Graco BetaCell 241D Operation
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Graco BetaCell 241D Operation

Metering unit
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Operation
BetaCell 241D
Metering Unit
Important Safety Instructions
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3A0258A

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Summary of Contents for Graco BetaCell 241D

  • Page 1 Operation BetaCell 241D 3A0258A Metering Unit Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

  • Page 2: Table Of Contents

    Contents GENERAL SAFETY INFORMATION ....................... 4 Acceptable Equipment Uses........................4 OPERATIONAL SAFETY PROCEDURES....................5 General Description..........................6 Specifications............................8 System Dimensions..........................8 Metering Unit ............................9 Hydraulic Power Pack .......................... 9 Buffer tanks ............................9 Factory Settings-Metering Unit......................10 Factory Settings-Hydraulic Power Pack ..................... 10 Dry Air or Nitrogen..........................
  • Page 3 Alarm Alerts ............................82 Warning and Fault Messages......................83 MAINTENANCE............................88 BetaCell 241 Maintenance Procedure....................89 BetaCell 241 Preventative Maintenance Schedule ................100 BetaCell 241Preventative Maintenance Procedures ................102 Graco Ohio Standard Warranty ......................110 Graco Ohio Information ........................110...

  • Page 4: General Safety Information

    GENERAL SAFETY INFORMATION It is necessary to understand and follow the instructions in this manual to insure proper and safe operation of the equipment. As with most mechanical equipment, certain safety precautions must be taken when the equipment discussed in this manual is operated or serviced.

  • Page 5: Operational Safety Procedures

    OPERATIONAL SAFETY PROCEDURES This safety information will not be repeated in the text of this manual. The symbols pertaining to this information will appear where appropriate to alert the operator to potential hazards. WARNING: The solvents and chemicals used with this equipment expose the operator to certain hazards.

  • Page 7: General Description

    General Description The Gusmer BetaCell 24:1 machine is manufactured to operate on 460V 3. 60 Hz electrical service with a current draw of approximately 100 amps. The operation of the machine combined with processing of the chemicals require precautionary measures described in the maintenance/operator's manual. The principle of operation is that two Gusmer pumps, one for Curative, and the other for Prepoly, deliver chemicals to a dispensing gun at the foam application station in a circulating manner.

  • Page 8: Specifications

    Specifications System Dimensions...

  • Page 9: Metering Unit

    Metering Unit Electric 63.3 FLA amps@ 3 x 460 volts; 60 Hz A-motor 5 hp vector B-motor 1 hp servo Max pressure 1500 psi Max oper pres 1200 psi Max output 15 lbs/min (110 cc/sec) Hydraulic Power Pack Motor 5 hp Flow rate 6 cc/rev (3 gpm) Max pressure 3000 psi Max oper pres 2800 psi...

  • Page 10: Factory Settings-Metering Unit

    Factory Settings-Metering Unit Max pressure sw 1500 psi Min pressure sw 40 psi Factory Settings-Hydraulic Power Pack Max pressure sw 2800 psi Min pres sw 1500 psi Acum. Pre charge 1200 psi Unload vlv-upper 2400 psi Unload vlv-lower 2200 psi Dry Air or Nitrogen 100-120 psi...

  • Page 11: Description Of Controls

    DESCRIPTION OF CONTROLS...

  • Page 12: Main Electric Panel

    Main Electric Panel Push to silence audible alarm White pilot light indicates that PLC power is ON White pilot light indicates that auxiliary 115 volt outlets are ON...
  • Page 13 Emergency Stop: interrupts control power Master Start: Turns ON control power; green pilot light indicates that control power is ON Typical Motor Start: momentary start to turn motor ON. Switch must be in the RUN position to start the motor from the HMI panel; green pilot indicates that the motor is ON Hour Meter...

  • Page 14: Main Menu Screen

    Main Menu Screen The Main Menu Screen permits selection of each of the screens indicated in the picture above by pressing the touch screen buttons. The Maintenance Menu is for qualified technicians and can only be Restricted Access accessed by password. IMPORTANT •...

