Graco 19Y486 User Manual

Instructions - Parts

Pneumatic Pump Control Module

3A7709B

User Interface for controlling and monitoring Graco Intelligent Paint Kitchen (IPK) Pneumatic Pumps. For professional use only.

19Y486 — Pneumatic Pump Control Module

Important Safety Instructions

Read all warnings and instructions in this manual, the supplied

ADCM manual, and the IPK manuals before using the equipment.

Save these instructions.

The 19Y486 Pump Control Module uses the 25B475 Advanced Display Control Module (ADCM). See manual 332013 (supplied) for complete warnings and approvals for the 25B475 ADCM.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Related Manuals ................................................	2
Warnings ...........................................................	3
Pump Control Module .........................................	7
Installation..........................................................	7
Hazardous Locations....................................	7
Grounding ...................................................	9
Cable Connection ........................................	11
Typical Installation .......................................	13
Operation...........................................................	14
Pressure Relief Procedure............................	14
Modes of Operation......................................	14
Display........................................................	15
Module Screens...........................................	16
Module Menu Bar.........................................	16
Module Keys................................................	16
Run Screens......................................................	17
Pump Control Chapter..................................	17
Totalizer Chapter .........................................	19
Agitator Chapter...........................................	20
Event Log Chapter.......................................	21
Setup Screens....................................................	22
Profile Chapter.............................................	22
Pressure Transducer Chapter.......................	27
Pump Setup Chapter....................................	29

Diagnostic Chapter ......................................	30
Totalizer Chapter .........................................	30
Modbus Chapter..........................................	31
Miscellaneous Chapter.................................	32
Error Code Troubleshooting ................................	35
Parts..................................................................	38
25B234 Pneumatic ADCM Display
Enclosure Assembly .......................	39
Accessories and Kits...........................................	41
Automatic Air Control Kit 19Y482..................	41
NXT Air Control Kit 19Y996 ..........................	42
Transducer I/P Kit 24V001............................	43
Pressure Transducer Kit for 4-ball Pumps
24R050Pressure Transducer Kit
for 2-ball Pumps 24Y245.................	43
Pressure Transducer Kit for Sanitary
Pumps 24X089...............................	44
California Proposition 65.....................................	44
Notes ................................................................	45
Appendix A - Modbus Variable Map.....................	45
AppendixB-ControlModuleProgramming...........	58
Graco Standard Warranty....................................	60

Related Manuals

Manual No.	Description

332013	Advanced Display Control Module (ADCM), Instructions-Parts

332196	IS Power Supply Modules, Instructions-Parts

3A1244	Graco Control Architecture Module Programming, Instructions

3A3382	High-Flo® 4–Ball Pumps, Instructions-Parts
3A3452	4–Ball Lowers with Open Wet Cup, Repair-Parts

333015	Endura-Flo™ 3D150, 3D350, 4D150, and 4D350 Diaphragm Pump, Instructions
307843	Air-Powered Glutton® Pumps, Instructions-Installation

3A7709B

Warnings

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

•Keep work area free of debris, including solvent, rags and gasoline.

•Do not plug or unplug power cords, or turn power or light switches on or off when flammable

fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

•Use only grounded hoses.

•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.

Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable vapors. To prevent fire and explosion:

•Clean plastic parts only in a well-ventilated area.

•Do not clean with a dry cloth.

3A7709B

Warnings

WARNING

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements.

•Installation should be in accordance with ANSI/ISA RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations” and the National Electrical Code® (ANSI/NFPA 70).

•Installation in Canada should be in accordance with the Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.

•For ATEX, install per EN 60079–14 and applicable local and national codes.

• Equipment that comes in contact with intrinsically safe terminals must meet the entity parameter requirements specified in Control Drawing 16M169. See Appendix A in Manual 332013. This includes safety barriers, DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when servicing.

•Without the safety barrier, the equipment is no longer intrinsically safe and must not be operated in hazardous locations, as defined in article 500 of the National Electrical Code (USA) or your local electrical code.

