Graco PrecisionFlo XL User manual

Instructions–Parts List
309375F
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
PrecisionFlo™XL Metering
Modules
5000 psi (345 bar, 34.5 MPa) Maximum Inlet Pressure
3500 psi (240 bar, 24 MPa) Maximum Fluid Working Pressure
120 psi (8.3 bar, 0.83 MPa) Maximum Air Working Pressure
For use when dispensing fluids that meet at least one of the following conditions for non-flammability:
DThe fluid has a flash point above 140_F (60_C) and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
DThe fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.
TI1418C

2 309375
Table of Contents
Instruction Manual Conventions 2. . . . . . . . . . . . . . .
List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Metering Assembly Overview 6. . . . . . . . . . . . .
Pneumatic Fluid Metering Assembly 7. . . . . . . . . . .
PrecisionFlo XL Pneumatic Fluid Regulator 7. . . . .
Typical Fluid Applications 7. . . . . . . . . . . . . . . . . . . .
Electric Fluid Metering Assembly 7. . . . . . . . . . . . . .
PrecisionFlo Metering Valve 7. . . . . . . . . . . . . . . . . .
PrecisionFlo XL Module Overview 8. . . . . . . . . . . . . .
Installing Fluid Metering Assembly 9. . . . . . . . . . . . .
Installing the Fluid Metering Assembly 11. . . . . . . .
Grounding the Fluid Metering Assembly 11. . . . . . .
Connecting Fluid Lines and Cables 11. . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 13. . . . . . . . . . . . . . . . . .
Prepare the System for Service 14. . . . . . . . . . . . . .
Servicing the Flow Meter 14. . . . . . . . . . . . . . . . . . . .
Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PrecisionFlo XL Modules 18. . . . . . . . . . . . . . . . . . .
Technical Data 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 34. . . . . . . . . . . . . . . . . . . . .
Graco Information 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction Manual
Conventions
The following table contains the abbreviations that are
used in this manual:
Abbreviation: Stands For:
PVC Poly Vinyl Chloride
psi pounds per square inch
V volts
Vac volts ac
Vdc volts dc
Reference numbers (10) and letters (A) in parentheses
in this manual’s text refer to the numbers and letters in
the illustrations.
List of Models
Table 1 — PrecisionFlo Module – Model Numbers
PrecisionFlo XL
Module No. Description
198245
High viscosity precision pneumatic regulator with helical gear flow meter
198245 Hi
g
h viscosit
y
p
recision
p
neumatic re
g
ulator with helical
g
ear flow meter
198245
High
viscosity
precision
pneumatic
regulator
with
helical
gear
flow
meter
gypp g g
198246
Low viscosity precision pneumatic regulator with helical gear flow meter
198246
L
ow v
i
scos
it
y prec
i
s
i
on pneuma
ti
c regu
l
a
t
or w
ith
h
e
li
ca
l
gear
fl
ow me
t
er
198247
Low viscosity precision pneumatic regulator with spur gear flow meter
198247 Low viscosit
y
p
recision
p
neumatic re
g
ulator with s
p
ur
g
ear flow meter
198247
Low
viscosity
precision
pneumatic
regulator
with
spur
gear
flow
meter
yp p g p g
198184
198184
Low viscosity precision pneumatic regulator without flow meter
198185
L
ow v
i
scos
i
ty prec
i
s
i
on pneumat
i
c regu
l
ator w
i
t
h
out
fl
ow meter
198187
High viscosity precision pneumatic regulator without flow meter
198188
Hi
g
h
v
i
scos
i
ty prec
i
s
i
on pneumat
i
c regu
l
ator w
i
t
h
out
fl
ow meter
233652 Low viscosity precision electric regulator without a flow meter
233653 Low viscosity precision electric regulator with spur gear flow meter
233654 Low viscosity precision electric regulator with helical gear flow meter
233672 High viscosity precision electric regulator without a flow meter
233673 High viscosity precision electric regulator with helical gear flow meter
245315 High viscosity precision electric regulator with helical gear flow meter and an
integrated pneumatic mastic regulator
245316 High viscosity precision electric regulator with an integrated pneumatic mastic
regulator, without flow meter

309375 3
Warnings
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
SKIN INJECTION HAZARD
Spray from the dispensing device, hose leaks, or ruptured components can inject fluid into your body
and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal attention.
DDo not point the dispensing device at anyone or at any part of the body.
DDo not put hand or fingers over the front of the dispensing device.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DFollow the Pressure Relief Procedure on page 13 whenever you are instructed to: relieve pres-
sure; stop dispensing; clean, check, or service the equipment; or install or clean a spray tip or
nozzle.
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.
DALWAYS wear eye protection and protective clothing when installing, operating, or servicing this
dispensing equipment.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause 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.
Follow the fluid manufacturer’s recommendations.
DProvide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DWear the appropriate protective clothing, gloves, eyewear, and respirator.

