Graco 3A2894F User Manual

Setup-Operation
ExactaBlend
AGP Advanced Glazing Proportioner
Not approved for use in explosive atmospheres or hazardous locations.
See page 4 for model information, including maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
3A2894F
EN
S100 Shown

Contents

Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Base Machines . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hose Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Important Isocyanate (ISO) Information . . . . . . . . 8
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 8
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8
Keep Components A and B Separate . . . . . . . . . 8
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 9
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9
Component Identification . . . . . . . . . . . . . . . . . . . 10
S100 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
U100 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
P100 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Display Module (DM) . . . . . . . . . . . . . . . . . . . . . 14
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . 17
Integrated Air Controls . . . . . . . . . . . . . . . . . . . 18
Fluid Control Module (FCM) . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Base Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 46
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . 49
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjust Packing Nuts . . . . . . . . . . . . . . . . . . . . . 52
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DM - Battery Replacement and Screen Cleaning 53
Software Update Procedure . . . . . . . . . . . . . . . 54
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Mechanical and Electrical . . . . . . . . . . . . . . . . . 55
Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 58
Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 60
Light Tower 24R824 . . . . . . . . . . . . . . . . . . . . . . 60
Low Level Sensors, 24R935
(S100 and P100 only) . . . . . . . . . . . . . . . . . 60
USB Kit, 24R936 . . . . . . . . . . . . . . . . . . . . . . . . 61
MD2 Nose Pieces . . . . . . . . . . . . . . . . . . . . . . . 61
Catalyst (B) Hoses . . . . . . . . . . . . . . . . . . . . . . . 61
Restrictor Kit, 24R804 . . . . . . . . . . . . . . . . . . . . 61
Caster Kit, 24T091 . . . . . . . . . . . . . . . . . . . . . . . 62
Mixer Elements for MD2 . . . . . . . . . . . . . . . . . . 62
Appendix A - DM Icons Overview . . . . . . . . . . . . . 64
Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . . 64
Run Screen Icons . . . . . . . . . . . . . . . . . . . . . . . 65
Appendix B - DM Setup Screens Overview . . . . . 66
Appendix C - DM Run Screens Overview . . . . . . 68
Appendix D - DM Error Codes . . . . . . . . . . . . . . . 70
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 78
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 3A2894F

Related Manuals

Manuals are available at www.graco.com. Component manuals below are in English:
System Manuals
332452 ExactaBlend AGP Advanced Glazing Proportioner, Parts
332453 ExactaBlend AGP Advanced Glazing Proportioner - Accessory Kits, Kit Instructions
Ram Manuals
3A0233 Air-Powered Ram, Instructions-Parts
Pump Manuals
312375
Check-Mate
Air Motor Manuals
3A1211
311238
SaniForce
®
NXT
333007 ExactaBlend AGP Air Motor, Instructions-Parts
®
Displacement Pumps, Instructions-Parts
Air Motors, Instructions-Parts
Air Motor, Instructions-Parts
Related Manuals
Displacement Pump Manuals
309577 Displacement Pump, Repair-Parts
Dispense Valve Manuals
312185 MD2 Valve, Instructions-Parts
308253
Ultra-lite
Pistol Grip Flo-Gun, Instructions-Parts
Flow Meter Manuals
308778 Volumetric Fluid Flow Meter, Instructions-Parts
309834 Helical Gear Fluid Flow Meters, Instructions-Parts
Fluid Filters Manuals
307273 Fluid Outlet Filter, Instructions-Parts List
Fluid Regulators Manuals
307517 Mastic Fluid Regulators, Instructions-Parts List
308647 Fluid Pressure Regulators, Instructions-Parts List
Pressure Pot Manuals
308369 5-, 10-, and 15-Gallon Pressure Tanks, Instructions-Parts List
Heated Platen Manuals
332511 ExactaBlend AGP Advanced Glazing Proportioner - Heated Platen Kit, Kit Instructions
Reference Manuals
3A1244
Graco Control Architecture
Module Programming
Val ve Manua ls
313342 Dosing Valve, Instructions-Parts
3A2894F 3

