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Graco DC12 Operation & Setup

Graco DC12 Operation & Setup

High-volume metering system
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Operation – Setup
DC12
High-Volume Metering System
For dispensing 2 component high viscosity Epoxy Adhesive or Tooling Paste
materials.
100 psi (0.7 Mpa, 7 bar) Maximum Air Inlet Pressure
2500 psi (17.2 Mpa, 172 bar) Maximum Working Pressure
Not designed for use in Explosive Atmospheres.
Important Safety Instructions
Read all warnings and instructions in this and
all supplied manuals. Save these instructions.
See page 3 for product configuration information
PROVEN QUALITY, LEADING TECHNOLOGY.
312767B

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Summary of Contents for Graco DC12

  • Page 1 Operation – Setup DC12 312767B High-Volume Metering System For dispensing 2 component high viscosity Epoxy Adhesive or Tooling Paste materials. 100 psi (0.7 Mpa, 7 bar) Maximum Air Inlet Pressure 2500 psi (17.2 Mpa, 172 bar) Maximum Working Pressure Not designed for use in Explosive Atmospheres.

  • Page 2: Table Of Contents

    Alarm History ……………………………. 21 Technical Data ……………………………………. 68 Pressure Status ………………………… 22 Dimensions ……………………………………….. 69 Material Processed …………………….. 23 Graco Standard Warranty ……………………… 70 Technician (HMI) Screens …………….. 24 Graco Information ……………………………….. 70 Supply Setup ……………………………. 25 Shot Meter Setup ……………………….. 26 Data Logs …………………………………...

  • Page 3: Product Configurator

    Product Configurator DC12 - Code: DC12 - Code: The Following table applies to the DC12 configurations and indicates all of the options available for each letter shown above. Code A Ratio and Supply Pumps Code D Flow Meters and Hoses...

  • Page 4: Accessories

    DC12 Accessories Ram Supply Pump Kits 255513 KIT,COMPLETE SEAL, L250CS (55:1 PUMP) 255509 KIT,COMPLETE SEAL, L200CS (36:1 PUMP) 255517 KIT,COMPLETE SEAL, L500CS (14:1 PUMP) 255615 KIT,BLEEDVALVE, ALL CARBON 94/0432-2/50 VALVE,CHECK,1""NPT,F,MS Shot Meter Components C23136 RATIO CYLINDER #1000 C23200 RATIO CYLINDER #500...

  • Page 5: Supplied / Related Manuals

    Manual, Operation DC12 DC12 Repair Part Description 312896 Manual, Repair DC12 Related Manuals The following manuals are for standard Dispense Valve, DC12 components used on the DC12 Part Description 310551 Manual,3/4 Ball Seat Applicator 310550 Manual,1/2 Ball Seat Applicator Supply Systems Part...

  • Page 6: Warnings

    • 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.
  • Page 7 Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.

  • Page 8: Component Identification

    Component Identification Typical Installation Lift Locations Fig. 1 Main System Parts List Description Description Base Frame Static Mixer A Supply System Performance Monitor Plus B Supply System Swivel Boom Shot Meter Automatic Base Purge Automatic Dispense Valve Ratio Monitor Option 312767B...

  • Page 9: Pneumatically Controlled

    Component Identification Fig. 2 Main System Parts List Description Description Pneumatic Performance Monitor Fixed Manual Dispense Valve Pneumatic Dispense Valve Control Solvent Hardware Fixed Automatic Dispense Valve Solvent Pump 312767B...

  • Page 10: Performance Monitor Plus

    Performance Monitor Plus Human Machine Interface (HMI) Screens Performance Monitor Plus includes an electric monitoring package with HMI and pendant station. The following pages detail the included features. See product configurator code C. Performance Monitor Plus is 1 of 4 control choices. Operator Level Screens Main Menu Screen Fig.

  • Page 11: Setup

    Performance Monitor Plus Operator Level Screens Setup Fig. 4 Description Description Supply Pumps Screen Access Button Previous Screen Access Button Dispense Setup Screen Access Button Main Screen Access Button Purge Settings Screen Access Button Run Mode Screen Access Button 312767B...

  • Page 12: Supply Pumps

    Performance Monitor Plus Operator Level Screens A1 and B1 Rams are located on the base machine. Tandem pumps are optional and will only appear on the screen if supplied with the system. See Related Manuals section for information on the Tandem option. Supply Pumps Fig.
  • Page 13 Supply Pump in the automatic mode (Auto Mode). In the Auto Mode the ram transfer pump will supply B2 In Use Button material pressure to the DC12 metering pump. See A1 In Use Button When a low level sensor is reached the machine will continue to pump until a preset time has expired.

