Graco SmartWare 262370 Instructions - Parts Manual Download Page 104

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Appendix C - Breakout Module (258999) Connections

104

3A0294J

Prox / Start - Stop Connector 5 - Grey

Pin Description

Pin Number

M12 Connector, 5 pin, Female, A code

Drum Low Digital Input

Phoenix Contact Part Number 1542761

Start / Stop Digital Input

Digital Input Power (24 volt)

Digital Input Ground

Shield Digital

Pressure Connector 6 - Blue

Pin Description

Pin Number

M12 Connector, 5 pin, Female, B code

Pressure Differential Analog Input +

Phoenix Contact Part Number 1543650

Pressure Differential Analog Input -

Pressure Power (5 volt)

Pressure Ground

Shield Analog

Shot Active Connector 8 - Grey

Pin Description

Pin Number

M8 Connector, 4 pin, Female

Shot Active (5 volts) or Not Active (0 volts)

Analog Output

Phoenix Contact Part Number 1694376

Shot Active Power (5 volt)

Shot Active Ground

Shield Analog

Air Motor Connector 9 - Grey

Pin Description

Pin Number

M12 Connector, 8 pin, Female, A code

Motor Top Reed Switch Digital Input

Phoenix Contact Part Number 1542774

Motor Bottom Reed Switch Digital Input

Reed Switch Ground

Linear Sensor Analog Input

Linear Sensor Power (5 volt)

Linear Sensor Ground

Shield Analog

Summary of Contents for SmartWare 262370

Page 1: ...ual post ram with NXT2200 and larger air motors Kit 262371 for D200 For D200 3 inch dual post ram with NXT1800 and smaller air motors Kit 262372 for D200S For D200S 6 inch dual post ram with NXT2200 a...

Page 2: ...62 Change Operation Mode 62 Select a Shot Number 64 Select a Shot Sequence 64 Dispense a Shot 65 Pause or Cancel a Shot 65 Errors 66 Errors with Light Tower 66 Clear Errors 66 Error Codes 67 Shutdown...

Page 3: ...uctions Parts 311827 Dura Flo Displacement Pumps 145cc 180cc 220cc 290cc Instruc tions Parts 311825 Dura Flo Displacement Pumps 430cc 580cc Instructions Parts 311828 Dura Flo Pump Packages 145cc 180cc...

Page 4: ...ords 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 grou...

Page 5: ...Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch cut...

Page 6: ...unt dispensed is based on the pump size Typical Applications Cartridge fill Potting Encapsulating Mold making Batching or kitting Compatibility SmartWare shot dispense kits are compatible with J serie...

Page 7: ...you push on the brake the SmartWare kit pump does not stop pumping the instant it receives a stop signal Therefore during the time it takes for the dispense valve to physically close fluid is still b...

Page 8: ...G Power Switch within shroud H Displacement Pump J Wet Cup K Fluid Outlet L Fluid Inlet M Platen Bleed Port N Platen R Ram S Air Valve Assembly T Pressure Sensor Assembly U Linear Sensor Assembly Incl...

Page 9: ...Power Supply under shroud G Power Switch within shroud H Displacement Pump J Wet Cup K Fluid Outlet L Fluid Inlet P Floor Mount Stand T Pressure Sensor Assembly V Valve Assembly Included in SmartWare...

Page 10: ...present operation mode Possible operation modes shot mode sequence mode manual mode and park mode Arrows Up Down Navigate up or down within a screen or to a new screen Soft Keys Soft keys activate the...

Page 11: ...fields press to make data selections or to enter changes Right In screens that have editable fields press to move to the right while in a field Cancel Cancel a selection or edited data Returns to the...

Page 12: ...f each display screen FIG 6 Setup Mode Screen Components Soft Keys Enter Exit Screen Setup fields spe cific to current setup screen Scroll up through screens Current setup screen number Scroll down th...

Page 13: ...ification 3A0294J 13 Setup Mode Screen Structure The following figure demonstrates the flow of the setup mode screens beginning with setup screen 1 For details on each setup screen see Setup Mode Deta...

