Graco DC12 Manual

Operation – Setup
PROVEN QUALITY, LEADING TECHNOLOGY.
DC12
High-Volume Metering System 312767B
For dispensing 2 component high viscosity Epoxy Adhesive or Tooling Paste
materials.
100 psi (0.7 Mpa, 7 bar) Maximum Air Inlet Pressure
2500 psi (17.2 Mpa, 172 bar) Maximum Working Pressure
Not designed for use in Explosive Atmospheres.
Important Safety Instructions
Read all warnings and instructions in this and
all supplied manuals. Save these instructions.
See page 3 for product configuration information

Table of Contents
2312767B
Product Configurator ………………………….. 3
Accessories …..………………………….. 4
Supplied / Related Manuals .……………………5
Warnings ………………………………………….. 6
Component Identification ….………………….. 8
Electrically Controlled ……………………8
Automatic Dispense Valve ………………8
Swivel Boom …………………………….. 8
Optional Ratio Monitoring ……………… 8
Base Purge ……………………………… 8
Pneumatically Controlled ………………. 9
Manual Dispense Valve ………………… 9
Solvent Flush ……………………………..9
Performance Monitor Plus ……………………. 10
Human Machine Interface ……………... 10
Operator (HMI) Screens……………….. 10
Main Menu ………………………………. 10
Setup …………………………………….. 11
Supply Pumps …………………………… 12
Dispense Setup ……………………….… 14
Purge Settings ………………………….. 16
Run Mode ……………………………….. 18
Status ……………………………………. 20
Alarm History ……………………………. 21
Pressure Status ………………………… 22
Material Processed …………………….. 23
Technician (HMI) Screens …………….. 24
Supply Setup ……………………………. 25
Shot Meter Setup ……………………….. 26
Data Logs …………………………………27
Pressure Setup ………………………….. 28
Ratio Monitor Package …………………………. 29
Component Identification ………………. 29
Ratio Setup Screen …………………….. 30
Pneumatic Performance Monitor …………….. 31
Pneumatic Dispense Valve Control ………….. 32
Setup ………………………………………………. 33
Location ………………………………….. 33
Boom Installation ……………………….. 34
Electrical Requirements …………………36
Start-Up …………………………………………….37
Loading Material ………………………… 38
Priming System …………………………………. 39
Performance Monitor Plus Control ……. 39
Pneumatic Dispense Valve Control …… 40
Manual Control ………………………….. 41
Pressure Monitor Setup ……………………….. 43
Performance Monitor Plus ………………43
Pneumatic Monitor Pneumatic ………….44
Operation …………………………………………. 47
Performance Monitor Plus ……………... 49
Pneumatic Dispense Valve Control …… 50
Manual Control ………………………….. 50
Ratio Check – Performance Monitor Plus …...51
Ratio Check – Pneumatic DV Control ………..52
Ratio Check – Manual Control ………………… 52
Drum Change …………………………………….53
Performance Monitor Plus ………………54
Pneumatic DV Control ………………….. 54
Manual Control ………………………….. 54
Pressure Relief ……………………………………55
Performance Monitor Plus ………………55
Pneumatic DV Control ………………….. 56
Manual Control ………………………….. 56
Mixer Flush ……………………………………….. 57
Base Purge ………………………………. 57
Solvent Flush ……………………………. 58
Maintenance ……………………………………… 60
Troubleshooting ………………………………….61
Supply System ……………………………61
Shot Meter ……………………………….. 61
Performance Monitor Plus Alarms …….. 64
Technical Data…………………………………….68
Dimensions ………………………………………..69
Graco Standard Warranty ……………………… 70
Graco Information ………………………………..70

