pt2020 programmable pneumatic pump controller - high …pneumatic pump controller for controlling...

Instructions-PartsC

PT2020 Programmable Pneumatic Pump Controller

For controlling pneumatic intensifier pumps used for proof pressure testing. For professional use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

See page 3 for model information.

Important Safety InstructionsRead all warnings and instructions in this manual, and other related manuals on page 3, before using the equipment. Save all instructions.

3A6828DEN

2 3A6828D

ContentsModels and Approvals . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Mounting the Enclosure . . . . . . . . . . . . . . . . . . . 7Connecting the Transducer . . . . . . . . . . . . . . . . . 7Updating the Software . . . . . . . . . . . . . . . . . . . . 8

Getting the Software . . . . . . . . . . . . . . . . . . . 8Installing the Software . . . . . . . . . . . . . . . . . 8

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 9Single Pump Installation . . . . . . . . . . . . . . . . 9Components Supplied by HiP . . . . . . . . . . . . 9Additional Modular System Components . . . 9Three Pump Installation . . . . . . . . . . . . . . . 10Components Supplied by HiP . . . . . . . . . . . 11Additional Modular System Components . . 11Single Pump Enclosure Components . . . . . 12Three Pump Enclosure Components . . . . . 13One Pump Wiring Diagram (26C600) . . . . . 15Three Pump Wiring Diagram (26C601) . . . 21

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Pressure Relief Procedure . . . . . . . . . . . . . . . . 27

Controller Operation . . . . . . . . . . . . . . . . . . . . . . . 28Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Screen Buttons . . . . . . . . . . . . . . . . . . . . . . 28Action Buttons . . . . . . . . . . . . . . . . . . . . . . 28Entry Fields . . . . . . . . . . . . . . . . . . . . . . . . . 28Data Field Keypads . . . . . . . . . . . . . . . . . . 28

Logging In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Logging Out . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Setting Pressure Units . . . . . . . . . . . . . . . . . . . 30Setting Up the Transducer . . . . . . . . . . . . . . . . 31

Selecting a Transducer . . . . . . . . . . . . . . . . 31Zeroing the Transducer . . . . . . . . . . . . . . . 32Calibrating the Transducer . . . . . . . . . . . . . 32

Setting Up the Pump . . . . . . . . . . . . . . . . . . . . . 33Setting Up Tests . . . . . . . . . . . . . . . . . . . . . . . . 35

Creating a New Pressure Test . . . . . . . . . . 35Creating a New Cycle Test . . . . . . . . . . . . . 37

Setting Up the System . . . . . . . . . . . . . . . . . . . 40Setting Date and Time . . . . . . . . . . . . . . . . 40Verifying the System Information . . . . . . . . 41Setting the System Peripherals . . . . . . . . . 41Setting Up the Accessory Sensor . . . . . . . . 42Setting System Alarms . . . . . . . . . . . . . . . . 43

Setting System Parameters . . . . . . . . . . . . 44Run Screen Operations . . . . . . . . . . . . . . . . . . . . . 45

Running a Test . . . . . . . . . . . . . . . . . . . . . . . . . 45Home Screen Manual Mode . . . . . . . . . . . . . . . . . 46File Management . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Managing Pressure Test Results . . . . . . . . . . . 47Transferring Pressure Test Results . . . . . . 47Purging Pressure Test Results . . . . . . . . . . 47

Transferring System Settings . . . . . . . . . . . . . . 47Exporting System Settings . . . . . . . . . . . . . 47Importing System Settings . . . . . . . . . . . . . 47

Transferring Pressure Tests . . . . . . . . . . . . . . . 48Exporting Pressure Tests Settings . . . . . . . 48Importing Pressure Tests Settings . . . . . . . 48

Locating Test Data via FTP Client . . . . . . . . . . . 48Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Optimizing Performance . . . . . . . . . . . . . . . . . . 50Viewing Alarm Events . . . . . . . . . . . . . . . . . . . . 50

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Replacing the Transducer . . . . . . . . . . . . . . . . . 51Replacing the Electronic Air Regulator . . . . . . . 51

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52PT2020 Single Pump Enclosure . . . . . . . . . . . . 52PT2020 Three Pump Enclosure . . . . . . . . . . . . 54

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 55Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

PT2020 Single Pump Controller . . . . . . . . . . . . 56PT2020 Three Pump Controller . . . . . . . . . . . . . 57

Technical Specifications . . . . . . . . . . . . . . . . . . . . 59Graco High Pressure Equipment Company Standard

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3A6828D 3

Models and Approvals

Single Pump Models

PT2020 Controller Models (Part number includes enclosure,

transducer, and cord set)Transducer Pressure, in ksi (kilopound/in2)

Cord Set

Controller with Cord Set & Transducer

Only Approvals

Enclosure (PN 26C600) Only Approvals

25N950 10 US

N/A

25N951 25 US

25N952 40 US

25N953 60 US

25N954 75 US

25D815 10 UK

25D816 25 UK

25D817 40 UK

25D818 60 UK

25D819 75 UK

25D820 10 EU

25D821 25 EU

25D822 40 EU

25D823 60 EU

25D824 75 EU

25D825 10 AU

25D826 25 AU

25D827 40 AU

25D828 60 AU

25D829 75 AU

Conforms to UL STD 508ACertified CSA STDS C22.2 No. 14

4 3A6828D

Three Pump Models

PT2020 Controller Models (Part number includes enclosure,

transducer, and cord set)Transducer Pressure, in ksi (kilopound/in2)

Cord Set

Controller with Cord Set & Transducer

Only Approvals

Enclosure (PN 26C601) Only Approvals

25S015 10 US

N/A

25S016 25 US

25S017 40 US

25S018 60 US

25S019 75 US

25S000 10 UK

25S001 25 UK

25S002 40 UK

25S003 60 UK

25S004 75 UK

25S005 10 EU

25S006 25 EU

25S007 40 EU

25S008 60 EU

25S009 75 EU

25S010 10 AU

25S011 25 AU

25S012 40 AU

25S013 60 AU

25S014 75 AU

Conforms to UL STD 508ACertified CSA STDS C22.2 No. 14

Warnings

3A6828D 5

WarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

FIRE AND EXPLOSION HAZARDWhen flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be aware that flammable fumes can ignite or explode. To help prevent fire and explosion:• Use equipment only in well-ventilated area.• Eliminate all ignition sources, such as cigarettes and portable electric lamps.• Ground all equipment in the work area.• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.• Use only grounded hoses.• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until

you identify and correct the problem.• Keep a working fire extinguisher in the work area.ELECTRIC SHOCK HAZARDThis equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.• Turn off and disconnect power cord before servicing equipment.• Connect only to grounded electrical outlets.• Use only 3-wire extension cords.• Ensure ground prongs are intact on power and extension cords.• Do not expose to rain. Store indoors.

