Compact Twin Flow. Operation - Maintenance B

Transcription

1 Operation - Maintenance Compact Twin Flow B Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. Machine shown may be different from your machine

2 Contents Safety Precautions... 3 Machine Features... 4 Main Touch Screen... 5 Main Touch Screen continued... 6 CALIBRATE Screen... 7 CALIBRATE Screen continued... 8 SHOT FLOW screen... 9 SHOT FLOW screen continued PUMP PRESSURE screen PUMP PRESSURE screen continued SERVO CONTROL screen TEMPERATURE screen MONITOR screen Diagnostics screen Recipe Preview Screen LOAD RECIPE screen EDIT RECIPE screen SAVE RECIPE screen DELETE RECIPE screen Initial Startup Material Pump Servo Start Up Sequence Adjusting the Limit Switches Dry Run Priming the Hoses Ratio Check Daily Operations Phasing the Pumps Phasing the Pumps Shut Down Material Ratio Adjustment Piston Replacement Piston Replacement Continued Periodic Maintenance Troubleshooting Graco Ohio Standard Warranty Graco Ohio Information

3 Safety Precautions This manual provides installation, operation, and maintenance instructions. 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 CAUTION WEAR EAR PROTECTION WEAR EYE PROTECTION 3

4 Machine Features Posiload Machine: CONTROL POWER Switch Provides power for the electrical circuitry in the console. OFF: ON: Electrical power is not applied to the electrical circuitry and the internal white lamp is dimmed. Electrical power is applied to the electrical circuitry and the internal white lamp is illuminated. EMERGENCY STOP Button When the EMERGENCY STOP button is pressed and released, all power is removed from the machine. The pumps will immediately stop in place. The dispense valve will close. Touch Panel The Touch Panel is used to control all function on the machine. See the following sections for operation of the different screens. Foot Switch The foot switch is used to initiate a pump cycle when operating in the SHOT or CONT pump mode. Throughout this manual the foot switch will be referred to as the START device. From the SHOT FLOW screen when the SHOT is pressed, and the START device is pressed and released, the machine will cycle then stop and wait for the next start signal. If the START device is pressed and held, the machine will run continuously. Valves: Check Valves Check valves allow material to flow from the pumps to the material hoses but prevents material from flowing back. 4

5 Main Touch Screen Your SN number is displayed here TEMP PANEL button The TEMP PANEL button is selected to make the TEMPERATURE screen to appear. (See the TEMPERATURE screen section in this manual for more information.) PRESSURE PANEL button The PRESSURE PANEL button is selected to make the PRESSURE PANEL screen to appear. (See the PRESSURE PANEL screen section in this manual for more information.) SHOT FLOW button The SHOT FLOW button is selected to make the SHOT FLOW screen to appear. (See the SHOT FLOW screen section in this manual for more information.) MONITOR PANEL button The MONITOR PANEL button is selected to make the MONITOR screen to appear. (See the MONITOR screen section in this manual for more information.) CALIBRATE PANEL button The CALIBRATE PANEL button is selected to make the CALIBRATE screen to appear. (See the CALIBRATE screen section in this manual for more information.) SERVO CONTROL PANEL button The SERVO CONTROL PANEL button is selected to make the SERVO CONTROL screen to appear. (See the SERVO CONTROL screen section in this manual for more information.) 5

6 Main Touch Screen continued SET UP RECIPES button The SET UP RECIPES button is selected to make the Recipe Preview screen to appear. (See the RECIPES screen section in this manual for more information.) The recipe screen is used for the following purposes: 1. To manually edit the configuration of this machine (which is also done in the buttons previously shown). 2. To install previously recorded machine configurations known as recipes. (Upload to controller) DIAGNOSTICS button The DIAGNOSTICS button is selected to make the DIAGNOSTICS screen to appear. (See the DIAGNOSTICS screen section in this manual for more information.) 6

7 CALIBRATE Screen NOTE: The WATLOW Temperature Controllers located on the front panel of the machine are as indicators only, no adjustment of these controllers are required. T/C WIND SET PT N7:60 button/indicator (Temperature Control Window Set Point) This button/indicator shows the range of the material temperature (this range is shown in ± C ). For example: If the material temperature was set to 90C and the T/C WIND SET PT indicator was set to 10 the temperature of the material would be between 80C and 100C. To change the T/C WIND SET PT N7:60 indicator (Temperature Window Control Set Point) do the following: 1. Select T/C WIND SET PT N7:60 button, a numeric keypad should appear. 2. Enter in the new material temperature range required. 3. Press the ENTER button. 4. The new material temperature range should appear in the T/C WIND SET PT N7:60 indicator. T/C SHUT PT N7:51 button/indicator (Temperature Control Shutdown Set Point) This button/indicator shows the absolute maximum material temperature in C. For example: If this indicator was set to 110C and the material exceeded this temperature (such as a catastrophic heater failure), the power to all the heater ovens will be disabled. To change the T/C SHUT PT N7:51 indicator (Temperature Control Shutdown Set Point) do the following: 1. Select T/C SHUT PT N7:51 button, a numeric keypad should appear. 2. Enter in the new maximum material temperature required. 3. Press the ENTER button. 4. The new material maximum temperature should appear in the T/C SHUT PT N7:51 indicator. 7

