Instructions - Parts SmartWare™ Shot Dispense Kit 3A0294G EN Accurate metered dispensing kit for one component materials. Kits are compatible with Check-Mate® pumps and Dura-Flo™ pumps; both alone and as part of a supply system. For professional use only. Not approved for use in European explosive atmosphere locations. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 System Description . . . . . . . . . . . . . . . . . . . . . . . . . 6 Typical Applications . . . . . . . . . . . . . . . . . . . . . . . 6 Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Critical System Parameters . . . . . . . . . . . . . . . . . 6 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . .
Related Manuals Related Manuals Manuals are available at www.graco.com. Component manuals in U.S.
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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse 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.
System Description System Description SmartWare shot dispense kits contain everything needed to convert a supply system or a pump system into a dosing system. The kits enable you to dose a preset amount of single-component material without using flowmeters or gear meters in the fluid stream. Instead, a sensor tracks the pump position so that the pump acts like a flowmeter. The amount dispensed is based on the pump size.
Theory of Operation Theory of Operation SmartWare shot dispense kits do not use flowmeters in the material path to measure the volume pumped. Instead the kit measures the volume pumped by using the following calculation. See FIG. 1 for a graphical representation. Just like a car does not stop the instant you push on the brake, the SmartWare kit pump does not stop pumping the instant it receives a stop signal.
Component Identification Component Identification SmartWare Kit for D200 and D60 Rams SmartWare Kit for S20 Rams B U* C* S* B S* A D C* J K H J K M D H E*, F*, G* R M T* E*, F*, G* T* N R N FIG.
Component Identification Component Identification (cont.) SmartWare Kit for Floor Mount Pumps SmartWare Kit for Wall Mount Pumps A B A C* C* B J K V* H D J E*, F*, G* T* L E*, F*, G* K P H L FIG.
Component Identification User Interface FIG. 5: Display Module NOTICE To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. Table 1: Display Module Button Functions Button Function Mode Select between Run and Setup modes. Shot Start the present operation mode. Possible operation modes: shot mode, sequence mode, manual mode, and park mode Arrows Up/Down Navigate up or down within a screen or to a new screen.
Component Identification Table 2: Display Soft Key Icons Icon Function Enter Screen In screens that have editable fields, press to access the fields and make changes. Exit Screen In screens that have editable fields, press to exit edit mode. Enter In screens that have editable fields, press to make data selections or to enter changes. Right In screens that have editable fields, press to move to the right while in a field. Cancel Cancel a selection or edited data. Returns to the original data.
Component Identification User Interface Display For details regarding the user interface display, see , page 92. Display Screen Components The following figures call out the navigational, status, and general informational components of each display screen. Scroll up through screens } Current setup screen number Scroll down through screens Setup fields specific to current setup screen Soft Keys Enter/Exit Screen FIG.
Component Identification Setup Mode Screen Structure The following figure demonstrates the flow of the setup mode screens beginning with setup screen 1. For details on each setup screen, see - Setup Mode Details on page 94.
Component Identification Run Mode Screen Structure There are only two run mode screens: run and information. However, there are four modes within the run screen: shot, sequence, manual and park. The following figure demonstrates the flow of the modes in the run screen beginning with power up screen 1. For details on each run mode, see - Run Mode Details on page 100.
Grounding Grounding The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit. To reduce the risk of static sparking, ground the pump, the object being dispensed to, and all other dispensing equipment used or located in the dispensing area. All electrical wiring must be done by a qualified electrician and comply with local codes and regulations.
Installation Installation Install Kits 262370 and 262372 1. Close both shutoff valves on the air control panel. The procedures in this section are specific to each shot dispense kit. Follow only the installation instructions for your particular kit. Shutoff Valve For supply system or pump assembly installation instructions, refer to the Supply Systems Operation manual or your pump packages instructions-parts manual.
Installation 3. Install the electronics subassembly (1) to the side of the power supply bracket using four screws (34). Also secure the bracket to the bottom of the air control bracket using two screws (29) and two lock washers (28). 5. Loosen two screws on the top air controls bracket. Install the display module bracket (2) using two screws (29) and lock washers (28) to secure it to the air controls bracket. 2 1 28 29 29 r_262370_3A0294_9a 28 FIG. 14: Install Display Module Bracket 34 6.
Installation c. Loosely install the air valve assembly (3). Grease the o-ring included with the air valve assembly. Install the o-ring and then finish installing the air valve assembly. Secure with screw. 7. Install the linear sensor assembly (18) and the reed switch sensor (22). a. D200 systems only: disconnect the air motor. Loosen nut below crossbar. Use wrench to hold thread adapter in place and loosen threaded rod above crossbar with another wrench.
