3A2152B - LSR Select, Instructions - Parts, English3A2152B EN Instructions - Parts LSR Select...

3A2152BEN

Instructions - Parts

LSR SelectPlural-component, variable-ratio proportioner. For dispensing liquid silicone rubber into injection molds. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

See page 3 for model information, including maximum work-ing pressure and approvals.

Important Safety InstructionsRead all warnings and instructions in this manual. Save these instructions.

ti18092a

Contents

2 3A2152B

ContentsContents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Important Two-Component Material Information . 6

Keep Components A (Red) and B (Blue) Separate 6

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6Component Identification . . . . . . . . . . . . . . . . . . . . 8Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Pressure Relief Procedure . . . . . . . . . . . . . . . . 18Base Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . 19Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20System Calibration Procedure . . . . . . . . . . . . . 23Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Common Problems . . . . . . . . . . . . . . . . . . . . . . 26Machine Alarms . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30IAM/AM Status Indicators . . . . . . . . . . . . . . . . . 37

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Base Pump Piston Replacement . . . . . . . . . . . 38Inhibitor/Catalyst/Color Pump Rebuild . . . . . . . 39Motor Coupling . . . . . . . . . . . . . . . . . . . . . . . . . 42Valve Stack Rebuild . . . . . . . . . . . . . . . . . . . . . 44Position Sensor on Inlet/Outlet Valve Replacement

46

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Control Frame Base Pump, 24M094 . . . . . . . . . 48Base Pump Wet Section, 24L880 . . . . . . . . . . . 50Base Pump Lower, 24L878 . . . . . . . . . . . . . . . . 52Base Pump Inlet/Outlet Valves, 24L977 . . . . . . 54Base Pump Inlet/Outlet Valve Plumbing, 24M007 .

56Base Pump Inlet/Outlet Valve Plumbing, 24M118 .

58Valve Stack, 24L893 . . . . . . . . . . . . . . . . . . . . . 60Inhibitor/Catalyst/Color Pump Drive (1093 Valve),

24L905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Inhibitor/Catalyst/Color Pump Drive (1093 Valve),

24L969 and 24L968 . . . . . . . . . . . . . . . . . . 64Needle Adapter Assembly, 24L906 . . . . . . . . . . 66Non-Drip Valve, 24L907 . . . . . . . . . . . . . . . . . . 67Valve Stack, 24M039 . . . . . . . . . . . . . . . . . . . . . 68Solenoid Valve, 24M048 . . . . . . . . . . . . . . . . . . 71Control Cabinet Exterior, 24L993 . . . . . . . . . . . 72Control Cabinet Interior, 24L871 . . . . . . . . . . . . 74

Control Schematics, 24L890 . . . . . . . . . . . . . . . . . 76HMI Operation Overview . . . . . . . . . . . . . . . . . . . . 84Appendix A - HMI Screens Overview . . . . . . . . . . 86Appendix B - Logging In and Out . . . . . . . . . . . . 104Appendix C - Setting Home Position on Pumps 105Appendix D - Selecting the Outlet Valve, Mounting

the Stack to the Press . . . . . . . . . . . . . . . . . . 107Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Graco Standard Warranty . . . . . . . . . . . . . . . . . . 112Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 112

Related Manuals

3A2152B 3

Related ManualsManuals are available at www.graco.com.

Component manuals in U.S. English:

Models

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

See Accessories starting on page 110 for color valve addition and pressure monitoring systems.

Manual Description

311827 Dura-Flo™ Lowers Instructions-Parts

308418 Dura-Flo™ 750 Pumps Instructions-Parts List

310550 1/2” NPT Fluid Port Ball Seat Applicator

Model

Full Load Peak

Amps Per Phase*

Voltage (phase)

System Watts

Max Flow Rate

oz/sec (cc/sec)

Approximate Output per Cycle (A+B)

oz (cc)

Maximum Fluid Working Pressure

psi (MPa, bar)

24M093 26 A 208-230 (3) 6000 0.3 (10) 5 (150) 1000 (7, 69)

Warnings

4 3A2152B

WarningsThe 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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARDThis equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-tric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.• All electrical wiring must be done by a qualified electrician and comply with all local codes and reg-

ulations.

+

SKIN INJECTION HAZARDHigh-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point dispensing device at anyone or at any part of the body.• Do not put your hand over the fluid outlet.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,

or servicing equipment. • Tighten all fluid connections before operating the equipment.• Check hoses and couplings daily. Replace worn or damaged parts immediately.

TOXIC FLUID OR FUMES HAZARDToxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENTYou must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhala-tion of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac-

turer.

Warnings

3A2152B 5

FIRE AND EXPLOSION HAZARDFlammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help pre-vent fire and explosion:

• Use equipment only in well ventilated area.• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic

drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline.• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.• Ground all equipment in the work area. See Grounding instructions.• Use only grounded hoses.• Hold gun firmly to side of grounded pail when triggering into pail.• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.• Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARDMisuse 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. See Technical Data in all equipment manuals.• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-facturer’s replacement parts only.

• Do not alter or modify equipment.• Use equipment only for its intended purpose. Call your distributor for information.• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.• Do not kink or over bend hoses or use hoses to pull equipment.• Keep children and animals away from work area.• Comply with all applicable safety regulations.

MOVING PARTS HAZARDMoving 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.• Pressurized equipment can start without warning. Before checking, moving, or servicing equip-

ment, follow the Pressure Relief Procedure and disconnect all power sources.

WARNING

Important Two-Component Material Information

6 3A2152B


Keep Components A (Red) and B (Blue) Separate

Changing Materials• When changing materials, flush the equipment mul-

tiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

Cross-contamination can result in cured material in fluid lines which could cause serious injury or dam-age equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (Red) and component B (Blue) parts.


3A2152B 7

Component Identification

8 3A2152B


FIG. 1: Machine Overview

ti18094a

A

ti18095a

ti18093a

H

D FB

K

LM

JN

G

E

C

P


3A2152B 9

Label Component Function

A Valve Stack Assembly where catalyst, inhibitor, and color (optional) are injected into the base chemical and mixed together.

B 1093 Valve (Inhibitor) Valve that injects inhibitor into the base chemical and slows the effect of the catalyst mix. The chemical can be adjusted to affect the cure time within a ratio range from 1-6%.

C Pressure monitor (Inhibitor) Monitors the pressure of the inhibitor valve.(Optional - See Accessories on page 110 for details.)

D 1093 Valve (Catalyst) Valve that injects catalyst into the base chemical and cures the material. The chemical has a fixed ratio of 1%.

E Pressure monitor (Catalyst) Monitors the pressure of the catalyst valve.(Optional - See Accessories on page 110 for details.)

F 1093 Valve (Color) Valve that injects pigment into the base chemical and colors the material. The chemical can be adjusted within a ratio from 0-6%.(Optional - See Accessories on page 110 for details.)

G Pressure monitor (Color) Monitors the pressure of the color valve.(Optional - See Accessories on page 110 for details.)

H Mixer with Cooling Jacket. Mixes the material through a static mixer and has a cooling jacket to main-tain temperature.

J Control Panel The Human Machine Interface (HMI) to allow the user to control the machine.

K Single Acting Pump A one directional pump that forces the base chemical to the valve stack. The pump only applies force in the down stroke.

L Pump Inlet Valve A valve that opens and closes and allows the base chemical being sup-plied from a feed system to enter the machine.

M Pump Outlet Valve A valve that opens and closes and allows the base chemical being sup-plied from the machine to enter the valve stack.

N Base Material Hose The material hose line provides the base chemical to the valve stack.

P Pressure Monitor (Screw) Monitors the pressure of the screw inlet.(Optional - See Accessories on page 110 for details.)


10 3A2152B

FIG. 2: Electrical Panel

ti18096a

AA

ti18097a

AB

AE

AC

AF

AD

AG

Components are found within enclosure.

CB1CB2

FU-1FU-2

FU-6FU-7

FU-3FU-5

FU-9

FU-4FU-8

FU-10


3A2152B 11

Most circuit breakers are located inside the power distri-bution box. The main block of circuit breakers in the power distribution box is detailed below.

Label Component Function

AA Disconnect Turns the main power ON/OFF of the machine

AB HMI Machine controls. Allows the user to enter/read data

AC Ethernet Port Communication port to a PLC

AD Power ON/OFF Turns the power ON/OFF for the controls

AE E-Stop Emergency stop button to turn OFF power of the machine

AF Audio Alarm Alerts operator of a machine fault through sound

AG Foot Switch Signals machine to start cycle when pressed

Label Component Size (Amps) Type Used in Models

CB1 24 VDC Power 5 N/A All

CB2 PLC Power Supply 5 N/A All

FU-1 Drive Control Power 10 LPJ-10SP Bussman All

FU-2 Drive Control Power 10 LPJ-10SP Bussman All

FU-3 Drive Motor Power 20 KTK-R-20 Bussman All



FU-6 Drive Control Power 10 LPJ-10SP Bussman Kit 24M126

FU-7 Drive Control Power 10 LPJ-10SP Bussman Kit 24M126

FU-8 Drive Motor Power 20 KTK-R-20 Bussman Kit 24M126



Setup

12 3A2152B

SetupInitial Machine SetupPerform this setup procedure to prepare the machine for initial operation.

1. Locate the machine.

a. Locate the machine on a level surface and bolt to the floor. See Technical Data starting on page 108 for space requirements and mounting hole pattern.

b. Connect the valve stack to the screw inlet located on the press. External brackets may be required to support the stack. Install a valve between the mixer and the screw. The valve can be controlled by the LSR system. See Appendix D - Selecting the Outlet Valve, Mounting the Stack to the Press on page 107.

2. Connect the electrical cord.

Electrical Cord Requirements

NOTE: Power cord is not supplied. See the following table.