8 CALIBRATE Screen continued NOTE: The WATLOW Temperature Controllers located on the front panel of the machine are as indicators only, no adjustment of these controllers are required. TEMP SET PT N7:54 button/indicator (Mixed Material Temperature Set Point Control) This button/indicator shows the range of the mixed material temperature (this range is shown in ± C ). For example: If the mixed material temperature was set to 90C and TEMP SET PT N7:54 indicator was set to 10 the temperature of the material would be between 80C and 100C. To change the TEMP SET PT N7:54 indicator (Mixed Material Temperature Set Point) do the following: 1. Select TEMP SET PT N7:54 button, a numeric keypad should appear. 2. Enter in the new material temperature range required. 3. Press the ENTER button. 4. The new material temperature range should appear in the TEMP SET PT N7:54 indicator. PSI HIGH SET PT N7:40 button/indicator (Pump Servo PSI High Set Point) This button/indicator shows the material pressure at which the machine pump servomotor will stop generating material pressure (shut off) in psi or MPa. To change the PSI HIGH SET PT N7:40 indicator (Pump Servo PSI High Set Point) do the following: 1. Select PSI HIGH SET PT N7:40 button, a numeric keypad should appear. 2. Enter in the new material high shut off pressure required. 3. Press the ENTER button. 4. The new material high shut off pressure should appear in the PSI HIGH SET PT N7:40 indicator. PSI LOW SET PT N7:42 button/indicator (Pump Servo PSI Low Set Point) This button/indicator shows the material pressure at which the machine pump servomotor will start generating material pressure (start up) in psi or MPa. To change the PSI LOW SET PT N7:42 indicator (Pump Servo PSI Low Set Point) do the following: 1. Select PSI LOW SET PT N7:42, a button at numeric keypad should appear. 2. Enter in the new material low start up pressure required. 3. Press the ENTER button. 4. The new material high shut off pressure should appear in the PSI LOW SET PT N7:42 indicator. RESET TO FACTORY button When this button is selected, it will return all factory values to the CALIBRATION screen indicators. 8

9 SHOT FLOW screen PUMP MODE SHOT Button When the SHOT Button is selected, the machine pump will run one cycle when the foot switch or START CYCLE button is pressed. Depending on shot size, the machine may take more than one shot. OFF Button When this button is selected the power to the material pump servomotor will be disabled. CONT Button The purpose of this button is to allow the machine continually cycle the pumps in order to empty material from the tanks when a start device is pressed. RECIRC button When this button is selected, the material pump servomotor will cycle at preset rate to make a flow rate needed for material recirculation. NOTE: Prior to using this button, you should turn the required ball valves to the recirculation position of the corresponding tank. See the tank recirculation section of this manual for more information. PUMP MODE HOME Button The pumps will immediately move to the home limit switch and remain in the home position. This position is used when the machine ready to dispense material. EXTEND Button The pumps will immediately move to the retract limit switch and remain in the retracted (parked) position. RETRACT Button The pumps will immediately move to the retract limit switch and remain in the retracted (parked) position. This is used for machine shutdown or when the machine remains inactive or idle for long periods of time. 9

10 SHOT FLOW screen continued For more information on the use of these buttons see the Daily Operation Section of this manual. START CYCLE button This button will activate the machine to run the pre-selected sequence defined in this screen. SHOT SIZE (cc s) button/indicator This button/indicator shows the volume setting of the material of the SHOT SIZE volume in cubic centimeters (cc s). To change the SHOT SIZE volume, do the following: 1. Select SHOT SIZE button, a numeric keypad should appear. 2. Enter in the material shot size volume as required. 3. Press the ENTER button. 4. The new shot size volume should appear in the SHOT SIZE indicator. FLOW RATE (cc s/sec) button/indicator This button/indicator shows the volume setting of the material FLOW RATE volume in cubic centimeters (cc/sec). To change the FLOW RATE volume, do the following: 1. Select FLOW RATE button, a numeric keypad should appear. 2. Enter in the material flow rate volume as required. 3. Press the ENTER button. 4. The new shot size volume should appear in the FLOW RATE indicator. RUN SETUP PROGRAM button When this button is selected a factory preinstalled setup program will upload into the CTC Parker Automation memory. Included in this setup program are various setup parameters that were previously installed by the factory or by the operator. RUN MAIN PROGRAM button When this button is selected a factory-preinstalled program will upload into the CTC Parker Automation memory. This program will give the machine the various instructions to perform the actual operations. For more information on the use of these buttons see the Daily Operation Section of this manual. SERVO POWER ON button This button connects electrical power to the machines servomotor material pump. SERVO POWER OFF button This button disconnects electrical power to the machines servomotor material pump. SERVO ENABLE ON button This button enables the machines servomotor to drive the material pump. DRIVE ENABLE button This button enables the machines drive run material pump. RESET SERVO button This button will reset the machines servomotor to drive the material pump. 10

