Graco PR70 Series Operation And Maintenance Manual

Page 1

Operation and Maintenance

PR70 2 Component

Liquid Dispensing Systems

PR70 All Models

100 PSI (0.7 Mpa, 7 bar) Maximum Air Inlet Pressure For Dispensing Multi-part Sealants and Adhesives Not Designed for Use in Explosive Atmospheres

Important Safety Instructions

Read all warnings and instructions in this manual.

312393C

PROVEN QUALITY, LEADING TECHNOLOGY.

GRACO OHIO INC. 8400 PORT JACKSON AVE. NW, NORTH CANTON, OH 44720-5464

Phone: 330.966.3000 Fax: 330.966.3006

LiquidControlService@graco.com LiquidControlParts@graco.com

www.liquidcontrol.com

Page 2

Contents

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

Models ....................................................... 3

PR70 Accessories..................................................6

Supplied Manuals ..................................... 7

Related Manuals .......................................7

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

Installation............................................... 10

General Information .............................................10

Unpacking ............................................................10

Locate and Install the PR70.................................10

Machine Setup .....................................................10

Component Identification ...................... 11

HMI Control and Indicators.................... 12

HMI Main Run Screen..........................................13

Run Screen Operation............................ 13

Tank Level Sensing and Velocity Change (“ ”) Options (C6)

.........................................................22

Password Setup / Clearing (C5).............23

Setting/Clearing an Administrative Password:..........23

Setting/Clearing a Maintenance ONLY Password:24

Resetting Passwords ...........................................24

Miscellaneous Machine Features .......... 25

HMI Hibernate Mode............................................25

HMI Startup Animation Sequence........................25

HMI Demo Mode Operation .................................25

Pressure Relief Procedure .....................26

Standby/Shutdown Procedure...............26

Error Codes ............................................. 26

Error Code Table.....................................27

ICON Descriptions .................................. 29

Machine Mode Selection......................................13

Machine Operation: Shot Mode ..........................13

Machine Operation: Operator Mode ...................13

Shot Number Selection ........................................13

Machine Disable Mode (“ ”red) .......... 14

Setup Screens......................................... 14

Entering the Setup Screens.................................14

Setup Screens with Passwords Enabled.............14

Machine Priming..................................... 16

Machine Calibration................................ 16

Piston Position Calibration (C1)...........................16

Phasing (C2) ........................................................17

Open Dispense Valve (ODV) Setting (C3)...........17

Machine Calibration Shots (C4)...........................18

Shot Size Definition (M2)........................ 19

Ratio Checks........................................... 19

Maintenance ............................................ 31

Software Upgrades, Run Token.............31

Run Token............................................................31

Troubleshooting...................................... 32

Repair....................................................... 33

Major Mechanical Assemblies, and Attachments 33

Base Frame Assembly.........................................34

Air Cylinder Assemblies, and Rebuild Kits...........35

Drive Block Assembly ..........................................38

Pump Assemblies and Rebuild Kits .....................38

Piston Cylinders or Metering Tubes.....................41

Hose Assemblies .................................................44

Miscellaneous Mechanical Assemblies................45

Wiring Diagrams .....................................48

Technical Data.........................................50

Dimensions..............................................51

Miscellaneous Machine Setups............. 20

Manual Control Options (M1)...............................20

Purge Timer / Alarm Settings (M2) ......................20

Cycle Counter and Silent Mode Control (M3).........21

Date and Time Settings (M4)...............................22

312393C 2 of 52

Graco Ohio Standard Warranty .............52

Page 3

Models

A PR70 system can be ordered with many different options from the configurator below. The example PR70 system part number illustrated below contains the highlighted choices from the charts on pages 3 - 6.

PR70 - 2 - BT - BF - A - A7 - A4 - 2 - 3 - 1 - 1 - N - 2 - N - N - N - 2 - N - N - N

Code : A B-C D-E F G-H I-J K L M N O P Q R S T U V W

The following configuration P/N was assigned to the machine shipped with this manual:

PR70- - - - - - - - - - - - - - - - - - -

Code : A B-C D-E F G-H I-J K L M N O P Q R S T U V W

The following part number fields apply for PR70 part numbering Configurator process. Items highlighted in italics, refer to “Super Standard” items with are typically stocked, and provide the best delivery dates.

2007 Product Configurator - PR70

Code A

1 3.0" (4,560mm2) Air Motor 2 4.5" (10,260mm2) Air Motor 3 3.0" Air Motor with hydracheck 4 4.5" Air Motor with hydracheck 5 Electric Drive

Code B High Volume Piston Material

A Nylon A Nylon B UHMWPE B UHMWPE

Code C High Volume Piston Size

1 2 100, Nylon Only 2 100, Nylon Only 3 4 140, Nylon Only 4 140, Nylon Only 5 6 180 6 180 7 200 7 200 8 220 8 220 9 A 260 A 260 B 280 B 280 C 300 C 300 F G 360 G 360 H 400 H 400

J 440 J 440

M 520 M 520

R 560 R 560 S 600 S 600 T U 720 U 720

W 800 W 800

X 880 X 880 Y

Z Custom Low Volume Side, consult factory (SST Only)

Motor

High Volume Piston

Low Volume Piston

Check Valve

High Volume Hose

Air Motor Information

80, Nylon Only, Super Standard

120, Nylon Only, Super Standard

160, Super Standard

240, Super Standard

320, Super Standard

480, Super Standard

640, Super Standard

960, Super Standard

Low Volume Hose

Dispense Valve

Mixer

Applicator Mounting

Power Cord

Pressure Transducers

High Volume Tank

High Volume Lib

Low Volume Tank

Low Volume Lib

Low Level Sensors

Heat Controller

Wet Test

Code D

Code E Low Volume Piston Size

80, Nylon Only, Super Standard

120, Nylon Only, Super Standard

160, Super Standard

240, Super Standard

320, Super Standard

480, Super Standard

640, Super Standard

960, Super Standard

Low Volume Piston Material

Off-board Tank Stand

312393C 3 of 52

Page 4

Models

2007 Product Configurator - PR70 (Continued)

Code F

Check Valve

A Standard Check Valve

G-H High Volume Hose

A1 3/16" (4.8mm) - 2.5' (0.6m) A2 3/16" (4.8mm) - 10' (3.0m) A3 3/16" (4.8mm) - 15' (4.6m) A4 1/4" (6.5mm) - 2.5' (0.6m) A5 1/4" (6.5mm) - 10' (3.0m) A6 1/4" (6.5mm) - 15' (4.6m) A7 3/8" (9.5mm) - 2.5' (0.6m) A8 3/8" (9.5mm) - 10' (3.0m)

A9 3/8" (9.5mm) - 15' (4.6m) AA 1/2" (13mm) - 2.5' (0.6m) AB 1/2" (13mm) - 10' (3.0m)

AC 1/2" (13mm) - 15' (4.6m) AG 3/4" (19mm) - 10' (3.0m) AH 3/4" (19mm) - 15' (4.6m)

B4 Heated, 1/4" (6.5mm) - 2.5' (0.6m) B5 Heated, 1/4" (6.5mm) - 10' (3.0m) B6 Heated, 1/4" (6.5mm) - 15' (4.6m) B7 Heated, 3/8" (9.5mm) - 2.5' (0.6m) B8 Heated, 3/8" (9.5mm) - 10' (3.0m) B9 Heated, 3/8" (9.5mm) - 15' (4.6m) BA Heated, 1/2" (13mm) - 2.5' (0.6m) BB Heated, 1/2" (13mm) - 10' (3.0m)

BC Heated, 1/2" (13mm) - 15' (4.6m) BG Heated, 3/4" (19mm) - 10' (3.0m) BH Heated, 3/4" (19mm) - 15' (4.6m)

Code K Dispense Valve

1 None 2 MD2, Valve Only 1:1 3 MD2, Valve Only with 10:1 Nose 4 MD2, Handheld 1:1 5 MD2, Handheld with 10:1 Nose 6 MD2, Lever 1:1 7 MD2, Lever with 10:1 Nose

Code L Mixer Type

N None

1 3/16” (4.8mm) x 32 2 1/4" (6.5mm) x 24 3 3/8” (9.8mm) x 24 4 3/8” (9.8mm) x 36 5 3/8” (9.8mm) Combo 6 1/4" (6.5mm) x 24 Luer Lock 7 3/16” (4.8mm) x 32 Luer Lock

Code M Applicator Mounting

N None, Customer Mount Controls and Applicator

1 Mast Mount, Controls & MD2 Applicator machine mounted 2 Mast Mount, Controls Only

I-J Low Volume Hose

AC 1/2" (13mm) - 15' (4.6m) AG 3/4" (19mm) - 10' (3.0m) AH 3/4" (19mm) - 15' (4.6m)

B4 Heated, 1/4" (6.5mm) - 2.5' (0.6m)

B5 Heated, 1/4" (6.5mm) - 10' (3.0m)

B6 Heated, 1/4" (6.5mm) - 15' (4.6m)

B7 Heated, 3/8" (9.5mm) - 2.5' (0.6m)

B8 Heated, 3/8" (9.5mm) - 10' (3.0m)

B9 Heated, 3/8" (9.5mm) - 15' (4.6m) BA Heated, 1/2" (13mm) - 2.5' (0.6m) BB Heated, 1/2" (13mm) - 10' (3.0m) BC Heated, 1/2" (13mm) - 15' (4.6m) BG Heated, 3/4" (19mm) - 10' (3.0m) BH Heated, 3/4" (19mm) - 15' (4.6m)

Code N

1 2 3 4 5 6 7 8 9

Code O

N No Y Installed

120VAC North American Cord Set 10A, 250V US Cord Set 10A, 250V Continental Europe 10A, 250V U.K./Ireland 10A, 250V Israel 10A, 250V Australia 10A, 250V Italy 10A, 250V Switzerland 10A, 250V,Denmark 10A, 250V India

Power Cord Option

Pressure Transducer

312393C 4 of 52

Page 5

Models

Code P

High Volume Tank

N None

1 1-1/2" (38mm)NPT FLANGE, No Tanks 2 8L, Twin PE Tanks (High and Low Volumes) and Lid 3 8L one 120 VAC 50/60 Hz agitator 4 8L two 120 VAC 50/60 Hz agitators 5 8L w Shut-off 6 8L one 120 VAC 50/60 Hz agitator w/ Shut-off

7 8L two 110/120 VAC agitators w/Shut-off S 8L one 240 50/60 Hz VAC agitator T 8L two 240 50/60 Hz VAC agitators U 8L one 240 50/60 Hz VAC agitator w/Shut-off

W 8L two 240 50/60 Hz VAC agitators w/Shut-off

D 8L one pneumatic agitator E 8L two pneumatic agitators K 8L one pneumatic agitator w/Shut-off P 8L two pneumatic agitators w/Shut-off A 3L SST B 7.5L SST C 3L SSTw/ Shut-Off F 7.5L SST w/ Shut-Off G 7.5L SST w/ Heat 240 VAC H 7.5L SST w/ Shut-off & Heat 240 VAC

J 30L SST

L 30L SST Heat 240/1 M 60L SST R 60L SST Heat 240/1 X Accumulator, Viton Y Accumulator, EP