Page 14: ...ollowing figure demonstrates the flow of the modes in the run screen begin ning with power up screen 1 For details on each run mode see Run Mode Details on page 100 Run Screen Shot Mode Run Screen Seq...

Page 15: ...conductive metal pails placed on a grounded surface Do not place the pail on a nonconductive sur face such as paper or cardboard which interrupts grounding continuity To maintain grounding continuity...

Page 16: ...Shot Dispense kits are not approved for use in explosive atmospheres Follow the location guidelines and instructions provided in the Supply Systems Operation manual or your pump packages instructions...

Page 17: ...trols bracket Install the display module bracket 2 using two screws 29 and lock washers 28 to secure it to the air controls bracket 6 Install the air valve subassembly 3 a Use two wrenches to remove t...

Page 18: ...l the fitting and air hose on the back of the new air valve assembly Use two wrenches to tighten 7 Install the linear sensor assembly 18 and the reed switch sensor 22 a D200 systems only disconnect th...

Page 19: ...linear sensor cable through the lift ring adapter Install the lift ring adapter torque to 30 36 ft lbs 40 6 48 8 N m See FIG 21 h Route the linear sensor cable through the hole on the lift ring adapte...

Page 20: ...gh center hole in the crossbar Install lock washers and nuts onto threaded rod both above and below crossbar Use wrench to hold lift ring adapter and tighten threaded rod into lift ring adapter using...

Page 21: ...FIG 28 Breakout Module Connections Pressure Sensor Extension Air Motor Cable Cable LCM Cable Solenoid Extension Cable Light Tower Shot Status Drum Low 1 Start Stop 2 Not Used Changeover Solenoid 26237...

Page 22: ...ule Dispense Valve Solenoid Valve Pressure Sensor Cable Air Motor Cable Pressure Sensor Extension Cable CAN Cable LCM Cable Solenoid Extension Cable Solenoid Cable Solenoid Cable Optional Air Lines su...

Page 23: ...onics subassembly cover 4 12 Install the electronics subassembly cover Install the back cover first and hand tighten the screws to secure Then install the front cover hand tighten the screws to secure...

Page 24: ...crews 28 Also secure the bracket to the bottom of the air con trol bracket using two screws 24 and two lock washers 23 4 Install the light tower bracket 26 to the top air con trols bracket using three...

Page 25: ...ing the air valve assembly Secure with screw d Install the new air motor slider valve label that is included with the air valve assembly See FIG 37 e Coat the gauge fitting with PTFE tape and then rei...

Page 26: ...h the screw 21 NOTE For air motor models M07xxx M12xxx and M18xxx which have the large mufflers remove the muf fler before installing the reed switch Reinstall the muf fler after the reed switch in in...

Page 27: ...Motor Cable Cable LCM Cable Solenoid Extension Cable Light Tower Shot Status Drum Low 1 Start Stop 2 Not Used Changeover Solenoid r_262371_3A0294_75a Connect Cable 20 262371 Cable Identification Desc...

Page 28: ...nse Valve Solenoid Valve Linear Sensor Reed Switch Cable Pressure Sensor Cable Air Motor Cable Pressure Sensor Extension Cable CAN Cable LCM Cable Solenoid Extension Cable Solenoid Cable Solenoid Cabl...

Page 29: ...onics subassembly cover 4 14 Install the electronics subassembly cover Install the back cover first and hand tighten the screws to secure Then install the front cover hand tighten the screws to secure...

Page 30: ...he air motor using two screws 30 and two washers 31 4 Install the air valve subassembly 3 a Use two wrenches to remove the air hose elbow fitting and pressure gauge from the air controls b Remove the...

Page 31: ...e linear sensor assembly 18 and the reed switch sensor 22 a Remove the air motor top cover using a flat head screwdriver b Use a wrench to remove the air motor lift ring Then remove the lift ring adap...

