Custom RC 3A0146C Polyurethane Processing Equipment EN400 69 50 3 3000 (20.6, 206) 230 138 50 or 60 3 3000 (20.6, 206) RC-200 460 116 60 3 3000 (20.6, 206) MixHead Manuals Part Description

3A0146CEN

Operation - Maintenance

Custom RCPolyurethane Processing Equipment

For dispensing controlled ratio shots of resin and isocyanate.

3000 psi (20.6 MPa, 206 bar) Maximum Working Pressure

Important Safety InstructionsRead all warnings and instructions in this and all supplied manuals. Save these instructions.

Standard RC-100 shown without Hoses

ti11588b

2 3A0146C EN

ContentsModels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 7Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . 7Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7Keep Components A and B Separate . . . . . . . . . . 7Foam Resins with 245 fa Blowing Agents . . . . . . . 7Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 7Component Identification . . . . . . . . . . . . . . . . . . . . 8

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 8Main System Parts List . . . . . . . . . . . . . . . . . . . . 8System Schematic . . . . . . . . . . . . . . . . . . . . . . 10Main Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Human Machine Interface (HMI) Screens . . . . . 13MixHead Hydraulic Unit . . . . . . . . . . . . . . . . . . . 29Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Pumpline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Temperature Control . . . . . . . . . . . . . . . . . . . . . 31Other Components . . . . . . . . . . . . . . . . . . . . . . 31Optional Variable Frequency Drive . . . . . . . . . . 31

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Connecting Electrical Cord . . . . . . . . . . . . . . . . 33Day Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . 34Optional Boom . . . . . . . . . . . . . . . . . . . . . . . . . 34Optional “Press” or “Simple” Interface . . . . . . . . 35Manual Mode Pouring with Press Interface . . . . 36Automatic Mode Pouring with Press Interface . 36Pouring using “Press” Interface Signals . . . . . . 36

New Machine Maintenance . . . . . . . . . . . . . . . . . . 37Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

MixHead Hydraulic Unit Motor . . . . . . . . . . . . . 38Pumpline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Pouring Operation . . . . . . . . . . . . . . . . . . . . . . . . . 40Low and High Pressure Circulation . . . . . . . . . . 40Pour Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . 40Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 40Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . 41Pouring Requirements . . . . . . . . . . . . . . . . . . . 41Beginning the Pour . . . . . . . . . . . . . . . . . . . . . . 41

Night Mode Operation . . . . . . . . . . . . . . . . . . . . . . 42Starting Night Mode . . . . . . . . . . . . . . . . . . . . . 42Requirements for Continuing Night Mode . . . . . 42

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Overnight/Weekend . . . . . . . . . . . . . . . . . . . . . . 43Long-Term Shutdown . . . . . . . . . . . . . . . . . . . 43

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Calibrate Mode . . . . . . . . . . . . . . . . . . . . . . . . . 44Temperature Control . . . . . . . . . . . . . . . . . . . . . 44Pouring Settings . . . . . . . . . . . . . . . . . . . . . . . . 46MixHead Settings . . . . . . . . . . . . . . . . . . . . . . . 47Chemical Flow Settings . . . . . . . . . . . . . . . . . . . 47Day Tank Settings . . . . . . . . . . . . . . . . . . . . . . . 48Flow Measurement Controls . . . . . . . . . . . . . . . 49

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 53Air Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . 53Hydraulic Pressure Relief . . . . . . . . . . . . . . . . . 53Chemical Line Pressure Relief . . . . . . . . . . . . . 53

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Purge Air from Metering Pump . . . . . . . . . . . . . 54Drain the Water Separator . . . . . . . . . . . . . . . . . 54Check Desiccant . . . . . . . . . . . . . . . . . . . . . . . . 54Replace Desiccant . . . . . . . . . . . . . . . . . . . . . . . 54Check/Replace Metering Pump

Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 55Check the Accumulator Pre-Charge . . . . . . . . . 55Pre-Charge the Accumulator . . . . . . . . . . . . . . . 56Check Tightness of all Clamps and Fittings . . . 56Check Hoses for Wear . . . . . . . . . . . . . . . . . . . . 56Check, Adjust Automatic Unloading Valve Pressure

Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Check Hydraulic Fluid and Filter . . . . . . . . . . . . 57Replace Hydraulic Fluid and Filter . . . . . . . . . . 57Replace the PLC battery . . . . . . . . . . . . . . . . . . 57Empty the Day Tank . . . . . . . . . . . . . . . . . . . . . 57

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Alarm Status Screen . . . . . . . . . . . . . . . . . . . . 59Alarm History Screen . . . . . . . . . . . . . . . . . . . . 60Alarms List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . 63

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 66Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 66

Models

3A0146C EN 3

Models

See Connecting Electrical Cord, page 33, for cord specifications.

Related ManualsAll custom machines come with a custom assembly drawings manual.

Model Voltage AmpsFrequency

(Hz) PhaseMaximum Working Pressure,

psi (MPa, bar)

RC-20

460 31 60 3 3000 (20.6, 206)

400 31 50 3 3000 (20.6, 206)

230 62 50 or 60 3 3000 (20.6, 206)

RC-40

460 31 60 3 3000 (20.6, 206)

400 31 50 3 3000 (20.6, 206)

230 62 50 or 60 3 3000 (20.6, 206)

RC-100

460 69 60 3 3000 (20.6, 206)

400 69 50 3 3000 (20.6, 206)

230 138 50 or 60 3 3000 (20.6, 206)

RC-200 460 116 60 3 3000 (20.6, 206)

MixHead Manuals

Part Description

312752 S-Head Operation and Maintenance

312753 L-Head Operation and Maintenance

Auto-Fill Manuals

Part Description

308443 Husky™ 1040 Air-Operated Diaphragm Pumps

309815 Feed Pump Kits

311882 T2 2:1 Ratio Transfer Pump

Flow Meter Manuals

Part Description

308778 Volumetric Fluid Flow Meter(Part 52.7.5G only)

Ball Seat Applicator Manual

Part Description

310551 Ball Seat Applicator

Air Regulator Manual

Part Description

308167 Low Volume Air Regulators

Warnings

4 3A0146C EN

WarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

DANGERHIGH VOLTAGE ELECTRIC SHOCK HAZARDThis equipment uses high voltage power. Improper contact with high voltage equipment will cause death or serious injury.• Turn off and disconnect power at main switch before disconnecting any cables and before servicing

equipment.• This equipment must be grounded. Connect only to grounded power source.• All electrical wiring must be done by a qualified electrician and comply with all local codes and

regulations.

WARNINGTOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.• Read MSDS’s to know the specific hazards of the fluids you are using.• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.• Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, includingeye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:• Protective eyewear, and hearing protection.• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

SKIN INJECTION HAZARDHigh-pressure fluid from dispense valve, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.• Do not point dispense valve at anyone or at any part of the body.• Do not put your hand over the end of the dispense nozzle.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.• Tighten all fluid connections before operating the equipment.• Check hoses and couplings daily. Replace worn or damaged parts immediately.

PRESSURIZED EQUIPMENT HAZARDFluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment. • Tighten all fluid connections before operating the equipment.• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Warnings

3A0146C EN 5

FIRE AND EXPLOSION HAZARDFlammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:• Use equipment only in well ventilated area.• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline.• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fume

are present.• Ground all equipment in the work area. See Grounding instructions.• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they

are antistatic or conductive.• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment

until you identify and correct the problem.• Keep a working fire extinguisher in the work area.

PRESSURIZED ALUMINUM PARTS HAZARDUse of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemicalreaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or prop-erty damage.• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or flu-

ids containing such solvents.• Many other fluids may contain chemicals that can react with aluminum. Contact your material sup-

plier for compatibility.

EQUIPMENT MISUSE HAZARDMisuse can cause death or serious injury.• Do not operate the unit 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

component. 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 your material, request MSDS forms from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-

facturer’s replacement parts only.• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create

safety hazards.• Make sure all equipment is rated and approved for the environment in which you are using it.• Use equipment only for its intended purpose. Call your distributor for information.• Route hoses and cables away from traffic 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 area.• Comply with all applicable safety regulations.

MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts.• Keep clear of moving parts.• Do not operate equipment with protective guards or covers removed.• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

WARNING

Warnings

6 3A0146C EN

BURN HAZARDEquipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:• Do not touch hot fluid or equipment.

WARNING

Isocyanate Hazard

3A0146C EN 7

Isocyanate Hazard

Material Self-ignition

Moisture Sensitivity of IsocyanatesIsocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO lube pump reservoir (if installed) filled

with Graco Throat Seal Liquid (TSL™), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contam-inated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

Keep Components A and B Separate

Foam Resins with 245 fa Blowing AgentsNew foam blowing agents will froth at temperatures above 90°F (33°C) when not under 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 clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• Most materials use ISO on the A side, but some use ISO on the B side.

• Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

Spraying or dispensing materials containing isocya-nates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventila-tion in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate per-sonal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

The amount of film formation and rate of crystalli-zation varies depending on the blend of ISO, the humidity, and the temperature.

NOTICETo prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocy-anate) and component B (resin) parts.

Component Identification

8 3A0146C EN


Typical Installation

Main System Parts List

FIG. 1

104

108

103

105

106

107

110

101111

109

101

102

103

104

105

108

109

110

111

ti11590b

ti11591b

Standard RC-100 shown, refer to assembly drawings manual for other models

Ref Description101 Base Unit102 Iso Pumpline103 Poly Pumpline104 Tanks105 MixHead

106 Temperature Control System107 Volumetric Flow Meters (optional)108 Poly Tank Agitator (optional)109 Boom110 Main Panel111 MixHead Hydraulic Unit

Ref Description


3A0146C EN 9


10 3A0146C EN

System Schematic

NOTE: On standard RC-200 models, the heater is located in the return line instead of the high-pressure line.

A

B

C

D


3A0146C EN 11

A

B

C

D


12 3A0146C EN

Main Panel

Key:AA Alarm HornAB Main Power IndicatorAC Iso Agitator Speed Control Turn-DialAD Human Machine Interface (HMI)AE Emergency Stop

AF Control Power Push-button/IndicatorAG Poly Agitator Speed Control Turn-DialAH Main Power Lockout BarAJ Main Power SwitchAK Main Panel Vents

Safety

Emergency Stop

There is one Emergency Stop located at the main elec-tric console and one Emergency Stop at the end of each installed pour pendant; see FIG. 2 and FIG. 17. Pushing any Emergency Stop will turn off control power and stop all motors. The Emergency Stops stay in position when hit, so before control power can be turned on they must be reset by twisting and pulling out.

Lockout

A lockout has been provided to lock the main power off and to lock the main panel door closed. To lockout the machine, first turn the machine off by turning the main handle to the off position. Then, while wiggling the power handle, pull out the horizontal black bar on the handle. While holding the bar in the out position, insert a padlock through the open area in the bar and lock.

FIG. 2

1

Only installed if the machine has a variable speed agitator for that chemical.

1

1

AA

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AK

ti11592b


3A0146C EN 13

Human Machine Interface (HMI) Screens

When main power is turned on, the HMI will automatically turn on.

Main Menu Screen

Key:BA Set System ClockBB Login/LogoutBC Current Alarm StatusBD Last Shot DataBE Screen Access buttons sectionBF Main Menu screen accessBG Status screen accessBH Machine Control screen access

BJ Tank Control screen accessBK Pour Time Editor screen accessBL Setup screen accessBM Flow Control screen accessBN Scaling screen accessBP Alarm HIstory screen accessBR Alarm Status screen accessBS Display System Info

Last Shot Data

The control system records the actual shot time after the shot has occurred. The control system also captures the flow rates and ratio for the last shot. The flow rate is cap-tured shortly after the shot begins.