Electrical Cord Wires by Model

230V, 3 phase: L1, L2, L3, GND

a. Connect green wire to ground (GRN).

b. Use a screw driver to tighten the terminals to 12 in-lb (1.4 N•m)

The machine is not properly grounded until this setup procedure is performed. To prevent risk of electric shock, do not start the machine until this setup proce-dure is completed.

NOTICE

To prevent machine damage, do not expose system to rain.

FIG. 3: Valve Stack Outletti18098a

3/4” NPT Male

Installing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Table 1: Power Cord Requirements

ModelCord Requirements

AWG (mm2)

230V, 3 phase 8 (8.4), 3 wire + ground

FIG. 4: Electrical Disconnect

ti18099a

L1

L2

L3

GND

Setup

3A2152B 13

3. Ground the system.

a. Control enclosure and pump: grounded through power cord. See Connect the electrical cord. on page 12.

b. Valve stack: Follow your local code.

c. Fluid supply containers: Follow your local code.

d. Solvent pails used when flushing: follow your local code. Use only metal pails, which are con-ductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

e. To maintain grounding continuity when flushing or relieving pressure, hold grounded metal pail firmly to a metal part of dispense valve then initi-ate a dispense.

4. Connect the press output signal to the customer input located in the panel.

Add customer signal from the press when the press is ready to load the screw by either:

a. Connecting a 24 VDC signal from the press to the relay CR-CS.

b. Connecting a dry contact signal across lines 8 and 6850 on the terminal assembly. Refer to Control Schematics, 24L890, page 76, for additional clarity.

This equipment must be grounded.

FIG. 5: Relay CR-CS

CR-CS

A1 A2

123386

CUSTOMER START

CONNECT 24VDC STARTSIGNAL FROM PRESS

Setup

14 3A2152B

5. Install Feed System.

Feed components are purchased separately and not a part of this system.

Recommended feed parameters:

• Base feed pressure:Load base pump with 300-800 psi fluid pres-sure.

• Base fluid hose connection:1” NPT male.

• Inhibitor/Catalyst/Color feed pressure:Load 1093's with 200-400 psi fluid pressure.

• Inhibitor/Catalyst/Color hose connection:JIC(04)

6. Connect the Base Pump to the Valve Stack.

a. Connect the fluid hose from the outlet of the base pump to the inlet of the Valve stack.

b. Connect the motor cables in the first conduit to the matching servo motors on the valve stack.

c. Connect the encoder cables in the second con-duit to the matching servo motors on the valve stack.

NOTICE

Use at least 10 layers of PTFE tape and use pipe dope on the fluid inlet fitting to prevent galling.

FIG. 6: 1” NPT Base Inlet Connection

FIG. 7: Connection Port

ti18100a

1” Inlet

ti18101a

(Other connec-tions are found on other side of visual)

NOTICE

Use at least 10 layers of PTFE tape and use pipe dope on the fluid inlet fitting to prevent galling.

FIG. 8: Base Outlet to Valve Stack Connection

FIG. 9: Electrical Cable Connections

ti18102a

ti18103a

MotorCables

EncoderCables

Setup

3A2152B 15

d. Connect the sensor lines and solenoid lines in the third conduit to the matching valves on the valve stack.

e. If using kit 24M127, connect the pressure trans-ducer cables in the third conduit to the matching transducers on the valve stack.

f. Connect the ground wire in the sensor conduit to the screw holding the solenoid valves to the stack.

g. A set of clamps is supplied to keep the three sections of conduit together. This can be mounted on the press.

7. Connect the Air Supply.

a. Connect a 1/4” in. air supply to the solenoid valve inlet on the valve stack.

b. Connect a 1/4 in. air supply to the solenoid valve inlet on the base frame.

FIG. 10: Clamps

11.00

.50

11.50

ti18104a

NOTICETo prevent machine damage, air supply must be fil-tered and dried.

FIG. 11: Air Supply Connection - Valve Stack

FIG. 12: Air Supply Connection - Base

ti18105a

1/4” Air Supply

ti18106a

1/4” Air Supply

Setup

16 3A2152B

8. Connect chiller with 1/4” tubing.

9. Perform Startup procedure on page 17.

10.Perform Human Machine Interface (HMI) setup.

Refer to Appendix A - HMI Screens Overview starting on page 86 for more information.

a. Navigate to DRIVE/VALVE setup screen. Push the ENABLE drive button for each component to enable the drives.

b. If the drives have been unplugged, refer to Appendix C - Setting Home Position on Pumps starting page 105.

c. Verify the indicators read that each drive is HOME. If not, push the HOME PUMP push but-ton.

11.Perform Flushing Procedure start-ing on page 19.

12.Perform System Calibration Pro-cedure starting on page 23.

FIG. 13: Chiller Connections

ti18201a

Coolant In

Coolant Out

NOTICE

The machine is tested with oil at the factory. Flush out the oil with a compatible solvent before loading the machine with material.

Operation

3A2152B 17

Operation

Startup

1. Perform all required maintenance tasks. See Main-tenance starting on page 25.

2. Check for leaks.

3. Check feed system fluid levels.

4. Turn the main disconnect switch to the ON position. The HMI will start running through its startup proce-dure. This takes about a minute.

5. Push the power on button. The white pilot light will illuminate.

Shutdown

Short Term/End of shift

1. Verify the cooling jackets are on and the mixed material is being chilled. Keeping the mixed mate-rial cool will keep the material from curing as fast.

2. Perform Base Purge, page 19.

3. Perform Pressure Relief Procedure, page 18.

4. Turn the main disconnect switch to the “OFF” posi-tion.

Extended periods

1. Perform Base Purge, page 19.

2. Perform Pressure Relief Procedure, page 18.

3. Turn the main disconnect switch to the “OFF” posi-tion.

4. Remove the cooling jacket from the mixer.

5. Remove the mixer from the screw.

6. Remove the bottom block from the mixer stack.

7. Clean the mixer and bottom block with a compatible solvent.

NOTICE

To avoid curing the material within the mixer, do not run the catalyst without the inhibitor.

Operation

18 3A2152B

Pressure Relief Procedure

Pressure Relief Method with Power:

1. If the mixer is connected to the screw of the press, put a container at the end of the screw.

2. Use the press controls to bleed the screw of mate-rial.

3. Go to the DRIVE/VALVE CONTROL screen.

4. Press the SET MAN'L MODE button.

5. Press the OPEN SCREW VALVE button.

6. Let the pressure drop to 0 psi/MPa/bar.

Pressure Relief Method with No Power:

1. If the mixer is connected to the screw of the press, put a container at the end of the screw.

2. Use the press controls to bleed the screw of mate-rial.

3. Press the orange override buttons on the solenoid valve assembly.

4. Let the pressure drop to 0 psi/Mpa/bar.

In the following step, any pressure in the lines will be instantly relieved which may lead to material spraying out of the valve and splashing in the bucket. Use appropriate protective wear to prevent contact with materials.

NOTICE

This procedure relieves pressure from the dispense lines only. To avoid personal injury, refer to the feed system documentation to relieve pressure from the feed lines.

FIG. 14: Override Button

ti18105a

Operation

3A2152B 19

Base Purge

1. Navigate to the AUTO MODE SETUP SCREEN.

2. Set the CATALYST PERCENT OF MIX to zero.

3. Set the INHIBITOR PERCENT OF MIX to 6%.

4. Press the footswitch and take about fifteen shots to get the existing catalyst out of the mixer.

5. Verify the mix will not cure by wiping a small amount of mixed material from the last shot on the heated mold in the press and seeing if the material cures.

6. If the material cures, take some more shots, testing the material until the material does not cure.

To start dispensing again after a base purge, go to the AUTO MODE SETUP screen, set the catalyst back to 1% and begin dispensing. After the same amount of shots that took to base purge, material with catalyst should begin to dispense through the mixer. To verify this, wipe a small amount of mixed material from the last shot on the heated mold in the press and see if the material cures.

Flushing Procedure

Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing a new fluid. All fluid components are compatible with common sol-vents. Use only moisture-free solvents. See Technical Data on page 108 for a list of wetted components to ver-ify compatibility of solvent with wetted materials. See solvent manufacturer's information for material compati-bility. Do not use water.

Ground the solvent pails used when flushing: Refer to Ground the system. on page 13.

If flushing with a compatible solvent, perform the follow-ing procedure:

1. Perform Shutdown, page 17.

2. Disconnect the valve stack from the screw located on the press.

3. Disconnect the base pump inlet from the feed pump.

4. Connect the flushing hose into the base pump inlet.

5. Perform Startup, page 17.

6. Navigate to the DRIVE/VALVE CONTROL screen.

7. Press the SET IN MAN'L MODE button to put the system in manual mode.

8. Push the base OPEN INLET VALVE, OPEN OUT-LET VALVE, and OPEN SCREW VALVE buttons so there is a clear path to flush.

9. Start flushing.

10. When the silicone is no longer dispensing from the mixer, stop flushing.

NOTE: Even though flushing will get the majority of the material out of the stack and mixer, disassemble the blocks and mixer and clean these parts individually.

NOTICE

Mixed material with start to gel in the mixer if the machine is idle for a prolonged periods of time, causing machine damage. Perform a base purge as required.

Flush equipment only in a well-ventilated area. Do not dispense flammable fluids. Do not turn on heaters while flushing with flammable solvents.

Operation

20 3A2152B

Priming

Overview: Prime the base, add the inhibitor, and then add the catalyst. This assumes all feed system pumps are loaded, primed and ready to dispense.

NOTE: Prime with the valve stack not connected up to the screw located on the press.

