Graco BetaCell 241D Operation Download Page 12

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Main Electric Panel

Push to silence audible alarm

White pilot light indicates that PLC power is ON

White pilot light indicates that auxiliary 115 volt outlets are ON

Summary of Contents for BetaCell 241D

Page 1: ...Operation BetaCell 241D Metering Unit 3A0258A Important Safety Instructions Read all warnings and instructions in this manual Save these instructions...

Page 2: ...en 25 Flow Control Screen 27 Sequence Entry Screen 28 AutoStart Set Up Screen 30 Sleep Mode Set Up Screen 31 Pre Poly Refresh Set Up Screen 32 Flow Control Screen 33 Shot Calibration Screen 34 Toleran...

Page 3: ...e 72 Directional Valve 72 Return Line Filter 73 INSTALLATION SET UP 74 Installation 75 Hoses 76 Buffer tanks 77 Hydraulic System 77 DAILY PROCEDURES 78 Daily Start Up 79 Daily Shutdown 79 FAULT MANAGE...

Page 4: ...of this equipment must therefore make their own determination as to the suitability of the information contained in this manual to their specific operation and requirements There should be no assumpti...

Page 5: ...source The electrical service must be installed and maintained by a qualified electrician High Pressure WARNING This equipment has or is used with equipment that has hydraulic components capable of p...

Page 6: ...6...

Page 7: ...irculation system ensures constant and accurate temperature control PID programming of the temperature controllers allows operation within a given temperature range Operation outside the designated ra...

Page 8: ...Specifications System Dimensions 54 108 98 3 16...

Page 9: ...e 6 cc rev 3 gpm Max pressure 3000 psi Max oper pres 2800 psi Max temp 160 F Reservoir 8 gal Accumulator 85 cu in Min cycle time 3 sec Buffer tanks Construction Pre Poly steel ASME certified Curative...

Page 10: ...pressure sw 1500 psi Min pressure sw 40 psi Factory Settings Hydraulic Power Pack Max pressure sw 2800 psi Min pres sw 1500 psi Acum Pre charge 1200 psi Unload vlv upper 2400 psi Unload vlv lower 220...

Page 11: ...11 DESCRIPTION OF CONTROLS 1...

Page 12: ...12 Main Electric Panel Push to silence audible alarm White pilot light indicates that PLC power is ON White pilot light indicates that auxiliary 115 volt outlets are ON...

Page 13: ...Turns ON control power green pilot light indicates that control power is ON Typical Motor Start momentary start to turn motor ON Switch must be in the RUN position to start the motor from the HMI pane...

Page 14: ...enu is for qualified technicians and can only be accessed by password IMPORTANT This manual describes two chemical components the Pre Polymer A and the Curative B The HMI Screens follow the convention...

Page 15: ...15 Help Screen A Help Screen is available for each of the Menu Screens...

Page 16: ...es that a particular component is ON or set for normal operation A blue pilot indicates that a component is OFF A yellow pilot light indicate that a component is not set for normal operation SP window...

Page 17: ...rol in MAN if the tolerance limits are DISABLED The following conditions must be satisfied for a GO signal No active faults A B pumps ON Recirculation valves CLSD Ratio control in AUTO Hydraulic press...

Page 18: ...icates the state Data windows indicate the PV s NOTE Each time the Pre Poly pump is turned OFF it will default to 50 RPM and flow control to MAN Curative default is inches per second Press the set poi...

Page 19: ...utoStart cycle Sleep Mode Press to ON automatically sets the machine to a pre set operating condition as follows Hydraulic motor OFF Pre Poly flow 30 grams sec Curative 2 grams sec Pre Poly heater 120...

Page 20: ...OFF the motor pilot light indicates the state Press to turn ON and OFF the heater pilot light indicates the state Press the set point data window a keypad will appear select the temperature and press...

Page 21: ...ically maintain the tank level to the set point The tank will operate below the set point level for the duration of the pre set dwell time At the expiration of the dwell time the AutoFill valve will O...

Page 22: ...ing processed Indicates the active shot in a sequence Indicates the completed shots in a sequence Indicates an incomplete shot Indicates that this shot in a sequence is disabled and will be bypassed Y...

