Graco BDS Operation manual

309279
Rev. A
First choice when
quality counts.t
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Batch Dispense System
Proportioning Controller
Model No. BDS, Series E
250 psi (1.7 MPa, 17 bar) Maximum Incoming Fluid Pressure
125 psi (0.9 MPa, 9 bar) Maximum Incoming Air Pressure
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 2001, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Parts

2 309279
Table of Contents
Conventions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Controls And Indicators 6. . . . . . . . . . . . .
How The Batch Dispense Systems Works 7. . . . .
Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before beginning... 11. . . . . . . . . . . . . . . . . . . . . . . . .
Select the System Location 11. . . . . . . . . . . . . . . . .
Install the Fluid Supply 12. . . . . . . . . . . . . . . . . . . . .
Connect the Electrical Supply 13. . . . . . . . . . . . . . .
Ground the System 13. . . . . . . . . . . . . . . . . . . . . . . .
Check the Resistance 14. . . . . . . . . . . . . . . . . . . . . .
Connect Other Wiring 14. . . . . . . . . . . . . . . . . . . . . .
Before Beginning Operation 15. . . . . . . . . . . . . . . . .
Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 16. . . . . . . . . . . . . . . . . .
System Pressure 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Startup Sequence 17. . . . . . . . . . . . . . . . . . . .
Purging 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Recipe 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Operating Screen 19. . . . . . . . . . . . . . . . . . . . .
Password Screen (optional) 19. . . . . . . . . . . . . . . . .
User Selectable Screen (optional) 19. . . . . . . . . . .
Recipe Selection Screen 19. . . . . . . . . . . . . . . . . . .
View Recipe Screen 20. . . . . . . . . . . . . . . . . . . . . . .
Quantity Screen 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Recipe Status Screen 21. . . . . . . . . . . . . . . . . . . . . .
Manual Dispense Screen 21. . . . . . . . . . . . . . . . . . .
Dispense Complete Screen 21. . . . . . . . . . . . . . . . .
Manual Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Operating Screen 22. . . . . . . . . . . . . . . . . . . . .
Manual Control Screen 22. . . . . . . . . . . . . . . . . . . . .
Valve Air Pressure Screen 22. . . . . . . . . . . . . . . . . .
Scale Setup 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Screen 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarms 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Over Dispense Alarm 25. . . . . . . . . . . . . . . . . . . . . .
Under Dispense Alarm 25. . . . . . . . . . . . . . . . . . . . .
Time Out Alarm 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
No Scale Input Alarm 25. . . . . . . . . . . . . . . . . . . . . .
Setup 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Setup Menu Screen 26. . . . . . . . . . . . . . . . . . .
Initial Setup 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Setup 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To add new employees or edit existing
employee entries 27. . . . . . . . . . . . . . . . . . . . . . .
To set measurement units: 29. . . . . . . . . . . . . . . . . .
To edit User Screen #1: 30. . . . . . . . . . . . . . . . . . . .
To add or edit description for User Screen #1: 31.
To edit User Screen #2: 32. . . . . . . . . . . . . . . . . . . .
To add or edit description for User Screen #2: 33.
To edit User Screen #3: 34. . . . . . . . . . . . . . . . . . . .
To add or edit description for User Screen #3: 35.
Edit Valve Parameters 36. . . . . . . . . . . . . . . . . . . . . .
Add Valve 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Add Recipe 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edit Existing Recipe 42. . . . . . . . . . . . . . . . . . . . . . . .
Reports 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To generate a Batch Report: 44. . . . . . . . . . . . . . . .
To generate a Valve Report: 46. . . . . . . . . . . . . . . . .
Screen Maps 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Recipe Screens 47. . . . . . . . . . . . . . . . . . . . . . .
Edit and Add Recipe Screens 48. . . . . . . . . . . . . . .
Edit and Add Valve Screens 49. . . . . . . . . . . . . . . . .
System Setup and Reporting Screens 50. . . . . . . .
Clean Screen, Manual Control, Alarm, and Scale
Setup Screens 51. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X-Purge Option 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Display Indicators 61. . . . . . . . . . . . . . . . . . . . .
Rapid Exchanger Timer Functions 62. . . . . . . . . . .
Rapid Exchanger Timer Settings 62. . . . . . . . . . . . .
Setup Procedure 63. . . . . . . . . . . . . . . . . . . . . . . . . .
Important Notes: 63. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rapid Exchanger Purging Setup 64. . . . . . . . . . . . .
Rapid Exchanger Purging Operation 65. . . . . . . . .
Troubleshooting 66. . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 68. . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 68. . . . . . . . . . . . . . . . . . . . . . . .

