Graco 3A2894U, ExactaBlend AGP Advanced Glazing Proportioner Owner's Manual

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Graco 3A2894U, ExactaBlend AGP Advanced Glazing Proportioner Owner's Manual | Manualzz

Setup-Operation

ExactaBlend ™ AGP

Advanced Glazing

Proportioner

For dispensing two component silicone, polysulfide, and urethane materials.

For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

See page 4 for model information, including maximum working pressure and approvals.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

3A2894U

EN

S100 Shown

Contents

2

Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Base Machines . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Important Isocyanate (ISO) Information . . . . . . . . 8

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 8

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8

Keep Components A and B Separate . . . . . . . . . 8

Moisture Sensitivity of Isocyanates . . . . . . . . . . 9

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9

Component Identification . . . . . . . . . . . . . . . . . . . 10

S100 Models - 55 Gallon/5 Gallon (200 Liter/20

Liter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

S100 Model - 5 Gallon/5Gallon (20 Liter/20 Liter)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

U100 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

P100 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . 14

Display Module (DM) . . . . . . . . . . . . . . . . . . . . . 15

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Main Display Components . . . . . . . . . . . . . . . . 17

DM Screen Navigation Diagram . . . . . . . . . . . . 18

Integrated Air Controls . . . . . . . . . . . . . . . . . . . 19

Fluid Control Module (FCM) . . . . . . . . . . . . . . . 21

Light Tower 24R824 . . . . . . . . . . . . . . . . . . . . . 22

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Base Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 47

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . 50

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Adjust Packing Nuts . . . . . . . . . . . . . . . . . . . . . 53

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

DM - Battery Replacement and Screen Cleaning 54

Software Update Procedure . . . . . . . . . . . . . . . 55

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Mechanical and Electrical . . . . . . . . . . . . . . . . . 56

Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 59

Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 61

Low Level Sensors, 24R935

(S100 and P100 only) . . . . . . . . . . . . . . . . . 61

Calibration Check Assembly, 24R777 . . . . . . . . 61

USB Kit, 24R936 . . . . . . . . . . . . . . . . . . . . . . . . 61

MD2 Nose Pieces . . . . . . . . . . . . . . . . . . . . . . . 61

Catalyst (B) Hoses . . . . . . . . . . . . . . . . . . . . . . . 62

Restrictor Kit, 24R804 . . . . . . . . . . . . . . . . . . . . 62

Restrictor Kit 24W146 . . . . . . . . . . . . . . . . . . . . 62

Caster Kit, 24T091 . . . . . . . . . . . . . . . . . . . . . . . 62

Mixer Elements for MD2 . . . . . . . . . . . . . . . . . . 63

Appendix A - DM Icons Overview . . . . . . . . . . . . . 64

Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . . 64

Run Screen Icons . . . . . . . . . . . . . . . . . . . . . . . 65

Appendix B - DM Setup Screens Overview . . . . . 66

Appendix C - DM Run Screens Overview . . . . . . 68

Appendix D - DM Error Codes . . . . . . . . . . . . . . . 70

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 78

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 80

3A2894U

Related Manuals

Related Manuals

Manuals are available at www.graco.com. Component manuals below are in English:

System Manuals

332452

332453

ExactaBlend AGP Advanced Glazing Proportioner, Parts

ExactaBlend AGP Advanced Glazing Proportioner - Accessory Kits, Kit Instructions

Ram Manuals

3A0233

Pump Manuals

312375

Air-Powered Ram, Instructions-Parts

312376

Check-Mate ® Displacement Pumps, Instructions-Parts

Check-Mate ® Pump Packages, Instructions-Parts

Air Motor Manuals

3A1211

311238

333007

SaniForce ™ Air Motors, Instructions-Parts

NXT ® Air Motor, Instructions-Parts

ExactaBlend AGP Air Motor, Instructions-Parts

Displacement Pump Manuals

309577 Displacement Pump, Repair-Parts

Dispense Valve Manuals

312185

308253

MD2 Valve, Instructions-Parts

Ultra-lite ™ Pistol Grip Flo-Gun, Instructions-Parts

Flow Meter Manuals

308778

309834

Volumetric Fluid Flow Meter, Instructions-Parts

Helical Gear Fluid Flow Meters, Instructions-Parts

Fluid Filters Manuals

307273 Fluid Outlet Filter, Instructions-Parts List

Fluid Regulators Manuals

307517

308647

Mastic Fluid Regulators, Instructions-Parts List

Fluid Pressure Regulators, Instructions-Parts List

Pressure Pot Manuals

308369 5-, 10-, and 15-Gallon Pressure Tanks, Instructions-Parts List

Heated Platen Manuals

332511 ExactaBlend AGP Advanced Glazing Proportioner - Heated Platen Kit, Kit Instructions

Reference Manuals

3A1244 Graco Control Architecture ™ Module Programming

Valve Manuals

313342 Dosing Valve, Instructions-Parts

3A2894U 3

4

Models

Models

Base Machines

Part No.

25E001

Chemical

Industry

24R809

25A476

24R810

24X098

24R811

24R812

24R813

24R814

24R815

24R816

Silicone

Urethane*

Polysulfide

Description

AGP-S100 System, 5 gallon/5 gallon

(20 liter/20 liter) machine

AGP-S100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine with boom.

Low volume platen single wiper.

AGP-S100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine with boom.

Low volume platen dual wiper.

AGP-S100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine.

Low volume platen single wiper.

AGP-S100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine

Low volume platen dual wiper.

AGP-U100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine with boom

AGP-U100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine

AGP-U100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine with boom and pressure pot

AGP-U100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine with pres sure pot

AGP-P100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine with boom

AGP-P100 System, 55 gallon/5 gallon

(200 liter/20 liter) machine

Ratio

(by Weight)

1:1

6:1 to 14:1

Maximum Working Pressure psi (MPa, bar)

MD2:

3000 (21, 207)

Ultra-lite with flexible hose mixer:

3000 (21, 207)

Ultra-lite with Tri-core mixer:

4000 (28, 276)

* An agitator is recommended for urethane applications utilizing a pressure pot. Set the agitator to 25-50 rpm.

3A2894U

Models

Hose Kits

Part No.

24R832

24R833

24R834

24T092

24T094

24U253

24T093

24X094

25A426

25C238

25C239

25C240

Hose Kit

Reference

No.

#1

#2

#3

#4

#6

#7

#5

#8

#9

#10

#11

#12

Base Hose in. (cm)

5/8 x 120 (1.6 x 305)

Catalyst Hose 1 in. (cm)

Catalyst Hose 2 in. (cm)

1/8 x 60 (0.3 x 152) 1/8 x 60 (0.3 x 152)

1/4 x 60 (0.6 x 152) 1/8 x 60 (0.3 x 152)

1/4 x 60 (0.6 x 152) 1/4 x 60 (0.6 x 152)

3/8 x 60 (1.0 x 152) 1/4 x 60 (0.6 x 152)

1/2 x 60 (1.3 x 152) 3/8 x 60 (1.0 x 152)

3/32 x 60 (0.2 x 152) 3/32 x 60 (0.2 x 152)

1/8 x 60 (0.3 x 152) 3/32 x 60 (0.2 x 152)

1/4 x 120 (0.6 x 305)

3/4 x 53 (1.9 x 135) +

5/8 x 120 (1.6 x 305) 3/32 x 180 (0.2 x 457)

NA

NA

Catalyst Hose 3 in. (cm)

NA

NA

NA

NA

NA

NA

NA

NA

NA

5/8 x 120 (1.6 x 305) 3/8 x 60 (1.0 x 152) 1/8 x 60 (0.3 x 152)

3/4 x 53 (1.9 x 135) +

5/8 x 120 (1.6 x 305)

1/4 x 60 (0.6 x 152) 1/4 x 60 (0.6 x 152) 1/4 x 60 (0.6 x 152)

1/4 x 60 (0.6 x 152) 1/4 x 60 (0.6 x 152)

NA

1/8 x 60 (0.3 x 152)

Dispense Valves

Part No.

