Graco 333587C User Manual

Operation

E-Flo

iQ Dispense

333587C

System

For dispensing and metering sealants, adhesives, and other medium to high viscosity fluids. For professional use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

See page 5 for system component information.

Important Safety Instructions

Read all warnings and instructions in this manual and in all related manuals before using the equipment. Save all instructions.

Contents

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

Dispense System Configurator . . . . . . . . . . . . . . . . 4

Dispense System Components. . . . . . . . . . . . . . . . 5

iQ Ram Supply Units . . . . . . . . . . . . . . . . . . . . . . 5

iQ Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . 6

Hose Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Dispense System Pressure . . . . . . . . . . . . . . . . . . . 7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Dispense System Component Identification . . . . 11

Tandem Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Supply Unit Component Identification . . . . . . . . . 13

iQ Ram Supply Unit . . . . . . . . . . . . . . . . . . . . . . 13

Power Disconnect . . . . . . . . . . . . . . . . . . . . . . . 14

Integrated Air Controls (AG) . . . . . . . . . . . . . . . 15

Integrated Air Line Accessories . . . . . . . . . . . . . 15

Advanced Display Module (ADM) . . . . . . . . . . . 16

ADM Display Details. . . . . . . . . . . . . . . . . . . . . . . . 17

ADM LED Status Descriptions . . . . . . . . . . . . . . 19

ADM Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

ADM Soft Keys. . . . . . . . . . . . . . . . . . . . . . . . . . 20

iQ Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

System Setup Screen . . . . . . . . . . . . . . . . . . . . 23

Style Definitions . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pump Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Heat Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Advanced Setup. . . . . . . . . . . . . . . . . . . . . . . . . 31

Connect Light Tower Assembly . . . . . . . . . . . . . 33

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 34

Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Tandem Priming when Changing Drums . . . . . . 37

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Ram Run Screen . . . . . . . . . . . . . . . . . . . . . . . . 38

Tandem Run Screen . . . . . . . . . . . . . . . . . . . . . 39

Run Screen Editing Mode . . . . . . . . . . . . . . . . . 42

Heat Run Screen . . . . . . . . . . . . . . . . . . . . . . . . 42

Job Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Events and Errors . . . . . . . . . . . . . . . . . . . . . . . 45

Pressure Relief Procedure. . . . . . . . . . . . . . . . . . . 46

Shutdown the System . . . . . . . . . . . . . . . . . . . . . . 48

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Pump Maintenance Screen 1. . . . . . . . . . . . . . . 49

Pump Maintenance Screen 2. . . . . . . . . . . . . . . 50

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Pump Diagnostics Screen . . . . . . . . . . . . . . . . . 51

Heat Diagnostics Screen . . . . . . . . . . . . . . . . . . 51

Pressure Diagnostics Screen . . . . . . . . . . . . . . . 52

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

View Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Troubleshoot Errors . . . . . . . . . . . . . . . . . . . . . . 53

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

USB Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Download Procedure . . . . . . . . . . . . . . . . . . . . . 64

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Job Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Automation Log . . . . . . . . . . . . . . . . . . . . . . . . . 65

System Configuration Settings . . . . . . . . . . . . . . 65

Custom Language File . . . . . . . . . . . . . . . . . . . . 65

Create Custom Language Strings . . . . . . . . . . . 66

Upload Procedure. . . . . . . . . . . . . . . . . . . . . . . . 66

Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Discrete Inputs/Outputs . . . . . . . . . . . . . . . . . . . 67

Job Cycle Timing Diagram . . . . . . . . . . . . . . . . . 69

Discrete Timing Diagram . . . . . . . . . . . . . . . . . . 70

Communications Gateway Module (CGM). . . . . 71

Prime Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Depressurize Diagram . . . . . . . . . . . . . . . . . . . . 87

System Enable - Remote Start Diagram . . . . . . 88

Acknowledge - Clear Error Diagram. . . . . . . . . . 88

Manual Crossover Diagram . . . . . . . . . . . . . . . . 89

Data Exchange Diagram . . . . . . . . . . . . . . . . . . 89

Power Reset Diagram . . . . . . . . . . . . . . . . . . . . 90

Heat CGM Timing Diagram . . . . . . . . . . . . . . . . 90

Heat Module Acknowledge-Clear Error Diagram 91 Heat Zone Acknowledge-Clear Error Diagram . . 91

Heat CGM Data Exchange Diagram . . . . . . . . . 92

Connection Details . . . . . . . . . . . . . . . . . . . . . . . 93

Gateway Setup Screens . . . . . . . . . . . . . . . . . . . 96

Integration Feedback Screens . . . . . . . . . . . . . . 99

Technical Specifications . . . . . . . . . . . . . . . . . . . 100

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . 101

End of Product Life . . . . . . . . . . . . . . . . . . . . . . 101

California Proposition 65 . . . . . . . . . . . . . . . . . . . 101

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 102

2 333587C

Related Manuals

Related manuals in English:

Manual Description

333585 iQ Dispense Valves, Instructions-Parts

333586 E-Flo iQ Dispense System, Installation-Parts

3A6321 ADM Token In-System Programming

312493 Light Tower Kit Instructions

3A1244 Graco Control Architecture Module

3A6482 APD20 Advanced Precision Driver

313138 Supply System Communications Gateway

Module Installation Kit

Related Manuals

333587C 3

Dispense System Configurator

The E-Flo iQ dispense system provides the flexibility to configure a complete system to meet your specific needs. This includes offering multiple combinations of the following components:

• iQ Ram Supply Units

• iQ Dispense Valves

• Hoses and connectors

For dispense system component information, see Dispense System Components on page 5.