309279 3
Conventions
The following conventions are used in this manual to
help guide you through the information.
DWhen you are instructed to “Press” something, this
usually refers to pressing your finger on the Batch
Dispense System’s touch screen to select an item
or initiate an action.
DBold text in a sentence indicates a button or text
on the screen that you can press to make a selec-
tion or carry out an action. For example, “Press
Run Recipe on the Main Operating Screen.”
Bold text may also be used for emphasis.
DItalicized text shown on a screen diagram or in the
text indicates the text may vary according to how
the system parameters have been configured. For
example, the units of measure shown in the manual
may be gallons. The units you see on the screen-
may be liters, quarts, or cubic centimeters.
DNOTE: is used to call your attention to additional
helpful information.
DNumbers and letters in parentheses in the text,
such as (A) or (7), refer to reference numbers and
letters in the figures. Numbers in parentheses may
also indicate metric conversions of units of mea-
sure.

4 309279
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
FIRE EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
DThe Batch Dispense System Controller must only be installed and serviced by a qualified electrician.
DThe controller is designed for use in a non-hazardous location as defined in the National Electrical
Code (USA). To install the Batch Dispense equipment in a Class 1, Division 1, Group C and D
environment, the X-purge option must be properly installed. Follow the instructions on pages 60–66.
DGround the equipment and dispense only into grounded, conductive containers. See Ground the
System on page 9.
DIf there is any static sparking while using the equipment, stop dispensing immediately. Identify
and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or material.
DDo not smoke in the dispense area.
DExtinguish all open flames or pilot lights in the dispense area.
DKeep the dispense area free of debris, including solvent, rags and gasoline.
DDo not operate a gasoline engine in the dispense area.
DKeep liquids away from the electrical components.
DDisconnect electrical power at the main switch before servicing the equipment.
DThe battery inside the Batch Dispense System Controller may explode if mishandled, which could
cause serious injury and property damage. Do not recharge or disassemble the battery. Do not
expose the battery to fire or heat. The battery is intended for use at normal temperatures, where
high temperature cycles are not expected to exceed 212_F (100_C).
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
DKnow the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
DStore hazardous fluid in an approved container. Dispose of the hazardous fluid according to all local,
state, and national guidelines.
DWear appropriate protective clothing, gloves, eyewear, and respirator.

309279 5
WARNING
PRESSURIZED EQUIPMENT HAZARD
Fluid from the dispense valves, hose leaks, or ruptured components can splash fluid in the eyes or on
the skin and cause serious injury.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DFollow the Pressure Relief Procedure on page 16 whenever you: are instructed to relieve the pres-
sure; stop dispensing; clean, check, or service the equipment; and install or clean the valve tip.
DTighten all the fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. See the
instruction manuals of the individual Batch Dispense System components for their maximum work-
ing pressures.
DRoute the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
DDo not use the hoses to pull the equipment.
DDo not move pressurized equipment.
DUse fluids or solvents that are compatible with the equipment wetted parts. See the Technical Data
section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DComply with all applicable local, state, and national fire, electrical and safety regulations.

