ACCUTINTER 3212 at3200
Contents
1. FLASH ROM S18809 Fluid Management PART NO S15385 S16281 S18809 S21599 21217 DESCRIPTION SERIAL PORT CABLE ASSEMBLY DISPENSE CONTROL BOARD FLASH ROM 256K FLOPPY DRIVE CAN SENSOR Accutinter 3200 47 POWER SUPPLY S21650 POWER CABLE S21650 B o ka AUX PC PORT L 54601346 PORT S21899 G DISPENSE CONTROL BOARD OUTLET 616281 51007266 e PROCESSOR BOARD S21716 48 Fluid Management PART NO S15995 S21138 S21597 S21650 5121899 51007266 546013462. JCollect IPrepaid ITaxable Fax copy of exemption certificate QUANTITY PART DESCRIPTION UNIT NUMBER PRICE S S S S S S S S S S Comments Name Pease print Signature Date Accutinter 3200 35 PARTS SECTION LJ NOZZLE E FLOPPY TOUCH p DRIVE GUART gt SHELF 0 CANISTORS CAN SENSOR 0 0 CANISTER __ COVERS q 7 4 GEAR Te CNN REDUCER MOTOR POWER PUMP gt SUPPLY 5 Figure 22 Location of Major Components Accessible From Front 36 Fluid Management PARTS SECTION POWER SUPPLY BUILT IN COMPUTER Y PUMPS Z YN LAW Vo dmm 2727 AN R LT 27 IN PT 89 T 37 VALVES DISPENSE CONTROL BOARD Figure 23 Location of Major Components Accessible From Back The remainder of this section illustrates the location of parts along with lists of part numbers Accutinter 3200 PARTS SECTION PUMP BODY S15500 ELBOW 29 FITTING 54600326 ADAPTOR S15625 B B NT E LL LLLI INTAKE T Qo S03879 COUPLING HALF S03482 38 Fluid Management PAR
3. in the User Manual and change all colorant levels to FULL NOTE To ensure accurate results you must allow the aeration in the colorant to escape Allow to sit at least 12 hours before proceeding 14 Fluid Management INSTALLATION INITIAL DISPENSE Determine if the Accutinter is operating by performing a purge 1 Place a container under the dispense nozzle as shown below DISPENSE 4 DISPOSABLE CONTAINER Figure 4 Dispense Test 2 Press or using the touch mouse click once on the Maintenance icon as shown in Figure 5 Figure 5 Selecting Maintains Screen 3 From the screen in Figure 6 press the Ctrl and keys or click once on the Purge tab with the touch mouse This will open a new screen Accutinter 3200 15 INSTALLATION 4 Press the Ctrl and keys or click once on the button on the screen shown in Figure 6 Press or click once on the Purge button on 5 a 1 AL Tasis D Figure 6 Purge Screen 6 Check that each colorant comes out in a straight steady stream If the dispense is erratic repeat these steps Z amp Berriat Tests Lm Hipi Main omm TO GOOD DISPENSE BAD DISPENSE AR Figure 7 Dispense Guality Test The Acc
4. A R A R A R A R 1 2 A R A R A R A R A R A R Accutinter 3200 43 PARTS SECTION i ZA gt STOP S21995 S06488 SHELF S21712 gt SCREW im _ SF0028C3N10 U 0 7 J C WASHER S4000326 NUT NUT WASHER S4000003 S4000027 S01670 LIGHT NOZZLE BOARD N S21709 S01178 ORPHICE N S21710 KI Q 7 Q lt gt 44 Fluid Management PARTS SECTION PART NO DESCRIPTION NO REO S01670 WASHER 3 16 ID X 3 8 OD X 1 16 2 S06488 CAN POSITIONING STOP 1 501178 BOUNG HOLE LIGHT RESISTOR BOARD 1 521709 NOZZLE BLOCK 1 521710 ORPHICE 1 PER COLORANT A R S21712 SHELF 1 21995 SHELF MOUNTING BRACKET 2 S4000003 NUT 1 4 20 2 S4000027 NUT 10 32 2 S40003262 LOCK WASHER 1 2 2 SF0028C3N10 NUT 10 31 2 Accutinter 3200 45 SERIAL FLOPPY PORT DRIVE S15385 S21599 CAN SENSOR S21700 DISPENSE CONTROL BOARD S16281 za ag l d reg NEES wees Geer
5. S19198 S21408 S21410 S21413 S5608210 DESCRIPTION FUSE 1A 250V POWER INPUT CONNECTOR FUSE SLOW BLOW 250V FUSE SLOW BLOW 2A 250V 14 COLOR CRT MONITOR TOUCH MOUSE TERMINAL BLOCK TERMINAL BLOCK TERMINAL BLOCK END PLATE TERMINAL BLOCK END BLOCK NO REQ Accutinter 3200 51 FUSE 3A SLO BLOW S5108248 BACK OF HIGH SPEED SOLID STATE RELAY S6288 7 RECIRCULATION MOTOR SOLID STATE RELAY LOW SPEED S6288 ACCUTINTER RELAY PANEL S65217 LOW VOLTAGE HIGH VOLTAGE eg fta RECTIFIER 512595 512595 HIGH SPEED 2 TEST BUTTON 501339 a FUSE F 15 A SLO BLOW S06286 2 AGITATION 4 z MOTOR AGITATION amp SOLID STATE PUMP MOTOR gt RELAY TEST SWITCHES S6288 51717 52 Fluid Management PART NO DESCRIPTION NO REO S01339 PUSHBUTTON 1PER PUMP MOTOR 1 2 S06268 FUSE 15 AMP SLOW BLOW 1 S1717 TOGGLE SWITCH SPDT 2 S6288 SOLID STATE RELAY 3 S12595 FULL WAVE BRIDGE RECTOFYER 2 S65217 RELAY PANEL ASSEMBLY 1 S5108248 FUSE 3 AMP SLOW BLOW 1 Accutinter 3200 53 HARDWARE WARRANTY If within one year from the date of shipment or one year from the proven date of installation any eguipment covered by this manual shall prove to be defective in materials or workmanship upon examination by FLUID MANAGE MENT SELLER SELLER will supply ident