FIG. 3

Screen is only accessible when logged in as one of the “Supervisor” usernames. If not logged in this button will appear as a key image, noting that screen access is password protected.

Flow Control button is only visible if Flow Meters are installed.

Shown on all screens.

When two MixHeads are installed, the Last Shot Data will have two columns of information.

Button is used to gain access to the Options Select screen where machine configuration is entered. This screen is only accessible to Graco personnel.

Screen is only accessible if temperature control or auto-fill is installed.

1

2

3

4

5

6

2

3

BA BB

BD

BE

BF BG BH BJ BK BL BM BN BP BR

4

BC

1

BS

56


14 3A0146C EN

Login/Logout

To gain access to certain screens, the user must be logged in with an appropriate username and password. There are two levels of passwords for customers and one for Graco personnel. Logging in as any of the “Main-tenance” usernames will allow access to the Pump Cali-bration screen. Logging in as any of the “Supervisor” usernames will allow the user to change the default set-ting of the MixHead cleanout piston to normally open or normally closed, as well as the ability to change the screen language, temperature units, passwords, and access to the Temperature Log/Gain and Scaling screens. The “Factory” user names are for Graco per-sonnel only.

Setting the System Clock

To adjust the system clock, first turn on main power and then control power. When the HMI finishes loading the Main Menu screen, select “Set System Clock.” Then select each date and time button in the “PanelView Clock/Calendar” screen to enter the current information. There will be a short delay between hitting the return arrow and the new information being displayed on the PanelView screen.

Key Icon

When a screen is not accessible to the current user, the text in the screen access button on the bottom of the screen will be replaced with a key icon. To access a screen that is currently inaccessible, log in as the appro-priate username then press the desired screen access button.

FIG. 4

Enter the hour item as the 24-hour time. For exam-ple, 1 PM is entered as “13”. The machine will auto-matically convert the time in the upper left corner of the screen to display the appropriate AM/PM time.


3A0146C EN 15

Status Screen

Key:CA HeaterCB Agitator StatusCC Tank LevelCD Auto-FillCE Heat ExchangerCF Metering Pump MotorCG Fluid FlowCH Circulation ValveCJ MixHead Hydraulic Unit Status

CK Flowrate (grams per second)CL MixHead Piston Position RectanglesCM Calibrate modeCN Automatic modeCP Manual modeCQ MAG drive temperatureCR Fault StatusCS Night Mode Status

In the figure below, only the Iso side has been labeled. The items on the Poly side are the same as those on the Iso side.

FIG. 5

3

4

51 6

2

1

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 is gray, no fluid is in that section. When it is colored, there is fluid passing through that section.

The color indicates whether the chemical is being cooled. Blue is cooling, gray is not cooling.

Red indicates heating, black indicates no action.

The approximate current fluid level is shown on the screen.

Gray indicates no action, red for iso or blue for poly indicates refilling.

Also shown on the Machine Control screen.

Only if MAG drive is installed for that chemical.

Shown on all screens.

Shown only if Flow Meters are installed.

1

2

3

4

5

6

7

8

9

A

CA

CB CC CD

CE

CF

CG

CH

CJ

CK

CL

CM

CN

CP

7

7

7

CQ89 CRCS

A

CE 3


16 3A0146C EN

Manual, Automatic, Calibrate Modes

With control power on, any of these three modes can be selected. When a certain mode is selected, the related button will turn green.

System Status Indicators

The status of all system conditions is shown. This includes various temperatures and pressures through-out the system. The relative position of these sensors is shown schematically on the screen. Other system indi-cators include motor status, tank level, temperature con-trol and, if installed, auto-fill 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 beginning a pour besides pressing the start button.

MixHead In Cycle Indicator

• shows green when a pour has been started and the controls are in the stages of a pouring operation

MixHead Pouring Indicator

• Shows green when the control system has com-manded a pour. This occurs regardless of whether the MixHead is turned on or off.

Cleaning Piston Open Indicator

• top rectangle of the three shown

• green when the cleaning piston is open

Cleaning Piston Closed Indicator

• middle rectangle of the three shown

• green when the cleaning piston is closed

Material Piston Open indicator

• bottom rectangle of the three shown

• green when the material piston is open


3A0146C EN 17

Machine Control Screen

Key:DA Low Level Bypass On/Off ControlDB MixHead Hydraulic Motor Start/StopDC MixHead Control screen access

DD Iso/Poly Agitator Motor Start/StopDE Night Mode On/OffDF Flow 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 Conditions Data

The data along the bottom of the screen for flow, ratio, and temperature display the machine's outlet conditions.

FIG. 6

1

Buttons shown only if the machine has an agitator installed for that chemical.

Only shown when low level option is enabled.

Shown only if Flow Meters are installed.

1

2

3

DA

DB

DD

DD

DE

DC

1 DD

2

DF3

The Iso and Poly metering pump motors cannot be started when the MixHead Hydraulic Motor is off. This protects from fluid spill that could occur if chemicals were to flow through the MixHead with-out the material piston held shut by hydraulic pres-sure.


18 3A0146C EN

MixHead Control Screen

Key:SA MixHead OffSB MixHead OnSC Current pendant channel selectedSD Preset time for current channel

SE Cleanout piston normally closed selectionSF Cleanout piston normally open selectionSG Current default status of cleanout pistonSH MixHead #2 section

Normally Open/Closed

The cleanout piston default state is determined by whether normally open or normally closed is selected on the MixHead Control screen. Normally open means that when the machine is not pouring the cleanout piston will be open and normally closed is the opposite.

FIG. 7

SB

SF

SC

SG

1

SA

3

SE

SH

SD

3

MixHead #2 section of screen only shown if second MIxHead is installed.

Only shown if L-Head is installed.

Only shown if logged in as one of the “Supervisor” usernames.

1

2

3

2

2

2


3A0146C EN 19

Tank Control Screen

Key:EA Auto-Fill On/OffEB Ideal Temperature SetpointEC Temperature Control On/OffED High Temperature Alarm Setpoint

EE Low Temperature Alarm SetpointEF Fail to Fill Alarm DelayEG Fill DelayEH Actual Temperature

Iso, Poly Temperature Control

The temperature control portion of the screen is identi-cal for Iso and Poly streams. The heading above each area displays the current chemical temperature.

Temperature Control On/Off and Indicators

These buttons are used to turn temperature control on or off. When a metering pump motor 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 motor is off, the indicator below will show “Permit-ted”. If the temperature control is off for any reason, the indicator will display “not permitted” to show that the temperature control will not turn on when the metering pump motor is turned on.

FIG. 8

1

Buttons only shown if Auto-Fill is installed.

Only shown if Temperature Control is installed.

Button only shown if temperature control or auto-fill is installed.

1

2

3

1

1

EA

EB

EC ED

EF

EE

EG

EH

3

2 2


20 3A0146C EN

Pour Time Editor Screen

Key:FA Preset Pour Timers, seconds durationFB Press Interface Automatic Mode Pour TimeFC First Group

FD Previous GroupFE Next GroupFF Last Group

The Pour Time Editor screen 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 particular pour time preset, select that button and enter the new time.

“TIMER #” is the “channel” number shown on the status screen. The selected channel, or timer, can be changed using only the pour pendant, if installed.

FIG. 9

Shown only if machine is set-up to use Press Interface

Shown only if a second MixHead is installed. Press button to select which MixHead timers to edit.

1

2

1

FA

FBFC

FD

FE

FF

2


3A0146C EN 21

Setup Screen

Key:GA Pressure Build TimeGB Night Mode On/Off TimeGC Iso, Poly Specify GravityGD Cleanout Delay setting

GE Cleanout Extend Time settingGF Pressure Hold TimeGG Screen Setup screen accessGH Password Setup screen access

See Settings section on page 44 for more information.

Night Mode On/Off Time

See Night Mode Operation on page 42 for more infor-mation.

FIG. 10

Only shown if L-Head installed.

Only shown if logged in as one of the “Supervisor” username.

1

2

1GA

GB

GC

GF

GE

GD1

GG

GH

2

2


22 3A0146C EN

Screen Setup Screen

Key:TA Language SelectionTB Temperature Units SelectionTC Current Temperature Units Selection

Language Selection

To select a language press and hold the desired lan-guage button for about three seconds. The text on all of the screens will slowly change to the new language within about 30 seconds.

Temperature Units Selection

To have temperature information displayed in Celsius or Fahrenheit, press the appropriate button.

This screen is accessible from the Setup screen but only when logged in as one of the “Supervisor” usernames.

FIG. 11

TATB

TC


3A0146C EN 23

Password Setup Screen

Key:UA UsernameUB Password

Usernames

To change a username, select a username and type the new name. Regardless of the names for each user, the top four names listed will have “Maintenance” level access and the bottom three will have “Supervisor” level access.

Changing Passwords

To change one of the existing passwords, touch the password and enter the new password in the new win-dow.

This screen is accessible from the Setup screen but only when logged in as one of the “Supervisor” usernames.

FIG. 12

UA UB


24 3A0146C EN

Flow Control Screen

Key:HA Manual Flow ControlHB Automatic Flow ControlHC Total Flow Rate Warning/Shutdown Tolerance (percent)HD Flow Ratio Warning/Shutdown Tolerance (percent)HE Iso Flow (grams per second)HF Total Flow (grams per second)HG Poly Flow (grams per second)

HH Flow RatioHJ Manual Mode Poly Motor RPM SetpointHK Manual Mode Iso Motor RPM SetpointHL Automatic Mode Ratio Setpoint (Poly divided by Iso)HM Automatic Mode Total Flow Setpoint (grams per second)HN Pump Calibration screen accessHP MixHead #2 Flow Control section

Manual Flow Control

Enables use of the Manual Mode Motor Percent Set-points. When in Manual mode, motor speed remains constant.

Automatic Flow Control

Enables use of the Automatic Mode Setpoints and machine will continually adjust motor speeds to meet setpoints.

Flow Rate/Ratio Warning/Shutdown Tolerance

Allowable error in flow rate/ratio when automatic mode is enabled for flow control. When outside the warning range, an alarm will be displayed. When outside the shutdown range, the MixHead will not shoot.

This screen is only available if Flow Meters are installed.

FIG. 13

HAHB

HC

HE HG

HJ

HF

HH

HK HLHM

Only shown if logged in as one of the “Maintenance” or “Supervisor” usernames.

Only shown if Variable Frequency Drives are installed.

Only shown if second MixHead is installed.

1

2

3

1

HDHN

HP

2 2 2 2

3

2


3A0146C EN 25

Pump Calibration Screen

Key:VA MixHead Number selectionVB Iso Hi Speed Calibration Setpoint PercentVC Iso Low Speed Calibration Setpoint PercentVD Poly High Speed Calibration Setpoint Percent

VE Poly Low Speed Calibration Setpoint PercentVF Start CalibrationVG Stop Calibration

High/Low Speed Calibration Percent

This is the high and low calibration speeds that will be used when the Start Calibration button is pressed.

Start/Stop Calibration

Pressing the Start Calibration button will calibrate the motor speed to the flow rate input on the Flow Control screen. The motors will spin at high speed for one min-ute then at low speed for one minute. If at any time the calibration needs to stop, press the Stop Calibration but-ton or hit the Emergency Stop.

