Graco Aerobotix RC50 Instructions Manual Download Page 2

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313813A

Contents

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

Graco Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Non-Graco Manuals . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 7

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . 7

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7

Keep Components A and B Separate . . . . . . . . . . 7

Foam Resins with 245 fa Blowing Agents . . . . . . . 7

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 7

Component Identification . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Info . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Requirements . . . . . . . . . . . . . . . . . . 13

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Check Resistance . . . . . . . . . . . . . . . . . . . . . . . 14

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pumpline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Human Machine Interface (HMI) Screens . . . . . 17

Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Pumpline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Temperature Control . . . . . . . . . . . . . . . . . . . . 35

Other Components . . . . . . . . . . . . . . . . . . . . . . 36

Variable Frequency Drive . . . . . . . . . . . . . . . . . 37

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Day Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Dispense Gun Hoses . . . . . . . . . . . . . . . . . . . . 39

Optional Robot Interface . . . . . . . . . . . . . . . . . . 40

New Machine Maintenance . . . . . . . . . . . . . . . . . . 41

Pouring Operation . . . . . . . . . . . . . . . . . . . . . . . . . 42

Low and High Pressure Circulation . . . . . . . . . . 42

Pouring Requirements . . . . . . . . . . . . . . . . . . . 42

Beginning the Pour . . . . . . . . . . . . . . . . . . . . . . 42

Night Mode Operation . . . . . . . . . . . . . . . . . . . . . . 43

Starting Night Mode . . . . . . . . . . . . . . . . . . . . . 43

Requirements for Continuing Night Mode . . . . . 43

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Overnight/Weekend . . . . . . . . . . . . . . . . . . . . . 44

Long-Term Shutdown . . . . . . . . . . . . . . . . . . . 44

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Temperature Control . . . . . . . . . . . . . . . . . . . . . 45

Pouring Settings . . . . . . . . . . . . . . . . . . . . . . . . 47

MixHead Settings . . . . . . . . . . . . . . . . . . . . . . . 48

Chemical Flow Settings . . . . . . . . . . . . . . . . . . . 48

Day Tank Settings . . . . . . . . . . . . . . . . . . . . . . . 48

Flow Measurement Controls . . . . . . . . . . . . . . . 49

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 53

Air Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . 53

Chemical Line Pressure Relief . . . . . . . . . . . . . 53

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Purge Air from Metering Pump . . . . . . . . . . . . . 54

Drain the Water Separator . . . . . . . . . . . . . . . . . 54

Check/Replace Metering Pump

Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Check Tightness of all Clamps and Fittings . . . 55

Check Hoses for Wear . . . . . . . . . . . . . . . . . . . . 55

Replace the PLC battery . . . . . . . . . . . . . . . . . . 55

Empty the Day Tank . . . . . . . . . . . . . . . . . . . . . 56

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Alarm Status Screen . . . . . . . . . . . . . . . . . . . . 57

Alarm History Screen . . . . . . . . . . . . . . . . . . . . 58

Alarms List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . 61

Recommended Spare Parts . . . . . . . . . . . . . . . . . 62

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Graco Ohio Standard Warranty . . . . . . . . . . . . . . 66

Graco Ohio Information . . . . . . . . . . . . . . . . . . . . . 66

Summary of Contents for Aerobotix RC50

Page 1: ...8023 3000 psi 21 MPa 206 bar Maximum Fluid Working Pressure 80 psi 550 kPa 5 5 bar Maximum Air Inlet Pressure Important Safety Instructions Read all warnings and instructions in this manual and all su...

Page 2: ...e Circulation 42 Pouring Requirements 42 Beginning the Pour 42 Night Mode Operation 43 Starting Night Mode 43 Requirements for Continuing Night Mode 43 Shutdown 44 Overnight Weekend 44 Long Term Shutd...

Page 3: ...ngs Filters Flow Meter Cable Heat Exchanger Level Sensors Motors Pump and Motor Assembly Sub Component Manuals Manual No Relates to Part Description U80756 All Assembly Drawings Manual 309475 234269 H...

Page 4: ...ash can shock burn or cause death An arc flash in explosive atmospheres can cause an explosion Do not install the Main Control Panel which is not intrinsically safe in a hazardous area as defined in A...

