGNMENT
NUT, RETAINER
QTY
2
2
2
Ref
4
5
6
P/N
15K805
15K868
84/013027/11
Description
BLOCK, DRIVE, PR70S
WASHER, SPERICAL, ½ DIA. MODIFIED
LABEL, HAND CRUSH, 1.3 X 1.1, TRIANGLE,
ISO
Pump Assemblies and Rebuild Kits
Figure 46: PR70 Pump Assembly (LC0112)
312393G
35 of 50
QTY
1
2
1
Pump Assembly
Key:
Ref
1
2
3
4
6
7
8
P/N
106258
108712
120887
120890
120982
15K786
15K787
Description
ORING, VIT, JCB
NUT, HEX, M8 X 1.25, MS
POSIPAK, 0.375ID X 0.625OD, COIL
RING, RET, INT, 1.00, SS
SCREW, SHC, M8 X 1.25 X 65, MS, E
HOUSING, PUMP, PR70S, MACHINED
CAP, END, PUMP, PR70S, MACHINED
QTY
2
2
2
2
8
1
2
To install a new Check Valve Rebuild Kit:
1. With the machine in an idle state and a bucket
below the dispense valve to catch material, fully
extend the piston by pressing
screen.
in the M1
2. To prevent machine movement, press
(red).
3. With a bucket below the check valve to be
replaced, disconnect the male hose fitting from
the check valve housing (13), by loosing the hose
from the housing. Catch any material draining
from the hose into the bucket.
4. Remove the check valve housing (13) from the
pump endcap (8) by loosening the housing with a
wrench.
5. Remove the existing check valve (14) from the
housing (13) by inserting a screwdriver or dowel
rod into the female threaded end of the check
valve housing.
6. With the new check valve ball guide (item #3 in
figure 43) on a bench with the open end up,
install the check valve spring (item 2 of figure 47)
into the guide.
Ref
9
10
11
12
13
14
P/N
15K803
15K804
15K824
15K828
15K895
LC0093
Description
COLLAR, PUMP
HOUSING, BEARING, SEAL, PR70S
SHAFT, PISTON, 3/8, PR70S, SS
WASHER, SEAL, 3/8, PR70S, SS
HOUSING, CHECK VALVE
KIT, REBUILD, VALVE, CHECK, PR70S
QTY
2
2
2
2
2
2
8. With the rounded inside surface of the check valve
seat (item 4 of figure 47) facing down, place the seat
on top of the check valve ball.
9. Holding both ends of the assembled check valve
assembly, install the check valve into the un-threaded
end of the check housing (13) with the ball end facing
out. Apply some pressure to the valve to snugly fit the
completed check valve into the housing and the fit the
check valve seat (item 4 of figure 47) into the valve
guide.
10. Verify when the assembled check valve and housing
(13) are turned up-side down, that the contents of the
valve stays in place.
11. Re-insert the new valve and valve housing into the
pump end cap, using a wrench.
12. Re-install the material male hose fitting into the check
valve housing using a wrench.
13. Before re-using the machine for operation, activate a
few shots to purge any air present in the material hose
lines due to the procedure.
14. Re-calibrate the machine if necessary.
7. Install the check valve ball (item 1 of figure 47) on
top of the spring.
Figure 47: PR70 Check Valve Rebuild Kit (LC0093)
Key:
Ref
1
2
P/N
105445
121084
312393G
Description
BALL,CHECK VALVE
SPRING, 0.30OD X 0.44LG, 22#/IN, 20PSI, S
QTY
1
1
Ref
3
4
P/N
15D312
196832
Description
BUSHING, BALL GUIDE
SEAT, LAPPED, CHECK VALVE
QTY
1
1
36 of 50
Pump Assembly
Figure 48: PR70 Rear Pump Rebuild Kit (LC0094)
Key:
Ref
1
2
P/N
106258
120890
Description
ORING, VIT, JCB
RING, RET, INT, 1.00, SS
QTY
1
1
To install a new Rear Pump Rebuild Kit:
1. Drain the pump by taking several shots with either
the tank ball valves closed (if installed), or by
activating enough shots to empty the tanks.