This screen is accessible from the Flow Control screen but only if logged in as one of the “Mainte-nance” or “Supervisor” usernames and Variable Frequency Drives are installed.

FIG. 14

VA

VB

VC

VF VG

VD

VE


26 3A0146C EN

Scaling Screen

Key:JA Current K Factor ValueJB Test Shot Actual Weight (grams)JC Iso Calibration Shot start buttonJD Poly Calibration Shot start buttonJE Calibration Shot stop buttonJF Temperature Log/Gains screen access

JG Flowrate Filter On/OffJH Last Shot DataJJ Calculate New K Factor buttonJK Flow Meter Reading (grams per second)JL Test Flowrate (grams per second)

See Calibrating Machine-Calculated Mass Flow on page 51 for more information.

Flowrate Filter

The flowrate input and display may be filtered to provide a more stable display of flow rate by turning the filter ON. Instantaneous flow rate changes are displayed with the filter turned off.

This screen is only accessible when logged in as one of the “Supervisor” usernames.

FIG. 15: This screen is for qualified technicians only and is password protected.

JA JB

JC

JD

JE

JF

JG

JH

JJ

JL

JK


3A0146C EN 27

Temperature Log/Gains Screen

Key:KA Up ScaleKB Down ScaleKC PenKD Move LeftKE HomeKF End

KG PauseKH Move RightKJ Poly Heat GainKK Poly Cool GainKL Iso Heat GainKM Iso Cool Gain

See Temperature Gains section on page 45.

This screen is accessible from the Scaling screen.

FIG. 16: This screen is for qualified technicians only and is password protected.

KDKC

KM

KL

KK

KJ

KE

KA

KF KG KH

KB


28 3A0146C EN

Alarm History and Alarm Status Screens

See Troubleshooting section on page 59 for Alarm screens details.


3A0146C EN 29

MixHead Hydraulic UnitThe MixHead hydraulic unit is designed to operate the MixHead pistons at a sufficient pressure to overcome sticking and at a sufficient speed to ensure proper mix-ing. It is the accumulator that actually opens the Mix-Head while the power pack recharges the accumulator. Because of this a sufficient time for recharging must be allowed between each discharge of the accumulator.

To protect against mechanical failure of the hydraulic unit components, an electric over pressure switch is installed in the pressure line, see table at the beginning of the Settings section on page 44 for switch setting. This limit switch will shut down the hydraulic motor and be accompanied by alarms. In this event, the cleaning piston maintains its position. The accumulator pre-charge automatically positions the MixHead mate-rial piston.

There is also a low-pressure switch and a temperature limit switch in the hydraulic reservoir, see table at the beginning of the Settings section on page 44 for switch settings. The more frequent the shots the more heat generated by the system. This limit switch will shut down the hydraulic motor and trigger an alarm.

The component that controls the high and low hydraulic pressure limits is the automatic unloading valve. This dual acting valve has two separate settings: one to define the upper operating pressure limit and the other to define the lower operating pressure limit. When the accumulator is charged to the maximum limit, the auto-matic unloading valve diverts pump flow to the circula-tion line. During this circulation, pressure is maintained in the accumulator by a check valve in the unloading valve. When the accumulator is below the upper limit, the unloading valve automatically directs flow to recharge the accumulator. See table at the beginning of the Settings section on page 44 for factory automatic unloading valve settings.

A low-pressure switch is also provided to prevent fail-ures in the event the hydraulic pressure is not sufficient to open the MixHead. When tripped, this limit switch will prevent the MixHead from opening and will trigger an alarm. See table at the beginning of the Settings sec-tion on page 44 for switch setting.

The success of any hydraulic system is dependent on the quality and maintenance of the hydraulic fluid. A return line filter is provided to maintain the fluid and assure the reliable operation of the unloading and direc-tional valves. See Maintenance section on page 54.

Directional Valve (if L-Head installed)

The directional valve controls the directional movement of the cleaning piston and material piston in the L-Head.

If electricity is interrupted by a power failure, fault or an Emergency Stop, the cleaning piston will remain open or closed. The material piston will default to closed posi-tion.

A minimum of 5 seconds between shots is recom-mended.


30 3A0146C EN

Tanks

To ensure proper supply of material to the MixHead, the machine includes temperature conditioned and pressur-ized day tanks.

Temperature conditioning is accomplished by circulating the chemicals through a heat exchanger and optional heater in the return line to tank. The operator-selected temperature is maintained by the program.

To assure adequate chemical pressure at the inlet to the metering pump, the tank must be pressurized with dry air to the specification listed in the table at the beginning of the Settings section on page 44.

The fluid level in the tank must be manually maintained between 60% to 90% full to assure proper temperature and aeration control, unless the optional Auto-Fill sys-tem is installed. A tank fluid level sight gauge is also pro-vided.

Should the pressure in a tank rise excessively while the tank is refilling, an operator adjustable pressure relief valve is provided to assist the regulator in bleeding the pressure. The recommended set point for this valve is listed in the table at the beginning of the Settings sec-tion on page 44.

Level Sensor

A sensitivity adjustment is provided for the level sensors to compensate for various liquid 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 excess moisture and particulate matter from the shop air, a water separator is provided. For the day tanks only, a desiccant air dryer is provided to charge the day tanks. To prevent contamination of the air system by a reaction of the iso fumes with the poly fumes, the systems are isolated by means of separate check valves.

Adjust Day Tank Settings

See Day Tank Settings section on page 48 for more information.

NOTICERelieving tank pressure may introduce moist air into the system causing crystallization and damage to the machine.

The pumps must never be run dry. If the metering pump is not properly supplied with fluid and pressure during operation, cavitation will result. This will dam-age the pump and will lead to an “off ratio” condition.

NOTICEThe metering pump inlet filter prevents particulate mat-ter from damaging the precision metering pumps. The filter element is a basket type and should it become clogged, it will cause cavitation of the pump resulting in damage to the pump. Therefore, it is necessary that the filter be properly serviced at all times. See Mainte-nance section on page 54.

The minimum recommended supplied dry air pres-sure is listed in the table at the beginning of the Settings section on page 44.


3A0146C EN 31

PumplineBoth pumps are protected on the inlet side by a basket filter and a low-pressure switch. Day tank pressure below the setting of the Metering Pump Low Inlet Pres-sure switch will cause a warning alert and the affected metering pump motor will shutdown. See the table at the beginning of the Settings section on page 44 for switch setting.

The pumps are protected on the outlet side by a mechanical relief valve and a pressure switch, see the table at the beginning of the Settings section on page 44 for settings. Should this pressure be exceeded, and the affected metering pump motor will automatically stop and will be accompanied by alarms.

A minimum pressure switch is also provided to protect the MixHead from chemical crossover. All pressure switches and relief valves are factory set and should not be adjusted.

Temperature Control

Heat Exchanger

On RC-20, RC-40, RC-100 models, the heat exchanger cools the chemical in the outlet line before moving to the MixHead. On RC-200 models, the heat exchanger cools the chemical in the return line before returning to the tank. The heat exchanger is controlled by the HMI and will open and close the water inlet valves as neces-sary to maintain the desired fluid temperatures.

Optional Stand Alone Chiller

A separate, stand alone water chiller may be purchased to improve the efficiency of the heat exchanger. The function of the chiller is to cool the inlet water flowing to the heat exchanger thus cooling the material faster.

Optional Heater

On RC-20, RC-40, RC-100 models, the optional heater heats the material to the desired temperature before moving to the MixHead. On RC-200 models, the optional heater heats the material to the desired temper-ature before returning to the tank.

Over-Temperature Switches

For operation information, see Temperature Control section on page 44. For factory settings, see the table at the beginning of the Settings section on page 44.

Other Components

Circulation Valve

A pneumatically operated Circulation Valve allows low pressure operation at startup and between shots. It transfers flow from the outlet of the heaters to the circu-lation loop and directly back to the day tanks which bypasses circulation through the MixHead.

Circulation Valve Override

For fault analysis or setup, a circulation valve override screw is provided on the air control valve to manually open and close the circulation valves. Turn to operate.

Optional Variable Frequency DriveThe variable frequency drive enables control of the metering pump motor rpm as well as advanced flow control from the HMI.

See Adjusting Metering Pump Motor RPM (if VFD is installed) on page 48 and Calibrating Machine-Calcu-lated Mass Flow on page 51 for more information on Variable Frequency Drive operation.

Setup

32 3A0146C EN

Setup

The machine is assembled on a heavy-duty steel frame that accepts all the major operating components. The machine will arrive from the factory pre-assembled, completely tested and ready for installation. If the unit includes a boom, the unit will come fully assembled with the boom detached. Setting the unit in place, providing electric service to the main electric console, connecting the air supply, servicing the hydraulic and day tanks, connecting the hoses and gun, and, if included, install-ing the boom is required.

Prior to installing the machine, check for any damage that may have occurred during transit. If any damage is found, notify Graco immediately.

The machine is to be installed on a flat surface 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 drained of all fluids and the chemical hoses were detached.

The machine has been designed to prevent the acciden-tal connection of chemical hoses to the wrong source. The Iso pressure hose is color coded red for pressure and red/white for return. The Poly pressure hose is color-coded blue for pressure and blue/white for return.

Avoid breathing of vapors and contact with Isocya-nate as some people have severe allergic reactions. See Isocyanate Hazard on page 7.

Setup

3A0146C EN 33

Connecting Electrical Cord

All Models: Connect three power leads to L1, L2, and L3. Connect green to ground (GND).

Power cord is not supplied. See following table.

Model Voltage AmpsCord Specification

AWG (mm2)

RC-20460 31 10 (5.3)400 31 10 (5.3)230 62 6 (13.3)

RC-40460 31 10 (5.3)400 31 10 (5.3)230 62 6 (13.3)

RC-100460 69 4 (21.2)400 69 4 (21.2)230 138 1 (42.4)

RC-200 460 116 1 (42.4)

ti3248a

L1

L2L3

GND

Setup

34 3A0146C EN

Day Tanks

Tanks

Connect all hoses and slowly pressurize each tank while checking for any leaks. See Settings section on page 44 for suggested pressure procedure.

Chemical Feed System

Each day tank has an inlet port on the back, where the chemical feed line gets connected.

Each tank has an auto-fill air solenoid valve located on the center column between the two tanks. Air lines need to be run from these air solenoid valves to the proper feed pump.

Hydraulic System• Fill the hydraulic fluid reservoir with approved

hydraulic oil. See Maintenance on page 54 for pro-cedure and the table at the beginning of the Set-tings section on page 44 for reservoir capacity.

• Charge the accumulator. See Maintenance section on page 54 for procedure.

• Fully close manual unloading valve. See Compo-nent Identification section on page 8 for location.

The hydraulic unit is fully tested at the factory and drained of all hydraulic fluid prior to shipment. Before operating, service with hydraulic fluid as recommended in Maintenance section.

Optional BoomThe boom comes detached and will need to be installed before use.

Setup

3A0146C EN 35

Optional “Press” or “Simple” Interface

This machine is capable of being controlled by an exter-nal machine using three interface options: “Press,” “Sim-ple,” and “Normal.” “Normal” interface is the default interface and does not require any additional setup.

When “Simple” or “Press” interface is selected, the machine is able to utilize advanced interactivity with a Press. The machine also responds differently to the but-tons on the pour pendant, as outlined in this section.