6 309279
Introduction
Operator Controls And
Indicators
See figure 1 on page 7.
Operator Controls
All the Batch Dispense System’s (BDS) operator
controls are on the door of the main cabinet. The
power switch (47) turns all power to the cabinet on or
off.
Pressing in the emergency stop (E-stop) button (7)
turns off all electrical and pneumatic outputs. During
normal operation, the E-stop button is pulled to the
“out”position.
Scale Platform
The scale platform (B) is typically located at the base
of the BDS. The platform surfaces are stainless steel
for easy cleaning. There are no operator controls on
the scale itself.
Display
The display (A) provides the operator interface for the
the Batch Dispense System. The display is a 10.4”
(264 mm) VGA 640 x 480 TFT Screen with Analog
Resistive touch input. The touch screen allows the
operator to access all necessary screens to run, edit
and add a recipe, edit valve parameters, perform scale
calibration, edit machine setup parameters, and man-
age reports by pressing selections displayed on the
screen.
Main Operating Screen
The Main Operating Screen has buttons that can be
pressed to access the following functions:
Run RecipeĊto dispense a recipe in automatic
mode.
Manual CntrlĊto dispense material manually.
SetupĊto configure the system setup (including
passwords, units of measure, and user screens), add
and configure recipes and valves, and view and print
reports.
Scale SetupĊto select and calibrate the scale.
Clean ScreenĊto inactivate the touch screen to
clean it.
BATCH
DISPENSE
SYSTEM
Run Recipe Setup Clean Screen
Manual Cntl Scale Setup Exit
Main Operating Screen
Screen Navigation
The BDS screens have one or more of the following
elements to use to access or enter information:
DButton: press to access another screen.
DArrow: press to view a list of options.
DText Box: press to activate the box and place the
cursor in it so you can type information.
NOTE: You can press the Tab key on your keyboard to
move the cursor to the next field on the screen.
Valve Type:
Select a Valve Name or Valve Number to Edit Parameters
2
Valve #: Valve Name: Green
Valve #:
Unit of Measure:
Specific Gravity:
Dispense Tolerance%:
VOC Content lbs/Gal:
Drop Time (milliseconds):
Circulate Interval (minutes):
Circulate Duration (minutes):
Valve Name:
Maximum Flow Rate:
Add New Return to Main Menu
Minimum Flow Rate:
Automatic
Green
1
Pounds
0.959
5
7
5
2
10
25
5.23
Arrow
Text
Box
Button

309279 7
Introduction
How The Batch Dispense
Systems Works
Usage
The standard BDS can proportion most two, three or
more component epoxy or polyurethane paints, sol-
vents, inks and a variety of other materials. Depending
on the model selected, up to 20 different fluids (compo-
nents) can be dispensed automatically, and any num-
ber of other materials (liquids, powders, etc.) can be
added manually. The BDS is not for use with “quick–
setting”paints (those with a pot life of less than 15
minutes).
Fluid Supply
The system can be set up to dispense components
supplied from pressure tanks or feed pumps. The
materials can be transferred from their original contain-
ers or from central paint recirculating lines. Each
component material is supplied separately to the BDS
unit. The standard BDS is designed to accurately
dispense batches of 0.6 quarts (0.57 liters) to 55
gallons (208 liters), at average maximum flow rates of
1 GPM (3.8 LPM).
Controller Start Up Sequence
To turn on the BDS, turn the power switch (47) to ON
and make sure the E-stop button (7) is not depressed.
See figure 1. The controller (29) start up sequence
may take up to 5 minutes. The projects and all self
diagnostics are performed during this time. Please wait
for the Main Operating Screen to appear on the Indus-
trial PC (A) before doing anything else with the control-
ler. Any selections made on the screen during start up
may interfere with the process and cause inaccurate
dispenses.
NOTE: If a password is requested during the initial
startup and system configuration, the system is
shipped with “P”as the password.
Figure 1 –Batch Dispense System (BDS)
TI0709
7
47
29
A
B