Description

24P217 MD2 dispense valve with handle

24P223 Ultra-lite 6000 with 36 element flexible hose mixer

24P221 Ultra-lite 6000 with 36 element Tri-core mixer

3A2894U 5

6

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama tion 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.

ELECTRIC SHOCK HAZARD

This equipment must be grounded .

Improper grounding, setup, or usage of the system can cause elec tric shock.

• Turn off and disconnect power cord before servicing equipment.

• Connect only to grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors

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 equip ment, follow the Pressure Relief Procedure and disconnect all power sources.

3A2894U

3A2894U

Warnings

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help pre vent 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. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock .

Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 manu facturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre ate safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read 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.

7

Important Isocyanate (ISO) Information

8

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac turer.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material sup plier for compatibility.

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in some two component materials.

Isocyanate Conditions Material Self-ignition

Spraying or dispensing materials containing isocya nates 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 ventila tion 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.

Some materials may become self-igniting if applied too thick. 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 dam age equipment. To prevent cross-contamination:

• Never interchange component A and component

B wetted parts.

• Never use solvent on one side if it has been con taminated from the other side.

3A2894U

Moisture Sensitivity of

Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure; forming 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.

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

• 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 pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with

ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropri ate lubricant when reassembling.

NOTE: The amount of film formation and rate of crystal lization varies depending on the blend of ISO, the humidity, and the temperature.

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• 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 chemi cal compatibility.

3A2894U

Important Isocyanate (ISO) Information

9

Component Identification

Component Identification

S100 Models - 55 Gallon/5 Gallon (200 Liter/20 Liter)

D

F

H

L

J

B

V

M

H

J

P

A

M

K

E

C

G

F

F IG . 1: S100 55/5 Gallon Models

Key:

A Display Module (DM)

B Boom ✿

C Ram - Base (A) Chemical*

D Ram - Catalyst (B) Chemical*

E Dispense Valve*

F Integrated Air Controls

G Electrical Enclosure

10

H Flow Meters*

J Fluid Regulator*

K Calibration Check Assembly ✿

L Fluid Control Module (FCM)

M Material Pressure Gauges

N Catalyst (B) Filter ✿

P Fluid Regulator Adjustment

Controls the pressure to the base (A) fluid regulator.

R Pressure Pot (U100 only)*

S Air Motor (U100 only)*

T Displacement Pump (U100 only)*

U Dosing Valve (P100 only)*

V Light Tower

* Refer to specific component manual for more detailed information.

✿ Where applicable.

3A2894U

S100 Model - 5 Gallon/5Gallon (20 Liter/20 Liter)

F

Component Identification

J

P

H

V

A

M

D

F

IG

. 2: S100 5/5 Gallon Models

NOTE:

Refer to key found on page 10.

L

M

C

G

J

H

3A2894U 11

Component Identification

U100 Models

H

L

J

V

M

H

J

E

B

P

A

M

K

F

C

G

S

F

T

N

R

F IG . 3: U100 Models

NOTE:

Refer to key found on page 10.

12 3A2894U

P100 Models

H

L

J

V

M

H

B

A

P

K

M

E

U

D

Component Identification

C

G

F

N

F

R

F IG . 4: U100 Models

NOTE:

Refer to key found on page 10.

3A2894U 13

Component Identification

Electrical Enclosure

DB

DA

F IG . 5: Electrical Enclosure

Key:

DA Power Switch

Turns electrical power on or off.

DB 24VDC Power Supply

Converts input power to 24 VDC.

14 3A2894U

Component Identification

Display Module (DM)

User Interface

BB

BF

BG

BD

BA BE BC

F

IG

. 6: DM Component Identification - Front

Key:

BA System Enable/ Disable

Enables/disables the system. When the system is disabled, dispense operation is disabled.

BB Soft Keys

Defined by application using the DM.

BC Cancel

Cancel a selection or number entry while in the process of entering a number or making a selection.

BD Enter

Acknowledge changing a value or making a selection.

BE Lock/Setup

Toggle between run and setup screens. If setup screens are password protected, button toggles between run and password entry screen.

BF Field Selection

Navigate to another field when the DM is in setup mode.

These buttons have no function when the DM is in run mode.

BG Increase / Decrease / Field Selection

Increase or decrease the selected value. Navigate to another field.

3A2894U 15

Component Identification

F IG . 7: DM Component Identification - Rear

BH Model Number

Identification tag for the DM.

BJ CAN Cable Connections

Electrical connection for power and communication to other GCA devices.

BK Module Status LEDs

Visual indicators to show the status of the DM:

Green Solid - Power provided.

Green Off - No power.

Yellow Flashing - Communication with other GCA devices occurring.

Red Solid Bad DM or machine is in critical status

Red Flashing Wrong program uploaded.

BL Token/Battery Access Cover

Access cover for token and battery.

16

BL

BH

BK

BJ

3A2894U

Component Identification

Main Display Components

The following figure calls out the navigational, status, and general informational components of each screen.

Current date and time

Previous screen Current screen

Next screen

Faults, Status

Function display

F IG . 8: Main Display Components

Selection screen

3A2894U 17

Component Identification

DM Screen Navigation Diagram

Home

Run Screens

Purge/Prime Screen

Alarm Log Screen

Information Screen

Calibration Check Screen

Totalizer Screen or or

Password

Entry

(if enabled)

Setup Screens

+

Screen 1

System Settings

+

Screen 2

Calibration/

Material Settings

+

Screen 3

Display/Date/Time

+

Screen 4*

USB Settings

+

Screen 5

Part Number/Version

+

+ softkey moves between screens in ascending order softkey moves between screens in descending order

* This applies only if a USB is installed. If a USB is not installed, Part Number/Version becomes

Screen 4 and there is no Screen 5.

F IG . 9: Screen Navigation Diagram

18 3A2894U

Component Identification

Integrated Air Controls

Base (A) Side

All Models

Catalyst (B) Side

S100 Models

CF

CF

CE

CD

CC

CG

CE

CD

CC

CG

CB

CB

CJ

CA

F IG . 10: Integrated Air Controls

Key:

CA Main Air Slider Valve

Turns air on and off to the entire system. When closed, the valve relieves pressure downstream.

CB Ram Air Regulator

Controls the ram up and down pressure and blowoff pressure.

CC Ram Director Valve

Controls the ram direction.

CD Exhaust Port with Muffler

CE Air Motor Regulator

Controls the air pressure to the motor.

CF Air Motor Slider Valve

Turns air on and off to the air motor. When closed, the valve relieves air trapped between it and the motor. Push the valve in to shutoff.

CG Blowoff Button

Turns air on and off to push the platen out of an empty drum.

CJ Catalyst Air Slider Valve

Turns air on and off to the catalyst motor only. When closed, the valve relieves pressure down stream.

CK Voltage to Pneumatic Regulator (V/P)

Electrically controlled air regulator.

3A2894U 19

Component Identification

Catalyst (B) Side

U100 Models

CF

CE

CG

CJ

Catalyst (B) Side

P100 Models

CK

CF

CE

CD

CC

CB

F IG . 11: Integrated Air Controls

NOTE:

Refer to key found on page 19.

