Graco 25A693 User manual

Instructions
Intelligent Intelligent
IntelligentPaint Paint PaintKitchen Kitchen Kitchen3A4030C
EN
Used Used
Usedto to toremotely remotely remotelymonitor monitor monitorand and andcontrol control controlequipment equipment equipmentused used usedin in ina a apaint paint paintkitchen. kitchen. kitchen.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandallrelated
manualsbeforeusingtheequipment.Save Save
Savethese these theseinstructions. instructions. instructions.
TouchscreenBoxandSupervisorBox
componentsshown.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
ControlComponents.............................................2
ComponentManuals.............................................3
Warnings.............................................................4
IntelligentPaintKitchenOverview..........................7
InstallationandWiring.........................................25
SoftwareSetup...................................................44
TouchscreenSoftware........................................57
NetworkSetupandCon󰘰guration........................92
SetUptheEmailServer...............................94
CreateaPassword......................................95
Operation...........................................................97
EventsandLogs...............................................121
Troubleshooting................................................131
SystemSoftwareTasks....................................133
Repair..............................................................137
Parts................................................................140
KitsandAccessories.........................................143
Dimensions......................................................144
TechnicalSpeci󰘰cationsfortheTouchscreen
Box,SupervisorBox,andExpansion
Box....................................................146
AppendixA:SystemDesign..............................147
AppendixB:Cables..........................................150
AppendixC:ElectricalSchematics.....................151
AppendixD:Communication
Con󰘰guration......................................154
AllenBradleyPowerFlex.............................154
Mitusbishi..................................................157
AppendixE:NodeIDAssignments....................158
AppendixF:AgitatorPartNumbers....................159
AppendixG:UpdatetheIntelligentPaintKitchen
Software.............................................160
AppendixH:Master/ClientSetup.......................161
Con󰘰gureMultipleDisplays........................162
AtPowerUp..............................................163
DuringNormalOperation............................163
Control Control
ControlComponents Components Components
Thefollowingcomponentsaredescribedinthismanual.Forallothercomponents,seethespeci󰘰ccomponent
manual.
Part Part
Part
No. No.
No.Description Description
DescriptionUsage Usage
UsageOperating Operating
Operating
Voltage Voltage
VoltageApprovals Approvals
Approvals
25A693Touchscreen
Box
Usedtomonitorandcontrol
functionsofthepaintkitchen
componentslocatedinside
thehazardouslocation.The
operatorusestheTouchscreen
interfacetoviewandremotely
controlconditionsandsettings.
100–240VAC
25A830SupervisorBoxUsedtocommunicatebetween
thePumpControlModule,the
TankControlModule,Variable
FrequencyDrives/Inverters,and
theTouchscreenBox.Contains
thesoftwarecontrolsused
tomonitorandcontrolpaint
kitchencomponentsandsystem
performance.
100–240VAC
25A843ExpansionBoxOneormoreExpansionBoxes
areneededifthepaintkitchen
hasmorecomponentsthancan
󰘰tinsidetheSupervisorBox
25A830.
100–240VAC
9902741
ConformstoULSTD508A
Certi󰘰edtoCSASTDC22.2No.14
Notapprovedforuseinhazardous
locationsorexplosiveatmospheres.
23A4030C

ComponentManuals
Component Component
ComponentManuals Manuals Manuals
ThefollowingisalistofGracocomponentmanualswritteninEnglish.Thesemanualsandanyavailable
translationscanbefoundatwww.graco.com.
Manual Manual
ManualNo. No. No.Description Description
Description
333389E-Flo®DC2-BallPistonPumps
3A2096E-Flo®DC4-BallPistonPumps
3A3384E-Flo®DC4-BallPumps,SealedorwithOpenWetCup
3A3453E-Flo®DC2000,3000,and4000CirculationPumps
3A2526E-Flo®DCMotor
3A4409E-Flo®DCMotor,ThreePhase
3A2527E-Flo®DCControlModuleKit(PumpControlModule)
3A5991TankControlModuleKit
3A5753ReedSwitch(CycleCount)Kit
406421ProximitySensorAccessoryKit
311595PneumaticBackPressureRegulators
3A4548ElectricDrivenBack-GearDrumAgitators
3A4553ElectricDirectDriveAgitator
3A4793VariableFrequencyDrives
313542BeaconTower
Thefollowingcomponentmanualscanbefoundonthemanufacturer’swebsite.
Manual Manual
ManualNo. No. No.Description Description
Description
SV01N_13418587LenzeACTech,SMVector-FrequencyInverterOperatingInstructions
TI01000FEndress+HauserTechnicalInformation,Level󰘱exFMP50GuidedWaveRadar
3A4030C3