1. Disconnect the mixer and valve stack from the screw located on the press.

2. Place a waste container under the mixer.

3. Prime the base component.

a. Go to the DRIVE/VALVE CONTROL Screen.

b. ENABLE the base drive.

c. HOME the base drive.

d. In the ALL window, press the SET MAN'L MODE button.

e. When the Base indicates the pump is HOME, press the EXTEND PUMP button and wait for the base pump to fully extend.

f. Push the OPEN INLET VALVE button and verify the indicator shows OPEN.

g. Push the OPEN OUTLET VALVE button and verify the indicator shows OPEN.

h. If a customer supplied valve is installed between the mixer and screw, push the OPEN SCREW VALVE button and verify the screen shows OPEN.

i. When all valves are open and there is a clear path from the inlet valve to the mixer, slowly increase the air pressure on the feed pump until the feed pump begins to cycle.

j. Let the feed pump cycle until air free base mate-rial comes out the end of the mixer.

k. Press the CLOSE OUTLET VALVE push button and verify the Indicator shows CLOSED.

l. Press the CLOSE SCREW VALVE push button and verify the indicator shows CLOSED.

m. Press the HOME PUMP push button. The actu-ator shaft will rise and the feed pump will cycle to charge the pump.

n. Adjust the feed pump air pressure so the base material pressure shows approximately 500 psi (3.4 MPa, 34 bar). The pressure read-out shows on either the STARTUP, STATUS, or PRESSURE LOG screens.

4. Prime the inhibitor pump (1093 valve).

a. Turn the air pressure on the inhibitor feed pump so that the actual material pressure is around 300 psi (2.1 MPa, 21 bar). This is an estimate based on the air pressure on the feed pump and the power factor of the pump. If pressure trans-ducers are included (kit 24M127), the inhibitor pressure readout can be seen on either the STARTUP, STATUS, or PRESSURE LOG screens.

b. On the DRIVE/VALVE CONTROL screen, push the SET AUTO MODE button.

c. If a customer supplied screw valve is being used, push the AUTO SCREW VALVE push button.

d. Verify all pumps are ENABLED and HOME.

e. Go to the AUTO MODE SETUP screen.

f. Set the TOTAL FLOW RATE to 4-6cc/sec.

g. Set the INHIBITOR PERCENT OF MIX to 6%

h. Set the CATALYST PERCENT OF MIX to zero.

i. If color is used (Kit 24M126), Set the COLOR PERCENT OF MIX to zero.

Operation

3A2152B 21

j. Verify the BASE PERCENT OF MIX is 94% and the TOTAL PERCENT (REF) is 100%

k. Press and hold the footswitch down. The base pump and inhibitor pump (1093 valve) will start to dispense.

l. When the base pump hits the end travel, release the footswitch; both pumps will reload.

m. When the pumps are reloaded, repeat this about fifteen times to verify the volume of the mixer has inhibitor through the mixer and the material coming out is air-free.

5. Prime the catalyst pump (1093 valve).

a. Turn the air pressure on the catalyst feed pump so that the actual material pressure is around 300 psi (2.1 MPa, 21 bar). This is an estimate based on the air pressure on the feed pump and the power factor of the pump. If pressure trans-ducers are included (kit 24M127), the catalyst pressure readout can be seen on either the STARTUP, STATUS, or PRESSURE LOG screen.

b. On the DRIVE/VALVE CONTROL screen, push the SET AUTO MODE button.





g. Set the INHIBITOR PERCENT OF MIX to 6%

h. Set the CATALYST PERCENT OF MIX to 1%.

i. If color is used (Kit 24M126), Set the COLOR PERCENT OF MIX to zero.

j. Verify the BASE PERCENT OF MIX is 93% and the TOTAL PERCENT (REF) is 100%

k. Press and hold the footswitch down. The base pump, inhibitor, and catalyst pump (1093 valve) will start to dispense.

l. When the base pump hits the end travel, release the footswitch; all pumps will reload.

m. When the pumps are reloaded, repeat this about fifteen times to verify the volume of the mixer has catalyst through the mixer and the material coming out is air-free.

6. Prime the color pump (1093 valve). Valid only if kit 24M126 is being used.

a. Turn the air pressure on the color feed pump so that the actual material pressure is around 300 psi (2.1 MPa, 21 bar). This is an estimate based on the air pressure on the feed pump and the power factor of the pump. If pressure trans-ducers are included (kit 24M128), the color pressure readout can be seen on either the STARTUP, STATUS, or PRESSURE LOG screens.

b. On the DRIVE /VALVE CONTROL screen, push the SET AUTO MODE button.





NOTICE

After the catalyst has been added, the material is able to cure. To avoid machine damage from long idle times, perform a Base Purge, page 19.

NOTICE


Operation

22 3A2152B

g. Set the INHIBITOR PERCENT OF MIX to 6%.

h. Set the CATALYST PERCENT OF MIX to 0% or 1%.

i. Set the COLOR PERCENT OF MIX to the desired percent.

j. Verify the TOTAL PERCENT (REF) is 100%

k. Press and hold the footswitch down. All pumps will start to dispense.

l. When the base pump hits the end travel released the footswitch; all pumps will reload.

m. When the pumps are reloaded, repeat this about fifteen times to verify the volume of the mixer has color through the mixer and the mate-rial coming out is air-free.

Operation

3A2152B 23

System Calibration Procedure

Perform this entire procedure if any of the following con-ditions are met:

• The machine is new.• The materials in the system have been

changed.

Software Settings:

1. Go to the AUTO MODE SETUP screen.

2. Enter the flow rate and ratio percentages.

3. Go to the DRIVE/VALVE SETUP screen.

4. ENABLE ALL the drives.

5. HOME the pumps of they are not home.

Prime the Machine:

1. Press the footswitch or give a maintained signal from the press to begin pumping.

2. After dispensing close to a full shot, release the footswitch or signal from the press and let the pumps reload.

3. Repeat this until air-free material is dispensed.

4. Repeat around fifteen more times to ensure the new mix of material has traveled through the mixer.

5. Connect the mixer to the customer supplied screw inlet valve.

6. Repeat more shots until air free material is dis-pensed out of the screw.

Balancing the pump pressure:

The key to getting consistent ratios is to dispense at roughly the same pressure as the pumps are being fed from the feed system. The screen below shows all pres-sures.

NOTE: Pressures can only viewed if kit 24M127 is installed.

The blue line is the base pump pressure. The pressure is around 500 psi (3.4 MPa, 35 bar) when done loading. The dispense pressure is around 400 psi (2.8 MPa, 28 bar). These two pressures are close enough to give repeatable shots. They could be even closer by adjusting the feed pump air pressure down until the material pressure is 400 psi (2.8 MPa, 28 bar). If the reload pressure of the base was 800 psi (5.6 MPa, 55 bar) and the dispense pressure was around 200 psi (1.4 MPa, 14 bar), the dis-pense would not be repeatable.

The red line is the inhibitor. The inhibitor is balanced, the load pressure is a little under 400 psi (2.8 MPa, 28 bar) and the dispense pressure is almost the same. In this particular screen, only base and inhibitor are being dispensed. The green line is the catalyst and always is reading the load pressure, right around 400 psi (2.8 MPa, 28 bar).

If the transducer kit (24M127) isn't used, the base pres-sure is all that can be monitored. The pressure of the inhibitor and catalyst can be estimated by looking at the base pressure at dispense and setting the air pressure in the feed pumps for the inhibitor and catalyst so the material pressure of them is similar to the base. The air pressure multiplied by the feed pump power factor is roughly the material pressure.

NOTICE


StartDisp.

EndDisp.

PumpsReload

Operation

24 3A2152B

DispensingAfter the pressures are balanced and the system is dis-pensing air free material, the mixer is ready to connect to the screw inlet located on the press. The mixer outlet is 1” NPT. Continue priming through the screw.

Determining the flow rate:

Once the mixer is connected to the screw, the flow rate needs to be adjusted so the flow rate does not fill the screw too fast or too slow. See the charts below show-ing only the mixer pressure.

If the kit for the transducers isn't used, a gauge at the screw inlet will give an indication of the pressure rise or fall while dispensing.

Maintenance

3A2152B 25

Maintenance

Task Schedule

Inspect fluid lines for leaks and signs of wear Daily

Remove mixer and check for gelling material Weekly

Check all fittings and connections, tighten as necessary As necessary

Troubleshooting

26 3A2152B

Troubleshooting

Before performing any troubleshooting procedure:

1. Perform Pressure Relief Procedure on page 18.

2. Turn power off.

Common Problems

Problem Cause Diagnostic Solution

General- System won't dispense

Control power not on

Power on button not pushed

Control power pilot light not illumi-nated Push power on button

E-stop pushed Control power pilot light not illumi-natedUntwist E-stop, push power on button

System not in AUTO MODE

Not put in auto mode after power up

Indicator shows ratio check mode or manual mode Put in auto mode

Pumps not enabled Powered up without enabling or fault Enabled indicators or alarmClear fault if necessary, enable ALL drives

Base pump load sensor not reading

Sensor not connected Visually check connection Reconnect sensor

Sensor bad Check PLC input/sensor voltage Replace bad sensor

Base pump not loaded

No pressure on feed pump

Pump shaft extended, actuator shaft retracted, feed pump pressure gauge

Put pressure on feed pump to load

No material in feed pump drum

Pump shaft extended, actuator shaft retracted, check ram level Change drum

Base Pump not homeDrive fault Fault on HMI screen Clear fault, re home

System powered up with pump not home Fault on HMI screen Home pump motor

Base pump load/dis-pense valves didn't shift

No air on solenoid valves Check air pressure to valves

Put minimum 80psi air pres-sure on solenoid valves

Bad electric connection Pilot light on solenoid valves Re connect cable to sole-noid valve

Valve position sensors not reading

Manually toggle valves open and closed, watch sensor LED's

Reposition sensors

Replace sensor

Troubleshooting

3A2152B 27

Inh/Cat pump load/dis-pense sensor not work-ing

Bad connection Visually check connection Reconnect sensor

Bad sensor Check PLC input/sensor voltage Replace bad sensor

Inh/Cat Pump not homeDrive fault Fault on HMI screen Clear fault, re home

System powered up with pump not home Fault on HMI screen Home pump motor

Inh/Cat pump load/dis-pense valves didn't shift

No air on solenoid valves Check air pressure to valves

Put minimum 80psi air pres-sure on solenoid valves

Bad electric connection Pilot light on solenoid valves Reconnect cable to sole-noid valve

Mixer plugged Mixed material cured Very high pressure Tear down and clean out mixer/stack assembly

Customer supplied screw valve not opening

Air lines to valve back-wards Very high pressure

Check air connections, swap if necessary

Valve cured up Very high pressure Tear down and clean out screw valve

General- Mixed material won't cure

Catalyst not being added

Catalyst percentage not set to 1% Verify HMI Set to 1%

Broken lead screw nut Motor turns but no linear movement Replace lead screw nut

Catalyst added is no good

Contaminated with moisture from air Catalyst is yellow, not clear Replace catalyst

General- Mixed material cures too fast or cures even when base purging

Catalyst still being added

Catalyst percentage still set at 1% Verify HMI Set to zero percent

Bad seal on catalyst non drip valve

Pull catalyst valve out of stack and inspect

Replace non drip valve seat.