4 309375
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, warnings, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your
Graco distributor.
DOnly use the PrecisionFlo metering valve with the PrecisionFlo Control Assembly.
DOnly use a dispensing device appropriate for the fluid and application method, and capable of
operating at the highest possible fluid supply pressure the module may experience.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DDo not disassemble the PrecisionFlo metering valve motor. The motor contains powerful mag-
nets, which could attract metal objects and create a hazardous condition if the motor end plates
are removed. Contact your Graco distributor for motor service.
DDo not exceed the maximum working pressure of the lowest rated system component. The
maximum working pressure of the PrecisionFlo metering valve is shown on the fluid head.
Other components may have lower working pressure ratings.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
DDo not use the hoses to pull the equipment.
DUse only fluids that are compatible with the equipment wetted parts. See the Technical Data
sections of all the equipment manuals. Read the fluid manufacturer’s warnings.
DComply with all applicable local, state and national fire, electrical and other safety regulations.
DDo not touch the metal heat sink on the metering valve when the surface is hot.
DDo not cover the PrecisionFlo metering valve; the motor needs air ventilation for cooling.
DDo not attempt to modify the programming of the module. Any modification of the programming
could result in serious injury or damage to the module.
MOVING PARTS HAZARD
Moving parts, such as the fluid needle, can pinch fingers.
DDo not operate the equipment with the guard removed.
DKeep clear of any moving parts when starting or operating the equipment.

309375 5
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.
DGround the equipment and the object being sprayed. The PrecisionFlo metering valve is grounded
through proper connection of the two electrical cables. See Ground the Fluid Metering Assem-
bly on page 11.
DIf there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and corrected the
problem.
DMake sure all electrical work is performed by a qualified electrician only.
DHave any checks, installation, or service to electrical equipment performed by a qualified electrician
only.
DMake sure all electrical equipment is installed and operated in compliance with applicable codes.
DDo not install the PrecisionFlo module in a hazardous area, as defined in Article 500 of the National
Electrical Code (USA).
DMake sure power is disconnected when servicing and repairing equipment.
DKeep the dispensing area free of debris, including solvent, rags, and gasoline.
DBefore operating the equipment, extinguish all open flames or pilot lights in the dispense area.
DDo not smoke in the dispensing area.
DDisconnect the two electrical cables from the PrecisionFlo metering valve before servicing the
valve.
DKeep liquids away from the electrical components
DTurn off power to the PrecisionFlo module before disconnecting any cables connected to the con-
trol assembly or fluid metering assembly.
DDisconnect electrical power at the main switch before servicing the equipment.

6 309375
Fluid Metering Assembly Overview
Pneumatic Fluid Metering Assembly
The fluid metering assembly (Fig. 1) can be attached
to a robot arm, or mounted on a pedestal. Main com-
ponents of the fluid metering assembly are:
DPrecisionFlo XL pneumatic fluid regulator (A)
Dflow meter (B) to precisely measure the amount of
fluid dispensed (optional)
Dsolenoid air valve (C) that controls a dispense
device
Dvoltage to pressure (v/p) controller (D) for adjusting
the air pressure to the fluid regulator (A)
Fig. 1
B
C
A
DTI1417C
PrecisionFlo XL Pneumatic Fluid
Regulator
The PrecisionFlo XL pneumatic fluid regulator is a pre-
cision fluid pressure regulator that uses air pressure to
control fluid pressure and to provide fast response to
electronic commands and ensure a precisely con-
trolled, continuous flow of material.
The PrecisionFlo XL module combines continuous
pressure control with the ability to change bead profiles
almost instantaneously. When used with one of the
optional flow meters, the PrecisionFlo XL module
automatically adjusts for fluctuations in the operating
environment, such as material viscosity, temperature,
and robot speed, while maintaining the desired dis-
pense rate.
The PrecisionFlo XL metering valve is electrically
controlled by the PrecisionFlo XL module and consis-
tent material flow is assured by a closed-loop pressure
control design which also adjusts for flow rate. The
module responds to robot-supplied signals to provide
an accurate and consistent output flow based on a
comparison of actual to desired flow rates.
Typical Fluid Applications
DPVC Sealer
DPlastisols
DSound deadening materials
DBody panel reinforcement

309375 7
Fluid Metering Assembly Overview
Electric Fluid Metering Assembly
The fluid metering assembly (Fig. 2) can be attached
to a robot arm, or mounted on a pedestal. Main com-
ponents of the fluid metering assembly are:
DPrecisionFlo metering valve (A )
Dflow meter (B) to precisely measure the amount of
fluid dispensed and close the flow control loop
Dsolenoid air valve (C) that controls a dispense
device
Dmetering valve closer (D)
Dsolenoid air valve (E) that controls the metering
valve’s closer
Fig. 2
D
B
A
C
E
TI1554A
PrecisionFlo Metering Valve
The PrecisionFlo metering valve (Fig. 3) is a precision
fluid pressure regulator that uses a magnetic linear
servo motor to regulate material pressure and flow.
The needle assembly is directly connected to the linear
servo motor, so the needle responds immediately to
any motor movement.
TI1394A
Fig. 3
PrecisionFlo XL
Metering Valve

