Graco EVR Instructions Manual
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Graco EVR Instructions Manual

Graco EVR Instructions Manual

Electric variable ratio proportioner
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Instructions
EVR
Electric Variable Ratio Proportioner
For use with two-component sealant and adhesive materials. For professional use only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
2000 psi (13.8 MPa, 138 bar) Maximum Fluid Inlet Pressure
3500 psi (24.1 MPa, 241 bar) Maximum Fluid Outlet Pressure
Important Safety Instructions
Read all warnings and instructions in
this manual and in related manuals
before using the equipment. Save these
instructions.
3A8565C
EN

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  • Page 1 Instructions 3A8565C Electric Variable Ratio Proportioner For use with two-component sealant and adhesive materials. For professional use only. Not approved for use in explosive atmospheres or hazardous (classified) locations. 2000 psi (13.8 MPa, 138 bar) Maximum Fluid Inlet Pressure 3500 psi (24.1 MPa, 241 bar) Maximum Fluid Outlet Pressure Important Safety Instructions Read all warnings and instructions in this manual and in related manuals...

  • Page 2: Table Of Contents

    Troubleshooting ......23 EVR Error Codes ......25 Advanced Display Module (ADM) Operation .

  • Page 3: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion point symbol alerts you to a general warning and the hazard 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. Product-spe- cific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
  • Page 4 Warnings WARNING MOVING PARTS 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. • Equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
  • Page 5 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 6: Keep Components A (Red) And B (Blue) Separate

    Warnings Keep Components A (Red) and A (Red) and B (Blue) B (Blue) Separate Components NOTE: Material suppliers can vary in how they refer to plural component materials. For all machines: Cross-contamination can result in cured material in fluid lines which could cause serious injury or •...

  • Page 7: Component Identification

    AB CAN Distribution Block Electric Driver Required components supplied with the system. Incoming Power Connection EVR systems configured without pumps are pro- Pump Inlets vided with drain/relief valves, which must be Pump Outlets installed after the pumps are assembled, but before Driver Communication and I/O Connectors placing the system into service.

  • Page 8: Interior Components

    Component Identification Interior Components . 2: Interior Components Key: Power Electronics Cover Ground Lug Communications Gateway Module (CGM) Disconnect Block Terminal Block Connections Circuit Breakers CB-1 (Unit B) CB-2 (Unit A) 3A8565C...

  • Page 9: Advanced Display Module (Adm)

    Component Identification Advanced Display Module (ADM) User Interface TI12362a1 . 3: ADM Component Identification - Front Buttons Callout Button Function Callout Button Function Soft Defined by application using ADM. System Enables/disables system. When Keys enable/ system is disabled, temperature disable control and dispense operation are Cancel Cancel a selection or number entry...
  • Page 10 Component Identification ti12363a1 . 4: ADM Component Identification - Rear Key: ADM Module Status LEDs (AN) Conditions AJ Flat Panel Mount AK Model Number AL USB Module Interface Module Status LED AM CAN Cable Connections Signal Description AN Module Status LEDs AP Accessory Cable Connections Green on System is powered up.

  • Page 11: Installation

    . 5: Power Cord EVR: grounded through the power cord (customer sup- 2. Remove the four screws to separate the EVR Frame plied). Cover (T) and Power Disconnect Switch (C) from the EVR Frame (S) on the electrical driver.
  • Page 12 6. Place the power wires into the open area on either side of the Power Disconnect Switch (C) as space permits. 7. Reinstall the EVR Frame Cover (T) and Power Dis- connect Switch (C) using the four screws removed in step 2.

  • Page 13: Install Vented Oil Cap Before Using Equipment

    Installation Install Vented Oil Cap Before Using Equipment The driver gear-box is shipped from the factory pre-filled with oil. The temporary unvented cap (PX) prevents oil leaks during shipment. This temporary cap must be replaced with the vented oil cap (PY), supplied with the equipment, before use.

  • Page 14: Setup

    Setup Setup After placing the EVR in the desired area of operation: NOTE: Make sure the EVR is placed on a level surface. See Dimensions on page 72 for space requirements. Port #6 1. Anchor the EVR to a fixed mounting location. See Dimensions on page 72.