First,

Second

and

Third

Digit

EQC

E-Flo iQ

System

Fourth

Digit

Revision

Fifth Digit Sixth Digit

Seventh

Digit

Platen

Single or

Tandem

S Single H Heated Y Yes T Tan-

dem

Heat

Option

A Ambient

Valve

Option

Eighth Digit

Ram Supply Unit Options

Size

A 3 in.

B 3 in.

C 3 in.

D 3 in.

F 3 in.

G 3 in.

H 3 in.

J 3 in.

K 6.5 in.

M 6.5 in.

N 6.5 in.

P 6.5 in.

Drum

Size

20 L

(5 Gal) CS EPDM

20 L

(5 Gal) CS

20 L

(5 Gal) CM EPDM

20 L

(5 Gal) CM

200 L

(55 Gal) CS EPDM

200 L

(55 Gal) CS

200 L

(55 Gal) CM EPDM

200 L

(55 Gal) CM

200 L

(55 Gal) CS EPDM

200 L

(55 Gal) CS

200 L

(55 Gal) CM EPDM

200 L

(55 Gal) CM

Pump

Material

Seal

Material

Neo-

prene

Neo-

prene

Neo-

prene

Neo-

prene

Neo-

prene

Neo-

prene

Ninth Digit

Fieldbus

Option

A Ether-

Net/IP

B PROF-

INET

C PROFI-

BUS

D Devi-

ceNet

N None

Digits Ten

through

Seventeen

Hose

Options for

Tandem

Hoses (Dig-

its 10-13)

and Supply

Hoses (Dig-

its 14-17)

(See Hose

Options on

page 6)

Digits

Eighteen

through

Twenty Seven

Valve Options

(See the iQ

Dispense

Valves Instruc-

tions - Parts

manual for

valve model

options)

KEY:

CS = Carbon Steel Severe Duty

CM = Carbon Steel MaxLife

4 333587C

Dispense System Components

NOTE: The Heated option for the E-Flo iQ system is for warm melt applications with a maximum temperature of 70° C

(158° F).

iQ Ram Supply Units

Check the identification plate (ID) on the back of the ram post near the Power Junction Box (AJ) for the seven-digit part number of the iQ ram supply unit. Use the following matrix to define the construction of the unit, based on the seven digits.

For example, Part No. EZC2422 represents an electric supply unit (EZ), a carbon steel Check-Mate 200 Severe Duty dis-

placement pump (C2), a 3 in. ram (4), a 5-gallon platen with a neoprene seal (2), and an ADM (2).

The digits in the following matrix do not correspond to the reference numbers in the Parts drawings and lists.

EZ C2 4

First

and

Second

Digit

(Electric

Supply

System)

Third and Fourth Digit Fifth Digit

Check-Mate Pump Options Ram Options

Pump

Size

Material

C1 200cc CS Ambient

C2 200cc CS Heated

C3 200cc CM Ambient

C4 200cc CM Heated

Heated/

Ambient

<70° C 2 D200 3 in.

<70° C 4 D60 3 in.

Name Size

1 D60 3 in.

3 D200s 6.5 in.

5 D200 3 in.

6 D200s 6.5 in.

Drum

Size Style

20 L

(5 Gal) Ambient 1

200 L

(55 Gal) Ambient 2

200 L

(55 Gal) Ambient 3

Heated

20 L

(5 Gal)

200 L

(55 Gal)

200 L

(55 Gal)

<70° C 4

Heated

<70° C 5

Heated

<70° C 6

Sixth Digit

Platen and Seal Options

Platen

(5 Gal) CST/AL Neoprene

(5 Gal) CST/AL EPDM

200 L

Platen

Size

Material

20 L

(55

Gal) AL Neoprene

(55

Gal) AL Neoprene

(55

Gal) AL EPDM

(55

Gal) AL EPDM

Material Wiper

Seventh

Digit

Interface

Options

Seal

Single

Double

Heated/

Ambient Interface

Ring Ambient 2 ADM

Heated

Ring

Ring Ambient

Ring

Ring Ambient

Ring

Ring Ambient

Ring

<70° C 4No ADM

Heated

<70° C

Heated

<70° C

Heated

<70° C

KEY:

CS = Carbon Steel Severe Duty

CM = Carbon Steel MaxLife

CST/AL = Carbon Steel/Aluminum AL = Aluminum

333587C 5

Dispense System Components

iQ Dispense Valves

Check the identification plate on the valve for the ten-digit part number of the iQ dispense valve. Use the following matrix to define the construction of the valve, based on the ten digits. For example, Part No. V25AB060BA represents a valve (V) with 1/4 in. NPT inlet ports (25), NPT tip (A), ball/seat type (B), 60 mm outlet block length (060), solenoid (B), with no heat (A).

