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Graco 313875J User's Manual

1. Green on only System is powered up and there are For information about ADM error and event codes see no error conditions present Appendix D ADM Event and Error Codes Overview Yellow on An advisory exists page 69 Red flashing A deviation exists Before performing any troubleshooting procedure Red on The system is shut down due to an alarm occurring 1 Perform Pressure Relief Procedure on page 46 Errors include advisories deviations or alarms so 2 Turn Main Power Switch to the OFF position green will only be on when none of these occur A yellow light can be on at the same time as red flashing or solid 3 Allow equipment to cool Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also deter mine that all circuit breakers switches and controls are properly set and wiring is correct before assuming there is a problem Common Problems Problem o o jCase Solution O General 0 2 Display Module completely Verify main power switch is ON dark Thrown circuit breaker Check machine breakers and reset Tighten 5 pin cable on Advanced Display Module Bad display module Replace Advanced Display Module No or incorrect amount of Tank empty Install new drum of fluid material dispensed from Air in material Prime the machine
2. 80 Overview 80 USB Opblions na eee 80 Download Log Files 80 Log Files Folder Structure 81 Transfer System Settings 83 Update Custom Language 84 Technical Data se y UE ES 87 DIMERSIONS ected x CE E EE EM 87 Graco Standard Warranty 88 313875J Related Manuals Manuals are available at www graco com Component manuals in English System Manual 312764 VPM Repair Parts Power Distribution Box Manual 3A0239 Power Distribution Boxes Instruc tions Parts Pumpline Manuals 312375 Check Mate Displacement Pumps 3A0021 Vertical Hydraulic Driver Repair Parts Valve Manuals 310550 1 2 in NPT Fluid Port Ball Seat Applicator 310551 3 4 in NPT Fluid Port Ball Seat Applicator 3A1792 DV Series Dispense Valves Flow Meter Manual 309834 Helical Gear Fluid Flow Meter 3A1937 Heated Platen Kits 313875J Helated Manuals Models Models Full Load Peak 1 ad Maximum 1 ad Phase Approximat Fluid Max Flow eOutput Working Rateo per Cycle Hydraulic Pressure Heated Heated che Ib min A B Pressure psi MPa System Description C Platen Platen kg min gal liter Ratio bar 24 000 No Heat puas 24F874 mounted BA 76A dispense F3 24F875 Valve v 55A 62A Fi 240509 VPM 12 55A 62A Mast 27 600 mounted 24J510 dispense
3. a From the Calibration screen press Wiii to access the Learn Mode screen 35 Operation b Place a waste container below the ratio check valves The next steps will cause the machine to dispense material c Press i it then The pump will travel to bottom most position d After the pump stops moving press En then press Gl The pump will travel to the top most position NOTE During this process the system learned the mechanical limits of piston travel If the pump did not reach either piston mechanical travel limit for any rea son repeat the procedure 21 Press B to exit the Setup screens 22 Press Pi repeatedly to select Operator mode then press to accept 23 Press to enter the Setup screens then press left or right to navigate to the main Calibration screen Flow Meter No Flow Meter Calibration 24 If flow meters are installed refer to Flow Meter or Flow Ratio Calibration starting on page 39 If flow meters are not installed refer to No Flow Meter Machine Calibration starting on page 40 36 Flow Rate and Ratio Learning 25 At the main Calibration screen press EZ all learned data Previous OF 729 10 Cal Max 14506 HAAQ Cal Min 1162 11376 Range 13500 15000 Range 1000 1500 7 Erase Control Data Previous 7 26 0 NOTE This will not affect the weight calibration that was just completed 26 Press B to exit the Setup screens
4. if enabled Setup Screens N 22 Maintenance z Supply z Conditioning 1 S Conditioning 2 N Conditioning 3 Operation 31 Operation Navigation Overview For all ADM screens to be accessible and functional the ADM must be enabled and an operating mode other than Standby or Disabled must be selected NOTE The optional Diagnostic screen can be enabled from Advanced 3 screen see page 64 To navigate between screens use the arrow keys on the ADM keypad To access the Setup screens press rH If the Setup screens password is turned on use the ADM keypad to enter the password then press 4 1 For Setup screens information see dix B ADM Setup Screens Overview on page 59 For Run screens information see Appendix C ADM Run Screens Overview on page 65 H Password 0 M m Hu Active Errors 01213 10 14 37 Standby Password Dl If a screen has been entered by pressing Lal or if the system is in editing mode then navigating to a different screen will be disabled As applicable exit the screen and editing mode to re enable screen navigation 32 Change ADM Values To edit information in a screen such as a shot definition or a system setting like time or date format follow this general process 1 Press NOTE Operator mode flow settings are edited using a slightly different process To edit dispensing settings when in Operator mode see Dispense in O
5. Desktop 12 amp Documents i My Computer IBM PRELOAD CH 2 DNDJCD RW Drive Di Sa Removable Disk E O CanSolarData Z Car Search china Trip fMyCamera K GRACO F 06200799 F 06201073 c 2 773 LIP am Tools Help G Back 3 2 Search maa ENGRACOD6201073 DOWNLOAD ni BAG Address x 2 Pa DISPTEXT TXT 3 E SETTINGS TXT Folders uti G Back 3 2 Search iz k K EGRACO 6201073 DOWNLOAD DATAOOOZ Desktop 2 ae My Documents ie My Computer o L See IBM PRELOAD CH 26 DVDICD RW Drive Dr Removable Disk E CanSolarData EZ Car Search Oh China Trip fMyCamera zip GRACO amp T 05200799 it 06201073 DOWNLOAD 002 773 Lipi am Appendix E USB Operation Bre x Li ERROR C5V E 2 5 NEL 3 5YSTEM CSY Fic 19 DOWNLOAD DATAxxxx Folders Each time a stick drive is inserted into the ADM USB port a new folder named DATAxxxx is created The number at the end of the folder name is incremented each time a stick drive is inserted and data is transferred through the USB In each DATAxxxx folder there are three log files They are formatted as csv comma separated value files and can be opened by most text editors or data processing programs such as Excel Example 1 ERROR File Th
6. 27 Press Pi repeatedly to select Shot mode then press to accept 28 Select a defined shot that will provide a 10 second or longer dispense at the flow rate and ratio intended to be used during normal system opera tion NOTE If the ambient temperature is significantly below 68 F 20 C then the flow rate for the machine will need to be decreased For most materials at 68 F 20 C ata 2 1 to 3 1 ratio a maximum flow rate of 335 g s or 335 cc s can be expected The machine should not be oper ated much below 120 g s or 120 cc s at a 2 1 to 3 1 ratio 313875J 29 On the main run screen verify the ratio check valve button r1 is not active 0726 10 19 23 Trendi Errors Events PI Ma Active Errors psi T 100 0 ceis 2651 p AO woods NOTE This verifies material dispenses through the static mixer 30 Place bucket under the end of the static mixer 31 Press eJ to begin dispensing then write down the A Red and B Blue dispense pressures shown on the ADM NOTE During the dispense an off ratio deviation may be generated and that is ok 32 Repeat the previous step until the System Learning New Setpoint advisory turns off and the light tower yellow lights turns from yellow to green 33 Base purge the mixer to clear mixer of mixed mate rial NOTE A base purge will dispense only the B Blue material to push all mixed material out of the mixer Base purge settings are defi
7. VPM 25 shown AJ AL AF FiG 2 Component Identification 11 313875J Component Identification VPM 12 ti17703a NANG a 16 22 i PARO p 21 YAN TR ANM TE h MEN MUM x ON AA FIG 3 313875J 12 Component Identification BF Blowoff Air Supply Line Connector BG Platen Lift Rod BH Pump Bleeder Valve BJ Pump Wet Cup BK Material Line BA Vertical Hydraulic Driver BB Pump Lower BC Platen BD Integrated Air Controls BE Platen Bleed Port RAM Assembly Q L 5 en en en BE v wb ovv vv vvv C NS 9 ly NN 1 AS 4 zA E EM SA LAY C LI IN N CN T D Ca A 2 EAE ME ME IP TPG lt nd en en BJ BB 13 ti17705a BF 313875J Component Identification Integrated Air Controls Circuit Breakers The integrated air controls include e Main air slider valve CA turns air on and off to A NU AN the ram system When closed the valve relieves pressure downstream Most circuit breakers are located inside the power distri bution box The main block of circuit breakers in the Ham air regulator CB controls ram up and down power distribution box is shown below with detailed pressure and blow
8. tem will lock Once the update is complete the ADM will tell the user to cycle power to apply the updates 8 When the software is done updating remove the USB stick drive 9 Turn the Main Power Switch to the OFF position then back to the ON position 10 Plug the USB stick drive into a computer 11 Navigate to the UPLOAD folder and remove the DISPTEXT TXT file 84 NOTE Immediately following uploading the language file remove the DISPTEXT TXT file from the UPLOAD folder to prevent accidental loss of data the next time the USB stick drive is inserted into the ADM USB port If there is a DISPTEXT TXT file in the UPLOAD folder when the USB stick drive is inserted into the ADM USB the software will automatically begin updating 313875J Appendix E USB Operation Example SETTINGS TXT File Example DISPTEXT TXT File Ox8000200e Ox8000200f Oxe000z2010 0002011 0002015 0 50002019 0 5000201 000201 313875 0 00000000 0 00000001 0 00000000 0 00042 1 0 0002 1 0 00000000 0 00000000 0 0000 60 4T UNE KN yy The user should never attempt to modify the SET 5 een ag stom m TINGS TXT file in any way Graco is not responsible u J for damages caused by an improperly modified Hari 5 file setup file E 3 EDA 4 ka 10
9. and set the Ratio Deviation Yo to any number greater than or equal to 5 NOTE The Alarm 967 can be turned back on after this setup and calibration procedure is completed 14 Set the Pressure Imbalance Alarm to 2000 psi 137 9 bar 13 8 MPa 15 Navigate to the main Calibration screen F Previous 07 290 Hu Cal Max 14506 14405 CE Cal Min 1162 276 Previous 1 1 Range 13500 15000 Range 1000 1500 Previous 07 28 10 3138754 Operation 16 Press MA 10212 00 35 Standby Sequences ster m No Active Errors Specific Gravity RED EG Specific Gravity BLUE 1 250 E Setpoint x 17 Enter the specific gravities for the tvvo materials in the system NOTE The specific gravities do not need to be exact but should be close 18 Press E to exit the Setup screens Prime the Machine Refer to Priming section on page 30 Piston Position Learning 19 Navigate to the Calibration screen 20 Perform Learn Mode NOTE Learn Mode will teach the system the mechani cal limits of piston travel It must be performed whenever the pump line is rebuilt or if any other maintenance is performed that may affect the mechanical tolerances in the pump line If the machine does not appear to be uti lizing the full extent of the pump stroke or if the machine appears to be contacting the end of the hydraulic cylin der perform the Learn Mode procedure
10. broken Broken motor shaft Replace motor Red Tank Con Fault Blue Tank Con Fault Red Inline Con Fault Blue Inline Con Fault Red Hose Con Fault Blue Hose Con Fault Red Chiller Con Fault High current to relay 1 Broken contactor Replace contactor Blue Chiller Con Fault Red Blanket l High Temp Defective RTD Replace RTD Defective High Power Temperature Control Replace High Power Temperature Control Module Tank blanket is above the Blue Blanket defined high alarm limit Mes High Temp Alarm Module Loose connections Tighten connections Red Tank Con Fault Blue Tank Con Fault Red Inline Con Fault Blue Inline Unexpected current to relay 1 Shoned modde If temperature is being affected by a zone that has been disabled replace heat module Blue Hose Con Fault Red Chiller Con Fault Blue Chiller Con Fault Motor Controller Fault A general fault has occurred within the MCM Cycle power if the error persists the MCM will need to be replaced lation Internal hardware failure 78 313875J Appendix D ADM Event and Error Codes Overview Error Error Code Error Description Type Cause The requested controlling System incorrectly setup and ensure that all pages have properly defined WSCO Setpoint value pressure or flow is Deviation values outside the limits of the system Redefine shot with control parameters within the limits Shot incorrectly defined of the system Gel ti
11. heated platen to enable dispensing in lower temperature approval of a system environments Part Description Pat Description OC 24E269 400V Non CE Conversion Kit 246267 B Blue Side Kit 24E272 400V CE Conversion Kit 24E268 A Red Side Kit 4 313875J Warnings Warnings The 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 symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause elec tric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment e Connect only to grounded power source e All electrical wiring must be done by a qualified electrician and comply with all local codes and reg ulations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear chemically impermeable gloves when spraying dispensing or cleaning equipment
12. lt Diagnostic N Errors N N Events N Home Screens Disabled The Home screen is the first screen that displays when the machine is started and when switching from the Setup screens to the Run screens The Home screen shows the current fluid pressure at the pump outlets The operating mode can be selected from the Home screen The available operating modes are Operator Sequence Shot Standby Night and Disabled System Off PE 1211 Home KAO In Disabled mode machine operation is disabled and the setup screens cannot be accessed Standby 57 Trends Errors m Active Errors This operating mode is only used at initial startup and is pressed when In Standby mode the user can park the pumps perform a base purge and close the dispense valve See Shut down on page 45 for base purge and parking the pumps procedure 313875J 65 Appendix C ADM Run Screens Overview Shot 400 0 ccs 2631 pD 1000 This mode allows the user to dispense using one of the defined shots See Shots screen on page 59 Shot defi nition including flow ratio progress and size is shown at the bottom of the screen The user can also dispense a ratio check shot Sequence 0721710 09 57 e Trends Errors Sequence C Mo Active Errors 100 0 ccs 100 1 LAAL 000 This mode allows the user to dispense using one of the defined sequences See Sequences on page