SKIN INJECTION HAZARDHigh-pressure fluid from dispensing device, 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 dispensing device at anyone or at any part of the body.• Do not put your hand over the fluid outlet.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment. • Tighten all fluid connections before operating the equipment.• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings

6 3A6828D

EQUIPMENT MISUSE HAZARDMisuse 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 Specifications in all equipment manuals.• Use fluids and solvents that are compatible with equipment wetted parts. See Technical

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheets (SDSs) from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine

manufacturer’s replacement parts only.• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create

safety hazards.• Make sure all equipment is rated and approved for the environment in which you are using it.• 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.

PERSONAL PROTECTIVE EQUIPMENTWear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

Installation

3A6828D 7

Installation

Grounding

Enclosure, controller, analog input, and transducer: grounded through the power cord. Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified electrician.

Pump: refer to your pump’s instruction manual.

Air and fluid hoses: use only electrically conductive hoses.

Air compressor: follow manufacturer’s recommenda-tions.

Fluid supply container: follow local code.

Mounting the Enclosure1. See Typical Installation, on page 9, for location of

the enclosure relative to the pneumatic intensifier pump.

2. See Dimensions, on page 57, to determine the size of the flat surface needed for the enclosure.

3. Use the slots in the Mounting Feet (27) (see Parts, on page 53) or the Dimensions, on page 57, to drill holes in the mounting surface for customer-supplied mounting screws.

Connecting the Transducer

1. Follow the Pressure Relief Procedure on page 27.

2. Turn the Disconnect Switch (8) to the OFF position. (See FIG. 3 on page 12.)

3. Attach the Transducer (S) close to the pump’s Out-let Port (M). (See FIG. 1 on page 9.)

4. Connect the Transducer Cable (R) from the Pres-sure Transducer Connection (10) to the Transducer (S).

5. Turn the Disconnect Switch (8) to the ON position.

All electrical wiring must be done by a qualified elec-trician and comply with all local codes and regula-tions.

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Installation

8 3A6828D

Updating the Software

The PT2020 has a USB Port on the front cover for updating the software, and for importing and exporting data.

NOTE: Settings and pressure test data may be lost when updating software. See File Management, on page 48, for saving and restoring settings and pressure test data.

Getting the Software1. Contact HiP customer assistance for the latest soft-

ware.

2. Move the “Default_PPC7x” folder and “arnbcfg.xml” file to the root directory of a USB drive.

Installing the Software1. Follow the Pressure Relief Procedure on page 27.

2. Turn the Disconnect Switch (8) to the OFF position. (See FIG. 1 on page 9.)

3. Insert the USB drive with the new software into the USB Port on the front cover of the enclosure. (See FIG. 1 on page 9.)


5. Wait for the PT2020 to update. Updates can take up to five minutes. Do not turn the system off during the update, as this can prevent the unit from operating. The Home screen will appear once the update is complete.

6. Turn the Disconnect Switch (8) to the OFF position.

7. Remove the USB drive.

Installation

3A6828D 9

Typical Installation

Single Pump Installation

FIG. 1 is an example of enclosure installation with a pressure test system. Your installation may differ from what is shown here.

Components Supplied by HiPThe following components, see FIG. 1, are supplied by HiP:

Additional Modular System ComponentsThe following components, see FIG. 1, are available from HiP or supplied by the customer:

FIG. 1: Single Pump System Layout

A*B*

C*

D*

E*

Fluid SupplyContainer

F

J*

K

P* L

M

N

R*

S*

T

Enclosurepanel display

USB &EthernetPorts

G HUnitUnderTesting

B Pneumatic Filter*

D PT2020 Controller*

R Transducer Cable*

S Transducer*

T Power Cord*

* Required component

A Main Pneumatic Supply Line*

C Bleed-type Master Pneumatic Valve*

E Pump*

F Strainer (at the fluid supply container)

G Isolation Valve (PT2020-controlled)

H Pressure Release Valve (PT2020-controlled)

J Fluid Pressure Relief Valve*

K Fluid Inlet Line

L Inlet Port

M Outlet Port

N Fluid Outlet Line to Hydraulic System

P Supply Fluid Shutoff Valve*


Installation

10 3A6828D

Three Pump Installation

FIG. 2 is an example of an enclosure installation with a pressure test system. Your installation may differ from what is shown here.

FIG. 2: Three Pump System Layout

A*B*

C*

D*

E*

Fluid SupplyContainer

F J*

K

P*

L M

N

R*

S*

T

Enclosurepanel display

USB & Ethernet Ports

G H

K

P*

E*

U*

L

M

UnitUnderTesting

L

Installation

3A6828D 11

Components Supplied by HiPThe following components, see FIG. 2, are supplied by HiP:

Additional Modular System ComponentsThe following components, see FIG. 2, are available from HiP or supplied by the customer:

B Pneumatic Filter*

D PT2020 Controller*

R Transducer Cable*

S Transducer*

T Power Cord*


A Main Pneumatic Supply Line*

C Bleed-type Master Pneumatic Valve*

E Pump*

F Strainer (at the fluid supply container)

G Isolation Valve (PT2020-controlled)

H Pressure Release Valve (PT2020-controlled)

J Fluid Pressure Relief Valve*

K Fluid Inlet Line

L Inlet Port

M Outlet Port

N Fluid Outlet Line to Hydraulic System

P Supply Fluid Shutoff Valve*

U Fill Pump*


Installation

12 3A6828D

Single Pump Enclosure Components

FIG. 3: Enclosure Components

6

9

8

7

32

1

45

1011

12

Mounting Holes

Mounting Holes

1314

31

1 Electronic Regulator

2 M12 Cable Connection

3 Pneumatic Hose Connection

4 Regulator Base

5 Base Screws

6 Backplate

7 Filter

8 Disconnect Switch

9 Power Cable Connection

10 Pressure Transducer Connection

11 I/O Cards

12 Ethernet Connections

13 Isolate Valve Air Solenoid

14 Pressure Release Valve Air Solenoid

31 Analog Input Connection

Installation

3A6828D 13

Three Pump Enclosure Components

FIG. 4: Enclosure Components

6

9

8

7

32

1

45

31

11

12

Mounting Holes

Mounting Holes

13

14

10

Fill Pump Air SolenoidElectronic Regulator, Pump 1

Electronic Regulator, Pump 2

Installation

14 3A6828D

1 Electronic Regulator

2 M12 Cable Connection

3 Pneumatic Hose Connection

4 Regulator Base

5 Base Screws

6 Backplate

7 Filter

8 Disconnect Switch

9 Power Cable Connection

10 Pressure Transducer Connection

11 I/O Cards

12 Ethernet Connections

13 Isolate Valve Air Solenoid


31 Analog Input Connection

Installation

3A6828D 15

One Pump Wiring Diagram (26C600)

FIG. 5: One Pump Wiring Diagram (1 of 6)

ABL CDEFGHIJK

01

23

45

67

89

1011

1213

1415

E1L

NG

RD

112

34

56

CB1

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12

34

PS1

L+N-

GN

D

V-V-V+V+

CU

STOM

ER SU

PPLIED

VO

LTAG

E100VAC

-240VA

C/60H

Z,

CU

STOM

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SUPPLY

PO

WE

R C

OR

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MEET U

L508A CE

RTIFIC

ATIO

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, 15 AMP

, 14AW

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240VAC, 15 A

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, 14 AW

G

INSTALL G

RO

UN

D W

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ON

NEC

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ENC

LOSU

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OO

R TO

BOD

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18 AW

G G

RE

EN

WIR

E.