Inhibitor not being added

Inhibitor percentage set to zero or not high enough

Verify HMI Increase inhibitor percent-age

Broken lead screw nut Motor turns but no linear movement Replace lead screw nut

Problem Cause Diagnostic Solution

Troubleshooting

28 3A2152B

Machine AlarmsThe following is a list of possible alarms.

# DESCRIPTION TYPE CAUSE SOLUTION1 INPUT POWER OFF FAULT Alarm N/A N/A

2 CONTROL POWER OFF FAULT Alarm Power on button not pressed/Estop pressed Push power on button

3 24VDC POWER OFF FAULT Alarm N/A N/A

4 BASE PUMP OVERTRAVEL Shutdown

Pump is extended too far in either direction

Get pump back within travel limits

5 INHIBITOR PUMP OVERTRAVEL Shutdown

6 CATALYST PUMP OVERTRAVEL Shutdown

7 COLOR PUMP OVERTRAVEL Shutdown

8 BASE PUMP OVER CURRENT Shutdown

Motor or transmission malfunction

Check/replace motor or transmission

9 INHIBITOR PUMP OVER CURRENT Shutdown

10 CATALYST PUMP OVER CURRENT Shutdown

11 COLOR PUMP OVER CURRENT Shutdown

12 BASE DRIVE OVER TEMP Shutdown

Excessive heat exists in the power circuitry

Reduce duty cycle, check for clogged vents, defective fan

13 INHIBITOR DRIVE OVER TEMP Shutdown

14 CATALYST DRIVE OVER TEMP Shutdown

15 COLOR DRIVE OVER TEMP Shutdown

16 BASE MOTOR OVER TEMP ShutdownHigh ambient motor temperature and/or excessive current

Operate within continuous torque rating for ambient temperature maximum

17 INHIBITOR MOTOR OVER TEMP Shutdown

18 CATALYST MOTOR OVER TEMP Shutdown

19 COLOR MOTOR OVER TEMP Shutdown

20 BASE DRIVE FEEDBACK ERROR ShutdownFeedback wiring is open, shorted, or miss-ing

Check motor encoder wiring.21 INHIBITOR DRIVE FEEDBACK ERROR Shutdown

22 CATALYST DRIVE FEEDBACK ERROR Shutdown

23 COLOR DRIVE FEEDBACK ERROR Shutdown

24 BASE DRIVE OVERLOAD Shutdown

Load limit of motor/drive has been exceeded Check for blocked fluid path

25 INHIBITOR DRIVE OVERLOAD Shutdown

26 CATALYST DRIVE OVERLOAD Shutdown

27 COLOR DRIVE OVERLOAD Shutdown

28 BASE MOTOR POSITION ERROR Shutdown

Position error limit was exceeded Check for blocked fluid path

29 INHIBITOR MOTOR POSITION ERROR Shutdown

30 CATALYST MOTOR POSITION ERROR Shutdown

31 COLOR MOTOR POSITION ERROR Shutdown

32 BASE RATIO CHECK SHOT OUT OF RANGE Alarm

Shot size entered too large or small

Change shot size within lim-its

33 INHIBITOR RATIO CHECK SHOT OUT OF RANGE Alarm

34 CATALYST RATIO CHECK SHOT OUT OF RANGE Alarm

35 COLOR RATIO CHECK SHOT OUT OF RANGE Alarm

36 BASE AXIS FAULT Shutdown

Drive has faulted Check drive diagnostic win-dow37 INHIBITOR AXIS FAULT Shutdown

38 CATALYST AXIS FAULT Shutdown

39 COLOR AXIS FAULT Shutdown

Troubleshooting

3A2152B 29

40 BASE PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too highCheck for blocked fluid path, lower flow rate

41 BASE PRESSURE LOW LIMIT Shutdown Pump not running, no material being fedCheck pump, check material level

42 INHIBITOR PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too highCheck for blocked fluid path, lower flow rate

43 INHIBITOR PRESSURE LOW LIMIT Shutdown Pump not running, no material being fedCheck pump, check material level

44 CATALYST PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too highCheck for blocked fluid path, lower flow rate

45 CATALYST PRESSURE LOW LIMIT Shutdown Pump not running, no material being fedCheck pump, check material level

46 COLOR PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too highCheck for blocked fluid path, lower flow rate

47 COLOR PRESSURE LOW LIMIT Shutdown Pump not running, no material being fedCheck pump, check material level

48 SCREW PRESSURE HIGH LIMIT Shutdown Fluid path blocked, flow rate too highCheck for blocked fluid path, lower flow rate

49 SCREW PRESSURE LOW LIMIT Shutdown Fluid not being dis-pensed Check pumps

50 PRESSURE SHUTDOWN ALARM Alarm Any pressure out of specCheck pump with pressure fault

51 BASE LOAD VALVE OPEN FAULT Alarm Valve not shifting to open position

Check/replace bad sensor, Check/correct air pressure, valve stuck

52 BASE LOAD VALVE CLOSE FAULT Alarm Valve not shifting to closed position

53 BASE DISPENSE VALVE OPEN FAULT Alarm Valve not shifting to open position

54 BASE DISPENSE VALVE CLOSE FAULT Alarm Valve not shifting to closed position

55 INHIBITOR VALVE SHIFT DISPENSE FAULT Alarm Spool valve not shifting to open position

56 INHIBITOR VALVE SHIFT LOAD FAULT Alarm Spool valve not shifting to closed position

57 CATALYST VALVE SHIFT DISPENSE FAULT Alarm Spool valve not shifting to open position

58 CATALYST VALVE SHIFTLOAD FAULT Alarm Spool valve not shifting to closed position

59 COLOR VALVE SHIFT DISPENSE FAULT Alarm Spool valve not shifting to open position

60 COLOR VALVE SHIFT LOAD FAULT Alarm Spool valve not shifting to closed position

# DESCRIPTION TYPE CAUSE SOLUTION

Troubleshooting

30 3A2152B

Drive FaultsThe drives have a diagnostic window that should have a “4” when everything is normal.

If a drive has a problem, a series of numbers flash in this window. Below is a list of error codes.

Error Code

Fault Message RSLogix (HIM) Problem or Symptom Potential Cause Possible Resolution

General Power (PWR) indicator not ON

No ac power or auxiliary logic power.

Verify ac control power is applied to the Kinetix 2000 system.

Internal power supply malfunction.

Call your Rockwell Automa-tion sales representative to return module for repair.

Motor jumps when first enabled

Motor wiring error. • Check motor wiring.• Run Hookup test in RSLogix 5000 software.

Incorrect motor chosen. Verify the proper motor is selected.

Digital I/O not working correctly

I/O power supply discon-nected.

Verify connections and I/O power source.

E00 BusUndervoltage Fault (Blown fuse)

A blown fuse was detected on the inverter PCB

Blown fuse. Call your Rockwell Automa-tion sales representative to return module for repair.

ti18126a

Troubleshooting

3A2152B 31

E04 Motor Overtemp Fault (Motor Overtemp)

Motor thermal switch tripped

High ambient motor tem-perature and/or exces-sive current

• Operate within (not above) the continuous torque rating for the ambient temperature 40 °C (104 °F) maximum.• Lower ambient temperature, increase motor cooling.

Motor wiring error. Check motor wiring at MF connector on the IAM/AM.

Incorrect motor selec-tion.

Verify the proper motor has been selected.

E05 Drive Overcurrent Fault (Power Fault)

Self-protection of the Intelligent Power Mod-ule (IPM) is indicating a major power related fault condition

Motor cables shorted. Verify continuity of motor power cable and connector.

Motor winding shorted internally.

Disconnect motor power cables from the motor. If the motor is difficult to turn by hand, it may need to be replaced.

Kinetix 2000 drive tem-perature too high.

• Check for clogged vents or defective fan.• Make sure cooling is not restricted by insufficient space around the unit.

Operation above contin-uous power rating and/or product environmental ratings.

• Verify ambient temperature is not too high.• Operate within the continuous power rating.• Reduce acceleration rates.

Kinetix 2000drive has a short circuit, overcur-rent, or failed compo-nent.

Remove all power and motor connections, and preform a continuity check from the dc bus to the U, V, and W motor outputs. If a continuity exists, check for wire fibers between terminals, or send drive in for repair.

E06 HardOvertravel Fault (+/- Hard Overtravel)

Axis moved beyond the physical travel limits in the positive/negative direction

Dedicated overtravel input is inactive.

• Check wiring.• Verify motion profile.• Verify axis configuration in soft-ware.

E07 MotFeedbackFault (Motor Feedback Loss)

The feedback wiring is open, shorted, or miss-ing.

• Check motor encoder wiring.• Run Hookup test in RSLogix 5000 software.

Error Code


Troubleshooting

32 3A2152B

E09 BusUndervoltage Fault (Bus Undervolt-age)

With three-phase power present, the dc bus volt-age is below its limit

DC bus voltage for 230V system is below 137V

• Verify voltage level of the incoming ac power.• Check ac power source for glitches or line drop.• Install an uninterruptible power supply (UPS) on your ac input.