Setup

• A press interlock arrangement as basic as a limit switch to close contact only when the press is fully closed and ready for a pour (the “Press Pour Request” contact)

• A limit switch to close contact only when the press is fully open and finished with it’s cycle (the “Press Cycle Complete” contact)

An arrangement with the two items above can use the metering unit’s “Ready” signal to know when the meter-ing unit is ready for a pour request. It can also use the metering unit’s “Pour Complete” signal to know when the pour is finished so the press can finish it’s cycle.

“Simple” Interface Configuration

If the metering unit is configured with the “Simple” inter-face instead of “Press” interface, then only the “Metering Unit Pour Complete” interlock contact is available. This only sends a signal to notify the press that the pour is complete.

Signals From the Metering Unit

Metering Unit Ready Contact

This contact is closed as long as all of the metering unit’s pour permissives are met, see Pouring Require-ments section on page 41. Pour requests are ignored unless this contact is closed. Once a pour request has been received and a pour has been started, the meter-ing unit will not accept a second pour request until the needed “Press Cycle Complete” signal is received. The “Pour Request” signal from the press must also have been turned “Off” since the last “Pour Request” was sent to the metering unit. These requirements provide the “anti-repeat” feature needed to prevent multiple pours into the same press or mold.

Metering Unit Pour Complete Contact

The closing of this contact means that a pour was started and has stopped (the pour may have been stopped prematurely or may have poured to comple-tion). This contact closes for one second when the pour stops. If the L-Head is installed, which comes with a Cleanout Piston, then the closing of the “Pour Complete” contact is delayed until the cleanout motion is finished. This signal should be used to start the press cure timer and to reset the pour start signal which must remain true or “On” for the pour to continue to completion.

Signals To the Metering Unit

Press Pour Request Contact

The transition of this contact from open to closed initi-ates the pour request. This contact then acts as a pour permissive (it must be held on during the pour sequence). If the contact opens during the pour sequence, the pour will be canceled (or stopped short if already started). Normally the press control system holds the pour request signal true or “On” until the “Pour Complete” signal is received from the metering unit. This signal provides the press with the means to request a pour and also to stop a pour.

Refer to manual 312751 for an electrical schematic that shows electrical hook-ups needed to install a “Press Interface.”

Setup

36 3A0146C EN

Press Cycle Complete Contact

Once a pour is requested and the pour has been started, another pour cannot be started until the “Press Cycle Complete” signal is received. “Press Cycle Com-plete” usually means the cure timer has expired and the press is opened. The duration of this signal’s contact closure should be at least one second. Once a pour has been started, the metering unit will not start another pour until both of the following events have occurred:

• The “Pour Request” signal from the press must have been turned “Off” since the last “Pour Request” was sent to the metering unit

• The “Press Cycle Complete” signal must have been received by the metering unit

Operation Sequence

Preparation for pouring

To start the sequence, the operator must place the metering unit in the correct state. Automatic mode should be entered, alarms cleared and reset, and the appropriate pumps started. If all metering unit permis-sives are met, then the “Metering Unit Ready” contact should be “On” (closed). The metering unit must have received a “Pour Complete” signal and the press’s “Pour Start” signal must have been turned “Off” since the last pour. If the above requirements are met, then the meter-ing unit will respond to a pour request.

Pouring

When the “Pour Request” contact closes, the metering unit control system begins it’s pouring procedure. If a single metering unit is equipped with two MixHeads and is servicing two presses, then the “Pour Request” must remain closed until the metering unit finishes servicing the other press. Additionally, the “Pour Request” contact must remain closed while the metering unit is pouring the requesting press. If the “Pour Request” signal opens before the pour is started, the pour will be canceled. If the “Pour Request” signal opens while the pour is in progress, the pour will be stopped short.

After Pouring

After the pour stops (whether timed to completion or stopped short), the metering unit will signal the end of the pour by closing the “Pour Complete” contact for one (1) second. The press can then begin it’s cure timer and proceed through it’s automatic cycle. The metering unit will not allow another pour into that same press until after the press’s “Cycle Complete” (press open) signal has been received and the “Pour Request” signal from the press has been turned “Off”.

Manual Mode Pouring with Press InterfaceThe press interface is not intended “Manual Mode” pour-ing. If the machine is in “Manual Mode” and a pour is started by pressing the pour start push-button on the pendant, then a timed pour will be performed for the pre-set duration for the channel number selected on the pour pendant thumb-switches. The pour start button does not need to be held down to complete the pour and the timed pour can be stopped early by pressing the pour stop button on the pendant.

Automatic Mode Pouring with Press InterfaceThe press interface signals are used for “Automatic Mode” pouring. When in “Automatic Mode”, the pour time will be determined by the time value entered in the “Press Interface Automatic Mode Pour Time” button on the Pour Time Editor screen, see FIG. 9 on page 20.

Pouring using “Press” Interface SignalsThe machine and Press will interact as defined in the Optional “Press” or “Simple” Interface section on page 35.

New Machine Maintenance

3A0146C EN 37

New Machine Maintenance

Metering Pump 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. See Check/Replace Metering Pump Inlet Filter on page 55 for instructions.

Start-Up

38 3A0146C EN

Start-Up

See Main Panel section on page 12 for more informa-tion.

1. Purge air from metering pump. See Maintenance section on page 54 for procedure.

2. If the machine is locked-out, remove the lock and push the black bar back into the power handle.

3. Turn on main power by turning the power handle so it points to “ON.”

4. When the HMI reaches the main menu screen, gen-eral settings can be changed.

5. Turn on the control power by hitting the green push-button on the main panel. The button will be lit when control power is on.

6. Navigate to the Machine Control screen and turn on the MixHead Hydraulic Motor.

7. Turn on the pump motors.

MixHead Hydraulic Unit Motor

Before Turning on the MixHead Hydraulic Unit Motor

• Check hydraulic fluid level using the sight gauge

• Open all valves blocking normal oil flow

• Close the manual unloading valve by turning all the way clockwise

Requirements for Operation

• Control power on

• Night Mode off

• MixHead Hydraulic Unit High-Pressure alarm inac-tive

• MixHead Hydraulic Unit Motor Overload alarm inac-tive

Starting the MixHead Hydraulic Unit Motor

If any electrical work has been done on this machine, the rotational direction of the Hydraulic motor should be checked. This is indicated by the rotational arrow and must be maintained at all times. If the rotation is incor-rect, change any two of the power leads on the main ter-minal strip.

If the hydraulic fluid has recently been replaced, check the sight gauge to ensure the reservoir has been prop-erly refilled. The hydraulic system must not be operated dry.

To start the MixHead Hydraulic Motor, ensure main power and control power are on and navigate to the Machine Control screen on the HMI and select the Mix-Head Hydraulic Motor button, see FIG. 6 on page 17.

The machine operates at high pressure and high volt-age. Be careful during operation and always wear the appropriate protective gear.

If an Emergency Stop has been pressed, it will need to be rotated and pulled out to be reset before control power can be turned on.

Before turning on the pump motors, make sure there is sufficient chemical in both day tanks and that the day tank air pressure is at the suggested setting. See Settings section on page 44.

If any of the following requirements are not met, the MixHead Hydraulic Unit will stop and/or not be per-mitted to start.

The overload relays on the motor starter must be manually reset before the motor can be restarted after an overload.

NOTICEDo not attempt to change rotation by entering the motor junction box. This will void the warranty.

Start-Up

3A0146C EN 39

Pumpline

Before starting the Metering Pump Motors

• Tank levels should be checked

• All ball valves blocking normal chemical flow should be opened

• Blanket pressure on each tank should be set

• Air in metering pumps must be purged. See Purge Air from Metering Pump on page 54.

• MixHead Hydraulic Motor on

• Manual or Automatic Mode selected (see Pouring Operation, page 40)

Requirements for Operation

• Control Power on

• Night Mode off

• MixHead Hydraulic Motor on

• MixHead Hydraulic Low Pressure alarm inactive

• Iso and Poly Metering Pump Overload alarm inac-tive

• Iso and Poly Metering Pump Inlet Low-Pressure alarm inactive

• Iso and Poly High-Pressure alarms inactive

• Iso and Poly Tank Low-Level alarms inactive.

See Alarms List, page 60, for more information.

Starting Metering Pump Motors

Navigate to the Machine Control screen, and turn on the MixHead Hydraulic Motor, then turn on the desired material pump motors.

The MixHead Hydraulic Motor must be running before starting the Iso and Poly metering pump motors.

The metering pump motors cannot be started in Calibrate Mode but will remain running if Calibrate Mode is selected after the metering pump motors are started.

If any of the below requirements are not met, the iso and poly metering pump motors will stop and/or not be permitted to start.

Pouring Operation

40 3A0146C EN

Pouring Operation

Low and High Pressure CirculationWhen the metering pump motors are first turned on, the machine will enter low pressure circulation. After that the machine will stay in or return to low pressure circula-tion if the following conditions are met.

• A pour has not occurred since the metering pump motors were started

• If the preset High Pressure Hold Time has elapsed since the last pour occurred and calibrate mode has not been selected.

When any of the following conditions are met, the machine will be in high pressure circulation.

• Calibrate mode is selected

• The pour start button 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

Pour Pendant

When in Manual Mode, press and hold the Start button until the desired amount of product has been dispensed, then release the Start button. When in Automatic Mode, select the desired channel using the pour pendant, then press and release the Start button to make a shot for the preset amount of time.

If an Automatic mode shot needs to stop before the pre-set time has elapsed, push the Stop button on the pen-dant. To stop the pour but keep motors running, hit one of the Emergency Stops. If you wish to perform long shots without specific durations, program one of the channels to have a very long duration, then hit the stop whenever the needed amount has been poured. This will minimize wear on the Start button.

On L-Head models, pushing the Cleaning Piston button on the pour pendant will activate the cleaning piston. Each push of the cleaning piston button will move the piston from the open to the closed position or from the closed to the open position. The cleaning piston is used to clear the pouring nozzle of accumulated material.

Pendant Channel

The channel number is the number selected on the pen-dant and can be anything from 00 to 99. The channel number refers to the preset timer number discussed in the Pour Time Editor Screen section, page 20.

• All channels from 01 to 99 can be used for pouring, provided the preset timer on the Pour Time Editor screen is not set to zero seconds.

If channel 00 is selected on the pour pendant, nothing will occur when the start button is pushed.

Manual ModeIn manual mode, a pour occurs when the pour initiation button is pressed and held and stops when the button is released. If a pour pendant is attached to the machine, then the pour initiation button is the start push-button on the pendant.

FIG. 17: Pour Pendant

Emergency StopChannel

Stop

Start

Cleaning Piston

Pouring Operation

3A0146C EN 41

Automatic ModeIn automatic mode with a pour pendant attached, a pour is initiated by pushing and releasing the pendant start button. The duration of the pour is determined by the preset time for the selected channel number. If the pour needs to be stopped before the preset time has elapsed, hit one of the Emergency Stop buttons, or the stop but-ton on the Pour Pendant. See Pour Time Editor Screen, page 20, for information on preset timers.

Pouring RequirementsThe following requirements must be met in order for a pour to occur.

• Main Power on

• Control Power on

• Night Mode off

• Manual or Automatic Mode selected

• MixHead Hydraulic Pump on

• MixHead on

• MixHead Hydraulic Low-Pressure Alarm inactive

• Iso and Poly Metering Pump Motors on

• Pendant Channel selected with desired preset pour time

• Iso and Poly Fail To Build Pour Pressure Alarm inac-tive

• Iso and Poly Low Pour Pressure Alarm inactive

• Iso and Poly Tank Low Level Alarms inactive

If all of the above requirements are satisfied, then the “MixHead Pour Ready” indicator on the Status Screen will be green, see page 15.

