3A2152B - LSR Select, Instructions - Parts, English€¦ · 3A2152B EN Instructions - Parts LSR...

3A2152BEN

Instructions - Parts

LSR SelectPlural-component, variable-ratio proportioner. For dispensing liquid silicone rubber into injection molds. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

See page 3 for model information, including maximum work-ing pressure and approvals.

Important Safety InstructionsRead all warnings and instructions in this manual. Save these instructions.

ti18092a

Contents

2 3A2152B

ContentsContents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Important Two-Component Material Information . 6

Keep Components A (Red) and B (Blue) Separate 6

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6Component Identification . . . . . . . . . . . . . . . . . . . . 8Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Pressure Relief Procedure . . . . . . . . . . . . . . . . 18Base Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . 19Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20System Calibration Procedure . . . . . . . . . . . . . 23Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Common Problems . . . . . . . . . . . . . . . . . . . . . . 26Machine Alarms . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30IAM/AM Status Indicators . . . . . . . . . . . . . . . . . 37

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Base Pump Piston Replacement . . . . . . . . . . . 38Inhibitor/Catalyst/Color Pump Rebuild . . . . . . . 39Motor Coupling . . . . . . . . . . . . . . . . . . . . . . . . . 42Valve Stack Rebuild . . . . . . . . . . . . . . . . . . . . . 44Position Sensor on Inlet/Outlet Valve Replacement

46

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Control Frame Base Pump, 24M094 . . . . . . . . . 48Base Pump Wet Section, 24L880 . . . . . . . . . . . 50Base Pump Lower, 24L878 . . . . . . . . . . . . . . . . 52Base Pump Inlet/Outlet Valves, 24L977 . . . . . . 54Base Pump Inlet/Outlet Valve Plumbing, 24M007 .

56Base Pump Inlet/Outlet Valve Plumbing, 24M118 .

58Valve Stack, 24L893 . . . . . . . . . . . . . . . . . . . . . 60Inhibitor/Catalyst/Color Pump Drive (1093 Valve),

24L905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Inhibitor/Catalyst/Color Pump Drive (1093 Valve),

24L969 and 24L968 . . . . . . . . . . . . . . . . . . 64Needle Adapter Assembly, 24L906 . . . . . . . . . . 66Non-Drip Valve, 24L907 . . . . . . . . . . . . . . . . . . 67Valve Stack, 24M039 . . . . . . . . . . . . . . . . . . . . . 68Solenoid Valve, 24M048 . . . . . . . . . . . . . . . . . . 71Control Cabinet Exterior, 24L993 . . . . . . . . . . . 72Control Cabinet Interior, 24L871 . . . . . . . . . . . . 74

Control Schematics, 24L890 . . . . . . . . . . . . . . . . . 76HMI Operation Overview . . . . . . . . . . . . . . . . . . . . 84Appendix A - HMI Screens Overview . . . . . . . . . . 86Appendix B - Logging In and Out . . . . . . . . . . . . 104Appendix C - Setting Home Position on Pumps 105Appendix D - Selecting the Outlet Valve, Mounting

the Stack to the Press . . . . . . . . . . . . . . . . . . 107Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Graco Standard Warranty . . . . . . . . . . . . . . . . . . 112Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 112

Related Manuals

3A2152B 3

Related ManualsManuals are available at www.graco.com.

Component manuals in U.S. English:

Models

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

See Accessories starting on page 110 for color valve addition and pressure monitoring systems.

Manual Description

311827 Dura-Flo™ Lowers Instructions-Parts

308418 Dura-Flo™ 750 Pumps Instructions-Parts List

310550 1/2” NPT Fluid Port Ball Seat Applicator

Model

Full Load Peak

Amps Per Phase*

Voltage (phase)

System Watts

Max Flow Rate

oz/sec (cc/sec)

Approximate Output per Cycle (A+B)

oz (cc)

Maximum Fluid Working Pressure

psi (MPa, bar)

24M093 26 A 208-230 (3) 6000 0.3 (10) 5 (150) 1000 (7, 69)

Warnings

4 3A2152B

WarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point symbol alerts you to a general warning and the hazard 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 HAZARDThis equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-tric shock.

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

• Connect only to grounded power source.• All electrical wiring must be done by a qualified electrician and comply with all local codes and reg-

ulations.

+

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

• Do not point dispensing device at anyone or at any part of the body.• Do not put your hand over the fluid outlet.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,

or servicing equipment. • Tighten all fluid connections before operating the equipment.• Check hoses and couplings daily. Replace worn or damaged parts immediately.

TOXIC FLUID OR FUMES HAZARDToxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENTYou 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, hearing loss, inhala-tion of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac-

turer.

Warnings

3A2152B 5

FIRE AND EXPLOSION HAZARDFlammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help pre-vent fire and explosion:

• Use equipment only in well ventilated area.• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic

drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline.• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.• Ground all equipment in the work area. See Grounding instructions.• Use only grounded hoses.• Hold gun firmly to side of grounded pail when triggering into pail.• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.• Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARDMisuse 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 from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-facturer’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 HAZARDMoving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.• Do not operate equipment with protective guards or covers removed.• Pressurized equipment can start without warning. Before checking, moving, or servicing equip-

ment, follow the Pressure Relief Procedure and disconnect all power sources.

WARNING

Important Two-Component Material Information

6 3A2152B


Keep Components A (Red) and B (Blue) Separate

Changing Materials• When changing materials, flush the equipment mul-

tiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

Cross-contamination can result in cured material in fluid lines which could cause serious injury or dam-age equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (Red) and component B (Blue) parts.


3A2152B 7

Component Identification

8 3A2152B


FIG. 1: Machine Overview

ti18094a

A

ti18095a

ti18093a

H

D FB

K

LM

JN

G

E

C

P


3A2152B 9

Label Component Function

A Valve Stack Assembly where catalyst, inhibitor, and color (optional) are injected into the base chemical and mixed together.

B 1093 Valve (Inhibitor) Valve that injects inhibitor into the base chemical and slows the effect of the catalyst mix. The chemical can be adjusted to affect the cure time within a ratio range from 1-6%.

C Pressure monitor (Inhibitor) Monitors the pressure of the inhibitor valve.(Optional - See Accessories on page 110 for details.)

D 1093 Valve (Catalyst) Valve that injects catalyst into the base chemical and cures the material. The chemical has a fixed ratio of 1%.

E Pressure monitor (Catalyst) Monitors the pressure of the catalyst valve.(Optional - See Accessories on page 110 for details.)

F 1093 Valve (Color) Valve that injects pigment into the base chemical and colors the material. The chemical can be adjusted within a ratio from 0-6%.(Optional - See Accessories on page 110 for details.)

G Pressure monitor (Color) Monitors the pressure of the color valve.(Optional - See Accessories on page 110 for details.)

H Mixer with Cooling Jacket. Mixes the material through a static mixer and has a cooling jacket to main-tain temperature.

J Control Panel The Human Machine Interface (HMI) to allow the user to control the machine.

K Single Acting Pump A one directional pump that forces the base chemical to the valve stack. The pump only applies force in the down stroke.

L Pump Inlet Valve A valve that opens and closes and allows the base chemical being sup-plied from a feed system to enter the machine.

M Pump Outlet Valve A valve that opens and closes and allows the base chemical being sup-plied from the machine to enter the valve stack.

N Base Material Hose The material hose line provides the base chemical to the valve stack.

P Pressure Monitor (Screw) Monitors the pressure of the screw inlet.(Optional - See Accessories on page 110 for details.)


10 3A2152B

FIG. 2: Electrical Panel

ti18096a

AA

ti18097a

AB

AE

AC

AF

AD

AG

Components are found within enclosure.

CB1CB2

FU-1FU-2

FU-6FU-7

FU-3FU-5

FU-9

FU-4FU-8

FU-10


3A2152B 11

Most circuit breakers are located inside the power distri-bution box. The main block of circuit breakers in the power distribution box is detailed below.

Label Component Function

AA Disconnect Turns the main power ON/OFF of the machine

AB HMI Machine controls. Allows the user to enter/read data

AC Ethernet Port Communication port to a PLC

AD Power ON/OFF Turns the power ON/OFF for the controls

AE E-Stop Emergency stop button to turn OFF power of the machine

AF Audio Alarm Alerts operator of a machine fault through sound

AG Foot Switch Signals machine to start cycle when pressed

Label Component Size (Amps) Type Used in Models

CB1 24 VDC Power 5 N/A All

CB2 PLC Power Supply 5 N/A All

FU-1 Drive Control Power 10 LPJ-10SP Bussman All

FU-2 Drive Control Power 10 LPJ-10SP Bussman All

FU-3 Drive Motor Power 20 KTK-R-20 Bussman All



FU-6 Drive Control Power 10 LPJ-10SP Bussman Kit 24M126

FU-7 Drive Control Power 10 LPJ-10SP Bussman Kit 24M126

FU-8 Drive Motor Power 20 KTK-R-20 Bussman Kit 24M126



Setup

12 3A2152B

SetupInitial Machine SetupPerform this setup procedure to prepare the machine for initial operation.

1. Locate the machine.

a. Locate the machine on a level surface and bolt to the floor. See Technical Data starting on page 108 for space requirements and mounting hole pattern.

b. Connect the valve stack to the screw inlet located on the press. External brackets may be required to support the stack. Install a valve between the mixer and the screw. The valve can be controlled by the LSR system. See Appendix D - Selecting the Outlet Valve, Mounting the Stack to the Press on page 107.

2. Connect the electrical cord.

Electrical Cord Requirements

NOTE: Power cord is not supplied. See the following table.

Electrical Cord Wires by Model

230V, 3 phase: L1, L2, L3, GND

a. Connect green wire to ground (GRN).

b. Use a screw driver to tighten the terminals to 12 in-lb (1.4 N•m)

The machine is not properly grounded until this setup procedure is performed. To prevent risk of electric shock, do not start the machine until this setup proce-dure is completed.

NOTICE

To prevent machine damage, do not expose system to rain.

FIG. 3: Valve Stack Outletti18098a

3/4” NPT Male

Installing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Table 1: Power Cord Requirements

ModelCord Requirements

AWG (mm2)

230V, 3 phase 8 (8.4), 3 wire + ground

FIG. 4: Electrical Disconnect

ti18099a

L1

L2

L3

GND

Setup

3A2152B 13

3. Ground the system.

a. Control enclosure and pump: grounded through power cord. See Connect the electrical cord. on page 12.

b. Valve stack: Follow your local code.

c. Fluid supply containers: Follow your local code.

d. Solvent pails used when flushing: follow your local code. Use only metal pails, which are con-ductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

e. To maintain grounding continuity when flushing or relieving pressure, hold grounded metal pail firmly to a metal part of dispense valve then initi-ate a dispense.

4. Connect the press output signal to the customer input located in the panel.

Add customer signal from the press when the press is ready to load the screw by either:

a. Connecting a 24 VDC signal from the press to the relay CR-CS.

b. Connecting a dry contact signal across lines 8 and 6850 on the terminal assembly. Refer to Control Schematics, 24L890, page 76, for additional clarity.

This equipment must be grounded.

FIG. 5: Relay CR-CS

CR-CS

A1 A2

123386

CUSTOMER START

CONNECT 24VDC STARTSIGNAL FROM PRESS

Setup

14 3A2152B

5. Install Feed System.

Feed components are purchased separately and not a part of this system.

Recommended feed parameters:

• Base feed pressure:Load base pump with 300-800 psi fluid pres-sure.

• Base fluid hose connection:1” NPT male.

• Inhibitor/Catalyst/Color feed pressure:Load 1093's with 200-400 psi fluid pressure.

• Inhibitor/Catalyst/Color hose connection:JIC(04)

6. Connect the Base Pump to the Valve Stack.

a. Connect the fluid hose from the outlet of the base pump to the inlet of the Valve stack.

b. Connect the motor cables in the first conduit to the matching servo motors on the valve stack.

c. Connect the encoder cables in the second con-duit to the matching servo motors on the valve stack.

NOTICE

Use at least 10 layers of PTFE tape and use pipe dope on the fluid inlet fitting to prevent galling.

FIG. 6: 1” NPT Base Inlet Connection

FIG. 7: Connection Port

ti18100a

1” Inlet

ti18101a

(Other connec-tions are found on other side of visual)

NOTICE

Use at least 10 layers of PTFE tape and use pipe dope on the fluid inlet fitting to prevent galling.

FIG. 8: Base Outlet to Valve Stack Connection

FIG. 9: Electrical Cable Connections

ti18102a

ti18103a

MotorCables

EncoderCables

Setup

3A2152B 15

d. Connect the sensor lines and solenoid lines in the third conduit to the matching valves on the valve stack.

e. If using kit 24M127, connect the pressure trans-ducer cables in the third conduit to the matching transducers on the valve stack.

f. Connect the ground wire in the sensor conduit to the screw holding the solenoid valves to the stack.

g. A set of clamps is supplied to keep the three sections of conduit together. This can be mounted on the press.

7. Connect the Air Supply.

a. Connect a 1/4” in. air supply to the solenoid valve inlet on the valve stack.

b. Connect a 1/4 in. air supply to the solenoid valve inlet on the base frame.

FIG. 10: Clamps

11.00

.50

11.50

ti18104a

NOTICETo prevent machine damage, air supply must be fil-tered and dried.

FIG. 11: Air Supply Connection - Valve Stack

FIG. 12: Air Supply Connection - Base

ti18105a

1/4” Air Supply

ti18106a

1/4” Air Supply

Setup

16 3A2152B

8. Connect chiller with 1/4” tubing.

9. Perform Startup procedure on page 17.

10.Perform Human Machine Interface (HMI) setup.

Refer to Appendix A - HMI Screens Overview starting on page 86 for more information.

a. Navigate to DRIVE/VALVE setup screen. Push the ENABLE drive button for each component to enable the drives.

b. If the drives have been unplugged, refer to Appendix C - Setting Home Position on Pumps starting page 105.

c. Verify the indicators read that each drive is HOME. If not, push the HOME PUMP push but-ton.

11.Perform Flushing Procedure start-ing on page 19.

12.Perform System Calibration Pro-cedure starting on page 23.

FIG. 13: Chiller Connections

ti18201a

Coolant In

Coolant Out

NOTICE

The machine is tested with oil at the factory. Flush out the oil with a compatible solvent before loading the machine with material.

Operation

3A2152B 17

Operation

Startup

1. Perform all required maintenance tasks. See Main-tenance starting on page 25.

2. Check for leaks.

3. Check feed system fluid levels.

4. Turn the main disconnect switch to the ON position. The HMI will start running through its startup proce-dure. This takes about a minute.

5. Push the power on button. The white pilot light will illuminate.

Shutdown

Short Term/End of shift

1. Verify the cooling jackets are on and the mixed material is being chilled. Keeping the mixed mate-rial cool will keep the material from curing as fast.

2. Perform Base Purge, page 19.

3. Perform Pressure Relief Procedure, page 18.

4. Turn the main disconnect switch to the “OFF” posi-tion.

Extended periods

1. Perform Base Purge, page 19.

2. Perform Pressure Relief Procedure, page 18.

3. Turn the main disconnect switch to the “OFF” posi-tion.

4. Remove the cooling jacket from the mixer.

5. Remove the mixer from the screw.

6. Remove the bottom block from the mixer stack.

7. Clean the mixer and bottom block with a compatible solvent.

NOTICE

To avoid curing the material within the mixer, do not run the catalyst without the inhibitor.

Operation

18 3A2152B

Pressure Relief Procedure

Pressure Relief Method with Power:

1. If the mixer is connected to the screw of the press, put a container at the end of the screw.

2. Use the press controls to bleed the screw of mate-rial.

3. Go to the DRIVE/VALVE CONTROL screen.

4. Press the SET MAN'L MODE button.

5. Press the OPEN SCREW VALVE button.

6. Let the pressure drop to 0 psi/MPa/bar.

Pressure Relief Method with No Power:

1. If the mixer is connected to the screw of the press, put a container at the end of the screw.

2. Use the press controls to bleed the screw of mate-rial.

3. Press the orange override buttons on the solenoid valve assembly.

4. Let the pressure drop to 0 psi/Mpa/bar.

In the following step, any pressure in the lines will be instantly relieved which may lead to material spraying out of the valve and splashing in the bucket. Use appropriate protective wear to prevent contact with materials.

NOTICE

This procedure relieves pressure from the dispense lines only. To avoid personal injury, refer to the feed system documentation to relieve pressure from the feed lines.

FIG. 14: Override Button

ti18105a

Operation

3A2152B 19

Base Purge

1. Navigate to the AUTO MODE SETUP SCREEN.

2. Set the CATALYST PERCENT OF MIX to zero.

3. Set the INHIBITOR PERCENT OF MIX to 6%.

4. Press the footswitch and take about fifteen shots to get the existing catalyst out of the mixer.

5. Verify the mix will not cure by wiping a small amount of mixed material from the last shot on the heated mold in the press and seeing if the material cures.

6. If the material cures, take some more shots, testing the material until the material does not cure.

To start dispensing again after a base purge, go to the AUTO MODE SETUP screen, set the catalyst back to 1% and begin dispensing. After the same amount of shots that took to base purge, material with catalyst should begin to dispense through the mixer. To verify this, wipe a small amount of mixed material from the last shot on the heated mold in the press and see if the material cures.