11 PUMP PRESSURE screen Sections only shown if items are installed HIGH PRESSURE SET POINT indicator This indicator shows the current material pump high-pressure set point setting. This setting was previously preset in the PSI HIGH SET PT N7:40 in the CALIBRATION screen. For more information on the HIGH PRESSURE SETPOINT settings, see the CALIBRATION screen section of this manual. ACTUAL MOLD PRESSURE indicator This indicator shows the current material outlet hose and mold pressure. LOW PRESSURE SET POINT indicator This indicator show the current material pump low pressure set point setting. This setting was previously preset in the PSI HIGH SET PT N7:42 in the CALIBRATION screen. For more information on the HIGH PRESSURE SETPOINT settings, see the CALIBRATION screen section of this manual. HIGH MOLD PRESSURE PUMPING STOP message box This indicator is illuminated when the material outlet hose and /or material mold pressure reaches the HIGH PRESSURE SET POINT indicator setting. When indicator is activated, the material pump servomotor is stopped. For more information on the HIGH PRESSURE SHUTDOWN SETPOINT settings, see the CALIBRATION screen section of this manual. LOW MOLD PRESSURE PUMPING STOP message box This indicator is illuminated when the material outlet hose and /or material mold pressure reaches the LOW PRESSURE SET POINT indicator setting. When indicator is activated, the material pump servomotor is restarted. For more information on the LOW PRESSURE SETPOINT settings, see the CALIBRATION screen section of this manual. 11

12 PUMP PRESSURE screen continued SYSTEM HIGH PRESSURE ALARM indicator This indicator is illuminated when the material outlet hose and / or material mold pressure is at a high pressure shutdown condition, previously set with the PSI HIGH SET PT N7:40 button seen in the CALIBRATION screen section. This indicator usually becomes active when there is a catastrophic loss of pressure. When indicator is activated, the material pump servomotor is stopped. For more information on the LOW PRESSURE SHUTDOWN SETPOINT settings, see the CALIBRATION screen section of this manual. SYSTEM LOW PRESSURE ALARM indicator This indicator is illuminated when the material outlet hose and / or material mold pressure is at a low pressure shutdown condition, previously set with the PSI LOW SET PT N7:42 button seen in the CALIBRATION screen section. This indicator usually becomes active when there is a high pressure condition. When indicator is activated, the material pump servomotor is stopped. For more information on the HIGH PRESSURE SHUTDOWN SETPOINT settings, see the CALIBRATION screen section of this manual. Optional A Vacuum Pump (B Vacuum Pump) button These buttons control the A and B material tank vacuum pump. ON button When selected the vacuum pump is currently activated. OFF button When selected the vacuum pump is currently deactivated. Optional A TANK AGITATOR and B TANK AGITATOR buttons The Agitator Speed Controller enables/disables the electric agitator and also increases/decreases the tank agitator speed. OFF button The tank agitator is disabled and the material in the tank is not agitated. ON button The tank agitator is enabled and the material in the tank is being agitated to low or high speed. LOW SPEED button The tank is agitated at the minimum speed when the ON button is selected. HIGH SPEED button The tank is agitated at the maximum speed when the ON button is selected. 12

13 SERVO CONTROL screen DRIVE ENABLE #3 This button when pressed will enable the servo drive. RUN SETUP PROGRAM button #4 When this button is selected a factory preinstalled setup program will upload into the CTC Parker Automation memory. Included in this setup program are various setup parameters that were previously installed by the factory or by the operator. RUN MAIN PROGRAM button #5 When this button is selected a factory-preinstalled program will upload into the CTC Parker Automation memory. This program will give the machine the various instructions to perform the actual operations. SERVO POWER ON button #1 and #2 This button connects electrical power to the machines servomotor material pump. SERVO POWER OFF button #1 and #2 This button disconnects electrical power to the machines servomotor material pump. DRIVE ENABLE ON/OFF button #3 This button enables/disables the machines servomotor to drive the material pump. HOME Button The pumps will immediately move to the home limit switch and remain in the home position. This position is used when the machine ready to dispense material. RESET SERVO button This button will reset the machines servomotor to drive the material pump. 13