Beginning the PourAfter both streams reach the required pour pressure and the preset pressure build time elapses, the MixHead is commanded to open and the pour occurs.

If Pendant Channel “00” or any channel with a pour time of “0.00” seconds is selected, a pour will not occur.

Night Mode Operation

42 3A0146C EN

Night Mode Operation

Night Mode is used to maintain chemical temperature and to circulate the chemicals in low-pressure circula-tion during periods when the machine is not is use, such as at night or over a weekend. At specified intervals Night Mode cycles the pumps on and off. If installed, the temperature control may also be cycled on and off. Dur-ing Night Mode, the agitators may be turned on or off when desired but will not cycle on or off with the “on-time” and “off-time” periods. To run agitators, simply turn them on as usual either before or after beginning Night Mode.

When Night Mode is turned on, the period of time known as “off-time” begins. The machine stays at rest for the specified amount of time, which will be displayed on the screen and counted down until the time has elapsed.

When the specified duration for off-time has elapsed, the period known as “on-time” begins. During on-time, the Iso and Poly Pumps and MixHead Hydraulic Unit are on. If installed, the Temperature Control will also be acti-vated. Just as in off-time, the amount of time remaining will be displayed on the screen. When on-time has elapsed, the pumps are turned 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 15.

Starting Night Mode

A small “Ready” indicator is located just under the words “Night Mode” on the Machine Control Screen. The “Ready” indicator on the Machine Control Screen will show green when all requirements for turning Night Mode on have been satisfied. If the “Ready” indicator is not green, then Night Mode cannot be turned on.

The following requirements must be met to start night mode.

• Main and Control power on

• MixHead Hydraulic Motor turned off

• Iso Pump turned off

• Poly Pump turned off

Requirements for Continuing Night ModeIf any of the following requirements are not met, night mode will stop.

• Control power on

• Manual mode selected

• MixHead Hydraulic Unit Motor Overload alarm inac-tive

• MixHead Hydraulic Unit High Temperature alarm inactive

• MixHead Hydraulic Unit High-Pressure alarm inac-tive

• MixHead Hydraulic Unit Low-Pressure alarm inac-tive

• MixHead #1 Pour Piston Failure alarm inactive

• Iso and Poly Pump Motor Overload alarms inactive

• Iso and Poly Metering System Inlet Low-Pressure alarms inactive

• Iso and Poly High-Pressure alarms inactive

• Iso and Poly Tank Low-Level alarms inactive

• If an L-Head is installed the following requirements must also be met

• MixHead Pour Piston Failure alarm inactive

• MixHead Cleanout Piston Failure alarm inactive

NOTICENight mode enables machine operation when person-nel are not present. If the machine encounters a prob-lem during Night mode, such as a hose rupture or electrical problem, property damage may result.

See FIG. 6 on page 17.

Once Night Mode is on, the previous items cannot be started until Night Mode is turned off.

Shutdown

3A0146C EN 43

Shutdown

Overnight/WeekendIf using Night Mode to circulate chemicals and maintain chemical temperature, see the Night Mode Operation section on page 42. Otherwise, follow these steps.

1. Turn off all motors using the Machine Control screen.

2. Turn off main power and lockout. See Lockout on page 12.

Long-Term Shutdown

1. Turn off all motors by using the Machine Control screen.


3. Empty both day tanks completely. See Empty the Day Tank on page 57.

4. Empty metering pump inlet filter by unscrewing drain plug.

5. Empty metering pumps by unscrewing drain plug on bottom of pump.

6. Using a bucket to catch 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 hose.

8. Fill each tank 1/2 full with mesamoll.

9. Remove lock on main power.

10. Turn on main power and control power.

11. Run the system in calibrate mode for 45 minutes. See Calibrate Mode on page 44.

12. Repeat steps 3 through 11 until the machine is thor-oughly flushed.

13. Turn off all motors using the Machine Control screen.


NOTICEDo not disconnect or relieve tank pressure. Dry air pressure must be maintained at all times. If moist air is allowed in the tank, isocyanate crystallization may result.

The system must be completely flushed before long-term shutdown to prevent chemical crystalliza-tion within the MixHead, metering pumps, tanks, and chemical lines.

Settings

44 3A0146C EN

Settings

Calibrate ModeSome settings will require running the machine in Cali-brate mode to adjust. Calibrate mode puts the machine into high pressure circulation and is used most com-monly to adjust the chemical line pressures or flowrate.

With the MixHead motor and metering pump motors on, select Calibrate mode from the Machine Control or Sta-tus screen.

To remove the machine from calibrate mode, select manual or automatic mode, or hit one of the Emergency Stops.

Temperature Control The high and low temperature setpoints on the HMI are used to alert the operator of an out-of-limit condition. When these alarms are triggered, the pumps will still function and pouring will not be stopped.

There is a mechanical heater switch that will shut off power to the heater if the chemical temperature goes above the setting. The pumps will continue to run if the heater is shut off so that the chemical can be cooled by flowing through the Heat Exchanger.

Built into the HMI program there is an absolute high temperature alarm that will shut down the pumps when triggered.

If a MAG drive motor is installed, a MAG drive over-tem-perature alarm is provided to prevent motor overheating. See table at beginning of this section for alarm setting.

Temperature Control On/Off

Temperature Control is turned on/off from the Tank Con-trol screen, see FIG. 8 on page 19. With Temperature Control turned on, the heat exchanger and heater will work to maintain each chemical temperature to the input temperature setpoint. The heat exchanger works to cool the fluid with water from the inlet. Water inlet valves con-trol cooling by cycling open and closed as necessary. The heater works to heat the material by exposing the chemical to heated rods that are turned on and off as necessary.

Temperature Switch Pressures MAG drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170° F (76.7°C)Chemical Absolute High Temperature . . . . . . . . . . . . . . . . . . . . 180°F (82.2°C)Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180°F (82.2°C)MixHead Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160ºF (71.1°C)

Pressure Switch Pressures Max Metering Pump Outlet . . . . . . . . . . . . . . . . .3200 psi (22.0 MPa, 220 bar)Min Metering Pump Outlet (in high pressure mode) . . . . . . . . . . . . . . . . . . . .1500 psi (10.3 MPa, 103 bar)Min Metering Pump Inlet . . . . . . . . . . . . . . . . . . . 10 psi (0.068 MPa, 0.68 bar)Max Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . 2800 psi (19.3 MPa, 193 bar)Min Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . .1500 psi (10.3 MPa, 103 bar)

Settings Day Tank Operating Air Pressure . . . . . . . . . . . . . . 40 psi (0.27 MPa, 2.7 bar)Supplied Air Pressure . . . . . . . . . . . . 80-120 psi (0.55-0.83 MPa, 5.5-8.3 bar)Day Tank Pressure Relief Valve . . . . . . . . . . . . . . . . 75 psi (0.51 MPa, 5.1 bar)Supplied Water Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 psi (2.76 bar)Supplied Water Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65°F (18°C)Automatic Unloading Valve Upper Limit . . . . . . .2400 psi (16.5 MPa, 165 bar)Automatic Unloading Valve Lower Limit . . . . . . .2100 psi (14.4 MPa, 144 bar)Accumulator Pre-Charge . . . . . . . . 1350-1500 psi (9.3-10.3 MPa, 93-103 bar)

NOTICEThe temperature control should always be turned on when the machine is turned on unless there is a spe-cific reason not to. With the temperature control turned off, the chemical temperature will slowly heat up until it eventually triggers one of the over-tempera-ture alarms. If the MAG drive over-temperature alarm caused the shutdown, the machine will not be able to be started until the machine has cooled to signifi-cantly below the over-temperature setting.

Settings

3A0146C EN 45

Temperature Setpoint

The temperature setpoint is the goal temperature for the chemical. The machine will automatically maintain the temperature of the chemical within a reasonable range from the input temperature setpoint based on the cur-rent gain settings, see Temperature Gains, page 45.

High Temperature Setpoint

The high temperature setpoint is the temperature at which the high temperature alarm will be triggered to notify the operator that there is a problem and the machine should be inspected for the cause. This alarm is disabled for the first thirty minutes of operation to allow the chemical temperature to stabilize without unnecessary alarms. The suggested high temperature varies by chemical but should be the highest tempera-ture at which the chemical will react as desired when mixed at the MixHead.

Low Temperature Setpoint

The low temperature setpoint is the temperature at which the low temperature alarm will be triggered to notify the operator that there is a problem and that the machine should be inspected for the cause. The low temperature setpoint should be the lowest temperature at which the chemical will as desired react at the Mix-Head.

Temperature Gains

Gains are shown on the Gains Control screen, see FIG. 16 on page 27. This screen is accessed from the Scal-ing screen, see FIG. 15 on page 26. Gains control two things: temperature fluctuation from the setpoint and heating time at startup. The default setting for all four Gains is “100”. This setting will maintain a reasonable margin for temperature as well as a reasonable time for heating at initial startup.

If the temperatures are not controlled to your desire with the gains set to the default settings of “100”, you may be able to adjust the gains to make the machine work better for your application. Things to consider when adjusting the gains:

• It is recommended that all four gains be set to the same number

• Higher gains will lead 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 require higher gains to keep the materials from overheating

• Higher flow rates may accept lower gains without overheating

To adjust the gains, first turn off the chemical pump motors, then navigate to the Scaling screen and select “Temp Gains”. Ensure that all four gains are shown as “100.” If not, set them to the factory setting of “100”, turn on the chemical pump motors, and let the chemical tem-peratures stabilize into a pattern check whether adjust-ment is needed.

If you wish to change the gain settings, turn off the chemical pump motors, and alter the gain settings to get the desired results as suggested in the previous para-graphs. Be aware of the temperatures while waiting for the machine to stabilize into a pattern. If at any time the chemicals begin getting too hot, hit the Emergency Stop and reset the gains to 100. Repeat the procedure until chemical temperatures are maintained as desired.

NOTICEAdjusting the temperature gains should only be per-formed by a technician knowledgeable in the opera-tion of this machine. Incorrect adjustment of the temperature gains can lead to overheating, erratic temperature control, and/or poor chemical reaction at the MixHead during pours due to poor temperature control.

If the temperature gains have been altered and temperature control is not performing as desired, reset all four gains to “100.”

If Night mode is used then the chemical tempera-ture is maintained, so higher gains are not needed.

NOTICELowering the gains can lead to the materials and pumps overheating.

The procedure below will help to find gains that will maintain temperature within a desired margin, but will also effect warm-up time.

Settings

46 3A0146C EN

To check initial heating time, once the chemicals have cooled to ambient temperature turn on the pumps and heaters. If it takes too long to heat up, either raise the gains or consider using Night Mode to maintain chemi-cal temperature during down-time.

Pouring Settings

Iso, Poly Specific Gravity

Chemical specific gravities are entered from the Setup screen, see FIG. 10 on page 21. This entry is used to calculate mass flow in grams by multiplying by the volu-metric flow measured by the flow meter. It is very impor-tant that the chemicals’ correct specific gravities are entered, to ensure accurate pours.