2. Disconnect the pump shaft (item 11 of Figure 46)
from the drive block assembly by loosening the
shaft locking nut (item 2 of Figure 46), then turning
the shaft with a wrench while preventing the drive
block alignment rod (item 2 of Figure 45) from
rotating with a wrench. Manually push the pump
shaft forward toward the extend position to separate
the shaft from the drive block.
3. Remove the shaft lock nut from the shaft.
Ref
3
P/N
120887
Description
POSIPAK, 0.375ID X 0.625OD, COIL
10. Apply 1 layer of thin masking tape over the male
threads of the pump shaft, which mates with the
drive block. This will prevent the threads from
damaging the seal or Posipak (3).
11. Using extreme caution, slide the pump shaft through
the hole in the bearing housing as indicated in
Figure 48. Align the bearing housing in position
next to the pump housing.
12. Re-install the pump collar over the bearing housing
and attach it to the pump housing using the 2
screws (item 5 on Figure 46) previously removed.
Torque the screws as specified in note
Figure 46.
4. Remove the pump collar (item 9 on Figure 46) from
the pump housing (item 7 on Figure 46) by
removing the 2 screws (item 5 on Figure 46).
13. Remove the masking tape from pump shaft.
5. Slide the pump bearing housing (item 10 of Figure
46) away from the pump housing to remove.
15. Re-install the pump shaft to the drive block
alignment rod.
6. Remove the existing rear pump build components
(refer to Figure 48 items) from the pump bearing
housing.
16. Re-tighten the lock nut.
7. Using a clean dry cloth, remove any existing grease
from the bearing housing.
8. Apply new high temperature grease lubricant (Graco
P/N 115982) to the inside of the pump bearing
housing, and the new rebuild components.
of
14. Re-install the pump shaft lock nut to the pump shaft.
17. Open the tank ball valves (if installed) and put more
material into the tanks.
18. Instigate several shot to fill the pump with new
material.
19. Re-calibrate and re-phase the machine, due to the
procedure performed.
9. Install the new rebuild kit components into the
bearing housing as indicated in Figure 48.
312393G
QTY
1
37 of 50
Pistons & Metering Tubes
Piston Cylinders or Metering Tubes
Figure 49 PR70 Nylon and UHMWPE Piston Replacement Kits
Key:
Ref
1
2
Description
Piston
Screw
QTY
1
1
Ref
3
When ordering a piston replacement kit, the following
intelligent part numbering system applies for Nylon
based pistons:
Description
Oring
QTY
2
The items indicated in Figure 49 above will be
supplied with the kit. Refer to the Models section for
the available standard piston sizes.
LCF - 120
Code :
A
Piston Size (mm2)
When ordering a UHMWPE replacement kit, the
following numbering applies:
LCE - 160
Code :
A
Piston Size (mm2)
312393G
38 of 50
Pistons & Metering Tubes
installed), or by activating enough shots to empty
the tanks.
To install a new Piston or Piston/Cylinder
Replacement Kit:
1. Drain the machine pistons by instigating several
shots with either the tank ball valves closed (if
3. Remove the pump end caps (item 8 of figure 46)
by removing the 4 end cap screws (item 6 of
figure 46). Allow the cap to hang by the hose.
4. Remove the cylinder and Orings (items 1 and 6 of
figure 50) from the pump housing (item 7 of figure
46) and pump cap.
5. Select an operating mode, then fully extend the
pistons by activating the
screen.
option in the M1
6. To prevent machine movement, press
(red).
7. Remove the existing piston (1) and any front or
rear washers (items 3 & 4 of figure 50) from the
pump shaft (item 11 of figure 46) by removing the
piston screw (2). A wrench will be required near
the drive block to prevent the pump shaft from
rotating while the screw is removed.
8. Install the new piston and any rear or front
washers, by re-installing the piston screw into the
pump shaft. When tightening the piston screw,
tighten the screw until the piston stops rotating,
then turn the screw an additional ¼ turn.
Part No.
LC1080
LC1100
LC1120
LC1140
LC1160
LC1180
LC1200
LC1220
LC1240
LC1260
LC1280
LC1300
LC1320
LC1360
LC1400
LC1440
LC1480
LC1520
LC1560
LC1600
LC1640
LC1720
LC1800
LC1880
LC1960
312393G
Rev.
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
Series
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
2. To prevent machine movement, press
(red).
9. Select an operating mode, then retract the
pistons by pressing
in the M1 screen.