Page 5: ...SA or your local electrical code Do not install the Main Control Panel which is not intrinsically safe in a hazardous area as defined in Article 500 of the National Electrical Code USA or your local e...

Page 6: ...ildren and animals away from work area Comply with all applicable safety regulations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on s...

Page 7: ...pressure especially if agitated To reduce frothing minimize preheating in a circulation system Changing Materials When changing materials flush the equipment mul tiple times to ensure it is thoroughly...

Page 8: ...56 for further Graco component identification See non Graco component manuals for further non Graco component identification FIG 1 RC50 Base Front View Key AA Heat Exchangers AB Pressure Gauges AC Vol...

Page 9: ...ponent Identification 313813A 9 FIG 2 RC50 Base Rear View Key AJ Poly Tank Agitator AK Poly Tank AL Iso Tank AM Iso Filter AN Iso Heater AP Iso Tank Agitator AK AL ti14338a AN POLY Side ISO Side AJ AP...

Page 10: ...n Light DC Control Power On Button DD Emergency Stop Button DE Main Disconnect Switch DF Warning Labels DG Main Control Panel DE DA DB Replacement Danger and Warning labels tags and cards are availabl...

Page 11: ...mponents is allowed only if high integrity equipotential system is realized between the points of bonding Do not operate system with safety barrier cover removed Main Control Panel Install in the non...

Page 12: ...rol panel This wiring must not come near or in contact with any non intrinsically safe wiring 2 Any replacement of intrinsically safe barriers must be an identical replacement to maintain intrinsicall...

Page 13: ...Disconnect Switch DE 2 Ground the Main Control Panel to a true earth ground See Grounding page 14 Connect Main Control Panel to Main Junction Box See U80638 schematic Connect Main Control Panel to Pum...

Page 14: ...ue earth ground through main control panel See U80638 schematic Pumpline Motors Connect a ground wire to a true earth ground through main control panel See U80638 schematic Agitator Motors Connect a g...

Page 15: ...C50 Base Module Applicator Group not all items shown NOTE Assemblies not shown to scale NON HAZARDOUS LOCATION ONLY HAZARDOUS CLASSIFIED LOCATION CLASS I DIV I GROUP D Poly Tempered Water Unit Iso Tem...

Page 16: ...alarm inactive Iso and Poly High Pressure alarms inactive Iso and Poly Tank Low Level alarms inactive See Alarms List page 59 for more information Starting Metering Pump Motors Navigate to the Machin...

Page 17: ...Tank Control screen access BK Pour Time Editor screen access BL Setup screen access BM Flow Control screen access BN Scaling screen access BP Alarm HIstory screen access BR Alarm Status screen access...

Page 18: ...gain access to the Scaling screen the user must log in as a Maintenance user Password 10 The Factory user name is reserved for Graco factory personnel to set initial parameters on the machine Setting...

Page 19: ...on the Iso side FIG 7 4 5 1 6 2 1 Status is indicated by a red background and the word OFF or a green background and the word ON The path the fluid follows is indicated by these lines When the line i...

Page 20: ...ll status MixHead Status Indicators The Status Screen includes several indicators that show machine operation status MixHead Pour Ready Indicator shows green when all requirements are made for beginni...

Page 21: ...the HMI The material will dispense for the duration of time assigned to the channel set The time duration can be set for each chan nel under the Pour Time Editor Automatic Mode Status The Automatic Mo...

Page 22: ...w Information Motors Start and Stop Buttons These buttons control whether a specific motor is run ning and the current status of each motor will be dis played below each set of buttons System Outlet C...

Page 23: ...Key EA Auto Fill On Off EF Fail to Fill Alarm Delay EG Fill Delay Iso Poly Temperature Control The Temperature Control Screen is accessible by press ing the Temperature Control button See Temperature...

Page 24: ...tor is on and the asso ciated temperature control is on the indicator below will indicate ON and when it is off it will indicate OFF When temperature control is on but the associated metering pump mot...

Page 25: ...en allows entry of a pour time preset for each of the 99 available channels To access different groups of presets push the First Group Prev Group Next Group and Last Group buttons To change a particul...

