Graco 312393J Pr70 2 Component Liquid Dispensing Systems Users Manual Systems, Operation And Maintenance, English

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Operation and Maintenance

PR70™

2 Component

Liquid Dispensing Systems

PR70 All Models

3000 psi (21 MPa, 207 bar) Maximum Working Pressure

100 PSI (0.7 MPa, 7 bar) Maximum Air Inlet Pressure

For Dispensing Multi-part Sealants and Adhesives.

Not Designed for Use in Explosive Atmospheres.

Important Safety

Instructions

Read all warnings and

instructions in this manual.

312393J

EN

312393G 2 of 50

Contents

Contents .................................................... 2

PR70 Accessories .................................................. 3

Supplied Manuals ..................................... 4

Related Manuals ....................................... 4

Warnings ................................................... 5

Installation ................................................. 7

General Information ............................................... 7

Unpacking .............................................................. 7

Locate and Install the PR70 ................................... 7

Machine Setup ....................................................... 7

Component Identification ........................ 8

HMI Control and Indicators ...................... 9

HMI Main Run Screen .......................................... 10

Run Screen Operation ............................ 10

Machine Mode Selection ...................................... 10

Machine Operation: Shot Mode .......................... 10

Machine Operation: Operator Mode ................... 10

Shot Number Selection ........................................ 10

Machine Disable Mode (“ ”red) .......... 11

Setup Screens ......................................... 11

Entering the Setup Screens ................................. 11

Setup Screens with Passwords Enabled ............. 11

Machine Priming ..................................... 13

Machine Calibration ................................ 13

Piston Position Calibration (C1) ........................... 13

Phasing (C2) ........................................................ 14

Open Dispense Valve (ODV) Setting (C3) ........... 14

Machine Calibration Shots (C4) ........................... 15

Shot Size Definition (M2) ........................ 16

Ratio Checks ........................................... 16

Miscellaneous Machine Setups ............. 17

Manual Control Options (M1) ............................... 17

Purge Timer / Alarm Settings (M2) ...................... 17

Cycle Counter and Silent Mode Control (M3) ......... 18

Date and Time Settings (M4) ............................... 19

Tank Level Sensing and Velocity Change (“ ”)

Options (C6) ......................................................... 19

Password Setup / Clearing (C5) ............. 20

Setting/Clearing an Administrative Password: .......... 20

Setting/Clearing a Maintenance ONLY Password:21

Resetting Passwords ........................................... 21

Miscellaneous Machine Features .......... 22

HMI Hibernate Mode ............................................ 22

HMI Startup Animation Sequence ........................ 22

HMI Demo Mode Operation ................................. 22

Pressure Relief Procedure ..................... 23

Standby/Shutdown Procedure ............... 23

Error Codes ............................................. 23

Error Code Table ..................................... 24

ICON Descriptions .................................. 26

Maintenance ............................................ 28

Software Upgrades, Run Token ............. 28

Run Token ............................................................ 28

Troubleshooting ...................................... 29

Repair ....................................................... 30

Major Mechanical Assemblies, and Attachments 30

Base Frame Assembly ......................................... 31

Air Cylinder Assemblies, and Rebuild Kits ........... 32

Drive Block Assembly .......................................... 35

Pump Assemblies and Rebuild Kits ..................... 35

Piston Cylinders or Metering Tubes ..................... 38

Hose Assemblies ................................................. 41

Miscellaneous Mechanical Assemblies ................ 43

Wiring Diagrams ..................................... 46

Technical Data ......................................... 48

Dimensions .............................................. 49

Graco Ohio Standard Warranty ............. 50

Graco Information ................................... 50

Models

312393G 3 of 50

PR70 Accessories

Mixer and Shroud Options

LC0063 Mixer, 3/16 (6.5 mm) x 32, 10 Mixers with shroud LC0081 Mixer, 3/8 (9.8 mm) combo, 50 Mixers

LC0057 Mixer, ¼ (6.5 mm) x 24, 10 Mixers with shroud LC0083 Mixer, 1/4 (6.5 mm) x 24 Luer Lock, 50 Mixers

LC0058 Mixer, 3/8 (9.8 mm) x 24, 10 Mixers with shroud LC0082 Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 50 Mixers

LC0059 Mixer, 3/8 (9.8 mm) x 36, 10 Mixers with shroud LC0084 Mixer, 3/16 (4.8 mm) x 32, 250 Mixers

LC0060 Mixer, 3/8 (9.8 mm) Combo, 10 Mixers with shroud LC0085 Mixer, 1/4 (6.5 mm) x 24, 250 Mixers

LC0061 Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 10 Mixers with shroud LC0086 Mixer, 3/8 (9.8 mm) x 24, 250 Mixers

LC0062 Mixer, ¼ (6.5 mm) x 24 Luer Lock, 10 Mixers with shroud LC0087 Mixer, 3/8 (9.8 mm) x 36, 250 Mixers

LC0077 Mixer, 3/16 (4.8 mm) x 32, 50 Mixers LC0088 Mixer, 3/8 (9.8 mm) combo, 250 Mixers

LC0078 Mixer, ¼ (6.5 mm) x 24, 50 Mixers LC0089 Mixer, 3/16 (4.8 mm) x 32 Luer Lock, 250 Mixers

LC0079 Mixer, 3/8 (9.8 mm) x 24, 50 Mixers LC0090 Mixer, ¼ (6.5 mm) x 24 Luer Lock, 250 Mixers

LC0080 Mixer, 3/8 (9.8 mm) x 36, 50 Mixers

MD2 Valve Kits

255217 MDS2, kit rebuild, air cylinder 255219 MD2, Soft Seat rebuild, needle and nose

255218 MD2, kit rebuild, back-end of wet section (no needle or seat) 255220 MD2, convert Soft Seat nose to Hard Seat (Hard

Seat rebuild), needle and nose

Other Accessories

LC0097 Desiccant Dryer, 3/8” NPT with adapter and cartridge LC0100 Vacuum Transfer Pump, 240V, down to 25 Tor

r

LC0098 Desiccant Dryer refill cartridge LC0091 3.0” Air Cylinder rebuild kit

LC0095 Nitrogen Kit for 30L and 60L tank, 1 tank LC0092 4.5” Air Cylinder rebuild kit

LC0096 Nitrogen Kit for 30L and 60L tank, 2 tanks LC0093 Check Valve rebuild kit

LC0008 Cord, I/O interface and footswitch part LC0094 Rear Pump Seal rebuild kit

LC0099 Vacuum Transfer Pump, 120V, down to 25 Tor

r

Manuals

312393G 4 of 50

Supplied Manuals

The following manuals will be supplied with the

PR70.

PR70 Operation

Refer to these documents for detailed machine

information.

Part Description

312393 Manual, Operation & Maintenance

PR70

PR70 Feed System

Part Description

312394 Manual, Tank/Feed System, PR70

Dispense Valve, MD2

Part Description

312185 Manual, Dispense Valve, MD2

* Heat Control Module(s)

Part Description

312413 Manual, Heat Control, Tank/Hoses

Related Manuals

The following manuals are for accessories to be used PR70 Operation

with the PR70 machine. Part Description

312393 Manual, Operation & Maintenance PR70

PR70 Feed System

Part

Description

312394 Manual, Tank/Feed System, PR70

Dispense Valve, MD2

Part Description

312185 Manual, Dispense Valve, MD2

Heat Control Module(s)

Part Description

312413 Manual, Heat Control, Tank/Hoses

* The Heat Control Module manual is not provided for machines that do not have a Heated Tank and/or Hose

component.

Warnings

312393G 5 of 50

Warnings

The 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.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

SKIN INJECTION HAZARD

High-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.

TOXIC 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.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent

fire and explosion:

• Use and clean 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 lights on or off when flammable fumes are present.

• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See

Grounding instructions.

• Use only Graco grounded hoses.

• Check gun resistance daily.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from

system.

• Keep a working fire extinguisher in the work area.

Warnings

312393G 6 of 50

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. For complete information about

your material, request MSDS forms from distributor or retailer.

• 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.

• 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 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.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area

of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes,

burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

Installation

312393G 7 of 50

Installation

General Information

Accessories are available from Graco. Make certain all

accessories are adequately sized and pressure-rated to

meet your system needs.

Figures 2 thru 4 are only a guide for identifying system

components and for assisting in installation. Contact

your Graco distributor or Graco Ohio Customer Service

for assistance in designing a system to suit your

particular needs.

Unpacking

1. Inspect the shipping container carefully for damage.

Contact the carrier promptly if there is damage.

2. Open the box and inspect the contents carefully.

There should not be any loose or damaged parts in

the container.

3. Compare the packing slip against all the items in

the box. Report any shortage or other inspection

problems immediately.

4. Remove the PR70 system components from the

container. Do not lift the machine by the tanks.

Locate and Install the PR70

1. Locate a bench top or equivalent location to

mechanically mount the PR70 dispensing machine.

Verify the location has access to compressed air,

AC power and is well ventilated.

2. Place the PR70 onto the designated location. Allow

to the machine to rest on the rubber feet provided.

3. Turn the Shield Locking Screws clockwise on both

sides to remove the PR70 protective shield.

4. Attach the PR70 frame to the selected location by

installing fasteners (not provided with unit) thru the

4 mounting holes. Refer to Figure 1 for mounting

hole dimensions.

Machine Setup

Avoid contact with electrical inter-connects, when connecting electric

power to the machine. Read all manufacturer’s warning and material

MSDS to know the specific hazards of the material used.

1. Connect a compressed airline to the input air in the

back of the machine.

2. Load material into the on-board or off-board tanks

feeding the machine.

3. Using the power cord provided, connect AC power

(100-240V, 50/60 Hz, single-phase) to the machine.

Figure 1: Mounting Hole Dimensions for Installing the PR70 Machine (dimensions in inches/mm)

Component Identification

312393G 8 of 50

Component Identification

Key:

A Dispense Valve (DV)

B HMI (Human Machine Interface)

C Static Mixer

D Shield Locking Screw

E Power Switch

F Air Filter

G Customer Input Receptacle

H Protective Shield

I Air Pressure Regulator

J Ball Valve (Optional)

K A and B Tanks (Onboard,

Polyethylene versions illustrated).