Flushing Procedure

Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing a new fluid. All fluid components are compatible with common sol-vents. Use only moisture-free solvents. See Technical Data on page 108 for a list of wetted components to ver-ify compatibility of solvent with wetted materials. See solvent manufacturer's information for material compati-bility. Do not use water.

Ground the solvent pails used when flushing: Refer to Ground the system. on page 13.

If flushing with a compatible solvent, perform the follow-ing procedure:

1. Perform Shutdown, page 17.

2. Disconnect the valve stack from the screw located on the press.

3. Disconnect the base pump inlet from the feed pump.

4. Connect the flushing hose into the base pump inlet.

5. Perform Startup, page 17.

6. Navigate to the DRIVE/VALVE CONTROL screen.

7. Press the SET IN MAN'L MODE button to put the system in manual mode.

8. Push the base OPEN INLET VALVE, OPEN OUT-LET VALVE, and OPEN SCREW VALVE buttons so there is a clear path to flush.

9. Start flushing.

10. When the silicone is no longer dispensing from the mixer, stop flushing.

NOTE: Even though flushing will get the majority of the material out of the stack and mixer, disassemble the blocks and mixer and clean these parts individually.

NOTICE

Mixed material with start to gel in the mixer if the machine is idle for a prolonged periods of time, causing machine damage. Perform a base purge as required.

Flush equipment only in a well-ventilated area. Do not dispense flammable fluids. Do not turn on heaters while flushing with flammable solvents.

Operation

20 3A2152B

Priming

Overview: Prime the base, add the inhibitor, and then add the catalyst. This assumes all feed system pumps are loaded, primed and ready to dispense.

NOTE: Prime with the valve stack not connected up to the screw located on the press.

1. Disconnect the mixer and valve stack from the screw located on the press.

2. Place a waste container under the mixer.

3. Prime the base component.

a. Go to the DRIVE/VALVE CONTROL Screen.

b. ENABLE the base drive.

c. HOME the base drive.

d. In the ALL window, press the SET MAN'L MODE button.

e. When the Base indicates the pump is HOME, press the EXTEND PUMP button and wait for the base pump to fully extend.

f. Push the OPEN INLET VALVE button and verify the indicator shows OPEN.

g. Push the OPEN OUTLET VALVE button and verify the indicator shows OPEN.

h. If a customer supplied valve is installed between the mixer and screw, push the OPEN SCREW VALVE button and verify the screen shows OPEN.

i. When all valves are open and there is a clear path from the inlet valve to the mixer, slowly increase the air pressure on the feed pump until the feed pump begins to cycle.

j. Let the feed pump cycle until air free base mate-rial comes out the end of the mixer.

k. Press the CLOSE OUTLET VALVE push button and verify the Indicator shows CLOSED.

l. Press the CLOSE SCREW VALVE push button and verify the indicator shows CLOSED.

m. Press the HOME PUMP push button. The actu-ator shaft will rise and the feed pump will cycle to charge the pump.

n. Adjust the feed pump air pressure so the base material pressure shows approximately 500 psi (3.4 MPa, 34 bar). The pressure read-out shows on either the STARTUP, STATUS, or PRESSURE LOG screens.

4. Prime the inhibitor pump (1093 valve).

a. Turn the air pressure on the inhibitor feed pump so that the actual material pressure is around 300 psi (2.1 MPa, 21 bar). This is an estimate based on the air pressure on the feed pump and the power factor of the pump. If pressure trans-ducers are included (kit 24M127), the inhibitor pressure readout can be seen on either the STARTUP, STATUS, or PRESSURE LOG screens.

b. On the DRIVE/VALVE CONTROL screen, push the SET AUTO MODE button.

c. If a customer supplied screw valve is being used, push the AUTO SCREW VALVE push button.

d. Verify all pumps are ENABLED and HOME.

e. Go to the AUTO MODE SETUP screen.

f. Set the TOTAL FLOW RATE to 4-6cc/sec.

g. Set the INHIBITOR PERCENT OF MIX to 6%

h. Set the CATALYST PERCENT OF MIX to zero.

i. If color is used (Kit 24M126), Set the COLOR PERCENT OF MIX to zero.

Operation

3A2152B 21

j. Verify the BASE PERCENT OF MIX is 94% and the TOTAL PERCENT (REF) is 100%

k. Press and hold the footswitch down. The base pump and inhibitor pump (1093 valve) will start to dispense.

l. When the base pump hits the end travel, release the footswitch; both pumps will reload.

m. When the pumps are reloaded, repeat this about fifteen times to verify the volume of the mixer has inhibitor through the mixer and the material coming out is air-free.

5. Prime the catalyst pump (1093 valve).

a. Turn the air pressure on the catalyst feed pump so that the actual material pressure is around 300 psi (2.1 MPa, 21 bar). This is an estimate based on the air pressure on the feed pump and the power factor of the pump. If pressure trans-ducers are included (kit 24M127), the catalyst pressure readout can be seen on either the STARTUP, STATUS, or PRESSURE LOG screen.

b. On the DRIVE/VALVE CONTROL screen, push the SET AUTO MODE button.





g. Set the INHIBITOR PERCENT OF MIX to 6%

h. Set the CATALYST PERCENT OF MIX to 1%.

i. If color is used (Kit 24M126), Set the COLOR PERCENT OF MIX to zero.

j. Verify the BASE PERCENT OF MIX is 93% and the TOTAL PERCENT (REF) is 100%

k. Press and hold the footswitch down. The base pump, inhibitor, and catalyst pump (1093 valve) will start to dispense.

l. When the base pump hits the end travel, release the footswitch; all pumps will reload.

m. When the pumps are reloaded, repeat this about fifteen times to verify the volume of the mixer has catalyst through the mixer and the material coming out is air-free.

6. Prime the color pump (1093 valve). Valid only if kit 24M126 is being used.

a. Turn the air pressure on the color feed pump so that the actual material pressure is around 300 psi (2.1 MPa, 21 bar). This is an estimate based on the air pressure on the feed pump and the power factor of the pump. If pressure trans-ducers are included (kit 24M128), the color pressure readout can be seen on either the STARTUP, STATUS, or PRESSURE LOG screens.

b. On the DRIVE /VALVE CONTROL screen, push the SET AUTO MODE button.





NOTICE

After the catalyst has been added, the material is able to cure. To avoid machine damage from long idle times, perform a Base Purge, page 19.

NOTICE


Operation

22 3A2152B

g. Set the INHIBITOR PERCENT OF MIX to 6%.

h. Set the CATALYST PERCENT OF MIX to 0% or 1%.

i. Set the COLOR PERCENT OF MIX to the desired percent.

j. Verify the TOTAL PERCENT (REF) is 100%

k. Press and hold the footswitch down. All pumps will start to dispense.

l. When the base pump hits the end travel released the footswitch; all pumps will reload.

m. When the pumps are reloaded, repeat this about fifteen times to verify the volume of the mixer has color through the mixer and the mate-rial coming out is air-free.

Operation

3A2152B 23

System Calibration Procedure

Perform this entire procedure if any of the following con-ditions are met:

• The machine is new.• The materials in the system have been

changed.

Software Settings:

1. Go to the AUTO MODE SETUP screen.

2. Enter the flow rate and ratio percentages.

3. Go to the DRIVE/VALVE SETUP screen.

4. ENABLE ALL the drives.

5. HOME the pumps of they are not home.

Prime the Machine:

1. Press the footswitch or give a maintained signal from the press to begin pumping.

2. After dispensing close to a full shot, release the footswitch or signal from the press and let the pumps reload.

3. Repeat this until air-free material is dispensed.

4. Repeat around fifteen more times to ensure the new mix of material has traveled through the mixer.

5. Connect the mixer to the customer supplied screw inlet valve.

6. Repeat more shots until air free material is dis-pensed out of the screw.

Balancing the pump pressure:

The key to getting consistent ratios is to dispense at roughly the same pressure as the pumps are being fed from the feed system. The screen below shows all pres-sures.

NOTE: Pressures can only viewed if kit 24M127 is installed.

The blue line is the base pump pressure. The pressure is around 500 psi (3.4 MPa, 35 bar) when done loading. The dispense pressure is around 400 psi (2.8 MPa, 28 bar). These two pressures are close enough to give repeatable shots. They could be even closer by adjusting the feed pump air pressure down until the material pressure is 400 psi (2.8 MPa, 28 bar). If the reload pressure of the base was 800 psi (5.6 MPa, 55 bar) and the dispense pressure was around 200 psi (1.4 MPa, 14 bar), the dis-pense would not be repeatable.

The red line is the inhibitor. The inhibitor is balanced, the load pressure is a little under 400 psi (2.8 MPa, 28 bar) and the dispense pressure is almost the same. In this particular screen, only base and inhibitor are being dispensed. The green line is the catalyst and always is reading the load pressure, right around 400 psi (2.8 MPa, 28 bar).

If the transducer kit (24M127) isn't used, the base pres-sure is all that can be monitored. The pressure of the inhibitor and catalyst can be estimated by looking at the base pressure at dispense and setting the air pressure in the feed pumps for the inhibitor and catalyst so the material pressure of them is similar to the base. The air pressure multiplied by the feed pump power factor is roughly the material pressure.

NOTICE


StartDisp.

EndDisp.

PumpsReload

Operation

24 3A2152B

DispensingAfter the pressures are balanced and the system is dis-pensing air free material, the mixer is ready to connect to the screw inlet located on the press. The mixer outlet is 1” NPT. Continue priming through the screw.

Determining the flow rate:

Once the mixer is connected to the screw, the flow rate needs to be adjusted so the flow rate does not fill the screw too fast or too slow. See the charts below show-ing only the mixer pressure.

If the kit for the transducers isn't used, a gauge at the screw inlet will give an indication of the pressure rise or fall while dispensing.

Maintenance

3A2152B 25

Maintenance

Task Schedule

Inspect fluid lines for leaks and signs of wear Daily

Remove mixer and check for gelling material Weekly

Check all fittings and connections, tighten as necessary As necessary

Troubleshooting

26 3A2152B

Troubleshooting

Before performing any troubleshooting procedure:

1. Perform Pressure Relief Procedure on page 18.

2. Turn power off.

Common Problems

Problem Cause Diagnostic Solution

General- System won't dispense

Control power not on

Power on button not pushed

Control power pilot light not illumi-nated Push power on button

E-stop pushed Control power pilot light not illumi-nated

Untwist E-stop, push power on button

System not in AUTO MODE

Not put in auto mode after power up

Indicator shows ratio check mode or manual mode Put in auto mode

Pumps not enabled Powered up without enabling or fault Enabled indicators or alarm Clear fault if necessary,

enable ALL drives

Base pump load sensor not reading

Sensor not connected Visually check connection Reconnect sensor

Sensor bad Check PLC input/sensor voltage Replace bad sensor

Base pump not loaded

No pressure on feed pump

Pump shaft extended, actuator shaft retracted, feed pump pressure gauge

Put pressure on feed pump to load

No material in feed pump drum

Pump shaft extended, actuator shaft retracted, check ram level Change drum

Base Pump not homeDrive fault Fault on HMI screen Clear fault, re home

System powered up with pump not home Fault on HMI screen Home pump motor

Base pump load/dis-pense valves didn't shift

No air on solenoid valves Check air pressure to valves Put minimum 80psi air pres-

sure on solenoid valves

Bad electric connection Pilot light on solenoid valves Re connect cable to sole-noid valve

Valve position sensors not reading

Manually toggle valves open and closed, watch sensor LED's

Reposition sensors

Replace sensor

Troubleshooting

3A2152B 27

Inh/Cat pump load/dis-pense sensor not work-ing

Bad connection Visually check connection Reconnect sensor

Bad sensor Check PLC input/sensor voltage Replace bad sensor

Inh/Cat Pump not homeDrive fault Fault on HMI screen Clear fault, re home

System powered up with pump not home Fault on HMI screen Home pump motor

Inh/Cat pump load/dis-pense valves didn't shift

No air on solenoid valves Check air pressure to valves Put minimum 80psi air pres-

sure on solenoid valves

Bad electric connection Pilot light on solenoid valves Reconnect cable to sole-noid valve

Mixer plugged Mixed material cured Very high pressure Tear down and clean out mixer/stack assembly

Customer supplied screw valve not opening

Air lines to valve back-wards Very high pressure Check air connections,

swap if necessary

Valve cured up Very high pressure Tear down and clean out screw valve

General- Mixed material won't cure

Catalyst not being added

Catalyst percentage not set to 1% Verify HMI Set to 1%

Broken lead screw nut Motor turns but no linear movement Replace lead screw nut

Catalyst added is no good

Contaminated with moisture from air Catalyst is yellow, not clear Replace catalyst

General- Mixed material cures too fast or cures even when base purging

Catalyst still being added

Catalyst percentage still set at 1% Verify HMI Set to zero percent

Bad seal on catalyst non drip valve

Pull catalyst valve out of stack and inspect

Replace non drip valve seat.

Inhibitor not being added

Inhibitor percentage set to zero or not high enough

Verify HMI Increase inhibitor percent-age

Broken lead screw nut Motor turns but no linear movement Replace lead screw nut

Problem Cause Diagnostic Solution

Troubleshooting

28 3A2152B

Machine AlarmsThe following is a list of possible alarms.

# DESCRIPTION TYPE CAUSE SOLUTION1 INPUT POWER OFF FAULT Alarm N/A N/A

2 CONTROL POWER OFF FAULT Alarm Power on button not pressed/Estop pressed Push power on button

3 24VDC POWER OFF FAULT Alarm N/A N/A

4 BASE PUMP OVERTRAVEL Shutdown

Pump is extended too far in either direction

Get pump back within travel limits

5 INHIBITOR PUMP OVERTRAVEL Shutdown

6 CATALYST PUMP OVERTRAVEL Shutdown

7 COLOR PUMP OVERTRAVEL Shutdown

8 BASE PUMP OVER CURRENT Shutdown

Motor or transmission malfunction

Check/replace motor or transmission

9 INHIBITOR PUMP OVER CURRENT Shutdown

10 CATALYST PUMP OVER CURRENT Shutdown

11 COLOR PUMP OVER CURRENT Shutdown

12 BASE DRIVE OVER TEMP Shutdown

Excessive heat exists in the power circuitry

Reduce duty cycle, check for clogged vents, defective fan

13 INHIBITOR DRIVE OVER TEMP Shutdown

14 CATALYST DRIVE OVER TEMP Shutdown

15 COLOR DRIVE OVER TEMP Shutdown

16 BASE MOTOR OVER TEMP ShutdownHigh ambient motor temperature and/or excessive current

Operate within continuous torque rating for ambient temperature maximum

17 INHIBITOR MOTOR OVER TEMP Shutdown

18 CATALYST MOTOR OVER TEMP Shutdown

19 COLOR MOTOR OVER TEMP Shutdown

20 BASE DRIVE FEEDBACK ERROR ShutdownFeedback wiring is open, shorted, or miss-ing

Check motor encoder wiring.21 INHIBITOR DRIVE FEEDBACK ERROR Shutdown

22 CATALYST DRIVE FEEDBACK ERROR Shutdown

23 COLOR DRIVE FEEDBACK ERROR Shutdown

24 BASE DRIVE OVERLOAD Shutdown

Load limit of motor/drive has been exceeded Check for blocked fluid path

25 INHIBITOR DRIVE OVERLOAD Shutdown

26 CATALYST DRIVE OVERLOAD Shutdown

27 COLOR DRIVE OVERLOAD Shutdown

28 BASE MOTOR POSITION ERROR Shutdown

Position error limit was exceeded Check for blocked fluid path

29 INHIBITOR MOTOR POSITION ERROR Shutdown

30 CATALYST MOTOR POSITION ERROR Shutdown

31 COLOR MOTOR POSITION ERROR Shutdown

32 BASE RATIO CHECK SHOT OUT OF RANGE Alarm

Shot size entered too large or small

Change shot size within lim-its

33 INHIBITOR RATIO CHECK SHOT OUT OF RANGE Alarm

34 CATALYST RATIO CHECK SHOT OUT OF RANGE Alarm

35 COLOR RATIO CHECK SHOT OUT OF RANGE Alarm

36 BASE AXIS FAULT Shutdown

Drive has faulted Check drive diagnostic win-dow

37 INHIBITOR AXIS FAULT Shutdown

38 CATALYST AXIS FAULT Shutdown

39 COLOR AXIS FAULT Shutdown

Troubleshooting

3A2152B 29

40 BASE PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too high

Check for blocked fluid path, lower flow rate

41 BASE PRESSURE LOW LIMIT Shutdown Pump not running, no material being fed

Check pump, check material level

42 INHIBITOR PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too high


43 INHIBITOR PRESSURE LOW LIMIT Shutdown Pump not running, no material being fed


44 CATALYST PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too high


45 CATALYST PRESSURE LOW LIMIT Shutdown Pump not running, no material being fed


46 COLOR PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too high


47 COLOR PRESSURE LOW LIMIT Shutdown Pump not running, no material being fed


48 SCREW PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too high


49 SCREW PRESSURE LOW LIMIT Shutdown Fluid not being dis-pensed Check pumps

50 PRESSURE SHUTDOWN ALARM Alarm Any pressure out of spec

Check pump with pressure fault

51 BASE LOAD VALVE OPEN FAULT Alarm Valve not shifting to open position

Check/replace bad sensor, Check/correct air pressure, valve stuck

52 BASE LOAD VALVE CLOSE FAULT Alarm Valve not shifting to closed position

53 BASE DISPENSE VALVE OPEN FAULT Alarm Valve not shifting to open position

54 BASE DISPENSE VALVE CLOSE FAULT Alarm Valve not shifting to closed position

55 INHIBITOR VALVE SHIFT DISPENSE FAULT Alarm Spool valve not shifting to open position

56 INHIBITOR VALVE SHIFT LOAD FAULT Alarm Spool valve not shifting to closed position

57 CATALYST VALVE SHIFT DISPENSE FAULT Alarm Spool valve not shifting to open position

58 CATALYST VALVE SHIFTLOAD FAULT Alarm Spool valve not shifting to closed position

59 COLOR VALVE SHIFT DISPENSE FAULT Alarm Spool valve not shifting to open position

60 COLOR VALVE SHIFT LOAD FAULT Alarm Spool valve not shifting to closed position

# DESCRIPTION TYPE CAUSE SOLUTION

Troubleshooting

30 3A2152B

Drive FaultsThe drives have a diagnostic window that should have a “4” when everything is normal.