Page 32: ...e FIG 58 j Install the reed switch sensor 22 Secure with the 1 in 25 mm screw 24 and o ring 23 pro vided See FIG 58 k Connect the strain relief guide 26 to the reed switch sensor Use a wrench to tight...

Page 33: ...ring 38 and pressure sensor 35 use zip ties 32 to secure the cable to the ram and air hose 8 Install cables Reference the cable identification table on the next page and FIG 63 for a diagram of cable...

Page 34: ...1524 DB25 15T859 1 blue None 120 3048 Pigtail 16G589 AM1 LS1 RS1 52 1320 8 Motor cable 15Y051 9 grey AM1 118 2997 2 Air Solenoid Extension 122030 1 yellow SX1 20 508 Solenoid Extension 3 red Y1 yellow...

Page 35: ...enoid Valve Pigtail Pressure Sensor Cable Air Motor Cable Pressure Sensor Extension Cable CAN Cable LCM Cable Solenoid Extension Cable Solenoid Cable Solenoid Extension Cable optional kit Air Lines su...

Page 36: ...embly bracket 1 so that they will fit under the electronics subassembly cover 4 11 Install the electronics subassembly cover hand tighten the screws to secure 12 Install the power supply cord 14 13 Op...

Page 37: ...the air motor using two screws 25 and two washers 24 4 Install the air valve subassembly 3 a Use two wrenches to remove the air hose elbow fitting and pressure gauge from the air controls b Remove th...

Page 38: ...n the back of the new air valve assembly Use two wrenches to tighten 5 Install the linear sensor 17 a Remove the lift ring or plug b Insert magnet holder and magnet into the top of the motor shaft usi...

Page 39: ...onnect pressure sensor at PT1 d Install the o ring 33 and pressure sensor 29 use zip ties 26 to secure the cable to the ram and air hose 8 Install cables Reference the cable identification table on th...

Page 40: ...122487 PS1 None 60 1524 DB25 15T859 1 blue None 120 3048 Pigtail 16G589 AM1 LS1 RS1 52 1320 8 Motor cable 15Y051 9 grey AM1 118 2997 2 Air Solenoid Extension 122030 3 red Y1 yellow 20 508 Accessory Ki...

Page 41: ...Valve Pump Pigtail Pressure Sensor Cable Air Motor Cable Pressure Sensor Extension Cable CAN Cable LCM Cable Solenoid Extension Cable Solenoid Cable Air Lines supplied by user supplied by user option...

Page 42: ...tie them close to the electronics bracket 1 so that they will fit under the electronics subassembly cover 4 11 Install the electronics subassembly cover Install the back cover first and hand tighten t...

Page 43: ...ws 36 washers 37 and nuts 38 4 Install the electronics subassembly 1 to the side of the adapter bracket using four screws 30 and washers 29 5 Install the display bracket 2 to the electronics sub assem...

Page 44: ...to 30 36 ft lbs 40 6 48 8 N m See FIG 86 e Place the new o ring 20 on the lift ring adapter 19 and apply the supplied adhesive to the threads See FIG 86 f Route the linear sensor cable through the lif...

Page 45: ...he cover Snap the air motor cover back into place 8 Without integrated air controls only Install valve subassembly 6 and fittings a Apply the supplied adhesive to the adapter fit ting 31 Screw the fit...

Page 46: ...FIG 93 for a diagram of cable con nections FIG 91 Install Valve Assembly with air controls r_262375_3A0294_35a 6 31 33 32 FIG 92 Breakout Module Connections Air Motor Cable LCM Cable Solenoid Extensio...

Page 47: ...Air Valve Assembly Breakout Module Dispense Valve Solenoid Valve Linear Sensor Switch Cable Air Motor Cable CAN Cable LCM Cable Solenoid Extension Cable Solenoid Cable Solenoid Cable Air Lines suppli...

Page 48: ...onics bracket 1 so that they will fit under the elec tronics subassembly cover 4 13 Install the air lines 34 a Connect the air lines to the valve subassembly 6 as shown b Run the air lines between the...