Figure 2: Typical PR70 (Back View, without Hoses)

Key:

A Pump Assembly

B Solenoid Valves

C Air Cylinder Assembly

D DC Power Supply

E Fluid Control Module (FCM)

Figure 3: PR70 Back View with Shield, Tanks, DV and HMI Removed.

Component Identification

312393G 9 of 50

Key:

A Drive Block

B Hydracheck (optional)

C Check Valve

D Cylinder (Metering Tube)

E Rear Bearing

F Phase Adjustment Screw/Locking

Nut

G Mounting Hole in Base Frame

Figure 4: PR70 Top View with Shield, Tanks, DV and HMI Removed.

HMI Control and Indicators

Figure 5: PR70 HMI Controls

Key:

A Screen, Display Area

B, D Up and Down Keys

C Up and Down Key LED

E Enter Key LED

F Enter Key

G-J Soft Keys 1 thru 4 (Left to Right).

K Shot Mode ICON

L Shot Mode LED

M Mode Select Key

N Operator Mode ICON

O Operator Mode LED

P Red Stop or Cancel Key (used to stop machine

operation)

Q Lock Key (used to enter and exit setup screens)

R Green Go Key (used to request a shot)

S Display area

T Diagnostic LED’s

U HMI Rear Access Panel (used to access clock

battery and for reprogramming the HMI).

Run Screens

312393G 10 of 50

HMI Main Run Screen

Figure 6: Typical PR70 Main Run Screen (Shot and Operator Modes) Respectively)

Key:

A Shot Number Field (“x” in Operator Mode)

B Shot Size Field (“XXXXXX” in Operator Mode)

C Shot weight/mass unit of measure (Grams).

D Tank Fill Status Indicators

E Pistons Status Field

F Cycle Counter

G DV status Field

H Purge Timer status Field

I Error code status Field

J Current Date Field (DD-MM-YY)

K Current Time Field (24 Hr. Format)

Run Screen Operation

Read all manufacturer’s warning and material MSDS to know the

specific hazards of the material used.

Machine Mode Selection

To dispense material, one of the following 2 modes

must be selected;

• Shot mode dispenses a predetermined amount

of material when the machine receives a “Go”

command.

• Operator mode dispenses material as long as

the machine is receiving a “Go” command.

To select Shot mode:

1. Press until .

2. Press to accept or to cancel.

To select Operator mode:

3. Press until .

4. Press to accept or to cancel.

Machine Operation: Shot Mode

1. Place the item or part to be filled below the

dispense valve static mixer

2. Press (green) or the footswitch to start the shot.

3. To cancel the shot, press .

Machine Operation: Operator Mode

1. Place the item or part to be filled below the

dispense valve static mixer.

2. Press and hold (green) or the footswitch to start

the shot. The machine will continue to dispense

until the (green) or the footswitch is released.

The pistons will not retract unless they are almost fully

extended. They will automatically retract after 4

minutes. The machine will beep to signal that it is about

to retract. To manually retract the machine, press .

Shot Number Selection

In Shot mode, up to 5 predefined shot sizes may be

selected. To select a shot:

1. When the machine is idle (not dispensing a shot)

press or to select the new shot size.

2. Press to accept, or to cancel.

Disable Mode, Entering Set-up Screens

312393G 11 of 50

Machine Disable Mode (“ ”red)

Figure 6: Typical Run Screen when Machine in

“Disable” Mode

1. At any time and from any screen, to immediately

disable all machine motion, press (red).

2. If activated, the purge timer will be disabled

3. To resume operation, the machine must be put

back into an operating mode as described in the

Machine Mode Selection section.

4. If activated, the purge timer will not restart until a

shot is taken.

Setup Screens

Before the machine will operate properly, it must be

calibrated and shot size information must be entered.

Entering the Setup Screens

1. From the Run screen press . If no password

has been programmed into the HMI, the

Programming Mode Selection Screen (Figure 7)

will be displayed.

Figure 7: Programming Mode Selection Screen

2. To enter the calibration screens, press . To

enter the maintenance screens, press . Refer

to Figure 9 for a screen navigation diagram.

Setup Screens with Passwords Enabled

1. From the Run screen press . If a password has

been programmed, the Password Entry Screen

(Figure 8) will be displayed.

Figure 8: Password Entry Screen

2. Enter the 6 digit password by pressing the

corresponding soft keys, G-J in Figure 5.

3. After the 6th digit has been entered, press .

4. If the correct password has been entered, the

Programming Mode Selection Screen will be

displayed. Refer to Figure 9 for a screen navigation

diagram.

5. If the incorrect password has been entered, the

password entry will need to be repeated until the

correct 6-digit sequence is entered.

6. To abort the password entry, press .

Screen Layout

312393G 12 of 50

Figure 9: PR70 Screen Navigation Diagram

Priming and Calibration

312393G 13 of 50

Machine Priming

Before the machine can be properly calibrated with

material, it will need to be primed.

Read all manufacturer’s warning and material MSDS to know the

specific hazards of the material used.

From the Run Screen press then press . The

following screen will be displayed.

Figure 10: Maintenance Screen for Priming (M1)

Key:

A Full Retract ICON

B Full Extend ICON

C Change Dispense Valve Mode

= Always Open

= Always Closed

= Opens at Cylinder Entrance (Automatic)

D Current Piston Position

E Current Dispense Valve Mode

F Screen Number (C1)

G & keys will navigate to adjacent screens.

1. Place a waste container under the dispense valve

to capture any dispensed material.

2. Press until the upper ICON is .

3. Press to extend the piston fully.

4. Press to retract the piston fully.

5. Repeat steps 3 and 4 until both materials dispense

from the valve without air.

6. Press twice to return to the Run screen.

Machine Calibration

Before the machine will accurately dispense, it must

be calibrated.

Be careful not to pinch fingers when manually moving the machine

drive block.

Piston Position Calibration (C1)

This step should be executed the 1st time the machine

is setup, and may not need to be re-executed unless

the position sensor, an electronic component or a piston

has been replaced.

From the Run Screen press then press . The

following screen will be displayed.

Figure 11: Piston Position Calibration Screen (C1)

Key:

A Full Extend position number from last calibration

B Full Extend Command ICON

C Full Retract position number from last calibration

D Full Retract Command ICON

E Cylinder Entrance position from last calibration

F Cylinder Entrance Command ICON

H Current Piston Position Field

I Screen Number (C1)

J & keys will navigate to adjacent screens.

1. Place a waste container under the dispense valve

to capture any dispensed material.

2. With air pressure applied to the machine, press .

3. The piston should fully extend and a number

between 3600 to 3900 should appear for ‘H’

4. Press to accept the number or to keep the

current number.

5. Press .

6. The piston should fully retract and a number

between 1250 to 1600 should appear for ‘H’.

7. Press to accept the number or to keep the

current number.

8. Decrease the air pressure by adjusting the machine

air pressure regulator to a minimal value (i.e. ~ 10 -

20 psi).

9. Press .

Priming and Calibration

312393G 14 of 50

10. The machine pistons should extend slowly until they

encounter the cylinder entrance and a number

between 2000 to 2400 should appear for ‘H’.

11. If the pistons do not move, manually move the

piston by pulling on the machine drive block, until

mechanical resistance is encountered at the

cylinder entrance.

12. Press to accept the number or to keep the

current number.

13. Adjust the Air Pressure Regulator back to a

reasonable value for proper machine operation.

14. Press twice to return to the Run screen.

Phasing (C2)

To enable the machine to dispense the correct ratio of

material from the A and B tanks and to mix properly,

both materials will need to enter the static mixer at the

same time. Phasing shots will need to be executed to

visually verify that the 2 materials are exiting the

dispense valve at the same time.

Remove any static mixer attached to the dispense

valve, and replace it with a ratio check nozzle. Place a

waste container under the valve to capture any

dispensed material.

From the Run screen, press , then press , and then

press once. The following will screen will be displayed.

Figure 12: Phasing Calibration Screen (C2)

Key:

A A material leads B ICON

B Adjust B side Forward ICON

C B material leads A ICON

D Adjust A side Forward ICON

E A and B Exit the Same Time ICON

F Do NO Mechanical Adjustment ICON

G Phase Shot Request ICON

I Screen Number (C2)

J & keys will navigate to adjacent screens.

K Decrease Phase Shot Percentage Amount ICON

L Current Phase Shot Percentage Amount

M Increase Phase Shot Percentage Amount ICON

1. Select the location where the piston will reverse

(from the extend to retract motion) by pressing or

keys. Pressing will decrease the phasing

shot. Pressing will increase the phasing shot. A

“+” value indicates that the piston will reverse beyond

the cylinder entrance. A “-“ value indicates the piston

will reverse prior to reaching the cylinder entrance.

2. Press (green) or the footswitch.

3. During the shot execution, visually monitor the 2

materials exiting the ratio check nozzle. If the

timing of the 2 materials exiting the nozzle cannot

be properly observed, press or accordingly,

then repeat step 2.

4. If the A side material exits the ratio nozzle before

the B side material (“ ”), turn the B piston

Phase Adjustment Screw/ Locking nut and shaft

counterclockwise to move the B piston forward, as

indicated on the ICON. Slight adjustments in

the piston shaft will be significant. Adjustments of a

quarter turn are typical.

5. If the B side material exits the ratio nozzle before

the A side material (“ ”), turn the A piston

Phase Adjustment Screw/ Locking nut and shaft

counterclockwise to move the A piston forward, as

indicated on the ICON.

6. Repeat step 2 until both materials exit the ratio

check nozzle at the same time (“ ”).

7. Press twice to return to the Run screen.

Open Dispense Valve (ODV) Setting (C3)

The next step in the calibration process is to determine

the proper position to open the Dispense Valve (DV)

during the shot.

Advancing or increasing the opening position (in milli-

meters) will build more pressure in the material hoses

prior to the dispense valve opening. If the Dispense

Valve opens too late in the shot, a surge of material

can occur or the piston could stall. If the Dispense

Valve opens to early in the shot, material “drooling” at

the beginning of the dispense cycle could occur.

From the Run screen, press , then press , and then

press 2 times. The following screen will be displayed.

Priming and Calibration

312393G 15 of 50

Figure 13: Open Dispense Valve (ODV) Screen (C3)

Key:

A Current ODV Adjustment (in mm from the cylinder

entrance).

B Adjust ODV value Option ICON.

C Relative ODV Position ICON with respect to

cylinder entrance (This ICON will move right or

left at +/- mm transition).