  • Page 15: Help Screen

    Help Screen A Help Screen is available for each of the Menu Screens.

  • Page 16: Status Screen

    Status Screen All data windows are viewed in real time • Green pilot light indicates that a particular component is ON or set Pilot light convention for normal operation. • A blue pilot indicates that a component is OFF • A yellow pilot light indicate that a component is not set for normal operation •...
  • Page 17 • MAN: Depress the trigger and hold; the shot will continue as long as the trigger is held • AUTO: momentarily trigger the gun and release. The shot will continue automatically until the preset shot size is completed; yellow indicates MAN and green pilot light indicates AUTO •...

  • Page 18: Machine Control Screen

    Machine Control Screen • Press to turn ON and OFF the pump; pilot light indicates the state • Data windows indicate the PV’s NOTE: • Each time the Pre Poly pump is turned OFF; it will default to 50 RPM and flow control to MAN •...
  • Page 19 AutoStart • Press to ON; automatically starts the machine in a preprogrammed sequence. Once started, select the Status Screen to monitor progress of the AutoStart • AutoStart will not start if the Pre poly tank temperature is below 95 deg F or the Curative is below 80 deg F •...

  • Page 20: Tank Control Screen

    Tank Control Screen • Press to turn ON and OFF the motor; pilot light indicates the state • Press to turn ON and OFF the heater; pilot light indicates the state • Press the set point data window, a keypad will appear; select the temperature and press enter PV indicates the process temperature...
  • Page 21 AutoFill: • Press to turn ON and OFF the AutoFill system; Yellow pilot light indicates OFF and green indicates ON • AutoFill will automatically maintain the tank level to the set point • The tank will operate below the set point level for the duration of the pre set dwell time.

  • Page 22: Operator Screen

    Operator Screen NOTE: Screen shown changes depending on the car being processed. Indicates the active shot in a sequence. Indicates the completed shots in a sequence. Indicates an incomplete shot. Indicates that this shot in a sequence is disabled and will be bypassed. Yellow shows the shot size and green verifies the size of shot taken.
  • Page 23 Scroll up or down to select one of the four sequences available. At the completion of the last shot in a sequence, it is necessary to reset to the first shot. The gun will be NOGO when waiting for a reset.

  • Page 24: Maintenance Menu

    Maintenance Menu • Press to access the Maintenance screen • Password Required...

  • Page 25: Maintenance Screen

    Maintenance Screen Press to ON; permits servicing of the MixHead by bypassing machine interlocks. The following permissives are required: • Pre Poly pump OFF • Curative pump OFF • Hydraulic power pack ON • Push to enable or disable the main panel alarm horn •...
  • Page 26 • Press the data window, a keypad will appear. Select the minimum time between shots and press enter. A MixHead NOGO will be maintained until this time has elapsed • Press to turn the empty cycle ON and OFF. If the AutoFill system is ON, the tank will empty to the 20% level and automatically refill.

  • Page 27: Flow Control Screen

    Flow Control Screen This screen is for qualified technicians only. • Press to select AUTO or MAN; green pilot light indicates AUTO, yellow pilot light indicates MAN • Anytime MAN is selected, the pumps will automatically be set to the default manual speed setting •...

  • Page 28: Sequence Entry Screen

    Sequence Entry Screen The Sequence Entry Screen permits the selection of 4 sequences, each containing 10 separate shot sizes in grams. These shots can then be dispensed in order; starting at the first enabled shot and continuing in order through to the last enabled shot. Only the ENABLED shots are active. •...
  • Page 29 • Press the list selector • Scroll up or down to select the shot for data entry • Press the data window, a keypad will appear. Select the offset plus or minus and press enter • Press to enter the new offset into the group •...

  • Page 30: Autostart Set-Up Screen

    AutoStart Set-Up Screen This screen is for qualified technicians only...

