Graco Compact Twin Flow User manual

Operation - Maintenance
Compact Twin Flow
313549B
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Machine shown may be different
from your machine

2
Contents
Safety Precautions .......................................... 3
Machine Features ............................................ 4
Main Touch Screen.......................................... 5
Main Touch Screen continued ....................... 6
CALIBRATE Screen......................................... 7
CALIBRATE Screen continued....................... 8
SHOT FLOW screen ........................................ 9
SHOT FLOW screen continued .................... 10
PUMP PRESSURE screen ............................. 11
PUMP PRESSURE screen continued........... 12
SERVO CONTROL screen............................. 13
TEMPERATURE screen................................. 14
MONITOR screen ........................................... 17
Diagnostics screen........................................ 18
Recipe Preview Screen ................................. 19
LOAD RECIPE screen ................................... 20
EDIT RECIPE screen ..................................... 21
SAVE RECIPE screen .................................... 22
DELETE RECIPE screen ............................... 23
Initial Startup.................................................. 24
Material Pump Servo Start Up Sequence.... 25
Adjusting the Limit Switches ....................... 26
Dry Run .......................................................... 27
Priming the Hoses ......................................... 28
Ratio Check .................................................... 29
Daily Operations ............................................ 30
Phasing the Pumps ....................................... 31
Phasing the Pumps ....................................... 32
Shut Down ...................................................... 33
Material Ratio Adjustment ............................ 34
Piston Replacement ...................................... 35
Piston Replacement Continued ................... 36
Periodic Maintenance.................................... 37
Troubleshooting ............................................ 38
Graco Ohio Standard Warranty.................... 40
Graco Ohio Information ................................ 40

3
Safety Precautions
This manual provides installation, operation, and maintenance instructions. Read this manual before you install and
operate your machine. Use your machine only as directed.
Safety Terms within our manuals
Cautions are given where failure to observe the instruction could result in damage to the equipment, associated
equipment, and/or process. Warnings are given where failure to observe the instruction could result in injury or death to
people.
Some examples follow.
Safety Labeling on our machinery
All our machines carry the following safety labels wherever necessary:
• Danger Labels indicate an imminently hazardous situation, which, if not avoided, could result in death or serious
injury.
• Warning Labels indicate potentially hazardous situations which, if not avoided, could result in death or serious
injury.
• Caution Labels indicate an unsafe practice that may result in moderate or minor injury.
• Notice Labels state a company policy. Some examples are:
Snuff-back can be monitored with DV
MODE in AUTO, but must be
adjusted with DV MODE in OPEN
Caution
Make sure EMERGENCY STOP is
locked in before manually aligning
the ratio block to the ratio beam.
WARNING
DO NOT OPERATE THIS
MACHINE WITH
GUARD(S) DETACHED
DANGER
UNPLUG MACHINE
BEFORE OPENING
ENCLOSURE
WARNING
OVERCURRENT
PROTECTION
PROVIDED AT MACHINE
SUPPLY TERMINALS
NOTICE
WEAR EAR
PROTECTION
CAUTION
WEAR EYE
PROTECTION
CAUTION

4
Machine Features
Posiload Machine:
CONTROL POWER Switch
Provides power for the electrical circuitry in the console.
OFF: Electrical power is not applied to the electrical circuitry and the internal white lamp is
dimmed.
ON: Electrical power is applied to the electrical circuitry and the internal white lamp is
illuminated.
EMERGENCY STOP Button
When the EMERGENCY STOP button is pressed and released, all power is removed from the
machine. The pumps will immediately stop in place. The dispense valve will close.
Touch Panel
The Touch Panel is used to control all function on the machine. See the following sections for
operation of the different screens.
Foot Switch
The foot switch is used to initiate a pump cycle when operating in the SHOT or CONT pump
mode. Throughout this manual the foot switch will be referred to as the START device.
From the SHOT FLOW screen when the SHOT is pressed, and the START device is pressed and
released, the machine will cycle then stop and wait for the next start signal. If the START device
is pressed and held, the machine will run continuously.
Valves:
Check Valves
Check valves allow material to flow from the pumps to the material hoses but prevents material
from flowing back.