20 3A2894U

Component Identification

Fluid Control Module (FCM)

EG

EF

EE

EB

ED

EH

EC

EA

F IG . 12: FCM

Key:

EA Port 1 - Air Shut off Valve

Controls the air to the base (A) material regulator.

Port 1 - Low Level Sensors (Optional)

Low level input for the both materials. Refer to

Accessories and Kits , page 61, for more details.

Includes splitter.

EB Port 2 - Flow Meters

Base (A) and Catalyst (B) flow meter input. Includes splitter

EC Port 3 - Solenoid Valve (P100 only)

To open and close the dosing valve.

ED Port 4 - Voltage to Pneumatic (V/P) Regulator

Controls the air to the catalyst (B) material regulator.

EE Port 5 - Audible Light Tower

Visual and audible indicator of machine status. Refer to page 21 for more details.

EF Port 6 - Not Used

EG Port 7 - Not Used

3A2894U

EH CAN Connection

Supplies power and communication to GCA components.

21

Component Identification

Light Tower 24R824

Visual and audible indicator of machine status.

Status Description

Red - Solid An error has occurred and requires maintenance.

Red and Green - Solid Allows a dispense but notifies the user of an uncleared error

(e.g. low level).

Green - Solid

Green - Flashing

Machine is ready to dispense

Machine is okay. Gel timer has expired.

F IG . 13: Light Tower

22 3A2894U

EB

EA

ED

Component Connection Reference from

FCM (S100 Model Shown)

Component Identification

EB

EA

EE

F IG . 14: Component Connection Reference from FCM

3A2894U

EC

23

Installation

Installation

NOTICE

To avoid flow meter malfunction, do not use PTFE tape on NPT threads. Only apply pipe sealant, Loc tite ® #565 or equivalent, to all NPT threads when installing.

1. Locate the Machine Base.

Locate the machine on a level surface. Refer to

Dimen sions , page 78, for space requirements.

2. Assemble the Hose Clamps and Swivel Assembly onto the Boom Base.

a. Torque the swivel assembly fasteners to

24 ft-lb (33 N•m).

b. Hand tighten all hose clamps.

NOTE:

Refer to steps 9 and 11 for visual clarity of hose

clamp placement.

S100 Shown

Swivel

Assembly

Calibration Check only

24 3A2894U

3. Install the Boom Base onto the Machine Base.

Slide the boom base into the machine base mast.

Installation

5. Install the Front Boom Arm onto the Boom Base.

Torque all fasteners to 24 ft-lb (33 N•m).

(3) Places

4. Assemble the Hose Clamps onto the Front Boom Arm.

Hand tighten all hose clamps.

NOTE:

Refer to steps 9 and 11 for visual clarity of hose

clamp placement.

6. Install the Fluid Plate onto the

Front Boom Arm.

NOTICE

Injury may occur if the fluid plate is lifted by only one person. Use a hoist, multiple people, or remove the fluid regulators prior to installation.

7. Light Tower Installation

a. Fasten the light tower bracket to the boom assembly. Torque the nut to 24 ft-lb (33 N•m).

Resin Hose Clamp

Calibration check only

3A2894U 25

Installation b. Mount the light tower to the bracket. Hand tighten the light tower nut.

c. Connect the cable from the light tower to port 5 located on the Fluid Control Module (FCM).

8. Calibration Check Only: Install the Calibration Check Assem

-

bly and Material Tubes onto the Boom Assembly.

a. Tighten all fittings to prevent leaking.

b. Tighten all hose clamps to secure material lines.

NOTE: For additional assembly details, refer to the

ExactaBlend AGP Advanced Glazing Proportioner -

Accessories, Instructions manual.

26 d. Torque the fluid plate fasteners to 24 ft-lb

(33 N•m).

e. Install the fluid regulators if removed for instal lation.

3A2894U

9. Route and Connect the

Base (A) Material Hoses.

a. Tighten all fittings to prevent leaking.

b. Tighten all hose clamps to secure material lines.

Installation

10.P100 Only: Install the Dosing

Valve.

a. Tighten all fittings to prevent leaking.

b. Install the air supply from the catalyst inte grated air controls.

c. Connect the solenoid cable from port “3” of the

FCM. Refer to

Fluid Control Module (FCM) , page 21. Allow enough length for lifting the ram

out of material container.

Label “100”

S100 Shown

3A2894U 27

Installation

11.Route and Connect the Cata

-

lyst (B) Material Hose.

a. Tighten all fittings to prevent leaking.

b. Tighten all hose clamps to secure material lines.

U100 Shown

S100 Shown

P100 Shown

28 3A2894U

12.Route and Connect the Air

Hoses and Electrical Lines.

Secure the electrical lines to the boom using electrical tape or zip ties.

NOTE: Securing the ground cable to the fluid plate is required for the proper grounding of the machine.

NOTE: S100 and U100 models are shown below. For

P100 models, the V/P is located on the catalyst air con -

trols. Refer to Integrated Air Controls , page 19.

Label “102”

Installation

13.Assemble the Base (A) Mate

-

rial Whip Hose.

Tighten all fittings to prevent leaking.

Machine End

Dispense End

Label “103”

CAN Cable

Ground Cable

3A2894U

S100 Shown

29

Installation

14.Assemble the Catalyst (B) Material Whip Hose.

Refer to PKE 2863 found at http://graco.custhelp.com/app/answers/detail/a_id/2863 or by utilizing the QR code below for recommended hose size configurations, pin sizes, and calibration numbers. Tighten all fittings to prevent leaking.

NOTE:

Refer to Restrictor Kit, 24R804 , page 62, for purchase. Restrictor pin size is for typical applications and are

for reference only. It may be necessary to install other pins or configurations to obtain balanced pressures.

#1 = 0.094 in. (2.4 mm) • #2 = 0.098 in. (2.5 mm) • #3 = 0.102 in. (2.6 mm)

NOTE: Refer to

Catalyst (B) Hoses , page 62, for additional hose sizes available.

a. Select the fluid plate to restrictor housing hose.

Install the adapter.

c. Select the restrictor housing to dispense valve hose. Install the restrictor housing to dispense valve hose to the restrictor pin assembly or union.

b. Select the restrictor pin or union.

U100 with MD2: Install the union to the fluid plate to restrictor housing hose. If utilizing the restrictor pin assembly, the restrictor pin

assembly will be installed in step d.

All other Configurations: Install the restrictor pin assembly or union to the fluid plate to restrictor housing hose.

Note the orientation of pin and pin housing.

d.

U100 with MD2: If utilizing the restrictor pin assembly, replace the swivel union found on the MD2 with the restrictor pin assembly.

30 3A2894U

15.Connect the Catalyst (B) and

Base (A) Material Whip Hoses to the Fluid Plate.

NOTICE

Damage to the moisture-lok hoses may result in moisture sensitive material to cure within the hose.

To avoid machine damage, avoid damaging the pro tective coating on the moisture-lok hoses.

a. Tighten all fittings to prevent leaking.

Installation c.

MD2: Tape sleeve 8 in. (20 cm) behind the high volume fitting to allow adequate movement of the gun handle.

8 in. (20 cm)

Ultra-Lite: Tape sleeve just behind manifold block.

Base

Catalyst b. Slide protective sleeve over base and catalyst hoses.

d. Pull the other end of the protective sleeve tightly and secure with electrical tape.

3A2894U 31

Installation

16.MD2 Only: Connect the Air

Fitting and Route the Air

Hose.

a. Remove the plug located on the catalyst (B) integrated air control.