DC bus voltage fell below the undervoltage limit while an axis on the follower power rail was enabled

Disable follower axis before removing power.

E10 DriveOvervoltage Fault (Bus Overvolt-age)

The dc bus voltage is above its limit

Excessive regeneration of power. When the motor is driven by an external mechanical power source, it may regenerate too much peak energy through the drive power supply. The system faults to save itself from an overload.

• Change the deceleration or motion profile. • Use a larger sys-tem (motor and Kinetix 2000 drive). • Install shunt module.

DC bus voltage for 230V system is over 410V

Verify input is within specifica-tions.

E11 MotFeedbackFault (Illegal Hall State)

State of Hall feedback inputs is incorrect

Bad connections. • Verify the Hall wiring at the MF connector on the IAM/AM.• Verify 5V power supply to the encoder.

E16 Softovertravel Fault (+/- Software Over-travel)

Axis position exceeded maximum software setting. • Verify motion profile.• Verify overtravel settings are appropriate.

E18 OverSpeedFault (Overspeed Fault)

Motor speed has exceeded 150% of maximum rated speed. The 100% trip point is dictated by the lesser of the user velocity limits or the motor rated base speed.

• Check cables for noise.• Check tuning.

E19 PositionErrorFault (Follow Error)

Position error limit was exceeded. • Increase the feed forward gain.• Increase following error limit or time.• Check position loop tuning.• Verify sizing of system.• Verify mechanical integrity of system within specification limits.

E20 MotFeedbackFault (Mtr Fdbk AQB)

Motor Encoder State Error

The motor encoder encountered an illegal transition.

• Use shielded cables with twisted pair wires.• Route the feedback away from potential noise sources.• Check the system grounds.• Replace the motor/encoder.

E21 AuxFeedbackFault (Aux Feedback Comm)

Communication was not established with an intelli-gent encoder.

Verify auxiliary encoder wir-ing.

E30 MotFeedbackFault (Motor Feedback Comm)

Communication was not established with an intelli-gent encoder.

• Verify motor selection.• Verify the motor supports auto-matic identification.• Verify motor encoder wiring.

Error Code


Troubleshooting

3A2152B 33

E34 GroundShortFault (Ground Fault)

Excessive ground cur-rent in the converter was detected

Wiring error. • Check motor power wiring.• Check input power wiring.

Motor internal ground short.

Replace motor.

Internal malfunction. Disconnect motor power cable from drive and enable drive with current limit set to 0. If fault clears, then a wiring error or motor internal problem exists. If fault remains, call your sales representative.

Grounded control power terminal (applies to 230V systems only).

• Remove ground from control power input.• Source control power from three-phase input power. Refer to the Power Wiring Examples on page 169 for more information.• Add isolation transformer for control power.

E35 DriveUndervoltage Fault (Pre-charge Fault)

Converter pre-charge cycle failed

Low AC input voltage. Check input ac voltage on all phases.

Internal malfunction. Call your sales representative. E36 DriveOvertemp Fault

(System Overtempera-ture)

Converter thermal switch tripped

Excessive heat exists in the power circuitry.

• Reduce acceleration rates.• Reduce duty cycle (ON/OFF) of commanded motion.• Increase time permitted for motion.• Use larger Kinetix 2000 con-verter.• Check for clogged vents or defective fan.• Make sure cooling is not restricted by insufficient space around the unit.

E37 PowerPhaseLoss Fault (Phase Loss Flt)

• One or more phases of the input ac power is missing.• Axis was enabled when main (three-phase) power was removed.• Common bus follower axis was enabled when dc bus power was removed.

• Check input ac voltage on all phases.• Disable axis before removing power.

E38 SERCOSFault (SER-COS Ring Flt)

The SERCOS ring is not active after being active and operational

Cable disconnected. Check that fiber-optic cable is present and connected prop-erly.

E39 DriveHardFault (Self Sense Flt)

Self-sensing Commuta-tion Startup Error

Motion required for self-sensing startup com-mutation was obstructed.

• Verify that there are no impedi-ments to motion at startup, such as hard limits.• Increase self-sensing current if high friction or load conditions exist.• Check motor or encoder wiring using wiring diagnostics.

Error Code


Troubleshooting

34 3A2152B

E43 DriveEnableInput Fault (Drive Enable Flt)

Missing Drive Enable Input Signal

• An attempt was made to enable the axis through software while the Drive Enable hardware input was inactive.• The Drive Enable input transitioned from active to inactive while the axis was enabled.

• Disable the Drive Enable Input fault.• Verify that Drive Enable hard-ware input is active whenever the drive is enabled through software.

E50 SERCOSFault (SER-COS Same ADDR)

Duplicate node address detected on SERCOS ring. Verify that each SERCOS drive is assigned a unique node address.

E54 DriveHardFault (Ifbk HW Fault)

Current feedback hardware fault detected. Replace the module.

E60 DriveHardFault (Unknown Axis)

Illegal ID bits detected. Replace the module.

E61 AuxFeedbackFault (Aux Fdbk AQB)

Auxiliary Encoder State Error

The auxiliary encoder encountered an illegal transition.

• Use shielded cables with twisted pair wires.• Route the feedback away from potential noise sources.• Check the system grounds.• Replace the motor/encoder.

E62 AuxFeedbackFault (Aux Fdbk Loss)

The feedback wiring is open, shorted, or missing. Check the motor feedback cable connectors/wiring to the IAM/AM and motor.

E63 AuxFeedbackNoise (Aux Fdbk Noise)

Noise on auxiliary feed-back cable

Recommended ground-ing, per installation instructions, has not been followed.

• Verify grounding.• Route feedback cable away from noise sources.• Refer to System Design for Con-trol of Electrical Noise Reference Manual, publication GMC-RM001.

E64 MotorFeedbackNoise (Mtr Fdbk Noise)

Noise on motor feedback cable

E65 No Fault Message (condition indicated by on-screen mes-sage) (Hookup Fault)

Hookup procedure failed Motor or feedback device malfunction.

• Check motor power/feedback wiring.• Refer to on-screen message for resolution.

E66 No Fault Message (condition indicated by on-screen mes-sage) (Atune Flt)

Autotune procedure failed

Motor or feedback device malfunction.

• Check motor power/feedback wiring.• Refer to on-screen message for resolution.• Perform Hookup in RSLogix 5000 software.• Consult RSLogix 5000 help screen.

E67 DriveHardFault (Task init)

Operating system failed Software initialization fault detected due to hardware failure.

• Cycle power.• If fault persists, replace module.

E68 DriveHardFault (SCANport Comm)

DPI communication failed

The DPI device or cable is faulty.

Check DPI connections.

E69 DriveHardFault (Objects Init)

Non-volatile memory is corrupt due to control board hardware failure.

Load default parameters, save to non-volatile memory, and recycle power or reset the drive.

Error Code


Troubleshooting

3A2152B 35

E70 DriveHardFault (NV Mem Init)

Non-volatile memory is corrupt due to control board software error.

Load default parameters, save to non-volatile memory, and recycle power or reset the drive.

E71 DriveHardFault (Mem-ory Init)

RAM or Flash memory validation failure • Cycle power.• If fault persists, replace module.

E72 DriveOvertemp Fault (Drive Overtemp)

Inverter thermal switch tripped

The fan on the IAM or an AM failed.

Replace the failed module.

The cabinet ambient temperature is above rat-ing.

Check the cabinet tempera-ture.

The machine duty cycle requires an RMS current exceeding the continu-ous rating of the control-ler.

Change the command profile to reduce speed or increase time.

The airflow access to the Kinetix 2000 system is limited or blocked.

Check airflow and re-route cables away from the Kinetix 2000 system.

E73 Communicate (Back-plane Comm)

Power rail CAN communications failed. Check module for proper mount.

Power rail connection shorted or open. Check power rail and module for foreign objects.

E74 DriveOvercurrent Fault (Bus OverCur-rent)

DC link current exceeds rating

Motor or transmission malfunction.

• Check for proper motor sizing.• Check/replace transmission device.• Check/replace motor.

IAM not properly sized. • Check for proper IAM sizing.• Install larger kW rated IAM.

E75 DriveOvervoltage Fault (Shunt Time Out)

The IAM, AM, or SM has exceeded its shunt resis-tor continuous rating.

• Use a properly sized shunt or modify duty cycle of the applica-tion.• System uses internal shunt and requires external shunt for addi-tional capacity.

E76 DriveHardFault (CAN Init)

DPI hardware initializa-tion fault detected

Control board hardware failure.

• Reset System.• If fault persists, replace sys-tem module.

E78 DriveHardFault (SER-COS Init)

Control hardware fault detected. • Cycle power.• If fault persists, replace module.

E79 DriveOvervoltage Fault (Shunt Module Flt)

Shunt module temperature fault LED indicator is steady red.

Refer to Temperature Fault LED Indicator on page 141.

Shunt module shunt fault LED indicator is steady red.

Refer to Shunt Fault LED Indi-cator on page 141.

Module missing from power rail. • Install missing module on power rail.• Fill empty slot with slot filler module.

E80 DriveHardFault (CPLD Flt)

Control hardware fault detected. Replace module.

E81 DriveHardFault (Com-mon Bus Flt)

Follower IAM detected ac input power being applied.

Remove ac input power con-nections from follower IAM.

Error Code


Troubleshooting

36 3A2152B

E90 DriveHardFault (Pre-charge Timeout Flt)

Pre-charge resistor power exceeds the resistor rat-ing.

Allow resistor to cool.

All oth-ers

RESERVED Call your local Rockwell Auto-mation sales representative.

Error Code


Troubleshooting

3A2152B 37

IAM/AM Status Indicators

Drive Status LED Indicators

Comm Status LED Indicator

Bus Status LED Indicator

Drive Status LED Indicator Status Potential Cause Possible Resolution Off Normal, no faults N/A N/A Steady Red Drive faulted Seven-segment Fault Status dis-

play shows an error code Fault exists, refer to Seven-segment LED Indicator Error Codes begin-ning on page 134.

