Graco 244561 User Manual

Instructions-Parts

ProDispense™

Used to meter and dispense paints, coatings, solvents, water, and lubrication fluids.
For Professional Use Only.

Not for use in explosive atmospheres.

309301G

Part No. 244561 Electronic Preset Dispense System

Important Safety Instructions

Read all warnings and instructions in this manual.
Save these instructions.
See page 4 for maximum working fluid pressure
and system component information.

ENG

Conforms to ANSI/UL
standard 3121-1
CAN/CSA C22.2 No 1010-1-92

Contents

ProDispense System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

How the ProDispense System Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Install the Fluid Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mount the Fluid Panel(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connect the Air and Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Install the Remote Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Mount the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connect the Cables and Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Ground the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Check the Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect a Printer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Connect to a PC or Alarm (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Before Beginning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

System Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Fluid Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Recipe Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Calibrate Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dispense Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Run Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fluid Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Alarm History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Operation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Loading Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Manual Dispense. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Automatic Dispense. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Purging Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Removing and Installing Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2 309301G

Replacing Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Replacing Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Replacing Membrane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Replacing Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Replacing Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Replacing Fluid Panel Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Servicing Fluid Panel 244599. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Servicing Fluid Panel 244600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Servicing Fluid Panel 244601 and 246837. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Servicing Fluid Panel 246838. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Servicing Fluid Panel 246839. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Wiring Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Part No. 244561, Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Part No. 244599, Fluid Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Part No. 244600, Fluid Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Part No. 244601, Fluid Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Part No. 246837, Fluid Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Part No. 246838, Fluid Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Part No. 246839, Fluid Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Graco Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

309301G 3

ProDispense System Components

ProDispense System Components

Follow the instructions in this manual (309301) and refer to the component manuals for addi­tional warning, operation, service, and parts information. See the table below for:

• maximum working pressure of the fluid panels

• component part numbers and manual numbers

• parts list page numbers

Fluid Panels Part No. 244599

Oil/Lubricant

Maximum Working Pressure 1500 psi (10 MPa, 103 bar) 250 psi (1.7 MPa, 17 bar) 3000 psi (21 MPa, 207 bar)
Fluid Meter Part No. 238618 513891 239716

Manual No. 308245 — 308778

Dispense Valve Part No. — — 205612

Manual No. — — 306715

Parts List Page No. 64 65 66

Fluid Panels Part No. 246837

Grease/Paint

Maximum Working Pressure 3000 psi (21 MPa, 207 bar) 3000 psi (21 MPa, 207 bar) 3000 psi (21 MPa, 207 bar)
Fluid Meter Part No. 244292 — 246190

Manual No. 308778 — 309834

Dispense Valve Part No. 205612 205612 205612

Manual No. 306715 306715 306715

Parts List Page No. 69 70 71

ProDispense Controller Part No. 244561

Parts List Page No. 62

244600

Water/Antifreeze

246838

Meterless

244601

Grease/Paint

246839

Sealants

Remote Operator Station Part No. 116669

4 309301G

Conventions

The following conventions are used in this manual to help guide you through the information.

Warning Symbols

The warning symbol alerts you to the possibility of serious injury or death if you do not follow
the instructions.

Symbols, such as fire, explosion, or electric shock hazard (shown at left), alert you to the spe­cific hazard. Read the main Warnings on pages 6-7 for detailed information about the hazard
indicated.

Caution Symbol

The caution symbol alerts you to the possibility of equipment or property damage or to opera­tion errors if you do not follow the instructions.

Note Symbol

The note symbol is used to call your attention to additional helpful information.

Conventions

Amount 20 qts

Recipe#

ID#

1. Enter the ID
number.

• Italicized text in a screen diagram indicates the text may vary according to how the sys-

tem parameters have been configured. For example, the units of measure shown in the
manual may be qts (quarts). The units you see on your screen may be pounds, kilograms,
quarts, gallons, or liters.

• A shaded box is used to indicate a value/field that can be edited on the controller

screen.

1

• A circled number in a screen diagram relates a field on the screen to a step in a proce-

dure.

1

• Numbers and letters in parentheses in the text, such as (A) or (7), refer to reference num-

bers and letters in the figures.

• When you need to press a key during a procedure, the key is indicated by an icon as

shown in the following example: Press Start to begin the dispense.