13. to calibrate 34 7 8 9 Navigate to the System 2 screen Ob W11 20 40 m Calibration Maintenance r3 m Mo Active Errors cal Enable Gel Timer Mix Head Pump Line Hydraulic Level Sensor Hydraulic ETD Supply Low Lewel Sensor Dispense Valve Paste Base Purge Setpoint 2D si Select a base purge flow rate A value of approxi mately 200 g s or 200 cc s is recommended If installed check the Supply Low Level Sensor option 10 Verify the correct Dispense Valve type is selected 11 Navigate to the System 3 screen 0728 10 1826 Calibration Maintenance m Active Errors Red Label Blue Label BLUE Pressure Imbalance Alarm 2000 psi SEQUENCE Flowmeter Type HG6000 557 100 kd Alarm Deviation X Ratio 313875J 12 Select the flow meter types installed on your sys tem For VPM 25 systems select HG6000 for the A Red side and SRZ 100 for the B Blue side For VPM 12 systems select HG6000 for both sides If no flow meters are installed select the Dis able option as indicated below and proceed to step 14 12 07 11 14 17 4 Calibration Maintenance standby m No Active Errors Red Label Blue Label BLL E Flowmeter Type Disabled w Disabled Alarm Pressure Imbalance Alarm A000 psi Deviation X Ratio 13 Set the Ratio Alarm 96 to O to turn off ratio alarms
14. 1000 hours or 12 months 17 to 32 C whichever comes first 90 F and above 500 hours or 6 months 32 C and above whichever comes first Check Hydraulic Fluid Level Check hydraulic fluid level on dipstick A Fluid level must be between indent marks B on dipstick Refill as required with approved hydraulic fluid see Technical Data on page 87 If fluid is dark in color change fluid and filter ti7861a1 47 Maintenance Install Upgrade Tokens NOTE The Motor Control Module Fluid Control Mod ule and Temperature Control Module connection to the system is temporarily disabled during the installation of upgrade tokens To install software upgrades 1 Use correct software token stated in the table See Graco Control Architecture Module Programming manual for instructions NOTE Upgrade all modules in the system to the software version on the token even if you are replacing only one or two modules Different soft ware versions may not be compatible All data in the module System Settings USB Logs Recipes Maintenance Counters may be reset to factory default settings Download all settings and Fic 14 Remove Access Cover user preferences to a USB before the upgrade for ease of restoring them following the upgrade See manuals for locations of specific GCA compo nents The software version history for each system can be viewed in the technical support section at
15. 2 Check for leaks 3 Check hydraulic fluid levels 4 Check pump wet cup fluid levels 5 Check feed system fluid levels 6 Turn Main Power Switch to the ON position The splash screen will be displayed on the ADM until it is finished loading GRACO Lr L 7 When the ADM is finished loading press enable the ADM The System Status Indicator Light next to will illuminate green 8 Press Pi repeatedly to select a different operating mode then press to accept NOTE The Setup screens cannot be accessed when Disabled mode is the active operating mode Also cer tain machine functions and setup changes are disabled when Standby mode is selected 28 313875J Change Drum KA Excessive air pressure in the material drum could cause the drum to rupture causing serious injury The platen must be free to move out of the drum Never use drum blowoff air with a damaged drum Remove Drum 1 Open main air slider valve on the integrated air con trols and set ram air regulator to 40 psi 0 28 MPa 2 8 bar 2 Setram director valve handle to UP then immedi ately press and hold the blowoff air button until the platen is completely out of the drum Use minimum amount of air pressure necessary to push the platen out of the drum 3 Helease the blowoff air button and allow the ram to rise to its full height 4 Remove drum Install Drum 1 If platen is inside a drum perform Re
16. 60 The shot definition for the shot used in the current sequence position is shown at the bottom of the screen Shot defi nition information shown includes flow ratio progress and size 66 Operator Home SINE mi Ma Active Errors 300 0 x s 19145 100 2 2280 2723390 This mode allows users to dispense without using defined shot numbers or sequences Use EN to set flow rate and ratio The user can also dispense a ratio check shot Prime 08 2010 13 49 Diagnostic Errors Events Prime C Mo Active Errors 150 0 214 30130 1 00 2 176470 Se This mode allows users to prime each pump individually 313875J Errors Screen 06 27 11 02 02 Horne Disabled Appendix C ADM Run Screens Overview Maintenance Varta Hoe gt Events 2148 Events m Active Errors m Active Errors Date Time Code ClassDescription O62 00 15 06127 1 00 15 SZ OOT2 AT 20 28 Dez 7T 20 28 ISO AT 20 28 MH L A USE Update Failed WODS A High Ratio WODS A High Ratio CACT A Comm Error Blue M M WODS A High Ratio CACT A Comm Error Blue M M l l ig 15148 IT 20 25 WODS A High Ratio T 20 25 WODS A High Ratio OBA 20 22 CACT A Comm Error Blue M M OOF IT 2022 WODS A High Ratio The Errors screens display the 50 most recent system errors Each error entry includes a description and error code along with a date and time sta
17. Cali bration procedure on page 34 313875J Setup Adjust Motor Control Module Selector Switch NOTICE If the Motor Control Module is replaced the selector switch must be set prior to initial startup of the Motor Control Module or damage may occur The Motor Control Module uses an 8 position selector switch S to set system maximum working pressure See FIG 13 The system can be configured to run in two pressure ranges 0 3000 psi 0 20 7 MPa 0 207 bar For systems vvith all components rated to 3000 psi maximum vvorking pressure or higher e 0 2000 psi 0 13 8 MPa 0 138 bar For systems vvith one or more component rated less than 3000 psi maximum vvorking pressure For example if the hoses are rated to 2500 psi then the 0 2000 psi range must be used See the following table for MCM selector switch S posi tion setting for each maximum working pressure Switch Position 2000 psi MWP 3000 psi MWP MCM A Red The factory setting for the Motor Control Module selector switch is 2000 psi if the machine is shipped with no hoses or hoses rated to 2000 psi maximum working pressure If the machine is shipped with hoses rated to 3000 psi maximum working pressure or higher then the factory setting for the selector switch is 3000 psi The selector switch position will be properly set at the factory for new systems When a motor control module is replaced the selector switch must be set to the cor rec
18. Motor Temperature Sensor LVDT A Red MCM only Three way Splitter to Hydraulic Directional Valve Oil Overtemperature Switch Ratio Check Solenoid Valve 3 5 B Blue MCM only Three way Splitter to Hydraulic Directional Valve Oil Overtemperature Switch Third connection is not used Pressure Transducer for material side controlled by the MCM 10 11 12 3 1 313875J Component Identification 17 Component Identification Advanced Display Module ADM User Interface TI12362a1 FiG 7 ADM Component Identification Front Buttons Function ADM Enable disable ADM M Softkeys Defined by icon next to softkey Enable E Abort Abort current Abort current operation Disable E lobo aa change acknowledge error System Displays system status select item toggle selected item Toggle between Run and Setup Setup screens Screens Stop all system processes Toggle H Arrow Navigate within a screen or to a new Keys screen Status Run Indicator LED 18 313875J Component Identification R P ti12902a Fic 8 ADM Component Identification Rear Key J Flat Panel Mount N Module Status LEDs K Model Number Identification Label P Accessory Cable Connection USB Interface see Appendix E USB Operation R Software Token Access Cover beginning on page 80 S Battery Access Cover CAN Cable Connection to See ADM Troubleshooting on page 53 for LED status informat
19. PERSONAL PROTECTIVE EQUIPMENT x You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury hearing loss inhala tion of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer SKIN INJECTION HAZARD High 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 313875J 5 Warnings FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion e Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and pla
20. WWW graco com Application 16G365 VPM Advanced Display Module Motor Control Module High Power Temperature Control Module Communication Gateway Module 16G407 Ratio Monitoring Flow Meters Fluid Control Module 48 313875J Advanced Display Module ADM d Replace Battery A lithium battery maintains the ADM clock when power is not connected To replace the battery 1 Disconnect power to the ADM 2 Remove rear access panel 3 Remove the old battery and replace with a new CR2032 battery 4 Replace rear access panel Install Upgrade Token See Install Upgrade Tokens on page 48 Cleaning Use any alcohol based household cleaner such as glass cleaner to clean the ADM Spray on the rag then wipe ADM Do not directly spray the ADM 313875J Maintenance Motor Control Module MCM u A Keep heat sink fins clean at all times Clean them using compressed air NOTE Do not use conductive cleaning solvents on the module Heat Sink Fins r 257396 3b9905 02b FiG 15 Clean Heat Sink Fins Install Upgrade Token See Install Upgrade Tokens on page 48 Fluid Control Module FCM u PA Install Upgrade and Key Tokens See Install Upgrade Tokens on page 48 49 Maintenance 50 313875J Troubleshooting Troubleshooting A I Light Tower Optional amp Signal Description
21. attempt to prevent damage System Settings file is Replace the system settings file with a backup or new t fil USB Update The ADM tried to upload a Ur ile Failed vetersellihas fil but talled System Settings file is Ensure that the first line in the settings txt file contains y 9 intended for another the text GMS If not replace the file with the proper system system update file Failing sensors lf error persists the motor will need to be replaced Alarm Ensure the d sub connector to the motor is connected Loose connection 200 and the vviring is intact An error has been detected on Encoder Faultithe motor position sensor 3138754 77 Appendix D ADM Event and Error Codes Overview Error Error Code Error Description Type Cause Nel Make sure the directional valve has povver Make sure the cord to the directional valve is connected to the correct port and the cord is not damaged Th for had Directional valve failure The directional valve will need to be replaced e motor has reached a Hydraul r pack speed that should not be i 7 nn The hydraulic power pack will need repair reached in normal operation Alarm Defect 3 Roo and was shutdown to prevent possible damage Motor no longer coupled Reset coupler per specifications and retighten set to hydraulic pump screws Supply tube from hydraulic pump to Bad directional valve connection Retighten or replace supply tube manifold is loose or
22. be exited When Learn mode is active a Learning New Set Point advisory is generated and the yellow light on the light tower is illuminated After Learn mode is complete the advisory is cleared 33 Operation System Setup and Calibration Perform this entire procedure if any of the following con ditions are met e The machine is new One or both materials in the system have changed since last performing this procedure Flow rate ratio or ambient temperature has changed If the software has been updated verify all software set tings in the first section of this procedure are still correct If any incorrect software setting is found perform this entire setup and calibration procedure Software Settings 1 With the machine on press to enable the ADM The LED next to the button should be green 2 Press Pi repeatedly to select Standby mode then press to accept 3 Press B to enter the Setup screens 4 Navigate to the System 1 screen 0802 10 12 39 4e Calibration Maintenance Prime m Active Errors Inlet psi Type Check Mate v Siza B wi Fa Inlet psi Type Check Mate Size 250 v 5 Verify the correct pumps and pump sizes are selected For the standard VPM system the B Blue pump should be a Check Mate 500 and the A Red pump should be a Check Mate 250 6 Select volume or weight for the dispense mode Weight mode is recommended because it is easier
23. detected Retighten or replace supply tube Over pressure valve dumping to tank 7777 H Check to ensure there is no blockage material lines exceeded the maximum Make sure the requested pressure is within the max operating pressure as defined operating pressure which can be found on the setup in the setup screens screen System 1 Orifices blocked Clear blockage Hose blocked Clear blockage or replace hose as necessary Dispense valve failed to Check to make sure the dispense valve is properly open configured and connected to the MCM Blue Invalid maximum Pressure Shutdown pressure defined 313875J 73 Appendix D ADM Event and Error Codes Overview Error Error Code Error Description Type Cause E Ensure the material flow is equally restricted on both Dispense line is clogged material lines On the ADM go into the setup screens gt System gt Pressure imbalance is land ensure the pressure imbalance value is the defined too lovv maximum acceptable to prevent unnecessary alarms which will abort dispenses Orifice blocks closed off Verify that one or both of the orifice blocks dispense too much on one or both when adjusted to the fully open position then adjust The pressure difference PADO Pressure between the Red and Blue Imbalance material is greater than the defined amount Relieve system pressure and remove the orifice from the orifice block and inspect for pack out Clean or replace as neces
24. for initial operation AN A The machine is not properly grounded until this setup procedure is performed To prevent risk of electric shock do not start the machine until this setup proce dure is completed 1 Locate the machine NOTICE To prevent machine damage do not expose system to rain NOTICE If lifting the machine is required use a forklift at the base of the machine Do not lift the machine by plac ing forks at the top of the RAM assembly frame a Locate the machine on a level surface See Dimensions on page 87 for space require ments b Lockthe wheels once the machine is in place 2 VPM 25 systems only Install the boom a Install boom into support 22 b Connect air line on boom to boom director valve located on boom support c Install mixer onto boom d Connect electrical cables from base to boom e Connect fluid lines from base to boom VPM 12 systems only If the mast was shipped disassembled install the mast a Use four bolts and washers to install mast onto base Connect air line on mast to mast director valve Install mixer onto mast Connect electrical cables from base to mast Connect fluid lines from base to mast 313875J 4 Fill pump wet cups 2 3 full with IsoGuard Select fluid 5 Back off air regulators to their full counterclockwise position and c
