Graco PR-Xv Instructions Manual
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Graco PR-Xv Instructions Manual

Graco PR-Xv Instructions Manual

Variable ratio metering system
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Instructions
PR-Xv
Variable Ratio Metering System
For accurate metering, mixing, and dispensing of two-component materials. For
professional use only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure.
Important Safety Instructions
Read all warnings and instructions in this manual,
your repair-parts manual, and your dispensing
valve manuals before using the equipment. Save
these instructions.
PR-Xv Metering Unit
PR-Xv Control Unit
3A9328D
EN

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Summary of Contents for Graco PR-Xv

  • Page 1 100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure. Important Safety Instructions Read all warnings and instructions in this manual, your repair-parts manual, and your dispensing valve manuals before using the equipment. Save these instructions. PR-Xv Metering Unit PR-Xv Control Unit...

  • Page 2: Table Of Contents

    Component Identification ....9 PR-Xv Control Unit ..... . . 63 PR-Xv Metering Unit, Supply Pump Feed .

  • Page 3: Models

    NOTE: The ratio range of PR-Xv 100cc metering system (1:1 volume ratio system) is from 1:1 to 5:1. The ratio range of PR-Xv 75cc metering system (2:1 volume ratio system) is from 2:1 to 10:1. NOTE: Any PR-Xv system can be converted to Profinet communication mode by ordering SD card 2000359 and performing Software update, page 50.

  • Page 4: Safety Symbols

    Safety Symbols Safety Symbols The following safety symbols appear throughout this manual and on warning labels. Read the table below to understand what each symbol means. Symbol Meaning Symbol Meaning Do Not Place Hands or Other Body Electric Shock Hazard Parts Near Fluid Outlet Do Not Stop Leaks with Hand, Equipment Misuse Hazard...

  • Page 5: General Warnings

    General Warnings General Warnings The following warnings apply throughout this manual. Read, understand, and follow the warnings before using this equipment. Failure to follow these warnings can result in serious injury. WARNING ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
  • Page 6 General Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion: • Use equipment only in well-ventilated area.

  • Page 7: Keep Components A And B Separate

    General 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 8: Typical Installation

    . 2 and F . 3 are only a guide for identifying system components and for assisting in installation. Contact your Graco distributor or Graco China Customer Service for assistance in designing a system to suit your specific needs. Main Power .

  • Page 9: Component Identification

    AG Base Unit AH Piston Observation Hole Different types of Static Mixer Package (AA, page 9) and are available from Graco. Make certain the Static Mixer Package (AA, page 9) is adequately sized and pressure-rated to meet your system needs.

  • Page 10: Pr-Xv Control Unit

    Component Identification PR-Xv Control Unit BG BH BJ Left View Bottom View Front View . 3: PR-Xv Control Unit Key: BA Human Machine Interface (HMI) Display BB Control Power On/Off Buttons BC Emergency Stop (E-stop) Switch BD Main Power Switch...

  • Page 11: Installation

    2 × Φ0.315 in. (8.00mm) through 5.905 in. 5.905 in. (150.00 mm) (150.00 mm) 2.756 in. Mounting holes (70.00 mm) 4 × Φ0.335 in. (8.50mm) through 5.905 in. (150.00 mm) . 4: Mounting Hole Dimensions for Installing the PR-Xv Metering Unit - Supply Pump Feed...

  • Page 12: Grounding

    PR-Xv Metering Unit (J, page 8): Grounded through the PR-Xv Installation Plate. Use the supplied ground wire and clamp to ground the metal PR-Xv Installation Plate or Customer Robot to a true earth ground. . 5 Grounding PR-Xv Control Unit (G, page 8): grounded through the power cord.

  • Page 13: Connecting Lines And Cables

    10) and cables. 4. Follow the marks on the PR-Xv Control Unit (G, 1. Connect the PR-Xv Air Line (N, page 8) to the air page 8) and the cables to connect the junction box, inlet of the Junction Box Assembly (AC, page 9).

  • Page 14: Startup

    1. Make sure the air line and the cables are correctly connected to the system. 2. Locate the Power Switch (BD, page 10) at the left of the PR-Xv Control Unit (G, page 8) and turn the power on. 3. Press the Control Power on Button (BB, page 10) to open HMI displays.