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.Seeyourcomponentmanualforwarningsthatarespeci󰘰c
tothosecomponents.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,intheworkareacanigniteorexplode.
Paintorsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰re
andexplosion:
•Useequipmentonlyinawell-ventilatedarea.
•Eliminateallignitionsourcessuchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayof󰘱ushsolventathighpressure.
•Keepworkareafreeofdebris,includingsolvent,rags,andgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintoapail.Donotusepailliners
unlesstheyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock,Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinawell-ventilatedarea.
•Donotoperateelectrostaticgunsintheequipmentworkarea.
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingorinstallingequipment.
•Connectonlytoagroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
43A4030C

Warnings
WARNING WARNING
WARNING
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromdispensingdevice,hoseleaks,orrupturedcomponentswillpierce
skin.Thismaylooklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Get
immediate immediate
immediatesurgical surgical surgicaltreatment. treatment. treatment.
•Engagetriggerlockwhennotdispensing.•
•Donotpointdispensingdeviceatanyoneoratanypartofthebody.
•Donotputyourhandoverthe󰘱uidoutlet.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopdispensingandbeforecleaning,
checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestaSafetyDataSheet(SDS)from
yourdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
3A4030C5

Warnings
WARNING WARNING
WARNING
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cut,oramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisequipmentincludes
butisnotlimitedto:
•Protectiveeyewearandhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
63A4030C

IntelligentPaintKitchenOverview
Intelligent Intelligent
IntelligentPaint Paint PaintKitchen Kitchen KitchenOverview Overview Overview
TheIntelligentPaintKitchen(alsoknownasIPK)isaplatformofcompatiblesensors,controllers,pumps,
agitators,andcommunicationcomponentsthatcanbecombinedtocreateacustomizedpaintcirculation
system.TheIntelligentPaintKitchencoverscomponentsthatareinstalledinsidetwotypesofphysical
space,hazardousandnon-hazardouslocations:
•The󰘱uidhandlingcomponentsandcontrolcomponentsarelocatedinoneormorehazardouslocations,
typicallyonestationforeachpaintcolor.
•Theremotemonitoringandcontrolcomponentsarelocatedinanon-hazardouslocation,upto1000feet
(330meters)awayfromthe󰘱uidhandlingcomponents.
Sensorscontinuouslymonitorconditionswithinthe󰘱uidcirculationsystem.Typicallydatasuchastanklevel,
agitatorspeed,pressureatoneormorelocations,and󰘱owrateiscollectedfromeachstationandsenttoa
PumpControlModule,whichisattachedtoeachagitatorandpump.ThePumpControlModuleandTank
ControlModuleallowlocalcontrolandprovideremotemonitoringandcontrolofcomponentsusingasingle
optical󰘰berconnection.SettingsprogrammedintotheSupervisorModuleandTouchscreenModuledisplay
thecurrentconditionsandallowuserstoadjusttheconditionsfromaremotelocation.
EachIntelligentPaintKitcheninstallationisunique.Stationcomponentsareselectedandsizedaccordingto
yourrequirements.Somecontrolsandsensorsareoptional,andanysystemcanbecon󰘰guredtoprovidethe
necessarycontrols,locallyandremotely.
3A4030C7