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Main Touch Screen
TEMP PANEL button
The TEMP PANEL button is selected to make the TEMPERATURE screen to appear.
(See the TEMPERATURE screen section in this manual for more information.)
PRESSURE PANEL button
The PRESSURE PANEL button is selected to make the PRESSURE PANEL screen to appear.
(See the PRESSURE PANEL screen section in this manual for more information.)
SHOT FLOW button
The SHOT FLOW button is selected to make the SHOT FLOW screen to appear.
(See the SHOT FLOW screen section in this manual for more information.)
MONITOR PANEL button
The MONITOR PANEL button is selected to make the MONITOR screen to appear.
(See the MONITOR screen section in this manual for more information.)
CALIBRATE PANEL button
The CALIBRATE PANEL button is selected to make the CALIBRATE screen to appear.
(See the CALIBRATE screen section in this manual for more information.)
SERVO CONTROL PANEL button
The SERVO CONTROL PANEL button is selected to make the SERVO CONTROL screen to appear.
(See the SERVO CONTROL screen section in this manual for more information.)
Your SN number is displayed here

6
Main Touch Screen continued
SET UP RECIPES button
The SET UP RECIPES button is selected to make the Recipe Preview screen to appear.
(See the RECIPES screen section in this manual for more information.)
DIAGNOSTICS button
The DIAGNOSTICS button is selected to make the DIAGNOSTICS screen to appear.
(See the DIAGNOSTICS screen section in this manual for more information.)
The recipe screen is used for the following purposes:
1. To manually edit the configuration of this machine (which is also done in the buttons previously shown).
2. To install previously recorded machine configurations known as recipes. (Upload to controller)

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CALIBRATE Screen
NOTE: The WATLOW Temperature Controllers located on the front panel of the machine are as indicators
only, no adjustment of these controllers are required.
T/C WIND SET PT N7:60 button/indicator (Temperature Control Window Set Point)
This button/indicator shows the range of the material temperature (this range is shown in ±C°). For example: If the
material temperature was set to 90C°and the T/C WIND SET PT indicator was set to “10” the temperature of the
material would be between 80C°and 100C°.
To change the T/C WIND SET PT N7:60 indicator (Temperature Window Control Set Point) do the following:
1. Select T/C WIND SET PT N7:60 button, a numeric keypad should appear.
2. Enter in the new material temperature range required.
3. Press the ENTER button.
4. The new material temperature range should appear in the T/C WIND SET PT N7:60 indicator.
T/C SHUT PT N7:51 button/indicator (Temperature Control Shutdown Set Point)
This button/indicator shows the absolute maximum material temperature in C°. For example: If this indicator was
set to 110C°and the material exceeded this temperature (such as a catastrophic heater failure), the power to all the
heater ovens will be disabled.
To change the T/C SHUT PT N7:51 indicator (Temperature Control Shutdown Set Point) do the following:
1. Select T/C SHUT PT N7:51 button, a numeric keypad should appear.
2. Enter in the new maximum material temperature required.
3. Press the ENTER button.
4. The new material maximum temperature should appear in the T/C SHUT PT N7:51 indicator.

