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Instructions 3A4030C Intelligent Intelligent Intelligent Paint Paint Kitchen Paint Kitchen Kitchen Used to to to remotely remotely monitor monitor and and control control equipment equipment used used in in in a a a paint paint kitchen. kitchen. For For professional professional use use only.
Usage Usage Usage Approvals Approvals Approvals Voltage Voltage Voltage 25A693 Touchscreen Used to monitor and control 100–240 VAC functions of the paint kitchen components located inside the hazardous location. The operator uses the Touchscreen interface to view and remotely 9902741 control conditions and settings.
Component Manuals Component Manuals Manuals Component Component Manuals The following is a list of Graco component manuals written in English. These manuals and any available translations can be found at www.graco.com. Manual No. Description Description Description Manual Manual 333389 E-Flo® DC 2-Ball Piston Pumps 3A2096 E-Flo®...
Warnings Warnings 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 or on warning labels, refer back to these warnings.
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Warnings WARNING WARNING WARNING SKIN SKIN SKIN INJECTION INJECTION HAZARD INJECTION HAZARD HAZARD High-pressure fluid from dispensing device, 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 surgical treatment.
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Warnings WARNING WARNING WARNING MOVING MOVING MOVING PARTS PARTS HAZARD PARTS HAZARD HAZARD Moving parts can pinch, cut, or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. •...
Intelligent Paint Kitchen Overview Intelligent Paint Paint Kitchen Kitchen Overview Overview Intelligent Intelligent Paint Kitchen Overview The Intelligent Paint Kitchen (also known as IPK) is a platform of compatible sensors, controllers, pumps, agitators, and communication components that can be combined to create a customized paint circulation system.
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(PD) in the hazardous location and the Touchscreen Box (J) or a Programmable Logic Controller (also known as PLC). The Supervisor Box converts information from the Graco Touchscreen Box (J) or Programmable Logic Controller into fiber optic signals used by the system components.
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Agitator Continuously mixes and stirs the contents, preventing fluid from separating, setting, (Primary or drying on the inside of the tank. This agitator can be either a Graco electric agitator Tank), page or a user-supplied agitator. If an electric agitator is used, an additional Variable Frequency Drive/Inverter (B) is needed to control the agitator speed.
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Agitator Continuously mixes and stirs the contents, preventing fluid from separating, setting, (Secondary or drying on the inside of the tank. This agitator can be either a Graco electric agitator Tank), page or a user-supplied agitator. If an electric agitator is used, an additional Variable Frequency Drive/Inverter (B) is needed to control the agitator speed.
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Intelligent Paint Kitchen Overview E E E - - - Flo Flo DC DC Pump Pump (C) Pump Each station can contain one E-Flo DC pump (C). The pump’s job is to continuously circulate a specific paint color through the paint kitchen, making that color available for spraying.
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Intelligent Paint Kitchen Overview Pump Pump Pump Control Control Control Module Module Module (PD) (PD) (PD) Pressure Pressure Transducer Pressure Transducer Transducer (K) 24P822, 24P822, 24P822, 17V232 17V232 17V232 24R050, 24R050, 24X089 24R050, 24X089 24X089 The Pump Control Module (PD) is a Modbus RTU Install the Pressure Transducer (K) using one of the node in the station.
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Intelligent Paint Kitchen Overview Back Back Back Pressure Pressure Regulator Pressure Regulator Regulator (E) Run/Stop Run/Stop Switch Run/Stop Switch Switch (U) and Controller Controller Controller (F) 16U729 16U729 16U729 24V001 24V001 24V001 Install the Run/Stop Switch (U) using the Run/Stop Switch Kit 16U729.
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Intelligent Paint Kitchen Overview Tank Control Control Module Module (TD) (TD) Tank Tank Control Module (TD) Radar Radar Level Radar Level Level Sensor Sensor (M, Sensor (M, T) T) T) 25D293, 25D293, 25D294 25D293, 25D294 25D294 17S843 17S843 17S843 A Radar Level Sensor (M, T) is used to monitor the A Tank Control Module (TD) is needed for a station level of material inside the tank.
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Intelligent Paint Kitchen Overview Fill Fill Fill Pump Pump Transfer Pump Transfer Solenoid Transfer Solenoid Solenoid (P) Agitator Agitator (L, Agitator (L, R) R) 24Z671 24Z671 24Z671 One agitator (L, R) is typically mounted on each tank. The agitator’s purpose is to keep the fluid mixed, The Fill Pump Transfer Solenoid (P) engages the without incorporating air into the fluid.
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Variable Frequency Drives/Inverters may be obtained Intelligent Paint Kitchen. For complete warnings and from Graco or from a variety of manufacturers. operation instructions, see the Variable Frequency Supported Variable Frequency Drive/Inverter Drives manual 3A4793.
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Intelligent Paint Kitchen Overview Supervisor Box Box (A) Supervisor Supervisor 25A830 25A830 25A830 As shipped, the Supervisor Box (A) contains the data table to create a large datamap with each node Supervisor Module (36), power supply, switch, slotted in a specific set of addresses. Ethernet switch, and one fiber optic converter.
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Intelligent Paint Kitchen Overview Fiber Fiber Fiber Optic Optic Optic Converter Converter Converter 24N978 24N978 24N978 Installed inside the Supervisor Box (A) and the Expansion Box, each serial to fiber optic converter sends data to and receives data from one Pump Control Module (PD) installed in the hazardous location of a station.
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Intelligent Paint Kitchen Overview Expansion Expansion Expansion Box 25A843 25A843 25A843 Use an Expansion Box when your system requires Expansion Boxes are shipped with one fiber optic more fiber optic converters than can fit in the converter (38) installed. Each box also contains one Supervisor Box (A).