Page 26: ...ravity GD Cleanout Delay setting GE Cleanout Extend Time setting GF Pressure Hold Time See Settings section on page 45 for more information Night Mode On Off Time See Night Mode Operation on page 43 f...

Page 27: ...Setpoint HL Automatic Mode Ratio Setpoint Iso divided by Poly HM Automatic Mode Total Flow Setpoint grams per second HN Iso Hi Speed Calibration Setpoint Percent HP Iso Low Speed Calibration Setpoint...

Page 28: ...control When outside the warning range an alarm will be displayed When outside the shutdown range the MixHead will not shoot High Low Speed Calibration Percent This is the high and low calibration spe...

Page 29: ...ding grams per second JL Test Flowrate grams per second See Calibrating Machine Calculated Mass Flow on page 50 for more information Flowrate Filter The flowrate input and display may be filtered to p...

Page 30: ...n Key KA Up Scale KB Down Scale KC Pen KD Move Left KE Home KF End KG Pause KH Move Right This screen is accessible from the Scaling screen FIG 16 This screen is for qualified technicians only and is...

Page 31: ...Operation 313813A 31 Alarm History and Alarm Status Screens See Troubleshooting section on page 57 for Alarm screens details...

Page 32: ...or MD Level Sensor ME Metering Pump Inlet Filter MF Tank Outlet to Pump Ball Valve MG Water Separator MH Tank Fluid Level Sight Gauge MJ Tank Outlet Ball Valve MK Day Tank Incoming Air Valve ML Tank D...

Page 33: ...properties Turn clock wise to increase sensitivity and counterclockwise to decrease sensitivity Metering Pump Inlet Filter Air Pressure System The air supplied to the machine must be dry To remove exc...

Page 34: ...ing Pump Low Inlet Pressure switch will cause a warning alert and the affected metering pump motor will shutdown See the table at the beginning of the Set tings section on page 45 for switch setting...

Page 35: ...o maintain the desired fluid temper atures Tempered Water Unit The stand alone tempered water units improve the effi ciency of the heat exchanger The function of the tem pered water units are to cool...

Page 36: ...old Circulation Valve A pneumatically operated Circulation Valve remotely mounted allows low pressure operation at startup and between shots It transfers flow from the outlet of the flow meter through...

Page 37: ...cy drive enables control of the metering pump motor rpm as well as advanced flow control from the HMI See Adjusting Metering Pump Motor RPM on page 48 and Calibrating Machine Calculated Mass Flow on p...

Page 38: ...in an area that permits easy access to all areas of the machine for maintenance and operation The metering unit was plumbed wired and tested at the factory For transporting purposes the unit was drain...

Page 39: ...Setup 313813A 39 Dispense Gun Hoses Key SA Poly Return to Tank SB Poly Pressure SC Iso Pressure SD Iso Return to Tank FIG 21 Dispense Gun Hose Setup SB SA SC SD ti14338a1...

Page 40: ...a tion mode and readies itself for dispensing 6 The RC System turns on the RC System Ready for Dispense signal 7 The Robot System turns on the Robot System Dis pense command 8 The RC System opens the...

Page 41: ...p Inlet Filter During the first week of operating a new machine the fil ter should be inspected every other day If the element is dirty clean it with solvent or replace it with a new one as required S...

Page 42: ...utton has been pressed but Pres sure Build Time has not yet elapsed A pour has finished but High Pressure Hold Time has not yet elapsed Pouring Requirements The following requirements must be met in o...

Page 43: ...urned off and off time begins This sequence of going from off time to on time and back will continue until Night Mode is turned off To see how the night mode information is displayed see Status Screen...

Page 44: ...tch spilled material remove lowest hose from heat exchanger This will empty the heat exchanger and heater and all chemical lines above 7 Tighten metering pump drain plug and reattach heat exchanger ho...

Page 45: ...heater works to heat the material by exposing the chemical to heated rods that are turned on and off as necessary Temperature Setpoint The temperature setpoint is the goal temperature for the chemica...

Page 46: ...to faster heating at initial startup but will increase the temperature fluctuation Lower gains will lead to smaller temperature mar gins and slower heating at initial startup Lower chemical flow rates...

Page 47: ...e Setup screen see FIG 13 on page 26 This is the time that the meter ing system will stay in high pressure after a pour has been completed This time should be increased if shots are to be performed in...