25. one pump moves but material may drip from the other ratio check dis pense valve when opened 2 30 Verify RAM director valve is in the DOWN position and air pressure is applied to the RAM Press Pi repeatedly to select Prime Mode then press to accept Check the dispense settings shown at the bottom of the screen UR 4 If desired change the dispense settings a Press EN to enter editing mode b Usethe left and right arrow keys to select the item to change 150 0 gs 1 00 2 30130 5470 556 7 g c Use the numeric keypad to type the new value d Press to accept the new value e Press to exit editing mode Press to select the A Red side Press O to begin dispensing A Red material Continue dispensing until clean air free material is dispensed from both sides then press amp to stop dispensing Press to select the B Blue side Press O to begin dispensing B Blue material Continue dispensing until clean air free material is dispensed from both sides then press amp to stop dispensing 313875J Operation ADM Operation Overview NOTE After startup press 9 to enable the ADM Navigation Diagram Errors Events nm qu N Password Entry 313875J Run Screens N Errors 1 N l Optional gt gt gt Events 1 77 Maintenance 77 Diagnostic Home N N N N N Errors 2 Events 2 N N
26. os 15 20 1 25 laus MH Oxa0002000 Dx00000030 Li s Ox80002002 0x00000001 MES 40 Ox80002003 Ox00000000 pag Ox80002004 0 00000001 14 60 Ox80002005 0 00000000 ma an Ox80002006 0 00000000 IE 100 Ox80002007 0 00000001 G Oxa0002008 Ox00000000 Br 120 Oxa000200a Ox0000ff05 145 Ox82000200c 0 00000000 160 0x80002004 Ox00000000 21 180 m M 419 MN D SPTEXT 4 Appendix E USB Operation 86 313875J Technical Data Technical Data Air Inlet Pressure 85 100 psi 0 59 0 69 MPa 5 9 6 9 bar Wetted Parts u rer b Rn Ballar ay Ran Stainless steel UHMW carbon steel Fluid Viscosity Range Paste Fluid Flow Range VPM 25 12 25 kg min 26 55 Ib min VPM 12 10 12 kg min 22 26 Ib min Hydraulic Reservoir Capacity 8 gal 30 liters each Recommended Hydraulic Fluid Citgo A W Hydraulic Oil ISO Grade 46 Dimensions The dimensions of the machine vary by machine layout Ram in the lowered position Ram in the lowered position 9 ft 3 in 2 82 m Ram in the raised position 11ft4in 3 45 m B Width 7 ft 8 in 2 34 m C Depth 15 ft 10 in 4 83 m 4 OM SG NG NG vA AN b SANA Pana VA 313875J a f S I mo P gt y 9 ft 3 in 2 82 m Ram in the raised position 11 ft 4
27. suc cessfully transferred from the USB drive to the ADM EQU5 R Logs Down The Error Event and Shot data logs were successfully transferred from the ADM to a USB drive ERO1 R Shot Count A counter from the shot counters main ERO2 R Seq Posi A counter from the sequence counters EQU2 R Settings Uploaded EQUS R Language Downloaded EQUA R Language Uploaded tion Count Reset rial Volume Reset material volume was reset to zero rial Weight Reset material weight was reset to zero Count Reset Hed pump was reset to zero rial Volume Reset material volume was reset to zero material weight was reset to zero Count Reset Blue pump was reset to zero rial Weight Reset 69 Appendix D ADM Event and Error Codes Overview Error Codes Error Error Code Error Description Type Cause Solution The three point calibration data is invalid system will operate in weight mode but will attempt to volumetrically calculate weight This will lead to consistent shots which will be offset for the desired dispense amount The system will ignore the Invalid Auto calibration data gathered and will use information gathered during dispenses 0500 Weight Cal Deviation Invalid data Re calibrate the machine If any messages appeared indicating why the Deviation Invalid data calibration failed attempt to fix the problem then re run the calibration Red Blanket Blue Blanket Red Inline Bad heaters Measure resistance o
28. to parts which may cause electric shock or other serious injury if work is not performed properly Have a qualified electrician connect power and ground to main power switch terminals All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations 24 Electrical Cord Requirements NOTE Power cord is not supplied See the following table Table 1 Power Cord Requirements Cord Requirements AWG mm 230V 3 phase 8 8 4 3 wire ground 400V 3 phase 6 13 3 4 wire ground T 1 Hesidual Current Device RCD must be rated at 300 mA if installed Electrical Cord Wires by Model 230V 3 phase L1 L2 L3 GND 400V 3 phase L1 L2 L3 N GND Electrical Requirements See Models on page 4 for detailed electrical require ments information a Use 5 32 in or 4 mm hex allen wrench to con nect the power leads to L1 L2 L3 and N as applicable b Connect green wire to ground GND N L3 L2 L1 r 24C686 313998 1a Fic 12 400V 3 phase shown 313875J Power Line Voltage Surges Power conversion equipment can be sensitive to voltage fluctuations on incoming power The Motor Control Mod ule falls under the category of power conversion equip ment because energy is stored on a capacitive bus and then modulated to control a brushless motor Engi neered design takes this into account and withstands a wi
29. to the proper Blue High l L322 Deviation port and that the cord is not damaged Material Level i sensor l Blue Auto lOr A UMA DISCS n 0058 eve Check for loose or disconnected wires or plugs expected Deviation connection Refill Timeout Bad level sensor Replace level sensor Red Auto 4 No material is actually l L6A1 cm Deviation Make sure the feed pumps are operating properl Refill Timeout The tank stand has been filing being fed DEP P 9 propeny L6B2 72 313875J Appendix D ADM Event and Error Codes Overview Error Error Code Error Description Type Cause Low oil level Check oil level and if low add more hydraulic fluid Check to ensure the hydraulic oil level sensor is Loose bad connection properly connected to the MCM and that the wire has a not been damaged The volume of oil in the tank is 7 7 7 7 Bad level sensor MBH1 Low Oil Level Alarm needed for the system to go 7 7 7 end aie and early 7 properly operate eak in hydraulic driver detection tubing Replace seals as necessary an replace lost oil Leak in the hydraulic Inspect the hydraulic reservoir fittings and filter for reservoir heat leaks Repair or replace as necessary and replace exchanger lost oil The motor magnetism has If error persists and performance can no longer Low Motor l Prolonged exposure to l l l MBN1 decreased to the point where Advisory satisfy the user requirements the motor will need to Performance heat or high
30. transferred Once the download is complete the SETTINGS TXT file will be located in the DOWN LOAD folder NOTICE The user should never attempt to modify the SET TINGS TXT file in any way Graco is not responsible for damages caused by an improperly modified setup file 2 Plug the USB stick drive into a computer 3 Navigate to the DOWNLOAD folder 4 Copy the SETTINGS TXT file from the DOWNLOAD folder into the UPLOAD folder 5 Remove the USB stick drive from the computer and install it into the ADM USB port for the second machine The software will automatically begin updating 313875J NOTE Before the update begins the ADM automatically shuts down the system aborting any in progress dis pensing When the software is updating a pop up box will appear to inform the user of the update and the sys tem will lock Once the update is complete the ADM will tell the user to cycle power to apply the updates 6 When the software is done updating remove the USB stick drive 7 Turn the Main Power Switch to the OFF position then back to the ON position 8 Plug the USB stick drive into a computer 9 Navigate to the UPLOAD folder and remove the SETTINGS TXT file NOTE Immediately after uploading the settings remove the SETTINGS TXT file from the UPLOAD folder to pre vent accidental loss of data the next time the USB stick drive is inserted into the ADM USB port If there is a SETTINGS TXT file in the UPLOAD f
31. user operate the machine in weight mode when flow meters are not installed or have been disabled NOTE In weight mode the ratio displayed is a weight ratio and should not be considered as volumetric ratio 40 Press to enter the Setup screens then press left or right to navigate to Advanced 3 screen Turn off the Enable Ratio Check Weight Mode Entry option 100212 05 40 Conditioning COW standby C Mo Active Errors L Disable Dispensing From Display 1 Disable Modifying Temp Setpoint Disable Operator Mode How Adjustments m Disable Operator Made Ratio Adjustments Temperature Alarm Disables Dispense L Complete Dispense With Setpoint Error _ Enable Shot Aborted Notification L Enable Ratio Check Weight Made Entry 12 Trigger For Dispense Press and navigate to the shot definition screen Define a shot which is 10 times larger than the desired flow rate selected This will set approxi mately a 10 second dispense time Example If the dispense rate is 300 grams second set the amount to 3000 grams 3 Press to exit the setup screen and verify the ratio check option is not selected 12 0711 15 47 Diagnostic Errors Shot C No Active Errors 250 0 ers DLL 258000 g 4 Place a waste container under the mixer Press O to begin dispensing and record the aver age A Red and B Blue pressures shown on the ADM NOTE The dispense can be aborted early after record ing by p
32. voltage performance is greatly reduced be replaced l Visually check to ensure the pump is moving if not Motor failure Toe ensure the motor is wired properly If motor is moving but pump is not and pressure is not Hydraulic power pack Ti ilm building they hydraulic povver pack may need servicing EE ada abaka Check to ensure the linear position sensor is properly connected to the MCM and the wiring has not be the linear position sensor damaged Failure of the linear en Pump Failed The MCM attempted to move Geom Sensor Replace the linear position sensor N4A1 p the pump but no movement Deviation Motor longer coupled Reset coupler per specifications and retighten set to hydraulic pump screws Supply tube from hydraulic pump to manifold is loose or broken Broken motor shaft Replace motor Verify that no outside forces are stopping the pump from moving then inspect over pressure valve for damage or debris Pressure has risen to an Thermal unsafe level due to thermal l l KA Open the dispense valve manually or open the valves P400 Pressure expansion of materials All Deviation High pressure AIN to bleed pressure Rise conditioning zones have automatically been turned off PAA1 Red Pressure Alarm Dispense valve failed to Check to make sure the dispense valve is properly Shutdovvn open configured and connected to the MCM Bad dispense valve Replace dispense valve The material pump pressure P4B2 Alarm to Maye was
33. 2 3138754 Troubleshooting ADM Troubleshooting ti12902a Fic 16 ADM Component Identification Rear ADM System Status LEDs B Conditions Module Status LED ED signal Description Green on on Run mode Run mode System on on Sa flashing EE mode System on Run Mode System off ADM Module Status LEDs N Conditions Module Status LED Signal Description USB Module Status LEDs L Conditions Module Status LED Signal Description Green flashing flashing System is powered up is powered up Downloading information to USB Green Yellow ADM is busy USB cannot transfer Flashing information when in this mode 313875J 53 Troubleshooting Motor Control Module Diagnostic Information Table 3 LED Status Signal Green on System is powered up Yellow on Internal communication in progress Red solid MCM hardware failure Replace MCM Red flashing fast Uploading software Red flashing slow Token error remove token and upload software token again Sade po T3 4 O O O H E 9 lt LIGO FO O zi pm 2 r 257396 3b9905 07b Fic 17 LED Signals 54 313875J Acceptable Size and Duration of Power Line Voltage Fluctuations The Motor Control Module is designed to withstand volt age fluctuations from the
34. 4 00 00 32 Advanced Sequences value standby m Mo Active Errors 5 Repeat the previous two steps as desired 6 Press B to deactivate Using the Hl button The E button can be used to calculate an x 1 ratio from a non x 1 ratio For example if the desired ratio is 2 the button can be used to convert 5 2 to 2 5 1 This screen allows the user to edit shot definitions The 2 vee contents of this screen change based on the Dispense Mode Shots may be defined by flow rate and by 2 time duration volume or weight depending on the Dis 1 From the Shots screen press pense Mode selection See System 1 on page 61 for EE o 2 1 2 3 4 5 B 9 10 mm l 1 z m mx ceo Dispense Mode options 2 Navigate to the B B column Using the B button 3 Press E The e button can be used to change multiple shot 4 Enter the non x 1 ratio in the column The cal definitions at once culated x 1 ratio will automatically be displayed in the Een column and in the shot definition 5 Press ix 1 From the Shots screen press Ka 2 Press amp l 3 Navigate to a shot definition value 313875J 59 Appendix B ADM Setup Screens Overview Sequences 11 16 10 12 441 Shot Calibration Prime C Mo Active Errors ccc C O 2 coo This screen allows the user to edit sequence definitions The contents of this screen change based on
35. 60A 76A 230 3 valve 24J511 reduced v 62 A 400 3 flow Full load amps with all devices operating at maximum capabilities Fuse requirements at various flow rates and mix chamber sizes may be less 31 200 2 Platens Values are dependent on installed pump size Values shown are for largest available pump size Flow rate is independent of frequency 50 60 Hz Flow rate increases with flow meters removed i The maximum fluid working pressure for the base machine without hoses is 3000 psi 21 MPa 207 bar If hoses rated at less than 3000 psi are installed the system maximum fluid working pressure becomes the rating of the hoses If 2000 psi hoses were purchased and installed by Graco the working pressure for the machine is already setup for the lower 2000 psi 14 MPa 138 bar working pressure by Graco If the machine was purchased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed see Adjust Motor Control Module Selector Switch on page 27 for the procedure to setup the machine for higher rated hoses The change in work ing pressure is made by changing a rotary switch setting in the Motor Control Module The minimum pressure rat ing for hoses is 2000 psi Do not install hoses with a pressure rating lower than 2000 psi Accessories Heated Platen Kits Power Distribution Box Conversion Kits The Heated Platen kits convert the standard platen to a These conversion kits convert the voltage and CE
