Graco BDS Instructions-Parts List Manual
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Graco BDS Instructions-Parts List Manual

Graco BDS Instructions-Parts List Manual

Batch dispense system proportioning controller
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INSTRUCTIONS-PARTS LIST
Parts
INSTRUCTIONS
Batch Dispense System
Proportioning Controller
Model No. BDS, Series E
250 psi (1.7 MPa, 17 bar) Maximum Incoming Fluid Pressure
125 psi (0.9 MPa, 9 bar) Maximum Incoming Air Pressure
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 2001, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
309279
First choice when
quality counts.t
Rev. A

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  • Page 1 250 psi (1.7 MPa, 17 bar) Maximum Incoming Fluid Pressure 125 psi (0.9 MPa, 9 bar) Maximum Incoming Air Pressure GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 ECOPYRIGHT 2001, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    ......Graco Standard Warranty .....

  • Page 3: Conventions

    Conventions D Italicized text shown on a screen diagram or in the The following conventions are used in this manual to help guide you through the information. text indicates the text may vary according to how the system parameters have been configured. For example, the units of measure shown in the manual D When you are instructed to “Press”...

  • Page 4: Symbols

    Symbols Warning Symbol Caution Symbol CAUTION WARNING This symbol alerts you to the possibility of damage to This symbol alerts you to the possibility of serious or destruction of equipment if you do not follow the injury or death if you do not follow the instructions. instructions.
  • Page 5 INSTRUCTIONS D Read all instruction manuals, tags, and labels before operating the equipment. D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor. D Do not alter or modify this equipment. D Check equipment daily. Repair or replace worn or damaged parts immediately.

  • Page 6: Introduction

    The scale platform (B) is typically located at the base of the BDS. The platform surfaces are stainless steel The BDS screens have one or more of the following for easy cleaning. There are no operator controls on elements to use to access or enter information: the scale itself.

  • Page 7: How The Batch Dispense Systems Works

    (208 liters), at average maximum flow rates of 1 GPM (3.8 LPM). Controller Start Up Sequence To turn on the BDS, turn the power switch (47) to ON and make sure the E-stop button (7) is not depressed. See figure 1. The controller (29) start up sequence may take up to 5 minutes.
  • Page 8 Introduction Operating Cycle 5. The operator enters the dispense quantity. The number entered will be in the units of measure that were selected during setup. NOTE: See page 19 for full sequence of Run screens. 1. To begin operation, the operator presses Run Recipe on the Main Operating Screen.
  • Page 9 Continue retrieval. Batch 12. Pressing Main Menu will return the BDS to the 9. Abort can be pressed on the Recipe Status Main Operating Screen. Screen at any time to stop a dispense at the step currently running in the recipe.
  • Page 10 Introduction System Fine Tuning Main Menu The actual volume of fluid dispensed in each batch can vary slightly from the calculated targets. However, the controller monitors this variance and reports an error if Edit Existing Recipe Add Recipe the desired tolerance is not maintained. Edit Valve Parameters Add Valve In order to minimize this variance, the controllers...

  • Page 11: Installation

    FLAMMABLE OR TOXIC VAPOR HAZARD D Locate the BDS in a vibration free area: away from Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Do punch presses, heavy fork lift traffic, rail lines and...

  • Page 12: Install The Fluid Supply

    Optional Fluid Supplies Instead of pressure tanks (A), the BDS can be supplied by pail or drum pumps or central paint recirculating lines if they are available. An air piloted, fluid pressure regulator is required on each supply line at the input to the BDS.

  • Page 13: Connect The Electrical Supply

    Installation Connect the Electrical Ground the BDS as instructed here and in the individu- al component manuals. Refer to figure 3 and the Supply system and controller drawings starting on page 54. WARNING Controller FIRE, EXPLOSION, AND Connect the controller’s green-yellow ground terminal ELECTRIC SHOCK HAZARD block to the NEMA enclosure’s grounding lug.