S100 Shown U100 Shown P100 Shown b. Install the air fitting if required. Use sealant on the threads and tighten to prevent leaking.

S100 Shown U100 Shown

c. Route the air line beside the other air hoses that were routed in step 12.

P100 Shown

32 3A2894U

Installation

17.Ultra-lite Tri-core Only:

Replace the Relief Valve on

Both Integrated Air Controls.

Replace the standard relief valve found on both the base (A) and catalyst (B) integrated air controls with the relief valve for the Ultra-lite Tri-core dispense valve.

18.U100 Models Only: Locate and Connect the Pressure

Pot

a. Locate the pressure pot on the machine base.

b. Connect the chemical line from the pressure pot to the fluid filter inlet using fitting provided.

S100 Shown c. Connect the air line from the Base (A) Inte grated Air Controls to the pressure pot.

U100 Shown

3A2894U 33

Installation

19.Install Accessories.

Refer to the ExactaBlend AGP Advanced Glazing Pro portioner - Accessory Kits manual for details.

20.Connect Air to the Machine.

NOTE: Air inlet port size is 3/4 npt (f).

21.Connect Electrical Power to

Machine.

Connect the power cord to the electrical enclosure.

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode.

Improper grounding can cause electric shock.

Grounding provides an escape wire for the electric current.

Machine: Grounded through customer supplied power cord.

Fluid supply container: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive sur face, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: hold metal part of the gun/dis pense valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

34 3A2894U

Setup

Setup

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

When software is updated on the DM, the software is then automatically updated on all connected GCA com ponents. A status screen is shown while the software is updating to indicate the progress. When the status bar is complete, press to continue.

The DM will display an error message when initialization is complete. This error occurs because the machine has not been calibrated. Press to acknowledge the error and continue with the setup procedure.

When the main electrical power is turned on, the splash screen will be displayed until communication and initial ization is complete.

3A2894U 35

Setup

1. Purge Material Lines.

d. Open the base (A) main air slider valve.

To avoid personal injury or machine damage, adjust all air regulators counter-clockwise prior to turning the main air on.

a. Load material.

Ram: Perform the “Change Drums” procedure in the Air-Powered Ram manual.

Pressure Pot: Perform “Filling the Tank” pro cedure in the 5-, 10-, and 15-Gallon Pressure

Tanks manual. An agitator is recommended for urethane applications utilizing a pressure pot.

Set the agitator to 25-50 rpm.

b.

Calibration Check Assembly Only: Close the calibration check assembly.

e. Set the base (A) air motor regulators to 10 psi

(70 kPa, 0.7 bar).

To avoid personal injury or machine damage, do not exceed 25 psi on the base (A) material until a steady flow of material has been established.

c. Close the base (A) air motor slider valve.

f. Set the fluid regulator adjustment to 40 psi

(280 kPa, 2.8 bar).

36 g. Place the base (A) hose end into a waste con tainer.

3A2894U

h. Activate on the DM.

l. Deactivate on the DM.

Setup i. Open the base (A) air motor slider valve.

m. Close the base (A) air motor slider valve.

j. Increase the base (A) air motor regulator as required to have material flow out of the hose.

n. Repeat steps a through m for the catalyst (B)

hose. Refer to

Integrated Air Controls , page 19, for visual clarity.

NOTE: Activate on the DM when prompted and all slider valves refer to the catalyst (B) air controls.

k. Dispense the material into the waste container until the base (A) material hose is purged and free of air.

3A2894U 37

Setup

2. Connect the dispense appli

-

cator.

MD2:

a. Connect both base (A) and catalyst (B) material hoses to the dispense applicator.

b. Activate both and on the DM.

Ultra-lite:

a. Connect the base (A) hose to the base (A) inlet fitting.

b. Connect the catalyst (B) hose to the catalyst (B) inlet fitting.

c. Open the catalyst (B) ball valve and dispense material into a waste container until the dis pense valve has been purged and is free of air.

d. Activate on the DM.

c. Open the catalyst (B) ball valve and dispense material into a waste container until the dis pense valve has been purged and is free of air.

d. Close the catalyst (B) ball valve and dispense material into a waste container until only base (A) is present.

38 3A2894U

3. Calibration Check Assembly

Only: Purge material lines to the calibration check assem

-

bly.

a. Open the base (A) and catalyst (B) air motor slider valves.

Setup c. Place a waste container underneath the cali bration check assembly.

d. Remove the JIC caps from the calibration check assembly.

e. Open the calibration check assembly.

b. Activate both and on the DM.

3A2894U 39

Setup f. Dispense the material into the waste container until both the base (A) and catalyst (B) material lines have been purged and are free of air.

g. Close the calibration check assembly.

4. Calibrate the machine.

Perform the following procedure during initial setup of the machine, if the flow meters were replaced, or if the machine needs to be recalibrated.

a. Engage the trigger lock.

b. Open the base (A) and catalyst (B) air motor slider valves.

h. Clean the nozzles of the calibration check assembly and install the JIC caps.

i. Activate on the DM.

c. Set the base (A) and catalyst (B) air motor regu lators.

MD2 or Ultra-lite with flexible hose:

70 psi (480 kPa, 4.8 bar).

Ultra-lite with Tri-core :

85 psi (586 kPa, 5.9 bar)

40 3A2894U

d. Set the fluid regulator adjustment to 40 psi

(280 kPa, 2.8 bar).

Setup g. Activate to signal the machine of the fol lowing calibration shot.

h.

MD2: Install the calibration nozzle onto the dis pense applicator.

e. Place two separate containers on two separate scales and zero the scales. These containers

will be used in step j.

NOTE: Weight units of the scales are to be set as grams.

f. Navigate to setup Screen 2 .

NOTE: Screen 2 is already shown if this procedure is performed during the initial setup of the machine.

Screen 2 - Recalibration i. Disengage the trigger lock.

Screen 2 - Initial Calibration

3A2894U 41

Setup j. Dispense the chemicals into two separate con tainers.

MD2: Chemical will be dispensed through the applicator.

Ultra-lite: Chemical will be dispensed through the calibration check assembly.

l. Weigh both containers separately and input the values of both chemicals into setup Screen 2 .

NOTE: To change a value in a desired field, perform the following.

• Press or desired field to be changed.

to highlight the

• Press to activate the desired field or to activate/deactivate an option.

• Press or to change the value of the selected field.

• Press to set the value.

NOTE: Weight units are in grams.

k. Continue to dispense the chemical into the containers until both status bars are complete.

NOTE: If the light tower is installed, a green light will be illuminated when the status bars are complete.

42 3A2894U

m. Press to signal the machine that the cali bration procedure is complete. The machine will automatically calculate the K factor of both materials.

n. Engage the trigger lock.

o.

MD2: Remove the calibration nozzle and install a static mixer on the dispense valve.

p. Navigate to the

Home

screen.

5. Set the Display Module (DM).

Perform the following tasks to fully setup the DM. Refer

to Appendix A - DM Icons Overview , page 64, for

clarity.

a. Define general system settings. See Screen 3

,

page 67.

Setup b. Define specific system settings. See

Screen 1 , page 67.

c.

P100 with Ultra-Lite Tri-core Mixer: Select

the 85 psi (5.9 bar) option box. See Screen 1 , page 67.

3A2894U 43

Startup

Startup

4. Open the base (A) and catalyst (B) main air slider valves.

Do not operate machine without all covers and shrouds in place.

1. Engage the trigger lock.

2. Install the static mixer or nozzle onto the dispense applicator. See specific applicator manual for details.

NOTE: Cutting more than two outlet steps on the static mixer may increase the chance of the mixing elements being pushed out of the static mixer.