IntelligentPaintKitchenOverview
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
ThissectiondescribesthecomponentsinatypicalIntelligentPaintKitchensystemcontainingonestation.
Figure1IntelligentPaintKitchenSystemwithOne
FluidStation,OnePump,andTwoTanks(Typical
Installation)
Table Table
Table1 1 1Component Component ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Ref. Ref.
Ref.Component Component ComponentDescription Description
Description
ASupervisor
Box,page17
ContainsthecommunicationshubfortheIntelligentPaintKitchen.Itmustbeinstalled
inanon-hazardouslocation.
TheSupervisorBoxfacilitatescommunicationbetweenthePumpControlModule
(PD)inthehazardouslocationandtheTouchscreenBox(J)oraProgrammable
LogicController(alsoknownasPLC).TheSupervisorBoxconvertsinformationfrom
theGracoTouchscreenBox(J)orProgrammableLogicControllerinto󰘰beroptic
signalsusedbythesystemcomponents.
OneSupervisorBoxcancontrolupto10stations(20ifanExpansionBoxisused).
EachstationisconnectedtotheSupervisorBoxwithapairofoptical󰘰bercables.
BVariable
Frequency
Drive/In-
verter,page
16
Controlsthespeedofanelectricagitator.Itmustbeinstalledinanon-hazardous
location.
OneVariableFrequencyDrive/Inverterisneededforeachelectricagitator.The
VariableFrequencyDrive/InvertercommunicateswiththeSupervisorBox(A)usinga
RS-485cableconnection.
CE-FloDC
Pump,page
11
Anelectriccirculationpumpforuseinthehazardouslocation.Itcanbeasingleor
doubleE-FloDCpump.
ForIntelligentPaintKitchencommunication,thepumpmustbeanadvanced
modelwithaPumpControlModule(PD)andcommunicationcapabilityrequiredfor
connectiontotheSupervisorModule,locatedintheSupervisorBox(A).
83A4030C

IntelligentPaintKitchenOverview
Ref. Ref.
Ref.Component Component ComponentDescription Description
Description
EBack
Pressure
Regulator,
page13
Installedinthe󰘱uidreturnline.AlsoknownastheBPR,itiscontrolledpneumatically
tomaintain󰘱uidpressureinthe󰘱uidcirculationsystem.
FBack
Pressure
Regulator
Controller,
page13
AllowscontroloftheBackPressureRegulator(E),eitherlocallyusingthePump
ControlModule(PD)orremotelyusingtheTouchscreenBox(J).
GPrimaryTankProvides󰘱uidforthepaintkitchen.ThePrimaryTankiskept󰘰lledwithacontrolled
amountof󰘱uid,󰘰lledasneededfromtheSecondaryTank(H)andconstantlystirred
bytheAgitator(L).As󰘱uidispumpedthroughthepaintkitchen,󰘱uidiscontinuously
drawnfromandreturnedbacktothistank.
HSecondary
Tank
Containsthe󰘱uidusedto󰘰llthePrimaryTank(G)asneeded.Mustbemanually
re󰘰lledorreplacedwhenempty.ThetankordrummayhaveanAgitator(R)and
RadarLevelSensor(T)installedforcommunicationwiththeIntelligentPaintKitchen
software.
JTouchscreen
Box,page20
Auserinterfaceforsetup,operation,andmonitoringofsystemdevices.Itmustbe
installedinanon-hazardouslocation.
TheTouchscreenBoxcanbeconnectedtoaSupervisorBox(A).Itcommunicates
withtheSupervisorBoxusingModbusTCP.
KPressure
Transducers
(Sensors),
page12
OneortwoPressureTransducersmaybeinstalledtomeasurethepressureinside
thepaintkitchencirculationlines.EachPressureTransducercommunicateswiththe
SupervisorBox(A),whichmonitorsthepressureandcontrolstheE-FloDCPump(C)
tomaintainthe󰘱uidpressureofthe󰘱uidleavingthepump.ThePressureTransducer
canmonitorpressureatthepumpoutlet,attheBackPressureRegulator(E),orboth.
LAgitator
(Primary
Tank),page
15
Continuouslymixesandstirsthecontents,preventing󰘱uidfromseparating,setting,
ordryingontheinsideofthetank.ThisagitatorcanbeeitheraGracoelectricagitator
orauser-suppliedagitator.
Ifanelectricagitatorisused,anadditionalVariableFrequencyDrive/Inverter(B)
isneededtocontroltheagitatorspeed.
MRadarLevel
Sensor
(Primary
Tank),page
14
Detectsandcommunicatesthe󰘱uidlevelinthePrimaryTank(G).
NPneumatic
Remote
TransferFill
Pump
Air-operateddoublediaphragmpumpforuseinthehazardouslocation.Itspurpose
isto󰘰llthePrimaryTank(G)fromtheSecondaryTank(H),asneeded.
PFillPump
Transfer
Solenoid,
page15
ActivatesthePneumaticRemoteTransferFillPump(N)whenever󰘱uidinthePrimary
Tank(G)fallsbelowthelevelspeci󰘰edintheIntelligentPaintKitchensoftware.When
thePrimaryTankis󰘰lledtotheuser-speci󰘰edlevel,thepumpshutsoff.
PDPump
Control
Module,
page12
Intrinsicallysafecontrolmodulewithuserinterfaceforuseinthehazardouslocation.
OneisneededforeachE-FloDCpump(C).ThePumpControlModuleconnectsto
thepumpandpump-relatedcomponents.Itprovidesthecommunicationconnection
betweenthestationandtheSupervisorBox(A).ConnectstotheSupervisorBox
byapairof󰘰beropticcables.
3A4030C9

