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Graco 313296J User's Manual

1. A 1 4 To heated X manifold 243697 Nee 87 U D E r wm2179 313269 4a Fic 3 Tandem Supply System ey Ham A X Wet Cup Ram B Z Main Air Line not supplied Air Motor AD Air Motor Solenoid Ram A and B Heated Check Mate Displacement Pump Ram A and B AE Junction Box Ram A and B Heated Platen Ram A and B AF Cable Track Ram A and B Drum Empty Sensor partially hidden Ram A and B Display Module Ram A only Electrical Enclosure Ram A and B Integrated Air Controls Ram A and B see page 10 Fluid Control Module inside shroud Ram A and B CAN Communication Cable Lift Ring Air Motor Platen Bleed Port Pump Outlet Platen Lift Rod cdaozxcrommoou zm 313296J 9 Component Identification NOTE See Fic 2 and Fic 3 Before you install the system you should be familiar with the following compo nents Reference numbers and letters in parentheses in the text refer to the callouts in the figures Both rams A and B include a Check Mate Pump D platen E integrated air controls J drum empty sen sor F and fluid control module K Only Ram A includes the display module G Drum empty sensor F Signals drum empty condi tion See 11 page 19 Display module G Mounted on Ram A only P
2. KK wy 439 439 439 Ye ets lt Side View 459 406 461 415 416 AAF Q Wek 27 2727 419 417 421 423 424 313296 Electrical Enclosure Parts Ref Part 401 402 403 101682 404 100016 405 100015 406 15X754 407 289697 408 256270 409 114417 410 121070 411 x 255774 412 150651 413 15R535 414 117831 415 100035 416 122148 417 122619 418 122129 419 122128 420 16A573 421x 122122 422 122317 423 122125 424 123141 425 111640 426 157021 427 428 257341 429 121597 430x 15 999 431 432x 121000 433 100023 434 100133 435 100307 436 437 438 439 440 441 442x 121612 443 112788 444 445 15W905 451 452 16H441 453 100166 454 123507 456 277674 457 186620 313296 Qty Description ENCLOSURE DOOR enclosure SCREW cap sch WASHER lock NUT hex mscr BRACKET mounting electrical MODULE cube base MODULE low power temp SCREW self tap pan hd SC
3. Never pressurize warm melt supply system while using warm melt materials before turning on heat Many warm melt materials tend to expand when heat ing and may cause a heated hose to burst Avoid the potential of bursting a hose by opening the dispense valve during system heat up and lock the dispense valve trigger open every time you shut the system down NOTE Operate at the lowest temperature and pres sure necessary for your application 1 Turn the main disconnect on the electrical control panel door to the ON position 2 Press while in the Heat Run screen to turn the heaters on for enabled heat zones Fic 18 Heat Run Screen Ram A 26 313296J Prime 2 21116 v p 1 Make sure the system is at required temperature 2 Tandem Systems Only To prime the active ram ensure that the system is not in Run Mode To prime the inactive ram ensure that the system is on and in Run Mode 3 Single Systems Only To prime the ram ensure that the system is on The system may or may not be in Run Mode Prime active ram not Run Mode 6 30 11 Beene O 0 Tt cnin 1000 1000 1 Fic 19 Ram Operation Screen Tandem System Prime inactive ram in Run Mode 6 30 11 fx334 Tt cin 1000 f Fic 20 Ram Operation Screen Tandem System 1000 7 4 If using a manu
4. DISPLAY MEMBRANE SWITCH peu 9 uao1o 9 2 pesnun 1 1467 AINGOW AV IdSIa uondo 14671 lt an an an lt gt lt gt _ _______ pini eJ uondo 2J283 seudeq sse1d jenno 1e 9 sse1d U 194 2 1 1615 55 14 1 2 1 1 eiqeo Josueg eunsseJd pini woog yamg p youmg paey 100W yous 401 OIN 2 jeeur 1 8 9882 AFINGOW 1 ainda wey 5 090 HO WIEM 1 py NWO opAvz Z Nvo eiqeo 1 ai us THA NHO S9MVOL eiqeo aiqeo NALW1d Jayeaig sina G B duy B 91920 E NOLOVINOO 7JONINOO Em vos pelg 91989 SMWOL eIqeo uolsue xq 9 0 Jayeaig S piis duy 8 H uoisuajx3 G ea uoisuajx3 Jayeaig
5. as al ean ear NLY 2 jeufis 1 S 9 1 NvO 6 1 peeg aes pasnun 2 t 0 1 2 opAvz Z opAvz 2 1 IHS 1 MHS ALdW3 wna 0 Ko Jenids 0 Atana pue iai A Mane UM EUM 9 putos ay 2 qc El piousos Josues ME lr m m i m d 4 GION310S SEZIZ Nid GION310S D200 Single Ram Schemat NLY piouajos 2 leuis 1 pau s 9 poy ueeio p ues 2 pesnun 1 Wnaa guae NOILdO ALdW3 40 1467 uondo 44817 am uum ED a a a pP pini eJ uondo sse1d 9 13 4 Z 1 paay peas OIN Z
6. r wm29yy 31329b6 5 313296J 83 Parts T gt AON HE XE 2 2 E gt 0 A 2 A g QUod BORD 2 1 s N wn 258 233 259 260 261 237 ni 236 235 313296 84 Parts 227 S NON N Su 2 NN Al N N eo E X 5 5 E a D 22 yy 9 X 7 N 282 283 284 201 202 234 262 201 202 222 85 313296 Parts 265 241 D60 Warm Melt Kits Ref 201 202 203 204 205 206 Part 100016 121112 288543 27 589 27 590 255383 207 24F493 20847 20948 2109 2119 102040 212 16C377 15X968 2139 110755 214 121253 215 216 217 218 219 2208 222 223 86 114417 123375 121070 121001 289697 289696 Description WASHER lock SCREW cap sch BRACKET hose spring COVER shroud front COVER shroud rear BRACKET light tower MODULE display BRACKET pendant pivot BRACKET mounting assy SCREW shcs 1 4 unc x 4 25 NUT
7. Jexyeejg dwy 8 G od MOV eur eJnso pu3 313296J 62 Electrical Schematics Joyeeug dwy 2 YOLOVLNOD vos Joyeoug dwy 8 8 Jeyeeug qnoi dwy 8 D200 Ram B Schematic MOVHL 318VO eJnso ou3 eiqeo TANNYS S9NWOL eIqeo ejqe SMNOV elqeo Sjqe ejqe Sjqe ejqeo Lid ud ALdW3 2 GION310S 1 WOO pasnun 2 1 TVNOIS 9 WOO pasnun 2 1 ALdW3 MOTWNYG uondo Wey HOW UEM TWNOIS WOO pasnun 2 1 ALdW3 105 NLY Prouejos 2 iuis 06 1 pesnun 2 jeubis 1 pini Jamis eiqe5 uondo ouney ssedeq im 9 1 0 NWO Z 9 IHS s plousjos sosuag 2 sosuag 1
8. 55 Gallon Platen 1 Turn off main disconnect 1 Use two people to set pump onto platen 2 Remove screws 80 or 257 from back pump heater shroud 52 or 234 2 Secure pump to platen with screws 103a and xiu clamps 103b See FIG 41 D200 Shown 4 3 Lower motor 4 See Reconnect Displacement Pump in Check Mate Pump Packages manual 20 30 and 60 Liter Platen 52 NOTE Before installing a 20 30 or 60 liter platen to a pump with an intake adapter install adapter and 80 or 257 o ring 1 Place o ring on pump intake See FIG 42 2 Use two people to set pump onto platen 3 Secure pump to platen with screws 308 Fic 43 Remove Pump Shroud 4 Lower air motor 5 See Reconnect Displacement Pump in 3 Remove ground wires Check Mate Pump Packages manual 4 Remove pump heater front shroud 51 or 233 313296J 51 Repair 5 Remove pump heater bands 44 or 227 a Remove screws from both pump heaters b Pry heater bands apart and remove from pump c Disconnect wires from heater bands Inspect wires for damage and replace with new wires included with pump heaters if necessary See Electrical Schematics page 61 d Remove RTD sensor 46 or 229 Loosen screw on sensor support 45 or 228 and slide RTD out KA 1 45 or 228 46 or 229 110 44 or 227 7 ti17720a ODON Fic 44 Remove
9. down D200s Shown 104 Dimensions D60 Models 11 ram down ram up C Model in mm in mm in mm in mm in mm in mm in mm 060 92 7 2355 62 7 1593 14 0 356 18 0 457 24 0 610 28 0 711 47 0 1194 313296 105 Technical Data Technical Data Max air input pressure supply system D60 3 in dual post 5 gal 20 L 16 gal 60 L 30 gal EAE CARES D200 3 in dual post 55 gal 200 L D200s 6 5 in dual post 55 gal 200 L Max fluid and air working pressure Wetted parts and weight displacement pump Platen Codes see page 4 Part number Wetted parts 257729 5 gal 201 L 257734 8 gal 301 257738 16 gal 60 H 257731 5 gal 201 257736 8 gal 30 L Y 257741 16 gal 601 8 255662 55 gal 200 9 255663 55 gal 200 Maximum operating temperature supply system Sound dali sucer Scop poi Ext
10. 1 8 JINON lOH INOO p 2 E ssnd 318Y9 A3 S NWO 0 0 NYO b H NYO 2 2 Z 1 1 THS DISPLAY MEMBRANE SWITCH 7 AV IdSIG pesnun 1enids ejqeo 2 uoi woog z uis dol dor Josuas Irej amp ig 100W wey pJepuejs 9 1 NWO 9pAvz 2 1 qus egeo NALV1d Jexyeeug dwy 62 uoisugx3 vos 3g egeo Lig J9yeoH uoisuax3 Jeyealg S pin 8 e qeo uoisuey3 Jayeaig EDO S 8 eiqeo UND G dung e qeo MOV 19113 eur Yay 61 313296 Electrical Schematics peeg eue 9 1
11. 419 421 Fic 31 Inside View of Electrical Enclosure 3 Check for damaged or loose wires Check connec tions from cable track 34 Check Ground Fault Circuit Interrupter 1 With electrical enclosure door still open switch main disconnect 421 back on Have a qualified electrician restore power to main disconnect while electrical enclosure door is open 2 Press Test button on ground fault circuit interrupter 419 The blue switch should flip to the middle or opposite side NOTE Do not perform this test while the system is in operation 3 Press blue switch back into place to reset breaker 419 Fic 32 Ground Fault Circuit Interrupter 4 Switch main disconnect off 313296J Maintenance Pump Heaters 4 Check for damaged wires and connections 1 Turn the main disconnect on the electrical control 5 Ensure heaters 44 or 227 are secure so they can panel door to the OFF position to disconnect power not rotate on pump 2 Remove four screws 80 or 257 from back pump shroud 52 or 234 D200 Shown D200 Shown 80 or 257 Fic 34 Pump Heaters Fic 33 Remove Pump Shroud 3 Remove pump heater front shroud 51 or 233 313296J 35 Alarms Alarms Warm Melt alarms alert you to a problem a
12. y uowwog 2 1 pesnun 8 2 9 pae S peas JOJON y dn Jojo OIN 2 ynduj jeeur 1 FINGOW JOHINOO dvd 5508 E 1 avo a E a q E S A3 NWO Mc arre cL TED EE wey OL 5 Josueg 1 2010 63 313296J Electrical Schematics D200 Displacement Pump and Platen Schematics c ES p z 21 5 gt Q c Q Q 6 Q op e 22 gt a 64 313296J Electrical Schematics IC D200 Junction Box Schemat 2 2 2 11 MS NAD 11 MS NAD WOSN3S 018 NND WOSN3S 018 NND 341 M 0111 5 NND 831V3H NND WOSN3S 018 3S0H WOSN3S 018 350 2 31 1 350 31 3 150 LV LNONId 26 40 JINNO N31V Id 01 3JV 19 L3LIH M gt 1 4 5012 3 01 26 80133NN02 Nid SL 0 03 13 849 31V 1H d31V3H N31 V3H 0200 31 14 4303 048 65 313296J Electrical Schematics NV WIV 1d 11 19 3LIH M
13. Diving Temperature Control Modules The last digit in the temperature control module alarm codes identify the heat zone Alarm Above Setpoint RTD on wrong module Verify RTD wire and heater Cleared from Heat Run power cord is attached to screen See Heat Run Deviation Above Setpoint correct heat module Screen page 101 Shorted module module Deviation Below Setpoint Tripped circuit breaker Visually check circuit Cleared from Heat Run breaker for a tripped condi screen See Heat Run tion Screen page 101 Low power Measure voltage across input terminals on power line filter Voltage should measure between 190 and 250 Vac Cable unplugged loose wire Check for loose or discon nected wires and plugs Circuit breaker not setfor L2 Visually check circuit and L3 breaker for proper setting of L2 and L3 Bad heaters Measure resistance of heater GFCI has been tripped Visually check GFCI for a tripped condition Customer supplied main circuit Measure voltage across the breaker tripped disconnect switch Voltage should measure between 190 and 275 Vac 313296J 39 Alarms Alarm Code Alarm Problem Cause Clear Alarm Temperature Control Modules continued No Temp Rise Tripped circuit breaker Visually check circuit Cleared from Heat Run breaker for a tripped condi screen See Heat Run tion Screen page 101 Low power Measure voltage across
14. dwy 8 n uondo 2Jres ssedeq Joyeaug JAMO 6 29 duy 8 Sg duy g uesa 8 2 9 2 X NEUES p y 1010W w 5 wonog 1010 y 2 youms dn 1010 LL 001 oN 2 BIO seur 1 0 MOVaL 3 18vO 8 29314 eur JOYLNOD WerBid 1010N eJnso pou3 uondo ues wie 09 V wey OL 69 3132965 Electrical Schematics 0500 0500 0010 OLEV BLE Y3LYIH HLIM GSGNIONI lt 00cV 08 01 D60 Pump and Platen Schematic NNOWHS 14084 GNONHS dWfd 552 313296J 70 Electrical Schematics IC D60 Junction Box Schemat J N YN 2 HJ1I MS NND 211 MS NND WOSN3S 014 NND WOSN3S 14 NND 3141 M QT3IHS d31V3H NND 8 1 3 NND HOSN3S 14 3S0H 05 35 14 350 YN djlV3H 350 d31V3H 3S0H N31V ld 01 dWNd 01 34050133 01 SS3NHVH 1198 199 80133NN0J NId Gl OH E LL ibd T NS aga N11V3H 0803 8 1 3 0203 004 u31V3H 0200 N31Vd 0 00 33018 TvNIWa31 Lal 3 02
15. 104 D200 NIOGGCIS roce 104 2 5 haie eh dto 105 Technical Data 5 329253555 ot EY RR EIER 106 Graco Standard Warranty 108 Graco Information 108 313296J Helated Manuals Related Manuals Manuals are available at www graco com Component Manuals in U S English Description 313528 Tandem Supply Systems Operation 313529 Tandem Supply Systems Repair Parts 313526 Supply Systems Operation 313527 Supply Systems Repair Parts Check Mate Displacement Pumps 312375 Instructions Parts Check Mate Pump Packages 312376 Instruction Parts 200 cc Check Mate Displacement Pump 312408 Repair Parts 311238 NXT Air Motor Instructions Parts 312374 Air Controls Instructions Parts Two Zone Enclosure Expansion Kit 0099 Instructions Parts Two Zone and Four Zone Enclosure 3A0100 Accessory Kits Instructions Parts 3A0135 Bracket Mounting Kits Parts 312491 Pump Fluid Purge Kit Instructions 312492 Drum Roller Kit Instructions 312493 Light Tower Kit Instructions 309160 Heated Hose Instructions Parts Hotmelt Warm Melt Heated Fluid Regula 312396 tor Instructions Parts 307517 Mastic Fluid Regulator Instructions Parts Pressure Compensating Valve 309133 Instructions Parts Heated Header and Manifold 309181 Instructions Parts Hot Melt Dispense Guns 311209 Instructions Parts 310538