Code Q High Volume Tank Cover

1 On-board Dust Cover

2 On-board Clamp Down

3 On-board Vacuum Degas

4 On-board Agitate 120VAC 50/60 Hz

5 On-board Agitate 240VAC 50/60 Hz

6 On-board Agitate 120VAC 50/60 Hz & DEGAS

7 On-board Agitate 240VAC 50/60 Hz & DEGAS

8 On-board Agitate 120VAC 50/60 Hz, DEGAS & Fill Port

9 On-board Agitate 240VAC 50/60 Hz, DEGAS & Fill Port S On-board Agitate Pneumatic T On-board Agitate Pneumatic & DEGAS U On-board Agitate Pneumatic, DEGAS & Fill Port A Off-board Clamp Down-30L B Off-board Clamp Down-60L C Off-board Vacuum Degas -30L F Off-board Vacuum Degas - 60L G Off-board Agitate SST - 30L H Off-board Agitate SST - 60L

J Off-board Vacuum Degas & Agitate SST - 30L

L Off-board Vacuum Degas & Agitate SST - 60L M Off-board Vacuum Degas/Agitate/Fill Port/Slinger SST -30L R Off-board Vacuum Degas/Agitate/Fill Port/Slinger SST - 60L V Off-board Pneumatic Agitate SST - 30L

Code Q

W Off-board Pneumatic Agitate SST - 60L

X Off-board Pneumatic Vacuum Degas & Agitate SST - 30L Y Off-board Pneumatic Vacuum Degas & Agitate SST - 60L Z Off-board Vacuum Degas/Pneumatic Agitate/FP SST -30L K Off-board Vacuum Degas/Pneumatic Agitate/FP/SST - 60L N None

Code R

N None 1 1-1/2" (38mm)NPT FLANGE, No Tanks A 3L SST B 7.5L SST C 3L SST w/ Shut-off F 7.5L SST w/ Shut-off G 7.5L SST Heat 240 V H 7.5L SST w/ Shut-off & Heat 240V

J 30L SST

L 30L SST Heat 240/1

M 60L SST

R 60L SST Heat 240/1

Code S Low Volume Tank Covers

Accumulator, Viton

X Y Accumulator, EP

1 On-board Dust Cover 2 On-board Clamp Down 3 On-board Vacuum Degas 4 On-board Agitate 120VAC 50/60 Hz 5 On-board Agitate 240VAC 50/60 Hz 6 On-board Agitate 120VAC 50/60 Hz & DEGAS 7 On-board Agitate 240VAC 50/60 Hz & DEGAS 8 On-board Agitate 120VAC 50/60 Hz, DEGAS & Fill Port 9 On-board Agitate 240VAC 50/60 Hz, DEGAS & Fill Port S On-board Agitate Pneumatic T On-board Agitate Pneumatic & DEGAS U On-board Agitate Pneumatic, DEGAS & Fill Port A Off-board Clamp Down-30L B Off-board Clamp Down-60L C Off-board Vacuum Degas -30L F Off-board Vacuum Degas - 60L G Off-board Agitate SS - 30L H Off-board Agitate SS - 60L

J Off-board Vacuum Degas & Agitate SS - 30L

L Off-board Vacuum Degas & Agitate SS - 60L

M Off-board Vacuum Degas/Agitate/Fill Port/Slinger SST -30L

R Off-board Vacuum Degas/Agitate/Fill Port/Slinger SST - 60L V Off-board Pneumatic Agitate SST - 30L

W Off-board Pneumatic Agitate SST - 60L

High Volume Tank Cover (cont’d)

Low Volume Tank Options

312393C 5 of 52

Page 6

Models

2007 Product Configurator – PR70 (Continued)

Code T Low Level Sensor Options

1 None 2 PE Tanks 3 Steel Tanks On-Board 4 Steel Tanks Off-Board 5 Steel Tanks 1 On / 1 Off-board 6 2 Accumulator 7 1 Accumulator & 1 Off-board Tank 8 1 Accumulator & 1 On-board Tank

Code U Heat Zone Controller

N None 1 1 Off Board Tank (1 zone) 2 1 On Board Tank (1 Zone) 3 2 Off Board Tanks 4 2 On Board Tanks 5 1 Off Board Tank / 1 On Board Tank OR 1 Hose 6 2 Off Board Tanks / 1 Hose 7 1 Off Board Tank / 1 On Board Tank & 1 Hose OR 2 Hoses 8 2 On Board Tanks / 1 Hose OR 1 On Board Tank / 2 Hoses 9 2 Off Board Tanks / 2 Hoses A 1 Off Board Tank / 1 On Board Tank / 2 Hoses B 2 On Board Tanks / 2 Hoses

Code V Wet Test

Code W

Wet Test (Note: Material must be supplied; No

Dealer/Distributor discounts apply)

N No Wet Test

Off-Board Tank Stands

N None, or NA 2 Tank Stand (1 or 2 tanks)

PR70 Accessories

Mixer and Shroud Options

LC0063 Mixer, 3/16 (6.5 mm) x 32, 10 Mixers with shroud LC0081 Mixer, 3/8 (9.8 mm) combo, 50 Mixers

LC0057 Mixer, ¼ (6.5 mm) x 24, 10 Mixers with shroud LC0083 Mixer, 1/4 (6.5 mm) x 24 Luer Lock, 50 Mixers

LC0058 Mixer, 3/8 (9.8 mm) x 24, 10 Mixers with shroud LC0082 Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 50 Mixers

LC0059 Mixer, 3/8 (9.8 mm) x 36, 10 Mixers with shroud LC0084 Mixer, 3/16 (4.8 mm) x 32, 250 Mixers

LC0060 Mixer, 3/8 (9.8 mm) Combo, 10 Mixers with shroud LC0085 Mixer, 1/4 (6.5 mm) x 24, 250 Mixers

LC0061 Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 10 Mixers with shroud LC0086 Mixer, 3/8 (9.8 mm) x 24, 250 Mixers

LC0062 Mixer, ¼ (6.5 mm) x 24 Luer Lock, 10 Mixers with shroud LC0087 Mixer, 3/8 (9.8 mm) x 36, 250 Mixers

LC0077 Mixer, 3/16 (4.8 mm) x 32, 50 Mixers LC0088 Mixer, 3/8 (9.8 mm) combo, 250 Mixers

LC0078 Mixer, ¼ (6.5 mm) x 24, 50 Mixers LC0089 Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 250 Mixers

LC0079 Mixer, 3/8 (9.8 mm) x 24, 50 Mixers LC0090 Mixer, ¼ (6.5 mm) x 24 Luer Lock, 250 Mixers

LC0080 Mixer, 3/8 (9.8 mm) x 36, 50 Mixers

MD2 Valve Kits

255217 MDS2, kit rebuild, air cylinder 255219 MD2, Soft Seat rebuild, needle and nose

255218 MD2, kit rebuild, back-end of wet section (no needle or seat) 255220

Other Accessories

LC0097 Desiccant Dryer, 3/8” NPT with adapter and cartridge LC0100 Vacuum Transfer Pump, 240V, down to 25 Torr

LC0098 Desiccant Dryer refill cartridge LC0091 3.0” Air Cylinder rebuild kit

LC0095 Nitrogen Kit for 30L and 60L tank, 1 tank LC0092 4.5” Air Cylinder rebuild kit

LC0096 Nitrogen Kit for 30L and 60L tank, 2 tanks LC0093 Check Valve rebuild kit

LC0008 Cord, I/O interface and footswitch part LC0094 Rear Pump Seal rebuild kit

LC0099 Vacuum Transfer Pump, 120V, down to 25 Torr

MD2, convert Soft Seat nose to Hard Seat (Hard Seat rebuild), needle and nose

312393C 6 of 52

Page 7

Manuals

Supplied Manuals

The following manuals will be supplied with the

PR70 Operation

PR70. Refer to these documents for detailed machine

Part Description information. 312393 Manual, Operation & Maintenance

PR70

PR70 Feed System

Part Description

312394 Manual, Tank/Feed System, PR70

Dispense Valve, MD2

Part Description 312185 Manual, Dispense Valve, MD2

* Heat Control Module(s)

Part Description 312413 Manual, Heat Control, Tank/Hoses

Related Manuals

The following manuals are for accessories to be used with the PR70 machine.

PR70 Feed System

Part

312394 Manual, Tank/Feed System, PR70

312185 Manual, Dispense Valve, MD2

312413 Manual, Heat Control, Tank/Hoses

* The Heat Control Module manual is not provided for machines that do not have a Heated Tank and/or Hose

component.

PR70 Operation

Part

312393 Manual, Operation & Maintenance PR70

Dispense Valve, MD2

Part Description

Heat Control Module(s)

Part Description

Description

312393C 7 of 52

Page 8

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

SKIN INJECTION HAZARD

High-pressure fluid from dispense valve, 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 dispense valve at anyone or at any part of the body.

• Do not put your hand over the end of the dispense nozzle.

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

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

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 MSDS’s 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.

• Always wear impervious gloves when spraying or cleaning equipment.

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 and clean 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 lights on or off when flammable fumes are present.

• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions.

• Use only Graco grounded hoses.

• Check gun resistance daily.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from system.

• Keep a working fire extinguisher in the work area.

312393C 8 of 52

Page 9

Warnings

WARNING

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 Data 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 forms from distributor or retailer.

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

• Do not alter or modify equipment.

• 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.

MOVING PARTS HAZARD

Moving parts can pinch 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 in this manual. Disconnect power or air supply.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

312393C 9 of 52

Page 10

Installation

General Information

Accessories are available from Graco. Make certain all accessories are adequately sized and pressure-rated to meet your system needs.

Figures 2 thru 4 are only a guide for identifying system components and for assisting in installation. Contact your Graco distributor or Graco Ohio Customer Service for assistance in designing a system to suit your particular needs.

Unpacking

1. Inspect the shipping container carefully for damage. Contact the carrier promptly if there is damage.

2. Open the box and inspect the contents carefully. There should not be any loose or damaged parts in the container.

3. Compare the packing slip against all the items in the box. Report any shortage or other inspection problems immediately.

4. Remove the PR70 system components from the container. Do not lift the machine by the tanks.

Locate and Install the PR70

1. Locate a bench top or equivalent location to mechanically mount the PR70 dispensing machine.

Verify the location has access to compressed air, AC power and is well ventilated.

2. Place the PR70 onto the designated location. Allow to the machine to rest on the rubber feet provided.

3. Turn the Shield Locking Screws clockwise on both sides to remove the PR70 protective shield.

4. Attach the PR70 frame to the selected location by installing fasteners (not provided with unit) thru the 4 mounting holes. Refer to Figure 1 for mounting hole dimensions.

Machine Setup

Avoid contact with electrical inter-connects, when connecting electric power to the machine. Read all manufacturer’s warning and material MSDS to know the specific hazards of the material used.

1. Connect a compressed airline to the input air in the back of the machine.

2. Load material into the on-board or off-board tanks feeding the machine.

3. Using the power cord provided, connect AC power (100-240V, 50/60 Hz, single-phase) to the machine.

Figure 1: Mounting Hole Dimensions for Installing the PR70 Machine (dimensions in inches/mm)

312393C 10 of 52

Page 11

Component Identification

Key:

A Dispense Valve (DV) B HMI (Human Machine Interface) C Static Mixer D Shield Locking Screw E Power Switch F Air Filter G Customer Input Receptacle H Protective Shield I Air Pressure Regulator J Ball Valve (Optional) K A and B Tanks (Onboard,

Polyethylene versions illustrated).

Figure 2: Typical PR70 (Back View, without Hoses)

Figure 3: PR70 Back View with Shield, Tanks, DV and HMI Removed.

