Graco 1093 Manual instruction

3A0261K
EN
Setup - Operation
1053/1093
Control Box
Patented meter and dispense system for precise one-component micro-dispensing. Not
for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
CONTROL POWER

23A0261K
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification . . . . . . . . . . . . . . . . . . . . 6
Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve Connection Kits . . . . . . . . . . . . . . . . . . . . . . . 9
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Motor Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjust Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dispensing Operation . . . . . . . . . . . . . . . . . . . . . . 16
HMI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Screen Navigation Diagrams . . . . . . . . . . . . . . 17
Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Metering Valve Control Screen . . . . . . . . . . . . . 19
Shot Size Screen . . . . . . . . . . . . . . . . . . . . . . . 21
Level 1 Control Screen . . . . . . . . . . . . . . . . . . . 22
Level 2 Control Screen . . . . . . . . . . . . . . . . . . . 23
Purge Timer Screen . . . . . . . . . . . . . . . . . . . . . 25
Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor Status Screen . . . . . . . . . . . . . . . . . . . . . 28
Supervisor Screen . . . . . . . . . . . . . . . . . . . . . . 29
Supervisor Help Screen . . . . . . . . . . . . . . . . . . 31
Motor Error Codes Screen . . . . . . . . . . . . . . . . 32
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 33
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Customer Inputs/Outputs . . . . . . . . . . . . . . . . . . . 34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42

Related Manuals
3A0261K 3
Related Manuals
Component manuals in U.S. English.
Part Description
313566 Dispensit 1093
313812 Dispensit 1053-10B
334001 1053 Valve 24V Solenoid Replacement Kit,
Instructions
334002 1093 Valve 24V Solenoid Replacement Kit,
Instructions

Warnings
43A0261K
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 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
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 MSDS’s 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 impervious gloves when spraying or cleaning equipment.
• If this equipment is used with isocyanate material, see additional information on isocyanates in Iso-
cyanate Conditions Section of this manual.
PERSONAL PROTECTIVE EQUIPMENT
You 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, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
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.
• 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.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-
tric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only 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.

Warnings
3A0261K 5
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
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
component. See Technical Data in all equipment manuals.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual 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.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many
solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property
damage. See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s warnings.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
WARNING

Component Identification
63A0261K
Component Identification
Control Boxes
Power input/fuse holder, 81/0365-3/11, can be set to either 115V or 230V. To determine what voltage it is currently
set to, look at the port and read what is showing through the cover window. To switch voltage, open the fuse holder
cover with a small screwdriver, pull the fuse holder out, flip the fuse holder 180°, push the fuse holder back in, and
snap the fuse holder cover back into place.
NOTE: Fuse part number: V-21610P
120 V power cord part number: 81/1051-1/11
240 V power cord part number: 121054
FIG. 1: Motor Driven Control Box
Key:
A Emergency Stop
B Control Power Switch
C Touch Panel
D Alarm Speaker
E Power Input
F Start Options Connection
H A Tank Level Controls Connection
J B Tank Level Controls Connection
K Customer Signal Terminals
L Dispense Valve I/O Connection
M Foot Switch
U Motor Connection
E
D
F
H,J
L
U
K
B
A
C
M

Component Identification
3A0261K 7
Valve
FIG. 2: Valve
Key:
AA Motor Release Knob
AB Motor
AC Amplifiers Up/Home/Down
AD Prox-Photo Reflecting Sensor Up
AE Prox-Photo Reflecting Sensor Home
AF Prox-Photo Reflecting Sensor Down
AG Metering Rod Stroke
AA
AB
AC
AD, AE
AF
AG

