Page 2 - Contents
2 309301G Contents ProDispense System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 WARNING . . . . ...
Page 4 - ProDispense System Components
ProDispense System Components 4 309301G ProDispense System Components Follow the instructions in this manual (309301) and refer to the component manuals for addi-tional warning, operation, service, and parts information. See the table below for: • maximum working pressure of the fluid panels • compo...
Page 5 - Conventions; Warning Symbols
Conventions 309301G 5 Conventions The following conventions are used in this manual to help guide you through the information. • Italicized text in a screen diagram indicates the text may vary according to how the sys-tem parameters have been configured. For example, the units of measure shown in th...
Page 6 - WARNING; FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD; TOXIC FLUID HAZARD; EQUIPMENT MISUSE HAZARD
WARNING 6 309301G WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in fire, explosion or electric shock. • Installation and service of electrical components must be completed by a qualified elect...
Page 7 - HIGH PRESSURE FLUID HAZARD/SKIN INJECTION HAZARD
WARNING 309301G 7 WARNING HIGH PRESSURE FLUID HAZARD/SKIN INJECTION HAZARD Fluid Panels 244599 and 244601 can be operated at very high fluid pressure (see page 4). High pres-sure spray from dispense valves, hoses, or ruptured components can inject fluid into your body and cause an extremely serious ...
Page 8 - Overview; How the ProDispense System Works; Usage
Overview 8 309301G Overview How the ProDispense System Works Usage The ProDispense system enables you to accurately dispense preset amounts of up to three different fluids or to manually dispense fluid as desired. The fluid meters provide accurate fluid flow readings to the controller. Controller to...
Page 9 - Main Components; ProDispense Controller; Display and EasyKeyTM Pad
Overview 309301G 9 Main Components ProDispense Controller The controller is used to setup the ProDispense system, fluids, and recipes, calibrate the meters, and select a recipe or preset a dispense. The controller totalizers enable you to view fluid dispense information and print the following repor...
Page 11 - Remote Operator Stations
Overview 309301G 11 Power Switch (A) On = Off = . (On side of controller) Operation Mode Switch (B) and Key (C) The position of the switch (B) determines which mode of operation you are in: Dispense Mode or Setup Mode . A key (C) supplied with the ProDispense system is inserted into the switch and t...
Page 12 - Fluid Panels
Overview 12 309301G Fluid Panels There are six types of fluid panels available: • 244599 — Oil and Lubricant Fluid Panel • 244600 — Water and Antifreeze Fluid Panel • 244601 — Grease and Paint Fluid Panel • 246837 — Grease and Paint Fluid Panel • 246838 — Meterless Fluid Panel (meter supplied by use...
Page 14 - Installation
Installation 14 309301G Installation • F IG . 5 is not an actual system design. Contact your Graco distributor for assistance in designing your system. • See detailed installation instructions, beginning on page 18. • Be sure all accessories are adequately sized and pressure rated to meet the system...
Page 15 - Install the Fluid Supplies
Installation 309301G 15 Install the Fluid Supplies The ProDispense fluid panels can be supplied by pressure tanks, pail or drum pumps, or cen-tral recirculating lines. The fluid supply must be free of pressure spikes, commonly caused by a pump stroke changeover. If necessary, install pressure regula...
Page 16 - Connect the Air and Fluid Lines
Installation 16 309301G Mount the Fluid Panel(s) Mount the fluid panel(s) on a flat, sturdy surface. Install 1/4” or M6 fasteners in the four 0.28” mounting holes (C1) and secure the fluid panel (C) to the mounting surface. Connect a ground wire (G) as instructed on page 20. Connect the Air and Flui...
Page 17 - Install the Remote Operator Station
Installation 309301G 17 Fluid Panel 246838 Connect an air supply line (8) to the 1/4” npt(f) solenoid valve port. The air supply must be fil-tered to 10 micron to lengthen solenoid valve life. Connect the fluid supply line (11) to the meter inlet. Connect a fluid dispense line (12) to the 3/8” npt(m...