6. This manual is to be used in conjunction with the other documentation that comes with the eguipment HOW TO USE THIS MANUAL The manual is organized into four 4 sections including this one Each section is divided into sub sections that cover a given Accutinter topic The intent is to pro vide a basic reference work that can be used to address installation and maintenance issues SAFETY The Accutinter line of precision colorant dispensers is a safe and effective collec tion of quality equipment This equipment is designed to bring many years of oper ation In order to avoid damage to the equipment or bodily injury basic precautions and warnings must be observed For the Accutinter line these basic precautions and warnings are accompanied by special labels Warning Labels There are a number of warning labels on the Accutinter dispenser Read all of these labels Keep the labels clean so they are easy to read If the warning labels become damaged or unreadable purchase new labels from Fluid Management See the Parts List section of this manual for ordering information Safety Information in This Manual Improper maintenance can shorten the life of this equipment Performing proce dures improperly can be hazardous and could result in serious injury or death The precautions and procedures stated in this manual apply to installers and mainte nance personnel This manual must be read thoroughly before installing or main taining this
7. WITHOUT THE SELLER S PRIOR PER MISSION OR HAS BEEN SUBJECTED TO ANY ACCIDENT CASUALTY MISAPPLICATION ALTERATION ABUSE OR MISUSE NO OTHER WARRANTY EITHER EXPRESS OR IMPLIED AND INCLUDING A WARRANTY OR MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE HAS BEEN OR WILL BE MADE BY OR ON BEHALF OF SELLER OR BY OPERATION OF LAW WITH RESPECT TO THE EQUIPMENT AND ACCES SORIES OR THEIR INSTALLATION USE OPERATION REPLACEMENT OR REPAIR SELLER SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR ANY INCIDEN TAL SPECIAL OR CONSEQUENTIAL DAMAGE RESULTING FROM THE USE OR OPERATION OF THE EQUIPMENT WHETHER OR NOT SELLER WAS APPRISED OF THE POSSIBILITY OF SUCH DAMAGES IRRESPECTIVE OF ANY STATUTE THE BUYER RECOGNIZES THAT THE EXPRESS WARRANTY SET FORTH ABOVE IS THE EXCLUSIVE REMEDY TO WHICH IT IS ENTITLED AND WAIVES ALL OTHER REMEDIES STATUTORY OR OTHERWISE REPAIR OR REPLACEMENT SHALL BE BUYER S SOLE REM EDY UNDER THIS WARRANTY Fluid Management SOFTWARE WARRANTY I FLUID MANAGEMENT SELLER warrants that it has the right to grant a license for use of the Software included in its eguipment IL SELLER warrants for a period of ninety 90 days from the date of sale of its equipment that the Software will substantially conform with the functionality described in the Manual accompanying the equipment This warranty is void if a Software error or malfunction is caused by machine malfunction by mod
8. and no pieces missing Rinse all parts thoroughly with clear water Valve Reassembly 1 2 The parts should all be clean and dry Refer Figure 16 on page 24 to reassemble the valve Valve Insertion CAUTION Do not cross thread the screws in the f aluminum bar NOTE When installing the valve be sure that the words IN and OUT 1 stamped on the brass valve bodv are placed in the proper direction The side labeled IN should be coming from the pump and the side labeled OUT should be going to the dispense nozzle Install the valve on the valve bar and secure with the two socket head screws Figure 17 Installing Valve 26 Fluid Management MAINTENANCE 10 1 12 13 Verify that the hose clamps are in place the hose ends before pushing tubing in If a heat gun is available heat the hose ends Push the hoses over the fittings Tighten the hose clamps Reconnect the power plug to the valve WARNING Dangerous AC current exists in this equipment Take all precautionary steps to avoid contact with AC power Restore power to the dispenser and turn on the recirculation switch so that the pumps are turning at low speed The recirculation switch is located on the relay panel Check for leaks around the valve fittings Turn the recirculation switch off Manually dispense approximately 5 10 ounces of colorant into a clean container to purge any air introduced into the
9. equipment It should be kept near the machine for reference and periodically be reviewed by all personnel who work with the equipment Some Accutinter 3200 INTRODUCTION actions involved in operation and maintenance of the machine can cause serious accidents if they are not performed in the manner described in this manual Proper precautions must be taken during the maintenance of this equipment Care lessness and disregard for safety can result in damage to the equipment and injury or even death to the technician This manual contains statements regarding safety precautions The precautions are categorized as follows WARNING The warning sign indicates that a high probability of serious injury or death exists if N the hazard is not avoided These safety messages describe precautions that must be taken to avoid the hazard CAUTION A caution is used to signify that precautions must be taken to avoid actions that could damage the equipment NOTE This word is used for information regarding the equipment that may be used by the service technician to make the procedure easier to perform This equipment uses AC and DC power to operate AC power can cause injury and even death Most of the procedures in this manual can and should be performed with the equipment disconnected from the power source WARNING There are maintenance procedures detailed in this manual that are required to be N performed with the eguipment powered War