First Digit

Second and

Third Digit

Fourth Digit Fifth Digit

Size Tip Size Type

Sixth, Seventh,

and Eighth Digit

Outlet Block

Length

Ninth Digit Tenth Digit

Action Heat

Valve

1/4 in. NPT

A 1/4 in. NPT B Ball/Seat 000 NA B

Mounted

A None

Solenoid

60 mm

C 0.6 mm S Snuff-Back 060

*Remote Solenoid

B Heated

Block

D 1.0 mm T Tip Seal 200

200 mm

F 1.3 mm

G 1.7 mm

* Remote solenoid supplied by customer.

NOTE: Refer to the iQ Dispense Valves Instructions-Parts manual for additional information about iQ Dispense Valves. See Related Manuals on page 3

Hose Options

Working

Pressure

Temperature

Rating

4000 psi (28

MPa, 276 bar) at

-65° F - 400° F (101° C - 204°

Part No. JIC Dash Size Length Heat

04 19M404 -10 (5/8 in, 15.9 mm) 6 ft Heated

05 19M405 -10 (5/8 in, 15.9 mm) 10 ft Heated

06 19M406 -10 (5/8 in, 15.9 mm) 15 ft Heated

07 19M407 -10 (5/8 in, 15.9 mm) 20 ft Heated

08 19M408 -10 (5/8 in, 15.9 mm) 25 ft Heated

11 19M411 -12 (3/4 in, 19.0 mm) 6 ft Heated

12 19M412 -12 (3/4 in, 19.0 mm) 10 ft Heated

13 19M413 -12 (3/4 in, 19.0 mm) 15 ft Heated

14 19M414 -12 (3/4 in, 19.0 mm) 20 ft Heated

15 19M415 -12 (3/4 in, 19.0 mm) 25 ft Heated

16 19M416 -16 (1 in, 25.4 mm) 6 ft Heated

17 19M417 -16 (1 in, 25.4 mm) 10 ft Heated

18 19M418 -16 (1 in, 25.4 mm) 15 ft Heated

19 19M419 -16 (1 in, 25.4 mm) 20 ft Heated

20 19M420 -16 (1 in, 25.4 mm) 25 ft Heated

Working

Pressure

Temperature

Rating

4000 psi (28

MPa, 276 bar) at

-65° F - 212° F (-54° C - 100°

3000 psi (21

MPa, 207 bar) at

213° F - 400° F

(101° C - 204°

Part No. JIC Dash Size Length Heat

65 17K265 -10 (5/8 in, 15.9 mm) 6 ft Ambient

66 17K266 -10 (5/8 in, 15.9 mm) 10 ft Ambient

67 17K267 -10 (5/8 in, 15.9 mm) 15 ft Ambient

68 17K268 -10 (5/8 in, 15.9 mm) 20 ft Ambient

69 17K269 -10 (5/8 in, 15.9 mm) 25 ft Ambient

72 17K272 -12 (3/4 in, 19.0 mm) 6 ft Ambient

73 17K273 -12 (3/4 in, 19.0 mm) 10 ft Ambient

74 17K274 -12 (3/4 in, 19.0 mm) 15 ft Ambient

75 17K275 -12 (3/4 in, 19.0 mm) 20 ft Ambient

76 17K276 -12 (3/4 in, 19.0 mm) 25 ft Ambient

77 17K277 -16 (1 in, 25.4 mm) 6 ft Ambient

78 17K278 -16 (1 in, 25.4 mm) 10 ft Ambient

79 17K279 -16 (1 in, 25.4 mm) 15 ft Ambient

80 17K280 -16 (1 in, 25.4 mm) 20 ft Ambient

81 17K281 -16 (1 in, 25.4 mm) 25 ft Ambient

00 No Hose N/A N/A N/A

6 333587C

Dispense System Pressure

Due to factors such as the dispense system design, the material being pumped, and the flow rate, the dynamic pressure will not reach the rated working (stall) pressure of the system.

Pump Working (Stall) Pressure Max Dynamic (Run) Pressure

Lower Size psi bar MPa psi bar MPa

Dispense System Pressure

Check-Mate

200CS/CM

4,000 290 29.0 3,905 269 26.9

333587C 7

Warnings

DANGER

WARNING

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 symbols refer 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.

SEVERE ELECTRIC SHOCK HAZARD

This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• This equipment must be grounded. Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

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

• Do not put your hand over the fluid outlet.

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

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

8 333587C

Warnings

WARNING

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure and disconnect all power sources.

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 sparking).

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

• Never spray or flush solvent at high pressure.

• 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.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are anti-static or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical 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.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

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

333587C 9

Warnings

WARNING

SPLATTER HAZARD

Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen, splatter may occur.

• Use minimum air pressure when removing platen from drum.

TOXIC FLUID OR FUMES HAZARD

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

• Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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.

10 333587C

Dispense System Component Identification

*Circular Electrical Connection

*Square Electrical Connection

*Circular Electrical Connection

*Square Electrical Connection

Dispense System Component Identification

NOTE: Figure 1 shows a typical E-Flo iQ dispense

system installation with an iQ ram supply unit, hoses, connectors, and an iQ dispense valve. Some installations may require only one hose depending on the needs of the system.

FIG. 1: E-Flo iQ Dispense System

Key:

A iQ Ram Supply Unit B iQ Dispense Valve C First Hose from Supply System D Second Hose to iQ Dispense Valve E Ram Supply System Fitting to First Hose

F First Hose Fitting to Second Hose G Second Hose Fitting to Swivel H Swivel Fitting J Swivel to Valve Fitting

* Applies to heated hoses only.