Installation c. Use a wrench to remove the air motor lift ring. Then remove the lift ring adapter and both g. Route the linear sensor cable through the lift ring adapter. Install the lift ring adapter; torque to 30-36 ft-lbs (40.6-48.8 N•m). See FIG. 21. Lift Ring O-rings Adapter r_262373_3A0294_before _linear o-rings. Discard the adapter and both o-rings. h. Route the linear sensor cable through the hole on the lift ring adapter. i. Apply the supplied adhesive to the lift ring threads.
Installation l. 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 the strain relief guide and to secure it to the top plate of the air motor. 25 p. D200 systems only: reconnect the air motor. Install threaded rod through center hole in the crossbar. Install lock washers and nuts onto threaded rod, both above and below crossbar.
Installation b. Apply the supplied sealant to the adapter (36), the manifold (37), and the pressure valve. Install all three in the order listed. See FIG. 27. c. Disconnect sensor cable at PT1. Install the o-ring (41) and pressure sensor (38); use zip ties (35) to secure the cable to the ram and air hose. 9. Install cables. Reference FIG.
Air Lines AV (supplied by user) Solenoid Valve LCM Cable (supplied by user) Dispense Valve FV Solenoid Cable Optional Kit Solenoid Extension Cable Y-Adapter Air Valve Assembly Solenoid Cable Display Breakout Module Light Tower Pigtail PT1 AM1 LS1 CAN Cable Reed Switch Cable RS1 Pump ti18232a Power Supply PS1 Pressure Sensor Cable Linear Sensor Cable Pressure Sensor Extension Cable Air Motor Cable Foot switch (optional kit) Low drum (optional kit) Installation FIG.
Installation 10. Secure cables to the air hose using zip ties. Tighten all zip ties and then cut off the excess. 13. Install the power supply cord (14). 11. Bundle the cables and zip tie them close to the electronics bracket (1) so that they will fit under the electronics subassembly cover (4). 12. Install the electronics subassembly cover. Install the back cover first and hand tighten the screws to secure. Then install the front cover; hand tighten the screws to secure.
Installation Install Kit 262371 1. Close both shutoff valves on the air control panel. 3. Install the electronics subassembly (1) to the side of the power supply bracket using four screws (28). Also secure the bracket to the bottom of the air control bracket using two screws (24) and two lock washers (23). Shutoff Valve 1 23 24 Shutoff Valve FIG. 32: Close Shutoff Valves 28 2. Install the power supply bracket (27) to the ram post using four screws (24) and lock washers (23). r_262371_3A0294_29a FIG.
Installation 5. Loosen two screws on the top air controls bracket. Install the display module bracket (2) using two screws (24) and lock washers (23) to secure it to the air controls bracket. c. Loosely install the air valve assembly (3). Grease the o-ring included with the air valve assembly. Install the o-ring and then finish installing the air valve assembly. Secure with screw. r_262371_3A0294_31a 2 24 23 3 O-ring Screw Slider Valve Label r_262370_3A0294_11a FIG.
Installation a. Remove the lift ring or plug. b. Insert magnet and magnet holder into the top of the motor shaft using the magnet installation tool. c. Install the linear sensor assembly into the top plate of the air motor. r_262374_3A0294_71a NOTE: For air motor models M07xxx, M12xxx, and M18xxx, which have the large mufflers, remove the muffler before installing the reed switch. Reinstall the muffler after the reed switch in installed. 8. Install the linear sensor (17). 20 21 Muffler 17 FIG.
Installation d. Install the o-ring (33) and pressure sensor (32); use zip ties (35) to secure the cable to the ram 11. Install cables. Reference the table below and FIG. 46 for a diagram of cable connections. and air hose. Light Tower 32 Shot Status Drum Low (1)/ Start/Stop (2) 33 Solenoid Extension Cable Pressure Valve Pressure Sensor Extension Cable Not Used 30 Air Motor Cable 31 r_262370_3A0294_20a Changeover Solenoid LCM Cable FIG. 44: Breakout Module Connections FIG.
Air Lines AV Solenoid Valve (supplied by user) LCM Cable (supplied by user) Dispense Valve FV Solenoid Cable Solenoid Extension Cable Y-Adapter Air Valve Assembly Solenoid Cable Display (supplied by user) Breakout Module (optional kit) Light Tower AM1 PT1 CAN Cable ti18235a Power Supply PS1 Pressure Sensor Cable RS1 Pump LS1 Linear Sensor/Reed Switch Cable Pressure Sensor Extension Cable Air Motor Cable Foot switch (optional kit) Low drum (optional kit) Installation FIG.
Installation 12. Secure cables to the air hose using zip ties. Tighten all zip ties and then cut off the excess. 15. Install the power supply cord (13). r_262371_3A0294_40a 13. Bundle the cables and zip tie them close to the electronics bracket (1) so that they will fit under the electronics subassembly cover (4). 14. Install the electronics subassembly cover. Install the back cover first and hand tighten the screws to secure. Then install the front cover; hand tighten the screws to secure.