16. 8 Single Supply Systems 8 Tandem Supply Systems 9 Integrated Air Controls 10 Air Line Accessories 11 2 Button Interlock Air Controls 11 Communications Gateway Module 11 Fluid Control Module 12 User Interface 13 InstallallOH mo a 17 Location Requirements 17 5 od di a 17 ae ae ee eek ee 17 Connect Power Source 18 Install Adjust Drum Low or Empty Sensor 19 Light Tower Accessory 19 Attach Drum Stops 20 Check Resistance 21 Hose Installation and Care 23 Overview of Temperature Control Settings 23 SEUD 32 552 x oie RE s acie eu 24 ae RE 24 Set Values on Display Module 24 Load Material 25 System Heat Up 26 PIME 2525 BR 27 Operation So ee ee eh Quo wd enc 28 Pressure Relief Procedure 28 LOCK serrera 28 Start and Adjust
17. FiG 13 Drum Stop Location 20 313296J Check Resistance Check the Resistance Between the Supply System and the True Earth Ground AM A Installation Sensor Resistance Checks AN Conduct these electrical checks with the main dis connect OFF The resistance between the supply system compo nents and true earth ground must be less than 0 25 ohms Have a qualified electrician check the resistance between each supply system component and the true earth ground The resistance must be less than 0 25 ohms If the resistance is greater than 0 25 ohms a dif ferent ground site may be required Do not operate the system until the problem is corrected NOTE Use a meter that is capable of measuring resistance at this level 3132965 NOTE For dispense valve and hose sensor resis tance checks refer to your dispense valve manual or hose manual The supply system includes a heat sensor and controller for each of the four heated zones To check sensor resistance 1 Make sure the power is off and that the disconnect switch is in the OFF position 2 Make electrical resistance checks for the compo nents 3 Replace any parts that have resistance readings that do not comply with the ranges listed in Table 6 NOTE Check resistance at ambient room tempera ture 637 77 F 17 25 Table 6 RTD Sensor Resistance Zone Component Connector Pin Range
18. dwy 8 G Liz SSANUYVH d 18vO 2931 eur eJnso ou3 67 313296J Electrical Schematics D60 Ram A Schematic uondo 48 wey eee NLU plousjos c 108 HIV piousjos 1 3 WN9Is 07 WOO pasnun 2 7 1 4 WNOSIS n Woo ALdW3 Wnsia pasnun 2 JOMOd Saser ESSE Jenids ejqe NOILdO ALdW3 MPG WNOIS Woo pesnun 2 JOMOd Aldana peeg 9 1 peog opAve 2 Snqpier4 0 2pA S npolN 4 e vC 2 uondo Aemaye peog GION3 IOS piouajos 2 2 plousjog 1 F 1euids ejqe peu s p 2 pesnun Jamo 346 uondo 1461 aum eu UND ae Plouajos pini M uondo 2 im gt gt aa 0 1 peog aog y NWO opAwz 2 9 HS p H NWO Z 1 HS DISPLAY
19. A Z 2 ALA fA 7 28 or 215 Fic 55 Remove FCM 6 Replace with new FCM and secure with screws Reconnect cables to FCM Load the correct FCM software for the system Fol low the steps in Upgrade FCM Software on page 59 Replace Base 1 2 Disconnect power to system Remove FCM 36 or 220 See Replace Fluid Con trol Module Disconnect CAN cable s from FCM 36 or 220 Remove screws 28 or 215 and ground screw 30 or 217 from base 33 or 219 See FIG 55 Replace with new base and secure with screws Heconnect CAN cable s Set selector switch to A for Ram A or for Ram B See FIG 55 Reinstall See Replace Fluid Control Mod ule Upgrade FCM Software NOTE Order kit 16C027 for an upgrade token See Graco Control Architecture Module Programming manual for instructions 59 Repair Replace Cable Track D200 and D200S Supply Systems Only NOTE Order Kit 257163 for replacement 1 Disconnect power to system 2 Disconnect all 10 cables from back of electrical enclosure 13 or 14 Sr E EE Ses 6 m o o i n S 1 4 7 o Fic 56 Back View of Electrical Enclosure
20. Single Supply System or Supply System A 16 313296J 76 NOTE See Component Identification starting on page 8 to identify the components included in your Warm Melt supply system Ref Part 2 5 6 240066 240069 240067 240070 240068 240071 257748 257749 257750 257623 257624 255305 255315 255392 103347 108124 313296 Description RAM ASSEMBLY D60 3 in RAM ASSEMBLY RAM ASSEMBLY D200s 6 5 in RAM ASSEMBLY D200si 6 5 in RAM ASSEMBLY D200 3 in RAM ASSEMBLY D200 in PUMP Check Mate see manual 312375 for parts PLATEN 20 liter double wiper cst polyurethane PLATEN 20 liter double wiper sst polyurethane PLATEN 30 liter double wiper cst polyurethane PLATEN 30 liter double wiper sst polyurethane PLATEN 60 liter double wiper cst polyurethane PLATEN 60 liter double wiper sst polyurethane PLATEN 55 gal PTFE coated o ring EPDM PLATEN 55 gal o ring EPDM PLATEN 55 gal o ring neoprene KIT mounting pump 3 in 20 liter for NXT 2200 air motors KIT mounting pump 3 in 20 liter for NXT 3400 and 6500 air motors KIT mounting pump 3 in 55 gal
21. NWO 2 1 9 T IPA vC 7 H NWO peeg eyue J c 2 1 snqplel4 O P ve Aemayes uondo NOILdO A LdIWN3 go am peu s c 2 pesnup 1 1 pesnun uondo 9 wey oL 9 1 9 1 peag oyue4 9 5 9 H NVO 02 NWO SEL SLES AMAT AEA TA RADARSAT y HI NVO 2 NVO opAvz 2 2 2 2 0 9 IHS 1 1 nem C ML EUM LL NLY 2 GIONG OS GION3IOS 1 1 3 s prouejos 1 Josueg dui 2 IVN9IS v 2 josues a Woo e 1 4 16 v pesnun 2 o WOO 1 1 E T ALdW3 pesnup 2 7 1eniids E 2 u a 1 5 91929 amp 8 um 14611 JInGON AV IdSIG uondo 1467
22. 0210 ee lt 9 350 01 NId SL 0213 0113 0113 P M01144 FINGOW 14510 lt 01 av ND avg 5504 OND 01 1015 5133 0 4 1405012 4 1991419313 0200 Cable Track Schematic 4 ASVHd 319 15 1072 313296J 66 Electrical Schematics GION310S NLY 2 jeuis piouajos 1 J 2 4 id 1 ALdW3 2lo temod 1 0 ends Wnsia A1awa pue al C pU ETAT 2 leuBis piouajos 1 Wa 6 NOILdO ALdW3 MOT WNYG D60 Single Ram Schematic 9 1 b H NYO 9pAvz 2 1 T2pAvc 7 t NYO 2 uly 2 snaps 5 emag 5 dvd 5508 d18v9 1 9 TINVO 9 1 0 NYO v H op vz 2 2 0 aus 1 peeg 9 1 NvO s T peeg eyue4 0 b H NYO opAvz opAvz 2 Z 1 MHS 0 NLY 2 leuBls piousjos 1
23. 2345 12335551 43b 5 73 Status Screen 1 To reset a job total for a single ram A or B press to access the fields navigate to the value and press m When prompted press to confirm If the job total is reset A and B totals will also be reset Press to exit edit mode NOTE Grand totals cannot be reset 102 Maintenance Screen The maintenance screen enables operators to establish a preventive maintenance schedule based on the sys tem application and repair history This screen displays the number of maintenance units remaining before pre ventive maintenance is due for the platen seals and pump NOTE If a maintenance interval is set to 0 the dis play will be a series of dashes Current count remaining until platen requires maintenance Platen maintenance is reported in drums Current count remaining until pump requires maintenance Pump maintenance is reported in units set by the maintenance unit control 18 in the Advanced Setup screen 1 The example shown in FIG 74 is set to units of 1000 pump cycles Te Fic 74 Maintenance Screen To reset a counter press to access the fields nav igate to the value and press m When prompted press d to confirm Press to exit edit mode 313296J Alarm Screen The alarm screens display the type of alarm currently occurring on each ram Once an alarm is resolved use this screen to clear the alarm NOTE For more informa
24. 3 Remove screws 71 from bracket 50 that connect cable track 42 to electrical enclosure 13 or 14 and ram 13 or 14 Fic 57 Cable Track Bracket 60 FIG 99 12 13 14 96 Remove screws 12 from junction box cover 96 and junction box 78 Loosen strain relief nut 90 and remove junction box cover Disconnect all wires in junction box Pull wires out of strain relief Hemove mounting screws 71 washer 72 and nut 73 securing cable track assembly 42 to junc tion box 4 B 42242 1 72 73 91 90 58 Junction Box Lift out cable track assembly and cables Replace with new cable track kit Secure new cable track to junction box using mounting screws Run wires through strain relief and reconnect all wires in junction box See D200 Junction Box Schematic page 65 Reinstall strain relief nut and junction box cover Secure junction box using screws Reattach cable track to bracket Use screws to secure bracket holding cable track to electrical enclosure and ram Reconnect all 10 cables to back of electrical enclo sure Reconnect power to system 313296J Electrical Schematics Electrical Schematics peeg 2 2 Mams 4 S npolN Aemayes uondo
25. Adjust ram air regulator BB as needed Set the director valve BC to neutral and close the platen bleed port J 2 Button Interlock If system 1 Refer to Fic 2 Fic 3 and Fic 4 Close all air regu has this feature press and hold both buttons to start lowering the ram See 5 page 11 17 Heated Platen NOTE Follow steps below for both rams if using a tandem warm melt supply system lators and air valves 2 Open main air slider valve BA and set ram air reg ulator BB to 40 psi 0 28 MPa 2 8 bar Set direc tor valve handle BC to UP and let the ram rise to its full height 2 Button Interlock If the system has this feature ram will stop as it nears the top Press and hold both buttons to raise ram completely See FIG 5 on page 11 3 Lubricate the platen seals D with grease or other lubricant compatible with the fluid you will pump 4 Remove the drum cover and smooth the surface of the fluid with a straightedge 5 Puta full drum of fluid on the ram base slide it back against the drum stops and center it under the platen D An optional drum roller kit is available to make it easier to load the drum on the base Order Kit 255627 6 Remove bleed stick from platen bleed port J See FIG 17 7 If drum has a plastic liner pull it over edge of drum Secure liner with tape wrapped around circumfer ence of drum 3132965 25 Setup System Heat Up Ed LU 2116
26. MEMBRANE SWITCH JINON AV IdSIa p p 18061 85914 uowwog 2 p snun 1 jewod seid jeu p 0 O o9 B sseid Z Josuag eunsseJg PINJA D 0 6 4 S 91482 45 Josueg uondo PIN e UND UND UND UND VS UND UND SS 8 8 8 5 seaury 2 4 MG 1eeur 9 9 9 paay G 9 00 L i 1030 p 0 0 2 mm Z yomg 00N 0 ______ 401 lo ON LE Indu 9 WI pasy sosuag W uld 891482 VWVd s v JINON c 2 0 a 40 0 4 as wey 09d HOW dva 5508 A35 s p H NWO 2 2 Z 1 MHS NVO 91929 TAANNYS 9MWVOI elqeo Jeyeeig nouo ammod Sz Bi N31V ld 2 9MY04 31q29 uoisuoy3 2 2 2 Jeyeeig duyg Jey
27. Ulsal Us Ulsal Us mode Fic 71 Ram Operation Screen Tandem System The Ram Operation screen will display the appropriate icon and highlight the corresponding soft key if the sys tem is e depressurized 101 0 e in Recirculate mode 5 e orifaramis in Prime mode al ar 3132965 Heat Run Screen The Heat Run screen displays information for four to six heat zones See Fic 72 for information about each zone For each zone the icon on the upper right is pres ent if the zone is enabled otherwise the space is blank The temperature unit is shown in the upper right of the menu bar An alarm icon displays in the bottom right if there is an alarm or deviation on a heat zone Press the soft key under the alarm icon to clear the alarm or devia tion NOTE Heat zones five and six are located in the two zone expansion kit Heat zones seven through ten are located on Ram B Heat zones eleven and twelve are located in the two zone expansion kit The last digit in the temperature control module alarm codes represents the zone reporting the alarm Zone Temperature Control Number Module Alarm Code _ 2 S B __ 00 0 4 ____ 62 5 B2 8 2 9 2 System component being heated Zone number Current zone temperature Fic 72 Heat Run Screen Ram A 313296J Appendix A User Interface Display From the Heat Run screen users can view heat zone
28. lock hex CABLE M12 Kits 24D009 24K670 only CABLE splitter FCM empty air Kits 24D010 24D011 24K671 24K673 only WASHER plain KNOB display SCREW self tap pan hd SUPPRESSOR ferrite bead SCREW machine 8 32 x 1 3 8 CABLE CAN female female 1m MODULE base MODULE fluid control BRACKET mounting bottom BRACKET mounting 255 Qty NO C9 4 4 Ref 224 225 2217 228 229 232 233 234 235 236 239 240 241 247 248 249 250 253 254 255 256 257 258 2599 2600 248 272 273 277674 16 430 121980 16J890 16D383 15W706 ENCLOSURE pump front 16K771 201 r 24c491 5 Description ENCLOSURE cube door HARNESS HEATER pump 725 watt SUPPORT sensor SENSOR RTD shielded BRACKET mounting accessory box Qty N S ENCLOSURE pump front SST 15W707 ENCLOSURE pump rear 16K772 116343 100014 100015 15Y051 123507 16A574 16H441 121255 16A539 C31012 110637 ENCLOSURE pump rear SST CONDUIT 12 9 mm COUPLER conduit ground SCREW cap hex hd NUT hex mscr CABLE M12 8 pin f m WIRE grounding panel WIRE grounding door WIRE grounding COVER SCREW countersunk 6 32 x 0 38 BOX junction box CLAMP SCREW mach pan head BRACKET mount O RING CONNECTOR
29. vent before use See Purge System step 2 Purge System Purging the system before the initial use can prevent material contamination which may cause the material to fail or perform poorly NOTICE Purge the system before performing the initial material loading procedure The system was factory tested using a light soluble oil a soybean oil or some other oil as tagged Flush the system to avoid contaminating the material that has been designated for initial material loading To purge the system perform the following procedure 1 Select the material for the initial material load 2 Verify whether the factory test oil and the initial material load are compatible a Ifthe two substances are compatible omit the remaining steps in this procedure and refer to the start up and operation instructions b Ifthe two substances are incompatible perform the remaining steps in this procedure to flush the system at ambient temperature AN 11 n Use fluids that are chemically compatible with the equipment wetted parts See the Technical Data sec tions in the equipment manuals 24 Ae This equipment should not be used with more than one type of fluid due to potential compatibility issues that could result in an unpredictable reaction Graco recommends using new hoses when chemicals are changed or care must be taken to assure that all traces of