  • Page 14: Dispense Setup

    Performance Monitor Plus Operator Level Screens Dispense Setup Fig. 6 Description Description Continuous Continuous Dispense Mode Ratio Check Auto Ratio Check Auto Mode Timed Shot Timed Shot Dispense Mode Ratio Check Open Ratio Check Open Shot Time sec Dispense time in seconds Ratio Check Close Ratio Check Close Dispense Valve Auto...
  • Page 15 Performance Monitor Plus Operator Level Screens Ratio Check Auto Select this mode to dispense material through the Dispense Setup Cont. Ratio Valves during normal operation. See Fig. 6 Ratio Valve Open Continuous Mode This button will override and open the Ratio Valves When a start signal is given during normal operation regardless of Dispense Mode.

  • Page 16: Purge Settings

    Performance Monitor Plus Operator Level Screens Purge Settings Fig. 7 Description Description Purge Timer ON/OFF ON / OFF buttons Base Mixer Purge Start / Stop buttons Current Time Min Display Field Main Screen Access Button Purge Interval Min Input Field Setup Screen Access Button Alarm Dwell Sec...
  • Page 17 Performance Monitor Plus Operator Level Screens Purge Settings Cont. See Fig. 7 The Purge Time feature will only work when the system is ready to dispense and the Purge Timer is ON. The Purge Timer is disabled during a fault. Purge Timer ON / OFF The Purge Timer can be used to dispense material through the mixer during idle times and help prevent...

  • Page 18: Run Mode

    Performance Monitor Plus Operator Level Screens Run Mode Fig. 8 Description Description Supply Pump Level Status Purge ON/OFF ON / OFF buttons Supply Pump Cycles/Minute Control Power Control Power Indicator Inlet pressure to Shot Meter Silence Alarm Silence Alarm Button Outlet pressure of Shot Meter Main Screen Access Button...
  • Page 19 Performance Monitor Plus Operator Level Screens Run Mode Cont. See Fig. 8 Optional Features are not displayed on the Run Mode Screen when not configured with the system. For example Ratio Monitor Window is displayed when system is equipped with Ratio Monitoring option.

  • Page 20: Status

    Performance Monitor Plus Operator Level Screens Status Fig. 9 Description Description Alarm History Screen Access Button Previous Screen Access Button Pressure Status Screen Access Button Main Screen Access Button Material Totals Screen Access Button Ratio History Screen Access Button 312767B...

  • Page 21: Alarm History

    Performance Monitor Plus Operator Level Screens Alarm History Fig. 10 For Detailed information on the Alarm messages see the Troubleshooting section of this manual. Delete Alarm Message This button will confirm existing alarms and delete non-active alarms. 312767B...

  • Page 22: Pressure Status

    Performance Monitor Plus Operator Level Screens Pressure Status Fig. 11 Description Description Current Inlet Pressure psi A vs. B outlet Max variation A to B set point Current Outlet Pressure psi Pressure History Screen Access Button Inlet Low Pressure Inlet pressure low set point A psi vs.

  • Page 23: Material Processed

    Performance Monitor Plus Operator Level Screens Material Processed Fig. 12 Enter material specific gravity from the Dispense Setup screen. The specific gravity is used to calculate the material processed. Archive Current Liters Current Liters This button will log the material usage information Displayed amount of material dispensed in liters.

  • Page 24: Technician (Hmi) Screens

    Performance Monitor Plus Technician Level Screens The following screens require a user name and password. Technician User Name: tech Technician Password: dc121111 See the Main Menu screen to Login. Technician Screen Fig. 13 Description Description Alarm Status Screen Access Button Ratio Setup Screen Access Button Supply Setup...

  • Page 25: Supply Setup

    Performance Monitor Plus Technician Level Screens Supply Setup Fig. 14 Description Description Cycles/min Cycles/min of supply air motor Low Level shut down time Low Level shut down Input field High limit High limit Input Field Previous Screen Access Button High Limit When the high limit value is reached the machine will fault.

  • Page 26: Shot Meter Setup

    Performance Monitor Plus Technician Level Screens Shot Meter Setup Fig. 15 Calibrate Shot Meter Volume Archive Meter Setup This feature is not required for correct machine This button will log the calibration information onto a operation. It is used to adjust for the difference USB drive when installed on the machine.