Installation Install Kit 262373 1. Close both shutoff valves on the air control panel. 3. Install display bracket subassembly (2) to the bottom of the air motor using two screws (30) and two washers (31). 2 Shutoff Valve 5 31 Shutoff Valve 30 r_262373_3A0294_29a FIG. 49: Close Shutoff Valves FIG. 51: Install Display Bracket 2. Install the electronics subassembly (1) to the back of the bracket on the ram post using four screws (29) and washers (28). 4. Install the air valve subassembly (3). a.
Installation c. Loosely install the air valve assembly (3). Grease the o-ring included with the air valve assembly. Install the o-ring and then finish installing the air valve assembly. Secure with the two screws that are included with the air valve 5. Snap the display (5) into the display bracket. See FIG. 51. 6. Install the linear sensor assembly (18) and the reed switch sensor (22). a. Remove the air motor top cover using a flat head screwdriver. assembly.
Installation e. Place the o-ring (20) on the lift ring adapter (19), and apply the supplied adhesive to the threads. See FIG. 57. j. Install the reed switch sensor (22). Secure with the 1 in. (25 mm) screw (24) and o-ring (23) provided. See FIG. 58. 22 Lift Ring 23 19 24 18 13 r_262373_3A0294_after_linear 20 FIG. 57: Install Linear Sensor f. Route the linear sensor cable through the lift ring adapter. Install the lift ring adapter; torque to 30-36 ft-lbs (40.6-48.8 N•m). See FIG. 57.
Installation 7. Install the pressure sensor on the pump bleed port. a. Use a wrench to remove the pressure valve. 8. Install cables. Reference the cable identification table on the next page and FIG. 63 for a diagram of cable connections. Light Tower Shot Status Drum Low (1)/ Start/Stop (2) Pressure Valve Solenoid Extension Cable Pressure Sensor Extension Cable Not Used FIG. 60: Remove Pressure Valve b. Apply the supplied sealant to the adapter (33), the manifold (34), and the pressure valve.
Installation 262373 Cable Identification Part Power Cable 122487 PS1 None 60 (1524) DB25 15T859 1(blue) None 120 (3048) Pigtail 16G589 AM1 LS1/RS1 52 (1320.8) Motor cable 15Y051 9(grey) AM1 118 (2997.2) 1(yellow) 3(red) 5(grey) AV SX1 Y1(yellow) Y2(orange) SX1 FV 2(yellow) 6(blue) PT1 Air Solenoid Extension Solenoid Extension Accessory Kit cable Air Solenoid Fluid Solenoid Pressure Sensor Extension 34 122030 121806 16F562 Labels (relative to graphic) Length in.
3A0294G AV (supplied by user) Solenoid Valve Solenoid Extension Cable Solenoid Cable LCM Cable (supplied by user) Dispense Valve FV Air Valve Assembly Solenoid Cable Air Lines SX2 Y-Adapter Solenoid Extension Cable Display Breakout Module (optional kit) Light Tower Pigtail PT1 AM1 LS1 CAN Cable Reed Switch Cable RS1 Pump ti18234a Power Supply PS1 Pressure Sensor Cable Linear Sensor Cable Pressure Sensor Extension Cable Air Motor Cable Foot switch (optional kit) Low drum (
Installation 9. Secure cables to the air hose using zip ties. Tighten all zip ties and then cut off the excess. 12. Install the power supply cord (14). 10. Bundle the cables and zip tie them close to the electronics subassembly bracket (1) so that they will fit under the electronics subassembly cover (4). 11. Install the electronics subassembly cover; hand tighten the screws to secure. Install Power Supply Cord 1 4 r_262373_3A0294_42a FIG. 65: Install Power Supply Cord 13.
Installation Install Kit 262374 1. Close both shutoff valves on the air control panel. 3. Install display bracket subassembly (2) to the bottom of the air motor using two screws (25) and two washers (24). 24 2 Shutoff Valve 5 Shutoff Valve r_262374_3A0294_66a 25 FIG. 66: Close Shutoff Valves FIG. 68: Install Display Bracket 2. Install the electronics subassembly (1) to the back of the bracket on the ram post using four screws (23) and washers (22). 4. Install the air valve subassembly (3). a.
Installation c. Loosely install the air valve assembly (3) Remove air pressure gauge if necessary. Grease the o-ring included with the air valve assembly. Install the o-ring and then finish installing the air valve assembly. Secure with the two screws that are included with the air valve 5. Install the linear sensor (17). a. Remove the lift ring or plug. b. Insert magnet holder and magnet into the top of the motor shaft using the magnet installation tool. c.