IntelligentPaintKitchenOverview
Ref. Ref.
Ref.Component Component ComponentDescription Description
Description
RAgitator
(Secondary
Tank),page
15
Continuouslymixesandstirsthecontents,preventing󰘱uidfromseparating,setting,
ordryingontheinsideofthetank.ThisagitatorcanbeeitheraGracoelectricagitator
orauser-suppliedagitator.
Ifanelectricagitatorisused,anadditionalVariableFrequencyDrive/Inverter(B)
isneededtocontroltheagitatorspeed.
SDCPower
SupplyWith
Barrier(user-
supplied)
PowerstheTankControlModule(TD).Itmustbeinstalledinanon-hazardous
location.
ElectricpowertoeachTankControlModulerequiresaseparatebarrier.
TRadarLevel
Sensor
(Secondary
Tank),page
14
Detectsandcommunicatesthe󰘱uidlevelintheSecondaryTank(H).
TDTankControl
Module,
page14
Intrinsicallysafecontrolmodulewithuserinterfaceforuseinthehazardouslocation.
OneisneededforeachSecondaryTank(H)thatusesanelectricagitator(R)or
RadarLevelSensor(T).TheTankControlModuleconnectstorelatedcomponents
inthehazardouslocationandtothePumpControlModule(PD),providinga
communicationconnectionbetweenthestationandtheSupervisorBox(A).
URun/Stop
Switch,page
13
Wheninstalled,stopsorpausestheE-FloDCPump(C)duringoperation.The
Run/StopSwitchdoesnotdisconnectpowertothepump,butitdoesstoporpause
thepump.
XReedSwitch
(notshown),
page13
EnsuresthatthePrimaryTank(G)doesnotgetover󰘰lled.IfthePneumaticRemote
TransferFillPump(N)isrunningbutthe󰘱uidlevelinthePrimaryTankisnot
changing,theReedSwitchsignalcausestheIntelligentPaintKitchensoftwareto
shutdownthepump.
—Expansion
Box(not
shown),page
19
Providesroomforextraserialto󰘰beropticconverters,oncethemainSupervisorBox
(A)isfull.Itmustbeinstalledinanon-hazardouslocation.
TheExpansionBoxcanholdanadditional12󰘰beropticconverters.
103A4030C

IntelligentPaintKitchenOverview
E E
E- - -Flo Flo FloDC DC DCPump Pump Pump(C) (C) (C)
EachstationcancontainoneE-FloDCpump(C).
Thepump’sjobistocontinuouslycirculateaspeci󰘰c
paintcolorthroughthepaintkitchen,makingthat
coloravailableforspraying.EachE-FloDCpump
maintainsaconstant󰘱uidpressureor󰘱owratewithin
thesystem.
Pumppressuresensorsand󰘱owsensorsconnect
tothePumpControlModule(PD).Eachpumpcan
belocallycontrolledusingitsPumpControlModule.
SeePumpControlModule(PD)24P822,17V232,
page12.
TosetupconnectionstotheE-Flopump,see
ConnectionstotheE-FloDCPump,page26.For
completewarningsandoperationinstructions,see
thefollowingmanuals:
•E-FloDC2-BallPistonPumpmanual333389
•E-FloDC4–BallPistonPumpmanual3A2096
•E-FloDC4–BallPumpmanual3A3384
Figure2E-FloDCPumpwithPumpControlModule
Figure3E-FloDC2000,3000,or4000HighVolume
PumpwithPumpControlModule
3A4030C11