10. of the various major com ponents Agitation Memory Encoder Up to 16 Valves Motor Display Relay Panel 4 Motor 2 Dispense Control Board X If used Keyboard E 4 If used Serial Serial Computer with Floppy Conn Hand Drive Figure 1 Overall Block Diagram A DC motor a second motor is optional drives all the pumps simultaneously with a speed reducer and drive chain An encoder wheel and magnetic hall effect sensor provide a known number of electrical pulses per revolution of the motor These pulses are counted by the dispense control board Figure 2 is a simplified block diagram of the tinting operation as observed in one colorant The positive displacement pump delivers a fixed volume of colorant per revolution From the pump output port the colorant is pushed to the input of a three way solenoid valve The valve diverts the colorant to one of two locations External container Back to the canister which holds the colorant Accutinter 3200 INTRODUCTION y AGITATOR amp AGITATOR V U 1 MOTOR MOTOR CONTROL SYSTEM poe XE Figure 2 Block Diagram of Tinting Operation The colorant in each canister is periodically agitated by a paddle assembly driven by a motor These agitat
11. off and replace the covers 32 Fluid Management MAINTENANCE NOTES Accutinter 3200 33 MAINTENANCE 34 Fluid Management PARTS SECTION PARTS SECTION This section is designed to assist you in Performing service functions and Identifying parts All repairs must be performed by gualified service personnel TERMS Unless prior arrangements have been made parts will be shipped UPS COD All prices are F O B Wheeling Illinois and are subject to change without notice In all correspondence or phone orders for parts please state model number and serial number of the Miller Mixer Order less than 25 00 will be assessed a 5 00 handling charge RETURNS No parts are to be returned without prior authorization A Returned Goods Authorization number is reguired Accutinter 3200 33 PARTS SECTION EGUIPMENT MAINTENANCE LOG RECORD MODEL NUMBER HERE RECORD SERIAL NUMBER HERE SERVICE DESCRIPTION amp PARTS REPLACED SERVICED DATE STATE IF UNDER WARRANTY BY 34 Fluid Management PARTS SECTION SPARE PARTS ORDER Fluid Management Parts Order Form Photocopy and use this form to Mail or fax orders to Fluid Managementa unit of IDEX Phone 1 800 462 2466 1023 South Wheeling Road Fax 1 847 537 5530 Wheeling IL 60090 Sold Ship Number PHONEZ Ship Via
12. page 31 Dispense water into a container and dispose in a manner consistent with local pollution control standards Repeat step numbers 4 and 5 until water runs nearly clear Repeat step numbers 4 through 6 for each channel Dispense all water from all channels It may be helpful to brush the sides of the canisters to free material Pour the colorants that were removed in step numbers 2 and 3 back into the appropriate canisters Dispense colorant until pure colorant comes from each channel Discard in a manner consistent with local pollution standards Test as appropriate Accutinter 3200 19 MAINTENANCE Canister 8 Agitator Cleaning The agitators and canisters can be cleaned in one of two 2 ways e Disassembly Svstem Flush Disassembly amp Cleaning 1 Find a clean container for each colorant in the system These containers will be used to store the colorant for later reintroduction back into the system 2 Dispense all of the colorant from the channel until all of the colorant is gone from each canister 3 Liftup and remove the agitation blade assembly 4 Clean the agitation blade assembly thoroughly in soap and warm water 5 Discard the water in a manner consistent with local pollution control standards 6 Clean the canister in place thoroughly in soap and warm water 7 Dispense all water from all channels 8 Pour the colorants that were removed in step 2 back into the appropriate cani
13. system Make sure that the colorant does not flow through the recirculation port Replace the lower rear cover Restore power to the Accutinter Test as appropriate Accutinter 3200 27 MAINTENANCE LOADING COLORANT NOTE When filling the canisters with colorant the recirculation deflector should never be covered Open one colorant container at a time and pour immediately into the appropriate canister RECIRCULATION DEFLECTOR BAD m LEVEL A Figure 18 Filling Canisters 1 Remove the canister covers from each canister on the Accuitnter 2 Open one container of colorant at a time 3 Pour the colorants slowly into the appropriate canisters not exceeding the level defined by the recirculation deflector 4 Update the colorPro software under the setup icon CAUTION If the software is not properly updated the f Accutinter will not function properlv LUBRICATION Oil Level Check And Lubrication The speed reducer connects the shaft of the dispenser motor to the drive chain and pumps The speed reducer requires verv little maintenance provided the oil level is properlv maintained The oil level should be checked periodicallv and the level should be maintained if leakage occurs The oil must be changed each time maintenance procedures are preformed that require gearbox disassembly 28 Fluid Management MAINTENANCE Excessive noise or vibration during the recirculation cycle i