D Cylinder Entrance ICON (stationary).

I Screen Number (C3)

J & keys will navigate to adjacent screens.

1. To adjust the ODV position with respect to the

cylinder entrance, press .

2. Press to increase the value or to decrease

the value. Values of – 5.0 mm to + 5.0 mm are

allowed.

3. Press to accept the value or to retain the

previous value. The default value from the factory

is – 1.0 mm.

4. Press twice to return to the Run screen.

Machine Calibration Shots (C4)

Read all manufacturer’s warning and material MSDS to know the

specific hazards of the material used.

Calibration shots are necessary to program the

machine to properly dispense the correct amount of

material. Several short CAL shots (“ ”) and several

long CAL shots (“ ”) are required.

Remove the ratio check nozzle, install the static mixer

intended to be used, and adjust the air pressure to the

level intended for use during normal operation.

The air pressure must be set to operating

conditions for this step. Significant changes

in air pressure could adversely affect shot

accuracy.

From the Run screen, press , then press , then press

3 times. The following screen will be displayed.

Figure 14: Stroke Calibration (CAL) Screen (C4)

Key:

A Short Shot Column ICON

B Last/Current Short Shot weight (mass) entry.

C Long Shot Column ICON

D Last/Current Long Shot weight (mass) entry.

E Grams (Weight or Mass unit used)

F Short Shot ICON

G Long Shot ICON

I Screen Number (C4)

J & keys will navigate to adjacent screens.

1. Press to arm the machine to take a short CAL

shots. The icon will be highlighted (“ ”). Press

to de-arm the machine.

2. Place the empty container below the static mixer,

and press (green) or the footswitch.

3. Press and discard the contents of the material

dispensed

4. Repeat the previous 2 steps until the static mixer is

filled with material. Verify the material dispensed

from the mixer is mixed properly.

5. Place a container on a scale and tare (zero) it.

6. Place the tared container below the static mixer,

and press (green) or the footswitch.

7. Press to erase existing average weight data.

8. Place the container with the dispensed material on

the tared scale.

9. Enter the mass in grams into the HMI, by pressing

or accordingly.

10. Press to accept the number. The number

entered will be transferred to the right of the

average icon (“ ”).

11. Repeat steps 5 through 10, skipping step 7, several

times. Each additional shot weight will be averaged

in the row with the previous shots.

Priming and Calibration

312393G 16 of 50

12. Press to arm the machine to take a long CAL

shots. The icon will be highlighted (“ ”). Press

to de-arm the machine.

13. Place a container on a scale and tare (zero) it.

14. Place the tared container below the static mixer,

and press (green) or the footswitch.

15. Press to erase existing average weight data.

16. Place the container with the dispensed material on

the tared scale.

17. Enter the mass in grams into the HMI, by pressing

or accordingly.

18. Press to accept the number. The number

entered will be transferred to the right of the

average icon (“ ”).

19. Repeat steps 13 through 18, skipping step 15,

several times. Each additional shot weight will be

averaged in the row with the previous shots.

20. Press to de-arm the cal shot.

21. Press twice to return to the Run screen.

Shot Size Definition (M2)

To dispense in Shot Mode, one or more, up to 5, shot

sizes need to be entered. This step is not required for

Operator mode.

From the Run screen, press , then press , and then

press once. The following screen will be displayed.

Figure 15: Shot Size and Purge Timer Screen (M2)

Key:

A Shot Number

B Shot Size (in grams).

C Purge Timer Setting (Turned OFF in Figure 15).

D Purge Timer Alarm Setting.

E Define Shot ICON

F Set Purge Timer ICON

G Purge Timer Warning ICON.

I Screen Number (M2).

J & keys will navigate to adjacent screens.

1. Press . The following screen will be displayed:

Figure 16: M2 Shot Definition Screen

2. Press or to select a shot number to define.

3. Press or to enter the shot size.

The shot size (in grams) must be greater

than the Short CAL Shot size from the

previous C4 calibration screen.

4. Press to accept the value or to retain the

previous value.

5. Repeat the previous 2 steps for other shot sizes as

required.

6. Press to exit the Shot Definition screen.

7. Press twice to return to the Run screen.

Ratio Checks

Read all manufacturer’s warning and material MSDS to know the

specific hazards of the material used.

This is a procedure to verify the weight ratio between

the 2 materials. This is easiest to do with two scales.

1. From the Run screen, put the machine in Shot

mode (“ ”). See page 13.

2. Verify that the machine is properly calibrated and

phased as outlined in the calibration section.

3. Remove any static mixer attached to the dispense

valve and replace it with a ratio check nozzle.

Place a waste container under the valve to capture

any dispensed material.

4. Select a shot size between the Short and Long CAL

shot sizes previously done, by pressing or

and to accept.

5. Place the empty container below the Ratio Check

Nozzle and the footswitch. Discard this shot.

Priming and Calibration

312393G 17 of 50

6. Place an empty container on a scale, and tare

(zero) the scale. Repeat the process with a 2nd

container on a 2nd scale.

7. Place both containers under the ratio check nozzle,

positioned so one container captures material A,

and the 2nd container captures material B.

8. Press the footswitch.

9. After the material is dispensed, place each

container on the same scale, and measure the net

mass of each of the materials. Record the mass of

both the A and B materials.

10. Divide the A material mass by the B material mass

to obtain the material ratio being dispensed.

Miscellaneous Machine Setups

The following sections outline how to configure various

optional settings.

Manual Control Options (M1)

The user can control the machine’s piston position and

displacement valve operation manually the M1 screen.

From the Run Screen press then press . The

following screen will be displayed.

Figure 17: Maintenance Screen (M1)

Key:

A Full Retract ICON

B Full Extend ICON

C Change Dispense Valve Mode

= Always Open

= Always Closed

= Opens at Cylinder Entrance (Automatic)

D Current Piston Position

E Current Dispense Valve Mode

F Screen Number (C1)

G & keys will navigate to adjacent screens.

Manual Piston Control:

1. Press to extend the piston.

2. Press to retract the piston.

Manual DV Control:

1. To change the DV operation press the third blue

key from the left.

2. When the Current Dispense Valve Mode (E in

Figure 17) is , the valve will open and stay open

regardless of the piston position.

3. When the Current Dispense Valve Mode is , the

valve will close and stay closed regardless of the

piston position.

4. When the Current Dispense Valve Mode is , the

valve will be in automatic mode, opening when the

pump gets to the cylinder entrance and closing

when it gets to the end of the cylinder.

5. Press twice to return to the Run screen.

Purge Timer / Alarm Settings (M2)

When activate, the Purge Timer will automatically

dispense a shot if the machine is idle (not dispensing

material) for a programmed duration of time. This

prevents the mixed material from hardening in the

static mixer. To set the Purge Timer;

From the Run screen, press , then press , and then

press once. The following screen will be displayed.

Figure 18: M2 after Purge Timer Selection

1. Press .

2. Press or to enter the purge timer value.

This idle time allowed before the machine will

automatically dispense a shot to clear the mixer.

Miscellaneous Machine Setups

312393G 18 of 50

3. Press to accept the value or to retain the

previous value.

Figure 19: M2 after Purge Shot Size Prompt

4. Press or to enter the purge shot size (in

grams). Enter a number with at least as much

volume as the mixer.

5. Press to accept the value or to retain the

previous value.

6. Press twice to return to the Run screen.

Activating the purge timer automatically activates the

purge alarm . This is the amount of time before

the purge timer reaches zero that the machine will

sound a warning beep to signaling that it is about to

take a purge shot. To change the Purge Alarm value;

From the Run screen, press , then press , and then

press once. The following screen will be displayed.

Figure 20: M2 after Purge Alarm Selection

1. Press .

2. Press or to enter the purge alarm duration

(in seconds). The minimum value is 2 seconds,

and a maximum of 59 seconds or the value of the

purge timer if the timer is more than 59 seconds.

3. Press to accept the value or to retain the

previous value.

4. Press twice to return to the Run screen.

Cycle Counter and Silent Mode Control (M3)

Resetting the Cycle Counter:

The cycle counter shown on the Run screen, see Figure

6, shows the number of pump cycles since the last time

the cycle counter was reset. To reset the cycle counter:

From the Run screen, press , then press , and then

press 2 times. The following screen will be displayed.

Figure 21: M3 Cycle Counter and Silent Mode Control

Key:

A Total Pump Cycle Counter Value (Not Resettable)

B Resettable Cycle Counter Value

C Current Silent Mode State ICON

Silent Mode Off

Silent Mode On

D Reset Cycle Counter ICON

E Toggle Silent Mode ICON.

I Screen Number (M3)

J & keys will navigate to adjacent screens.

1. Press .

2. Press to accept the value or to retain the

previous value.

3. Press twice to return to the Run screen.

Silent Mode Operation:

The default setting is , Silent Mode Off, where audio

feedback is provided when a valid key (1 short tone), or

an invalid key (3 short tones) is pressed.

In , Silent Mode On, audio feedback is not provided.

Silent Mode On has no effect on the audio sounds

provided for the purge timer alarm, an error code, or

when power is initially applied to the machine.

To toggle or change the silent mode:

From the Run screen, press , then press , and

then press 2 times. Screen M3, see Figure 21, will

be displayed.

1. Press or .

2. Press to accept the change or to retain the

previous setting.

3. Press twice to return to the Run screen.

Miscellaneous Machine Setups

312393G 19 of 50

Date and Time Settings (M4)

At the bottom right corner of the Run screen the date is

shown in DD-MM-YY format and the time is shown in

HH:MM, 24 hour format. The formats cannot be changed.

To set the current date:

From the Run screen, press , then press , and then

press 3 times. The following screen will be displayed.

Figure 23: M4 Screen for Setting the Date and Time

Key:

A Current Date (DD-MM-YY)

B Current Time (HH:MM, 24 Hour Format)

C Current Software Revision

Dsp = Display Module

FCM = Fluid Control Module

D Date Set ICON

E Time Set ICON.

I Screen Number (M4)

J & keys will navigate to adjacent screens.

1. Press . The M4 screen will appear as follows.

Figure 24: M4 Screen after Date Set Selection

3. Press and to enter the year.

4. Press to accept the change or to retain the

previous setting.

5. Press and to enter the month.

6. Press to accept the change or to retain the

previous setting.