IntelligentPaintKitchenOverview
Pump Pump
PumpControl Control ControlModule Module Module(PD) (PD) (PD)
24P822, 24P822,
24P822,17V232 17V232 17V232
ThePumpControlModule(PD)isaModbusRTU
nodeinthestation.EachPumpControlModuleis
wiredusingapairof󰘰beropticcablestoa󰘰beroptic
converterinstalledinsideaSupervisorBox(A).
Allcommunicationsbetweencomponentsonthe
non-hazardouslocationandthehazardouslocation
sidespasstoorfromthePumpControlModulealong
the󰘰beropticconnection.
ThePumpControlModuleservesastheconnection
pointandpowersourceforotherpaintkitchen
components,includingtheRadarLevelSensor
(M,T),FillPumpTransferSolenoid(P),andBack
PressureRegulatorController(F).
PowertothePumpControlModuleissuppliedby
theE-FloDCpump(C).EachPumpControlModule
hasitsownsoftwareinstalledtosendinstructions
fromtheIntelligentPaintKitchensoftwaretothe
connectedcomponents,andtosendsignalsfrom
thosecomponentsbacktotheIntelligentPaint
Kitchensoftware.
Figure4PumpControlModule
Forinformationonconnectingcablestothecorrect
portsforpumpcontrol,seethecableconnection
sectionoftheDCControlModuleKitmanual3A2527
andSetUpPumpControlModuleCon󰘰gurable
I/O,page49inthismanual.SeetheDCControl
ModuleKitmanual3A2527forcompletewarnings
andoperationinstructions.
Pressure Pressure
PressureTransducer Transducer Transducer(K) (K) (K)
24R050, 24R050,
24R050,24X089 24X089 24X089
InstallthePressureTransducer(K)usingoneofthe
followingkits:
•24R050:PressureTransducer,NPT
•24X089:PressureTransducer,InlineTri-Clamp
1.Tomeasure󰘱uidpressure,installthePressure
Transducerinthe󰘱uidlinewithatee󰘰tting.
•IfclosedloopcontrolisenabledonSetup
Screen8(transducer1)orSetupScreen9
(transducer2),installthetransducernearthe
pumpoutlet,notneartheendofthecirculation
line.
•IfclosedloopcontrolisnotenabledonSetup
Screen8(transducer1)orSetupScreen9
(transducer2),installthetransducerwhere
needed.
2.ConnectthetransducercabletoPort7
(transducer1)orPort10(transducer2)onthe
PumpControlModule(PD)orTankControl
Module(TD).
123A4030C

IntelligentPaintKitchenOverview
Back Back
BackPressure Pressure PressureRegulator Regulator Regulator(E) (E) (E)
and and
andController Controller Controller(F) (F) (F)
24V001 24V001
24V001
PaintreturningtothePrimaryTank(G)passes
throughthepneumaticBackPressureRegulator(E),
whichmaintainsthepressureinthepaintcirculation
system.
Thepressuresettingiscontrolledusingthepro󰘰le
settinginthePumpControlModule(PD).TheBack
PressureRegulatorsettingcanchangeautomatically
wheneveradifferentpumppro󰘰leisselected.
InstallaBackPressureRegulatorController24V001
(F)inthehazardouslocationtoprovideintrinsically
safecontrolofthebackpressureregulator.TheBack
PressureRegulatorControllerautomaticallycontrols
inputairpressuretomaintainthe󰘱uidsystemback
pressureasspeci󰘰edinthepumpcontrolsoftware.
SignalstoandfromtheBackPressureRegulator
ControllerpassthroughthePumpControlModule,
allowingforclosedlooppressurecontrolinthe
circulationline.Forcompletewarningsandoperation
instructions,seethePneumaticBackPressure
Regulatormanual311595.
Figure5BackPressureRegulatorandController
Run/Stop Run/Stop
Run/StopSwitch Switch Switch(U) (U) (U)
16U729 16U729
16U729
InstalltheRun/StopSwitch(U)usingtheRun/Stop
SwitchKit16U729.
1.MounttheswitchnearthePumpControlModule
(PD),usingthebracketprovided.
2.ConnecttheswitchcabletoPort4onthePump
ControlModule(PD).
Forcompletewarningsandoperationinstructions,
seetheE-FloDCControlModuleKitmanual3A2527.
Reed Reed
ReedSwitch Switch Switch(X) (X) (X)
17W772, 17W772,
17W772,241405 241405 241405
InstalltheReedSwitch(X).
•ForHusky515and716models,useReedSwitch
(CycleCount)Kit241405.Forcompletewarnings
andoperationinstructions,seetheProximity
SensorAccessoryKitmanual406421.
•ForHusky1050models,useReedSwitch(Cycle
Count)Kit17W772.Forcompletewarningsand
operationinstructions,seetheReedSwitch(Cycle
Count)Kitmanual3A5753.
3A4030C13