  • Page 31: Sleep Mode Set-Up Screen

    Sleep Mode Set-Up Screen This screen is for qualified technicians only...

  • Page 32: Pre Poly Refresh Set-Up Screen

    Pre Poly Refresh Set-Up Screen This screen is for qualified technicians only • Bypass valves OPEN and pressure at pump limited to 120psi • Pre Poly refresh mode is set to ON at the Tank Screen Refresh Mode: • To prevent exceeding the shelf life of the pre poly component, the refresh mode allows the tank to be emptied to a pre set point and refilled with fresh material •...

  • Page 33: Flow Control Screen

    Flow Control Screen This screen is for qualified technicians only. Calibration is performed one component at a time through the respective jet at operating pressure and temperature with the other component isolated from the mixing chamber by a blank jet. Follow the procedures as outlined on the Help Screen...

  • Page 34: Shot Calibration Screen

    Shot Calibration Screen This screen is for qualified technicians only • Press the list selector • Scroll up or down to select the shot group for data entry • Press the data window, a keypad will appear. Select the offset plus or minus and press enter •...

  • Page 35: Tolerance Setup Screen

    Tolerance Setup Screen This screen is for qualified technicians only • Scroll the list to select the parameter for data entry • Press the data window, a keypad will appear. Select the offset plus or minus and press enter...
  • Page 36 • Press to enter the new offset into the group • Press to ENABLE or DISABLE the tolerance feature; green pilot light indicates ENABLED and the yellow pilot light indicates DISABLED...

  • Page 37: Description Of Major Components

    DESCRIPTION OF MAJOR COMPONENTS...

  • Page 38: System Schematic

    System Schematic...

  • Page 39: Overview

    Overview Buffer tanks Great emphasis is always placed on the outlet of the metering pump such as the flow and pressure produced; however, the importance of the inlet side of the pump cannot be overlooked. If the metering pump is not properly supplied, cavitation will result.

  • Page 40: Metering

    Metering The purpose of the metering pump is to meter the material in precise quantity and deliver it to the pour gun under sufficient pressure to affect the proper mix. The pump for the Pre Polymer component is a seal-less rotary piston pump driven by a magnetic coupler.

  • Page 41: Transducers

    Transducers Separate pressure and temperature transducers monitor the pressure and temperature to the gun and prevent operation outside of operator pre set limits. Recirculation The A and B components are constantly in recirculation through the gun chamber which creates the following advantages: •...

  • Page 42: Pneumatic System

    Pneumatic System The importance of the Dry Air supply cannot be overstressed as it provides a moisture-free medium to charge the operating tanks. To prevent contamination of the air system by a reaction of the Pre- Polymer fumes with the Curative fumes, the systems are isolated by means of separate check valves.

  • Page 43: Air Regulator

    Pressure Gage Air Regulator Regulator Regulator Curative Pre Polymer Side Side Shutoff Valve Shutoff Valve Operation Adjust the regulator clockwise to increase buffer tank pressure; counterclockwise to decrease. This is a self-bleeding regulator and will bleed excess tank pressure to maintain set point. Recommended buffer tank pressure is 60 psi.

  • Page 44: Buffer Tank

    Buffer tank...
  • Page 45 Fumes piped away by others in accordance with plant specifications...
  • Page 46 ITEM DESCRIPTION SCHEMATIC PARTS I.D. Number 1 Magnetic level indicator 2 Magnetic Level Sensor 3 Jacket drain valve 4 Jacket temperature limit switch 5 Water jacket heater 6 Material temperature thermocouple 7 Water jacket thermocouple 8 Water level indicator 9 Vented filler cap 10 Manual vent valve 11 Tank relief valve 12 Tank safety relief valve...

  • Page 47: Jacket Heater

    Jacket Heater Start-Up Determine that the tank jacket is fully serviced with approximately 15 gallons of heat transfer fluid before starting the heater. Maintenance Service the jacket with a 50% solution of water and glycol as required and check the level monthly. The system should be drained and filled with new heat transfer fluid once per year.