8 309279
Introduction
Operating Cycle
NOTE: See page 19 for full sequence of Run screens.
1. To begin operation, the operator presses Run
Recipe on the Main Operating Screen.
BATCH
DISPENSE
SYSTEM
Run Recipe Setup Clean Screen
Manual Cntl Scale Setup Exit
2. If a password is required, it would be entered next.
3. Two more optional screens may appear which
require the operator to select tracking information
from drop down lists.
4. The operator selects the desired recipe to run. The
selection can be made using the recipe number or
the recipe name. The recipe can be viewed to
verify it is the correct recipe or the operator can
select to run the recipe.
Select Recipe to Load
View Recipe
Recipe # Recipe Name
Run Recipe Main Menu
Current Recipe Selection
Recipe E
Recipe Name
5. The operator enters the dispense quantity. The
number entered will be in the units of measure that
were selected during setup.
Enter quantity of units to dispense
Continue Main Menu
6. By selecting to continue on the next two screens,
the operator is verifying that the scale was cleared
and cleaned off and that a container of the correct
size has been placed on the scale.
7. The Recipe Status Screen shows the operator
which step of the recipe is currently running.
Recipe Name Recipe # Amount
Abort
Batch Hold
Batch
Resume
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Step 10
Step 11
Step 12
Step 13
Step 14
Step 15

309279 9
Introduction
8. If a manual dispense is required, the operator is
prompted for the correct amount to dispense.
When the manual dispense is complete, the opera-
tor presses Continue Batch. The BDS verifies that
the correct amount was dispensed and then con-
tinues with the next step in the recipe.
A manual dispense is required at this
time. Please dispense material until the
actual value is equal to the setpoint.
Setpoint: XXX
Actual: XXX
Continue
Batch
9. Abort can be pressed on the Recipe Status
Screen at any time to stop a dispense at the step
currently running in the recipe.
10. When a dispense is complete or aborted, the
Dispense Complete Screen appears showing the
amount of material dispensed.
DISPENSE COMPLETE
Dispensed XXX of (recipe name)
Preview
Report Main Menu
11. The operator can view the batch report by pressing
Preview Report and print the report if desired. The
dispense data is also stored electronically for later
retrieval.
12. Pressing Main Menu will return the BDS to the
Main Operating Screen.
13. Once the batch is complete, the operator typically
removes the container from the platform and
agitates the material either manually or with a
power mixer.

10 309279
Introduction
System Fine Tuning
The actual volume of fluid dispensed in each batch can
vary slightly from the calculated targets. However, the
controller monitors this variance and reports an error if
the desired tolerance is not maintained.
In order to minimize this variance, the controllers
minimum flow, maximum flow and drop time parame-
ters must be set for automatic valves and adjusted for
each particular fluid and its delivery system. The
automatic valve parameters are edited in Setup mode.
Minimum Flow Setting: adjusts the slow flow rate
for material during a dispense. The lower the number,
the slower the flow of fluid when it gets near the set-
point.
Maximum Flow Setting: adjusts the fast flow rate
for material during a dispense. This is the rate at which
the fast pour is done. The higher the number, the faster
the flow of fluid when it gets near the setpoint.
Drop Time Setpoint: adjusts the amount of time
the valve is open when the dispense amount is very
close to the setpoint, but a little more material is need-
ed. The higher the number, the longer the valve will
stay open.
Main Menu
Add Valve
System Setup
Edit Valve Parameters
Reports
Exit
Edit Existing Recipe Add Recipe
Valve Type:
Select a Valve Name or Valve Number to Edit Parameters
2
Valve #: Valve Name: Green
Valve #:
Unit of Measure:
Specific Gravity:
Dispense Tolerance%:
VOC Content lbs/Gal:
Drop Time (milliseconds):
Circulate Interval (minutes):
Circulate Duration (minutes):
Valve Name:
Maximum Flow Rate:
Add New Return to Main Menu
Minimum Flow Rate:
Automatic
Green
1
Pounds
0.959
5
7
5
2
10
25
5.23