NOTE: If using the mixer element kit 24T035, assemble the sleeve onto the MD2 dispense applicator prior to fastening the 1/4 NPT outlet adapter. Hand tighten the

1/4 NPT outlet adapter.

5. Open the base (A) and catalyst (B) air motor slider valves.

6. Verify the base (A) and catalyst (B) air motor regula tors are set to the correct pressure.

MD2 or Ultra-lite with flexible hose:

70 psi (480 kPa, 4.8 bar).

Ultra-lite with Tri-core :

85 psi (586 kPa, 5.9 bar)

3. Turn the power on at the electrical enclosure.

44 3A2894U

7.

P100 with Ultra-Lite Tri-core Mixer: Verify that the 85 psi (5.9 bar) option box is selected. Refer to

Screen 1 , page 67.

Startup shows “OK” and the light tower, if installed, illumi nates green.

8. Verify the ram director valve is set to lower the ram.

9. The DM will show a standby screen when power is first supplied to the machine. Press the

Home

screen.

to go to r_255179_purge

NOTE: Additional dispensing may be required in order to ensure a good mixture.

NOTE:

The Home

screen will indicate “Not OK” and the light tower, if installed, will illuminate red until the next step is completed.

10. Disengage the trigger lock.

NOTE: If a new static mixer has been installed, a base purge is recommended to prevent side walling. Perform

Base Purge , page 46.

11. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun until the Display Module

3A2894U 45

Base Purge

Base Purge

Base purge results in the purging of the base (A) chem ical through the dispense valve. Base purging prevents mixed material within the dispense applicator from cur ing. The machine will remain pressurized and electri cally connected.

1. Navigate to the

Purge/Prime

screen.

NOTE: Verify both pumps are activate.

2. Close the catalyst (B) ball valve located near the dispense applicator.

3. Dispense material into a waste container until only the base (A) chemical is present.

4. Engage the trigger lock.

46 3A2894U

Pressure Relief

Procedure

MD2:

a. Remove the static mixer.

Pressure Relief Procedure

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the

Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing the equipment.

1.

If electrical power is supplied to the machine , perform

Base Purge , page 46.

If electrical power is not supplied to the machine , continue to the next step.

2.

S100 and P100: Close the base (A) and catalyst (B) air motor slider valves.

U100: Close the base (A) air motor slider valve and the supply ball valve on the pressure pot. Bleed the air from the pressure pot by opening the manual bleed valve.

b. Open the catalyst (B) ball valve located near the dispense applicator.

c. Disengage the trigger lock.

d. Trigger the gun to relieve pressure into a waste container.

e. Verify the pressure gauges display “0”.

3A2894U 47

Pressure Relief Procedure f. Close the base (B) and catalyst (A) main air slider valves.

Ultra-lite:

a. Remove the JIC caps from the calibration check assembly.

b. Place a waste container underneath the cali bration check assembly.

g.

If electrical power is not supplied to the machine, place a waste container underneath the pump bleed valves. Open the pump bleed valves.

NOTE: For U100 systems, the catalyst bleed valve is located on the pump outlet filter.

c. Open the calibration check assembly to relieve pressure into a waste container.

h. Clean the nose of the dispense valve or bleed valve.

i. Install the night cap onto the MD2.

d. Verify the pressure gauges display “0”.

48 3A2894U

e. Close the calibration check assembly.

Shutdown

Shutdown

1. Perform Pressure Relief Procedure , page 47.

2. Turn the power off at the electrical enclosure.

f. Clean the nozzles of the calibration check assembly and install the JIC caps.

g. Close the base (A) and catalyst (B) main air slider valves.

h.

If electrical power is not supplied to the machine, place a waste container underneath the pump bleed valves. Open the pump bleed valves. Clean the pump bleed valves once complete.

NOTE: For U100 systems, the catalyst bleed valve is located on the pump outlet filter.

3A2894U 49

Calibration Check

Calibration Check

Perform the calibration check procedure to verify the calibration of the flow meters are correct.

1. Perform

Base Purge , page 46.

2. Navigate to the

Home

screen.

5.

MD2 Only: Install the calibration nozzle onto the dispense applicator.

6. Open the catalyst (B) ball valve located near the dispense applicator.

3. Activate on the DM.

4. Remove the static mixer.

50 3A2894U

Calibration Check

7.

Calibration Check Assembly Only: Dispense material into a waste container at the calibration check assembly to verify the V/P shown on the DM is at the correct value.

NOTE: A restrictor pin for the catalyst (B) restrictor housing may be required to obtain 5 psi (35 kPa,

0.3 bar) or above for the V/P shown on the DM.

9. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun until the Display Module shows “OK”.

8. Disengage the trigger lock.

10. Place two separate containers on two separate scales and zero the scales. These containers will be

used in step 11.

NOTE: Weight units of the scales are to be set as grams.

3A2894U 51

Calibration Check

11. Dispense the chemicals into two separate contain ers.

MD2: Chemical will be dispensed through the applicator.

Ultra-lite: Chemical will be dispensed through the calibration check assembly.

13. Weigh both containers separately and calculate the ratio (A/B) of the two chemicals.

14. Compare the ratio calculated from the weighed containers with the ratio shown on the DM.

15. If the ratio comparison is acceptable, press

on the DM or repeat steps 10 through 14

twice if more verification is required. Press clear all values if more than three samples are required.

to

16. If the ratio comparison is unacceptable , perform

Calibrate the machine. page 40.

12. Continue to dispense the chemical into the contain ers until a 400 gram shot has been dispensed.

NOTE: A value will be shown on the DM when a dis pense is complete. This is the value the machine was running at based on the flow meter values.

52 3A2894U

Maintenance

Maintenance

Task

Refer to specific component manual for more detailed infor mation.

Check catalyst (B) filter assembly to prevent crystallization.

Verify calibration check assembly outlets are clear and unob structed.

Check desiccant.

Check restrictor housing and pin assembly to prevent crystalliza tion.

U100: Check iso lube bottle for discoloration.

Perform

Shutdown and install

nightcap.

Adjust packing nuts.

Schedule

As Required

Weekly

Weekly

Weekly

Weekly

Daily

Daily

When TSL has seeped through the packing nut

Adjust Packing Nuts

4. Fill dosing valve packing nut with throat seal liquid

(TSL).

5. After TSL is added, tighten dosing valve packing nuts 1/4 turn after nut contacts packings; about

145-155 in-lb (16-18 N•m).

TSL

NOTE: There must be no pressure when adjusting the packing nuts. Air pressure in the feed tanks is too much.

1. Follow

Pressure Relief Procedure , page 47,

including relieving air pressure in the tanks.

2. Fill metering pump packing nuts with throat seal liq uid (TSL).

3. After TSL is added, torque metering pump packing nuts to 50 ft-lb (67.5 N•m). Follow instructions in

Xtreme Lowers manual 311762.

Filters

Once a week check, clean, and replace (if needed) the following filters.

• S100 and U100 Models:

Catalyst pump outlet filter comes with a 60 mesh filter. Two pack 60 mesh filter replacement kit,

224459, is available.

• P100 Models:

Catalyst pump outlet filter comes with a 30 mesh filter. Two pack 30 mesh filter replacement kit,

224458, is available.

Seals

Once a week, check and tighten throat seals on the pumps and dosing valve.

3A2894U 53

Maintenance

DM - Battery Replacement and Screen Cleaning

Battery Replacement

A lithium battery maintains the DM clock when power is not connected.