G1

FB1

09-8-H

09-8-HD

A 0V1

DA 24V1

1218

BN

1018

BU

314 WH

214 BK

614

GN

714

WH

814

BK

414 WH

514 BK

918

BU

1118

BN

114 GN

Installation

16 3A6828D


ABL CDEFGHIJK

01

23

45

67

89

1011

1213

1415

11_RS232 TXD

12_RES

13_RES

14_+24V BC/X2X L.

15_+24V BC/X2X L.

16_GN

D

21_RS232 R

XD

22_RS232 G

ND

23_RES

24_+24V I/O

25_+24V I/O

26_GN

D

PLC1 ST1B&R AutomationX20PS9400

DIS1

4PPC70.070M

-20F001

CB 0V1

CB 24V1

CB G

1

08-8-K

08-9-K

I F1IF2

PLC1 BC1B&R AutomationX20BC0083

ENET1

USB1

W3\ETH

ERN

ET

W3\ETH

ERN

ET

W4\ETH

ERN

ET

W4\ETH

ERN

ET

W5\U

SB

W5\U

SB

12GN

D

IF1

IF2

IF3

CN

1\GR

Y10-8-F

230.34

GY

1218

BN

1618

BU

1518

BN

1718

GN

1318

BN

1018

BU

Installation

3A6828D 17


ABL CDEFGHIJK

01

23

45

67

89

1011

1213

1415

11_DI1

12_DI3

13_DO

1

14_AI+1I

15_AI+1U

16_AI-U/I

21_DI2

22_DI4

23_DO

2

24_AO+1I

25_AO+1U

26_AO-1U

/I

PLC1 ST2B&R AutomationX20CM8281

V1V2

CN

1

12345

CN

1\BLU

CN

1\BLU

W1\W

HT

W1\W

HT

CB

0V2

CU

STOM

ER C

ON

NEC

TS TO C

N1

FLA: 24 VDC

4-20mA (25m

A max)

PRESSU

RE

REG

ULATO

R

W1\BLU

CN

1\BRN

W1\BR

N

D A24V2TB1

PR1

ITV3050-04N3BL4

D A0V2

TB1

1234

CN

1\GR

Y09-6-K

230.34

GY

2218

BK

1918

BK

270.34

BU

250.34

WH

240.34

BN

200.34

BN

210.34

BU

2918

BU

2618

BK

1818

BK

Installation

18 3A6828D


ABL CDEFGHIJK

01

23

45

67

89

1011

1213

1415

11_DI1

12_DI3

13_DO

1

14_AI+1I

15_AI+1U

16_AI-U/I

21_DI2

22_DI4

23_DO

2

24_AO+1I

25_AO+1U

26_AO-1U

/I


CN

2

1 2 345

CU

STOM

ER C

ON

NEC

TS TO C

N2

FLA: 24 VDC

4-20mA (25m

A max)

CN

2\BLU

CN

2\BLU

CN

2\GR

YD

A G2 D

A 24V3TB1

CN

2\BRN

CN

2\BLKD

A

0V30.34

BK

370.34

BN

390.34

GY

380.34

BU

Installation

3A6828D 19


TB1

11P

S1:V+

12P

LC1 ST1:25_+24V I/O

15D

IS1:1

24V1D

A

24V1C

B

J24V1

J

20B

RN

TB1 24V2:A

24B

RN

TB1 24V2:D

24V2D

A

C24V2

B

J24V2

J

37B

RN

TB1 24V3:D

24V3D

A

C24V3

B

J24V3

J

9P

S1:V-

10PLC

1 ST1:26_GN

D

16D

IS1:2

0V1D

A

0V1C

B

J0V1

J

7000-13561-9720050C

N1

BR

N1

MU

RR

ELEKTRO

NIK

7000-13561-9720050

CN

1

ITV3050-04N3BL4

W1

BR

N1

SMC

ITV3050-04N3BL4

PR1

7000-13522-9720050C

N2

BR

N1

MU

RR

ELEKTRO

NIK

7000-13522-9720050

CN

2

Installation

20 3A6828D


TB1

19V1

22V2

27BLUTB1 0V2:B

29P

LC1 ST2:26_AO

-1U/I

0V2D

A

0V2C

B

J0V2

J

BLKTB1 0V3:A

0V3D

A

C0V3

B

J0V3

J

1E1:G

6PS1:G

ND

17D

IS1:GN

D23

GR

YTB1 G

1:C

G1

BA

G1

CB

39G

RY

TB1 G2:D

G2

DA

CG

2B

ITV3050-04N3BL4

W1

BLU3

SMC

ITV3050-04N3BL4

PR1

7000-13522-9720050C

N2

BLK4

MU

RR

ELEKTRO

NIK

7000-13522-9720050

CN

2

7000-13561-9720050C

N1

GR

Y5

MU

RR

ELEKTRO

NIK

7000-13561-9720050

CN

1

7000-13522-9720050C

N2

GR

Y5

MU

RR

ELEKTRO

NIK

7000-13522-9720050

CN

2

Installation

3A6828D 21

Three Pump Wiring Diagram (26C601)

FIG. 11: Three Pump Wiring Diagram (1 of 6)

ABL CDEFGHIJK

01

23

45

67

89

1011

1213

1415

E1L

NG

RD

112

34

56

CB1

3A

12

34

PS1

L+N-

GN

D

V-V-V+V+

CU

STOM

ER SU

PPLIED VO

LTAGE

100VAC-240VAC

/60HZ,

CU

STOM

ER TO

SUPPLY PO

WER

CO

RD

TO M

EET UL508A C

ERTIFIC

ATION

120VAC, 15 AM

P, 14AWG

NEM

A 5/15P240VAC

, 15 AMP, 14 AW

G

G1

FB1

09-8-H

09-8-HD

A 0V1

DA 24V1

1218

BN

1018

BU

314 WH

214 BK

614

GN

714

WH

814

BK

414 WH

514 BK

918

BU

1118

BN

114 GN

Installation

22 3A6828D


ABL CDEFGHIJK

01

23

45

67

89

1011

1213

1415

11_RS232 TXD

12_RES

13_RES

14_+24V BC/X2X L.

15_+24V BC/X2X L.

