Installation - Operation Shot Controller 312878J ENG For use with non-flammable polyurethane foams. For professional use only. Not approved for use in European explosive atmosphere locations. 2000 psi (13.8 MPa, 138 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual and the Hydraulic Reactor™ Operation manual. Save all instructions.
Related Manuals Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 6 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . 6 Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 6 Keep Components A and B Separate . . . . . . . . . .
Models Models IPH-25 SERIES Part, Series Full Load Peak Amps* Voltage Per Phase (phase) System Watts Primary Heater Watts Max Flow Rate◆ lb/min (kg/min) Approximate Output per Cycle (A+B) gal. (liter) Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi (MPa, bar) 255814, B 69 230V (1) 15960 8000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255815, B 46 230V (3) 15960 8000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255816, B 35 400V (3) 15960 8000 22 (10) 0.063 (0.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.
Warnings WARNING ELECTRIC SHOCK HAZARD Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment. • Connect only to grounded power source. • All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
Isocyanate Hazard Isocyanate Hazard • 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. • Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.
Component Identification Component Identification IPH System A B D C ti11820a Model 255811 shown FIG.
Component Identification Human Machine Interface (HMI) AG AA AD AB AE AC AF FIG. 2 Key: AA AB AC AD Up arrow key Down arrow key Mode select button Top soft key AE Bottom soft key AF Initiate shot button AG LCD screen NOTICE To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.
Component Identification Icons Icon Function Shown on Screen(s) General Icons Confirm changes • All Exit without saving changes • All Next • • • Setup screen #1 Setup screen #3 Run screen when Learn Mode is enabled Previous • • Setup screen #1 Run screen when Learn Mode is enabled Learn Mode Active Indicator (shown in lower-left corner) • Run screen when Learn Mode is enabled Reset Piston Counter to Zero • Setup screen #1 Define Shot Amount • Setup screen #2 Define Sequence Modes •
Component Identification Icon 10 Function Shown on Screen(s) Disable Run Screen Shot Editing • Setup screen #7 Enter Learn Mode • Setup screen #8 Exit Learn Mode • Setup screen #8 312878J
Component Identification Run Screen BB BA 3 BC BD BE BF BM BL BG BK 1 BJ 2 BH 1 When no errors are active, “E” will be displayed.
Setup Screen 1 Setup Screen 2 Setup Screen 5 Run Screen Shot Editing Splash Screen th bo c ld se ho r 3 nd s fo s a ey es k Pr rrow a Turn on HMI Setup Screen 8 Exit setup screens and return to Idle Run Screen by pressing and holding both soft keys for 3 sec Setup Screen 7 Setup Screen 6 START Press up arrow key to access Setup Screen 8 Press down arrow key Press up arrow key Press down arrow key Press up arrow key Press down arrow key Press up arrow key Press down arrow key Press up arrow
Conversion Kit Installation Conversion Kit Installation The IPH-25 and IPH-40 systems include a hydraulic proportioner and conversion kit 24A024 and are assembled at the factory. These instructions are for installing Conversion Kit 24A024 onto an existing H-25 or H-40 hydraulic proportioner. See Parts on page 34 for Conversion Kit 24A024 parts. Install New Reversing Switch Activator Plate CA ti11756a FIG. 5 1. Remove front cover (CA).
Conversion Kit Installation Install Linear Sensor 4 6 10 9 21 14 13 8 12 7 12 13 14 15 5 15 11 ti11759a FIG. 6 5. Place the magnet bracket plate (9) on the left side of the activator plate (21). 6. Pass two socket head cap screws (10) through the bottom two holes of magnet bracket plate (9) and activator plate (21). 7. Place the magnet bracket spacer (8) on top of the activator plate (21). Linear Sensor Assembly The holes in the magnet bracket spacer (8) are off-center.
Conversion Kit Installation Install Electrical Enclosure DE DC DD DB DA ti11757a Key: DA DB DC DD DE Screw Electrical enclosure cover Electrical enclosure Wire access cover screws Electrical cabinet FIG. 8 18. Remove three screws (DD) holding wire access cover to the electrical cabinet. 23. Install electrical enclosure cover (DB) to electrical enclosure using two screws (DA). 19. Remove wire access cover from the left side of the electrical cabinet (DF). The wire access cover will not be re-used.
Conversion Kit Installation Install Shot Controller 29. Connect the “pump” plug to J12 on the motor control board. EC 2 30. Connect the “temp” plug to the “data” connector on the temperature control board. EA 31. Connect wire harness to the linear sensor. 32. Connect 3-pin plug to J5 on the motor control board. 33. Connect 5-pin plug to J6 on the motor control board. 34. Connect the two power leads to the fan fuse block. 1 35. Replace electrical cabinet front cover (CB).