Page 18 - Mount the Controller
Installation 18 309301G Mount the Controller Mount the controller on a flat, sturdy surface as instructed below. 1. Loosen the four screws (A1), disconnect the two cables (A2, A3) and remove the control-ler cover (A). 2. Install 0.44” or M11 fasteners in the four 0.51” mounting knockouts (B1) and se...
Page 19 - Connect the Cables and Power Cord
Installation 309301G 19 Connect the Cables and Power Cord On the bottom of the controller, there are meter and solenoid cable connectors for three Fluid panels. The row of connectors marked 1A , 2A , and 3A are for solenoid cable connections. The row of connectors marked 1B , 2B , and 3B are for met...
Page 20 - Ground the System; Check the Resistance
Installation 20 309301G Ground the System ProDispense Controller: Connect a ground wire (G1) to the grounding lug (H1) on the bottom of the controller. Connect the other end of the ground wire to a true earth ground. Fluid Panels: Connect a ground wire (G) to the grounding lug (H) on the junction bo...
Page 22 - Before Beginning Operation
Installation 22 309301G Before Beginning Operation • Check all fluid and air connections for correctness and tightness. • Follow the Startup procedure on page 23.
Page 23 - Startup
Startup 309301G 23 Startup Follow this procedure to start the ProDispense system for the first time (initial startup) or after the system has been shut down. 1. Turn on the power. The ProDispense system startup screen will display while the system is starting, then the Run screen (page 30) or System...
Page 24 - Pressure Relief Procedure; Shutdown
Pressure Relief Procedure 24 309301G Pressure Relief Procedure 1. Shut off the fluid supply to the ProDispense fluid panel. Follow the Pressure Relief Proce-dure for the fluid supply system. 2. Place the dispense line [or direct the dispense valve] into a waste container. 3. To begin dispensing, tur...
Page 25 - Setup Mode; Screen Navigation
Setup Mode 309301G 25 Setup Mode Screen Navigation To enter Setup Mode: You must have the key supplied with the system. Insert the key into the switch and turn it to Setup Mode . The System Setup screen appears. The name of the screen that is currently displayed is highlighted. Press the left or rig...
Page 26 - System Setup Screen
Setup Mode 26 309301G System Setup Screen Use system setup to enter the date, time, language to display, dispense mode, means of rec-ipe selection and station number. System To setup the system: 1. Type the current date: day (1-31) , month (1-12) , year (2000-2099) . 2. Type the current time: hour (...
Page 27 - Fluid Setup Screen; To set up the fluids:
Setup Mode 309301G 27 Fluid Setup Screen Use fluid setup to designate the parameters for each fluid you will dispense. Fluids Fluid parameters must be set before the fluid can be used in a recipe. To set up the fluids: You can have 1-3 fluid panels connected to the ProDis-pense controller. Setup the...
Page 28 - Recipe Setup Screen; To setup the recipes:; To calibrate a meter:
Setup Mode 28 309301G Recipe Setup Screen Use recipe setup to configure your recipes by assigning a recipe number and designating Tar-get Amounts for each fluid in the recipe. * Calibrate Meter Screen Use this screen to calibrate your fluid panel meters. All values are in cubic centimeters (cc). Rec...
Page 30 - Run Screen; Recipe Dispense
Dispense Mode 30 309301G Run Screen Use the Run screen to dispense a recipe or individual fluids. The Run screen displays either Recipe Dispense or Fluid Dispense, depending on which Dispense Mode was selected in System setup. Idle, Dispense, and Alarm Status In each of the fluid columns, under the ...
Page 31 - Fluid Dispense
Dispense Mode 309301G 31 Fluid Dispense Fluid Dispense displays in the Run screen if “Fluid Sta-tion” is selected as the Dispense Mode. Fluid Dispense allows you to select a fluid panel and the amount to dis-pense on an individual basis. 1. Place the fluid panel dispense line into the recepta-cle. 2...
