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Graco Pro Xpc 24Y307, Instructions Manual

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Instructions

Pro Xpc™ Auto Controller

333266D

EN

For controlling the Graco Pro Xpc Auto Electrostatic Spray Guns. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

Important Safety Instructions

Read all warnings and instructions in this manual and in your

Pro Xpc™ Auto Electrostatic Air Spray Gun manual. Save these

instructions.

PROVEN QUALITY. LEADING TECHNOLOGY.

Summary of Contents for Pro Xpc 24Y307

Page 1: ...Spray Guns For professional use only Not approved for use in explosive atmospheres or hazardous locations Important Safety Instructions Read all warnings and instructions in this manual and in your Pro Xpc Auto Electrostatic Air Spray Gun manual Save these instructions PROVEN QUALITY LEADING TECHNOLOGY ...

Page 2: ...on 18 Signals 19 Analog Inputs 23 Analog Outputs 23 Digital Inputs 24 Digital Outputs 24 Timing Diagrams 24 Controller Display and Features 30 Screen Areas 30 Icons 30 Input Keys and Switches 31 Additional Features 31 Setup 33 Setup Screen 0 35 Setup Screen 1 35 Setup Screen 2 36 Setup Screen 3 36 Setup Screen 4 37 Setup Screen 5 37 Setup Screen 6 37 Setup Screen 7 37 Setup Screen 8 38 Setup Scree...

Page 3: ... Controller solventborne 100 kV 24Y308 Pro Xpc Auto Controller waterborne 60 kV Approved System Components Specific controllers guns and gun power cables must be used together Refer to the table below for compatible models Controller Gun Models Gun Power Cables Product Type Approvals 24Y307 LC1020 LC2020 Solventborne 24Y308 LC1028 LC2028 17H040 17H041 17H042 Waterborne 333266D 3 ...

Page 4: ...king occurs Do not use equipment until you identify and correct the problem Check gun resistance and electrical grounding daily Use and clean equipment only in a well ventilated location Never spray or flush solvent at high pressure Always turn the electrostatics off when flushing cleaning or servicing equipment Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps a...

Page 5: ...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 location Comply with all applicable safety regulations TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on the skin inhaled or swallowed Read the Safety Data Sheet SDS to know the specific hazards...

Page 6: ...s three interlocks These interlocks must be satisfied before the system will operate Check and follow all National State and Local codes regarding properly interlocking your spray system Also see Ventilate the Spray Booth page 12 Installation Options Installation details vary widely depending on the system requirements This section shows three typical installations They are not actual system design...

Page 7: ...played 24VDC Interlock Discrete I O cable pin 19 If required Pin 19 on the Discrete I O Cable Connection is used to indicate the condition of a 0VDC 24VDC signal being used as an interlock This pin can be used to connect to an external device such as a ventilation interlock signal to the controller Input signal values are 0 0VDC or GND Interlock not satisfied electrostatics cannot be enabled 1 24VD...

Page 8: ...e display screen 2 Remove power from the controller 3 Remove 4 screws and take off the access cover 4 Locate the interlock switches on the main board When the switches are in the ON position the interlocks are considered satisfied Switch 1 is the 24VDC Interlock pin 19 on the Discrete I O cable Switch 2 is the SAFE POSITION Interlock Pin 18 on the Discrete I O cable Symbols in A9 and A10 see Screen...

Page 9: ...from operating without ventilation fans operating Non Hazardous Location Hazardous Location KEY A Pro Xpc Auto Air Spray Gun B Pro Xpc Auto Controller C Gun Power Cable D Fluid Supply F Fluid Hose Ground Bracket G Fluid Bracket Ground Wire H Fluid Supply Tube Graco supplied to gun fluid inlet maximum 8 ft 2 4 m length Graco Waterborne Fluid Supply Hose from L to gun inlet hose must be a single unin...

Page 10: ...rlocks To reduce the risk of fire and explosion the controller B must be electrically interlocked with the spray booth ventilation fans to prevent the gun from operating without ventilation fans operating Non Hazardous Location Hazardous Location KEY A Pro Xpc Auto Air Spray Gun B Pro Xpc Auto Controller C Gun Power Cable D Fluid Supply E Integration Signals E1 Discrete I O Cable pin 1 E2 Discrete ...