IntelligentPaintKitchenOverview
Tank Tank
TankControl Control ControlModule Module Module(TD) (TD) (TD)
17S843 17S843
17S843
ATankControlModule(TD)isneededforastation
thathasaSecondaryTank(H)withlevelmonitoring.
TheTankControlModuledoesthefollowing:
•ProvidestheelectricalpowerandtheI/O
connectionsneededtooperatetwotankRadar
LevelSensors(M,T),agitatorspeeds,andtransfer
pumplogic
•Monitorsandprovidesrealtimetanklevel
informationtotheIntelligentPaintKitchensoftware
•Controlsagitatormotorspeed
•TurnstheFillPumpTransferSolenoid(P)onand
offtokeepthePrimaryTank(G)󰘰lledtothecorrect
level
ElectricalpowertotheTankControlModulecomes
fromtheDCPowerSupplywithBarrier(S)locatedin
thenon-hazardouslocation.
Withinapaintkitchen,theTankControlModule
isconnecteddirectlytothePumpControlModule
(PD)withapairof󰘰beropticcables.Allsignalsto
andfromtheTankControlModulepassthrough
thePumpControlModule.ATankControlModule
isneededinasystemthathasnoPumpControl
Module.ConnecttheTankControlModuletoa󰘰ber
opticconverterintheSupervisorBox(A).
NOTE: NOTE:
NOTE:ThePumpControlModuleandTankControl
Modulelookidenticaltoeachother,buttheyarenot
interchangeable.Eachtypeofcontrolmodulehasits
ownuniquesoftwareinstalled.
Figure6TankControlModule
Forcompletewarningsandoperationinstructions,
seetheTankControlModulemanual3A5991.
Radar Radar
RadarLevel Level LevelSensor Sensor Sensor(M, (M, (M,T) T) T)
25D293, 25D293,
25D293,25D294 25D294 25D294
ARadarLevelSensor(M,T)isusedtomonitorthe
levelofmaterialinsidethetank.
•25D293-ContainsanEndress+Hauser™
FMP50™wave-guidedradarsensorwithFM
approval.
•25D294-ContainsanEndress+Hauser™
FMP50™wave-guidedradarsensorwithATEX
andIECExapproval.
Forcompletewarnings,approvals,andoperation
instructions,seethemanufacturer’smanual
(supplied).
Adigitaldisplayallowsthecurrentleveltoberead
locally.
SuitableRadarLevelSensorsmaybeobtainedfrom
variousmanufacturers.
TheRadarLevelSensorsoftwarecommunicates
tankleveldatatothePumpControlModule(PD)or
TankControlModule(TD),whichcanbesettoturn
onthePneumaticRemoteTransferFillPump(N)to
re󰘰llthetankwhenneeded.
Figure7RadarLevelSensor
143A4030C