•Do not install equipment approved only for non-hazardous location in a hazardous area. See the ID label for the intrinsic safety rating for your model.

•Do not use intrinsically safe equipment with a power supply that has no barrier. Intrinsic safety may be compromised.

•Ground the power supply. A voltage limiting safety barrier must be properly grounded to be effective. For proper grounding, use a 12 gauge minimum ground wire. The barrier’s ground must be within 1 ohm of true earth ground.

•Do not remove any cover until power has been removed.

•Do not substitute system components as this may impair intrinsic safety.

3A7709B

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, 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. Getimmediate surgical treatment.

•Do not spray without tip guard and trigger guard installed.

•Engage trigger lock when not spraying.

•Do not point gun at anyone or at any part of the body.

•Do not put your hand over the spray tip.

•Do not stop or deflect leaks with your hand, body, glove, or rag.

•Follow the Pressure Relief Procedure when you stop spraying 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.

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 Specifications in all equipment manuals.

•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheets (SDSs) from distributor or retailer.

•Do not leave the work area while equipment is energized or under pressure.

•Turn off all equipment and follow the PressureReliefProcedurewhen equipment is not in use.

•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

•Do not alter or modify equipment. Alterations or modifications may void agency approvals and create 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.

3A7709B

Warnings

WARNING

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. 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 manufacturer.

3A7709B

Pump Control Module

The Pump Control Module is a user interface for the setup and control of pneumatic pumps. It is an Advanced Display Control Module (ADCM) that uses specialized software to allow the user to remotely set the mode of pump operation, and to monitor and control pressure and flow rate.

The screen backlight is factory set to remain on, even without screen activity. See

Setup Miscellaneous 1, page 32, to set the brightness and backlight timer. Press any key to restore the settings.

Keys are used to input numerical data, enter setup screens, navigate within a screen, scroll through screens, and select setup values.

Installation

For installation and setup instructions, see the Advanced Display Control Module (ADCM) manual 332013.

Hazardous Locations

Do not substitute or modify system components as this may impair intrinsic safety. For installation, maintenance, or operation instructions, read the instruction manuals provided: 3A7709 and 332013. Do not install equipment approved only

for non-hazardous location in a hazardous location. See the identification label for the intrinsic safety rating for your model.

Intrinsically safe equipment should not be used with a power supply that has no IS barrier. Do not move units from a non-IS installation to an IS installation. IS equipment that has been used with a non-IS power

supply must not be returned to a hazardous location. Always use an IS barrier with IS equipment.

•Install according to Control Drawing Number 16M169. See Appendix A in the Advanced Display Control Module (ADCM) manual 332013.

•Installation in the US should be in accordance with ANSI/ISA RP12.06.01, “Installation of Intrinsically Safe Systems for Hazardous (Classified)

Locations,” and the National Electrical Code® (ANSI/NFPA 70).

•Installation in Canada should be in accordance with the Canadian Electrical Code, CSA C22.1, Part 1, Appendix F.

•For ATEX, install per EN 60079-14 and applicable local and national codes.

•Multiple earthing of components is allowed only if a high integrity equipotential system is realized between the points of bonding.

•Do not remove any cover until power has been removed.

3A7709B

Installation

Non-Hazardous Location

Hazardous Location

Figure 1 Installation in a Hazardous Location

KEY:

APump Control Module

BPower Supply Module

CPower Accessory Cable

DIS Power Cable (50 ft., 15 m), to terminal 3. See Cable Connection, page 11.

EGround wire and clamp for Pump Control Module. PN 223547 is not supplied.

3A7709B

Installation

Grounding

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

Non-

Hazardous

Location

Hazardous

Location

ti20264a

Pump Control Module: Grounded through the IS Power Cable (34) to the IS barrier (29) in the Power Supply Module. (See

Power Supply Module Grounding, page 10.) If the mounting bracket is used, connect a ground wire (E) to the screw at the top of the bracket to a true earth ground. (See Figure 1.)

Power Supply Module: Follow the grounding instructions in the Power Supply Module manual 332196.