If a drive has a problem, a series of numbers flash in this window. Below is a list of error codes.

Error Code

Fault Message RSLogix (HIM) Problem or Symptom Potential Cause Possible Resolution

General Power (PWR) indicator not ON

No ac power or auxiliary logic power.

Verify ac control power is applied to the Kinetix 2000 system.

Internal power supply malfunction.

Call your Rockwell Automa-tion sales representative to return module for repair.

Motor jumps when first enabled

Motor wiring error. • Check motor wiring.• Run Hookup test in RSLogix 5000 software.

Incorrect motor chosen. Verify the proper motor is selected.

Digital I/O not working correctly

I/O power supply discon-nected.

Verify connections and I/O power source.

E00 BusUndervoltage Fault (Blown fuse)

A blown fuse was detected on the inverter PCB

Blown fuse. Call your Rockwell Automa-tion sales representative to return module for repair.

ti18126a

Troubleshooting

3A2152B 31

E04 Motor Overtemp Fault (Motor Overtemp)

Motor thermal switch tripped

High ambient motor tem-perature and/or exces-sive current

• Operate within (not above) the continuous torque rating for the ambient temperature 40 °C (104 °F) maximum.• Lower ambient temperature, increase motor cooling.

Motor wiring error. Check motor wiring at MF connector on the IAM/AM.

Incorrect motor selec-tion.

Verify the proper motor has been selected.

E05 Drive Overcurrent Fault (Power Fault)

Self-protection of the Intelligent Power Mod-ule (IPM) is indicating a major power related fault condition

Motor cables shorted. Verify continuity of motor power cable and connector.

Motor winding shorted internally.

Disconnect motor power cables from the motor. If the motor is difficult to turn by hand, it may need to be replaced.

Kinetix 2000 drive tem-perature too high.

• Check for clogged vents or defective fan.• Make sure cooling is not restricted by insufficient space around the unit.

Operation above contin-uous power rating and/or product environmental ratings.

• Verify ambient temperature is not too high.• Operate within the continuous power rating.• Reduce acceleration rates.

Kinetix 2000drive has a short circuit, overcur-rent, or failed compo-nent.

Remove all power and motor connections, and preform a continuity check from the dc bus to the U, V, and W motor outputs. If a continuity exists, check for wire fibers between terminals, or send drive in for repair.

E06 HardOvertravel Fault (+/- Hard Overtravel)

Axis moved beyond the physical travel limits in the positive/negative direction

Dedicated overtravel input is inactive.

• Check wiring.• Verify motion profile.• Verify axis configuration in soft-ware.

E07 MotFeedbackFault (Motor Feedback Loss)

The feedback wiring is open, shorted, or miss-ing.

• Check motor encoder wiring.• Run Hookup test in RSLogix 5000 software.

Error Code


Troubleshooting

32 3A2152B

E09 BusUndervoltage Fault (Bus Undervolt-age)

With three-phase power present, the dc bus volt-age is below its limit

DC bus voltage for 230V system is below 137V

• Verify voltage level of the incoming ac power.• Check ac power source for glitches or line drop.• Install an uninterruptible power supply (UPS) on your ac input.

DC bus voltage fell below the undervoltage limit while an axis on the follower power rail was enabled

Disable follower axis before removing power.

E10 DriveOvervoltage Fault (Bus Overvolt-age)

The dc bus voltage is above its limit

Excessive regeneration of power. When the motor is driven by an external mechanical power source, it may regenerate too much peak energy through the drive power supply. The system faults to save itself from an overload.

• Change the deceleration or motion profile. • Use a larger sys-tem (motor and Kinetix 2000 drive). • Install shunt module.

DC bus voltage for 230V system is over 410V

Verify input is within specifica-tions.

E11 MotFeedbackFault (Illegal Hall State)

State of Hall feedback inputs is incorrect

Bad connections. • Verify the Hall wiring at the MF connector on the IAM/AM.• Verify 5V power supply to the encoder.

E16 Softovertravel Fault (+/- Software Over-travel)

Axis position exceeded maximum software setting. • Verify motion profile.• Verify overtravel settings are appropriate.

E18 OverSpeedFault (Overspeed Fault)

Motor speed has exceeded 150% of maximum rated speed. The 100% trip point is dictated by the lesser of the user velocity limits or the motor rated base speed.

• Check cables for noise.• Check tuning.

E19 PositionErrorFault (Follow Error)

Position error limit was exceeded. • Increase the feed forward gain.• Increase following error limit or time.• Check position loop tuning.• Verify sizing of system.• Verify mechanical integrity of system within specification limits.

E20 MotFeedbackFault (Mtr Fdbk AQB)

Motor Encoder State Error

The motor encoder encountered an illegal transition.

• Use shielded cables with twisted pair wires.• Route the feedback away from potential noise sources.• Check the system grounds.• Replace the motor/encoder.

E21 AuxFeedbackFault (Aux Feedback Comm)

Communication was not established with an intelli-gent encoder.

Verify auxiliary encoder wir-ing.

E30 MotFeedbackFault (Motor Feedback Comm)

Communication was not established with an intelli-gent encoder.

• Verify motor selection.• Verify the motor supports auto-matic identification.• Verify motor encoder wiring.

Error Code


Troubleshooting

3A2152B 33

E34 GroundShortFault (Ground Fault)

Excessive ground cur-rent in the converter was detected

Wiring error. • Check motor power wiring.• Check input power wiring.

Motor internal ground short.

Replace motor.

Internal malfunction. Disconnect motor power cable from drive and enable drive with current limit set to 0. If fault clears, then a wiring error or motor internal problem exists. If fault remains, call your sales representative.

Grounded control power terminal (applies to 230V systems only).

• Remove ground from control power input.• Source control power from three-phase input power. Refer to the Power Wiring Examples on page 169 for more information.• Add isolation transformer for control power.

E35 DriveUndervoltage Fault (Pre-charge Fault)

Converter pre-charge cycle failed

Low AC input voltage. Check input ac voltage on all phases.

Internal malfunction. Call your sales representative. E36 DriveOvertemp Fault

(System Overtempera-ture)

Converter thermal switch tripped

Excessive heat exists in the power circuitry.

• Reduce acceleration rates.• Reduce duty cycle (ON/OFF) of commanded motion.• Increase time permitted for motion.• Use larger Kinetix 2000 con-verter.• Check for clogged vents or defective fan.• Make sure cooling is not restricted by insufficient space around the unit.

E37 PowerPhaseLoss Fault (Phase Loss Flt)

• One or more phases of the input ac power is missing.• Axis was enabled when main (three-phase) power was removed.• Common bus follower axis was enabled when dc bus power was removed.

• Check input ac voltage on all phases.• Disable axis before removing power.

E38 SERCOSFault (SER-COS Ring Flt)

The SERCOS ring is not active after being active and operational

Cable disconnected. Check that fiber-optic cable is present and connected prop-erly.

E39 DriveHardFault (Self Sense Flt)

Self-sensing Commuta-tion Startup Error

Motion required for self-sensing startup com-mutation was obstructed.

• Verify that there are no impedi-ments to motion at startup, such as hard limits.• Increase self-sensing current if high friction or load conditions exist.• Check motor or encoder wiring using wiring diagnostics.

Error Code


Troubleshooting

34 3A2152B

E43 DriveEnableInput Fault (Drive Enable Flt)

Missing Drive Enable Input Signal

• An attempt was made to enable the axis through software while the Drive Enable hardware input was inactive.• The Drive Enable input transitioned from active to inactive while the axis was enabled.

• Disable the Drive Enable Input fault.• Verify that Drive Enable hard-ware input is active whenever the drive is enabled through software.

E50 SERCOSFault (SER-COS Same ADDR)

Duplicate node address detected on SERCOS ring. Verify that each SERCOS drive is assigned a unique node address.

E54 DriveHardFault (Ifbk HW Fault)

Current feedback hardware fault detected. Replace the module.

E60 DriveHardFault (Unknown Axis)

Illegal ID bits detected. Replace the module.

E61 AuxFeedbackFault (Aux Fdbk AQB)

Auxiliary Encoder State Error

The auxiliary encoder encountered an illegal transition.

• Use shielded cables with twisted pair wires.• Route the feedback away from potential noise sources.• Check the system grounds.• Replace the motor/encoder.

E62 AuxFeedbackFault (Aux Fdbk Loss)

The feedback wiring is open, shorted, or missing. Check the motor feedback cable connectors/wiring to the IAM/AM and motor.

E63 AuxFeedbackNoise (Aux Fdbk Noise)

Noise on auxiliary feed-back cable

Recommended ground-ing, per installation instructions, has not been followed.

• Verify grounding.• Route feedback cable away from noise sources.• Refer to System Design for Con-trol of Electrical Noise Reference Manual, publication GMC-RM001.

E64 MotorFeedbackNoise (Mtr Fdbk Noise)

Noise on motor feedback cable

E65 No Fault Message (condition indicated by on-screen mes-sage) (Hookup Fault)

Hookup procedure failed Motor or feedback device malfunction.

• Check motor power/feedback wiring.• Refer to on-screen message for resolution.

E66 No Fault Message (condition indicated by on-screen mes-sage) (Atune Flt)

Autotune procedure failed

Motor or feedback device malfunction.

• Check motor power/feedback wiring.• Refer to on-screen message for resolution.• Perform Hookup in RSLogix 5000 software.• Consult RSLogix 5000 help screen.

E67 DriveHardFault (Task init)

Operating system failed Software initialization fault detected due to hardware failure.

• Cycle power.• If fault persists, replace module.

E68 DriveHardFault (SCANport Comm)

DPI communication failed

The DPI device or cable is faulty.

Check DPI connections.

E69 DriveHardFault (Objects Init)

Non-volatile memory is corrupt due to control board hardware failure.

Load default parameters, save to non-volatile memory, and recycle power or reset the drive.

Error Code


Troubleshooting

3A2152B 35

E70 DriveHardFault (NV Mem Init)

Non-volatile memory is corrupt due to control board software error.

Load default parameters, save to non-volatile memory, and recycle power or reset the drive.

E71 DriveHardFault (Mem-ory Init)

RAM or Flash memory validation failure • Cycle power.• If fault persists, replace module.

E72 DriveOvertemp Fault (Drive Overtemp)

Inverter thermal switch tripped

The fan on the IAM or an AM failed.

Replace the failed module.

The cabinet ambient temperature is above rat-ing.

Check the cabinet tempera-ture.

The machine duty cycle requires an RMS current exceeding the continu-ous rating of the control-ler.

Change the command profile to reduce speed or increase time.

The airflow access to the Kinetix 2000 system is limited or blocked.

Check airflow and re-route cables away from the Kinetix 2000 system.

E73 Communicate (Back-plane Comm)

Power rail CAN communications failed. Check module for proper mount.

Power rail connection shorted or open. Check power rail and module for foreign objects.

E74 DriveOvercurrent Fault (Bus OverCur-rent)

DC link current exceeds rating

Motor or transmission malfunction.

• Check for proper motor sizing.• Check/replace transmission device.• Check/replace motor.

IAM not properly sized. • Check for proper IAM sizing.• Install larger kW rated IAM.

E75 DriveOvervoltage Fault (Shunt Time Out)

The IAM, AM, or SM has exceeded its shunt resis-tor continuous rating.

• Use a properly sized shunt or modify duty cycle of the applica-tion.• System uses internal shunt and requires external shunt for addi-tional capacity.

E76 DriveHardFault (CAN Init)

DPI hardware initializa-tion fault detected

Control board hardware failure.

• Reset System.• If fault persists, replace sys-tem module.

E78 DriveHardFault (SER-COS Init)

Control hardware fault detected. • Cycle power.• If fault persists, replace module.

E79 DriveOvervoltage Fault (Shunt Module Flt)

Shunt module temperature fault LED indicator is steady red.

Refer to Temperature Fault LED Indicator on page 141.

Shunt module shunt fault LED indicator is steady red.

Refer to Shunt Fault LED Indi-cator on page 141.

Module missing from power rail. • Install missing module on power rail.• Fill empty slot with slot filler module.

E80 DriveHardFault (CPLD Flt)

Control hardware fault detected. Replace module.

E81 DriveHardFault (Com-mon Bus Flt)

Follower IAM detected ac input power being applied.

Remove ac input power con-nections from follower IAM.

Error Code


Troubleshooting

36 3A2152B

E90 DriveHardFault (Pre-charge Timeout Flt)

Pre-charge resistor power exceeds the resistor rat-ing.

Allow resistor to cool.

All oth-ers

RESERVED Call your local Rockwell Auto-mation sales representative.

Error Code


Troubleshooting

3A2152B 37

IAM/AM Status Indicators

Drive Status LED Indicators

Comm Status LED Indicator

Bus Status LED Indicator

Drive Status LED Indicator Status Potential Cause Possible Resolution Off Normal, no faults N/A N/A Steady Red Drive faulted Seven-segment Fault Status dis-

play shows an error code Fault exists, refer to Seven-segment LED Indicator Error Codes begin-ning on page 134.

Comm Status LED Indicator Status Potential Cause Possible Resolution Steady Green Communication

ready No faults or failures. N/A

Flashing Green Establishing com-munication

System is still in the process of establishing SERCOS communica-tion.

Wait for steady green LED indica-tor.

Node address setting on the drive module does not match SERCOS controller configuration.

Verify proper node switch setting.

Off No communica-tion

Loose fiber-optic connection. Verify proper fiber-optic cable con-nections.

Broken fiber-optic cable. Replace fiber-optic cable.

Receive fiber-optic cable con-nected to SERCOS transmit con-nector and vice versa.

Check proper SERCOS fiber-optic cable connections.

Bus Status LED Indicator Status Condition

Steady Green Bus power is present, axis enabled. No faults or failures.

Normal when:• 24V is applied to Hardware Enable Input (IOD/AF-43).• MSO instruction is commanded in RSLogix 5000 software.

Flashing Green Bus power is present, axis disabled. No faults or failures.

Normal when:• 24V is not applied to Hardware Enable Input (IOD/AF-43).• MSO instruction is not commanded in RSLogix 5000 software.

Off Bus power not present. • Normal when bus power is not applied.• Fault exists, refer to Seven-segment LED Indicator Error Codes section beginning on page 134.

Bus power is present in follower IAM.

• Follower IAM is not configured as CommonBus Follow in RSLogix 5000 software.• After dc bus voltage is applied, a 2.5 second delay before the LED indi-cator begins flashing green is normal operation to provide common bus leader time to complete pre-charge.

Repair

38 3A2152B

Repair

Base Pump Piston Replacement


2. Use a wrench to remove the outlet feed fittings at the bottom of the pump.

3. Remove the three nuts.

4. Remove the lower.

5. See the Dura-Flo Manual for rebuild information.

NOTE: Installation is the reverse of removal.

NOTE: When rebuilding base pump, verify piston pack-ings are assembled accordingly. Refer to FIG. 15 for visual clarity.

NOTE: Check balls are not installed.

FIG. 15: Base Pump

ti18108a

ti18109a

Note orientation of piston pack-ings when assembling.

Repair

3A2152B 39

Inhibitor/Catalyst/Color Pump Rebuild

FIG. 16: Inhibitor/Catalyst/Color Pump Rebuild

ti18110a

904

925

903

801 821814

906905

824802

806803

912 922 921 907

909 913924 915

920

932

9381003

902

Repair

40 3A2152B

Disassembly of 1093 valve sectionRefer to FIG. 16 for the following steps.

1. Remove motor (826) from Mounting Plate (818).

2. Remove valve from valve stack by removing the four screws (705) that are holding the valve to the plate (938).

3. On the right side of the valve, remove Valve End Cap (909). The Valve Piston (913) will be inside the end cap.

NOTE: If necessary, remove Valve Piston (913) from Valve End Cap (909) by applying low air pressure through valve air inlet to push out the Valve Piston (913).