Page 32 - Fluid Totals Screen
Dispense Mode 32 309301G Fluid Totals Screen Press the left or right arrow key to select Totals. The Fluid Totals screen shows how much of each of the fluids has been dispensed overall. Two totals are shown. Grand totals are tracked from the time the system is first started up and they are not reset...
Page 33 - Alarm History Screen; Out of Tolerance Alarm
Dispense Mode 309301G 33 Alarm History Screen Press the left or right arrow key to select Alarms. This screen summarizes the last five alarms that have occurred. Out of Tolerance Alarm This alarm occurs when the current actual dispense is either less than target – tolerance or greater than target + ...
Page 34 - Operation Procedures; Loading Fluid Lines; Manual Dispense
Operation Procedures 34 309301G Operation Procedures Loading Fluid Lines Follow this procedure to load the fluid lines and purge out any air: 1. Place the dispense line [or direct the dispense valve] into a waste container. 1. To begin loading fluid, turn the Operator Station dispense switch to ON [...
Page 35 - Purging Fluid; Emergency Stop
Operation Procedures 309301G 35 Purging Fluid Follow this procedure to purge the fluid lines: 1. Connect the fluid supply line to a solvent supply. Set the fluid supply pressure as low as possible to avoid splashing. 3. Continue dispensing until fluid lines are clean. 4. Turn the dispense switch to ...
Page 36 - Troubleshooting; Problem
Troubleshooting 36 309301G Troubleshooting Problem Cause Solution Out of Tolerance Alarm Dispense is under or over tolerance limit set for the fluid. Run screen shows tolerance difference for last dispense. Use the value to determine whether you should: • Increase the tolerance value • Model 244601 ...
Page 37 - Service; Removing and Installing Controller
Service 309301G 37 Service Removing and Installing Controller To remove controller: 2. Disconnect meter (F), solenoid (E), and power (P) cables and ground wire (G) from the bottom of the controller (B). See F IG . 13. . 3. Loosen the four screws (A1) and carefully remove the controller cover (A). Se...
Page 39 - Replacing Display Board
Service 309301G 39 Replacing Display Board 2. Remove controller cover (A). See page 37, steps 1-4. 3. Unplug keypad (D) ribbon cable from the display board. Note position of cable in connec-tor. Arrow indicates pin #1, reconnect with pin #1 engaged. 4. Remove four nuts (C1) from the board. See F IG ...
Page 40 - Replacing Display; Replacing Membrane
Service 40 309301G Replacing Display 1. Follow steps 1 through 6 in the procedure for replacing the display board. 2. Remove the display (C). See F IG . 15. 3. Install the par ts in reverse order of disassembly. Replacing Membrane 1. Follow steps 1-6 in the procedure for replacing the display board,...
Page 41 - Replacing Main Board
Service 309301G 41 Replacing Main Board 2. Remove controller cover. See page 37, steps 1-4. 3. Unplug all wire connectors (G) from the main board (H). See F IG . 16. 4. Squeeze release clips and pull the main board (H) away from the din rail (J). 5. Install parts in reverse order of disassembly. 1. ...
Page 42 - Replacing Power Supply
Service 42 309301G Replacing Power Supply 2. Remove controller cover. See page 37, steps 1-4. 3. Unplug all wire connectors from the power supply. 4. Pull the tab up with a screw driver and remove the power supply from the din rail. See F IG . 17. 5. Install parts in reverse order of disassembly. 1....
Page 43 - Replacing Fluid Panel Junction Box
Service 309301G 43 Replacing Fluid Panel Junction Box 2. Disconnect three cables (C) from the junction box (J). See F IG . 18. 3. Remove four screws (K) and remove junction box cover (L). 4. Disconnect meter and solenoid wires (M) from the terminal block. 5. Loosen two strain relief connectors (N) t...