Page 48: ...t Mode must be off Appropriate Metering Pump Motors must be on When the preceding requirements are met 1 Select manual mode and high pressure override to put the machine into high pressure circulation...

Page 49: ...ed 1 With one person standing at the HMI and the other at the metering pump turn dial put the machine in calibrate mode 2 Navigate to the Status screen to view the flowrate 3 Turn the metering pump di...

Page 50: ...Factor inputs for each chemical The flow meters are calibrated at the factory and will never need to be calibrated unless harmful materials pass through them such as solvents or materials includ ing...

Page 51: ...r as Necessary 16 Remove the calibration bucket weigh and calculate the dispensed material weight 17 On the scaling screen the weight of the shot calcu lated by the machine will be shown If this match...

Page 52: ...e to the off position and lockout 23 Relieve air pressure hydraulic fluid pressure and chemical line pressure See Pressure Relief Pro cedure on page 53 24 Open valve on blocked chemical side Repeat fo...

Page 53: ...he tanks Chemical Line Pressure Relief 1 Turn off and lockout main power 2 Relieve tank air pressure See Air Pressure Relief procedure 3 Ensure there is no pressure in the chemical lines by looking at...

Page 54: ...nd o ring as required 6 Liberally coat the o ring and surrounding surfaces with a moisture free grease Procedure Frequency Purge Air from Metering Pump Daily before use Drain the Water Separator Daily...

Page 55: ...mps and fittings as necessary Check Hoses for Wear Look for wear on all hoses where they come into contact with anything Over time rubbing may wear down the hose and increase the chance for a hose rup...

Page 56: ...ng of material from the 5 psi charge 7 Close the tank supply valve and replace the drain plug If no further maintenance is anticipated leave the 5 psi charge of dry air on the tank Otherwise vent the...

Page 57: ...rm conditions are indicated on the Alarm Status screen which can be selected from the menu bar along the bot tom of all screens A new alarm condition will cause an alarm to sound and the new alarm mes...

Page 58: ...ory Screen This screen stores all alarms that have been triggered See the table at the beginning of the Settings section on page 45 for pressure and temperature switch settings FIG 23 Sort button Push...

Page 59: ...ecified on the Flow Control Screen this alarm will be displayed Iso Poly Metering System Alarms Iso Poly Pump Motor Overload Alarm This alarm causes an immediate stop of the meter ing pump motor If th...

Page 60: ...30 minutes after startup to allow for chemical temperatures to stabilize Iso Poly MAG Drive High Temperature This alarm exists only for machines with MAG drives The alarm is triggered when the MAG dri...

Page 61: ...ctor on pressure switch Iso Poly Pump Low Pour Pressure or Failure to Build Pressure Alarm banner Red fault light ON Fault horn ON MixHead locked CLOSED 1 Check air supply pressure 2 Adjust Iso Poly j...

Page 62: ...6312 18 3 Oiler 1 1 17746 13 Gauge 0 160 PSI 2 1 Tank Agitators Part List for one Agitator Assembly U70375 Agitator Assembly Exp Proof 1 1 0128 3 Agitator Cover Gasket 1 1 20021 3 28 Gasket 150 Flange...

Page 63: ...1 6690 24 155 Fuse 100A LPJ 100SP 3 3 6690 24 160 Fuse Adapter 3 3 6690 24 164 Fuse Fuse block 26 5 6690 24 37 Fuse 30A LPJ 30SP 6 3 6690 24 35 Fuse 20A LPJ 20SP 6 3 6690 24 293 Fuse Class J 15A Time...

Page 64: ...Contact Block NC Self Monitoring 1 1 6690 1 42 Relay Base 8 4 6690 1 40 Relay DPDT 8 4 6690 1 41 Relay Ret Clip 8 4 V Z787 Meter Flowmeter 24VDC Intrins 2 1 U70202 Barrier Instrinsically Safe 4 2 U70...

Page 65: ...mperature 180 F 82 2 C Output 8 75 50 lb min at a 2 5 1 ratio Iso rich Day tank capacity each Poly 20 gallons 75 7 liters nominal Iso 60 gallons 227 1 liters nominal Sound power per ISO 9614 2 76 5 dB...

Page 66: ...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...

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