Graco ExactaBlend 24R200 Operation Manual

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Page 1

Kit Instructions

ExactaBlend™ AGP Advanced Glazing Proportioner

332511B

Heated Platen Kit

For heating bulk supply of medium to high viscosity polysulfide and urethane materials. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

24R200

Heated platen kit, high volume

Refer to ExactaBlend AGP Advanced Glazing Proportioner, Setup-Operation manual for maximum working pressure and model information.

Important Safety Instructions

Read all warnings and instructions in this manual and the ExactaBlend AGP Advanced Glazing Proportioner, Setup-Operation man ual. Save all instructions.

Page 2

Related Manuals

Refer to ExactaBlend AGP Advanced Glazing Propor tioner, Setup-Operation manual for the complete list of related manuals.

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

System Description . . . . . . . . . . . . . . . . . . . . . . . 3

Power Requirements . . . . . . . . . . . . . . . . . . . . . 3

Component Identification . . . . . . . . . . . . . . . . . . . . 4

Heated Platen Kit . . . . . . . . . . . . . . . . . . . . . . . . 4

Heat Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Platen Maintenance . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Common Problems . . . . . . . . . . . . . . . . . . . . . . 16

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Replace Platen Heaters and Sensor . . . . . . . . . 18

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Heated Platen Kit, 24R200 . . . . . . . . . . . . . . . . 20

Heat Enclosure, 24R870 . . . . . . . . . . . . . . . . . . 24

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Warnings

WARNINGWARNINGWARNING

WARNING

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama tion 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.

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 at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

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

BURN HAZARD

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

• Do not touch hot fluid or equipment.

Overview

System Description

The heated platen kit is a field installed kit to add heat to the platen. The additional heat may change the viscosity properties of the material and allow the material to flow easier through the system.

Power Requirements

A 25A (minimum) - 30A (maximum) circuit breaker must be installed on the incoming power supply.

Nominal Voltage** Wattage Amps*

240 V 3,500 per Platen 20

* Add to power requirements of ExactaBlend AGP

Advanced Glazing Proportioner system. Amps maxi mum per leg shown.

** 190-264 voltage range acceptable.

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Component Identification

Heated Platen Kit

FIG. 1: Heated Platen Kit

Key:

A RTD Temperature Sensor BHeater Coil C Temperature Limit Switch D Junction Box E Heat Electrical Enclosure F Main Power Switch

G Heater Power Switch HHeat Controller

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Heat Controller

1 2

Component Identification

FIG. 2: Heat Controller

Key:

AA Current Temperature AB Power is Supplied to Heater AC Power is Supplied to Heat Overtemp Contactor AD Desired Temperature AE Temperature Adjustment

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Installation

To avoid serious injury or machine damage, all electrical connections need to be done by a qualified electrician in compliance with local codes.

Grounding

Ground the system as instructed within this manual.

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

1. Access the Platen

a. Perform Change Drums procedure in the

Air-Powered Ram manual. Do not load a new drum.

b. Perform Shutdown procedure in the Exacta

Blend AGP Advanced Glazing Proportioner, Setup-Operation manual.

c. Thoroughly clean all material that may be found

on the top of the platen.

d. Turn off all sources of power to the machine.

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2. Install the Heat Coils and the Thermostat Switch.

- (6) 1/4-20 Studs

- (6) Flat Washers

- (6) Lock Washers

- (6) Nuts

- (1) Thermostat

- (2) Washers

- (2) Screws

- (3) Ground Wires

- (2) Lock Washers

- (2) Nuts

- (1) Terminal Lug

Installation

3. Connect the Ground Wires.

Connect the ground wires to the terminal lug and to the platen covers (not shown in view). Attach the conduit to the platen cover and route the wires through the conduit when connections are complete.

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Installation

- (2) “B” Leads

- (3) “A” Leads

- (1) RTD

- (1) Washer

- (1) M5 Screw

4. Connect the Power Leads.

Label “A” and “B” leads for identification in step 10. Route all the wires through the conduit when connections are complete.

5. Mount the RTD.

Route the wire through the conduit when connections are complete.

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6. Attach the Platen Covers.

- (1) Conduit

- (1) Fastener

- (2) Covers

- (1) Plug

- (1) Fastener

NOTICE

To prevent damage to wires, ensure wires are not pinched when assembling and securing platen cov ers.