309279 11
Installation
Before beginning...
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
Installing and servicing the equipment
requires access to parts which could
cause a serious injury if the work is not
performed properly.
DDo not install or service this equip-
ment or perform any of the following
installation and adjustment proce-
dures unless you are trained and
qualified.
DComply with all applicable local,
state, and national fire, electrical, and
other safety regulations.
WARNING
FLAMMABLE OR TOXIC VAPOR
HAZARD
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do
not operate the dispense station unless
ventilation fans are operating. Follow all national,
state, and local codes regarding air exhaust veloc-
ity requirements.
DThe following manuals are included with the Batch
Dispense System. Follow the instructions in this
manual and refer to the component manuals for
additional warning, operation, service, and parts
information.
30929 Ċ Batch Dispense System Manual
(this manual)
30816 Ċ Air Regulator Manual
308169 Ċ Air Filter Manual
306 15 Ċ Dispense Valve Manual
DBe sure all accessories are adequately sized and
pressure rated to meet the system requirements.
NOTE: If a password is requested during the initial
startup and system configuration, the system is
shipped with “P”as the password.
DThe Typical Installation shown in figure 1 is only a
guideline for selecting and installing system compo-
nents and accessories and is not an actual system
design. Contact your Graco distributor for assis-
tance in designing your system.
Select the System Location
WARNING
FIRE AND EXPLOSION HAZARD
The controller is designed for use in a
non-hazardous location as defined in the
National Electrical Code (USA). To install
the Batch Dispense equipment in a
Class 1, Division 1, Group C and D
environment, the X-purge option must be
properly installed. Follow the instructions on pages
60–66. Contact your Graco distributor for more
information.
It is important to follow the BDS location requirements
below to ensure optimum operating results.
DLocate the BDS in a vibration free area: away from
punch presses, heavy fork lift traffic, rail lines and
other devices which produce significant, low fre-
quency, mechanical vibrations. The vibrations from
these items could cause performance problems.
DShield the BDS scale platform from direct air
streams that are perpendicular to the scale surface.
Changes in direct air flow against the scale platform
could result in weight discrepancies.
DLocate the BDS to minimize material handling. If
there will be multiple users, a central location that
meets the above requirements is ideal.
DAnchor the BDS to a poured concrete surface. Bolt
the BDS frame in all four corners, with a minimum
of 3/8 inch diameter bolts.
DOnce the Batch Dispense System is anchored in it’s
final position, level the scale platform by adjusting
the four feet on the base of the platform. Make sure
that the platform is stable and does not “rock”.

12 309279
Installation
Figure 2 –Typical Installation
A
KEY
A Pressure Tank
B Air Regulator
C Air Shutoff Valve
D Fluid Shutoff Valve
E Controller Assembly*
F X-Purge Assembly*
G Dispense Valve
H Fluid Regulator and
Gauge
J Valve Support
K Stand and Frame
L Scale
M Printer
N I.S. Scale Option
* The controller (E) is designed for use in a non-hazardous location as defined in the National Electrical Code (USA). To install the Batch
Dispense equipment in a Class 1, Division 1, Group C and D environment, the X-purge option (F) must be properly installed. Follow the
instructions on pages 60–66.
B C
D
F*
*E
G
H
K
NonĆhazardous Area Hazardous Area
J
L
I.S. Scale Option
N
M
Install the Fluid Supply
Connect the fluid and air supply lines as shown in the
system and controller drawings starting on page 54.
The installation and operation instructions in this manu-
al generally presume a standard system, using pres-
sure tanks (A) to supply the paint components and sol-
vent. The optional fluid supplies listed below are
possible variations and their effect on the instructions.
Optional Fluid Supplies
Instead of pressure tanks (A), the BDS can be supplied
by pail or drum pumps or central paint recirculating
lines if they are available. An air piloted, fluid pressure
regulator is required on each supply line at the input to
the BDS.
Other than references to the pressure tanks, operation
using other fluid supplies is the same as described in
this manual. For maintenance and safety, you must
install a fluid shutoff valve between each supply line
and the BDS.
The fluid supply must be free of pressure spikes, which
are commonly caused by a pump stroke changeover. If
necessary, install pressure regulators or a surge tank
on the fluid supply outlets. Note that this will also
reduce the fluid supply pressure.