7. Press and to enter the day.

8. Press to accept the change or to retain the

previous setting.

9. Press twice to return to the Run screen.

To set the current time:

1. Press . The M4 screen will appear as follows.

Figure 25: M4 after Time Set Selection

2. Press and to enter the hour (0 - 23).

3. Press to accept the change or to retain the

previous setting.

4. Press and to enter the minutes (0 - 59).

5. Press to accept the change or to retain the

previous setting.

6. Press twice to return to the Run screen.

Tank Level Sensing and Velocity Change

(“ ”) Options (C6)

If tank level sensors are installed into the system, an

alarm is generated when a tank is almost empty. If the

feature is turned ON, a Tank A low (“ ”), a Tank B

low (“ ”), or a both tanks are low (“ ”) error will be

generated if the condition exists.

The machine also measures the piston velocity and

will generate an alarm if the piston velocity has

changed significantly since the machine was last

calibrated. A significant change is piston velocity,

usually caused by a change in air pressure, can

degrade shot size accuracy.

The user has the capability to turn the feature OFF

by selecting a level of 0%, or ON by selecting levels

of 20%, 40% or 60%. For instance, if 40% is selected,

and the piston velocity changes by + or – 40%, an error

code will be generated after the corresponding shot to

inform the operator of the situation. If the velocity

increases above the selected level, a error will be

generated, and if the velocity decreases below the

selected level a error will be generated.

The feature is automatically disabled when the

machine is in Operator mode, or when the machine is

executing a purge shot.

From the Run screen, press , then press , then press

5 times. The following screen will be displayed.

Miscellaneous Machine Setups

312393G 20 of 50

Figure 26: Tank Level and (C6)

Key:

A Current Tank Level Mode

= OFF, = ON

B Current level

= OFF

= 20% change before warning

= 40% change before warning

= 60% change before warning

D Turn ON / OFF Tank Level Sensing ICON

E Change Level ICON

I Screen Number (C6)

J & keys will navigate to adjacent screens.

To turn the Tank Level Sensors On/Off:

1. Press or .

2. Press to accept the change or to retain the

previous setting.

3. Press twice to return to the Run screen.

To turn the Velocity Change On/Off:

1. Press .

2. Press to accept the change or to retain the

previous setting.

3. Press twice to return to the Run screen.

Password Setup / Clearing (C5)

The machine has the capability to limit access to the

Maintenance and Calibration screens. The password

option can be configured into 1 of the following 3

possibilities:

a. No Password (default configuration, when machine

shipped): All users can access all setup screens to

configure the system.

b. One password (“ ”): Allows access to both the

maintenance and calibration screens ( + ).

c. Two passwords:. One password allows access to

both the calibration and maintenance screen ( =

+ ). The second password only allows

access to the maintenance screens ( = ).

To alter the password configuration:

From the Run screen, press , then press , and then

press 4 times. The following screen will be displayed.

Figure 29: C5 Screen with at least 1 Password

Configured

Key:

A Administrative Password ICON

B Access Indicator for Administrative Password

D Entry Status (Only filled after password change).

E Maintenance ONLY Password ICON

F Access Indicator for Maintenance ONLY Password

G Administrative Password Set/Clear ICON

H Maintenance ONLY Password Set/Clear ICON

I Screen Number (C5)

J & keys will navigate to adjacent screens.

Setting/Clearing an Administrative Password:

1. Press . The following screen will appear.

Password Setting/Clearing

312393G 21 of 50

Figure 30: Administrative Password Entry with NO

Previous Password Stored

If a previous Administrative password has

been entered, the number at the top of the

screen is the existing password. A zero

indicates no Administrative password.

To clear the password, enter “000000”.

2. Enter a 6-digit sequence, by pressing the

corresponding soft keys, G-J in Figure 5. After the

6th key entry, the enter LED will blink.

3. Press to accept.

4. Re-enter the same 6-digit number.

5. Press to accept.

6. If both 6-digit passwords match, the C5 screen will

be displayed, and an “OK” after the first row of

symbols. If the 2 numbers do not match, the

process will need to be repeated.

7. Press twice to return to the Run screen.

Setting/Clearing a Maintenance ONLY

Password:

1. Press . The following screen will appear.

Figure 31: Maintenance ONLY Password Entry with

NO Previous Password Stored

If a previous Maintenance Only password

has been entered, the number at the top of

the screen is the existing password. A zero

indicates no Administrative password.

To clear the password, enter “000000”.

2. Enter a 6-digit sequence, by pressing the

corresponding soft keys, G-J in Figure 5. After the

6th key entry, the enter LED will blink.

3. Press to accept.

4. Re-enter the same 6-digit number.

5. Press to accept.

6. If both 6-digit passwords match, the C5 screen will

be displayed, and an “OK” after the second row of

symbols. If the 2 numbers do not match, the

process will need to be repeated.

7. Press twice to return to the Run screen.

With a Maintenance ONLY password, after the user

enters the password from the Password Entry screen,

the following screen will be displayed.

Figure 32: Mode Selection Screen after

Maintenance ONLY Password Entry

Resetting Passwords

If for whatever reason, the passwords for the machine

are not known, the passwords can be reset.

To reset all the passwords to 000000:

1. Temporarily remove power to the HMI.

2. Re-apply power to the HMI.

3. Immediately after the completion of the startup

sequence ( ,,,,, ….), press and hold

the second soft key for at least 6 seconds.

If the press and hold does not start

immediately after the animation sequence, or

the press and hold is interrupted, the

procedure will need to be restarted at step 1.

4. After 6 seconds, the HMI will generate a single tone

indicating that the passwords have been cleared.

5. New passwords may be entered by following the

steps in Password Setup / Clearing.

Hibernate and Demo Modes

312393G 22 of 50

Miscellaneous Machine Features

HMI Hibernate Mode

To help preserve the life of the HMI backlight, the

HMI will enter a Hibernate mode after the machine

has remained idle for an extended period of time.

To exit Hibernate mode, the user simply needs to

activate a HMI key or the machine footswitch.

When in Hibernate mode, the HMI LCD backlight

will be turned OFF, and the enter LED will blink at a

slow duty cycle (1 part ON, 8 parts OFF).

If the machine performs a purge shot when the HMI

is hibernating, the HMI will remain in Hibernate mode.

HMI Startup Animation Sequence

When power is applied to the machine, the

electronics need time to initialize communication.

An “Hour Glass” animation sequence is generated

(, , , , , ….). Attempts to use the

machine during the startup period will be rejected.

HMI Demo Mode Operation

The machine HMI is equipped with a demonstration

mode. When in “Demo Mode”, the HMI will not send

any requests to the Fluid Control Module and the

machine will not operate. The HMI will simulate

normal operation and provide audio feedback to the

user. All Demo Mode Maintenance and Calibration

screens are identical to screens provided in normal

mode operation.

Demo Mode can be used as a training tool for the

user. The user simply has to connect the HMI unit to

a separate power supply module, and the HMI will

operate normally without the machine attached.

Any calibration, passwords, shot sizes, purge timer

settings, or other miscellaneous settings entered

while operating in Demo mode WILL NOT alter any

normal mode settings. Also, the first time Demo

mode is entered, all the calibration & maintenance

screen setups previously described will need to be

repeated.

To configure the HMI into and out of Demo Mode:

1. Temporarily remove power to the HMI.

2. Re-apply power to the HMI.

3. Immediately after the completion of the startup

sequence ( ,,,,, ….), press and

hold the first soft key for at least 6 seconds.

If the press and hold does not start

immediately after the animation sequence,

or the press and hold is interrupted, the

previous and this step may need to be

repeated.

4. After 6 seconds, the HMI will generate a single

tone and the Demo Mode ON or OFF state will

be changed.

5. When in Demo Mode, a “D” will remain on the

bottom left-hand corner of the Run screen, as

indicated in the following figure.

Figure 33: Typical Run Screen in Demo Mode

6. To switch the HMI out of Demo Mode, repeat the

previous steps.

Limitations of Demo Mode Simulation

Even though Demo Mode provides a good training

simulation for the user, it does have limitations when

compared to the HMI operating in normal mode.

• On the Run screen, all the shot mode shots are

simulated as single piston stroke shots

regardless of the shot size and calibration

numbers entered.

• The run screen animation sequence of the piston

movement is not as gradual as in real operation.

• On the Run screen, during Operator mode

operation, a stalled piston condition is not

simulated.

• The piston cycle counter is not stored for use

after power interruption, so if power is cycled to

the HMI, the cycle count will be reset.

• The piston position numbers provided on the C1

screen are simulated.

• All error codes will be NOT be generated, except

a stuck key error (E11) if the condition exists.

Pressure Relief and Shutdown Procedures, Error Codes

312393G 23 of 50

Pressure Relief Procedure

With the machine in an idle state:

1. If the machine pistons are not fully retracted,

retract the pistons by pressing in the M1

screen. See Figure 17.

2. Manually open the dispense valve by pressing

the third M1 soft key until the “ ” ICON is

shown in the Current DV field. See Figure 17.

3. Remove the incoming air pressure by closing the

air inlet valve (item 13 in Figure 54).

Standby/Shutdown Procedure

If the machine is to remain idle for an extended

period of time, implement the following:

1. Remove any static mixer installed at the end of

the dispense valve.

2. Place a container below the valve, and activate a

small shot to flush material away from the end of

the valve.

3. To prevent accidental pump movement, press

(red).

4. With a clean rag, clean the end of the dispense

valve to remove excess material.

5. Install a nightcap at the end of the valve.

Error Codes

When the machine is operating and a fault is

detected, it will report the condition by generating an

error code. Error codes are typically generated

when the machine is idle after dispensing a shot.

When error codes are generated, a screen will be

displayed which contains an animation sequence, the

error code number and an ICON symbol representing

the condition detected. The HMI will also output an

error code tone sequence. The tone sequence

cannot be disabled.

When errors are generated, the machine will

automatically be disabled and remain in an idle state

until the user acknowledges the condition. Any active

purge timer present prior to error code generation will

be suspended, and will need re-started by requesting

a shot after the error is acknowledged.

The following typical screen is generated when an

error code is generated:

Figure 34: Typical Error Code Screen

Key:

A Error Code Animation Field

B Error Code Number Field

D Error Code ICON

E Error Code Acknowledgement ICON

When an error code is generated, the user will need

to acknowledge the condition by pressing the soft key

under the ICON.