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Intelligent Paint Kitchen Overview Touchscreen Box Box (J) Touchscreen Touchscreen 25A693 25A693 25A693 The Touchscreen Box (J) is an optional component A 2 GB SD flash card can be used to install and in the Intelligent Paint Kitchen. The Touchscreen Box update the software used by the Touchscreen Box.
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Intelligent Paint Kitchen Overview Touchscreen Box Box Connections Connections Touchscreen Touchscreen Connections Power and communication connections are made using the ports located along the bottom of the Touchscreen Box. Figure 14 Touchscreen Box Connections Ref. Function Function Function Ref. Ref. Power USB device connection for PC (USB B) RS-485 Port B (not used)
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Intelligent Paint Kitchen Overview Examples of of of Component Component Connections Connections Examples Examples Component Connections The following diagrams illustrate different ways to connect Intelligent Paint Kitchen components. Use the diagram that corresponds to the components used in your station. Connect each of the lettered components to the corresponding lettered port on the Pump Control Module (PD) or Tank Control Module (TD), as shown.
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Intelligent Paint Kitchen Overview Connections in in in a a a System System with with No No Pump Pump Control Control Module Module and and One One Tank Tank Control Control Module Module Connections Connections System with Pump Control Module Tank Control Module...
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Intelligent Paint Kitchen Overview Connections in in in a a a System System with with One One Pump Pump Control Control Module Module and and One One Tank Tank Control Control Module Module Connections Connections System with Pump Control Module Tank Control Module...
Installation and Wiring Installation and and Wiring Wiring Installation Installation Wiring Before Installation Installation Before Before Installation Before installation, verify the following: • All system and component documentation is available during installation. To reduce the risk of fire, explosion, or electric shock, only install equipment in a hazardous •...
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Installation and Wiring Connections to to to the the E E E - - - Flo Flo DC DC Pump Pump Connections Connections Pump For complete warnings and operation instructions for the E-Flo DC pump, see the following manuals: Manual Manual Manual Description...
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NOTE: The following illustrations show connections NOTE: NOTE: Follow these steps to ground the Radar Level to a Graco-approved Radar Level Sensor. If you are Sensors (M, T): not using a Graco-approved Radar Level Sensor, 1. Loosen the ground screw and attach a ground contact your distributor.
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Termi- Description Description Description Note Note Note the Graco Variable Frequency Drive/Inverter (B). Graco Variable Frequency Drives/Inverters include Internal DC +10 VDC, max 10 parts 17N041, 17N042, and 17N043. For complete supply for warnings and operation instructions for Graco speed pot...
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Components Follow these steps to install the RS-485 module, As a best practice to avoid confusion, clearly label which is shipped with Graco Variable Frequency each component mounted in the non-hazardous and Drives/Inverters (B) 17N041, 17N042, and 17N043. hazardous locations.
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Installation and Wiring Supervisor Box Supervisor Supervisor Connect Connect Connect Power Power to to to the Power the Supervisor Supervisor Box Supervisor 4. Tighten the strain relief. 5. Connect the supply ground wire to the protective earth ground terminal (7b) provided in the enclosure.
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Installation and Wiring Install the the Serial Serial to to to Fiber Fiber Optic Optic Converters Converters Install Install Serial Fiber Optic Converters Every Intelligent Paint Kitchen must have one NOTE: NOTE: NOTE: Mount each component onto the DIN rail before making power or communication connections Supervisor Box (A) installed in the non-hazardous before...
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Installation and Wiring Set DIP DIP Switches Switches Switches on on the the Fiber Fiber Optic Fiber Optic Optic Converters Converters Converters Each Supervisor Box (A) contains one to ten fiber optic converters (38). Each station requires one converter, and each Supervisor Box is shipped with one fiber optic converter.
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Installation and Wiring Connect Connect Connect DC DC Power Power Power to to to the the Fiber Fiber Fiber Optic Optic Converters Optic Converters Converters Supervisor Supervisor Supervisor Box: Box: Each Supervisor Box (A) is Box: shipped with one fiber optic converter installed and connected to the 24 VDC power supply.
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Installation and Wiring Label Label Label the the Fiber Fiber Optic Fiber Optic Converters Optic Converters Converters For Intelligent Paint Kitchen maintenance and troubleshooting purposes, it is important to know which station is connected to each fiber optic converter. If your Intelligent Paint Kitchen system controls multiple stations, it is recommended to mark each fiber optic converter with a label (for example, 3), clearly indicating the station connected to that fiber...
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Installation and Wiring If an Expansion Box is used with the Supervisor Wire Color Wire Wire Color Color Box (A), continue the series so that all fiber optic White/Blue converters are connected to the Supervisor Module (36) in one long series. Blue NOTE: The Modbus (RS-485) shield wire is intended to be connected to the EMC ground terminal (7a) in...
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Installation and Wiring Wire the the Variable Variable Frequency Frequency Drive/Inverter Drive/Inverter to to to the the Supervisor Supervisor Module Module Wire Wire Variable Frequency Drive/Inverter Supervisor Module Each electric agitator in the Intelligent Paint Kitchen If a station is connected to multiple Variable system can be remotely controlled by a Variable Frequency Drives/Inverters, wire the Variable Frequency Drive/ Inverter (B) installed in the...
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Installation and Wiring Expansion Box Expansion Expansion Connect Connect Connect Power Power to to to the Power the Expansion Expansion Box Expansion 4. Tighten the strain relief. 5. Connect the supply ground wire to the protective earth ground terminal (7b) provided in the enclosure.
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Installation and Wiring Connect Pump Pump and and Tank Tank Control Control Modules Modules to to to the the Supervisor Supervisor Box Connect Connect Pump Tank Control Modules Supervisor Use fiber optic cables to connect each fiber optic 3. Connect the Pump Control Module in the converter to a Pump Control Module (PD).