Grounding
83A0261K
Grounding
This product must be grounded. In the event of an elec-
trical short circuit, grounding reduces the risk of electric
shock by providing an escape wire for the electric cur-
rent.
Grounding plug units: this product is equipped with a
cord having a grounding wire with an appropriate
grounding plug. The plug must be plugged into an outlet
that is properly installed and grounded in accordance
with all local codes and ordinances.
Hard-wired units: the grounding wire must be used. All
electrical wiring must be done by a qualified electrician
and comply with all local codes and regulations.
Air and fluid hoses: use only electrically conductive
hoses.
Fluid supply container: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a non-conductive sur-
face, such as paper or cardboard, which interrupts
grounding continuity.
Kits
NOTE: 80/2957-1/50 1053/1093 control requires three
sensor switches to operate. Valve, control, and connec-
tion kits are sold separately. Some assembly required.
Mounting adapter kit 24V674 may be required for
mounting the solenoid to the 1053 valve.
‡ Mounting side plate 01/2983/97 may be required for
mounting the solenoid to the 1093 valve.
Part Description
24E846Connection kit; for 1053 models that include
1 switch
24E845Connection kit; for 1053 models that include
2 switches, including the following assem-
blies:
A2A10007, A2A10008, A2A10009,
A2A10010, A2A10011, A2A1001,
A2A10015, A2A10016, A2A10018,
A2A10019, A2A10020, A2A10200,
A2A10300, A2A10301, A2A10302,
A2A10303, A2A10304, A2A10305,
A2A10306, A2A10307, A2A10308,
A2A10309
24E847‡ Connection kit; for 1093 models, including
the following assemblies:
A2A05401, A2A05402, A2A05403,
A2A05404, A2A05405, A2A05406

Valve Connection Kits
3A0261K 9
Valve Connection Kits
These valve connection kits enable certain valves to be used with this control package. Each kit contains the
mechanical, electrical, and pneumatic hardware needed to install the valve. See associated drawing for hardware
location and wiring information.
24E845, 1053 Dispense Valve with Added
Up and Down Validation/Actuation Kit
NOTE: PX-HOME must be below PX-UP. PX-HOME
may have been supplied in top hole. If so move to the
appropriate location as shown.
17
18,
3,
25
4, 5
24
27
27
2
26,
23
23
1
22
14, 15, 16
19,
20,
21
28
6
SOL-CSV
SOL-OSV
LS-CSV
LS-OSV
AMP-D
AMP-U
AMP-HOME
PG-2
PX-HOME
PX-D
PX-U

Valve Connection Kits
10 3A0261K
24E845 Electrical socket schematic
Ref Part Description Quantity
196/0098/99 SCREW, socket head, 10-24x1.50 2
216C798 PLATE, mounting, 1053, dsub, 15 pin 1
3ADM00022 COVER, connector, dsub, 15p, 45deg 1
481/0360-N/11 SCREW, jack, connector, dsub, type a 2
5B2050001 NUT, allen, 4-40, alloy 2
6297331 SCREW, cap, 4x1/4 2
14 81/1265/11 BRACKET, end 2
15 297639 SCREW, cap, button head 2
16 81/0283-DIN/11 RAIL, din 0.01
17 F0200075 CABLE, prox-photo 2
18 81/0378-2/25 STRAP, ground, ring, #10, 16ga 1
19 100166 NUT, full hex 1
20 96/0005-2/99 WASHER, lock, ext, #10 1
21 84/0130-25/11 LABEL, prot earth(grnd).375x.375 1
22 16D050 AMPLIFIER, 1chan, photo, pnp, 24vdc 2
23 94/0740-A/99 FITTING, elbow, swivel, 1/4tubex10-32 2
24 127629 VALVE, solenoid, 4 way, 3 position, 24V 1
25 82/0217-A/11 MUFFLER, air, 1/8 NPT 2
26 127632 SCREW, socket head, 4-40x1.00 2
27 94/0705-1/96 FITTING, elbow, swivel, 1/4 tube 3
28 17A412 WASHER, split, #4 2
WLDB(H
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Valve Connection Kits
3A0261K 11
24E846, 1053 Dispense Valve with Added
Up Validation/Actuation Kit
NOTE: PX-HOME must be below PX-UP. PX-HOME
may have been supplied in top hole. If so move to the
appropriate location as shown.
17
18, 3,
25
4, 5
24
27
27
2
26,
23
23
1
22
14, 15, 16
19,
20,
21
28
6
SOL-CSV
SOL-OSV
LS-CSV
LS-OSV
AMP-D
AMP-U
AMP-HOME
PG-2
PX-HOME
PX-D
PX-U