Page 23: ...r sequences available At the completion of the last shot in a sequence it is necessary to reset to the first shot The gun will be NOGO when waiting for a reset Indicates gun status green pilot light i...

Page 24: ...24 Maintenance Menu Press to access the Maintenance screen Password Required...

Page 25: ...interlocks The following permissives are required Pre Poly pump OFF Curative pump OFF Hydraulic power pack ON Push to enable or disable the main panel alarm horn Press to OPEN the recirculation valves...

Page 26: ...ned until this time has elapsed Press to turn the empty cycle ON and OFF If the AutoFill system is ON the tank will empty to the 20 level and automatically refill If the AutoFill system is OFF the tan...

Page 27: ...ight indicates MAN Anytime MAN is selected the pumps will automatically be set to the default manual speed setting Enter manual set points as required Press the data windows a keypad will appear Selec...

Page 28: ...e shots can then be dispensed in order starting at the first enabled shot and continuing in order through to the last enabled shot Only the ENABLED shots are active Press the list selector Scroll up o...

Page 29: ...he shot for data entry Press the data window a keypad will appear Select the offset plus or minus and press enter Press to enter the new offset into the group Press to enable or disable a shot in the...

Page 30: ...30 AutoStart Set Up Screen This screen is for qualified technicians only...

Page 31: ...31 Sleep Mode Set Up Screen This screen is for qualified technicians only...

Page 32: ...Tank Screen Refresh Mode To prevent exceeding the shelf life of the pre poly component the refresh mode allows the tank to be emptied to a pre set point and refilled with fresh material Must be in Sle...

Page 33: ...chnicians only Calibration is performed one component at a time through the respective jet at operating pressure and temperature with the other component isolated from the mixing chamber by a blank je...

Page 34: ...qualified technicians only Press the list selector Scroll up or down to select the shot group for data entry Press the data window a keypad will appear Select the offset plus or minus and press enter...

Page 35: ...nce Setup Screen This screen is for qualified technicians only Scroll the list to select the parameter for data entry Press the data window a keypad will appear Select the offset plus or minus and pre...

Page 36: ...36 Press to enter the new offset into the group Press to ENABLE or DISABLE the tolerance feature green pilot light indicates ENABLED and the yellow pilot light indicates DISABLED...

Page 37: ...37 DESCRIPTION OF MAJOR COMPONENTS 2...

Page 38: ...38 System Schematic...

Page 39: ...selected temperature A low RPM mixer moves the material in contact with the heated walls of the tank to assure an even temperature gradient To assure adequate pressure at the inlet to the metering pu...

Page 40: ...rms The pumps are protected on the outlet side by a pressure switch factory set to 1200 psi Should this pressure be exceeded both pumps will automatically stop and be accompanied by audible and visual...

Page 41: ...on the proximity switch All timing functions are started and stopped by this switch Hydraulic Power Pack The hydraulic power pack is the prime mover for the pour gun and provides the pressure to open...

Page 42: ...mer fumes with the Curative fumes the systems are isolated by means of separate check valves The recommended air pressure required to charge the buffer tanks is 60 psi NOTE The minimum recommended air...

Page 43: ...will bleed excess tank pressure to maintain set point Recommended buffer tank pressure is 60 psi NOTE Pressure below 40 psi will cause a warning alert and both pumps will shutdown Maintenance There i...

Page 44: ...44 Buffer tank 2 1 6 7 5 8 9 4 3...

Page 45: ...45 13 10 12 Fumes piped away by others in accordance with plant specifications 11...

Page 46: ...8 3 Jacket drain valve 29 4 Jacket temperature limit switch 35 5 Water jacket heater 30 6 Material temperature thermocouple 32 7 Water jacket thermocouple 31 8 Water level indicator 9 Vented filler ca...

Page 47: ...with approximately 15 gallons of heat transfer fluid before starting the heater Maintenance Service the jacket with a 50 solution of water and glycol as required and check the level monthly The syste...

Page 48: ...n of rotation as indicated by the rotational arrow and must be maintained at all times If the rotation is incorrect change any two of the power leads on the main terminal strip Maintenance There is no...