10. To prevent machine movement, press
(red).
11. Lubricate the new o-rings with a high temperature
grease, Graco P/N 115982 or equivalent. Place
the lubricated o-rings into the inside circle
placements in the pump housing and pump end
caps.
12. Install the cylinder between the pump housing
and end cap, then secure the cylinder and Orings
by re-attaching the 4 end cap screws (item 6 of
figure 46).
13. Open the tank ball valves (if installed) or put more
material into the tanks.
14. Instigate several shot to fill the pump with new
material.
15. Re-calibrate the machine, due to the procedure
performed.
NYLON PISTONS (SEE FIGURE 50)
Frt.
Tube
Piston
Washer
Area
Item 1
Item 2
Item 3
80
LCC080
LCB080
15M089
100
LCC100
LCB 100
15M089
120
LCC120
LCB 120
NOT REQ
140
LCC 140
LCB 140
NOT REQ
160
LCC 160
LCB 160
15M099
180
LCC 180
LCB 180
15M099
200
LCC 200
LCB 200
15M099
220
LCC 220
LCB 220
15M099
240
LCC 240
LCB 240
15M100
260
LCC 260
LCB 260
15M100
280
LCC 280
LCB 280
15M100
300
LCC 300
LCB 300
15M100
320
LCC 320
LCB 320
15M100
360
LCC 360
LCB 360
15M100
400
LCC 400
LCB 400
15M100
440
LCC 440
LCB 440
15M100
480
LCC 480
LCB 480
15M100
520
LCC 520
LCB 520
15M100
560
LCC 560
LCB 560
15M101
600
LCC 600
LCB 600
15M101
640
LCC 640
LCB 640
15M101
720
LCC 720
LCB 720
15M101
800
LCC 800
LCB 800
15M101
880
LCC 880
LCB 880
15M101
960
LCC 960
LCB 960
15M101
Back
Washer
Item 4
NOT REQ
NOT REQ
NOT REQ
NOT REQ
15K887
15K887
15K887
15K887
15K887
15K887
15K887
15K887
15K888
15K888
15K888
15K888
15K888
15K888
15K888
15K888
15K890
15K890
15K890
15K890
15K890
Screw
O-ring
Item 5
Item 6
120933
120874
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Pistons & Metering Tubes
Part No.
LC2160
LC2180
LC2200
LC2220
LC2240
LC2260
LC2280
LC2300
LC2320
LC2360
LC2400
LC2440
LC2480
LC2520
LC2560
LC2600
LC2640
LC2720
LC2800
LC2880
LC2960
Rev.
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
Series
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
NYLON PISTONS (SEE FIGURE 50)
Frt.
Tube
Piston
Washer
Area
Item 1
Item 2
Item 3
160
LCA160
LCB160
15M099
180
LCA180
LCB 180
15M099
200
LCA200
LCB 200
15M099
220
LCA220
LCB 220
15M099
240
LCA240
LCB 240
15M100
260
LCA260
LCB 260
15M100
280
LCA280
LCB 280
15M100
300
LCA300
LCB 300
15M100
320
LCA320
LCB 320
15M100
360
LCA360
LCB360
15M100
400
LCA400
LCB400
15M100
440
LCA440
LCB440
15M100
480
LCA480
LCB480
15M100
520
LCA520
LCB520
15M100
560
LCA560
LCB560
15M101
600
LCA600
LCB600
15M101
640
LCA640
LCB640
15M101
720
LCA720
LCB720
15M101
800
LCA800
LCB800
15M101
880
LCA880
LCB880
15M101
960
LCA960
LCB960
15M101
Back
Washer
Item 4
15K887
15K887
15K887
15K887
15K887
15K887
15K887
15K887
15K888
15K888
15K888
15K888
15K888
15K888
15K888
15K888
15K890
15K890
15K890
15K890
15K890
Screw
O-ring
Item 5
Item 6
120933
120874
Front and Rear Washer Reference Guide
Tube Area
Frt. Washer
Back Washer
080 to 119
15M089
NOT REQ
120 to 159
NOT REQ
NOT REQ
160 to 239
15M099
15K887
240 to 319
15M100
15K887
320 to 559
15M100
15K888
560 to 639
15M101
15K888
640 to 960
15M101
15K890
Figure 50: Available PR70 Piston and Cylinder (Metering Tubes) Kits
Key:
Ref
1
2
3
Description
Cylinder or Metering Tube
Piston
Front Washer
312393G
QTY
1
1
See
Fig.