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100 feet (30 m) 17B160 330 feet (100 m) Use cables 17T898, 16M172, 16M173, or 17B160, depending on the length needed. Graco recommends using the shortest cable needed to make the fiber optic connections. Figure 39 Connect Fiber Optic Converter to Pump...
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Installation and Wiring Touchscreen Box Touchscreen Touchscreen Connect Connect Connect Power Power to to to the Power the Touchscreen Touchscreen Box Touchscreen 4. Tighten the strain relief. 5. Connect the supply ground wire to the protective earth ground terminal (7b) provided in the enclosure.
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Installation and Wiring Connect Connect Connect the the Supervisor Supervisor Supervisor Box Box to to to the I/O Module Module Module Touchscreen Touchscreen Touchscreen Box 17T198 17T198 17T198 The Touchscreen Box (J) requires a communication The I/O module is part of the optional light tower kit connection to the first Supervisor Box (A).
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Installation and Wiring Connect Connect Connect the the Light Light Tower Light Tower to to to the Tower the Touchscreen Touchscreen Touchscreen 4. Install a black jumper wire between terminals 1 and 4 on the I/O module. 5. Connect the light tower wires to the I/O module If the optional light tower accessory is used, mount as follows: and wire it to the Touchscreen Box (J).
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• Expansion Box or Boxes • Expansion Box or Boxes NOTE: If you turn the power off to the Touchscreen The Graco logo displays while the system initializes, Box only, the system continues to operate. followed by the Stations screen.
Software Setup Software Setup Setup Software Software Setup Software Overview Overview Software Software Overview The Intelligent Paint Kitchen uses software that – Level Sensor for the Primary/Secondary Tank allows the components to communicate with each Agitators (M, T) other. The software is also used to set up the system –...
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Software Setup Set Up Up Pump Pump Controls Controls Set Up Up Tank Tank Controls Controls Pump Controls Tank Controls For complete warnings and operation instructions, For complete warnings and operation instructions, see the E-Flo DC Control Module Kit manual 3A2527. see the Tank Control Module Kit manual 3A5991.
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Software Setup Control Control Control Module Module Module Software Software Software Pump Control Modules and Tank Control Modules Name Name Name Function Function Function located in each hazardous location can be set up Toggle Toggle between Run screens locally, using the keypad and display to access and and Setup screens.
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Software Setup Set Up Up a a a Pump Pump Pump Control Control Module Control Module Module for for Modbus Modbus Communication Modbus Communication Communication Follow these steps to set up a Pump Control Module 4. Select a control location (local or remote) from (PD) using the keypad and display.
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Software Setup Set Up Up a a a Tank Tank Control Tank Control Module Control Module Module for for Modbus Modbus Communication Modbus Communication Communication Follow these steps to set up a Tank Control Module 4. Set the Modbus node ID from 1 to 247. (TD) using the keypad and display.
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Software Setup Set Up Up Pump Pump Control Pump Control Control Module Module Configurable Module Configurable I/O Configurable Use the Pump Control Module (PD) keypad and 3. Press the Enter Screen key to enter the screen display to set up configurable inputs and outputs. and edit the settings.
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Software Setup Option Icon Screen Function Option Option Icon Icon Screen Screen Function Function Primary Tank Low Configures Port 4 pin 4 as an output Alarm Output to allow for the connected device to receive an alarm when the volume of the Primary Tank is below the value that is defined in the Primary Tank Low field...
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NOTE: NOTE: The following steps describe connections to 2. Use the Up Arrow and Down Arrow keys to a Graco-approved Radar Level Sensor. If you are navigate to Setup Screen 3. not using a Graco-approved Radar Level Sensor, contact your distributor.
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Radar Level Sensor Use this procedure to configure Graco part numbers Press E E E to enter the setup screen, press + + + to highlight the setup menu, and then press E E E to enter the setup 25D298 and 25D294 (Endress+Hauser FMP50 Radar Level Sensors).
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Software Setup Setup Screen Screen Function Setup Setup Screen Function Function Full calibration Enter the distance (LF) between the minimum (0%) and the maximum level (0%). The minimum is the bottom of the probe and the maximum is the “full” level. Level Displays the measured level (LL) of the material before...
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Keypad Frequency Drive/Inverter manufactured by Lenze Keypad Keypad (Graco part numbers 17N041, 17N042, and 17N043). The following steps require you to program For Variable Frequency Drives/Inverters made by information directly into a Lenze Variable Frequency a different company, see their documentation for Drive/Inverter.
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Software Setup Using the the Lenze Lenze Keypad Keypad and and Display Display Using Using Lenze Keypad Display 1. On the Lenze Variable Frequency Drive/Inverter 2. Set the P-codes to the following: keypad, press to go into Program mode. P P P - - - code code code Setting...
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For connection information, see Variable Frequency Drive/Inverter Connections, page 28. If the Variable Frequency Drive/Inverter was purchased from Graco, the jump Press to access the Variable Frequency is pre-installed. But if the Variable Frequency Drive/Inverter menu. See...
Touchscreen Software Touchscreen Software Software Touchscreen Touchscreen Software Touchscreen Touchscreen Icons Touchscreen Icons Icons Use the Touchscreen software to enter information and display software settings and current conditions in the Intelligent Paint Kitchen system. The software The following icons appear along the bottom of the is located in the Supervisor Box (A), but the data input Stations screen and other Run screens.
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Controls Onscreen Onscreen Controls When you power up, the Graco logo displays for Navigate through the software by pressing buttons, approximately five seconds, followed by the Stations keys, fields, and icons with your finger. Pressing any screen. To begin, press one of the icons along the of the controls on the screen brings you to another bottom of the screen.
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Touchscreen Software Ref. Description Ref. Ref. Description Description Popup screens appear when you need to select a command, enter a numerical value, or specify whether a condition exists. For example, selecting Yes Yes or No No, and turning a component on or off.