309279 13
Installation
Connect the Electrical
Supply
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
DThe Batch Dispense System must be
electrically connected using approved
explosion proof conduit and fittings.
DA qualified electrician must complete
all wiring connections.
DRefer to local code for the explosion proof
power supply requirements in your area.
DAlso read and follow the warnings on page 4.
Connect the BDS to a 110 VAC grounded electrical
supply, with an approved disconnect conduit, and
fittings, as required by local electrical codes. Use the
system and controller drawings starting on page 54 to
make the electrical connections.
Ground the System
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
DThe Batch Dispense System must be
electrically connected to a true earth
ground; in the electrical system is not
sufficient.
DAll wires used for grounding must be
10 gauge minimum.
DA qualified electrician must complete all ground-
ing and wiring connections and check the resist-
ance as instructed
DRefer to you local code for the requirements for
a “true earth ground”in your area.
DAlso read and follow the warnings on page 4.
Ground the BDS as instructed here and in the individu-
al component manuals. Refer to figure 3 and the
system and controller drawings starting on page 54.
Controller
Connect the controller’s green-yellow ground terminal
block to the NEMA enclosure’s grounding lug. Connect
a ground wire (A) from the enclosure (C) to a true earth
ground (B).
Batch Dispense Valve Manifold
Electrically connect the mounting surface for the BDS
valve manifold to a true earth ground point to dissipate
static electricity generated as fluid is dispensed.
Figure 3 –Grounding the System
AB
C

14 309279
Installation
Feed Pumps or Pressure Pots
Use a ground wire and clamp to electrically connect
each of the supply pumps or pots to a true earth
ground. See your separate pump or pressure pot
manual.
Air and Fluid Hoses
Use only grounded hoses for supply lines.
Fluid Supply Container
Ground the container according to your local code.
All Containers Filled when Dispensing
Use only metal pails or containers, which are conduc-
tive, placed on the grounded scale surface. Do not
place the pail on a non-conductive surface, such as
paper or cardboard, which interrupts the grounding
continuity.
Check the Resistance
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock the resistance between
the BDS components and true earth
ground must be less than 25 ohms.
Have a qualified electrician check the resistance
between each BDS component and the true earth
ground. The resistance must be less than 25 ohms. If
the resistance is greater than 25 ohms, a different
ground site may be required. Do not operate the sys-
tem until the problem is corrected.
Connect Other Wiring
Refer to the system and controller drawings starting on
page 54.
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
DThe Batch Dispense System must be
electrically connected using approved
explosion proof conduit and fittings
DA qualified electrician must complete
all wiring connections.
DRefer to your local code for the explosion proof
wiring requirements in your area.
Industrial PC
The Industrial PC is pre-connected at the factory. Do
not change the cable length. If the Industrial PC,
Industrial PC cable, or the barrier blocks fail, identify
and correct the source of the problem first. Then
replace the failed components with identical, approved
components only. Service must only be performed by a
qualified electrician.
Scale Platform
The scale platform is pre-connected at the factory. Do
not change the cable length. The platform is connected
to the controller through approved, intrinsically safe
barrier blocks. If the platform, platform cable, or the
barrier blocks fail, identify and correct the source of the
problem first. Then replace the failed components with
identical, approved components only. Service must
only be performed by a qualified electrician.

309279 15
Installation
Connect the Industrial PC Interface Cable
The Industrial PC interface cable is terminated on the
controller (inside the cabinet) with an eight pin ethernet
cable. Any connections to the controller cabinet must
be made through approved fittings and connectors
only. Connections must only be installed by a qualified
electrician. Maximum cable length is 50 feet (15.2 m).
Printer Cable (optional)
The optional printer cable is terminated inside the
controller cabinet with a 25 pin “D”connector on the
parallel port of the controller. This port is not used if the
printer option is not purchased. Communication is
standard parallel. Any connections to the controller
cabinet must be made through approved fittings and
connectors only. Connections must only be installed by
a qualified electrician. Maximum cable length for
parallel communication is 25 feet (7.6 m).
Before Beginning Operation
DCheck all fluid and air connections for correctness
and tightness.
DFollow the Initial Startup Sequence on page 17.
DShipping will affect scale calibration. Be sure to
calibrate the scale after setting up the software.