Non-

Hazardous

Location

Hazardous

Location

ti20217a

Power Supply Module Located in	Power Supply Module Located in Haz-
Non-Hazardous Location	ardous Location

KEY

APump Control Module

BPower Supply Module and Barrier

The power cable CANNOT have the cable shield tied to the coupling nut. 500 VAC isolation

1is required. The power cable and circuit board are isolated from the Pump Control Module enclosure. They have conductive paths to SEPARATE grounds.

The power cable CAN have the cable shield tied to the coupling nut. The power cable coupling

2nut and Pump Control Module have conductive paths to a COMMON ground.

3A7709B

Installation

Power Supply Module Grounding

NOTE: The callouts and identifications on this page reflect those used in the IS Power Supply Modules manual (332196), and are included here only for reference and for consistency with manual 332196.

Figure 2 Power Supply Module Grounding

KEY:

N 13

14+

14–

14L

14N

Supply Ground Wire

Supply Line Wire

Supply Neutral Wire

Ground Terminal Block

Power Supply output power

Power Supply input power

Ground (from the Ground Terminal Block (13) to the G-Barrier (29))

G-Barrier

34IS Power Cable (from the G-Barrier (29) to the Pump Control Module (A, see Figure 1); installed in factory)

3A7709B

Installation

Cable Connection

Order a power accessory cable (C) from Table 1. Connect the cable to Port 3 on the bottom of the control module (see Figure 3). Connect the other end to the power barrier (see Figure 1). Connect other cables as described in Table 2.

Figure 3 Pump Control Module Connectors

Table 1 Power Accessory Cable

Cable Part No.	Description
16K509	Intrinsically safe power cable, 52 ft (16 m)

16K615	Intrinsically safe power cable, 105 ft (32 m)

Table 2 ADCM Cable Connections

ADCM Port	Connector Purpose	Connection	Notes
Number
1	Fiber Optic Receive		Fiber optic receive line used for
1	Fiber Optic Receive		Modbus communications
			Modbus communications
2	Fiber Optic Transmit		Fiber optic transmit line used for
2	Fiber Optic Transmit		Modbus communications
			Modbus communications
		Pin 1 – CAN Low	CAN data low line for GCA
			communication. CAN
			communication is not used
			on this product.
		Pin 2 – Power	Power supply voltage
3	Power Input	Pin 3 – Common	Power supply common
			CAN data high line for
		Pin 4 – CAN High	GCA communication. CAN
		Pin 4 – CAN High	communication is not used on this
			communication is not used on this
			product.
		Pin 5 – Shield	Cable shield

3A7709B

Installation

		Pin 1 – Voltage	Connected to the system input
			voltage (Power Input Pin 2)

		Pin 2 – Reed Switch 1 Input	Downstroke input for reed switch.
			Input can be configured
		Pin 3 – Auxiliary Output	Not used at this time
4	Auxiliary IO
4	Auxiliary IO	Pin 4 – Reed Switch 2 Input	Upstroke input for reed switch.
			Potential to be configured as
			input capture, but currently not
			supported in component library.
		Pin 5 – Common	Connected to the system input
			voltage common (Power Input Pin
			3)
5	Fiber Optic Receive		Mirror of fiber optic receive port 1
6	Fiber Optic Transmit		Mirror of fiber optic transmit port 2

	Pressure Transducer 1		A differential voltage input. This
7			port can support multiple pressure
7			transducer ranges (see Pressure
			Transducer Chapter, page 27).
			Monitors pump outlet pressure.
	4–20 mA Output 1		Used to control the air inlet to
			the pump to regulate the system
8			fluid pressure. The I2P provides
8			a response correlated to the inlet
			air pressure, with a 0–100% drive
			signal controlling pressure to a
			boost value.
	4–20 mA Output 2		Used to control any back pressure
9			regulator (BPR). At 4 mA (0%) the
9			BPR is completely open, and at
			20 mA (100%) the BPR is fully
			closed.
	Pressure Transducer 2		A differential voltage input. This
			port can support multiple pressure
10			transducer ranges. Monitors the
10			pressure at the BPR, but can be
			pressure at the BPR, but can be
			used anywhere in the system
			(including air inlet pressure).