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Touchscreen Software Viewing the the Navigation Navigation Path Path Viewing Viewing Navigation Path or from the Station Status screen. Depending on which Run screen icon is highlighted in green, you know the path you took to get there. You can access many of the Intelligent Paint Kitchen software screens using many different navigation For ease of navigation, the Run screen icon that you paths.
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Using the Setup Screens Using the the Setup Setup Screens Screens Using Using Setup Screens Using the the Setup Setup Menu Menu Using Using Setup Menu Initial setup of an Intelligent Paint Kitchen requires you to enter the physical specifications of your stations and their components into the Intelligent Most system setup tasks are accessed through the Paint Kitchen software:...
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Using the Setup Screens Button Button Button Description Description Description Supervisor Press to display the Supervisor Configuration screen, used to access these Intelligent Configuration Paint Kitchen software functions: • View the status of each Supervisor Box in the system. • View or edit the IP address and the subnet mask, and the gateway used by the Supervisor network.
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Using the Setup Screens Setup Prerequisites Prerequisites Create the the Stations Stations Setup Setup Prerequisites Create Create Stations Before beginning these setup procedures, all paint Begin the setup process by entering the number of kitchen components must meet these conditions: stations in the system.
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Using the Setup Screens Configure Each Each Station Station Configure Configure Each Station When the stations have been created Use this procedure to specify the equipment installed Create the Stations, page 63), each station in one specific station. If the system contains multiple must be individually configured.
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Using the Setup Screens Table 4 4 4 Fields Fields on on the the Station Station Configuration Configuration Screen Screen Table Table Fields Station Configuration Screen Field Field Field Description Description Description Yes if the station has a Primary Tank. Primary Tank Select Yes No if there is no Primary Tank installed.
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Using the Setup Screens Name Each Each Station Station Name Name Each Station When the stations were created using the Intelligent For example, if your system has 14 paint kitchens, Paint Kitchen software ( Create the Stations, page 63), stations 1–10 might be connected to the Supervisor each station was given a unique number.
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Using the Setup Screens Turn on on Node Node Communication Communication Turn Turn Node Communication After entering the generated node IDs into each 4. Initially, the blue Off Off button indicates that Variable Frequency Drive/Inverter, each Pump all communication is turned off between the Control Module, and each Tank Control Module, Intelligent Paint Kitchen software and the turn on communication between the Intelligent Paint...
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Using the Setup Screens Set Up Up E E E - - - Flo Flo DC DC Pumps Pumps Pumps After turning on node communication to each Use this procedure to specify the pump installed in component, each pump in the system must be one specific station.
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Using the Setup Screens Table 5 5 5 Fields Fields on on the the E E E - - - Flo Flo DC DC Setup Setup Screen Screen Table Table Fields Setup Screen Field Field Field Description Description Description Station Number The current station number being displayed: •...
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Using the Setup Screens Field Field Field Description Description Description Off Production Enable/Disable Off Production mode on pump. Profile • Profile 4 indicates Off Production station with no tank control • Tank Fill is disabled • Tank Freeze alarm is enabled Production Enable/Disable Production profile.
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Using the Setup Screens Set Up Up Tank Tank Control Control Modules Modules Tank Control Modules Each station may contain a Secondary Tank (H), Use this procedure to specify the Secondary Tank used to provide fluid to the Primary Tank (G). components installed in one specific station.
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Using the Setup Screens Item Item Item Description Description Description Local / Remote Local to control the selected agitator and tank fill logic from the Tank Control Select Local Local Control Module in the hazardous location. Remote to control the selected agitator and tank fill logic from the Intelligent Select Remote Remote Paint Kitchen software in the non-hazardous location.
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Using the Setup Screens Set Up Up Primary Primary Tanks Tanks Primary Tanks Each station contains one Primary Tank (G) , which NOTE: NOTE: NOTE: When Tank Volume is configured (see provides the fluid that is pumped throughout the Configure Primary Tank Volume, page 77), the circulation system.
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Using the Setup Screens Table 7 7 7 Fields Fields on on the the Primary Primary Tank Tank Setup Setup Screen Screen Table Table Fields Primary Tank Setup Screen Item Item Item Description Description Description Station Number The current station number being displayed: •...
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Using the Setup Screens Set Up Up Primary Primary Agitator Agitator Primary Agitator Figure 69 Primary Agitator Screen 5. Press each item’s data field and use the keypad that displays to specify the equipment used in the selected station. 1. Press on any Run screen to enter the Setup NOTE: NOTE:...
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Using the Setup Screens Table 8 8 8 Fields Fields on on the the Primary Primary Agitator Agitator Setup Setup Screen Screen Table Table Fields Primary Agitator Setup Screen Item Item Item Description Description Description Station Number The current station number being displayed: •...
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Using the Setup Screens Configure Primary Primary Tank Tank Volume Volume Configure Configure Primary Tank Volume Figure 70 Primary Tank Configuration Screen 5. Press each item’s data field and use the keypad that displays to specify the equipment used in the selected station.
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Using the Setup Screens Table 9 9 9 Fields Fields on on the the Primary Primary Tank Tank Configuration Configuration Screen Screen Table Table Fields Primary Tank Configuration Screen Item Item Item Description Description Description Station Number The current station number being displayed: •...
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Using the Setup Screens Set Up Up Secondary Secondary Tanks Tanks Secondary Tanks Every Secondary Tank must be individually Use this procedure to specify the Secondary Tank configured. installed in one specific station. If the system contains multiple stations, use this procedure separately for the drum in each station.
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Using the Setup Screens Table 10 10 Fields Fields on on the the Secondary Secondary Tank Tank Setup Setup Screen Screen Table Table Fields Secondary Tank Setup Screen Item Item Item Description Description Description Station Number The current station number being displayed: •...
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Using the Setup Screens Set Up Up Secondary Secondary Agitator Agitator Secondary Agitator Figure 72 Secondary Agitator Screen 5. Press each item’s data field and use the keypad that displays to specify the equipment used in the selected station. For a list of fields, see 1.