After the user activates the key, the error number

generated in the Figure 34 example, will be displayed

on the bottom left hand corner of the Run screen,

while the condition is still present.

Figure 35: Typical Run Screen with an Active

Error Code Condition

The example E12 number on the main run screen will

remain on the run screen as long as the error

condition exists. If the problem is corrected the

example E12 number will be removed.

If more than 1 error code condition exists for the

machine, the corresponding “EXX” numbers will be

listed on the bottom left corner, separated by

commas.

Error Code Table

312393G 24 of 50

Error Code Table

Title # Cause, Details ICON

Stuck Key Error E11 A key on membrane has been active (pressed) for > 30 seconds continuously.

Replace the HMI. This error code does not require user acknowledgment and

will clear itself automatically if the condition is removed.

Communication

Error

E12 The Display module has lost communication with the Fluid Control Module.

Material dispensing will be disabled if this condition exists. Check

communication cables between the 2 electronic components, or check the

HMI and/or the Fluid Control Module.

This error will be regenerated continuously while the condition exists.

No or Invalid Run

Token Error

E13 The Run Token in the FCM is missing (not installed), or does not have the

correct data.

Piston Stroke

Time-out Error

E21 A piston stroke action has taken > 55 seconds. Typically caused by no/too

little air pressure to the machine or a mechanical interference with the piston

has occurred. Check machine input line pressure.

Less than

Minimum Shot

Requested Error

E23 User has requested a shot < the minimum allowable size entered during

calibration. (< 15% of stoke, N/A in Operator Mode).

Improper

Calibration Error

E24 The calibration done on the machine is invalid, so the requested shot cannot

be executed. For instance, a Large Stroke Calibration Shot mass which is

less than the Short Stroke Calibration Shot mass (C4 screen) will create this

error code. If the wiring to the linear position transducer is reversed this error

will appear. If invalid piston positions are calibrated into the machine (C1

screen) this error will appear.

Delta Velocity

(“V”) Minus Error

E25 The piston velocity is slower than the calibration velocity measured, by the

percentage amount selected by the user (20%, 40% or 60%). If the user

selects 0%, this monitoring or alarm feature is disabled.

If generated, shot size accuracy may be degraded. Typically the problem is

created when the machine pressure regulator is adjusted to different value

from when the machine was calibrated. Another less likely cause could be a

mechanical failure with dispensing (worn piston, etc.). This error will not be

generated for a purge shot or when the machine is in Operator mode.

Delta Velocity

(“V”) Plus Error

E26 The piston velocity is faster than the calibration velocity measured, by the

percentage amount selected by the user (20%, 40% or 60%). If the user

selects 0%, this monitoring or alarm feature is disabled.

If generated, shot size accuracy may be degraded. Typically the problem is

created when the machine pressure regulator is adjusted to different value

from when the machine was calibrated. Another less likely cause could be a

mechanical failure with dispensing (worn piston, etc.). This error will not be

generated for a purge shot, or when the machine is in Operator mode.

Low Material

Level, Tank A

Alarm or Error

E27 Tank A is low (only generated if tank sensing is enabled). Fill tank A with

material.

Tank level errors will be generated after every shot if the condition still exists.

Low Material

Level, Tank B

Alarm or Error

E28 Tank B is low (only generated if tank sensing is enabled). Fill tank B with

material.

Tank level errors will be generated after every shot if the condition still exists.

Error Code Table

312393G 25 of 50

Low Material

Level, Both Tanks

Alarm or Error

E29 Both tanks are low (only generated if tank sensing is enabled). Fill both tanks

with material.

Tank level errors will be generated after every shot if the condition still exists.

Bad Linear

Position Sensor

E50 There is a fault with the linear position sensor. Check wiring or replace.

Table 1: Error Code Table

ICON Tables

312393G 26 of 50

ICON Descriptions

Key Key Description Screen

Maintenance and Calibration Screens Enter / Exit. All

Shot Mode / Operator Control Mode Selection. Run

Shot Request (green) Run, C2,

C4

Red Stop or Cancel (Stops Operation Immediately, regardless of Screen). All

Up (Used to Raise Numerical Entry, Screen Navigation or Shot Selection). Many

Down (Used to Lower Numerical Entry, Screen Navigation or Shot Selection). Many

Enter (Used to Accept Entry). Many

Soft (Changes Function, Depending Upon Screen). All

Table 2: PR70 HMI ICON Table

ICON Description Screen

Calibration Screens.

Maintenance Screens.

Option Abort or Escape. Many

Piston Full Extend. C1, M1

Piston Full Retract. C1, M1

Metering Tube or Cylinder Entrance. C1

Phasing Shot. C2

Decrease Phasing Shot. C2

Increase Phasing Shot. C2

Open Displacement Valve (DV) Position Adjustment. C3

Tables 3: PR70 Screen ICON Tables

ICON Tables

312393G 27 of 50

ICON Description Screen

Short Stroke Calibration Shot C4

Long Stroke Calibration Shot C4

Administrative Password Set/Clear C5

Maintenance Only Screens Password Set/Clear C5

Tank Level Sensing ON C6

Tank Level Sensing OFF C6

Delta Velocity Set Level (0 = OFF) C6

Displacement Valve Always Open M1

Displacement Valve Always Closed M1

Displacement Valve Automatic Operation M1

Shot Size Definition M2

Purge Timer Set/Clear M2

Purge Shot Size M2

Purge Alarm Setting M2

Zero Cycle Counter M3

Silent Mode ON M3

Silent Mode OFF M3

Set Date M4

Set Time M4

Tables 4: PR70 Screen ICON Tables (Continued)

Maintenance, Software Upgrades and Run Token

312393G 28 of 50

Maintenance

The following items should be checked daily, once

during a shift, or as required for the application:

• Air Filter - Check air filter and release any water

circuit water trapped in the base of the filter.

• Tanks – Check material levels and refill as

necessary. Verify the material reservoirs are

vented properly.

• Air Dryer - Check the condition of the desiccant air

dryer, and replace if necessary.

• Pump Shafts – Clean both pump shafts with

solvent and lubricate with approved lubricant such

as mesamoll or Silicon oil.

• Dispense Head – Dismantle, clean thoroughly and

re-assemble. Lubricate all parts with a thin coat of

approved lubricant, or silicon oil.

• Ratio Check – If material ratio is critical for the

application, implement the ratio check procedure as

required.

Software Upgrades, Run Token

When software in the HMI or Fluid Control Module

(FCM) needs updating, a black Graco update token is

used.

Figure 36: Standard Graco Data Token

To transfer an updated software program from the

token to the PR70 HMI or FCM:

1. Turn OFF the AC power switch in the back of the

machine.

2. If updating the Fluid Control Module (FCM), open

the access door to the FCM by loosening the 2

access screws. Remove the Blue Run token from

the FCM.

3. If updating the Human Machine Interface (HMI),

remove the HMI from the mounting bracket and

remove the back cover by removing the 4 screws on

the back of the enclosure.

4. Insert a black programming token into the slot

provided. Make sure it snaps into place when

inserted.

5. Turn ON the AC power switch.

6. Verify the red LED on the FCM or HMI starts

blinking at a fast steady rate, then the red LED

stops flashing accordingly. Verify the Green LED is

on continuously, and the amber LED blinks every

few seconds.

7. Turn OFF the AC power switch.

8. Remove the programming token from the FCM or

HMI. If the second electronic component needs

updating, insert the token into the other electronic

module. If the FCM was re-programmed, re-insert

the blue run token in the slot provided.

9. If programming a second electronic module, repeat

steps 5 through 8.

10. Re-apply machine power.

11. Go to the M4 screen to verify the new software

revision(s).

Run Token

The PR70 Fluid control module (FCM) contains a blue

run token, installed in the socket provided. It has

identical appearance to the black programming token,

but is blue.

If the token is not installed into the FCM, the machine

will not operate, and an E13 error will be generated on

the display module. Hence, if the FCM software is

updated, it will need to be re-installed at the end of the

re-programming procedure.

Troubleshooting

312393G 29 of 50

Troubleshooting

Before starting any troubleshooting procedures:

1. Relieve pressure (refer to Pressure Relief

Procedure Section).

2. Disconnect AC power to the machine.

3. Allow the machine to cool, if the machine has a heat

control option.

Try the recommended solutions in the order given for

the each problem to avoid unnecessary repairs. Also

verify all circuit breakers, switches, and controls are

properly set and wiring is correct before assuming there

is a problem.

PROBLEM CAUSE SOLUTION

HMI Display Completely Dark

No Power Verify rear AC Power switch is ON.

Fuse Blown Replace Machine fuses (Refer to “Miscellaneous

Mechanical Assemblies” Section).

Loose connection Tighten 5 pin cable on HMI.

Bad HMI Replace HMI

No or incorrect amount of

material dispensed from either

side

Ball Valve Closed Open Tank Ball Valve (if installed).

Tank empty Fill tank with material

Tank Clogged Verify no obstruction in the tank

Air in material Prime the machine until the air is removed.

Check valve malfunction Remove, clean or replace check valve.

Piston worn or broken Remove and replace piston if worn.

Piston stalled (E21 Error)

Input Air Reduced or

removed

Re-connect input air line to machine. Increase

air pressure regulator adjustment.

Mixer blocked Replace static mixer. Incorporate or decrease

purge time amount to prevent mixer blockage.

ODV adjustment too late Re-adjust the ODV setting to occur sooner (C3

screen section).

Blocked Check valve Remove check valve, clean and replace.

Air Cylinder Failure Remove air cylinder and re-install cylinder kit

items if necessary.

Significant material leaking

from pump rear seal

Pump Shaft worn Remove pump shaft assembly, and re-install rear

pump re-built kit.

Material dispensed not correct

weight

Specific gravity of 1 or more

of the 2 materials has

changed since calibration.

Mix materials in tanks, dispense another shot,

then re-weigh. Re-calibrate if necessary (C4

section).

Machine Air pressure has

changed since calibration.

Re-adjust air pressure regulator to value used

when machine was calibrated, or re-calibrate (C4

section). Turn ON or decrease % level.

Not enough material in 1 or

more tanks

Check tank levels, and fill and prime if

necessary.

Mixer has slight obstruction Replace static mixer. Re-prime machine.

Check valve malfunction Remove check valve(s), clean or replace if

necessary.