Installation r_262374_3A0294_71a NOTE: For air motor models M07xxx, M12xxx, and M18xxx, which have the large mufflers, remove the muffler before installing the reed switch. Reinstall the muffler after the reed switch is installed. d. Install the o-ring (33) and pressure sensor (29); use zip ties (26) to secure the cable to the ram and air hose. 29 19 33 Pressure Valve 20 27 Muffler 28 FIG. 73: Install Reed Switch r_262370_3A0294_20a FIG. 75: Install Pressure Sensor 7.
Installation 262374 Cable Identification Description Part Labels (relative to graphic) Length in. (mm) Power Cable 122487 PS1 None 60 (1524) DB25 15T859 1(blue) None 120 (3048) Pigtail 16G589 AM1 LS1/RS1 52(1320.8) Motor cable 15Y051 9(grey) AM1 118 (2997.
3A0294G LCM Cable (supplied by user) (supplied by user) Solenoid Valve Solenoid Extension Cable Solenoid Cable Dispense Valve FV Air Valve Assembly Solenoid Cable Air Lines AV SX2 Y-Adapter Solenoid Extension Cable Display Breakout Module (optional kit) Light Tower AM1 Pigtail PT1 CAN Cable ti18236a Power Supply PS1 Pressure Sensor Cable Reed Switch Cable RS1 Pump LS1 Linear Sensor Cable Pressure Sensor Extension Cable Air Motor Cable Foot switch (optional kit) Low drum (
Installation 9. Route all cables out the top of the electrical enclosure. Make sure there is enough slack to extend ram to full height. Secure cables to the air hose using zip ties. Tighten all zip ties and then cut off the excess. 13. Open the air shutoff valves on the air control assembly. 10. Bundle the excess cable length and zip tie them close to the electronics bracket (1) so that they will fit under the electronics subassembly cover (4). 11. Install the electronics subassembly cover.
Installation Install Kit 262375 4. Install the electronics subassembly (1) to the side of the adapter bracket using four screws (30) and washers (29). 1. Shut off the air supply to the system. 2. Floor stand kit only: Install the control mount bracket (39) to the pump using two screws (36), and washers (37 and 40). 39 40 37 1 r_262375_3A0294_28a 29 30 FIG. 82: Install Electronics Assembly 36 r_262375_3A0294_26a FIG. 80: Install Control Mount Bracket 5.
Installation 6. Snap the display (5) into the display bracket. 7. Install the linear sensor assembly (18) and the reed switch sensor (22). e. Place the new o-ring (20) on the lift ring adapter (19), and apply the supplied adhesive to the threads. See FIG. 86. a. Remove the air motor top cover using a flat head screwdriver. Lift Ring 19 r_262373_3A0294_after_linear 20 18 13 ti8218b FIG. 84: Remove Air Motor Cover b. FIG. 86: Install Linear Sensor Use a wrench to remove the air motor lift ring.
Installation j. Install the reed switch sensor (23). Secure with the 1 in. (255 mm) screw (25) and o-ring (24) provided. n. Remove the plug in the air motor cover. Route the linear sensor cables through the hole in the back of the cover. Snap the air motor cover back into place. 23 24 Plug 25 Screw Cover FIG. 87: Install Reed Switch Sensor k. Connect the strain relief guide (27) to the reed switch sensor. Use a wrench to tighten the 1/2 in.
Installation 9. With integrated air controls only: Install valve assembly (6) and fittings. a. Apply the supplied adhesive to the pipe nipple fitting (32). Screw the fitting into the air control assembly. b. c. Screw the entire assembly onto the pipe nipple fitting. Use two wrenches to tighten. 10. Install cables. Reference the cable identification table below and FIG. 93 for a diagram of cable connections. Apply the supplied adhesive to the adapter fitting (31) and the pipe swivel fitting (33).
3A0294G Solenoid Cable (supplied by user) Solenoid Valve Solenoid Extension Cable Y-Adapter LCM Cable (supplied by user) Dispense Valve FV Air Valve Assembly Air Lines AV Solenoid Cable Display Breakout Module (optional kit) Light Tower Air Motor Cable LS1 ti18233a Power Supply PS1 Reed Switch Cable RS1 Pump Linear Sensor Switch Cable CAN Cable AM1 Pigtail Foot switch (optional kit) Low drum (optional kit) Installation FIG.
Installation 11. Install the pressure sensor on the pump bleed port. a. Use a wrench to remove the pressure valve. 13. Install the air lines (34). a. Connect the air lines to the valve subassembly (6) as shown. Plugged Pressure Valve FIG. 94: Remove Pressure Valve b. Apply the supplied sealant to the adapter (42), the manifold (43), and the pressure valve. Install all three in the order listed. r_262375_3A0294_41a FIG. 96: Install Air Lines - Air Valve 44 b.
Installation 14. Install the electronics subassembly cover (4); hand tighten the screws to secure. 4 FIG. 98: Install Cover 15. Install the power supply cord (14). r_262375_3A0294_43a Install Power Supply Cord r_262375_3A0294_43a FIG. 99: Install Power Supply Cord 16. Turn on air supply to the system.
