Graco PR-Xv30 Instructions Manual
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Graco PR-Xv30 Instructions Manual

Graco PR-Xv30 Instructions Manual

Variable ratio metering system
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Instructions
PR-Xv30
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-Xv30 Metering
Unit, Mini TC
Dispense Valve
PR-Xv30 Control Unit
3B0212B
EN

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  • 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-Xv30 Metering PR-Xv30 Control Unit Unit, Mini TC Dispense Valve...

  • Page 2: Table Of Contents

    Keep Components A and B Separate ..7 PR-Xv30 Control Unit ..... 57 Changing Materials .

  • Page 3: Models

    SST: Stainless steel material CER: Ceramic material The communication mode is installed in the control unit. NOTE: Any PR-Xv30 system can be converted to Profinet communication mode by ordering Profinet modebus kit 2006777, or converted to Ethernet-IP communication mode by ordering Ethernet-IP modebus kit 2007139, and then performing Add Communication Module, page 45.

  • 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 TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using. •...

  • 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

    AD Drive Assembly AE Inlet Valve AF Installation Plate 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-Xv30 Control Unit

    Component Identification PR-Xv30 Control Unit BG BH BJ Left View Bottom View Front View . 3: PR-Xv30 Control Unit Key: BA Human Machine Interface (HMI) Display BB Servo Driver Power On/Off Buttons BC Emergency Stop (E-stop) Switch BD Main Power Switch...

  • Page 11: Installation

    2 × Φ0.315 in. (8.00mm)through 7.087 in. 7.087 in. (180.00 mm) (180.00 mm) 0.886 in. Mounting holes (22.50 mm) 4 × Φ0.335 in. (8.50mm) through 1.772 in. (45.00 mm) . 4: Mounting Hole Dimensions for Installing the PR-Xv30 Metering Unit - Supply Pump Feed...

  • Page 12: Grounding

    Fluid supply container: follow local code. current. Solvent pails used when flushing: follow local code. PR-Xv30 Metering Unit (J, page 8): Grounded through Use only conductive metal pails placed on a grounded the PR-Xv30 Installation Plate. Use the supplied ground surface.

  • Page 13: Connecting Lines And Cables

    Installation Connecting Lines and Cables 1. Connect the PR-Xv30 Air Line (N, page 8) to the air inlet of the Junction Box Assembly (AC, page 9). The maximum air pressure is 100 psi (0.7 MPa, 7 bar). The air flow is over 1 CFM.

  • Page 14: Flush Before Using Equipment

    Installation Junction Box Air Inlet Cable Pressure Sensor A Cable Pressure Sensor B Cable Servo Encoder B Cable Servo Motor B Cable Servo Motor Servo Encoder A Cable A Cable . 6: System Connections Flush Before Using Equipment The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts.

  • Page 15: 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-Xv30 Control Unit (G, page 8) and turn the power on. 3. Press the Servo Driver Power on Button (BB, page 10) to open HMI displays.

  • Page 16: Hmi Display Operation And Identification

    HMI Display Operation and Identification HMI Display Operation and Identification Screen Navigation Diagrams Navigation on Main Screen Note: The following only displays the navigation on the System Main Screen. Select button in any other screens that have the button can also enter the System Main Screen. See next page Automatic Main Screen 1 (see page 21)
  • Page 17 HMI Display Operation and Identification Navigation on Automatic Screens Automatic Main Screen 2 (see page 22) Maintenance Screen (see page 24) Automatic Main Screen 1 Automatic Main Screen 1 Job Record Screen (see page 21) (see page 21) (see page 25) See next page Signal Check Screen 2 Signal Check Screen 1...
  • Page 18 HMI Display Operation and Identification Navigation on Manual Screens System Main Screen Automatic Main Screen 1 (See page 27) (see page 21) Manual Main Screen Signal Check Screen 1 (See page 28) (Manual) (See page 29) System Main Screen Signal Check Screen 2 (See page 27) (Manual) (See page 29) See next page...
  • Page 19 HMI Display Operation and Identification Navigation on Setup Screens Note: The following only displays screen interaction by buttons of . The operator can also click the title bar at the top of the screen to complete the screen interaction. System Main Screen (See page 27) Setup Screen 1 - Reload Setup Screen 8- De-pressurization...
  • Page 20 HMI Display Operation and Identification Advanced Setup Screen 1 (see page 36) Setup Screen 8- Advanced Setup Screen 2 Setup Screen 1 - Reload De-pressurization (see page 36) (see page 30) Advanced Setup Screen 3 (see page 37) Advanced Setup Screen 4 (see page 38)

  • Page 21: Automatic Main Screen 1

    HMI Display Operation and Identification Automatic Main Screen 1 current pressure of A material, and part B shows current pressure of B material. . 8 Automatic Main Screen 1 Open the control unit and wait for some time. The system will display ‘Automatic Main Screen 1’. The content and functions of this screen are as follows: Information bar •...