333587C 11

Dispense System Component Identification

*Circular Electrical Connection

*Square Electrical Connection

*Circular Electrical Connection

*Square Electrical Connection

*Circular Electrical Connection

Tandem Ram

NOTE: FIG. 2 shows a typical E-Flo iQ dispense system

installation with a Tandem iQ ram supply unit, hoses, connectors, and an iQ dispense valve. Some installations may not require Supply Hose 2 (D) to iQ Dispense Valve (B) depending on the needs of the system.

FIG. 2: Tandem E-Flo iQ Dispense System

Key:

A iQ Ram Supply Unit 1 B iQ Dispense Valve C Supply Hose 1 D Supply Hose 2 E Tandem Block Fitting to Supply Hose 1 F Supply Hose 1 Fitting to Supply Hose 2 G Supply Hose 2 Fitting to Swivel H Swivel Fitting J Swivel Fitting to Valve K iQ Ram Supply Unit 2

L Tandem Hose 1 M Tandem Hose 2 N Ram Supply Unit 1 Fitting to Tandem Hose 1 P Ram Supply Unit 2 Fitting to Tandem Hose 2 R Tandem Block S Ball Valves

* Applies to heated hoses only.

12 333587C

Supply Unit Component Identification

*AX

*ZA

Ambient System

Heated System

iQ Ram Supply Unit

D200 3 in. Dual Post Shown

Supply Unit Component Identification

FIG. 3: iQ Ram Supply Unit

Key:

AA Ram Assembly AB Electric Driver AC Displacement Pump AD Platen AE Fluid Check Valve AF Advanced Display Module (ADM) AG Integrated Air Controls (see Figure 6) AH Platen Bleed Port AJ Power Junction Box AK Power Junction Box Switch AL Platen Lift Rod AM Pump Bleed Valve AN Wet Cup

333587C 13

AR Air Line (not supplied) AS Air Line Drain Valve (not supplied) AT Air Filter (not supplied) AU Bleed Type Air Shutoff Valve (required) (not supplied) AV Level Sensors AW Outlet Pressure Transducer AX *Heat Control Box AY Platen Valve Kit (optional) AZ Disconnect Switch (See Power Disconnect on page 14) ZA *Pump Heater ZB Recirculation Hose ZC Pump Relief Valve

* Parts on heated systems only.

Supply Unit Component Identification

Heated System

Ambient System

Power Disconnect

Every E-Flo iQ Dispense System has a red and yellow Disconnect Switch which shuts off power to the entire system. The location of the switch is different for ambient and heated systems. See Figure 4.

On ambient systems, the Disconnect Switch (AZ) is located on the Power Junction Box (AJ).

On heated systems, the Disconnect Switch (AZ) is located on the Heat Control Box (AX). Heated systems also have a red and black Power Junction Box Switch (AK) located on the Power Junction Box (AJ). The Power Junction Box Switch (AK) removes power to everything EXCEPT heat. The Disconnect Switch (AZ) removes power to the entire system, including heat.

. 4. Power Disconnect

14 333587C

Supply Unit Component Identification

1/4 NPT Plug

Integrated Air Controls (AG)

The integrated air controls include:

• Main Air Slider Valve (BA): turns air on and off to

the system. When closed, the valve relieves pres-

sure downstream.

• Ram Air Regulator (BB): controls Ram up and

down pressure and blowoff pressure.

• Ram Director Valve (BC): controls Ram direction.

• Exhaust Port with Muffler (BD)

• Blowoff Button (BE): turns air on and off to push

the Platen (D) out of an empty drum.

Integrated Air Line Accessories

See Figure 3.

• Air Line Drain Valve (AS): removes condensed

water from the air line. Not supplied.

• Air Line Filter (AT): removes harmful dirt and mois-

ture from the compressed air supply. Not supplied.

• Second Bleed-type Air Valve (AU) (required): iso-

lates Air Line accessories for servicing. Locate upstream from all other Air Line accessories. Not supplied.

. 5. Integrated Air Control Module

333587C 15

Supply Unit Component Identification

Advanced Display Module (ADM)

Front and Rear Views

FIG. 6: ADM Component Identification

Key: CA Startup/Shutdown

Starts up or shuts down the system. Toggles between Active and Inactive system.

CB System Status Indicator LED CC Pump Soft Stop

Stops all pump processes and disables the pump. Also stops all heating processes and disables the heat. This is not a safety or emergency stop.

CD Soft Keys

Defined by the icon on the screen next to the soft key. Performs the specific operation for that icon when pressed.

CE Cancel

Cancels a selection or number entry while in the process of entering a number or making a selection. Cancels the pump processes. Exits a screen without saving changes.

CF Enter

Select to update a field, accept a selection or value, acknowledge an event, enter a screen, and toggle selected items.

CG Lock/Setup

Toggles between Run screens and the iQ Menu.

CH Directional Keypad

Navigate within a screen or to a new screen.

CJ Numeric Keypad

Input numeric values.

CK Part Number Identification Label CL USB Interface CM CAN Cable Connection

Power and communication.