36. 9 Ratio Calculator see Using the E button on page 59 Return to Previous Main Screen Calibrate Piston Position On Main Calibration screen Calibrate Weight Dispense On Flow Meter Calibration screen Use Dispensed Material Weight to Calibrate Flow Meters Use Dispensed Material Volume to Calibrate Flow Meters Calibrate Flow Meters Learn Bottom Most Piston Position 313875J Icon Description Learn Top Most Piston Position Go to Next Calibration Screen Begin Weight Calibration Shot EN NN EN NN EN NM EN 57 Appendix A ADM Icons Overview Home Screen Icons Icon Description Prime A Red Side Nh Select Operating Mode Prime B Blue Side Initiate Dispense m Erase Selected Item Park Piston KG Erase All Items Shown Park Piston Disabled Weight Close Dispense Valve Piston Cycles Perform Base Purge Selected Shot Number No Shot Number Selected Selected Sequence and Sequence Position No Sequence Selected Skip to Next Shot in Sequence Abort Sequence Edit Operator Mode Flow Properties 58 313875J Appendix B ADM Setup Screens Overview Appendix B ADM Setup Screens Overview Setup Screens Navigation Diagram N 22 Maintenance z Supply 2 Conditioning 1 N z2 Calibration 2 System 1 Conditioning 2 N Shots 4 Type the new value then press enter All values below the selected shot will change to the new 01 0
37. Instructions 5 g TM 313875J VPM R Hydraulic Plural Component High Viscosity Variable Ratio Proportioner For pouring and dispensing sealants and adhesives For professional use oniy Not approved for use in European explosive atmosphere locations Read all warnings and instructions in this manual Save these instructions e Important Safety Instructions See page 4 for model information including maximum working pressure and approvals VPM 25 EES PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 MOGEIS EORR COE KAPA nido AA 4 ACCOSSOIIBS hee RR b 4 Vuarn nds z Da a haa ai 5 important Tvvo Component Material nformation 7 Isocyanate Conditions 7 Material Self ignition 7 Keep Components A Red and B Blue Separate 7 Moisture Sensitivity of Isocyanates 8 Changing Materials 8 A Red and B Blue Components 8 Component Identification 10 VEM Z aces 12 Hydraulic Power Pack 15 Motor Control Module MCM 16 Advanced Display Module ADM 18 Fluid Control Module FCM 21 SEUD guya da mana lo ota a 22 Initial Machine Setup 22 Adjust Motor Control Modu
38. RTD Replace RTD Defective High Power Temperature Control Module Loose connections Tighten connections Defective cooling valve Replace High Power Temperature Control Module 313875J Appendix D ADM Event and Error Codes Overview Error Error Code Error Description Type Cause VVBH1 Red Blanket Ctrl Shutdovvn Blue Blanket Ctrl Shutdovvn Red nline Ctrl Shutdovvn Blue Inline Ctrl Overheated Turn conditioning zone off Wait a few minutes If the Shutdown PCB over temperature Temperature Control condition does not clear or regenerates consistently Red Hose Ctrl Module replace heater module Shutdown Blue Hose Ctrl Shutdown Red Chiller Ctrl Shutdown Blue Chiller Ctrl Shutdown Motor Control ne voltage to the MCM has dropped to a level where Alarm Supply lines providing Check incoming voltage to ensure it is above the Undervoltage l Red Blanket Overvoltage Blue Blanket Overvoltage Red Inline Overvoltage Blue Inline Overvoltage Hed Hose Overvoltage Blue Hose Overvoltage Red Chiller Overvoltage Blue Chiller Overvoltage Incoming line voltage is Measure voltage across disconnect switch Voltage High line voltage should measure between 190 and 264 Vac The voltage to the MCM has Motor Control reached an unsafe level and Supply lines providing Check incoming voltage to ensure it is below the Overvoltage has been shutdown in an high voltage maximum operating voltage
39. aced Loose or bad connection Check RTD wiring Bad RTD Replace RTD 75 Appendix D ADM Event and Error Codes Overview Error Error Code Error Description Type Cause 76 Red Blanket RTD Fault Blue Blanket RTD Fault RTD 2 is giving no or invalid Red Chiller data RTD Fault Blue Chiller RTD Fault No Heat Red Tank No Heat Blue Tank No Heat Red Inline No temperature rise No Heat Blue Inline No Heat Red Hose No Heat Blue Hose No Cooling Red Chiller Al m No temperature decline No Cooling Blue Chiller Red Blanket Temp Cutoff Blue Blanket Temp Cutoff Heater overtemperature cutoff Red Inline p Temp Cutoff Blue Inline Temp Cutoff Loose or bad connection Check RTD wiring Bad RTD Replace RTD Tripped circuit breaker Visually check circuit breaker for a tripped condition Measure voltage across input terminals on power line Low Power filter Voltage should measure between 190 and 264 Vac Check for loose or disconnected wires or plugs power Bad heater s Measure resistance of heater s Tripped circuit breaker Visually check circuit breaker for a tripped condition Disconnect the valve and measure the voltage across the wires when the chiller is running to ensure 24V is being delivered to the valve If so the cooling valve will likely need replacing Chilled water supply off Turn on chilled water supply Loose or bad connection Check RTD wiring Defective
40. ally be selected upon completion of the shot 6 Check the ADM for errors and pop up notifications that could indicate a faulty dispense Press to acknowledge any displayed errors 43 Operation Dispense in Operator Mode 7 Check the ADM for errors and pop up notifications that could indicate a faulty dispense Press to Operator Mode begins dispensing when io is pressed acknowledge any displayed errors and stops when it is pressed again NOTE If a footswitch is used press and hold to dis pense Release to stop dispensing 1 Navigate to the Home screen 2 Press Pi repeatedly to select Operator Mode then press to accept 3 Check the dispense settings shown at the bottom of the screen 01 04 00 00 31 2 Home EO No Active Errors BLUE O psi 7 23 psi m G L zi 1 00 1 gt 43 57190 723399 4 If desired change the dispense settings a Press EN to enter editing mode b Usethe left and right arrow keys to select the item to change c Use the numeric keypad to type the new value d Press to accept the new value e Press to exit editing mode 5 Press O to begin dispensing 6 Press amp to stop dispensing 44 313875J Shutdown Shutdown Short term 7 Place container under the mixer and allow mixer to drain completely 1 Place container under mixer NOTICE Preventing material from draining from the mixer 2 If using a moisture sensitive material park p
41. cked a pop up notification will be displayed when a shot is aborted Enable Ratio Check Weight Mode Entry This option is for machines without flow meters When this box is checked after any ratio check shot a popup window will appear asking the user to enter the dispensed weights Press the Cancel button to abort the entry or press the Enter button to record the new values Advanced 4 L Enable Downloading of USB Logs Enable USE Errors Date of Last Download Do T1 This screen is for enabling the optional Diagnostic screen and for enabling USB log downloading and USB errors For more information about USB operation see Appendix E USB Operation on page 80 For more information about the optional screens see Diagnostic Screen screen on page 68 Advanced 5 10 02 12 05 37 te Conditioning Shots standby C Mo Active Errors Module 5 Advanced Display 15573 102 004 USB Configuration 16 575 101 001 MCM Application Blue 16E95 105 012 Component Blue 16 014 103 001 MCM Application Red 16E95 105 012 Component Red 16 014 109 001 Flowmeter 160755 101005 Numbers shown are for reference only and may be different on your system This screen displays software information 313875J Appendix C ADM Run Screens Overview Appendix C ADM Run Screens Overview Run Screens Navigation Diagram N zz Errors 1 i Errors 2 N Events 1 22 Maintenance N Events 2 Optional _
42. ctive Errors L Disable Dispensing From Display a L Disable Modifying Temp Setpoint Disable Operator Mode Flow Adjustments Disable Operator Mode Ratio Adjustments Temperature Alarm Disables Dispense Lu L Complete Dispense With Setpoint Error 2 _ Enable Shot Aborted Notification 1 Enable Ratio Check Weight Mode Entry 2x Trigger For Dispense This screen allows the user to control the availability of some key system features 64 Disable Dispensing From Display Check this box to disable dispensing from the ADM A footswitch dispense valve trigger or other external signal will be the only way to initiate a dispense Disable Modifying Temp Setpoint Check this box to disable modifying temperature setpoints from the Run screens This is only applicable if temperature control items are installed and enabled Disable Operator Mode Flow Adjustments When checked the user will not be able to change the flow on operator mode Home Run screen Disable Operator Mode Ratio Adjustments When checked the user will not be able to change the ratio on operator mode Home Run screen Temperature Alarm Disables Dispense When checked any active alarm from any temperature zone will disable dispensing Complete Dispense with Setpoint Error When this box is checked the shot will continue dispens ing even if the system never reaches the desired setpoint Enable Shot Aborted Notification When this box is che
43. d to turn on all enabled conditioning zones EBOO R Stop Button The Red stop button was pressed on EBRO R Night Mode While in night mode the system has Recirc Off automatically stopped the low recircu lation mode and turned off all condi tioning zones EBR1 R Setup val One or more of the setup values has ECA1 R Red Mate The Red materials specific gravity was ECB2 R Blue Mate The Blue materials specific gravity was ECHO R Learn Mode A learn mode calibration was success EHOO R Gel Timer The gel timer expired and the system ELOO R System Pow The System was powered on EMOO R System The System was powered off Powered Off ENC1 R Cal Point 1 A value for the first point in the three ENC2 R Cal Point 2 A value for the second point in the ENCA R Cal Point 1 The running average for point one of ENC5 R Cal Point 2 The running average for point two of ENDO R Ratio Check A ratio check shot was dispensed from Dispense the ratio check calibration screen ENNO R Automatic The system was successfully charac Cal Performed terized with the Automatic calibration 313875J Event Code and String EQU1 R Settings Downloaded The system settings were successfully transferred from the ADM to a USB drive The system settings file was success fully transferred from the USB drive to the ADM The custom language file was suc cessfully transferred from the ADM to a USB drive The custom language file was
44. de range of conditions but it is possible for supplied power to occasionally fall outside the tolerable range in industrial plants with high amperage reactive pulsed loads such as welding equipment If the tolerable range is exceeded an overvoltage condition is flagged and the system will shut down in an alarm state to protect itself and alert the user of unstable power Excessive or repeated overvoltage may permanently damage hard ware The MAX HOLD feature on a multimeter can be used to determine peak DC voltage on the line DC is the proper setting as opposed to AC because peak voltage is the critical parameter that affects the DC voltage level stored on the capacitive bus in power conversion equip ment Reading should not regularly exceed approxi mately 400VDC to avoid tripping the 420VDC alarm level in the Motor Control Module If power quality is sus pect power conditioning or isolation of the device s causing poor power quality is recommended Consult a qualified electrician if there are any concerns about the available power supply Power Line Test Steps with Multimeter i Set multimeter to DC voltage li Connect multimeter probes to supplied power line iii Press Min Max successively to show the peak positive and negative DC voltages iv Confirm readings do not exceed 400VDC Motor Control Module alarm issued at 420VDC 313875J Setup The chart below shows the permissible magnitude and duration of
45. e to be replaced level No power to fan Check cord to make sure fan has power Debris in fan or fan grill clear debris from fan fan grill Try to stop fan by lightly pressing on the center with a Low air volume from fan pencil eraser If the fan slows down easily it will need to be replaced Cable unplugged loose power Check for loose or disconnected wires or plugs T3H1 Motor temperature is approaching a level where damage is possible so the Advisory Motor Temp Cutback 0050 motor control module is limiting Move machine to an area below 120 F the output to a safe level conditions are too ho Motor pump coupler may be rubbing on hydraulic pump T3N1 Reset coupler per specifications and retighten set SCrews 74 313875J Appendix D ADM Event and Error Codes Overview Error Error Code Error Description Type Cause Defective RTD Replace RTD Defective High Power Temperature Control Replace High Power Temperature Control Module Module Blue Tank High Fluid Temp Red Inline High Fluid Temp Blue Inline Fluid temperature is above the defined high alarm limit The temperature the MCM has reached a level where product life will be decreased drastically and has been shutdown for protection Motor Control High Temp The hydraulic oil is at a temperature where performance is impacted Alarm significantly and has resulted in a system shutdown Oil Temp Shutdown Mot
46. e 1 ERROR file is the Errors and Events log file Error Log S N 06201073 Software Part Number 16N420 Software Version 1 01 002 Date DO 0 o DW B W m x N NIN NN M N NP v y k v y ND UB o NKO U on Na Up WIN pO 28 29 I4 4 b M 313875J 4 23 2012 11 09 1 ERROR 3 Time Error Log 4 11 2012 14 12 17 No Active Errors 4 11 2012 14 13 26 No Active Errors 4 11 2012 14 14 14 No Active Errors 4 11 2012 14 15 00 No Active Errors 4 11 2012 14 17 11 P4D0 A Pressure Imbalance 4 11 2012 14 17 17 Error Cleared P4D0 A Pressure Imbalance 4 11 2012 14 17 31 DDA1 D Red Pump Cavitation 4 11 2012 14 17 44 DDB2 D Blue Pump Cavitation 4 11 2012 14 20 18 Error Cleared DDA1 D Red Pump Cavitation 4 11 2012 14 20 18 Error Cleared DDB2 D Blue Pump Cavitation 4 11 2012 14 20 46 PADO A Pressure Imbalance 4 11 2012 14 20 52 Error Cleared PADO A Pressure Imbalance 4 11 2012 14 23 59 No Active Errors 4 11 2012 14 24 00 No Active Errors 4 11 2012 14 48 47 No Active Errors 4 11 2012 14 48 48 No Active Errors 4 11 2012 14 50 03 No Active Errors 4 11 2012 14 50 10 No Active Errors 4 11 2012 14 50 18 No Active Errors 4 12 2012 7 51 33 No Active Errors 4 12 2012 7 52 35 DDA1 D Red Pump Cavitation 4112 2912 7 52 39 nnR2 nr Blue Pumn Cavitation Event Log ECOX R Setup Values Changed ECOX R Setup Values Changed ECOX R Setup Values Changed ECOX R Setup Values Changed No Event No Event No Event No Event No E