14 TEMPERATURE screen Sections only shown if recirculation is installed A TANK MATERIAL button/indicator This button/indicator shows the temperature setting of the material in the A material tank temperature in C. The A TANK MATERIAL indicator will show the current tank temperature setting. To change the A material oven temperature, do the following: 1. Select A TANK MATERIAL button, a numeric keypad should appear. 2. Enter in the material set point temperature required. NOTE: This temperature must be within the set point range. 3. Press the ENTER button. 4. The new material temperature should appear in the A TANK MATERIAL indicator. Optional A Recirc Hose button/indicator This button/indicator shows the set point of the material in the A component recirculation hose in C. The recirculation indicator will show the current material temperature setting. To change the A component recirculation material temperature, do the following: 1. Select A recirculation button, a numeric keypad should appear. 2. Enter in the material set point temperature required. NOTE: This temperature must be within the set point range. 3. Press the ENTER button. 4. The new material temperature should appear in the A recirculation indicator. A DISP. HOSE button/indicator This button/indicator shows the set point of the material in the A component dispense hose in C. A component dispense hose temperature indicator will show the current dispense hose material temperature setting. To change the A component dispense hose temperature, do the following: 1. Select A DISP. HOSE button, a numeric keypad should appear. 2. Enter in the material set point temperature required. NOTE: This temperature must be within the set point range. 3. Press the ENTER button. 14

15 4. The new material temperature should appear in the A DISP. HOSE indicator. B TANK MATERIAL button/indicator This button/indicator shows the temperature setting of the material in the B material tank in C. The B TANK MATERIAL indicator will show the current oven temperature setting. To change the B material tank temperature, do the following: 1. Select B TANK MATERIAL button, a numeric keypad should appear. 2. Enter in the material set point temperature required. NOTE: This temperature must be within the set point range. 3. Press the ENTER button. 4. The new material temperature should appear in the B TANK MATERIAL indicator. Optional B Recirc Hose button/indicator This button/indicator shows the set point of the material in the B recirculation hose in C. The B recirculation indicator will show the current material temperature setting. To change the recirculation material temperature, do the following: 1. Select B recirculation button, a numeric keypad should appear. 2. Enter in the material set point temperature required. NOTE: This temperature must be within the set point range. 3. Press the ENTER button. 4. The new material temperature should appear in the B recirculation indicator. B DISP. HOSE button/indicator This button/indicator shows the set point of the material in the B component dispense hose in C. B component dispense hose temperature indicator will show the current dispense hose material temperature setting. To change the B component dispense hose temperature, do the following: 1. Select B DISP. HOSE button, a numeric keypad should appear. 2. Enter in the material set point temperature required. NOTE: This temperature must be within the set point range. 3. Press the ENTER button. The new material temperature should appear in the B DISP. HOSE indicator. 15

16 MATERIAL TEMPERATURE indicator This is the current mixed material temperature at the outlet of mixer shroud. Material temperature status indicator. This gives the status of the current mixed material temperature. TEMP NOT READY: The material is currently below specified temperature limits. MATERIAL TEMP OK: The current material temperature is at specified limits. MATERIAL TEMP HIGH: The material is currently above specified temperature limits. NOTE: When the material is above a specified temperature, a material overheat alarm will be enabled. SILENCE ALARM button: This button will silence the material overheat alarm. ADJUST TEMPERATURE INCR TEMP button (Increment Temperature) This button will increment all the temperature settings by 1C every time the button is pressed. DECR TEMP button (Decrement Temperature) This button will decrease all the temperature settings by 1C every time the button is pressed NOTE: For more information on the material temperature set points, see the CALIBATION screen section of this manual. 16

17 MONITOR screen PUMP PRESSURE (psi) indicators ACTUAL This indicator gives the current pump outlet pressure in PSI (pounds per square inch). MATERIAL TEMP(C) indicators ACTUAL This indicator gives the current material temperature in C (Celsius). SET POINT This indicator is for future development; it reads the same as the actual indicator. SHOT SIZE (cc s) indicator ACTUAL This indicator gives the current shot size in cc s (Cubic Centimeters). FLOW RATE (cc s/s) indicator ACTUAL This indicator gives the current flow rate in cc/sec (Cubic Centimeters per Seconds). VOLUME DISPENSED (cc s) indicator This indicator gives the current amount of material dispensed to the mold in cc (Cubic Centimeters). A and B MATERIAL LEVEL and PRESSURE LEVEL status indicators These indicators will give the status of the A and B material level of the tanks and the pressure level of the material pumps. 17

18 Diagnostics screen This screen is used for advanced troubleshooting only. All settings on this screen can be changed using the other screen described in this manual. All indicators seen in this screen can be viewed using the other screens seen in this manual. 18

19 Recipe Preview Screen The preview screen will display the current machine configuration or recipe. This recipe can be edited or changed as required, then saved, either as an existing recipe or a new recipe. This new recipe can now be uploaded to the controller where the machine can operate from memory. To load a new recipe: press the LOAD RECIPE button to make the LOAD RECIPE screen to appear. For more information see the LOAD RECIPE screen in this manual. To edit a recipe that is currently loaded: press the EDIT RECIPE button to make the EDIT RECIPE screen to appear. For more information see the EDIT RECIPE screen in this manual. To send a recipe to the controller that is currently loaded or edited: press the SEND RECIPE TO CONTROLLER button. To return to the MAIN screen: press the exit arrow button see as the in the picture above. NOTE: If you have recently loaded or edited a new recipe the machine will not operate in this configuration until you press the SEND RECIPE TO CONTROLLER button. 19