4. Remove Seal Plate (924).

5. Repeat steps 3 and 4 with the left side of the valve.

6. Push the Spool/Sleeve (917) out with a finger. If the Spool/Sleeve does not slide out, tap gently using a wood or plastic dowel.

A worn spool and sleeve assembly must be replaced with a new (matched) assembly. If you are rebuilding multiple valves be sure to keep the spools and sleeves matched.

7. Remove Inlet/Outlet Block (932) from Valve Body (907).

8. Remove O-Rings (920) from Valve Body (907).

9. Remove Spool Wet Seal Retainers (915) on the left and right of the Valve Body (907).

10. Remove Valve Body (907) from Oil Cup Retainer (925) by removing Screws (927).

11. Remove Metering Sleeve (906) from Valve Body (7).

12. Remove Oil Cup Retainer (925) by removing screws (824) shoulder bolt.

13. Remove Seal Cup (903) from Oil Cup Retainer (925). Remove Posipak Rod Seal (904) from Seal Cup (903).

14. Slide Guide Rods out of Connection Block (806).

15. Remove Metering Rod (902) from Connection Block (806).

16. Remove Non Drip valve (1003) from Inlet/Outlet (932).

Assembly of 1093 valve sectionNOTE: Check the Metering Rod (902), Metering Sleeve (906), and Spool/Sleeve Assembly (917) and Valve Body (907) for wear. Replace as necessary.

1. Install four lubricated O-rings (919) onto the Spool/Sleeve Assembly (917). Lubricate the Spool Rod and the outside of the Spool Rod Sleeve along with the inside of the Valve Body (907).

2. Insert the Spool/Sleeve Assembly (917) carefully into the Valve Body (907). Be sure to align the Bot-tom holes of the Sleeve piece of the Spool/Sleeve (917) with the outlet, inlet, and transducer holes of the Valve Body (907).

Install the spool wet seal retainer on the main body

3. Install a lubricated O-ring (921) on the left side of the Valve Body (907) next to the sleeve of the Spool/Sleeve assembly (917).

4. Install two lubricated Posipak Seals (922) wet seal retainer (915) so that the O-ring side of both Posi-paks will be facing the Valve Body (917). Be sure to

NOTICE

Avoid damaging U-cups and Poipak seals when installing. Verify they are lubricated and tuck the lips of the seal inward before uniformly pushing them into position.

ti18111a

Top Hole

Bottom Holes Outlet Inlet

Transducer Hole

Repair

3A2152B 41

tuck the lip of the Posipak into its cavity to avoid damage.

5. Position the wet seal retainer with the oil cup upwards and slide over the Spool part of the Spool/Sleeve Assembly (917) with the counterbore for the Seal Retainer (915) facing out. Slide the Seal Retainer (915) over the Spool and install two Screws (923). Install the Rod Sleeve and connect the motor and motor coupling assembly.

6. Repeat steps 3 through 5 for the right side Seal Plates.

Install the Metering Sleeve and Connect the Motor & Motor Coupling Assembly

7. Lubricate the dispense sleeve bore in the Valve Body (907). Insert the Metering Sleeve (906) into the Valve Body (907).

8. Place lubricated O-ring (905) over the Metering Sleeve (906) and against the Valve Body (907).

9. Insert the Seal Cup (903) into the Retainer Oil Cup (925).

10. Slide a lubricated Posipak Seal (904) into the Seal Cup (903) with the o-ring side facing down toward Valve Body (907).

11. Lubricate the Metering Rod (902) and slide carefully through the Posipak Seal (904), Seal Cup (903) and Oil Cup Retainer (925) so that the Metering Rod (902) projects about 1/2” through this assembly.

12. Using the projecting Metering Rod (902) to guide the assembly into the Metering Sleeve (906), slide the Oil Cup Retainer (925) down against the Valve Body (907) and secure with Screws (927).

13. Pull the Metering Rod (902) away from the Valve Body (907) so that the end is only slightly in the Metering Sleeve (906).

14. Slide the key slot in the Connection Block (804) over the end of the Metering Rod (902).

15. Insert the Guide Rods (803) through the Connection Block (806) and into the Oil Cup Retainer (925).

NOTE: If the Motor and Motor Coupling Assembly had been disassembled, then reassemble per the instruc-tions below before proceeding to step 19.

16. Position the Motor and Motor Coupling Assembly above the Main Body Assembly and bring them together so that the Guide Rods (803) enter their holes in the Drive Assembly (901) and the end of the Lead Screw (814) seats in the Connection Block (804).

17. Install the Screws (805/807) into the Connection Block (806).

18. Install the left Side Block 3-Slot (802) with Screws (824/808). Install the clear plastic Guards (822) so that the access hole in the guard toward the bottom. Secure with Screws (823).

Mount the Valve End Caps to the Seal Plate Cups

19. Install a lubricated U-cup Seal (912) into the groove of the left Spool Shift Piston (913). The piston is thicker on one side of the groove. The lip of the seal must be facing the thicker section.

20. Lubricate the bore in the End Cap (909). Slide the Spool Shift Piston (913) into the left End Cap (909) tucking the lip of the U-cup seal (912) into the End Cap (909) carefully.

21. Install shift spool position cycle detection sensors (926) with screws (928). Align Nubon sensor with hole in Seal Retainer (924).

22. Install the Piston/End Cap onto the left Spool Wet Retainer (915) using four Screws (908/931). Tighten the screws in a cross pattern gradually to prevent binding due to misalignment.

23. Push the Spool Rod (917) into the left side until the Spool Rod (917) contacts the piston. Repeat steps 19 through 22 for the right side.

24. Install lubricated O-rings (920) to the Valve Body (907) and attach the Inlet Block (932) with Screws.

25. Install the Inlet/Outlet Block (932) with Screws. Remount the valve. Install the home and spool sen-sors being careful not to overtighten the set screws. Install the air supply lines and connect the power.

Repair

42 3A2152B

Motor Coupling

FIG. 17: Motor Coupling Assembly

ti18110a

ti18112a

827

828

826

830

819

818

816815

817

813

812

811

814

810

809

831

808

824

801

822

823

833

821

803

804

806

805

820823

822

802

807

Repair

3A2152B 43

Disassembly of motor coupling section1. Remove Screws (805) to disconnect Connection

Block (804) from Lead Screw Connector Block.

2. Remove Lead Screw Connecting Block from lead screw by removing the FHSC screw (807).

3. Remove Mounting Plate (818) from drive assembly by removing SHC Screws (819).

4. Remove bearing Retaining Sleeve (817) from drive assembly by removing screws (810).

5. Remove Lead Screw (814) and Lead Screw Nut (813) with the ball bearing assembly (812/811) attached.

Motor and motor coupling assembly1. Assemble Motor Coupler by inserting Roll Pins

(825) and Screws (816).

NOTE: This step is only required if the motor coupler has been disassembled for service or removed from the motor.

2. Assemble Lead Screw Nut (813) with Bearing (812) and E-ring (811).

3. Thread Lead Screw (814) into Lead Screw Nut assembly until lead screw is flush with top of nut.

4. Slide Lead Screw & Nut Assembly into Lead Screw Housing (809).

5. Slide Bearing Retaining Sleeve (817) on to the lead screw assembly, taking care to line up the slots in the two pieces (809) and (817). Secure in place with Screws (810).

6. Secure Motor Mounting Plate (818) to Lead Screw Housing (809) using Socket Head Cap Screws.

7. Place Motor Coupler (815) on motor shaft and lightly snug Screws (816) leaving about 3/8” of motor shaft visible between Motor Coupler and motor. Insert Motor Coupler (815) through Motor Mounting Plate (818), align 3 Roll Pins and insert into Lead Screw Nut (813) and gently seat the motor.

NOTE: This step is only required if the motor coupler has been disassembled for service or removed from the motor.

8. Remove motor and motor coupler, tighten Screws (816) and reassemble securing motor to Motor Mounting Plate using Socket Head Cap Screws (827).

Repair

44 3A2152B

Valve Stack Rebuild

FIG. 18: Valve Stack Assemblies

ti18113a

1217

1212

1201

1204

1202

1205

1213

1213

1204

1205

1204

1205

1204

1205

1208

1213

130513041305

1306

1307

13081309

1216

Mixer Step Face Up

Repair

3A2152B 45

The valve stack is a series of blocks put together with socket head cap screws. Each block contains a plastic mixer (1205). The only reason to service this would be if the material started to gel, if the color was being changed, or before a long shut down. If the material started to gel, the best place to start is the bottom block where the catalyst is injected. There should be no gell-ing above that point. To disassemble the valve stack:


2. Remove the base hose from the Swivel Fitting (1217) at the top of the stack.

3. Remove the inhibitor, catalyst and color valves from the valve stack. Remove the Bolts (705) from the Plate (938).

4. Turn off the flow of coolant to the Cooling Jacket (704) and Block (1309) and relieve any coolant pressure.

5. Remove the Cooling Jacket (704) from the Pipe Mixer (1308).

6. Remove the Pipe Mixer (1308) and valve stack from the screw on the press.

7. Remove the Cooling Block (1309) from the valve stack

8. Move the stack to a bench to disassemble.

9. Carefully use a pipe wrench to remove the Pipe Mixer (1308).

10. Remove the bottom four Socket Head Screws (1213) from the Bottom Outlet Block (1208).

11. Remove the Bottom Outlet Block (1208) from the Catalyst Pump Port (1203).

12. Remove the Plastic Mixer (1205) from the Block (1208).

NOTE: The old mixer should be replaced with a new one each time.

13. Remove the Top Inlet Block (1201) from the Inhibi-tor Pump Port (1203) by removing four Socket Head Cap Screws (1212).

14. Remove the Plastic Mixer (1205).

15. Remove the four Socket Head Cap Screws (1213) in the Inhibitor Pump Port Block (1203).

16. Remove the Inhibitor Pump Port Block (1203).

17. Remove the four Socket Head Cap Screws (1213) from either the Spacer Block (1206) or the Color Block (1206) if using kit 24M126.

18. Remove the Mixer (1205) from this Spacer Block (1206) or Color Block (1206).

Before reassembly, check all sealing surfaces for scratches. Make sure any traces of silicone are removed. Replace the Plastic Mixers (1205), the Top Inlet Block Oring (1202), and the other Block Orings (1204). Use an oring lubricant on the seals to reassem-ble.

Reassembly is the reverse of disassembly. Be sure the plastic mixers are positioned correctly with the small step facing up as shown. Refer to FIG. 18.

Repair

46 3A2152B

Position Sensor on Inlet/Outlet Valve Replacement

FIG. 19: Inlet/Outlet Valve

ti18117a

405

407

407

403

408

402404

409

406

401

Repair

3A2152B 47

See valve manual 310550 for more information.

1. Remove and bleed air pressure from valve.

2. Remove valve cap (402).

3. Disconnect coupling (404) from valve shaft (401).

4. Remove air cylinder (405) from valve cap (402).

5. Lubricate and replace o ring (403).

6. Perform any other valve maintenance as required. See Graco manual 310550.

7. Reattach air cylinder (405) to valve cap (402).

8. Pull air cylinder (405) shaft out and attach coupling (404).

9. Attach coupling (404) to valve shaft (401) and piston (401).

Parts

48 3A2152B

Parts

Control Frame Base Pump, 24M094

ti18114a

113

114

115

104,105,106

102,108,109

101,120

116

110,111

103

110,112

107

119117

118

Parts

3A2152B 49

Software already loaded when received.

Ref Part Description Qty101 16M370 FRAME,assembly,LSR,aluminum 1102 24L878 PUMP,base assembly,DURA-FLOW 750, 1103 24M007 VALVE,base assembly,DURA-FLOW 750,I 1104 24L933 ENCLOSURE,assembly,LSR select 1105 24L871 PANEL,back,assembly,LSR select,1 1106 24L890 CONTROL,wiring diagram,LSR select 1 1107 81/0136-G/25 GUARD,footswitch assembly,w/cord,15' 1108 16M397 CABLE,feedback,base pump,5 meter 1109 16M398 CABLE,power,base pump,5 meter 1110 24M118 VALVE,assembly,solenoid,base pump,A 2111 121022 ELBOW,swivel,1/4tube x 1/4NPT 1112 125733 FITTING,tee,1/4tube x 1/4 NPT 1113 24M050 HARNESS,assembly, LSR, stack 1114 24M049 HARNESS,assembly,LSR,stack,motor,11' 1115 24M051 HARNESS,assembly,LSR,stack,sensor,11' 1116 24M111 CLAMP,assembly,hose,(1)1-5/8ID 1117 24M112 CLAMP,assembly,hose,(3)1-5/8ID 1118 125968 COVER,cables,5-3/4”OD,16”LG 1119 114271 STRAP,retaining 6120 125920 COVER,T-slot,gray,78.74”,10mm 2

121 16K956 SOFTWARE,HMI,LSR 1122 16K957 SOFTWARE,PLC,LSR 1123 16K958 SOFTWARE,PLC,LSR,select 1

Parts

50 3A2152B

Base Pump Wet Section, 24L880

ti18115a

201

202

Parts

3A2152B 51

Ref Part Description Qty201 L180SS PUMP,recip, displacement 1202 16M221 HOUSING,valve,(7.5CM),base pump 1

Parts

52 3A2152B

Base Pump Lower, 24L878

ti18116a

318

319

310

313

312

314

315

316

317

301

302

303

308

304

305

309

305

306

307

311

305

306

307

Parts

3A2152B 53

Replacement Danger and Warning labels, tags, and cards are available at no cost.

Item not shown.

Ref Part Description Qty301 16K892 MOTOR,servo 1302 125874 ACTUATOR,linear,ET100,w/o motor 1303 121797 SCREW,cap,socket 4304 114766 BOLT,cap hex head 4305 101044 WASHER,plain 12306 100018 WASHER,lock,spring,1/2” 6307 555395 NUT,1/2-13 6308 16M223 PLATE,adapter,ET100,DF750,pump 1309 617374 PLATE,pump,mounting 1310 118435 GROMMET 1311 123999 SCREW,cap,hex head 4312 16M224 GUARD,tube,base pump 1

313 84/0130-27/11 LABEL,hand crush,1.3 X 1.1,triangle,ISO 1314 15F837 ROD,tie 3315 100128 WASHER,lock 3316 555396 NUT,5/8-11 hex 3317 24L880 pump,displacement,mod 1318 16M222 SHAFT,drive,holder,sensor,M27-2 1319 81/0440-1/11 SWITCH,proximity,24VDC,NO,PNP 1

320 81/0399/11 CONNECTOR,field,straight,female 1

Parts

54 3A2152B

Base Pump Inlet/Outlet Valves, 24L977

ti18117a

405

407

407

403

408

402404

409

406

401

Parts

3A2152B 55

Ref Part Description Qty401 918537 APPLICATOR,ball seat,1/2 port 1402 16M353 CAP,cylinder 1403 103338 PACKING,o-ring 1404 16M352 COUPLING,piston,air cylinder,cycle 1405 125917 CYLINDER,air, 1406 125918 SWITCH,proximity,4MM,PNP/NPN,24VDC,3W 2407 82/0217-A/11 MUFFLER,air,1/8NPT,mini 2408 121022 ELBOW,swivel,1/4TUBEX1/4NPT 2409 81/0398/11 CONNECTOR,field,straight 2

Parts

56 3A2152B

Base Pump Inlet/Outlet Valve Plumbing, 24M007

ti18118a

501

502504

505

506

507

510

508

509

501

502

503

505

504

506512513

514515

503

511

Parts

3A2152B 57

Ref Part Description Qty501 125925 FITTING,swivel,3/”4X1” 2502 15U426 BUSHING,reducing 2503 24L977 APPLICATOR,ball seat,1/2 port 2504 166242 FITTING,elbow,street,90 degree 2505 15M859 FITTING,adapter,male,swivel,1/2 SST 2506 114572 FITTING,nipple,hex 3507 V-565208080808SS CROSS,1/2NPT 1508 123980 FITTING,swivel,3/4X1/2 1509 122763 FITTING,elbow,straight,3/4NPT 1510 504174 BUSHING,pipe 1511 24L981 HOSE,coupled 1512 122656 BUSHING,1/2X1/4NPT 1513 124517 SENSOR,pressure,PGM,ambient 1514 81/0428/11 CONNECTOR,PT06F106S MIL 1515 81/0099-4/11 CORD,20/4,5A,PVC,300V,80degree C 10

Parts

58 3A2152B

Base Pump Inlet/Outlet Valve Plumbing, 24M118

ti18119a

604

608

605

602

603

606

607

604

608

605

602

603

606

607

601

Parts

3A2152B 59

Ref Part Description Qty per Valve601 123513 FERRULE,wire,18AWG 3602 81/0287-3/11 CORD,18/3,7A 8603 83/0028-C/11 CONNECTOR,cable,solenoid 1604 120900 VALVE,power,4W,SSSR,1/4NPT,24VDC 1605 121021 MUFFLER,air,1/4NPT 2606 121022 ELBOW,swivel,1/4TUBEX1/4NPT 2607 054130 TUBE,.250 OD 6608 15F979 SCREW,pan head 2