IntelligentPaintKitchenOverview
Fill Fill
FillPump Pump PumpTransfer Transfer TransferSolenoid Solenoid Solenoid(P) (P) (P)
24Z671 24Z671
24Z671
TheFillPumpTransferSolenoid(P)engagesthe
PneumaticRemoteTransferFillPump(N)when
the󰘱uidlevelinthePrimaryTank(G)fallsbelowa
user-speci󰘰edlevel.Thesolenoiddisengagesthe
pumpwhenthe󰘱uidlevelrisestoauser-speci󰘰ed
level.
TheFillPumpTransferSolenoidcontainsaMAC™
valvethatcarriesFM,ATEX,andIECExapprovals.
Connections: Connections:
Connections:
•Theairinletconnectstoauser-providedsource
ofairpressure.
•TheairoutletconnectstothePneumaticRemote
TransferFillPump.
Agitator Agitator
Agitator(L, (L, (L,R) R) R)
Oneagitator(L,R)istypicallymountedoneachtank.
Theagitator’spurposeistokeepthe󰘱uidmixed,
withoutincorporatingairintothe󰘱uid.
Eachagitatormaybeelectricorpneumatic;however,
theIntelligentPaintKitchensystemcanonly
communicatewithanelectricagitator.
Anelectricagitator’sspeediscontrolledbya
VariableFrequencyDrive/Inverter(B).Every
VariableFrequencyDrive/Inverterismountedin
thenon-hazardouslocation,buttheIntelligentPaint
Kitchensystemallowsthespeedtobecontrolled
locallywiththePumpControlModule(PD)orthe
TankControlModule(TD).Forcompletewarnings
andoperationinstructions,seetheagitatormanual.
Figure8Agitator(electricdirectdriveandback-gear
modelsshown)
3A4030C15

IntelligentPaintKitchenOverview
Variable Variable
VariableFrequency Frequency FrequencyDrive/Inverter Drive/Inverter Drive/Inverter(B) (B) (B)
17N041, 17N041,
17N041,17N042, 17N042, 17N042,17N043 17N043 17N043
TheVariableFrequencyDrive/Inverter(B)controls
thespeedofanACelectricagitator.Suitable
VariableFrequencyDrives/Invertersmaybeobtained
fromGracoorfromavarietyofmanufacturers.
SupportedVariableFrequencyDrive/Inverter
manufacturersincludeLenzeSMVectorandAllen
BradleyPowerFlex4M.
Model Model
ModelInput Input InputOutput Output
OutputHP HP
HP
17N041120–240VAC
(singlephase)
240VAC
(threephase)
1
17N042208–240VAC
(singleorthree
phase)
208–240VAC
(threephase)
1
17N043380–480VAC
(threephase)
380–480VAC
(threephase)
1
OneVariableFrequencyDrive/Inverterisneeded
foreachelectricagitatorinthesystem.Software
installedineachVariableFrequencyDrive/Inverter
allowscommunicationbetweeneachVariable
FrequencyDrive/InverterandtheSupervisorBox
(A).Warnings,installation,andoperationdetails
arecontainedintheprovidedVariableFrequency
Drive/Invertermanual.
VariableFrequencyDrives/Invertersarenot
approvedforuseinhazardouslocations.Theymust
beinstalledinthenon-hazardouslocationofthe
IntelligentPaintKitchen.Forcompletewarningsand
operationinstructions,seetheVariableFrequency
Drivesmanual3A4793.
Figure9VariableFrequencyDrive/Inverter
163A4030C

IntelligentPaintKitchenOverview
Supervisor Supervisor
SupervisorBox Box Box(A) (A) (A)
25A830 25A830
25A830
Asshipped,theSupervisorBox(A)containsthe
SupervisorModule(36),powersupply,switch,
Ethernetswitch,andone󰘰beropticconverter.Install
additional󰘰beropticconvertersasneeded,onefor
eachstation.
InstalledinsideeachSupervisorBox,theSupervisor
Modulecontainsthesoftwarethatrunsthe
IntelligentPaintKitchen.TheSupervisorModule
communicateswithPumpControlModules(PD),
TankControlModules(TD),andVariableFrequency
Drives/Inverters(B)usingModbusRTU.The
SupervisorModulesetsupaModbusaddressing
datatabletocreatealargedatamapwitheachnode
slottedinaspeci󰘰csetofaddresses.
TheSupervisorBoxcancommunicateviaModbus
TCPwiththeTouchscreenBox(J).
TheSupervisorModulecanmanageupto20
stations.Upto10󰘰beropticconverterscan󰘰tinthe
SupervisorBox.Ifadditional󰘰beropticconverters
areneededbeyondwhat󰘰tsintheSupervisorBox,
anExpansionBoxcanbeusedtocreatemorespace.
SeeExpansionBox25A843,page19.
Figure10SupervisorBoxComponents
Ref Ref
RefFunction Function
Function
2PowerRockerSwitch
7aEMCGroundTerminal
7bProtectiveEarthGroundTerminal
34PowerLineFilter
35PowerSupplyUnit,2amp,24VDC
36SupervisorModule
37Ethernet,eightportswitch
38SerialtoFiberOpticConverter,page18
45StrainRelief
56TerminalBlock
EC3EthernetConnector1(network
connection)
EC4EthernetConnector2(connectto
TouchscreenBox)
3A4030C17