Models

Models

Base Machines

Chemical
Part No.
24R809
24R810
24R811
24R812
24R813
24R814
24R815
24R816
* An agitator is recommended for urethane applica-
tions utilizing a pressure pot. Set the agitator to 25-50 rpm.
Industry
Silicone
Urethane*
Polysulfide
Description
AGP-S100 System, 55 gallon/5 gallon (200 liter/20 liter) machine with boom
AGP-S100 System, 55 gallon/5 gallon (200 liter/20 liter) machine
AGP-U100 System, 55 gallon/5 gallon (200 liter/20 liter) machine with boom
AGP-U100 System, 55 gallon/5 gallon (200 liter/20 liter) machine
AGP-U100 System, 55 gallon/5 gallon (200 liter/20 liter) machine with boom and pressure pot
AGP-U100 System, 55 gallon/5 gallon (200 liter/20 liter) machine with pres­sure pot
AGP-P100 System, 55 gallon/5 gallon (200 liter/20 liter) machine with boom
AGP-P100 System, 55 gallon/5 gallon (200 liter/20 liter) machine
Ratio
(by Weight)
6:1 to 14:1
Maximum Working Pressure
psi (MPa, bar)
MD2:
3000 (21, 207)
Ultra-lite with flexible hose mixer:
3000 (21, 207)
Ultra-lite with Tri-core mixer:
4000 (28, 276)
4 3A2894F

Hose Kits

Hose Kit
Reference
Part No.
24R832 #1
24R833 #2 1/4 x 60 (0.6 x 152) 1/8 x 60 (0.3 x 152)
24R834 #3 1/4 x 60 (0.6 x 152) 1/4 x 60 (0.6 x 152)
24T092 #4 3/8 x 60 (1.0 x 152) 1/4 x 60 (0.6 x 152)
24T093 #5 1/8 x 60 (0.3 x 152) 3/32 x 60 (0.2 x 152)
24T094 #6 1/2 x 60 (1.3 x 152) 3/8 x 60 (1.0 x 152)
24U253 #7 3/32 x 60 (0.2 x 152) 3/32 x 60 (0.2 x 152)
No.
Base Hose
in. (cm)
5/8 x 120 (1.6 x 305)
Catalyst Hose 1
in. (cm)
1/8 x 60 (0.3 x 152) 1/8 x 60 (0.3 x 152)
Catalyst Hose 2
in. (cm)

Dispense Valves

Part No. Description
24P217 MD2 dispense valve with handle
24P223 Ultra-lite 6000 with 36 element flexible hose mixer
24P221 Ultra-lite 6000 with 36 element Tri-core mixer
Models
3A2894F 5

Warnings

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, 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
WARNINGWARNINGWARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec­tric shock.
Turn off and disconnect power cord before servicing equipment.
Connect only to grounded electrical outlets.
Use only 3-wire extension cords.
Ensure ground prongs are intact on power and extension cords.
Do not expose to rain. Store indoors
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.
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.
Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
6 3A2894F
Warnings
WARNING
WARNINGWARNINGWARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. 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.
Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic 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 Dat a in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.
Do not leave the work area while equipment is energized or under pressure.
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.
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 MSDSs to know the specific hazards of the fluids you are using.
Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
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. This 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
3A2894F 7

Important Isocyanate (ISO) Information

WARNING
WARNINGWARNINGWARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or prop­erty damage.
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or flu­ids containing such solvents.
Many other fluids may contain chemicals that can react with aluminum. Contact your material sup­plier for compatibility.
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in some two component materials.

Isocyanate Conditions

Spraying or dispensing materials containing isocya­nates creates potentially harmful mists, vapors, and atomized particulates.
Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventila­tion in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.
To prevent contact with isocyanates, appropriate per­sonal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-ignition

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:
Never interchange component A and component B wetted parts.
Never use solvent on one side if it has been con­taminated from the other side.
Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.
8 3A2894F

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure; forming small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and the life of all wetted parts.
Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.
Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.
Use only moisture-proof hoses compatible with ISO.
Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.
Always lubricate threaded parts with an appropri­ate lubricant when reassembling.
Important Isocyanate (ISO) Information
NOTE: The amount of film formation and rate of crystal­lization varies depending on the blend of ISO, the humidity, and the temperature.

