Graco Fluid Automation 633, Operation

Page 1: ... for use in explosive atmospheres or hazardous locations See page 3 for model information including maximum working pressure and approvals If the visuals in the printed copy are unclear refer to the electronic version available on www graco com Important Safety Instructions Read all warnings and instructions in this manual Save these instructions ...

Page 2: ... Shutdown 41 Pressure Relief Procedure 42 Manual Mode 42 Dispense Head Solenoid 42 Bleed Valves 43 Operation 43 Testing Procedures 44 Pump Testing 44 Troubleshooting 45 Calibrate Pressure Transducers 45 Schematics 46 Dimensions 49 Model 633 49 Model 633 SR657 1M LR 50 Technical Data 51 Graco Standard Warranty 52 Graco Information 52 Related Manuals Manual Description 332354 633 Meter Mix Dispense ...

Page 3: ...matic adjustment during material dispense 633 SR657 1M LR PLC Potentiometer Controlled Fixed Ratio Meter Mix Dispense System mounted to a Pneumatic Controlled 1 1 to 2 1 Variable Ratio 55 Gallon Feed Machine Dispense System has proportional pneumatic control to provide automatic adjustment during material dispense Machine uses B442M Base Pumps Machine has 6 in 15 cm ram air cylinders Paral lel Low...

Page 4: ...e 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 EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment ...

Page 5: ...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 com ponent 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 yo...

Page 6: ...r covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources SPLATTER HAZARD Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin During blow off of platen splatter may occur Use minimum air pressure when removing platen from drum WARNING ...

Page 7: ...mber Pump Started B Air Inlet C Operator Interface Panel D Main Air Solenoid E Automatic Pressure Regulator and Air Motor Solenoids F Cylinder Pressure Transducer G Refill Solenoid J Bleed Ball Valve K Refill Valve L Feed Pressure Gauge M Pump Linear Position N Stop Button FIG 1 633 A C B D E G F J K M L N ...

Page 8: ...Air Solenoid E Automatic Pressure Regulator and Air Motor Solenoids F Cylinder Pressure Transducer G Refill Solenoid J Bleed Ball Valve K Refill Valve L Feed Pressure Gauge M Pump Linear Position N Stop Button FIG 2 633 SR657 1M LR A B D E G F J K M L C N Refer to the SR657 1M LR Meter Mix Dispense Systems Operation manual for additional component callouts ...

Page 9: ... pressure gauges should read the same as each other during normal operation of the machine Solvents These are rarely used with modern 1 1 silicones For cleaning methylene chloride or white spirits solvent are used Methylene chloride is recommended because it is non flammable NOTICE To avoid machine damage do not exceed 120 psi 0 8 MPa 8 3 bar air pressure at the machine inlet To avoid serious inju...

Page 10: ...Screen Navigation 10 332078C Screen Navigation ...

Page 11: ...Screen Navigation 332078C 11 ...

Page 12: ...Screen Navigation 12 332078C Refer to Screen 1 page 25 for mor details ...

Page 13: ...Screen Navigation 332078C 13 Refer to Screen 2 page 26 for mor details ...

Page 14: ...Screen Navigation 14 332078C Refer to Screen 3 page 26 for mor details ...

Page 15: ...Screen Navigation 332078C 15 Refer to Screen 4 page 27 for mor details ...

Page 16: ...Screen Navigation 16 332078C ...

Page 17: ...Screen Navigation 332078C 17 ...

Page 18: ...escription Shows the current mode of the machine Navigates to the screen where the user can select the mode to run the machine Navigates to a screen showing All pressures being monitored on the machine Grams remaining in the Cylinder The color injector spacing The next color injection point Navigates to screens that allow configuration of the machine Pressure Setpoints Refill Setpoints Pressure Th...

Page 19: ... allowing the user to select if a condition is either a Warning keeps the machine running or a Fault stops dispensing Navigates to a screen showing the history of alarms that have occurred Navigates to a screen showing what IO is currently active Navigates to a screen showing the software part number and version installed on the machine Icon Description ...