30. 284966 purchase separately Parts included in Low or Empty Sensor Kit 255469 pur chase separately Parts included in Drum Low and Empty Sensor Kit 24C530 purchase separately Parts included in 3 in Ham Bracket Mounting Kit 24C628 purchase separately Parts included in 6 5 in Ram Bracket Mounting Kit 24C660 purchase separately Parts included in Platen Heater Kit 24C493 purchase separately Parts included in Pump Heater Kit 24C495 purchase separately Parts included in Platen Cover Kit 255691 purchase separately Parts only available in Display Mounting Kit 24C653 purchase separately Parts only available in Cover Connector Kit 256883 purchase separately Heplacement electronic components do not have Warm Melt specific software installed Therefore use software upgrade token 16C027 to install software before use 313296J Parts Warm Melt Kits for D60 Systems Kit 24D009 CST 24K670 SST with Display for D60 and D60i Systems Kit 24D010 CST 24K671 SST with Display for Ram A of Tandem D60 and D60i Systems Kit 24D011 CST 24K673 SST without Display for Ram B of Tandem D60 and D60i Systems NO 01 202 210 203 Kit 24D010 Shown 209 NY 213 MI 208 204
31. 93 Appendix A User Interface Display Status The current system status is displayed on the right of the menu bar If there is an error an event icon and either a text description of the event or the standard error code for the event is displayed If there are no errors or deviations nothing is displayed Mode The mode section displays the current system mode The current mode is highlighted Error The current system error is displayed in the menu bar There are four possibilities No Icon No information or no error has occurred Advisory Soft Keys Icons above the soft keys indicate which mode or action is associated with each soft key Soft keys that do not have an icon above them are not active in the current screen Jump In Jump Out In screens that have editable fields press to access the fields and make changes When changes are complete press to exit edit mode 94 Navigation within Screens Press to open drop down menus on Setup screens Also press to enter changes or make a selection Press to navigate to new screens and to navigate left and right within a screen Also press select digits within a field to change Press to navigate to new screens and to navigate up and down within a screen Also press to move between fields within a drop down menu and to increment or decrement numbers within a field 3132965 Setup Mode Screens Setup mode screens are divided into six secti
32. Power Temperature Control Module s 2 Disconnect two CAN cables from base 407 3 Remove four screws 409 and ground screw 410 from base 4 Replace with new base and secure with screws 5 Reconnect two CAN cables to base 6 Set selector switch to 0 for TCM labeled 2 on Ram A 1 for TCM labeled 3 on Ram A 2 for TCM labeled 4 on Ram A for TCM labeled 2 on Ram B 6 for TCM labeled 3 on Ram B 7 for TCM labeled 4 on Ram B Selector Switch TI12361a FiG 50 Set Selector Switch 7 Reinstall low power TCM See Replace Low Power Temperature Control Module s NOTE Reuse brackets 412 413 to install new high power TCM Replace High Power Temperature Control Module 1 Open enclosure door 402 Disconnect outbound power supply and RTD cables from high power 411 See FIG 49 2 Remove electrical enclosure side panel 436 See Electrical Enclosure Parts on page 90 3 Disconnect all four incoming cables 432 428 429 431 from high power TCM See Fic 48 4 Remove both screws 415 that secure brackets 412 413 of high power to electrical enclo sure Remove high power TCM See Electrical Enclosure Parts on page 90 5 Follow steps in reverse order to install new high power TCM 56 NOTE Reuse brackets 412 413 to install new high power TCM 6 Upload the correct TCM software from kit 16C027
33. Ram 28 Start and Adjust Pump 28 Automatic 29 Manual Crossover 29 Recirculate Function 30 Depressurize Function 30 Change 244260252 eeu3 PASE bts 31 sine RC 32 Maintenance mo eon 32 Replace Throat Seals 32 Platen Maintenance 33 Electrical Enclosure 34 PUMP Healets DRE as 35 2 oa oe oe 36 Diagnose 36 Clear Alarms 36 2 Alarm Codes and Troubleshooting 36 Troubleshooting 44 47 MOLDOE A nim dace d esed de a dei y dea eR 47 Displacement Pump 48 Disconnect Pump from Platen 50 Connect Pump to 51 Replace Pump Heaters 51 Replace Platen Heaters and Sensor 52 Replace Platen 5 54 Replace Ram Piston Rod Seals 54 Electrical Enclosure 55 Display User Interface 58 Replace Fluid Control Module 59
34. Sensor Error or multiple down strokes with User Interface Display out an up stroke page 93 Damaged or disconnected air Check that air motor sen motor sensors sors are connected Inspect air motor sensor harness for damage L21X A Drum Low Deviation Drum low sensor has been Replace empty drum with activated full drum to clear L22X B Drum Low Deviation WK1X A Fluid Solenoid Discon Solenoid unplugged Check that solenoid cable Deviation automatically nected Deviation is connected cleared by solution WKOX B Fluid Solenoid Discon Damaged solenoid wires Inspect solenoid cable for on damage nected Deviation ML1X Rebuild Platen Seals Counter has reached pro Perform platen mainte Cleared from Maintenance grammed platen maintenance nance see Supply Sys screen See Appendix A ML2X Deviation automatically cleared by solution B Rebuild Platen Seals interval tems Repair Parts manual User Interface Display page 93 MA1X Rebuild Pump Counter has reached pro Perform pump mainte Cleared from Maintenance grammed pump maintenance nance See Check Mate screen See Appendix A MA2X Rebuild Pump interval Displacement Pump man User Interface Display ual page 93 3132965 37 Alarms Alarm Code Alarm Problem Cause Clear Alarm Fluid Control Module continued DA1X Pump Runaway A Pump is running faster than Correct runaway condition Cleared from Ram Alarm
35. Software page 59 for selector switch loca tions 4 Replace access cover Heating is slow Heater defective Measure resistance of Follow Heater Resistance heater Checks page 22 1 Low power Measure voltage across If voltage is lower than terminals 2T1 and 4T2 on expected use electrical main disconnect Voltage schematic to locate should measure between faulty wiring or connec 190 and 275 Vac tion Have a qualified electri cian service electrical components Heating over shoots RTD on wrong module Verify for given zone that Verify RTD wire or heater temperature does not power cord is attached to increase when zone is dis correct heat module Shorted module abled Replace module Alternate ram has an empty Verify ram has material Heplace empty drum sensor activated Alternate pump is not Verify alternate ram is Prime pump primed ready to run Alternate pump has an See Alarm Codes and See Alarm Codes and Does not crossover active alarm Troubleshooting page Troubleshooting page 36 36 46 313296J Repair Repair For smaller platens D60 3 in supply systems A N Remove junction box Remove screws 278 from junc 8 tion box 255 and remove cover 271 Remove junc To reduce the risk of serious injury follow the Pres tion box from bracket 258 sure Relief Procedure and the Load Material pro cedure prior to performing repair procedures Air Motor R
36. between the empty sen sor EE and FCM connector see FIG 7 page 12 with the empty low sensor splitter cable 313296J Installation 4 Attach the sensor to the corresponding connector on the splitter cable For drum low attach the sen sor to connector 1 For drum empty attach the sen sor to connector 2 5 Power system on 6 Make precise adjustments by moving the sensor within the slot on the sensor bracket Use the yellow indicator on the sensor cable to indicate a drum low or empty condition Light Tower Accessory Order the 255468 Light Tower Accessory as a diagnos tic indicator for supply systems See TABLE 5 for a description of light tower signals Table 5 Light Tower Signals Sims Description Yellow flashing A low priority error exists Yellow on A medium priority error exists Red flashing A high priority error exists Hed on The system is shut down due to error conditions 19 Installation Attach Drum Stops Supply systems are shipped with drum stops in place to 1 Locate the correct set of mounting holes on the ram help position the drum on the ram For replacement base parts order Kit 255477 The kit includes two each of capscrews FA lock washers not shown and drum 2 Using the capscrews FA and lock washers not stops FB shown attach the drum stops FB to the ram base D200 Shown Fic 12 Attach Drum Stops 55 gal 200 L 8 gal 30 L 5 gal 20 L
37. drop down menus on Setup fields Press to enter changes and make a selection Arrows Left Right Navigate left or right to a new screen Navigate left or right within a screen while in Jump In mode See Appendix A User Interface Display page 93 for more information Navigate up or down within a screen or to a new screen Move between selections within a drop down menu e Increment or decrement the selected numerical field within a selection menu 313296J 13 Component Identification Table 3 Display Module Button Functions Soft Key Soft keys activate the mode or action represented by the icon above each button in the LCD See Table 4 for soft key modes and actions Table 4 Display Soft Key Icons Depressurize Depressurize relieves fluid pressure from the pump outlet to below the platen on the currently active ram T If system is pressurized press button e When prompted to depressurize the system select or Depressurizing the active ram will depressurize both rams NOTE If additional user supplied check valves have been added to the system only the active ram will be depressurized You must perform manual crossover and select depressurize again to depressurize both rams See Crossover section of this table on page 15 If system is depressurized press button e When prompted to pressurize the system select 4 or DX Pump Prime e Tandem ram if pump is off activates the air solenoi
38. filter monitoring or if there is no fil DE Select if drum low sensor is installed on ter installed on the system system Set for A and B rams Set low limit 0 1000 psi for pressure drop that will issue an error Set the low limit to detect a filter element collapse or a missing element Set high limit 0 5000 psi for pressure drop that will issue an error Set the high limit to detect a clogged filter Fic 66 Hardware Setup Screen 2 313296J 97 Appendix A User Interface Display Advanced Setup Screens The Advanced Setup screens enable users to set units adjust values set formats and view software informa tion for each component Press to scroll through the Advanced Setup screens Once in the desired Advanced Setup screen press to access the fields to make changes Press to exit edit mode NOTE Must exit edit mode to scroll through the Advanced Setup screens Advanced Setup Screen 1 This screen enables users to set units that display on other screens NOTE On two zone and four zone enclosure acces sory kit only 2 1 settings are available Select units of measurement for volume Select between cycles gal gal oz and liters cc Set units of measurement for maintenance intervals Select between cycles drums gal and liters Set units of measurement for pressure Select between psi and bar Set the password Use digits 0 9999 0000 no password 18 Set units o
39. has a pump runaway drum empty or not primed alarm If this occurs correct the error and clear the alarm from the Alarm screen See Alarm Screen page 103 for details 313296J Operation Manual Crossover Tandem Warm Melt Supply System Only Manual crossover can only be initiated if the following conditions are met e inactive ram is not in the drum empty error condi tion pump runaway and not primed alarms do not exist To initiate a manual crossover to the inactive ram 1 From the Ram Operation screen press the Cross over key The display prompts the operator to confirm 2 Select d to confirm manual crossover operation or select to cancel Fic 26 Crossover Function Screen NOTE If the active ram has a pump runaway error or drum empty error the system will attempt an automatic crossover 29 Operation Recirculate Function Recirculate mode pumps fluid from the drum through the pump and back into the drum on the currently active ram To enter Recirculate mode 1 Setthe motor air regulator to 30 psi 0 2 MPa 2 1 bar 2 From the Ram Operation screen press the Recircu late key A The display prompts the operator to confirm 3 Select to confirm recirculation or select to cancel Fic 27 Enter Recirculate Mode 4 Adjust motor air regulator to obtain desired flow rate NOTE While in Recirculate Mode the manual crossover function cannot be use