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CALIBRATE Screen continued
NOTE: The WATLOW Temperature Controllers located on the front panel of the machine are as indicators
only, no adjustment of these controllers are required.
TEMP SET PT N7:54 button/indicator (Mixed Material Temperature Set Point Control)
This button/indicator shows the range of the mixed material temperature (this range is shown in ±C°). For example:
If the mixed material temperature was set to 90C°and TEMP SET PT N7:54 indicator was set to “10” the
temperature of the material would be between 80C°and 100C°.
To change the TEMP SET PT N7:54 indicator (Mixed Material Temperature Set Point) do the following:
1. Select TEMP SET PT N7:54 button, a numeric keypad should appear.
2. Enter in the new material temperature range required.
3. Press the ENTER button.
4. The new material temperature range should appear in the TEMP SET PT N7:54 indicator.
PSI HIGH SET PT N7:40 button/indicator (Pump Servo PSI High Set Point)
This button/indicator shows the material pressure at which the machine pump servomotor will stop generating
material pressure (shut off) in psi or MPa.
To change the PSI HIGH SET PT N7:40 indicator (Pump Servo PSI High Set Point) do the following:
1. Select PSI HIGH SET PT N7:40 button, a numeric keypad should appear.
2. Enter in the new material high shut off pressure required.
3. Press the ENTER button.
4. The new material high shut off pressure should appear in the PSI HIGH SET PT N7:40 indicator.
PSI LOW SET PT N7:42 button/indicator (Pump Servo PSI Low Set Point)
This button/indicator shows the material pressure at which the machine pump servomotor will start generating
material pressure (start up) in psi or MPa.
To change the PSI LOW SET PT N7:42 indicator (Pump Servo PSI Low Set Point) do the following:
1. Select PSI LOW SET PT N7:42, a button at numeric keypad should appear.
2. Enter in the new material low start up pressure required.
3. Press the ENTER button.
4. The new material high shut off pressure should appear in the PSI LOW SET PT N7:42 indicator.
RESET TO FACTORY button
When this button is selected, it will return all factory values to the CALIBRATION screen indicators.

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SHOT FLOW screen
PUMP MODE
SHOT Button
When the SHOT Button is selected, the machine pump will run one cycle when the foot switch or START
CYCLE button is pressed. Depending on shot size, the machine may take more than one shot.
OFF Button
When this button is selected the power to the material pump servomotor will be disabled.
CONT Button
The purpose of this button is to allow the machine continually cycle the pumps in order to empty material
from the tanks when a start device is pressed.
RECIRC button
When this button is selected, the material pump servomotor will cycle at preset rate to make a flow rate
needed for material recirculation. NOTE: Prior to using this button, you should turn the required ball
valves to the recirculation position of the corresponding tank. See the tank recirculation section of this
manual for more information.
PUMP MODE
HOME Button
The pumps will immediately move to the home limit switch and remain in the home position. This position
is used when the machine ready to dispense material.
EXTEND Button
The pumps will immediately move to the retract limit switch and remain in the retracted (parked) position.
RETRACT Button
The pumps will immediately move to the retract limit switch and remain in the retracted (parked) position.
This is used for machine shutdown or when the machine remains inactive or idle for long periods of time.

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SHOT FLOW screen continued
For more information on the use of these buttons see the Daily Operation Section of this manual.
START CYCLE button
This button will activate the machine to run the pre-selected sequence defined in this screen.
SHOT SIZE (cc’s) button/indicator
This button/indicator shows the volume setting of the material of the SHOT SIZE volume in cubic centimeters
(cc’s).
To change the SHOT SIZE volume, do the following:
1. Select SHOT SIZE button, a numeric keypad should appear.
2. Enter in the material shot size volume as required.
3. Press the ENTER button.
4. The new shot size volume should appear in the SHOT SIZE indicator.
FLOW RATE (cc’s/sec) button/indicator
This button/indicator shows the volume setting of the material FLOW RATE volume in cubic centimeters (cc/sec).
To change the FLOW RATE volume, do the following:
1. Select FLOW RATE button, a numeric keypad should appear.
2. Enter in the material flow rate volume as required.
3. Press the ENTER button.
4. The new shot size volume should appear in the FLOW RATE indicator.
RUN SETUP PROGRAM button
When this button is selected a factory preinstalled setup program will upload into the CTC Parker Automation
memory. Included in this setup program are various setup parameters that were previously installed by the factory or
by the operator.
RUN MAIN PROGRAM button
When this button is selected a factory-preinstalled program will upload into the CTC Parker Automation memory.
This program will give the machine the various instructions to perform the actual operations.
For more information on the use of these buttons see the Daily Operation Section of this manual.
SERVO POWER ON button
This button connects electrical power to the machines’ servomotor material pump.
SERVO POWER OFF button
This button disconnects electrical power to the machines’ servomotor material pump.
SERVO ENABLE ON button
This button enables the machines’ servomotor to drive the material pump.
DRIVE ENABLE button
This button enables the machines’ drive run material pump.
RESET SERVO button
This button will reset the machines’ servomotor to drive the material pump.