  • Page 22: Functional Buttons

    Servo ready: The signal indicates that the motor is working. • Servo alarm: The signal indicates that 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-Xv30 control unit needs to be restarted.
  • Page 23 HMI Display Operation and Identification Dispense valve and inlet valves status at the volume of flow rate preset in the ‘Shot Setup’. • ‘Shot No.’ can be selected by touch screen or customer signals. Preset shot numbers include 40 styles (from 0 to 39). •...

  • Page 24: Maintenance Screen

    HMI Display Operation and Identification Maintenance Screen Sequence mode . 10 Maintenance Screen On the Maintenance Screen, select the button to When the system works in automatic status, the display the Automatic Main Screen 1. Customer Control Unit can send ‘dispense’ signal to initiate the sequence.

  • Page 25: Job Record Screen

    HMI Display Operation and Identification Job Record Screen Signal Check Screen 1 (Auto) . 12 Signal Check Screen 1 (Auto) . 11 Job Record Screen On the Signal Check Screen 1 (Auto), select the On the Job Record Screen, select the button to button to display the Automatic Main Screen 1.

  • Page 26: Signal Check Screen 2 (Auto)

    HMI Display Operation and Identification Signal Check Screen 2 (Auto) Output signals status The output signals display shows the current signal status from the control unit. • Standby: The system has checked the home position, but is not pre-charged. . 13 Signal Check Screen 2 (Auto) •...

  • Page 27: Error Message Screen

    HMI Display Operation and Identification Error Message Screen System Main Screen . 14 Error Message Screen . 15 System Main Screen On the System Main Screen, the operator can check On the Error Message Screen, select the button to the system basic information, and switch the system to display the Automatic Main Screen 1.

  • Page 28: Manual Main Screen

    HMI Display Operation and Identification Manual Main Screen Functional buttons • : Select to display the System Main Screen. This button can only be used when the system is in standby or has an alarm. When on the System Main Screen, the system will not work in automation mode.

  • Page 29: Signal Check Screen 1 (Manual)

    HMI Display Operation and Identification Signal Check Screen 1 (Manual) Signal Check Screen 2 (Manual) . 17 Signal Check Screen 1 (Manual) . 18 Signal Check Screen 2 (Manual) On the Signal Check Screen 1 (Manual), select the On the Signal Check Screen 2 (Manual), select the button to display the Manual Main Screen.

  • Page 30: Setup Screen

    HMI Display Operation and Identification Setup Screen Maximum reload time Setup Screen 1 - Reload Set reload time limit. If the reload process exceeds the time limit, the system will send out an alarm as a reload time out. Reload type setup .
  • Page 31 HMI Display Operation and Identification Setup Screen 2 - Shot Setup Screen 3 - Bead . 21 Bead Setup Screen (Preset value) . 20 Shot Setup Screen On the Shot Setup Screen, select the button to display the System Main Screen. Select the button to return to the previous screen.
  • Page 32 HMI Display Operation and Identification Setup Screen 4 - Sequence Setup Screen 5- Style . 23 Sequence Setup Screen . 24 Style Setup Screen On the Sequence Setup Screen, select the button On the Style Setup Screen, select the button to to display the System Main Screen.
  • Page 33 HMI Display Operation and Identification Setup Screen 6- Purge Purge warning and alarm time • Purge alarm time: Set the purge request timer. When the system is not dispensing, it starts the countdown for the time set by the operator. When time is up, the system will send out the purge alarm signal.
  • Page 34 HMI Display Operation and Identification Setup Screen 7- Pre-charge Pre-charge rate The operator may set two separate pre-charge rates. The system will pre-charge at the ‘Hi’ speed until reaching the decelerate point. The decelerate point is the target pressure at which the system will switch from the "Hi"...
  • Page 35 System Main Screen. Select the to different materials. For detailed information, please button to return to the previous screen. Select the contact your Graco distributor. button to continue to the next screen. • Max depressurization time: The operator may set a...

  • Page 36: Advanced Setup Screen

    HMI Display Operation and Identification Advanced Setup Screen Advanced Setup Screen 2 Advanced Setup Screen 1 . 29 Advanced Setup Screen - 2 . 28 Advanced Setup Screen - 1 Select the button to display the System Main Screen. Select the button to return to the previous Select the button to display the System Main...
  • Page 37 HMI Display Operation and Identification Precharge resource Advanced Setup Screen 3 The operator may choose whether these resources come from Always, None, Distributed I/O communication or Gateway (Profinet) communication. Display option is unavailable. NOTE: The Gateway option is only included in the Profinet communication mode.