Page 49: ...egulator set point Operation Operation is automatic The valve is factory set to start relief at 70 psi and can be field adjusted by a qualified technician as required Maintenance There is no normal op...

Page 50: ...een 80 100 psi The adjustment is lead sealed and must not be tampered with Breaking the lead seal and tampering with the factory setting is DANGEROUS and voids any warranty NOTE The valve outlet is 3...

Page 51: ...51 Return Line Check Valve This valve is provided to isolate the buffer tank pressure from the return line Maintenance There is no normal operating maintenance Check Valve...

Page 52: ...surface of the liquid and containing a magnet with positive polarity There is a magnetostrictive position feedback sensor mounted to the instrument which sends a continuous signal to the PLC indicatin...

Page 53: ...nk pressure during refill to a minimum Bulk System By others The bulk storage circulation loop is temperature conditioned and pressurized to a pressure that exceeds the pressure in the buffer tank It...

Page 54: ...om the Tank Control Screen and will permit the level to bypass the SP full point and continue to empty down to the pre set refresh point AutoFill ON at the refresh point the cycle will end and the tan...

Page 55: ...55 AutoFill Valve Maintenance There is no normal operating maintenance Position Indicator...

Page 56: ...y Stop The valve defaults to the CLOSED position when Main air is CLOSED Control power is lost The Gun Service Switch is selected ON The yellow indicator shows the position of the valve Perpendicular...

Page 57: ...l occur and both pumps will shutdown This is an indication that The filter may need to be serviced The buffer tank pressure is too low The buffer tank is not up to temperature Maintenance During the f...

Page 58: ...otary piston pump driven by a magnetic coupling The integrated closed loop control and motor drive maintain an accuracy of 0 1 of set point The pump provides excellent performance and resistance to co...

Page 59: ...ng pump is a continuous delivery piston pump uniquely designed to deliver pulse less flow with no pressure fluctuations during reversals It is the ideal pump for accurate and reliable delivery of the...

Page 60: ...60 Pressure Transducer Operation Operation is automatic The over and under pressure set points are factory set and cannot be changed Maintenance No routine maintenance is required...

Page 61: ...e curative heater is constructed from stainless steel to prevent possible chemical reaction Heater Rod The pre heater contains 6 heating elements rated 1500 watts each Start Up Determine that the pre...

Page 62: ...62 Flow Meters The flow meters are mass style on the pre poly and curative components Maintenance There is no periodic maintenance required Pre Polymer Curative...

Page 63: ...hrough the gun This allows operation of the pumps at reduced pressures for start up and temperature conditioning Operation This valve is automatically opened during Normal operation It may also be man...

Page 64: ...ode of operation For set up and trouble shooting purposes the valve can be operated externally by manually depressing the override button Turn clockwise to lock in place Maintenance There is no normal...

Page 65: ...65 Hydraulic Power Pack Schematic...

Page 66: ...s service factor will also determine the amount of cooling required if any to maintain the hydraulic fluid at temperatures below 150 F The more frequent the shots the more heat generated by the system...

Page 67: ...e length of the hoses and the duty cycle For a moderate duty cycle and hose lengths of less than 50 feet location directly on the PowerPack manifold will provide satisfactory performance For operation...

Page 68: ...mit switch 6 Manual unloading valve 7 Return line filter fill port 8 Level Temperature Gage Start Up The direction of rotation is indicated by the rotational arrow and must be maintained at all times...

Page 69: ...periodically serviced as described in the Maintenance Manual Hydraulic Fluid The hydraulic unit is fully tested at the factory and drained of all hydraulic fluid prior to shipment Before operating ser...

Page 70: ...anual unloading valve is CLOSED Turn on the hydraulic motor and allow the pressure to stabilize Adjust the overpressure O limit clockwise to raise the pressure Slowly crack the manual unloading valve...

Page 71: ...re charge pressure The pre charge pressure and ambient temperature should be recorded at installation Be sure the pressure is zero in the hydraulic chamber before checking the pre charge that is recom...

