Custom PR. Operation - Maintenance 3A0241A. This machine is intended to dispense two-component, silicone-based materials only.

Transcription

1 Operation - Maintenance Custom PR 3A0241A This machine is intended to dispense two-component, silicone-based materials only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

2 Contents Safety Precautions...3 Machine Features...4 Status Screen...6 LEVEL 1 CONTROL Screen...7 LEVEL 2 CONTROL Screen...10 Periodic Maintenance...11 Vacuum Ready Lid...12 Gravity Feed Tank...15 Vacuum Pumps...16 Electric Agitator...18 Pneumatic Drive Agitator...19 Graco Ohio Standard Warranty...20 Graco Ohio Information

3 Safety Precautions This manual provides installation, operation, and maintenance instructions for Graco Ohio Inc. meter, mix, and dispense machines. Read this manual before you install and operate your machine. Use your machine only as directed. Safety Terms within our manuals Cautions are given where failure to observe the instruction could result in damage to the equipment, associated equipment, and/or process. Warnings are given where failure to observe the instruction could result in injury or death to people. Some examples follow. Caution Snuff-back can be monitored with DV MODE in AUTO, but must be adjusted with DV MODE in OPEN WARNING Make sure EMERGENCY STOP is locked in before manually aligning the ratio block to the ratio beam. Safety Labeling on our machinery All our machines carry the following safety labels wherever necessary: Danger Labels indicate an imminently hazardous situation, which, if not avoided, could result in death or serious injury. Warning Labels indicate potentially hazardous situations which, if not avoided, could result in death or serious injury. Caution Labels indicate an unsafe practice that may result in moderate or minor injury. Notice Labels state a company policy. Some examples are: DANGER DO NOT OPERATE THIS MACHINE WITH GUARD(S) DETACHED WARNING UNPLUG MACHINE BEFORE OPENING ENCLOSURE NOTICE OVERCURRENT PROTECTION PROVIDED AT MACHINE SUPPLY TERMINALS CAUTION WEAR EAR PROTECTION CAUTION WEAR EYE PROTECTION 3

4 Machine Features Control Power and Emergency Stop Buttons Touch Screen Advanced Display Module Air Pressure Control Knob and Gage PR70 (See PR70 manuals) 4

5 Machine Features CONTROL POWER Switch The 1 indicates the ON button. The 0 indicates the OFF button. Provides power for the electrical circuitry in the console. ON button OFF: ON: The red 0 button is pressed, electrical power is not applied to the machine circuitry and the internal white lamp is dimmed. NOTE: The PLC will still have power applied. The green 1 button is pressed, electrical power is applied to the machine circuitry and the internal white lamp is illuminated. OFF button EMERGENCY STOP Button When the EMERGENCY STOP button is pressed, all power is removed from the machine. To recover from an EMERGENCY STOP condition, twist the EMERGENCY STOP button clockwise and release the EMERGENCY STOP button PUMP AIR PRESSURE Gauge and Regulator The PUMP AIR PRESSURE regulator controls how much air pressure is fed to the air cylinder driving the pumps. The pump air pressure can be monitored on the PUMP AIR PRESSURE gauge. Touch Panel The Touch Panel is used to control all function on the machine. See the following sections for operation of the different screens. NOTE: The Level 1 screen will appear with any change of state of any tank material level sensor (If equipped). NOTE: On all touch Screen buttons: The 1 indicates that the button is active or currently selected. The 0 indicates that the button is inactive or not selected. Power is applied to the PR70 machine through the Control Power switch. Control Power must be on to activate the PR70. All PR70 functions are described in the PR70 manuals. The Touch Panel does not affect PR70 operation. 5

6 Status Screen NOTE: The 1 indicates that the button is in the ON position the 0 indicates that the button is in the OFF position. Dispense Ready indicator Indicates the PR70 is not active and will accept a start signal via the PR4 I/O cable. See the PR70 manuals for more information. Dispense Complete indicator Indicates that the PR70 dispense ready signal has transitioned from high to low idivating that the machine has cycled. This signal will be held for 1 second after the dispense ready signal is ativated. CONTRAST + button This button increases the contrast of the touch screen. CONTRAST - button This button decreases the contrast of the touch screen. PLC Program indicator This indicator gives the currently installed PLC program version and revision level. HMI Program indicator This indicator gives the currently installed HMI program (touch screen) version and revision level. PR70 Fault Message This is an informational message only which will only be viewable when the PR70 has an active fault. All PR70 functions are handled through the PR70 Advanced Display Module. 6

7 LEVEL 1 CONTROL Screen NOTE: If the A TANK STATUS and the B TANK STATUS indicator both displays 'LEVELS NOT ACTIVE' then the level control feature is not installed on this machine. Press the Main button to exit from this screen. NOTE: The Level 1 screen will appear with any change of state of any tank material level sensor (If equipped). The Level 1 screen will also appear during any Auto-Fill fault condition. For example: If the Pump mode screen is displayed on the touch screen and a level sensor changes state (e.g. Material low or material high) the Level 1 screen will be displayed and the Pump mode screen will disappear. A TANK STATUS indicator This indicator gives information on the A component tank filling process, the messages possible that this indicator can display are: MATERIAL HIGH MATERIAL LOW MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE B TANK STATUS indicator This indicator gives information on the B component tank filling process, the possible messages that this indicator can display are: MATERIAL HIGH MATERIAL LOW MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE For more information on the Tank Status Indicator Messages, see the Tank Fill Message table in this manual. NOTE: Level sensors are not connected to the PR70 and cannot be controlled via the Advanced Display Module. 7