  • Page 27: Data Logs

    Performance Monitor Plus Technician Level Screens Data Logs Fig. 16 Clear Log Buttons In order to use the Data Log feature a USB Use the clear log buttons to delete current logging drive must be installed. The USB port is located on information.

  • Page 28: Pressure Setup

    Performance Monitor Plus Technician Level Screens Pressure Setup Fig. 17 See Fig. 11 Pressure Status for information on pressure fields See Pressure Monitor Setup section of this manual for detailed information. 312767B...

  • Page 29: Ratio Monitor Package

    Performance Monitor Plus Technician Level Screens Ratio Monitor (Optional) Fig. 18 Components included with Ratio Monitor Description Control Box A and B Flow meters Flow Meter Displays located on the control box will indicate measured specific gravity and material temperature only. All control features for Ratio Monitoring are shown on the HMI.

  • Page 30: Ratio Setup Screen

    Performance Monitor Plus Technician Level Screens Ratio Monitor Cont. See Fig. 18 Target Weight Ratio Ratio Monitor ON / OFF Enter the Target weight ratio to be monitored. The Enable or Disable the Ratio Monitor shut down input field is based on X components of A to 1 feature using these buttons.

  • Page 31: Pneumatic Performance Monitor

    Pneumatic Performance Monitor Pneumatic Performance Monitor includes an all Pneumatic Control Box. This control option is a monitor only and does not shut down the machine in the event of an alarm. The Pneumatic Performance Monitor can be used with or without the Pneumatic Dispense Valve Control.

  • Page 32: Pneumatic Dispense Valve Control

    Pneumatic Dispense Valve Control Pneumatic Dispense Valve Control includes an all Pneumatic Control Box. This control option is for the operation of the Automatic Dispense Valves and Ratio Valves. See Fig. 26 The Pneumatic Dispense Valve Control can be used with or without the Pneumatic Performance Monitor.

  • Page 33: Setup

    Prior to installing the machine, check for any damage that may have occurred during transit. If any damage is found notify Graco immediately. The machine is to be installed on a flat surface in an area that permits easy access to all areas of the machine for maintenance and operation.

  • Page 34: Boom Installation

    Setup Optional Boom Fig. 22 Fig. 23 312767B...
  • Page 35 Setup Boom Cont. See Fig. 22 and 23 Automatic Dispense Valve will be installed on boom arm. The boom arm weight is 180 lbs (82KG). Description Vertical Mast Locking Collar Spacer Clevis Pin and E-Ring Pneumatic Cylinder Bushing, clevis Bushing Boom Arm Boom Assembly 1.

  • Page 36: Electrical Requirements

    Electrical Requirements only apply to machines equipped with Performance Monitor Plus control package. See Configurator code C. The DC12 with Performance Monitor Plus is available in 2 voltages: 1. 120V / 1PH / 50-60HZ 2. 230V / 1PH / 50-60 HZ...

  • Page 37: Start-Up

    Start-Up Integrated Air Controls The Integrated air controls include: • Main air slider valve (BA): turns air on and off to the system. When closed, the valve relieves pressure downstream. • Ram air regulator (BB): controls ram up and down pressure and blow-off pressure. •...

  • Page 38: Loading Material

    3. Remove Drum cover and smooth the surface of the fluid with a straightedge. 4. Put a full drum of fluid on the DC12 ram base, slide it back against the drum stops, and center it under platen (D). Use caution when rolling drum onto DC12 frame.

  • Page 39: Priming System

    Priming System Machines equipped with Performance Monitor Plus Refer to Fig. 1 Fig. 28 Pendant Station Automatic Ratio Valve Refer to Fig. 26 1. Remove lower dispense block and mixer before priming system. Fig. 26 Manual Ratio Valve Refer to Fig. 27 Description 1.

  • Page 40: Pneumatic Dispense Valve Control

    Priming System Machines equipped with Machines equipped with Performance Pneumatic Dispense Valve Control Monitor Plus Cont. Refer to Fig. 21 8. Select the Run Mode Screen. At this time Automatic Ratio Valve the Green Pilot light on the Pendant station Refer to Fig.

  • Page 41: Manual Control

    Priming System 6. Open A and B Material Shut Off Valves at Machines with Manual Dispense the same time. Valve Control 7. Place containers under A and B ratio valves. 8. Open Manual Ratio Valves. 9. Move Slider Valves to the ON position on both A and B Supply Pumps.
  • Page 42 Priming System 312767B...