  • Page 48: Mixer

    Mixer Start-Up The direction of rotation as indicated by the rotational arrow and must be maintained at all times. If the rotation is incorrect, change any two of the power leads on the main terminal strip. Maintenance There is no normal operating maintenance.

  • Page 49: Buffer Tank Pressure Relief Valve

    Buffer tank Pressure Relief Valve Lock Nut Manual Adjust This valve is provided to supplement the pressure regulator for rapid relief of pressure above the regulator set point. Operation Operation is automatic. The valve is factory set to start relief at 70 psi and can be field adjusted by a qualified technician as required.

  • Page 50: Buffer Tank Safety Relief Valve

    Buffer tank Safety Relief Valve Safety Relief Fumes piped away by others in accordance with plant specifications This valve is provided to prevent over pressurizing the buffer tank above its ASTM maximum pressure rating. CAUTION: The safety relief valve is factory tested and certified for a cracking pressure between 80-100 psi.

  • Page 51: Return Line Check Valve

    Return Line Check Valve Check Valve This valve is provided to isolate the buffer tank pressure from the return line. Maintenance There is no normal operating maintenance.

  • Page 52: Autofill System

    AutoFill System Magnetic Liquid Level Indicator Level Sensor High Level Fault 100% Refill Level Visual Level Empty Level Low Level Operation The liquid level in the instrument is sensed by a float riding on the surface of the liquid and containing a magnet with positive polarity. There is a magnetostrictive position feedback sensor mounted to the instrument which sends a continuous signal to the PLC indicating the liquid level by percentage of full.
  • Page 53 The set points are as follows: • High Level Fault @ 100%. • Tank refill level @ 80%. • Tank Empty Level @ 20%. • Tank Low Level Automatic operation freeze @ level 10%. There is a visual system of flags that will change color as the magnet passes.
  • Page 54 Tank Refresh For maintenance purposes or to purge the tank of stale material, refresh Cycle cycle has been provided. The cycle can be selected from the Tank Control Screen and will permit the level to bypass the SP% full point and continue to empty down to the pre set refresh point.

  • Page 55: Autofill Valve

    AutoFill Valve Position Indicator Maintenance There is no normal operating maintenance.

  • Page 56: Inlet Safety Valve

    Inlet Safety Valve Position Operation Operation of this valve is completely automatic to close and isolate the buffer tank in the event of an Emergency Stop. The valve defaults to the CLOSED position when: • Main air is CLOSED • Control power is lost •...

  • Page 57: Metering Pump Inlet Filter

    Metering Pump Inlet Filter Caution: HAND TIGHTEN ONLY Operation The pump inlet filter is to prevent particulate matter from damaging the precision metering pumps. The filter element is a bag type and should it become clogged, it will cause cavitation of the pump resulting in damage to the pump.

  • Page 58: Metering System

    Metering System Pre-Polymer Pump Inlet Outlet The Pre-polymer metering pump is a seal-less rotary piston pump driven by a magnetic coupling. The integrated closed loop control and motor drive maintain an accuracy of 0.1% of set point. The pump provides excellent performance and resistance to corrosive wear and with the magnetic drive, the pump is maintenance free.

  • Page 59: Curative Pump

    The pump is protected on the inlet side by a bag filter with a 400-micron nylon filter element. Maintenance No routine maintenance is required. Curative Pump Pumps shown without Safety Guards for clarity. DO NOT operate the machine with Safety Guards removed. The Gusmer metering pump is a continuous delivery piston pump uniquely designed to deliver pulse-less flow with no pressure fluctuations during reversals.

  • Page 60: Pressure Transducer

    Pressure Transducer Operation Operation is automatic. The over and under pressure set points are factory set and cannot be changed. Maintenance No routine maintenance is required.