Valve Connection Kits
12 3A0261K
24E846 Electrical socket schematic
Ref Part Description Quantity
196/0098/99 SCREW, socket head, 10-24x1.50 2
216C798 PLATE, mounting, 1053, dsub, 15 pin 1
3ADM00022 COVER, connector, dsub, 15p, 45deg 1
481/0360-N/11 SCREW, jack, connector, dsub, type a 2
5B2050001 NUT, allen, 4-40, alloy 2
6297331 SCREW, cap, 4x1/4 2
14 81/1265/11 BRACKET, end 2
15 297639 SCREW, cap, button head 2
16 81/0283-DIN/11 RAIL, din 0.01
17 F0200075 CABLE, prox-photo 1
18 81/0378-2/25 STRAP, ground, ring, #10, 16ga 1
19 100166 NUT, full hex 1
20 96/0005-2/99 WASHER, lock, ext, #10 1
21 84/0130-25/11 LABEL, prot earth(grnd).375x.375 1
22 16D050 AMPLIFIER, 1chan, photo, pnp, 24vdc 1
23 94/0740-A/99 FITTING, elbow, swivel, 1/4tubex10-32 2
24 127629 VALVE, solenoid, 4 way, 3 position, 24V 1
25 82/0217-A/11 MUFFLER, air, 1/8 NPT 2
26 127632 SCREW, socket head, 4-40x1.00 2
27 94/0705-1/96 FITTING, elbow, swivel, 1/4 tube 3
28 17A412 WASHER, split, #4 2
%/$&. 5(' %/$&. 5('
%/. %/.
:+,7( :+,7( %52:1
%51
%52:1
%/8
%51 %/8 %/. %/8 %51 :+7 :+7 %51 %/. 5(' %/. 5(' *51
,1&/8'(':,7+%$6(9$/9(
%/8 %/8 %51
%/8
%51
+22.83)25)6:,7&+ ,1&/8'(':,7+%$6(9$/9( +22.83)2586:,7&+ ,1&/8'(':,7+%$6(9$/9(
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62/&69
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WLDB(H

Valve Connection Kits
3A0261K 13
24E847, 1093 Dispense Valve with Added
Actuation Kit
NOTE: PX-HOME must be below PX-UP. PX-HOME
may have been supplied in top hole. If so move to the
appropriate location as shown.
4, 5
6
27
3
24
18, 19, 20
25
21
26, 28
PX-HOME
PX-UP
PX-DOWN
LS-OSV
LS-CSV
SOL-CSV
SOL-OSV
PG-2

Valve Connection Kits
14 3A0261K
24E847 Electrical socket schematic
Ref Part Description Quantity
3ADM00022 COVER, connector, dsub, 15p, 45deg 1
481/0360-N/11 SCREW, jack, connector, dsub, type a 2
5B2050001 NUT, allen, 4-40, alloy 2
6297331 SCREW, cap, 4x1/4 2
18 81/0378-2/25 STRAP, ground, ring, #10, 16ga 1
19 100166 NUT, full hex 1
20 96/0005-2/99 WASHER, lock, ext, #10 1
21 84/0130-25/11 LABEL, prot earth(grnd).375x.375 1
24 127629 VALVE, solenoid, 4 way, 3 position, 24V 1
25 82/0217-A/11 MUFFLER, air, 1/8 NPT 2
26 127632 SCREW, socket head, 4-40x1.00 2
27 94/0705-1/96 FITTING, elbow, swivel, 1/4 tube 3
28 17A412 WASHER, split, #4 2
WLDB(H
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%/. %/.
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,1&/8'(':,7+%$6(9$/9(
%/. %/.
%51 %51
%/8

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

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Setup
3A0261K 15
Setup
Motor Driven
1. Connect Dispense Valve I/O, Start Options, and
Motor logic cables. If level controls are installed,
connect Level Controls logic cables.
2. Adjust customer supplied air pressure regulator to
80 psi (0.6 MPa, 6 bar).
3. Perform Setup procedure for dispense valve and
feed system components. See Related Manuals on
page 3.
Adjust Amplifier
The amplifier should be adjusted if:
• Debris or vibration changed the distance/axis
between the sensor and metering block (13).
• Replacing the sensor.
1. Navigate to the Motor Status screen.
2. Ensure the metering rod connection block (13) is
aligned with the sensor.
3. If the display shows a “0” for the sensor switch being
adjusted, increase the amplifier intensity adjustment
screw until the sensor switch display changes to “1”.
4. Repeat for each sensor switch installed on assem-
bly.
NOTICE
Feed system and main logic control system must
use separate air supplies.
VERIFYINCOMING VOLTAGE
BEFORECONNECTING POWER
WITHVOLTAGESWITCH SETTING
VALVEI/O MOTOR
3
24
1
AUDIO ALARM
STARTOPTIONS