  • Page 14: Check The Resistance

    Have a qualified electrician check the resistance to the controller through approved, intrinsically safe between each BDS component and the true earth barrier blocks. If the platform, platform cable, or the ground. The resistance must be less than 25 ohms. If...

  • Page 15: Before Beginning Operation

    Installation Connect the Industrial PC Interface Cable Before Beginning Operation The Industrial PC interface cable is terminated on the D Check all fluid and air connections for correctness controller (inside the cabinet) with an eight pin ethernet and tightness. cable. Any connections to the controller cabinet must be made through approved fittings and connectors D Follow the Initial Startup Sequence on page 17.

  • Page 16: Operation

    Operation Pressure Relief Procedure 6. Press the Valve # arrow and press the number that corresponds to the valve or material line that you would like to open. Then press Open Valve. WARNING Manual Dispense PRESSURIZED EQUIPMENT HAZARD Select Valve to Dispense/Open Change Valve Psi The system pressure must be manually relieved to prevent the system from...

  • Page 17: System Pressure

    System Purge, page 18. Leave the solvent in the system. 2. Make sure all cabinet doors are closed and locked. 3. Turn on the air pressure to the BDS and set the supply air regulator (63) to 80 psi (552 kPa, 5.5 bar) minimum.

  • Page 18: Purging

    Operation Purging 8. Press the Valve # arrow and press the number that corresponds to the valve or material line that you are purging. Then press Open Valve. To purge the valves or the entire system, follow the instructions below. Manual Dispense Select Valve to Dispense/Open Change Valve Psi...

  • Page 19: Run Recipe

    Run Recipe Screen How to Use Run Recipe BATCH Use Run Recipe to dispense a recipe in automatic DISPENSE mode. SYSTEM Main Operating Screen ⇒ Press Run Recipe. Run Recipe Setup Clean Screen Manual Cntl Scale Setup Exit Password Screen (optional) If a password is requested, Please enter Password ⇒...

  • Page 20: View Recipe Screen

    Run Recipe Screen How to Use View Recipe Screen Recipe # Recipe Name Valve # Valve Name Parts You can either press Select Recipe to select a differ- Step 1 Step 2 ent recipe or press Run Recipe to start the recipe on Step 3 Run Recipe the screen.

  • Page 21: Recipe Status Screen

    Run Recipe Screen How to Use Recipe Status Screen Recipe Name Recipe # Amount This screen will show the status of the recipe. When a Step 1 Step 2 recipe step is active, the step box is green. Abort Step 3 Step 4 Step 5 ⇒...

  • Page 22: Manual Control

    Manual Control Screen How to Use Manual Control BATCH Use Manual Control to dispense material manually DISPENSE (used to obtain a sample, purge the valve, or relieve pressure). SYSTEM Main Operating Screen ⇒ Press Manual Control. Run Recipe Setup Clean Screen Manual Cntl Scale Setup Exit...

  • Page 23: Scale Setup

    Scale Setup Screen How to Use Scale Setup BATCH Use Scale Setup to calibrate your scale. DISPENSE Main Operating Screen SYSTEM ⇒ Press Scale Setup. IMPORTANT If you are changing scales, note the Run Recipe Setup Clean Screen following: Manual Cntl Scale Setup Exit D You must insure the excitation and signal voltages...

  • Page 24: Clean Screen

    Clean Screen Screen How to Use Clean Screen Use to inactivate the touch screen so you can wipe it clean. BATCH DISPENSE CAUTION SYSTEM To avoid damaging the screen, do not use solvents or chemicals to clean the screen. Do not wipe the screen with anything abrasive or rough.

  • Page 25: Alarms

    Alarms Screen How to Use Over Dispense Alarm This alarm occurs when too much material was Over Dispense dispensed for the current batch. ⇒ Press Continue to accept this amount and Continue continue with the batch, –or– Abort Press Abort to stop the batch. Under Dispense Alarm Under Dispense This alarm occurs when not enough material was...

  • Page 26: Setup

    Reports (page 44) Sort and view various data- Initial Setup base reports. To initially setup the BDS system, you usually go Add Recipe (page 40) Setup recipes. See Edit though the setup options in the following order: Existing Recipe, above, for more information.