Page 11: ...ating Non Hazardous Location Hazardous Location KEY A Pro Xpc Auto Air Spray Gun B Pro Xpc Auto Controller C Gun Power Cable D Fluid Supply E Robot or Reciprocator F Fluid Hose Ground Bracket G Fluid Bracket Ground Wire H Fluid Supply Tube Graco supplied to gun fluid inlet maximum 8 ft 2 4 m length Graco Waterborne Fluid Supply Hose from L to gun inlet hose must be a single uninterrupted length J F...

Page 12: ...follow all National State and Local codes regarding air exhaust velocity requirements NOTE High velocity air exhaust will decrease the operating efficiency of the electrostatic system The minimum allowable air exhaust velocity is 60 ft minute 19 linear meters minute Install the Pro Xpc Auto Spray Gun See the Pro Xpc Auto Air Spray Gun Manual 332992 for installation instructions Interlock Waterborne...

Page 13: ...ce 3 Using the controller as a template mark the mounting holes on the panel 4 Drill mounting holes in the panel and attach the controller with two 6mm screws provided Wall Mount An optional wall mount bracket 17H288 is available to mount the controller on any flat wall 1 See Dimensions page 56 2 Determine mounting location Ensure that the wall is strong enough to support the weight of the mounting...

Page 14: ...d by a hose with a maximum length of 8 ft 2 4 m Fluid Tube for solventborne systems only ground the fluid tube by connecting it to the grounded fluid bracket Fluid Hose for waterborne systems only the hose is grounded through the conductive layer Install the hose as instructed in the gun manual Electrostatic Air Spray Gun ground the gun by connecting the gun power cable to a properly grounded contro...

Page 15: ...Back panel D Input Power Connection B Enclosure E Discrete I O Cable Connection use in a system that requires integration C Front Plate with control and display elements F Gun Power Cable Connection G Ground Connection H CAN Connection not enabled 333266D 15 ...

Page 16: ...system interlock When the system interlock pin is connected to line voltage the controller is enabled and the system symbol will appear on the controller See Screen Areas page 30 Controller Input Power Connection Pin No Function Wire Marking 1 Neutral conductor power supply 1 2 Phase 100 240 VAC 2 3 System Interlock ON OFF 100 240 VAC ON 3 Controller Power Cord PE Grounding PE Green Yellow 3 Conne...

Page 17: ... Error Reset Green 4 Remote Enable Disable Yellow 5 Electrostatics Enable Gray 6 Safe to Move Output Pink 7 Error Output Blue Controller 8 I O Ground Red 9 Current Setpoint Input Black 10 Voltage Setpoint Input Purple 11 Reserved Input Gray Pink 12 I O Ground Red Blue 13 Actual Spraying Current Output White Green 14 Actual Spraying Voltage Output Brown Green 15 Electrostatic Discharge White Yellow...

Page 18: ...d the connecting device REMOTE Input Operation In order to accept remote input commands from the discrete I O interface the following conditions must be met The discrete I O interface must be selected by setting Parameter P02 1 See Setup Screen 2 page 36 The REMOTE Enable input on the Discrete I O cable pin 4 must have 24VDC logical 1 applied to it to select REMOTE mode Connect the desired input s...

Page 19: ... It is not possible to change the settings of these Presets remotely 3 Digital Input Error Reset Use to allow error codes to be acknowledged remotely Acknowledging an error code does not correct the condition that created the error 0 1 transition Reset all reported errors NOTE Additional errors will be logged regardless of the state of the Error reset but to perform additional error resets will re...

Page 20: ...Use to set the current setpoint µA nominal value The REMOTE current setpoint input applies when Preset 0 P000 is selected and the controller is in REMOTE operation The input voltage or current is used to create a relational output current value for the gun electrostatics power supply The larger the input value the greater the electrostatics current setpoint 0 10V received input 0 150µA desired gun...

Page 21: ...electrostatic power supply The larger the value on this pin the greater the ouput voltage at the gun 0 max kV gun output 0 10V or 4 20mA pin output The type of output is selected on Setup Screen 4 page 37 max kV 100 kV solventborne or 60 kV waterborne 15 Digital Output Electrostatic Discharge Output Use to indicate when electrostatics have been fully discharged Set the electrostatic discharge time...