Page 49: ...s subassembly cover 4 hand tighten the screws to secure 15 Install the power supply cord 14 16 Turn on air supply to the system FIG 98 Install Cover 4 r_262375_3A0294_43a FIG 99 Install Power Supply C...

Page 50: ...hose to dispense valve and tighten 6 Shut off the air valve by pressing the Air On Off soft key on the display module 7 Back off the air regulators to their full counterclock wise position and close a...

Page 51: ...e gun valve trigger 9 Open the material line drain valve and the pump bleeder valve Have a container ready to catch the drainage 10 Leave the pump bleeder valve open until you are ready to spray dispe...

Page 52: ...drain purge valve slightly by rotating counterclockwise c Increase pressure on the air regulator until the pump begins to move Run the pump until no air is released from the drain purge valve or unti...

Page 53: ...rop down box Press to select the desired units 5 Press to save selection 6 Press to navigate to the next drop down box and perform the same two steps 7 Press to navigate to the specific gravity SG fie...

Page 54: ...avigate to the shot number field 4 Press to scroll through the 25 shot numbers 5 Press to select the desired shot number 6 Press to navigate to the fluid weight field 7 Press and to increment or decre...

Page 55: ...3 2 Press to access the fields 3 Press to navigate to the shot sequence field Press to select the field 4 Press to scroll through the shot sequences 5 Press to select the desired shot sequence 6 Pres...

Page 56: ...field Follow steps 4 5 to enter and confirm the password 7 Press to exit edit mode Disable Password To disable the password follow Set Password page 56 to change the password to 00000 Reset Password...

Page 57: ...options 5 Press to select the correct pump size for the system 6 Press to exit edit mode Enable Disable Pump Functions See Setup Screen 5 Enable Disable Pump Func tions page 96 for a description of ea...

Page 58: ...rs steps to set either the empty drum alarm or low drum advisory Refer to the Errors section on page 66 for more infor mation on alarms and advisories and how to clear an alarm or advisory The low emp...

Page 59: ...enance Parameters Set the amounts of material moved through the pump and dosing valve that will result in a maintenance advi sory or alarm 1 Navigate to setup screen 8 2 Press to access fields to make...

Page 60: ...st as large as the pump volume under the dispense valve 4 Hold down or the foot switch to run the sys tem The manual mode icon will flash The pump will go through the first changeover stop to measure...

Page 61: ...ation values will automatically update and the spe cific weight on setup screen 1 will update The calibration procedure is now complete Set Shot Accuracy Errors Use this screen to set the shot volume...

Page 62: ...des shot mode sequence mode manual mode and park mode This section explains each operation mode See page 92 for more details about the operation modes and the run screens Use the following instruction...

Page 63: ...art After all of the shots in a sequence have completed the sequence will start over at the first shot Manual Mode Manual mode runs the pump when is pressed or when the dispense valve is triggered Use...

Page 64: ...6 to select and dispense another shot 8 When you are finished selecting and dispensing shots press to exit edit mode Select a Shot Sequence Sequences are defined in setup screen 3 See Define Shot Seq...

Page 65: ...is on 2 Follow Select a Shot Number page 64 or Select a Shot Sequence page 64 3 Press or step on the foot switch purchase separately to begin dispensing The shot progress bar will display on the scree...

Page 66: ...occur the system continues running and or displays next to the operation mode field Errors with Light Tower If you have a system that uses a light tower errors are indicated by the light tower as well...

Page 67: ...output or exhausted material supply Decrease air pressure Decrease material output Replace material supply drum DD Pump Cavitation Red Solid Pump is diving down more than a half a stroke because of ex...

Page 68: ...spense Valve Red Solid Dispense valve is stuck open Check air solenoid wiring and air connection Replace or repair if necessary Check dispense valve air con nection Replace or repair if nec essary WJ...