3A7709B

Installation

Typical Installation

Figure 4 Typical Installation

KEY:

A Pump control module

GAir motor

HAir line shutoff valve

JAir supply line

KAir line filter

LBleed-type master air valve

MBack-pressure regulator (BPR)

NSelf-relieving piloted air regulator

P Reed switches

R1 Pressure transducer at outlet of pump

R2 Pressure transducer at BPR

SPump inlet hose

TFluid filter

UFluid inlet shutoff valve

3A7709B

Operation

Pressure Relief Procedure

Modes of Operation

Follow the Pressure Relief Procedure whenever you see this symbol.

Pressure Control

When the system is in pressure control mode, the pump controls the pressure provided at the outlet of the pump with closed-loop control. The unit controls the air into the pump using an I2P while monitoring the outlet pressure with a differential pressure sensor. The control loop updates at the top of the cycle. The pressure target should be reached within five cycles.

Unexpected activation of the pump could result in serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts. Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1.Ensure the pump is off by pressing the pump shutdown button on the pump control module (A).

2.Close the bleed-type master air valve (L).

3.Open all fluid drain valves in the system, having a waste container ready to catch drainage. Leave drain valves open until you are ready to spray again.

Flow Control

When the system is in flow control mode, the pump controls to a flow rate using pressure. Flow rate is estimated on cycles/minute and volume displacement. The control loop updates at the top of the cycle for traditional air motors and at the left cycle of an AODD or Glutton®. The flow rate target should be reached within five cycles.

Hybrid

When the system is in control pump mode, the pump controls to a pressure target while also updating the BPR setpoint to control the flow rate. The user is required to enter a pressure target, flow rate target, and a maximum flow rate value. The system first achieves the pressure target. Next, if the system is running too fast or slow based on the flow rate target, the system adjusts the BPR target to achieve the flow rate target. If the BPR target is at either 100% or 0%, the flow rate target may not be achieved.

Open Loop

When the system is in open loop mode, a fixed air pressure is applied to the pump inlet. The system will operate similarly to a manual air regulator. Changing the percentage set point up or down adjusts the air applied to the air motor inlet.

NOTE: This mode of operation is only recommended if the other modes cannot be used, but the pump still needs to operate. To troubleshoot error codes see Error Code Troubleshooting, page 35.

3A7709B

		Operation
Display
Overlay

	Overlay Keys
	Page Navigation	Setpoint Incrementation
	The up arrow is used to move to the previous	When the user is in an entry field, the up arrow
	page. If the user is at Page 1, pressing the up	is used to increment the value. If the value is at
Up Arrow	arrow causes the pages to roll over to the last	“9”, pressing the up arrow will cause the value
	page.	to roll over to “0”.
	Page Navigation	Setpoint Decrementation
	The down arrow is used to move to the next	When the user is in an entry field, the down
	page. If the user is at the last page, pressing	arrow is used to decrement the value. If the
Down	the down arrow causes the pages to overflow	value is at “0”, pressing the down arrow will
Arrow	and display the first page.	cause the value to roll over to “9”.
	Chapter Navigation	Setup
	The right arrow is used to move to the next	To enter or exit Setup, the user will press and
Right	chapter. If the user is at the last chapter,	hold the right arrow key for three seconds.
Right	pressing the right arrow will wrap around to the
Arrow /	first chapter.
Setup
	Field Entry
	Pressing the enter key activates a field for editing, activates the changes in a highlighted field,
Enter	selects a highlighted option in a menu, and selects or unselects a checkbox.
Enter
	Stop Pump
	Pressing the shutdown key will stop the pump.
Shutdown
	Field Entry
	When the user is in a menu or a numeric field, pressing the cancel key causes the display to
Cancel	exit field entry mode and revert back to the previous screen.
Cancel

3A7709B

Operation

Module Screens

There are two sets of screens (Books): Run and Setup. Run and Setup books contain chapters, and every chapter contains pages. Chapters are accessed by using the right arrow key. At the bottom of the screen there are dots to indicate the number of chapters and to highlight the current chapter. If you navigate past the chapter you want to display, you need to continue pressing right arrow key to wrap back to the chapter you would like to update.