14. 20 MOTOR BRUSHES 1 SET PER MOTOR A R Accutinter 3200 41 PARTS SECTION SET SCREW S12148 t Oeil Ce Opi Oc 99 SPROCKET S15513 PUMP MOUNT ASSEMBLY 515503 PUMP S15504 CCW S15543 CW fel SPIDER S01038 KEY S15179 HUB S15603 CHAIN S06393 SPROCKET S65153 p T SCREW WASHER 501119 LOCK S00217 WASHER S00219 SPEED REDUCER S06662 S19470 42 Fluid Management PARTS SECTION PART NO S00217 S00219 S01038 S01119 S06393 S06662 S12148 S15179 S15503 S15504 S15513 S15543 S15603 S65153 DESCRIPTION FLAT WASHER 3 8 LOCK WASHER 3 8 SPLIT COUPLING SPIDER 1 PER PUMP SCREW 3 8 16 X 1 1 4 CHAIN 1 4 PITCH X 71 LINKS 1 ASSEMBLY PER PUMP LESS 1 SPEED REDUCER SET SCREW 1 4 20 X 5 16 2 PER PUMP KEY 3 16 X 1 1 PER PUMP MOTOR PUMP MOUNTING ASSEMBLY 1 PER PUMP PUMP CCW WELDMENT SPROCKET WITH HUB 1 PER PUMP MOTOR PUMP CW COUPLING HUB 1 PER PUMP MOTOR WELDMENT SPROCKET 1 PER PUMP NO REQ
15. 3 Fluid Management Accutinter 3200 Series Maintenance Manual Part 23106 Rev A 10 23 97 CONFIDENTIAL PROPERTY OF FLUID MANAGEMENT C COPYRIGHT 1999 FLUID MANAGEMENT AS AN UNPUBLISHED WORK ALL RIGHTS RESERVED This material cannot be copied or disclosed to others without the prior written permission of Fluid Management Fluid Management A Unit of IDEX Corporation 1023 Wheeling Road Wheeling Illinois 60090 5776 Telephone 847 537 0880 1 800 462 2466 Fax 847 537 5530 TABLE OF CONTENTS INTRODUCTION GENERAL SCOPE OF MANUAL HOW USE THIS MANUAL SAFETY INSTALLATION VERIFY SITE REQUIREMENTS UNPACKING PRE INSTALLATION INSPECTION CONNECT TO POWER SOURCE INTERFACE CONNECTIONS START UP INITIAL DISPENSE MAINTENANCE COVER REMOVAL INSTALLATION CLEANING LOADING COLORANT LUBRICATION PARTS SECTION 11 17 33 Accutinter 3200 Fluid Management INTRODUCTION INTRODUCTION GENERAL The Accutinter 3200 is a microprocessor controlled colorant dispenser used for custom blending of paint This completely self contained unit is controlled by a built in computer loaded with ColorPro software The software is fully menu driven and is designed for ease of use The software has an on line help utility that contains information found in the User Manual Figure 1 shows an overall block diagram of the unit indicating the interconnection
16. DESCRIPTION MICROPROCESSOR PROCESSOR BOARD MEMORY BOARD 8 MB NOT SHOWN DUAL VOLTAVE POWER SUPPLY PHONE LINE PORT POWER RECEPTICAL MONITOR PORT NO REQ Accutinter 3200 49 END BLOCK 85608210 Eo DIN MONITOR C C 1 2 3 415 6 7 8 9 10111 12 13 14 15 16 17 18 Q E Um 516378 JJ 1 7 a END p PLATE TERMINAL S21408 settle CONNECTOR TERMINAL S01520 lt 621410 FUSE S01791 FUSE S01463 L X LT A FUSE S01752 KEYBOARD TOUCH MOUSE S19198 50 Fluid Management PART NO S01463 S01520 S01752 S01791 S16378
17. ELLER or 32 The information is in or comes into the public domain through no act or omission on the part of BUYER or 3 3 The information is rightfully disclosed to BUYER by a third party with SELLER s approval and without restriction on disclosure 4 BUYER agrees that the Software and all copies and versions made by BUYER are and shall remain the sole property of SELLER BUYER agrees to include SELLER s proprietary notice on all copies of the Software in whole or in part and in any form made by the BUYER 5 obligations set forth in this Agreement shall survive the termination of this or any other Agreement with SELLER Fluid Management Fluid Management Part 23106 Rev A 23 23 97 1023 Wheeling Road Wheeling Illinois 60090 5776 Voice 847 537 0880 800 462 2466 Fax 847 537 5530
18. INTENANCE HEAT THIS AREA FAULTY VALVE HEAT GUN HEAT THIS AREA Figure 15 Heating the Barbed Fitting NOTE If you are cleaning or repairing the existing valve proceed to the next section If you are installing a new replacement valve proceed to Installing the New Valve Valves Disassembly USE 3 4 OPEN END WRENCH SPRING END SMALL END USE ADJUSTABLE QUICK RELEASE FITTING BARBED FITTING UES 1 OPEN END WRENCH USE 9 19 OPEN WRENCH ON 90 DEGREE FITTING Figure 16 Exploded View of Valve 1 Remove the 90 fitting from the solenoid coil Turn the fitting counter clockwise 24 Fluid Management MAINTENANCE 2 Remove the 1 nut to release the solenoid from the neck of the valve NOTE If a spanner wrench is not available an adjustable wrench may be used reinsert the 90 fitting and use the wrench on the two flats above the threads on the valve body 3 Use a spanner wrench to remove the silver neck from the brass valve base Grasp the valve at the base but not the end The two pieces inside the valve are a spring and a viton poppet assembly Accutinter 3200 25 MAINTENANCE Valve Cleaning 1 2 3 4 5 Prepare a solution of water Clean all parts thoroughly with the soapy water using a small synthetic brush Be sure no debris is embedded in the viton seat of the poppet Check that there are no slices in the poppet