To replace the battery:

1. Disconnect power to the DM.

NOTE: This can be done by removing the CAN cable from the bottom of the DM.

2. Remove rear access panel.

3. Remove the old battery and replace with a new

CR2032 battery.

4. Properly dispose the old lithium battery according to local codes.

5. Replace rear access panel.

6. Connect the power to the DM and reset the clock

through Screen 3 . Refer to Appendix B - DM

Setup Screens Overview for more detail.

Cleaning

Use any alcohol-based household cleaner, such as glass cleaner, to clean the DM. Spray on the rag then wipe DM. Do not directly spray the DM. Replaceable screen protectors, 15M483, are available.

54 3A2894U

Maintenance

Software Update Procedure

When software is updated on the DM, the software is then automatically updated on all connected GCA com ponents. A status screen is shown while the software is updating to indicate the progress.

Refer to PKE 2823 found at http://graco.cus

thelp.com/app/answers/detail/a_id/2823/ or by utiliz ing the QR code below for software version history.

6. Turn the power switch to ON.

NOTICE

A status is shown while software is updating to indi cate progress. To prevent corrupting the software load, do not remove token until the status screen disappears.

NOTE: When the screen turns on, the following screen will appear.

1. Turn the power switch to OFF.

2. Remove the DM from the bracket.

3. Remove the token access panel.

F IG . 15: Remove Access Cover

4. Insert and press software upgrade token (Token part no.16V853) firmly into the slot.

5. Install the DM onto the bracket.

Icon Description

Update successful.

Update unsuccessful.

Update complete, no changes necessary

Update was successful/complete but one or more GCA modules did not have a CAN boot-loader, so the software was not updated in that module.

7. Remove the token.

8. Replace the token access panel.

9. Press to continue.

3A2894U 55

Troubleshooting

Troubleshooting

1. Follow Pressure Relief Procedure , page 47, before checking or repairing a dispense valve.

2. Check all possible problems and causes before disassembling the dispense valve.

Mechanical and Electrical

PROBLEM

No flow of catalyst (B).

Clogged gun nose.

Clogged injector housing (Ultra-lite only).

CAUSE

Dispense Applicator

Clogged restrictor housing

Ball valve is closed.

V/P is off.

Dosing valve leaking at rod.

Dosing valve between main housing and outlet housing.

Dosing valve not cycling

Dispense valve will not dis pense material.

Dispense valve will not stop material dispense.

No air to catalyst (B) pump.

No catalyst ram down pressure.

Loose or worn packings.

Bad o-ring.

Bad cable.

Bad power valve.

Trigger lock engaged.

No air to MD2.

Clogged mixer.

Ultra-lite has cured material in it.

No air to MD2.

Bad seal in MD2.

Ultra-lite seal is worn

SOLUTION

Clean or replace the gun nose.

Clean or replace the injector housing.

Clean or replace the restrictor housing and pin.

Open the ball valve.

Ensure the power is on.

Ensure the machine is in dispense mode.

Ensure V/P is turned on when machine enters Purge/Prime mode.

Turn air on.

Ensure that there is pressure to the catalyst ram and that the control lever is in the down position.

Tighten packing nut. If leak continues, replace the packings.

Replace both o-rings on the seat.

Replace the cable.

Replace the power valve.

Disengage the trigger lock.

Connect air to the MD2.

Turn on the air.

Clean or replace Tri-core or Flex mixer.

Clean or replace.

Connect air to the MD2.

Turn on the air.

Repair the MD2. Refer to the MD2 for more details

Replace the seal.

56 3A2894U

Troubleshooting

PROBLEM

No material flow.

CAUSE

Material supply is off.

Clogged mixer.

V/P won't turn on.

NOTE: The V/P turns off after 30 seconds of no activity. It will turn on during dispense or when entering Purge/Prime mode.

V/P reads “0”.

V/P does not match information on the information screen.

Clogged restrictor

Fluid Plate

Bad cable.

Disconnected cable.

Air supply to V/P shut off.

Air supply is restricted.

Faulty V/P.

V/P obtains 85 psi (586 kPa,

5.86 bar) and then alarms.

Flow rate is too high.

Too much restriction in the catalyst (B) hose.

Flowmeter clogged.

Bad flowmeter.

Catalyst (B) air motor pressure is too low.

Clogged restrictor housing.

Abnormal pressures during operation or after dispense

Pressures not balanced.

Ball/seat not seating properly in fluid regulator(s).

Restrictor pin not seating in housing.

SOLUTION

Ensure the base (A) solenoid valve is on and has pressure.

Ensure the catalyst (B) V/P is on and has pressure.

Ensure the motor(s) have air pressure.

Ensure there is sufficient down pres sure and the control lever is in the down position.

Replace the static mixer.

Clean or replace the Tri-core or hose mixer.

Clean or replace the restrictor.

Replace the cable.

Connect the cable.

Turn on the air supply to the V/P.

Replace with a minimum 3/4 in. ID hose.

Replace V/P

Reduce the flow rate.

Resize the hoses to reduce restriction.

Clean or replace the flow meter.

Replace the flowmeter.

Catalyst (B) air motor pressure is too low.

Clean or replace restrictor housing and pin.

Change catalyst hose size.

Clean or replace ball/seat.

Use a fitting behind the restrictor housing with an inner diameter that will not allow the pin to back out.

Light does not blink green, red, and off in sequence when the machine is first turned on.

Light Tower

Bad connection or cable

Bad light stack.

Ensure cable is connected or replace the cable.

Replace light stack.

3A2894U 57

Troubleshooting

PROBLEM

Abnormal pump pressures during operation.

Pump moves during stall.

Pump does not run.

CAUSE

Pump

Worn or damaged packings.

Bad check valves.

Malfunctioning check valves.

No air supply to the pump.

Catalyst (B) ball valve is closed.

Clogged mixer.

Ultra-lite has cured material in it.

Clogged restrictor

SOLUTION

Replace the packings.

Clean or replace the check valves.

Clean or replace the check valves.

Turn on the air or increase the air pres sure.

Open the ball valve.

Replace or clean the mixer.

Clean or replace.

Clean or replace the restrictor.

58 3A2894U

Troubleshooting

Display Module

CODE

F6B3-A

F6A3-A

F5D0-A

F9D4-A

F9D5-A

R4D0-A

R1D0-A

R9CX-A

L1C1-D

N/A

PROBLEM

Base Flow Meter Error

Catalyst Flow Meter Error

Machine not calibrated

CAUSE

Flow meter signal is not detected.

Flow meter is clogged.

Flow rate is too low.

Flow meter signal is not detected.

Flow meter is clogged.

Flow rate is too low.

Calibration sequence has not been performed.

SOLUTION

Check the base flow meter cable.

Replace the sensor.*

Clean the flow meter.

Increase the system flow rate.

Check the catalyst flow meter cable.

Replace the sensor.*

Clean the flow meter.

Increase the system flow rate.

Perform the Calibration procedure or enter the known calibration val ues.

Increase the system flow rate.

Increase the restriction in the cata lyst flow path.

Decrease the system flow rate.

High Ratio Alarm

Low Ratio Alarm

Insufficient Restrictions /

Unbalanced Pressure

Check Pump Base/Catalyst

Drum

Purge Timer Expired

Reduce the restriction in the catalyst flow path.

Ratio is too high.

Re-calibrate the machine.

Catalyst material line is plugged.

Check the material supply.

The flow for the base is too high and the flow for the catalyst is too low.

Adjusted flowrate between dis penses.

Ratio is too low.

Base flow rate is too low.

Adjusted flowrate between dis penses.