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Using the Setup Screens Table 11 11 Fields Fields on on the the Secondary Secondary Agitator Agitator Setup Setup Screen Screen Table Table Fields Secondary Agitator Setup Screen Item Item Item Description Description Description Station Number The current station number being displayed: •...
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Using the Setup Screens Configure Secondary Secondary Tank Tank Volume Volume Configure Configure Secondary Tank Volume Figure 73 Secondary Tank Configuration Screen 5. Press each item’s data field and use the keypad that displays to specify the equipment used in the selected station.
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Using the Setup Screens Table 12 12 Fields Fields on on the the Secondary Secondary Tank Tank Configuration Configuration Screen Screen Table Table Fields Secondary Tank Configuration Screen Item Item Item Description Description Description Station Number The current station number being displayed: •...
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Using the Setup Screens Create Pump Pump Profiles Profiles Create Create Pump Profiles Every pump installed in a station is used to constantly Use this procedure to create up to four profiles for circulate fluid through the paint kitchen. The pump each pump.
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Using the Setup Screens 6. Set up a profile for the pump located in the selected station. Each column (#1, #2, #3, and #4) in the table contains the parameters for one profile. Press each item’s data field and use the keypad that displays to create each pump profile.
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Using the Setup Screens Set Up Up Agitator Agitator Profile Profile Agitator Profile Figure 75 Primary Agitator Profile Screen Figure 76 Secondary Agitator Profile Screen 4. On the Station Station Number Station Number keypad, enter the number Number of the station to be configured. The number in the field is the station that is 1.
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Using the Setup Screens 6. Repeat steps 3–6 for each additional station in the system. Table 13 13 Fields Fields on on the the Agitator Agitator Profiles Profiles Screen Screen Table Table Fields Agitator Profiles Screen Item Description Item Item Description Description Station Number...
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Using the Setup Screens Set Up Up Production Production Schedule Schedule Production Schedule Figure 77 Production Schedule Setup Screen Item Description Ref. Ref. Ref. Item Item Description Description Preset Production schedule preset: • 1–3 Time Each day offers up to 6 different times to toggle between production and off production: •...
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Using the Setup Screens Set Up Up Notifications Notifications Notifications When an alarm or event occurs, email notifications 4. On the Email Address screen, press the data can be automatically sent by email or text message. field for each column, then use the popup keypad Use this procedure to enter up to ten email addresses to enter information for each person to receive for up to ten users.
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Using the Setup Screens Optional Text Text Message Message Using Using Email Email Optional Optional Text Message Using Email When connected to an SMTP server, you can send 555–555–5555, use 5555555555@txt.att.net as the SMS text messages using the email-to-text services address.
NOTE: NOTE: NOTE: Do not modify these settings from the default provided on this page without contacting 2. On the Setup Menu screen, press HMI Graco. Otherwise, the Touchscreen Module Configuration Configuration. Configuration cannot control or monitor the system. 3. On the Display Configuration screen, press Port...
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4. Confirm that communication to the Supervisor communication by pinging the system. Box is working properly. NOTE: NOTE: Do not modify these settings unless instructed NOTE: by Graco. 1. Press on any Run screen to enter the Setup menu screen. 2. Press Supervisor Supervisor Configuration...
Network Setup and Configuration Set Up Up the the Email Email Server Server Email Server Use the Email Setup Screen to access the screens b. To enter the changes and have them take Apply. The SMTP Server used to configure the SMTP server, and to enter effect, press Apply Apply email addresses to which notifications of Intelligent...
Network Setup and Configuration Create a a a Password Password Create Create Password Change or or or Disable Disable the the Password Password Change Change Disable Password Create a numeric password when you want to limit the ability to change Intelligent Paint Kitchen settings. If a password is enabled for the Intelligent Paint If a password has been created, you are prompted to Kitchen software, any user who knows the current...
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Network Setup and Configuration Security Security Security Levels Levels Levels There are two levels of Administrator access: Administrator: Right to access and change all • Administrator: Administrator: values • Operator: Operator: Right to change E-Flo DC active profile Operator: Figure 79 Security Levels Screen 3A4030C...
Operation Operation Operation Operation Using the the Run Run Screens Screens Using Using Screens While the Intelligent Paint Kitchen is operating, use the top-level Run screens to control the system and view current operating conditions in each station. Access the Run screens by pressing the icon on the bottom of the Touchscreen interface.
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Operation Manage Manage Manage Production Production Schedule Production Schedule Schedule Figure 80 Production Schedule Setup Screen Ref. Ref. Ref. Item Item Item Description Description Description Preset Current roduction schedule preset: • 1–3 Time Each day offers up to 6 different times to toggle between production and off production: •...
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Operation Ref. Item Description Ref. Ref. Item Item Description Description Stations Allows grouping of stations that will be controlled by the production schedule. Weekend Mode Sets all current preset Saturday and Sunday times to off production. 3A4030C...
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Operation View View View the the Graphs Graphs Screen Graphs Screen Screen Use the graphs screen to display live or historical 1. Press on any Run screen. data for a selected component in a station or conditions in the station. 2.
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Operation 3. Use the controls on the graph to change the view or type of data displayed. Figure 81 Example: Graph Screen 4. When finished, press to return to the Graph Menu screen. Item Description Item Item Description Description Shows the percent, pressure, or speed of the parameter being measured, e.g., tank level. Units of measure depends on the graph type.
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Operation View View View the the Stations Stations Screen Stations Screen Screen The Stations screen displays component-level Each control icon displayed in a row indicates information for every component in the station. From a component that is physically installed in the this screen, you can quickly evaluate the status of station and has been configured to communicate your fluid.