Key:

A Pump Assembly B Solenoid Valves C Air Cylinder Assembly D DC Power Supply E Fluid Control Module (FCM)

312393C 11 of 52

Page 12

Component Identification

Key:

A Drive Block B Hydracheck (optional) C Check Valve D Cylinder (Metering Tube) E Rear Bearing F Phase Adjustment Screw/Locking

Nut

G Mounting Hole in Base Frame

Figure 4: PR70 Top View with Shield, Tanks, DV and HMI Removed.

HMI Control and Indicators

Figure 5: PR70 HMI Controls

Key:

A Screen, Display Area B, D Up and Down Keys C Up and Down Key LED E Enter Key LED F Enter Key G-J Soft Keys 1 thru 4 (Left to Right). K Shot Mode ICON L Shot Mode LED M Mode Select Key

N Operator Mode ICON O Operator Mode LED P Red Stop or Cancel Key (used to stop machine

operation) Q Lock Key (used to enter and exit setup screens) R Green Go Key (used to request a shot) S Display area T Diagnostic LED’s

U HMI Rear Access Panel (used to access clock

battery and for reprogramming the HMI).

312393C 12 of 52

Page 13

Run Screens

HMI Main Run Screen

Figure 6: Typical PR70 Main Run Screen (Shot and Operator Modes) Respectively)

Key:

A Shot Number Field (“x” in Operator Mode) B Shot Size Field (“XXXXXX” in Operator Mode) C Shot weight/mass unit of measure (Grams). D Tank Fill Status Indicators E Pistons Status Field

F Cycle Counter G DV status Field H Purge Timer status Field I Error code status Field J Current Date Field (DD-MM-YY) K Current Time Field (24 Hr. Format)

Run Screen Operation

Read all manufacturer’s warning and material MSDS to know the specific hazards of the material used.

Machine Mode Selection

To dispense material, one of the following 2 modes must be selected;

• Shot mode dispenses a predetermined amount of material when the machine receives a “Go” command.

• Operator mode dispenses material as long as the machine is receiving a “Go” command.

3. To cancel the shot, press

Machine Operation: Operator Mode

1. Place the item or part to be filled below the dispense valve static mixer.

2. Press and hold the shot. The machine will continue to dispense

until the

The pistons will not retract unless they are almost fully extended. They will automatically retract after 4 minutes. The machine will beep to signal that it is about

to retract. To manually retract the machine, press

(green) or the footswitch is released.

(green) or the footswitch to start

To select Shot mode:

1. Press

2. Press to accept or to cancel.

To select Operator mode:

3. Press

4. Press

until .

to accept or to cancel.

Machine Operation: Shot Mode

1. Place the item or part to be filled below the dispense valve static mixer

2. Press

312393C 13 of 52

(green) or the footswitch to start the shot.

Shot Number Selection

In Shot mode, up to 5 predefined shot sizes may be selected. To select a shot:

1. When the machine is idle (not dispensing a shot)

press

2. Press

or to select the new shot size.

to accept, or to cancel.

Page 14

Disable Mode, Entering Set-up Screens

Machine Disable Mode (“ ”red)

2. To enter the calibration screens, press . To

enter the maintenance screens, press to Figure 9 for a screen navigation diagram.

. Refer

Setup Screens with Passwords Enabled

1. From the Run screen press . If a password has

Figure 6: Typical Run Screen when Machine in

“Disable” Mode

1. At any time and from any screen, to immediately

disable all machine motion, press (red).

been programmed, the Password Entry Screen (Figure 8) will be displayed.

2. If activated, the purge timer will be disabled

3. To resume operation, the machine must be put back into an operating mode as described in the Machine Mode Selection section.

4. If activated, the purge timer will not restart until a shot is taken.

Setup Screens

Before the machine will operate properly, it must be calibrated and shot size information must be entered.

Entering the Setup Screens

1. From the Run screen press . If no password has been programmed into the HMI, the Programming Mode Selection Screen (Figure 7) will be displayed.

Figure 8: Password Entry Screen

2. Enter the 6 digit password by pressing the corresponding soft keys, G-J in Figure 5.

3. After the 6

4. If the correct password has been entered, the Programming Mode Selection Screen will be displayed. Refer to Figure 9 for a screen navigation diagram.

5. If the incorrect password has been entered, the password entry will need to be repeated until the correct 6-digit sequence is entered.

6. To abort the password entry, press

digit has been entered, press .

Figure 7: Programming Mode Selection Screen

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Page 15

Screen Layout

Figure 9: PR70 Screen Navigation Diagram

312393C 15 of 52

Page 16

Priming and Calibration

Machine Priming

Before the machine can be properly calibrated with material, it will need to be primed.

Read all manufacturer’s warning and material MSDS to know the specific hazards of the material used.

From the Run Screen press then press . The following screen will be displayed.

Figure 10: Maintenance Screen for Priming (M1)

Key:

A Full Retract ICON B Full Extend ICON C Change Dispense Valve Mode

= Always Open

= Always Closed

= Opens at Cylinder Entrance (Automatic) D Current Piston Position E Current Dispense Valve Mode F Screen Number (C1)

& keys will navigate to adjacent screens.

1. Place a waste container under the dispense valve

to capture any dispensed material.

2. Press

3. Press

until the upper ICON is .

to extend the piston fully.

Be careful not to pinch fingers when manually moving the machine drive block.

Piston Position Calibration (C1)

This step should be executed the 1st time the machine is setup, and may not need to be re-executed unless the position sensor, an electronic component or a piston has been replaced.

From the Run Screen press following screen will be displayed.

Figure 11: Piston Position Calibration Screen (C1)

Key:

A Full Extend position number from last calibration B Full Extend Command ICON C Full Retract position number from last calibration D Full Retract Command ICON E Cylinder Entrance position from last calibration F Cylinder Entrance Command ICON H Current Piston Position Field I Screen Number (C1)

& keys will navigate to adjacent screens.

1. Place a waste container under the dispense valve to capture any dispensed material.

2. With air pressure applied to the machine, press

3. The piston should fully extend and a number between 3600 to 3900 should appear for ‘H’

4. Press

to accept the number or to keep the

current number.

then press . The

4. Press to retract the piston fully.

5. Repeat steps 3 and 4 until both materials dispense from the valve without air.

6. Press

twice to return to the Run screen.

Machine Calibration

Before the machine will accurately dispense, it must be calibrated.

312393C 16 of 52

5. Press

6. The piston should fully retract and a number between 200 to 400 should appear for ‘H’

7. Press

to accept the number or to keep the

current number.

8. Decrease the air pressure by adjusting the machine air pressure regulator to a minimal value (i.e. ~ 10 20 psi).

9. Press

Page 17

Priming and Calibration

10. The machine pistons should extend slowly until they encounter the cylinder entrance and a number between 1600 to 1900 should appear for ‘H’.

11. If the pistons do not move, manually move the piston by pulling on the machine drive block, until mechanical resistance is encountered at the cylinder entrance.

12. Press

to accept the number or to keep the

current number.

13. Adjust the Air Pressure Regulator back to a reasonable value for proper machine operation.

14. Press

twice to return to the Run screen.

Phasing (C2)

To enable the machine to dispense the correct ratio of material from the A and B tanks and to mix properly, both materials will need to enter the static mixer at the same time. Phasing shots will need to be executed to visually verify that the 2 materials are exiting the dispense valve at the same time.

Remove any static mixer attached to the dispense valve, and replace it with a ratio check nozzle. Place a waste container under the valve to capture any dispensed material.

From the Run screen, press

press

once. The following will screen will be displayed.

, then press , and then

1. Select the location where the piston will reverse

(from the extend to retract motion) by pressing

keys. Pressing will decrease the phasing

shot. Pressing

will increase the phasing shot. A “+” value indicates that the piston will reverse beyond the cylinder entrance. A “-“ value indicates the piston will reverse prior to reaching the cylinder entrance.

2. Press

(green) or the footswitch.

3. During the shot execution, visually monitor the 2 materials exiting the ratio check nozzle. If the timing of the 2 materials exiting the nozzle cannot

be properly observed, press

or accordingly,

then repeat step 2.

4. If the A side material exits the ratio nozzle before

the B side material (“ ”), turn the B piston Phase Adjustment Screw/ Locking nut and shaft counterclockwise to move the B piston forward, as

indicated on the

ICON. Slight adjustments in the piston shaft will be significant. Adjustments of a quarter turn are typical.

5. If the B side material exits the ratio nozzle before

the A side material (“

”), turn the A piston Phase Adjustment Screw/ Locking nut and shaft counterclockwise to move the A piston forward, as

indicated on the

ICON.

Figure 12: Phasing Calibration Screen (C2)

Key:

A A material leads B ICON B Adjust B side Forward ICON C B material leads A ICON D Adjust A side Forward ICON E A and B Exit the Same Time ICON F Do NO Mechanical Adjustment ICON G Phase Shot Request ICON I Screen Number (C2)

& keys will navigate to adjacent screens. K Decrease Phase Shot Percentage Amount ICON L Current Phase Shot Percentage Amount M Increase Phase Shot Percentage Amount ICON

6. Repeat step 2 until both materials exit the ratio

check nozzle at the same time (“

7. Press

twice to return to the Run screen.

”).

Open Dispense Valve (ODV) Setting (C3)

The next step in the calibration process is to determine the proper position to open the Dispense Valve (DV) during the shot.

Advancing or increasing the opening position (in millimeters) will build more pressure in the material hoses prior to the dispense valve opening. If the Dispense Valve opens too late in the shot, a surge of material can occur or the piston could stall. If the Dispense Valve opens to early in the shot, material “drooling” at the beginning of the dispense cycle could occur.

From the Run screen, press

press

2 times. The following screen will be displayed.

, then press , and then

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Page 18

Priming and Calibration

Figure 13: Open Dispense Valve (ODV) Screen (C3)

Key:

A Current ODV Adjustment (in mm from the cylinder

entrance). B Adjust ODV value Option ICON. C Relative ODV Position ICON with respect to

cylinder entrance (This ICON will move right or

left at +/- mm transition). D Cylinder Entrance ICON (stationary). I Screen Number (C3)

& keys will navigate to adjacent screens.

1. To adjust the ODV position with respect to the

cylinder entrance, press

From the Run screen, press

, then press , then press

3 times. The following screen will be displayed.

Figure 14: Stroke Calibration (CAL) Screen (C4)

Key:

A Short Shot Column ICON B Last/Current Short Shot weight (mass) entry. C Long Shot Column ICON D

Last/Current Long Shot weight (mass) entry.

E Grams (Weight or Mass unit used) F Short Shot ICON G Long Shot ICON I Screen Number (C4)

& keys will navigate to adjacent screens.

2. Press

to increase the value or to decrease the value. Values of – 5.0 mm to + 5.0 mm are allowed.

3. Press

to accept the value or to retain the previous value. The default value from the factory is – 1.0 mm.

4. Press

twice to return to the Run screen.

Machine Calibration Shots (C4)

Read all manufacturer’s warning and material MSDS to know the specific hazards of the material used.

Calibration shots are necessary to program the machine to properly dispense the correct amount of

material. Several short CAL shots (“

long CAL shots (“

”) are required.

”) and several

Remove the ratio check nozzle, install the static mixer intended to be used, and adjust the air pressure to the level intended for use during normal operation.

The air pressure must be set to operating conditions for this step. Significant changes in air pressure could adversely affect shot accuracy.

1. Press to arm the machine to take a short CAL

shots. The icon will be highlighted (“

”). Press

to de-arm the machine.

2. Place the empty container below the static mixer,

and press

(green) or the footswitch.

3. Press and discard the contents of the material dispensed

4. Repeat the previous 2 steps until the static mixer is filled with material. Verify the material dispensed from the mixer is mixed properly.