16_GN

D

21_RS232 R

XD

22_RS232 G

ND

23_RES

24_+24V I/O

25_+24V I/O

26_GN

D

PLC1 ST1B&R AutomationX20PS9400

DIS1

4PPC70.070M

-20F001

CB 0V1

CB 24V1

CB G

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26 3A6828D


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Operation

3A6828D 27

Operation

Pressure Relief ProcedureFollow the Pressure Relief Procedure whenever you see this symbol.

1. Press the Stop button on the controller display to ensure the PT2020 controller is in an Off state.

2. Close the Bleed-type Master Pneumatic Valve (C).

3. Close the Supply Fluid Shutoff Valve(s) (P).

4. Bleed the pressure by opening the user-supplied Fluid Pressure Relief Valve (J).

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you are finished operating the pump, and before cleaning, checking, or servicing the equipment.

Controller Operation

28 3A6828D


Navigation

Screen ButtonsScreen buttons allow you to access any of the three pri-mary screens from anywhere in the system. With the exception of the Settings button, all screen buttons are available from any screen.

Action Buttons

Entry Fields

Data Field KeypadsSelecting a data field will display either an alphanumeric or numeric keypad, depending on whether the field is primarily for text or numbers. Common features include a backspace key (next to the entry display), a save key (the check mark), and a cancel key (a circle with an “X”).

Home - Press from any other screen to return to the Home screen.

Run - Press to display the Run screen (see page 46), where you can select and run any pre-configured tests (see page 35).

Settings - Press to display the Setup screen (see page 40), where you can select Transducer, Pump, Units, Pressure Tests, and System Settings for configura-tion. This is also where you can access the Alarm Log and File Management.

This button will not be available while the pump is running.

Stop - Press to stop the pump, bleed the air pressure to the pump to 0 PSI.

Forward - This button is used on the Setup screens and indicates another screen is available for the corresponding selection. Press this button to display related screen.

Back - Press to return to the previous screen. Any changes to the current screen will be saved.

Toggle - Press to toggle between Off (white background) and On (green back-ground).

Menu - Select to display a list of menu options.

Field - Select to display an alphanumeric or numeric keypad. See Data Field Key-pads.

FIG. 17

Alphanumeric Keypad Numeric Keypad


3A6828D 29

Logging InThe Startup screen is displayed when the PT2020 con-troller is first turned on or when the Logout button is pressed.

1. Select the blank Login field to display an alphanu-meric keypad.

2. Enter the login code (up to three characters). The login code is used to track who is running the pres-sure tests. It appears in the Current User field at the top of the screens.

3. Press the Login button to display the Home screen without the Login dialog box.

Logging OutPress the Logout button on the Home screen.

FIG. 18 Home Screen, before logging in

Login field

FIG. 19 Home Screen, after logging in

Homebutton

Runbutton

Settingsbutton

Stopbutton


30 3A6828D

Setting Pressure UnitsThe pressure units (PSI, BAR, or MPa) set on the Units screen are used throughout all of the PT2020 controller screens, unless otherwise noted.

1. Press the Settings button to display the Setup screen.

2. Select Units to display the Units screen.

3. Press the toggle button next to the appropriate pres-sure unit.

FIG. 20 Setup Screen

FIG. 21 Units Screen


3A6828D 31

Setting Up the Transducer

Selecting a TransducerThe following steps assume you have already installed a Graco-supplied pressure transducer.


2. Select Transducer to display the Transducer screen.

3. Press the toggle button next to the maximum pres-sure (in PSI) rated for your transducer.

NOTE: For non-Graco-supplied transducers, or other custom 4-20 mA transducers, select Custom to display the Custom screen, and enter the Max Transducer Pressure rated for the transducer.

FIG. 22 Transducer Screen

FIG. 23 Transducer Custom Screen


32 3A6828D

Zeroing the TransducerGraco-supplied pressure transducers will not be cali-brated, and will need to be zeroed before running pres-sure tests. Zeroing a non-calibrated transducer effectively sets the low pressure setting of the trans-ducer to 0 PSI within the system.

1. After Selecting a Transducer (on page 31), press the Stop button and perform the Pressure Relief Procedure on page 27.

2. With 0 PSI in the system, press the Zero button on the Transducer screen.

Calibrating the TransducerCalibrated pressure transducers do not need to be zeroed, but their calibration parameters will need to be entered on the Calibration screen.

1. After Selecting a Transducer (on page 31), press the Stop button and perform the Pressure Relief Procedure on page 27.

2. With 0 PSI in the system, press the Calibrate button on the Transducer screen after Selecting a Trans-ducer to display the Calibration screen.

3. Select the Low Pressure and High Pressure fields, in turn, and enter the calibration parameters (both mA and PSI) from the transducer calibration sheet.

NOTE: The Reset button will reset all fields on the Cali-bration screen to default values.

FIG. 24 Transducer Screen

FIG. 25 Transducer Calibration Screen


3A6828D 33

Setting Up the PumpThe following steps assume you have already con-nected a pump to the PT2020 controller. The parame-ters on the Pump screen are used to calculate the pump ratio, which is based on the Max Fluid Pressure Rating and the Max Air Pressure Rating. The Pump Ratio can-not be directly entered.

NOTE: One pump systems have only one pump for setup (see Step 7), while three pump systems include a fill pump (see Step 3) and two standard pumps (see Step 7).

1. Press the Settings button. Three pump sys-tems will display the Pump selection screen. One pump systems will go directly to the Pump screen (see Step 7).

2. Select Pump to display the Pump selection screen.

3. Select Fill Pump to display the fill pump’s screen.

4. Select the Max Fluid Pressure Rating field and use the keypad to enter the maximum pressure of the fill pump.

NOTE: Unlike pumps 1 and 2, which use a pneumatic air regulator to switch the pumps on and off, the fill pump uses a pneumatic valve to do so. The pneumatic valve will deliver 100% of the incoming air pressure to the fill pump when it is on.

5. Press the check mark on the numeric keypad to save the pump pressure and display the Pump Selection screen.

6. Select Pump 1 to display pump 1’s screen.

To reduce the risk of skin injection and damage to the pump, ensure the user-supplied Fluid Pressure Relief Valve (J) is set at or below the maximum working pressure of the pump. Refer to your pump’s instruc-tion manual for specifics.

FIG. 26 Pump Selection Screen (Three Pumps Systems Only)

FIG. 27 Fill Pump Screen (Three Pump Systems Only)


34 3A6828D

7. The remaining steps are the same for both pump 1 and pump 2 in three pump systems and for one pump systems.

8. Select the Max Fluid Pressure Rating field and use the keypad to enter the maximum pressure of the connected pump. This is typically noted in the pump’s instruction manual as the maximum working pressure.

9. Press the check mark on the numeric keypad to save the pump pressure.

10. Select the Max Air Pressure Rating field and use the keypad to enter the maximum air pressure for the connected pump. This is the maximum air pressure that the pump can handle, and is typically noted on the pump or in the pump’s instruction manual.