  • Page 27: System Setup

    Setup Screen How to Use System Setup Main Menu Use to set system wide variables. Edit Existing Recipe Add Recipe Main Setup Menu ⇒ Edit Valve Parameters Add Valve Press System Setup. Reports System Setup Exit Please Enter Password to Access the Password Screen following screen ⇒...
  • Page 28 Press the down arrow and select the appropriate ****** access level: Password Administrator Access Level Administrator a. Administrator – Allows full access to all BDS Normal User screens. Power User Accept Cancel b. Normal User – Allows access to run time screens.

  • Page 29: To Set Measurement Units

    Setup Screen How to Use To set measurement units: System Setup Menu System Setup Menu Screen ⇒ Press Select Measurement Units. Edit User Screen #1 Select Measurement Units Edit User Screen #2 Change System Passwords Edit User Screen #3 Return to Main Menu Unit of Measure Screen Select Machine Unit of Measure: ⇒...

  • Page 30: To Edit User Screen #1

    Setup Screen How to Use To edit User Screen #1: System Setup Menu System Setup Menu Screen ⇒ Press Edit User Screen #1. Edit User Screen #1 Select Measurement Units Edit User Screen #2 Change System Passwords Edit User Screen #3 Return to Main Menu Edit User Screen #1 Screen Edit User Screen #1...

  • Page 31: To Add Or Edit Description For User Screen #1

    Setup Screen How to Use To add or edit description for Editing USERID for User User Screen #1: Screen #1 NOTE: For this example the description for User John USERID Screen #1 is USERID. A user ID (description 1) and password (description 2) are requested.

  • Page 32: To Edit User Screen #2

    Setup Screen How to Use To edit User Screen #2: System Setup Menu System Setup Menu Screen ⇒ Press Edit User Screen #2. Edit User Screen #1 Select Measurement Units Edit User Screen #2 Change System Passwords Edit User Screen #3 Return to Main Menu Edit User Screen #2 Screen Edit User Screen #2...

  • Page 33: To Add Or Edit Description For User Screen #2

    Setup Screen How to Use To add or edit description for Editing AIRCRAFT for User User Screen #2: Screen #2 NOTE: For this example the description for User AIRCRAFT Screen #2 is AIRCRAFT. An aircraft identification (description 1) and tail number (description 2) are 27245 TAILNUMBER requested.

  • Page 34: To Edit User Screen #3

    Setup Screen How to Use To edit User Screen #3: System Setup Menu System Setup Menu Screen ⇒ Press Edit User Screen #3. Edit User Screen #1 Select Measurement Units Edit User Screen #2 Change System Passwords Edit User Screen #3 Return to Main Menu Edit User Screen #3 Screen Edit User Screen #3...

  • Page 35: To Add Or Edit Description For User Screen #3

    Setup Screen How to Use To add or edit description for Editing MODEL for User User Screen #3: Screen #3 NOTE: For this example the description for User Deluxe MODEL Screen #3 is MODEL. The model (description 1) and color (description 2) are requested. COLOR ⇒...

  • Page 36: Edit Valve Parameters

    12, or 20 automatic valves. The valve variables are Edit Existing Recipe Add Recipe set with default values at the factory. Edit Valve Parameters Add Valve NOTE: Contact your Graco distributor if your system requires additional automatic valves. Reports System Setup Main Setup Menu Exit ⇒...
  • Page 37 Setup Screen How to Use Screen for Automatic Valves Edit Valve Parameters Screen ⇒ Press the Valve # or Valve Name down arrow to Select a Valve Name or Valve Number to Edit Parameters select a different valve to edit. Green Valve #: Valve Name:...