20 LOAD RECIPE screen The purpose of this screen is to allow the reading of machine configurations as Recipes from memory. To load a recipe do the following: (If you are at the Recipe Preview screen press the LOAD RECIPE button to get to the screen shown above) 1. Select a recipe by touching the recipe loaded on the touch screen, the recipe that you touch will have a yellow rectangle around the recipe. 2. Verify that the recipe that you selected is in the RECIPE LOAD MESSAGE WINDOW in the top of the LOAD RECIPE screen. 3. To load the selected recipe, press the ACCEPT button. 4. The RECIPE PREVIEW screen should appear with the new recipe loaded. NOTE: To escape the LOAD RECIPE screen press the CANCEL button. NOTE: If you have recently loaded or edited a new recipe the machine will not operate in this configuration until you press the SEND RECIPE TO CONTROLLER button from the RECIPE PREVIEW screen. \ 20

21 EDIT RECIPE screen The purpose of this screen is to allow changes of machine configurations or Recipe previously loaded and save the machine configuration to memory. To edit the values of a recipe in the EDIT RECIPE screen do the following: (If you are at the Recipe Preview screen press the EDIT RECIPE button to get to the screen shown above) 1. Select a recipe value by touching the value the touch screen. A numeric keypad will appear. 2. Enter the new value that is required and press the ENTER button. NOTE: If you press the UPDATE RECIPE VALUES FROM CONTROLLER button, the current recipe from the machine will reload into the EDIT RECIPE screen. 3. To load the edited recipe, press the LEAVE EDIT button. The PREVIEW RECIPE screen should appear, then press the SEND RECIPE TO CONTROLLER button to load the recipe to the controller. 4. To save the edited recipe to disk; press the SAVE RECIPE button. This will make the SAVE RECIPE screen to appear. See SAVE RECIPE screen section of this manual for more information. NOTE: To escape the EDIT RECIPE screen press the LEAVE EDIT button. To enable or disable the items of a recipe in the EDIT RECIPE screen do the following: 1. Select an item by touching the touch screen, the item that you touch will have a yellow rectangle around the recipe (the item is located under the description along with the * if enabled). 2. To enable or disable an item (depending on the current configuration) press the RECIPE ITEM ENABLE or RECIPE ITEM DISABLED button. 21

22 SAVE RECIPE screen NOTE: Your screen keyboard may differ than what is shown on this illustration. To save the new recipe to an existing recipe disk do the following: 1. Select a recipe by touching the recipe loaded on the touch screen, the recipe that you touch will have a yellow rectangle around the recipe. This recipe will also appear in the RECIPE SAVE MESSAGE WINDOW. 2. Press the ACCEPT button. This will save the recipe to disk under the name selected. The previous screen will appear. To save as a new recipe do the following: 1. Select a recipe by touching the recipe loaded on the touch screen, the recipe that you touch will have a yellow rectangle around the recipe. This recipe will also appear in the RECIPE SAVE MESSAGE WINDOW. 2. Press the RECIPE SAVE MESSAGE WINDOW, a screen keyboard will be displayed, and a yellow curser will appear at the RECIPE SAVE MESSAGE WINDOW on the name of the recipe in the window. 3. Enter the new recipe name. 4. Press the ACCEPT button. This will save the recipe to disk under the name entered. The previous screen will appear. NOTE: To escape the SAVE RECIPE screen press the CANCEL button. 22

23 DELETE RECIPE screen To delete a recipe do the following: 1. Select the recipe to be deleted by touching the recipe n the touch screen, the recipe that you touch will have a yellow rectangle around the recipe. This recipe will also appear in the RECIPE DELETE MESSAGE WINDOW. 2. Press the ACCEPT button. This will delete the recipe. The previous screen will appear. NOTE: To escape the DELETE RECIPE screen press the CANCEL button. 23

24 Initial Startup The machine is completely factory assembled and tested. However, due to packing convenience, some on-site reassembly may be required. 1. Close all ball valves and close all other valves within feed systems unique to machine. NOTE: Steps 2-4 are only for machines with air. 2. Place an in-line regulator and shutoff valve between the machine and the air supply. 3. Connect a 1/2 or larger diameter air supply line to the air inlet for tank agitators. 4. Increase the pump air pressure to 20 psi and then reduce it to 0 psi. This will signal any air leaks. 5. Connect material hoses to the proper pump outlets. Secure remaining ends at dispense valve. If equipped with mild steel and stainless steel pump assemblies, make sure the hose fitting material matches the pump material. The pumps and hoses are color coded at the factory. When connecting hoses, match hose colored tape to the pump assembly colored tape for proper installation. 6. Lubricate the pump seal housing with grease. 7. Connect the required electrical power to the machine as indicate on the machine serial number plate and logic drawing enclose. 8. Check the tightness of all fittings before proceeding. 24