309301G 5

WARNING

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result
in fire, explosion or electric shock.

• Installation and service of electrical components must be completed by a qualified electrician.

• Do not install the ProDispense controller, fluid panels, or remote operator station in a hazardous

location.

• Ground the equipment. See Ground the System, page 20.

• If there is any static sparking while using equipment, stop dispensing immediately. Identify and

correct the problem.

• Provide fresh air ventilation to avoid buildup of flammable fumes.

• Eliminate all ignition sources, such as cigarettes.

• Avoid spilling fluids onto electrical components.

• Turn off the ProDispense controller power switch before servicing equipment.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.

• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and

solvent manufacturer.

• Know the specific hazards of the fluid you are using.

• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,

state and national guidelines.

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

• This equipment is for professional use only.

• Read all instruction manuals, tags, and labels before operating the equipment.

• Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

• Do not alter or modify this equipment.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not exceed the maximum working pressure stated on the equipment or in the Technical Data,

page 71.

• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Techni-

cal Data in all equipment manuals and the fluid manufacturer warnings.

• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose

Graco hoses to temperatures above 180° F (82° C) or below -40° F (-40° C).

• Comply with all applicable local, state, and national fire, electrical, and safety regulations.

6 309301G

WARNING

WARNING

HIGH PRESSURE FLUID HAZARD/SKIN INJECTION HAZARD

Fluid Panels 244599 and 244601 can be operated at very high fluid pressure (see page 4). High pres­sure spray from dispense valves, hoses, or ruptured components can inject fluid into your body and
cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on
the skin can also cause a serious injury.

The following precautions should be taken for high pressure fluid dispensing:

• Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-

cal treatment.

• Do not place a rag over the end of the nozzle and “blow back” fluid to clear the nozzle.

• Follow the additional precautions under LOW PRESSURE FLUID HAZARD.

LOW PRESSURE FLUID HAZARD

Fluid Panel 244600 is for low pressure use only (see page 4). Fluid coming from the dispense valves,
leaks or ruptured components can splash in the eyes or on the skin and cause serious injury.

The following precautions should be taken for either high or low pressure fluid dispensing:

• Wear protective eyewear.

• Do not put your hand or fingers over the valve nozzle or hose.

• Do not point the dispense valve or hose at anyone or at any part of the body.

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

• Follow the Pressure Relief Procedure on page 24 before cleaning, checking, or servicing the

equipment or installing or cleaning the dispense valve nozzle.

• Tighten all fluid connections before operating the equipment.

• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.

309301G 7

Overview

Overview

How the ProDispense System Works

Usage

The ProDispense system enables you to accurately dispense preset amounts of up to three
different fluids or to manually dispense fluid as desired. The fluid meters provide accurate fluid
flow readings to the controller. Controller totalizers use the meter flow readings to calculate
fluid volume and usage and display the information on the screen. The controller can store the
parameters for up to 250 recipe dispenses.

Fluid Supply

The ProDispense system can dispense fluids supplied from pressure tanks or feed pumps.
Each fluid is supplied separately to the ProDispense fluid panels.

Choice of Recipe Dispense or Fluid Dispense

You can choose Fluid Dispense mode to individually enter a fluid preset volume and dispense
the fluid. Or you can choose Recipe Dispense mode to dispense a preset recipe. A recipe
allows you to select or set up to three preset fluid volumes simultaneously.

Regardless of which dispense mode you choose, a dispense tolerance must be entered for
each fluid. The controller monitors the Target and Actual dispense values and reports an error
if the tolerance is not maintained.

8 309301G

Remote

Operator Station

10’ (3.05 m) station

cable standard*

Fluid Panel

Overview

Main Components

ProDispense Controller
with display and
EasyKey™ pad

50’ (15.24 m) meter &
solenoid cables

FIG. 1

Oil/Lubricant Grease/Paint Water/Antifreeze

*20’ (6.1 m) station cable extension 198456 is available.

ProDispense Controller

The controller is used to setup the ProDispense system, fluids, and recipes, calibrate the
meters, and select a recipe or preset a dispense. The controller totalizers enable you to view
fluid dispense information and print the following reports:

• Alarm history report

• Totals report

• Configuration Setup report

• Fluid Setup report

• Recipe Setup report

• Run report

Display and EasyKey™ Pad

The EasyKey™ pad is the operator interface for the ProDispense system. The keypad con­sists of number keys, enter key, scrolling (arrow) keys, and operation (start, stop, clear, and
print) keys.