19. TS SECTION PART NO DESCRIPTION NO REO S03482 PUMP COUPLING HALF 2 PER A R S03879 PUMP INTAKE FITTING 1 OD X 3 8 1 PER PUMP A R S15550 SLEEVE MOUNTED 2GPM 1 PER COLORANT A R S15625 PUMP OUTPUT ADAPTOR 1 PER A R S19470 PUMP MOTOR 2ND MOTOR OPTIONAL 1 2 S4600326 ELBOW FITTING 1 PER PUMP A R Accutinter 3200 39 PARTS SECTION COVER S03301 SENSOR S50180 N 650118 CONNECTOR 501367 m MOUNTING BRACKET COVER DISK amp HUB PETS LOCATION 50152 1 VOC OSA O 0O BRACKET D 501834 CT y TERMINAL 520354 ole E E SC SCREW 03005 LOCK WASHER CONNECTOR 801123 501312 Fluid Management 40 PARTS SECTION PART NO DESCRIPTION NO REO S01123 LOCK WASHER 6 1 PNE ENCODER A R S01312 ENCODER SENSOR CONNECTOR 1 PER A R S03484 SPACER 1 PER MOTOR A R S03301 COVER 1 PER ENCODER A R S01367 ENCODER CONNECTOR 1 PER A R S03005 SCREW 6 32 X 1 4 1 PER ENCODER A R S01834 ENCODER SENSOR BRACKET 1 PER A R S19470 PUMP MOTOR 2ND OPTIONAL A R S50118 ENCODER MAGNET 1 PER A R S50163 ENCODER BRACKET 1 PER ENCODER A R S50180 ENCODER SENSOR 1 PER A R S41008
20. U is temporarily inoperable BUYER may transfer the use of the Software to a backup central processing unit until operable status is restored to the CPU In addition BUYER may make copies of the Software for purposes of backup only 4 This Software License is assignable and transferable in connection with the equipment for which this Manual is provided Proprietary Information 1l BUYER acknowledges that the Software for the equipment set forth in this Manual constitutes proprietary and confidential information of SELLER and that the protection of this information is of the highest importance BUYER agrees to keep the Software in strict confidence to take appropriate steps to ensure that persons authorized to have access to the Software shall refrain from any unauthorized reproduction or disclosure of the Software and to restrict access to and display of the Software to BUYER S personnel who need to access or display the Software to enable BUYER to use the Software as contemplated by this Agreement and who have been advised of and have agreed to treat the Software in accordance with BUYER S obligations 2 BUYER will not lend sell give lease or otherwise disclose the Software or any associated programs derived or developed from the Software without the prior express written approval of SELLER 3 BUYER will not be liable for disclosure of any Software if 3 1 The information is rightfully known to BUYER prior to receipt of it from S
21. ated colorant prevents the parts from moving Valves Removal 1 Remove power by disconnecting power cord from power source 2 Place an empty 32 ounce can under the dispense nozzle Opening a line will cause colorant to drain 3 Open the lower rear cover exposing the valves Figure 11 on page 22 shows the location of the valves Accutinter 3200 21 MAINTENANCE VALVES Figure 11 Location of Valves Unplug the small power plug from the valve FAULTY VALVE Figure 12 Unplugging Valve Power Connector Using a 3 16 ball nose Allen wrench remove the socket head screws that hold the faulty valve to the valve bar The hoses will hold the faulty valve in place NOTE Some colorant will drain from the valve and hoses Have small containers or paper towels handy 22 Fluid Management MAINTENANCE FAULTY SOCKET HEAD SCREW 3 16 BALL NOSE ALLEN WRENCH Figure 13 Removing the Valve Using a flat blade screw driver or 1 4 nut driver loosen the hose clamps on the three colorant lines Move the clamps away from the valve TOP HOSE E FLAT BLADE SEAME SCREW DRIVER FAULTY VALVE Figure 14 Removing Hose Clamp from Barbed Fitting NOTE If a heat gun is available slowly heat the area around each barbed fitting Applying heat to the hose at the fitting makes removal easier to perform Remove all three hoses from the valve Accutinter 3200 23 MA
22. crews for reinstallation CLEANING The long term and reliable operation of the Accutinter is largely dependent upon keeping the system clean Spills on the surface of the Accutinter or Accutinter sen sors should be wiped up as they occur This section addresses the procedures involved in cleaning and maintaining the cleanliness of the Accutinter and its components 18 Fluid Management MAINTENANCE Pump Cleaning Disassembly of pumps for cleaning is not recommended The internal cleaning of pumps should only be done by flushing the entire system To clean the pump refer to the Tubing Cleaning section of this manual Tubing Cleaning With the passage of time tubing may need to be cleaned of coagulated colorant It may not be necessary to remove tubing to do this The following steps represent a method by which all of the components in the plumbing system can be cleaned The intent is to flush out the system 1 10 1 12 Find a clean container for each colorant in the system These containers will be used to store the colorant for later reintroduction back into the system Dispense all of the colorant from one channel until all of the colorant is gone from the canister Repeat step number two 2 for each of the remaining channels Fill one 1 canister with hot tap water and recycle for five 5 minutes A switch on the relay panel can be used recycle colorant See Recirculation Switch Location on