  • Page 61: Pre-Heaters

    Pre-Heaters Curative Over Temp Safety Switch Pre Polymer Heater Element Thermocouple Operation The operation of the pre heaters is completely automatic within the PLC program to maintain the operator set point. Pre Polymer The Gusmer HyBrid style heater is constructed from aluminum with a low watt density that will give very stable temperature control during static and operating conditions.

  • Page 62: Flow Meters

    Flow Meters Curative Pre Polymer The flow meters are mass style on the pre poly and curative components. Maintenance There is no periodic maintenance required.

  • Page 63: Recirculation Valve

    Recirculation Valve Pneumatically operated bypass valves transfer flow from the outlet of the pre-heaters to the recirculation loop and directly back to the buffer tank thus bypassing recirculation through the gun. This allows operation of the pumps at reduced pressures for start-up and temperature conditioning. Operation This valve is automatically opened during Normal operation.

  • Page 64: Control Valve

    Control Valve Manual Override Operation Directs air to open or close the recirculation valves. Control of the valve is either automatic or manual depending on the mode of operation. For set-up and trouble shooting purposes, the valve can be operated externally by manually depressing the override button.

  • Page 65: Hydraulic Power Pack

    Hydraulic Power Pack Schematic...

  • Page 66: Overview

    Overview The Gusmer PowerPack is a high performance hydraulic unit designed to operate the gun at a sufficient pressure to prevent sticking and at a sufficient speed to assure proper mixing. The PowerPack incorporates a precision, high pressure, fixed output gear pump in combination with an automatic pressure unloading valve and an accumulator.
  • Page 67 To protect against a mechanical failure of the valve, an electric over pressure switch, factory set to 2800 psi is installed in the pressure line. This limit switch will shut down the hydraulic motor and be accompanied by audible and visual alarms. In this case, the directional valve defaults to the gun CLOSED position and the accumulator pre-charge automatically closes the gun.

  • Page 68: Power Pack

    Power Pack 1. Accumulator 2. Automatic unloading valve 3. Pressure switches 4. Directional valve 5. Temperature limit switch 6. Manual unloading valve 7. Return line filter & fill port 8. Level/Temperature Gage Start-Up The direction of rotation is indicated by the rotational arrow and must be maintained at all times.

  • Page 69: Hydraulic Fluid

    The hydraulic system must not be operated dry. Prior to start-up, service the hydraulic reservoir with a recommended hydraulic fluid. See the table below. Maintenance The hydraulic reservoir and fluid must be periodically serviced as described in the Maintenance Manual. Hydraulic Fluid The hydraulic unit is fully tested at the factory and drained of all hydraulic fluid prior to shipment.

  • Page 70: Unloading Valve

    Unloading Valve NOTE: Different valve shown for clarity. Orientation of the adjustment screws is the same. “O” over “U” under pressure pressure Pressure Adjustment The pressure limits can be field adjusted as follows • Determine that the accumulator is pre-charged to 1920 psi and that the manual unloading valve is CLOSED.

  • Page 71: Accumulator

    Accumulator The condition of the accumulator is primarily determined by periodic checking of the pre-charge pressure. The pre-charge pressure and ambient temperature should be recorded at installation. Be sure the pressure is zero in the hydraulic chamber before checking the pre-charge that is recommended at 1200 psi. Maintenance Service as required following the procedures in the Maintenance Manual.

  • Page 72: Manual Unloading Valve

    Manual Unloading Valve This valve must be fully CLOSED IMPORTANT Any leakage across this valve at high pressure will cause the hydraulic temperature to rise dramatically; therefore, this valve must be fully closed at all times during normal operation. Directional Valve Directional Valve Manually Activate...

  • Page 73: Return Line Filter

    Return Line Filter Filter Inside Maintenance Service periodically to maintain the condition gage in the green. Maintain the service schedule following the procedures in the Maintenance Manual.

  • Page 74: Installation & Set-Up

    INSTALLATION & SET-UP IT IS RECOMMENDED THAT THE BetaCell 241 BE COMMISSIONED BY A FACTORY TRAINED TECHNICIAN...