16 309279
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or dispensing accidentally. To
reduce the risk of an injury from accidental spray
from the valves, splashing fluid, or moving parts,
follow the Pressure Relief Procedure whenever
you:
Dare instructed to relieve the pressure,
Dstop dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips.
1. Return to the Main Operating Screen.
BATCH
DISPENSE
SYSTEM
Run Recipe Setup Clean Screen
Manual Cntl Scale Setup Exit
2. Relieve fluid and air pressure at the component
and solvent feed pumps or pressure pots, as
explained in their separate instruction manuals.
3. Turn off all of the fluid supply ball valves.
4. Place a container under the selected valve to catch
the material.
5. Press Manual Cntrl.
6. Press the Valve # arrow and press the number that
corresponds to the valve or material line that you
would like to open. Then press Open Valve.
Manual Dispense
Open Valve Close Valve Main Menu
Valve #
Select Valve to Dispense/Open
45
Current Valve Selected
Valve #
Valve Name
Change Valve Psi
NOTE: To open the valve, you must increase the valve
air pressure as instructed in the following step.
7. Press Change Valve Psi. Type a new value in the
text box or use the up arrow to increase the value.
Then press OK.
Setpoint: MAN VALVE OPEN
OK Skip Cancel
Value
Current Value _________
New Value
Default Alternate
x
8. The new value displays under Change Valve Psi
on the Manual Dispense Screen. Do not press
Close Valve until the material stops flowing from
the valve to ensure the pressure was fully relieved.
NOTE: The valve will remain open until Close Valve is
pressed or will close automatically after 30 seconds.
9. Repeat opening and closing all valves that need to
have pressure relieved to finish the Pressure Relief
Procedure.
10. Press Main Menu to return to the Main Operating
Screen.

309279 17
Operation
System Pressure
WARNING
COMPONENT RUPTURE HAZARD
Do not exceed the maximum working
pressure of the lowest rated system
component. See the instruction manuals
of the individual system components for their
maximum working pressures.
Initial Startup Sequence
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 16 whenever you are instructed
to relieve the pressure. stop dispensing, before
checking or servicing equipment, or installing or
cleaning fluid tips.
See figure 4.
1. The BDS is typically tested with lightweight oil. To
prevent contamination of your fluids, thoroughly
purge the system with solvent as instructed in
System Purge, page 18. Leave the solvent in the
system.
2. Make sure all cabinet doors are closed and locked.
3. Turn on the air pressure to the BDS and set the
supply air regulator (63) to 80 psi (552 kPa, 5.5
bar) minimum.
4. Turn on the electrical power to the BDS through
the main disconnect.
5. Turn the Main Power Switch (7) to ON. Make sure
the E-stop button (47) is in the “out”position.
NOTE: Pressing the E-stop button in disables all
electrical and pneumatic outputs.
6. The Industrial PC (29) will go through its load and
boot up procedures and then display the Main
Operating Screen (A). This procedure may take up
to five minutes and is necessary to load all the
correct data for recipe and valve operation, as well
as other necessary project information. Do not
make any selections until this procedure is com-
plete and the Main Operating Screen is displayed.
7. If this is the first time your are starting up the
system, setup information is required before you
dispense material. See the Setup section, starting
on page 26, to enter the necessary setup values,
such as recipes, scale factors, valve and system
parameters.
8. Position the container (C) you are filling in the
center of the scale platform (B). Centering rings
and other accessories are available to simplify this
action.
Figure 4 –Batch Dispense System (BDS)
TI0709
7
47
29
C
B
63
A