Comm Status LED Indicator Status Potential Cause Possible Resolution Steady Green Communication

ready No faults or failures. N/A

Flashing Green Establishing com-munication

System is still in the process of establishing SERCOS communica-tion.

Wait for steady green LED indica-tor.

Node address setting on the drive module does not match SERCOS controller configuration.

Verify proper node switch setting.

Off No communica-tion

Loose fiber-optic connection. Verify proper fiber-optic cable con-nections.

Broken fiber-optic cable. Replace fiber-optic cable.

Receive fiber-optic cable con-nected to SERCOS transmit con-nector and vice versa.

Check proper SERCOS fiber-optic cable connections.

Bus Status LED Indicator Status Condition

Steady Green Bus power is present, axis enabled. No faults or failures.

Normal when:• 24V is applied to Hardware Enable Input (IOD/AF-43).• MSO instruction is commanded in RSLogix 5000 software.

Flashing Green Bus power is present, axis disabled. No faults or failures.

Normal when:• 24V is not applied to Hardware Enable Input (IOD/AF-43).• MSO instruction is not commanded in RSLogix 5000 software.

Off Bus power not present. • Normal when bus power is not applied.• Fault exists, refer to Seven-segment LED Indicator Error Codes section beginning on page 134.

Bus power is present in follower IAM.

• Follower IAM is not configured as CommonBus Follow in RSLogix 5000 software.• After dc bus voltage is applied, a 2.5 second delay before the LED indi-cator begins flashing green is normal operation to provide common bus leader time to complete pre-charge.

Repair

38 3A2152B

Repair

Base Pump Piston Replacement


2. Use a wrench to remove the outlet feed fittings at the bottom of the pump.

3. Remove the three nuts.

4. Remove the lower.

5. See the Dura-Flo Manual for rebuild information.

NOTE: Installation is the reverse of removal.

NOTE: When rebuilding base pump, verify piston pack-ings are assembled accordingly. Refer to FIG. 15 for visual clarity.

NOTE: Check balls are not installed.

FIG. 15: Base Pump

ti18108a

ti18109a

Note orientation of piston pack-ings when assembling.

Repair

3A2152B 39

Inhibitor/Catalyst/Color Pump Rebuild

FIG. 16: Inhibitor/Catalyst/Color Pump Rebuild

ti18110a

904

925

903

801 821814

906905

824802

806803

912 922 921 907

909 913924 915

920

932

9381003

902

Repair

40 3A2152B

Disassembly of 1093 valve sectionRefer to FIG. 16 for the following steps.

1. Remove motor (826) from Mounting Plate (818).

2. Remove valve from valve stack by removing the four screws (705) that are holding the valve to the plate (938).

3. On the right side of the valve, remove Valve End Cap (909). The Valve Piston (913) will be inside the end cap.

NOTE: If necessary, remove Valve Piston (913) from Valve End Cap (909) by applying low air pressure through valve air inlet to push out the Valve Piston (913).

4. Remove Seal Plate (924).

5. Repeat steps 3 and 4 with the left side of the valve.

6. Push the Spool/Sleeve (917) out with a finger. If the Spool/Sleeve does not slide out, tap gently using a wood or plastic dowel.

A worn spool and sleeve assembly must be replaced with a new (matched) assembly. If you are rebuilding multiple valves be sure to keep the spools and sleeves matched.

7. Remove Inlet/Outlet Block (932) from Valve Body (907).

8. Remove O-Rings (920) from Valve Body (907).

9. Remove Spool Wet Seal Retainers (915) on the left and right of the Valve Body (907).

10. Remove Valve Body (907) from Oil Cup Retainer (925) by removing Screws (927).

11. Remove Metering Sleeve (906) from Valve Body (7).

12. Remove Oil Cup Retainer (925) by removing screws (824) shoulder bolt.

13. Remove Seal Cup (903) from Oil Cup Retainer (925). Remove Posipak Rod Seal (904) from Seal Cup (903).

14. Slide Guide Rods out of Connection Block (806).

15. Remove Metering Rod (902) from Connection Block (806).

16. Remove Non Drip valve (1003) from Inlet/Outlet (932).

Assembly of 1093 valve sectionNOTE: Check the Metering Rod (902), Metering Sleeve (906), and Spool/Sleeve Assembly (917) and Valve Body (907) for wear. Replace as necessary.

1. Install four lubricated O-rings (919) onto the Spool/Sleeve Assembly (917). Lubricate the Spool Rod and the outside of the Spool Rod Sleeve along with the inside of the Valve Body (907).

2. Insert the Spool/Sleeve Assembly (917) carefully into the Valve Body (907). Be sure to align the Bot-tom holes of the Sleeve piece of the Spool/Sleeve (917) with the outlet, inlet, and transducer holes of the Valve Body (907).

Install the spool wet seal retainer on the main body

3. Install a lubricated O-ring (921) on the left side of the Valve Body (907) next to the sleeve of the Spool/Sleeve assembly (917).

4. Install two lubricated Posipak Seals (922) wet seal retainer (915) so that the O-ring side of both Posi-paks will be facing the Valve Body (917). Be sure to

NOTICE

Avoid damaging U-cups and Poipak seals when installing. Verify they are lubricated and tuck the lips of the seal inward before uniformly pushing them into position.

ti18111a

Top Hole

Bottom Holes Outlet Inlet

Transducer Hole

Repair

3A2152B 41

tuck the lip of the Posipak into its cavity to avoid damage.

5. Position the wet seal retainer with the oil cup upwards and slide over the Spool part of the Spool/Sleeve Assembly (917) with the counterbore for the Seal Retainer (915) facing out. Slide the Seal Retainer (915) over the Spool and install two Screws (923). Install the Rod Sleeve and connect the motor and motor coupling assembly.

6. Repeat steps 3 through 5 for the right side Seal Plates.

Install the Metering Sleeve and Connect the Motor & Motor Coupling Assembly

7. Lubricate the dispense sleeve bore in the Valve Body (907). Insert the Metering Sleeve (906) into the Valve Body (907).

8. Place lubricated O-ring (905) over the Metering Sleeve (906) and against the Valve Body (907).

9. Insert the Seal Cup (903) into the Retainer Oil Cup (925).

10. Slide a lubricated Posipak Seal (904) into the Seal Cup (903) with the o-ring side facing down toward Valve Body (907).

11. Lubricate the Metering Rod (902) and slide carefully through the Posipak Seal (904), Seal Cup (903) and Oil Cup Retainer (925) so that the Metering Rod (902) projects about 1/2” through this assembly.

12. Using the projecting Metering Rod (902) to guide the assembly into the Metering Sleeve (906), slide the Oil Cup Retainer (925) down against the Valve Body (907) and secure with Screws (927).

13. Pull the Metering Rod (902) away from the Valve Body (907) so that the end is only slightly in the Metering Sleeve (906).

14. Slide the key slot in the Connection Block (804) over the end of the Metering Rod (902).

15. Insert the Guide Rods (803) through the Connection Block (806) and into the Oil Cup Retainer (925).

NOTE: If the Motor and Motor Coupling Assembly had been disassembled, then reassemble per the instruc-tions below before proceeding to step 19.

16. Position the Motor and Motor Coupling Assembly above the Main Body Assembly and bring them together so that the Guide Rods (803) enter their holes in the Drive Assembly (901) and the end of the Lead Screw (814) seats in the Connection Block (804).

17. Install the Screws (805/807) into the Connection Block (806).

18. Install the left Side Block 3-Slot (802) with Screws (824/808). Install the clear plastic Guards (822) so that the access hole in the guard toward the bottom. Secure with Screws (823).

Mount the Valve End Caps to the Seal Plate Cups

19. Install a lubricated U-cup Seal (912) into the groove of the left Spool Shift Piston (913). The piston is thicker on one side of the groove. The lip of the seal must be facing the thicker section.

20. Lubricate the bore in the End Cap (909). Slide the Spool Shift Piston (913) into the left End Cap (909) tucking the lip of the U-cup seal (912) into the End Cap (909) carefully.

21. Install shift spool position cycle detection sensors (926) with screws (928). Align Nubon sensor with hole in Seal Retainer (924).

22. Install the Piston/End Cap onto the left Spool Wet Retainer (915) using four Screws (908/931). Tighten the screws in a cross pattern gradually to prevent binding due to misalignment.

23. Push the Spool Rod (917) into the left side until the Spool Rod (917) contacts the piston. Repeat steps 19 through 22 for the right side.

24. Install lubricated O-rings (920) to the Valve Body (907) and attach the Inlet Block (932) with Screws.

25. Install the Inlet/Outlet Block (932) with Screws. Remount the valve. Install the home and spool sen-sors being careful not to overtighten the set screws. Install the air supply lines and connect the power.

Repair

42 3A2152B

Motor Coupling

FIG. 17: Motor Coupling Assembly

ti18110a

ti18112a

827

828

826

830

819

818

816815

817

813

812

811

814

810

809

831

808

824

801

822

823

833

821

803

804

806

805

820823

822

802

807

Repair

3A2152B 43

Disassembly of motor coupling section1. Remove Screws (805) to disconnect Connection

Block (804) from Lead Screw Connector Block.

2. Remove Lead Screw Connecting Block from lead screw by removing the FHSC screw (807).

3. Remove Mounting Plate (818) from drive assembly by removing SHC Screws (819).

4. Remove bearing Retaining Sleeve (817) from drive assembly by removing screws (810).

5. Remove Lead Screw (814) and Lead Screw Nut (813) with the ball bearing assembly (812/811) attached.

Motor and motor coupling assembly1. Assemble Motor Coupler by inserting Roll Pins

(825) and Screws (816).

NOTE: This step is only required if the motor coupler has been disassembled for service or removed from the motor.