  • Page 15: Flushing

    Setup Flushing d. Assemble, connect and tighten the component A (Red) inlet hose to the A Pump Inlet (J). 4. Attach the fluid outlet hoses to the Pump Outlets (K). To avoid fire and explosion, always ground equip- ment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.

  • Page 16: Operation

    NOTE: The EVR is tested with oil at the factory. Flush eyes. To prevent cross-contamination of the equip- out the oil with a compatible solvent before dispensing.

  • Page 17: Shutdown

    Check your materials for compatibility with zinc plating and sulfur before reusing any material that passed through them, as it may inhibit curing. 1. Press the enable/disable key on the ADM disable the EVR, and verify it is inactive. 3A8565C...

  • Page 18: Adjust Material Inlet Pressure

    4. Adjust both inlet regulators (if used) so that there is times. Use only enough feed pressure to adequately no air pressure on them and that the regulator pres- feed the EVR pumps. The minimum feed pressure is 70 sure gauge reads zero. psi (0.48 MPa, 4.83 bar).

  • Page 19: Maintenance

    If oil is low, open ber ports regularly, see dispense valve manual fill cap (FB) and add Graco Part No. 16W645 ISO 220 valve manual silicone-free synthetic EP gear oil. See F . 15.

  • Page 20: Change The Oil

    2. Turn the Power Disconnect Switch (C) to the OFF ft-lb (25-30 N•m). position. 4. Open the fill cap (FB) and add Graco Part 16W645 3. Perform the Pressure Relief Procedure on page ISO 220 silicone-free synthetic EP gear oil. Check the oil level in the sight glass (FC).

  • Page 21: Adm - Battery Replacement And Screen Cleaning

    Maintenance ADM - Battery Replacement and 6. Turn the Power Disconnect Switch (C) to the ON position. Screen Cleaning 7. Navigate to Maintenance Screen 1 on the ADM (see page 41). Press to enter Calibration mode. Battery Replacement 8. Press the icon to begin calibration.

  • Page 22: Grease Cup Maintenance

    Maintenance Grease Cup Maintenance Frequency of greasing intervals is dependent on material being pumped. As a basic schedule, lubricate pump with grease after 250 gallons of product ( five drums of 55 gallon pails) has been passed through the pump. If the grease has become hardened, remove the hardened materials or grease.

  • Page 23: Troubleshooting

    3. Turn the Power Disconnect Switch (C) OFF. Try the recommended solutions in the order given for NOTE: For Online help, visit http://help.graco.com for each problem, to avoid unnecessary repairs. Also, causes and solutions to each error code. determine that all circuit breakers, switches, and con- trols are properly set and wiring is correct before assuming there is a problem.
  • Page 24 Troubleshooting Problem Cause Solution Proportioning System 1. Observe gauge to determine which pump is losing pressure. 2. Determine in which direction the Proportioning pump does not hold pump has stalled by observing Pump piston or intake valve leaking pressure when stalled which directional valve indicator light is on.

  • Page 25: Evr Error Codes

    Troubleshooting EVR Error Codes Error Code Type Code Description Cause Solution Inlet pressure too high, causing retract stroke to Reduce inlet supply pressure. require too much torque Pump sizes too large for motor to drive at the operat- Reduce pump size.
  • Page 26 Troubleshooting Error Code Type Code Description Cause Solution Verify CAN cable is plugged in System unable to Comm. Error _____ Remove and reconnect CAN CAT_ Advisory communicate with tank Tank Stand cable, taking care not to cross stand thread the connector nut Verify CAN cable is plugged in System is unable to Comm.
  • Page 27 Troubleshooting Error Code Type Code Description Cause Solution The flow rate requested by Reduce the flow rate so that the Gel Flow Exceeds Max the gel timer exceeded the F4GX Alarm gel timer flow rate is below the Flow max flow rate (26 cycle per max flow rate pump) L1T_...
  • Page 28 Troubleshooting Error Code Type Code Description Cause Solution Inspect for leaks in fluid path. Increase operating pressure by Pressure exceeds increasing feed pressure and/or user-defined limit restriction in the feed hoses. P1F_ Alarm Low Pressure Inlet _ Decrease user-defined pressure limit.
  • Page 29 Troubleshooting Error Code Type Code Description Cause Solution Inspect for hardened material or obstructions to flow. Attempt to purge material at a reduced flow rate. Pressure exceeds P4D_ Alarm High Pressure Outlet _ Reduce operating pressure by user-defined limit reducing flow rate and/or restric- tion in the hose and valve.
  • Page 30 Troubleshooting Error Code Type Code Description Cause Solution Inspect for hardened material or obstructions to flow. Attempt to purge material at a Pressure exceeds system P9D_ Alarm High Pressure Outlet _ reduced flow rate. limit Reduce operating pressure by reducing flow rate and/or restric- tion in the hose and valve.