Setup Setup NOTE: For setup procedures specific your supply system or pump assembly, refer to the Supply Systems Operation manual or your specific pump package instructions-parts manual. 8. Connect the air line from the air source to the system air inlet. See FIG. 101. Refer to your specific pump manual to determine the correct air supply flow requirements. Connect an air supply hose that is capable of meeting the required flow to the air motor air inlet.
Pressure Relief Procedure Pressure Relief Procedure 10. Leave the pump bleeder valve open until you are ready to spray/dispense again. Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts 1. Lock the gun/valve trigger. 11.
Prime/Purge Prime/Purge 9. Prime or purge hose and gun/valve. 1. Follow Pressure Relief Procedure on page 51. a. If necessary, change to manual mode in the run screen. See Change Operation Mode, page 62. 2. Priming only: replace pail of material if necessary. b. Hold a metal part of the gun/valve firmly to the side of a grounded metal pail. c. Press and hold or step on the foot switch (purchase separately) until all air in the hose is purged 3.
Set System Parameters Set System Parameters NOTE: Refer to Appendix B - Tips, page 102, for setup guidelines and tips. 7. Press to navigate to the specific gravity (SG) field. Set Units and Specific Gravity 1. Navigate to setup screen 1. NOTE: If the specific gravity is unknown, use the calibration routine to enter it automatically. See Calibrate on page 60 for calibration instructions. 8. Press and to increment or decre- ment to the specific gravity of the material being dispensed. 9. Press 10.
Set System Parameters Define Shot Size 6. Press to navigate to the fluid weight field. 7. Press and Up to 25 shots (1 – 25) can be defined in the setup shot screen. to increment or decre- ment to the desired shot size. 8. Press to accept the shot size. 9. Define another shot size. a. Press b. To define a shot size: to move to the shot number field. Repeat steps 4 through 8 to define the next shot size. 1. Navigate to setup screen 2. 10. Press 2. Press 3. Press to exit edit mode.
Set System Parameters Define Shot Sequence Up to 5 sequences (A – E) can be programmed. Each sequence can have up to 14 shot positions and each shot position can be one of the possible 25 shots. NOTE: Only shots that are already defined can be added to a shot sequence. 7. Press and to navigate through each shot position and to select shot numbers. NOTE: When a shot number is selected the shot volume box will display. To edit a shot sequence: 1. Navigate to setup screen 3. 8.
Set System Parameters Set Password Disable Password NOTE: When the password is “00000,” the setup screens can be accessed without entering a password. To disable the password, follow Set Password, page 56, to change the password to “00000.” 1. Navigate to setup screen 4. Reset Password If the password is forgotten, it can be reset without losing the current settings or shot data. 1. Disconnect power to the user interface. 2. Reconnect power to the user interface. 3.
Set System Parameters Select Pump Enable/Disable Pump Functions 1. Navigate to setup screen 4, if necessary. See Setup Screen 5 - Enable/Disable Pump Functions, page 96, for a description of each pump function. 1. Navigate to setup screen 5. 2. Press to access fields to make changes. 2. Press 3. Press to access fields to make changes. to navigate to the pump selection field. 3. Press to navigate to each pump func- tion field. 4. Press to scroll through the pump options. 5. Press system. 4.
Set System Parameters Enable/Disable Errors Set Low/Empty Drum Error See , page 92, for an explanation of each error function. Follow the Enable/Disable Errors steps to set either the empty drum alarm or low drum advisory. 1. Navigate to setup screen 6. Refer to the Errors section on page 66 for more information on alarms and advisories, and how to clear an alarm or advisory. The low/empty drum error code empty drum alarm for the low drum advisory When 2. Press 3. Press 5.
Set System Parameters Set Pump Runaway Error Set Maintenance Parameters 1. Navigate to setup screen 7. Set the amounts of material moved through the pump and dosing valve that will result in a maintenance advisory or alarm. 1. Navigate to setup screen 8. 2. Press to access fields to make changes. 3. Press to navigate to the pump runaway Total Volume Dispensed Maintenance Setpoint cycle rate field. 4. Press and to increment or decre- ment to the desired cycle rate.
Set System Parameters Calibrate The actual weight/volume of material dispensed may vary slightly from the displayed weight/volume. Use the following procedure to calibrate the system as needed. 5. Release the start button or foot switch. The hour glass icon is updated and the shot mode icon will display. Calibration values can be set manually. However, it is recommended to run the calibration procedure when needed. 1. Navigate to setup screen 10. 6.
Set System Parameters 9. Remove any excess material from the dispense valve, if necessary. Include this material in the weight of the shot. 10. Weigh the shot on the scale. 11. Press and to enter the shot weight in the weight field. Set Shot Accuracy Errors Use this screen to set the shot volume deviation from the shot setpoint that will cause an advisory or alarm. NOTE: If either the advisory field or alarm field is set to zero, the error is disabled. 1. Navigate to setup screen 11. 12.