47. ed to calibrate the flow meters This works regardless of whether the selected dispense mode is weight or volume 40 With 01 active and with pre weighed buckets below the ratio check valves press O to begin dispensing a ratio check dispense 37 Operation 41 Weigh the two buckets and use the net weight of each dispensed material to calculate the actual ratio of the dispensed material 42 f the calculated ratio of the weighed materials does not match the ratios displayed on the ADM go to step 1 to re calibrate the flow meters 43 If the calculated ratio of the weighed materials matches the ratio displayed on the ADM then navi gate to the System 3 screen and change the ratio alarm percentage to the desired percentage 44 If at any point in the future the ratio flow rate or ambient temperature changes from what was used while performing this procedure go to step 1 NOTE If the ratio or flow rate is changed to a ratio or flow rate that has not been calibrated by performing this procedure the system will generate a Learning New Setpoint advisory The system usually produces a good dispense ratio during the learning process however the advisory is generated to inform the user of the condition The system can store calibration data in its memory for up to five different flow rates and ratios NOTE If the ambient temperature changes significantly from the ambient temperature seen while performing this calibration p
48. either side Significant material leaking Pump shaft worn and or shaft seal Remove pump shaft assembly and reinstall see from pump seal worn pump manual for instructions and rebuild kit Material dispensed not cor Specific gravity of one or more of the Perform calibration procedure rect weight two materials has changed since cali bration Check valve malfunction Remove check valve clean or replace as necessary Piston worn or broken Replace piston Proportioning System Proportioning pump does not Pump piston or intake valve leaking Observe gauges to determine which pump is los hold pressure when stalled ing pressure Determine in which direction the pump has stalled by observing which directional valve indi cator light is on Repair the valve 313875J on when an advisory exists at the same time as a devi 51 Troubleshooting Problem Material imbalance Inadequate flow from pump cavitation Increase fluid supply to proportioning pump Worn pump inlet valve ball seat or gasket repair as necessary Erratic pump movement Pump cavitation Feed pump pressure is too low adjust pressure to within required range Pump output low Obstructed fluid hose or mixer fluid Open clear use hose with larger ID hase posman xu u Worn piston valve or intake valve in See pump manual for appropriate repair procedure Inadequate feed pump pressure Check feed pump pressure and adjust to within bul 5
49. el low or empty b Attach low empty sensor bracket A to mount ing bracket B C Attach the actuator D to the ram piston rod near the top so it passes in front of the sensor E at the correct level for drum low or drum empty 12 Install material drums See Install Drum procedure page 29 13 Perform Startup procedure page 28 14 Perform ADM setup NOTE All ADM setup items are located in the Setup screens See Appendix B ADM Setup Screens Over view beginning on page 59 for more information See ADM Operation Overview on page 31 for help with operating the ADM including how to modify settings a Navigate to Advanced 1 screen then set gen eral system settings See page 63 26 b Navigate to Advanced 2 screen then set units of measure See page 63 c Navigate to Advanced 3 screen then enable disable system features See page 64 d Navigate to System 1 screen then define con trol mode dispense mode and pump informa tion See page 61 e Navigate to System 2 screen then define dis pense valve details and other system settings See page 61 f Navigate to System 3 screen then define labels pressure imbalance and flow meter details See page 62 g Navigate to Shots screen then define shots See page 59 h Navigate to Sequences screen then define sequences See page 60 i If desired navigate to Maintenance screen then reset counters See page 62 15 Perform System Setup and
50. etup Screens Overview System 2 06 27 11 20 40 e Calibration Maintenance C No Active Errors Enable Gel Timer Pump Line Hydraulic Level Sensor Hydraulic ETD Supply Low Level Sensor Dispense Valve Base Purge Setpoint 00 0 g s Mix Head This screen allows the user to set the Gel Timer proper ties and set which items are installed on the machine NOTICE The correct dispense valve option must be selected Selecting an incorrect dispense valve option will lead to erratic machine performance When enabling the Gel Timer the user must select one of the 100 available shot definitions to use as the Gel Shot This shot will be dispensed when the Idle Period expires The Idle Period will begin after a dispense is completed Any dispense operation in the middle of the timer countdown will reset the Idle Period counter The system will generate an audible alarm that will begin the user entered number of seconds before the Idle Period expires The hydraulic level sensor and hydraulic RTD for the pump line must be enabled when installed in the sys tem If the sensors are not marked as enabled they will be ignored 61 Appendix B ADM Setup Screens Overview System 3 072610 19 26 Calibration Maintenance m No Active Errors Red Label t Blue Label BLUE SEQUENCE Pressure Imbalance Alarm Z000 psi Flowmeter Type 00 SRZ 100 kd Alarm i h F Th
51. f the claimed defect If the claimed defect is verified Graco 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 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 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 These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any c
52. f heater Blue Inline An over current was detected on the output Blue Hose Overcurrent Red Chiller Voltage should measure between 190 and 264 Vac Shorted Temperature If temperature rises for a zone that has been disabled Motor Over detected on a phase and has Arm motor Current been shutdown to prevent Short circuit of motor Check wiring to the motor to ensure no bare wires are pat Curent aun tomiho nah Aam lng oag Joadand above ha minum volage requirements A4M1 Alarm 2 Current drawn from the wall during load load and is above the minimum voltage requirements Short circuit of motor Check wiring to the motor to ensure no bare wires are Alarm Blue Chiller Unplug the directional valve so pressure will not build and try to move the motor again If this Motor rotor has become succeeds then the power pack may need to be replaced If the motor is still unable to move the bearings or hydraulic pump have likely failed in the motor and will need to be replaced A hardware current fault has occurred causing a system shutdown Motor Over Blue Blanket Control Fault Red Inline Control Fault Blue Inline Control Fault Unexpected current to Shorted Temperature If temperature rises for a zone that has been disabled heater chiller Control Module replace Temperature Control Module Control Fault Control Fault Red Chiller Blue Chiller Control Fault 70 313875J Appendix D ADM Event and Error Codes Overview E
53. he amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Keep the pump wet cups filled with IsoGuard Select part 24F516 The lubricant creates a bar rier between the ISO and the atmosphere e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been contam inated from the other side e Always lubricate threaded parts with ISO pump oil or grease when reassembling Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A Red side but some use ISO on the B Blue side See the follow ing section A Red and B Blue Components IMPORTANT Material suppliers can vary in how they refer to plural component materials Be aware that when standing in front of the manifold on proportioner e Component A Red is on the left side e Component B Blue is on the right side For all machines e The A Red side is
54. ify equipment Use equipment only for its intended purpose Call your distributor for information Houte hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equip ment follow the Pressure Relief Procedure and disconnect all power sources 6 313875J Important Two Component Material Information vf BURN HAZARD MING Equipment surfaces and fluid that s heated become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment SPLATTER HAZARD Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin During blow off of platen splatter may occur e Use minimum air pressure when removing platen from drum Important Two Component Material Information Isocyanate Conditions Keep Components A Red and B Blue Separate Spraying or dispensing materials containing isocya 60 nates creates potentially harmful mists vapors and FE Cross contamination can result in cured material in atomi
55. in 3 45 m 7 ft 8 in 2 34 m 6 ft 1 in 1 86 m 87 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco 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 Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco 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 component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification o
56. incoming power supply If the incoming power supply goes outside of the tolerable range an over voltage condition is flagged and the sys tem shuts down in an alarm state Excessive or repeated over voltage may permanently damage hard ware The chart below shows the permissible magnitude and duration of temporary over voltage events Consult a qualified electrician if there are any concerns about the available power supply Troubleshooting Maximum Permissible Transient Voltage Surges Constructed from ITIC 1996 curve referenced by IEC 61000 2 4 1400 1200 lt 1 MW Max Surge Power 1200Vac 1697Vdc 1000 E T 800 O 600 S 480Vac 679Vdc 150 KW Max Surge Power 5 50 KW 5 336Vac 475Vdc WI 575757 No Power Limit 0 0 000001 0 00001 0 0001 0 001 0 01 0 1 1 10 Time seconds 3138754 55 Troubleshooting Fluid Control Module Diagnostic Information System is powered up Internal communication in progress Red solid FCM hardware failure Replace FCM Red flashing fast Uploading software Red flashing slow Token error Remove token and upload software token again Module Status LEDs ti12337a1 FIG 18 56 313875J Appendix A ADM Icons Overview Appendix A ADM Icons Overview Setup Screen Icons pasom Erase Selected Item Erase All Items Shown Change Multiple Values see Using the B button on page 5
57. intended for ISO hardeners and catalysts e The B Blue side is intended for polyols resins and bases NOTE For machines with material volume ratios other than 1 1 the higher volume side is typically the B Blue side 313875J A Red and B Blue Components 313875J 9 Component Identification Component Identification AG Boom Lift Lever AH Mixer AA Advanced Display Module see page 18 AB Hydraulic Power Pack AJ Main Power Switch AK Air Supply Inlet AC Vertical Hydraulic Driver AD RAM Assembly AL Electrical Enclosure AE Ratio Check Dispense Valves Ports AF Power Distribution Box AD 6 7 ER NUT Lu cS zi 14 Ha and N Uwe KIN KA IA WA LLAMA LE 74 Pret ee NAN 7 oH el R y A ae lt N zn WE a LAN AY a a AAG SY SSS m SEIN O d J i S y AR POSS3 DSSS333 ON WELZ d ELT Ma Mn EE N PA So N c er TE ZN x 5 _ o e aN fy AI A ru Q Ve e ISAN TY MA mr VPM 25 shown I lt AK ti17693a AA AL FiG 1 Component Identification 313875J 10 Component Identification ti17702a 1477 kag m ENT o 7 d F YZ YA bi x OK ZANCA S RECON NN 7 NG ASIS I An fe N M JESUSEeSSJJj22293225 LLLI TL LLL BAS
58. ion See Maintenance section beginning on page 47 for battery replacement and software update procedures 313875J 19 Component Identification ADM Screen Components See the ADM appendix sections beginning with Appendix A ADM Icons Overview on page 57 for more informa tion Current date and time Previous screen Current screen Next screen Operating Mode 11 16 10 13 41 4 Shots Calibration b Faults Status Prime m Mo Active Errors Enter Exit screen Previous n d screen no Current Settings Detail C c0 c3 c3 C3 CI O DO 2 ODO D 3 O Fic 9 Main Display Components Typical Setup Screen Current date and time Previous screen Current screen Next screen Operating Mode 07 2010 14 23 El Trends Errors Faults Status Shot m Active Errors Change Operating E Mode Vi E E psi Initiate Dispense Initiate Ratio Check Dispense Dispense Details Zu 4 2631 DE agg s Fic 10 Main Display Components Home Screen Shot mode shown 20 313875J Component Identification Fluid Control Module FCM The fluid control module is located inside the electrical enclosure ti12337a1 ti12336a1 D B FIG 11 Key A Module Connection Screws B Access Cover C Module Status LEDs D CAN Connectors one is connected to MCM other is unused 313875J 21 Setup Setup Initial Machine Setup Perform this setup procedure to prepare the machine
59. is O enter 3000 if an HG6000 flow meter is installed in that side and 700 if the SRZ 100 flow meter is installed in that side NOTE In the following steps the weight of the dis pensed materials is used to calibrate the flow meters This works regardless of whether the selected dispense mode is weight or volume 5 Weigh two buckets and record the weight of each then place below the ratio check valves 6 With two buckets in place to catch material dis pensed from the ratio check valves press O to begin dispensing 7 After dispensing for at least 10 seconds press to stop dispensing NOTE If available a footswitch can also be used 313875J Operation 8 Weigh both buckets and enter the net weight of each material dispensed in the last two fields pro vided on the screen NOTE After the weights are entered the K factor will be shown to the right of the weights The previous K factor is shown to the left of the weight entry fields 9 Repeat steps 5 8 until the new K factor shown is within 196 of the previous K factor NOTE If the new K factor is not within 196 of the previ ous K factor the machine may need further priming to remove any trapped air in the material lines NOTE The ratio of the weights entered may not match the requested ratio This is ok for now 10 Select re to exit the flow meter calibration screen 39 Operation No Flow Meter Machine Calibration It is highly recommended that the