11. Press the check mark on the numeric keypad to save the pump pressure.

FIG. 28 Pump 1 Screen

(One Pump System) (Three Pump System)


3A6828D 35

Setting Up TestsThree-pump systems require you to specify which pumps to use for each setpoint. Both pumps can be selected to run them in parallel.

When both pumps are enabled, the system will run both pumps simultaneously. The pumps will stop when they hit their maximum rated pressure or the setpoint pres-sure is reached.

Two setpoints can be used to run the pumps in series, if needed. For example, setpoint 1 could be set up to run pump 1, and setpoint 2 to run pump 2.

Creating a New Pressure Test


2. Select Pressure Tests to display the Tests screen.

3. Press the New Pressure Test button to display a Pressure Test Setpoint Overview screen with a blank Name field. Each pressure test has it’s own Overview screen.

4. Select the Name field and use the keypad to enter the name of the new pressure test. Press the Save button next to the Name field. The Tests screen reappears with the name of the new test added to the list of tests.

5. Select the desired test from the test list to redisplay the Pressure Test Setpoint Overview screen for that test.

FIG. 29 Tests Screen

FIG. 30 Pressure Test Setpoint Overview Screen


36 3A6828D

6. Press the New Setpoint button to display the Set-point screen. You can set up to 30 setpoints for each pressure test.

7. Enter the pressure for the setpoint in the Pressure field.

NOTE: The pressure entered is limited to the pump’s maximum fluid pressure rating entered on the pump setup page. (See Setting Up the Pump, page 33.)

8. In the Time field, enter the time for the setpoint to be held or monitored before moving on to the next set-point or ending the pressure test.

9. Select one of the following Setpoint Types from the menu list:

• Hold - This maintains the setpoint pressure for the duration entered in the Time field. Air pres-sure is maintained on the pump.

• Decay - This builds pressure up to the setpoint pressure before starting a pressure decay test. The pressure will overshoot the setpoint during buildup to ensure the decay starts at the actual setpoint. The pressure decay will be measured over the duration entered in the Time field. Once the decay is started, air pressure is removed from the pump.

The Decay Allowed field is the maximum pres-sure decay allowed below the setpoint. An alarm is tripped if the actual decay exceeds the entered value. The percent value will automati-cally change with the amount entered, and vice versa.

• Interact - This builds pressure up to the set-point pressure and holds for interaction by the operator. A popup window reminds the operator that manual interaction is required for the test to continue. Examples include actuating a valve or checking for leaks.

The Interaction Type menu list includes two popup window options: Visual Check and Man-ual Operation.

FIG. 31 Setpoint Screen

FIG. 32 Decay Fields

FIG. 33 Interaction Fields


3A6828D 37

• Ramp - This builds pressure up to the setpoint pressure by ramping the pressure based on a user settable ramp rate. Once it reaches the setpoint pressure it’ll hold the pressure for the duration entered in the Time field before moving on to the next setpoint or ending the pressure test.

The Ramp Rate field determines how much pressure per second is added as it ramps up to the setpoint. It determines how fast the pressure builds.

10. In the Stabilize Time field, enter the duration for the system to wait and “settle” at the setpoint pressure before starting the actual test.

11. Select the pump, or pumps, to enable for this test. (Three pump systems only.)

NOTE: The Delete Setpoint button will delete the cur-rent setpoint from the test.

12. (Three pump models only) To enable and configure the fill pump, return to the Pressure Test Setpoint Overview screen and press the Fill Pump button to display the Fill Pump Enable screen.

13.

NOTE: The fill pump is automatically inserted as set-point 1 if enabled. The fill pump will run before anything else for the specified time in order to fill the system first.

14. Select Fill Pump field to enable the fill pump.

15. In the Fill Time field, enter the time for the fill pump to run.

16. Select the Dump Valve Open field if the fill pump should run with the dump valve open. If not selected, the dump valve will be closed.

FIG. 34 Ramp Fields

FIG. 35 Fill Pump Enable Screen


38 3A6828D

Creating a New Cycle TestThe cycle test is available for both single- and three-pump systems. It cycles between two different sets of high and low pressures for a user-defined num-ber of cycles. The test passes when all of the cycles have been completed. The test fails if a leak is detected or triggers an “unable to build pressure” alarm. The number of cycles completed is saved with the test result data.


2. Select Tests to display the Tests screen.

3. Press the New Cycle Test button to display a Cycle Test Setpoint Overview screen with a blank Name field. Each cycle test has it’s own Overview screen.

4. Select the Name field and use the keypad to enter the name of the new cycle test. Press the Forward button to open the Cycle Test Setpoint screen.

FIG. 36 Tests Screen

FIG. 37 Cycle Test Setpoint Overview Screen

FIG. 38 Cycle Test Setpoint Screen


3A6828D 39

5. In the 1st Pressure field, enter the pressure for the first half of the cycle.


6. In the 1st Pressure +/- (tolerance) field, enter a pressure value. The test will regulate the pressure for the first half of the cycle until it falls within the 1st Pressure tolerance before moving on to the hold portion of the cycle test.

7. In the Time field under the 1st Pressure field, enter the time for the first pressure to be held before mov-ing on to the second pressure.

8. In the 2nd Pressure field, enter the pressure for the second half of the cycle.


9. In the 2nd Pressure +/- (tolerance) field, enter a pressure value. The test will regulate the pressure for the second half of the cycle until it falls within the 2nd Pressure tolerance before moving on to the hold portion of the cycle test.

10. In the Time field under the 2nd Pressure field, enter the time for the second pressure to be held before moving on to the next cycle.

11. In the Number Cycles field, enter the number of cycles to be run during the test.

12. Use the Pump #1 and #2 fields to enable the pumps that will be used during the test.

13. Press the back arrow key to save the setpoint and return to the Cycle Setpoint Overview screen.


40 3A6828D

Setting Up the System


2. Select System Settings to display the System screen.

Setting Date and Time1. Select Date/Time on the System screen to display

the System Date/Time screen.

2. Enter the current date in the Date fields.

3. Enter the current time (in 24-hr format) in the Time fields.

4. Press the Back button to return to the System screen.

FIG. 39 System Screen

FIG. 40 System Date/Time Screen


3A6828D 41

Verifying the System InformationSelect System Info on the System screen to display the System Info screen. This screen displays the IP address for the controller, the version of the installed controller software, and the current language setting.

NOTE: English is currently the only language available. Additional languages can be selected from this screen as they become available.

Setting the System Peripherals1. Select Peripherals on the System screen to display

the System Peripherals screen. This screen is used to set behavior for the following peripherals if they exist in your system:

• Dump Valve is a pneumatic air valve used to automatically relieve pressure following the completion of a test or during a cycle test. It also relieves pressure when an alarm occurs or when the Stop button is pressed. See the Pres-sure Release Valve (H) in FIG. 1 and FIG. 2.

• Isolation Valve is a pneumatic air valve used to isolate the UUT (unit under test) or EUT (equip-ment under test) from the pump. See the Isola-tion Valve (G) in FIG. 1 and FIG. 2.