25 Material Pump Servo Start Up Sequence This is the sequence that will allow the material pump servo s to operate. From the SHOT FLOW screen do the following: 1. Under SERVO POWER select the ON button. 2. Under SERVO ENABLE select the ON button. 3. Press the DRIVE ENABLE button. 4. Press the RUN SETUP PROGRAM button. 5. Press the RUN MAIN PROGRAM. The material will now be active, and will respond the various pump modes and commands. 25

26 Adjusting the Limit Switches The over travel limit switch are factory adjusted, when tripped, they will stop the servo motor from going into an extreme over travel condition. The home adjustment switch allows set the piston at the beginning of the dispense tube. Do not adjust the Retract or Extend limit switches. To adjust the HOME position switch do the following: 1. Loosen the knurled knobs securing the home limit switch. Open both ratio check valves. 2. From the SHOT FLOW screen, do the Material Pump Servo Start Up Sequence (If required), then press the RETRACT Button, the machine moves to the retract position. 3. Press the HOME button, and watch for material dispensing from the dispense valve. 4. The home limit switch is set properly when the piston is at the point of the metering tubes material entrance, very little material will be dispensed (the amount of the material will not be enough to drip from the ratio check nozzles if not a small surge or bump of material may be seen.). Readjust the HOME limit switch and repeat steps 1 and 3 until there is no to very little to no material (as previously mentioned) when the machine is moves from retract to home position. NOTE: Both ratio checks must dispense material at the same time. If one ratio check dispenses material prior to the other, then, see the Phasing section in this manual for more information. The center position on the HOME switch scale is the approximate HOME position. 26

27 Dry Run A Dry Run demonstrates the machine s controls and dispensing steps. It also verifies that the machine is working correctly before loading material. 1. From the MAIN Screen. Select the SHOT FLOW button. From the SHOT FLOW screen, do the Material Pump Servo Start Up Sequence (if required). 2. Under PUMP COMMANDS press the RETRACT button. 3. Set the SHOT SIZE for a large shot. See adjusting the Shot Size. 4. Press the SHOT button. 5. Press and release the start device (START CYCLE button or foot switch). Machine takes one cycle and stops, depending on flow rate selected. 6. Press and hold the start device. Machine cycles continuously. 7. Press the OFF button. The machine stops. 8. Press the EXTEND button. The servo extends the pumps. Then press the RETRACT button. 12. Press the CONT button. 13. Press and release the start device. The machine cycles continuously. 14. Press the STOP button. The machine stops cycling. 15. Press the RETRACT button. The macine retracts. 16. Press the HOME button. Machine will home and is now ready for next function. 27

28 Priming the Hoses Priming the Hoses ensures that air-free material is flowing through the material hoses and out the dispense valve outlet. Before proceeding, load the machine with materials. Priming is critical to keep the PosiRatio working properly. NOTE: To prime the hoses without the outlet pressure sensor installed, the high pressure and low pressure setpoints must be set to maximum (500 psi) value. A priming recipe can be saved to simplify priming setup. 1. Set the Shot Size as required. See adjusting the Shot Size. 2. Do the Material Pump Servo Start Up Sequence (If Required). 3. From the SHOT/FLOW screen. Under PUMP MODE press the SHOT button. 4. At the pump outlets, close the ratio check ball valves. 5. Remove the dispense valve from its mount if necessary. 6. Hold the material hose and dispense valve outlet at a constant incline from the pumps so that air can be pushed out by the material when the machine is cycled. Avoid sags in the hoses! 7. Position a waste container under the outlet to catch dispensed material. Select the start device. 8. While keeping the hoses at a constant incline, cycle the machine slowly until all signs of air have disappeared. Then release the start device. To avoid material spitting, keep flow rate low. 9. Once air-free material is flowing from the outlet, press the RETRACT button. 10. Remount the dispense valve before proceeding. 11. Load recipe to run application before starting production. 28

29 Ratio Check The Ratio Check is a simple procedure where individual samples of material are collected, weighed, and compared to the manufacturer s desired outputs. We recommend that you do a ratio check by weight at least once a day, and if the machine is used in production for more than one shift, then once a shift. A ratio check log is included with this binder. Before proceeding, phase the pumps and prime the ratio check valves (if equipped) and material hoses. 1. Open the ratio check ball valves and close the material hose ball valves. Cycle the machine several times into a waste container to clear and prime. 2. Weigh six small empty cups and label as A1, A2, and A3. Record on Ratio Check form. 3. Set the shot size to 100%. See Adjusting the Shot Size. 4. From the SHOT FLOW screen do the Material Pump Servo Start Up Sequence (If Required) press the SHOT button. 5. Place empty cups under the nozzles. 6. Press and release the start device. 7. Repeat steps 5 and 6 with all three sets of labeled cups. Always take a dump shot into a waste container before taking weights. 8. Reweigh all three cups and record results on form. 9. Complete weight calculations. If significantly different, see Troubleshooting section. 10. Open the material hose ball valves and close the ratio check ball valves. 29