Ref
4
5
6
Description
Back Washer
Screw
Oring
QTY
See Fig.
1
2
40 of 50
Pistons
2. To prevent machine movement, press
(red).
3. Remove the existing Piston plug (1) from the pump
end cap (item 8 of figure 46) with a wrench.
Remove the existing Oring (2).
Figure 51 PR70 Piston Plug Assembly
4. Lubricate the new Oring with a high temperature
grease, Graco P/N 115982 or equivalent. Place the
lubricated Oring into the cap location of the end cap.
Key:
5. Re-install the piston plug (1) back into the end cap.
Ref
1
2
P/N
15K815
111457
Description
Plug
Oring
QTY
2/Machine
2/Machine
To install a new Piston Plug Assembly:
1. Drain the machine pistons by instigating several
shots with either the tank ball valves closed (if
installed), or by activating enough shots to empty
the tanks.
6. Open the tank ball valves (if installed) or put more
material into the tanks.
7. Instigate several shot to fill the pump with new
material.
8. Re-calibrate the machine, due to the procedure
performed.
Hose Assemblies
Figure 52 Piston to DV Hose Assemblies
312393G
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Hose Assemblies
Figure 53 Heated Piston to DV Hose Assemblies
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Miscellaneous Assemblies
Miscellaneous Mechanical Assemblies
Figure 54: PR70 Power Entry Bracket Assembly (LC0106)
Key:
Ref
1
2
3
4
5
6
7
8
9
10
P/N
119912
121018
120876
120882
120883
120910
120916
120993
15K798
15K800
Description
SCREW, PAN, M3X6, PHILLIPS, SS
ELBOW, SWVL, 3/8 X ¼ NPT, FXM, 90DE
PWR SUPPLY, 24VDC, 40W, 100-240VAC IN
FILTER, 1/4NPT
NUT, HEX, 7/8-14, MS
PWR ENTRY, 120/240VAC, DUAL FUSE, EMI
SCREW,FHSC, M3X0.5 X 10, SS
NUT, HEX, M5X0.8, WITH STAR WASHER
BRACKET, SWITCH, AIR
FITTING, BULKHEAD
QTY
3
1
1
1
1
1
2
2
1
1
Ref
11
12
13
14
15
16
17
18
19
P/N
84/0130-26/11
LC0034
121178
121179
121180
94/0762/99
94/0430/99
81/1054-4/11
LC0031
Description
LABEL, PE
HARNESS, WIRE, REMOTE SIGNAL
VALVE, LOCKOUT, ¼ NPT
QUIKCLAMP, ¼ NPT
MULTIPORT, [3] ¼ NPT
VALVE, RELIEF, ¼ NPT, M, 110PSI, SIL
PLUG, SKT HD, ¼ NPT, MS
FUSE 5X20MM, 4AMP, FAST, TYPE F, 250VAC
CABLE ASSY, POWER IN
To Replace the Fuses:
2. Replace the blown fuse(s) (18) into the fuse holder.
1. Remove the machine fuse holder from the PWR
Entry module (6) by inserting a flat-head
screwdriver between the holder and the back the
PWR Entry module (The fuse holder is above
where AC power is connected to the machine).