18 309279
Operation
Purging
To purge the valves or the entire system, follow the
instructions below.
Purging the Valves
You may need to purge the valves for a number of
reasons, such as changing materials, performing
maintenance on a fluid component, or before extended
shut down of the system. To purge the valves, follow
the instructions below:
1. Identify the valve name and supply pump for the
valve you want to purge.
2. Place a container under the selected valve to catch
the material.
3. Remove excess material from the supply pump.
4. Safely shut down the supply pump, following the
instructions provided with the pump.
5. Place an adequate supply of flush solvent into the
pump feed container.
6. Safely restore pressure to the supply pump.
7. Press Manual Cntrl on the Main Operating
Screen.
BATCH
DISPENSE
SYSTEM
Run Recipe Setup Clean Screen
Manual Cntl Scale Setup Exit
8. Press the Valve # arrow and press the number that
corresponds to the valve or material line that you
are purging. Then press Open Valve.
Manual Dispense
Open Valve Close Valve Main Menu
Valve #
Select Valve to Dispense/Open
45
Current Valve Selected
Valve #
Valve Name
Change Valve Psi
NOTE: To open the valve, you must increase the valve
air pressure as instructed in the following step.
9. Press Change Valve Psi. Type a new value in the
text box or use the up arrow to increase the value.
Then press OK.
Setpoint: MAN VALVE OPEN
OK Skip Cancel
Value
Current Value _________
New Value
Default Alternate
x
10. The new value displays under Change Valve Psi
on the Manual Dispense Screen. Do not press
Close Valve until only clean solvent flows from the
valve.
NOTE: The valve will remain open until Close Valve is
pressed or will close automatically after 30 seconds.
11. If the valve closes automatically before the line is
completely purged, press Open Valve and repeat
the process as needed.
Purging the System
To purge the system, repeat the valve purging proce-
dure above for each of the material valves.

309279 19
Run Recipe
Screen How to Use
BATCH
DISPENSE
SYSTEM
Run Recipe Setup Clean Screen
Manual Cntl Scale Setup Exit
Run Recipe
Use Run Recipe to dispense a recipe in automatic
mode.
Main Operating Screen
⇒Press Run Recipe.
Please enter Password
Continue Main Menu
Password Screen (optional)
If a password is requested,
⇒Press the password entry box to place the cursor
in the box.
⇒Type the password.
⇒Press OK in the confirmation popup to accept and
enter the password.
⇒Press Continue.
Please select (user selectable)
Continue Main Menu
User Selectable Screen (optional)
⇒Press the arrow to see a list of options.
⇒Press the desired option.
⇒Press Continue.
Select Recipe to Load
View Recipe
Recipe # Recipe Name
Run Recipe Main Menu
Current Recipe Selection
Recipe E
Recipe Name
Recipe Selection Screen
⇒Press Recipe # or Recipe Name arrow to see a
list of options.
⇒Press the desired recipe.
You can either press View Recipe to verify your
selection or press Run Recipe to start the recipe.
⇒Press View Recipe to look at the Recipe Screen.
NOTE: Recipe 0 is pre-programmed to be a one
valve, auto-dispense recipe.

20 309279
Run Recipe
Screen How to Use
Recipe # Recipe Name
Select Recipe
Main Menu
Valve # Valve Name Parts
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Step 10
Step 11
Step 12
Step 13
Step 14
Step 15
Run Recipe
View Recipe Screen
You can either press Select Recipe to select a differ-
ent recipe or press Run Recipe to start the recipe on
the screen.
⇒Press Run Recipe to start the recipe.
Enter quantity of units to dispense
Continue Main Menu
Quantity Screen
NOTE: Units of measure is selected during setup.
⇒Press the quantity box to place the cursor inside it
and type the amount to dispense.
⇒Press the Enter key.
⇒On the confirmation screen, press OK.
⇒Press Continue.
Please clear and clean scale platform
Continue Main Menu
⇒Press Continue
Please place container large enough to
hold ### units on scale
Continue Main Menu
⇒Press Continue.