60. is screen allows the user to edit the labels for the A Red and B Blue sides of the machine The labels set for the A Red and B Blue sides of the machine are displayed throughout the screens Labels are limited to five characters Deviation Ratio The pressure imbalance alarm can also be set This is the difference between the A Red and B Blue side material pressures before an alarm occurs The flowmeter types are defined on this screen The available flow meter types are Disabled HG6000 or SRZ 100 The ratio deviation value is the allowable per centage before the machine displays a pop up notifica tion The ratio alarm value is the allowable percentage difference before the machine will stop a dispense Keyboard Screen 01 14 10 14 07 Susten WEN Standby m Ma Active Errars Red Label CTTO X EE This screen is used to edit the A Red and B Blue labels on the ADM Use arrow keys to select the desired letter and press to accept the letter Press to exit the keyboard 62 Maintenance 2 DO c on FC axa a e nin ooooooooo This screen shows shot number and sequence position counters Use the Counters dropdown menu to select which set of counters to view Conditioning Refill Setting Refill Timeout ilminute ilminute Refill Sensor Type Low Temp Sensor v Low Temp Sensor v Do not use the check boxes on this screen If a low level senso
61. ith new waste containers below the ratio check nozzles start the dispense by pressing the foot switch or Gl At the end of the dispense enter the A Red and B Blue material weights into the prompt boxes Enter the weight of each bucket for both materials 12 07 11 14 33 Diagnostic Errors E hot m No Active Errors Enter Red Side 0 00 iz 427 psi 560 psi 2920 als S L gs 3 00 Me 200002 313875J Operation NOTE After entering the net weight of B Blue material the ADM will inform the user how close the respective flow of the pump was to the desire rate 12 07 11 15 47 Diagnostic Errors Active Errors Bil e 459 psi uu U 2423 gis 2200 es 3 00 q par 11 Press to accept the information NOTE The ADM will respond by generating a System Learning Setpoint advisory and the corresponding advi sory light will be illuminated on the machine light tower if installed 12 07 11 15 48 ee Diagnestic rine Errors 2423 gis 2200 es 3 00 L i 2500 0 g 12 Press to accept the advisory Repeat steps 10 through 11 until the percentages approach zero and the advisory is removed NOTE The machine will be calibrated for the flow and ratio selected once the advisory is removed 13 If the user needs to operate at a second flow or ratio repeat the calibration process for the second desired flovv or ratio NOTE The machine will store the necessary c
62. laim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco 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 or otherwise FOR GRACO CANADA CUSTOMERS The 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 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 For patent information see www graco com patents Original instructions This manual contains Eng
63. le Selector Switch 27 Star LUD Et 28 Change Dr m e suave ice mese nep wears 29 Remove Drum 29 E eg dc 7 29 Primin AA 30 Operation Jed cx eor AG woe CR 31 ADM Operation Overview 31 Machine Operation Overview 33 System Setup and Calibration 34 DISPENSING kenne 43 Shutdown 13 45 Short lerM 45 ENG Ol SAIL aiio dieit 45 Pressure Relief Procedure 46 Maintenance 9445460 SERA ERA GA RI E XR de 47 Install Upgrade Tokens 48 Advanced Display Module ADM 49 Motor Control Module MCM 49 Fluid Control Module FCM 49 Troubleshooting 3 cow ENNA 9 x ER 51 Light Tower Optional 51 Common Problems 51 ADM Troubleshooting 53 Motor Control Module 54 Fluid Control Module 56 2 Appendix A ADM Icons Overview 57 Setup Screen Icons 57 Home Screen Icons 58 Appendix B ADM Setup Screens Overview 59 Appendix C ADM Run Screens Overview 65 Optional Screens 68 Appendix D ADM Event and Error Codes Overview 69 Event COGS un nass e s ALA MR de Aa 69 EITOFCOGOS ua giten B s ER us gon 70 Appendix E USB Operation
64. lish MM 313875 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised November 2012
65. lose all shutoff valves 6 Install Flow Meters NOTE This system ships with the flow meters removed The illustrations below shows what the flow meters will look like after they are installed Call Tat N N o IX KP KP IX KP Ko 1 S XO GO GO KEM KP KP Ko B E Hi o Y o FT N il O AN A Red Side B Blue Side a Place the flovv meter in position as shovvn in the illustration below The flow direction arrow is 313875J Setup pointed up and the sensor is on the outlet side top as shown of the flow meter 221 ZAAT LLN B Blue Side A Red Side b Hand tighten flow meter fittings to allow proper positioning of the entire assembly c Install the output plumbing hand tight The out let plumbing includes the pressure sensor and pressure gauge NOTICE To prevent damage be careful when handling the pressure sensor and pressure gauge assembly because the pressure sensor cable is attached A Red Side d Align the flow meter assembly and fully tighten all fittings 23 Setup e Connect the flow meter cable B Blue Side A Red Side 7 Connect 1 2 in NPT female air supply to air inlet NOTICE To prevent machine damage supplied air must be dried and filtered ti17708a s Connect electrical cord AN _ Installing this equipment requires access
66. lses Previous pulses Kg 2g 8 K Factor fel ig x M x XO E This screen is for calibrating the flow meters 313875J System 1 08 02 10 12 39 Calibration Maintenance Prime mi No Active Errors Max Working Pressure 2000 psi q zd r qa Inlet psi Inlet psi Type Check Mate v Type Check Mate size 250 m size 500 m Dispense Made Weight O r This screen allows the user to set mechanical system settings and the Dispense Mode setting Dispense mode can be set to volume or weight Dis pense mode controls how dispense quantities are mea sured Dispensing must be calibrated see System Setup and Calibration on page 34 for more informa tion Pump sizes and inlet pressures must be entered on this screen The inlet pressure is the minimum allowable fluid inlet pressure If the inlet pressure is below this value dispensing is disabled If pump sizes and inlet pressures are not entered properly system performance will be affected The maximum working pressure for the machine is dis played on this screen The maximum working pressure is dependent on the installed hoses and is set to the lowest rated system component If 2000 psi hoses are installed and the maximum working pressure displayed is not 2000 psi see Adjust Motor Control Module Selector Switch on page 27 for instructions to set the maximum working pressure for hoses 313875J Appendix B ADM S
67. mer shot is below the minimum dispense amount or set for a invalid pressure flow The MCM has determined that the gel If you are certain that the shot is within parameters timer shot will not be able try running the Learn Mode routine found in the setup to be executed based screen Calibration If the error persists a gel shot with parameters entered in reduced control parameters is required On the ADM go into the setup screens gt System gt Select a different shot or modify existing shot data The shot that was entered for the gel timer is not a valid shot This must be fixed before the gel timer will function properly Invalid Gel WSDO Timer Definition Deviation the ADM 313875J 79 Appendix E USB Operation Appendix E USB Operation NOTICE Low quality USB stick drives may lead to burning out the USB port on the ADM Use only high quality USB stick drives Overview There are 3 main uses for the USB e Ability to download a log of up to the past 50 000 errors events or jobs that can contain over 150 000 snapshots of critical dipsense information e Download modify and upload custom language files e Download and upload system configurations This data includes most user selectable and user configurable settings e This data does not include pump counters error and event logs shot and sequence counters USB Options The only options for USB on the ADM are in Advanced 4 see
68. move Drum procedure 2 f the platen is not at its full height set ram director valve handle to UP and allow the ram to rise to its full height 3 nspect platen and if necessary remove any remaining material or material build up 4 Lubricate the platen seals with grease or other lubri cant compatible with the fluid you will pump NOTICE To avoid damage to the platen seals do not use a drum that is dented or damaged 5 Place full drum on the ram base slide it back against the drum stops and center it under the platen 6 Remove the drum cover and smooth the surface of the fluid with a straightedge 313875J 7 Change Drum Remove bleed stick from platen bleed port J If drum has a plastic liner pull it over edge of drum Secure liner with tape wrapped around circumfer ence of drum Set the director valve to DOWN and lower the ram until fluid appears at the top of the platen bleed port J Adjust ram air regulator as needed Increase air pressure to the ram if the pump does not prime properly with heavier fluids Decrease air pressure if fluid is forced out around the top seal or platen Set the director valve to neutral and close the platen bleed port J Perform Priming procedure see page 30 29 Priming Priming 1 Place waste containers below both ratio check dis pense valves NOTE Both ratio check dispense valves will be open when dispensing in Prime Mode Only
69. mp There are 5 pages displaying 10 errors each See the Troubleshooting section beginning on page 51 for a detailed description of all system errors Events Screen 05 27 11 0 04 E Errors Maintenance 23 Disabled mi No Active Errors Date Time Code ClassDescription DENT 02 25 EBOO R Stop Button Pressed OB AIT 0224 EOUT R Settings Downloaded O2 02 24 EQUS R Language Downloaded O27 0205 EOUS R Logs Downloaded ES co iE O27 0203 EOUT R Settings Downloaded 06127 1 0150 06127 1 0155 06127 1 0154 06127 1 0154 06127 1 01 49 EGLIS E Language Downloaded EQUS R Logs Downloaded EQUS R Logs Downloaded ELOO R System Powered On EMOO R System Powered Off GEO BE The Events screens display the 200 most recent events Each event includes a description and event code along with a date and time stamp There are 20 pages display ing 10 events each See the Troubleshooting section beginning on page 51 for a detailed description of all system events 313875J l l g 41 mx 80026134 4453 3902512 4163 This screen displays historical information for each pump including material usage and pump cycles The material usage units are shown next to the 21 e Or icons and depend on the selected Dispense mode The batch counters are resettable but the total counters are not 67 Appendix C ADM Run Screens Overview Optional Screens Diagnostic Screen The optional Diagnostic screen ca
70. n be enabled in the Advanced 4 screen see page 64 07 20 10 17 58 m Maintenance Diagnostic Horne 23 Standby m Active Errors Temperaturet F Capacitor Motor Hydraulic 54 vo 95 fe Current CAmps BUS Phase 1 Phase 2 Phase 3 O O g Voltage Volts Speed RPM BLS Motor Motor Motor gt 40 O 340 g The Diagnostic screen shows status information for vari ous system components Status Screen The status screen provides all of the operational func tionality of the Home screen except for operating mode selection Refer to the Home screen and operating mode descriptions for information on this functionality In addition to the functionality provided by the Home screen the Status screen also provides material condi tioning information and control 3 15 12 11 18 m Harne Errars standby C Mo Active Errors 68 313875J Appendix D ADM Event and Error Codes Overview Appendix D ADM Event and Error Codes Overview Event Codes Event Code and String Triggers EAAO R Base Purge Base purge performed EADO R Pump s One or both pumps were parked Parked EA10 R Red Pump 75777 red pump has been primed Prime EA20 R Blue Pump The blue pump has been primed Pme e EE EAOO R Disp A dispense has occurred of the given Occurred Shot EARO R Night Mode While in night mode the system has Recirc On automatically entered a low recircula tion mode and attempte
71. ned on the System 2 Screen see page 61 a Press Pi repeatedly to select Standby Mode then press to accept b Press IHE c Press O to begin dispensing 313875J Operation NOTE Continue base purge until clean material comes out of the end of the mixer d When all mixed material is pushed out of the mixer press to stop dispensing 34 Press repeatedly to select Shot Mode then press to accept 35 Press 0 to activate the ratio check valves NOTE Be ready to adjust ratio check valves immedi ately after performing the following step 36 With buckets below the ratio check valves press O to begin dispensing 37 While dispensing adjust the ratio check opening adjustment screws until both material line pressures are approximately equal to the pressures recorded in step 31 NOTE If adjusting the ratio check opening screws after a ratio check dispense the pressure difference due to the adjustment will not be shown until the next dispense NOTE After the ratio check dispense pressures are properly adjusted a ratio check dispense can be per formed The ratio check dispense should be at least 10 seconds 38 If the pressures are correctly adjusted prior to com pleting the shot press to stop dispensing 39 If the pressures were not correctly adjusted prior to the shot finishing go to step 36 to repeat Ratio Check NOTE In the following steps the weight of the dis pensed materials is us
72. off pressure information in the following table See the power distri bution box manual for more information e Ram director valve CC controls ram direction e Exhaust port with muffler CD CBS vu OBIO Blowoff button CE turns air on and off to push the platen out of an empty drum o je 400 3 50 60 INCOMING PWR 3 Hoge 820v8 20 098 24C687 313873 5 1c 230V 400V 3 phase 3 phase Component CB5 5A Fic 4 Component Identification 5A 5A Miscellaneous 14 313875J Component Identification Hydraulic Power Pack 257442 313873 5 1t nn H 257442_313873 5_2t Shown with shroud removed FIG 5 Key A 8 Gallon Hydraulic Oil Reservoir see Technical Data on page 87 for specificati
73. older when the USB stick drive is inserted into the ADM USB port the software will automatically begin updating 83 Appendix E USB Operation Update Custom Language Use the following process to customize the text on the ADM The language file DISPTEXT TXT can be modi fied in Excel but must be saved as a Unicode Text file with the extension TXT in order for it to properly import 1 Insert a high quality USB stick drive into the ADM USB port on the system with the settings to be transferred Once the download is complete the DISPTEXT TXT file will be located in the DOWN LOAD folder 2 Plug the USB stick drive into a computer 3 Navigate to the DOWNLOAD folder 4 Copy the DISPTEXT TXT file from the DOWNLOAD folder to your computer 5 Use any data processing software such as Excel to edit the DISPTEXT TXT file a In the first column locate the string to change b Inthe second column of the same row enter the new string c Savethe file as a Unicode Text file The name must remain DISPTEXT TXT 6 Copy the edited DISPTEXT TXT file into the UPLOAD folder 7 Remove the USB stick drive from the computer and insert it into the ADM USB port The software will automatically begin updating NOTE Before the update begins the ADM automatically shuts down the system aborting any in progress dis pensing When the software is updating a pop up box will appear to inform the user of the update and the sys