23. ical or substantially similar replacement equipment parts or at SELLER s option will repair or allow credit for such equipment In addition within the United States and Canada labor costs are covered for the first six months following shipment or proven installation date for repairs to the follow ing components crankshafts motors speed reducers circuit boards relays relay panels power supplies transform ers frames gear pumps solenoid valves canholders bearings and clutch springs All labor must be approved in advance by SELLER and performed by a Fluid Management Authorized Service Center PURCHASER MUST NOTIFY SELLER OF A WARRANTY CLAIM WITHIN THIS PERIOD NO RETURNS ARE AUTHORIZED WITHOUT A RETURN GOODS AUTHORIZATION FORM Any repair or replacement pro vided hereunder shall be warranted against defects in material or workmanship for the unexpired portion of the equip ment warranty This warranty does not cover software which is covered by separate warranty Disclaimer THIS WARRANTY SHALL BE APPLICABLE ONLY IF THE EQUIPMENT SHALL BE THE PROPERTY OF THE ORIGINAL PURCHASER OR USER AND SHALL HAVE BEEN PROPERLY USED OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MANUAL OR INSTRUCTIONS PROVIDED WITH THE EQUIP MENT AND FOR THE PURPOSE FOR WHICH SOLD NORMAL WEAR AND TEAR IS NOT COVERED BY THIS WARRANTY THIS WARRANTY SHALL NOT BE APPLICABLE IF THE EQUIPMENT OR ANY PART THEREOF HAS BEEN REPAIRED OR REPLACED BY THE BUYER
24. ification of the Software or equipment not made by SELLER or by incorrect data or procedures used by BUYER S personnel or if BUYER fails to apply the current release of the Software provided to BUYER BUYER S SOLE AND EXCLUSIVE REMEDIES UNDER THIS WARRANTY ARE 1 THE COR RECTION OF THE SOFTWARE SO THAT IT PERFORMS AS WARRANTED CORRECTION WILL BE BY ERROR MAINTENANCE WHICH MAY INCLUDE THE REPAIR OR REPLACEMENT OF THE SOFTWARE OR 2 IF AFTER REPEATED EFFORTS SELLER DETERMINES THAT IT IS UNABLE TO MAKE THE SOFTWARE PERFORM AS WARRANTED BUYER MAY RETURN THE EQUIPMENT TO SELLER AT BUYER S EXPENSE SELLER SHALL NOT BE LIABLE FOR ANY ACTUAL OR CONSEQUENTIAL DAMAGES INCURRED BY BUYER EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY SELLER MAKES NO WARRANTIES EXPRESS OR IMPLIED CONCERNING THE SOFTWARE INCLUDING ALL WARRANTIES OR MERCHANTABILITY AND FIT NESS FOR A PARTICULAR PURPOSE Software License 1 SELLER grants to BUYER subject to the terms and conditions contained in this Software License non exclusive and non transferable license except as provided below to use the proprietary computer software programs and related materials Soft ware in association with SELLER s equipment set forth in this Manual 2 BUYER shall have the right to use the Software solely for its own internal operation at the Location where first placed in oper ation and on the Central Processing Unit CPU described in this Manual 3 When the CP
25. ion motors located on the bottom of the canisters are pow ered by 115 VAC The entire system runs on 115 VAC This incoming power is converted to Svolts DC for the electronics microprocessor and circuit boards e 24 volts DC for solenoids and relays A constant voltage transformer provides 19 volts AC which is converted to a low DC voltage This power is used to run the pump motor at low speed for recircula tion of colorants and low speed dispenses The pump is driven at high speed with 130 Volts DC for high speed dispensing The model 3200 Accutinter has a built in computer that stores the formulas on a hard disk drive The built in computer has an externally accessible floppy drive located on the tight side of the machine 6 Fluid Management INTRODUCTION SCOPE OF MANUAL This manual provides instructions for installation and scheduled maintenance of the Accutinter It is intended to be used by service technicians and operators General knowledge of the operation of the Accutinter is practical when maintaining this equipment Review the User Manual that came with the Accutinter or refer to the on line help utility before performing any service procedures on the equipment This manual is shipped with each Accutinter 3200 along with the following docu mentation Accutinter 3200 schematic Getting Started with ColorPro Manual 20936 Accutinter Service Guide P N 22763
26. lecting Setup Screen Accutinter 3200 13 INSTALLATION 2 From the next screen select the External Data tab 3 Select the appropriate color matching system and click on the Add button Follow the prompts as required Scale Configuration The model 3200 Accutinter is designed to use an external scale for color calibra tion The scale configuration is done in FM Text PREPARING AND FILLING THE CANISTERS Refer to Canister Layout in the User Manual before filling the canisters The Accutinter is shipped with a quantity of colorant in the canisters Shake or stir depending on what the manufacturer recommends for their colorant enough color ant to fill each canister Each small canister orange plastic cover holds six 6 quarts of colorant Each large canister red plastic cover holds five 5 gallons of colorant These canisters must be filled nut not overfilled to capacity for the Accutinter to operate properly 1 Open the colorant compartments by raising the compartment top covers NOTE Make sure that you fill all of the canisters to the full level just under the bottom of the deflector shield If the colorant covers wire of the agitation blade the canister is overfilled 2 Pullthe cap off each canister one at a time and fill with the appropriate colorant until the canister is filled The full level 3 each of the remaining canisters with colorants 4 Refer to COLORANT LEVELS