Product Configurator
3312767B
DC12 - 1 - 1 - 1 - 1 - 2 - 1
Code: A B C D E F
Ratio and Supply Pumps
Dispense Valve, Ratio
Check, and Mounting
Controls
Flow Meters and Hoses
Mixer Flush
Recommended Spares
DC12 - - - - - -
Code: A B C D E F
The Following table applies to the DC12 configurations and indicates all of the options available
for each letter shown above.
Code A Ratio and Supply Pumps Code D Flow Meters and Hoses
1 2:1 with A1 and B1 NXT Pumps 1 2:1 Flow Meter Package for Swivel Boom
2 1:1 with A1 and B1 NXT Pumps 2 1:1 Flow Meter Package for Swivel Boom
3 2:1 No Supply Pumps 3 2:1 Flow Meter Package for Fixed Mixer
4 1:1 No Supply Pumps 4 1:1 Flow Meter Package for Fixed Mixer
5 2:1 with A1, A2 and B1 NXT Pumps 5 2:1 No Flow Meters for Swivel Boom
6 1:1 with A1, A2, B1 and B2 NXT Pumps 6 1:1 No Flow Meters for Swivel Boom
Code B Dispense Valve, Ratio Check, and
Mounting 7 2:1 No Flow Meters for Fixed Mixer
1 Auto Disp. Valve and Auto Ratio
with Swivel Boom 8 1:1 No Flow Meters for Fixed Mixer
2 Auto Disp. Valve and Auto Ratio
with Fixed Mixer Code E Mixer Flush
3 Auto Disp. Valve and Manual Ratio
with Fixed Mixer 1 Solvent Pump and Hardware for Fixed Mixer
4 Manual Disp. Valve and Manual Ratio with Fixed Mixer 2 Solvent Pump and Hardware for Swivel Boom
Code C Controls 3 Solvent Hardware for Fixed Mixer
1 Performance Monitor Plus 240V, 1PH,
50-60 HZ 4 Solvent Hardware for Swivel Boom
2 Performance Monitor Plus 120V, 1PH,
50-60 HZ 5 Auto Base Purge for Fixed Mixer
3 Pneumatic Performance Monitor,
Auto Disp. Valve 6 Auto Base Purge for Swivel Boom
4 Pneumatic Performance Monitor,
Manual Disp. Valve 7 Manual Base Purge for Fixed Mixer
5 Pneumatic Auto Disp. Valve, No Monitor Code F Recommended Spares
6 No Controls for Manual DV only 1 2:1 Recommended Spares Kit
2 1:1 Recommended Spares Kit
3 2:1 Recommended Spares Kit Tandem
4 1:1 Recommended Spares Kit Tandem
N None

DC12 Accessories
4312767B
Ram Supply Pump Kits
255513 KIT,COMPLETE SEAL, L250CS (55:1 PUMP)
255509 KIT,COMPLETE SEAL, L200CS (36:1 PUMP)
255517 KIT,COMPLETE SEAL, L500CS (14:1 PUMP)
255615 KIT,BLEEDVALVE, ALL CARBON
94/0432-2/50 VALVE,CHECK,1""NPT,F,MS
Shot Meter Components
C23136 RATIO CYLINDER #1000
C23200 RATIO CYLINDER #500
C24166 KIT,REPAIR,RATIO CYLINDER
C05032 PACKING,CUP, PISTON #1000 (2 REQ'D)
C23350 PACKING,CUP, PISTON #1500 (2 REQ'D)
C07067 KIT,REPAIR,4 WAY VALVE
Dispense Valve and Mixer Components
15T682 MANIFOLD,MIX,OUTLET
15T683 MANIFOLD,MIX,INLET
918540 KIT,REPAIR,3/4 BALL SEAT
918538 KIT,REPAIR,1/2 BALL SEAT
60/0008-A/98 MIXER,ASSY,1""X12EL ( 2 Per Assembly)
U70010 COUPLING,1",SS
107078 PACKING,O-RING,TEF (2 Required)