Changing Materials

NOTICE
Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.
When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
Always clean the fluid inlet strainers after flushing.
Check with your material manufacturer for chemi­cal compatibility.
3A2894F 9

Component Identification

Component Identification

S100 Models

J
L
H
B
H
M
J
M
D
F
F
K
G
FIG. 1: S100 Models
Key:
A Display Module (DM) BBoom C Ram - Base (A) Chemical* D Ram - Catalyst (B) Chemical* E Dispense Valve* F Integrated Air Controls G Electrical Enclosure
P
C
A
E
H Flow Meters* J Fluid Regulator* K Calibration Check Assembly L Fluid Control Module (FCM) M Material Pressure Gauges N Catalyst (B) Filter P Fluid Regulator Adjustment
Controls the pressure to the base (A) fluid regulator.
R Pressure Pot (U100 only)* S Air Motor (U100 only)* T Displacement Pump (U100 only)* U Dosing Valve (P100 only)*
* Refer to specific component manual for more detailed
information.
10 3A2894F

U100 Models

Component Identification
J
L
H
B
M
H
M
J
E
K
P
A
S
F
G
C
FIG. 2: U100 Models
NOTE: Refer to key found on page 10.
F
T
N
R
3A2894F 11
Component Identification

P100 Models

J
L
H
D
F
M
B
H
E
M
K
P
A
U
G
C
F
N
R
FIG. 3: U100 Models
NOTE: Refer to key found on page 10.
12 3A2894F
Component Identification
3A2894F 13
Component Identification

Display Module (DM)

User Interface

BB
BF
BA
BE
FIG. 4: DM Component Identification - Front
Key:
BA System Enable/ Disable
Enables/disables the system. When the system is disabled, dispense operation is disabled.
BB Soft Keys
Defined by application using the DM.
BC Cancel
Cancel a selection or number entry while in the process of entering a number or making a selection.
BD Enter
Acknowledge changing a value or making a selection.
BE Lock/Setup
Toggle between run and setup screens. If setup screens are password protected, button toggles between run and password entry screen.
BF Field Selection
Navigate to another field when the DM is in setup mode. These buttons have no function when the DM is in run mode.
BG
BD
BC
BG Increase / Decrease / Field Selection
Increase or decrease the selected value. Navigate to another field.
14 3A2894F
BL
Component Identification
BH
BK
FIG. 5: DM Component Identification - Rear
BH Model Number
Identification tag for the DM.
BJ CAN Cable Connections
Electrical connection for power and communication to other GCA devices.
BK Module Status LEDs
Visual indicators to show the status of the DM:
Green Solid - Power provided. Green Off - No power. Yellow Flashing - Communication with other GCA
devices occurring.
Red Solid - Bad DM or machine is in critical status Red Flashing - Wrong program uploaded.
BL Token/Battery Access Cover
Access cover for token and battery.
BJ
3A2894F 15
Component Identification
Main Display Components
The following figure calls out the navigational, status, and general informational components of each screen.
Current date and time
Function display
Previous screen
Current screen
Selection screen
Faults, Status
Next screen
F
IG. 6: Main Display Components
16 3A2894F

Electrical Enclosure

Component Identification
DB
DA
FIG. 7: Electrical Enclosure
Key:
DA Power Switch
Turns electrical power on or off.
DB 24VDC Power Supply
Converts input power to 24 VDC.
3A2894F 17
Component Identification