Page 20: ...ne will check if it requires refilling This Purges A Material through the system by applying air to the feed cylinders opening the refill valve and the A outlet valve The purge process continues as long as the Screw Rotate Signal is active NOTE Before resuming normal operation using a mold be sure to run enough material through the unit in Auto Mode that it begins to cure This purges B Material th...

Page 21: ...fill the pump cylinders while this button is pressed Letting go of the button mid refill will cause the machine to stop refilling Begins a Manual Feed cycle This will continue until either the cylinder reaches the end or a Man ual Refill is initiated Turns each injector On or Off Enables or disables frequency faults for the color injectors It can also occur if the injector is activat ing faster th...

Page 22: ...ressure in the Throat or Mix portion of the unit Shows the current mode of the machine Animation of the refill valve The default color is red indicating that it is closed It turns green when the valve is opened Indicates the pressure in each cylinder of the unit Indicates how much material is remaining in the cylinder Indicates how many grams the unit will dispense between color injections Indicat...

Page 23: ...Screen Identification 332078C 23 Alarm History Screen Shows a history of the alarms generated by the unit System IO Screen Shows what inputs and outputs are active on the unit ...

Page 24: ... Calibrate Pressure Transducers page 45 Indicates the actual position of the pump Calibration of the plunger position is password protected Enter the password here After 5 minutes of inactivity the unit will automatically log out The default password is 3717 Buttons are to be used in Manual Mode and are password protected Extend Plunger will open the dispense valve and extend the plunger all the w...

Page 25: ... not refill until the screw rotate signal turns off The unit monitors the pressure before the material enters the hoses and makes adjustments to maintain this pressure NOTE There may be a pressure drop at the outlet of the mixer The unit will leave the inlet valves open until the specified pressure has been reached because the material is compressible This insures that the unit has been refilled a...

Page 26: ...ng if the unit takes longer to refill Amount of time the buzzer is on during a fault Icon Description Specific gravity of the mixed material can be obtained from the material supplier If the specific gravity of the material is not known 1 0 is a default value Percent of color to be injected with the amount of material being dispensed There are sepa rate editable boxes for colors 1 and 2 The field ...

Page 27: ...ense cycles of the machine If the one component material pressure drops below the other component material pressure by X amount the machine will alert the user This is the amount of time before the alarm is checked after the refill done bit activates It allows the data in the analog unit to stabilize prior to checking for a fault ...

Page 28: ...l the condition is corrected Unit can have 4 levels of users that can log into it Touching this field will navigate to another screen where one can choose the level they want to operate at The login process is completed by entering the password into this field Logs the user out of the system The user will also be logged out after 5 minutes of inactivity on the operator interface If the correct pas...

Page 29: ...reen It selects user levels and allows the System Admin to change passwords User Level Description Default Password Level 1 User Not Currently Used 1970 Level 2 Setup Change Not Currently Used 1971 Level 3 Supervisor Not Currently Used 1972 Level 4 System Administrator Changes Passwords Warning Fault Levels 1973 ...

Page 30: ...re To change the password touch the field When finished press the Confirm button New passwords are not official until the Confirm button is pressed Pressing the return button before Confirm will cancel the changes Level 1 User Not Currently Used Level 2 Setup Change Not Currently Used Level 3 Supervisor Not Currently Used Level 4 System Administrator Changes Passwords Warning Fault Levels ...

Page 31: ...he warning has never been generated before the machine runs out of colorant the low level sensor may need to be recalibrated This event may be configured as an Alert or a Warning on the Alarm Setting Screen A warning will allow the machine to keep dispensing an alert will stop and prevent dispensing until the tank is filled Recalibration With the material empty press the Empty switch on the low le...

Page 32: ...led refer to the SR657 1M LR Meter Mix Dispense Systems Operation manual for additional details This event may be configured as an Alert or a Warning on the Alarm Setting Screen A warning will allow the machine to keep dispensing an alert will stop and prevent dispensing until the tank is filled The pressure in the metering unit cylinder is below the expected value Verify the following Be out of m...