2. Assemble Lead Screw Nut (813) with Bearing (812) and E-ring (811).

3. Thread Lead Screw (814) into Lead Screw Nut assembly until lead screw is flush with top of nut.

4. Slide Lead Screw & Nut Assembly into Lead Screw Housing (809).

5. Slide Bearing Retaining Sleeve (817) on to the lead screw assembly, taking care to line up the slots in the two pieces (809) and (817). Secure in place with Screws (810).

6. Secure Motor Mounting Plate (818) to Lead Screw Housing (809) using Socket Head Cap Screws.

7. Place Motor Coupler (815) on motor shaft and lightly snug Screws (816) leaving about 3/8” of motor shaft visible between Motor Coupler and motor. Insert Motor Coupler (815) through Motor Mounting Plate (818), align 3 Roll Pins and insert into Lead Screw Nut (813) and gently seat the motor.

NOTE: This step is only required if the motor coupler has been disassembled for service or removed from the motor.

8. Remove motor and motor coupler, tighten Screws (816) and reassemble securing motor to Motor Mounting Plate using Socket Head Cap Screws (827).

Repair

44 3A2152B

Valve Stack Rebuild

FIG. 18: Valve Stack Assemblies

ti18113a

1217

1212

1201

1204

1202

1205

1213

1213

1204

1205

1204

1205

1204

1205

1208

1213

130513041305

1306

1307

13081309

1216

Mixer Step Face Up

Repair

3A2152B 45

The valve stack is a series of blocks put together with socket head cap screws. Each block contains a plastic mixer (1205). The only reason to service this would be if the material started to gel, if the color was being changed, or before a long shut down. If the material started to gel, the best place to start is the bottom block where the catalyst is injected. There should be no gell-ing above that point. To disassemble the valve stack:


2. Remove the base hose from the Swivel Fitting (1217) at the top of the stack.

3. Remove the inhibitor, catalyst and color valves from the valve stack. Remove the Bolts (705) from the Plate (938).

4. Turn off the flow of coolant to the Cooling Jacket (704) and Block (1309) and relieve any coolant pressure.

5. Remove the Cooling Jacket (704) from the Pipe Mixer (1308).

6. Remove the Pipe Mixer (1308) and valve stack from the screw on the press.

7. Remove the Cooling Block (1309) from the valve stack

8. Move the stack to a bench to disassemble.

9. Carefully use a pipe wrench to remove the Pipe Mixer (1308).

10. Remove the bottom four Socket Head Screws (1213) from the Bottom Outlet Block (1208).

11. Remove the Bottom Outlet Block (1208) from the Catalyst Pump Port (1203).

12. Remove the Plastic Mixer (1205) from the Block (1208).

NOTE: The old mixer should be replaced with a new one each time.

13. Remove the Top Inlet Block (1201) from the Inhibi-tor Pump Port (1203) by removing four Socket Head Cap Screws (1212).

14. Remove the Plastic Mixer (1205).

15. Remove the four Socket Head Cap Screws (1213) in the Inhibitor Pump Port Block (1203).

16. Remove the Inhibitor Pump Port Block (1203).

17. Remove the four Socket Head Cap Screws (1213) from either the Spacer Block (1206) or the Color Block (1206) if using kit 24M126.

18. Remove the Mixer (1205) from this Spacer Block (1206) or Color Block (1206).

Before reassembly, check all sealing surfaces for scratches. Make sure any traces of silicone are removed. Replace the Plastic Mixers (1205), the Top Inlet Block Oring (1202), and the other Block Orings (1204). Use an oring lubricant on the seals to reassem-ble.

Reassembly is the reverse of disassembly. Be sure the plastic mixers are positioned correctly with the small step facing up as shown. Refer to FIG. 18.

Repair

46 3A2152B

Position Sensor on Inlet/Outlet Valve Replacement

FIG. 19: Inlet/Outlet Valve

ti18117a

405

407

407

403

408

402404

409

406

401

Repair

3A2152B 47

See valve manual 310550 for more information.

1. Remove and bleed air pressure from valve.

2. Remove valve cap (402).

3. Disconnect coupling (404) from valve shaft (401).

4. Remove air cylinder (405) from valve cap (402).

5. Lubricate and replace o ring (403).

6. Perform any other valve maintenance as required. See Graco manual 310550.

7. Reattach air cylinder (405) to valve cap (402).

8. Pull air cylinder (405) shaft out and attach coupling (404).

9. Attach coupling (404) to valve shaft (401) and piston (401).

Parts

48 3A2152B

Parts

Control Frame Base Pump, 24M094

ti18114a

113

114

115

104,105,106

102,108,109

101,120

116

110,111

103

110,112

107

119117

118

Parts

3A2152B 49

Software already loaded when received.

Ref Part Description Qty101 16M370 FRAME,assembly,LSR,aluminum 1102 24L878 PUMP,base assembly,DURA-FLOW 750, 1103 24M007 VALVE,base assembly,DURA-FLOW 750,I 1104 24L933 ENCLOSURE,assembly,LSR select 1105 24L871 PANEL,back,assembly,LSR select,1 1106 24L890 CONTROL,wiring diagram,LSR select 1 1107 81/0136-G/25 GUARD,footswitch assembly,w/cord,15' 1108 16M397 CABLE,feedback,base pump,5 meter 1109 16M398 CABLE,power,base pump,5 meter 1110 24M118 VALVE,assembly,solenoid,base pump,A 2111 121022 ELBOW,swivel,1/4tube x 1/4NPT 1112 125733 FITTING,tee,1/4tube x 1/4 NPT 1113 24M050 HARNESS,assembly, LSR, stack 1114 24M049 HARNESS,assembly,LSR,stack,motor,11' 1115 24M051 HARNESS,assembly,LSR,stack,sensor,11' 1116 24M111 CLAMP,assembly,hose,(1)1-5/8ID 1117 24M112 CLAMP,assembly,hose,(3)1-5/8ID 1118 125968 COVER,cables,5-3/4”OD,16”LG 1119 114271 STRAP,retaining 6120 125920 COVER,T-slot,gray,78.74”,10mm 2

121 16K956 SOFTWARE,HMI,LSR 1122 16K957 SOFTWARE,PLC,LSR 1123 16K958 SOFTWARE,PLC,LSR,select 1

Parts

50 3A2152B

Base Pump Wet Section, 24L880

ti18115a

201

202

Parts

3A2152B 51

Ref Part Description Qty201 L180SS PUMP,recip, displacement 1202 16M221 HOUSING,valve,(7.5CM),base pump 1

Parts

52 3A2152B

Base Pump Lower, 24L878

ti18116a

318

319

310

313

312

314

315

316

317

301

302

303

308

304

305

309

305

306

307

311

305

306

307

Parts

3A2152B 53

Replacement Danger and Warning labels, tags, and cards are available at no cost.

Item not shown.

Ref Part Description Qty301 16K892 MOTOR,servo 1302 125874 ACTUATOR,linear,ET100,w/o motor 1303 121797 SCREW,cap,socket 4304 114766 BOLT,cap hex head 4305 101044 WASHER,plain 12306 100018 WASHER,lock,spring,1/2” 6307 555395 NUT,1/2-13 6308 16M223 PLATE,adapter,ET100,DF750,pump 1309 617374 PLATE,pump,mounting 1310 118435 GROMMET 1311 123999 SCREW,cap,hex head 4312 16M224 GUARD,tube,base pump 1

313 84/0130-27/11 LABEL,hand crush,1.3 X 1.1,triangle,ISO 1314 15F837 ROD,tie 3315 100128 WASHER,lock 3316 555396 NUT,5/8-11 hex 3317 24L880 pump,displacement,mod 1318 16M222 SHAFT,drive,holder,sensor,M27-2 1319 81/0440-1/11 SWITCH,proximity,24VDC,NO,PNP 1

320 81/0399/11 CONNECTOR,field,straight,female 1

Parts

54 3A2152B

Base Pump Inlet/Outlet Valves, 24L977

ti18117a

405

407

407

403

408

402404

409

406

401

Parts

3A2152B 55

Ref Part Description Qty401 918537 APPLICATOR,ball seat,1/2 port 1402 16M353 CAP,cylinder 1403 103338 PACKING,o-ring 1404 16M352 COUPLING,piston,air cylinder,cycle 1405 125917 CYLINDER,air, 1406 125918 SWITCH,proximity,4MM,PNP/NPN,24VDC,3W 2407 82/0217-A/11 MUFFLER,air,1/8NPT,mini 2408 121022 ELBOW,swivel,1/4TUBEX1/4NPT 2409 81/0398/11 CONNECTOR,field,straight 2

Parts

56 3A2152B

Base Pump Inlet/Outlet Valve Plumbing, 24M007

ti18118a

501

502504

505

506

507

510

508

509

501

502

503

505

504

506512513

514515

503

511

Parts

3A2152B 57

Ref Part Description Qty501 125925 FITTING,swivel,3/”4X1” 2502 15U426 BUSHING,reducing 2503 24L977 APPLICATOR,ball seat,1/2 port 2504 166242 FITTING,elbow,street,90 degree 2505 15M859 FITTING,adapter,male,swivel,1/2 SST 2506 114572 FITTING,nipple,hex 3507 V-565208080808SS CROSS,1/2NPT 1508 123980 FITTING,swivel,3/4X1/2 1509 122763 FITTING,elbow,straight,3/4NPT 1510 504174 BUSHING,pipe 1511 24L981 HOSE,coupled 1512 122656 BUSHING,1/2X1/4NPT 1513 124517 SENSOR,pressure,PGM,ambient 1514 81/0428/11 CONNECTOR,PT06F106S MIL 1515 81/0099-4/11 CORD,20/4,5A,PVC,300V,80degree C 10