Integrated Air Controls

CG
Base (A) Side
All Models
Catalyst (B) Side
S100 Models
CF
CF
CE
CE
CD
CD
CC
CC
CG
CA
FIG. 8: Integrated Air Controls
Key:
CA Main Air Slider Valve
Turns air on and off to the entire system. When closed, the valve relieves pressure downstream.
CB Ram Air Regulator
Controls the ram up and down pressure and blowoff pressure.
CC Ram Director Valve
Controls the ram direction.
CD Exhaust Port with Muffler CE Air Motor Regulator
Controls the air pressure to the motor.
CF Air Motor Slider Valve
Turns air on and off to the air motor. When closed, the valve relieves air trapped between it and the motor. Push the valve in to shutoff.
CB
CB
CJ
CG Blowoff Button
Turns air on and off to push the platen out of an empty drum.
CJ Catalyst Air Slider Valve
Turns air on and off to the catalyst motor only. When closed, the valve relieves pressure down stream.
CK Voltage to Pneumatic Regulator (V/P)
Electrically controlled air regulator.
18 3A2894F
Component Identification
CF
Catalyst (B) Side
U100 Models
CE
Catalyst (B) Side
P100 Models
CK
CF
CE
CD
CC
CG
IG. 9: Integrated Air Controls
F
NOTE: Refer to key found on page 18.
CB
CJ
3A2894F 19
Component Identification

Fluid Control Module (FCM)

EC
EA
EB
ED
EH
FIG. 10: FCM
Key:
EA Port 1 - Air Shut off Valve
Controls the air to the base (A) material regulator.
Port 1 - Low Level Sensors (Optional)
Low level input for the both materials. Refer to Accessories and Kits, page 60, for more details. Includes splitter.
EB Port 2 - Flow Meters
Base (A) and Catalyst (B) flow meter input. Includes splitter
EC Port 3 - Solenoid Valve (P100 only)
To open and close the dosing valve.
ED Port 4 - Voltage to Pneumatic (V/P) Regulator
Controls the air to the catalyst (B) material regulator.
EE Port 5 - Audible Light Tower (Optional)
Visual and audible indicator of machine status. Refer to
Accessories and Kits, page 60, for more details. EF Port 6 - Not Used EG Port 7 - Not Used
EG
EF
EE
EH CAN Connection
Supplies power and communication to GCA components.
20 3A2894F
EA
Component Identification
Component Connection Reference from
FCM (S100 Model Shown)
ED
EB
EB
EA
EC
EE
FIG. 11: Component Connection Reference from FCM
3A2894F 21

Installation

Installation
NOTICE
To avoid flow meter malfunction, do not use PTFE tape on NPT threads. Only apply pipe sealant, Loc-
®
tite
#565 or equivalent, to all NPT threads when
installing.
1. Locate the Machine Base.
Locate the machine on a level surface. Refer to Dimen­sions, page 76, for space requirements.
S100 Shown
2. Assemble the Hose Clamps and Swivel Assembly onto the Boom Base.
a. Torque the swivel assembly fasteners to 24 ft-lb
(33 N•m).
b. Hand tighten all hose clamps.
NOTE: Refer to steps 8 and 10 for visual clarity of hose clamp placement.
Swivel
Assembly
Calibration Check only
22 3A2894F
Installation
3. Install the Boom Base onto the Machine Base.
Slide the boom base into the machine base mast.
4. Assemble the Hose Clamps onto the Front Boom Arm.
5. Install the Front Boom Arm onto the Boom Base.
Torque all fasteners to 24 ft-lb (33 N•m).
(3) Places
6. Install the Fluid Plate onto the Front Boom Arm.
NOTICE
Injury may occur if the fluid plate is lifted by only one person. Use a hoist, multiple people, or remove the fluid regulators prior to installation.
Hand tighten all hose clamps.
NOTE: Refer to steps 8 and 10 for visual clarity of hose clamp placement.
Resin Hose Clamp
Calibration check only
a. Torque the fluid plate fasteners to 24 ft-lb
(33 N•m).
b. Install the fluid regulators if removed for installa-
tion.
3A2894F 23
Installation
7. Calibration Check Only: Install the Calibration Check Assembly and Material Tubes onto the Boom Assembly.
a. Tighten all fittings to prevent leaking.
b. Tighten all hose clamps to secure material lines.
NOTE: For additional assembly details, refer to the ExactaBlend AGP Advanced Glazing Proportioner ­Accessories, Instructions manual.
8. Route and Connect the Base (A) Material Hoses.
a. Tighten all fittings to prevent leaking.
b. Tighten all hose clamps to secure material lines.
S100 Shown
24 3A2894F
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