Page 22: ... a position in which it is safe to turn on electrostatics without arc detection 0 Electrostatics activation is locked out by this input 1 Electrostatics activation is not locked by this input NOTE Switching from 1 to 0 does not turn off electrostatics 19 Digital Input 24VDC Interlock Input The controller will not turn on electrostatics unless this and all other interlock inputs have been satisfied ...

Page 23: ...s Input current limit Yes 25mA Accuracy 1 typical Analog Outputs The analog outputs are used to communicate actual values to other devices such as a PLC The outputs can be configured to be either voltage or current outputs This setting applies to all outputs simultaneously The analog outputs require an external 24VDC voltage to be connected to Analog Output External Power discrete I O interface pin...

Page 24: ...agrams The system control logic is responsible for turning on and off the electrostatic generator There are several operation modes of the spray system It is important that these are understood for proper integration and safety The operation modes are Standby Electrostatics held in off mode SAFE POSITION Turn on electrostatics using the SAFE POSITION system Spray Fluid and electrostatics enabled a...

Page 25: ...isabled by using one or a combination of the following signals Electrostatic Enable Low 24VDC Interlock Low SAFE POSITION Interlock Low System interlock power connector Low Powering off the electrostatics controller System Interlock Input 24VDC Interlock Input SAFE POSITION Interlock Input Electrostatic Enable Input Electrostatics 333266D 25 ...

Page 26: ...s in the SAFE POSITION the location in which it is safe to turn on electrostatics its control system robot PLC etc applies the SAFE POSITION Interlock input of 24VDC on the Controller Discrete I O cable This will satisfy the SAFE POSITION Interlock in the Pro Xpc Auto Controller and allow the electrostatics at the gun to be enabled by the Pro Xpc Auto Controller After the arc detection blanking ti...

Page 27: ...controlled by Configurations C2 See Setup Screen 10 page 39 The time is illustrated by tC2 in the timing diagram on this page A REMOTE Enable Disable Input B System Power Interlock 24VDC Interlock and SAFE POSITION Interlock C Program Select or Analog Setpoints D Electrostatics Enable Input E Electrostatics F Safe To Move Output G Electrostatic Discharge Output H tC1 Time as set by parameter C1 J t...

Page 28: ...n be used to prevent electrostatics being turned on during flushing The electrostatics can also be turned off by pressing the off button on the controller This will turn off the controller Solvent Supply Paint Supply Enabled Electrostatics Disabled Not controlled by electrostatic controller A Fluid lines free of solvent OK to turn on electrostatics 28 333266D ...

Page 29: ...stem that it is ok to begin painting again REMOTE Enable Disable Input All Interlocks Electrostatic Enable Input Error Reset Error Output Electrostatics Safe to Move Output Electrostatic Discharge Output Fluid Supply Part Conveyor Applicator Movement A Hold high until error output is low B Fix error condition tC1 Time as set by parameter tC1 tC2 Time as set by parameter tC2 Not controlled by elect...

Page 30: ...us information A6 REMOTE operation enabled A7 Electrostatics active triggered A8 System interlock connection satisfied A9 SAFE POSITION Interlock satisfied A10 24VDC Interlock satisfied A11 Electrostatics triggered Icons Icon Explanation Electrostatic voltage displayed in kV Electrostatic current displayed in μA Electrostatics activate trigger REMOTE operation mode active Blinks when the keyboard loc...

Page 31: ...es to allow Preset selection Display of preset values of the current Preset Display of the actual values Error acknowledgement Activate deactivate the keyboard lock 1 Press the key and the T8 key at the same time 2 The display blinks when the keyboard lock is activated 3 The keyboard lock is cancelled by pressing the same key combination again The keyboard lock status remains stored when switching...

Page 32: ...k will be removed Maintenance counts state active non active and setpoints are NOT reset NOTE By restoring factory defaults all user made settings will be set to factory default 1 Press off on the controller 2 Press and hold 3 Press on on the controller The CLr display blinks 4 Wait for approximately 5 seconds until CLr disappears 5 Release the key 6 All values are reset Auto Power Save Mode The d...