  • Page 15: Hmi Display Operation And Identification

    HMI Display Operation and Identification HMI Display Operation and Identification Screen Navigation Diagrams NOTE: Use the icons or corresponding “F” keys to navigate between screens. For example, navigation using icons is shown in the following diagrams. The “F” keys are shown along the bottom of each screen. Navigation on Main Screen NOTE: The following only displays the navigation on the System Main Screen.
  • Page 16 HMI Display Operation and Identification Navigation on Automatic Screens Automatic Main Screen Maintenance Screen (See page 21) (See page 24) See next page Error Message Screen (See page 24) Signal Check Screen (Auto) (See page 25) Job Record Screen (See page 27) ???? Automatic Main Screen (See page 21)
  • Page 17 HMI Display Operation and Identification Part A and Part B Automatic Main Screen Torque Trend Screen (See page 21) (See page 25) Part A and Part B Pressure Trend Screen (See page 26) Status Check Screen (See page 26) Automatic Main Screen (See page 21) See next page...
  • Page 18 HMI Display Operation and Identification Navigation on Manual Screens Automatic Main Screen System Main Screen (See page 21) (See page 28) Manual Main Screen Signal Check Screen (See page 29) (Manual) (See page 29) System Main Screen (See page 28) See next page...
  • Page 19 HMI Display Operation and Identification Navigation on Setup Screens System Main Screen Shot Setup Screen Pre-charge Setup Screen (See page 28) (See page 31) (See page 41) Bead Setup Screen Purge Setup Screen (See page 32) (See page 39) Note: If sequence mode is enabled Sequence Setup Screen Reload Setup Screen...
  • Page 20 HMI Display Operation and Identification Advanced Setup Screen 1 (See page 34) Advanced Setup Screen 2 De-pressurization Setup Reload Setup Screen (See page 35) Screen (See page 38) (See page 33) Advanced Setup Screen 3 (See page 37)

  • Page 21: Start Center

    . 8 Start Center Screen . 10 Automatic Main Screen The content and functions of this screen are as follows: When the PR-Xv control unit is powered on, select ‘Start’ in the ‘Start Center’ screen and the system Information Bar performs the self check.

  • Page 22: Working Information

    HMI Display Operation and Identification Pressure • When Volume is selected: left materials in cc are displayed. Flow Rate To show the dispense rate of a mixture of Part A and B. Working Information To show the current pressure. The current pressure is shown in psi.
  • Page 23 HMI Display Operation and Identification For preset program of bead mode, see Bead Function Icons Setup Screen, page 32. Press ‘F1’ or select the icon to display When HMI Display is selected and sequence mode is System Main Screen, page 28. enabled, the system switches to sequence mode.

  • Page 24: Maintenance Screen

    HMI Display Operation and Identification Maintenance Screen Error Message Screen . 12 Error Message Screen . 11 Maintenance Screen On the Error message screen, press ‘F1’ or select On the Maintenance Screen, press ‘F1’ or select to display the Automatic Main Screen. display the Automatic Main Screen.

  • Page 25: Signal Check Screen (Auto)

    HMI Display Operation and Identification Signal Check Screen (Auto) Torque Trend Screen . 14 Part A Torque Trend Screen . 13 Signal Check Screen (Auto) On the part A and B Torque Trend Screen, press ‘F1’ or On the Signal Check Screen, press ‘F1’ or select select to display the Automatic Main Screen.

  • Page 26: Pressure Trend Screen

    Servo alarm: Something is wrong with the motor. Operator should push the reset button or send a remote reset signal. If reset does not work, the PR-Xv control unit needs to be restarted. Motor Position This display shows the number of motor steps.

  • Page 27: Job Record Screen

    HMI Display Operation and Identification Job Record Screen Piston Position Green signals show the current piston positions of part A and B. Valve Status . 17 Job Record Screen Green signals show if the action signals of inlet valves and dispense valves are activated. On the Job Record Screen, press ‘F1’...

  • Page 28: System Main Screen

    HMI Display Operation and Identification System Main Screen System Information Screen . 18 System Main Screen . 19 System Information Screen On System Main Screen, the operator can switch the On the System Information Screen, press ‘F1’ or select system to Automatic mode, Manual mode, Setup to display System Main Screen.

  • Page 29: Manual Main Screen

    HMI Display Operation and Identification Manual Main Screen Executions of are functioned together with executions of . For example: Execution Description Select part A to execute base purge. Base purge parameters are set in Purge Setup Screen, page 39. A confirmation should be performed before base purge.
  • Page 30 HMI Display Operation and Identification Current Pressure Purge and Base Purge Volume To display purge and base purge volume. To show the current pressure of part A and B. Motor Torque Dispense Volume To show the motor torque of part A and B. Mode Selection To show current one shot volume for part A and B.