8 LEVEL 1 CONTROL Screen con t Silence Alarm button This button will silence the audio alarm when pressed. NOTE: There are customer connections detailed on the controls drawings. These can be used for remotemonitoring of the low level sensors. 8

9 LEVEL 1 CONTROL Screen con t Tank Status Indicator Messages Indication MATERIAL HIGH Cause This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the 'A' or B component tank material level reaches the high level proximity switch (If equipped with high level proximity switch). MATERIAL LOW FILLING MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE FILL FAULT This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the 'A' or B component tank material level reaches the low level proximity switch (If equipped with low level proximity switch). This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the 'A' or B component tank material is currently refilling in the tank refilling process. (If equipped with tank refilling.) This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the 'A' or B component tank material level is between the high and the low level proximity switch (If equipped with low level and high level proximity switch). This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the machine senses a high material level and a low material of the 'A' or B component tank simultaneously. (If equipped with low level and high level proximity switch). This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the high or low level proximity switches are not installed for the tank that the TANK STATUS indicator that is being displayed. This will be displayed in the A TANK STATUS or the B TANK STATUS indicator when the tank material is currently refilling and the tank material level does not reach the high level proximity switch within the time previously entered into the FILL TIMER button seen in the LEVEL2 CONTROL screen. 9

10 LEVEL 2 CONTROL Screen NOTE: In the LEVEL 1 CONTROL Screen if the A TANK STATUS and the B TANK STATUS indicators both displays 'LEVELS NOT ACTIVE' then the level control feature is not installed on this machine. Press the Main button to exit from this screen. Silence Alarm button: This button will silence the low level audio alarm when pressed. The audio alarm will also be silenced when the material can be filled above the high level proximity switch on both tanks. 10

11 Periodic Maintenance Daily (once a shift or as required) Water Trap Bowl Material Reservoirs Check air circuit water trap valve and release any water, as necessary, through the base outlet. Check material levels and refill as necessary. Ensure that the material reservoirs are vented properly. (Dry Air, Nitrogen, etc.) Air Dryer Pump Shafts Dispense Head Check the condition of the desiccant air dryer (if equipped). See PR70 manual. See PR70 manual. *Refer to Daily Operation and Shutdown Sections of the manual, if material is leaking refer to the Troubleshooting Section of this manual. Maintenance Parts The following items may be required for routine maintenance. Part Description 82/0703-G/11 GUN, grease, 3 oz, with cartridge of grease 82/0703-GH/11 HOSE EXTENSION, gun, grease, 18 in. 84/0123-2/50 LUBRICANT, oil, silicone, 8 oz bottle 84/0058-2/50 LUBRICANT, mesamoll, 8 oz bottle 84/0277/11 BALLDRIVER, L hex wrench, 13 piece set 81/1097-CV6/11 COVER, PET, 6 in., operator interface 11

12 Vacuum Ready Lid Vacuum Transfer draws material into the tank through a hose connecting the tank fill port and the material source. Test all machine features and controls before loading material for the first time. 1. Secure the tank lid. Pump Feed Ball Valve Closed Illustration 2. Close the pump feed ball valves on the bottom of the tank. 3. Connect a supply line from the material source to the fill port ball valve. 4. Turn on the air agitator to the desired speed. Provide a slow steady agitation (if equipped). Atmospheric Ball Valve Closed Material Tank Fill Port Ball Valve Open Vacuum Pump Ball Valve Open Material Fill Position 5. Close the atmospheric ball valve, turn the material tank vacuum pump on and open the vacuum pump ball valve. Note: If equipped will nitrogen, a nitrogen gas supply line may connected to the atmospheric ball valve. 12

13 6. Open the material tank fill port ball valve seen in the Material fill position illustration. Material will vacuum load into the tank. 7. From the CONTROL panel, watch for the HIGH indicator for the corresponding material tank. If your machine is equipped with no high level sensor then do not fill the tank passed ½ to 2/3 of the tank capacity. Material Tank Fill Port Ball Valve Open 8. Close the material tank fill port ball valve when the tank is full. This is seen when the HIGH indicator are illuminated. 9. Allow material to vacuum and agitate until it is fully degassed. Then, close the vacuum pump ball valve. Turn off the vacuum pump. Atmospheric Bleed Ball Valve Open Vacuum Ball Valve Closed Atmospheric Position Illustration 10. Open the atmosphere bleed ball valve. NOTE: Some machine may have nitrogen gas or pneumatic pressure supply lines connected to the atmosphere bleed ball valve; in this is the case, then, open the atmosphere bleed ball valve and apply 2 to 3 psi, do not exceed the maximum psi rating labeled on the tank. 13