Parts

60 3A2152B

Valve Stack, 24L893

ti18160a

704 706

708

703

702

701

705,707

709

712

711

710

Parts

3A2152B 61

Ref Part Description 24L893 Qty

24M126 Qty

24M127 Qty

701 24L968 VALVE,1093,10A-4TS0-250-V-DISP 1702 24L969 VALVE,1093,10A-4TS0-625-V-DISP 1703 24M039 MIXER,stack assembly,(2)1093,w/cool 1704 24M040 JACKET,cooling assembly,3/4X12 pipe 1705 101682 SCREW,SHC,1/4-20X0.625 4706 24M048 VALVE,assembly 1707 110755 WASHER,plain 4708 24L969 VALVE,1093,10A-4TS0-625-V-DISP 1709 16M448 BLOCK,stack,module 1710 124517 SENSOR,pressure,PGM,ambient 1711 81/0428/11 CONNECTOR,PT06F1065 MIL 1712 81/0099-4/11 CORD,20/4,5A,PVC,300’,80 degree. 1

Parts

62 3A2152B

Inhibitor/Catalyst/Color Pump Drive (1093 Valve), 24L905

ti18112a

814

809

831

821

801

824

822

823

820

805806

807

803

804

823822

827

828

826

819

818

815

817

813

812

811

821808

802

824

816 810

825

808

916

Parts

3A2152B 63


Ref Part Description Qty801 01/2983/97 PLATE,tie,front,PD,1.5B 1802 01/2982/97 PLATE,tie,back,PD44 1803 01/2706-A/99 ROD,guide,1093,1.5BX2.0S 2804 A2010204 1093,connector,metering rod 1805 96/0260/98 SCREW,SHC,8-32X0.63,SS 2806 A2010205 1093,connector,lead screw 1807 96/0458/99 SCREW,FHSC,10-32X0.50 1808 96/0328-2/98 SCREW,SHC,shoulder 4809 01/2990/97 HOUSING,leadscrew 1810 96/0273/99 SCREW,BHSC,8-32X0.19 2811 V-98585A112 RING,retaining,external,0.625 1812 84/0129/11 BEARING,ball,.625IDX1.375OD 1813 16M285 NUT,leadscrew,drive 1814 01/2994-1/25 LEADSCREW,drive,1093 1815 16M284 COUPLER,leadscrew,12MM,motor,shaft 1816 96/0363/99 SCREW,SHC,6-32X0.38 2817 01/2992/97 RETAINER,bearing,leadscrew 1818 16M286 PLATE,moutning 1819 GC2192 SCREW,SHDC,SS,.164X.375 4820 01/2993-S/89 SPACER,drive nut 1821 A2010208 1093,spacer,drive 4822 01/2995-1/11 GUARD,side,1093 2823 297639 SCREW,cap,button head,8-32X.38 4824 96/0328-3/98 SCREW,SHC,shoulder 4825 96/0206/98 PIN,roll,1/8X.50,SS 3826 16K891 MOTOR,servo,enclosure 1827 113003 SCREW,SHC,10-32X0.63 4828 C19277 WASHER,lock,split,hi-collar 4

831 84/0130-27/11 LABEL,hand crush 1

Parts

64 3A2152B

Inhibitor/Catalyst/Color Pump Drive (1093 Valve), 24L969 and 24L968

927

925

903

904

905

902

906

907

909

934933

915

936

935

910

911

914

912913

924923 916

926

928

929

922

921

937

931910

909

908

911

914912

913924

929

915

923926,928

917921

922

917

919

939940938

ti18120a

930

920

932

Parts

3A2152B 65

Ref Item Description24L969

Qty24L969

Qty901 24L905 KIT,1093,driveE assembly,servo motor 1 1902 A2010207-10S 1093,rod,metering,5/8,SS 1

16M328 ROD,1093,metering,1/4,SS 1903 A2010203-10 1093,oil cup,large,5/8 1

16M329 CUP,1093,oil,large,1/4 1904 D2000064 POSIPAK,5/8IDX7/8OD 1

D2000042 POSIPAK,1/4IDX1/2OD 1905 103559 PACKING,o-ring 1 1906 A2010206-10D 1093,sleeve,metering,5/8 1

16M327 SLEEVE,1093,metering,1/4,PTFE 1907 16M324 VALVE,1093,main 1 1908 96/0509/98 SCREW,SHC,10-32X2.50 4 4909 16D002 CAP,END,air cylinder 2 2910 123453 FITTING,1/4tube x 1/8NPT 2 2911 111098 PACKING,o-ring,cylinder 2 2912 95/0601/01 U-CUP,1-3/16IDX1-1/2OD 2 2913 A2000009-1 1093,piston,spool 2 2914 01/2801-1/97 TUBE,AIR CYL,spool,1093 2 2915 A2000006-1 1093,retainer,seal,wet,spool valve 2 2916 110208 PLUG,pipe,headless,1/8NPT 4 4917 16M330 SPOOL,1092,assembly 1 1918 J1000002 PIN,ROLL,1/8X.38 2 2919 108195 PACKING,o-ring 4 4920 556553 O-RING,-008 FKM-A 2 2921 555684 O-RING,-018 FKM-A 2 2922 D2000040 POSIPAK,3/8IDX5/8OD 2 2923 95/0894/11 POSIPAK,1"IDX1-3/8"OD 2 2924 A2000007-1 1092,retainer,seal 2 2925 A2010202 1093,retainer,oil cup,large 1 1926 81/0440-1/11 SWITCH,proximity,24VDC,NO,PNP 2 2927 96/0307-1/99 SCREW,SHC,10-24X1.00 4 4928 96/0575/98 SCREW,FHSC,4-40X0.31 2 2929 B4000023 SCREW,SHC,10-32X1.25 4 4930 84/1050-400/11 DECAL,material 1 1931 617559 SCREW,cap,SCH 4 4932 24L906 NEEDLE,1092,adapter,single 1 1933 123538 BUTTON,snap-on,1/4tube 1 1934 61/2904-YL/11 TUBING,0.160IDX0.250OD 6 6935 123537 BUTTON,snap-on,1/4tube 1 1936 61/2904-GN/11 TUBING,0.160IDX0.250OD 6 6937 125916 SCREW,SHC,10-32X0.25 1 1

Parts

66 3A2152B

Needle Adapter Assembly, 24L906

938 16M326 BRACKET,mounting,module 1 1939 96/0125/99 SCREW,SHC,10-24X0.50 4 4940 100020 WASHER,lock,split,#10,MS 4 4941 81/0398/11 CONNECTOR,field,straight 1 1

Ref Item Description24L969

Qty24L969

Qty

ti18121a

1001

1002

1004

1003

1004

Ref Part Description Qty1001 124998 FITTING,adapter 11002 16M287 BLOCK,1092,inlet/outlet,9/16-18 11003 24L907 VALVE,assembly 11004 B4000016 SCREW,SHC,10-32X1.00 2

Parts

3A2152B 67

Non-Drip Valve, 24L907

Ref Part Description Qty1101 01/0013-S/98 STEM,NDV,5/8,11/16,special seat 11102 97/0208/98 SPRING,.250 ODX1.00LG,8.99LB 11103 16M288 HOUSING,5/8,SS,soft seat,SAE 11104 01/0014/98 PIN,NDV,5/8,11/16,SS 11105 103648 PACKING,o-ring 11106 16M289 VALVE,head,NDV,5/8,11/16,PTFE 11107 120336 O-RING,packing 1

ti18122a

1101

11061102

1103

1104

1107

1105

Parts

68 3A2152B

Valve Stack, 24M039

ti18123a

1217

1212

1201

1202

1213

1203

1213

1204

1205

1219

1204

1205

1203

1204

1205

1208

1213

1217

1202

1204

1201

12161216

1205

1204

Parts

3A2152B 69

Ref Part Description 24M039 Qty

24M126 Qty

1201 16M450 BLOCK,stack,inlet 11202 103559 PACKING,o-ring 11203 16M448 BLOCK,stack,module,mix,inlet,10 21204 559011 O-RING,(-022) FKM 41205 C26213 CARTRIDGE,mixer 41208 16M451 BLOCK,stack,module,mix,outlet 11212 107445 SCREW,SHC,1/4-20X1.50 41213 113194 SCREW,cap,socket 121216 122763 FITTING,elbow,3/4NPT,90,3K 11217 125925 FITTING,swivel,3/4”X1”,SST,3K 11219 16M448 BLOCK,stack,module,mix,inlet 1

16M449 BLOCK,stack,module,mix 1

Parts

70 3A2152B

Cooling jacket, 24M040

Ref Part Description Qty1301 16M453 JACKET, cooling, 3/4x12 pipe mixer 11302 94/0417/99 CLAMP, hose, 3"-2-1/16" 21303 116658 FITTING, tube, male (1/4 npt) 21304 100721 PLUG, pipe 21305 121022 FITTING, elbow, male, 1/4 npt 41306 96/0442/99 SCREW, shc, 3/8-16x1.25 21307 100133 WASHER, lock, 3/8 21308 100731 WASHER 21309 16M452 JACKET, cooling, stack, module, mix 1

ti18202a

1304

1306,

1309

1305

1302

1301

1302

1303

1307,1308

Parts

3A2152B 71

Solenoid Valve, 24M048

Kit 24M126 adds an extra solenoid valve to the sys-tem.

Part not shown.

Ref Part Description 24M048 Qty

24M126 Qty

1401 83/0082/11 VALVE,power,4W,SSSR,24VDC 3 11402 83/0081/11 PLUG,1/4 11403 G0050125 VALVE,solenoid,manifold kit 1

1404 122522 CONNECTOR,5 pin 11405 551789 SCREW 21406 82/0337/11 PLUG,one-touch 1

1407 82/0414/11 MUFFLER 1

ti18105a

1403

1406

1402

1401

Parts

72 3A2152B

Control Cabinet Exterior, 24L993

ti181096a

1528

1527

1503,

1501

1514,

1512,

1520

1511

1524

1523

1519

1517

1525

1505,

1502

1526

1510

1521,

1504,1506,1508

1515

15131507,1508,1509

1522

Parts

3A2152B 73


Part not shown.

Ref Part Description Qty1501 24L932 ENCLOSURE,LSR select,painted 11502 16K902 CONTROL,panelview 700 PLUS 6 11503 81/2060-E/11 BUTTON,mush 11504 81/2060-EL/11 LEGEND,e-stop,60MM,plain 11505 81/2080-1/11 BLOCK,contact,NO 11506 81/2070/11 LATCH,operator 11507 81/2060-P/11 OPERATOR,PB,dual 11508 81/2081-1/11 BLOCK,contact,NC 21509 81/2072-2/11 LIGHT,LED,white,24VDC,latch 11510 16M354 FAN,ENC,22VAC,4” 11511 81/0369-EG/11 GRILL,exhaust,4”,w/filter 11512 81/0114-3/11 ALARM,audio 11513 81/0114-VC/11 COVER,volume control,audio alarm 11514 6690-34-299 ETHERNET bulkhead pass thru 11515 6690-34-300 ETHERNET cap & lanyward 11517 81/0372-2/86 CONNECTOR,PVC,1.25” 3

1518 5-742-B-TB8 T-BOLT KIT,10MM slot 81519 125795 GRIP,cord 61520 168491 EMBLEM,GRACO 1

1522 15M511 LABEL,warning,PR70 11523 81/1060-4/25 CONNECTOR,4P w/key 11524 84/0101-BI/11 LEGEND,start options 11525 84/0101-FC/11 LEGEND,control power 11526 84/0101-AT/11 LEGEND,audio power 11527 16K317 LABEL,legend,ethernet 1

1528 196548 LABEL,caution,shock 1

Parts

74 3A2152B

Control Cabinet Interior, 24L871

ti18125a

1623 1624 1625, 1627, 1622 1603, 1601 1629,1626 1628 1638

1630,

1610

1611

16121613

1606,

1631

1644

1613

1614

1615

16501618,

1641,

1621

1619

1643

1642

16181618,

1618,1632,1619

16191634,1638

1604

1634,

1609

1608

1602

1614

1617

1616

1615

1640

Parts

3A2152B 75

Part not shown.

Ref Part Description24L871

Qty24M126

Qty24M127

Qty24M128

Qty1601 16K903 PANEL,back,60X36 11602 6690-34-301 SWITCH,ethernet,5 port 11603 24X024 DISCONNECT assembly,fused,30AMP 11605 24L930 TERMINAL,strip assembly,LSR select 11606 16K875 CONTROL,programmable,L45 11607 16K878 MODULE,SERCOS,drive,L4X 1 11608 16K879 MODULE,power supply,24 11609 16K877 MODULE,ehternet bridge 11610 6690-34-243 ANALOG module 11611 6690-34-143 MODULE,input,16 11612 6690-34-248 16 point relay 11613 6690-34-224 CAP,end 11614 16K885 MODULE,power rail 1 11615 16K882 MODULE,integrated axis 1 11616 16K884 MODULE,axis 11617 16K883 MODULE,axis 11618 16K880 KIT,I/O,feedback,SERCOS 3 11619 16K881 BATTERY,servo 2 1

1620 16K876 CLAMP,cable,kinetix drive 11621 81/0495-6/11 CONTACTOR,4P,6A,24VDC 1 11622 123359 RELAY,contactor,30A 1 11623 123386 RELAY,24VDC coil,SPDT 1 11624 123296 CIRCUIT,breaker,2P,5A,UL489 21625 116500 HOLDER,fuse,safety 2 21626 116821 FUSE,Bussman 2 21627 81/0033-H3/11 BLOCK,fuse,TYPE-CC,3pole,30A,IP 1 11628 81/0033-20/11 FUSE,type-CC,20A,time delay 3 31629 117666 TERMINAL,ground 11630 6690-20-47 DISTRIBUTION block 11631 6690-20-59 DISTRIBUTION block cover 11632 121808 POWER SUPPLY,24VDC 11633 120997 CORDSET,EURO,male,5PIN 11634 16M305 AMPLIFIER,UV-10,18-24VDC 1 3 1

1635 6690-34-164 6FT ethernet cable 21636 6690-34-163 3 FT ethernet cable 11637 16K890 CABLE,fiberoptic 4 21638 116610 SCREW,mach 51

1639 295709 SCREW,SHC,8-32X0.75 21640 113003 SCREW,SHC,10-32X0.63 6 4 6 21641 81/0163-A/11 PANDUIT,2.0”X3.0”X6' 181642 514014 RAIL,mount 3.581643 81/0164-A/11 COVER,panduit,2”X6' 181644 125957 MODULE,memory 11650 16K886 MODULE,power rail,filler 3

Control Schematics, 24L890

76 3A2152B

Control Schematics, 24L890N

OTE

:1.

ALL

WIR

ING

SH

ALL

BE

A M

INIM

UM

OF

90 D

EG C

, RAT

ED F

OR

TH

E VO

LTAG

E U

SED

, AN

D O

NE

OF

THE

FOLL

OW

ING

: MTW

, T

HH

N, A

WM

LIS

TED

TO

UL

758.

2. D

O N

OT

CRO

SS F

ILTE

RED

WIR

ES W

ITH

UN

FILT

ERED

WIR

ES.

3. D

C CO

NTR

OL

WIR

ING

SIZ

E 18

AW

G U

NLE

SS N

OTE

D.

4. W

IRIN

G S

UBJ

ECT

TO M

OVE

MEN

T SH

ALL

BE

PRO

VID

ED W

ITH

AD

DIT

ION

AL

PRO

TEC

TIO

N S

UCH

AS

INSU

LATI

NG

SLE

EVE,

WIR

E W

RAP,

OR

EQU

AL.

5. U

SE F

ERRE

LS O

N T

ERM

INA

L A

ND

DEV

ICE

CON

NEC

TIO

NS.

6. S

CHEM

ATIC

INCL

UD

ES A

LL O

PTIO

NS

AS

NO

TED

:

24

L872

IS T

HE

OPT

ION

FO

R A

FO

URT

H C

OM

PON

ENT

24L8

73 IS

TH

E O

PTIO

N F

OR

PRES

SURE

TRA

NSD

UCE

RS

24

L874

IS T

HE

OPT

ION

FO

R A

TRA

NSD

UCE

R O

N T

HE

FOU

RTH

CO

MPO

NEN

T.

7. R

EFER

ENCE

24L

871

FOR

BACK

PA

NEL

AN

D 2

4L93

3 FO

R

E

NCL

OSU

RE T

O G

ET A

CTU

AL

PART

NU

MBE

RS.

PART

NU

MBE

RS H

ERE

ARE

FO

R RE

FERE

NCE

ON

LY.