Operation Operation NOTE: The shot dispense kit controller modifies pump packages and supply systems. However, the operation procedures from the pump packages instructions-parts manuals and the Supply Systems Operation manual still apply. 4. Press to scroll through the operation mode choices. 5. Press to select the desired operation mode. Startup 1. Refer to your Supply System Operation manual or pump package instruction-parts manual for system startup instructions. 6. Press to exit edit mode. 2.
Operation Sequence Mode Park Mode Sequence mode dispenses a sequence of shots in a specific order. Sequences first need to be defined in setup screen 3. Up to five (A - E) sequences can be programmed. See Define Shot Sequence, page 55. Park mode dispenses material until the pump reaches the bottom of its stroke. Then the system will disable. After the first shot in a sequence completes, the next shot can start.
Operation Select a Shot Number Select a Shot Sequence Shots are defined in setup screen 2. See Define Shot Size, page 54, for instructions. Sequences are defined in setup screen 3. See Define Shot Sequence, page 55, for instructions. 1. Change operation mode to shot, if necessary. See Change Operation Mode, page 62, for instructions. 2. Press field 1. Change operation mode to sequence, if necessary. See Change Operation Mode, page 62, for instructions. to navigate to the shot number 2. Press .
Operation 6. Dispense the shot sequence. See Dispense a Shot, page 65. The actual volume dispensed will display under the desired dispense volume. Dispense a Shot 1. Ensure the air is on. 2. Follow Select a Shot Number, page 64, or Select a Shot Sequence, page 64. 3. Press or step on the foot switch (purchase separately) to begin dispensing. The shot progress bar will display on the screen during the shot. 7. Follow steps 2 through 6 to select and dispense another shot sequence. 8.
Errors Errors Clear Errors To clear an error: From the Run screen, press to navigate to the Information screen. The Information screen displays the current alarm or advisory, and the amount of remaining material in the drum. 1. Press 2. Press to access the fields. to navigate to the error code reset field. 3. Highlight the error code. Press to clear the error code. 4.
Errors Error Codes Code Icon Code Name Light Tower Code Cause Solution Alarms Shot volume is less than the error setpoint. B1 Shot Volume Red Solid Less than Error Setpoint Shot Volume Greater than Error Setpoint Red Solid B4 DA Pump Runaway Red Solid DD Pump Cavitation Red Solid Pump is diving down more than a Replace material supply drum. half a stroke because of exhausted material supply.
Errors Code Icon Code Name Light Tower Code Cause Solution Piston Red Solid Alarms (continued) Piston traveled less than one inch in ten seconds. L1 Drum Empty Red Solid Drum empty sensor tripped. Pressure Sensor Red Solid P6 WE Dispense Valve Red Solid Pressure sensor is disconReconnect pressure sensor. nected. Damaged pressure sensor wires. Replace pressure sensor. Dispense valve is stuck open. Check air solenoid wiring and air connection. Replace or repair if necessary.
Errors Code DF DG Icon Code Name Diving Up Diving Down Light Tower Code Cause Solution Deviations Red Flash- Pump leaking during up stroke. ing Replace worn piston valve or packings. Red Flash- Pump leaking during down ing stroke. Replace worn intake valve or priming rod seal. Advisories Shot volume is less than the advisory setpoint. Shot Volume Greater than Advisory Setpoint Yellow Solid Shot volume is greater than the advisory setpoint.
Shutdown Shutdown NOTICE Never leave water or water-base material in pump overnight. If you are pumping water-base material, flush with water first, then with a rust inhibitor, such as mineral spirits solvent (or white spirit). Relieve pressure, but leave rust inhibitor in pump to protect parts from corrosion. 1. Follow the Pressure Relief Procedure on page 51. 2. Remove the spray tip and tip guard from gun or remove the nozzle from the dispense valve. 4.
Maintenance Maintenance Supply System Maintenance Platen Maintenance To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 51. Preventive Maintenance Schedule The operating conditions of your particular system determine how often maintenance is required. Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.
Maintenance Upgrade Display Software Clean User Interface Display NOTICE To avoid damaging circuit board, wear a grounding strap. Use any alcohol-based household cleaner, such as glass cleaner, to clean the display. 1. Disconnect power. 2. Pull display out of bracket clips to remove it. 3. Remove screw and then access cover. Screw Access Cover Indicator Light Token r_26416_3a0294_token_explode FIG. 105: Upgrade Display Software 4. Insert and press token firmly into slot.
