Graco 3A0294G User Manual

Instructions - PartsSmartWare™ Shot Dispense KitAccurate metered dispensing kit for one component materials. Kits are compatible with Check-Mate® pump

Component Identification 10 3A0294GUser InterfaceFIG. 5: Display ModuleNOTICETo prevent damage to soft key buttons, do not press the buttons with shar

Appendix A - User Interface Display 100 3A0294GRun Mode DetailsRun mode enables users to perform material shots, adjust shot number, view shot volume/

Appendix A - User Interface Display3A0294G 101Information ScreenThis screen displays the present alarm or advisory, along with the current error icon

Appendix B - Tips 102 3A0294GAppendix B - TipsCalibration ProcedurePerforming the calibration procedure is not necessary for the system to work. Howev

Appendix C - Breakout Module (258999) Connections3A0294G 103Appendix C - Breakout Module (258999) Connections The following table provides description

Appendix C - Breakout Module (258999) Connections 104 3A0294GProx / Start - Stop Connector 5 - Grey Pin Description Pin NumberM12 Connector, 5 pin, Fe

Appendix D - Y-Adapter (124273) Connections3A0294G 105Appendix D - Y-Adapter (124273) ConnectionsThe Y-adapter is used when two components are connect

Accessories 106 3A0294GAccessoriesChangeover Kits, 262453 and 262464Use the changeover kit to increase shot accuracy and eliminate changeovers on shot

Technical Data3A0294G 107

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves th

Component Identification3A0294G 11Table 2: Display Soft Key IconsIcon FunctionEnter Screen In screens that have editable fields, press to access the f

Component Identification 12 3A0294GUser Interface DisplayFor details regarding the user interface display, see , page 92.Display Screen ComponentsThe

Component Identification3A0294G 13Setup Mode Screen StructureThe following figure demonstrates the flow of the setup mode screens beginning with setup

Component Identification 14 3A0294GRun Mode Screen StructureThere are only two run mode screens: run and information. However, there are four modes wi

Grounding3A0294G 15GroundingSupply System: ground the supply system as instructed in the grounding section of the Supply Sys-tems Operation manual.Pum

Installation 16 3A0294GInstallationThe procedures in this section are specific to each shot dispense kit. Follow only the installation instructions fo

Installation3A0294G 173. Install the electronics subassembly (1) to the side of the power supply bracket using four screws (34). Also secure the brack

Installation 18 3A0294Gc. Loosely install the air valve assembly (3). Grease the o-ring included with the air valve assembly. Install the o-ring and t

Installation3A0294G 19c. Use a wrench to remove the air motor lift ring. Then remove the lift ring adapter and both o-rings. Discard the adapter and b

2 3A0294GContentsRelated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Warnings . . . . . . . . . . . . . . . . . . . . . . . .

Installation 20 3A0294Gl. Connect the strain relief guide (26) to the reed switch sensor. Use a wrench to tighten the 1/4-20 x 1/2 in. screw (25) on t

Installation3A0294G 21b. Apply the supplied sealant to the adapter (36), the manifold (37), and the pressure valve. Install all three in the order lis

Installation 22 3A0294GFIG. 29: Cable Connections - D200S, D200, and D60 with Large NXTLight TowerPumpPowerSupplyDisplayY-AdapterAir ValveAssemblyBrea

Installation3A0294G 2310. Secure cables to the air hose using zip ties. Tighten all zip ties and then cut off the excess. 11. Bundle the cables and zi

Installation 24 3A0294GInstall Kit 2623711. Close both shutoff valves on the air control panel.2. Install the power supply bracket (27) to the ram pos

Installation3A0294G 255. Loosen two screws on the top air controls bracket. Install the display module bracket (2) using two screws (24) and lock wash

Installation 26 3A0294G8. Install the linear sensor (17). a. Remove the lift ring or plug.b. Insert magnet and magnet holder into the top of the motor