  • Page 38: Advanced Screen

    HMI Display Operation and Identification Advanced Screen Advanced Setup Screen 4 . 31 Advanced Setup Screen - 4 . 32 Advanced Screen Select the button to display the System Main On the Advanced Screen, select the button to Screen. Select the button to return to the previous display the System Main Screen.
  • Page 39 HMI Display Operation and Identification Dispense and Inlet valve • Dispense valve A: Select to open dispense valve A. • Dispense valve B: Select to open dispense valve B. • Inlet valve A: Select to open inlet valve A. • Inlet valve B: Select to open inlet valve B.

  • Page 40: Operation

    Servo Driver Power On/Off Buttons (BB, page 10) to turn on the power for the PR-Xv30 Drive Assembly (AD, page 9). This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from...
  • Page 41 Operation 5. When information bar displays “Standby”, press 8. Put a waste container under the dispense valve. to display System Main Screen. 9. Press on the Advanced Screen to display System Main Screen. . 36 System Main Screen 10. On the System Main Screen, press 6.

  • Page 42: Daily Start Up

    For daily start of the system, follow the below steps. on the System Main Screen to display Manual Main Screen. 1. Turn on the air for the supply pump and PR-Xv30 Metering Unit. Check the air pressure for the supply pump.
  • Page 43 15 to 25. If the PR-Xv30 system is connected with robot or motion table, follow the steps 7 to 14. If the PR-Xv30 15. On the Advanced Setup Screen, press system is used independently, follow steps 15 to 25.

  • Page 44: Ratio Check Procedure

    Operation Ratio Check Procedure 16. On the Manual Main Screen, select the “Shot” control mode and then press to execute Perform the Ratio Check Procedure at startup and after manual dispense. rebuild. 17. (optional step) Install the ratio check nozzle onto 1.

  • Page 45: Add Communication Module

    Operation Add Communication Module The following formula can be used when the density or specific gravity of both the “A” and “B” components are known and only one of the ratios: Install Communication Kit Weight Ratio Specific Gravity 1. Install the communication module onto the lower guide rail of the control board.
  • Page 46 Operation Communication Module Setup 4. Set gateway module IP address. 1. Go to 'SYCON.net' website. 2. Download and open 'Ethernet Device Setup' installation package. 3. Use 'Ethernet Device Setup' to search for gateway modules.
  • Page 47 Operation 5. Using SYCON.net, open the 6. Using SYCON.net, open the file and set the file'PRXV_GW_MODBUS_EIP.spj'. gateway module connection method to TCP, and set the search IP range.
  • Page 48 Operation 7. Search gateway, establish connection. 9. After downloading Firmware, repeat steps 1-5 to reset the module IP and establish a connection. 8. Download firmware. 10. Download the configuration file.

  • Page 49: Pressure Relief Procedure

    Operation Pressure Relief Procedure Flush the equipment Follow the Pressure Relief Procedure whenever you see this symbol. To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure. •...

  • Page 50: Shutdown

    To avoid injury from toxic fluids or fumes, such as 6. Turn off the Main Power Switch (BD, page 10) of splashing in the eyes or on skin, wear appropriate the PR-Xv30 Control Unit (G, page 8). personal protective equipment. Standard shutdown Main Power 1.
  • Page 51 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 Mini TC material have long pot life. Dispense Valve (AB, page 9). 1. Make sure the system finishes the current job. The 2.

  • Page 52: Maintenance

    Replace the seal kits of the Inlet Valve (AE, page 9) and the Mini TC Dispense Valve (AB, page 9). ✓ Inject grease to the lubricated kits of the PR-Xv30 Metering Unit (J, page 8). ✓ Replace the rods and needles of the Inlet Valve (AE, page 9) and the Mini TC Dispense Valve (AB, ✓...

  • Page 53: 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 54: Troubleshooting

    Cartridge or pail empty Exchange cartridge or pail Supply pump clogged Clean supply pump Air in PR-Xv30 Metering Unit Purge and prime the system Significant material leaking Pump shaft and/or shaft seal worn Remove pump shaft assembly and reinstall...
  • Page 55 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 Mini TC Dispense Valve (AB, page Clean Mini TC Dispense Valve (AB, page 9)
  • Page 56 Replace pressure sensor 1. Verify signal was correctly sent and System does not dispense or Signal error between platform and received. dispenses in the incorrect PR-Xv30 control unit 2. Verify signal cable is correctly amount/mode connected. Wrong “Dispense mode” Choose correct mode Wrong “Dispense type”...