Page 46 - Replacing Fluid Meter or Solenoid
Service 46 309301G Servicing Fluid Panel 244599 Replacing Fluid Meter or Solenoid 1. If necessary, purge ProDispense system (page 35). 3. Follow steps 3–5 on page 43 to disconnect meter and solenoid cables from the terminal block. 4. Disconnect fluid lines from the meter and solenoid. 5. Remove two ...
Page 50 - Replacing Fluid Meter, Solenoid, or Dispense Valve
Service 50 309301G Servicing Fluid Panel 244601 and 246837 Replacing Fluid Meter, Solenoid, or Dispense Valve 1. If necessary, purge ProDispense system (page 35). 3. Follow steps 3–5 on page 43 to disconnect meter and solenoid cables from the terminal block. 4. Disconnect fluid lines from the meter ...
Page 52 - Replacing Solenoid or Dispense Valve
Service 52 309301G Servicing Fluid Panel 246838 Replacing Solenoid or Dispense Valve 1. If necessary, purge ProDispense system (page 35). 3. Follow steps 3–5 on page 43 to disconnect meter and solenoid cables from the terminal block. 4. Disconnect fluid lines from the meter and dispense valve. Disco...
Page 56 - Wiring Charts; Control Box Wiring Chart
Service 56 309301G Wiring Charts Control Box Wiring Chart Wire / Harness Connection (Connector-Pin) Color Function Internal Wiring Fuse 1 PWR SW 1A black Fuse 2 PWR SW 2A black PWR SW 1 P Supply L black PWR SW 2 P Supply N black GND TB P Supply G green/yellow P Supply G P Supply - green/yellow P Sup...
Page 58 - Fluid Panel Wiring Chart
Service 58 309301G Fluid Panel Wiring Chart Harness Connection (Connector-Pin) Color Function 198426 Control box to fluid panel (1A, 2A, 3A) Pin-1 Pin-1 orange Pin-2 Pin-2 white Pin-3 Pin-3 green Pin-4 Pin-4 blue Pin-5 Pin-5 black Pin-6 Pin-6 red Pin-7 Pin-7 shield 198427 Control box to fluid panel ...
Page 60 - Accessories Wiring Chart
Service 60 309301G 246838 Fluid Panel (Grease) TB 6 black solenoid wires TB 8 black Accessories Wiring Chart Harness Connection (Connector-Pin) Color Function 197458 (5 ft., 1.52 m) 198669 (50 ft. 15.24 m) Printer Cable 2 1 shield 3 3 clear 1 5 black 4 jumper 6 Field Wiring Chart - Output Harness Co...
Page 62 - Parts; Description
Parts 62 309301G Parts Part No. 244561, Controller Ref. # Part # Description Qty. 3 197386 LABEL, power switch 1 4 116368 SWITCH, key, 2-position, includes item 4a 1 4a 116370 • KEY PACKAGE (2 duplicate keys) 1 5 116320 SWITCH, power 1 12 196975 POWER SUPPLY, 24 VDC 1 13 244952 BOARD, circuit, main ...
Page 70 - Notes
Page 71 - Technical Data
Technical Data 309301G 71 Technical Data Power Requirements Electrical . . . . . . . . . . . . . . . . . . . . 115/230 VAC, 1.6 amp maximum, 50 or 60 Hz Pneumatic . . . . . . . . . . . . . . . . . . . (Model 244601 only) 85-120 psi (0.59-0.9 MPa, 5.9-9 bar) at 1/4 cfm maximum (filtered to 10 micron)...
Page 73 - Accessories and Kits; Part Number
Accessories and Kits 309301G 73 Accessories and Kits Wetted Parts 244599 . . . . . . . . . . . . . . . . . . . . . . . aluminum, carbon steel, bronze, buna-N, stainless steel 244600 . . . . . . . . . . . . . . . . . . . . . . . brass, stainless steel, polyimide, polypropylene, EPDM o-ring, aluminum,...
Page 74 - Graco Standard Warranty
All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. This manual contains English. MM 309301 Graco Headquarters: Minneapolis International Offices: Bel...