74. ons Electric Motor Dipstick Hydraulic Housing Motor Control Module see page 16 Fan Hydraulic Oil Filter Hydraulic Fluid Drain Port IO nm 313875 15 Component Identification Motor Control Module MCM NOTICE If the Motor Control Module is replaced the selec When installed the end of the MCM with the power tor switch must be set prior to initial startup of the input connection 12 faces down and the end with the Motor Control Module or damage may occur See access cover A faces up Adjust Motor Control Module Selector Switch on page 27 The Motor Control Module uses an 8 position selector switch to set the system maximum working pressure The MCM is located in the Hydraulic Power Pack 11 13 m 41 r 257396 3b9905 03b Fic 6 MCM Component Identification 16 313875J Ref Description A Access Cover Module Status LEDs C Warning Label A Red MCM only ADM Power Distribution Box 1A 1B B Blue MCM only FCM Power Distribution Box NOTE 1A and 1B are interchangeable Three way Splitter to Oil Low Level Sensor Dispense Valve Solenoid Footswitch Oil Temperature Sensor Electric
75. ontrol data for both calibration points 41 Operation NOTE It is recommended that the user calibrate the machine at the extreme rates where it will be used Example If the machine is to be used at mixed flows between 300 amp 500 grams second at 3 1 ratio cali brate the machine at the two 300 and 500 grams sec ond extremes then stop the calibration process The machine will be very close to all requested flows and ratios in between 14 Turn off the Enable Ratio Check Weight Mode Entry option in the Advanced 3 screen The user can verify the machine calibration by performing a ratio check dispense and weighing the A Red and B Blue materials 11 0212 05 40 4 Conditioning CA standby m No Active Errors 1 Disable Dispensing From Display L Disable Modifying Temp Setpoint Disable Operator Mode How Adjustments m Disable Operator Mode Ratio Adjustments Temperature Alarm Disables Dispense L Complete Dispense With Setpoint Error _ Enable Shot Aborted Notification L Enable Ratio Check Weight Made Entry ex Trigger For Dispense 42 313875J Dispensing Dispense in Shot Mode To dispense in Shot mode at least one shot number must be defined Shots are defined on the Shots screen see page 59 1 Navigate to the Home screen 2 Press repeatedly to select Shot Mode then press to accept 3 f desired change the selected shot a Press E b Use numeric keypad to type the de
76. or temperature is too high Motor Temp land system has been Shutdown shutdown to prevent possible damage Red Tank RTD Fault Blue Tank RTD Fault Red Inline RTD Fault Blue Inline RTD Fault RTD 1 is giving no or invalid Red Hose data FTS Fault Blue Hose FTS Fault Red Chiller RTD Fault Blue Chiller RTD Fault 313875J Loose connections Tighten connections No power to fan Check cord to make sure fan has power Debris in fan or heatsink Clear debris from fan or heatsink Try to stop fan by lightly pressing on the center with a Low air volume from fan pencil eraser If the fan slows down easily it will need to be replaced Motor may be damaged Replace motor Debris is packed in the V MCM s heat sink fins Clear debris from MCM heat sink fins No Power to Fan Check cord to make sure fan has power Debris in fan or fan grill Clear debris from fan fan grill Try to stop fan by lightly pressing on the center with a Low air volume from fan pencil eraser If the fan slows down easily it will need to be replaced No power to fan Check cord to make sure fan has power Debris in fan or fan grill Clear debris from fan fan grill Try to stop fan by lightly pressing on the center with a Low air volume from fan pencil eraser If the fan slows down easily it will need to be replaced 52117 S nan Move machine to an area below 120 F conditions are too hot Motor may be damaged Motor may need to be repl
77. out and clean or T The pump failed to reach the 155 park position Dispense valve failed to Check to make sure the dispense valve is properly Pumps Not he type or size of the Red or On the ADM go into the setup screens gt System gt DSCO i p Blue material pumps have not Alarm 5 then make sure that the pump type and size are set 2 been defined system not MSS ied Failure of the dispense the valve has a proper air supply and seals Unu valve properly If not service the valve as necessary pressure the pump traveled F7D1 Deviation Pump Failed Visually inspect the machine and hoses for sign of more than it should in normal Material leak leakage NOTE This error will display after 2 full operation only applies to dead headed system to Stall piston strokes so the leak will be substantial Out of material Fill tanks L111 Red Low Deviation Tanks low on material Fill tanks with material Material Level L122 If the tanks appear to have plenty of material check to Loose broken connection make sure the level sensor is connected to the proper port and that the cord is not damaged Bad level sensor Replace level sensor Blue Low Low material level in tanks Deviation Material Level Red High ba L311 ca ng Deviation If the tanks appear to have plenty of material check to Material Level s High material level in tanks Defective fill valve make sure the level sensor is connected
78. p and material thickness decreases the ramp up feature will increase the flow rate until the desired flow rate is achieved NOTE Because the B Blue side is the high volume side it is closer to its maximum flow rate capacity than the A Red side pump Because a base purge is done before the system is shut down the first dispense after the system is turned on is always initiated at a reduced flow rate The ramp up fea ture will then increase the flow rate as described in the previous paragraph Also after ten minutes of idle time the first dispense will be at a reduced flow rate followed by the flow rate ramp up When the ramp up feature reduces the flow rate a Sys tem Dispensing Below Requested Set Point advisory is generated and the yellow advisory lamp on the light tower is illuminated If the system is able to achieve the desired flow rate the advisory is cleared 313875J Operation Learning Mode When a flow rate or dispense ratio is requested that the machine has not learned the system will use the pump volume of each pump to estimate the pump velocities needed then Learn mode will be used to adjust them to the correct flow rates The system will begin dispensing at the estimated pump velocity and each stroke per formed will be used to gather information and adjust the velocity After a number of strokes the system will have sufficient data to accurately dispense at the desired set point and Learning mode will
79. page 64 Enable Downloading of USB Loss Enable USB Errors Date of Last Download SF The first option is a checkbox that enables or disables the downloading of the Error Event and Shot Data log files The Shot Data log runs during all operating modes 80 The second option is the Erase icon which will reset the last download date to a time where all logs can be downloaded This will allow the user to download all USB log entries which may take over 2 hours if the log files are full The ADM does not monitor the USB logs to alert the user when data may be overwritten In order to minimize download times and the risk of losing data it is recommended that the user download the logs every 2 weeks or more often ifthe machine is used during more than one full shift a day Download Log Files If the Enable Downloading of USB Logs option is checked a USB stick drive can be used to download the log files To download the log files insert a high quality USB stick drive into the USB port in the bottom of the ADM The ADM will automatically begin downloading the log files as well as the custom language file DISP TEXT TXT and the system settings file SET TINGS TXT The status of the download will be shown in the Status bar If an error occurs during download remove the USB stick drive then re insert 313875J Log Files Folder Structure L3 DOWNLOAD File 22 Address 146 TI Edit wiew Favorites
80. perator Mode section on page 44 2 Once in the screen use the arrow keys to navigate to the desired item 3 Edit the value If the item has a drop down list to select from press to display the dropdown list Use the up and down arrow keys to highlight the desired item then press to select the item e Ifthe item is a numeric value use the numeric keypad on the ADM to type the new value then press to accept the value If the item is a select deselect or enable dis able checkbox option press to toggle the value f necessary press amp to cancel editing 4 Press Sil 313875J Machine Operation Overview Ramp Up Feature The purpose of the ramp up feature is to enable dis pensing at the correct ratio but at a reduced flow rate when materials are too thick to dispense at the correct flow rate As the fluid warms up due to the friction of moving through the system the Ramp Up feature will slowly increase the flow rate until the desired flow rate is achieved After a period of idle time the system will cool down and the fluids will not be as warm while dispens ing which may result in the Ramp Up feature being acti vated While the system is dispensing the ramp up feature monitors the torque supplied to the B Blue pump to verify it does not apply more torque than the pump can handle If it does it will reduce the flow rate in both pumps to maintain the required dispense ratio As the system warms u
81. r is used check the box for the Supply Low Level Sensor option on the System 2 screen see page 61 313875J Conditioning 1 03 15 12 11 12 4 Supply Advanced standby m No Active Errors NOTE Platen heaters are available as an option on the VPM system Conditioning 2 5 te Supply Advanced m No Active Errors NOTE Platen heaters are available as an option on the VPM system Conditioning 3 5 10 05 00 28 m Supply Advanced E hot No Active Errors Lal Might Made Conditioning Scheme Periodic r On Duration l minutes Off Duration minutes NOTE The VPM does not use Night mode conditioning Do not enable night mode 313875J Appendix B ADM Setup Screens Overview Advanced 1 3 Conditioning Shots m No Active Errors Language English Date Format Date 01 04 Time Bal Password Screen Saver 5 minutes Silent Made This screen allows the user to set the language date format current date time setup screens password screen saver delay and turn on or off silent mode Advanced 2 Oro 10 19 27 El Conditioning Shots Sequence C Mo Active Errors LA Volume Units Weight Units el Pressure Units losi ml Temperature Units Rate Units second w This screen allows the user to set the units of measure 63 Appendix B ADM Setup Screens Overview Advanced 3 10 02 12 05 40 4 Conditioning aa Shots standby z No A
82. ressing Esl 5 Select Standby mode and perform a base purge NOTE A base purge will dispense only the B Blue material to push all mixed material out of the mixer Base purge settings are defined on the System 72 screen see page 61 a Press 0 1 b Press O to begin dispensing c When all mixed material is pushed out of the mixer press amp to stop dispensing NOTE Approximately 1 to 2 liters of base material will need to be dispensed 6 Select Shot mode and select the ratio check option by pressing Col 313875J 7 Place waste containers below the ratio check noz zles and start a ratio check dispense Adjust the ratio check opening screws until the pressures dis played are near the values previously recorded when dispensing through the mixer step 4 8 Press to enter the Setup screens then press left or right to navigate to Advanced 3 screen Turn on the Enable Ratio Check Weight Mode Entry option 100 2 12 06 40 Conditioning PEME standby m No Active Errors L Disable Dispensing From Display tai 1 Disable Modifying Temp Setpoint Disable Operator Made How Adjustments 1 Disable Operator Mode Ratio Adjustments Temperature Alarm Disables Dispense L Complete Dispense With 5etpoint Error _ Enable Shot Aborted Notification L Enable Ratio Check Weight Made Entry 2x Trigger For Dispense 9 Press O to exit the setup screen and verify the ratio check option is selected 10 W
83. rocedure the system will need to learn the new temperature and the flow rate may need to be decreased If the original flow rate was 325 g s at 68 F 20 C and the temperature is now 46 F 8 C the user may want to select a flow rate of 150 g s or 150 cc s The machine will not automatically be aware of the temperature change but it will try to find the correct dispensing properties to compensate for the new tem perature If the ambient temperature changes signifi cantly go to step 1 It is important for the system to learn the new temperature because typical paste materials increase viscosity significantly as the temperature decreases below 68 F 20 C 38 313875J Flow Meter or Flow Ratio Calibration 1 At the main Calibration screen press KA to erase any previously learned flow meter calibration data NOTE At this point the Learning New Set Point advi sory will be generated 2 Select 23 to enter the flow meter calibration screen 07 21 10 10 00 Sequences System m No Active Errors Cal Setpoint RE z Ratio 1 K Factor 3000 0 00 0 pulses Kg 3 Previous gp le K Factor l l 2 x Ji x Ji m Wa a SEQUENCE re pulses 3 Onthe flow meter calibration screen enter the flow rate and ratio that will be used during normal opera tion NOTE It is recommended to use approximately 200 g s or 200 cc s and a ratio of approximately 2 0 1 4 f either K Factor value
84. rror Error Code Error Description Type Cause Tripped circuit breaker Visually check circuit breaker for a tripped condition No Red Inline No Blue Inline Current No current to the conditionin No Red Hose 9 zone Measure voltage across input terminals on power line filter Voltage should measure between 190 and 264 Vac No Blue Hose On the ADM go into the Setup screens to the System screens then make sure that the pump sizes are defined correctly The requested dispense Pumps are defined with ini the wrong size Small Shot amount is below the minimum g Requested shot is below the capabilities of the current pump setup the combined pump volumes is the minimum If the user has to be able to take the shot the system must be fitted with smaller pumps Comm Error Comm Error Comm Error Blue Tank Comm Error Comm Error Mix Head 2 Comm Error Hatio Monitor Comm Error Red Blanket Comm Error Blue Blanket Comm Error Red Inline Comm Error Blue Inline Comm Error E n am Loose broken connection Check connection Communication error 3138754 71 Appendix D ADM Event and Error Codes Overview Error Error Code Error Description Type Cause Pump cannot reach the Increase restriction in the system requested pressure The set point was not reached Deviation Pump cannot reach the Decrease restriction in the system requested flow D2A1 System underwent a change that ca