NOTE: Torque the platen cover fasteners to 60 +/- 10 in-lbs (6.8 +/- 1.1 N•m).

Installation

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Installation

- (1) 3/8-16 Bolt (Urethane)

- (1) M8 Bolt (Polysulfide)

- (1) Lock Washer

- (2) #8-32 Screws

- (2) Lock Washers

- (8) M6x16 Bolts

- (8) Washers

- (8) Lock Washers

- (8) Nuts

- (8) M6x25 Bolts

- (8) Washers

- (8) Lock Washers

- (8) Nuts

7. Mount the Junction Box.

a. Mount the junction box to the air motor located on the 55 gallon (208 liter) ram.

b. Route the conduit to the junction box from the platen.

8. Mount the Heat Electrical Panel on the 5 Gallon (19 liter) Ram.

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9. Route the Power Cord and Signal Cable to the Junction Box.

Routing

Secure the power cord and signal cable to the base (A) cross bar.

Installation

10.Connect the Leads in the Junction Box.

Connect “A” leads, “B” leads, ground, and signal cable within the junction box. Replace the cover.

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Installation

11.Connect the Power Cable from the Heat Electrical Enclosure to the Main Electrical Enclosure.

12.Connect Power to the Terminals and Ground.

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Setup

1 2

Desired Temperature

1. Turn the power on at the heated platen electrical enclosure.

2. Turn the power on at the heater power switch.

Setup

3. Set the desired platen temperature by pressing either the up or down arrow keys.

NOTE: Temperature is displayed in Fahrenheit.

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Operation

Startup

1. Turn the power on at the heated platen electrical enclosure.

2. Turn the power on at the heater power switch.

Shutdown

1. Turn the power off at the heater power switch.

NOTE: If the entire machine is to be disconnected from electrical power, turn the power off at the heated platen electrical enclosure.

3. Set the desired temperature. Refer to page 5 for details.

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Maintenance

Bleed Stick

Maintenance

Platen Maintenance

If the platen does not come out of the pail easily when the pump is being raised, the air assist tube or check valve may be plugged. A plugged valve prevents air from reaching the underside of the plate to assist in rais ing it from the pail.

1. Turn off main disconnect at the machine.

2. Allow equipment to cool.

3. Relieve pressure and disassemble air assist valve. Refer to Supply Systems Repair-Parts manual.

4. Clear air assist tube in platen. Clean all parts of valve and reassemble. Refer to Supply Systems Repair-Parts manual.

5. Remove bleed stick from platen. Push bleed stick through bleed relieve port (P) to remove material residue. See F

IG. 3.

Remove and Reinstall Platen Wipers

Refer to Supply Units Repair-Parts manual for instruc tions.

FIG. 3: Remove Platen Covers and Heaters

6. Remove platen covers. See F

a. Remove platen cover fasteners (F).

b. Remove both platen covers (C) and ground wire

from platen.

7. Remove any excess fluid. Use a soft wire brush on heater coils (H). See F

8. Inspect platen heater blocks (B) or heater (H) for burn or melt spots. Replace platen heater if neces sary. See F

9. Check for loose connections and damaged wires.

10. Follow steps in reverse order to reassemble platen.

NOTE: Torque platen cover fasteners (F) to 60 +/- 10 in-lbs (6.8 +/- 1.1 N•m) for 55 gallon platen.

IG. 3.

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Troubleshooting

Before performing any troubleshooting procedure:

1. Perform Pressure Relief Procedure In the Exacta Blend AGP Advanced Glazing Proportioner, Setup-Operation manual.

2. Turn off main disconnect at the machine.

3. Allow equipment to cool.

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and con trols are properly set and wiring is correct before assum ing there is a problem.

Common Problems

Problem Cause Verification Solution

Heating is slow. Low power. Measure voltage across cir

cuit breakers. Voltage should measure between 190 and 264 Vac.

Heating over shoots. Defective solid state relay. Verify for given zone that

temperature does not increase when zone is dis abled.

1. If voltage is lower than expected, use electrical schematic to locate faulty wiring or connec tion.

2. Have a qualified electri cian service electrical components.

Verify RTD wire or heater power cord is attached to correct heat module.

Replace relay.

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Problem Cause Verification Solution

No heat. Tripped circuit breaker. Visually check circuit

breaker for a tripped condi tion.