CN Module Status LEDs

Visual indicators to show the status of the ADM.

CP Token Access Cover

Access cover for blue software token.

CR Battery Access Cover CS Light Tower Connection

NOTE: If using a Tandem system, the AMD is only

included with the iQ Ram Supply Unit 1 (A)

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ADM Display Details

Blue Token

Date and Time

Navigation Arrows

Screen Menu

Status

System Mode

ADM Display Details

Use the Blue Token

The E-Flo iQ system includes a blue token that must be inserted into the ADM to initiate the E-Flo iQ software.

1. Remove the ADM from the bracket.

2. Use a hex wrench to remove the screws from the token access cover (CP).

Five seconds after the E-Flo iQ blue token is inserted into the ADM, the Graco power up screen switches to the E-Flo iQ power up screen. This screen remains on while the ADM runs through initialization and establishes communication with other modules in the system.

Menu Bar

The Menu Bar appears at the top of each screen (the following image is only an example).

3. Remove the access cover (CP).

4. Insert and press the blue software token firmly into the slot.

5. Replace the token access cover (CP) and insert and tighten the screw that holds it in place.

6. Mount the ADM on the bracket.

Power Up Screen

This screen appears when the ADM is powered up.

Date and Time

The date and time are always displayed in one of the following formats. The time is always displayed as a 24-hour clock.

•

DD/MM/YY HH:MM

•

YY/MM/DD HH:MM

•

MM/DD/YY HH:MM

Navigation Arrows

The left and right arrows are only visible when screen navigation is allowed.

333587C 17

ADM Display Details

Screen Menu

The screen menu indicates the currently active screen, which is highlighted. It also indicates the associated screens that are available by scrolling left and right.

System Mode

The current system mode is displayed in the lower left of the Menu Bar. System modes include: Pump Active, Pump Inactive, Job in Cycle, Pre-charge, Heat Inactive, Heat Off, Heat Soak, Heat at Temp, Heat in Setback.

Status

The current system status is displayed in the lower right of the Menu Bar.

Alarm/Deviation

The current system error is displayed in the middle of the Menu Bar. There are four possibilities.

Icon Function

No Icon No information or no error has occurred

Advisory

Deviation

Press on any Run screen to switch to the iQ Menu screens. If the system has a password lock, the Password screen is displayed. If the system is not locked (password is set to 0000), iQ Menu Screen 1 is displayed. Refer to iQ Menu on page 22 for additional information.

Press on any Setup screen to return to the Run screen.

Press the Enter soft key to activate the editing function on any screen.

Press the Exit soft key to exit the editing function and save any changes.

Use the other soft keys to select the function adjacent to them.

Use to exit a screen. Using this key while in editing mode will exit the screen without saving changes.

Use the keys on the ADM to move through the settings on a screen or drop down menu and to scroll through multiple screens on the right side of the display.

Alarm

Soft Keys

Icons next to the soft keys indicate which mode or action is associated with each soft key. Soft keys that do not have an icon next to them are not active in the current screen. See Advanced Display Module on page 16 and ADM Soft Keys on page 20.

NOTICE

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

Navigating the Screens

There are two types of screens:

Run screens control operations and display system status and data.

Setup screens control system parameters and advanced features. These screens are accessed through the iQ Menu.

Use the key to choose a field to update, to make a selection, to save a selection or value, to enter a screen, or to acknowledge an event.

Set Password

You can set a password to protect access to some selections on the iQ Menu screens. See iQ Menu on page 22. It can also be used when changing from Remote to Local control mode to protect against inadvertently changing control modes. To set or remove the password, select Advanced from iQ Menu 2. See Advanced Setup Screen 1 on page 31.

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ADM LED Status Descriptions

LED Conditions Description

System Status Green Solid Run Mode, System On

Green Flashing Setup Mode, System On Yellow Solid Run Mode, System Off Yellow Flashing Setup Mode, System Off

USB Status (CL) Green Flashing Data recording in progress

Yellow Solid Downloading information to USB Green and Yellow Flashing ADM is busy, USB cannot transfer information

when in this mode

ADM Status (CN) Green Solid Power applied to module

Yellow Flashing Active Communication Red Steady Flashing Software upload from token in progress Red Random Flashing or Solid Module error exists

ADM Icons

ADM Display Details

Icon Function

Alarm - See Troubleshooting, page 53 for more information.

Deviation - See Troubleshooting, page 53 for more information.

Advisory - See Troubleshooting, page 53 for more information.

Target for primary pressure and flow. Only displayed in priming mode.

Communication Error

No issues found with parameter or setting value

Missing or unexpected parameter or setting value

System is processing request (animated)

Pump position (animated). The pump coupler will move up and down in real time and indicate the approximate position of the pump. The pump will need to complete one full down stroke upon each power cycle before the position is valid.

Icon Function

Zone setpoint temperature showing the temperature the zone heats too when the heat is turned on.

Zone setback temperature showing the setback the zone goes to when the heat is in setback mode.

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ADM Display Details

ADM Soft Keys

Icon Function

Pump Operation Icon

Green: Start the Pump

Inverted Green: Stop the Pump

Red with Border (enabled): Indicates

that the pump cannot be started due to an alarm.

Red with No Border (not enabled):

Indicates that the system is not enabled and the pump cannot be started.