Page 72: ...s automatic however for setup and maintenance the valve can be operated manually by pressing in on the solenoid plunger To maintain the maximum performance of the gun the directional valve and accumul...

Page 73: ...73 Return Line Filter Maintenance Service periodically to maintain the condition gage in the green Maintain the service schedule following the procedures in the Maintenance Manual Filter Inside...

Page 74: ...74 INSTALLATION SET UP 3 IT IS RECOMMENDED THAT THE BetaCell 241 BE COMMISSIONED BY A FACTORY TRAINED TECHNICIAN...

Page 75: ...to be installed on a flat surface in an area that permits 360 degree access for maintenance and operation The metering unit was plumbed wired and tested at the factory For transporting purposes the un...

Page 76: ...76 Hoses 1 A pressure yellow 2 A return yellow white 3 B pressure green 4 B return green white 5 Hydraulic pressure close black 6 Hydraulic return open black white 1 3 4 6 5 2...

Page 77: ...ge with a 50 water and Glycol mixture Tanks Slowly pressurize each tank to 60 psi while checking for any leaks Hydraulic System Service the reservoir with 8 gallons of approved hydraulic oil Charge th...

Page 78: ...78 DAILY PROCEDURES 4...

Page 79: ...olation valves and the gun manual valves are OPEN Machine Cont Screen 4 Switch ON Autostart and wait until the AutoStart cycle is completed approximately 25 min DAILY START UP IS NOW COMPLETE THE MACH...

Page 80: ...80 FAULT MANAGEMENT 5...

Page 81: ...81 Alarm system Alarm Status Screen IMPORTANT During any alarm condition the gun will automatically default to the CLOSED position...

Page 82: ...ive audible and visual alarms as well as cause one or more of the following events Default to the Alarm Status screen Stop the metering pumps Turn off the respective heaters Close the MixHead or preve...

Page 83: ...C MOTOR OVERLOAD FAULT Alarm screen Red fault light ON Fault horn ON Hydraulic motor OFF Prepoly pump OFF Curative pomp OFF Gun locked CLSD Reset thermal overload Reset one time only HYDRAULIC POWER P...

Page 84: ...IGH TEMP FAULT Alarm screen Red fault light ON Fault horn ON Cur tank heater OFF Water level Temperature set point DRIVE FAULT Alarm screen Red fault light ON Fault horn ON Respective motor OFF Gun lo...

Page 85: ...rness Gun switch OUT OF TOLERANCE ALARM Alarm screen Red fault light ON Fault horn ON Gun locked CLSD Check temperature Check pressure Check flow rate COMPLETE FAULT LIST Curative Agitator Motor Overl...

Page 86: ...t Of Tolerance High Flowrate Out Of Tolerance Low Ratio Out Of Tolerance Low High Speed Counter Card Electronic Fuse Open High Speed Counter Card Initialization Failure PLC Battery Low Prepoly Autofil...

Page 87: ...ne Thermocouple Fault Prepoly Supply Line Thermocouple Fault Prepoly Supply Pressure Transducer Fault Prepoly Tank High Level Prepoly Tank Low Level Shutdown Prepoly Tank Low Level Warning Prepoly Tan...

Page 88: ...88 MAINTENANCE 6...

Page 89: ...rol screen via Main Menu on PV 9 Verify switches on front panel are in run position 10 Touch Auto Startup 11 Access Status screen via Main Menu on PV 12 System is ready when correct ratio is displayed...

Page 90: ...ntrol screen via Main Menu on PV 28 Touch Sleep Mode Sleep Mode NOTE Sleep Mode should only be used after system is fully operational 1 min 29 Access Machine Control screen via Main Menu on PV Auto Sh...

Page 91: ...n PV 46 Touch Flow Control Manual 47 Touch Curative Start Motor 48 Access Flow Control Auto system will increase output settings 49 Verify ratio and temperatures are at Setpoint 50 Access Operator scr...

Page 92: ...atio and temperatures are at setpoint 68 Access Operator screen via Main Menu on PV 69 Verify GO condition exists at bottom of screen 70 Select correct Sequence and touch Reset 71 Trigger Gun NOTE If...