  • Page 31: Advanced Display Module (Adm) Operation

    Advanced Display Module (ADM) Operation Advanced Display Module (ADM) Operation When main power is turned on by turning the Power 8. Enable/disable integration features. See Integra- Disconnect Switch (C) to the ON position, the splash tion Screen 1, page 43. screen will be displayed until communication and initial- ization is complete.

  • Page 32: Adm Screen Overview

    ADM Screen Overview ADM Screen Overview Home Screen System Active Recipe Error and Events State Selected Display Status of Valve To select a recipe, use the navigation keys to highlight the active recipe bar. Then press the Enter button to open a drop down menu where the desired recipe can be selected.
  • Page 33 ADM Screen Overview Along the right side of the home screen, there are icons that will allow the user to park, de-pressurize, purge, Purge: When pressed, the purge icon will purge and base purge. material from the pumps. To stop purging material from NOTE: The system must be active to access these icons.
  • Page 34 Tank Stand Status Information NOTE: The tank stand information and icons will only be shown when the tank stand is connected to the EVR network. Tank Status Fill Levels: These icons display the fill level of each of the tanks.
  • Page 35 ADM at the RPM set- This screen will only be displayed if the NOTE: point. Voltex Dynamic Mix Valve is connected to the EVR Network. 7. Motor Actual RPM: Shows what speed the motor is at during the ramp period. It is not direct feedback from the motor.

  • Page 36: Index Menu

    Log, Events, Errors, and Integration screens. NOTE: If the user selects operator mode for the shot size, the EVR will only dispense at the desired flow rate as long as an external trigger source or foot switch is active for that particular shot of the recipe.
  • Page 37 This screen allows the user to monitor inlet and outlet This screen allows the user to change the dispense pressures of the EVR during a dispense. The user can mode, rate units, pressure units, pressure imbalance specify a minimum and maximum allowable value for A alarm, and the pump line, and size of the A and B and B for both inlet and outlet pressures.
  • Page 38 After the icon is pressed, the EVR will begin recirculating the pumps and count down the Flow: The flow rate at which the system will automati- recirculation on timer.
  • Page 39 Otherwise, recirculation on and recirculation off will be 4400RPM. grayed out. EVR Dispense Wait: This will cause the EVR to wait If disabled is selected for the recirculation mode, all until the Voltex motor is up to speed before dispensing.
  • Page 40 The icon can also be used to abort a refill operation. NOTE: This screen will only be displayed if a tank stand is connected to the EVR network. Refill Setting: if a refill setting other than disabled is This screen allows the user to specify the operating...
  • Page 41 ADM Screen Overview Advanced Screen 1 This screen allows the user to change the language, date, and time shown on the ADM. The user can also set up a password and change the screen saver here. Maintenance Screen 1 This screen keeps track of the cycles of the A and B pump, both current and lifetime, as well as the number Advanced Screen 2 of times the dispense valve has opened and closed.
  • Page 42 If a non-zero number is entered in that field, and the corresponding pump or valve cycles exceeds that value, the EVR will generate and log an advisory informing the user of the Maintenance Screen 2 and 3 condition.
  • Page 43 PLC, as well as when the unit is sending outputs to a PLC. Integration inputs must be enabled by checking the box for the EVR to use the sig- nal. If the check box is not checked, the EVR will ignore the signal.
  • Page 44 ADM Screen Overview USB Plug-In Screen This screen will appear when a USB device is plugged into the ADM. Here the user can select dates to download data from the ADM to the USB device by pressing the left and right arrow icons on either side of the screen .