  • Page 31: Signal Check Screen (Manual)

    HMI Display Operation and Identification Signal Check Screen (Manual) Setup Screen Shot Setup Screen . 21 Signal Check Screen (Manual) On the Signal Check Screen (Manual), press ‘F1’ or . 22 Shot Setup Screen select to display the Manual Main Screen. On the Shot Setup Screen, press ‘F1’...
  • Page 32 HMI Display Operation and Identification Bead Setup Screen displayed on the top left of the keyboard. Enter a value within the displayed range. NOTE: The settings for shot rate are also applied to bead setup. See Bead Setup Screen, page 32. .
  • Page 33 HMI Display Operation and Identification Sequence Setup Screen De-pressurization Setup Screen . 25 Sequence Setup Screen . 26 De-pressurization Setup Screen On the Depressurization Setup Screen, press ‘F1’ or On the Depressurization Setup Screen, press ‘F1’ or select to display the System Main Screen. Press select to display the System Main Screen.

  • Page 34: Advanced Setup Screen

    Advanced Setup Screen 1 NOTE: Set different de-pressurization targets according to different materials. For detailed information, please contact your Graco distributor. • Max depressure time: Set the maximum time in seconds for the system to perform de-pressurization. If de-pressurization exceeds the set time, de-pressurization fails and the system activates the alarm.
  • Page 35 HMI Display Operation and Identification Pressure Unit Advanced Setup Screen 2 Select ‘psi’, ‘bar’ or ‘Mpa’ to customize the units used for pressure. Password Setup If this function is selected, a 4-digit number should be set. After the 4-digit number is set, the operator must be prompted to input the password before visiting manual screens or setup screens.
  • Page 36 HMI Display Operation and Identification Pressure Imbalance Alarm Metering Tube Size Set the size of metering tube per real situation. Set the pressure difference between part A and B in psi column, and select how the system reacts to the Home Speed pressure difference.
  • Page 37 HMI Display Operation and Identification Advanced Setup Screen 3 Dispense CMD Resource The operator may choose whether the Dispense Command (CMD) resource comes from Distributed I/O communication or Gateway (Profinet) communication. HMI Display option is unavailable. Sequence Mode Select to enable sequence mode by selecting ON, and disable sequence mode by selecting OFF.
  • Page 38 HMI Display Operation and Identification Reload Setup Screen Reload Request Setup When the piston reaches the set ‘Reload request position’, the system sends out signal for reloading and executes reloading command per the setup reload type. Meanwhile, the system continues dispensing. Reload Completion Setup .
  • Page 39 HMI Display Operation and Identification Purge Setup Screen Reload Type Setup The selected reload type is showed as green color. • Reload after each job: In this mode, the metering rods retract after every shot. This is the default . 31 Purge Setup Screen setup.
  • Page 40 HMI Display Operation and Identification • Warning Time: When the system completes jobs, Base Purge Setup the control unit counts down from the set ‘Pot life’. When it counts down to ‘0’, the system activates the alarm of purging. • Alarm Time: When the system completes jobs, the control unit counts down from the set ‘Idle Period’.
  • Page 41 HMI Display Operation and Identification Pre-charge Setup Screen The decelerate point is a relative point to the target pressure. For example, if the pre-charge pressure is 500 psi and the decelerate point is 75%, the system will start pre-charge at the ‘Hi’ speed, and switch to the ‘Lo’...

  • Page 42: Advanced Screen

    HMI Display Operation and Identification Advanced Screen Close Dispense Valves This shows that the dispense valves are open. Select to close dispense valve A or outlet valve B. Piston Movement Speed • Select to set movement speed of piston. . 33 Advanced Screen •...

  • Page 43: Operation

    NOTE: If the material is with low viscosity. You may flip the green button of Control Power On/Off Buttons the system dispense valve to the top, and then prime (BB, page 10) to turn on the power for the PR-Xv the system. Drive Assembly (AD, page 9).
  • Page 44 Operation 8. Press to display Advanced Screen. 4. Press on the Automatic Main Screen for about 3 seconds. . 39 Advanced Screen . 37 Automatic Main Screen 9. Remove the night cap from the TC Dispense Valve (AB, page 9). 5.
  • Page 45 Operation 12. Wait for part A and B to dispense in continuous and 15. Press to display the Reload Setup Screen. Set stable flow. Then select "A Outlet ON" and "B and check reload rate of part A and B. Outlet ON"...