5. Place a container on a scale and tare (zero) it.

6. Place the tared container below the static mixer,

and press

7. Press

(green) or the footswitch.

to erase existing average weight data.

8. Place the container with the dispensed material on the tared scale.

9. Enter the mass in grams into the HMI, by pressing

or accordingly.

10. Press to accept the number. The number entered will be transferred to the right of the average icon (“

”).

11. Repeat steps 5 through 10, skipping step 7, several times. Each additional shot weight will be averaged in the

row with the previous shots.

312393C 18 of 52

Page 19

Priming and Calibration

12. Press to arm the machine to take a long CAL

shots. The icon will be highlighted (“

to de-arm the machine.

13. Place a container on a scale and tare (zero) it.

14. Place the tared container below the static mixer,

and press

15. Press

16. Place the container with the dispensed material on the tared scale.

17. Enter the mass in grams into the HMI, by pressing

or accordingly.

18. Press entered will be transferred to the right of the average icon (“

19. Repeat steps 13 through 18, skipping step 15, several times. Each additional shot weight will be averaged in the row with the previous shots.

20. Press

21. Press

(green) or the footswitch.

to erase existing average weight data.

to accept the number. The number

”).

to de-arm the cal shot.

twice to return to the Run screen.

”). Press

I Screen Number (M2).

& keys will navigate to adjacent screens.

1. Press . The following screen will be displayed:

Figure 16: M2 Shot Definition Screen

2. Press or to select a shot number to define.

3. Press or to enter the shot size.

The shot size (in grams) must be greater than the Short CAL Shot size from the previous C4 calibration screen.

4. Press previous value.

5. Repeat the previous 2 steps for other shot sizes as required.

to accept the value or to retain the

Shot Size Definition (M2)

To dispense in Shot Mode, one or more, up to 5, shot sizes need to be entered. This step is not required for Operator mode.

From the Run screen, press

press

Figure 15: Shot Size and Purge Timer Screen (M2)

Key:

A Shot Number B Shot Size (in grams). C Purge Timer Setting (Turned OFF in Figure 15).

Purge Timer Alarm Setting.

E Define Shot ICON F Set Purge Timer ICON G Purge Timer Warning ICON.

once. The following screen will be displayed.

, then press , and then

6. Press

7. Press twice to return to the Run screen.

to exit the Shot Definition screen.

Ratio Checks

Read all manufacturer’s warning and material MSDS to know the specific hazards of the material used.

This is a procedure to verify the weight ratio between the 2 materials. This is easiest to do with two scales.

1. From the Run screen, put the machine in Shot

mode (“

2. Verify that the machine is properly calibrated and phased as outlined in the calibration section.

3. Remove any static mixer attached to the dispense valve and replace it with a ratio check nozzle. Place a waste container under the valve to capture any dispensed material.

4. Select a shot size between the Short and Long CAL

shot sizes previously done, by pressing

and

5. Place the empty container below the Ratio Check Nozzle and the footswitch. Discard this shot.

to accept.

”). See page 13.

312393C 19 of 52

Page 20

Priming and Calibration

6. Place an empty container on a scale, and tare (zero) the scale. Repeat the process with a 2 container on a 2

scale.

7. Place both containers under the ratio check nozzle, positioned so one container captures material A, and the 2

container captures material B.

8. Press the footswitch.

Miscellaneous Machine Setups

The following sections outline how to configure various optional settings.

Manual Control Options (M1)

The user can control the machine’s piston position and displacement valve operation manually the M1 screen.

From the Run Screen press following screen will be displayed.

then press . The

9. After the material is dispensed, place each container on the same scale, and measure the net mass of each of the materials. Record the mass of both the A and B materials.

10. Divide the A material mass by the B material mass to obtain the material ratio being dispensed.

Manual DV Control:

1. To change the DV operation press the third blue key from the left.

2. When the Current Dispense Valve Mode (E in

Figure 17) is

, the valve will open and stay open

regardless of the piston position.

3. When the Current Dispense Valve Mode is

, the valve will close and stay closed regardless of the piston position.

Figure 17: Maintenance Screen (M1)

Key:

A Full Retract ICON B Full Extend ICON C Change Dispense Valve Mode

= Always Open

= Always Closed

= Opens at Cylinder Entrance (Automatic) D Current Piston Position E Current Dispense Valve Mode F Screen Number (C1)

& keys will navigate to adjacent screens.

Manual Piston Control:

4. When the Current Dispense Valve Mode is , the valve will be in automatic mode, opening when the pump gets to the cylinder entrance and closing when it gets to the end of the cylinder.

5. Press

twice to return to the Run screen.

Purge Timer / Alarm Settings (M2)

When activate, the Purge Timer will automatically dispense a shot if the machine is idle (not dispensing material) for a programmed duration of time. This prevents the mixed material from hardening in the static mixer. To set the Purge Timer;

From the Run screen, press

press

once. The following screen will be displayed.

Figure 18: M2 after Purge Timer Selection

, then press , and then

1. Press to extend the piston.

2. Press to retract the piston.

312393C 20 of 52

1. Press .

2. Press

or to enter the purge timer value. This idle time allowed before the machine will automatically dispense a shot to clear the mixer.

Page 21

Miscellaneous Machine Setups

3. Press to accept the value or to retain the previous value.

Figure 19: M2 after Purge Shot Size Prompt

4. Press or to enter the purge shot size (in grams). Enter a number with at least as much volume as the mixer.

5. Press previous value.

6. Press

Activating the purge timer automatically activates the

purge alarm the purge timer reaches zero that the machine will sound a warning beep to signaling that it is about to take a purge shot. To change the Purge Alarm value;

From the Run screen, press

press

to accept the value or to retain the

twice to return to the Run screen.

. This is the amount of time before

, then press , and then

once. The following screen will be displayed.

From the Run screen, press

press

Figure 21: M3 Cycle Counter and Silent Mode Control

Key:

A Total Pump Cycle Counter Value (Not Resetable) B Resetable Cycle Counter Value C Current Silent Mode State ICON

D Reset Cycle Counter ICON E Toggle Silent Mode ICON. I Screen Number (M3)

1. Press .

2. Press

2 times. The following screen will be displayed.

Silent Mode Off

Silent Mode On

& keys will navigate to adjacent screens.

to accept the value or to retain the

previous value.

, then press , and then

Figure 20: M2 after Purge Alarm Selection

1. Press .

2. Press (in seconds). The minimum value is 2 seconds, and a maximum of 59 seconds or the value of the purge timer if the timer is more than 59 seconds.

3. Press previous value.

4. Press

or to enter the purge alarm duration

to accept the value or to retain the

twice to return to the Run screen.

Cycle Counter and Silent Mode Control (M3)

Resetting the Cycle Counter:

The cycle counter shown on the Run screen, see Figure 6, shows the number of pump cycles since the last time the cycle counter was reset. To reset the cycle counter:

3. Press

twice to return to the Run screen.

Silent Mode Operation:

The default setting is , Silent Mode Off, where audio feedback is provided when a valid key (1 short tone), or an invalid key (3 short tones) is pressed.

, Silent Mode On, audio feedback is not provided. Silent Mode On has no effect on the audio sounds provided for the purge timer alarm, an error code, or when power is initially applied to the machine.

To toggle or change the silent mode:

From the Run screen, press

then press be displayed.

1. Press

2. Press

previous setting.

3. Press

2 times. Screen M3, see Figure 21, will

or .

to accept the change or to retain the

twice to return to the Run screen.

, then press , and

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Page 22

Miscellaneous Machine Setups

Date and Time Settings (M4)

At the bottom right corner of the Run screen the date is shown in DD-MM-YY format and the time is shown in HH:MM, 24 hour format. The formats cannot be changed.

To set the current date:

From the Run screen, press

press

Figure 23: M4 Screen for Setting the Date and Time Key:

A Current Date (DD-MM-YY) B Current Time (HH:MM, 24 Hour Format) C Current Software Revision

D Date Set ICON E Time Set ICON. I Screen Number (M4)

1. Press . The M4 screen will appear as follows.

Figure 24: M4 Screen after Date Set Selection

3. Press and to enter the year.

4. Press

5. Press

6. Press

7. Press

8. Press to accept the change or to retain the

9. Press

3 times. The following screen will be displayed.

Dsp = Display Module FCM = Fluid Control Module

& keys will navigate to adjacent screens.

to accept the change or to retain the

previous setting.

and to enter the month.

to accept the change or to retain the

previous setting.

and to enter the day.

previous setting.

twice to return to the Run screen.

, then press , and then

1. Press

. The M4 screen will appear as follows.

Figure 25: M4 after Time Set Selection

2. Press and to enter the hour (0 - 23).

3. Press

previous setting.

4. Press

5. Press

previous setting.

6. Press

to accept the change or to retain the

and to enter the minutes (0 - 59).

to accept the change or to retain the

twice to return to the Run screen.

Tank Level Sensing and Velocity Change (“

”) Options (C6)

If tank level sensors are installed into the system, an alarm is generated when a tank is almost empty. If the

feature is turned ON, a Tank A low (“

low (“ generated if the condition exists.

The machine also measures the piston velocity and will generate an alarm if the piston velocity has changed significantly since the machine was last calibrated. A significant change is piston velocity, usually caused by a change in air pressure, can degrade shot size accuracy.

The user has the capability to turn the

by selecting a level of 0%, or ON by selecting of 20%, 40% or 60%. For instance, if 40% is selected, and the piston velocity changes by + or – 40%, an error code will be generated after the corresponding shot to inform the operator of the situation. If the velocity

increases above the selected level, a error will be generated, and if the velocity decreases below the

selected level a

The machine is in Operator mode, or when the machine is executing a purge shot.

From the Run screen, press

”), or a both tanks are low (“ ”) error will be

error will be generated.

feature is automatically disabled when the

, then press , then press

5 times. The following screen will be displayed.

”), a Tank B

feature OFF

levels

To set the current time:

312393C 22 of 52

Page 23

Miscellaneous Machine Setups

Figure 26: Tank Level and

Key:

A Current Tank Level Mode

= OFF, = ON

B Current

D Turn ON / OFF Tank Level Sensing ICON

level

= OFF

= 20% change before warning

= 40% change before warning

= 60% change before warning

(C6)

E Change I Screen Number (C6)

To turn the Tank Level Sensors On/Off:

1. Press or .

2. Press

3. Press

To turn the Velocity Change On/Off:

1. Press

2. Press

3. Press

& keys will navigate to adjacent screens.

previous setting.

Level ICON

to accept the change or to retain the

twice to return to the Run screen.

to accept the change or to retain the

twice to return to the Run screen.

Password Setup / Clearing (C5)

The machine has the capability to limit access to the Maintenance and Calibration screens. The password option can be configured into 1 of the following 3 possibilities:

a. No Password (default configuration, when machine

shipped): All users can access all setup screens to configure the system.

b. One password (“

maintenance and calibration screens (

c. Two passwords:. One password allows access to

both the calibration and maintenance screen (

+ ). The second password only allows

access to the maintenance screens (

To alter the password configuration:

From the Run screen, press

press

4 times. The following screen will be displayed.

”): Allows access to both the

+ ).

= ).

, then press , and then

Figure 29: C5 Screen with at least 1 Password

Configured

Key:

A Administrative Password ICON B Access Indicator for Administrative Password D Entry Status (Only filled after password change). E Maintenance ONLY Password ICON F Access Indicator for Maintenance ONLY Password G Administrative Password Set/Clear ICON H Maintenance ONLY Password Set/Clear ICON I Screen Number (C5)

& keys will navigate to adjacent screens.