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PUMP PRESSURE screen
HIGH PRESSURE SET POINT indicator
This indicator shows the current material pump high-pressure set point setting. This setting was previously
preset in the PSI HIGH SET PT N7:40 in the CALIBRATION screen. For more information on the HIGH
PRESSURE SETPOINT settings, see the CALIBRATION screen section of this manual.
ACTUAL MOLD PRESSURE indicator
This indicator shows the current material outlet hose and mold pressure.
LOW PRESSURE SET POINT indicator
This indicator show the current material pump low pressure set point setting. This setting was previously
preset in the PSI HIGH SET PT N7:42 in the CALIBRATION screen. For more information on the HIGH
PRESSURE SETPOINT settings, see the CALIBRATION screen section of this manual.
HIGH MOLD PRESSURE PUMPING STOP message box
This indicator is illuminated when the material outlet hose and /or material mold pressure reaches the
HIGH PRESSURE SET POINT indicator setting. When indicator is activated, the material pump
servomotor is stopped. For more information on the HIGH PRESSURE SHUTDOWN SETPOINT settings,
see the CALIBRATION screen section of this manual.
LOW MOLD PRESSURE PUMPING STOP message box
This indicator is illuminated when the material outlet hose and /or material mold pressure reaches the LOW
PRESSURE SET POINT indicator setting. When indicator is activated, the material pump servomotor is
restarted. For more information on the LOW PRESSURE SETPOINT settings, see the CALIBRATION
screen section of this manual.
Sections only
shown if items
are installed

12
PUMP PRESSURE screen continued
SYSTEM HIGH PRESSURE ALARM indicator
This indicator is illuminated when the material outlet hose and / or material mold pressure is at a high
pressure shutdown condition, previously set with the PSI HIGH SET PT N7:40 button seen in the
CALIBRATION screen section. This indicator usually becomes active when there is a catastrophic loss of
pressure. When indicator is activated, the material pump servomotor is stopped. For more information on
the LOW PRESSURE SHUTDOWN SETPOINT settings, see the CALIBRATION screen section of this
manual.
SYSTEM LOW PRESSURE ALARM indicator
This indicator is illuminated when the material outlet hose and / or material mold pressure is at a low
pressure shutdown condition, previously set with the PSI LOW SET PT N7:42 button seen in the
CALIBRATION screen section. This indicator usually becomes active when there is a high pressure
condition. When indicator is activated, the material pump servomotor is stopped. For more information on
the HIGH PRESSURE SHUTDOWN SETPOINT settings, see the CALIBRATION screen section of this
manual.
Optional A Vacuum Pump (B Vacuum Pump) button
These buttons control the “A” and “B” material tank vacuum pump.
ON button
When selected the vacuum pump is currently activated.
OFF button
When selected the vacuum pump is currently deactivated.
Optional A TANK AGITATOR and B TANK AGITATOR buttons
The Agitator Speed Controller enables/disables the electric agitator and also increases/decreases the tank
agitator speed.
OFF button
The tank agitator is disabled and the material in the tank is not agitated.
ON button
The tank agitator is enabled and the material in the tank is being agitated to low or high speed.
LOW SPEED button
The tank is agitated at the minimum speed when the ON button is selected.
HIGH SPEED button
The tank is agitated at the maximum speed when the ON button is selected.