Parts

58 3A2152B

Base Pump Inlet/Outlet Valve Plumbing, 24M118

ti18119a

604

608

605

602

603

606

607

604

608

605

602

603

606

607

601

Parts

3A2152B 59

Ref Part Description Qty per Valve601 123513 FERRULE,wire,18AWG 3602 81/0287-3/11 CORD,18/3,7A 8603 83/0028-C/11 CONNECTOR,cable,solenoid 1604 120900 VALVE,power,4W,SSSR,1/4NPT,24VDC 1605 121021 MUFFLER,air,1/4NPT 2606 121022 ELBOW,swivel,1/4TUBEX1/4NPT 2607 054130 TUBE,.250 OD 6608 15F979 SCREW,pan head 2

Parts

60 3A2152B

Valve Stack, 24L893

ti18160a

704 706

708

703

702

701

705,707

709

712

711

710

Parts

3A2152B 61

Ref Part Description 24L893 Qty24M126

Qty24M127

Qty701 24L968 VALVE,1093,10A-4TS0-250-V-DISP 1702 24L969 VALVE,1093,10A-4TS0-625-V-DISP 1703 24M039 MIXER,stack assembly,(2)1093,w/cool 1704 24M040 JACKET,cooling assembly,3/4X12 pipe 1705 101682 SCREW,SHC,1/4-20X0.625 4706 24M048 VALVE,assembly 1707 110755 WASHER,plain 4708 24L969 VALVE,1093,10A-4TS0-625-V-DISP 1709 16M448 BLOCK,stack,module 1710 124517 SENSOR,pressure,PGM,ambient 1711 81/0428/11 CONNECTOR,PT06F1065 MIL 1712 81/0099-4/11 CORD,20/4,5A,PVC,300’,80 degree. 1

Parts

62 3A2152B

Inhibitor/Catalyst/Color Pump Drive (1093 Valve), 24L905

ti18112a

814

809

831

821

801

824

822

823

820

805806

807

803

804

823822

827

828

826

819

818

815

817

813

812

811

821808

802

824

816 810

825

808

916

Parts

3A2152B 63

Replacement Danger and Warning labels, tags, and cards are available at no cost.

Ref Part Description Qty801 01/2983/97 PLATE,tie,front,PD,1.5B 1802 01/2982/97 PLATE,tie,back,PD44 1803 01/2706-A/99 ROD,guide,1093,1.5BX2.0S 2804 A2010204 1093,connector,metering rod 1805 96/0260/98 SCREW,SHC,8-32X0.63,SS 2806 A2010205 1093,connector,lead screw 1807 96/0458/99 SCREW,FHSC,10-32X0.50 1808 96/0328-2/98 SCREW,SHC,shoulder 4809 01/2990/97 HOUSING,leadscrew 1810 96/0273/99 SCREW,BHSC,8-32X0.19 2811 V-98585A112 RING,retaining,external,0.625 1812 84/0129/11 BEARING,ball,.625IDX1.375OD 1813 16M285 NUT,leadscrew,drive 1814 01/2994-1/25 LEADSCREW,drive,1093 1815 16M284 COUPLER,leadscrew,12MM,motor,shaft 1816 96/0363/99 SCREW,SHC,6-32X0.38 2817 01/2992/97 RETAINER,bearing,leadscrew 1818 16M286 PLATE,moutning 1819 GC2192 SCREW,SHDC,SS,.164X.375 4820 01/2993-S/89 SPACER,drive nut 1821 A2010208 1093,spacer,drive 4822 01/2995-1/11 GUARD,side,1093 2823 297639 SCREW,cap,button head,8-32X.38 4824 96/0328-3/98 SCREW,SHC,shoulder 4825 96/0206/98 PIN,roll,1/8X.50,SS 3826 16K891 MOTOR,servo,enclosure 1827 113003 SCREW,SHC,10-32X0.63 4828 C19277 WASHER,lock,split,hi-collar 4

831 84/0130-27/11 LABEL,hand crush 1

Parts

64 3A2152B

Inhibitor/Catalyst/Color Pump Drive (1093 Valve), 24L969 and 24L968

927

925

903

904

905

902

906

907

909

934933

915

936

935

910

911

914

912913

924923 916

926

928

929

922

921

937

931910

909

908

911

914912

913924

929

915

923926,928

917921

922

917

919

939940938

ti18120a

930

920

932

Parts

3A2152B 65

Ref Item Description24L969

Qty24L969

Qty901 24L905 KIT,1093,driveE assembly,servo motor 1 1902 A2010207-10S 1093,rod,metering,5/8,SS 1

16M328 ROD,1093,metering,1/4,SS 1903 A2010203-10 1093,oil cup,large,5/8 1

16M329 CUP,1093,oil,large,1/4 1904 D2000064 POSIPAK,5/8IDX7/8OD 1

D2000042 POSIPAK,1/4IDX1/2OD 1905 103559 PACKING,o-ring 1 1906 A2010206-10D 1093,sleeve,metering,5/8 1

16M327 SLEEVE,1093,metering,1/4,PTFE 1907 16M324 VALVE,1093,main 1 1908 96/0509/98 SCREW,SHC,10-32X2.50 4 4909 16D002 CAP,END,air cylinder 2 2910 123453 FITTING,1/4tube x 1/8NPT 2 2911 111098 PACKING,o-ring,cylinder 2 2912 95/0601/01 U-CUP,1-3/16IDX1-1/2OD 2 2913 A2000009-1 1093,piston,spool 2 2914 01/2801-1/97 TUBE,AIR CYL,spool,1093 2 2915 A2000006-1 1093,retainer,seal,wet,spool valve 2 2916 110208 PLUG,pipe,headless,1/8NPT 4 4917 16M330 SPOOL,1092,assembly 1 1918 J1000002 PIN,ROLL,1/8X.38 2 2919 108195 PACKING,o-ring 4 4920 556553 O-RING,-008 FKM-A 2 2921 555684 O-RING,-018 FKM-A 2 2922 D2000040 POSIPAK,3/8IDX5/8OD 2 2923 95/0894/11 POSIPAK,1"IDX1-3/8"OD 2 2924 A2000007-1 1092,retainer,seal 2 2925 A2010202 1093,retainer,oil cup,large 1 1926 81/0440-1/11 SWITCH,proximity,24VDC,NO,PNP 2 2927 96/0307-1/99 SCREW,SHC,10-24X1.00 4 4928 96/0575/98 SCREW,FHSC,4-40X0.31 2 2929 B4000023 SCREW,SHC,10-32X1.25 4 4930 84/1050-400/11 DECAL,material 1 1931 617559 SCREW,cap,SCH 4 4932 24L906 NEEDLE,1092,adapter,single 1 1933 123538 BUTTON,snap-on,1/4tube 1 1934 61/2904-YL/11 TUBING,0.160IDX0.250OD 6 6935 123537 BUTTON,snap-on,1/4tube 1 1936 61/2904-GN/11 TUBING,0.160IDX0.250OD 6 6937 125916 SCREW,SHC,10-32X0.25 1 1

Parts

66 3A2152B

Needle Adapter Assembly, 24L906

938 16M326 BRACKET,mounting,module 1 1939 96/0125/99 SCREW,SHC,10-24X0.50 4 4940 100020 WASHER,lock,split,#10,MS 4 4941 81/0398/11 CONNECTOR,field,straight 1 1

Ref Item Description24L969

Qty24L969

Qty

ti18121a

1001

1002

1004

1003

1004

Ref Part Description Qty1001 124998 FITTING,adapter 11002 16M287 BLOCK,1092,inlet/outlet,9/16-18 11003 24L907 VALVE,assembly 11004 B4000016 SCREW,SHC,10-32X1.00 2

Parts

3A2152B 67

Non-Drip Valve, 24L907

Ref Part Description Qty1101 01/0013-S/98 STEM,NDV,5/8,11/16,special seat 11102 97/0208/98 SPRING,.250 ODX1.00LG,8.99LB 11103 16M288 HOUSING,5/8,SS,soft seat,SAE 11104 01/0014/98 PIN,NDV,5/8,11/16,SS 11105 103648 PACKING,o-ring 11106 16M289 VALVE,head,NDV,5/8,11/16,PTFE 11107 120336 O-RING,packing 1

ti18122a

1101

11061102

1103

1104

1107

1105

Parts

68 3A2152B

Valve Stack, 24M039

ti18123a

1217

1212

1201

1202

1213

1203

1213

1204

1205

1219

1204

1205

1203

1204

1205

1208

1213

1217

1202

1204

1201

12161216

1205

1204

Parts

3A2152B 69

Ref Part Description 24M039 Qty24M126

Qty

1201 16M450 BLOCK,stack,inlet 11202 103559 PACKING,o-ring 11203 16M448 BLOCK,stack,module,mix,inlet,10 21204 559011 O-RING,(-022) FKM 41205 C26213 CARTRIDGE,mixer 41208 16M451 BLOCK,stack,module,mix,outlet 11212 107445 SCREW,SHC,1/4-20X1.50 41213 113194 SCREW,cap,socket 121216 122763 FITTING,elbow,3/4NPT,90,3K 11217 125925 FITTING,swivel,3/4”X1”,SST,3K 11219 16M448 BLOCK,stack,module,mix,inlet 1

16M449 BLOCK,stack,module,mix 1

Parts

70 3A2152B

Cooling jacket, 24M040

Ref Part Description Qty1301 16M453 JACKET, cooling, 3/4x12 pipe mixer 11302 94/0417/99 CLAMP, hose, 3"-2-1/16" 21303 116658 FITTING, tube, male (1/4 npt) 21304 100721 PLUG, pipe 21305 121022 FITTING, elbow, male, 1/4 npt 41306 96/0442/99 SCREW, shc, 3/8-16x1.25 21307 100133 WASHER, lock, 3/8 21308 100731 WASHER 21309 16M452 JACKET, cooling, stack, module, mix 1

ti18202a

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3A2152B - LSR Select, Instructions - Parts, English3A2152B EN Instructions - Parts LSR Select...

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Transcript of 3A2152B - LSR Select, Instructions - Parts, English3A2152B EN Instructions - Parts LSR Select...