  • Page 75: Installation

    Installation The BetaCell 241 machine is assembled on a heavy-duty steel frame that accepts all the major operating components. The machine will arrive from the factory pre-assembled, completely tested and ready for installation. It will be required to set the unit in place, provide electric service to the main electric panel, the air supply, service the hydraulic and buffer tanks, and connect the hoses and gun.

  • Page 76: Hoses

    Hoses 1. A-pressure (yellow) 2. A-return (yellow/white) 3. B-pressure (green) 4. B-return (green/white) 5. Hydraulic pressure close (black) 6. Hydraulic return open (black/white)

  • Page 77: Buffer Tanks

    Buffer tanks • Fill the tank jackets to the mid point of the sight gage with a 50% water Heated Jacket and Glycol mixture. • Slowly pressurize each tank to 60 psi while checking for any leaks. Tanks Hydraulic System •...

  • Page 78: Daily Procedures

    DAILY PROCEDURES...

  • Page 79: Daily Start-Up

    Daily Start-Up @ Main panel 1. Switch ON main power. 2. Switch ON control power. 3. Determine that all filter and pump isolation valves and the gun manual IMPORTANT: valves are OPEN. 4. Switch ON Autostart and wait until the AutoStart cycle is completed @ Machine Cont Screen (approximately 25 min).

  • Page 80: Fault Management

    FAULT MANAGEMENT...

  • Page 81: Alarm System

    Alarm system Alarm Status Screen IMPORTANT During any alarm condition, the gun will automatically default to the CLOSED position.

  • Page 82: Alarm History Screen

    Alarm History Screen Alarm Alerts The following alarms will give audible and visual alarms as well as cause one or more of the following events: • Default to the Alarm Status screen • Stop the metering pumps • Turn off the respective heaters •...

  • Page 83: Warning And Fault Messages

    Warning and Fault Messages FAULT AUTO ACTION SUPERVISOR REACTION • Alarm screen • Check fuse 24 VDC POWER OFF • Red fault light ON • 24 volt module FAULT • Fault horn ON • Alarm screen • Reset thermal overload, Reset HYDRAULIC MOTOR •...
  • Page 84 • Alarm screen • Manual bleed valve clsd HYDRAULIC POWER • Red fault light ON • Accumulator charge PACK LOW PRESSURE • Fault horn ON FAULT • Hydraulic motor OFF • Prepoly pump OFF • Curative pomp OFF • Gun locked CLSD •...
  • Page 85 • Alarm screen • Inlet valves OPEN PUMP LOW INLET • Red fault light ON • Basket filter element PRESSURE FAULT • Fault horn ON • Tank Pressure • Prepoly pump OFF • Tank temperature • Curative pomp OFF • Tank level •...
  • Page 86 • Curative Preheater Thermocouple Fault • Curative Pump Drive Fault • Curative Pump Homing Sequence Failure • Curative Pump Servo Actuator Not Homed • Curative Return Line Thermocouple Fault • Curative Supply Pressure Transducer Fault • Curative Supply Temperature Transducer Fault •...
  • Page 87 • Prepoly Return Line Thermocouple Fault • Prepoly Supply Line Thermocouple Fault • Prepoly Supply Pressure Transducer Fault • Prepoly Tank High Level • Prepoly Tank Low Level Shutdown • Prepoly Tank Low Level Warning • Prepoly Tank Thermocouple Fault...

  • Page 88: Maintenance

    MAINTENANCE...