  • Page 57: Dimensions

    PR-Xv30 Metering Unit, Supply Pump Feed 6.50 in. (165.00 mm) 4.04 in. (102.50 mm) 20.13 in. (511.40mm) . 55: PR-Xv30 Metering Unit Dimensions, Supply Pump Feed PR-Xv30 Control Unit 18.54 in. (471.00 mm) 16.93 in. (430.00 mm) 23.62 in. (600.00 mm) 9.92 in.

  • Page 58: Schematics

    Schematics Schematics...
  • Page 59 Schematics...
  • Page 60 Schematics...

  • Page 61: Cables Route

    Schematics Cables Route...

  • Page 62: Internal Cables

    Schematics Internal Cables Part Description Qty. 2008207 CABLE, motor encoder, U202 to X1 2008208 CABLE, motor power, U202 to X2 2008209 CABLE, motor encoder, U217 to X3 2008210 CABLE, motor power, U217 to X4 2008217 CABLE, CON8 to X7 2008268 CABLE, CON6 to U217 servo driver CU0054 CABLE, P13 to KM1 CU0055 CABLE, CON5 to U202 CU0056 CABLE, CON2 to U202...

  • Page 63: Terminal I/O Route

    Schematics route Terminal I/O 1243 1244 1611 1613 1621 1623 1631 1633 1641 TO CON9 1643 1651 1653 1661 1663 1671 1673 1681 1683 1693 1691 1701 1612 1614 1622 1624 1632 1634 1642 1644 TO CON9 1652 1654 1662 1664 1672 1674...

  • Page 64: Io Signals

    Schematics IO signals Signal Terminal Signal Name Cable No. Description Type INPUT CUST_IN ESTOP + 1243 Dry contact, passive signal, normally CUST_IN ESTOP - 1244 closed CUST_IN RELOAD 1611 To work with CUST_ IN COMMON, dry CUST_IN JOB START 1613 contact, normally open.

  • Page 65: Profinet And Ethernet Map

    Schematics Profinet and EtherNet map Control unit input from PCB 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...
  • Page 66 Schematics Name Units In Byte Description GATE_OUT_JOB_DURAT 21-22 Integer, unit is S GATE_OUT_DISP_TIMES 23-24 Integer GATE_OUT_DIS_AVOL 25-26 Part A dispense amount in current job, Integer, should multiply by 0.1, unit is CC GATE_OUT_DIS_BVOL 27-28 Part Bdispense amount in current job, Integer, should multiply by 0.1, unit is CC GATE_OUT_SHOT_NO 29-30...

  • Page 67: 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 68: 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 Make sure the system is in stops Switch (BC, page 10) is safety status.
  • Page 69 Appendix A - Error number message Error Error Error Name Description Cause Solution Type Error De-pressuri De-pressurization 1. De-pressurization target 1. Set proper target ze time out time exceeds the pressure is set too low de-pressurization pressure set maximum time 2.
  • Page 70 Appendix A - Error number message Error Error Error Name Description Cause Solution Type Error Part B Pressure B is too 1. Dispense outlet line clogged 1. Clean or replace dispense pressure high valve and other outlet parts 2. Dispense rate is too fast exceeds 2.
  • Page 71 Appendix A - Error number message Error Error Error Name Description Cause Solution Type Error Homing Homing fails 1. Home position sensor 1. Check and replace home failed disabled position sensor 2. Wrong installation position 2. Check and re-installation of home position sensor Home position sensor 3.
  • Page 72 Appendix A - Error number message Error Error Error Name Description Cause Solution Type Error Highest B Moving of metering 1. Improper position of limit 1. Re-install higher limit sensor limit has cylinder B touches sensor 2. Replace higher limit sensor been the higher limit 2.
  • Page 73 Appendix A - Error number message Error Error Error Name Description Cause Solution Type Error Metering Material in 1. Reload target is set too low 1. Set proper reload position tube B is metering cylinder B 2. Improper reload request 2.

  • Page 74: Appendix B: Hmi Parameter Limits

    Appendix B: HMI Parameter Limits Appendix B: HMI Parameter Limits Parameters Descriptions Motor Torque Range 0 – 0.24 lb·ft, or 0 – 0.32 N·m System Pressure Range 0 –1200 psi, or 0 to 8.3 MPa, or 0 – 83 bar Reload Pressure Range 0 –...

  • Page 75: Technical Specifications

    Viscosity Range 20–1,000,000 cps 303/304 Stainless Steel, Hard Chrome, Ceramic, UHMWPE, NBR, Carbon Wetted Parts Steel, PTFE Shot Size Range PR-Xv30 30cc: 0.01–30cc Shot Size Repeatability Flowrate 0.01–3.6 cc/s (Depends on material viscosity) Material Ratio 1:1 to 5:1 Inlet / Outlet Sizes...

  • Page 76: 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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