Manuals
5312767B
Supplied Manuals
The following manuals will be supplied
with the DC12. DC12 Operation
Refer to these documents for detailed
machine information. Part Description
312767 Manual, Operation DC12
DC12 Repair
Part Description
312896 Manual, Repair DC12
Related Manuals
The following manuals are for standard
components used on the DC12 Dispense Valve, DC12
Part Description
310551 Manual,3/4 Ball Seat Applicator
310550 Manual,1/2 Ball Seat Applicator
Supply Systems
Part
Description
312371 Supply System Operation Manual
312373 Supply System Repair-Parts Manual
312468 200 cc Pump Lower
312469 250 cc Pump Lower
312470 500 cc Pump Lower
Tandem Supply System
Part Description
312897 Operation and Maintenance

Warnings
6312767B
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation 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 when applicable.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Connect only to grounded power source.
• Do not expose to rain. Store indoors.
• All electrical wiring must be done by qualified electrician and comply with all local codes and
regulations.
SKIN INJECTION HAZARD
High-pressure fluid from dispense valve, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispense valve at anyone or at any part of the body.
• Do not put your hand over the end of the dispense nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
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.
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 and clean 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 lights on or off when flammable fumes are present.
• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See
Grounding instructions.
• Use only Graco grounded hoses.
• Check gun resistance daily.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from
system.
• Keep a working fire extinguisher in the work area.

Warnings
7312767B
WARNING
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.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about
your material, request MSDS forms from distributor or retailer.
• 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.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
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

Component Identification
8312767B
Typical Installation
Lift Locations
Fig. 1
Main System Parts List
Ref Description Ref Description
1 Base Frame 6 Static Mixer
2 A Supply System 7 Performance Monitor Plus
3 B Supply System 8 Swivel Boom
4 Shot Meter 9 Automatic Base Purge
5 Automatic Dispense Valve 10 Ratio Monitor Option

Component Identification
9312767B
Fig. 2
Main System Parts List
Ref Description Ref Description
1 Pneumatic Performance Monitor 4 Fixed Manual Dispense Valve
2 Pneumatic Dispense Valve Control 5 Solvent Hardware
3 Fixed Automatic Dispense Valve 6 Solvent Pump

Performance Monitor Plus
10 312767B
Human Machine Interface (HMI) Screens
Performance Monitor Plus includes an electric monitoring package with HMI and pendant station. The following
pages detail the included features. See product configurator code C. Performance Monitor Plus is 1 of 4 control choices.
Operator Level Screens
Main Menu Screen
Fig. 3
Key Description Key Description
Login Login Button Run Mode Screen Access Button
Logout Logout Button Alarm History Screen Access Button
Setup Screen Access Button Status Screen Access Button
Supply Pumps Screen Access Button Tech Screen Access Button

Performance Monitor Plus
11 312767B
Operator Level Screens
Setup
Fig. 4
Key Description Key Description
Supply Pumps Screen Access Button Previous Screen Access Button
Dispense Setup Screen Access Button Main Screen Access Button
Purge Settings Screen Access Button
Run Mode Screen Access Button

Performance Monitor Plus
12 312767B
Operator Level Screens
A1 and B1 Rams are located on the base machine. Tandem pumps are optional and will only appear on the screen if
supplied with the system. See Related Manuals section for information on the Tandem option.
Supply Pumps
Fig. 5
Key Description Key Description
Auto A or B Supply Auto Mode B1 In Use Select B1 pump in Auto Mode
Manual A or B supply Manual Mode B2 In Use Select B2 pump in Auto Mode
A1 In Use Select A1 pump in Auto Mode B1 Ram OK Status Indicator for Low Level
A2 In Use Select A2 pump in Auto Mode B2 Ram OK Status Indicator for Low Level
A1 Ram OK Status Indicator for Low Level B1 Pump ON/OFF Toggle Button in Manual Mode
A2 Ram OK Status Indicator for Low Level B2 Pump ON/OFF Toggle Button in Manual Mode
A1 Pump ON/OFF Toggle Button in Manual Mode Supply Ready A and B Supply ready indicator
A2 Pump ON/OFF Toggle Button in Manual Mode Control Power Control Power Indicator
Previous Screen Access Button Dispense Setup Screen Access Button