  • Page 46: Daily Start Up

    Automatic Main Screen. The system is ready for For daily start of the system, follow the below steps. jobs. 1. Turn on the air for the supply pump and PR-Xv Metering Unit. Check the air pressure for the supply pump.
  • Page 47 5. Pull up the E-stop Button (BC, page 10). Then press prime the ratio check nozzle. the green button of Control Power On/Off Buttons (BB, page 10) to turn on the power for the PR-Xv 11. (optional step) Perform Ratio Check Procedure, Drive Assembly (AD, page 9).
  • Page 48 Operation . 52 Install Static Mixer Package 24. Dispense into a waste container to prime the Static Mixer Package (AA, page 9). . 50 Manual Main Screen 17. On the Manual Main Screen, select the “Shot” 25. Press to display System Main Screen. Then control mode and then press to purge out press...

  • Page 49: Ratio Check Procedure

    Operation Ratio Check Procedure This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection and splashing, keep fingers and other body parts away from the spray tip. 6. Repeat until all three sets of cups have been used. To avoid injury from toxic fluids or fumes, such as splashing in the eyes or on skin, wear appropriate 7.

  • Page 50: Software Update

    If necessary, set the IP address after Edit communication connections software update. 1. Start PR-Xv control unit and push ‘Settings’ on the NOTE: Do not remove the SD card once it is inserted ‘Start Center’ screen. into the control unit, because the control unit can not work without the SD card.
  • Page 51 Operation 4. Select ‘Accessible devices in target subnet’ on the 6. Edit IP address directly on the ‘Step 3/4’ screen. ‘Step 1/4’ screen. Then select ‘>‘ to proceed to the Then select ‘>‘ to proceed to the next screen. next screen. 7.
  • Page 52 Edit network settings 10. Select ‘ON’ for the ‘Override’ item on the ‘Step 2/3’ screen. Then select ‘>‘ to proceed to the next 1. Start PR-Xv control unit and select ‘Settings’ on the screen. ‘Start Center’ screen. 11. Select ‘Accept’ on the ‘Step 3/3’ screen.

  • Page 53: Pressure Relief Procedure

    Operation Pressure Relief Procedure 3. Edit IP address directly from the ‘Network Interface’ screen. Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing 4.

  • Page 54: Flush The Equipment

    Operation Flush the equipment closed. Then the dispense valve will be opened. The whole system pressure is relieved. To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at 7.

  • Page 55: Shut Down

    Shut down 5. Press E-stop Button (BC, page 10). 6. Turn off the Main Power Switch (BD, page 10) of the PR-Xv Control Unit (G, page 8). This equipment stays pressurized until pressure is Main Power manually relieved. To help prevent serious injury from...
  • Page 56 Operation Short-time shutdown Run the system after short-time shutdown Base purge is used for short-time shutdown when the 1. Place a waste container below the TC Dispense material have long pot life. Valve (AB, page 9). 1. Make sure the system finishes the current job. The 2.

  • Page 57: Maintenance

    Replace the seal kits of the Inlet Valve (AE, page 9) and the TC Dispense Valve (AB, page 9). ✓ Inject grease to the lubricated kits of the PR-Xv Metering Unit (J, page 8). ✓ Replace the rods and needles of the Inlet Valve (AE, page 9) and the TC Dispense Valve (AB, page 9).

  • Page 58: Recycling And Disposal

    Recycling and Disposal Recycling and Disposal End of Product Life At the end of the product’s useful life, dismantle and recycle it in a responsible manner. • Perform the Pressure Relief Procedure on page • Drain and dispose of fluids according to applicable regulations.