Piston worn or broken Remove and replace piston(s) if necessary.

Machine dispensing off ratio

One tank is empty Check tank levels. Add material if necessary.

Tank Ball valve Closed Open tank ball valve. Re-prime machine.

Machine out of phase Re-phase machine (C2 section).

Check valve malfunction Remove check valve(s), clean or replace if

necessary.

Piston worn or broken Remove and replace piston(s) if necessary.

Pumps drawing material back

from valve hose

Check valve stuck open Remove check valve(s), clean or replace if

necessary.

Base Frame and Air Cylinder Assemblies

312393G 30 of 50

Repair

Major Mechanical Assemblies, and Attachments

Figure 38: PR70 Top View w/o Tanks with Footswitch and HMI Illustrated

Figure 39: PR70 Base Frame to Air Cylinder, Pump and Drive Block Attachments

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 LC0112 Pump Assembly, PR70 1 5 LC0107 Drive Block Assembly, PR70 1

2 120913 Screw, SHC, M8-1.25 x 25 4 6 121166 Screw, SHC, M6-1.0 x 40 4

3 120919 Nut, Hex, M14 7 LC0109 Base Frame Assembly 1

4 LC0110, or

LC0111

A

ir Cylinder Assemblies, 3.0” or 4.5” 1 8 121167 Screw, SHC, M8 - 1.25 x 40 4

Base Frame and Air Cylinder Assemblies

312393G 31 of 50

Figure 40: PR70 Power Entry Bracket and Control Bracket Assembly Attachments

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 120885 Screw, SHC, M5

–

0.8 x 14 4 3 LC0106 Power Entry Assembly, PR70 1

2 LC0108 Control Bracket Assembly, PR70 1 4 120885 Screw, SHC, M5

–

0.8 x 14 2

Base Frame Assembly

Figure 41: PR70 Base Frame Assembly (LC0109)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 120599 PIN, DOWEL, 3/8DIAX1.50LG, SS 2 5 15K796 CL

A

MP 1

2 120885 SCREW,SHC, M5-0.8X14,MS,E 2 6 LC0033 TRANSDUCER ASSY, LINEAR, PR70S 1

3 120913 SCREW,SHC, M8X1.25X25,MS, E 2 7 120918 GUIDE, LINEAR 1

4 15K788 FRAME, BASE, PR70S, MACHINED 1 8 120886 SCREW, SHC,M6-1.0X25,MS,E 4

Base Frame and Air Cylinder Assemblies

312393G 32 of 50

Air Cylinder Assemblies, and Rebuild Kits

Figure 42: PR70 Air Cylinder System and Schematic

Air Cylinder Assemblies

312393G 33 of 50

Figure 43: PR70 Air Cylinder Assemblies, 3.0” & 4.5” Diameters (LC0110 & LC0111)

Key:

(LC0110, 3.0” DIA. Assy., PR70) (LC0111, 4.5” DIA. Assy., PR70)

Ref P/N Description QTY Ref P/N Description QTY

1 107571 ORING, VIT, BAD 1 1 107571 ORING,VIT,BAD 1

2 114100 SCREW, SHC, M4X0.7X55, MS, E 3 2 114100 SCREW, SHC, M4X0. 7X55,MS,E 3

3 120875 ORING, VIT, CCE 1 3 104131 ORING,VIT,CDG 1

4 120880 SCREW, SHC, M8-1.25 X 125, MS, E 4 4 120880 SCREW,SHC,M8-1.25X125,MS,E 4

5 120881 BEARING, 1.00ID X 1.252 OD X 1.00LG, 1 5 120881 BEARING, 1.00IDX1.252ODX 1.00LG 1

6 120884 SCREW, SHC, M12-1.75 X 20, MS 1 6 120884 SCREW, SHC,M12-1.75X20,MS 1

7 120899 VALVE, 4W, 3P, COE, DSSC, ¼ NPT, 24VDC 1 7 120899 VALVE, 4W, 3P,COE, DSSC, 1/4NPT, 24VDC 1

8 120900 VALVE, PWR, 4W, SSSR, 1/4NPT, 24VDC 1 8 120900 VALVE,PWR,4W, SSSR, ¼ NPT, 24VDC 1

9 120922 MUFFLER, AIR, ¼ NPT, FLOW CONTROL 1 9 120922 MUFFLER,AIR, 1/4NPT, FLOW CONTROL 1

10 120923 ELBOW, SWVL, ¼ TUBE X 10-32, FXM, 90o, 1 10 120923 ELBOW, SWVL, ¼ X 10-32, FXM, 90o, CM/PL 1

11 120932 ORING, VIT, JDA 2 11 104271 ORING,VIT,JDG 2

12 121018 ELBOW, SWVL, 3/8 TUBE X ¼ NPT, FXM, 90o5 12 121018 ELBOW,SWVL,3/8TUBEX ¼ NPT, FXM, 90DE 5

13 121020 ELBOW, SWVL, EXT'D, ¼ X ¼ NPT, FXM, 90o1 13 121020 ELBOW, SWVL, EXT'D, ¼ X ¼ NPT, FXM, 90o1

14 121021 MUFFLER, AIR, ¼ NPT, BRONZE 3 14 121021 MUFFLER,AIR, ¼ NPT, BRONZE 3

15 121022 ELBOW, SWVL, ¼ TUBE X ¼ NPT, FXM, 90o2 15 121022 ELBOW, SWVL, ¼ TUBE X ¼ NPT, FXM, 90DE 2

16 15K790 TUBE, AIR CYL, 3.0 I.D., PR70S 1 16 15K789 TUBE, AIR CYL,4.5 I.D.,PR70S 1

17 15K791 BLOCK, AIR CYL, ROD END, PR70S 1 17 15K791 BLOCK, AIR CYL, ROD END, PR70S 1

18 15K792 BLOCK, AIR CYL, BLIND END, PR70S 1 18 15K792 BLOCK, AIR CYL, BLIND END, PR70S 1

19 15K793 PISTON,AIR CYL, 3.0 I.D., PR70S 1 19 15K794 PISTON, AIR CYL,4.5 I.D.,PR70S 1

20 15K795 ROD, PISTON, AIR CYL, PR70S 1 20 15K795 ROD, PISTON, AIR CYL,PR70S 1

Pump Assembly

312393G 34 of 50

To install a new Air Cylinder Kit:

1. Follow the Pressure Relief Procedure and turn off the

machine.

2. Disconnect the airline, remove the PR70 Shroud, and

remove the machine power entry assembly (item 3 or

Figure 40) from the machine by removing the 2

attachment screws (4 of Figure 40).

3. Remove the 2 air valves (items 7 & 8) from the cylinder

end block (18) by removing the 3 attachment screws (2).

4. Disconnect the air cylinder piston rod (20) from the

machine drive block assembly (item 5 of Figure 39) by

removing all hex nuts (item 3 of Figure 39) from the piston

rod (additional nuts may be installed if the machine has a

Hydracheck option). An open-end wrench will be

required to prevent the rod from turning when the nuts are

removed.

5. Disconnect the air cylinder from the machine frame base

assembly (item 7 of Figure 39) by removing the 4 screws

(item 8 of figure 39), which attach the cylinder rod end

block (17) to the frame. Access the screw through the 4

holes in the blind end block (18) using a long allen

wrench.

6. Remove the air cylinder by pulling on the cylinder from

the back of the machine.

7. With the cylinder partially removed, disconnect the

airlines at the air cylinder elbow fittings (12).

8. On a bench, disassemble the air cylinder by removing the

4 long screws (4), which connect the 2 cylinder blocks.

9. Inspect the cylinder tube (16) and piston (19) to verify no

scratches exists. Replace if necessary.

10. Using a clean dry cloth, remove any existing grease from

the inside of the tube (16), the outside of the piston (19)

and the cylinder rod (20).

11. Remove the 2 cylinder block o-rings (item 2 of Figure 40)

from the blocks and replace. Remove the piston o-ring

and replace (item 1 of Figure 40).

12. Remove the cylinder rod from the rod end block, then

remove the rod o-ring (item 3 of Figure 40) from the rod

end block and replace.

13. Liberally apply Graco high temperature lubricant Grease

(Graco P/N 115982) to the inside of the tube (16), the

outside of the piston (19), all the o-rings and the cylinder

rod (20).

14. Re-assemble the air cylinder. Attach the 2 drive blocks

by reinstalling the 4 long screws (4) finger tight. Then

torque the screws as specified in note of Figure 43 in

a crisscross pattern.

NOTICE

In the previous step, air cylinder damage may result if

screws are not installed in a crisscross pattern.

15. Air Cylinder damage may result if bolts are not installed in

a crisscross pattern.

16. Reinsert the air cylinder into the back of the machine by

inserting the cylinder rod through the hole in the base

frame and in the drive block.

17. Before the cylinder is completely in place, re-connect the

airlines to the cylinder block elbows fittings (12). Verify

the correct airlines are connected (see Figure 43).

18. Reattach the cylinder to the base frame by reinstalling the

4 screws (item 8 of Figure 39).

19. Reattach the cylinder to the drive block by reinstalling the

hex nut (item 3 of Figure 39) to the cylinder rod. Torque

the nut as specified in note of Figure 39.

20. Reattach the valves to the blind end block by reattaching

the 3 screws (2).

21. Reattach the power entry assembly by reinstalling the 2

attachment screws (item 4 of Figure 40).

22. Reconnect input air into the machine. Operate the

machine accordingly, and verify no air leaks are found.

Recalibrate the machine.

Figure 44: PR70 Air Cylinder Rebuild Kits, 4.5” and 3.0” Diameter Versions (LC0092 & LC0091).