30 The following steps illustrate the day-to-day operation of the PosiRatio. Before proceeding, perform all Daily Maintenance listed in the Periodic Maintenance section. Also complete all loading, priming, phasing, and ratio check procedures. Daily Operations WARNING In order for this machine to operate, this machine must have at least 1 recipe saved to memory on every start up. If no recipe is installed, the machine will fail to open the touch screen program leaving the machine inoperative. 1. Push the EMERGENCY POWER and press the control power to the ON position (if required). 2. Load the required recipe from the floppy disk (if required). (See the LOAD RECIPE Screen for more information). 3. Confirm that the material tanks level is normal and the material temperature is at the required temperature (see the MONITOR screen for more information). 4. Confirm that the machine maintenance, ratio checks, and calibrations, and have been completed at the required intervals. 5. Confirm that recipe data is correct. Example: flow rates, shots sizes, setpoints, etc. 6. Do the Material Pump Servo Start Up Sequence, then press the SHOT button. 7. Connect dispense valve to the mold to be filled. 8. From the MONITOR screen press the START CYCLE or foot switch. Monitor the required indicators. 9. When the mold is filled and the dispense cycle is complete, disconnect dispense valve from mold. 10. Connect dispense valve to the next mold to be filled. a) If the mold is identical to the previous, press the START CYCLE button or foot switch. b) If the mold is different you may have to load another recipe, go to step 2. 30

31 Phasing the Pumps When the machine begins pumping material, both pistons must enter the metering tubes at precisely the same time so that both materials start flowing simultaneously. This will ensure proper mixing and a very repeatable metered ratio. Follow these instructions at initial start-up and after a pump repair. Before proceeding, if your model is equipped with ratio check ball valves, first close the material hose ball valves and then open the ratio check ball valves. 1. From the SHOT FLOW screen do the Material Pump Servo Start Up Sequence (if Required), select the RETRACT button. 2. Open the ratio check ball valves and close the material hose ball valves. 3. Press the HOME button. 4. The pumps are in phase when the material begins to flow from the ratio check nozzle outlets at exactly the same time. 5. Readjust the HOME position switch as required, see Adjusting the Limit Switch section of this manual for more information. If the material from the A pump flows before the material from the B pump, loosen the jam nut and set screw. Then rotate the shaft of the B piston counterclockwise a quarter turn with an open end wrench positioned on the wrench flats. Cycle the machine again and, as before, sight across both outlet ports. Repeat until both materials flow simultaneously. If the material in the B pump begins to flow before the material in the A pump (overcompensation), rotate the shaft of the B piston clockwise in quarter-turn increments until both materials flow simultaneously. Always retighten the jam nuts and set screws, securing both pump shafts in the phased position. (see the Illustration next page) 31

32 Phasing the Pumps Throughout this manual, references to the A pump and B pump are used. The A and B pumps correspond to the particular material originally specified for use in this machine and relate to the corresponding label on the material supply and to the hoses. Any change of resin supplier may cause a need to relabel the supply, pumps, and hoses accordingly. PUMP SHAFT FLATS Adjustment screws and jam nuts 32

33 Shut Down 1. From the SHOT FLOW screen, select the RETRACT button, select the OFF button, 2. Press and release the EMERGENCY STOP button. Ensure everything is OFF. 3. Inspect the pump shafts for a material buildup. Clean and lubricate. 33

34 Material Ratio Adjustment If the samples obtained in the Ratio Check section are very close to each other, but outside the manufacturer s tolerances, then you need to adjust the ratio. Ratio Adjustment Beam Pointer Knob Pivot Bar 1. Turn From the SHOT FLOW screen do the Material Pump Servo Start Up Sequence (if Required), select the RETRACT button. 2. Press and release the HOME button. 3. Loosen the pointer knob and move the pointer to the new location. Move the pointer to the larger numbers if more material is needed to produce a smaller ratio, or to the smaller numbers if less material is needed to produce a larger ratio. 4. Tighten the pointer knob. 5. Press the RETRACT button. 8. Repeat the Ratio Check section and if necessary repeat the adjustments until the desired ratio is attained. If the pointer is moved more than 15 increments from the original position location, it is required to recheck and readjust phasing if necessary. 34