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Operation You can perform any of the following tasks from the Stations screen: Task Action Task Task Action Action Production column for the station, press Off Off. The button changes to On On and Enable production on In the Production Production a station turns green to indicate that the station is successfully enabled.
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Operation Station Station Station Status Status Screen Status Screen Screen The Station Status screen is a visual representation Use this screen to view detailed operating conditions of the components that are physically installed in a in the selected station and its components. Some station.
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Operation Ref. Ref. Ref. Item Item Item Description Description Description Pneumatic Remote Indicates the current status of the pump. Transfer Fill Pump Status indicates that the pump is stopped. indicates that the pump is transferring fluid to the Primary Tank. Back Pressure Displays the current Back Pressure Regulator setting in %.
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Operation Ref. Ref. Ref. Item Item Item Description Description Description Pump icon Press to display the Pump Status screen. The color of the icon indicates the status of the agitator. Primary tank icon Press to display the Primary Tank Status screen. The color of the icon indicates the status of the tank.
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Operation Pump Pump Pump Status Status Status Screen Screen Screen The Pump Status screen displays live operational Use this screen to view detailed and current data for the pump installed in the selected station. information for the primary pump in any station. Access this screen from the Stations screen (see View the Stations Screen, page 102).
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Operation Primary Primary Primary Tank Tank Tank Status Status Status Screen Screen Screen The Primary Tank Status screen displays live Use this screen to view current status and to view operational data for the Primary Tank installed in the or change level settings for the Primary Tank in the selected station.
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Operation Item Item Item Description Description Description Target Level (TL) Press to display a keypad used to specify the fluid level in the tank. This level (0–100%) must be in-between the high level alarm setting and the low level alarm setting Fill Level (FL) Press to display a keypad used to specify the tank fill percentage that turns on the remote transfer pump.
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Operation Secondary Secondary Secondary Tank Tank Status Tank Status Status Screen Screen Screen The Secondary Tank Status screen displays live Use this screen to view current status and to view or operational data for the Secondary Tank installed in change level settings for the Secondary Tank in the the selected station.
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Operation Agitator Agitator Agitator Run Run Screen Screen Screen Use this screen to view detailed and current information for the primary agitator in any station. The Agitator Run screen displays live operational data for the agitator installed in the selected station. Access this screen from the Stations screen (see View the Stations Screen, page 102).
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Operation Ref. Item Description Ref. Ref. Item Item Description Description Enable The read-only part of the field (On or Off) indicates the current status of the Variable Frequency Drive/Inverter controlling the selected agitator. • If the Variable Frequency Drive/Inverter is Off, press Enable to start the Variable Frequency Drive/Inverter.
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Operation Ref. Item Description Ref. Ref. Item Item Description Description Fault • No Fault • TMP Output Fault • Output (Transistor) Fault • Ground Fault • High Drive Temperature • Flying Start Fault • High DC Bus Voltage • Low DC Bus Voltage •...
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Operation Ref. Item Description Ref. Ref. Item Item Description Description Actual RPM Current agitator blade speed. • Direct Drive: 0-500 RPM • Back Gear: 0-50 RPM Set Point Set point for agitator: • Percentage: 0 -100% • Hertz: – Direct Drive: 2-18 Hz –...
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Operation View View View the the Pumps Pumps Pumps Screen Screen Screen The Pumps screen displays component-level information for the pump in each station. From this screen, you can navigate directly to any Station Press on any Run screen to display the screen and you can view current operational data for Pumps screen.
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Operation You can view the following information for each pump in the Intelligent Paint Kitchen system: Item Item Item Description Description Description Pressure Read-only. Indicates the current pressure at the outlet of the pump. Depending on the configuration, this column displays the following: •...
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Operation View View View the the Tanks Tanks Tanks Screen Screen Screen The Tanks screen displays fluid level and agitator speed information for every Primary Tank and Secondary Tank in the Intelligent Paint Kitchen Press on any Run screen to display the system.
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Operation You can perform any of the following tasks from the Tanks screen: Task Action Task Task Action Action Production column for the station, press Off Off. The button changes to On On and Enable a station In the Production Production turns green to indicate that the station is successfully enabled.
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• Connect an Ethernet cable to Port 1 on the bottom of the Touchscreen Box. See – Primary Agitator Frequency: Recorded 5-second the Touchscreen Connections section in intervals Touchscreen Box (J) 25A693, page – Secondary Agitator Frequency: Recorded 5-second intervals – Primary Tank Level: Recorded 60-second intervals –...
Events and Logs Events and and Logs Logs Events Events Logs Set Up Up Events Events Events System errors alert you of a problem and help prevent failures in the Intelligent Paint Kitchen from occurring. There are three types of events: Advisory, Use this procedure to specify how Intelligent Paint Deviation, and Alarm.
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Events and Logs View the the Event Event Log View View Event The Event Log contains a record of all advisories, • Station number where the event occurred. deviations, and alarms that have occurred in the • The error code that was detected. Go to the system.
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Events and Logs Error Codes Codes Error Error Codes NOTE: NOTE: When an error occurs be sure to determine the code before resetting it. If you forget which code NOTE: occurred, see View the Event Log, page 122 to view the last 200 errors, with date, time, station number, and description.
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Events and Logs Code Fault Problem Solution Code Code Fault Fault Problem Problem Solution Solution Phase U to Ground A phase to ground fault has been • Check the wiring between the drive Short detected between the drive and and motor. motor in this phase.
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Events and Logs Lenze Errors Errors Lenze Lenze Errors Code Fault Problem Solution Code Code Fault Fault Problem Problem Solution Solution F_AF High Temperature The drive is too hot inside. • Reduce the drive load. • Improve cooling. F_AL Assertion Level •...
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Events and Logs Code Fault Problem Solution Code Code Fault Fault Problem Problem Solution Solution F_IL Digital Input More than one digital input is set for Each setting can be used once Configuration (except settings 0 and 3). the same function. (P121–P124) Only one digital input is configures One input must be set to MOP Up,...