Conversion Kit Installation Disable Motor Standby Operation A shot delivered while the Reactor™ electric motor and hydraulic pump are ramping up to full speed may be inaccurate. Because of this, it is recommended that Motor Standby mode be disabled when the Shot Controller is installed. See the Standby section in the Reactor operation manual 312062 for information about disabling Standby mode.
Conversion Kit Installation Simplified Schematic, Shot Controller Wiring FA FK FL FJ FG FB FH FC 1 FF FE FD 1 See FIG. 18 on page 34 for detailed view.
312878J * * * * * * /04)/.!, $!4! 2%0/24).' +)4 * * * -/4/2 #/.42/, "/!2$ * * * %84%2.!, -!#().% #/.42/, #!",% '5. #!",% 1 #/--/. ,%&4 ).$)#!4)/. 2)'(4 ).$)#!4)/. * * Connect harness to J5 on Motor Control Board to return to spray operation. -%#(!.)#!, 2%6%23).' 1 37)4#( (!2.%33 * 0/7%2 #!",% 4/ 3(/4 #/.42/,,%2 -/4/2 #/.42/, (!2.%33 * #/..%#4/2 "/!2$ $!4! #!",% 4/ 3(/4 #/.42/,,%2 '2/5.$ #/--/. 0)34/.
Conversion Kit Installation Simplified Schematic, Alternate Gun Connection #/), 2%452. 3/,%./)$ 6!,6% $)30%.3% #/--!.$ $)30%.3% 2%15%34 !#4)6% 37)4#( 2%452. 3(/4 #/.42/,,%2 %,%#42)#!, %.#,/352% -!,% $" #/..%#4/2 ./2-!,,9 /0%. 37)4#( '5.
Setup Setup Hydraulic Proportioner Setup Setup Screen #2: Shot Number Definitions See hydraulic proportioner manual 312062. Controller Setup When in any of the setup screens, pouring is disabled. To enter the setup screens, press and hold the top soft key for three seconds. To exit the setup screens, press and hold both soft keys for three seconds. See FIG. 2 on page 8 for HMI button identification.
Setup To edit a shot sequence, navigate to setup screen #3. Hit the top soft key to move to the next screen then use the up and down arrows to highlight a shot sequence. Press the top soft key to select the highlighted sequence then use the arrow keys to navigate to the nth shot in that sequence and hit the top soft key to select. Once selected, use the arrow keys to change the nth shot in the sequence to a different shot number. See Setup Screen #2: Shot Number Definitions.
Setup Setup Screen #7: Enable/Disable Run Screen Shot Editing or “Initiate Shot” button To access the setup screens when the password is enabled, press the top soft key for three second and the password entry screen will appear. Enter the password and confirm to access the setup screens. Entering a Password Enabling the “Initiate Shot” button allows starting and stopping shots from both the gun and the “Initiate Shot” button.
Setup Learn Mode Obtain Piston Range Information To view the physical piston movement, remove the front cover (CA) from the machine. Replace the cover when finished using Learn mode. Learn mode will need to be used following the installation of the conversion kit, the linear sensor or its mounting bracket, or the shot controller. The IPH units are programmed at the factory so Learn mode will not need to used prior to pouring.
Setup Piston Size If the system is off-ratio with a B side piston size different from the A side piston, the impingers in the gun may need to be adjusted to achieve equal pressures in the A and B side chemical lines. For impinger adjustment procedure for the AR Pour Gun, see manual 312888 available at www.graco.com. Define Piston Size If piston diameter editing is aborted prior to confirming the entry of both piston diameters, no changes will be saved. 1.
Setup Optional External Machine Control GA Key: GF GB GG GC GH GD GJ GE GA GB GC GD GE GF GG GH GJ Pin #1: External Machine Return Ground Pin #2: Not used Pin #3: Not used Pin #4: Not Used Pin #5: Ground for Cable Shields Pin #6: Not used Pin #7: Shot Number or Sequence nth Shot Selection Pin #8: Dispense Request Pin #9: Ready Status FIG. 14: DB9 Male Connector on Electrical Enclosure Ready Status Line See FIG. 15 on page 28.
Setup Dispense Request Line See FIG. 15 on page 28. The gun must be configured to “Tap” mode to use the dispense request line. After Pin #7 has been grounded n+1 times, there must be a delay of four times the period Pin #7 was grounded for each of the n+1 repetitions. For example, if Pin #7 was grounded for 15 milliseconds then ungrounded for 15 milliseconds and so on, there must be a delay of 60 milliseconds before activating the Dispense Request line.