COM

PAC

TLO

GIX

8 PT 6690-34-243ANALOG INPUT MODULE

PAN

ELVI

EW P

LUS

OPE

RATO

R

16K878SERCOS ADAPTER MODULE

CPU

OUTPUT MODULE16 PT 6690-34-248

16K875

16K878SERCOS ADAPTER MODULE

16K877ETHERNET MODULE

16K879POWER SUPPLY

16 PT 6690-34-143INPUT MODULE

KIN

ETIX

16K884AXIS MODULE-9 AMP

16K882INTEGRATED AXIS MODULE

16K883AXIS MODULE-3 AMP

FIBE

ROPT

IC C

ABL

E

KIN

ETIX

16K882INTEGRATED AXIS MODULE

FIBE

ROPT

IC C

ABL

E

16K8

92BA

SE

16K891

CATALYST

INHIBITOR

ADDITIVE (FUTURE)

COLORANT

FUTURE COLORANT

DOUBLEWIDE

16K891

16K891

16K891

16K891

12 P

UM

P VA

LVE3

PO

S2

9 PU

MP

VALV

E2 P

OS1

11 P

UM

P VA

LVE3

PO

S1

10 P

UM

P VA

LVE2

PO

S2

5 10

93 V

ALV

E3 P

OS1

6

1093

VA

LVE3

PO

S2

7 PU

MP

VALV

E1 P

OS1

8

PUM

P VA

LVE1

PO

S2

2 10

93 V

ALV

E1 P

OS2

3

1093

VA

LVE2

PO

S1

4 10

93 V

ALV

E2 P

OS2

INPU

TS:

1 10

93 V

ALV

E1 P

OS1

15 E

STO

P

13 S

TART

SIG

NA

L

14 P

UM

P IN

REL

OA

D P

OSI

TIO

N

16 S

PARE

12 9

11

10 5 PU

MP

VALV

E 2

6 PU

MP

VALV

E 3

7

8

2 10

93 V

ALV

E 2

3

1093

VA

LVE

34

PUM

P VA

LVE

1

OU

TPU

TS:

1 10

93 V

ALV

E 1

15 S

PARE

13

14

16 S

PARE

INTE

RFAC

E

ETH

ERN

ET S

WIT

CH5

PORT

PRO

GRA

MM

ING

16K886POWER RAIL FILLER

SLO

T1SL

OT2

SLO

T3

5 SC

REW

PRE

SSU

RE

6 SP

ARE

7

SPA

RE

8 SP

ARE

2 10

93 P

RESS

URE

3

1093

PRE

SSU

RE

4 PU

MP

PRES

SURE

AN

ALO

G IN

:1

1093

PRE

SSU

RE

16K8

88

16K8

87

16K8

89

6690

-34-

248

6690

-34-

143

6690

-34-

243

6690

-34-

92

6690

-34-

92

U70

328

16K8

90FI

BERO

PTIC

CA

BLE

FIBEROPTIC CAB.16K890

FIBE

ROPT

IC C

ABL

E

16K8

90-3

FIBEROPTIC CAB.16K890

24L8

72O

NLY

6690

-34-

301

6690

-34-

163

6690

-34-

164

6690

-34-

164

16K9

02



ETH

ERN

ET

WH

ERE

USE

D IN

CIR

CUIT

LIN

E, L

OA

D A

ND

CO

NTR

OL

CON

DU

CTO

RS A

T LI

NE

VOLT

AGE

INTR

INSI

CALL

Y SA

FE W

IRIN

GVO

LTAG

E FR

OM

OTH

ER S

OU

RCES

(CU

STO

MER

SIG

NA

L)

AC G

ROU

ND

ED N

EUTR

AL

LESS

TH

AN

150

VO

LTS

AC C

ON

TRO

L CO

ND

UC

TORS

AT

LESS

TH

AN

150

VO

LTS

DC

CON

TRO

L CO

ND

UC

TORS

LIG

HT

BLU

E

WH

ITE/

BLU

E

WIR

E CO

LOR

GRE

EN/Y

ELLO

W

BLAC

K

GRO

UN

DD

C CO

MM

ON

ORA

NG

E

WH

ITE

BLU

E

RED


3A2152B 77

PG-1

1 2 3 4

BRN

BLK

BLU

BLK

1236

58

81/0

398/

11

PG-2

1 2 3 4

BRN

BLK

BLU

BLK

PG-3

1 2 3 4

BRN

BLK

BLU

BLK

PG-1

0

1 2 3 4

SHIE

LDRE

DBL

KG

RN

1225

22

5W

HT

1 2 3 4

BRN

WH

TBL

UBL

K

REF

1 2 3 4

BRN

WH

TBL

UBL

K

REF

1 2 3 4

BRN

WH

TBL

UBL

K

REF

1 2 3 4 5

SHIE

LD RED

BLK

WH

TBL

U

REF

PG-1

1

1 2 3 4

SHIE

LDRE

DBL

KG

RN

5W

HT

1 2 3 4 5

SHIE

LD RED

BLK

WH

TBL

U

REF

PG-1

2

1 2 3 4

SHIE

LDRE

DBL

KG

RN

5W

HT

1 2 3 4 5

SHIE

LD RED

BLK

WH

TBL

U

REF

1236

58

1236

58

GRE

Y CA

BLE

1212

01

PG-1

5

1 A C E F

SHIE

LD RED

WH

TG

RNW

HT

REF

81/0

428/

11

FDCBA E

INT

JMP

INT

JMP

CUT

ON

E EN

D O

FF

PG-1

7

1 2 3 4

BLK

7000

BLK

7060

BLK

7140

BLK

7420

1225

22

5RE

D 6

1 2 3 4 5

WH

TBL

UBL

KG

RY

REF

BRN

81/0

055-

MC4

/11

1236

58

1-1/

4" C

ON

DU

IT

HEA

T SH

RIN

K

81/0

398/

11

81/0

398/

11

1225

22

1225

22

24L8

72 O

NLY

24L8

73 O

NLY

24L8

74 O

NLY

24L8

73 O

NLY

I/O C

ABL

ES F

ROM

EN

CLO

SURE

TO

STA

CK

PX-V

110

93 IN

HIB

ITO

R SW

ITCH

ES

PX-V

210

93 C

OLO

R SW

ITCH

ES

PX-V

310

93 C

ATA

LYST

SW

ITCH

ES

PT-3

1093

CAT

ALY

ST T

RAN

SDU

CER

PT-2

1093

CO

LOR

TRA

NSD

UCE

R

PT-1

1093

INH

IBIT

OR

TRA

NSD

UCE

R

PT-5

SCRE

W T

RAN

SDU

CER

SOL-

OV

SOLE

NO

ID V

ALV

ES


78 3A2152B

L1

L1

L2

L220

3-24

0V/3

PH/5

0-60

HZ

60 AMP

DISC-1

30 A

MP

L1L2

240

249

247

245

242

210

238

236

234

232

230

228

226

224

222

220

218

214

216

212

208

206

204

202

200

241

248

244

246

243

211

239

237

235

233

231

229

227

225

223

221

219

215

217

213

209

207

205

203

201

290

299

297

295

292

260

288

286

284

282

280

278

276

274

272

270

268

264

266

262

258

25625

4

252

250

291

298

294

296

293

261

289

287

285

283

281

279

277

275

273

271

269

265

267

263

259

25725

5

253

251

L3 L3

L3

L2

CB1

L3

5A

2060

2080

PS-1 N

24V

DC

LFGV-V+

68

10 A

WG

DC

COM

HA

RNES

S 12

0997

BRN

WH

T

BLU

1

PG-P

S1

2

PG-P

S1

3

PG-P

S1

16 A

WG

8BL

U

824

VDC

6D

C CO

M

BLU

6W

HT

/BL

U0X

PB-1

BI

CRM

-1

34

2560

CRM

-1

A1

A2

PL-1W

0

PB-1

A

XO

REM

OTE

STO

P

2561

2562

2563

2563

PB-2

XO

E-ST

OP

CON

TRO

L PO

WER

6W

HT

/BL

U

86 6

6W

HT

/BL

U

CRM

-2

A1

A2

625

63

2060

2080

L2L2

CB2

5A

2160

2180

PS-2 L2L1 PE

10 A

WG

14 A

WG

2160

2180

8BL

U6

WH

T/B

LU

86

HM

I-1

PE+

_

ETH

ERN

ETPO

RT

86

CAB-

1

FU-L1

FU-L2

FU-L3

MCR

1

A1

A2

6W

HT

/BL

U6

8

CRM

-1

1314

2680

826

81

MCR

2

A1

A2

6W

HT

/BL

U6

TO K

2000

RAC

K1

TO K

2000

RAC

K226

82

POW

ER S

UPP

LYO

N P

LC

CR-2

1114

CR-3

1114

1218

08

16K8

79

81/0

194-

30/2

5

(3) 8

1/01

96-3

0/11

1232

96

1232

9681

/049

5-6/

11

81/0

495-

6/11

1233

59

1233

59

1233

86

1233

86

6690

-34-

301

8BL

U6

WH

T/B

LU

86

ETH

ERN

ET P

ORT

+

_

86

CAB-

2

HM

I

PLC

5 4 3 2 1

CAB-

3BU

LKH

EAD

6690

-34-

299

L1

L2FA

N

14A

16M

354

24L8

72 O

NLY

24L8

72 O

NLY

310,

312,

314

360,

362,

364

6690

-34-

164

6690

-34-

164

6690

-34-

163

16K9

02

698

WHT/BLU6W

HT

/BL

U6

WH

T/B

LU

8BL

U

BLU

CON

TRO

L PO

WER

BLK

BLK

L1

L2

ETH

ERN

ET

ET-1


3A2152B 79

340

349

347

345

342

310

338

336

334

332

330

328

326

324

322

320

318

314

316

312

308

306

304

302

300

341

348

344

346

343

311

339

337

335

333

331

329

327

325

323

321

319

315

317

313

309

307

305

303

301

390

399

397

395

392

360

388

386

384

382

380

378

376

374

372

370

368

364

366

362

358

356

354

352

350

391

398

394

396

393

361

389

387

385

383

381

379

377

375

373

371

369

365

367

363

359

357

355

353

351

L3L1

L2

L1L2

L3

IAM

-1

FU-3

20 A

MP

L1

L2

L3FU

-4

FU-5

12

34

MCR

1

56

L331

4031

41

L231

2031

21

L131

0031

01

FU-1

10 A

MP

L1

L2

FU-2

L230

60

L130

40

CRM

-2

34

3001

6816

K882

1 CO

NT

EN+

2 CO

NT

EN-

L1L2

L3

AM

-1

16K8

84

AM

-2

16K8

83

1 L1

2 L2

3 L3

4 G

ND

5 D

C+

6 D

C-

1 C

TRL

1

2 C

TRL

2

1

2

3 4

U V

W

GN

D

1

2

43

BRAKE

CR-2

A1

A2

1

2

3 4

U V

W

GN

D

IAM

-2

FU-8

20 A

MP

L1

L2

L3FU

-9

FU-1

0

12

34

MCR

2

56

L336

4036

41

L236

2036

21

L136

0036

01

FU-6

10 A

MP

L1

L2

FU-7

L235

60

L135

40

CRM

-1

12

3501

6816

K882

1 CO

NT

EN+

2 CO

NT

EN-

1 L1

2 L2

3 L3

4 G

ND

5 D

C+

6 D

C-

1 C

TRL

1

2 C

TRL

2

CR-3

A1

A2

81/0

033-

20/1

181

/003

3-H

3/11

1165

0011

6821

1233

59

1233

8612

3386

81/0

495-

6/11

3000

81/0

495-

6/11

3500

5 14

6 -10 +

GRN

WH

T/G

RNG

RYW

HT/

GRY

ORG

WH

T/O

RG

2 5 614

BLK

WH

T/BL

KRE

DW

HT/

RED

ORG

WH

T/O

RG

1

10 11

4

3

GRN

WH

T/G

RNG

RY

24L8

72 O

NLY

BRN

BLK

BLU

GRN

/YEL

SHIE

LD/B

RAID

BRN

BLK

BLU

GRN

/YEL

BATMOTOR

FEEDBACK

DAT

A+/

IM+

EPRW

_5VM

(2)

ECO

MM

(2)

DAT

A-/

IM-

MO

TOR

CABL

E (B

LK)

16M

396

INCO

MIN

G C

ABL

EG

ROU

ND

ED P

AD

SHIE

LD/B

RAID

MO

TOR

CABL

E (O

RG)

16M

398IN

HIB

ITO

RA

BSO

LUTE

EN

COD

ER16

K891

M2

BASE

ABS

OLU

TE E

NCO

DER

16K8

92M

1

1

2

3 4

U V

W

GN

D

1

2

43

BRAKE

5 14

6 -10 +

GRN

WH

T/G

RNG

RYW

HT/

GRY

ORG

WH

T/O

RG

BRN

BLK

BLU

GRN

/YEL

SHIE

LD/B

RAID

BAT

SHIE

LD/B

RAID

MOTORFEEDBACK

DAT

A+/

IM+

EPRW

_5VM

(2)

ECO

MM

(2)

DAT

A-/

IM-

MO

TOR

CABL

E (B

LK)

16M

396

ENCO

DER

CA

BLE

(BLK

)16

M39

5

INCO

MIN

G C

ABL

EG

ROU

ND

ED P

AD

COLO

RA

BSO

LUTE

EN

COD

ER16

K891

M4

1

2

3 4

U V

W

GN

D

5 14

6 -10 +

GRN

WH

T/G

RNG

RYW

HT/

GRY

ORG

WH

T/O

RG

BRN

BLK

BLU

GRN

/YEL

SHIE

LD/B

RAID

BATMOTOR

FEEDBACK

DAT

A+/

IM+

EPRW

_5VM

(2)

ECO

MM

(2)

DAT

A-/

IM-

MO

TOR

CABL

E (B

LK)

16M

396

INCO

MIN

G C

ABL

EG

ROU

ND

ED P

AD

CATA

LYST

ABS

OLU

TE E

NCO

DER

16K8

91M

3

CUT

PRO

TEC

TIVE

CO

VER

BACK

EXP

OSI

NG

BRA

IDSH

IELD

/BRA

ID

ENCO

DER

CA

BLE

(BLK

)16

M39

5

CUT

PRO

TEC

TIVE

CO

VER

BACK

EXP

OSI

NG

BRA

ID

SHIE

LD/B

RAID

ENCO

DER

CA

BLE

(BLK

)16

M39

5

CUT

PRO

TEC

TIVE

CO

VER

BACK

EXP

OSI

NG

BRA

ID

MOTORFEEDBACK

DAT

A+/

IM+

EPRW

_5VM

(2)

ECO

MM

(2)

DAT

A-/

IM-

INCO

MIN

G C

ABL

EG

ROU

ND

ED P

AD

SHIE

LD/B

RAID

ENCO

DER

CA

BLE

(GRN

)16

M39

7

CUT

PRO

TEC

TIVE

CO

VER

BACK

EXP

OSI

NG

BRA

IDTS

BM+

BM-

AM

+A

M-

X100

X11

H L

H L

H L

X100

X15

H L

81/0

033-

20/1

181

/003

3-H

3/11

1165

0011

6821

1233

59

66

3060

3040

3560

3540

WH

T/B

LU

WH

T/B

LU


80 3A2152B

540

549

547

545

542

510

538

536

534

532

530

528

526

524

522

520

518

514

516

512

508

506

504

502

500

541

548

544

546

543

511

539

537

535

533

531

529

527

525

523

521

519

515

517

513

509

507

505

503

501

590

599

597

595

592

560

588

586

584

582

580

578

576

574

572

570

568

564

566

562

558

556

554

552

550

591

598

594

596

593

561

589

587

585

583

581

579

577

575

573

571

569

565

567

563

559

557

555

553

551

88

24VD

C

24VD

C

BLU

6D

C CO

M6D

C CO

M

V IN

O+

V/I IN

O-

I IN O

+

ANLG

COM

NC NC

INH

IBIT

OR

VALV

E 1

PRES

SURE

COLO

RAN

TVA

LVE

2PR

ESSU

RE

CATA

LYST

VALV

E 3

PRES

SURE

BASE

D

URA

-FLO

WPR

ESSU

RE

21

35

46

OFFO

N

1 2 3 4 5 6

A B C D E F

+PO

WER

-OU

TPU

T/R

ETU

RN+O

UTP

UT

SHU

NTC

AL

ENA

BLE

+EXC

ITAT

ION

-EXC

ITAT

ION

+SIG

NA

L-S

IGN

AL

SHU

NT

CAL

RESI

STO

R

78

RED

BLK

GRN

WH

T50

31

5011

5011

PG-1

0

5432

5020

5010

5000

5030

5011

5031

SLO

T 1

88

24VD

C

24VD

C

BLU

688

6

COURSEZERO

FINEZERO

FINEGAIN

10V

5V 3V

WHT/BLU

V IN

1+

V/I IN

1-

I IN 1+

ANLG

COM

OFFO

N

1 2 3 4 5 6

A B C D E F

+PO

WER

-OU

TPU

T/R

ETU

RN+O

UTP

UT

SHU

NTC

AL

ENA

BLE

+EXC

ITAT

ION

-EXC

ITAT

ION

+SIG

NA

L-S

IGN

AL

SHU

NT

CAL

RESI

STO

R

AM

P-2

RED

BLK

GRN

WH

T51

61

5041

5041

PG-1

1

PT-2

5432

5150

5140

5130

5160

5041

5161

688

6

COURSEZERO

FINEZERO

FINEGAIN

10V

5V 3V

V IN

2+

V/I IN

2-

I IN 2+

ANLG

COM

OFFO

N

1 2 3 4 5 6

A B C D E F

+PO

WER

-OU

TPU

T/R

ETU

RN+O

UTP

UT

SHU

NTC

AL

ENA

BLE

+EXC

ITAT

ION

-EXC

ITAT

ION

+SIG

NA

L-S

IGN

AL

SHU

NT

CAL

RESI

STO

R

RED

BLK

GRN

WH

T52

91

5271

5271

PG-1

2

5432

5280

5270

5260

5290

5271

5291

688

6

COURSEZERO

FINEZERO

FINEGAIN

10V

5V 3VPOW

ERTR

AN

SDU

CER

AM

P-1

PT-1

AM

P-3

PT-3

V IN

3+

V/I IN

3-

I IN 3+

ANLG

COM

21

35

46

OFFO

N

1 2 3 4 5 6

A B C D E F

+PO

WER

-OU

TPU

T/R

ETU

RN+O

UTP

UT

SHU

NTC

AL

ENA

BLE

+EXC

ITAT

ION

-EXC

ITAT

ION

+SIG

NA

L-S

IGN

AL

SHU

NT

CAL

RESI

STO

R

78

RED

BLK

5421

5401

5401

F PG-1

4

DCBA

5410

5400

5390

5420

5401

5421

688

6

COURSEZERO

FINEZERO

FINEGAIN

10V

5V 3VAM

P-4

PT-4

E

+EXC

IT

-EXC

IT

-OU

TPU

T+O

UTP

UT

GRN

WH

T

6D

C CO

M6D

C CO

M

V IN

4+

V/I IN

4-

I IN 4+

ANLG

COM

NC NC

WHT/BLU

V IN

5+

V/I IN

5-

I IN 5+

ANLG

COM

V IN

6+

V/I IN

6-

I IN 6+

ANLG

COM

V IN

7+

V/I IN

7-

I IN 7+

ANLG

COM

21

35

46

OFFO

N

1 2 3 4 5 6

A B C D E F

+PO

WER

-OU

TPU

T/R

ETU

RN+O

UTP

UT

SHU

NTC

AL

ENA

BLE

+EXC

ITAT

ION

-EXC

ITAT

ION

+SIG

NA

L-S

IGN

AL

SHU

NT

CAL

RESI

STO

R

78

RED

5531

5511

5511

F PG-1

5

DCBA

5520

5510

5500

5530

5511

5531

688

6

COURSEZERO

FINEZERO

FINEGAIN

10V

5V 3VAM

P-5

PT-5

E

21

35

46

OFFO

N

78

21

35

46

78

NO

TE: S

MA

LL T

RAN

SDU

CERS

HAV

E JU

MPE

R SE

T TO

10V

,

LA

RGE

TRA

NSD

UCE

RS H

AVE

JUM

PER

SET

TO 5

V.