  • Page 43: Pressure Monitor Setup

    Fig. 1 enabling Pressure Monitor. (See Operation section in this manual) The DC12 equipped with the Performance Monitor Plus control package has a built in pressure monitor 3. Dispense material through mixer. From the available. Pressure Monitoring allows the user to Main Menu select Login.

  • Page 44: Pneumatic Monitor Pneumatic

    Refer to Fig. 20 3. Verify Pressure Monitor switch is in the OFF position on the Control Panel. Note: The DC12 equipped with the Pneumatic Indicators for pressure may show ON until Performance Monitor control package has a built in pressure switches have been set.
  • Page 45 Pressure Monitor Setup Machines equipped with Pneumatic Performance Monitor Refer to Fig. 20 Cont. Fig. 31 312767B...
  • Page 46 Pressure Monitor Setup 312767B...

  • Page 47: Operation

    Ratio Check section in this manual) 4. Flow Rate is determined by Ram Supply pump air pressure. The DC12 is driven with the A side supply ram (BE). Refer to Fig. 24 The A Side Supply Pressure will be higher than the B Side.
  • Page 48 Operation General Information all configurations Cont. Fig. 32 Running Pressures for 2:1 Adhesive Paste Air Motor PSI (BE) Air Motor PSI (BE) KG/MIN A Supply Ram B Supply Ram Approximate Flow Rate Running Pressures for 1:1 Light Weight Tooling Pastes Air Motor PSI (BE) Air Motor PSI (BE) KG/MIN A Supply Ram...

  • Page 49: Performance Monitor Plus

    Operation 13. Place a container under the static mixer. 14. Press the start button on the Pendant Station to begin Dispensing. Dispense Machines equipped with several seconds to prime the mixer before applying material to a product. Performance Monitor Plus Refer to Fig.

  • Page 50: Pneumatic Dispense Valve Control

    Operation Machines equipped with Pneumatic Dispense Valve Control See Fig. 21 See the Pneumatic Dispense Valve Control section of this manual for detailed information control features. 1. From Dispense Valve Control select A Feed Auto. Select B Feed Auto. Select Dispense Point Mix.

  • Page 51: Ratio Check - Performance Monitor Plus

    Ratio Check 12. Calculate the Weight Ratio A/B = Net weight of A in grams / Net weight of B in grams. Machines equipped with 13. Repeat steps 10-12 at least 5 times Performance Monitor Plus Refer to recording the weight ratios. If the system is Off Ratio proceed to the Troubleshooting Fig.

  • Page 52: Ratio Check - Pneumatic Dv Control

    Ratio Check Machines equipped with Manual Machines equipped with Dispense Valve Control See Fig. 29 Pneumatic Dispense Valve Control See Fig. 21 1. Close A and B Material Shut Off Valves. 2. Open Manual Dispense Valve to relief pressure between A and B material shut off See the Pneumatic Dispense Valve Control valves and mixer.

  • Page 53: Drum Change

    6. Remove the drum cover and smooth the surface of the fluid with a straightedge. 7. Place full drum on DC12 ram base. Slide it back against the drum stops, and center it under the platen (D).

  • Page 54: Performance Monitor Plus

    Drum Change Machines equipped with Machines equipped with Performance Monitor Plus Refer to Pneumatic Dispense Valve Control Fig. 1 Refer to Fig. 21 See the Performance Monitor Plus section See the Pneumatic Dispense Valve Control of this manual for detailed information on the HMI section of this manual for detailed information on screens.

  • Page 55: Pressure Relief

    Pressure Relief Procedure Machines equipped with Performance Monitor Plus Refer to Fig. 1 1. Close Supply air pressure valve. 2. Supply Ram Integrated Air Controls: Close the air motor slider valves (BF) and the main air slider valves (BA) on both Supply Pumps.

  • Page 56: Pneumatic Dv Control

    Pressure Relief Procedure All pneumatic machines Refer to Fig. 21 and Fig. 29 1. Close Supply air pressure valve. 2. Supply Ram Integrated Air Controls: Close the air motor slider valves (BF) and the main air slider valves (BA) on both Supply Pumps.

  • Page 57: Mixer Flush

    Mixer Flush Pneumatic Dispense Valve Control Refer to Fig. 21 2. Open Base Purge Ball Valve. From Dispense Valve Control Select Dispense Machines equipped with Base point OFF. Select A Feed Pump ON. A Supply Ram will deliver base material Purge Refer to Fig.