Page 69: ...sory Set point Yellow Solid Shot volume is greater than the advisory setpoint Increase the advisory setpoint on Setup screen 11 Increase shot consistency by decreasing speed and valve shutoff time and...

Page 70: ...run screen See Change Operation Mode page 62 6 Hold a metal part of the gun valve firmly to the side of a grounded metal pail and press or step on the foot switch purchase separately until clean solv...

Page 71: ...the platen does not come out of the pail easily when the pump is being raised the air assist tube or check valve may be plugged A plugged valve prevents air from reaching the underside of the plate to...

Page 72: ...d indicator light will flash until new software is completely loaded 7 Turn power off 8 Remove token 9 Reassemble access cover and screw 10 Snap display back into bracket and reconnect power Clean Use...

Page 73: ...atches pump vol ume but is consistently lower than nominal shot size System has not finished compen sating for lower overshoot Dispense more shots Shot volumes should converge on nominal Display volum...

Page 74: ...system specific repair procedures refer to your Supply Systems Repair Parts manual or pump package instructions parts manual Replace Display NOTE Order Kit 262539 for replacement 1 Disconnect power 2...

Page 75: ...e kit uses high side switches for all digital outputs When they are on the module power supply voltage is switched to the output pin When they are off the power supply voltage goes through a pull up r...

Page 76: ...put Schematic The SmartWare shot dispense kit uses low side switches for all digital inputs The input is off when nothing is con nected between the input pin and the ground pin The input is on when th...

Page 77: ...Parts 3A0294J 77 Parts Kits 262370 and 262372 30 33 28 29 29 28 34 5 2 29 28 4 31 28 29 32 3b 36 38 41 37 3a 3c...

Page 78: ...Parts 78 3A0294J Kits 262370 and 262372 continued 19 20 18 13 22 23 24 25 26 Inside the back of the NXT air motor 42 54 51 44 44 44 49 45 47 53 46 50 43 52 55 15...

Page 79: ...ng 1 9 16 sst 1 20 108014 O RING 1 21 113500 ADHESIVE anaerobic 1 22 119700 SENSOR reed switch 1 23 118605 O RING 1 24 120730 SCREW machined hex washer head 1 4 20 x 1 in 25 mm 1 25 107257 SCREW thd f...

Page 80: ...Parts 80 3A0294J Kit 262371 25 4 5 28 24 23 27 23 24 26 24 23 2 3c 24 23 3a 3b 30 32 33 31...

Page 81: ...Parts 3A0294J 81 Kit 262371 continued 17 20 21 18 19 35 47 44 37 37 37 42 38 40 46 39 43 36 45 48 14...

Page 82: ...solenoid 1 12 124273 CONNECTOR splitter 2 13 122622 CORD power 1 14 LABEL identification 1 17 24C404 KIT linear sensor 1 18 16E067 BUSHING 1 19 110782 O RING 1 20 24A032 SWITCH reed assy 1 21 15V719...

Page 83: ...Parts 3A0294J 83 Kit 262373 25 26 Inside the back of the NXT air motor 22 23 24 30 31 2 5 35 33 34 38 19 20 18 13 28 29 4 3a 3b 3c...

Page 84: ...Parts 84 3A0294J Kit 262373 continued 39 40 41 42 42 43 44 45 46 47 49 42 50 47 52 53 15...

Page 85: ...G747 MAGNET linear sensor 1 14 122622 CORD power 1 15 LABEL identification 1 18 287839 SENSOR assembly 1 19 15F772 ADAPTER lift ring 1 9 16 sst 1 20 108014 O RING 1 21 113500 ADHESIVE anaerobic 1 22 1...

Page 86: ...Parts 86 3A0294J Kit 262374 19 20 16 17 18 22 23 4 3a 5 2 24 25 27 29 28 32 3b 3c...

Page 87: ...Parts 3A0294J 87 Kit 262374 continued 33 34 35 36 36 37 38 39 40 41 43 36 44 43 46 47 13...