27. ndicates low oil level or worn elements To check the oil level 1 2 4 2 Disconnect power to the machine and remove the lower front cover Referring to the figure below remove the oil level plug located above the drive shaft OIL CHECK HOLE Figure 19 Inspecting Oil Level If oil does not seep out the level is low and should be topped up with one of the following lubricants AGMA 8 Amoco Cyl Oil No 680 Cylasstic TK680 Gulf Senate 680 Mobil 600 W Super Cyl Oil Hector 3000 5 Check for leaks at the housing bolts Tighten bolts if necessary Replace the dispenser s covers and restore power Chain Lubrication Periodic lubrication of the drive chains is recommended to ensure smooth operation If the chains are noisy or if they have not been lubricated in a year perform the following procedure to lubricate the chains Accutinter 3200 29 MAINTENANCE SOCKET 1 4 ALLEN WRENCH 1 2 WRENCH POWER PLUG 1 2 OPEN END WRENCH WITH MOTER POWER BOX amp FUSES WRENCH LUBRICATION OF CHAINS END WRENCH WITH MOTER POWER BOX amp FUSES REMOVED Figure 20 Chain Lubrication WARNING Dangerous AC current exists in this equipment Take all precautionary steps to avoid contact with AC power 1 Remove the lower front cover and the lower rear cover from the dispenser WARNING Keep hands and clothing clear of moving f machine par
28. nings regarding electrical shock hazards will accompany those procedures All electrical shock warnings must be heeded to ensure that these maintenance procedures may be performed safely Fluid Management INTRODUCTION NOTES 10 Fluid Management INSTALLATION INSTALLATION Record the Model Number and Serial Number on the parts section of this Manual These numbers are located on the back panel of the Accutinter VERIFY SITE REGUIREMENTS Before you begin the installation procedure inspect the installation site and ensure that it meets all necessary reguirements If the eguipment is installed in an inappro priate site routine maintenance and service procedures may be difficult to perform SPACE REGUIREMENTS Ensure that there will be ample space around the installed eguipment Some main tenance procedures reguire that service personnel have access to the rear of the eguipment If the eguipment is placed against a wall there must be sufficient room to move the Accutinter away from the wall There must be ample room at the front of the eguipment for the operator to move about The assembled Accutinter is approximately 50 inches 127 cm wide and 25 inches 64 cm deep The Accutinter weighs approximately 1000 pounds 450 kg Ensure that the floor at the operation site is level and that it will easily be able to withstand the weight of the eguipment AVAILABLE POWER CAUTION use of non dedicated AC elect
29. nt Take all precautionarv steps to avoid contact with AC power 12 Fluid Management INSTALLATION 1 Plug the single plug surge protector that you received with the machine into a 20 amp dedicated line 2 Plug the Accutinter and monitor into the surge protector INTERFACE CONNECTIONS The Accutinter is equipped with a serial interface to connect the dispenser to addi tional external equipment such as a scale or spectrophotometer color matching sys tem Connect the peripherals equipment as follows 1 Connect the serial port located on the left side of the Accutinter to the serial port on the peripherals 2 Connect electrical power to the peripherals START UP Once you have connected the Accutinter to AC power the computer will boot up and the display will show the ColorPro home page If an error message appears or the PC does NOT come up running ColorPro call 1 800 462 2466 for assistance To prepare the Accutinter for everyday operation refer to the software section of the Accutinter Service Guide Spectrophotometer Configuration The model 3200 Accutinter is designed to use a spectrophotometer for color match ing functions The following steps represent the process by which the color match ing system is configured in the Accutinter system 1 With ColorPro running and the main menu open press F4 or click once on the Setup icon uhr s Sebert Ad F6 TIPA GER AUTRE or Figure 3 Se