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SERVO CONTROL screen
DRIVE ENABLE #3
This button when pressed will enable the servo drive.
RUN SETUP PROGRAM button #4
When this button is selected a factory preinstalled setup program will upload into the CTC Parker
Automation memory. Included in this setup program are various setup parameters that were previously
installed by the factory or by the operator.
RUN MAIN PROGRAM button #5
When this button is selected a factory-preinstalled program will upload into the CTC Parker Automation
memory. This program will give the machine the various instructions to perform the actual operations.
SERVO POWER ON button #1 and #2
This button connects electrical power to the machines’ servomotor material pump.
SERVO POWER OFF button #1 and #2
This button disconnects electrical power to the machines’ servomotor material pump.
DRIVE ENABLE ON/OFF button #3
This button enables/disables the machines’ servomotor to drive the material pump.
HOME Button
The pumps will immediately move to the home limit switch and remain in the home position. This position
is used when the machine ready to dispense material.
RESET SERVO button
This button will reset the machines’ servomotor to drive the material pump.

14
TEMPERATURE screen
A TANK MATERIAL button/indicator
This button/indicator shows the temperature setting of the material in the ”A” material tank temperature in
C°. The A TANK MATERIAL indicator will show the current tank temperature setting.
To change the ”A” material oven temperature, do the following:
1. Select A TANK MATERIAL button, a numeric keypad should appear.
2. Enter in the material set point temperature required.
NOTE: This temperature must be within the set point range.
3. Press the ENTER button.
4. The new material temperature should appear in the A TANK MATERIAL indicator.
Optional A Recirc Hose button/indicator
This button/indicator shows the set point of the material in the “A” component recirculation hose in C°.
The recirculation indicator will show the current material temperature setting.
To change the “A” component recirculation material temperature, do the following:
1. Select A recirculation button, a numeric keypad should appear.
2. Enter in the material set point temperature required.
NOTE: This temperature must be within the set point range.
3. Press the ENTER button.
4. The new material temperature should appear in the A recirculation indicator.
A DISP. HOSE button/indicator
This button/indicator shows the set point of the material in the “A” component dispense hose in C°. “A”
component dispense hose temperature indicator will show the current dispense hose material temperature
setting.
To change the “A” component dispense hose temperature, do the following:
1. Select A DISP. HOSE button, a numeric keypad should appear.
2. Enter in the material set point temperature required.
NOTE: This temperature must be within the set point range.
3. Press the ENTER button.
Sections only
shown if
recirculation is
installed

15
4. The new material temperature should appear in the A DISP. HOSE indicator.
B TANK MATERIAL button/indicator
This button/indicator shows the temperature setting of the material in the ”B” material tank in C°. The B
TANK MATERIAL indicator will show the current oven temperature setting.
To change the ”B” material tank temperature, do the following:
1. Select B TANK MATERIAL button, a numeric keypad should appear.
2. Enter in the material set point temperature required.
NOTE: This temperature must be within the set point range.
3. Press the ENTER button.
4. The new material temperature should appear in the B TANK MATERIAL indicator.
Optional B Recirc Hose button/indicator
This button/indicator shows the set point of the material in the “B” recirculation hose in C°. The B
recirculation indicator will show the current material temperature setting.
To change the recirculationmaterial temperature, do the following:
1. Select B recirculation button, a numeric keypad should appear.
2. Enter in the material set point temperature required.
NOTE: This temperature must be within the set point range.
3. Press the ENTER button.
4. The new material temperature should appear in the B recirculation indicator.
B DISP. HOSE button/indicator
This button/indicator shows the set point of the material in the “B” component dispense hose in C°. “B”
component dispense hose temperature indicator will show the current dispense hose material temperature
setting.
To change the “B” component dispense hose temperature, do the following:
1. Select B DISP. HOSE button, a numeric keypad should appear.
2. Enter in the material set point temperature required.
NOTE: This temperature must be within the set point range.
3. Press the ENTER button.
The new material temperature should appear in the B DISP. HOSE indicator.