Performance Monitor Plus
13 312767B
Operator Level Screens
Supply Pumps Cont.
See Fig. 5
Auto Button – No Tandem pumps
This button is used to put the “A” or “B” Component
Supply Pump in the automatic mode (Auto Mode). In
the Auto Mode the ram transfer pump will supply
material pressure to the DC12 metering pump.
When a low level sensor is reached the machine will
continue to pump until a preset time has expired.
When the shut down time expires the machine will
indicate a fault and shut down.
Auto Button – Tandem pumps
This button is used to put the “A” or “B” Component
Supply Pump in the automatic mode (Auto Mode). In
the Auto Mode the ram transfer pump will supply
material pressure to the DC12 metering pump.
When a low level sensor is reached the system will
switch to the tandem pump. If both supply pumps
are low the machine will shut down after the low
level shut down timer expires.
When loading material into supply pump it is
recommended to prime the pump lower. This
requires a short down time during operation. See
the Drum Change procedure located in this manual.
Manual Button
This button is used to put the “A” or “B” Component
Supply Pump in the manual mode. The manual
mode is used for start-up, drum change, or
maintenance.
A1 In Use Button
This button is used to select the A1 pump to be used
during normal operation. The Supply Ready
indicator will not turn on until both supplies are in
Auto mode and a pump is selected for use.
A fault event, or E-stop will deselect any pump
in use. Pump In Use button must be selected to
continue operation.
A2 In Use Button
See A1 In Use Button
A1 Pump ON/OFF Button
This button will enable or disable the A1 supply
pump when in the manual mode.
A2 Pump ON/OFF Button
See A1 Pump ON/OFF Button
B1 In Use Button
See A1 In Use Button
B2 In Use Button
See A1 In Use Button
B1 Pump ON/OFF Button
This button will enable or disable the B1 supply
pump when in the manual mode.
B2 Pump ON/OFF Button
See B1 Pump ON/OFF Button

Performance Monitor Plus
14 312767B
Operator Level Screens
Dispense Setup
Fig. 6
Key Description
Key Description
Continuous Continuous Dispense Mode Ratio Check Auto Ratio Check Auto Mode
Timed Shot Timed Shot Dispense Mode Ratio Check Open Ratio Check Open
Shot Time sec Dispense time in seconds Ratio Check Close Ratio Check Close
Dispense Valve Auto Dispense Valve Auto Mode A Specific Gravity Input Field
Dispense Valve Open Dispense Valve Open B Specific Gravity Input Field
Dispense Valve Closed Dispense Valve Close Mixed Specific Gravity Display Field
Setup Screen Access Button Purge Settings Screen Access Button
Run Mode Screen Access Button

Performance Monitor Plus
15 312767B
Operator Level Screens
Dispense Setup Cont.
See Fig. 6
Continuous Mode
When a start signal is given during normal operation
the system will dispense through the Dispense
Valves or Ratio Valves until a stop signal is given.
Timed Shot Mode
When a start signal is given during normal operation
the system will dispense through the Dispense
Valves or Ratio Valves until a the shot timer has
expired.
This mode is recommended for taking ratio samples.
See Ratio Check section in this manual.
Shot Time sec
Amount of time system will dispense while in Timed
Shot Mode.
Dispense Valve Auto
Select this mode to dispense material through the
mixer during normal operation.
Dispense Valve Open
This button will override and open the Dispense
valves regardless of Dispense Mode.
CAUTION
Dispense Valve Open should only be used when
performing Pressure Relief Procedure, or for
maintenance. Opening Dispense Valve during
normal operation could affect machine
performance. See Pressure Relief Procedure in
this manual.
Dispense Valve Close
This button will close the Dispense Valves and is
used to prevent the Dispense Valves from opening
while in Ratio Mode Auto.
Ratio Check Auto
Select this mode to dispense material through the
Ratio Valves during normal operation.
Ratio Valve Open
This button will override and open the Ratio Valves
regardless of Dispense Mode.
CAUTION
Ratio Valve Open should only be used when
performing Pressure Relief Procedure, or for
maintenance. Opening Dispense Valve during
normal operation could affect machine
performance. See Pressure Relief Procedure in
this manual.
Ratio Valve Close
This button will close the Ratio Valves and is used to
prevent the Ratio Valves from opening while in
Dispense Valve Mode Auto.
A Specific Gravity G/CC
Enter the A component Specific gravity. This value
is used for material usage and flow rate calculations.
B Specific Gravity G/CC
Enter the B component Specific gravity. This value
is used for material usage and flow rate calculations.