The graphic LCD screen displays system status, setup information, and operation options that
can be selected using the keypad.

309301G 9

Number Keys

Overview

Previous Field

FIG. 2

Display

Start Stop Clear Print

Operation Keys

Next Field

Previous Screen

Next Screen

Enter
Key

Scrolling
Keys

Number Keys — type in setup or operation data.

Enter Key — press to accept and enter data.

If you press a scrolling key without pressing Enter, the cursor will move to the next field and
the information you typed will reset back to the previous data.

Scrolling Keys — press the up or down arrows to move between fields on the screen. Use the

left or right arrows to move between screens.

Operation Keys — use to operate the ProDispense system functions.

Start — press to start the current recipe dispense.

Stop — press to stop the current process.

Clear — press to clear an entry in an input field.

Print — press to print a report.

10 309301G

Overview

Power Switch (A)

On = Off = .

(On side of controller)

Operation Mode Switch (B) and Key (C)

The position of the switch (B) determines which mode of operation you are in:
Dispense Mode or Setup Mode . A key (C) supplied with the ProDispense system is

A

B

C

inserted into the switch and turned to change operation modes. The key cannot be removed
while the system is in Setup Mode.

Dispense Mode is used to dispense a recipe, fluid, check fluid totals, and to view the

alarms log.

Setup Mode is used to configure the system, fluid, and recipe parameters, and to cali-

brate the meters.

STOP

DISPENSE

AUTO ON

DISPENSE
START

ti1359a

Stop
button

Dispense
switch

Start
button

Remote Operator Stations

A cable connects the operator station to the fluid panel junction box. A separate operator sta­tion is needed for each fluid panel installed on the system. The dispense switch can be set to
dispense automatically (AUTO) or manually (ON).

If set to AUTO, the fluid panel will dispense when a recipe or fluid dispense is selected with
the controller and the start button is pressed either on the controller or the operator station.
The dispense will stop when the preset amount is reached or when the stop button is pressed
on either the controller or the operator station.

If set to ON, the fluid panel will begin dispensing immediately or when the dispense valve is
triggered. The dispense is stopped by releasing the trigger or turning the dispense switch to
AUTO or pressing the STOP button on the operator station.

309301G 11

Overview

Fluid Panels

There are six types of fluid panels available:

• 244599 — Oil and Lubricant Fluid Panel

• 244600 — Water and Antifreeze Fluid Panel

• 244601 — Grease and Paint Fluid Panel

• 246837 — Grease and Paint Fluid Panel

• 246838 — Meterless Fluid Panel (meter supplied by user)

• 246839 — Grease and Paint Fluid Panel

There are three cable connections on the fluid panel junction box for connecting:

• operator station to the solenoid connection

• controller to solenoid connection

• controller to meter connection

Signals from the controller and operator station communicate to the fluid panel(s) when to
start and stop dispensing. Signals from the fluid panel’s fluid meter communicate to the con­troller how much fluid has been dispensed.

A

C

244599 244601

A

B

C

244600

B

A

B

C

D

E

D

E

F

G

H

ti1433a

F

G

H

ti1434a

D

E

F

H

G

J

ti1435a

I

Key

A Controller Solenoid Connection

B Controller Meter Connection
C Operator Station Connection
D Junction Box
E Fluid Inlet
F Meter
G Solenoid
H Fluid Outlet
I Air Inlet
J Fluid Valve

FIG. 3

12 309301G

Overview

C

D

E

F

FIG. 4

B

246838

A

B

C

246837 246839

A

B

C

A

D

D

J

H

H

G

I

G

Key

A Controller Solenoid Connection

B Controller Meter Connection
C Operator Station Connection
D Junction Box
E Fluid Inlet
F Meter
G Solenoid
H Fluid Outlet
I Air Inlet
J Fluid Valve

J

E

J

F

I

H

I

G

309301G 13

Installation

Do not install or service this equipment unless you are trained and qualified.
Do not install the ProDispense controller, fluid panels, or remote operator station in a

hazardous location.