The flow could be turned down or a larger size hose could be used for the catalyst.

Run until the machine status states

“OK.”

Re-calibrate the machine.

Check the material supply.

Increase the base flow rate.

The restrictor pin is missing or under sized.

Hoses are not sized to properly balance the pressures.

Low level drum.

Gel timer has expired.

Run until the machine status states

“OK.”

Install a restrictor pin of the correct size.

Size the hoses so that the pressures are balanced.

Check the drum base or catalyst material level and replace it if neces sary.

Check the drum level sensor cable.

Use the machine. (Normal opera tion).

Dispense material into a waste con tainer.

Base purge the machine.

3A2894U 59

Troubleshooting

CODE PROBLEM

CUCX-V Duplicate Node Found

CACX-A

CAUX-A

FCM Missing

USB Disconnected

CAUSE

Unknown Software Error.

Unintended module plugged into the system.

FCM unplugged from CAN bus.

Damaged FCM.

Damaged FCM Base.

USB unplugged from CAN bus.

Damaged USB.

Damaged USB Base.

SOLUTION

Cycle the system power.

Verify that only necessary GCA modules are plugged into the sys tem.

Verify the FCM CAN cable is plugged in.

Replace the FCM.

Replace the FCM base.

Verify the USB CAN cable is plugged in.

Replace the USB.

Replace the USB base.

* Verify the sensor is working by going to the information screen and removing the flow meter sensor from the flow meter body. Wave a small metallic object back and forth over the sensor. A flow rate should be displayed on the screen for the sensor being tested.

60 3A2894U

Accessories and Kits

Accessories and Kits

Low Level Sensors, 24R935

(S100 and P100 only)

Alerts the user when material drums are empty.

USB Kit, 24R936

Allows the user to monitor and download information of the machine status.

Calibration Check Assembly,

24R777

Allows the user to watch the DM while performing the

Calibration Check

procedure. Kit is required for all

Ultra-lite dispense valve applications.

MD2 Nose Pieces

204

202

201

203

Ref Part Description

201 15V628 10:1 Nightcap

202 15K688 Retaining Nut

203 24P850 10:1 Ratio Check

204 256793 Assembly Tool

3A2894U 61

Accessories and Kits

Catalyst (B) Hoses

Allows the user to balance material pressure in the cat alyst (B) line by changing the hose diameter.

Part

16W047

16V531

16V219

16V220

16V221

Description

HOSE, assy, 3/32”x60”, 6k, nylon

HOSE, assy, 1/8”x60”, 6k, nylon

HOSE, assy, 1/4”x60”, 5k, ss, braid

HOSE, assy, 3/8”x60”, 5k, ss, braid

HOSE, assy, 1/2”x60”, 5k, ss, braid

Restrictor Kit, 24R804

Allows the user to balance material pressure in the cat alyst (B) line by changing the pin size.

106

106

105

102,

103,

104

101

Ref Part Description

101 16V360 HOUSING, restrictor, 1/4npt

102 16V356 PIN, restrictor, #1, 0.094 in.

103 16V359 PIN, restrictor, #2, 0.098 in.

104 16V357 PIN, restrictor, #3, 0.102 in.

105 124961 FITTING, 04jic x 1/4npt

106 124846 FITTING, 03jic x 1/4npt

107 119400 SEALANT, pipe, sst, pack

105

Restrictor Kit 24W146

Allows the user to balance material pressure in the cat alyst (B) line by changing the pin size without removal of the catalyst line.

307

310

301

305,

309

306

308

Ref Part Description

301 17B762 HOUSING, Restrictor, 3 Port

302 16V356 PIN, Restrictor, 0.094”

303 16V359 PIN, Restrictor, 0.98”

304 16V357 PIN, Restrictor, 0.102”

305 124961 FITTING, 04jic x 1/4 npt

306 17B763 PLUG, Restrictor, Pin

307 17B765 FITTING, Elbow, 0451C

308 111516 PACKING, O-Ring

309 124846 FITTING, 03jic x 1/4npt

310 061701 FITTING, 03jic x 04jic

311 119400 SEALANT, pipe, sst, pack

Caster Kit, 24T091

Includes four casters.

62 3A2894U

Mixer Elements for MD2

002

001

003

10 mm Mixer Elements

Ref Part Description

001 24T250

24T251

MIXER, assy, 10mm x 12 element -

25 count

MIXER, assy, 10mm x 12 element -

50 count

002 16V841 SLEEVE, mixer, no front thread

003 24T035

SLEEVE, mixer, thread x 1/4 NPT outlet

1/2 in. Mixer Elements

Ref Part Description

001 512288 MIXER, assy, 1/2 x 24 element

512289 MIXER, assy, 1/2 x 30 element

512286 MIXER, assy, 1/2 x 36 element

002 16T001 SLEEVE, mixer, 24 element

16T002 SLEEVE, mixer, 30 element

16T003 SLEEVE, mixer, 36 element

3A2894U

Accessories and Kits

63

Appendix A - DM Icons Overview

Appendix A - DM Icons Overview

Setup Screen Icons

Icon Description

Return to Home Screen

Left Navigation

Navigates to the previous screen.

Right Navigation

Navigates to the next screen.

Set Purge Timer

Allow the machine to remind the operator to take a shot before the chemical hardens in the gun. Timer starts once a dispense is complete.

Lock Ratio Setpoint

Lock the current ratio set point. Ratio setpoint will not be able to be adjusted when activated. Icon shown represents that it is not locked.

Low Level Sensor Option

Toggle if a low level sensor is installed or not installed on the machine. Icon shown represents not installed.

Base (A) Pump

Icon

Catalyst (B) Pump

Weight

System units are in grams

Flow Meter

Shows the calibration fac tor (K) after calibration has been performed.

Start Calibration

64

Description

Confirmation

Calendar / Date

Set the date format and current date.

Time

Set the current time in 24 hour format.

Password

Set a password to lock sys tem settings. Password

“0000” disables the lock.

Backlight Time

Set how long the screen will illuminate when idle before darkening. Entering

“0” disables the timer.

Audible Alarm

Allow the machine to sound an alarm when an error occurs.

Download Depth

Set how many hours of data the system will down load.

Log Intervals

Set the time interval that the system will record the machine status.

Display Module

3A2894U

3A2894U

Icon Description

Advanced Fluid Control

Module

Ultra-Lite Tri-core Mixer

(P100 Model Only)

Toggle if an ultra-lite tri-core mixer is installed on a P100 machine.

Ratio Alarm

I- Standard tolerance

Ratio Alarm

II - Wider tolerance

Ratio Alarm

III - Widest tolerance

Appendix A - DM Icons Overview

65

Appendix A - DM Icons Overview

Run Screen Icons

Icon Description

Return to Home Screen

Navigate to Purge/Prime Screen

Navigate to Alarm Log Screen

Navigate to Information Screen

Calibration Check

Changes the machine status to not okay in order to perform the calibra tion check procedure.

Calibration Reset

Clears all data and resets all sam ples to “0”.

Purge Timer Counter

Visual indicator to show the user the remaining idle time before another shot needs to be taken. The timer will begin to flash when expired.

Base (A) Pump Select

Icon will appear white when not activated, black when activated.

Catalyst (B) Pump Select

Icon will appear white when not activated, black when activated.

Error Number / Event Number

Date

Time

Error / Event Code

Navigate to Totalizer Screen

66 3A2894U

Appendix B - DM Setup Screens Overview

Appendix B - DM Setup Screens Overview

If the DM is showing a Run screen, press to access the Setup screens, which have a black header.