Setting/Clearing an Administrative Password:

1. Press . The following screen will appear.

312393C 23 of 52

Page 24

Password Setting/Clearing

Figure 30: Administrative Password Entry with NO

Previous Password Stored

If a previous Administrative password has been entered, the number at the top of the screen is the existing password. A zero indicates no Administrative password.

To clear the password, enter “000000”.

2. Enter a 6-digit sequence, by pressing the corresponding soft keys, G-J in Figure 5. After the 6th key entry, the enter LED will blink.

3. Press

4. Re-enter the same 6-digit number.

5. Press

to accept.

3. Press

4. Re-enter the same 6-digit number.

5. Press

6. If both 6-digit passwords match, the C5 screen will be displayed, and an “OK” after the second row of symbols. If the 2 numbers do not match, the process will need to be repeated.

7. Press

With a Maintenance ONLY password, after the user enters the password from the Password Entry screen, the following screen will be displayed.

to accept.

twice to return to the Run screen.

Figure 32: Mode Selection Screen after

Maintenance ONLY Password Entry

6. If both 6-digit passwords match, the C5 screen will be displayed, and an “OK” after the first row of symbols. If the 2 numbers do not match, the process will need to be repeated.

7. Press

twice to return to the Run screen.

Setting/Clearing a Maintenance ONLY Password:

1. Press . The following screen will appear.

Figure 31: Maintenance ONLY Password Entry with

NO Previous Password Stored

If a previous Maintenance Only password has been entered, the number at the top of the screen is the existing password. A zero indicates no Administrative password.

To clear

the password, enter “000000”.

Resetting Passwords

If for whatever reason, the passwords for the machine are not known, the passwords can be reset.

To reset all the passwords to 000000:

1. Temporarily remove power to the HMI.

2. Re-apply power to the HMI.

3. Immediately after the completion of the startup

sequence ( the second soft key for at least 6 seconds.

If the press and hold does not start immediately after the animation sequence, or the press and hold is interrupted, the procedure will need to be restarted at step 1.

4. After 6 seconds, the HMI will generate a single tone indicating that the passwords have been cleared.

5. New passwords may be entered by following the steps in Password Setup / Clearing.

, , , , , ….), press and hold

2. Enter a 6-digit sequence, by pressing the corresponding soft keys, G-J in Figure 5. After the 6th key entry, the enter LED will blink.

312393C 24 of 52

Page 25

Hibernate and Demo Modes

Miscellaneous Machine Features

HMI Hibernate Mode

To help preserve the life of the HMI backlight, the HMI will enter a Hibernate mode after the machine has remained idle for an extended period of time. To exit Hibernate mode, the user simply needs to activate a HMI key or the machine footswitch.

When in Hibernate mode, the HMI LCD backlight

will be turned OFF, and the enter LED will blink at a slow duty cycle (1 part ON, 8 parts OFF).

If the machine performs a purge shot when the HMI is hibernating, the HMI will remain in Hibernate mode.

HMI Startup Animation Sequence

When power is applied to the machine, the

electronics need time to initialize communication. An “Hour Glass” animation sequence is generated

, , , , , ….). Attempts to use the

( machine during the startup period will be rejected.

HMI Demo Mode Operation

The machine HMI is equipped with a demonstration mode. When in “Demo Mode”, the HMI will not send any requests to the Fluid Control Module and the machine will not operate. The HMI will simulate normal operation and provide audio feedback to the user. All Demo Mode Maintenance and Calibration screens are identical to screens provided in normal mode operation.

Demo Mode can be used as a training tool for the

user. The user simply has to connect the HMI unit to a separate power supply module, and the HMI will operate normally without the machine attached.

Any calibration, passwords, shot sizes, purge timer

settings, or other miscellaneous settings entered while operating in Demo mode normal mode settings. Also, the first time Demo mode is entered, all the calibration & maintenance screen setups previously described will need to be repeated.

WILL NOT alter any

If the press and hold does not start immediately after the animation sequence, or the press and hold is interrupted, the previous and this step may need to be repeated.

4. After 6 seconds, the HMI will generate a single tone and the Demo Mode ON or OFF state will be changed.

5. When in Demo Mode, a “D” will remain on the bottom left-hand corner of the Run screen, as indicated in the following figure.

Figure 33: Typical Run Screen in Demo Mode

6. To switch the HMI out of Demo Mode, repeat the previous steps.

Limitations of Demo Mode Simulation

Even though Demo Mode provides a good training simulation for the user, it does have limitations when compared to the HMI operating in normal mode.

• On the Run screen, all the shot mode shots are simulated as single piston stroke shots regardless of the shot size and calibration numbers entered.

• The run screen animation sequence of the piston movement is not as gradual as in real operation.

• On the Run screen, during Operator mode operation, a stalled piston condition is not simulated.

• The piston cycle counter is not stored for use after power interruption, so if power is cycled to the HMI, the cycle count will be reset.

• The piston position numbers provided on the C1 screen are simulated.

To configure the HMI into and out of Demo Mode:

1. Temporarily remove power to the HMI.

2. Re-apply power to the HMI.

3. Immediately after the completion of the startup

sequence ( hold the first soft key for at least 6 seconds.

312393C 25 of 52

, , , , , ….), press and

• All error codes will be NOT be generated, except a stuck key error (E11) if the condition exists.

Page 26

Pressure Relief and Shutdown Procedures, Error Codes

Pressure Relief Procedure

With the machine in an idle state:

1. If the machine pistons are not fully retracted,

retract the pistons by pressing screen. See Figure 17.

in the M1

2. Manually open the dispense valve by pressing

the third M1 soft key until the “ shown in the Current DV field. See Figure 17.

3. Remove the incoming air pressure by closing the air inlet valve (item 13 in Figure 54).

” ICON is

Standby/Shutdown Procedure

If the machine is to remain idle for an extended period of time, implement the following:

1. Remove any static mixer installed at the end of the dispense valve.

2. Place a container below the valve, and activate a small shot to flush material away from the end of the valve.

3. To prevent accidental pump movement, press

(red).

4. With a clean rag, clean the end of the dispense valve to remove excess material.

5. Install a nightcap at the end of the valve.

Error Codes

When the machine is operating and a fault is detected, it will report the condition by generating an error code. Error codes are typically generated when the machine is idle after dispensing a shot.

When error codes are generated, a screen will be displayed which contains an animation sequence, the error code number and an ICON symbol representing the condition detected. The HMI will also output an error code tone sequence. The tone sequence cannot be disabled.

When errors are generated, the machine will

automatically be disabled and remain in an idle state until the user acknowledges the condition. Any active purge timer present prior to error code generation will be suspended, and will need re-started by requesting a shot after the error is acknowledged.

Figure 34: Typical Error Code Screen

Key:

A Error Code Animation Field

B Error Code Number Field

D Error Code ICON E Error Code Acknowledgement ICON

When an error code is generated, the user will need to acknowledge the condition by pressing the soft key

under the

After the user activates the generated in the Figure 34 example, will be displayed on the bottom left hand corner of the Run screen, while the condition is still present.

Figure 35: Typical Run Screen with an Active

The example E12 number on the main run screen will remain on the run screen as long as the error condition exists. If the problem is corrected the example E12 number will be removed.

If more than 1 error code condition exists for the machine, the corresponding “EXX” numbers will be listed on the bottom left corner, separated by commas.

ICON.

key, the error number

Error Code Condition

The following typical screen is generated when an error code is generated:

312393C 26 of 52

Page 27

Error Code Table

Title # Cause, Details ICON

Stuck Key Error

E11

key on membrane has been active (pressed) for > 30 seconds continuously. Replace the HMI. This error code does not require user acknowledgment and will clear itself automatically if the condition is removed.

Communication Error

No or Invalid Run Token Error

Piston Stroke Time-out Error

Less than Minimum Shot Requested Error

Improper Calibration Error

Delta Velocity (“V”) Minus Error

E12 The Display module has lost communication with the Fluid Control Module.

Material dispensing will be disabled if this condition exists. Check communication cables between the 2 electronic components, or check the HMI and/or the Fluid Control Module.

This error will be regenerated continuously while the condition exists.

E13 The Run Token in the FCM is missing (not installed), or does not have the

correct data.

E21 A piston stroke action has taken > 55 seconds. Typically caused by no/too

little air pressure to the machine or a mechanical interference with the piston has occurred. Check machine input line pressure.

E23 User has requested a shot < the minimum allowable size entered during

calibration. (< 15% of stoke, N/A in Operator Mode).

E24 The calibration done on the machine is invalid, so the requested shot cannot

be executed. For instance, a Large Stroke Calibration Shot mass which is less than the Short Stroke Calibration Shot mass (C4 screen) will create this error code. If the wiring to the linear position transducer is reversed this error will appear. If invalid piston positions are calibrated into the machine (C1 screen) this error will appear.

E25 The piston velocity is slower than the calibration velocity measured, by the

percentage amount selected by the user (20%, 40% or 60%). If the user selects 0%, this monitoring or alarm feature is disabled.

Delta Velocity (“V”) Plus Error

Low Material Level, Tank A Alarm or Error

Low Material Level, Tank B Alarm or Error

If generated, shot size accuracy may be degraded. Typically the problem is created when the machine pressure regulator is adjusted to different value from when the machine was calibrated. Another less likely cause could be a mechanical failure with dispensing (worn piston, etc.). This error will not be generated for a purge shot or when the machine is in Operator mode.

E26 The piston velocity is faster than the calibration velocity measured, by the

percentage amount selected by the user (20%, 40% or 60%). If the user selects 0%, this monitoring or alarm feature is disabled.

E27 Tank A is low (only generated if tank sensing is enabled). Fill tank A with

material.

Tank level errors will be generated after every shot if the condition still exists.

E28 Tank B is low (only generated if tank sensing is enabled). Fill tank B with

material.

Tank level errors will be generated after every shot if the condition still exists.

312393C 27 of 52

Page 28

Error Code Table

Low Material Level, Both Tanks Alarm or Error

E29 Both tanks are low (only generated if tank sensing is enabled). Fill both tanks

with material.

Tank level errors will be generated after every shot if the condition still exists.

Bad Linear Position Sensor

E50

There is a fault with the linear position sensor. Check wiring or replace.

Table 1: Error Code Table

312393C 28 of 52

Page 29

ICON Tables

ICON Descriptions

Key Key Description Screen

Maintenance and Calibration Screens Enter / Exit. All

Shot Mode / Operator Control Mode Selection. Run

Shot Request

(green)

Red Stop or Cancel (Stops Operation Immediately, regardless of Screen). All

Up (Used to Raise Numerical Entry, Screen Navigation or Shot Selection). Many

Down (Used to Lower Numerical Entry, Screen Navigation or Shot Selection). Many

Enter (Used to Accept Entry). Many

Run, C2,

Soft (Changes Function, Depending Upon Screen). All

Table 2: PR70 HMI ICON Table

ICON Description Screen

Calibration Screens.

Maintenance Screens.