NOTE: This is only used for pressure decay tests.

• Accessory Sensor is a generic 4-20 mA input signal. A temp sensor is an example of a 4-20 mA device that may be connected to the analog input connection.

FIG. 41 System Info Screen

FIG. 42 System Peripherals Screen


42 3A6828D

2. Select one of the following settings from the Dump Valve and Isolate Valve menu lists:

• None - This is selected if the valve does not exist in your system.

• Normally Open - The valve is closed when air is applied.

• Normally Closed - The valve is open when air is applied.

3. Press the arrow next to Accessory Sensor to display the Accessory Sensor screen and to set up a generic 4-20 mA analog input. See Setting Up the Accessory Sensor, page 42.

4. Press the Back button to return to the System screen.

Setting Up the Accessory SensorThe Accessory Sensor screen requires a generic 4-20 mA analog sensor connected by cable to the Analog Input Connection (31) on the side of the PT2020 control box. You may use the pressure transducer cable (pn 19A841) available from Graco or your own cable that fits an M12 A-coded 5-pole male connection.

For devices that require a 24 V power source, connect the positive terminal of the device supplying the signal to pin 1 (+24 V) and the negative terminal to pin 3 (analog input signal). Connect the earth ground terminal of the device to pin 5 (earth ground).

For devices that are powered, connect the positive ter-minal of the device supplying the signal to pin 3 (analog input signal) and the negative terminal to pin 4 (DC ground). Connect the earth ground terminal of the device to pin 5 (earth ground).

Pressure Transducer Cable (19A841)

X Wire Color Y Analog Input Connection (31)

1 brown 1 +24 V

2 white 2 not used

3 blue 3 analog input signal

4 black 4 DC ground

-- green / yellow 5 earth ground

1

23

4

M12 A-Coded, 4-Pole Male Straight Connector

1

2

3

4

5

M12 A-Coded, 5-Pole Female Straight Connector

1

2

3

45

M12 A-Coded, 5-Pole Male Straight Connector


3A6828D 43

1. Select Accessory Sensor from the System Peripher-als screen to display the Accessory Sensor screen. The following is a blank screen with the default mA units.

2. In the Title field, enter a name that identifies the accessory sensor.

3. In High field row, enter the upper scale value and unit represented by the 20 mA signal. For example, FIG. 44 shows that the 20 mA signal represents 130°F.

4. In Low field row, enter the upper scale value and unit represented by the 4 mA signal. For example, FIG. 44 shows that the 4 mA signal represents -40°F.

5. To zero or calibrate the sensor signal, enter a value in the Offset field. This value will be subtracted from the sensor value displayed at the top of the screen.

FIG. 43 Accessory Sensor Screen

FIG. 44 Sample Temperature Sensor


44 3A6828D

Setting System AlarmsSelect System Alarms on the System screen to display the System Alarms screen.

Pressure Test Timeout

If enabled, the system will trigger an alarm if it does not reach the pressure setpoint within the specified time.

Over Pressure Limit

This sets a maximum pressure allowed over the highest setpoint for a pressure test. Any pressure over the max-imum pressure (the highest setpoint pressure plus the overpressure limit) will trigger an alarm and stop the test.

Example: A pressure test may include setpoints of 5000, 7000, and 10,000 PSI. If the overpressure limit is set to 500 PSI, the maximum pressure allowed during the pressure test is 10,500 PSI.

Leak Timeout

The system will trigger an alarm if pressure drops below the setpoint pressure for the specified time during a hold setpoint or if pressure drops below the expected pres-sure while ramping up to the setpoint pressure during a ramp setpoint.

FIG. 45 System Alarms Screen

To reduce the risk of skin injection and damage to the pump, set the overpressure limit to keep the maxi-mum pressure attainable under the maximum working pressure of the pump. Refer to your pump’s instruc-tion manual for specifics.


3A6828D 45

Setting System ParametersSelect System Parameters on the System screen to dis-play the System Parameters screen. This screen allows you to set the gain for the system.

Gain

The gain determines how quickly the system builds pressure, with 1 being the slowest and 100 being the fastest.

NOTE: The factory default gain setting is 10. You need to adjust the gain up or down for your application to opti-mize speed and minimize pressure overshoot.

• A higher gain can cause larger overshoots when building target setpoints, which may affect test accuracy or over-pressurize components.

• A lower gain can increase the time it takes to build pressure when testing large volumes.

Filter

The filter setting determines how much the pressure transducer signal is filtered.

• None or Low filtering allows the system to respond quickly to changes in pressure but allows pressure to fluctuate more.

• High filtering smooths out the pressure fluctuations but may add delay in response time or dampen pressure spikes.

FIG. 46 System Parameters Screen

Run Screen Operations

46 3A6828D

Run Screen Operations

Running a Test

1. Press the Run button to display the Run screen.

2. Press the Test Selection menu field and select the desired test from the menu list. (See Setting Up Tests on page 35.)

3. If you are tracking tests by product, select the Serial No. field to display a keypad and enter the product’s serial number. This number will be saved with the test result data.

4. Press the Start button to run the selected test. Once the Start button is pushed, it changes to a Stop but-ton, which can be used to stop the pressure test at any time.

The pressure is graphed on the display as the test is running. The pressure is recorded every 0.1 sec-onds during a test and saved with the test result data. See File Management, page 48, to download the test results data.

If the analog input is enabled, the analog input data is also recorded every 0.1 seconds during a test and saved with the test result data. See Setting Up the Accessory Sensor, page 42, to set up an analog accessory.

The Status field displays the current status of the PT2020 controller.

If an alarm is triggered during the test, it will appear in an Alarm popup window. Press the Acknowledge button to remove the popup window.

5. A Test Result popup window appears when the test is finished, indicating whether the “Test Passed” or the “Test Failed”. Press the Acknowledge button to remove the popup window.


7. Repeat steps 1 - 6 for each test.

FIG. 47 Run Screen

Home Screen Manual Mode

3A6828D 47

Home Screen Manual Mode

NOTE: The pumps must be set up correctly before using Manual Mode (see Setting Up the Pump, page 33).

1. Select a pump from the pump menu. (Three-pump systems only; single-pump systems default to whichever pump is connected.)

2. Use the “-” and “+” buttons to run the selected pump, and the stop button to stop.

Pressing “-” and “+” buttons for pumps 1 and 2 will decrease or increase the air supplied to the pump. The air is limited by the pump’s maximum air pressure rating.

A percentage of the pump’s maximum air pressure can be optionally entered. (This does not apply to the fill pump.)

The fill pump (three-pump systems only) can be turned off or on by pressing the “-” and “+” buttons, respec-tively.

The dump valve is automatically closed when running in Manual Mode.

If a pump needs to be run for priming with the dump valve open, create a test with the correct pump selected and the dump valves set properly on the peripheral screen (see Setting the System Peripherals, page 41).