Page 93: ...e air ball valve on top of Curative Buffer tank 84 Open inlet air ball valve 85 Access Flow Control screen via Maintenance Menu on PV 86 Put system from Auto Flow control to Manual 87 Start Curative m...

Page 94: ...ice due to thermal expansion 103 Touch alarm banner on PV to acknowledge fault 104 Close and Lock out inlet air ball valve 105 Open air ball valve on top of Pre Poly Buffer tank 106 Close Pre Poly Buf...

Page 95: ...quence and touch Reset 124 Trigger Gun NOTE After Orifice has been in for several minutes shut system down and re torque the Orifice due to thermal expansion 1 Verify Pre Poly and Curative Motors are...

Page 96: ...tainer 139 Open lid of filter assembly and remove bag filter and dispose of accordingly 140 Replace with new and verify proper fit in housing 141 Wipe o ring on lid clean of any residual chemical and...

Page 97: ...valve in front of machine into appropriate container 159 Close and Lock out ball valve 160 Remove SHCS that secure inlet flange to pump 161 Remove SHCS that secure outlet flange to pump 162 Disconnec...

Page 98: ...Remove main disconnect lock out and main power Remove and Replace Hydraulic Filter 182 Perform an Auto Start from complete shutdown 15 min 183 Perform an Auto Shut Down 184 Lock out main disconnect 1...

Page 99: ...ve Tanks 201 Touch Enable Empty Cycle this allows tanks to be depleted to the 30 level point before system will stop 202 System will not allow operator to dispense material after one of the tanks reac...

Page 100: ...5 Proximity Switch 54100 2 Remote Pour Handle 54193 011 Orifice AS NEEDED 54193 061 Orifice AS NEEDED GX 15 Dispensing Gun 54150 CSTM 54150 3 61 11 GX 15 Dispensing Gun Grease OR 100K SHOTS 54250 5 3...

Page 101: ...ump Rebuild 6317 58 Prepolymer Pump Replace Wet Calibrate Shot Size Calibration 6318 41 6318 43 Buffer tank Water glycol Check Change 6312 42 6312 42 1 Inlet Pre Poly Filter Replace Betacell 241 6312...

Page 102: ...s Hex Key Set Open End Wrenches 10 min 6690 7 15 Proximity Switch 54150 CSTM 54150 3 61 11 221 Turn off hydraulic Power unit 222 Remove hydraulic pressure from system 223 Remove Proximity harness atta...

Page 103: ...wrench 10 min 54150 CSTM 54150 3 61 11 GX 15 Dispensing Gun 241 Turn Chemical pumps off 242 Turn hydraulic power unit off via HMI 243 Relieve pressure by turning valve CCW and verify pressure is 0 psi...

Page 104: ...mulator CCW and verify pressure is 0 psi 262 Remove union and attach hose ends to dispensing gun black pressure attaches to 90 fitting on back of gun black white return attaches to extended gun fittin...

Page 105: ...k free 15 min Tools Open End Wrenches 6690 7 56 6690 7 57 3 Trigger Harness 3 Proximity Harness 287 Remove harness 288 Replace with new harness 5 min 38810 15 Curative Pump 289 Turn Curative pumps off...

Page 106: ...ith new repeat steps in opposite order 312 Open ball valves 313 Open locked out valves 314 Apply air to system 315 Start chemical pump and recirculate chemical 316 Pump will need to cycle to remove ai...

Page 107: ...air from Buffer tank 337 Lock out ball valve on bottom of buffer tank 338 Lock out inlet air ball valve 339 Open filter drain to remove residual chemical 340 Remove filter cover 341 Remove and replace...

Page 108: ...ose needle valve 362 Remove lock out 363 Follow startup procedure Tools Charging Harness 10 min Fluid 364 Turn hydraulic power unit off via HMI 365 Lock out electrical panel 366 Drain tank utilizing d...

Page 109: ...l panel 374 Remove and replace battery with PLC power on 375 Remove lock out 376 Follow startup procedure 5 min Indicator Lights 377 Remove lens from indicator light 378 Remove and replace bulb 379 Re...

Page 110: ...bove 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 conseque...

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