  • Page 38: Add Valve

    Setup Screen How to Use Add Valve Main Menu Use to establish setpoints for manual valves. A manual valve defines the manual addition of specific materials into a recipe at a prescribed amount. You Edit Existing Recipe Add Recipe can assign up to 1000 manual valves in the database. Manual valve numbers are automatically assigned.
  • Page 39 Setup Screen How to Use New Valve Parameters Screen Select a Valve Name or Valve Number to Edit Parameters Taupe Valve #: Valve Name: ⇒ To make changes to the parameters, press the Taupe Valve Name: text box next to the parameter you want to Valve #: Manual change.

  • Page 40: Add Recipe

    Setup Screen How to Use Add Recipe Main Menu Use to setup recipes. Recipes provide the sequencing order for dispensing multiple materials into a common tank. You can assign up to 1000 recipes in the data- Edit Existing Recipe Add Recipe base.
  • Page 41 Setup Screen How to Use Recipe Setup Screen Recipe: Name: Saddle ⇒ Press the Valve # or Valve Name down arrow Step Valve# Valve Name Step Description Part Size key and select the desired valve. Green Resin –or– Type the Valve # or Valve Name in the respective text box.

  • Page 42: Edit Existing Recipe

    Setup Screen How to Use Edit Existing Recipe Main Menu Use to establish the sequencing order for dispensing multiple materials into a common tank. Assign up to 1000 recipes in the database. Edit Existing Recipe Add Recipe Main Setup Menu Edit Valve Parameters Add Valve ⇒...
  • Page 43 Setup Screen How to Use Edit Recipe Screen Recipe: Name: Saddle ⇒ Press the desired text box and type in the new Step Valve# Valve Name Step Description Part Size value. Green Resin Solvent #1 Valve # and Valve Name have a list of options to Sweat Timer Sweat Time Seconds...

  • Page 44: Reports

    Configured Screen Report Batch Query Screen The Batch ID number is seven digits in length and is Query By: automatically generated by the BDS. Batch Reports can be queried either by Batch ID or by date. To BatchID query by Batch ID:...
  • Page 45 Setups Screen How to Use EDS BATCH – [BatchReport] Batch Report Screen Action Batch Report Recipe Number and Name: 19, 4valve ⇒ Batch: O227048 Date Run: ”8/14/2000 5:17:01 PM Press Action, located in the upper left corner of Jim Smith AIRCRAFT TAILNUMBER Step...

  • Page 46: To Generate A Valve Report

    Setup Screen How to Use To generate a Valve Report: ⇒ At the Main Setup Menu, press Reports. Batch Report Report Selection Screen ⇒ Valve Report Press Valve Report. The Valve Report provides a summary dispense Configured Screen Report record for all automatic and manual valves. Report Date Range Screen ⇒...

  • Page 47: Screen Maps

    Screen Maps BATCH DISPENSE Optional ENTER USER ID # SYSTEM Run Recipe Screens SETUP CLEAN RECIPE SCREEN MANUAL SCALE EXIT RETURN TO CONTINUE CONTROL SETUP MAIN SCREEN Optional ENTER JOB ID # RETURN TO CONTINUE MAIN SCREEN Optional SELECT RECIPE TO LOAD ENTER AIRCRAFT ID # RECIPE # RECIPE NAME...

  • Page 48: Edit And Add Recipe Screens

    Screen Maps Edit and Add Recipe Screens 309279...

  • Page 49: Edit And Add Valve Screens

    Screen Maps Edit and Add Valve Screens 309279...

  • Page 50: System Setup And Reporting Screens

    Screen Maps System Setup and Reporting Screens 309279...

  • Page 51: Clean Screen, Manual Control, Alarm, And Scale Setup Screens

    Screen Maps Clean Screen, Manual Control, Alarm, and Scale Setup Screens 309279...

  • Page 52: Troubleshooting

    No dispense No air supply Ensure air is supplied to the BDS Not enough air pressure to the fluid Increase the minimum fluid pressure regulator setting in fluid setup Loss of 24 VDC...
  • Page 53 Troubleshooting Problem Possible Cause Solution Dispense flow is too fast Maximum fluid pressure setting too Decrease maximum fluid pressure high setting Minimum fluid pressure setting too Decrease minimum fluid pressure high setting Valve needle travel set too long Shorten needle travel to more restricted setting Valve needle/nozzle size too large Install needle/nozzle kit with a smaller...