  • Page 58: Solvent Flush

    Mixer Flush Machines equipped with Solvent Flush Hardware Refer to Fig. 2 For information on solvent pump option see manual 308116. Use fluids and solvents that are compatible with the CAUTION equipment wetted parts. See Technical Data in all Solvent Flush will help prevent the static mixer from equipment manuals.
  • Page 59 Mixer Flush Machines equipped with Solvent Flush Hardware Cont. Machines equipped with Performance Monitor 11. Addition flushing in a recirculation mode is Plus recommended for at least 20 minutes. In a Refer to Fig. 1 recirculation mode open both A and B side 1.

  • Page 60: Maintenance

    Maintenance Schedule Procedure Frequency Perform Ratio Check procedure Daily Perform Mixer Flush procedure Daily Remove Lower Dispense Block and Clean Daily Remove Mixer Elements and Clean Daily Check Shot Meter Packings. Tighten if necessary. Daily Check Supply System Packings. Tighten if necessary. Daily Drain any water from filter in main airline.

  • Page 61: Troubleshooting

    Shot Meter Operating Pressures Refer to Fig. 32 The DC12 is a continuous volumetric metering pump. The inlet and outlet pressures can give an indication the status of the system. The Inlet pressures show if there is sufficient material supply to reliably reload the pumps.
  • Page 62 Troubleshooting Troubleshooting Chart Problem Cause Solution Inconsistent material mix Refer table 1 and Shot Material inlet pressures are not set Meter troubleshooting correctly. Erratic feed pump information Verify machine is on ratio. Remove mixer clean or Cured material on mix elements replace Metering Pump Piston worn or damaged Replace piston cups B supply pressure is too high...
  • Page 63 Troubleshooting Troubleshooting Chart Cont. Problem Cause Solution Meter pressures not balanced Improper operation of supply pumps Check for proper operation of material supply pumps. Verify Supply pump pressure is reloading metering pump. Perform ratio check procedure. Inadequate material supply to metering Verify supply pump pumps pressures.

  • Page 64: Performance Monitor Plus Alarms

    Troubleshooting Machines equipped with Performance Monitor Plus Refer to Fig. 1 The Following alarms will be displayed on the HMI. The Alarm History screen can be accessed from the Main, Run, or Status Screens. Refer to Fig. 10 Alarm Troubleshooting Chart Alarm Alarm Message Solution...
  • Page 65 Troubleshooting Alarm Troubleshooting Chart Cont. Alarm Alarm Message Solution Number Inlet pressure and outlet pressure are not balanced. Verify Inlet to Outlet variation value on pressure status screen. Turn Off Pressure Monitor in B PRESSURE VARIATION FAULT Technician section to troubleshoot. Turn on Pressure Monitor when machine is operating properly.
  • Page 66 Troubleshooting Alarm Troubleshooting Chart Cont. Alarm Alarm Message Solution Number Supply pumps not delivering enough material. Air in the system. Flow Rate too low. Target weight ratio HIGH RATIO ALARM is not correct. Verify in Technician screen. Ratio tolerance is too small. Verify in Technician section. Meter pump is worn or damaged.
  • Page 67 Troubleshooting 312767B...

  • Page 68: Technical Data

    Technical Data Category Data Standard Volume Ratios Other ratios, consult factory Maximum Flow Rate (1) 10 L/min Motionless Mixer 24 elements X 1 in Dia Maximum Fluid Pressure 2,500 psi (172 bar) Wetted Components Carbon Steel Material Supply System Dual NXT 55 gal (200 L) Platen Wipers EPDM Power Requirements (2)

  • Page 69: Dimensions

    Technical Data Dimensions Fig. 37 Description 86 in. (218 cm) 48 in. (122 cm) C Boom 110 in. (279 cm) C No Boom 80 in. (203 cm) D Ram Down 78.8 in. (200 cm) D Ram Up 113.4 in. (288 cm) 312767B...

  • Page 70: Graco Standard Warranty

    WITH RESPECT TO AUXILIARY EQUIPMENT AND COMPONENTS WHICH ARE MANUFACTURED BY OTHERS. Graco Ohio Inc. 8400 Port Jackson Ave NW N. Canton, OH 44720 Phone (330) 966-3000 Fax (330) 966-3006 Send e-mail for technical support to: LiquidControlService@Graco.com Send e-mail for parts orders to: LiquidControlParts@Graco.com Web Site: www.LiquidControl.com 312767B...

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