Graco FLUID 622-1A Instruction Manual

332077D
EN
Operation
622-1A Meter-Mix Unit
and Control Panel
For metering, mixing, and dispensing of silicone material.
For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
See page 2 for model information, including maximum
working pressure and approvals.
If the visuals in the printed copy are unclear, refer to the
electronic version available on www.graco.com.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.

Contents
2332077D
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 6
Model 622-1A . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . 8
Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Screen Identification . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 38
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . 40
Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Calibrate Pressure Transducers . . . . . . . . . . . . 41
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Model 622-1A . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48
Graco Information. . . . . . . . . . . . . . . . . . . . . . . . . 48
Related Manuals
Models
Manual Description
332338 622-1A Meter-Mix Unit and Control Panel,
Instructions-Parts
Part No.
Maximum Working
Pressures
psi (MPa, bar) Description
622-1A 3000 (21, 207)
PLC, Linear Potentiometer Controlled, Fixed Ratio, Meter Mix Dispense
Machine. Machine has proportional pneumatic control to provide auto-
matic adjustment during material dispense. Material supply to the
machine can be from 2.5-32 oz (74-946 ml) cartridges or a feed pump.

Warnings
332077D 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded.Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power cord before servicing equipment.
• Connect only to grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read 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 EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
SKIN INJECTION HAZARD
High-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.
• Engage trigger lock when not dispensing.
• 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

Warnings
4332077D
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
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. Do not use pail liners unless they
are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. 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.
• 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. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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.
WARNING

Warnings
332077D 5
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,
splatter may occur.
• Use minimum air pressure when removing platen from drum.
WARNING

Component Identification
6332077D
Component Identification
Model 622-1A
A Intensifier Override Button
B “A” Inlet Valve Override Button
C “B” Inlet Valve Override Button
D Color Injector Override Button
E Intensifier Pressure Regulator and Gauge
F Intensifier Ram Retract Button
G Cartridge Retaining Ring
J Bleed Valve
K Colorant Cartridge Regulator and Gauge
L Colorant Cartridge Pressure Cap
M Colorant Cartridge Retainer
N Material Hose Connection
P Material Pressure Gauge
R Colorant Injector Bleed Valve
S Colorant Injector Valve
T Double Pass Mixer with Water Jacket
U Optional Material Filter
V Optional Outlet Valve
W Emergency Stop
X Power On
Y Operator Interface Panel
Z Air Motor Solenoid
AA Linear Sensor Plug
AB Refill Valve
AC Main Air Connection
AD Ratio Sample Valve
FIG. 1: 622-1A
A
B
C
D
Z
AA

Component Identification
332077D 7
FIG. 2: 622-1A
J
G
F
E
K
L
M
N
P
R
S
T
U
V
X
W
Y
AB
AC
AD
AD

General Information
8332077D
General Information
Pressure Settings
All pressure settings are controlled through the Operator
Interface Panel. Refer to Screen 2, page 24, to set the
feed station pressure.
Fluid Pressure Gauges
All A and B material pressure gauges should read
the same as each other during normal operation of
the machine.
Solvents
These are rarely used with modern 1:1 silicones. For
cleaning, methylene chloride or white spirits solvent are
used. Methylene chloride is recommended because it is
non-flammable.
NOTICE
To avoid machine damage, do not exceed 120 psi
(0.8 MPa, 8.3 bar) air pressure at the machine inlet.
To avoid serious injury, do not use flammable
solvents for cleaning.

Screen Navigation
332077D 9
Screen Navigation

Screen Navigation
10 332077D

Screen Navigation
332077D 11
Refer to Screen 1, page 22, for more details.

Screen Navigation
12 332077D
Refer to Screen 2, page 23, for more details.

Screen Navigation
332077D 13
Refer to Screen 3, page 23, for more details.

Screen Navigation
14 332077D
Refer to Screen 4, page 24, for more details.

Screen Navigation
332077D 15

Screen Identification
16 332077D
Screen Identification
Main Screen
This is the default screen that shows up when the machine is powered on. It shows the current state of the machine
and navigates to all screens related to setup and running.
Icon Description
Shows the current mode of the machine.
Navigates to the screen where the user can select the mode to run the machine.
Navigates to a screen showing:
• All pressures being monitored on the machine
• Grams remaining in the Cylinder
• The color injector spacing
• The next color injection point
Navigates to screens that allow configuration of the machine.
• Pressure Setpoints
• Refill Setpoints
• Pressure Thresholds for Alarms
• Color Injection Parameters

Screen Identification
332077D 17
Navigates to a screen allowing calibration of:
• Pressure Transducers
• Cylinder Linear Position Sensor
Navigates to a screen allowing the user to select if a condition is either a Warning (keeps
the machine running) or a Fault (stops dispensing).
Navigates to a screen showing the history of alarms that have occurred.
Navigates to a screen showing what IO is currently active.
Navigates to a screen showing the software part number and version installed on the
machine.
Icon Description

Screen Identification
18 332077D
Mode Select Screen
The Mode Select Screen is used for the following:
• Select the mode to operate the machine in.
• Turn color injectors on or off.
• Enable/Disable Frequency Fault Alarms.
Icon Description
Allows the machine to operate in a fully automatic mode. It waits for a signal from the press to begin
dispensing material. It will dispense as long as the “Screw Rotate Signal” is present and there is
material left in the cylinders. Once the cylinder reaches a pre-determined refill point, it will begin
refilling. The screw rotate signal must turn off first before the machine will check if it requires refill-
ing.
This Purges A-Material through the system by reloading only the “A” material. The purge process
continues as long as the “Screw Rotate Signal” is active.
NOTE: Before resuming normal operation using a mold, be sure to run enough material through the
unit in Auto Mode that it begins to cure.
This purges B-Material through the system by reloading only the “B” material. The purge process
continues as long as the “Screw Rotate Signal” is active.
NOTE: Before resuming normal operation using a mold, be sure to run enough material through the
unit in Auto Mode that it begins to cure.
Allows the operator to fully control the unit through the use of buttons on the operator interface.
“Outlets Closed” is the default state. It allows the valve to open during a “Manual Feed”. Toggling
the button to “Outlets Open” keeps the outlet valve open at all times - even during a refill.
The unit will refill the pump cylinders while this button is pressed. Letting go of the button mid-refill
will cause the machine to stop refilling.
Begins a Manual Feed cycle. This will continue until either the cylinder reaches the end, or a “Man-
ual Refill” is initiated.
Turns each injector On or Off.
Enables or disables frequency faults for the color injectors. It can also occur if the injector is activat-
ing faster than it could reload.
Enables or disables the cartridges to maintain the packing pressure before dispensing.

Screen Identification
332077D 19
Monitor Screen
The Monitor Screen shows the vitals of the system at a glance. It indicates how much material remains in the pump
and what pressures are in the system. If color injection is enabled, it shows the injection interval and when the next
injection will occur.
Icon Description
Amount of pressure in the Throat or Mix portion of the unit.
Shows the current mode of the machine.
Animation of the refill valve. The default color is red - indicating that it is closed. It turns green when
the valve is opened.
Indicates the pressure in each cylinder of the unit.
Indicates how much material is remaining in the cylinder
Indicates how many grams the unit will dispense between color injections.
Indicates the next time a color injection will be made. It corresponds with the readout indicating how
many grams remain in the cylinder.

Screen Identification
20 332077D
Alarm History Screen
Shows a history of the alarms generated by the unit.
System IO Screen
Shows what inputs and outputs are active on the unit.