Option Abort or Escape. Many

Piston Full Extend. C1, M1

Piston Full Retract. C1, M1

Metering Tube or Cylinder Entrance. C1

Phasing Shot. C2

Decrease Phasing Shot. C2

Increase Phasing Shot. C2

Open Displacement Valve (DV) Position Adjustment. C3

312393C 29 of 52

Tables 3: PR70 Screen ICON Tables

Page 30

ICON Tables

ICON Description Screen

Short Stroke Calibration Shot C4

Long Stroke Calibration Shot C4

Administrative Password Set/Clear C5

Maintenance Only Screens Password Set/Clear C5

Tank Level Sensing ON C6

Tank Level Sensing OFF C6

Delta Velocity Set Level (0 = OFF) C6

Displacement Valve Always Open M1

Displacement Valve Always Closed M1

Displacement Valve Automatic Operation M1

Shot Size Definition M2

Purge Timer Set/Clear M2

Purge Shot Size M2

Purge Alarm Setting M2

Zero Cycle Counter M3

Silent Mode ON M3

Silent Mode OFF M3

Set Date M4

Set Time M4

Tables 4: PR70 Screen ICON Tables (Continued)

312393C 30 of 52

Page 31

Maintenance, Software Upgrades and Run Token

Maintenance

The following items should be checked daily, once during a shift, or as required for the application:

• Air Filter - Check air filter and release any water circuit water trapped in the base of the filter.

• Tanks – Check material levels and refill as necessary. Verify the material reservoirs are vented properly.

• Air Dryer - Check the condition of the desiccant air dryer, and replace if necessary.

• Pump Shafts – Clean both pump shafts with solvent and lubricate with approved lubricant such as mesamoll or Silicon oil.

• Dispense Head – Dismantle, clean thoroughly and re-assemble. Lubricate all parts with a thin coat of approved lubricant, or silicon oil.

• Ratio Check – If material ratio is critical for the application, implement the ratio check procedure as required.

4. Insert a black programming token into the slot provided. Make sure it snaps into place when inserted.

5. Turn ON the AC power switch.

6. Verify the red LED on the FCM or HMI starts blinking at a fast steady rate, then the red LED stops flashing accordingly. Verify the Green LED is on continuously, and the amber LED blinks every few seconds.

7. Turn OFF the AC power switch.

8. Remove the programming token from the FCM or HMI. If the second electronic component needs updating, insert the token into the other electronic module. If the FCM was re-programmed, re-insert the blue run token in the slot provided.

9. If programming a second electronic module, repeat steps 5 through 8.

10. Re-apply machine power.

11. Go to the M4 screen to verify the new software revision(s).

Software Upgrades, Run Token

When software in the HMI or Fluid Control Module (FCM) needs updating, a black Graco update token is used.

Figure 36: Standard Graco Data Token

To transfer an updated software program from the token to the PR70 HMI or FCM:

1. Turn OFF the AC power switch in the back of the machine.

2. If updating the Fluid Control Module (FCM), open the access door to the FCM by loosening the 2 access screws. Remove the Blue Run token from the FCM.

Run Token

The PR70 Fluid control module (FCM) contains a blue run token, installed in the socket provided. It has identical appearance to the black programming token, but is blue.

If the token is not installed into the FCM, the machine will not operate, and an E13 error will be generated on the display module. Hence, if the FCM software is updated, it will need to be re-installed at the end of the re-programming procedure.

3. If updating the Human Machine Interface (HMI), remove the HMI from the mounting bracket and remove the back cover by removing the 4 screws on the back of the enclosure.

312393C 31 of 52

Page 32

Troubleshooting

Before starting any troubleshooting procedures:

1. Relieve pressure (refer to Pressure Relief

2. Disconnect AC power to the machine.

HMI Display Completely Dark

No or incorrect amount of material dispensed from either side

Piston stalled (E21 Error)

Significant material leaking from pump rear seal

Material dispensed not correct weight

Machine dispensing off ratio

Pumps drawing material back from valve hose

Procedure Section).

PROBLEM CAUSE SOLUTION

No Power Verify rear AC Power switch is ON. Fuse Blown Replace Machine fuses (Refer to “Miscellaneous

Loose connection Tighten 5 pin cable on HMI. Bad HMI Replace HMI Ball Valve Closed Open Tank Ball Valve (if installed). Tank empty Fill tank with material Tank Cloged Verify no obstruction in the tank Air in material Prime the machine until the air is removed. Check valve malfunction Remove, clean or replace check valve. Piston worn or broken Remove and replace piston if worn. Input Air Reduced or removed Mixer blocked Replace static mixer. Incorporate or decrease

ODV adjustment too late Re-adjust the ODV setting to occur sooner (C3

Blocked Check valve Remove check valve, clean and replace. Air Cylinder Failure Remove air cylinder and re-install cylinder kit

Pump Shaft worn Remove pump shaft assembly, and re-install rear

Specific gravity of 1 or more of the 2 materials has changed since calibration. Machine Air pressure has changed since calibration.

Not enough material in 1 or more tanks Mixer has slight obstruction Replace static mixer. Re-prime machine. Check valve malfunction Remove check valve(s), clean or replace if

Piston worn or broken Remove and replace piston(s) if necessary. One tank is empty Check tank levels. Add material if necessary. Tank Ball valve Closed Open tank ball valve. Re-prime machine. Machine out of phase Re-phase machine (C2 section). Check valve malfunction Remove check valve(s), clean or replace if

Piston worn or broken Remove and replace piston(s) if necessary. Check valve stuck open Remove check valve(s), clean or replace if

3. Allow the machine to cool, if the machine has a heat control option.

Try the recommended solutions in the order given for the each problem to avoid unnecessary repairs. Also verify all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.

Mechanical Assemblies” Section).

Re-connect input air line to machine. Increase air pressure regulator adjustment.

purge time amount to prevent mixer blockage.

screen section).

items if necessary.

pump re-built kit. Mix materials in tanks, dispense another shot, then re-weigh. Re-calibrate if necessary (C4 section). Re-adjust air pressure regulator to value used when machine was calibrated, or re-calibrate (C4

section). Turn ON or decrease

% level. Check tank levels, and fill and prime if necessary.

necessary.

312393C 32 of 52

Page 33

Base Frame and Air Cylinder Assemblies

Repair

Major Mechanical Assemblies, and Attachments

Figure 38: PR70 Top View w/o Tanks with Footswitch and HMI Illustrated

Figure 39: PR70 Base Frame to Air Cylinder, Pump and Drive Block Attachments

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 LC0112 Pump Assembly, PR70 1 5 LC0107 Drive Block Assembly, PR70 1 2 120913 Screw, SHC, M8-1.25 x 25 4 6 121166 Screw, SHC, M6-1.0 x 40 4 3 120919 Nut, Hex, M14 7 LC0109 Base Frame Assembly 1 4 LC0110, or

LC0111

312393C 33 of 52

Air Cylinder Assemblies, 3.0” or 4.5” 1 8 121167 Screw, SHC, M8 - 1.25 x 40 4

Page 34

Base Frame and Air Cylinder Assemblies

Figure 40: PR70 Power Entry Bracket and Control Bracket Assembly Attachments

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 120885 Screw, SHC, M5 – 0.8 x 14 4 3 LC0106 Power Entry Assembly, PR70 1 2 LC0108 Control Bracket Assembly, PR70 1 4 120885 Screw, SHC, M5 – 0.8 x 14 2

Base Frame Assembly

Figure 41: PR70 Base Frame Assembly (LC0109)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 120599 PIN, DOWEL, 3/8DIAX1.50LG, SS 2 5 15K796 CLAMP 1 2 120885 SCREW,SHC, M5-0.8X14,MS,E 2 6 LC0033 TRANSDUCER ASSY, LINEAR, PR70S 1 3 120913 SCREW,SHC, M8X1.25X25,MS, E 2 7 120918 GUIDE, LINEAR 1 4 15K788 FRAME, BASE, PR70S, MACHINED 1 8 120886 SCREW, SHC,M6-1.0X25,MS,E 4

312393C 34 of 52

Page 35

Base Frame and Air Cylinder Assemblies

Air Cylinder Assemblies, and Rebuild Kits

Figure 42: PR70 Air Cylinder System and Schematic

312393C 35 of 52

Page 36

Air Cylinder Assemblies

Figure 43: PR70 Air Cylinder Assemblies, 3.0” & 4.5” Diameters (LC0110 & LC0111)

Key:

(LC0110, 3.0” DIA. Assy., PR70) (LC0111, 4.5” DIA. Assy., PR70)

Ref P/N Description QTY Ref P/N Description QTY

1 107571 ORING, VIT, BAD 1 1 107571 ORING,VIT,BAD 1 2 114100 SCREW, SHC, M4X0.7X55, MS, E 3 2 114100 SCREW, SHC, M4X0. 7X55,MS,E 3 3 120875 ORING, VIT, CCE 1 3 104131 ORING,VIT,CDG 1 4 120880 SCREW, SHC, M8-1.25 X 125, MS, E 4 4 120880 SCREW,SHC,M8-1.25X125,MS,E 4 5 120881 BEARING, 1.00ID X 1.252 OD X 1.00LG, 1 5 120881 BEARING, 1.00IDX1.252ODX 1.00LG 1 6 120884 SCREW, SHC, M12-1.75 X 20, MS 1 6 120884 SCREW, SHC,M12-1.75X20,MS 1 7 120899 VALVE, 4W, 3P, COE, DSSC, ¼ NPT, 24VDC 1 7 120899 VALVE, 4W, 3P,COE, DSSC, 1/4NPT, 24VDC 1 8 120900 VALVE, PWR, 4W, SSSR, 1/4NPT, 24VDC 1 8 120900 VALVE,PWR,4W, SSSR, ¼ NPT, 24VDC 1

9 120922 MUFFLER, AIR, ¼ NPT, FLOW CONTROL 1 9 120922 MUFFLER,AIR, 1/4NPT, FLOW CONTROL 1 10 120923 ELBOW, SWVL, ¼ TUBE X 10-32, FXM, 90 11 120932 ORING, VIT, JDA 2 11 104271 ORING,VIT,JDG 2 12 121018 ELBOW, SWVL, 3/8 TUBE X ¼ NPT, FXM, 90 13 121020 ELBOW, SWVL, EXT'D, ¼ X ¼ NPT, FXM, 90 14 121021 MUFFLER, AIR, ¼ NPT, BRONZE 3 14 121021 MUFFLER,AIR, ¼ NPT, BRONZE 3 15 121022 ELBOW, SWVL, ¼ TUBE X ¼ NPT, FXM, 90 16 15K790 TUBE, AIR CYL, 3.0 I.D., PR70S 1 16 15K789 TUBE, AIR CYL,4.5 I.D.,PR70S 1 17 15K791 BLOCK, AIR CYL, ROD END, PR70S 1 17 15K791 BLOCK, AIR CYL, ROD END, PR70S 1 18 15K792 BLOCK, AIR CYL, BLIND END, PR70S 1 18 15K792 BLOCK, AIR CYL, BLIND END, PR70S 1 19 15K793 PISTON,AIR CYL, 3.0 I.D., PR70S 1 19 15K794 PISTON, AIR CYL,4.5 I.D.,PR70S 1 20 15K795 ROD, PISTON, AIR CYL, PR70S 1 20 15K795 ROD, PISTON, AIR CYL,PR70S 1

, 1 10 120923 ELBOW, SWVL, ¼ X 10-32, FXM, 90o, CM/PL 1

5 12 121018 ELBOW,SWVL,3/8TUBEX ¼ NPT, FXM, 90DE 5

1 13 121020 ELBOW, SWVL, EXT'D, ¼ X ¼ NPT, FXM, 90

2 15 121022 ELBOW, SWVL, ¼ TUBE X ¼ NPT, FXM, 90DE 2

312393C 36 of 52

Page 37

Pump Assembly

To install a new Air Cylinder Kit:

1. Follow the Pressure Relief Procedure and turn off the machine.

2. Disconnect the airline, remove the PR70 Shroud, and remove the machine power entry assembly (item 3 or Figure 40) from the machine by removing the 2 attachment screws (4 of Figure 40).