Page 33: ...p Screen is then described in detail in the sections that follow the table PARAMETERS Setup Screen Display A1 Value Description Display A3 Values Display A4 Value 0 P00 Applicator Type Display A2 APP Use to define applicator type and features This selection is set in the factory and cannot be changed This selection is not overwritten if a Factory Default Reset is performed 0 Standard solventborne 1...

Page 34: ... the controller will use to calculate the spraying current voltage rate of change 0 01 1 00 by 0 01 0 01 default 9 C1 Arc detection blanking time setpoint sec Use to set the amount of time after turning on the high voltage during which arc protection is suppressed 0 0 2 0 by 0 1 0 5 default 10 C2 Discharge timer setpoint sec Use to set the time needed to fully discharge after turning off the high ...

Page 35: ...0 Std or 1 UUb and cannot be changed NOTE This parameter is not overwritten if a Factory Default Reset is performed Std Solventborne product UUb Waterborne product Setup Screen 1 Setup Screen 1 Parameter P01 displays the electrostatics control mode Ctrl in use The Pro Xpc Auto Controller is factory set to Current 1 CUrr and cannot be changed 333266D 35 ...

Page 36: ...18 for more information 2 CAn Do not use this selection if displayed Setup Screen 3 Use Setup Screen 3 Parameter P03 to select the input signal type for the discrete I O interface analog inputs Ai Press buttons T5 T6 to change the setting The options are 0 VoLt Analog voltage inputs are voltage type 0 10V This selection is the default 1 CUrr Analog current inputs are current type 4 20mA This setti...

Page 37: ...the system used for troubleshooting only Press buttons T5 T6 to change the setting A setting of 0 means nothing is logged A setting of 5 means everything is logged 2 is the default NOTE For logging a micro SD card must be inserted in the slot found on the main circuit board If a software update has been done by installing a micro SD card this card can be used for logging If no card has been instal...

Page 38: ...0 01 Default 0 10 shown Setup Screen 9 Use Setup Screen 9 Configuration C1 to select the time in seconds for which arc detection is disabled blanking period upon gun trigger This setting controls the time from when the electrostatics are enabled until arc detection is enabled Press buttons T3 T4 to change the setting User may wish to increase this setting depending on gun starting location See Arc ...

Page 39: ...tem has been discharged Verify that the system is discharged using the Fluid Voltage Discharge and Grounding Procedure in gun manual 332992 Range is 0 0 60 0 by 0 1 Solventborne default is 0 0 shown Waterborne default is 30 0 not shown Setup Screen 11 Use Setup Screen 11 Configuration C3 to set the interval of transition time in seconds from zero to charge or between electrostatic set points from o...

Page 40: ...A5 and set points for kV A1 and μA A2 The screen also displays actual values for kV and μA when the electrostatics are active triggered Actual values are displayed in green NOTE When in REMOTE operation these values cannot be changed using the display keys Use this screen to set the kV A1 and μA A2 set points for each Preset The set point is displayed in black Set points can be changed by pressing...

Page 41: ...ly hazardous electrical discharge The static arc limit is used to detect a grounded object that is stationary or slow moving The dynamic arc limit is used to detect grounded object that is fast moving For both static and dynamic arc limits lower values are more sensitive than higher values The set points can be changed by pressing the corresponding and keys See Arc Detection page 43 for more infor...

Page 42: ...ess the corresponding and simultaneously for a deactivated counter During the first activation a value of 1 is shown as the start value If monitoring has already been activated at some earlier point then the last stored value is displayed Set the desired service life for each wearing part using the and To deactivate monitoring press the corresponding and simultaneously for an active counter If the ...

Page 43: ...uisance errors Dynamic Arc Limit View or change on Run Screen 2 Location A2 Range 0 1 25 nS s Set the value lower to increase sensitivity and to turn off the electrostatics sooner if a grounded object is approaching the applicator at too high a speed Set the value higher to decrease sensitivity and to eliminate nuisance errors Must be set for each Preset NOTE Periodically check the function of the...

Page 44: ...page 26 for more information Description Setting Remarks C0 Arc Detection Dynamic Threshold Averaging Interval Compensation factor C0 on Setup Screen 8 Valid for all Presets Averaging interval for dynamic threshold Range 0 01 1 00 s by 0 01 Lower more sensitive C1 Arc Detection Blanking Time Compensation factor C1 on Setup Screen 9 Valid for all Presets Arc detection is suppressed from when high v...