Installation3A0294G 27d. Install the o-ring (33) and pressure sensor (32); use zip ties (35) to secure the cable to the ram and air hose.11. Install c

Installation 28 3A0294GFIG. 46: Cable Connections - D200 with Small NXTLight TowerPumpPowerSupplyDisplayY-AdapterAir ValveAssemblyBreakout ModuleDispe

Installation3A0294G 2912. Secure cables to the air hose using zip ties. Tighten all zip ties and then cut off the excess. 13. Bundle the cables and zi

Related Manuals3A0294G 3Related ManualsManuals are available at www.graco.com.Component manuals in U.S. English:Manual Description313526 Supply System

Installation 30 3A0294GInstall Kit 2623731. Close both shutoff valves on the air control panel.2. Install the electronics subassembly (1) to the back

Installation3A0294G 31c. Loosely install the air valve assembly (3). Grease the o-ring included with the air valve assembly. Install the o-ring and th

Installation 32 3A0294Ge. Place the o-ring (20) on the lift ring adapter (19), and apply the supplied adhesive to the threads. See FIG. 57.f. Route th

Installation3A0294G 337. Install the pressure sensor on the pump bleed port.a. Use a wrench to remove the pressure valve.b. Apply the supplied sealant

Installation 34 3A0294G262373 Cable IdentificationDescription Part Labels (relative to graphic)Lengthin. (mm) ConnectorsPower Cable 122487 PS1 None 60

Installation3A0294G 35FIG. 63: Cable Connections - S20 with Large NXTLight TowerPumpPowerSupplyDisplayY-AdapterAir ValveAssemblyBreakout ModuleDispens

Installation 36 3A0294G9. Secure cables to the air hose using zip ties. Tighten all zip ties and then cut off the excess. 10. Bundle the cables and zi

Installation3A0294G 37Install Kit 2623741. Close both shutoff valves on the air control panel.2. Install the electronics subassembly (1) to the back o

Installation 38 3A0294Gc. Loosely install the air valve assembly (3) Remove air pressure gauge if necessary. Grease the o-ring included with the air v

Installation3A0294G 39NOTE: For air motor models M07xxx, M12xxx, and M18xxx, which have the large mufflers, remove the muf-fler before installing the

Warnings 4 3A0294GWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point

Installation 40 3A0294G262374 Cable IdentificationDescription Part Labels (relative to graphic)Lengthin. (mm) ConnectorsPower Cable122487 PS1 None 60

Installation3A0294G 41FIG. 77: Cable Connections - S20 with Small NXTLight TowerPowerSupplyDisplayY-AdapterAir ValveAssemblyBreakout ModuleDispense Va

Installation 42 3A0294G9. Route all cables out the top of the electrical enclo-sure. Make sure there is enough slack to extend ram to full height. Sec

Installation3A0294G 43Install Kit 2623751. Shut off the air supply to the system.2. Floor stand kit only: Install the control mount bracket (39) to th

Installation 44 3A0294G6. Snap the display (5) into the display bracket.7. Install the linear sensor assembly (18) and the reed switch sensor (22).a.

Installation3A0294G 45j. Install the reed switch sensor (23). Secure with the 1 in. (255 mm) screw (25) and o-ring (24) provided. k. Connect the strai

Installation 46 3A0294G9. With integrated air controls only: Install valve assembly (6) and fittings.a. Apply the supplied adhesive to the pipe nipple

Installation3A0294G 47FIG. 93: Cable Connections - Wall Mount or Floor Stand Pumps with Large NXTLight TowerPumpPowerSupplyDisplayY-AdapterAir ValveAs

Installation 48 3A0294G11. Install the pressure sensor on the pump bleed port.a. Use a wrench to remove the pressure valve.b. Apply the supplied seala

Installation3A0294G 4914. Install the electronics subassembly cover (4); hand tighten the screws to secure.15. Install the power supply cord (14).16.