  • Page 59: Troubleshooting

    Cartridge or pail empty Exchange cartridge or pail Supply pump clogged Clean supply pump Air in PR-Xv Metering Unit Purge and prime the system Significant material leaking Pump shaft and/or shaft seal worn Remove pump shaft assembly and reinstall...
  • Page 60 Troubleshooting Problem Cause Solution Material weight incorrectly Needle or Static Mixer Package Replace needle or Static Mixer Package dispensed (AA, page 9) clogged (AA, page 9). Incorporate purge timer or decrease purge timer delay to prevent Static Mixer Package (AA, page 9) blockage TC Dispense Valve (AB, page 9) or Clean TC Dispense Valve (AB, page 9) or...
  • Page 61 Troubleshooting Problem Cause Solution High pressure TC Dispense Valve (AB, page 9) Clean TC Dispense Valve (AB, page 9) clogged Material in Static Mixer Package Replace Static Mixer Package (AA, page 9) (AA, page 9) and/or needle cured and/or needle 1.
  • Page 62 Solution 1. Verify signal was correctly sent and System does not dispense or Signal error between platform and received. dispenses in the incorrect PR-Xv control unit 2. Verify signal cable is correctly amount/mode connected. Wrong “Dispense mode” Choose correct mode Wrong “Dispense type”...

  • Page 63: Dimensions

    PR-Xv Metering Unit, Supply Pump Feed 10.98 in. (279.00 mm) 6.16 in. (156.50 mm) 29.88 in. (758.85 mm) . 59: PR-Xv Metering Unit Dimensions, Supply Pump Feed PR-Xv Control Unit 18.54 in. (471.00 mm) 16.93 in. (430.00 mm) 23.62 in. (600.00 mm) 9.92 in.

  • Page 64: Schematics

    Schematics Schematics...
  • Page 65 Schematics...
  • Page 66 Schematics...
  • Page 67 Schematics...
  • Page 68 Schematics...
  • Page 69 Schematics...

  • Page 70: Io Signals

    Schematics IO signals Signal Signal Name Description Style number address INPUT CUST_IN_DISPENSE I2.0 used to start dispensing in bead mode or shot mode CUST_IN_PURGE I2.1 used to start purge. CUST_IN_RELOAD I2.2 used to start reloading material. CUST_IN_STYLEBIT_0 I2.3 BIT0-3: 0-15, for select style CUST_IN_STYLEBIT_2 I2.4 CUST_IN_ESTOP...

  • Page 71: Profinet Map

    Schematics Profinet map Control unit input from PLC output Name Units In Byte Description GATE_IN_CMD_BITS JOB_START used to start job, normal DISPENSE used to start dispensing in bead mode or shot mode RELOAD used to start reloading material PURGE used to purge response REMOTE_RESET used to reset error MODE_SELECT...

  • Page 72: Timing Chart

    Schematics Timing chart Alarms present System in CUST_IN_JOB_START CUST_IN_MODE_SELECT CUST_IN_DISPENSE CUST_IN_RELOAD CUST_OUT_IN _JOB CUST_OUT_READY CUST_OUT_INDISPENSE CUST_OUT_ALARM CUST_OUT_INRELOAD CUST_OUT_IN_COMPLETE CUST_OUT_RELOAD_REQUEST System pre-pressure System Alarms present System in sequence mode CUST_IN_DISPENSE shot1 shot 2 shot3 …… …… …… …… shot 14 shot 15 CUST_OUT_READY CUST_OUT_INDISPENSE shot1...

  • Page 73: Appendix A - Error Number Message

    Appendix A - Error number message Appendix A - Error number message Error Error Error Name Description Cause Solution Type ---- No Error Error E-stop System emergency System Emergency Stop Switch Make sure the system is in safety , page 10 stops status.
  • Page 74 Appendix A - Error number message Error Error Error Name Description Cause Solution Type Error Motor torque Motor torque is over 1. Dispense outlet line clogged 1. Clean the dispense outlet is over limit limit 2. Dispense rate is too fast 2.

  • Page 75: Appendix B: Hmi Parameter Limits

    0 – 1200 psi, or 0 to 8.3 MPa, or 0 – 83 bar Pressure Offset Range -100 – 100 psi, or -0.69 – 0.69 MPa, or -6.9 – 6.9 bar Dispense Rate Range For PR-Xv 100cc For 1:1 ratio 0.08 – 16 cc/s For 2:1 ratio 0.12 –...

  • Page 76: Technical Specifications

    Shot Size Range PR-Xv 75 cc: 0.1–75 cc Shot Size Repeatability Flowrate 0.01–10 cc/s (Depends on material viscosity) PR-Xv 100 cc: 1:1 to 5:1 Material Ratio PR-Xv 75 cc: 2:1 to 10:1 Inlet / Outlet Sizes Air Inlet Size 1/4 in.

  • Page 77: California Proposition 65

    California Proposition 65 California Proposition 65 CALIFORNIA RESIDENTS WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.

  • Page 78: 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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