35 Piston Replacement Piston Replacement is advise when piston wears to the point that it will no longer seal against the metering tube, thus producing inaccurate output. 1. Close all ball valves within feed systems unique to the machine. 2. At the pump outlets close the material hose ball valves. 3. Open the ratio check ball valves. 4. Place clean container under both ratio check nozzles to collect recyclable materials. 5. From the SHOT FLOW screen, do the Material Pump Servo Start Up Sequence (if required), press the CONT button. Press the start device. 7. Allow the machine to cycle until empty, then press the OFF button. Traces of material will remain in the bottom the pump even when flow ceases. 8. When the pump is drain of material, press the RETRACT button. 9. Press the OFF button. 10. Place rags under the pump outlet; remove the three socket-head cap screws on each side and remover the metering tube. When removing the 3 socket-head cap screw, there will be a tremendous vacuum. Tightly grip the metering tube and pull hard to remove if from the housing. 11. Press the SHOT button under under PUMP MODE. 12. From the SHOT FLOW screen, set the FLOW RATE button/indicator to a low flow rate. 13. Press the EXTEND button. The piston will move forward, exposing it self from the housing. 14. Press the OFF button if the piston is in the desired position. 15. Press and release the EMERGENCY STOP to shut off power to the machine. 16. Remove and replace the piston, locknut and washers. Add PTFE tape to piston shaft installation area so that the piston fit snug (do not apply PTFE tape to the point that the tape will roll to the back of the piston when the piston is fitted on the shaft), tighten the locknut until the piston cannot be rotated by hand, then tighten it one-quarter turn more. Pistons may not have front and rear washers. Check the assembly drawings included with the manual. 17. Press the POWER ON button. MAIN Screen appears. Press the SHOT FLOW button. 35

36 Piston Replacement Continued 18. Press the RETRACT button under PUMP MODE. 19. Lubricate the new metering tube O-rings and reinstall the metering tube. 20. Perform all Loading, Priming, Phasing, and Ratio Check procedures before resuming production. 36

37 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 Check the condition of the desiccant air dryer. Clean both pump shafts with solvent and lubricate with Mesamoll. Dispense Head Dismantle, clean thoroughly, and reassemble. Lubricate all parts with a thin coat of Mesamoll. *Refer to Daily Operation and Shutdown Sections of the manual, if material is leaking refer to the Troubleshooting Section of this manual. 37

38 Troubleshooting Pumping (after satisfactory startup) Problem Cause Solution Pump stalling and no material being pumped despite adequate input pressure. Blocked mixer. Turn off air supply and remove hoses from mixer. Check hoses for flow. Pumps cycling satisfactorily but total material output dropped off, or one pump output lags behind the other. Pumps not discharging normal or full volume. Pumps not cycling at all or pumps not completely cycling. Pumps drawing material back down from hose. Closed outlet ball valves. Blocked check valve. One pump metering incorrectly. Low material level in reservoirs. Air in material (normally only high viscosity material). Piston worn or broken. Check valve malfunction. Flow controls set differently Air circuit failure. Check valve stuck open. Open ball valves Unlikely to be fully restricted, but possible. Dismantle, clean, and reinstall. Check both outputs from the hoses. If pumps are out of phase or if one pump is not discharging a full shot of material, see next solution. Refill reservoirs. Prime pump and hoses. Reload reservoir with minimum air entrapment. (Ask for technical advice.) See air in hose solution. Remove and inspect suspected piston. Replace if worn, damaged. Remove, clean, and reinstall the check valve. Readjust flow controllers. See Logic Circuit troubleshooting. Remove check valve and clean or replace. 38

39 Pumping (after satisfactory startup) Continued Problem Cause Solution Material continues to flow after pumps stop dispense stroke, or air bubble apparent at some part of the dispense stroke each time. Air in hose. Hose not primed correctly. Air in material entrapped during reservoir refill. Incline hose from check valve to outlet of hose. Avoid sags in hose. Cycle machine until all trapped air is discharged. Reload reservoir with minimum air entrapment. (Ask for technical advice.) Air in material being drawn into pump from behind check valve. Remove check valve and fitting in front of pump. Reinstall with PTFE tape. Air in material being drawn Tighten or seal as necessary. into pump through inlet hoses or coupler. Severe leaks at pump shaft. Pump shaft seals worn. Remove pump packing assembly and replace shaft Pumps remain in extended position and will not return. Roller trip switch faulty. seal set. If roller trip switch has air pressure applied but does not function when checked, replace. Pumps remain at rest in retracted position and do not move when the machine is signaled to start. Pumps remain in extended position and will not return. Pumps remain at rest in retracted position and do not move when the machine is signaled to start. Pump is out of calibration. Material cured on piston rod. Pump is out of calibration. Roller trip switch faulty. Pump is out of calibration. Material cured on piston rod. Pump is out of calibration. Recalibrate pump. Clean piston rod, apply Mesamoll. Recalibrate pump. If roller trip switch has air pressure applied but does not function when checked, replace. Recalibrate pump. Clean piston rod, apply Mesamoll. Recalibrate pump. Motionless Mixer (after satisfactory startup) Problem Cause Solution Material leaks past inlet valves of dispense valve, mixing block, or dispense block. Inlet valve O-ring or seals damaged or worn. Replace O-rings or seals. 39

40 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 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 Rev 03/