  • Page 54: Parts

    Parts Figure 5 – Batch Dispense System (20 valve) TI0859A 309279...
  • Page 55 Parts TI0860A Figure 6 – Typical Pneumatic Schematic 309279...
  • Page 56 Parts TI0863A Figure 7 – Electrical Schematic 309279...
  • Page 57 Parts Figure 8 – Electrical Schematic TI0862A 309279...
  • Page 58 Parts TI0861a Figure 9 – Electrical Schematic 309279...
  • Page 59 Parts Ref. Part No. Description Qty. Ref. Part No. Description Qty. 116355 POWER SUPPLY, 10 volt 104267 REGULATOR, air, see manual 308167 for parts 116356 BUTTON, emergency stop (E-stop) 106149 FILTER, air, see manual 308169 for parts 104029 CLAMP, ground 107142 VALVE, ball, bleed-type 116357...

  • Page 60: X-Purge Option

    X-Purge Option Figure 10 – Electrical and Pneumatic Schematic for X-Purge Option 309279...

  • Page 61: Led Display Indicators

    X-Purge Option Isolated Coil Voltage Power Control Switch Voltage Regulators Transformer Cable Header Pressure Switch Cable Header Logic Module Voltage Input Selector Cable Header Header (factory set for 120 or 220 VAC power) Redundant Safe Pressure Relay 1/4 Amp Input Fuse Redundant Rapid Rapid Exchanger Exchange Relay...

  • Page 62: Rapid Exchanger Timer Functions

    X-Purge Option Rapid Exchanger Timer Rapid Exchanger Timer Functions Settings Position Time in Minutes The Rapid Exchange Timer provides a time delay after Rapid Exchange pressure is detected to allow four volume exchanges prior to energizing the enclosure power relays. If Rapid Exchange pressure is lost or interrupted during the time delay cycle, the Electrical Power Control Unit is reset.

  • Page 63: Setup Procedure

    X-Purge Option Setup Procedure The volume exchange rate is based on a four enclo- sure volume exchange. Important Notes: The Startup Instruction Nameplate Exchange Time Slot Regardless of the conditions, the X-Purge option is will feature the standard factor for this system “ONE designed to automatically withhold power to the pro- MINUTE PER CUBIC FOOT”, but the unit may feature tected enclosure while inducing Rapid Exchanger, for...

  • Page 64: Rapid Exchanger Purging Setup

    X-Purge Option Rapid Exchanger Purging NOTE: The Rapid Exchange Pressure Gauge may now indicate a higher set pressure than was originally Setup set, this is normal for all Rapid Exchange purging systems. 1. Fully close the Enclosure Pressure Control Valve 9.

  • Page 65: Rapid Exchanger Purging Operation

    X-Purge Option Rapid Exchanger Purging 5. Turn the Enclosure Pressure Control Valve slowly counterclockwise to set the Enclosure Pressure Operation Indicator to a “safe” 0.25 inch pressure. The Safe Pressure LED should be on, the Alarm Active LED should turn off. WARNING 6.

  • Page 66: Troubleshooting

    X-Purge Option Troubleshooting The most common X-Purge system problems are covered below. For additional assistance, call Bebco Industries, Inc. – Customer Service Department at (409) 935–5743. Please have the system project number (located on green quality control tag attached to back of system mounting plate) available. Problem or Fault Possible Cause Solution...

  • Page 67: Technical Data

    Technical Data D Power requirement – 110 VAC, 5 amp D Container capacity – 1 quart (0.95 liter) cup up to 24 gallon (90.82 liter) tank D Dispenses 1 to 20 materials D Dispense volumes – 1/10 quart (0.09 liter) to 24 D Stores up to 1000 individual recipes gallons (90.82 liters) D Each recipe can include up to 15 steps...

  • Page 68: Graco Standard Warranty

    Graco distributor 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.

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