For the fill pump, create a test with just the fill pump enabled and not other setpoints. The dump valve can be selected as open on the Fill Pump Enable screen (FIG. 35, page 37).

FIG. 48 Home Screen

Manual airpressuredecrease

Manual airpressureincrease

Current air pressure as a percent-age of max-imum air pressure

File Management

48 3A6828D

File Management

Managing Pressure Test Results

Transferring Pressure Test Results1. Insert a USB drive in the USB Port in the front

cover.


3. Select File Management to display the Files screen.

4. Press the Test Results-->Transfer Files button to transfer all pressure test results to the USB drive.

5. Remove the USB drive from the USB Port.

Purging Pressure Test Results



3. Press the Test Results-->Purge Files button to delete all pressure test results from the PT2020 controller.

Transferring System Settings

Exporting System SettingsThis is useful for saving current settings when updating the PT2020 software.

1. Insert a USB drive in the USB Port in the front cover.



4. Press the Settings-->Export Settings button to transfer all system settings to the USB drive.


Importing System SettingsThis is useful for restoring saved settings after updating the PT2020 software.

1. Insert a USB drive in the USB Port in the front cover.



4. Press the Settings-->Import Settings button to trans-fer system settings from the USB drive.


FIG. 49 Files Screen

File Management

3A6828D 49

Transferring Pressure Tests

Exporting Pressure Tests Settings1. Insert a USB drive in the USB Port in the front

cover.



4. Press the Pressure Tests-->Export Tests button to transfer pressure test settings to the USB drive.


Importing Pressure Tests Settings1. Insert a USB drive in the USB Port in the front

cover.



4. Press the Pressure Tests-->Import Tests button to transfer pressure test settings from the USB drive.


Locating Test Data via FTP Client1. Connect your PC to the PT2020 with an Ethernet

cable.

2. Open an FTP client on your PC.

3. Enter the following in the FTP client:

• IP Address - This is found on the System Info screen (see Verifying the System Information on page 41). The default is “169.254.0.1”.

• Username - “guest”

• Password - “guest”

4. All test data is stored in the Test Results folder.

Troubleshooting

50 3A6828D

Troubleshooting

1. Follow Pressure Relief Procedure, page 27, before checking or repairing pump.


3. Disconnect the PT2020 from the AC outlet.

4. Check all possible problems and causes before dis-assembling pump.

5. Reconnect the PT2020 to the AC outlet after trou-bleshooting.


Alarm Trigger Condition Return to Standby Condition Solution

I/O Fault Whenever the PLC cannot communicate with the I/O cards. The I/O cards control the communication to the sen-sors and items being con-trolled.

Once all I/O is detected and user acknowledges the alarm.

Check the Ethernet cable that connects the PLC to the I/O cards and reseat the connec-tions, if necessary.

Contact Graco Tech Assis-tance.

No Transducer Whenever the 4-20 mA signal is not in range.

Once the alarm is acknowl-edged and the transducer is detected.

Verify the transducer is prop-erly connected by reseating the cable connections.

Contact Graco Tech Assis-tance.

Pressure Test Failed

Interaction failed by user, or pressure decay failed.

Once alarm is acknowledged and pressure is relieved.

Determine what caused the test to fail and rerun the test.

Over Pressure Pressure went above the max-imum test pressure + the over pressure allowed threshold.

Once the alarm is acknowl-edged and pressure is relieved.

Check for leaks in the system.

Lower the gain setting.

Increase the over pressure threshold if safe to do so.

Test Unsafe A test to be run would result in the pressure transducer being over pressured.

Once the alarm is acknowl-edged.

Pick a different pressure test to run.

Verify the transducer matches the transducer selected on the Transducer screen.

Use a transducer that is prop-erly sized for the pressure test.

Unable to Build Pressure

The Pressure Test Timeout timer expires before the set-point pressure is reached.


Check for any reason the sys-tem is not building pressure.

Increase the time on the Pres-sure Test Timeout timer.

Increase air supply pressure.

Troubleshooting

3A6828D 51

Optimizing Performance Viewing Alarm Events


2. Select Alarm Log to display the Alarm Log screen. Alarm events are listed in the order they occurred.

Test Unachievable A test to be run is over the maximum pressure of the pump.

Once the alarm is acknowl-edged.

Pick a different pressure test to run.

Verify the pump running the test matches settings on the Pump screen.

Use the proper pump for the test.

Leak Detected When the pressure drops below 90% of the setpoint for the specified leak timeout when doing a pressure hold test, or when the pressure drops below the expected pressure when doing a ramp test.


Check for leaks in the system.

Alarm Trigger Condition Return to Standby Condition Solution

Observed Behavior Correction

Pressure builds too slowly Verify the pump ratio matches the pump’s specifi-cations.

Increase the gain setting. See Setting System Parame-ters, page 45.

Pressure overshoots target Verify the pump ratio matches the pump’s specifi-cations.

Decrease the gain setting. See Setting System Param-eters, page 45.

Pressure can’t reach setpoint when running to the pump’s maximum fluid pressure rat-ing

Increase the incoming air pressure until the pump can reach its maximum fluid pres-sure rating. Do not exceed 145 PSI inlet air pressure.

FIG. 50 Alarm Log Screen

Repair

52 3A6828D

Repair

Replacing the TransducerSee Kits and Accessories, on page 56, for transducer kit numbers.



3. Disconnect the Transducer Cable (R) from the Transducer (S). (See FIG. 1 on page 9.)

4. Replace the Transducer (S) near the pump’s Outlet Port (M).

5. Connect the tRansducer Cable (R) to the new Transducer (S).


7. Return to Calibrating the Transducer on page 32 to calibrate the new transducer.

Replacing the Electronic Air RegulatorSee Kits and Accessories, on page 56, for air regula-tor kit numbers.



3. Disconnect the PT2020 from the AC outlet.

4. Open the enclosure.

5. Remove the M12 Cable (2) from the top of the Air Regulator (1).

6. Disconnect the Pneumatic Hose Connections (3) from the sides of the Air Regulator (1).

7. Loosen the four Screws (5) on the Base (4) of the Air Regulator (1) to remove the regulator assembly from the Backplate (6) of the enclosure.

8. Install the Pneumatic Hose Connections (3) to the new regulator

9. Use the included screws to attach the new Air Reg-ulator (1) to the included Base (4).

10. Use the included Screws (5) to attach the regulator assembly to the Backplate (6) of the enclosure.

11. Connect the Pneumatic Hose Connections (3) to the sides of the Air Regulator (1).

12. Attach the M12 Cable (2) to the top of the Air Regu-lator (1).

13. Close the enclosure.

14. Reconnect power to the controller.

FIG. 51 Replace the Regulator3

54

2 1

6

8

Parts

3A6828D 53

Parts

PT2020 Single Pump Enclosure

2 1 3

5

4

2729

28

30

8

8

16

9

10

1718

11

7

26

19

20

21

22

23

2425

1413

12

15

31

Parts

54 3A6828D

PT2020 Single Pump Enclosure Parts List

Replacement safety labels, tags, and cards are available at no cost.