Pages are accessed using the up and down arrows. At the right side of the screen there are dots to indicate the number of pages in this chapter and to highlight the current page.

Press and hold the right arrow / lock icon () for three seconds to enter or exit Setup.

NOTE: The screen automatically dims based on the load requirements.

Example: This set of Run Screens has three chapters (indicated by the bottom of the screen) and two pages (indicated by the squares on the right side of the screen).

Module Menu Bar

The Module Top Menu only displays on

Run Screens, page 17 and shows the following:

•Error Codes See

Error Code Troubleshooting, page 35.

•Current Profile Mode (Pressure Mode shown). See Profile Configuration Page, page 22.

•Time

Module Keys

The figure below is a view of the control module display and keys. Overlay, page 15, explains the function of the membrane keys on the control module. As you move through the screens, you will notice that most information is communicated using icons rather than words to simplify global

communication. The detailed screen descriptions in Run Screens, page 17, and Setup Screens, page 22, explain what each icon represents. The two keys are membrane buttons whose function correlates with the screen content to the immediate left of the button.

NOTICE

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

Figure 5 Control Module Keypad and Display

3A7709B

Run Screens

Run Screens are comprised of the runtime information that the system is monitoring and controlling, such as: Current Flow Rate, Cycle Per Minute, Pressure, Active Profile, etc. See Overlay, page 15, for information on how to make selections and enter data.

Pump Control Chapter

Pump Control Page 1

Figure 6 Pump Control Page 1

		Pump Control Page 1 Key
	Displays the current average pressure at the outlet of the pump in pressure units
	selected in setup.
Current Pressure	Range:
Current Pressure	•	PSI: 0 – 9999
	•	Bar: 0.0 – 999.9
	•	MPa: 0.00 – 99.99
Cycles Per Minute	Displays the current average cycles rate of the pump in cycles per minute.
Cycles Per Minute	Range: 00.0 – 99.9 CPM
	Range: 00.0 – 99.9 CPM
	Display the current flow rate of the pump. Number is calculated based on cycles
	per minute and displacement. The value is displayed in the flow rate units specified
	in setup.
	Range:
Current Flow Rate	•	Gallons/min: 0.0 – 999.9
	•	Liters/min: 0.0 – 999.9
	•	CC/min: 0 – 99999
	•	Oz/min: 0 – 99999
	•	CPM: 0.0 – 99.9

3A7709B

Run Screens

Pump Control Page 1 Key

	Command the pump to start or stop, as indicated by a play or pause icon. Press to
Run/Stop	toggle between the two icons.
	Range: 0 (	) – 1 (	)

	Default: 0 (Pause)
Profile Select	Select the profile (		) to run on the pump. Profiles are configured in Setup.
	Range: 1 – 4

	Default: Last value the pump was running

Pump Control Page 2

Figure 7 Pump Control Page 2

		Pump Control Page 2 Key
Back Pressure	Displays the current percent output being applied to the back pressure regulator. 0%
Regulator Percent	indicates fully open, while 100% indicates fully closed.
Output	Range: 0 – 100%
	Range: 0 – 100%
	Displays the average pressure indicated by pressure sensor 2. A common application
	is the pressure at the Back Pressure Regulator.
Back Pressure	Range:
Regulator Pressure	•	PSI: 0 – 999
	•	Bar: 0.0 – 99.9
	•	MPa: 0.00 – 9.99
	Displays the difference in pressure between the outlet of the pump and the second
	pressure transducer. Common application is to monitor pressure drop across the
	circulation line. In that application the second pressure transducer is installed at the
	BPR.
Delta Pressure	Range:
	•	PSI: 0 – 999
	•	Bar: 0.0 – 99.9
	•	MPa: 0.00 – 9.99

3A7709B

+ 42 hidden pages