Warnings3A0294G 5EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.• Do not operate the unit when fatigued or under the influence of dr

Setup 50 3A0294GSetupNOTE: For setup procedures specific your supply sys-tem or pump assembly, refer to the Supply Systems Operation manual or your sp

Pressure Relief Procedure3A0294G 51Pressure Relief Procedure1. Lock the gun/valve trigger.2. Change to manual mode in the run screen. See Change Opera

Prime/Purge 52 3A0294GPrime/Purge1. Follow Pressure Relief Procedure on page 51.2. Priming only: replace pail of material if necessary.3. Remove the s

Set System Parameters3A0294G 53Set System ParametersNOTE: Refer to Appendix B - Tips, page 102, for setup guidelines and tips.Set Units and Specific G

Set System Parameters 54 3A0294GDefine Shot SizeUp to 25 shots (1 – 25) can be defined in the setup shot screen.To define a shot size:1. Navigate to s

Set System Parameters3A0294G 55Define Shot SequenceUp to 5 sequences (A – E) can be programmed. Each sequence can have up to 14 shot positions and eac

Set System Parameters 56 3A0294GSet PasswordNOTE: When the password is “00000,” the setup screens can be accessed without entering a password. 1. Navi

Set System Parameters3A0294G 57Select Pump1. Navigate to setup screen 4, if necessary.2. Press to access fields to make changes.3. Press to naviga

Set System Parameters 58 3A0294GEnable/Disable ErrorsSee , page 92, for an explanation of each error function. 1. Navigate to setup screen 6.2. Press

Set System Parameters3A0294G 59Set Pump Runaway Error1. Navigate to setup screen 7.2. Press to access fields to make changes.3. Press to navigate

System Description 6 3A0294GSystem DescriptionSmartWare shot dispense kits contain everything needed to convert a supply system or a pump system into

Set System Parameters 60 3A0294GCalibrateThe actual weight/volume of material dispensed may vary slightly from the displayed weight/volume. Use the fo

Set System Parameters3A0294G 619. Remove any excess material from the dispense valve, if necessary. Include this material in the weight of the shot.10

Operation 62 3A0294GOperationNOTE: The shot dispense kit controller modifies pump packages and supply systems. However, the operation procedures from

Operation3A0294G 63Sequence ModeSequence mode dispenses a sequence of shots in a specific order. Sequences first need to be defined in setup screen 3.

Operation 64 3A0294GSelect a Shot NumberShots are defined in setup screen 2. See Define Shot Size, page 54, for instructions.1. Change operation mode

Operation3A0294G 656. Dispense the shot sequence. See Dispense a Shot, page 65. The actual volume dispensed will display under the desired dispense vo

Errors 66 3A0294GErrorsFrom the Run screen, press to navigate to the Information screen. The Information screen displays the current alarm or adviso

Errors3A0294G 67Error CodesCode Icon Code NameLight Tower CodeCause SolutionAlarmsB1Shot Volume Less than Error SetpointRed Solid Shot volume is less

Errors 68 3A0294GAlarms (continued)K1Piston Red Solid Piston traveled less than one inch in ten seconds.Verify dispense valve is not stuck closed.Veri

Errors3A0294G 69DeviationsDFDiving Up Red Flash-ingPump leaking during up stroke. Replace worn piston valve or packings.DGDiving Down Red Flash-ingPum

Theory of Operation3A0294G 7Theory of OperationSmartWare shot dispense kits do not use flowmeters in the material path to measure the volume pumped. I

Shutdown 70 3A0294GShutdown1. Follow the Pressure Relief Procedure on page 51.2. Remove the spray tip and tip guard from gun or remove the nozzle from

Maintenance3A0294G 71MaintenancePreventive Maintenance ScheduleThe operating conditions of your particular system determine how often maintenance is r

Maintenance 72 3A0294GUpgrade Display Software1. Disconnect power.2. Pull display out of bracket clips to remove it.3. Remove screw and then access co