RED

BLK

GRN

WH

T

RED

BLK

GRN

WH

T

RED

BLK

GRN

WH

T

RED

BLK

GRN

WH

T

RED

BLK

GRN

WH

T

#10-

32

#10-

32

#10-

32

1/4N

PT

1/4N

PT

SCRE

WPR

ESSU

RE

+EXC

IT

-EXC

IT

-OU

TPU

T+O

UTP

UT

RED

BLK

WH

TBL

U

1SH

IELD

SHIEL

D

1SH

IELD

SHIEL

DRE

DBL

KW

HT

BLU

1SH

IELD

SHIEL

DRE

DBL

KW

HT

BLU

POW

ERTR

AN

SDU

CER

POW

ERTR

AN

SDU

CER

POW

ERTR

AN

SDU

CER

POW

ERTR

AN

SDU

CER

BLK

GRN

WH

T

24L8

73 O

NLY

24L8

74 O

NLY

24L8

73 O

NLY

24L8

73 O

NLY

SHIEL

D


3A2152B 81

640

649

647

645

642

610

638

636

634

632

630

628

626

624

622

620

618

614

616

612

608

606

604

602

600

641

648

644

646

643

611

639

637

635

633

631

629

627

625

623

621

619

615

617

613

609

607

605

603

601

690

699

697

695

692

660

688

686

684

682

680

678

676

674

672

670

668

664

666

662

658

656

654

652

650

691

698

694

696

693

661

689

687

685

683

681

679

677

675

673

671

669

665

667

663

659

657

655

653

651

SLO

T 2

DC C

OM 2

0706050403

15141312

020100

11100908

DC C

OM 1

6W

HT

/BL

U

I:2/0

0IN

PUT

6000

I:2/0

1

I:2/0

2

I:2/0

3

I:2/0

4

I:2/0

5

I:2/0

6

I:2/0

7

I:2/0

8

I:2/0

9

I:2/1

0

I:2/1

1

I:2/1

2

I:2/1

3

I:2/1

4

I:2/1

5

6W

HT

/BL

U

88

24VD

C6

DC

COM

24VD

C6

DC

COM

BLU

WHT/BLU

88

24VD

C6

DC

COM

24VD

C6

DC

COM

BLU

WHT/BLU

INH

IBIT

OR

CLO

SE S

POO

L VA

LVE

1RE

LOA

D P

OSI

TIO

N

STA

RT M

ACH

INE

FOO

T SW

ITCH

CUST

OM

ER S

IGN

AL

STO

P M

ACH

INE

CUST

OM

ER S

IGN

AL

8BR

N1

PG-1

2

PG-1

BLK

63

PG-1

BLU

PX-C

SV1

6070

INH

IBIT

OR

OPE

N S

POO

L VA

LVE

1D

ISPE

NSE

PO

SITI

ON

BRN

4

PG-1

BLK

BLU

PX-O

SV1

6140

COLO

RAN

TCL

OSE

SPO

OL

VALV

E 2

RELO

AD

PO

SITI

ON

8BR

N1

PG-2

2

PG-2

BLK

6BL

U

PX-C

SV2

6210

COLO

RAN

TO

PEN

SPO

OL

VALV

E 2

DIS

PEN

SE P

OSI

TIO

N

BRN

4

PG-2

BLK

BLU

PX-O

SV2

6280

CATA

LYST

CLO

SE S

POO

L VA

LVE

3RE

LOA

D P

OSI

TIO

N

8BR

N1

PG-3

2

PG-3

BLK

6BL

U

PX-C

SV3

6350

CATA

LYST

OPE

N S

POO

L VA

LVE

3D

ISPE

NSE

PO

SITI

ON

BRN

4

PG-3

BLK

BLU

PX-O

SV3

6420

BASE

INLE

TCL

OSE

VA

LVE

1RE

LOA

D P

OSI

TIO

N(D

OW

N)

81

PG-4

2

PG-4

6

PX-C

V1

6490

BASE

INLE

TO

PEN

VA

LVE

1D

ISPE

NSE

PO

SITI

ON

(UP)

4

PG-4

PX-O

V1

6510

BASE

OU

TLET

CLO

SE V

ALV

E 2

RELO

AD

PO

SITI

ON

82

PG-5

6

PX-C

V2

6520

BASE

OU

TLET

OPE

N V

ALV

E 2

DIS

PEN

SE P

OSI

TIO

N

4

PG-5

PX-O

V2

6500

6570

6780

BASE

DU

RA-F

LO L

OW

ERSH

AFT

RET

RAC

TED

RELO

AD

PO

SITI

ON

8RE

DBR

N1

PG-7

2

PG-7

BLK

63

PG-7

BLU

PX-S

FT

FS-1

6850

8BL

U1

PG-8

2

PG-8

BRN

4

PG-8

GRN

YEL

8BL

U68

50

CUST

OM

ER S

TART

6920

8BL

UCU

STO

MER

STO

P

1

PG-5

GRN

GRN

3

PG-2 3

PG-3 3

PG-4

WH

T

3

PG-5

WH

T

BRN

BLK

BLU

BRN

BLK

BLU

RED

RED

BRN

BLK

BLU

BRN

BLK

BLU

BLK

WH

T

BRN

WH

T

BLU

BLK

BRN

WH

T

BLU

BLK

BRN

WH

T

BLU

BLK

24L8

72 O

NLY

CR-C

S

A1

A2

CR-C

S

1114

1233

86

1233

86

CUST

OM

ER S

TART

HO

OK

IN 2

4VD

C ST

ART

SIG

NA

L FR

OM

PRE

SS

CON

TRO

LPO

WER

ON

2563

259

BLU

CUST

OM

ER S

TART

8BL

U68

50

WIR

EDSP

ARE

WIR

EDSP

ARE

WH

T

BLU

BLU

BLU

WH

T

WH

T

STA

RT O

PTIO

NS

BLK

BLK


82 3A2152B

740

749

747

745

742

710

738

736

734

732

730

728

726

724

722

720

718

714

716

712

708

706

704

702

700

741

748

744

746

743

711

739

737

735

733

731

729

727

725

723

721

719

715

717

713

709

707

705

703

701

790

799

797

795

792

760

788

786

784

782

780

778

776

774

772

770

768

764

766

762

758

756

754

752

750

791

798

794

796

793

761

789

787

785

783

781

779

777

775

773

771

769

765

767

763

759

757

755

753

751

SLO

T 3

0706050403

15141312

01 02

OUTP

UT00

11100908

VAC

VDC

1VA

C VD

C 2

8A8A 24VD

C6

DC

COM

24VD

C6

DC

COM

WHT/BLU

8A

8

6D

C CO

M

24VD

C6

DC

COM

WHT/BLU

8A

O:3

/00

7000

O:3

/01

O:3

/02

O:3

/03

O:3

/04

O:3

/05

O:3

/06

7420

O:3

/07

O:3

/08

O:3

/09

O:3

/10

O:3

/11

O:3

/12

O:3

/13

O:3

/14

O:3

/15

INH

IBTO

RO

PEN

SPO

OL

VALV

E 1

DIS

PEN

SE P

OSI

TIO

N

SCRE

W V

ALV

E

SOL-

OSV

1

BLK

1

PG-1

7

2

PG-1

7

RED

6

7060

COLO

RAN

TO

PEN

SPO

OL

VALV

E 2

DIS

PEN

SE P

OSI

TIO

NSO

L-O

SV2

BLK

3

PG-1

7

RED

6

7140

CATA

LYST

OPE

N S

POO

L VA

LVE

3D

ISPE

NSE

PO

SITI

ON

SOL-

OSV

3

BLK

4

PG-1

7

RED

6

7200

BASE

INLE

TO

PEN

INLE

T VA

LVE

LOA

D P

OSI

TIO

N

BLU

BRN

6

7270

BASE

OU

TLET

OPE

N O

UTL

ET V

ALV

E D

ISPE

NSE

PO

SITI

ON

BLU

BRN

6

7340

7490

AUD

IOA

LARM

7500

WIR

EDSP

ARE

7570

WIR

EDSP

ARE

7640

WIR

EDSP

ARE

7710

WIR

EDSP

ARE

7780

WIR

EDSP

ARE

7850

WIR

EDSP

ARE

7910

WIR

EDSP

ARE

7990

WIR

EDSP

ARE

CRM

-1

56 8A 24

VDC

8BL

U

WH

TBR

N

BLU

BLK

SOL-

OV4

BLK

5

PG-1

7

RED

6W

HT

/BL

U

AA

-1

6

24L8

72 O

NLY

(CU

STO

MER

TO

SU

PPLY

ACTU

AL

FLU

ID V

ALV

E)

GRY

+ 1- 2

SOL-

OV1

BRN

BRN

GRN

/YEL

+ 1- 2

SOL-

OV2

GRN

/YEL

WIR

EDSP

ARE

AUD

IO A

LARM


3A2152B 83

HMI Operation Overview

84 3A2152B


To navigate between screens press the button at the bottom of the screen for the desired screen.

STARTUP/ MAIN MENU SCREEN

ALARM STATUS SCREEN

ALARM HISTORY SCREEN

PRESSURE LOGS SCREEN

COLOR PRESSURE / TORQUE / SPEED

LOG SCREEN

CAT. PRESSURE / TORQUE / SPEED

LOG SCREEN

INHIBITOR PRESS. / TORQUE / SPEED

LOG SCREEN

BASE PRESSURE / TORQUE / SPEED

LOG SCREEN

STATUS SCREEN

DRIVE / VALVE CON-TROL SCREEN

PRESSURE SETUP SCREEN

RATIO CHECK SETUP SCREEN

HOME SETUP SCREEN

AUTO MODE SCREEN


3A2152B 85

Change HMI ValuesTo edit a value such as flow rate or percentage, press the button.

The keypad comes up, enter the new value.

NOTE: The limits are displayed between the readout and keypad.

Appendix A - HMI Screens Overview

86 3A2152B

Appendix A - HMI Screens OverviewStartup Screens:

Standard Startup Screen

Startup Screen with Accessories Installed


3A2152B 87

NOTE: Various parts of the display are hidden based on what system is ordered or who is logged on.

1. In the upper right corner of this screen (and every screen) there is an indicator that says if there is a fault or not. The fault can be determined by looking at the Alarm Status screen by hitting the button in the lower right hand corner. Refer to Machine Alarms, page 28 for fault descriptions.

2. The gray box contains the number and revision of the program along with the time and date.

3. The first line in the blue box shows the status of each drive motor. The status may read:

• Fault: There is a drive fault.• Disabled: The drive needs enabled.• Home: The motor is in the home position and

ready to dispense.• Dispensing: The motor is moving and the pump

the motor is attached to should be dispensing.• Loading: The motor is moving and the pump the

motor is attached to should be moving towards the home position.

4. The second line in the blue box shows the settings for the current flow rate of each pump.

5. The third line shows the settings for current percent of each component to be dispensed.

6. The forth line show the pressure at the base pump and for part number 24M127 will show the pressure for the other pumps.


88 3A2152B

Status Screens:

Standard Status Screen

Status Screen with Accessories Installed


3A2152B 89

The Status screen pictorially represents the system and status of each item.

1. Base pump on left of screen:

a. Far left valve indicator shows if the base inlet valve is in the opened or closed position.

b. Right valve indicator shows if the base outlet valve is in the opened or closed position.

c. A pressure indicator shows the pressure of the base pump when loading or dispensing.

d. The box under the pressure indicator shows the drive status. This is the same status box that shows on startup screen.

2. The valve stack on the right of the screen.

This shows various assemblies depending on what has been installed on the system.

a. If the pressure is displayed, the screen shows the material feed pressure on the valve when the valve is in the load position and the pressure of the material when being injected into the stack when the valve is dispensing.

b. The box above the pressure reading indicated the drive status. This is the same status box that shows up on the startup screen.

Assembly Inhi

bito

r

Cat

alys

t

Col

or

Pre

ssur

e

24M093

24M126

24M127

24M128


90 3A2152B

Drive/Valve Control Screen:

Standard Drive/Valve Control Screen


3A2152B 91

Each gray box shows indicators and controls for the noted pump. The controls in the lower right box will operate all valves.

1. BASE/INHIBITOR/CATALYST valves windows, also COLOR if 24M126 is used. These windows control the pump indicated in the upper left corner of the window.

a. STATUS INDICATOR: The upper right corner has the drive status indicator. This is identical to the drive indicator on the startup and status screens.

b. ENABLE/DISABLE PUSHBUTTONS AND INDICATOR: On power up the drives are dis-abled. The indicator below the enable and dis-able push button will read “Disabled”. The drive must be enabled in order to run. In auto mode all drives must be enabled, even if they are not part of the recipe. For example, if base purging with base and inhibitor only, the catalyst drive would still need to be enabled. To enable the drive, press the enable push button. The indicator below will read “Enabled”. To disable the drive, for example to reset a fault, press the disable push button

c. HOME PUMP/CYCLE PUMP/EXTEND PUMP: If after enabling the drive, the indicator shows “Not Home”, The drive needs to be homed. Press the HOME PUMP push button to home the drive. All drives must be in the home posi-tion to start a shot in the auto mode. A drive does not have to be in the home position to be powered up. The CYCLE PUMP push button is used to make an individual pump take a single shot. The pump mode must be set in ratio check

and the drive must be enabled and in the home position. The pump will dispense a fixed shot and the flow rate defined on the RATIO CHECK SETUP screen. This is used for troubleshooting an individual pump. The EXTEND PUMP push button (base only) is used to cycle the pump to its fully extended position for priming. After the base pump is fully extended, pressing the HOME PUMP push button will return the pump to the home position.

d. OPEN/CLOSE INLET/OUTLET VALVE (base pump only): These push buttons manually open and close the inlet and outlet valves to the base pump in the MANUAL MODE. To open the inlet valve, push the OPEN INLET VALVE button. The indicator below will read “OPEN”. To close the inlet valve, push the CLOSE INLET VALVE push button. The indicator will read “CLOSED”. The same works for the outlet valve.