  • Page 45: Software Update

    See the following Icon table. Icon Description Update successful. 4. Insert and press EVR software upgrade token (TK, part no. 19C237) firmly into slot. Update unsuccessful. NOTE: There is no preferred orientation of token. Update complete, no changes necessary.

  • Page 46: I/O Integration

    24 VDC Digital Output Valve A • 24V is ON • 0V is OFF 24VDC Output 24V for dry contact closure Trigger Trigger Trigger a dispense on the EVR Output System Ready Output Alarm Present Ground/Return Ground Input Recipe Select Integration...

  • Page 47: Evr And Plc Connection

    Verify the PLC connection parameters are setup correctly. Input Assembly Instance Input Instance Size NOTE: The connection between the EVR and PLC will not be made if the PLC connection parameters are not Output Assembly Instance set up correctly. Output Instance Size...
  • Page 48 I/O Integration EVR Fieldbus Map 19C930 Automation Inputs (signal from EVR to PLC) Minimum Maximum Tag ID Description Data Type Value Value Byte Gel Shot is Dispensing Boolean Gel Shot Countdown Timer is Alarming Boolean Red Tank is Filling Boolean...
  • Page 49 I/O Integration EVR Fieldbus Map 19C930 Automation Inputs (signal from EVR to PLC) Minimum Maximum Tag ID Description Data Type Value Value Byte System Ratio Offset (-/+ X.XX) sint16 0.00 0.25 0-14 22-23 Active Recipe Flowrate (XXXX.XX uint16 69.33 0-14...

  • Page 50: Plc Outputs

    I/O Integration PLC Outputs EVR Fieldbus Map 19C930 Automation Outputs (signal from PLC to EVR) Minimum Maximum Tag ID Description Data Type Value Value Byte System Enable Request Boolean PLC Lockout Request * Boolean Operator Dispense/ Shot Boolean Request (Use discrete signal for proper...
  • Page 51 Min and Max Values NOTES: If set, control of the EVR from the ADM will be disabled. When in operator mode for recipe, the bit must be held high, if dropped low the operator mode will be completed, dispensing will stop and the dispense will be recorded into the shot log.

  • Page 52: Data Exchange

    I/O Integration Data Exchange NOTE: For EVR Data Exchange timing diagrams, see F . 26 page 65. EVR Fieldbus Map 19C930 Data Exchange Command Value Format and Minimum Maximum Name Read/Write (base 10 decimal) Units Value Value Red MCM Active Alarms bitfield...
  • Page 53 I/O Integration EVR Fieldbus Map 19C930 Data Exchange Command Value Format and Minimum Maximum Name Read/Write (base 10 decimal) Units Value Value 0 - Shot Recipe Look Up Type Read Only 1 - Operator XXXX.XX Recipe Look Up Flowrate Read Only 0.00...
  • Page 54 I/O Integration EVR Fieldbus Map 19C930 Data Exchange Command Value Format and Minimum Maximum Name Read/Write (base 10 decimal) Units Value Value 1-Low and High Sensor Installed 2-Low and Mid Sensor Installed Red Tank Sensor Configuration 3-Mid and Read/Write High Sensor...
  • Page 55 I/O Integration EVR Fieldbus Map 19C930 Data Exchange Command Value Format and Minimum Maximum Name Read/Write (base 10 decimal) Units Value Value Park After Recirculation is 0-Disable Read/Write Completed Enable 1-Enabled Voltex Active Alarms Bitfield Bitfield Read Only 4, 294,967,296...