Key:

(LC0092, 4.5” DIA. Rebuild Kit) (LC0091, 3.0” DIA. Rebuild Kit)

Ref P/N Description QTY Ref P/N Description QTY

1 104131 ORING, VIT, CDG 1 1 120875 ORING, VIT, CCE 1

2 104271 ORING, VIT, JDG 2 2 120932 ORING, VIT, JDA 2

3 107571 ORING, VIT, BAD 1 3 107571 ORING, VIT, BAD 1

Pump Assembly

312393G 35 of 50

Drive Block Assembly

Figure 45: PR70 Drive Block Assembly (LC0107)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 120891 SCREW, SHS, M6-1.0 X 8, MS 2 4 15K805 BLOCK, DRIVE, PR70S 1

2 15K801 ROD, ALIGNMENT 2 5 15K868 WASHER, SPERICAL, ½ DIA. MODIFIED 2

3 15K802 NUT, RETAINER 2 6 84/0130-

27/11 LABEL, HAND CRUSH, 1.3 X 1.1, TRIANGLE,

ISO 1

Pump Assemblies and Rebuild Kits

Figure 46: PR70 Pump Assembly (LC0112)

Pump Assembly

312393G 36 of 50

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 106258 ORING, VIT, JCB 2 9 15K803 COLLAR, PUMP 2

2 108712 NUT, HEX, M8 X 1.25, MS 2 10 15K804 HOUSING, BEARING, SEAL, PR70S 2

3 120887 POSIPAK, 0.375ID X 0.625OD, COIL 2 11 15K824 SHAFT, PISTON, 3/8, PR70S, SS 2

4 120890 RING, RET, INT, 1.00, SS 2 12 15K828 WASHER, SEAL, 3/8, PR70S, SS 2

6 120982 SCREW, SHC, M8 X 1.25 X 65, MS, E 8 13 15K895 HOUSING, CHECK VALVE 2

7 15K786 HOUSING, PUMP, PR70S, MACHINED 1 14 LC0093 KIT, REBUILD, VALVE, CHECK, PR70S 2

8 15K787 CAP, END, PUMP, PR70S, MACHINED 2

To install a new Check Valve Rebuild Kit:

1. With the machine in an idle state and a bucket

below the dispense valve to catch material, fully

extend the piston by pressing in the M1

screen.

2. To prevent machine movement, press (red).

3. With a bucket below the check valve to be

replaced, disconnect the male hose fitting from

the check valve housing (13), by loosing the hose

from the housing. Catch any material draining

from the hose into the bucket.

4. Remove the check valve housing (13) from the

pump endcap (8) by loosening the housing with a

wrench.

5. Remove the existing check valve (14) from the

housing (13) by inserting a screwdriver or dowel

rod into the female threaded end of the check

valve housing.

6. With the new check valve ball guide (item #3 in

figure 43) on a bench with the open end up,

install the check valve spring (item 2 of figure 47)

into the guide.

7. Install the check valve ball (item 1 of figure 47) on

top of the spring.

8. With the rounded inside surface of the check valve

seat (item 4 of figure 47) facing down, place the seat

on top of the check valve ball.

9. Holding both ends of the assembled check valve

assembly, install the check valve into the un-threaded

end of the check housing (13) with the ball end facing

out. Apply some pressure to the valve to snugly fit the

completed check valve into the housing and the fit the

check valve seat (item 4 of figure 47) into the valve

guide.

10. Verify when the assembled check valve and housing

(13) are turned up-side down, that the contents of the

valve stays in place.

11. Re-insert the new valve and valve housing into the

pump end cap, using a wrench.

12. Re-install the material male hose fitting into the check

valve housing using a wrench.

13. Before re-using the machine for operation, activate a

few shots to purge any air present in the material hose

lines due to the procedure.

14. Re-calibrate the machine if necessary.

Figure 47: PR70 Check Valve Rebuild Kit (LC0093)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 105445 BALL,CHECK VALVE 1 3 15D312 BUSHING, BALL GUIDE 1

2 121084 SPRING, 0.30OD X 0.44LG, 22#/IN, 20PSI, S 1 4 196832 SEAT, LAPPED, CHECK VALVE 1

Pump Assembly

312393G 37 of 50

Figure 48: PR70 Rear Pump Rebuild Kit (LC0094)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 106258 ORING, VIT, JCB 1 3 120887 POSIPAK, 0.375ID X 0.625OD, COIL 1

2 120890 RING, RET, INT, 1.00, SS 1

To install a new Rear Pump Rebuild Kit:

1. Drain the pump by taking several shots with either

the tank ball valves closed (if installed), or by

activating enough shots to empty the tanks.

2. Disconnect the pump shaft (item 11 of Figure 46)

from the drive block assembly by loosening the

shaft locking nut (item 2 of Figure 46), then turning

the shaft with a wrench while preventing the drive

block alignment rod (item 2 of Figure 45) from

rotating with a wrench. Manually push the pump

shaft forward toward the extend position to separate

the shaft from the drive block.

3. Remove the shaft lock nut from the shaft.

4. Remove the pump collar (item 9 on Figure 46) from

the pump housing (item 7 on Figure 46) by

removing the 2 screws (item 5 on Figure 46).

5. Slide the pump bearing housing (item 10 of Figure

46) away from the pump housing to remove.

6. Remove the existing rear pump build components

(refer to Figure 48 items) from the pump bearing

housing.

7. Using a clean dry cloth, remove any existing grease

from the bearing housing.

8. Apply new high temperature grease lubricant (Graco

P/N 115982) to the inside of the pump bearing

housing, and the new rebuild components.

9. Install the new rebuild kit components into the

bearing housing as indicated in Figure 48.

10. Apply 1 layer of thin masking tape over the male

threads of the pump shaft, which mates with the

drive block. This will prevent the threads from

damaging the seal or Posipak (3).

11. Using extreme caution, slide the pump shaft through

the hole in the bearing housing as indicated in

Figure 48. Align the bearing housing in position

next to the pump housing.

12. Re-install the pump collar over the bearing housing

and attach it to the pump housing using the 2

screws (item 5 on Figure 46) previously removed.

Torque the screws as specified in note of

Figure 46.

13. Remove the masking tape from pump shaft.

14. Re-install the pump shaft lock nut to the pump shaft.

15. Re-install the pump shaft to the drive block

alignment rod.

16. Re-tighten the lock nut.

17. Open the tank ball valves (if installed) and put more

material into the tanks.

18. Instigate several shot to fill the pump with new

material.

19. Re-calibrate and re-phase the machine, due to the

procedure performed.

Pistons & Metering Tubes

312393G 38 of 50

Piston Cylinders or Metering Tubes

Figure 49 PR70 Nylon and UHMWPE Piston Replacement Kits

Key:

Ref Description QTY Ref Description QTY

1 Piston 1 3 Oring 2

2 Screw 1

When ordering a piston replacement kit, the following

intelligent part numbering system applies for Nylon

based pistons:

LCF - 120

Code : A

Piston Size (mm2)

When ordering a UHMWPE replacement kit, the

following numbering applies:

LCE - 160

Code : A

Piston Size (mm2)

The items indicated in Figure 49 above will be

supplied with the kit. Refer to the Models section for

the available standard piston sizes.

Pistons & Metering Tubes

312393G 39 of 50

To install a new Piston or Piston/Cylinder

Replacement Kit:

1. Drain the machine pistons by instigating several

shots with either the tank ball valves closed (if

installed), or by activating enough shots to empty

the tanks.

2. To prevent machine movement, press (red).

3. Remove the pump end caps (item 8 of figure 46)

by removing the 4 end cap screws (item 6 of

figure 46). Allow the cap to hang by the hose.

4. Remove the cylinder and Orings (items 1 and 6 of

figure 50) from the pump housing (item 7 of figure

46) and pump cap.

5. Select an operating mode, then fully extend the

pistons by activating the option in the M1

screen.

6. To prevent machine movement, press (red).

7. Remove the existing piston (1) and any front or

rear washers (items 3 & 4 of figure 50) from the

pump shaft (item 11 of figure 46) by removing the

piston screw (2). A wrench will be required near

the drive block to prevent the pump shaft from

rotating while the screw is removed.

8. Install the new piston and any rear or front

washers, by re-installing the piston screw into the

pump shaft. When tightening the piston screw,

tighten the screw until the piston stops rotating,

then turn the screw an additional ¼ turn.

9. Select an operating mode, then retract the

pistons by pressing in the M1 screen.

10. To prevent machine movement, press (red).

11. Lubricate the new o-rings with a high temperature

grease, Graco P/N 115982 or equivalent. Place

the lubricated o-rings into the inside circle

placements in the pump housing and pump end

caps.

12. Install the cylinder between the pump housing

and end cap, then secure the cylinder and Orings

by re-attaching the 4 end cap screws (item 6 of

figure 46).

13. Open the tank ball valves (if installed) or put more

material into the tanks.

14. Instigate several shot to fill the pump with new

material.

15. Re-calibrate the machine, due to the procedure

performed.

NYLON PISTONS (SEE FIGURE 50)

Tube Piston

Frt.

Washer

Back

Washer Screw O-ring

Part No. Rev. Series Area Item 1 Item 2 Item 3 Item 4 Item 5 Item 6

LC1080 A A 80 LCC080 LCB080 15M089 NOT REQ

120933 120874

LC1100 A A 100 LCC100 LCB 100 15M089 NOT REQ

LC1120 A A 120 LCC120 LCB 120 NOT REQ NOT REQ

LC1140 A A 140 LCC 140 LCB 140 NOT REQ NOT REQ

LC1160 A A 160 LCC 160 LCB 160 15M099 15K887

LC1180 A A 180 LCC 180 LCB 180 15M099 15K887

LC1200 A A 200 LCC 200 LCB 200 15M099 15K887

LC1220 A A 220 LCC 220 LCB 220 15M099 15K887

LC1240 A A 240 LCC 240 LCB 240 15M100 15K887

LC1260 A A 260 LCC 260 LCB 260 15M100 15K887

LC1280 A A 280 LCC 280 LCB 280 15M100 15K887

LC1300 A A 300 LCC 300 LCB 300 15M100 15K887

LC1320 A A 320 LCC 320 LCB 320 15M100 15K888

LC1360 A A 360 LCC 360 LCB 360 15M100 15K888

LC1400 A A 400 LCC 400 LCB 400 15M100 15K888

LC1440 A A 440 LCC 440 LCB 440 15M100 15K888

LC1480 A A 480 LCC 480 LCB 480 15M100 15K888

LC1520 A A 520 LCC 520 LCB 520 15M100 15K888

LC1560 A A 560 LCC 560 LCB 560 15M101 15K888

LC1600 A A 600 LCC 600 LCB 600 15M101 15K888

LC1640 A A 640 LCC 640 LCB 640 15M101 15K890

LC1720 A A 720 LCC 720 LCB 720 15M101 15K890

LC1800 A A 800 LCC 800 LCB 800 15M101 15K890

LC1880 A A 880 LCC 880 LCB 880 15M101 15K890

LC1960 A A 960 LCC 960 LCB 960 15M101 15K890

Pistons & Metering Tubes

312393G 40 of 50

NYLON PISTONS (SEE FIGURE 50)

Tube Piston

Frt.