  • Page 89: Betacell 241 Maintenance Procedure

    BetaCell 241 Maintenance Procedure Description Procedure Time 1. Access Machine Control screen via Main Menu on PV 2. Touch Auto Startup 3. Access Status screen via Main Menu on PV 4. System is ready when correct ratio is displayed, temperatures Auto Startup from 10 min have reached process temperatures and a green GO is at the...
  • Page 90 19. Access Machine Control screen via Main Menu on PV 20. Verify switches on front panel are in run position 21. Touch Auto Startup 22. Access Status screen via Main Menu on PV 23. System is ready when correct ratio is displayed, temperatures have reached process temperatures and a green GO is at the bottom of screen 24.
  • Page 91 38. Close and Lock out inlet air ball valve 39. Open air ball valve on top of Curative Buffer tank 40. Close Curative Buffer tank outlet valve 41. Drain pressure in curative line by drain valve in front of machine Now maintenance can be performed on the curative system 42.
  • Page 92 59. Drain pressure in Pre Poly line by drain valve in front of machine Now maintenance can be performed on the Pre Poly system 60. Open Pre Poly Buffer tank outlet valve 61. Close air ball valve on top of Pre Poly Buffer tank 62.
  • Page 93 Resolve a High 15 min 72. Touch alarm banner on PV to acknowledge fault Pressure Curative Fault due to Gun 73. Close and Lock out inlet air ball valve Screen/Orifice 74. Open air ball valve on top of Curative Buffer tank 75.
  • Page 94 94. Open inlet air ball valve 95. Access Machine Control screen via Main Menu on PV 96. Touch Auto Shutdown 97. Wait 1 minutes, and Touch Auto Startup 98. Access Status screen via Main Menu on PV 99. System is ready when correct ratio is displayed, temperatures have reached process temperatures and a green GO is at the bottom of screen 100.Access Operator screen via Main Menu on PV...
  • Page 95 114.Open Pre Poly Buffer tank outlet valve 115.Close air ball valve on top of Pre Poly Buffer tank 116.Open inlet air ball valve 117.Access Machine Control screen via Main Menu on PV 118.Touch Auto Shutdown 119.Wait 1 minutes, and Touch Auto Startup 120.Access Status screen via Main Menu on PV 121.System is ready when correct ratio is displayed, temperatures have reached process temperatures and a green GO is at the...
  • Page 96 131.Wipe o-ring on lid clean of any residual chemical and install lid hand tight 132.Close Curative Filter Drain ball valve 133.Open Curative Buffer tank outlet valve and ball valve 134.Follow Curative pump startup procedure 135.Access Machine Control screen via Main Menu on PV 136.Touch Curative Stop Motor 137.Close and Lock out Curative Buffer tank outlet valve and ball valve...
  • Page 97 150.Remove any residual chemical on filter bowl threads and coat threads with grease 151.Replace filter bowl 152.Open ball valve and ball valve 153.Follow Curative pump startup procedure Remove and Replace 154.Access Machine Control screen via Main Menu on PV 40 min Pre Poly Pump 155.Touch Auto Shutdown 156.Lock out main disconnect...
  • Page 98 171.Purge air from lines by opening the drain valve in front of machine into appropriate container 172.Close drain valve 173.Proceed with Auto Startup from Complete Shut Down 174.Perform an Auto Shut Down 175.Lock out main disconnect 176.Open accumulator bleed valve to remove any residual pressure 177.Turn lid of filter assembly CCW to open Remove and Replace...
  • Page 99 191.Tighten SHCS (2) 192.Remove hydraulic hoses from old GX15 noting color coding and attachment points 193.Reattach to new GX15 gun 194.Reattach harnesses 195.Open valves on coupling block 196.Close accumulator bleed valve 197.Remove main disconnect lock out and main power 198.Perform an Auto Start from complete shutdown 199.While system is dispensing properly, access Maintenance Screen from Maintenance Menu 200.Touch Autofill Off for both the Pre Poly Tank and Curative...