Low power. Measure voltage across cir

cuit breakers. Voltage should measure between 190 and 264 Vac.

Cable unplugged/loose wire.

Incorrect temperature set point.

Check for loose or discon nected wires and plugs.

Verify zone has a correct temperature setting on the controller.

Contactor not closing. Turn on heat for zone A1

and ensure contactor closes.

Troubleshooting

Determine cause of tripped circuit breaker. Then repair fault and reset main circuit breaker.

1. If voltage is lower than expected, use electrical schematic to locate faulty wiring or connec tion.

2. Have a qualified electri cian service electrical components.

Attach plug/wire.

Enter Setup and enter cor rect temperature.

1. Verify that there are no other error conditions that would prevent heater from starting.

2. Replace contactor.

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Repair

Replace Platen Heaters and Sensor

55 Gallon Platen Heater and Sensor

1. Turn off main disconnect at the machine.

2. Allow equipment to cool.

3. Remove both platen cover fasteners (F).

4. Remove both platen covers (C) and ground wire from platen.

c. Disconnect four platen heater wires (labeled A

and B) and RTD sensor (R) connector in the ter minal box.

d. Remove screws and washers. Remove platen

heater blocks (B) and RTD sensor (R).

6. Install new platen heaters and RTD sensor (R). Secure RTD sensor (R) with screw and washer. Secure platen heater blocks with nuts and washers.

7. Label platen heater wires A and B. Reroute platen heater wires and platen RTD sensor (R) through the conduit to the junction box. Reconnect the four wires to the appropriate terminal block A and B. Reconnect the platen RTD sensor (R).

8. Reinstall junction box cover. Secure with screws and tighten strain relief nut.

9. Reconnect ground wire, and install platen covers. Secure platen covers with fasteners. Torque platen cover fasteners to 60 in-lbs +/- 10 in-lbs (6.8 +/-

1.1 N•m).

FIG. 4: Replace Platen Heaters and RTD sensor (R)

5. Remove platen heater blocks (B).

a. Use a hex wrench to remove three nuts (N) and

washers (L, W) from each heater block.

b. Remove screws from junction box cover.

Loosen strain relief nut, and remove junction box cover.

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Schematic

140

149

147

145

142

110

138

136

134

132

130

128

126

124

122

120

118

114

116

112

108

106

104

102

100

141

148

144

146

143

111

139

137

135

133

131

129

127

125

123

121

119

115

117

113

109

107

105

103

101

50-60HZ

1PH/

220V/

DISC100

L21L2

L11L1

GND

1L1

1L2

1L1

1L2

20A

1100

1120

1361

1381

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

LABEL WITH WIRE NUMBERS MARKED AS SHOWN

SEE XXXXXX FOR LABELS

1360

1380

CON120

HARNESS

16U358

HARNESS

16U358

HARNESS

16U354

HARNESS

16U354

SSR130

HARNESS

16A522

+24VDC

SIGNAL

1300

1280

1370

1390

BLU

BRN

GND

HARNESS

16U365

CRM

1180

HARNESS

16U353

HARNESS

16U345

HARNESS

16U345

HARNESS

16U356

HARNESS

16U356

TC-1

1371

1391

GND

1371

R-1

1392

EXC

SIGNAL

15B137

THERM SW

16D383

RTD

HARNESS

(16D383)