3. Remove the 2 air valves (items 7 & 8) from the cylinder end block (18) by removing the 3 attachment screws (2).

4. Disconnect the air cylinder piston rod (20) from the machine drive block assembly (item 5 of Figure 39) by removing all hex nuts (item 3 of Figure 39) from the piston rod (additional nuts may be installed if the machine has a hydracheck option). An open-end wrench will be required to prevent the rod from turning when the nuts are removed.

5. Disconnect the air cylinder from the machine frame base assembly (item 7 of Figure 39) by removing the 4 screws (item 8 of figure 39) which attach the cylinder rod end block (17) to the frame. Access the screw through the 4 holes in the blind end block (18) using a long allen wrench.

6. Remove the air cylinder by pulling on the cylinder from the back of the machine.

7. With the cylinder partially removed, disconnect the airlines at the air cylinder elbow fittings (12).

8. On a bench, disassemble the air cylinder by removing the 4 long screws (4) which connect the 2 cylinder blocks.

9. Inspect the cylinder tube (16) and piston (19) to verify no scratches exist. Replace if necessary.

10. Using a clean dry cloth, remove any existing grease from the inside of the tube (16), the outside of the piston (19) and the cylinder rod (20).

11. Remove the 2 cylinder block orings (item 2 of Figure 40) from the blocks and replace. Remove the piston oring and replace (item 1 of Figure 40).

12. Remove the cylinder rod from the rod end block, then remove the rod oring (item 3 of Figure 40) from the rod end block and replace.

13. Install Graco high temperature lubricant Grease (Graco P/N 115982) to the inside of the tube (16), the outside of the piston (19), all the orings and the cylinder rod (20).

14. Re-assemble the air cylinder. Attach the 2 drive blocks by reinstalling the 4 long screws (4). Torque

the screws as specified in note

of Figure 43.

15. Reinsert the air cylinder into the back of the machine by inserting the cylinder rod through the hole in the base frame and in the drive block.

16. Before the cylinder is completely in place, reconnect the airlines to the cylinder block elbows fittings (12). Verify the correct airlines are connected (see Figure 43).

17. Reattach the cylinder to the base frame by reinstalling the 4 screws (item 8 of Figure 39).

18. Reattach the cylinder to the drive block by reinstalling the hex nut (item 3 of Figure 39) to the cylinder rod. Torque the nut as specified in note

of Figure 39.

19. Reattach the valves to the blind end block by reattaching the 3 screws (2).

20. Reattach the power entry assembly by reinstalling the 2 attachment screws (item 4 of Figure 40).

21. Reconnect input air into the machine. Operate the machine accordingly, and verify no air leaks are found. Recalibrate the machine.

Figure 44: PR70 Air Cylinder Rebuild Kits, 4.5” and 3.0” Diameter Versions (LC0092 & LC0091).

Key:

(LC0092, 4.5” DIA. Rebuild Kit) (LC0091, 3.0” DIA. Rebuild Kit)

Ref P/N Description QTY Ref P/N Description QTY

1 104131 ORING, VIT, CDG 1 1 120875 ORING, VIT, CCE 1 2 104271 ORING, VIT, JDG 2 2 120932 ORING, VIT, JDA 2 3 107571 ORING, VIT, BAD 1 3 107571 ORING, VIT, BAD 1

312393C 37 of 52

Page 38

Pump Assembly

Drive Block Assembly

Figure 45: PR70 Drive Block Assembly (LC0107)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 120891 SCREW, SHS, M6-1.0 X 8, MS 2 4 15K805 BLOCK, DRIVE, PR70S 1 2 15K801 ROD, ALIGNMENT 2 5 15K868 WASHER, SPERICAL, ½ DIA. MODIFIED 2 3 15K802 NUT, RETAINER 2 6 84/0130-

27/11

LABEL, HAND CRUSH, 1.3 X 1.1, TRIANGLE, ISO

Pump Assemblies and Rebuild Kits

Figure 46: PR70 Pump Assembly (LC0112)

312393C 38 of 52

Page 39

Pump Assembly

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 106258 ORING, VIT, JCB 2 9 15K803 COLLAR, PUMP 2 2 108712 NUT, HEX, M8 X 1.25, MS 2 10 15K804 HOUSING, BEARING, SEAL, PR70S 2 3 120887 POSIPAK, 0.375ID X 0.625OD, COIL 2 11 15K824 SHAFT, PISTON, 3/8, PR70S, SS 2 4 120890 RING, RET, INT, 1.00, SS 2 12 15K828 WASHER, SEAL, 3/8, PR70S, SS 2 6 120982 SCREW, SHC, M8 X 1.25 X 65, MS, E 8 13 15K895 HOUSING, CHECK VALVE 2 7 15K786 HOUSING, PUMP, PR70S, MACHINED 1 14 LC0093 KIT, REBUILD, VALVE, CHECK, PR70S 2 8 15K787 CAP, END, PUMP, PR70S, MACHINED 2

To install a new Check Valve Rebuild Kit:

1. With the machine in an idle state and a bucket below the dispense valve to catch material, fully

extend the piston by pressing

in the M1

screen.

2. To prevent machine movement, press

(red).

3. With a bucket below the check valve to be replaced, disconnect the male hose fitting from the check valve housing (13), by loosing the hose from the housing. Catch any material draining from the hose into the bucket.

4. Remove the check valve housing (13) from the pump endcap (8) by loosening the housing with a wrench.

5. Remove the existing check valve (14) from the housing (13) by inserting a screwdriver or dowel rod into the female threaded end of the check valve housing.

6. With the new check valve ball guide (item #3 in figure 43) on a bench with the open end up, install the check valve spring (item 2 of figure 47) into the guide.

8. With the rounded inside surface of the check valve seat (item 4 of figure 47) facing down, place the seat on top of the check valve ball.

9. Holding both ends of the assembled check valve assembly, install the check valve into the un-threaded end of the check housing (13) with the ball end facing out. Apply some pressure to the valve to snugly fit the completed check valve into the housing and the fit the check valve seat (item 4 of figure 47) into the valve guide.

10. Verify when the assembled check valve and housing (13) are turned up-side down, that the contents of the valve stays in place.

11. Re-insert the new valve and valve housing into the pump end cap, using a wrench.

12. Re-install the material male hose fitting into the check valve housing using a wrench.

13. Before re-using the machine for operation, activate a few shots to purge any air present in the material hose lines due to the procedure.

14. Re-calibrate the machine if necessary.

7. Install the check valve ball (item 1 of figure 47) on top of the spring.

Figure 47: PR70 Check Valve Rebuild Kit (LC0093)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 105445 BALL,CHECK VALVE 1 3 15D312 BUSHING, BALL GUIDE 1 2 121084 SPRING, 0.30OD X 0.44LG, 22#/IN, 20PSI, S 1 4 196832 SEAT, LAPPED, CHECK VALVE 1

312393C 39 of 52

Page 40

Pump Assembly

Figure 48: PR70 Rear Pump Rebuild Kit (LC0094)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 106258 ORING, VIT, JCB 1 3 120887 POSIPAK, 0.375ID X 0.625OD, COIL 1 2 120890 RING, RET, INT, 1.00, SS 1

To install a new Rear Pump Rebuild Kit:

1. Drain the pump by taking several shots with either the tank ball valves closed (if installed), or by activating enough shots to empty the tanks.

2. Disconnect the pump shaft (item 11 of Figure 46) from the drive block assembly by loosening the shaft locking nut (item 2 of Figure 46), then turning the shaft with a wrench while preventing the drive block alignment rod (item 2 of Figure 45) from rotating with a wrench. Manually push the pump shaft forward toward the extend position to separate the shaft from the drive block.

3. Remove the shaft lock nut from the shaft.

4. Remove the pump collar (item 9 on Figure 46) from the pump housing (item 7 on Figure 46) by removing the 2 screws (item 5 on Figure 46).

5. Slide the pump bearing housing (item 10 of Figure

46) away from the pump housing to remove.

6. Remove the existing rear pump build components (refer to Figure 48 items) from the pump bearing housing.

7. Using a clean dry cloth, remove any existing grease from the bearing housing.

8. Apply new high temperature grease lubricant (Graco P/N 115982) to the inside of the pump bearing housing, and the new rebuild components.

10. Apply 1 layer of thin masking tape over the male threads of the pump shaft which mates with the drive block. This will prevent the threads from damaging the seal or Posipak (3).

11. Using extreme caution, slide the pump shaft through the hole in the bearing housing as indicated in Figure 48. Align the bearing housing in position next to the pump housing.

12. Re-install the pump collar over the bearing housing and attach it to the pump housing using the 2 screws (item 5 on Figure 46) previously removed.

Torque the screws as specified in note

Figure 46.

13. Remove the masking tape from pump shaft.

14. Re-install the pump shaft lock nut to the pump shaft.

15. Re-install the pump shaft to the drive block alignment rod.

16. Re-tighten the lock nut.

17. Open the tank ball valves (if installed) and put more material into the tanks.

18. Instigate several shot to fill the pump with new material.

19. Re-calibrate and re-phase the machine, due to the procedure performed.

9. Install the new rebuild kit components into the bearing housing as indicated in Figure 48.

312393C 40 of 52

Page 41

Pistons & Metering Tubes

Piston Cylinders or Metering Tubes

Figure 49 PR70 Nylon and UHMWPE Piston Replacement Kits

Key:

Ref Description QTY Ref Description QTY

1 Piston 1 3 Oring 2 2 Screw 1

When ordering a piston replacement kit, the following intelligent part numbering system applies for Nylon based pistons:

LCF - 120

Code : A

Piston Size (mm

)

When ordering a UHMWPE replacement kit, the following numbering applies:

LCE - 160

Code : A

Piston Size (mm

To install a new Piston or Piston/Cylinder Replacement Kit:

1. Drain the machine pistons by instigating several shots with either the tank ball valves closed (if installed), or by activating enough shots to empty the tanks.

2. To prevent machine movement, press

3. Remove the pump end caps (item 8 of figure 46) by removing the 4 end cap screws (item 6 of figure 46). Allow the cap to hang by the hose.

4. Remove the cylinder and Orings (items 1 and 6 of figure 50) from the pump housing (item 7 of figure

46) and pump cap.

5. Select an operating mode, then fully extend the

pistons by activating the

option in the M1

screen.

(red).

)

The items indicated in Figure 46 above will be supplied with the kit. Refer to the Models section for the available standard piston sizes.

312393C 41 of 52

6. To prevent machine movement, press

(red).

7. Remove the existing piston (1) and any front or rear washers (items 3 & 4 of figure 50) from the pump shaft (item 11 of figure 46) by removing the piston screw (2). A wrench will be required near the drive block to prevent the pump shaft from rotating while the screw is removed.

8. Install the new piston and any rear or front washers, by re-installing the piston screw into the pump shaft. When tightening the piston screw,

Page 42

Pistons & Metering Tubes

tighten the screw until the piston stops rotating, then turn the screw an additional ¼ turn.

9. Select an operating mode, then retract the

pistons by pressing

in the M1 screen.

10. To prevent machine movement, press

(red).

11. Lubricate the new orings with a high temperature grease, Graco P/N 115982 or equivalent. Place the lubricated orings into the inside circle placements in the pump housing and pump end caps.

12. Install the cylinder between the pump housing and end cap, then secure the cylinder and Orings by re-attaching the 4 end cap screws (item 6 of figure 46).