IntelligentPaintKitchenOverview
Fiber Fiber
FiberOptic Optic OpticConverter Converter Converter
24N978 24N978
24N978
InstalledinsidetheSupervisorBox(A)andthe
ExpansionBox,eachserialto󰘰beropticconverter
sendsdatatoandreceivesdatafromonePump
ControlModule(PD)installedinthehazardous
locationofastation.
DataissenttoandfromthePumpControlModule
(PD)alonga󰘰beropticcable.Aserialcable
connectionismadebetweeneach󰘰beroptic
converterandtheSupervisorModule,andthe󰘰ber
opticconverterswithinoneSupervisorBoxorone
ExpansionBoxareallwiredinseriestothe24VDC
powersupply.
Figure11SerialtoFiberOpticConverter
Item Item
ItemDescription Description Description
39Serialcommunicationconnectionto
SupervisorModule
4024VDCpowerconnection
RXFiberopticcableconnection;receives
datafromaPumpControlModule
TXFiberopticcableconnection;transmits
datatoaPumpControlModule
AGround
BTerminalDataB(+)
CTerminalDataA(-)
DTerminalD(notused)
ETerminalE(notused)
183A4030C

IntelligentPaintKitchenOverview
Expansion Expansion
ExpansionBox Box Box
25A843 25A843
25A843
UseanExpansionBoxwhenyoursystemrequires
more󰘰beropticconvertersthancan󰘰tinthe
SupervisorBox(A).EachSupervisorBoxmaybe
connecteddirectlytooneExpansionBoxtoconnect
toamaximumof20stations(7or10󰘰beroptic
convertersintheSupervisorBox,andupto12󰘰ber
opticconvertersintheExpansionBox).
TheExpansionBoxhasaDCpowersupplyinstalled
toprovidepowertothe󰘰beropticconverters.
ExpansionBoxesareshippedwithone󰘰beroptic
converter(38)installed.Eachboxalsocontainsone
powersupply(35),andoneSupervisorModule(36).
Installupto12󰘰bertoopticconverters(38)ineach
ExpansionBoxneededbythesystem.
Figure12ExpansionBoxComponents
Ref Ref
RefFunction Function
Function
2Powerrockerswitch
7aEMCgroundterminal
7bProtectiveearthgroundterminal
34Powerline󰘰lter
35Powersupplyunit,2amp,24VDC
38Serialto󰘰beropticconverter
45Strainrelief
56TerminalBlock
3A4030C19

IntelligentPaintKitchenOverview
Touchscreen Touchscreen
TouchscreenBox Box Box(J) (J) (J)
25A693 25A693
25A693
TheTouchscreenBox(J)isanoptionalcomponent
intheIntelligentPaintKitchen.TheTouchscreenBox
allowstheusertodothefollowingremotely:
•Setupthesystembeforeuseandcon󰘰gurethe
paintkitchencomponentstocommunicatewith
eachother
•Displaycurrentpaintkitchenconditionsand
settingsforremotemonitoringandcontrol
•Controlpaintkitchencomponentsandchange
operatingconditions
A2GBSD󰘱ashcardcanbeusedtoinstalland
updatethesoftwareusedbytheTouchscreenBox.
TheSDcardmustbeformattedusingtheFAT16󰘰le
system.
AUSBcablecanbeconnectedtodownloadthe
storedlog󰘰lesgeneratedbytheIntelligentPaint
Kitchensystem.
Figure13TouchscreenBoxComponents
Ref Ref
RefFunction Function
Function
2Powerrockerswitch
7bProtectiveearthgroundterminal
8Powersupply,24VDC
14Touchscreencontrolmodule
56Terminalblock
EC1Ethernetconnector1–networkconnection
EC2Ethernetconnector2–connecttoSupervisorBox
USB1USBcableforPC
USB2USBjumpdrive
203A4030C