Washer

Back

Washer Screw O-ring

Part No. Rev. Series Area Item 1 Item 2 Item 3 Item 4 Item 5 Item 6

LC2160 A A 160 LCA160 LCB160 15M099 15K887

120933 120874

LC2180 A A 180 LCA180 LCB 180 15M099 15K887

LC2200 A A 200 LCA200 LCB 200 15M099 15K887

LC2220 A A 220 LCA220 LCB 220 15M099 15K887

LC2240 A A 240 LCA240 LCB 240 15M100 15K887

LC2260 A A 260 LCA260 LCB 260 15M100 15K887

LC2280 A A 280 LCA280 LCB 280 15M100 15K887

LC2300 A A 300 LCA300 LCB 300 15M100 15K887

LC2320 A A 320 LCA320 LCB 320 15M100 15K888

LC2360 A A 360 LCA360 LCB360 15M100 15K888

LC2400 A A 400 LCA400 LCB400 15M100 15K888

LC2440 A A 440 LCA440 LCB440 15M100 15K888

LC2480 A A 480 LCA480 LCB480 15M100 15K888

LC2520 A A 520 LCA520 LCB520 15M100 15K888

LC2560 A A 560 LCA560 LCB560 15M101 15K888

LC2600 A A 600 LCA600 LCB600 15M101 15K888

LC2640 A A 640 LCA640 LCB640 15M101 15K890

LC2720 A A 720 LCA720 LCB720 15M101 15K890

LC2800 A A 800 LCA800 LCB800 15M101 15K890

LC2880 A A 880 LCA880 LCB880 15M101 15K890

LC2960 A A 960 LCA960 LCB960 15M101 15K890

Figure 50: Available PR70 Piston and Cylinder (Metering Tubes) Kits

Key:

Ref Description QTY Ref Description QTY

1 Cylinder or Metering Tube 1 4 Back Washer See Fig.

2 Piston 1 5 Screw 1

3 Front Washer See

Fig.

6 Oring 2

Front and Rear Washer Reference Guide

Tube Area Frt. Washer Back Washer

080 to 119 15M089 NOT REQ

120 to 159 NOT REQ NOT REQ

160 to 239 15M099 15K887

240 to 319 15M100 15K887

320 to 559 15M100 15K888

560 to 639 15M101 15K888

640 to 960 15M101 15K890

Pistons

312393G 41 of 50

Figure 51 PR70 Piston Plug Assembly

Key:

Ref P/N Description QTY

1 15K815 Plug 2/Machine

2 111457 Oring 2/Machine

To install a new Piston Plug Assembly:

1. Drain the machine pistons by instigating several

shots with either the tank ball valves closed (if

installed), or by activating enough shots to empty

the tanks.

2. To prevent machine movement, press (red).

3. Remove the existing Piston plug (1) from the pump

end cap (item 8 of figure 46) with a wrench.

Remove the existing Oring (2).

4. Lubricate the new Oring with a high temperature

grease, Graco P/N 115982 or equivalent. Place the

lubricated Oring into the cap location of the end cap.

5. Re-install the piston plug (1) back into the end cap.

6. Open the tank ball valves (if installed) or put more

material into the tanks.

7. Instigate several shot to fill the pump with new

material.

8. Re-calibrate the machine, due to the procedure

performed.

Hose Assemblies

Figure 52 Piston to DV Hose Assemblies

Hose Assemblies

312393G 42 of 50

Figure 53 Heated Piston to DV Hose Assemblies

Miscellaneous Assemblies

312393G 43 of 50

Miscellaneous Mechanical Assemblies

Figure 54: PR70 Power Entry Bracket Assembly (LC0106)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 119912 SCREW, PAN, M3X6, PHILLIPS, SS 3 11 84/0130-26/11 LABEL, PE 1

2 121018 ELBOW, SWVL, 3/8 X ¼ NPT, FXM, 90DE 1 12 LC0034 HARNESS, WIRE, REMOTE SIGNAL 1

3 120876 PWR SUPPLY, 24VDC, 40W, 100-240VAC IN 1 13 121178 VALVE, LOCKOUT, ¼ NPT 1

4 120882 FILTER, 1/4NPT 1 14 121179 QUIKCLAMP, ¼ NPT 2

5 120883 NUT, HEX, 7/8-14, MS 1 15 121180 MULTIPORT, [3] ¼ NPT 1

6 120910 PWR ENTRY, 120/240VAC, DUAL FUSE, EMI 1 16 94/0762/99 VALVE, RELIEF, ¼ NPT, M, 110PSI, SIL 1

7 120916 SCREW,FHSC, M3X0.5 X 10, SS 2 17 94/0430/99 PLUG, SKT HD, ¼ NPT, MS 2

8 120993 NUT, HEX, M5X0.8, WITH STAR WASHER 2 18 81/1054-4/11 FUSE 5X20MM, 4AMP, FAST, TYPE F, 250VAC 2

9 15K798 BRACKET, SWITCH, AIR 1 19 LC0031 CABLE ASSY, POWER IN 1

10 15K800 FITTING, BULKHEAD 1

To Replace the Fuses:

1. Remove the machine fuse holder from the PWR

Entry module (6) by inserting a flat-head

screwdriver between the holder and the back the

PWR Entry module (The fuse holder is above

where AC power is connected to the machine).

2. Replace the blown fuse(s) (18) into the fuse holder.

3. Re-install the holder into the PWR Entry Module.

Miscellaneous Assemblies

312393G 44 of 50

Figure 55: PR70 Control Bracket Assembly (LC0108)

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 84/0153-1/89 CLAMP, HARNESS, REUSEABLE, 5/8,NYL 2 6 121019 ELBOW, SWVL, 3/8 X 3/8 NPT, FXM, 90DE 1

2 120885 SCREW, SHC, M5-0.8 X 14, MS, E 2 7 LC0124 CONTROLLER, FCM 1

3 120897 REGULATOR, 100PSI, 3/8NPT, GAGE 1 8 15K797 BRACKET, ELECTRICAL, 1

4 120954 MANIFOLD, PN, 3/8NPTX3/8T X ¼ TX1/4T 1 9 84/0130-25/11 LABEL,.375X.375 1

5 120993 NUT, HEX, M5X0.8, WITH STAR WASHER 5 10 LC0035 HARNESS, WIRE, I/O 1

Figure 56: PR70 Shroud Assembly (LC0113)

Key:

Ref P/N Description QTY

1 15V962 SHIELD, PR70, FIXED RATIO, GCA 1

2 15M511 LABEL, WARNING 4

3 16P016 PR70, FIXED RATIO 1

Miscellaneous Assemblies

312393G 45 of 50

Figure 57: PR70 Hydracheck Components

Figure 58: PR70 HMI Components

Key:

Ref P/N Description QTY Ref P/N Description QTY

1 288446 Display Module, PR70 1 3 120999 Termination Plug 1

2 255235 Bracket, HMI 1

Wiring Diagrams

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Wiring Diagrams

Figure 59: PR70 Wiring Interconnect Illustration

Wiring Diagrams

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Figure 60: Wiring Diagram, PR70

(121685)

Technical Data

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Technical Data

Category Data

Metering Pump Effective Area 80 – 960 mm

2

(0.124 – 1.49 in

2

) per side

Small Air Cylinder Effective Area 4560 mm

2

(7.07 in

2

)

Large Air Cylinder Effective Area 10260 mm

2

(15.9 in

2

)

Maximum Stroke Length 38.1 mm (1.50 in)

Minimum Stroke Length 5.8 mm (0.23 in)

Volume per Cycle 2 – 70 cc (0.12 – 4.3 in

3

)

Pump Cycles per 1L (0.26 gal) 500 – 14.3

Ratios (fixed) 1:1 to 12:1 (depending upon cylinders selected)

Maximum Fluid Working Pressure 3000 psi (20.7 MPa, 207 bar)

Maximum Air Input Pressure 100 psi (0.7 MPa, 7 bar)

Maximum Cycle Rate 30 cpm

Maximum Operating Temperature 70 C (160 F), nylon pistons 50 C (120 F) UHMWPE pistons or PE Tanks

Air Inlet Size ¼ NPT (f)

Pump Fluid Outlet Size -03, -04, -06, -08 or –12 JIC fittings for 3/16 in (4.8 mm), ¼ in (6.4 mm), 3/8 in

(9.5 mm), ½ in (12.7 mm), ¾ in (19.1 mm) hoses

Wetted Parts 303/304, 17-4 PH, hard chrome, Chromex, carbide, Chemical Resistant

O-rings, PTFE, nylon, UHMWPE

Weight 55 kg (120 Lbs) typical with two 7.5L tanks

150 kg (330 Lbs) typical with two 60 L tanks

Sound Power Level

4 in Air Cylinder

Measured Per ISO Standard 9614-2

100 psi/30 cpm - 81 dBA

50 psi/15cpm – 77 dBA

Compressed Air < 10 scfm typical (varies with cycle times)

Electrical Power 100-240 V 50/60Hz, 1 phase for machine – 80 Watts

208-240V 50/60Hz, 1 phase for heat – 11 kW max.

120 or 240 VAC 50/60Hz 1 phase for on-board agitators, 80 Watts

240 VAC 50/60Hz 1 phase for off-board agitators, 830 Watts

Technical Data

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Dimensions

Figure 36: PR70 Dimensions (ON-Board PE Tank version Illustrated)

A typical PR70 Machine, with the standard On-Board twin 8 liter PE Tanks has the following dimensions:

Dimension In. (mm) Dimension In. (mm)

A (width) 18.49 (469.6) C (depth) 30.62 (777.7)

B (height) 26.39 (670.3) D (height in Back) 13.39 (340.1)

A typical PR70 Machine, with the standard On-Board 7.5 liter Stainless Steel Tanks has the following dimensions:

Dimension In. (mm) Dimension In. (mm)

A (width) 15.5 (393.7) C (depth) 30.62 (777.7)

B (height) 27.37 (695.2) D (height in Back) 13.39 (340.1)

Warranty and Graco Contact Information

312393G 50 of 50

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.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 312393

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2007, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revised November 2013

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. 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 CUSTOMERS

The 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 Information

For 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