16
NOTE:
For more information on the material temperature set points,
see the CALIBATION screen section of this manual.
MATERIAL TEMPERATURE indicator
This is the current mixed material temperature at the outlet of mixer shroud.
Material temperature status indicator.
This gives the status of the current mixed material temperature.
TEMP NOT READY: The material is currently below specified temperature limits.
MATERIAL TEMP OK: The current material temperature is at specified limits.
MATERIAL TEMP HIGH: The material is currently above specified temperature limits.
NOTE: When the material is above a specified temperature, a material overheat alarm will
be enabled.
SILENCE ALARM button: This button will silence the material overheat alarm.
ADJUST TEMPERATURE
INCR TEMP button (Increment Temperature)
This button will increment all the temperature settings by 1C°every time the button is pressed.
DECR TEMP button (Decrement Temperature)
This button will decrease all the temperature settings by 1C°every time the button is pressed

17
MONITOR screen
PUMP PRESSURE (psi) indicators
ACTUAL
This indicator gives the current pump outlet pressure in PSI (pounds per square inch).
MATERIAL TEMP(C) indicators
ACTUAL
This indicator gives the current material temperature in C°(Celsius).
SET POINT
This indicator is for future development; it reads the same as the actual indicator.
SHOT SIZE (cc’s) indicator
ACTUAL
This indicator gives the current shot size in cc’s (Cubic Centimeters).
FLOW RATE (cc’s/s) indicator
ACTUAL
This indicator gives the current flow rate in cc/sec (Cubic Centimeters per Seconds).
VOLUME DISPENSED (cc’s) indicator
This indicator gives the current amount of material dispensed to the mold in cc (Cubic Centimeters).
“A” and “B” MATERIAL LEVEL and PRESSURE LEVEL status indicators
These indicators will give the status of the “A” and “B” material level of the tanks and the pressure level of
the material pumps.

18
Diagnostics screen
This screen is used for advanced troubleshooting only. All settings on this screen can
be changed using the other screen described in this manual. All indicators seen in
this screen can be viewed using the other screens seen in this manual.

19
Recipe Preview Screen
The preview screen will display the current machine configuration or recipe. This recipe can be edited or
changed as required, then saved, either as an existing recipe or a new recipe. This new recipe can now be
uploaded to the controller where the machine can operate from memory.
To load a new recipe: press the LOAD RECIPE button to make the LOAD RECIPE screen to appear. For
more information see the LOAD RECIPE screen in this manual.
To edit a recipe that is currently loaded: press the EDIT RECIPE button to make the EDIT RECIPE
screen to appear. For more information see the EDIT RECIPE screen in this manual.
To send a recipe to the controller that is currently loaded or edited: press the SEND RECIPE TO
CONTROLLER button.
To return to the MAIN screen: press the exit arrow button see as the in the picture above.
NOTE: If you have recently loaded or edited a new recipe the machine will not operate in this
configuration until you press the SEND RECIPE TO CONTROLLER button.

20
LOAD RECIPE screen
The purpose of this screen is to allow the reading of machine configurations as “Recipes” from memory.
To load a recipe do the following:
(If you are at the Recipe Preview screen press the LOAD RECIPE button to get to the screen shown above)
1. Select a recipe by touching the recipe loaded on the touch screen, the recipe that you touch will have a
yellow rectangle around the recipe.
2. Verify that the recipe that you selected is in the RECIPE LOAD MESSAGE WINDOW in the top of the
LOAD RECIPE screen.
3. To load the selected recipe, press the ACCEPT button.
4. The RECIPE PREVIEW screen should appear with the new recipe loaded.
NOTE: To escape the LOAD RECIPE screen press the CANCEL button.
NOTE: If you have recently loaded or edited a new recipe the machine will not operate in this
configuration until you press the SEND RECIPE TO CONTROLLER button from the RECIPE
PREVIEW screen.
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