40. lower heater plate 318 Install upper heater plate 820 Reconnect ground wire and secure with screws 5 Label platen heater wires A and B as shown on page page 70 Reroute platen heater wires through the conduit to the junction box Reconnect the two wires to the appropriate terminal block A and B 6 Reinstall heat shield guard Secure with nuts Torque nuts to 45 5 in Ibs 5 1 0 6 Nem 7 Reconnect displacement pump using screws and clamps 8 Reinstall junction box cover and strain relief nut Secure cover with screws 53 Repair Replace Platen Wipers Refer to Supply Systems Repair Parts manual for instructions Replace Ram Piston Rod Seals 1 Support electrical enclosure 13 or 14 using a loop and a hoist 2 Remove screws from bracket 50 or 232 connect ing electrical enclosure 13 or 14 to ram piston rod and cable track 42 if applicable 42 13 or 14 50 or 232 47 Replace Rod Seals For 55 gallon platen D200 02005 supply sys tems Gently move cable track 42 and bracket 50 to side For smaller platens D60 supply systems Remove bracket 232 4 See Supply Systems Repair Parts manual for replacement instructions 5 Follow steps in reverse order to reinstall bracket cable track if applicable and the electrical enclo sure 54 313296J Electrical Enclosure Prior to repairing any component of the electrical enc
41. ohms Fluid Pump Pin 1 to 3 1050 1100 O Fic 14 RTD Connector Pins 21 Installation Heater Resistance Checks NOTE Check resistance at ambient room tempera ture 63 77 F 17 25 C Table 7 Resistance Chart of All Heaters Between Unit Range Component Terminals Voltage ohms Conduct these electrical checks with the main power disconnect OFF 1 Platen D200 15 5 5 NOTE For dispense valve and hose sensor resis Platen D60 80 10 10 tance checks refer to your dispense valve manual 37 5 5 or hose manual To check heater resistance 1 1 Make sure the power is off and that the disconnect switch is in the OFF position 2 Make electrical resistance checks for the compo nents Refer to Table 7 Heater terminal pins are 3 located on the back of the enclosure See FIG 2 page 8 3 Replace any parts whose resistance readings do not comply with the ranges listed in Table 7 FiG 15 Heater Terminal Pins 22 313296J Hose Installation and Care A 7 7 NOTE The warm melt supply system requires Graco single circuit material hoses rated at a maxi mum of 1920 Watts Hose Installation 1 Connect heated hose to the pump outlet 2 Usetwo wrenches to tighten Torque to 470 550 in lbs 53 1 62 1 Nem 3 Wrap exposed fittings on the pump outlet with Nomex insulation and secure insulation using fiber
42. platens D60 3 in supply systems Heinstall junction box 255 onto bracket 258 Use screws 278 to attach cover 271 See FIG 36 Displacement Pump Remove Displacement Pump Fic 37 D200 and D200s Pump Heater Shrouds 7 7 This procedure must be done while the system is still warm The material and equipment may still be hot Hefer to your Check Mate Displacement Pump manual to repair the displacement pump If the air motor does not require servicing leave it attached to its mounting If the air motor does need to be removed see Remove Air Motor page 47 D200 and D200s Supply Systems 1 Disconnect air hose and ground wire from air motor 2 See Disconnect Displacement Pump in Check Mate Pump Packages manual 3 Follow steps 1 4 of Replace Platen Heaters and Sensor section page 52 to remove pump heater 48 shrouds 51 52 pump heaters 44 and RTD sen sor 46 Ae 5 51 44 5 46 S 44 i 52 4 Raise air motor Loosen nut HB under ram bar and thread it down the threaded rod HC to the lift ring adapter HD holding the motor Use wrench on nut HA on top of ram bar to raise air motor 10648 Fic 38 Raise Air Motor 5 See Disconnect Pump from Platen page 50 to disconnect the displacement pump from the platen 6 Use two people to carefully lift out the dis
43. power female 3 pin lt 313296 Ref 2610 262 263 A 264 265 266 267 268 269 270 271 272 273 274 276 277 278 279 1 280 1 281 1 282 283 284 285 286 287 288 313296 Part 154075 151668 24B810 113970 C19208 102794 111640 100166 16A355 196548 114958 112788 122716 124131 103181 16K094 C33037 106245 157974 16K066 Description COVER connector LABEL warning LABEL warning RAIL din assy BUSHING strain relief 40 thread NUT strain relief M4O thread CONNECTOR bulkhead 15 pin SCREW cap sch WASHER lock NUT hex COVER junction box WASHER lock internal NUT full hex WIRE ground LABEL caution STRAP tie SCREW cap sch BRACKET sensor low empty SENSOR inductive M12 ACTUATOR sensor low empty SCREW WASHER lock SWITCH overtemp horizontal TAPE fiberglass SCREW WASHER CLAMP support 9 lt auk b b i o NO 4 5 138455 5858858 4 Parts Not shown Replacement Danger and Warning labels tags and cards are available at no cost Standard only on tandem supply systems Kits 240009 240010 24K670 and 24K671 Parts included in Low or Empty Sensor Kit 255469 purchase separately Parts included in Drum Low and Empty Sensor Kit 24C530 purchase separately Parts included in 3 in Ham Bracket Mounting Kit 24C628 purchase separately Pa
44. set runaway limit due to and clear alarm screen See Appendix A DA2X Pump Runaway User Interface Display Increased air pressure page 93 Increased fluid output Exhausted fluid supply Open fitting hose drain or bleed valve A Drum Empty Drum empty sensor has been Replace empty drum with Alarm automatically activated full drum to clear cleared by solution L12X B Drum Empty DB1X Not Primed The pump is not primed Set ram to Prime mode to Cleared from Ram Alarm automatically clear alarm screen or Ram Operation DB2X B Not Primed or manually clear alarm screen See Appendix A from Ram Alarm screen User Interface Display page 93 WJ1X Air Solenoid Discon Solenoid unplugged Check that solenoid cable Alarm automatically nected is connected cleared by solution WJ2X B Air Solenoid Discon Damaged solenoid wires Inspect solenoid wires for Alarm automatically cleared by solution Cleared from Ram Alarm screen See Appendix A DK1X Air Motor Sensor Error System has seen multiple up See air motor manual strokes without a down stroke DK2X B Air Motor Sensor Error or multiple down strokes with User Interface Display out an up stroke page 93 Damaged or disconnected air Check that air motor sen motor sensors sors are connected Inspect air motor sensor harness for damage L21X A Drum Low Deviation Drum low sensor has been Replace empty drum with ac
45. tandem warm melt supply system 1 Connect pump outlet fittings and hose not sup plied NOTE Be sure all components are adequately sized and pressure rated to meet the system s require ments 2 Besure the pump air valve is closed Then set the ram air regulator BB to 50 psi 0 35 MPa 3 5 bar Set the director valve BC to DOWN See Fic 4 page 10 313296J 3 Press while in the Ram Operation screen Do 22 0022 56 Fic 25 Ram Operation Screen Tandem System 4 When the confirmation screen appears with a prompt select nf to start the pump 5 Open the pump air valve BF and keep the director valve BC set to DOWN while pump is operating NOTE 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 Automatic Crossover Tandem Supply System Only _ Keep clear of the inactive ram as automatic cross over may occur unexpectedly To repair or adjust the ram first follow all steps of the Pressure Relief Pro cedure on page 28 The automatic crossover feature allows continuous flow and prevents system shutdown If the active ram encounters a pump runaway or drum empty alarm it will attempt an automatic crossover to the inactive ram The system will generate a crossover error if the active ram attempts an automatic crossover while the inactive ram
46. the operator to firm Select to confirm pressurize or select to cancel See FIG 28 Change Drums NOTE Follow this procedure to change the drum on a fully heated warm melt supply system NOTE Follow this procedure for either ram if using a tandem warm melt supply system NOTICE Do not use a drum of material that has been dented or otherwise damaged damage to the platen wiper can result 1 Push in the air motor slider valve BF to stop the pump See FIG 4 2 Setram director valve BC to UP to raise the platen D and immediately press and hold the blowoff air button BG until the platen D is completely out of 313296J Operation drum Use minimum amount of air pressure neces sary to push the platen out of the drum 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 3 Once the platen clears the drum release the blow off air button BG and allow the ram to rise to its full height 2 Button Interlock If system has this feature the ram will stop as it nears the top Press and hold both buttons to raise ram completely See FIG 5 4 Remove empty drum 5 Inspect platen and if necessary remove any remaining material or material build up 6 Place full drum on ram base 7 Lower ram and adjust the positio
47. transfer 1 329 100166 NUT full hex 1 318 PLATE heater lower 1 330 16A356 WIRE ground 1 319 HEATER includes wiring to 1 331 16H441 WIRE ground _ switch 336 332 111593 SCREW grounding 1 320 PLATE heater upper 1 335 15K616 LABEL safety 1 324 HOLDER RTD sensor 1 336 15B137 SWITCH thermal 1 337 104714 SCREW machine 338 103181 WASHER lock A Heplacement Danger and Warning labels tags and cards are available at no cost Parts that Vary by Heated Platen Model Heated Platen Models Qt 240066 20L 24D067 30L 24D068 60L 240069 20L 24D070 30L 24D071 60L Description Platen CS Platen CS Platen CS Platen SST Platen SST Platen SST 02 SPACER dual wiper 257694 257695 257696 262873 262874 257684 WIPER main 25 678 257679 257680 257675 257676 257677 e CO 4 C 5 7 s e j CO E 34 SPACER nylon 3 4 in 16J835 16J835 164835 313296 89 Parts Electrical Enclosure Parts 257158 for single supply systems and ram A of tandem supply systems 257291 for ram B of tandem supply systems 257158 Shown 402 403 404 405 456 408 409 410 90 411 CN G w 433 434 435 427 437 401 451 AN
48. 0 Warm Melt Kits Ref 11 12 13 14 154 16 17 18 194 20228 219 2242 23 24 25 26 279 28 313296J Part 100016 121112 115827 15X270 15G347 1277589 277591 1277590 277 592 1255383 15R108 100696 24F493 102040 1123328 15 968 166377 110755 121253 114417 Description WASHER lock SCREW cap sch SCREW cap hex hd 7 16 14 unc WASHER top hat SUPPORT hose hanger COVER shroud front for 3 in Ram for 6 5 in Ram COVER shroud rear for 3 in Ram for 6 5 in Ram BRACKET light tower for in Ram for 6 5 in Ram WASHER plain MODULE display BRACKET pendant pivot BRACKET mounting assy SCREW cap sch 1 4 20 unc NUT lock hex CABLE splitter FCM empty air CABLE FCM low hi air CABLE M12 DIN WASHER plain KNOB display SCREW self tap pan hd Qty 1 cl c D 0 68 97 98 Ref Part 29 30 121070 31 121001 121228 32 101213 33 289697 34124 122716 35 1 36H 289696 37 12 39 T on 40 414 277674 42V 257163 430 44 121980 45 16 890 460 160383 47 119832 48 Y 15 427 Parts r 24c491 5 Description SUPPRESSOR ferrite bead SCREW machine 88 32 x 1 3 8 CABLE CAN female female 0 5m Kits 240014 and 240017 only NUT full hex MODULE cube base SENSOR inductive M12 BRACKET sensor low empty MODULE fluid control ACTUATOR sensor
49. 1 go 7 184615 2 1 pasnun 1 ay p EUBIS 55914 c uondo 2Jmesj sedeq im ap ap Qu gt gt 194 Z 1 ejqeo 8 1eeur 2 9 v 2 5 uonog pasy S 5 wopog 2 yams doy dn pees 1040W youms OIN Z seaurq 1 peas Josueg 8 eiqeo V NVJ J1nGOlN JlOH NOO C V wey HOW WIEM D200 Ram A Schematic dvd ssnd 5 A3 9 1 p H NYO 2 0 NVO THAINHO SMwVOL eiqe NALV 1d 92 B ejqeo IOHINOO MG 22992 Nid SMWVOL eIqeo l am B EMEN B e qeo Jexyeejg 6 dwy 8 Jexyeejg 8 od
50. Component Identification Communications Gateway Module The Communications Gateway Module CGM provides a control link between Graco Control Architecture based systems and a selected fieldbus This provides the means for remote monitoring and control by external automation systems Data provided by the CGM to the fieldbus depends on which Graco Control Architecture based system and fieldbus are connected A data map supplied on a map token is defined for this pairing Once the data map has been loaded into the CGM it is stored internally and the map token is no longer required for operation See the Supply System Communications Gateway Mod ule Installation Kit manual for fieldbus parameter setup instructions and screen descriptions CGM Module Status LED Signals Green on System is powered up Yellow Internal communication in progress Red CGM hardware failure Solid Data map load failure Incorrect data map for fieldbus type No data map loaded The red LED will flash a code pause then repeat See Communications Gateway Module manual 312864 for diagnostic information Verify that you are using the correct token for your system and reinstall token If fails order new token Red 7 flashes 11 Component Identification Fluid Control Module Table 2 FCM Sensor Connections Ham A and Ram B Air motor solenoid wire labeled 3 drum low wire labeled 1 drum empty wire labeled 2 puse Air motor reed switc
51. HER lock NUT hex mscr CAP tube COVER SCREW countersunk 6 32 0 38 BRACKET cable and rack CLAMP SCREW machine pan hd SPRING hose hanger WASHER O RING CONNECTOR power female 3 pin COVER connector LABEL warning LABEL warning RAIL din assy BUSHING strain relief m40 NUT strain relief m40 CONNECTOR bulkhead 15 pin SCREW socket hd cap WASHER lock NUT hex WASHER lock NUT full hex WIRE ground pump WIRE ground platen LABEL caution WIRE ground Qty 2 1 a ll RKP POO O M 00 55 Ref 103 103a 103b 103c 104 106 107 108 Part 255392 102637 2 6025 109495 15Y051 124131 103187 109 15 137 110 16 094 111 112 113 114 115 116 117 114958 16 539 16 543 299653 C33037 112788 16A541 Description KIT mounting displacement pump SCREW CLAMP O RING STUD CABLE SCREW WASHER lock SWITCH thermal SWITCH overtemp horizontal STRAP TIE JUNCTION BOX BRACKET SHRINK TUBE TAPE fiberglass SCREW COVER junction box Qty LR A 5 34301 2565 A Not shown Replacement Danger and Warning labels tags and cards are available at no cost Kit 240012 only Kit 24D015 only Kits 24D013 and 24D016 only in tandem supply sys tems Parts included in Hose Hanger Kit