• FIG. 5 is not an actual system design. Contact your Graco distributor for assistance in

• See detailed installation instructions, beginning on page 18.

• Be sure all accessories are adequately sized and pressure rated to meet the system

• Be sure mounted surfaces and fasteners can support the weight of the equipment; hose,

Installation

designing your system.

requirements.

tubing and cable attachments; and fluid.

Key for F

1 ProDispense Controller with EasyKey™ Pad
2 Remote Operator Station
3 Oil/Lubricant Fluid Panel (244599)
4 Water/Antifreeze Fluid Panel (244600)
5 Grease/Paint Fluid Panel (244601)
6 Fluid Supply Pump
7 Fluid Supply
8 Air Supply Line
9 Dispense Valve
10 Ground Wire to true earth ground
11 Fluid Supply Line
12 Fluid Dispense Line
13 Fluid Shutoff Valve
14 Bleed-type Air Shutoff Valve
15 Optional Printer

IG. 5

14 309301G

Installation

14

15

10

13
11

1

EasyKey

TM

123

456

789

0

.

2

2

10

4

13

9

12

11

12

14

6

6

9

10

2

3

10

13

14

11

12

8

5

6

9

7

FIG. 5: ProDispense System - Typical Installation

Install the Fluid Supplies

For maintenance and safety, you must install:

• a fluid shutoff valve between each fluid supply line and the ProDispense fluid panel.

• a bleed-type air shutoff valve on the air supply line to the fluid supplies.

The ProDispense fluid panels can be supplied by pressure tanks, pail or drum pumps, or cen­tral recirculating lines.

The fluid supply must be free of pressure spikes, commonly caused by a pump stroke
changeover. If necessary, install pressure regulators or a surge tank on the fluid supply out­lets. Note that this will also reduce the fluid supply pressure.

7 7

ti1361a

309301G 15

Installation

Mount the Fluid Panel(s)

Mount the fluid panel(s) on a flat, sturdy surface. Install 1/4” or M6 fasteners in the four 0.28”
mounting holes (C1) and secure the fluid panel (C) to the mounting surface. Connect a
ground wire (G) as instructed on page 20.

13.4”

(315 mm)

12.4”

(340 mm)

C1

G

8”

(203 mm)

9”

(229 mm)

C

ti1357a

FIG. 6

Connect the Air and Fluid Lines

Fluid Panel 244599 and 244600

Connect the fluid supply line (11) to the 1/2” npt(f) meter inlet. See FIG. 5. Connect a fluid dis-
pense line (12) to the 1/2” npt(f) solenoid outlet. Connect the other end to the dispense valve
(9).

Fluid Panel 244601 and 246837

Connect an air supply line (8) to the 1/4” npt(f) solenoid valve port. The air supply must be fil­tered to 10 micron to lengthen solenoid valve life.

Connect the fluid supply line (11) to the 1/4” npt(f) meter inlet. Connect a fluid dispense line
(12) to the 3/8” npt(m) outlet of the dispense valve on the fluid panel. Connect the other end to
the dispense valve (9).

16 309301G

Installation

Fluid Panel 246838

Connect an air supply line (8) to the 1/4” npt(f) solenoid valve port. The air supply must be fil­tered to 10 micron to lengthen solenoid valve life.

Connect the fluid supply line (11) to the meter inlet. Connect a fluid dispense line (12) to the
3/8” npt(m) outlet of the dispense valve on the fluid panel. Connect the other end to the dis­pense valve (9).

Fluid Panel 246839

Connect an air supply line (8) to the 1/4” npt(f) solenoid valve port. The air supply must be fil­tered to 10 micron to lengthen solenoid valve life.

Connect the fluid supply line (11) to the 3/4” npt(f) meter inlet. Connect a fluid dispense line
(12) to the 3/8” npt(m) outlet of the dispense valve on the fluid panel. Connect the other end to
the dispense valve (9).

Install the Remote Operator Station

Mount the operator station (D) in a convenient location for the operator. Secure it with No. 10
or M5 fasteners through the four 0.22” mounting holes (D1). Connect the cable (D2) to the
fluid panel junction box connector marked

20 ft. (6.1 m) station cable extension 198456 is available.

D1

D

D2

C.

C

ti1451a

FIG. 7

309301G 17

Installation

Mount the Controller

Mount the controller on a flat, sturdy surface as instructed below.