Page 88: ...0 121806 CABLE solenoid 1 11 124273 CONNECTOR splitter 2 12 122622 CORD power 1 13 LABEL identification 1 16 24C404 KIT linear sensor 1 17 16E067 BUSHING 1 18 110782 O RING 1 19 24A032 SWITCH reed ass...

Page 89: ...Parts 3A0294J 89 Kit 262375 29 30 4 36 37 35 31 6 33 32 5 2 37 38 29 30 39 37 40 36 Stand Mount Bracket 46 6a 6b 6c 6d 6e 6g 6f 46e 46a 46d 46c 46b 44 43 42 1 1 1 Apply thread sealant to threads 1 45...

Page 90: ...Parts 90 3A0294J Kit 262375 continued 26 27 Inside the back of the NXT air motor 20 21 19 14 23 24 25 64 50 57 59 48 61 62 46 50 47 55 54 51 60 52 53 58 50 57 49 16...

Page 91: ...E anaerobic 1 23 119700 SENSOR reed switch 1 24 118605 O RING 1 25 120730 SCREW machined hex washer head 1 26 107257 SCREW thd forming hex washer head 1 27 120143 GUIDE strain relief 1 28 16E792 TOOL...

Page 92: ...Parts 92 3A0294J...

Page 93: ...ess dispense material shots clear errors and fill material drum Display Details Power Up Screen The following screen appears when the display module is powered up It remains on while the display modul...

Page 94: ...defined so that the system will dispense the predetermined quantity of material when the shot number is selected and a shot is initiated Refer to the following table for more informa tion Icon Functio...

Page 95: ...with shot number selected which also displays the shot volume box Setup Screen 4 Password and Pump Setup screen 4 enables users to set a password and select the pump size used by the specific system...

Page 96: ...to have the air pressure remain on after a shot completes Or uncheck the box to have the air pressure turn off after a shot completes Shot Switch Tap Mode Change shot switch mode There are two modes t...

Page 97: ...tch totalizer tracks and displays the amount of material since the last user reset Maintenance Totalizers Set the amounts of material moved through the pump and dosing valve that will result in a main...

Page 98: ...on process for top changeover bottom changeover and shot weight Refer to the following table for more infor mation Icon Function Shot Totalizer Records and displays the number of times each shot numbe...

Page 99: ...to the following table for more infor mation NOTE If either the advisory field or alarm field is set to zero the error is disabled Icon Function Advisory If the final shot volume is greater or less t...

Page 100: ...after the shot When the air valve is on the Current Mode box displays a black background and white icon And when the air valve is off the Current Mode box displays a white back ground and black icon F...

Page 101: ...lities The information screen is accessed by pressing either from the run screen Icon Function Description Advisory Advisories do not require atten tion therefore the system con tinues running and dis...

Page 102: ...pressure available to actuate the dispense valve Faster valve Use the smallest dispense valve that will work for your flow rate and pressure A small dispense valve will open and close faster which wil...

Page 103: ...amp 1 Yellow Digital Output 4 Phoenix Contact Part Number 1542761 Lamp 2 Red Digital Output 2 Digital Output Power 24 volt 1 Digital Output Ground 3 Shield Digital 5 Solenoid Air Fluid Connector 3 Red...

Page 104: ...543650 Pressure Differential Analog Input 2 Pressure Power 5 volt 1 Pressure Ground 3 Shield Analog 5 Shot Active Connector 8 Grey Pin Description Pin Number M8 Connector 4 pin Female Shot Active 5 vo...

Page 105: ...tor 1 Black Pin Description Pin Number M12 Connector 5 pin Female A code Digital Input or Output 4 Used for Drum Low Input and Solenoid Air Output Not Used 2 Power 1 Ground 3 Shield Digital 5 Branch C...

Page 106: ...motors order 262464 Foot Switch Kit 262530 The foot switch kit enables the operator to trigger the dispense valve using a foot pedal Dimensions For supply system or pump package dimensions refer to th...

Page 107: ...Technical Data 3A0294J 107...

Page 108: ...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 WARRAN...

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