8 309375
PrecisionFlo XL Module Overview
The block diagram in Fig. 4 shows an example of the
PrecisionFlo XL module.
The fluid metering assembly contains the components
that control and monitor fluid dispensing. It can be
attached to a robot arm or mounted on a pedestal.
The control assembly sends continuous voltage sig-
nals to the PrecisionFlo metering valve to control
opening and closing of the metering valve.
The control assembly receives input from the robot
controller, user-programmed values, and components
on the fluid metering assembly. The control assembly
uses this input to determine the signal it should send to
the controller.
The PrecisionFlo XL metering valves are electrically
controlled by the PrecisionFlo XL module, and consis-
tent material flow is assured by a closed–loop pressure
or closed–loop flow control design. The module re-
sponds to robot–supplied signals to provide an accu-
rate and consistent output flow based on a comparison
of actual to desired flow rates. The electric regulator
has a needle directly connected to the motor shaft,
yielding nearly instantaneous adjustments to the
material flow rate, while the pneumatic regulator uses
air pressure to control fluid pressure and to provide
fast response to electronic commands and ensure a
precisely controlled, continuous flow of material.
Dispense
Measure Volume
Style Bits 1, 2, 4, 8, 16
Volume Request
Fault Acknowledge
Fault Strobe
Dispenser Ready
Data Bus 16 bit
Volume Valid
Robot Controller
Flow Command
Gun On
Temperature Fault (from optional conditioning system)
Flow Meter
Outlet Pressure
Inlet Pressure
Fig. 4
PrecisionFlo XL
Control Assembly
PrecisionFlo XL
Control Assembly
PrecisionFlo XL
Fluid Metering Assembly
V/P Closer Signal

309375 9
Installing Fluid Metering Assembly
To install the fluid metering assembly hardware:
DInstall the PrecisionFlo fluid metering assembly
DGround the PrecisionFlo system
DConnect the PrecisionFlo fluid metering assembly
to the control assembly
DConnect fluid lines and cables
Installing the Fluid Metering Assembly
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury. Have only qualified electricians access the
fluid metering assembly .
Preparing to Install the Assembly
Before installing the fluid metering assembly:
DSee component manuals for specific data on com-
ponent requirements. Data presented here pertains
to the PrecisionFlo fluid metering assembly only.
DHave all system and subassembly documentation
available during installation.
DBe sure all accessories are adequately sized and
pressure-rated to meet the system’s requirements.
DUse only the Graco PrecisionFlo fluid metering
assembly with the PrecisionFlo control assembly.
Installing the Assembly
WARNING
EQUIPMENT MISUSE HAZARD
The fluid metering assembly weighs
approximately 60 lbs and should never
be moved or lifted by one person. Use
adequate personnel and support devices when
mounting, moving or handling the control assembly
to prevent equipment damage or personal injury.
1. Select a location for the PrecisionFlo fluid metering
assembly. Keep the following in mind:
DAllow sufficient space for installing and using
the equipment.
DMake sure all fluid lines, cables and hoses
easily reach the components they will be
connected to.
DMake sure the fluid metering assembly allows
the robot to move freely along all axes.
DMake sure the fluid metering assembly pro-
vides easy access for servicing its compo-
nents.
2. Locate and secure the PrecisionFlo XL fluid meter-
ing assembly to the robot (or other mounting
surface) with four 3/8 in. bolts through the 0.42 in.
diameter holes in the base plate. See the mounting
dimensions for the electric regulator system in Fig.
5.
Measurements, inches (mm)
A17.0 (432)
B16.0 (407)
C15.0 (381)
D14.0 (356)
Fig. 5
0.42 in. diameter
holes (typical)
A
B
C
D
Models 233652, 233653, 233654, 233672, 233673

10 309375
Installing Fluid Metering Assembly
3. See the mounting dimensions for the pressure/flow
regulating system in Fig. 6 and for the remote–
mount flow meter in Figs. 7 and 8.
Measurements, inches (mm)
Fig. 6 Fig. 7 Fig. 8
A17.0 (432) 20.0 (503) 20.0 (503)
B16.0 (407) 19.0 (483) 19.0 (483)
C15.0 (381) 8.0 (204) 8.0 (204)
D14.0 (356) 7.0 (178) 7.0 (178)
Air to
Dispense
Valve
Fig. 6
A
B
C
D
Pressure/flow regulating system
Air Inlet
1/4 npt (F)
Models 198245, 198246, 198247
Close
Open
4 mm
or 5/32”
tubing
TI1418d
Fig. 7
A
B
C
D
Pressure regulation only, remote-mount flow meter
Models 198184, 198185, 198187, 198188
TI
1
Fig. 8
A
B
C
Remote-mount flow meter
D
TI1553A
4. See the mounting dimensions for models with a
subplate and fluid inlet pressure regulator in Fig. 9.
Measurements, inches (mm)
A24.0 (609)
B23.0 (584)
C19.0 (483)
D18.0 (457)
Fig. 9
AB
C
D
Subplate and fluid inlet pressure regulator
Models 245315, 245316
TI1596A