30. rical service to the Accutinter may result in improper operation and damage to the equipment The Accutinter requires 115 VAC at 20 Amps on a dedicated line Ensure that the power supply is sufficient for the Accutinter and that it meets all national and local codes Accutinter 3200 11 INSTALLATION UNPACKING screwdriver and pair of scissors or diagonal cutters are required to unpack the Accutinter REMOVE PROTECTIVE COVERING 1 Remove plastic cover and nylon strapping from around the machine 2 Remove plastic wrapping from the keyboard 3 Remove cardboard protectors over the canisters 4 Remove packing blocks from back of the machine and from under the canister covers REMOVE INTERIOR CONTENTS Check contents against the packing slip Contact Customer Service if items are missing The surge suppressor and User Manual are packed in a separate box PRE INSTALLATION INSPECTION CAUTION The Accutinter weighs in excess of 1000 f pounds 450 kg Though it rolls on heavv dutv casters maneuvering the Accutinter is a two person job If the selected site meets all requirements move the Accutinter to the site Carefullv inspect the equipment for dents and scratches that mav have occurred during ship ment Report anv damage to the carrier and Fluid Management before installing the Accutinter CONNECT TO POWER SOURCE WARNING Ensure that all covers are in place Dangerous AC current exists in this equipme
31. sters 9 Purge each colorant dispense one ounce of colorant from each channel and discard in a manner consistent with local solution standards 10 Test as appropriate Nozzle Cleaning The Tubing Cleaning process covered in this section should be used in an effort to clean the valves before the decision is made to replace the nozzle the following steps represent the process by which a clogged nozzle can be cleared If you are troubleshooting nozzle problems you should try cleaning before considering replacement 1 Using a paper clip or similar device clear the nozzle channel being careful not to score any portion of the nozzle assembly Do this to each channel that may be effected 20 Fluid Management MAINTENANCE NOZZLE Figure 10 Nozzle Cleaning 2 Perform the purge operation observing the colorant streams It may be necessary to repeat this procedure several times before the nozzle is clear If this does not correct the problem the nozzle assembly must be changed 3 Ifthe nozzle is clear purge the system of air and perform appropriate tests Valve Cleaning If valve problems persist it may be necessary to disassemble the valve for cleaning This section describes a through disassembly and cleaning of the valves It also explains how the valve can be replaced with a new one It is a major operation and should be preformed only if the valves have become inoperative Valves may stop functioning if coagul
32. ts 30 Fluid Management MAINTENANCE Locate the recirculation switch and place it in the ON position hi Lip KA LOCATION OF RELAY PANEL BACK OF ACCUTINTER K RECIRCULATION SWITCH 2 X LL RELAY PANEL Figure 21 Recirculation Switch Location As the motor and chains are turning at low speed carefully spray a chain lubricant on the chains through at least one complete rotation of each chain It may be necessary to temporarily remove the power supply module to gain access to all the chains The wires to the module are long enough to leave it plugged in yet moved far enough away to provide access to the chain a Turn the recirculation switch off and disconnect power from the dispenser b Use a 1 2 open end wrench to remove the power supply module WARNING Dangerous AC current exists in this equipment Take all precautionary steps to avoid contact with AC power Accutinter 3200 31 MAINTENANCE WARNING Keep hands and clothing clear of moving f machine parts c Restore power and turn the recirculation switch on d Lubricate the remaining chains as specified in step 3 e Disconnect power and secure the power supply module in place 5 After lubrication turn the recirculation switch on for a few seconds 6 Turn the recirculation switch
33. utinter is ready to be put into operation Refer to the help screen or the User Manual before initiating a dispense 16 Fluid Management MAINTENANCE MAINTENANCE GENERAL This section of the manual provides information for routine maintenance of the Accutinter The main focus is on cleaning maintaining colorant levels and proper lubrication COVER REMOVAL INSTALLATION Many of the procedures in this section require the technician to remove and reinstall covers to gain access to components in the Accutinter This section shows the location of the covers and explains how to remove and replace them The following illustration shows the three covers that are removed for many of the maintenance procedures The lower front cover exposes the dispenser motor power supplies and fuses It also permits access to some of the canister agitation motors LOWER FRONT COVER Figure 8 Lower Front Cover Location Accutinter 3200 17 MAINTENANCE The lower rear cover exposes the relay panel with fuses valves pumps and remaining agitation motors UPPER REAR COVER LOWER REAR COVER Figure 9 Upper and Lower Rear Cover Location The upper rear cover permits access to the dispense control board and built in computer All lower covers are secured with captive screws The screws securing the upper rear cover are not captive When removing the upper rear cover retain the s
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