See the

DM Screen Navigation Diagram on page 18.

P100 Models

Screen 1

This screen allows you to set the purge timer, lock the ratio setpoint, toggle if low level sensors are installed, and toggle if an Ultra-lite with Tri-core mixer is installed on a P100 machine.

In addition, system token version 1.12.001 and above includes an alarm ratio sensitivity tolerance option. By default, the setting is “I” (standard for AGP since its release). From the drop down menu you can select “II”

( ) to set the tolerance for a wider sensitivity level or

“III” ( ) for the widest sensitivity level. If adjustment from the original software is not needed, leave the set ting on .

S100 and U100 Models

Screen 2

This screen allows you to calibrate the machine. See

Calibrate the machine.

page 40, for more details.

Screen 3

This screen allows you to format and set the current date and time, reset the password, adjust the backlight timer, and toggle sound/silent operation.

3A2894U 67

Appendix B - DM Setup Screens Overview

Screen 4

This screen is only displayed when the USB option is installed. The screen allows the user to enable down loading of USB logs, set log intervals, and set how many hours of data to download.

Screen 5

This screen is displayed as Screen 4 when the USB option is not installed. The screen displays information of part numbers and software versions that are cur rently found within the system. The USB information is only displayed when the USB option is installed.

68 3A2894U

Appendix C - DM Run Screens Overview

Appendix C - DM Run Screens Overview

If the DM is showing a Setup screen, press to

access the Run screens. See the DM Screen Naviga tion Diagram on page 18.

Purge/Prime

This screen allows the pumps to be run independently.

NOTE: All machine alarms are disabled when this screen is displayed on the DM.

NOTE: You can also press

Run screens.

or to access the

Home

This screen shows the current ratio and allows the user to access other screens.

• Press the corresponding to deactivate or acti vate the desired pump for operation.

NOTE: The screen below shows only the catalyst (B) pump selected.

• Press ratio.

or to increase or decrease the

• Press the corresponding screen or to toggle an option.

to access another

• Shows the current state of the machine (okay/not okay).

3A2894U 69

Appendix C - DM Run Screens Overview

Alarm Log

This screen displays the last 70 errors that have occurred.

Calibration Check

This screen displays the ratio after a calibration check dispense.

NOTE: Production material cannot be dispensed from this screen.

• Press or to show other errors.

Totalizer

This screen displays the total amount of material (in kilograms) dispensed for each pump.

Information

This screen displays diagnostic information useful in troubleshooting.

70 3A2894U

Appendix D - DM Error Codes

EGB9-R

EGBA-R

EGA9-R

EGAA-R

EGC7-R

ECCX-R

EADX-R

EBDX-R

CUCX-V

CACX-A

CAUX-A

ECB3-R

ECA3-R

ECDC-R

ECFB-R

EQU0-R

EQU0-D

EQU8-D

R9CX-A

F9D4-A

F9D5-A

R4D0-A

R1D0-A

L1C1-D

EHD0-R

E9D0-R

ELM0-R

EMM0-R

ENB6-R

ENA6-R

ENB7-R

ENA7-R

ENB8-R

ENA8-R

EGC6-R

Error Code Error Name

0000-0

CA00-A

F6B3-A

F6A3-A

F5D0-A

No Active Errors

Unrecognized Error

Pump A Check Flow Meter

Pump B Check Flow Meter

Machine has not been calibrated

System Flow Rate is too Low

System Flow Rate is too High

High Ratio Alarm

Low Ratio Alarm

Check Pump A Drum

Purge Timer Expired

System not ok for dispense

System Power On

System Power Off

Begin Flowmeter Calibration, Pump A

Begin Flowmeter Calibration, Pump B

End Flowmeter Calibration, Pump A

End Flowmeter Calibration, Pump B

Abort Flowmeter Calibration, Pump A

Abort Flowmeter Calibration, Pump B

Enter Purge/Prime Screen

Purge On, Pump A

Purge Off, Pump A

Purge On, Pump B

Purge Off, Pump B

Exit Purge/Prime Screen

Ratio Changed

Start Dispense

End Dispense

Duplicate Node Found

FCM Missing

USB Disconnected

Pump A K-factor Changed

Pump B k-factor Changed

Gel Timer Changed

Pressure Transducer Installed

USB Logs Downloaded

No Configuration

Disk Removed Too Early

Insufficient Restriction / Unbalanced Pressures Alarm

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Record Only

Advisory

Alarm

Error Type

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Deviation

Record Only

Record Only

Record Only

Record Only

Record Only

Alarm

Record Only

Record Only

Record Only

Record Only

Record Only

Deviation

Deviation

3A2894U

Appendix D - DM Error Codes

71

Schematics

Schematics

72

L

N

GND

L

N

GND

GND

N

L

3A2894U

Schematics

3A2894U 73

Schematics

74 3A2894U

Schematics

3A2894U 75

Dimensions

Dimensions

S100 55/5 Gal. (200/20 L) Shown

C

76

Dimension

A (Length)

B (Width)

C (Height)

US

(ft)

3.3

3.5

9.0

(with boom)

5.3

(without boom)

Metric

(m)

1.0

1.1

2.7

1.6

A

B

3A2894U

Dimensions

S100 5/5 Gal. (20/20 L)

C

A

Dimension

A (Length)

B (Width)

C (Height)

US

(ft)

3.3

2.3

4.6

Metric

(m)

1.0

0.7

1.4

3A2894U

B

77

Technical Data

Technical Data

ExactaBlend AGP Advanced Glazing Proportioner

Maximum fluid working pressure :

MD2 or

Ultra-lite with flexible hose mixer Installed

Maximum fluid working pressure :

Ultra-lite with Tri-core mixer Installed

Minimum flow rate 6:1 to 14:1 ratio (by weight)

Minimum flow rate 1:1 ratio (by weight)

Maximum flow rate 1:1 to 14:1 ratio (by weight)

Incoming air pressure required*

Maximum operating temperature

Voltage range

Maximum amperage

Sound pressure**

Wetted parts

US

3000 psi

4000 psi

Metric

21 MPa, 207 bar

28 MPa, 276 bar

1.10 lb/min

2.21 lb/min

8.82 lb/min

80-100 psi

500 g/min

1000 g/min

4000 g/min

0.6-0.7 MPa, 6.0-7.0 bar

120° F 50° C

90-264 VAC 50/60 Hz 1 phase

4

82 dB(A)

Zinc-plated carbon steel, aluminum ram plate, nitrile rubber wipers, chrome, stainless steel, UHMW polyethylene, PTFE, nylon, Buna-N

Inlet/Outlet Sizes

Fluid outlet base

1/2 npt (f)

Fluid outlet catalyst

1/4 npt (f)

Air inlet size

Weight

S100 5 Gal./5 Gal. (20 L/20 L) Model

All other models

Notes

512 lb.

865 lb.

3/4 npt (f)

232 kg

392 kg

* Startup pressures and displacement per cycle may vary based on suction condition, discharge head, air pres sure, and fluid type.

** Sound pressure measured 3.3 feet (1 meter) from equipment.

Refer to specific component manual for more details.

Flow Rate is dependent on the applicator, material viscosity, and material temperature.

California Proposition 65

CALIFORNIA RESIDENTS

WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.

78 3A2894U

NOTES:

Technical Data

3A2894U 79

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

Sealant and Adhesive Dispensing Equipment

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor, go to www.graco.com, or call to identify the nearest distributor.

If calling from the USA: 1-800-746-1334

If calling from outside the USA: 0-1-330-966-3000

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 3A2894

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision U, November 2021

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