Startup
16 3A0261K
Startup
NOTE: See HMI Operation starting on page 17 for
detailed HMI instructions.
1. Press the Control Power On button.
2. Navigate to the Metering Valve Control screen.
3. Press the Retract button.
NOTE: On Motor Driven models, when there is an
Emergency Stop condition or the system power is lost,
the shot selection resets to “0”. The operator must then
select a shot.
4. Navigate to the Supervisor screen.
5. Press the Valve Type selection button to select your
configuration.
6. Navigate to the Shot Size screen.
7. Select a shot number.
8. Navigate to the Metering Valve Control screen.
NOTE: Upon power up, “Error Code 130 Position Mod-
ule is not Enabled” will be shown. Press the Retract
(Home) button to allow the dispense valve metering rod
connecting block to move to the reload position.
9. Press the Shot button to select Shot Mode.
10. Verify air pressure is set to 80 psi (5.6 bar).
11. Perform feed system startup procedure(s). See
Related Manuals on page 3.
12. Perform dispense valve startup procedure. See
Related Manuals on page 3.
Dispensing Operation
NOTE: See HMI Operation on page 17 for detailed HMI
instructions.
The foot switch, the “Start” button, and the optional Cus-
tomer Start Signal can be used to initiate shots. These
are referred to as start devices.
Perform a Shot
1. Navigate to the Metering Valve Control screen.
2. Press the Retract button.
3. Press the Shot button to select Shot Mode.
4. Press and release the start device to perform one
shot.
Dispense Continuously
The valve dispenses continuously until the end of the
stroke is reached.
1. Navigate to the Metering Valve Control screen.
2. Under Metering Valve Control, press the Retract
button.
3. Press the Continuous button.
4. On Motor Driven models, press and hold the start
device to dispense continuously. Release the start
device to stop dispensing and retract the metering
rods.
Retract Piston
1. Navigate to the Metering Valve Control screen.
2. Under Metering Valve Control, press the Retract
button.
Extend Piston
1. Navigate to the Metering Valve Control screen.
2. Under Metering Valve Control, press the Extend
button.

HMI Operation
3A0261K 17
HMI Operation
Screen Navigation Diagrams
Motor Driven
FIG. 3
Main Screen
Metering Valve Control
Shot Size/Flow Rate
Level 1 Control Level 2 Control
Purge Timer
Status
Supervisor Supervisor Help
Motor Status Motor Error Codes

HMI Operation
18 3A0261K
Main Screen
NOTE: The Error Code button is shown on every screen
on the Motor Driven model.
Screen Access Buttons
All buttons on the main screen except for the Password
and Error Code buttons open a new specified screen.
For example, pressing the “Status” button opens the
Status screen.
Password
The password button enables the user to changes
values in certain screens.
To access the password press the Password Access
button (shown as “=0000”). When the keyboard appears
enter “5810” then press the Enter key.
Error Code
NOTE: The Error Code button is shown on every screen
On all screens that it is shown, the Error Code button
resets the error seen in the error string (shown as
“<0000000000”) and the error code number (shown as
“<000”). See the Motor Error Codes screen for more
information, page 32.

HMI Operation
3A0261K 19
Metering Valve Control Screen
NOTE: A “1” indicates that the button is in the “ON” posi-
tion. A “0” indicates that the button is in the “OFF” posi-
tion.
NOTE: The Error Code button is shown on every
screen. See the Main screen for definition.
Start button
When the Start button is pressed, the machine starts the
cycle for the selected Pump Mode.
Pump Mode
NOTE: The metering rods must be retracted prior to
changing any setting under Pump Mode. See Retract
Piston, page 16.
Retract Mode
The air cylinder and pumps immediately retract and
remain in the retracted position. This is used for mainte-
nance purposes only.
Extend Mode
The air cylinder and pumps immediately extend and
remain in the extended position. This position must be
selected when the pump is idle for a long period of time.
Shot Mode
The machine cycles the number of times displayed in
the Cycle Counter field when the start device is pressed
and released. The machine cycles continuously when
the start device is pressed and held.
Continuous (Operator Control) Mode
In this mode, the machine to dispense while the start
device is pressed. When the start device is released the
metering rods retract to the home position.

HMI Operation
20 3A0261K
DV Valve Mode
This mode actuates an optional dispense valve.
OPEN
In this mode, the dispense valve is held in the open
position, allowing material to pass through.
AUTO
In this mode, the dispense valve opens automatically
whenever the pump is cycled.
CLOSE
In this mode, the dispense valve is held closed.