Ref. Part Description Qty1 19A836 Electronic Air Regulator 1

2 M12 Cable Connection 1

3 Pneumatic Hose Connection 3

4 Regulator Base 1

5 Base Screws 4

6 Backplate 1

7 106149 Filter 1

8 Disconnect Switch Assembly 1

9 Power Cable Connection 1

10 Pressure Transducer Connection 1

11 I/O Card Modules 2

12 USB Port 1

13 Isolate Valve Air Solenoid 1


1

15 Ethernet Port 1

16 Controller 1

17 Circuit Breaker 2

18 Power Supply 1

19 Communication Card 1

20 Vent 1

21 Inlet Port 1

22 Outlet Port 1

23 Exhaust Port 1

24 Assembly Label 1

25 Branding Label 1

26 15G303 Electrical Warning Label 1

27 Mounting Foot 4

28 Sealing Washer 4

29 Bolt 4

30 Nut 4

31 Analog Input Connection 1

Parts

3A6828D 55

PT2020 Three Pump Enclosure

2 1a 3

5

4

2729

28

30

8

8

16

9

17

18

11

726

19

20

21

22

23

2425

1413

12

1510

31

1c

1b

Kits and Accessories

56 3A6828D

PT2020 Three Pump Enclosure Parts List

Replacement safety labels, tags, and cards are available at no cost.

Kits and AccessoriesRef. Part Description Qty

1a 19A836 Electronic Air Regulator 1 1

1b 19A836 Electronic Air Regulator 2 1

1c Fill Pump Solenoid 1

2 M12 Cable Connection 1

3 Pneumatic Hose Connection 3

4 Regulator Base 1

5 Base Screws 4

6 Backplate 1

7 106149 Filter 1

8 Disconnect Switch Assembly 1

9 Power Cable Connection 1

10 Pressure Transducer Connection 1

11 I/O Card Modules 2

12 h Port 1

13 Isolate Valve Air Solenoid 1


1

15 Ethernet Port 1

16 Controller 1

17 Circuit Breaker 2

18 Power Supply 1

19 Communication Card 1

20 Vent 1

21 Inlet Port 1

22 Outlet Port 1

23 Exhaust Port 1

24 Assembly Label 1

25 Branding Label 1

26 15G303 Electrical Warning Label 1

27 Mounting Foot 4

28 Sealing Washer 4

29 Bolt 4

30 Nut 4

31 Analog Input Connection 1

Part Number Description

26C600 Enclosure, PT2020, 1 Pump

26C601 Enclosure, PT2020, 3 Pump

19A837 Transducer, 10 ksi

25D654 Transducer, 25 ksi

25D655 Transducer, 40 ksi



19A841 Pressure Transducer Cable; all transduc-ers except 75 ksi

19A874 Pressure Transducer Cable; 75 ksi trans-ducer only

106149 Filter Kit

17B708 Air Filter Element

121057 Cord Set, UK

121056 Cord Set, Europe

121055 Cord Set, USA

124864 Cord Set, AUS

19A836 Electric Air Reglator

19A869 Transducer Kit, 10 ksi; with cable





Dimensions

3A6828D 57

Dimensions

PT2020 Single Pump Controller

FIG. 52 PT2020 Single Pump Controller Dimensions and Mounting Slots

Dimensions

58 3A6828D

PT2020 Three Pump Controller

FIG. 53 PT2020 Three Pump Controller Dimensions and Mounting Slots

Technical Specifications

3A6828D 59

Technical Specifications

California Proposition 65

PT2020 Programmable Pneumatic Pump ControllerUS Metric

Nominal Input Voltage 100 - 240 VAC; 50/60 Hz; 1 PhaseMaximum Input Current 2 AMaximum Air Inlet Pressure 145.0 PSI (1 MPa, 10.0 bar)Maximum Air Outlet Pressure 130.5 PSI (0.9 MPa, 9.0 bar)Dump Valve Pressure 145.0 PSI (1 MPa, 10.0 bar)Isolation Valve Pressure 145.0 PSI (1 MPa, 10.0 bar)Pneumatic Inlet Size 1/2 in. npt(f)Pneumatic Outlet Size 1/2 in. npt(f)Transducer Connection Sizes

10 K 1/4 in. npt(m)25 K HM440 K HF460 K HF475 K HF4

Operating Temperature Range 32° - 104° F 0° - 40° COverall Dimensions, 1 Pump (L x W x H) 16.00 in x 18.48 in. x 8.38 in. 40.64 cm x 46.94 cm x 21.29 cmOverall Dimensions, 3 Pump (L x W x H) 20.00 in x 20.61 in. x 8.38 in. 50.80 cm x 52.35 cm x 21.29 cmWeightEnclosure, One Pump System 30.0 lbs 13.6 kgEnclosure, Three Pump System 54.4 lbs 24.7 kg

CALIFORNIA RESIDENTS

WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A6828Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO HIGH PRESSURE EQUIPMENT CO. • 2955 West 17th Street • ERIE PA 16305 • USACopyright 2019, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.highpressure.comRevision D, January 2021

Graco High Pressure Equipment Company Standard WarrantyGraco High Pressure Equipment Company warrants all equipment referenced in this document which is manufactured by Graco High Pressure Equipment Company and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco High Pressure Equipment Company, Graco High Pressure Equipment Company will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco High Pressure Equipment Company to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco High Pressure Equipment Company’s written recommendations.

This warranty does not cover, and Graco High Pressure Equipment Company shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco High Pressure Equipment Company component parts. Nor shall Graco High Pressure Equipment Company be liable for malfunction, damage or wear caused by the incompatibility of Graco High Pressure Equipment Company equipment with structures, accessories, equipment or materials not supplied by Graco High Pressure Equipment Company, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco High Pressure Equipment Company.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco High Pressure Equipment Company distributor for verification of the claimed defect. If the claimed defect is verified, Graco High Pressure Equipment Company will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco High Pressure Equipment Company’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO HIGH PRESSURE EQUIPMENT COMPANY MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO HIGH PRESSURE EQUIPMENT COMPANY. These items sold, but not manufactured by Graco High Pressure Equipment Company (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco High Pressure Equipment Company will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco High Pressure Equipment Company be liable for indirect, incidental, special or consequential damages resulting from Graco High Pressure Equipment Company supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco High Pressure Equipment Company, or otherwise.

FOR GRACO HIGH PRESSURE EQUIPMENT COMPANY CANADA CUSTOMERSThe Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco High Pressure Equipment Company InformationFor the latest information about Graco High Pressure Equipment Company products, visit www.highpressure.com.

TO PLACE AN ORDER, contact your Graco High Pressure Equipment Company distributor or call to identify the nearest distributor.Toll Free: 1-800-289-7447 Fax: 814-838-6075

http://www.graco.com

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