Setup Pin #7: Shot Number or Sequence nth Shot Request Not Grounded 1 2 3 4 Grounded 15 mS 15 mS 15 mS 15 mS 15 mS 15 mS 15 mS 50 mS 4 X 15 mS 100 mS Pin #8: Dispense Request Not Grounded Grounded Dispensing begins Pin #9: Ready Status 24V signal < 5V signal 0 15 30 45 60 75 90 105 120 180 280 330 TIME (milliseconds) FIG.
Operation Operation The AR Pour Gun and shot controller modify the hydraulic proportioner to pour instead of spray but all operation procedures from hydraulic proportioner operation manual 312062 are applicable. Startup See hydraulic proportioner operation manual 312062. Change Shot Number Only shots with non-zero volumes/weights can be selected. To change the selected shot from the idle run screen, hit the up or down arrow keys.
Operation Sequence Mode Options Example Calibration Assume a programmed shot size of 250cc. In this example, the dispensed shot size as measured is 271cc. Calculate: 250 / 271 = 0.9225. Enter the amount 0.92 into the Calibration Factor for the programmed shot. The Shot Meter dispenses a programmed shot amount based on the measured motion of the pump during the shot delivery. This provides a precise and repeatable shot volume.
Operation Dispense Material A shot can be initiated using either the gun trigger or the “Initiate Shot” button. See “Tap” and “Hold” Gun Modes on page 22. Demo Mode Demo mode is an alternate operating mode that is identical to standard operation but with a few exceptions. When in Demo mode, pouring, control of the gun and hydraulic proportioner, and Learn mode are all disabled. Also, settings and passwords saved in Demo mode are separate from settings saved in normal operation. Enter/Exit Demo mode 1.
Pressure Relief Procedure Pressure Relief Procedure 4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) 1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual 312888. 2. Close gun fluid manifold valves A and B. See gun manual 312888. to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0. SA 3. Shut off feed pumps and agitator, if used. SB ti9879a 5. Engage gun safety lock. See gun manual 312888. 6.
Troubleshooting Troubleshooting A B Key: A B Error Code Error Icon FIG.
Parts Parts Model, Series 255811, B 255812, B 255813, B 255814, B 255815, B 255816, B 255819, A 255820, A 255821, B 255822, B 255823, B 255824, B 255825, B 255826, B Hydraulic Proportioner 253725 253726 253727 255400 255401 255402 255406 255407 253725 253726 253727 255400 255401 255402 Conversion Kit 24A024 24A024 24A024 24A024 24A024 24A024 24A024 24A024 24A024 24A024 24A024 24A024 24A024 24A024 Hydraulic Proportioner Refer to hydraulic proportioner repair manual 312063 for parts lists for each hydraul
Parts Ref 1* 2 3 4 5◆ 6◆ 7◆ 8◆ 9◆ 10◆ 11◆ 12◆ 13◆ 14◆ 15◆ 16† Part 262416 256217 256230 287839 17† 121002 15T859 18† 15T852 19† 15T602 20†◆ 21◆ 22▲ 189930 Description Qty PENDANT, shot meter 1 KIT, bracket, pendant 1 ENCLOSURE, electrical, assy 1 SENSOR, assembly 1 KIT, holder, magnet 1 BRACKET, mounting, linear sensor 1 BRACKET, mounting, magnet 1 SPACER, bracket, magnet 1 PLATE, clamp, bracket, magnet 1 SCREW, cap, sch 4 NUT, lock, hex 4 SCREW, cap, hex hd 2 WASHER, lock, spring 2 WASHER, plain 2 N
Technical Data Technical Data Category Maximum Fluid Working Pressure Fluid:Oil Pressure Ratio Data Models IPH-25 and IPH-40: 2000 psi (13.8 MPa, 138 bar) Model IPH-25: 1.91:1 Fluid Inlets Model IPH-40: 1.64:1 Component A (ISO): 1/2 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum Fluid Outlets Component B (RES): 3/4 npt(f), 250 psi (1.75 MPa, 17.
Performance Charts Performance Charts AR Pour Gun Impingers and Reactor Foam Performance Chart Pressure in psi (MPa, bar) 2000 (13.8, 138) 1500 (10.3, 103) A B C KEY A = IPH-25 at 50 Hz B = IPH-25 at 60 Hz C = IPH-40 at 50 Hz ❄D = IPH-40 at 60 Hz E = AR-C 23-B-1 impingers F = AR-C 36-C-1 Impingers G = AR-C 58-C-1 impingers ◆H = AR-D 59-D-1 front impinger and AR-D 58-C-1 rear impinger D 1000 (6.9, 69) E F 500 (3.4, 34) 0 G H 5 15 25 35 45 55 (2.3) (6.8) (11.4) (15.9) (20.5) (25.
Graco Ohio Standard Warranty Graco 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.