Troubleshooting Troubleshooting NOTE: Troubleshooting covered in this manual is specific to the shot dispense kits. Refer to your Supply Systems Repair-Parts manual or pump packages instructions-parts manual for system specific troubleshooting. For air motor or pump troubleshooting questions, refer to your NXT air motor instruction-parts manual or pump instructions-parts manual. See Related Manuals, page 3, for specific manual numbers. 1. Follow the Operation, page 62. 2.
Repair Repair The shot dispense kits do not include any repairable parts. They include only replacement parts. Therefore, see the Installation section that is specific to your kit for instructions on replacing kit parts. Also use the Electrical Schematics section, page 75, as a reference. For system specific repair procedures, refer to your Supply Systems Repair-Parts manual or pump package instructions-parts manual. Replace Display NOTE: Order Kit 262539 for replacement.
Electrical Schematics Electrical Schematics Digital Output Schematic The SmartWare shot dispense kit uses high side switches for all digital outputs. When they are on, the module power supply voltage is switched to the output pin. When they are off the power supply voltage goes through a pull up resistor that limits the current to a maximum of the supply voltage divided by 51100 (24 / 51100 = 0.00047 amps).
Electrical Schematics Digital Input Schematic The SmartWare shot dispense kit uses low side switches for all digital inputs. The input is off when nothing is connected between the input pin and the ground pin. The input is on when the ground pin is connected to the input pin.
Parts Parts Kits 262370 and 262372 5 2 29 28 4 3b 3a 32 3c 28 31 28 29 29 28 34 33 29 38, 41 30 37 36 3A0294G 77
Parts Kits 262370 and 262372 (continued) 19 20 Inside the back of the NXT air motor 25 18 13 26 22 24 23 44 15 52 42 46 43 44 51 47 53 50 55 44 78 54 45 49 3A0294G
Parts Kit 262370 and 262372 Parts Ref. Part 2 3 3a 3b▲ 3c 4 5 5a✿ 5b 6★ 7★ 8★ 9★ 10★ 11★ 12★ 13 14 15 18 19 20 21★ 22 23 24 25 26 27★ 28 29 30 31 32 33 34 35★ 36 Description Ref. Qty.
Parts Kit 262371 5 2 4 24 23 3b 3a 3c 23 26 23 24 24 28 27 23 24 32, 33 25 31 30 80 3A0294G
Parts Kit 262371 (continued) 18, 19 17 20, 21 37 14 45 35 39 36 37 44 40 46 43 48 37 3A0294G 47 38 42 81
Parts Kit 262371 Parts Ref. Part 2 3 3a 3b▲ 3c 4 5 5a✿ 5b 6★ 7★ 8★ 9★ 10★ 11★ 12★ 13★ 14 17 18 19 20 21 22★ 23 24 25 26 27 28 29★ 30 31 32 33 34★ 82 Description Ref. Qty.
Parts Kit 262373 22 23 24 35 19 20 5 3b 3a 3c 2 18 31 30 13 33 34, 38 28 29 4 Inside the back of the NXT air motor 25 26 3A0294G 83
Parts Kit 262373 (continued) 15 50 40 47 52 42 41 42 39 53 44 43 45 49 42 84 47 46 3A0294G
Parts Kit 262373 Parts Ref. Part 2 3 3a 3b▲ 3c 4 5 5a✿ 5b 6★ 7★ 8★ 9★ 10★ 11★ 12★ 13 14★ 15 18 19 20 21★ 22 23 24 25 26 27★ 28 29 30 31 32★ 33 34 35 37★ 38 Description Ref. Qty.
Parts Kit 262374 19, 20 2 5 24 3b 25 16 3a 27 17 28, 32 3c 18 22 23 4 29 86 3A0294G
Parts Kit 262374 (continued) 13 44 34 43 46 36 35 36 33 47 38 37 39 43 36 3A0294G 41 40 87
Parts Kit 262374 Parts Ref.
Parts Kit 262375 6c 1 46b 6a 46e 1 46a 6d 46d 1 46c 6f 6g 6b 6e 2 5 46 29 31 6 33 30 32 Stand Mount Bracket 37, 38 37 35 37 39 36 29 40 44 36 30 4 45 1 Apply thread sealant to threads.
Parts Kit 262375 (continued) Inside the back of the NXT air motor 20 26 21 19 27 14 23 24 25 64 16 46 61 62 48 59 58 49 57 50 60 50 47 52 51 57 53 50 55 90 54 3A0294G
Parts Kit 262375 Parts Ref.
Parts 92 3A0294G
Appendix A - User Interface Display Appendix A - User Interface Display Display Overview Display Details The display is divided into two main functions: Setup mode and Run mode.
Appendix A - User Interface Display Setup Mode Details Setup Screen 2 - Shot Size Setup mode screens enable users to view or modify system configuration data. Users can set units, set shot sizes, program shot sequences, set the password, select specific pump sizes, adjust pump configuration, setup errors, and view totalizers. Setup screen 2 enables users to program up to 25 shots (1 – 25).