92 3A2152B

2. ALL VALVES:

a. ENABLE/DISABLE DRIVES: These push but-tons work the same as the ENABLE/DISABLE DRIVE push buttons for each individual compo-nent, they just enable all the pumps or disable all the pumps at the same time. The enabled/disabled status is indicated in each individual component.

b. DRIVE FAULT RESET push button: If there is a drive fault (indicated in the status of each com-ponent or in the upper right corner of any screen), pushing the drive fault reset button will reset the fault.

c. DRIVE SHUTDN RESET push button: Neces-sary to reset the drive for certain faults if shut down. Use this push button to reset the drive if a fault shuts down the machine.

d. SET AUTO/RATIO/MAN'L mode push buttons: These are used to set the machine mode. When connected to the press the mode should be set to auto mode. Push the SET AUTO MODE push button. In auto mode, the button color will change from gray to green and will read “IN AUTO MODE”. The ratio check and manual modes are set the same way. The ratio check mode is used to run a pump individually and the manual mode is used for manually toggling valves when priming.

e. OPEN/CLOSE/AUTO SCREW VALVE push buttons and indicator. These buttons are used to setup the customer supplied valve between the outlet of the mixer and entrance of the screw. During normal running in auto mode the valve should be set to AUTO by pushing the AUTO SCREW VALVE push button. The indi-cator beneath the push buttons will read “AUTO”. The valve is set to be held open or closed by pushing the OPEN or CLOSE SCREW VALVE button. The valve should be held open or closed for priming and clean out.

f. RESET OVERTRAVEL FAULT push button (only visible when supervisor is logged in). This is one method used to reset an over travel fault which occurs when a pump axis goes beyond the defined range.

g. Status box in lower right corner (only visible when supervisor is logged in): This is used for additional troubleshooting. The status box dis-plays the actual motor position, actual motor speed, pressure and motor torque while running for each component.

NOTE: Negative speed or torque value indicates the motor is moving in thee negative direction. The position for home is 0.0, +/-.02 for the base, +/-.002 for the inhib-itor and catalyst.


3A2152B 93


94 3A2152B

Pressure Setpoint Screens:

Pressure Setpoint screen for basic system (24M093).NOTE: This screen is only accessible when the supervisor is logged in:

Pressure Setpoint screen for all (24M093, 24M126, 24M127, 24M128):


3A2152B 95

1. BASE/INHIBITOR/CATALYST/COLOR/MIXED Cur-rent Pressure (PSI) readout: This is the actual pressure in the pumps. If the pump is in the reload position, the readout shows the pressure of the material being pumped into the pump. If the pump is dispensing, the readout shows the pressure of the material being pumped to the stack. The MIXED pressure reading is the value between the mixer outlet and the inlet to the screw.

2. BASE/INHIBITOR/CATALYST/COLOR/MIXED high limit: This is the pressure that will shut the machine down if reached.

3. BASE/INHIBITOR/CATALYST/COLOR/MIXED low limit: This is the pressure that will shut the machine down if the pressure dips below. This is useful to shut down the system is a pump runs out of material and the component isn't being added to the mix. To ignore the low level, enter zero.

4. ENABLE/DISABLE PRESSURE SHUTDOWN push buttons and indicator. Push the Enable Pressure Shutdown button to enable the shutdown on a pres-sure fault.

NOTE: This is the default value. The indicator below the push buttons will read “ENABLED”. To disable the shut-down, push the Disable Pressure Shutdown button. It is recommended to leave this feature enabled. Check to see if it only looks at the low when dispensing.

5. ENABLE/DISABLE PRESSURE ALARM push but-tons and indicator. Push the Enable Pressure Alarm button to enable the alarm on a pressure fault.

NOTE: This is the default value. The indicator below the push buttons will read “ENABLED”. To disable the alarm, push the Disable Pressure Alarm button. It is rec-ommended to leave this feature enabled. This is used to keep running on a pressure fault, however the user will get an alarm signal that the pressure went over or under the specified values. When the pressure shut down is enabled, the alarm is also enabled.

6. CLEAR PRESSURE FAULT push button. In the event of a pressure shutdown fault, the system will not run again until the pressure is brought into the limits and the Clear Pressure Fault push button is pressed.


96 3A2152B

Ratio Check Setup Screen:

This screen is used to set up shot a flow rate values for each component to do a single shot for troubleshooting.

1. BASE/INHIBITOR/CATALYST/COLOR SHOT RANGE: This is used to set how far the pump will travel to dispense a shot. The value is entered in cc's and must be between the high and low limits of travel noted under “Shot Range”

2. BASE/INHIBITOR/CATALYST/COLOR DISP. SPEED RANGE: This is used to set how fast the pump will move to dispense a shot. The value is entered in cc's per second.

3. BASE/INHIBITOR/CATALYST/COLOR RELOAD SPEED RANGE: This is used to set how fast the pump will move to reload a shot. The value is entered in inches per second.

NOTE: This value is also used to reload the pump in auto mode.

4. Setup Home push button: This is used to access the screen to define the home position for a pump if the pump loses its home position information.


3A2152B 97

Setup Home (accessible by supervisor only):

This screen is used to define the home position for a pump if the pump loses its home position information. This only needs to be redone if the connection between the pump motor encoder and drive are disconnected.

1. ENABLE/DISABLE DRIVE push button and indica-tor: Identical function to buttons on DRIVE/VALVE CONTROL screen.

2. SET HOME push button: Used to set motor position to zero when pump is in the home position.

3. Position box: Show the current position of the pump motor. When the SET HOME push button is pushed, this should read close to zero.

See Appendix C - Setting Home Position on Pumps starting on page 105.


98 3A2152B

Auto Mode Setup Screen:

This screen is used to set up the recipe for the base, inhibitor, and catalyst (color also if 24M126 is used) in AUTO MODE.

1. TOTAL FLOW RATE (cc/sec) data entry in the TOTAL MIX box: This lets the user change the flow rate of mixed material that will load the screw on the press.

2. MAX SHOT POSSIBLE (cc) readout in the TOTAL MIX box: This shows how much material can be expected out of the pumps before they will reload.

NOTE: The shot in AUTO MODE is based on the time the signal from the press is held on. If the mold size pump sizes don't match, the screw may not be able to refill in a single pump shot. The value shown in this box is calculated from the percentages entered in each com-ponent below.

3. BASE/INHIBITOR/CATALYST/COLOR FLOW RATE (cc/sec) readout: This shows the calculated flow rate each pump will run at to achieve the flow rate entered in the total mix box and the percentage of each component needed in the recipe.

4. BASE PERCENT OF MIX: This is a readout only. The readout changes based on raising and lowering

the percentages of the other components. In order to dispense 100% base, adjust the inhibitor, catalyst and color percentages to zero.

5. INHIBITOR PERCENT OF MIX: This can be adjusted up or down by either pushing the square which will bring up the keypad to let an operator enter a numeric percentage or the up down arrow keys can be pushed to change the percentage in 0.05% increments/decrements.

6. CATALYST PERCENT OF MIX: This may be setup to be fixed at one percent. If this option is set to allow any user to change the value, the value can be adjustable the same way as the INHIBITOR PERCENT OF MIX. This value is not recommended to deviate from one percent.

7. COLOR PERCENT OF MIX: This only shows up with kit 24M126. The value adjusts the same way the INHIBITOR PERCENT OF MIX does.

8. CYCLE PUMPS push button. This will dispense the recipe at the flow rate as long as the button is held down. The button works the same way as the footswitch or customer signal. When the signal is dropped the pumps will reload.


3A2152B 99

Pressure Log Screen:

This screen is reached by the DATA LOGS push button at the bottom of every screen. This is useful for set up and troubleshooting. The screen is very useful when the kit 24M127 is used. On the basic system alone this only displays the base pressure. Once the PRESSURE LOG screen is up, new buttons show up along the bot‐tom of the screen for further diagnostics.

1. CLEAR PRESS. FAULT push button: This is used to clear a pressure fault.

2. BASE/INHIBITOR/CATALYST/COLOR/BLOCK OUT pressure readouts: These appear along right side of the screen and display the current pressure of each component.

NOTE: The colors match the line colors on the chart.

3. DATA LOG CONTROLS window: This contains push buttons to navigate around the chart.

a. UP SCALE push button: Moves the PSI scale on the left side of the chart up to view a higher pressure range.

b. DOWN SCALE push button: Moves the PSI scale on the left side of the chart down to view a lower pressure range.

c. PEN push button: Changes scaling based on the pen color (component).

d. MOVE LEFT/MOVE RIGHT push buttons: These scroll the time on the X axis to the right or left.

e. PAUSE push button: Stops the chart from recording.

f. HOME push button: Moves the chart to the time the recording started.

g. END push button: Starts the chart again if paused and moves to the current time.

4. BASE/CATALYST/COLOR/INHIBITOR Push but-tons: These bring up screens for each component for further information and troubleshooting.


100 3A2152B

BASE/CATALYST/INHIBITOR/COLOR LOG screens:

These are accessible from the PRESSURE LOG SCREEN. These screens are identical for each component; the base component is shown below as an example.

1. CLEAR DRIVE FAULT Push button: Clears faults on all drives. The button has the identical function to the CLEAR DRIVE FAULT push button on DRIVE/VALVE control screen.

2. ENABLE/DISABLE DRIVE Push buttons and Indi-cator: These enable or disable the drive. They have the identical function as the ENABLE/DIS-ABLE DRIVE push buttons on the DRIVE/VALVE SCREEN.

3. HOME PUMP/CYCLE PUMP Push buttons and indicator: These buttons home or cycle the pump. The function is identical to the HOME PUMP/CYCLE PUMP push buttons on the DRIVE/VALVE screen.

4. DATA LOG CONTROLS Window: The push buttons in this window work the same as they do in the PRESSURE LOG screen.

5. PRESSURE (psi) Readout: This shows the actual pressure valve of the component.

NOTE: This may not show if the option (24M127, 24M128) is not being used.

6. TORQUE (%) Readout: This displays the percent-age of full torque the motor is using.

NOTE: The torque value may read a negative value. The negative sign indicates the direction the motor is turning.

7. SPEED (RPS) Readout: This displays the actual speed of the motor in revolutions per second.

NOTE: The speed value may read a negative value. The negative sign indicates the direction the motor is turning.


3A2152B 101

ALARM HISTORY Screen:

This displays ALL alarms that have occurred.

1. The blue window contains the date and time the alarm and a description of the alarm. A list of alarm descriptions are in Machine Alarms on page 28.

2. SORT Push button: switches the order from newest to oldest or oldest to newest.

3. The assorted arrow keys page/scroll up or down the lists.


102 3A2152B

ALARM STATUS Screen:

This screen displays all active alarms. Once an alarm is corrected, the alarm is removed from this screen.

1. ALARM SILENCE Push button: If an alarm triggers the audio alarm, this button will silence the alarm.

2. ALARM RESET Push button: Some alarms require an operator to acknowledge the alarm by manually pushing this button.

3. The assorted arrow keys page/scroll up or down the list.

4. RESET ALARM DATA Push button: NEED TO SEE WHAT THIS DOES

5. SORT Push button: switches the order from newest to oldest or oldest to newest.

6. CLEAR PRESSURE FAULT Push button: This needs to be pushed to clear a pressure fault. The function of this is identical to the CLEAR PRES-SURE FAULT button on the PRESSURE SETUP SCREEN.


3A2152B 103

ALARM POP UP Screen:

Whenever an alarm occurs, this pops up to inform the operator there is a problem. This information also goes to the ALARM STATUS SCREEN.

1. CLEAR Push button: This clears the alarm.

2. ALARM SILENCE Push button: If an alarm triggers the audio alarm, this button will silence the alarm.

3. CLOSE Push button: This closes the pop up screen.

NOTE: The alarms are still captured on the ALARM HISTORY or ALARM STATUS screens.

Appendix B - Logging In and Out

104 3A2152B

Appendix B - Logging In and OutOn power up, the user is the default with limited access to screens. To log in to the supervisor level:

1. Press the login button on the Startup screen.

2. The login entry screen appears.

3. Press User (F2) button to enter supervisor. The Keyboard screen appears.

4. Type in supervisor and enter (the lower right key).

5. The Login entry screen pops up again.

6. Press Password (F3) button to enter the password. The Keyboard screen pops up again.

7. Type in the password “5810” and hit enter.

8. If the password is correctly entered, the Startup screen will show the user as supervisor.

9. To logout, press the logout button on the startup screen. The screen will show Default as the user if the Supervisor is logged out.

10. Items the supervisor only has access to:

a. The PRESSURE SETPOINTS screen.

b. The RATIO CHECK SETUP screen.

c. The SETUP HOME screen.

Appendix C - Setting Home Position on Pumps

3A2152B 105

Appendix C - Setting Home Position on PumpsThe motors driving the pumps have absolute encoders on them and do not lose their position on loss of power. However, if the encoder cables are disconnected, the home positions need to be reset.

NOTE: If the electrical connections between the encoder and drive need to be disconnected, make sure the actuator is in the home position before disconnect-ing the connector. This ensures everything is in position when the connector is reattached and the below steps will not be necessary to perform.

1. Login as supervisor and go to the SETUP HOME screen.

2. Disable the drives. The motors will be able to be turned manually.

3. Locate home position for the base pump.

a. Locate the base pump so the actuator is extended about 4-1/2”.

b. Remove the motor from the actuator.

c. Using a wood dowel rod, turn the coupling in the actuator to move to the home position. CW retracts, CCW extends.

d. Reattach the motor to the actuator.

4.50"

ti18127a

ti18128a

Appendix C - Setting Home Position on Pumps

106 3A2152B

4. Locate home position for the inhibitor, catalyst, and color pumps (1093 valves).

NOTE: There is no reason to disconnect the motors to move the couplings for these pumps.

a. Locate the inhibitor, catalyst and color pumps so there is about 5/16” between the block and connection bar.

b. Insert a screwdriver in the lower slot and turn the coupling.

c. Turning the coupling clockwise retracts the shaft, turning counter-clockwise extends the shaft.

5. When the pump home positions are set, push the SET HOME button.

6. Press the ENABLE DRIVE button.

7. The motor positions will now read zero

5/16"

ti18129a

ti18130a

Appendix D - Selecting the Outlet Valve, Mounting the Stack to the Press

3A2152B 107

Appendix D - Selecting the Outlet Valve, Mounting the Stack to the PressRecommended for the customer to connect an auto-matic shutoff valve between the screw on the press and the LSR Select mixer. The LSR select has a solenoid valve and controls to connect a double acting valve.

The mixer outlet is 3/4”NPT male. When the valve stack is attached to the screw, care should be taken to ensure the valve stack is mounted rigidly. External brackets may be required.

Outlet valve controls on HMI

ti18105a1/4” Air Supply for Outlet Valve

Technical Data

108 3A2152B

Technical Data

* Catalyst and inhibitor can be incremented individu-ally in 0.1% increments.

Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 to 10 cc's per second.

Ratio Range:

* Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0% - 1%

* Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0% - 6%

Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92% - 100%

Pigment (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 0% - 6%

Shot Size Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 180 cc's, depending on ratio

Cycle Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dispense into screw varies depending on shot size and flow rate. Pump reload time is 5 seconds

Maximum Fluid Pressre. . . . . . . . . . . . . . . . . . . . . . . . . 1000 psi (7 MPa, 69 bar)

Wetted Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 stainless steel, 304 stainless steel, polytetrafluoro-ethylene (PTFE), ultra high molecular weight polyeth-ylene (UHMW-PE) and fluoropolymer elastomer

Feed System Requirements (Not Included) . . . . . . . . . Pressure feed systems that can feed the pumps at a minimum of 400 psi (2.8 MPa, 28 bar).Base inlet: 1 inch female NPT.Catalyst/Inhibitor/Pigment inlet: ¼ inch JIC-4 male, 37° flare.

Press Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 inch NPT male thread to screw, inlet valve on screw required. Maintained 24 vdc signal from press to activate shot.

Sound Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.5 dB(A)

Weight, Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 pounds (15.8 Kg)

Weight, Base Pump and Electrical Panel . . . . . . . . . . . 400 pounds (182 Kg)

Service Requirements:

Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208-240 volts, 3 phase, 3 wire with ground, 50-60 hertz, 30 amps full load

Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 1 scfm at 80-100 psi, ¼ inch female NPT inlet

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60°F (10-15°C) chilled water for mixer jacket at approximately ½ gpm (1.9 lpm), ¼ inch female NPT inlet and outlet

Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approved to UL508a Standard

Technical Data

3A2152B 109

Dimensions

45 .5

0 in

115.

6 cm

63.5

0 in

161.

3 cm

81.1

9 in

206.

2 cm

36.0

0 in

91.4

cm

42.50 in108 cm

3 in7.6 cm

34.2

5 in

87.0

cm

24 in61 cm

4x 13/32 in

Valve Stack

Base Pump and Electrical Panel

ti18132a

29.77 in75.6 cm

38.6

2 in

98.1

cm

9.12 in23.2 cm

3/4 NPT

1.75 in4.5 cm

1.66 in4.2 cm

1.75 in4.5 cm

1.75 in4.5 cm1.66 in

4.2 cm

3/8-16 in

ti18131a

Accessories

110 3A2152B

Accessories24M126This kit is to add a third 1093 valve and necessary con-trols for the addition of color tinting.

24M127This kit adds pressure monitoring for the inhibitor valve, catalyst valve, and mixer outlet.

24M128This kit adds pressure monitoring for the third 1093 valve for color tinting.

NOTE: Kits 24M126 and 24M127 are required for the above kit to operate properly.

Accessories

3A2152B 111

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A2152

Graco Headquarters: MinneapolisInternational Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USACopyright 2011, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.comRevision B, May 2015

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

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

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

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

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

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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

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

Graco InformationFor the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.Phone: 612-623-6921 or Toll Free: 1-800-746-1334 Fax: 330-966-3006

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