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Events and Logs Code Fault Problem Solution Code Code Fault Fault Problem Problem Solution Solution F_PF Motor Overload Excessive motor load for too long. • Verify that P108 is set properly. • Verify that the drive and motor are the proper size for the application. F_rF Flying Restart The controller was unable to...
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Events and Logs E-Flo DC DC Errors Errors E-Flo E-Flo Errors Display Applicable Blink Type Description Display Display Applicable Applicable Blink Blink Type Type Description Description Code Code Code Motor Motor Motor Code Code Code None Basic Alarm The Mode Select knob is set between Pressure Flow .
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Events and Logs Display Applicable Blink Type Description Display Display Applicable Applicable Blink Blink Type Type Description Description Code Code Code Motor Motor Motor Code Code Code L1A0 None Alarm The flow rate is above the current profile flow limit set on Profile Screen 3.
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Events and Logs Display Applicable Blink Type Description Display Display Applicable Applicable Blink Blink Type Type Description Description Code Code Code Motor Motor Motor Code Code Code V4I_ Basic and Alarm Voltage supplied to motor is too high. Advanced V9M_ Basic and Alarm Low supply voltage detected at start up.
Troubleshooting Troubleshooting Troubleshooting Troubleshooting NOTE: Check all possible remedies before disassembling the system. NOTE: NOTE: Problem Problem Problem Cause Solution Cause Cause Solution Solution The Supervisor The Modbus settings are Make sure node communication is turned on. incorrect. Box (A) cannot Verify the Modbus settings on the Pump Control Module.
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Troubleshooting Problem Cause Solution Problem Problem Cause Cause Solution Solution The wiring is incorrect. Check the Modbus wiring between the Supervisor Module and the fiber to serial converter. • A = GND • B = Data B(+) – Blue/White • C = Data A(-) – White/Blue Fiber ports are Verify the fiber port setup.
System Software Tasks System Software Software Tasks Tasks System System Software Tasks View Software Software Versions Versions View View Software Versions 2. Press Versions Versions. Versions Use these steps to display the currently installed IPK, EFlo-DC EFlo-DC, 3. On the Versions screen, press IPK EFlo-DC versions of software in your Intelligent Paint Kitchen or Tank...
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System Software Tasks Calibrate Calibrate Calibrate the the Touchscreen Touchscreen Touchscreen Interface Interface Interface If pressing a control on the Touchscreen interface Proper calibration helps ensure that the displayed does not display the screen, calibrate the button, field, key, or icon corresponds to the location Touchscreen interface.
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System Software Tasks Use an an SD SD Card Card Card An SD flash card can be inserted into a slot on the 1. Press on any Run screen to enter the Setup left side of the Touchscreen Module (14). menu screen.
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System Software Tasks Set the the Time Time Time and and Date Date Date 4. On the Time screen, press the current date and time displayed on the screen. Set the correct time and date so the event log 5. Use the Label Label popup to enter the current time Label registers events as they occur.
Repair Repair Repair Repair Replace Replace the Replace the Battery Battery Battery on on the Individual items used in the Supervisor Box (A) and Touchscreen Box (J) are not repairable. If they fail, Touchscreen Touchscreen Module Touchscreen Module Module they must be replaced. The Touchscreen Module (14) uses a 3-volt lithium battery to run the internal clock during times when the system is not powered.
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Repair Replace a a a Fiber Fiber Optic Optic Converter Converter Replace the the Supervisor Supervisor Module Module Replace Replace Fiber Optic Converter Replace Replace Supervisor Module 1. Disconnect the power. 1. Disconnect the power. 2. Disconnect the + (white/blue) and – (blue) 2.
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Repair Replace the the Ethernet Ethernet Switch Switch for for the Replace the the Power Power Supply Supply for for the Replace Replace Ethernet Switch Replace Replace Power Supply Supervisor Module Module Supervisor Module Module Supervisor Supervisor Module Supervisor Supervisor Module 1.
Parts Parts Parts Parts Touchscreen Box, Box, 25A693 25A693 Touchscreen Touchscreen Box, 25A693 Part Description Part Description Part Part Description Description Part Part Description Description - - - - - 1▲ 15W776 LABEL, warning BLOCK, terminal - - - - -...
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Parts Supervisor Box, Box, 25A830 25A830 Supervisor Supervisor Box, 25A830 Part Part Part Description Description Description Part Part Part Description Description Description 1▲ 15W776 LABEL, warning 15V342 SWITCH, Ethernet, 8–port 116320 SWITCH, rocker, power 24N978 CONVERTER, serial to - - - - - CONNECTOR, fiber optic Ethernet, RJ45...
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Parts Expansion Box, Box, 25A843 25A843 Expansion Expansion Box, 25A843 Part Description Part Description Part Part Description Description Part Part Description Description - - - - - 1▲ 15W776 LABEL, warning CONNECTOR, circuit board, 5 position 116320 SWITCH, rocker, power - - - - - CONNECTOR, circuit - - - - -...
Kits and Accessories Kits and and Accessories Accessories Kits Kits Accessories Light Tower, Tower, 122193 122193 Transfer Pump Pump Mounting Mounting Kit, Kit, 17S959 17S959 Light Light Tower, 122193 Transfer Transfer Pump Mounting Kit, 17S959 I/O Module, Module, 17T198 17T198 Module, 17T198 Install this kit to transfer fluid from the Secondary...
Dimensions Dimensions Dimensions Dimensions Touchscreen Box Box Dimensions Dimensions Touchscreen Touchscreen Dimensions Metric Reference Reference Reference U.S. U.S. U.S. Metric Metric 15.00 in. 381.0 mm 17.50 in. 444.5 mm 8.51 in. 216.2 mm 12.00 in. 304.8 mm 16.75 in. 425.5 mm 3A4030C...