13. Open the tank ball valves (if installed) or put more material into the tanks.

14. Instigate several shot to fill the pump with new material.

15. Re-calibrate the machine, due to the procedure performed.

312393C 42 of 52

Page 43

Pistons

Figure 50: Available PR70 Piston and Cylinder (Metering Tubes) Kits

Key:

Ref Description QTY Ref Description QTY

1 Cylinder or Metering Tube 1 4 Back Washer See Fig. 2 Piston 1 5 Screw 1 3 Front Washer See Fig. 6 Oring 2

2. To prevent machine movement, press

3. Remove the existing Piston plug (1) from the pump end cap (item 8 of figure 46) with a wrench. Remove the existing Oring (2).

4. Lubricate the new Oring with a high temperature

Figure 51 PR70 Piston Plug Assemby

Key:

Ref P/N Description QTY

1 15K815 Plug 2/Machine 2 111457 Oring 2/Machine

To install a new Piston Plug Assembly:

1. Drain the machine pistons by instigating several shots with either the tank ball valves closed (if installed), or by activating enough shots to empty the tanks.

grease, Graco P/N 115982 or equivalent. Place the lubricated Oring into the cap location of the end cap.

5. Re-install the piston plug (1) back into the end cap.

6. Open the tank ball valves (if installed) or put more material into the tanks.

7. Instigate several shot to fill the pump with new material.

8. Re-calibrate the machine, due to the procedure performed.

(red).

312393C 43 of 52

Page 44

Hose Assemblies

Figure 52 Piston to DV Hose Assemblies

Figure 53 Heated Piston to DV Hose Assemblies

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Miscellaneous Assemblies

Miscellaneous Mechanical Assemblies

Figure 54: PR70 Power Entry Bracket Assembly (LC0106)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 119912 SCREW, PAN, M3X6, PHILLIPS, SS 3 11 84/0130-26/11 LABEL, PE 1 2 121018 ELBOW, SWVL, 3/8 X ¼ NPT, FXM, 90DE 1 12 LC0034 HARNESS, WIRE, REMOTE SIGNAL 1 3 120876 PWR SUPPLY, 24VDC, 40W, 100-240VAC IN 1 13 121178 VALVE, LOCKOUT, ¼ NPT 1 4 120882 FILTER, 1/4NPT 1 14 121179 QUIKCLAMP, ¼ NPT 2 5 120883 NUT, HEX, 7/8-14, MS 1 15 121180 MULTIPORT, [3] ¼ NPT 1 6 120910 PWR ENTRY, 120/240VAC, DUAL FUSE, EMI 1 16 94/0762/99 VALVE, RELIEF, ¼ NPT, M, 110PSI, SIL 1 7 120916 SCREW,FHSC, M3X0.5 X 10, SS 2 17 94/0430/99 PLUG, SKT HD, ¼ NPT, MS 2 8 120993 NUT, HEX, M5X0.8, WITH STAR WASHER 2 18 81/1054-4/11 FUSE 5X20MM, 4AMP, FAST, TYPE F, 250VAC 2 9 15K798 BRACKET, SWITCH, AIR 1 19 LC0031 CABLE ASSY, POWER IN 1

10 15K800 FITTING, BULKHEAD 1

To Replace the Fuses:

1. Remove the machine fuse holder from the PWR Entry module (6) by inserting a flat-head screwdriver between the holder and the back the PWR Entry module (The fuse holder is above where AC power is connected to the machine).

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2. Replace the blown fuse(s) (18) into the fuse holder.

3. Re-install the holder into the PWR Entry Module.

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Miscellaneous Assemblies

Figure 55: PR70 Control Bracket Assembly (LC0108)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 84/0153-1/89 CLAMP, HARNESS, REUSEABLE, 5/8,NYL 2 6 121019 ELBOW, SWVL, 3/8 X 3/8 NPT, FXM, 90DE 1 2 120885 SCREW, SHC, M5-0.8 X 14, MS, E 2 7 LC0124 CONTROLLER, FCM 1 3 120897 REGULATOR, 100PSI, 3/8NPT, GAGE 1 8 15K797 BRACKET, ELECTRICAL, 1 4 120954 MANIFOLD, PN, 3/8NPTX3/8T X ¼ TX1/4T 1 9 84/0130-25/11 LABEL,.375X.375 1 5 120993 NUT, HEX, M5X0.8, WITH STAR WASHER 5 10 LC0035 HARNESS, WIRE, I/O 1

Figure 56: PR70 Shroud Assembly (LC0113)

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Miscellaneous Assemblies

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 15G581 PLATE, NAME, VALVE COVER, P3 1 4 15K628 LABEL, PR70 1 2 120060 CLIP, SPEED TUBULAR 4 5 15M511 LABEL, WARNING, PR70 1 3 15K806 SHIELD, PR70S 1

Figure 57: PR70 Hydracheck Components

Figure 58: PR70 HMI Components

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 288446 Display Module, PR70 1 3 120999 Termination Plug 1 2 255235 Bracket, HMI 1

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Wirin

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g Diagrams

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Wiring Diagrams

Figure 59: PR70 Wiring Interconnect Illustration

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g Diagrams

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Figure 60: Wiring Diagram, PR70

Wirin

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Tech

nical Data

Technical Data

Category Data

Metering Pump Effective Area 80 – 960 mm2 (0.124 – 1.49 in2) per side

Small Air Cylinder Effective Area 4560 mm2 (7.07 in2)

Large Air Cylinder Effective Area 10260 mm2 (15.9 in2)

Maximum Stroke Length 38.1 mm (1.50 in)

Minimum Stroke Length 5.8 mm (0.23 in)

Volume per Cycle 2 – 70 cc (0.12 – 4.3 in3)

Pump Cycles per 1L (0.26 gal) 500 – 14.3

Ratios (fixed) 1:1 to 12:1 (depending upon cylinders selected)

Maximum Fluid Working Pressure 3000 psi (20.7 MPa, 207 bar)

Maximum Air Input Pressure 100 psi (0.7 MPa, 7 bar)

Maximum Cycle Rate 30 cpm

Maximum Operating Temperature 70 C (160 F), nylon pistons 50 C (120 F) UHMWPE pistons or PE Tanks

Air Inlet Size ¼ NPT (f)

Pump Fluid Outlet Size -03, -04, -06, -08 or –12 JIC fittings for 3/16 in (4.8 mm), ¼ in (6.4 mm), 3/8 in

(9.5 mm), ½ in (12.7 mm), ¾ in (19.1 mm) hoses

Wetted Parts 303/304, 17-4 PH, hard chrome, Chromex, carbide, Chemical Resistant

O-rings, PTFE, nylon, UHMWPE

Weight 55 kg (120 Lbs) typical with two 7.5L tanks

150 kg (330 Lbs) typical with two 60 L tanks

Sound Power Level 4 in Air Cylinder

100 psi/30 cpm - 81 dBA

50 psi/15cpm – 77 dBA

Measured Per ISO Standard 9614-2

Compressed Air < 10 scfm typical (varies with cycle times)

Electrical Power 100-240 V 50/60Hz, 1 phase for machine – 80 Watts

208-240V 50/60Hz, 1 phase for heat – 11 kW max.

120 or 240 VAC 50/60Hz 1 phase for on-board agitators, 80 Watts

240 VAC 50/60Hz 1 phase for off-board agitators, 830 Watts

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Technical Data

Dimensions

Figure 36: PR70 Dimensions (ON-Board PE Tank version Illustrated)

A typical PR70 Machine, with the standard On-Board twin 8 liter PE Tanks has the following dimensions:

Dimension In. (mm) Dimension In. (mm)

A (width) 18.49 (469.6) C (depth) 30.62 (777.7) B (height) 26.39 (670.3) D (height in Back) 13.39 (340.1)

Figure 37: PR70 Dimensions (ON-Board 7.5L Stainless Tanks version Illustrated)

A typical PR70 Machine, with the standard On-Board 7.5 liter Stainless Steel Tanks has the following dimensions:

Dimension In. (mm) Dimension In. (mm)

A (width) 15.5 (393.7) C (depth) 30.62 (777.7) B (height) 27.37 (695.2) D (height in Back) 13.39 (340.1)

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Warranty and Graco Contact Information

Graco Ohio Standard Warranty

The warranties contained herein are not made in regard to auxiliary equipment and components (see AUXILIARY EQUIPMENT AND COMPONENTS NOT MANUFACTURED BY SELLER). Unless otherwise specifically stated in writing, warranties are limited to the following: All proprietary goods designed, manufactured and sold by Seller are guaranteed against defective workmanship or material for a period of one (1) year after date of shipment from the factory, provided the goods are properly maintained and operated under the condition for which they were sold. This warranty does not cover seals or components that are out of specification due to normal wear and tear or improper maintenance of the equipment. All claims pursuant to the warranties must be made within such one (1) year period. If Buyer claims the goods are defective within the one (1) year period, Buyer shall notify Seller immediately, in writing. Seller may inspect, by authorized agent, the defective claim or issue shipping instructions for return of the goods to its factory. Seller shall have the option, at its sole discretion, if the goods are found to be defective, to correct the defect or defects by repair or replacement or refund the purchase price. Seller's obligation, with respect to such goods, shall be limited to the replacement or repair F.O.B. Seller's North Canton, Ohio facility, or refund of the purchase price, and in no event shall Seller be liable for consequential or special damages, or for transportation, installation, adjustment or other expenses which may arise in connection with such goods. The Seller assumes no liability for warranty claims that are found to be attributable to components or mixers, which are not supplied by Seller (see AUXILIARY EQUIPMENT AND COMPONENTS NOT MANUFACTURED BY SELLER). Any services and/or parts provided to correct problems associated with components and mixers not supplied by Seller shall be provided at the Buyer’s expense. The liability of Seller arising out of supplying such goods and services, or their use, whether on warranties or otherwise, shall not under any circumstances exceed the cost of the equipment and parts involved, and upon the expiration of the specified one (1) year warranty claims period, all such warranties and liabilities shall terminate. Seller assumes no liability for damages or expenses of any character, including those arising out of the installation, use or resale of such goods. No representation or other affirmation of fact not set forth herein, including, but not limited to, verbal or written statements regarding capacity, or suitability for use, or performance of the goods, shall be deemed to be a warranty or representation by Seller for any purpose, nor would they give rise to any liability or obligation of Seller whatsoever. NO WARRANTY OR GUARANTEE, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY AS TO MERCHANTABILITY OR FITNESS FOR ANY PURPOSE, IS MADE, EXCEPT AS SPECIFICALLY PROVIDED IN THIS AGREEMENT.

AUXILIARY EQUIPMENT AND COMPONENTS

NOT MANUFACTURED BY SELLER

To the extent that auxiliary equipment and components of other manufacturers (e.g. logic control hardware, valves, transfer pumps, motors, etc.) are included as part of the machine or system described in the quotation and data sheet attached hereto, it is understood that Seller acts only as an agent of Buyer in making such quotations and these products which are not manufactured by Seller are subject to the original manufacturer’s warranty policy. FURTHER, SELLER MAKES NO WARRANTIES OR GUARANTEES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR ANY PURPOSE AND ASSUMES NO LIABILITIES WITH RESPECT TO AUXILIARY EQUIPMENT AND COMPONENTS WHICH ARE MANUFACTURED BY OTHERS.

Graco Ohio Inc. 8400 Port Jackson Ave NW N. Canton, OH 44720 Phone (330) 966-3000 Fax (330) 966-3006

Send e-mail for technical support to:

LiquidControlService@Graco.com

Send e-mail for parts orders to: LiquidControlParts@Graco.com Web Site: www.LiquidControl.com

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