Preset Pour Timers

Preset Pour Timers are presets that enable quick execu-tion of pours with specific durations. To execute a pour of a specific length, change one of the preset pour tim-ers on the Pour Time Editor Screen, see page 20, then select that channel on the pour pendant. Select Auto-matic mode, and then hit the pour start button to execute a shot of the selected channel’s preset duration. The channel can be changed at any time and the next shot duration will be based on the preset time for the selected channel. If a channel has a time of “0.00” then no pour will occur, but the pressure will build and hold in the same manner as when a pour does occur.

Pressure Build Time

Pressure Build Time is set using the Setup screen, see FIG. 10 on page 21. When a pour is initiated the machine will build pressure to get ready to pour. Pres-sure Build Time gives the machine time to stabilize pres-sure. Once a pour is initiated the build timer begins and when the build time elapses if the machine has reached high pressure the pour will begin.

A new pour that is started before the machine goes out of high-pressure can begin pouring as soon as the pour push-button is pressed. The time the machine stays in high pressure is called “High Pressure Hold Time.”

High Pressure Hold Time

High Pressure Hold Time is set using the Setup screen, see FIG. 10 on page 21. 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 rapid succession, so the machine does not return to low pressure circulation. Allowing the machine to exit high pressure circulation between rapid shots will lead to a longer wait between shots.

Low Level Bypass On/Off

Low Level Bypass is turned on/off from the Machine Control screen, see FIG. 6 on page 17. Having Low Level Bypass on or off determines whether the metering pump motors will continue to run after the fluid level in either or both tanks drops below the low level sensor during an automatic mode shot.

During a pour with Low Level Bypass off, when the tank level drops below the low level sensor and that pour stops, the metering pump motors will stop.

During a pour with Low Level Bypass on, when the tank level drops below the low level sensor and that pour stops, the metering pump motors will continue to circu-late material.

Manual mode pours will always stop when fluid level drops below the low level sensor whether low level bypass is on or off.

Pours will not be allowed to start when the fluid level in either or both tanks is below the low level sensor.

Flow-Rate Display Filter

See FIG. 15 on page 26 for more information.

NOTICEUsing low level bypass allows the pumps to continue running when an automatic shot is performed and the fluid level in one or both tanks goes below the low level sensor. If your application will ever require per-forming an automatic shot that will dispense more than four gallons from one of the tanks, be very cau-tious of fluid level before performing shots to prevent pump cavitation from running the pumps without fluid in the tanks.

Settings

3A0146C EN 47

MixHead Settings

MixHead On/Off

The MixHead must be turned on to dispense chemical. When the MixHead is turned off, “dry cycling” will be enabled but will not occur unless all conditions required for starting a pour are met. Dry cycling is when the machine does everything necessary to do a pour with-out opening the material piston so that material is not dispensed.

To “dry cycle” the machine, execute a pour without turn-ing on the MixHead. The machine will go through the normal cycle for pouring, without dispensing material, and if anything is not running correctly an alarm will be triggered. Dry cycling is useful when an alarm has been triggered and the cause of the alarm needs to be found. In that situation, reset the alarm, attempt to fix the prob-lem, and “dry cycle” the machine to test whether the problem has been corrected, without wasting any mate-rial.

Cleanout Delay (if L-Head installed)

The delay between the end of a pour and the activation of the cleanout piston.

Cleanout Extend Time (if L-Head installed)

The amount of time the cleanout piston remains extended when hitting the “Cleaning Piston” button on the pour pendant.

Chemical Flow Settings

Adjusting Chemical Line Pressures

Having pressure equal between the iso and poly lines is important for proper mixing. The usual guideline for proper mixing is to have the difference in pressures less than a few hundred psi. Whenever the pressures are not equal adjust the chemical line pressures.

Before adjusting the MixHead orifices, ensure the follow-ing requirements have been met.

• Main and Control Power on

• Night Mode must be off

• MixHead Hydraulic Pump on

• Appropriate Metering Pump Motors must be on

• MixHead Hydraulic Low-pressure Alarm must be inactive

When the preceding requirements are met:

1. Select calibrate mode to put the machine into high-pressure circulation.

2. Using a hex key, adjust the orifice by turning the hand grip on either side of the MixHead very slowly while watching the pressure on the gauges above the main panel.

3. When the chemical line pressures are within 200 psi, select automatic or manual mode to exit Calibrate mode.

See Setup Screen on page 21 and Machine Con-trol Screen on page 17 for details about changing the following settings.

The pressure for the two chemical lines should be within 200 psi to avoid chemical crossover at the MixHead. Chemical crossover will lead to chemi-cals mixing and curing within the MixHead and will require more frequent MixHead rebuilding.

L-Head shown

ti11599b

Hand Grip

Hand Grip

Settings

48 3A0146C EN

Adjusting Metering Pump Motor RPM (if VFD is installed)

If Variable Frequency Drive is installed then the meter-ing pump motor rpm can be adjusted individually for both metering pump motors. This is done using the Flow Control Screen on the HMI, see FIG. 13 on page 24.

1. Navigate to the Flow Control screen.

2. Under the “Flow Control” heading, select “Manual” mode.

3. Under “Manual Mode Setpoints,” type in the desired metering pump motor percent for each motor.

Day Tank Settings

Adjusting Day Tank Air Pressure

1. Stop incoming air by closing the day tank incoming air valve.

2. Open day tank manual vent valve.

3. Allow the day tank charge pressure to bleed to 5 psi (0.034 MPa, 0.34 bar).

4. Close the day tank manual vent valve.

5. Open day tank incoming air valve.

6. Adjust pressure regulator fully clockwise.

7. Set day tank pressure by turning pressure regulator. See the table at the beginning of the Settings sec-tion on page 44 for recommended setting.

8. Adjust the pressure regulator counter-clockwise until it just starts to exhaust.

9. From this point, adjust the pressure regulator clock-wise one half-turn.

10. Lock valve knob in place.

Tank fumes will discharge when opening the day tank manual vent valve.

NOTICEDo not allow the pressure to drop below 5 psi as this may introduce moist air to the system. This is espe-cially important during periods of extended shutdown. See Moisture Sensitivity of Isocyanates, page 7.

Settings

3A0146C EN 49

Flow Measurement Controls

Adjusting Flowrate.

With Variable Frequency Drive and with Flow Meters

If a Variable Frequency Drive is installed then the Flow Control screen will be available. This screen can used to automatically adjust metering pump motor rpm so that the flow rate remains constant.

1. Turn on MixHead, MixHead Hydraulic Motor, and Metering Pump Motors.

2. Select calibrate mode.

3. Navigate to the flow control screen.

4. Select “Automatic” from the Flow Control screen to select Automatic mode.

5. Type in the desired grams per second and ratio.

6. If necessary, balance the chemical line pressures by slowly adjusting each orifice on the MixHead with a hex key until the pressure remains constant for at least five seconds.

Without Variable Frequency Drive and with Flow Meters

It is recommended that two people be used to perform this procedure most efficiently. To perform this proce-dure access to the pump turn-dial and the HMI will be needed.

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 dial for each chemical until the desired flowrate is reached.

With VFD and without Flow Meters

This procedure will give a good relation of motor speed to flow rate, but will not be accurate if the pressures vary during the test or during use. Make sure the material pump dial is set to maximum flow by turning all the way clockwise.

1. Using calibrate mode, set the metering pump motor to maximum RPM and adjust chemical line pressure to your desired operating pressure.

2. Catching the dispensed material using a pre-weighed bucket, execute an automatic shot of exactly 10 seconds.

3. Weigh the full bucket and subtract the empty bucket weight to find the dispensed material weight.

4. Divide the dispensed material weight by ten to find the flowrate in grams per second.

5. Repeat with lowest RPM and with the same pres-sure as with the first test.

6. Graph the results showing the relationship of flow-rate versus metering pump dial position.

Without VFD and without Flow Meters

Without a Variable Frequency Drive, the metering pump motors will always spin at the same rpm. To adjust the flowrate, use the pump turn dial. The following steps detail the steps needed to create a chart for flowrate at each pump turn-dial location.

1. Turn on the MixHead, Hydraulic Motor, and Metering Pump motors.

2. Turn the metering pump dial all the way counter-clockwise to read zero on the dial.

3. Put the machine in calibrate mode and adjust the chemical line pressures to your desired working pressure. This will need to remain constant for every repetition of this test.

4. Set the machine to perform a ten second shot.

a. Navigate to the pour time editor screen and change one of the timers to ten seconds.

b. Select the channel on the pour pendant associ-ated with the preset ten second shot.

5. Weigh an empty container capable of holding the dispensed material.

Ensure the chemical specific gravities are accurate and calibrate the flowrate accuracy before adjusting the flowrate. See Calibrating Machine-Calculated Mass Flow on page 51.

The speed of each metering pump motor speed will continually adjust to achieve the input flowrate and ratio.

Settings

50 3A0146C EN

6. Perform the shot and weigh the sample. Subtract the weight of the empty container.

7. Record the weight of the shot on a chart.

8. Repeat the procedure for every two to three turns of the metering pump dial until it is turned all the way clockwise.

9. Divide each shot weight by ten to find the flowrate in weight per second.

10. Graph the results showing the relationship of flow-rate versus metering pump dial position.

When the pump dial is turned, the pressure will change and the orifices on the MixHead will need to be adjusted. Letting the pressures vary between shots will minimize the usefulness of creating the flowrate chart.

Settings

3A0146C EN 51

Calibrating Machine-Calculated Mass Flow

The following procedure describes how to adjust the mass flowrate calculated by the machine. To calculate the mass flowrate, the machine uses the chemical spe-cific gravities entered on the Setup screen, the volumet-ric flow measured by the flow meters, and the K-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 abrasives, which are strongly discouraged for use in the machine.

While this procedure adjust the K-Factor, its purpose is to fine-tune the calculated specific gravity of each chem-ical used. Because of this, it is very important to have accurate chemical specific gravities entered on the Setup.

Parts/Tools Required

• 4 mm and 6 mm Hex Key

• Blocked orifice and nozzle assembly, see L-Head manual 312753A or S-Head manual 312752A for part number

• 5 Gallon Bucket to catch spilled material

• 5 Gallon Bucket to weigh dispensed material

• Weighing scale to measure weight of empty and filled bucket

Relieve Pressure

1. Turn off all motors.

2. Turn the main panel power handle to the off position and lockout.

3. Relieve air pressure, hydraulic fluid pressure, and chemical line pressure. See Pressure Relief Pro-cedure on page 53.

Change Orifice

4. Place a spill bucket under the MixHead.

5. At the MixHead, remove the four hex bolts on the chemical stream not being calibrated.

6. Remove the nozzle and orifice assembly and replace with the nozzle and blocked orifice assem-bly.

7. With the blocked nozzle inserted, replace the four hex bolts and tighten.

8. Remove the spill bucket.

Avoid breathing of vapors and contact with Isocya-nate as some people have severe allergic reactions. See Isocyanate Hazard on page 7.

This section applies only to systems with Flow Meters.

Scaling screen access is required for calibration. The Scaling screen can only be accessed when logged in using a specific username and password which is controlled by the owner of the machine. Before performing this procedure, ensure you can access the Scaling screen. To log in, navigate to the Main Menu screen, select “Login” and type in the appropriate username and password.

The specific gravities entered on the HMI at the fac-tory are for mesamoll which is used to test the machine before shipment. The specific gravities will need to be updated every time new chemicals are used.

Before performing this procedure, verify the specific gravities entered on the HMI are accurate for the chemicals currently in each tank. See Iso, Poly Specific Gravity on page 46.