Page 45: ...s Press and hold for 5 seconds from any SETUP screen Also shown on power up Press and hold for 5 seconds from any RUN screen Or press from SETUP SCREENS 8 11 Screens that are not implemented for the Pro Xpc Auto Controller are not shown Press from SETUP SCREENS 0 7 T1 T2 T1 T2 333266D 45 ...

Page 46: ...Screen Map RUN SETUP SCREENS 0 7 Parameters SETUP SCREENS 8 11 Configurations T1 T2 T1 T2 T1 T2 T1 T2 T1 T2 T1 T2 46 333266D ...

Page 47: ...Screen Map RUN SETUP SCREENS 0 7 Parameters SETUP SCREENS 8 11 Configurations T1 T2 T1 T2 T1 T2 333266D 47 ...

Page 48: ... voltage is too high Stop Verify gun power cable connection and replace cable if needed Replace gun power cable or gun power supply if needed H15 Arc detection static limit The static arc detection threshold is exceeded A grounded object came too close to the applicator Stop Verify closest distances to parts Verify paint conductivity Verifyspraying parametersassociated with static arc detection H1...

Page 49: ...n board if necessary H27 Memory verify failure Verification of the data written to the EEPROM failed None Verify all connections inside of controller are properly made Replace main board if necessary H80 Safety controller communication Error No response timeout to a request Error report on command execution Response data mismatch Stop H81 Safety controller self test failure The self test performed ...

Page 50: ...estart H903 Watchdog timeout Watchdog wasn t serviced timely Restart H904 Stack Overflow A stack overflow has been detected Restart H905 Hard fault error The CPU detected a hard fault Restart H999 Other fatal error Unspecified fatal error Restart Verify all connections inside of controller are properly made Restart controller Verify software version and upgrade if needed Replace main board if necessa...

Page 51: ...they must be replaced See Parts page 55 for a list of repair kits Main Circuit Board or Keypad Membrane Removal 1 Remove power from the system 2 Remove four screws then remove the controller access cover 3 Remove connectors from the main board and from the power supply as shown 333266D 51 ...

Page 52: ...nect the three remaining cables 5 Lift the main board carefully out of the module 6 Remove four nuts and washers Lift the power board carefully out of the module 7 Remove 4 spacers then remove the LCD panel 8 Remove 2 screws and lift out the membrane button panel 52 333266D ...

Page 53: ...r from the system 2 Remove four screws then remove the back access panel 3 Remove the two electrical connectors from the power board as shown 4 Gently pry the power board from the four retaining clips and remove the board as shown 333266D 53 ...

Page 54: ...ss cover onto the controller box Do not screw down 6 Apply power to the Pro Xpc Auto Controller and press the on button The screen should blink and display donE when the reprogramming is complete 7 Press any button to return to normal operation 8 Verify the software version by holding and at the same time 9 Switch off the Pro Xpc Auto Controller and remove power from the system 10 If desired remov...

Page 55: ...ons on removal and installation Kit Number Description 17H287 Main Board solventborne system only 17H661 Main Board waterborne system only 17H286 Power Board 17H285 Power Supply Board 17H283 Button Panel 17H282 LCD Panel Accessories Gun Power Cables Part No Description 17H040 Gun Power Cable 11 m 36 ft 17H041 Gun Power Cable 20 m 65 6 ft 17H042 Gun Power Cable 30 m 98 4 ft Mounting Brackets Part N...

Page 56: ...Dimensions Dimensions Controller 56 333266D ...

Page 57: ...Dimensions Flush Mount 6 26 in 15 9 cm 5 71 in 15 0 cm 7 65 in 19 4 cm 3 30 in 8 4 cm M6 X 1 mm 333266D 57 ...

Page 58: ...Dimensions Wall Mount Bracket 17H288 58 333266D ...

Page 59: ...requency 50 60 Hz Input Power 40 VA Nominal Output Voltage to the gun eff 10V Nominal Output Current to the gun max 1 2 A Protection Type IP54 Temperature Range 32 F 104 F 0 C 40 C Dimensions Width 6 81 in 173 mm Depth 9 84 in 250 mm Height 6 97 in 177 mm Weight approx 8 2 lbs approx 3 7 kg 333266D 59 ...

Page 60: ...es 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 ...

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