  • Page 56: Gm General Timing Diagrams

    NOTE: When dispensing a bead, it is recommend that the discrete trigger signal be used instead of the fieldbus trigger signal, due to the fact of timing issues and delays. EVR Gateway Run Park Automation Inputs (EVR Outputs) System On...
  • Page 57 I/O Integration EVR Gateway Run Purge Automation Inputs (EVR Outputs) System On PLC Lockout Active System Ready No Alarms are Present No Deviations are Present No Advisories are Present System is Purge Dispense Valve is Opened Automation Outputs (EVR Inputs)
  • Page 58 I/O Integration EVR Gateway Run Base Purge Automation Inputs (EVR Outputs) System On PLC Lockout Active System Ready No Alarms are Present No Deviations are Present No Advisories are Present System is Base Purge Dispense Valve is Opened Automation Outputs (EVR Inputs)
  • Page 59 I/O Integration EVR Gateway Run Depressurizing Automation Inputs (EVR Outputs) PLC Lockout Active No Alarms are Present No Deviations are Present No Advisories are Present System is Depressurizing Dispense Valve is Opened Automation Outputs (EVR Inputs) PLC Lockout Request Depressurizing Request...
  • Page 60 I/O Integration EVR Gateway Run Recipe in Operator Mode Automation Inputs (EVR Outputs) System On System Ready No Alarms are Present No Deviations are Present No Advisories are Present Recipe is Dispensing Dispensed Valve Open Automation Outputs (EVR Inputs) Operator Dispense/ Shot Request...
  • Page 61 I/O Integration EVR Gateway Start Shot Recipe Automation Inputs (EVR Outputs) System On PLC Lockout Active System Ready No Alarms are Present No Deviations are Present No Advisories are Present Dispensed Valve Open Automation Outputs (EVR Inputs) Operator Dispense/ Shot Request...
  • Page 62 I/O Integration EVR Gateway Stop Recipe Automation Inputs (EVR Outputs) System On PLC Lockout Active System Ready No Alarms are Present No Deviations are Present No Advisories are Present Dispensed Valve Open Automation Outputs (EVR Inputs) Operator Dispense/ Shot Request...
  • Page 63 I/O Integration EVR Gateway Run Recipe in Operator Mode with Voltex Automation Inputs (EVR Outputs) System On PLC Lockout Active System Ready No Alarms are Present No Deviations are Present No Advisories are Present Recipe is Dispensing Dispensed Valve Open...
  • Page 64 I/O Integration EVR Gateway Run Shot Recipe with Voltex Automation Inputs (EVR Outputs) System On PLC Lockout Active System Ready No Alarms are Present No Deviations are Present No Advisories are Present Recipe is Dispensing Dispensed Valve Open Voltex motor is at Target Speed...
  • Page 65 I/O Integration EVR Data Exchange Automation Inputs (EVR Outputs) PLC Lockout Active Selected Data Exchange Element Selected Data Exchange Element Value 49 Automation Outputs (EVR Inputs) PLC Lockout Request Desired Data Exchange Element 41 Desired Data Exchange Element Value 42...

  • Page 66: Error Codes

    I/O Integration Error Codes CCC_ Comm. Error Gateway _ F3N_ Unable to Maintain Flow 3mcp Error Codes Rate _ MA0_ Pump Cycles Exceeds Limit Alarms Bitfield MEDX Valve Cycles Exceeds Limit Number Alarm Code Alarm Name P9F_ High Pressure Inlet _ P9D_ High Pressure Outlet _ CATA...

  • Page 67: Recycling And Disposal

    Recycling and Disposal Recycling and Disposal End of Product Life At the end of a product’s useful life, recycle it in a responsible manner. At the end of the product’s useful life, dismantle and recycle it in a responsible manner. •...

  • Page 68: Schematics

    Schematics Schematics 3A8565C...
  • Page 69 Schematics 3A8565C...
  • Page 70 Schematics 3A8565C...
  • Page 71 Schematics 3A8565C...

  • Page 72: Dimensions

    Dimensions Dimensions A Machine Mounting Holes 20.1 in. (51 cm) For 3/8 in. (10mm) Mounting Fasteners B Machine Mounting Holes 26.7 in. (68 cm) C Total Machine Height 31 in. (79 cm) D Total Machine Length 40.3 in. (102 cm) E Total Machine Width 30.5 in.

  • Page 73: Technical Specifications

    Technical Specifications Technical Specifications Metric Maximum fluid working pressure ‡ 3500 psi 24 MPa, 241 bar Maximum fluid temperature 120°F 50°C Fluid circulation ports 1/4 NPS(m) Line voltage rating 200-240V, 1ph, 40A, 50/60 Hz Stainless steel, zinc-plated carbon steel, brass, tungsten Wetted parts carbide, chrome, fluoroelastomer, PTFE, ultra-high molec- ular weight polyethylene, silicon nitride...

  • Page 74: Graco 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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