52. Instructions Parts gt g GRACO Warm Melt Supply System S 313296J EN For use with heated bulk supply of medium to high viscosity sealant and adhesive materials Not for use in hazardous locations Intended for indoor use only D60 3 inch dual post 60 liter 16 gallon 30 liter 8 gallon and 20 liter 5 gallon sizes 150 psi 1 0 MPa 10 bar Maximum Air Inlet Pressure D200 3 inch dual post 200 liter 55 gallon 150 psi 1 0 MPa 10 bar Maximum Air Inlet Pressure 1 02005 6 5 inch dual post s AS 200 liter 55 gallon qmi 125 psi 0 9 MPa 9 bar Maximum Air Inlet Pressure 2101 1 Read all warnings and instructions in this manual Save these instructions e Important Safety Instructions See page 4 for model information The Graco Control Architecture Electric Components are listed in Intertek s Directory of Listed Products D200s WM2179 Shown PROVEN QUALITY LEADING TECHNOLOGY Contents Related 5 3 11908615 RR eee 4 Warnings ee 5 Edere ianuis 7 System Description 7 Power Requirements 7 Heat Control Zone Selection 7 Component Identification
53. KIT mounting pump 6 5 in 55 gal KIT mounting Check Mate pump VALVE safety relief located out of view on back side of air controls For systems with pumps P23xxx or P36xxx For systems with pumps P68xxx Qty Ref Part 13 15 16 257158 257291 240009 240010 240012 240013 240015 240016 240011 240014 240017 Description ENCLOSURE electrical see Electrical Enclosure Parts page 90 For single systems and Ram A For B KIT warm melt with display see Warm Melt Kits for D200 Systems page 78 or Warm Melt Kits for D60 Systems page 83 D60 Ram WMxxxx Models D60 Ram A TWxxxx Models D200 3 in Ram WMxxxx Models D200 3 in Ram A TWxxxx Models D200 6 5 in Ram WMxxxx Models D200 6 5 in Ram A TWxxxx Models KIT warm melt with no display see Warm Melt Kits for D200 Systems page 78 or Warm Melt Kits for D60 Systems page 83 D60 Ram B TWxxxx Models D200 3 in Ram B TWxxxx Models D200 6 5 in Ram B TWxxxx Models See Supply Systems Repair Parts manual for parts Stainless Steel Ram Conversion Kits For converting carbon steel Ram to stainless steel 24K670 24K671 24K673 24K675 24K676 24K677 24K678 24K679 24K680 D60 Ram WMxxxx Models D60 Ram A TWxxxx Models D60 Ram B TWxxxx Models D200 3 in Ram WMxxxx Models D200 3 in Ram A TWxxxx Models D200 3 in Ram B TWxxxx M
54. L 5in D200s iNT r 2 Button 60L 6 5 in 20051 no volt Interlock 16 Gal F SW coated 2 Button 601 Polyure no volt Interlock 16Gal DW thane PTFE 200L coated 55 Gal AL EPDM 200L 55 Gal AL EPDM Key Table 1 Check Mate Pump Identification Code Part D Dual post ram Pump Pump Part No see Pump Pump Part No see i 2 Button interlock Code manual 312376 Code manual 312376 Pump Code coated Polyure thane 2 5 Warm Melt PTFE Single Supply coated System See Table 1 Polyure for 2 digit CS CS Pump Code INT INT O oc o 19 5 2 thane PTFE TW Warm Melt Tandem Supply System s 6 5 In ram 2200 CM 200 6500 200 INT Integrated air controls P23LCS 2L P68LCS F Flat SW Single wiper P23LCM 2M P68LCM DW Dual wiper P23LSM 2U P68LSM DR Dual o ring NXT 3400 CM 200 P36LCS P36LCM P36LSM 4 3132965 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 syste
55. L2 Bad heaters Measure resistance of heater GFCI has been tripped Visually check GFCI for a tripped condition Customer supplied main circuit Measure voltage across the Component not plugged in Visually check circuit Cleared from Heat Run breaker for a tripped condi screen See Heat Run Screen page 101 Measure voltage across input terminals on power line filter Voltage should measure between 190 and 250 Vac Visually check circuit breaker for proper setting of L2 and L3 disconnect switch Voltage should measure between 190 and 250 Vac Ensure zone is set for type of hardware connected to it If temperature rises for a Cleared from Heat Run zone that has been dis screen See Heat Run abled replace heat mod Screen page 101 ule Measure resistance of RTD Cleared from Heat Run and verify it is within valid screen See Heat Run range Screen page 101 Bad RTD connection loose Check for loose or discon wire nected wires and plugs Ensure a component is plugged into zone report ing error If nothing is plugged in disable zone 313296J 41 Alarms Alarm Code Alarm Problem Cause Clear Alarm PCB Overtemperature Overheated Temperature Turn heat zone off Waita from Heat Run Control Module few minutes If the condi screen See Heat Run tion does not clear on its Screen page 101 own replace heater mod ule High Line Volta
56. L3 ON OLI D o Fic 52 Circuit Breakers aay 3 Replace with new circuit breaker Use tabs on bot tom of breaker to select L2 and L3 4 Snap new circuit breaker into place and reconnect wires Replace Electrical Enclosure 1 Ensure power to electrical enclosure is discon nected 2 Disconnect heater and RTD cables from each TCM 3 Remove plug and use lift ring not included at top of electrical enclosure 13 or 14 313296J Repair 4 Remove screws 12 or 202 and washers 11 or 201 from bottom bracket 39 or 222 and side bracket 50 or 232 of enclosure D200 Shown plug 7 11 or 201 12 or 202 50 or 232 13 14 39 or 222 Fic 53 Replace Electrical Enclosure 5 Lift enclosure off and replace with new enclosure 6 Secure new electrical enclosure to bottom and side brackets with screws and washers 7 heater and RTD cables to each TCM 8 Reconnect power to power line filter AN Have a qualified electrician reinstall main incoming power to system and electrical enclosure 57 Repair Display User Interface Upgrade Display Software NOTICE To avoid damagin
57. Pump Heaters 6 Install new pump heater bands and secure with screws NOTE To ease pump heater band installation first install heater bands on middle of displacement pump Then slide heater band up or down into cor rect location 7 Reinstall RTD sensor and tighten screw on sensor support NOTE Ensure RTD is flush to pump before tighten ing screw 8 Reinstall pump heater front shroud 9 Reinstall ground wires 10 Reinstall back pump heater shroud and secure with screws 52 Replace Platen Heaters and Sensor 55 Gallon Platen Heater and Sensor 1 Turn off main disconnect 2 Remove both platen cover fasteners 70 3 Remove both platen covers 49 and ground wire from platen 82 ti18061a Fic 45 Replace Platen Heaters and RTD Sensor 4 Remove platen heater blocks 43 a Use a hex wrench to remove three nuts 59 and washers 11 64 from each heater block Remove screws 12 from junction box cover 96 Loosen strain relief nut 91 and remove junction box cover Disconnect four platen heater wires labeled A dn B and RTD sensor connector in the terminal box See Electrical Schematics page 61 3132965 d Remove screws 58 and washers 82 Remove platen heater blocks 43 and RTD sensor 46 Install new platen heaters and RTD sensor Secure RTD sensor with screw and washer Secure platen heater bl
58. REW machine pan hd MODULE high power temp BRACKET high power temp mod ule BRACKET mounting high power 1 temp module SCREW machine pan hd 4 A SCREW machine pan hd 20 BAR buss smissline 17 125 in 1 CIRCUIT breaker smissline 10A 4 257291 includes qty of 3 COVER buss bar CIRCUIT breaker WIRE power SWITCH disconnect ROD connecting on off RELAY contactor CIRCUIT breaker smissline 25A WASHER lock internal WASHER lock internal 1 KIT bar ground HARNESS wiring high power temp module CABLE CAN 90 female 90 female CABLE 14 in CABLE M8 male ferrules CABLE CAN female female 0 5 m WASHER flat WASHER lock NUT hex PANEL side 3 low power heat modules 1 hp GASKET low power heat module GASKET high power heat module LABEL junction box CORD grip PG 7 GRIP cord CONNECTOR thru M12 m x f SCREW cap socket hd LATCH quarter turn HANDLE selector on off SEAL hole plug 0 5 in WIRE grounding door NUT full hex WIRE ground ENCLOSURE cube door LABEL ground KR LR ON a Uea Nae NY 0 Ref Part 458 112905 459 123373 460 123374 461 466 125789 467 123615 Not shown Parts Qty Description WASHER plain 6 FILTER power line single phase 1 SUPPLY power 24 2 5A 1 60W included in only 257158 COVER buss bar single 1 CABLE CAN female fe
59. Replace Cable Track 60 Electrical Schematics 61 Hal A Schemat gt eat ee wae ed 61 D200 Single Ram Schematic 61 D200 Ram A Schematic 62 D200 Ram B Schematic 63 D200 Displacement Pump and Platen Schematics 64 D200 Junction Box Schematic 65 D200 Cable Track Schematic 66 D60 Single Ram Schematic 67 D60 Ram A Schematic 68 D60 Ram B Schematic 69 D60 Pump and Platen Schematic 70 D60 Junction Box Schematic 71 D60 Cable Harness Schematic 72 Electrical Enclosure Schematic 73 Electrical Enclosure Schematic 74 Paris 25525 32505 ERAS esp xd 76 Warm Melt Kits for D200 Systems 78 Warm Melt Kits for 060 Systems 83 Electrical Enclosure 90 5 92 Appendix A User Interface Display 93 Display Overview 93 Display Details 93 Setup Mode Screens 95 Run Mode ScreenS 100 DIMENSIONS i e
60. See Upgrade Temperature Control Module Soft ware page 56 for instructions 7 Remove cover of new high power TCM and set selector switch to 0 for Ram A or 1 for Ram B gt al 2 Selector Switch 1112360a FiG 51 Set Selector Switch Upgrade Temperature Control Module Software NOTE Order kit 16C027 for an upgrade token See Graco Control Architecture Module Programming manual for instructions 313296J Replace Circuit Breakers 1 Open enclosure door 402 Disconnect wires from circuit breaker 417 419 2 Pushin circuit breaker tab and pull out breaker N OLA OLB OL2 OL3 ON aay LIV 1 4 OLA OLB OL2 OLS3 ON OLI VIL Z OLA OLB OL2 OL3 ON OLI OLA OLB OL2 ON OLA OLB OL2 O
61. Therm O Flow9 Automatic Dispense Valves Instructions Parts 309376 EnDure Automatic Dispense Valves Instructions Parts Communications Gateway Module 312664 Instructions Parts Supply System Communications Gate 313138 way Module Installation Kit Instruc tions Parts 406681 Platen Cover Kit Instructions 313296J 3 Models Models Check the identification plate ID for the 6 digit part number of your warm melt supply system Use the following matrix to define the construction of your system based on the six digits For example Part No WM2979 represents a Warm Melt supply system WM a carbon steel Check Mate 200 Severe Duty displacement pump with an NXT 3400 air motor pump code 29 a 6 5 in dual post ram with integrated air controls 7 and a 55 gallon uncoated platen with an EPDM seal 9 NOTE Some configurations in the following matrix cannot be built See the Product Selection guide for available systems To order replacement parts see Parts section in this manual and in manual 313527 The digits in the matrix do not correspond to the Ref Nos in the Parts drawings and lists 11157A First Third and Second Digit Fourth Digit DataTra k Platen Platen Platen Seal Style Voltage Air Controls Size Style Material Material 201 no volt bGal F SW 20L D200 no volt 5 Gal F DW 2 Button 30 L D200i no volt Interlock JL 8Ga F SW 30
62. X08 f 71 313296J Electrical Schematics D60 Cable Harness Schematic Qqv3puring Jv 18 E Xv 1g 2 N31V ld 3L IH M E 020 E OELQ 11 dWNd N31V ld 01 01 lt 9 350 01 Nid Sb 084 1 JINGOW 14510 M01134 OL 3189 avg 5508 9 01 3015 5122 02 0 ONV 3415013 3 1V318123113 4 JSVHd 419 15 10172 313296J 72 Electrical Schematics Electrical Enclosure Schematic 114405 09 23 1154 11 LIZ HOLJVINO ZV ONEL EIG 21 11 avassng 3NIISSIWS o1nso 2u3 9407 GROUND BUSS BAR O OV 4 X Val 37189 A18 IND A18 82113 1 11 83 0 123 02510 1011 1314 031 14405 LO MS 3 015113 73 313296 Electrical Schematics Electrical Enclosure Schematic 0019 7 180d S 1404 1404 010 LWHdH ONT E19 217 LIZ HO0LJVINO zY ONEL 618 218 Ll 9J1n 0 2U3 8 NVH 9 407 GROUND BUSS BAR O OV 123 02510 10 5 Qv3aux ig WO E 6 831113 3 11 1041 A18 09 A18 MOd 01114 01114405 34015012 313296J 74 313296J Electrical Schematics 75 Parts Parts D200s Rams Shown Supply System B
63. 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 claim 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 wa
64. a system to suit your particular needs Location Requirements e Refer to Dimensions page 104 for ram mounting and clearance dimensions e Install indoors only and not near water or any other liquid that is sprayed Location NOTICE Always lift supply system at proper lift locations see FIG 2 to avoid equipment damage Do not lift in any other way 1 Attach a lifting sling at the proper lift spots Lift off the pallet using a crane or a forklift See Fic 2 for proper lift locations 2 Position the ram so the air controls and electrical enclosure are easily accessible Ensure that there is enough space overhead for the ram to raise fully 3 Using the holes in the ram base as a guide drill holes for 1 2 in 13 mm anchors 4 Ensure that the ram base is level in all directions If necessary level the base using metal shims Secure the base to the floor using 1 2 in 13 mm anchors that are long enough to prevent the ram from tipping 3132965 Installation Grounding Ground the supply system as instructed here and in the individual component manuals AL The power source conduit is not an adequate ground for the system The unit must be bonded to either the building ground or a true earth ground To reduce the risk of static sparking ground the pump the object being dispensed to and all other dispensing equip ment used or located in the dispensing area All elec trical wiring must be done