Page 33: ...n Preset Screen 2 may need to be increased The Refill Fault Timer on Preset Screen 2 may need to be increased This indicates that the feed unit could not provide enough pressure during refill Verify that it is functioning properly and is providing enough pressure to the unit If installed refer to the SR657 1M LR Meter Mix Dispense Systems Operation manual for additional details Verify that a reaso...

Page 34: ...ill result in inconsistent mix ture in the material This can be fixed by decreasing the shot size of the injector This will cause it to inject material more often The color injector is designed to dispense the entire contents in about 0 2 seconds This depends on the air pressure supplied to the color injector The refill time is approximately the same as the dispense time It also relies upon the ai...

Page 35: ...e c Fluid Supply Containers follow your local code d Dispensing target container follow your local code e To maintain grounding continuity when flushing or relieving pressure hold a grounded metal pail firmly to a metal part of the dispense valve then initiate dispense 4 Connect the Screw Rotate Signal a Refer to Schematics page 46 for screw rotate signal connections NOTE The screw rotate signal t...

Page 36: ...g Place the platen if needed on top of the colo rant with the head of the screw facing up h Place the Colorant Tank Cover back on the tank Be sure to seat the o ring into the groove before tightening the screws or clamps i Adjust the Colorant Tank Regulator to the desired pressure For 2000 centipoise colorant 50 psi 345 kPa 3 4 bar should be sufficient j Attach the color line to the color injector...

Page 37: ...e Calibration Screen from the Main Screen b Using the specific gravity data from the material manufacturer enter the data in the column labeled S G 2 Prime Pumps and Material Line Connections Once the feed system pumps and lines have been primed and connected to the metering unit it is time to prime the metering unit pumps and material supply lines Purging through each hose individually a Put the ...

Page 38: ...w assembly with the static mixer assembly from the press 3 Adjust the Colorant Injector Shot Size To properly deliver the correct percentage of colorant to the A and B material streams the color injector must be set correctly Use these procedures to correctly set the Color Injector Shot Size on the Preset Screen a Perform Pressure Relief Procedure page 42 b Disconnect the color injector from the m...

Page 39: ... the manifold assembly k Prime the injector 4 Adjust the Feed Station Pressure Refer to the SR657 1M LR Meter Mix Dispense Sys tems Operation manual for additional details a Monitor the pressures in the individual cylinders during a dispense b Set the Packing Pressures on the Preset Screen to the pressures monitored in the previ ous step c Set the feed station material pressure to 50 100 psi 345 k...

Page 40: ... position To start the machine 1 Make sure the feed system is in a ready state and is pressurized 2 Reset the Stop Button if it had been pressed 3 Press the control power button 4 Select the desired mode NOTE Typical operation is Auto Mode Moving parts can pinch or amputate fingers When the pump is operating and when raising or lowering the pail shelf keep fingers and hands away from the pump inta...

Page 41: ...4 Leave the water cooling circuit running during machine idle times Long Term Perform the procedure if the machine will be left idle more than the pot life of the material 1 Perform Short Term Shutdown procedure 2 Remove all assemblies that contain mixed material and clean those components NOTICE Machine damage may occur from the mixed material if left idle more than the pot life of the material R...

Page 42: ...cally and if the dispense head can flow material freely 1 Press and hold the solenoid override button to open the dispense valve for the A material side 2 Release the solenoid override button once the ana log pressure gauge reads 0 psi 3 Repeat steps 1 through 2 for the B material side 4 Press the Stop button This equipment stays pressurized until pressure is manually relieved To help prevent seri...

Page 43: ...ll be relieved in the fluid lines between the pump and the check valve 5 Verify the analog pressure gauge reads 0 psi 6 Repeat for the B Pump Bleed Valve Operation Normal operation of the machine will take place in Auto Mode The metering unit will wait for a screw rotate signal from the press or factory automation to start dis pensing material In the following step any pressure in the lines will b...