The calibration procedure consists of dispensing one chemical at a time to measure the exact weight dispensed, without worrying about chemical reac-tions. To do this, the orifice for the chemical line not being calibrated needs to be replaced with a blocked orifice.

The blocked orifice prevents spilling of the chemical not being calibrated during the calibration shot. It also prevents contaminating unused chemical line when the material piston is withdrawn during the shot.

Settings

52 3A0146C EN

Execute Calibration Shot

9. Unlock the main power handle and turn on.

10. Turn on control power.

11. Turn on MixHead.

12. Turn on MixHead Hydraulic Motor.

13. Turn on the metering pump motor for the chemical to be calibrated, which will have the one open orifice at the MixHead.

14. Turn on Automatic Mode.

15. Log in to gain access to the Scaling screen.

16. Measure the weight of the clean, dry, and empty cal-ibration bucket in grams. Record this measurement or tare the scale.

17. Place the calibration bucket in an appropriate loca-tion to catch the dispensed material.

18. Navigate to the Scaling screen and under “Single Stream Calibration Shots” press the button labeled as the chemical to be calibrated.

19. Press the pour start button. A shot lasting the preset time for the channel selected on the pour pendant will begin.

Adjust K-Factor as Necessary

20. Remove the calibration bucket, weigh, and calculate the dispensed material weight.

21. On the scaling screen the weight of the shot calcu-lated by the machine will be shown. If this matches the weight of material dispensed then the machine is accurately calculating the flowrate for that chemi-cal. If so, move to step 25.

22. If the displayed weight does not match the weight of the dispensed material, touch the “Test Shot Act Weight (gm)” and enter the exact weight in grams of the dispensed material.

23. Record the current K-Factor and then hit the “Calcu-late New K-Factor.” This will change the K-Factor so

the machine will accurately calculate dispensed weight.

Repeat to Test New K-Factor

24. Repeat the procedure as desired to test flow mea-surement accuracy with new K-Factor.

Change Orifice

25. Turn off all motors.

26. Turn the main panel power handle to the off position and lockout.

27. Relieve air pressure, hydraulic fluid pressure, and chemical line pressure. See Pressure Relief Pro-cedure on page 53.

28. Remove nozzle and blocked orifice assembly and replace with original nozzle and orifice assembly for normal operation.

Repeat for other Chemical Line

29. Repeat the calibration procedure as necessary with the other chemical line.

Because this procedure is for fine-tuning, having even a small amount of material splash out of the bucket will affect the calibration effectiveness. The bucket should be held at an angle to prevent mate-rial splashing.

Pressure Relief Procedure

3A0146C EN 53

Pressure Relief Procedure

Before performing system maintenance, system pres-sure must be relieved.

Air Pressure Relief

1. Turn off and lockout main power. See Lockout sec-tion on page 12 for procedure.

2. Close day tank incoming air supply valve (MK). See Tanks section on page 30.

3. Disconnect air supply hose from water separator. See Tanks section on page 30.

4. Bleed air pressure from system by opening the pressure relief valve on top of each day tank. See Tanks section on page 30.

5. Ensure there is no air pressure in the tanks by look-ing at the pressure gauges mounted on the tanks.

Hydraulic Pressure Relief1. Turn off and lockout main power. See Lockout sec-

tion on page 12 for procedure.

2. Open manual unloading valve by turning fully coun-terclockwise. Watch hydraulic pressure gauge to ensure pressure is relieved. See MixHead Hydrau-lic Unit section on page 29.

3. Ensure there is no hydraulic fluid pressure by look-ing at the hydraulic pressure gauge.

Chemical Line Pressure Relief1. Turn off and lockout main power. See Lockout sec-

tion on page 12 for procedure.

2. Relieve tank air pressure. See Air Pressure Relief procedure.

3. Ensure there is no pressure in the chemical lines by looking at the pressure gauges mounted above the main panel.

NOTICERelieving air pressure in the machine means that the supplied dry air will be replaced by moist, room air. Do not leave the machine exposed to moist air for more than 30 minutes to prevent isocyanate crystallization.

If the machine must be left without air pressure for more than 30 minutes, the day tanks must be emptied and thoroughly flushed. See Long-Term Shutdown on page 43.

When the metering pump motors are turned off, all chemical line pressure is relieved except for the pressure coming from the tank blanket air pressure.

Maintenance

54 3A0146C EN

Maintenance

Schedule

Purge Air from Metering Pump1. Place a small bucket under valve opening.

2. Open the bleed valve on the metering pump case slowly.

3. Keep valve open until a steady stream of fluid, with no air or bubbles, is released from the bleed valve.

4. Close the bleed valve.

Drain the Water SeparatorThis procedure is performed with the system pressur-ized.

1. Pressurize the air system.

2. If desired, place container underneath water sepa-rator to catch expelled water.

3. Depress purge valve.

4. Release valve when all traces of water are gone.

Check DesiccantWhen desiccant is new, it will be blue. Over time, the desiccant will fade to pink. Replace the desiccant before it is completely pink. The speed at which the desiccant is used will vary depending on the amount of moisture in the incoming air supply.

Replace Desiccant

1. Disconnect the air supply.

2. Remove the desiccant bowl and service with fresh desiccant.

3. Replace the bowl and bowl guard.

4. Reconnect the air supply.

Procedure Frequency

Purge Air from Metering Pump Daily before use

Drain the Water Separator Daily

Check Desiccant Daily

Check Metering Pump Inlet Filter Weekly

Check Accumulator Pre-Charge Weekly

Check Tightness of all Clamps and Fittings Monthly

Check Hoses for Wear Monthly

Check Automatic Unloading Valve Pressure Limits Monthly

Check Hydraulic Fluid and Filter Monthly

Replace PLC battery As Needed

Empty the Day Tanks As Needed

Relieve air pressure. See Pressure Relief Proce-dure on page 53.

Do not pressurize the air system without the bowl guard in place. The bowl could burst under pressure.

Maintenance

3A0146C EN 55

Check/Replace Metering Pump Inlet Filter

See manual 312751 for filter and o-ring part numbers.

To Remove/Inspect the Filter

1. Turn the main power handle to the off position and lockout.

2. Relieve day tank pressure. Make sure the tank air pressure gauges read zero pressure.

3. Close day tank ball valve to prevent flow from the tank to the pump inlet filter.

4. Remove filter cap and visually inspect the filter ele-ment for particles.

To Replace the Filter

5. Replace the element and o-ring as required.

6. Liberally coat the o-ring and surrounding surfaces with a moisture free grease.

7. Ensure that the element is properly seated in the bowl and replace the cap.

8. Hand tighten the clamp.

9. Open the tank ball valve and check for leaks.

10. Apply day tank pressure.

11. Remove lock on main power.

12. Turn on main power and then control power.

13. Start motors and run for at least 60 minutes to circu-late the material that has been exposed to moist air.

Check the Accumulator Pre-Charge1. Turn on main power and control power.

2. Making sure the manual unloading valve is closed by turning fully clockwise.

3. Turn on the Hydraulic Motor to build pressure.

4. After a few seconds, turn off the MixHead Hydraulic Motor from the HMI.

5. Open the manual unloading valve by turning coun-terclockwise very slowly until the pressure begins to drop at a rate of about 100 psi per second.

6. Turn the manual unloading valve fully clockwise to close the valve.

Always relieve day tank pressure and close the tank bleed valve to prevent fluid flow to the metering pump inlet filter. Failure to do this can lead to getting sprayed with chemical when opening the filter.

NOTICEDo not open the metering pump inlet filter cap imme-diately before leaving the machine at rest for a long period of time. This will introduce moist air to the chemical and may cause the chemical to react and not mix properly when dispensed.

This procedure requires exposing the chemicals to moist air. Have all necessary tools and parts nearby to minimize the amount of time the chemicals are exposed to the moist air prevent isocyanate crystalli-zation.

One indication that the metering pump inlet filter requires service is the low inlet pressure alarms when there is adequate day tank pressure and fluid volume in the tanks. At first the pressure will drop slowly, but when it

reaches the accumulator charge pressure, it will begin to drop quickly to zero. The pressure at which it starts to drop quickly is the accumulator charge. For instance, if it is dropping slowly and then begins to drop quickly at 1300 psi, then the accumulator pre-charge is 1300 psi.

Maintenance

56 3A0146C EN

Pre-Charge the Accumulator

Graco Charging Harness 6316-18 can be purchased to aid in quick charging of the accumulator.

1. Turn off main power and lockout.

2. Open the manual unloading valve and bleed the hydraulic pressure to zero.

3. Connect the charging harness to the accumulator.

4. Connect the other end of the harness to the nitrogen bottle.

5. Slowly open the nitrogen bottle valve while observ-ing the pressure gauge.

6. When the correct pressure is reached, close the nitrogen valve.

7. Open the bleed valve on the charging harness to relieve residual pressure in the charging harness.

8. Remove the charging harness and replace the bot-tle guard.

Check Tightness of all Clamps and Fittings1. Turn off main power and lock out.

2. Wait until all parts are cool to the touch.

3. Walk around the machine and inspect for loose clamps and fittings.

4. Tighten clamps and fittings as necessary.

Check Hoses for WearLook 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 rupturing. Replace all hoses with noticeable wear.

Check, Adjust Automatic Unloading Valve Pressure LimitsIf the Automatic Unloading Valve is replaced or if the hydraulic pressure limits vary from the factory setting, then the hydraulic pressure limits may need to be reset.

1. Determine that the accumulator is pre-charged to the specification in the table at the beginning of the Settings section on page 44, and that the manual unloading valve is closed by turning all the way clockwise.

2. Turn on the hydraulic motor and allow the pressure to stabilize.

3. Open the hydraulic pressure manual unloading valve one quarter-turn counter-clockwise so the pressure cycles between the low and high-pressure setting.

4. On the automatic unloading valve, adjust the over-pressure limit clockwise to raise the pressure.

5. Adjust the under-pressure limit clockwise to raise the pressure.

6. Make small adjustments to the under pressure limit and repeat the bleed process to check the new pressure setting.

During this procedure the nitrogen bottle, the accu-mulator, and the charging harness will all be under significant pressure.

NOTICEUse dry nitrogen gas only to prevent isocyanate crys-tallization. See the table at the beginning of the Set-tings section on page 44 for recommended Accumulator charge.

Under Pressure Limit Adjustment

Over Pressure Limit Adjustment

ti11600b

Maintenance

3A0146C EN 57

Check Hydraulic Fluid and Filter To check the cleanliness and level of the hydraulic fluid, look at the sight gauge on the side of the hydraulic fluid tank, see page 30. If the level is low, add fluid to raise the level. If the fluid becomes cloudy, replace. If hydrau-lic fluid replacement is necessary, replace the filter at the same time.

To check the condition of the hydraulic fluid return line filter inspect the hydraulic fluid filter gauge, page 30. If the needle is in the green, the filter is in good condition. If the needle begins to move into the yellow or is already in the red, replace the filter and the hydraulic fluid.

Replace Hydraulic Fluid and Filter

1. Turn off the main power and lockout.

2. Open the manual unloading valve and bleed the hydraulic pressure to zero.

3. Remove the hydraulic drain plug and drain the res-ervoir into a suitable container.

4. Replace the drain plug.

5. Service the reservoir with clean material up to the full point on the sight gauge.

6. Replace the filter element.

7. Close the manual unloading valve.

8. Check the accumulator pre-charge and service as required.

Replace the PLC battery

If a “PLC Battery Low” alarm is triggered, the battery will need to be replaced.