65. ables are A 30A minimum 60A maximum circuit breaker not available for other possible combinations provided must be installed on the incoming power sup ply See Table 1 and Technical Data page 106 for more information regarding electrical requirements ZONE 1 ZONE 2 ZONE 3 ZONE 4 Control Control Control Control 1920 Watts max 1920 Watts max Fic 1 Heat Control Zone Selection 313296J 7 Component Identification Component Identification Single Supply Systems D200s Ram Shown Lift Locations NOTE Do not use air motor lift ring S to lift entire system d 8 DNS RA CO FIO 1 T S LET SS cz Fic 2 Single Supply System 40 Co Ram Assembly V Platen Lift Rod Air Motor X Wet Cup Heated Check Mate Displacement Pump Z Main Air Line not supplied Heated Platen AD Air Motor Solenoid Display Module AE Junction Box Electrical Enclosure AF Cable Track Integrated Air Controls see FIG 4 Fluid Control Module inside shroud Lift Ring air motor Platen Bleed Port Pump Outlet 112 Y a Component Identification Tandem Supply Systems D200s Rams Shown Supply System A Supply System B AD B N 5 AS C Cus
66. al dispense valve unlock the dis pense valve trigger and place dispense valve over a waste container 5 Press the Pump Prime key The display DAR prompts the operator to confirm See FIG 21 Select v to begin prime 313296J Setup Fic 21 Prime Confirmation 6 When the timer expires the air motor solenoid LED will turn off 7 Prime the system until a smooth flow of material dis penses from the dispense valve 8 Lockthe dispense valve trigger lock NOTE To exit Prime Mode before the timer expires press the Pump Prime key The display a prompts the operator to confirm See Fic 22 Select FiG 22 Exit Prime Mode Confirmation NOTE To extend the prime time counter select Ma in Fic 22 Display prompts operator to confirm See Fic 23 Select Td to reset 12345 00000 Fic 23 Reset Prime Time Counter Confirmation 27 Operation Operation Pressure Relief Procedure gt 2 E i 21116 This procedure describes how to relieve pressure for the supply system Use this procedure whenever you shut off the system and before checking or adjusting any part of the system 1 Lockthe dispense valve trigger 2 Press On Off key If system is On display will highlight Select to turn off Fic 24 System Function Screen See 4 page 10 Close the air motor s
67. by a qualified electrician and comply with local codes and regulations Pump use a ground wire and clamp Loosen grounding lug locknut and washer Insert one end of supplied ground wire into slot in lug and tighten locknut securely Connect other end of wire to a true earth ground See FiG 10 tia250a Fic 10 Ground Pump Air and fluid hoses use only electrically conductive hoses Air compressor follow manufacturer s recommenda tions Dispense valve ground through connection to a prop erly grounded fluid hose and pump 17 Installation Fluid supply container follow local code NOTE See Power Requirements page 7 for circuit protection requirements Object being sprayed follow local code 1 Open electrical enclosure door and locate power Solvent pails used when flushing follow local code line filter Use only conductive metal pails placed on a grounded surface Do not place the pail on a nonconductive sur 2 Have a qualified electrician perform the following face such as paper or cardboard which interrupts steps grounding continuity a Connect your plant power to the electrical To maintain grounding continuity when flushing or enclosure power line filter according to local relieving pressure hold metal part of the dispense codes A 1 3 8 in 35 mm diameter opening is valve firmly to the side of a grounded metal pail then provided on the side of the enclosure adjace
68. ct Enter Setup and enter cor point temperature setting on rect temperature Heat Run screen Bad heater Measure resistance of Unplug suspected heater heater zone from heater module Follow Heater Resis tance Checks page 22 If resistance is outside allowable value replace heater s Contactor not closing Turn on heat for zone A1 or 1 Verify cable 15W902 B1and ensure contactor from the high power closes is connected cor rectly Verify that there are no other error conditions that would prevent heater from starting Verify there is 24 Vdc between 2 wires on 15W902 If not replace high power TCM See Alarms page 36 contactor 313296J 45 Troubleshooting ____ Missing module Modules not on network Verify attached modules Enter Setup screen and through Advanced Setup scroll to Advanced Setup screens 4 and 5 screens 4 and 5 These screens lists all compo nents corresponding soft ware revision number on network Cable disconnected Verify all green LEDs Reconnect replace faulty illuminated and yellow cable LEDs are flashing Module with wrong rotary Verify rotary switch is set Remove power from switch setting correctly unit access cover and visually check rotary switch setting If incorrect set to cor rect setting See Upgrade Tempera ture Control Module Software page 56 and Upgrade FCM
69. d and the inactive ram can not be primed To exit Recirculate Mode press the Recirculate key M The display prompts the operator to confirm Select v to confirm or select to cancel See FiG 27 You must exit Recirculate Mode before depressuriz ing or initiating a crossover 30 Depressurize Function Follow the Pressure Relief Procedure page 28 Shutting off power or removing power from the sys tem will not depressurize the system When the system is pressurized the depressurize func tion relieves fluid pressure from the pump outlet to below the platen on the currently active ram However when the system is depressurized pressing the depres surize key will restore fluid pressure Depressurize System From the Ram Operation screen press the Depressur ize key The display prompts the operator to con firm Select T d to confirm depressurize or select Ma to cancel Fic 28 Depressurize Function Screen 313296J NOTE Depressurizing the active ram will depressurize both rams However if additional user supplied check valves have been added to the system only the active ram will be depressurized To depressurize both rams perform manual cross over see Manual Crossover page 29 and then press the Depressurize key Pressurize System From the Ram Operation screen press the Depressur ize key The display prompts
70. d on the active ram Tandem ram if pump is on activates the air solenoid on the inactive ram which enables you to purge air and prime the pump Pump Prime as Single ram activates air solenoid whether or not pump is on clears the Pump Not Primed deviation or alarm depending on setup selection and resets the drum volume remaining to the drum fill volume setpoint for pump being primed Press button e When prompted to prime the ram select d to prime Press button to exit Prime Mode or to reset counter to the prime time e When prompted to exit Prime Mode select to exit or to reset prime counter Recirculate Recirculate Mode pumps fluid from the drum through the pump and back into the drum on the currently active ram Set motor air regulator to 30 psi 0 2 MPa 2 1 bar before pressing Recirculate key If system is not in Recirculate Mode press button When prompted to turn recirculation on select y or Ma Adjust motor air regulator to obtain desired flow rate If system is in Recirculate Mode press button e When prompted to turn recirculation off select af or 574 14 313296J Component Identification Table 4 Display Soft Key Icons Crossover key transitions the active ram to inactive and inactive ram to active Available on Warm Melt Tandem Supply Systems only NOTE If an alarm is present on the inactive ram crossover will not be successful Manual crossover is disabled i
71. e Unexpected Contactor Cur Broken Temperature Control rent Module 3132965 Disconnected or loose wire Verify cable 15W902 from Screen See Heat Run High Power Temperature Screen page 101 Control Module is con nected correctly Verify there is 24V between both wires on 15W902 If there is not 24V replace High Power Temperature Control Module Cleared from Heat Run screen See Heat Run Screen page 101 Turn heat zone for platen off If there is still 24V across wires on 15W902 replace Temperature Con trol Module 43 Troubleshooting Troubleshooting X 1 Follow Pressure Relief Procedure page 28 AAS before disassembling any part of the warm melt mE supply system NOTE Troubleshooting covered in this manual is 2 Disconnect all power to the warm melt supply sys specific to warm melt heat functions Refer to Sup tem before repairing ply Systems Repair Parts manual and or Tandem Supply Systems Repair Parts manual for ram trou 3 Check all possible problems before disassembling bleshooting Refer to Check Mate Pump Packages any part of the warm melt supply system manual for pump troubleshooting soiion No power Customer supplied main Measure voltage across Determine cause of the circuit breaker tripped disconnect switch voltage tripped circuit breaker should measure between Then repair fault and reset 190 and 250 Vac main circuit b
72. ealg dwy 8 Joyeeig dwy g G 1 91929 i LI LLL Lic MOV 31870 eur einso ou3 313296J 68 Electrical Schematics D60 Ram B dvd 5508 A3 wg NWO 31929 S 1 9 1 peag l1 Nvo eiqeo 0 H NYO GRE 2 9PAvC 1 IHS 0 greet in i i etim ess NLY 2 dIONJTOS GION31OS jeu6is 1 v NLY 2 1 S p eueros jeuBls piousjos 1 gt 1osuag idu 3 5 2 10sues TWNOIS 9 WO gr o eoa pasnun 2 EET S 1 x 1 eiqe Jexyeeug 8 3 nol indui ALdW3 auc G au 1 Aoin a Jeniids uoisuayx3 2 1 NOILdO ALdW3 MOT WNYG HOIOVINOO Janos me A vos 2 elg gt 7 teubis jeubis 2 0 urea 2 1 0l iO pesnun W Jexeelg UOISU9 X3 age piouejos M gno G Md did
73. emove Air Motor Remove junction box For 55 gallon platen D200 and D200s supply systems Hemove two screws 61 securing junction box to air motor Remove junction box and temporarily secure to platen rod 3 2 258 aN 255 271 278 Fic 36 Remove D60 Junction Box 61 3 See Disconnect Displacement Pump 2 Check Mate Pump Packages manual LAM 96 e 90 91 To reduce the risk of serious injury or damage to equipment make sure the main disconnect is off Fic 35 Remove D200 and D200s Junction Box before continuing with this procedure 4 See Supply System repair manual for air motor removal instructions 313296J 47 Repair Install Air Motor 1 See Supply System repair manual for air motor installation instructions 2 Reinstall junction box For 55 gallon platen D200 and D200s supply sys tems Remove junction box from platen rod Rein stall junction box to air motor using move two screws 61 See FIG 35 For smaller
74. ernal power supply requirements AC power units 150 psi 1 0 MPa 10 bar 150 psi 1 0 MPa 10 bar 125 psi 0 9 MPa 9 bar See table below See Check Mate Displacement Pump manual 312375 Stainless steel polyurethane PTFE coated nitrile poly ethylene nitrile PTFE 303 sst 304 sst 316 sst 17 4PH sst Electroless nickel aramind reinforced elastomer rub ber based PSA polyurethane polyethylene nitrile zinc plated carbon steel buna 1018 carbon steel 304 sst 316 sst 17 4PH sst PTFE EPDM PTFE coated aluminum zinc plated carbon steel 316 sst EPDM aluminum zinc plated carbon steel 316 sst 158 F 70 C See NXT Air Motor manual 311238 220 250 Vac 50 60 Hz single phase 57 amps full load current Maximum Fluid Working Pressure and Flow Rate at Full Air Pressure 100 psi Maximum Air Inlet Pressure psi MPa bar Pressure psi MPa bar 23 100 0 7 7 0 2300 16 1 161 NXT2200 6200 43 4 434 Maximum Fluid Working Displacement Flow Rate gpm Ipm Pump 07 74 1 161 52 120 ED 2020 91 0 64 6 4 Weight See the identification plate ID for the weight of your supply system 106 313296J Technical Data 313296J 107 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 pu
75. eves air trapped between it and the air motor Push the valve in to shutoff The air solenoid AD the air motor valve BF and the main air slider valve BA must be open for air to flow Blowoff button BQ turns air on and off to push the platen out of an empty drum ti10438a FiG 4 Integrated Air Controls 313296J Air Line Accessories See Supply Systems Operation manual Air line drain valve Not included Air line filter removes harmful dirt and moisture from compressed air supply Not included e Second bleed type air valve isolates air line accessories and supply system for servicing Locate upstream from all other air line accessories Not included Air relief valve automatically relieves excessive pressure Not included 2 Button Interlock Air Controls D60i D200i and D200si Models Systems that have 2 Button Interlock controls have the following additional components e 2 Module See the Air Controls manual for information e Roller switch CA shuts off air supply when it contacts the bracket actuator Operator must push and hold the activation buttons simultaneously to resume ram movement Activation Buttons ti10843a1 FiG 5 2 Button Module Bracket actuator CB attaches to the platen lift rod When platen is outside of drum actuator makes contact with the roller switch CA c ti10846a Fic 6 Roller Switch and Bracket Actuator 313296J