Yellow: Indicates that the pump has an active alarm but still allows the valve and platen to be depressurized. The pump can still be primed only if it is a “pump not primed” alarm.

Enter or exit editing mode for a particular screen.

Access the Style Definitions screens.

Icon Function

Access the Advanced System Setup screens.

Access the Maintenance function.

Access the Fieldbus Gateway Setup screens.

Access the Integration Feedback screens.

Globalize selection. Apply a style setting to all of the styles in Style Definitions or a heat setting to all of the heat zones in Heat Settings.

Confirm globalizing a setting.

Cancel globalizing a setting.

Access a keyboard screen to create or change a style name.

Reset offsets to zero when calibrating pressure transducers.

Access the Pump Setup screens.

Access the Heat Setup screens.

Access the Diagnostics function.

Access the Events logs.

Access the Errors logs.

Access the Job Log.

Access the Troubleshooting function.

Access the System Setup screen.

Tandem systems only. Toggle between Pump 1 and Pump 2.

Local / Remote control toggle.

Pump is locked in remote control via fieldbus interface.

Enter or exit pump priming mode. A “1” or “2” will show on the icon in Tandem systems to indicate which pump will be primed.

Enter or exit drum depressurization mode. (If equipped with optional fluid solenoid.) A “1” or “2” will show on the icon in Tandem systems to indicate which pump will be depressurized.

Enter or exit valve depressurization mode.

Turn heat zones on and off.

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Icon Function

Place all heat zones into setback and out of setback.

Enter or exit manual pump movement mode.

Move to the top.

Move upward.

Move downward.

Move to the bottom.

Reset Cycle Counter.

Toggle between lifetime and resettable.

ADM Display Details

Calibrate.

Continue.

Previous screen.

Search.

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iQ Menu

The iQ Menu screens provide access to settings that help to ensure the proper operation and maintenance of the system. These functions can be performed when the ADM is either in Active or System OFF Mode.

1. Provide power to the system to turn on the ADM.

2. Press on the ADM from any Run screen to go to the iQ Menu screens.

iQ Menu Screen 1

If you set a password, the menu will be displayed with red locks above the menu selections with parameters that can be changed. Enter your password when prompted to access these screens.

The selections that do not have a red lock have information that can be viewed but not changed and would not require a password. See Advanced Setup Screen 1 on page 31 for information about setting a password.

iQ Menu Screen 2

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Setup

To prevent personal injury from pressurized fluid such as skin injection or splashing fluid, make sure that all components in your system are rated to the maximum pressure the system is capable of attaining. All components must be rated for maximum pressure even if the pump is operated below maximum pressure.

NOTICE

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

NOTICE

To prevent damage to components in the system, all components must be rated to the maximum pressure the system is capable of attaining.

Setup

Use the drop down menu to select the type of system as either Ram or Tandem.

NOTE: Changing the system type resets the pumps in the system.

When you select Ram, the only action required at this screen is if the pump has a heat module installed. Press

It is important to set up the parameters of your system before operating the E-Flo iQ system. These are accessed through the iQ Menu. After starting up the

ADM, press the key from the Run screen to go to the iQ Menu screens. Refer to iQ Menu on page 22.

System Setup Screen

Press the soft key at the iQ Menu screen 2 to access the System Setup screen.

the key in the Heat box to configure it for heat.

All other fields are automatically set when the blue token is inserted on an installed system. The System is displayed as Ram. The box below the iQ icon next to the System field indicates that it is an E-Flo iQ system.

The Pump shows as Installed. The Serial Number should match the serial number printed on the driver ID tag. As a backup to the driver serial number, the serial number of the current board will be displayed instead. The serial number for the control board is also displayed in the detailed software status screens. See Advanced

Setup Screen 4 on page 33.

When you select Tandem, a field for the second pump

is displayed on the screen showing Uninstalled. Select Installed from the drop down menu.

Press the soft key to enter editing mode.

333587C 23

Setup

When you select installed, the Serial Number will be automatically populated to match the serial number printed on the driver ID tag on Pump 2.

If Pump 2 has a heat module installed, press the key in the Heat box to enable it.

1. Press the soft key to enter editing mode.

2. Enter a Style identifier from 0-16. This is the designation the system uses for the type of dispensing based on how you define the style here.

3. Bead is automatically selected as the Style Mode.

Press the soft key to exit editing mode.

Style Definitions

Press the soft key at the iQ Menu screen 1 to access the Style Definitions setup screens. This function allows you to identify the style for dispensing material and configure the settings of the style.

NOTE: Before accessing these settings, you need to select if your system is running in Local or Remote control mode. See Control Modes on page 40.

Style Screen 1 - Style Definition

NOTE: When in Local control mode, you cannot select

Source at this screen, but you can still enter Values. The Source fields can be changed in Remote control mode.

4. From the Source drop-down menus, select the Pre-Charge and Flow Rate as either Local or Fieldbus. When you select Local, enter the appropriate corresponding number in the Value column. A Fieldbus selection does not require a value.

NOTE: The optional Communications Gateway Module (CGM) is required to use fieldbus.

5. Press the soft key to save your changes and exit editing mode.

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Setup

Name the Style

You can also name the Style. While still in Style screen

1, Press the soft key to advance to a keyboard screen to create or change the name of the style based on your needs.