Performance Monitor Plus
16 312767B
Operator Level Screens
Purge Settings
Fig. 7
Key Description
Key Description
Purge Timer ON/OFF ON / OFF buttons Base Mixer Purge Start / Stop buttons
Current Time Min Display Field Main Screen Access Button
Purge Interval Min Input Field Setup Screen Access Button
Alarm Dwell Sec Input Field Dispense Setup Screen Access Button
Purge Shot Time Sec Input Field Run Mode Screen Access Button
Base Purge Feature is shown if equipped with machine.
See Automatic Base Purge feature on Configurator Code E.

Performance Monitor Plus
17 312767B
Operator Level Screens
Purge Settings Cont.
See Fig. 7
The Purge Time feature will only work when
the system is ready to dispense and the Purge
Timer is ON. The Purge Timer is disabled during a
fault.
Purge Timer ON / OFF
The Purge Timer can be used to dispense material
through the mixer during idle times and help prevent
curing in the mixer. When ON the Current Time will
count down. Before dispensing an alarm will sound
indicating the machine will automatically dispense.
CAUTION
The Purge Timer feature is used to prevent the
mixer from curing during normal operation. The
machine will automatically dispense after the
purge warning is given. Ensure material will be
dispensed into a suitable container while using
this feature.
Purge Interval Min
Enter the time in minutes between purge cycles
when system is idle.
Alarm Dwell Sec
Input the amount of warning time before the
machine dispenses a purge shot. Before a purge
shot the machine will pulse an alarm for the amount
of time entered in this field. In addition the Amber
Indicator on the pendant station will flash.
Purge Shot Time Sec
Time the system will dispense a purge shot.
Base Mixer Purge
Start will activate the A supply and dispense material
through mixer.

Performance Monitor Plus
18 312767B
Operator Level Screens
Run Mode
Fig. 8
Key Description Key Description
1 Supply Pump Level Status Purge ON/OFF ON / OFF buttons
2 Supply Pump Cycles/Minute Control Power Control Power Indicator
3 Inlet pressure to Shot Meter Silence Alarm Silence Alarm Button
4 Outlet pressure of Shot Meter Main Screen Access Button
5 Flow rate display grams/sec Dispense Setup Screen Access Button
6 Dispense Status Icon Supply Pump Screen Access Button
7 Ratio Monitor Window Purge Settings Screen Access Button
8 Start / Stop Dispense Alarm History Screen Access Button
9 Ratio Valves Icon Status Screen Access Button
10 Dispense Valve Icon
1
2
3
4 5 6
7
8
910

Performance Monitor Plus
19 312767B
Operator Level Screens
Run Mode Cont.
See Fig. 8
Optional Features are not displayed on the
Run Mode Screen when not configured with the
system. For example Ratio Monitor Window is
displayed when system is equipped with Ratio
Monitoring option.
Dispense Status Icon
This icon displays the ready to dispense indicator.
This indicator is also found on the pendant station.
The Dispense Valve or Ratio Valve indicator is
displayed. The Dispense mode is displayed shot or
Cont (continuous).
Ratio Monitor Window
Weight Ratio is displayed in A: B (X: 1.00)
Flow Rate is displayed in KG/min

Performance Monitor Plus
20 312767B
Operator Level Screens
Status
Fig. 9
Key Description Key Description
Alarm History Screen Access Button Previous Screen Access Button
Pressure StatusScreen Access Button Main Screen Access Button
Material Totals Screen Access Button
Ratio History Screen Access Button