76. f measurement for temperature Select between F and 2 1000 ET Fic 67 Advanced Setup Screen 1 98 Advanced Setup Screen 2 This screen enables users to set the pump size in cc cycle and the drum fill volume in volume units The drum fill volume is the amount of material in a new drum which is used to calculate the volume of material remaining during operation NOTE These values must be entered accurately for the volume remaining estimates on the Ram Opera tion screen to be accurate Set pump size cc cycle for each ram Check Mate Select between 60 100 200 250 and 500 Dura Flo Select between 145 180 220 290 430 580 and 1000 Set fill volume for each drum Use dig its 1 9999 Change between a Check Mate or Dura Flo pump 313296J Advanced Setup Screen 3 This screen enables users to set the date time and date format Function HE Set date format Select between MM DD YYYY and DD MM YYYY 4 Set current date Set current time xb D 11904 4 0 11 78 08 gt Fic 69 Advanced Setup Screen 3 313296J Appendix A User Interface Display Advanced Setup Screens 4 and 5 These screens display the software part number and version information for the system components Only system components that are detected via the system data bus will be displayed on these screens E C
77. g circuit board wear a grounding strap NOTE Order kit 16C027 for an upgrade token See Graco Control Architecture Module Programming manual for instructions Replace Display NOTE Order Kit 24F493 for replacement Software token 16C027 is required to install software before use NOTICE To avoid damaging circuit board wear a grounding strap 1 Disconnect power 2 Pull display 20 out of bracket 22 clips to remove it 3 Disconnect CAN cable s from display 20 4 Replace with new display Reconnect CAN cable s 5 Load the correct display software for the system Follow the steps in Upgrade Display Software on page 58 NOTE Token is not included with display and must be ordered separately 58 313296J Replace Fluid Control Module 1 Disconnect power to system 2 Remove front shroud 16 or 204 and back shroud 17 or 205 D200 Shown e J 17 205 Fic 54 Remove Shrouds 3 Disconnect all cables from FCM 36 or 220 4 Remove access door 41 or 224 5 Loosen both captive screws from FCM and pull FCM off base 33 or 219 3132965 41 07224 Repair Captive jm Screws gt 220 217 78 36
78. ge Incoming line voltage is too Measure voltage across Cleared from Heat Run high disconnect switch Voltage screen See Heat Run should measure between Screen page 101 190 and 250 Vac No Line Voltage Tripped circuit breaker Visually check circuit Cleared from Heat Run Low Line Voltage breaker for a tripped condi screen See Heat Run tion Screen page 101 GFCI has been tripped Visually check GFCI for a tripped condition Cable unplugged loose wire Check for loose or discon nected wires and plugs Cleared from Heat Run screen See Heat Run Screen page 101 High DC Voltage Faulty DC power supply Measure that DC supply output is 24V If not replace supply 42 313296J Alarms Alarm Code Alarm Problem Cause Clear Alarm Temperature Control Modules continued Low DC Voltage Module High Contactor Current Faulty DC power supply Broken Temperature Control Broken contactor Cleared from Heat Run screen See Heat Run Screen page 101 Measure that DC supply output is 24V If not replace supply If DC supply is supplying 24V when disconnected from system check which module is causing short Check this by connecting one module at a time and then measuring for 24V Cleared from Heat Run screen See Heat Run Screen page 101 Replace contactor Low Contactor Current Broken contactor Replace contactor Cleared from Heat Run Broken Temperature Control Modul
79. glass tape 4 Connect hose adapter to green receptacle on junc tion box Fic 16 Connect Hose to Junction Box 5 Securely tighten the 16 pin electrical connectors on long heated hose leads into 16 socket receptacles on the end of the hose adapter 6 Securely tighten the 8 socket electrical connectors on short heated hose leads into 8 pin receptacle located on the dispense valves Hose Care Guidelines Refer to the Hotmelt Warm Melt Heated Hose manual for details regarding hose care guidelines 313296J Installation Mechanical Setup 1 Fill displacement pump wet cup 2 8 full with Graco Throat Seal Liquid TSL 2 Turn all air regulators to their full counterclockwise position 3 Connect a 3 4 in 19 mm air line from an air source to the system air inlet Refer to the pump perfor mance curves in the Check Mate Pump Packages manual to determine your air supply flow require ments NOTE Quick disconnects restrict flow for large air motors Overview of Temperature Control Settings Temperature controls are set in Setup mode See Setup Mode Screens on page 95 for information about setting temperature controls See Run Mode Screens on page 100 for information on controlling temperatures for each zone 23 Setup Setup The pump was tested with lightweight oil which is left in the fluid passages to protect parts To avoid contaminat ing fluid with oil flush the pump with a compatible sol
80. h sensors LI Filter pressure at inlet and outlet CAN communication From Ram A to display module CAN communication A and B 15 ft 4 57 m from Ram A FCM to Ram B FCM CAN Cable 2 112337 9 112336 CAN Cable 1 FiG 7 FCM Sensor Connections 12 313296J Component Identification User Interface Fic 8 Display Module Table 3 Display Module Button Functions On Off Powers air motor solenoid ON and OFF from Ram Operation screen FIG 71 page 100 e When ON the air motor solenoid is ON and the pump of the active ram is pressurized When OFF the air motor solenoids are OFF CAUTION Turning the air motor solenoid OFF relieves pressure from the pump motor It does not depressurize the fluid pressure Follow the Pressure Relief Procedure page 28 NOTE The ram up down and blowoff air is independent of the electronic controls and can be operated anytime the main air slider valve is open and air pressure is available Powers heat ON and OFF from Heat Run screen FiG 72 page 101 e When ON the enabled heat zones are ON When OFF all heat zones are OFF Cancel Cancel a selection or number entry while in the process of entering a number or making a 52 selection Setup Toggle between run and setup screens a e Setup changes can be made while system is operating e f setup screens are password protected button toggles between run and password entry screen Opens
81. information for each ram put heat zones into Setback mode turn heaters on and off for enabled heat zones and change the individual zone temperature settings View Heat Zone Information To view heat zone information press to scroll through the Heat Run screens NOTE Must exit edit mode to scroll through the Heat Run screens Setback Mode To put heaters into setback mode for enabled heat Zones press The setpoint for each zone will be decreased by the setback amount set on Heater Sys tem Setup Screen page 95 Turn On Heaters See System Heat Up page 26 for instructions Change Zone Temperature Setting Press to access the fields to make changes Use the navigation buttons to move to the desired heat zone Enter the new temperature and press to save the change Press to exit edit mode 101 Appendix A User Interface Display Status Screen This screen displays the job totals and grand totals If there is a filter or an error issued there will be a second screen Press to scroll to through the Status screens Job total column indicates pump cycle 12345 count total for a single job Grand total column indicates pump cycle Heb count total for all jobs 1234567 Displays pump cycle count for Ram A for a single job and all jobs Displays pump cycle count for Ram B for a single job and all jobs Displays pump cycle count for entire sys tem for a single job and all jobs HeB
82. input terminals on power line filter Voltage should measure between 190 and 250 Vac Cable unplugged loose wire Check for loose or discon nected wires and plugs Circuit breaker not setfor L2 Visually check circuit and L3 breaker for proper setting of L2 and L3 Bad Measure resistance of heater s GFCI has been tripped Visually check GFCI for a tripped condition Customer supplied main circuit Measure voltage across the breaker tripped disconnect switch Voltage should measure between 190 and 275 Vac Over current Bad heaters Measure resistance of Cleared from Heat Run heater screen See Heat Run Wrong zone type Ensure zone is set for type Screen page 101 of hardware connected to it High voltage Measure voltage across the disconnect switch Voltage should measure between 190 and 275 Vac Shorted module If temperature rises for a zone that has been dis abled replace heat mod ule 40 313296J Alarms Alarm Code Alarm Problem Cause Clear Alarm Temperature Control Modules continued Low power and L3 breaker tripped Wrong zone type Unexpected Current Shorted module Invalid RTD Reading Bad RID Undercurrent Tripped circuit breaker tion Over temperature protection is Allow zone to cool down activated Cable unplugged loose wire Check for loose or discon nected wires and plugs Circuit breaker not set for
83. is function LUN Ean A T 62 System Setup 95 Appendix A User Interface Display NOTE Must exit edit mode to scroll through the heat zones Displays selected heat zone Press A1 to scroll through each heat Zone Set the temperature setpoint for each heat zone Set the number of degrees the setpoint will be decreased by when the heat zone is in setback mode Set the number of degrees the heat zone can go above the setpoint before an alarm is issued Set the number of degrees the heat zone can go above the setpoint before a devia tion is issued Select to enable the heat zone leave blank C to disable the heat zone T Shared zone Select to enable zone for both ram A and ram B i 415 OV La Ne FiG 63 Heater System Setup Screen 96 Maintenance Setup Screen The Maintenance Setup screen enables users to set maintenance intervals for rebuilding platen seals and rebuilding the pump Set the number of drums 0 9999 between platen seal maintenance Setting the num ber of pump cycles to 0 disables this func tion If using a tandem system set for each ram A rebuild platen seals error is issued when maintenance is required See Alarm Codes and Troubleshooting on page 36 Set the number of pump cycles 0 9999 between pump maintenance Setting the number of pump cycles to 0 disables this function If using a tandem system se
84. lider valve BF and the main air slider valve BA on ram s 4 Setthe ram director valve to DOWN The ram will slowly drop e Jog the director valve up and down to bleed air from ram cylinders 6 Unlock the dispense valve trigger 7 Hold a metal part of the dispense valve firmly to the side of a grounded metal pail and trigger the dis pense valve to relieve pressure 8 Lock the dispense valve trigger 9 Open all fluid drain valves on ram s Have a con tainer ready to catch the drainage Leave fluid drain valves open until ready to dispense again 28 If you suspect that the dispense tip nozzle or hose is completely clogged or that pressure has not been fully relieved after following the steps above very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually then loosen completely Now clear the tip nozzle or hose Trigger Lock Always engage the trigger lock when you stop dispens ing to prevent the gun from being triggered accidentally by hand or if dropped or bumped Start and Adjust Ram 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 To start and adjust the ram s follow the Load Material procedure on page 25 Start and Adjust Pump NOTE Follow steps below for both pumps if using a
85. lo sure 13 or 14 turn the main disconnect on the electri cal control panel door to the OFF position to disconnect power Ls Power is still connected to the power line filter 459 even after the main disconnect is open Avoid con tact with the power line filter Replace Low Power Temperature Control Module s 1 Open enclosure door 402 Disconnect the follow ing cables from low power TCM 408 e incoming power supply cable 430 outbound power supply cable see 49 e HTD cable 459 Captive Screw 430 408 Captive Screw 411 428 431 429 432 Fic 48 Internal View of Electrical Enclosure 313296J Repair 408 Outbound Power RTD 411 Outbound Power RTD Fic 49 Back View of Electrical Enclosure 2 Loosen both captive screws 409 holding low power TCM 408 to base 407 remove low power TOM See FiG 48 3 Follow steps in reverse order to install new low power TCM 4 Upload the correct TCM software for the system See Upgrade Temperature Control Module Soft ware page 56 for instructions 55 Repair Replace Base 1 Remove low power TCM See Replace Low
86. low empty BRACKET mounting bottom for 3 in for 6 5 in Ram BRACKET mounting for 3 in Ram for 6 5 in ENCLOSURE cube door CABLE track CONDUCTOR block heater HEATER pump 725 watt SUPPORT sensor SENSOR RTD shielded BOLT eye 3 8 14 x 6 HEATER coil Qty 1 1 1 na 81 Parts Ref Part 4999 50 51 151 706 52 15W707 53 54 56 117026 57 116343 58 100014 100058 59 100015 609 100133 61 C19837 620 63 64 176692 65 100307 66 C34132 67 15Y051 68 123507 69 16H441 71 120223 72 100020 73 100179 74 111218 75 76 121255 78 16 941 79 C31012 80 110637 814 119958 82 110170 839 849 859 86 159075 07A 15H668 89 90 91 92 24B810 93 113970 94 C19208 95 102794 97 111640 98 100166 99 16A355 100 16A356 101A 196548 102 16A574 82 Description COVER platen front assy BRACKET mounting top in 6 5 in Ram ENCLOSURE pump front ENCLOSURE pump rear CONDUIT 12 9 mm COUPLER conduit SCREW shcs m5 x 12 SCREW ground SCREW cap hex hd for 3 in ram for 6 5 in ram NUT hex mscr WASHER flat SCREW cap hex hd STUD 3 8 16 x 1 25 PLUG finishing 13 16 in nickel plated WASHER flat NUT hex HANGER CABLE M12 WIRE grounding WIRE grounding FASTENER platen cover SCREW machine flat hd WAS