HARNESS

16A574

HARNESS

16A574

255733

24E265

HARNESS

16A356

GND

1382

SSR130

POWER

OFF ON

SW-1

432

Schematic

332511B 19

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Parts

Heated Platen Kit, 24R200

FIG. 5: Heated Platen Kit

20 332511B

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16,

33 34

Parts

FIG. 6: Heated Platen Kit

332511B 21

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Parts

Ref Part Description Quantity

1 --- FERRULE, wire, 14awg 2 2 --- FASTENER, platen, cover 2 3 --- COUPLER, conduit 2 4 --- ENCLOSURE, platen, heated 1 5 --- COVER, platen front, assembly 2 6 --- PLUG, finishing, 13/16, nickel plate 1 7 --- STUD, 1/4-20 x 1.25 6 8 16D383 SENSOR, RTD, 1k ohm, shielded 1 9 --- NUT, full hex, 10-32 2 10 --- FERRULE, wire, 14awg, twin 1 11 --- CONDUCTOR, block, heater 2 12 --- WIRE, ground 2 13 --- WIRE, ground 1 14 15V427 HEATER, coil 2 15 --- CONDUIT, 12.9mm 2.70 16 --- SCREW, cap, 3/8-19x3/4 1 17 --- WASHER, M5 1 18 --- SCREW, cap, 8-32x1/2 2 19 --- WASHER, lock, 3/8 1 20 --- WASHER, lock, internal, M5 2 21 --- WASHER, flat, #6 2 22 --- NUT, hex, 1/4-20 6 23 --- WASHER, lock, 1/4 6 24 261821 CONNECTOR, wire, 6awg 2 25 --- GRIP, cord, 0.39-0.56, 1/2 1 26  15J075 LABEL, safety, hot surface & energized 1 27 --- SCREW, M5-0.8x12mm 1 28 --- WASHER, flat, special 6 29 --- SCREW, ground, M5-0.8x13mm 1 30 --- BRACKET, enclosure, platen 1 32 --- TUBE, shrink 1 33 --- SCREW, machine, 6-32x3/8 2 34 --- WASHER, lock external, #6 2 35 15B137 SWITCH, over temperature 1 36 --- GRIP, cord, straight 1

22 332511B

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Ref Part Description Quantity

37 --- BRACKET, mount, top 2 38 --- BRACKET, mounting, ram 2 39 24R870 MODULE, heat 1 40 --- WASHER, M6 16 41 --- SCREW, socket head, M6x25mm 8 42 --- SCREW, socket head, M6x16mm 8 43 --- WASHER, lock, M6 16 44 --- NUT, hex, M6 16 45 --- SCREW, cap, M8x20mm 1

 Replacement Danger and Warning labels, tags and

cards are available at no cost.

--- Not available for individual sale.

Parts

332511B 23

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Parts

109

128

109

127

107

108

110

116

108

134

132

106

136

111

101, 112,

113

Heat Enclosure, 24R870

FIG. 7: Heat Module

24 332511B

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102,

104

114,

115

122

121

119

124

118

120

125

123

122

129

118

130

131

139

130

117

102,

103

126

Parts

FIG. 8: Heat Module

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Parts

Ref Part Description Quantity

101 --- NUT, machine hex, M4-0.7 2 102 --- NUT, hex, M5-0.8 5 103 --- WASHER, lock, external, M5 3 104 --- WASHER, plain, #10 2 106 --- RETAINER, cord 1 107 121148 HANDLE, disconnect, electrical 1 108 --- GRIP, cord 2 109 --- SCREW, M5-0.8x10mm 4 110 126999 SWITCH, disconnect, 32a 1 111 24R941 MODULE, controller, heat, program 1 112 127106 RELAY, solid-state, 240v/50a 1 113 127107 COVER, relay, solid-state, 240v/50 1 114 --- LATCH, operator 1 115 --- BLOCK, contact, normally open 1 116 --- SWITCH, operator, selector 1 117 --- HARNESS, single, 16ga, black 2 118 --- HARNESS, single, 16ga, black 3 119 --- HARNESS, single, 10ga, green/yellow 1 120 --- HARNESS, single, 10ga, black, 2 121 --- HARNESS, single, 10ga, green/yellow 1 122 --- HARNESS, single, 16ga, black 2 123 --- HARNESS, single, 16ga, green/yellow 1 124 --- HARNESS, double, 10ga, black 2 125 --- HARNESS, 3 connector, 12ga 1 126 --- MODULE, din 1 127 --- BRACKET, mounting, heat, ram 1 128 --- COVER, bracket, mounting, heat, ram 1 129 --- HARNESS, sing, 16ga, black 2 130 --- HARNESS, sing, 16ga, black 3 131 --- HARNESS, m8, 4pin 1 132 --- CONNECTOR, power, panel mount 1 134 --- GRIP, cord 1 136  196548 LABEL, warning, shock 1 139 121599 CORD, power, v-lock 1

 Replacement Danger and Warning labels, tags and

cards are available at no cost.

--- Not available for individual sale.

26 332511B

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Parts

332511B 27

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Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

Sealant and Adhesive Dispensing Equipment

For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor, go to www.graco.com and select “Where to Buy” in the top blue bar, or call to find the nearest distributor.

If calling from the US: 800-746-1334 If calling from outside the US: 0-1-330-966-3000

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 332511

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision B, January 2017