1. Turn off main power.

2. If necessary, unlock the main panel door.

3. Open the main panel door.

4. Locate the PLC battery, which should be in the HMI on the back of the main panel door.

5. Replace battery.

6. Close main panel door and lock the main panel if necessary.

7. The system clock and date may need to be reset.

Empty the Day Tank

1. Turn the main power handle to the off position and lockout.

2. Close tank air supply valve.

3. Depressurize day tank to approximately 5 psi.

4. Place container to catch tank fluid.

Use only recommended hydraulic fluids.

On RC-20, RC-40, and RC-100 models, be pre-pared to collect 10 gallons of fluid when emptying tank.On RC-200 models, be prepared to collect 20 gal-lons of fluid when emptying tank.

This procedure requires entering the main panel where the main power is routed. To avoid serious injury or death, disconnect main power source at the wall using breaker or by unplugging the machine.

See the day tank capacity in the table at the begin-ning of the Settings section on page 44. To avoid a potential mess, always prepare to collect up to the full capacity.

Maintenance

58 3A0146C EN

5. Open the tank outlet valve and the tank drain valve and empty tank into the container.

6. Be careful as the last of the tank fluid is released, there will be a semi-uncontrolled spitting 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 charge to zero pressure.

NOTICEIf the machine will be left with zero pressure for more than 30 minutes, the day tanks must be emptied and thoroughly flushed to avoid chemical crystallization and machine damage. See Long-Term Shutdown on page 43.

Troubleshooting

3A0146C EN 59

TroubleshootingSee the table at the beginning of the Settings section on page 44 for temperature and pressure alarm settings.

Alarm Status Screen

Key:RA Alarm SilenceRB Alarm Reset

RC Reset Alarm Data

Alarm 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 message will immediately appear in the alarm display section. Pressing the “Alarm Silence” button will silence the alarm beeper and pressing “Alarm Reset” will reset the alarm if the fault is absent. Alarms must be silenced, cleared, and reset prior to restarting any motors stopped by the alarm.

FIG. 18

RA

RB

RC

Troubleshooting

60 3A0146C EN

Alarm History Screen

This screen stores all alarms that have been triggered.

See the table at the beginning of the Settings section on page 44 for pressure and temperature switch settings.

Alarms List

Pouring Alarms

If a pouring alarm has been triggered, and the cause is unknown, “dry cycling” the machine may be helpful in finding the cause. See the MixHead On/Off section on page 47 for more information.

Any alarm that will stop the MixHead Hydraulic Unit operation will stop a pour.

Iso/Poly Failed To Build Pour Pressure Alarm

• This alarm occurs during pressure build. A timer in the PLC controller will stop the pour sequence if the metering pump fails to develop minimum pouring pressure within a set time. Typically 15 seconds lon-ger than the pressure build time is allowed before this alarm will occur.

Iso/Poly Low Pour Pressure Alarm

• If the chemical pressure during a pour drops below the setting for the Low Pour Pressure Switch will be tripped and will stop the pour. Improper orifice adjustment is a possible cause.

FIG. 19

Sort button. Push to sort by name or time of alarm.1

1

Troubleshooting

3A0146C EN 61

Iso/Poly High-Pressure Alarm

• The High-Pressure alarm can occur any time the pressure at the pump discharge rises above the set-ting on the high-pressure switch at the pump dis-charge. This alarm stops both the Iso and Poly pumps and stops any pour in progress. This may be caused by improper orifice adjustment.

Ratio Out Of Tolerance Warning/Shutdown

• When the dispensing ratio is outside of the toler-ance specified on the Flow Control Screen this alarm will be displayed.

Flow Rate Out Of Tolerance Warning/Shutdown

• When the total flow rate is outside of the tolerance specified 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 the motor overload alarm has occurred, the overload button on the starter must be reset before the motor can be started.

Iso, Poly Metering Pump Inlet Low-Pressure Alarm

• This alarm is generated any time the inlet pressure at the metering pump drops below the setting of the inlet low-pressure switch. This alarm stops the affected metering pump motor.

Possible causes for this alarm:

• Metering pump inlet filter may be clogged and need to be serviced

• Day tank pressure is too low

• Pump inlet valve is closed and need to be opened to allow fluid flow from tank

Iso, Poly Metering Pump High-Pressure Alarm

• This alarm is generated any time the pressure at the metering pump rises above the set point on the high-pressure switch, located at the metering pump discharge. Both the Iso and the Poly pump motors stop when one of them triggers the high pressure switch.

MixHead Hydraulic Unit Alarms

MixHead Hydraulic Motor Overload Alarm

• This alarm causes an immediate stop of the hydrau-lic pump motor. If the motor overload alarm has occurred, the alarm and the overload button on the starter must be reset before the motor can be started.

MixHead Hydraulic High-Pressure Alarm

• This alarm stops the MixHead hydraulic pump. This alarm occurs if hydraulic pressure rises above the setpoint on the MixHead hydraulic high-pressure switch.

MixHead Hydraulic Low-Pressure Alarm

• This alarm stops both the Iso and Poly pumps and stops any pouring operation that is in progress. This alarm occurs if hydraulic pressure drops below the set point on the MixHead hydraulic low-pressure switch. This alarm protects the MixHead from cross-over that could occur if hydraulic pressure dropped too low to shut the MixHead.

MixHead Hydraulic High Temp Warning Alarm

• This alarm warns of excessive hydraulic oil temper-ature.

Tanks Alarms

Iso/Poly Tank Low Level Alarm

• This alarm will occur when the tank level reaches 10%. This alarm affects the running of the pump fed by the tank and affects pouring depending on whether the Low Level Bypass is turned on or off.

Iso/Poly Tank Auto-Fill Failed to Fill

• This alarm is triggered when the Auto-Fill fails to fill within the time specified on the Tank Control page. This alarm protects from overfilling the tanks in the event one of the top fluid level sensors fail.

Iso/Poly Tank Agitator Motor Overload

• This alarm is triggered when the agitator motor overloads.

Any alarm that stops the MixHead Hydraulic Pump will also stop the Iso and Poly pumps.

Troubleshooting

62 3A0146C EN

MixHead Alarms

(MixHead #_) Material Plunger Failure

• This alarm is triggered when a MixHead material piston does not open or close.

(MixHead #_) Cleanout Plunger Failure

• This alarm is triggered when a MixHead cleaning piston does not open or close. This alarm is often triggered when a high or low pressure switch stops a pour.

Temperature Alarms

Poly/Iso Heater High Temperature

• This alarm is triggered when the temperature reaches the heater high temperature switch setting. In this event, the heater will need to cool to the heater switch “on-temperature” setting.

Iso/Poly Low/High Temperature

• These alarms are triggered when the iso or poly chemical temperature goes outside of the range specified by the high and low temperature setpoints on the Tank Control screen. These alarms will not trigger within the first 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 drive temperature reaches the high temperature setting specified in the table at the beginning of the Set-tings section on page 44. When this alarm is trig-gered, the metering pump motors will shutdown and will not be able to be started until the temperature drops below the setpoint.

Other Alarms

PLC Battery Low

• PLC Battery needs to be replaced. See Mainte-nance section on page 54.

Iso/Poly Absolute High Pressure

• This alarm is triggered when metering pump outlet pressures exceeds the absolute high pressure set-ting.

Troubleshooting

3A0146C EN 63

Troubleshooting Chart

FaultAutomatic Actiontaken by Machine Solution

Hydraulic Motor Overload • Alarm banner • Red fault light ON• Fault horn ON • Hydraulic motor OFF• MixHead locked CLOSED

1. Reset thermal overload ONE TIME ONLY2. Check overload set point 3. Check motor current draw

Hydraulic Motor High Pressure • Alarm banner • Red fault light ON• Fault horn ON• Hydraulic motor OFF• MixHead locked CLOSED

1. Check automatic unloading valve2. Check DIN connector on pressure switch

Hydraulic Motor Low Pressure • Alarm banner• Red fault light ON• Fault horn ON• MixHead locked out

1. Ensure manual unloading valve is CLOSED 2. Check Accumulator charge 3. Check pressure switch set point 4. Check DIN connector on pressure switch

Iso, Poly Heater High Temp • Alarm banner • Yellow alarm light ON• Fault horn ON • Heater OFF

1. Check high temperature set point 2. Check Power cube 3. Allow heater to cool, reset limit switch ONE

TIME ONLY

Iso, Poly Pump High Pressure • Alarm banner• Red fault light ON• Fault horn ON• Iso pump OFF• Poly pump OFF

1. All pressure Iso, Poly valves OPEN 2. Check/clean Iso, Poly jet3. Check Iso, Poly output 4. Check Iso, Poly temperature 5. Check DIN connector 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 jet3. Check Iso, Poly output 4. Check Iso, Poly temperature 5. Check DIN connector on pressure switch

Iso Pump Low Inlet Pressure • Alarm banner• Red fault light ON• Fault horn ON• Iso pump OFF

1. Open all metering pump inlet valves2. Check day tank air pressure3. Check for clogged inlet basket filter 4. Check DIN connector on pressure switch

Tank Low Level • Alarm banner • Red fault light ON • Fault horn ON• MixHead locked CLOSED

1. Check fluid level and add fluid as necessary. Turn Auto-Fill ON if installed.

2. Adjust fluid sensor sensitivity

MixHead Trigger Fault • Alarm banner• Red fault light ON• Fault horn ON• MixHead locked CLOSED

1. Check MixHead switch harness2. Check MixHead switch

Prox Fault • Alarm banner• Red fault light ON• Fault horn ON• MixHead locked CLOSED

1. Check Prox switch harness2. Check Prox switch

Technical Data

◆ Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum flow.

Category Data

Maximum Fluid Working Pressure 3000 psi (20.6 MPa, 206 bar)

Maximum Air Working Pressure 100 psi (0.68, 6.8 bar)

Maximum Fluid Temperature 180°F (82.2°C)

Maximum Output◆ Model RC-20: 17.4 lb/min (7.9 kg/min)Model RC-40: 34.8 lb/min (15.8 kg/min)Model RC-100: 87 lb/min (39.5 kg/min)Model RC-200: 200 lb/min (90.7 kg/min)

Line Voltage Requirement See Connecting Electrical Cord, page 33

Amperage Requirement See Connecting Electrical Cord, page 33

Hydraulic reservoir capacity RC-20, RC-40, RC-100: 10 gal (37.8 liters)RC-200: 20 gal (75.7 liters)

Day tank capacity (each), varies depending on installed tanks

20 gallons (75.7 liters) nominalOR60 gallons (227.1 liters) nominal

Accumulator hydraulic fluid capacity 1 gal (3.7 liters)

Recommended hydraulic fluid Premium Hydraulic Oil, ISO Viscosity Grade 68

Sound power, per ISO 9614-2 76.5 dB(A)

Sound pressure, 1 m from equipment 82.6 dB(A)

Wetted Parts Aluminum, Stainless Steel, Trivalent Chromium Plated Carbon Steel, Nylon 6, PTFE, Perifluorinated elastomers & EPDM O-rings

Technical Data

3A0146C EN 65

Graco Standard Warranty

66 3A0146C EN

Graco Standard WarrantyGraco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in 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 WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. 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 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 BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERSThe Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco InformationFor the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.Toll Free: 1-800-746-1334 or Fax: 330-966-3006

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A0146

Graco Headquarters: MinneapolisInternational Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USACopyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.comRevised 02/2012

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