  • Page 100: Betacell 241 Preventative Maintenance Schedule

    BetaCell 241 Preventative Maintenance Schedule Parent Gusmer Description 3 Wks 3 Mon 1 Yr Component Part No. Curative 6312-32-230 Screen Proximity 6690-7-15 Switch Remote Pour GX-15 54100-2 Handle Dispensing 54193-011 Orifice AS NEEDED 54193-061 Orifice AS NEEDED OR 100K GX-15 54150-CSTM SHOTS Dispensing...
  • Page 101 BetaCell 241 Preventative Maintenance Schedule Parent Gusmer Description 3 Wks 3 Mon 1 Yr Component Part No. Rebuild Curative Pump 38810-15 Prepolymer 6317-58 Replace Pump Wet Calibrate Shot Size Betacell Calibration 6318-41 Buffer tank Check Change 6318-43 Water/glycol 6312-42 Inlet Pre Poly Replace 6312-42-1 Filter...

  • Page 102: Betacell 241Preventative Maintenance Procedures

    BetaCell 241Preventative Maintenance Procedures (Refer to Standard Maintenance Procedures for Detailed Step-By-Step Instructions) Gusmer Part Description Procedure Time 212.Turn Curative pump off 213.Remove air from Buffer Tank 214.Remove pressure from system. 215.Close curative valves on remote coupling block Curative Screen 216.Remove Filter Plug and remove screen 6312-32-230 10 min...
  • Page 103 Gusmer Part Description Procedure Time mixing chamber Note: verify o-rings are on orifice 234.Open valve on Coupling Block 235.Turn system on Tools: Open end wrench 236.Turn system off and relieve pressure. 237.Close valves on Coupling block Orifice 238.With open end wrench, remove and replace orifice in 54193-061 (54150-CSTM mixing chamber Note: verify o-rings are on orifice...
  • Page 104 Gusmer Part Description Procedure Time 254.Turn hydraulic power unit off via HMI 255.Relieve pressure by turning needle valve below Accumulator, CCW and verify pressure is 0 psi 256.Remove hydraulic hoses from dispensing gun and replace with new 257.Before attaching to gun, attach ends of hoses together with a 7/16 JIC union 258.Close needle valve 259.Turn hydraulic power unit on via HMI for several...
  • Page 105 Gusmer Part Description Procedure Time 276.Turn Curative pumps off. 277.Bleed air from Buffer tank 278.Lock out ball valve on bottom of buffer tank 279.Lock out inlet air ball valve 3’ B-Supply 280.Close Curative valves on Coupling block 54250-2 Hose 281.Remove and replace hose 15 min 54250-4 3’...
  • Page 106 Gusmer Part Description Procedure Time 302.Pump will need to cycle to remove air from pump 303.Verify leak free Tools: Hex Key Set, Open End Wrenches 304.Turn Prepolymer pump off. 305.Bleed air from Buffer tank 306.Lock out inlet air 307.Close ball valve before pump 308.Remove hoses/fittings attached to pump, plug hose with proper plugs 309.Remove HHCS securing pump/mag housing to motor...
  • Page 107 Gusmer Part Description Procedure Time 325.Lock out ball valve on bottom of buffer tank 326.Lock out inlet air ball valve 327.Open filter drain to remove residual chemical 328.Remove filter cover 329.Remove and replace filter element 330.Replace cover and secure hand tight 331.Open locked out valves 332.Apply air to system 333.Follow startup procedure...
  • Page 108 Gusmer Part Description Procedure Time 352.Close needle valve 353.Remove lock out 354.Follow startup procedure 355.Turn hydraulic power unit off via HMI 356.Lock out electrical panel 357.Relieve pressure by turning needle valve CCW and verify pressure is 0 psi 358.Remove accumulator cap and attach accumulator harness to accumulator and nitrogen tank 6316-44 Accumulator...
  • Page 109 Gusmer Part Description Procedure Time 373.Lock out electrical panel 374.Remove and replace battery with PLC power on PLC Battery 5 min 375.Remove lock out 376.Follow startup procedure 377.Remove lens from indicator light 378.Remove and replace bulb Indicator 5 min Lights 379.Replace indicator lens 380.Push indicator assembly to verify bulb is working...

  • Page 110: Graco Ohio Standard Warranty

    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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