3. Re-install the holder into the PWR Entry Module.
312393G
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QTY
1
1
1
2
1
1
2
2
1
Miscellaneous Assemblies
Figure 55: PR70 Control Bracket Assembly (LC0108)
Key:
Ref
1
2
3
4
5
P/N
84/0153-1/89
120885
120897
120954
120993
Description
CLAMP, HARNESS, REUSEABLE, 5/8,NYL
SCREW, SHC, M5-0.8 X 14, MS, E
REGULATOR, 100PSI, 3/8NPT, GAGE
MANIFOLD, PN, 3/8NPTX3/8T X ¼ TX1/4T
NUT, HEX, M5X0.8, WITH STAR WASHER
QTY
2
2
1
1
5
Ref
6
7
8
9
10
P/N
121019
LC0124
15K797
84/0130-25/11
LC0035
Description
ELBOW, SWVL, 3/8 X 3/8 NPT, FXM, 90DE
CONTROLLER, FCM
BRACKET, ELECTRICAL,
LABEL,.375X.375
HARNESS, WIRE, I/O
Figure 56: PR70 Shroud Assembly (LC0113)
Key:
Ref
1
2
3
P/N
15V962
15M511
16P016
312393G
Description
SHIELD, PR70, FIXED RATIO, GCA
LABEL, WARNING
PR70, FIXED RATIO
QTY
1
4
1
44 of 50
QTY
1
1
1
1
1
Miscellaneous Assemblies
Figure 57: PR70 Hydracheck Components
Figure 58: PR70 HMI Components
Key:
Ref
1
2
P/N
288446
255235
312393G
Description
Display Module, PR70
Bracket, HMI
QTY
1
1
Ref
3
P/N
120999
Description
Termination Plug
QTY
1
45 of 50
312393G
Figure 59: PR70 Wiring Interconnect Illustration
Wiring Diagrams
Wiring Diagrams
46 of 50
312393G
Figure 60: Wiring Diagram, PR70
Wiring Diagrams
47 of 50
(121685)
Technical Data
Technical Data
Category
Metering Pump Effective Area
Data
2
2
80 – 960 mm (0.124 – 1.49 in ) per side
Small Air Cylinder Effective Area
4560 mm2 (7.07 in2)
Large Air Cylinder Effective Area
10260 mm2 (15.9 in2)
Maximum Stroke Length
38.1 mm (1.50 in)
Minimum Stroke Length
5.8 mm (0.23 in)
Volume per Cycle
2 – 70 cc (0.12 – 4.3 in3)
Pump Cycles per 1L (0.26 gal)
Ratios (fixed)
Maximum Fluid Working Pressure
Maximum Air Input Pressure
500 – 14.3
1:1 to 12:1 (depending upon cylinders selected)
3000 psi (20.7 MPa, 207 bar)
100 psi (0.7 MPa, 7 bar)
Maximum Cycle Rate
Maximum Operating Temperature
30 cpm
70 C (160 F), nylon pistons 50 C (120 F) UHMWPE pistons or PE Tanks
Air Inlet Size
Pump Fluid Outlet Size
Wetted Parts
Weight
Sound Power Level
4 in Air Cylinder
Measured Per ISO Standard 9614-2
¼ NPT (f)
-03, -04, -06, -08 or –12 JIC fittings for 3/16 in (4.8 mm), ¼ in (6.4 mm), 3/8 in
(9.5 mm), ½ in (12.7 mm), ¾ in (19.1 mm) hoses
303/304, 17-4 PH, hard chrome, Chromex, carbide, Chemical Resistant
O-rings, PTFE, nylon, UHMWPE
55 kg (120 Lbs) typical with two 7.5L tanks
150 kg (330 Lbs) typical with two 60 L tanks
100 psi/30 cpm - 81 dBA
50 psi/15cpm – 77 dBA
Compressed Air
< 10 scfm typical (varies with cycle times)
Electrical Power
100-240 V 50/60Hz, 1 phase for machine – 80 Watts
208-240V 50/60Hz, 1 phase for heat – 11 kW max.
120 or 240 VAC 50/60Hz 1 phase for on-board agitators, 80 Watts
240 VAC 50/60Hz 1 phase for off-board agitators, 830 Watts
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Technical Data
Dimensions
Figure 36: PR70 Dimensions (ON-Board PE Tank version Illustrated)
A typical PR70 Machine, with the standard On-Board twin 8 liter PE Tanks has the following dimensions:
Dimension
A (width)
B (height)
In. (mm)
18.49 (469.6)
26.39 (670.3)
Dimension
C (depth)
D (height in Back)
In. (mm)
30.62 (777.7)
13.39 (340.1)
A typical PR70 Machine, with the standard On-Board 7.5 liter Stainless Steel Tanks has the following dimensions:
Dimension
A (width)
B (height)
312393G
In. (mm)
15.5 (393.7)
27.37 (695.2)
Dimension
C (depth)
D (height in Back)
In. (mm)
30.62 (777.7)
13.39 (340.1)
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Warranty and Graco Contact Information
Graco Ohio Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of nonGraco 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.
Toll Free: 1-800-746-1334 or Fax: 330-966-3006
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.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 312393
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2007, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised November 2013
312393G
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