Troubleshooting3A0294G 73TroubleshootingNOTE: Troubleshooting covered in this manual is spe-cific to the shot dispense kits. Refer to your Supply Sys-

Repair 74 3A0294GRepairThe shot dispense kits do not include any repairable parts. They include only replacement parts. Therefore, see the Installatio

Electrical Schematics3A0294G 75Electrical SchematicsDigital Output SchematicThe SmartWare shot dispense kit uses high side switches for all digital ou

Electrical Schematics 76 3A0294GDigital Input SchematicThe SmartWare shot dispense kit uses low side switches for all digital inputs. The input is off

Parts3A0294G 77PartsKits 262370 and 262372303328292928345229284312829323b3638, 41373a3c

Parts 78 3A0294GKits 262370 and 262372 (continued)192018132223242526Inside the back of the NXT air motor42545144444449454753465043525515

Parts3A0294G 79Kit 262370 and 262372 Parts✿ The bare display module does not have SmartWare software already installed. Use the software upgrade token

Component Identification 8 3A0294GComponent IdentificationKey:A Lift RingB Air MotorC* Display ModuleD Air ControlsE* Air Solenoid (under shroud)F* Po

Parts 80 3A0294GKit 262371254528242327232426242323c24233a3b3032, 3331

Parts3A0294G 81Kit 262371 (continued)1720, 2118, 1935474437373742384046394336454814

Parts 82 3A0294GKit 262371 Parts✿ The bare display module does not have SmartWare software already installed. Use the software upgrade token (5b) to i

Parts3A0294G 83Kit 2623732526Inside the back of the NXT air motor222324303125353334, 3819201813282943a3b3c

Parts 84 3A0294GKit 262373 (continued)3940414242434445464749425047525315

Parts3A0294G 85Kit 262373 Parts✿ The bare display module does not have SmartWare software already installed. Use the software upgrade token (5b) to in

Parts 86 3A0294GKit 26237419, 20161718222343a522425272928, 323b3c

Parts3A0294G 87Kit 262374 (continued)3334353636373839404143364443464713

Parts 88 3A0294GKit 262374 Parts✿ The bare display module does not have SmartWare software already installed. Use the software upgrade token (5b) to i

Parts3A0294G 89Kit 2623752930436373531633325237, 3829 3039374036Stand Mount Bracket466a6b6c6d6e6g6f46e46a46d46c46b444342111Apply thread sealant to thr

Component Identification3A0294G 9Component Identification (cont.)Key:A Lift RingB Air MotorC* Display ModuleD Air ControlsE* Air Solenoid (under shrou

Parts 90 3A0294GKit 262375 (continued)2627Inside the back of the NXT air motor20211914232425645057594861624650475554516052535850574916

Parts3A0294G 91Kit 262375 Parts✿ The bare display module does not have SmartWare software already installed. Use the software upgrade token (5b) to in

Parts 92 3A0294G

Appendix A - User Interface Display3A0294G 93Appendix A - User Interface DisplayDisplay OverviewThe display is divided into two main functions: Setup

Appendix A - User Interface Display 94 3A0294GSetup Mode DetailsSetup mode screens enable users to view or modify system configuration data. Users can

Appendix A - User Interface Display3A0294G 95Setup Screen 3 - Shot SequenceSetup screen 3 enables users to program up to five sequences (A – E). Each

Appendix A - User Interface Display 96 3A0294GSetup Screen 5 - Enable/Disable Pump FunctionsSetup screen 5 enables users to enable and disable functio

Appendix A - User Interface Display3A0294G 97Setup Screen 7 - Setup Pump Runaway and Drum SizeSetup screen 7 enables users to set the pump runaway cyc

Appendix A - User Interface Display 98 3A0294GSetup Screen 9 - Shot and Error TotalizerSetup screen 9 enables users to view the shot and error totals.

Appendix A - User Interface Display3A0294G 99Setup Screen 11 - Shot Accuracy ErrorsSetup screen 11 enables users to set the shot volume difference fro