14 11. Open the material feed ball valve. NOTE: Skip the next step if the pump and hose are already primed with material. 12. At initial material loading, or after pump maintenance, do the following: a. Open the material feed ball valve. Allow all air to vent from the pump. b. Close the material feed ball valve. c. Repeat degassing steps to rid the material of the air that vented from the pump. 13. Open all material feed ball valve. NOTE: Repeat the degassing procedure any time you add additional material to the tank or vent air into the tank. 14

15 Gravity Feed Tank A Gravity Feed Tank uses the force of gravity to draw material into the pump. Test all machine features and controls before loading material for the first time. Do not operate machine with material under vacuum. 1. Remove the lid from the material reservoir. 2. Slowly pour or ladle the material into the tank (down the side of the tank wall preferably) to entrap as little air as possible. 3. Allow sufficient time for any air to vent from the pump. 4. Replace and secure the material tank lid, making sure that the vent valves are in the opened position. 15

16 Vacuum Pumps Details: 6.9 CFM Vacuum Pump package with pump mounted on/off switch, inlet chemical trap, outlet oil mist filter, and 1 in. x 120 in. vacuum rated hose and fittings for one tank. The package is designed for vacuum degassing of material in a vacuum rated feed tank. The degassing process helps to assure that dispensed material meets the target properties required for the application. Component List: Oil sealed rotary vane single stage 6.9 CFM vacuum pump with 0.75 HP, VAC or VAC, depending on selection, single phase, 50/60 Hz drive motor, cordset, and pump mounted switch. Pump is rated to obtain a maximum vacuum level of 0.1. Inlet chemical trap with activated carbon filter, sight glass and 1.8 liter capacity prevents froth or spray generated by the degassing process from carrying over to the pump. Trapped liquid level is visible in the sight glass and the hand-tightened drain plug allows easy draining. Outlet mist filter captures oil mist to assure a clean operating environment and meet regulatory requirements. An odor element neutralizes the smell of oil mist and the translucent lower filter allows visual oil level monitoring. Vacuum rated 1 in. x 120 in. hose and fittings are for connection to a vacuum rated feed tank. Operation W hen the oil is degassed, the pump will based out at or near it's published ultimate vacuum. It is helpful to keep a simple log book as eventually the ultimate vacuum will begin to degrade. This is one indication that the oil should be changed. Also, visual inspection of the oil is necessary to ensure pump longevity. If the oil begins to go dark it must be changed. Our application group recommends an isolation valve at the pump inlet with an appropriate vacuum gauge. A summary of operation and technique to base-line the pump include the following. NOTE: See the following image. 1. Change pump oil (necessary to adequately baseline the vacuum pump). 2. Install inlet isolation valve and appropriate vacuum gauge. 3. Close pump inlet isolation valve. 4. Turn on vacuum pump with gas ballast valve full open. 5. Run pump for 1/2 hour to allow pump to warm up (having the gas ballast open allows the pump to heat up faster). 6. Record base vacuum with gas ballast on (baseline with gas ballast open). 7. Close gas ballast valve and record base vacuum (baseline with gas ballast closed). 8. Open gas ballast valve to full on position. 9. Open inlet isolation valve at pump. 10. Execute process. 11. Once process is complete close inlet isolation valve at pump. 12. Run pump for at least 1/2 hour with gas ballast valve open to full. 13. Check and record pressure after 1/2 hour. Pump should baseline to pressure recorded with gas ballast open. Run longer if needed. 14. Close gas ballast valve. 15. Check and record pressure which should baseline to pressure recorded. 16. Turn off vacuum pump. Inspect oil and record color. Use the attached color chart and guidelines in attached document. 16

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18 Electric Agitator Specifications The electric agitator assembly has a 0.5 HP AC electric motor, 30:1 gear reducer, and a shaft/blade assembly. A three position selector switch allows low speed (29 rpm), high speed (58 rpm) or OFF. For materials with a maximum viscosity of 100,000 centipoise and maximum material temperature of 275 F. General Info The Agitator Speed Controller enables/disables the electric agitator and also increases/decreases the tank agitator speed. OFF: The tank agitator is disabled and the material in the tank is not agitated. LOW: The tank agitator is enabled and the material in the tank is agitated at the minimum speed. HIGH: The tank agitator is enabled and the material in the tank is agitated at the maximum speed. 18

19 Pneumatic Drive Agitator The pneumatic drive agitator assembly has a 0.5 HP pneumatic motor, a 15:1 gear reducer, and a shaft/blade assembly. The pneumatic agitator includes a needle valve to adjust rotational speed. From 20 to 120 rpm. For materials with a maximum viscosity of 100,000 centipoise and maximum material temperature of 275F. 19

20 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 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 Ohio Information TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Toll Free: or Fax: 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. This manual contains English. MM 3A0241 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO OHIO INC PORT JACKSON AVE NW, NORTH CANTON, OH Copyright 2009, Graco Ohio Inc. is registered to ISO