85. sary Out of material Fill tanks with material Feed system defective Replace defective item r re tran r is properl PEAT Red Pressure eens Wad PARA AE Check to ensure the pressure transducer is properly Sensor Fault The pressure sensor is installed and all wires are properly connected Blue providing invalid no pressure Bad sensor sensor Replace pressure transducer Pressure readings Sensor Fault No material in pump Fill tanks Red Tank Low Fluid Temp Blue Tank Low Fluid Temp Red Inline Low Fluid Tripped circuit breaker Visually check circuit breaker for a tripped condition Temp Blue Inline Low Fluid Material fillers may have packed out in an orifice Fluid temperature is below the defined low alarm limit Low Fluid Temp Blue Hose Measure voltage across input terminals on power line Low Fluid Low power filter Voltage should measure between 190 and 264 Temp Vac Red Chiller Low Fluid Temp Blue Chiller Low Fluid Bad heater s Measure resistance of heater s Temp The hydraulic oil temperature No power to fan Check cord to make sure fan has power is approaching a level where Debris in fan or fan grill Clear debris from fan fan grill damage is possible so the gt E Deviation Try to stop fan by lightly pressing on the center with a Motor Control Module is L NS i i If the f d ilv it will d limiting the output to a safe ow air volume from fan pencil eraser e fan slows down easily it will ne
86. sired shot number c Press to accept The shot number defini tion details will be shown on the bottom of the screen NOTE Only defined shot numbers can be entered If an undefined shot number is entered it will be ignored 4 Press eJ to begin dispensing the active shot To abort the shot at any time press amp shot will continue until the predefined amount has been dispensed 5 Check the ADM for errors and pop up notifications that could indicate a faulty dispense Press to acknovvledge any displayed errors 3138754 Operation Dispense in Sequence Mode Sequences can be defined on the Sequences screen Sequences are defined on the Sequences screen see page 60 1 Navigate to the Home screen Press Pi repeatedly to select Sequence Mode then press to accept If desired changed the selected sequence a Press EH once b Press the right arrovv key on the ADM keypad once c Use the up and down arrow keys to select a sequence d Press UTE to accept If desired press 2 to skip to the next defined shot position in the sequence Repeat as desired To go to the first defined position in the sequence press 5 5 Press to begin dispensing the active shot NOTE To abort the shot at any time press Or O If the shot is not aborted material will continue to dispense until the predefined amount has been dis pensed The next position in the Sequence will automat ic
87. stic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS 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 manu facturer s replacement parts only Do not alter or mod
88. t setting by the user prior to initial startup To change the maximum working pressure rating of the system in the field all outlet components including hoses and dispense valve must be rated at or above the new system maximum working pressure rating For example if the new system rating will be 3000 psi all system components must be rated to at least 3000 psi maximum working pressure 313875J Do not install components rated to less than the highest pressure in the selected pressure range For example if the 0 2000 psi range is selected do not install items rated less than 2000 psi If the 0 3000 psi range is selected do not install items rated less than 3000 psi Doing so may lead to overpressurization and ruptured components High pressure fluid from 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 To set the Motor Control Module selector switch 1 Turn machine power off 2 Remove the access cover D See FIG 13 3 Set the selector switch S 4 Install access cover D 27 Startup Startup Na Moving parts can pinch or amputate fingers When the pump is operating and when raising or lowering the ram keep fingers and hands away from the pump intake platen and lip of the drum 1 Perform all required maintenance tasks See Main tenance on page 47
89. temporary over voltage events Maximum Permissible Transient Voltage Surges Constructed from ITIC 1996 curve referenced by IEC 61000 2 4 1400 1200 lt 1 MW Max Surge Power 1200Vac 1697Vdc 1000 o o o e o lt 150 KW Max Surge Power 480Vac 679Vdc Voltage Volts RMS gt 288Vac 407Vdc N e o 0 0 000001 0 00001 0 0001 0 001 0 01 0 1 1 10 Time seconds 9 Ground the system WAS This equipment must be grounded a VPM grounded through power cord See Con nect Electrical Cord step 8 on page 24 b Dispense Valve follow your local code c Fluid supply containers follow your local code d Dispensing target container follow your local code e To maintain grounding continuity when flushing or relieving pressure hold grounded metal pail firmly to a metal part of dispense valve then ini tiate a dispense 10 Check hydraulic fluid levels The hydraulic reservoirs are filled at the factory See Technical Data on page 87 for hydraulic fluid specifica tions 25 Setup 11 1f applicable attach and adjust drum low empty sensor NOTE An optional kit can be purchased to indicate either when the drum is low or when it is empty A E e CN YA KH A z 7 D z2 B N P I is ti10916a a Position ram at desired lev
90. the Dis pense mode Dispense detail is shown as volume time or weight depending on which Dispense Mode is selected See System 1 on page 61 for Dispense Mode options NOTE 5 sequences with 20 positions each are avail able across 10 pages Calibration Main 0772810 19 23 4 Sequences System SEQUENCE mi Active Errors Previous 041290 T Cal Max 14506 14408 Cal Mir 162 11276 cg Previous Range 13500 16000 Range 1000 1500 Erase Control D Previous 0 7 26 0 This screen shows calibration data for the system and provides access to the individual calibration screens See System Setup and Calibration on page 34 for how to use the calibration screens The date next to each key represents the last time that function was performed The Cal Min and Cal Max values are the system recognized extreme ends of piston travel 60 Calibration Learn Mode 0728110 124 Sequences System SEQUENCE Mo Active Errors Learn Mode 1162 1276 re UL 3402 4757 LII LII 14505 14403 This screen is for learning the mechanical limits for pis ton travel Calibration Weight Specific Gravity RED HEZ Specific Gravity BLUE 1 230 Setpoint gis 2 This screen is for calibrating weight Calibration Flow Meters 072110 10 00 Sequences System SEQUENCE Mo Active Errors x Cal Setpoint itd Ratio 1 I Factor 3000 0 00 0 pu
91. umps a Navigate to the Home screen may cause material in the mixer to harden and dam age the dispense block b Press Pi repeatedly to select Standby Mode 8 Turn Main Power Switch to the OFF position then press to accept 9 Close air inlet ball valve c Press Pa to park pump Material will dis End of Shift pense when the pumps are in the parked posi 1 tion they vvill stop moving Perform Short term Shutdovvn procedure 2 Remove disassemble and flush mixer 3 Allow material to drain completely from the mixer prior to base purge 4 Perform base purge NOTE A base purge will dispense only the B Blue material to push all mixed material out of the mixer Base purge settings are defined on the System 2 screen see page 61 a Press 0 1 b Press O to begin dispensing c When all mixed material is pushed out of the mixer press amp to stop dispensing NOTE The user can disable changing the flow ratio or both on the Advanced 3 setup Screen NOTE Approximately 1 to 2 liters of base material will need to be dispensed 5 Press m to park pumps again 6 Press v 313875J 45 Pressure Relief Procedure Pressure Relief Procedure 1 Perform Shutdown procedure 2 Setthe ram director valve to neutral position 3 Place a waste container below each ratio check valve 2 F ADIDAS 2 In the following step any pressure in the lines will be instantl
92. used a Erase learned System Data found in the setup i l large drop in restriction screens under calibration D3A1 The set point was exceeded Deviation such as new orifices r Make sure the material lines are open and have No material in pumps proper feed pressure This calibration lets the MCM Recalibrate the machine Rerun the learn mode calibration know where the ends of the eda BANANA TA Check to ensure the pressure transducer is properly pump are If the data gathered installed and all wires are properly connected Invalid Learn D5A1 Deviation Mode Data during this process is outside of normal parameters the machine will operate with a greatly reduced stroke Loose bad connection to Check to ensure the linear position sensor is properly linear position sensor installed and all wires are properly connected The linear position sensor is D6A1 Alarm Bad linear position Verify pump moves to limits if problem persists sensor replace linear position sensor Bad linear position mm Replace linear position sensor sensor Linear position sensor may be loose where attached to pump housing returning data that should not be possible during normal operation Re tighten the sensor and re calibrate the machine being supplied or Deviation ui lma Verify that feed pumps are supplying material DDB2 Blue Pump given pump pressure on feed system Cavitation Debris or packout in the Inspect filter for debris of filler pack
93. vent No Event No Event No Event EMOO R System Powered Off ELOO R System Powered On EM00 R System Powered Off ELOO R System Powered On EM00 R System Powered Off ELOO R System Powered On EMOO R System Powered Off EL00 R System Powered On No Event No Event 4 Active Shot Number 81 Appendix E USB Operation Example 2 JOB File The 2 JOB file is the Shot Data log file A B D 1 Job Log 2 S N 06201073 3 Software Part Number 16N420 4 Software Version 1 01 002 5 4 23 2012 11 09 6 Requested Requested Requested Inline Blue Inline Blue Hose Blue Hose Blue Inline Red Hose Red FT5 Hose Red 7 Date Time RTD Temp Temp FTS Temp Temp RTD Temp Temp B 4 11 2012 14 16 52 3 4 11 2012 14 16 54 10 4 11 2012 14 16 56 11 4 11 2012 14 16 58 12 4 11 2012 14 17 00 13 4 11 2012 14 17 02 14 4 11 2012 14 17 04 15 4 11 2012 14 17 07 16 4 11 2012 14 17 09 17 4 11 2012 14 17 11 R 18 4 11 2012 14 17 28 KOW 2 0 WA He Ready Example 3 SYSTEM File The 3 SYSTEM file is the Software Version log file A B C D 1 System Software Log 2 S N 06201073 3 Software Part Number 16N420 4 Software Version 1 01 002 5 4 23 2012 11 11 7 Date Time Node Software Version 8 4 23 2012 6 53 49 MCM Application Blue 1 01 108 3 4 23 2012 6 53 49 MCM Component Blue 1 09 001 10 4 23 2012 6 53 49 Blue Tank Monitor 1 01 001 11 4 23 2012 6 53 49 Red Primar
94. y Heat 1 05 008 12 4 23 2012 6 53 49 Blue Hose Heat 1 05 008 13 4 23 2012 6 53 49 USB Configuration 1 07 001 14 4 23 2012 6 53 49 Advanced Display 1 01 003 15 4 23 2012 6 53 50 Blue Primary Heat 1 05 008 16 4 23 2012 6 53 51 Red Hose Heat 1 05 008 17 4 23 2012 6 53 54 Red Primary Heat 1 05 008 18 4 23 2012 6 53 56 Blue Primary Heat 1 05 008 19 20 21 M 4 H 3 SYSTEM J i4 82 313875J Appendix E USB Operation Transfer System Settings DOWNLOAD alib mr Q h d iD pO search f Folders X i m Address 3 E GRACO FFFFFFFF DOWNLOAD v Go Folders X Name Size Type Date Modified 12 2010 12 38 3 Desktop CJDATADOO001 File Folder 1 12 2010 12 38 PM x C3DATADO002 File Folder 1 12 2010 1 52 PM 3 My Computer i C3DATAO003 File Folder 1 12 2010 10 12 AM e Local Disk C C3DATADO04 File Folder 12 20 2004 12 00 AM sb DVD CD RW Drive D C3DATAODOS File Folder 1 12 2010 10 17 AM 3 w DIESEL E C3DATADOO6 File Folder 1 13 2010 9 01 AM GRACO DISPTEXT TXT 22 KB Text Document 1 13 2010 9 03 AM FFFFFFFF 2 SETTINGS TXT 43 KB Text Document 1 13 2010 9 03 AM 3 3 DOWNLOAD 01 C3 DATA0002 C3 DATA0003 DATAO004 5 6 C3 UPLOAD DVD Drive F x Use the following process to transfer system settings from one machine to another 1 Insert a high quality USB stick drive into the ADM USB port on the system with the settings to be
95. y relieved which may lead to material spraying out of the valve and splashing in the bucket Use appropriate protective wear to prevent contact with materials 4 Press the red override button on top of the pneu matic valve nearest the mixer This will open the ratio check valves and relieve any residual pressure in the fluid lines 46 313875J Maintenance mi X 2A A Check all sub component manuals for maintenance schedule and procedures Schedule Replace hydraulic oil and filter See table Inspect fluid lines for leaks and Daily signs of wear Check wet cup fluid level add IsoGuard Select fluid as neces sary Check hydraulic fluid level Weekly Verify vent holes on bottom of Weekly hydraulic power pack shroud are more often in clear and unobstructed dusty environ ments As necessary Monthly Check all fittings and connec tions tighten as necessary Use compressed air to remove dust buildup on control boards fan motor under shield hydrau lic oil coolers and component heat sink fins 313875J Maintenance Change Hydraulic Oil and Filter Change break in oil in a new unit after the first 250 hours of operation or within 3 months whichever comes first After initial break in see the following table for rec ommended oil and filter change schedule Table 2 Frequency of Oil Changes Ambient Recommended Temperature Frequency O to 90 F
96. zed particulates 77 i ii fluid lines which could cause serious injury or dam Read material manufacturer s warnings and material age equipment To prevent cross contamination of MSDS to know specific hazards and precautions the equipment s wetted parts never interchange related to isocyanates component A Red and component B Blue parts Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition Wi Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS 313875J 7 A Red and B Blue Components Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component foam and polyurea coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity If used this partially cured ISO will reduce performance and the life of all wetted parts NOTE T

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