Page 44: ...h will cause one pump to run at a higher pressure than the other Follow these steps 1 Enter into Auto Mode and verify the machine per forms a refill 2 Navigate to the Monitor screen and observe the material pressures after the fill valves close NOTE If the pressure on either side drops by 100 psi 0 7 MPa 7 bar or more the pump may be leaking internally Refer to Troubleshooting page 45 for pos sibl...

Page 45: ...ool Calibrate Pressure Transducers Perform this procedure when the Actual Value shown on the Calibration screen has a difference of 100 psi 7 MPa 0 7 bar from the value shown on the analog pressure gauge 1 Perform Pressure Relief Procedure on page 42 2 Navigate to the Calibration screen 3 Set the offset to 0 on the transducer being cali brated 4 Type the number displayed in the Actual field into t...

Page 46: ...05 104 103 102 101 5 8 5 8 BLK BLU 2161 2161 PRS5 PRS4 BLU BLK 1 4 1 4 3 3 G TOUCH SCREEN 1084 CABLE 485 2171 2161 MACHINE AIR ON 2161 2171 24 0VDC 2161 INPUTS SHT 2 RS232 SOL1 1032 SHT 4 OUTPUTS EM222 L1 N X2 1031 POWER SUPPLY PB1 1081 2171 FILTER 1032 LINE POWER ON CIRCUIT 24VDC 3 5A PB2 1084 X2 G PB2 OUTPUTS SHT 3 CPU224 LT1 2161 120 VAC 2 5A L1 G N SHT 4 OUTPUTS EM222 FU1 CRM CRM 9 FIL 1 PS 1 ...

Page 47: ...ED PSI 622 1A SOL13 OPEN A OUTLET VALVE 633 SOL2 OPEN B OUTLET 633 SOL3 Q1 1 Q1 0 Q0 7 3L 3121 3111 INJECTION MACHINE FAULT INPUT PUMP ONLINE MACHINE 1 3131 INJECTION MACHINE READY INPUT 3111 3111 GRN WHT BLU BLK CUSTOMER SIGNAL CABLE NOTE This machine is wired to accept either a 24vdc input or a dry contact as the screw rotate signal For a 24vdc input attach at terminals A B of CR1 For a dry cont...

Page 48: ...PRESSURE TRASDUCER RAM POSITION LINEAR TRASDUCER 24VDC 2161 2161 PT2 RED BLK WHT 1 2 3 2171 24VDC 2161 2161 PT3 RED BLK WHT 1 2 3 2171 24VDC 2161 2161 1042 5131 2171 2161 24VDC CRIMP TOGETHER INSIDE FERRULE 1041 1042 POWER SUPPLY 5VDC 30 WATT X2 PS 2 1032 L 120VAC N AC Neutral V V PROPORTIONAL AIR PRESSURE CONTROL ANALOG REGULATOR OPTION RED BLK RED BLU RED WHT 5 6 1 24VDC 2171 PROP AIR REG INPUT ...

Page 49: ...Dimensions 332078C 49 Dimensions Model 633 A C B Dimensions 633 A Height 72 in 183 cm B Width 36 in 91 cm C Depth 48 in 122 cm ...

Page 50: ...Dimensions 50 332078C Model 633 SR657 1M LR A C B Dimensions 633 SR657 1M LR A Height 85 in 216 cm B Width 64 5 in 164 cm C Depth 49 5 in 126 cm ...

Page 51: ...0 psi 1 2 m3 min 0 7 MPa 7 bar Materials of Construction Wetted materials on all models 303 304 316 Stainless Steel Hard Chrome Carbon Steel Carbide Weight 633 545 lb 247 kg 633 SR657 1M LR 2600 lb 1179 kg Notes Flow rates and viscosities are general estimates Flow rates drop as viscosity increases Fluids are expected to shear under pressure New applications or fluids should always be tested to de...