Appendix A - User Interface Display Setup Screen 3 - Shot Sequence Setup Screen 4 - Password and Pump Setup screen 3 enables users to program up to five sequences (A – E). Each sequence can have up to 14 steps and each step can be one of the possible 25 shots (programmed from the Shot Size setup screen). If any sequence contains either an undefined shot or one of the positions is undefined, no material will be dispensed when that shot is taken. Refer to the following table for more information.
Appendix A - User Interface Display Setup Screen 5 - Enable/Disable Pump Functions Setup screen 5 enables users to enable and disable functions that directly relate to pump activity. Disabling functions in this screen will prevent them from being used in run mode. Refer to the following table for more information. Setup Screen 6 - Enable/Disable Errors Setup screen 6 enables users to enable and disable specific error codes that will be issued if an alarm, advisory, or deviation is detected in the system.
Appendix A - User Interface Display Setup Screen 7 - Setup Pump Runaway and Drum Size Setup Screen 8 - Grand, Batch, and Maintenance Totalizer Setup screen 7 enables users to set the pump runaway cycle rate, drum size, and drum fill volume. Refer to the following table for more information. Setup screen 8 enables users to view the grand and batch totals for the pump. This screen also enables users to set maintenance setpoint amount for the pump and dosing valve.
Appendix A - User Interface Display Setup Screen 9 - Shot and Error Totalizer Setup Screen 10 - Calibration Setup screen 9 enables users to view the shot and error totals. Refer to the following table for more information. Setup screen 10 enables users to start the calibration process for top changeover, bottom changeover, and shot weight. Refer to the following table for more information. Icon Function Shot Totalizer Records and displays the number of times each shot number has occurred.
Appendix A - User Interface Display Setup Screen 11 - Shot Accuracy Errors Setup screen 11 enables users to set the shot volume difference from the shot setpoint that will cause an advisory or alarm. Refer to the following table for more information. Icon Function Advisory If the final shot volume is greater or less than the shot setpoint by the value entered in this field, an advisory is generated.
Appendix A - User Interface Display Run Mode Details Air Valve On/Off Run mode enables users to perform material shots, adjust shot number, view shot volume/time, monitor pump movement, and view shot time. Users can access the Information screen from the run screen, which enables them to clear errors and fill material drums. The system always starts with the run screen. See Operation, page 62, for instructions on using the Run screen. Press the Air On/Off button to turn the air valve on and off.
Appendix A - User Interface Display Information Screen The information screen is accessed by pressing either This screen displays the present alarm or advisory, along with the current error icon and error code. The information screen also displays the current volume of material in the drum. This screen also displays the average overshoot and the largest deviation from the average overshoot. from the run screen.
Appendix B - Tips Appendix B - Tips Calibration Procedure Tips for Better Accuracy Performing the calibration procedure is not necessary for the system to work. However, performing the procedure will increase shot accuracy depending on the changeover characteristics of your supply system. • Repeatable dispense components: Use a high quality and highly repeatability dispense valve and solenoid. Always use the greatest air pressure available to actuate the dispense valve.
Appendix C - Breakout Module (258999) Connections Appendix C - Breakout Module (258999) Connections The following table provides descriptions and pins of all connectors used on the breakout module. These can be used if the components are being wired directly to the breakout module. See Appendix D - Y-Adapter (124273) Connections, page 105, if the component is being connected to the Y-adapter (124273) before connecting to the breakout module.
Appendix C - Breakout Module (258999) Connections Prox / Start - Stop Connector 5 - Grey M12 Connector, 5 pin, Female, A code Phoenix Contact Part Number 1542761 Pin Number 4 2 1 3 5 Pressure Connector 6 - Blue M12 Connector, 5 pin, Female, B code Phoenix Contact Part Number 1543650 Pin Description Pressure Differential Analog Input + Pressure Differential Analog Input Pressure Power (5 volt) Pressure Ground Shield Analog Pin Number 4 2 1 3 5 Shot Active Connector 8 - Grey M8 Connector, 4 pin, Female
Appendix D - Y-Adapter (124273) Connections Appendix D - Y-Adapter (124273) Connections The Y-adapter is used when two components are connected to the same connector on the breakout module. The branch connectors, labeled 1 and 2, have identical pinouts and are combined in the trunk connector. The following table provides descriptions and pins of all connectors used on the Y-adapter.
Accessories Accessories Changeover Kits, 262453 and 262464 Foot Switch Kit, 262530 Use the changeover kit to increase shot accuracy and eliminate changeovers on shots that are less than 20% of the pump volume. There are two changeover kits available. For NXT2200 and larger air motors, order 262453. For NXT1800 and smaller air motors, order 262464. The foot switch kit enables the operator to trigger the dispense valve using a foot pedal.
Technical Data 3A0294G 107
Graco 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.