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Dimensions Supervisor Box Box and and Expansion Expansion Box Box Dimensions Dimensions Supervisor Supervisor Expansion Dimensions Figure 100 Supervisor Box Figure 101 Expansion Box Reference Reference Reference U.S. U.S. U.S. Metric Metric Metric 15.00 in. 381.0 mm 17.50 in. 444.5 mm 8.25 in.
Appendix A: System Design Appendix A: A: A: System System Design Design Appendix Appendix System Design If a station contains a Secondary Tank (H), a Tank 2. For each station, choose the components to build Control Module (TD) is needed to provide control that station’s fluid circulation system: over the tank’s agitator (R), Radar Level Sensor (M, a.
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Appendix A: System Design 4. Determine the type and number of paint kitchen 5. Determine the type, length, and number of cables components to be installed in the non-hazardous needed to connect the paint kitchen components location, needed to control the number of together: stations: a.
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Appendix A: System Design Scaling Up Up the the System System Scaling Scaling System Every Intelligent Paint Kitchen system has at least NOTE: NOTE: NOTE: One Supervisor Box can hold up to 10 fiber one Supervisor Box containing at least one fiber optic optic converters, and one Expansion Box can hold up converter.
Appendix B: Cables Appendix B: B: B: Cables Cables Appendix Appendix Cables The following cables are typically used to connect the components in an Intelligent Paint Kitchen system. Cable Cable Cable Type Type Type Length Length Length Part Part Part No. Ethernet Cable 1 foot (0.3 m) 121994 1.
Appendix C: Electrical Schematics Appendix C: C: C: Electrical Electrical Schematics Schematics Appendix Appendix Electrical Schematics Touchscreen Box Box Schematic Schematic Touchscreen Touchscreen Schematic TOUCHSCREEN CONTROL MODULE (17K908) RS485 AUXILIARY USB HOST RS232 RS485 RS232 DEVICE PORT B ETHERNET ETHERNET PORT A PORT A PORT B...
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Appendix C: Electrical Schematics Supervisor Box Box Schematic Schematic Supervisor Supervisor Schematic SHIELDED CABLE 17S109 WIRE 261098 CABLE 121994 GRN/YELLOW ETHERNET RS485 A B C D E SWITCH CONVERTER (15V342) SUPERVISOR (16K465) MODULE (17R317) 1 2 3 4 5 6 CLASS 2 BLACK CABLE 16W159...
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Appendix C: Electrical Schematics Expansion Expansion Expansion Box Box Schematic Schematic Schematic A B C D E CONVERTER (16K465) CABLE 16W159 CLASS 2 (USE CLASS 2 CONDUCTORS) + - - 24VDC POWER SUPPLY (121314) 18A996 (2 WIRE HARNESS) CLASS 1 SWITCH (116320) 18A995...
Appendix D: Communication Configuration Appendix D: D: D: Communication Communication Configuration Configuration Appendix Appendix Communication Configuration When installing a system, each component requires circuit. The termination resistor is installed on the communication cables. See the diagram below for fiber optic converter in the Supervisor Box in the sample configurations.
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Appendix D: Communication Configuration Parameters Parameters Parameters Parameter Value Description Parameter Parameter Value Value Description Description P046 1 = Keypad Start Source 2 = DigInTrmBlk 3 3 3 = = = Serial/DSI Serial/DSI Serial/DSI 4 = Network Opt 5 = EtherNet/IP P047 1 = Drive Pot Speed Source...
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Appendix D: Communication Configuration Parameter Value Description Parameter Parameter Value Value Description Description C126 0.1 – 60 seconds Communication Loss Time C127 0 = RTU 8-N-1 RS-485 Format 1 = RTU 8-E-1 2 = RTU 8-O-1 4 4 4 = = = RTU RTU 8 8 8 - - - N N N - - - 2 2 2 5 = RTU 8-E-2 6 = RTU 8-O-2...
Appendix F: Agitator Part Numbers Appendix F: F: F: Agitator Agitator Part Part Numbers Numbers Appendix Appendix Agitator Part Numbers 60 Hz Hz Direct Direct Drive Drive Direct Drive Part Part No. Part Description Description Description 25C453 3” Quick-clamp Flange Mount Agitator Motor 25C575 4”...
Software Software The Intelligent Paint Kitchen software can be updated 3. Double click to open the removable disk. when a new version is available from Graco. A USB 4. Replace the image.ci3 image.ci3 image.ci3 file with the updated file. A to USB B cable is needed for this procedure.
Appendix H: Master/Client Setup Appendix H: H: H: Master/Client Master/Client Setup Setup Appendix Appendix Master/Client Setup The intelligent paint kitchen offers a two screen • The default Client display should have a Port 2 IP solution where the user can view information from address of “192.168.1.51”.
Appendix H: Master/Client Setup Configure Multiple Multiple Displays Displays Configure Configure Multiple Displays Figure 112 Multiple Display Configuration Screen 3. Press Multiple Multiple Displays Multiple Displays. Displays 4. Press each field to enter or select configuration settings. For a list of fields, see Fields on the 1.
Appendix H: Master/Client Setup At At At Power Power Up During Normal Normal Operation Operation Power During During Normal Operation During power up, the HMIs will try to establish The current role of the display is always reported in communication. If one of the HMIs can’t be detected, the bottom left corner of the display.
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Appendix H: Master/Client Setup If the local display shows a role of “Client”, the user can press on “Client” to send a request to the Master to gain control. The following messages appear simultaneously on the local and remote HMIs. Local HMI Local Local...
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Appendix H: Master/Client Setup The following messages will appear on the local HMI depending on action from the remote HMI: Remote HMI HMI Action Action Local HMI HMI Message Message Remote Remote Action Local Local Message “Request Acknowledged” Acknowledged” “Request “Request Acknowledged”...
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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.
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