NOTE: The Style identifier is a system requirement. The Style Name option is not required. It is intended as a user-defined description for the application of each dispensing style. An example might be: Trunk Hem. The maximum length is 11 characters.

Apply a Style Setting Globally

While still in Style screen 1, pressing the globalize soft key applies a style setting across all of the styles. A message will appear prior to completing the change.

Press the soft key to complete applying the

selected parameter. Press the soft key to cancel the globalization.

Use the and soft keys to scroll the keyboard to select letters.

The soft key changes back and forth from lower and upper case.

The soft key erases everything you have typed.

The soft key is the backspace to delete one letter at a time.

Press the soft key to save the name and exit the

keyboard screen. Press the soft key to exit the screen without saving. Both actions return you to Style screen 1.

Style Screen 2 - Delays

Use the ADM Directional Keypad (CH) to navigate to Style screen 2.

Set the valve and motor On and Off delays.

333587C 25

Setup

Style Screen 3 - Integration

Use the ADM Directional Keypad (CH) to navigate to Style screen 3.

NOTE: You can only make changes to this screen in Remote mode. In Local mode, the screen appears as shown below.

1. In Remote mode, press the soft key to enter editing mode.

Pump Settings

Press the soft key at iQ Menu screen 1 to access the Pump setup screens. This function allows you to configure the operating settings for the pump and drum depending on the mode of operation.

Pump Screen 1 - Pump Settings

The following description is the same for both Ram and Tandem selections. For Tandem, Pump 1 and Pump 2 are shown in the Menu Bar. Use the ADM Directional Keypad to select each pump for configuration. The Tandem screen is shown below.

2. Set Style Enable and Go Signal fields to either Discrete or Fieldbus depending on your requirements. It is recommended that you select Discrete for the Go Signal to avoid start and stop delays.

3. Set Dispense Complete to Discrete, Fieldbus, or Timer. If you select Timer, enter the number of seconds for the timer from 0-999.

4. Press the soft key to save your changes and exit editing mode.

26 333587C

NOTE: in Tandem systems, it is recommended that both pumps should be configured with identical pimp settings.

Follow these steps to configure the operating settings for each pump in a Tandem system or a single pump in a Ram system.

1. Press the soft key to enter editing mode.

2. Configure the Over Pressure setting by entering a pressure limit.

Setup

3. Select Alarm, Deviation, or None from the drop down menu for the Error Type.

NOTE: The Over Pressure error will be triggered if the limit is exceeded for 1 second. An Alarm sends an error message and deactivates the system. A Deviation sends an error message but the system continues to operate.

4. The Pump Volume shows the pump size in cc and can be changed in editing mode if needed.

Pump Screen 2 - Drum Settings

Use the ADM Directional Keypad (CH) to navigate to Pump screen 2.

As with the first pump screen, Pump Screen 2 shows both pumps in the Menu Bar in a Tandem system as shown below.

NOTE: Pressure transducers are calibrated at the factory, but calibration may be necessary after extended use. The pump transducer offset and the valve transducer offset are shown in the Calibrate section.

5. Relieve pressure in the system using Valve depressurization. See Depressurization Mode on page 40.

6. Press the soft key to automatically reset the offsets to zero. You can also manually change the values and select minus or plus from the drop down menus as appropriate for the calibration.

7. Press the soft key to save your changes and exit editing mode.

The steps for configuring the settings are the same for both Ram and Tandem.

1. Select the soft key to enter editing mode.

2. Select the error type from Alarm, Deviation, and None for the Not Primed Event. This is triggered when a drum is replaced and the pump has not yet been primed. If Alarm is selected, the pump must be primed after replacing a drum and before returning to normal operation.

3. Enter the length of the pump Prime Timer between 1 and 9 minutes. Five minutes is the default value. See Priming Mode on page 41.

4. By default, the Low Sensor box is unchecked

(disabled). Press the key to enable the drum low deviation.

333587C 27

Setup

5. By default, the Empty Sensor box is checked

(enabled). Press the key to disable the drum empty alarm if needed.

NOTE: The Low Sensor and Empty Sensor errors are triggered 3 seconds after reaching a critical level.

6. Press the key to enable the Platen Valve setting. This must be enabled to be able to change flow rates between dispenses and to allow platen depressurization. This setting only applies to an E-Flo iQ system that has a Platen Valve installed.

7. Auto Depressurization allows the platen valve to open and depressurize the system back to the platen based on this setting. Enter a value between 1 and 24 hours.

NOTE: The Platen Valve must be enabled on the screen to trigger Auto Depressurization. If heat is installed, it places the system into setback. A zero value in the field disables this feature.

8. Press the soft key to save your changes and exit editing mode.

Heat Settings

NOTE: For Tandem systems, read this section first, then

refer to Tandem Heat Setup Screen 1 on page 29.

The heat zone number in the first column corresponds to the connector and heat zone on the Automatic Multi-Zone (AMZ) heat control. For example, heat zone number 4-7 corresponds to connector 4 and heat zone

7. For information about the AMZ, refer to the E-Flo iQ Supply Systems, Installation-Parts manual. See Related Manuals on page 3.