1. Loosen the four screws (A1), disconnect the two cables (A2, A3) and remove the control­ler cover (A).

2. Install 0.44” or M11 fasteners in the four 0.51” mounting knockouts (B1) and secure the
controller (B) to the mounting surface.

3. Reconnect the cables (A2, A3).

4. Install the controller cover (A) and secure it with the screws (A1).

FIG. 8

B1

A2

A3

A1

(441 mm)

(368 mm)

17.38”

14.5”

B1

B

TI1436a

8.5”

(216 mm)

11.3”

(287 mm)

A

TI1453A

FIG. 9

18 309301G

Installation

Connect the Cables and Power Cord

On the bottom of the controller, there are meter and solenoid cable connectors for three Fluid
panels. The row of connectors marked
row of connectors marked
cables as instructed below.

1B, 2B, and 3B are for meter cable connections. Connect the

1A, 2A, and 3A are for solenoid cable connections. The

1. Connect the solenoid cable (E) between controller connector
first fluid panel.

2. Connect the meter cable (F) between controller connector
fluid panel.

3. Repeat the cable connection for each of the fluid panels installed in the system (

1A and connector A on the

1B and connector B on the first

2A to A,

2B to B, etc.).

A knockout, marked , is provided for a customer supplied power input (P) cable with strain
relief or for wire conduit.

F

P

FIG. 10

309301G 19

E

TI1438a

Installation

Ground the System

The system must be properly grounded. Follow the instructions here and on page 6.

ProDispense Controller: Connect a ground wire (G1) to the grounding lug (H1) on the bottom

of the controller. Connect the other end of the ground wire to a true earth ground.

Fluid Panels: Connect a ground wire (G) to the grounding lug (H) on the junction box bracket.

Connect the other end of the ground wire to a true earth ground.

EasyKey

TM

123

456

789

0

.

H1

G1

H

G

TI1439a

FIG. 11

Feed Pumps or Pressure Pots: See your separate pump or pressure pot manual.

Air and Fluid Hoses: Use only grounded hose.

Fluid Supply Container: Ground the container according to your local code.

Solvent Pails Used when Purging: Ground pails according to your local code. Use conductive,

metal pails, placed on a grounded surface. Do not place pails on nonconductive surfaces,
such as paper or cardboard.

Check the Resistance

To reduce the risk of fire, explosion, or electric shock, the resistance between the ProBatch
components and true earth ground must be less than 1 ohm.

Have a qualified electrician check the resistance between each ProDispense component and
true earth ground. If the resistance is 1 ohm or greater, a different ground site may be
required. Do not operate the system until the problem has been corrected.

20 309301G

Installation

Connect a Printer (optional)

Connect the 5 ft. (1.52 m) printer cable (provided with printer kit 239873) between the printer
and controller printer connector marked . See F

Accessory Printer Cable 198669, 50 ft. (15.24 m) long, is available. Do not use longer cables.

IG. 5, page 15.

Connect to a PC or Alarm (optional)

The ProDispense system can be connected to a PC via Modbus RTU network protocol (6)
and/or audible alarms (7) as shown in F
instructions on page 26 to setup modbus station number and recipe selection. Contact your
Graco distributor for Modbus address mapping list.

IG. 12. Refer to field wiring chart, page 60. Follow

5

4

7

1

3

1

4

6

2

5

3

TI1454A

2

FIG. 12

309301G 21

Before Beginning Operation

• Check all fluid and air connections for correctness and tightness.

• Follow the Startup procedure on page 23.

Installation

22 309301G

Startup

Startup

Follow this procedure to start the ProDispense system for the first time (initial startup) or after
the system has been shut down.

1. Turn on the power. The ProDispense system startup screen will display while the system
is starting, then the Run screen (page 30) or System Setup screen (page 26) will appear,
depending on the mode of operation the system is in. For an explanation of operation
modes, see page 11.

FloSync

Startup screen

ProDispense: Rev. X.XX

2. If this is the initial startup, change to Setup Mode (page 25) and complete the setup pro­cedures.

3. Change to the Dispense Mode Run screen if you are not there already (page 29).

4. Make sure the dispense lines run into the proper reservoir.

5. Load the fluids (page 34).

Software revision

309301G 23