1. Press the soft key to enter editing mode.

2. The Zone Type column refers to the system component that the zone is heating. Select a zone type from the drop down menu for each zone. The options available in the drop down menu are:

•Hose

•Valve

• Manifold

• PGM (Precision Gear Motor)

• Flowmeter

• Press Reg (Pressure Regulator)

•Other

NOTE: The correct zone type has to be selected for the zone to properly heat. If an incorrect zone type is selected, errors, overshoots, and long heat up times can occur.

Press the soft key at the iQ Menu screen 1 to access the Heat setup screens. These screens allow you to configure the operating settings for the Heat function.

NOTE: Heat must be selected at the System Setup screen for these selections to be available. See the

System Setup Screen on page 23.

Heat Setup Screen 1

NOTE: There are two other zone types: platen and

pump. The zones for these are always 4-8 and 5-9, respectively, as shown above.

3. Enter a temperature for the zone setpoint

temperature ( ) column. This is the setpoint that the zone heats to when the heat is turned on. The temperature units can be changed from °C to °F in the Advanced settings screens. See Advanced Setup Screen 2 on page 32.

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Setup

4. Enter a temperature for the zone setback

temperature ( ) column. This is the setback that the zone goes to when the heat is in setback. The temperature units can be changed from °C to °F in the Advanced settings screens. See Advanced

Setup Screen 2 on page 32.

NOTE: If you change a setpoint temperature to a value

below the current setback temperature, that value becomes the new setback temperature. If you increase a setback temperature to a value above the current setpoint temperature, that value becomes the new setpoint temperature.

5. The column on the right side of the zone setback temperature column is for enabling the zone. Use

the key to enable zones.

NOTE: When enabled, the zone will be displayed on the Heat Run screen. When the box is disabled, the zone will not be displayed on the Heat Run screen and the errors for that zone will be ignored. See Heat Run

Screen on page 42.

Tandem Heat Setup Screen 1

Read all of Heat Setup Screen 1 starting on page 28 before reading this section.

The Heat Setup screens for Ram and Tandem are the same in appearance except Tandem has an additional column to the right for the second pump.

One of the advantages of a Tandem system is continuous operation if a pump needs to be shut down for any reason, such as changing a drum of material. In a heated system, it is equally important to maintain heat for the entire system when one of the pumps is shut down.

NOTE: Heated systems have a red and black Power Junction Box Switch (AK) that removes power to everything EXCEPT heat on the ram supply unit. This allows a ram supply unit to continue to heat the system with the power to the ram turned off. See Power Disconnect on page 14 for more information.

The Tandem Heat setup screen 1 allows you configure how you want heat to be controlled for the entire system.

6. Press the soft key to save your changes and exit editing mode.

Apply a Heat Setting Globally

While still in Heat Setup screen 1, press the globalize

soft key to apply a setpoint or setback heat setting

across all of the heat zones.

A message will appear prior to completing the change.

Press the soft key to complete applying the

selected parameter. Press the soft key to cancel the globalization.

Heat 1 in the Menu Bar is for the Heat Control Box (AX) on the Pump 1 ram and Heat 2 is for the Heat Control Box (AX) on the Pump 2 ram. The heat control box on each ram controls heat to its pump, platen, and the hose that runs from the pump to the Ball Valve (S) on the Tandem Block (R).

Since all components from the Tandem Block R) to the Dispense Valve (B) are shared by both pumps and need to be heated continuously while the system is in operation, you can designate one pump to control the shared components at this screen.

NOTE: The cables for heat from the shared components must be connected to the Heat Control Box (AX) on the designated pump.

333587C 29

Setup

In this example, the heat control box on Pump 1 (P1) is the one selected to heat the shared components running from the Tandem Block (R) to the Dispense Valve (B).

1. Press the soft key to enter editing mode.

2. Configure your Zone Type and setpoint and setback

temperatures as described in Heat Setup Screen 1 on page 28.

3. Use the key to enable the zones under P1 that will control the heat for the entire system.

NOTE: Since P1 will be the heat control for the shared components, you need to enable the same zones for P2 while at the Heat 1 screen. This sets P1 to control the heat for its pump, platen, and hose while also controlling the heat for the components that P1 and P2 share.

4. Use the key to enable the zones under P2 that are enabled under P1.

5. Use the ADM Directional Keypad (CH) to move to Heat 2 in the Menu Bar.

6. Use the key to enable only the pump and platen zones and the zone for the hose that runs from the ram supply unit for P2 to the Ball Valve (S) on the Tandem Block (R) since all others are controlled by P1.

Heat Setup Screen 2 - Heat Soak

Use the ADM Directional Keypad (CH) to navigate to Heat screen 2. This screen is the same for Ram and Tandem except for the additional Heat 2 selection in the Menu Bar. Make sure you configure heat soak time for both Heat 1 and Heat 2 in a Tandem system.

Press the soft key to enter editing mode.

The heat soak time in the far right column is the amount of additional time that the heat zone needs to ensure that the material is heated evenly throughout after the zone is up to temperature. Enter a time in minutes.

NOTE: Three minutes is the minimum amount of heat soak time needed to make sure that the dispense valve is completely up to temperature.

The Zone Types can only be changed at the Heat Setup screen 1. See Heat Setup Screen 1 on page 28.

Press the soft key to save your changes and exit this screen.

7. Press the soft key to save your changes and exit editing mode.

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