87. m can cause electric shock e Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source e All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations 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 e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area 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 BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns Do not touch hot fluid or equipment e Wait until equipment fluid has cooled completely SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pie
88. m on Status screen 1 There is a Drum Empty alarm Replace empty drum with full drum to clear 36 3132965 Alarms Alarm Code Alarm Problem Cause Clear Alarm Fluid Control Module continued DA1X Pump Runaway A Pump is running faster than Correct runaway condition Cleared from Ram Alarm set runaway limit due to and clear alarm screen See Appendix A DA2X Pump Runaway User Interface Display Increased air pressure page 93 Increased fluid output Exhausted fluid supply Open fitting hose drain or bleed valve A Drum Empty Drum empty sensor has been Replace empty drum with Alarm automatically activated full drum to clear cleared by solution L12X B Drum Empty DB1X Not Primed The pump is not primed Set ram to Prime mode to Cleared from Ram Alarm automatically clear alarm screen or Ram Operation DB2X B Not Primed or manually clear alarm screen See Appendix A from Ram Alarm screen User Interface Display page 93 WJ1X Air Solenoid Discon Solenoid unplugged Check that solenoid cable Alarm automatically nected is connected cleared by solution WJ2X B Air Solenoid Discon Damaged solenoid wires Inspect solenoid wires for Alarm automatically cleared by solution Cleared from Ram Alarm screen See Appendix A DK1X Air Motor Sensor Error System has seen multiple up See air motor manual strokes without a down stroke DK2X B Air Motor
89. male 1 TERMINAL bus bar L3 257291 1 only A Heplacement Danger and Warning labels tags and cards are available at no cost B Replacement electronic components do not have Warm Melt specific software installed Therefore use software upgrade token 16C027 to install soft ware before use 91 Accessories Accessories Platen Cover 255691 Two platen covers See manual 406681 for more infor mation for D200 platens Two Zone Expansion Kit 24C223 For adding two zones of heat to a Warm Melt Supply oystem The two extra zones are controlled through the Warm Melt display Two Zone Accessory Kit 24C222 Controls two zones of heat up to 212 F 100 C Four Zone Accessory Kit 24C526 Controls four zones of heat up to 212 F 100 C Light Tower Accessory Kit 255468 For use with Warm Melt or Tandem Supply Systems Low and Empty Sensor Kit 24C530 Indicates when the drum is low and empty Includes two sensors one to be used as a low sensor and one to be used as an empty sensor For use with Warm Melt to add a low sensor Ambient and Tandem supply sys tems 92 313296J Appendix A User Interface Display Appendix A User Interface Display Display Overview The user interface display is divided into two main func tions Setup mode and Run mode Setup Mode Functions The setup mode functions enable users to set and change the password configure system parameters set heat zone parame
90. mended by the fluid and solvent manufacturer e Gloves Hearing protection 6 3132965 Overview Overview System Description Table 1 Electrical Requirements Warm melt supply systems are used for melting and AC Panel Full Load pumping warm melt adhesives and high viscosity seal Voltage Amps ants 240 50 60 The system consists of an air powered ram that drives a Check Mate pump and a heated platen into a drum of Heat Control Zone Selection material The heated platen heats the material and the Warm melt supply systems have four heat zones see pump removes it from the drum The material is then Fic 1 pushed through a supply hose to the applicator e Zones 1 and 2 are always used for the heated All features of the warm melt supply system are con platen and the heated pump respectively trolled by Graco Control Architecture components Fluid Control Module FCM Temperature Control Modules TCM and the display module The FCM controls the motor and pump and the TCMs control the heaters The display module provides the user interface for the entire warm melt supply system Zones 3 and 4 are used for the heated hose and valve These zones are rated for 1920 watts at 240 volts Heated hoses have a 16 pin connector on the inlet end cable and an 8 pin connector on the outlet end cable All heated valves manifolds and heaters are equipped Power Requirements with an 8 pin matching connector Accessory c
91. n of the drum relative to the platen See Load Material on page 25 31 Maintenance Shutdown Follow the procedure below for normal system shut down such as at the end of the work day NOTICE Turning the system OFF relieves pressure from the pump motor however it does not depressurize the fluid pressure Follow the Pressure Relief Procedure page 28 NOTE The ram up down and blowoff air is indepen dent of the electronic controls and can be operated anytime the main air slider valve is open and air pressure is available 1 Press while in the Ram Operation screen to turn off the air motor Select nf to confirm 2 Press while in the Heater screen to turn off the heaters Select to confirm 3 Follow the Pressure Relief Procedure page 28 Maintenance To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pres sure Relief procedure 211116 pee fe Many warm melt materials tend to expand when heat ing and may cause a heated hose to burst Avoid the potential of bursting a hose by opening the dispense valve during system heat up and lock the dispense valve trigger open every time you shut the system down 32 Replace Throat Seals Quick Coupler Remove wet cup from displacement pump while attached to the ram to replace throat seals 1 Ensure displacement pump is at bottom
92. n single ram operation Press button e When prompted to initiate a crossover select or 4 Setback transitions the heaters into setback mode The setpoint for each zone will be decreased by the setback amount See Heater System Setup Screen page 95 and Heat Run Screen page 101 In screens that have editable fields press to access the fields and make changes See Appendix A User Interface Display page 93 for more information NOTICE To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails 313296J 15 Component Identification User Interface Display NOTE For details regarding the user interface dis play see Appendix A User Interface Display page 93 Display Screen Components The following figure calls out the navigational status and general informational components of each display screen Current Date and Time Navigation Status Mode Function Display Displays soft keys that are active for particular screen Soft Keys Fic 9 Display Screen Components 16 313296J Installation Accessories are available from Graco Make certain all accessories are adequately sized and pressure rated to meet the system s requirements Component Identification illustrations are only a guide for selecting and installing system components and accessories Contact your Graco distributor for assis tance in designing
93. nd help pre Diag nose Alarms vent system shutdown or application errors If an alarm occurs operation may stop and the following occurs See Alarm Codes and Troubleshooting page 36 for causes and solutions to each alarm code e Light tower indication changes if equipped e Status bar on the display shows the alarm descrip Clear Alarms Alarms are cleared by the solution s listed in the follow ing table or from the screen in which they appear Refer to Alarm Codes and Troubleshooting page 36 for details Alarm Codes and Troubleshooting Alarm Code Alarm Problem Cause Clear Alarm Fluid Control Module A Communication Error cannot communicate with Verify that power is sup Alarm automatically A Not Found FCM A plied cleared by solution Check that CAN cables are connected Verify that selector switch is set correctly FCM A Communication Error Ram cannot communicate with Verify that power is sup Alarm automatically B Not Found FCM B plied cleared by solution Check that CAN cables are connected Verify that selector switch is set correctly Replace FCM B Crossover Error Ram A Inactive ram has a Not Primed Set inactive ram to Prime Cleared from Ram Alarm alarm mode to automatically clear screen See Appendix A Crossover Error Ram B alarm User Interface Display There is a Runaway alarm Correct runaway condition Page 93 and clear alar
94. nt trigger the valve to the label This opening is suitable for a 1 in npt conduit or strain relief fitting supplied Connect Power Source b Connect a power protective ground to the cen The electrical enclosure comes already attached and ter post on the line end of the power line filter wired to the ram however before the supply system becomes functional you must connect the electrical NOTE Install safety insulation boots supplied on enclosure to a power source the power line Install 1 4 in ring lugs user sup plied on the power line and power protective ground line prior to connecting to the power line fil ter posts Have a qualified electrician connect power according to national state and local safety and fire codes NOTE Required voltage and amperage is noted on the electrical enclosure label Also see Table 1 Before running power to the unit make sure the plant electrical service meets the supply system s electrical requirements 18 313296J Install Adjust Drum Low or Empty Sensor 1 Position ram at desired level low or empty NOTE Follow Steps 2 through 4 only if installing the low sensor 2 Attach the low sensor to the existing sensor bracket EA above the existing empty sensor EE D200 Shown vm 28 Y LA FiG 11 Low or Empty Sensor Kit 3 Replace the existing cable
95. ocks with nuts and washers Label platen heater wires A and B as shown on page 64 Reroute platen heater wires and platen RTD sensor through the conduit to the junction box Reconnect the four wires to the appropriate terminal block A and B Reconnect the platen RTD sensor Reinstall junction box cover Secure with screws and tighten strain relief nut Reconnect ground wire and install platen covers Secure platen covers with fasteners Torque platen cover fasteners to 60 in lbs 10 in lbs 6 8 1 1 Nem Reconnect displacement pump using screws and clamps 20 30 and 60 Liter Platen Heater 1 2 Disconnect pump from platen Remove platen heater block 320 a Remove screws 278 from junction box cover 271 and remove junction box cover See page 86 b Remove strain relief nut 265 from junction box to allow space for wires See page 86 c Remove air fitting assembly from platen d Remove nuts 309 from the heat shield guard 324 e Remove screws 323 from upper heater plate 320 Remove upper heater plate and ground wire 313296J Repair 324 323 320 319 318 309 Air Fitting Assembly ti17717b Fic 46 Replace Platen Heaters 3 Remove platen heater 319 a Disconnect two platen heater wires labeled A and B in the terminal box See D60 Junction Box Schematic page 71 b Remove platen and heater 319 4 Install new platen heater 319 to
96. odels D200 6 5 in Ram WMxxxx Models D200 6 5 in Ram A TWxxxx Models D200 6 5 in Ram B TWxxxx Models Parts Qty 77 Parts Warm Melt Kits for D200 Systems Kit 240012 CST 24 675 SST with Display for D200 and D200i Systems Kit 24D015 CST 24K678 SST with Display for D200s and D200si Systems Kit 24D013 CST 24K676 SST with Display for Ram A of Tandem D200 and D200i Systems Kit 24D014 CST 24K677 SST without Display for Ram B of Tandem D200 and D200i Systems Kit 24D016 CST 24K679 SST with Display for Ram A of Tandem D200s and D200si Systems Kit 24D017 CST 24K680 SST without Display for Ram B of Tandem D200s and D200si Systems Kit 24D016 Shown Wow amp 76 17 r wm 2179 313296 5a 78 313296J Parts 42 88 N c E c 83 84 85 1 119984 79 313296J Parts 45 79 46 107 x2 108 x2 110 Torque to 60 10 in Ibs 6 8 1 1 Nem 49 43 107 108 109 46 56 82 80 68 69 97 98 103a 103b 57 99 ti17719a 48 57 97 100 102 ti17718a 3132965 D20
97. of stroke 2 Follow the Pressure Relief Procedure on page 28 3 Remove Quick Coupler Remove clip GC and slide coupling cover GB up to remove coupling GA 29 Remove Quick Coupler 4 Lift air motor rod to bring rod to top of stroke 5 Remove wet cup and packing cartridge according to instructions in displacement pump manual s 313296J Maintenance Platen Maintenance Remove and Reinstall Platen Wipers Refer to Supply Units Repair Parts manual for instruc tions 2116 If the platen does not come out of the pail easily when 70 the pump is being raised the air assist tube or check valve may be plugged A plugged valve prevents air from reaching the underside of the plate to assist in rais 49 ing it from the pail LJ 1 Turn off main disconnect 2 Helieve pressure and disassemble air assist valve Stick Refer to Supply Systems Repair Parts manual 3 Clear assist tube in platen Clean all parts of valve and reassemble Refer to Supply Systems Repair Parts manual 4 Remove bleed stick from platen Push bleed stick T through bleed relieve port T to remove material residue See FIG 30 r wm2179 313296 6a 5 Remove platen covers See 30 a Remove platen cover fasteners 70 or nuts 309 309 309 a b For 55 gallon platen D200 in and 02005 6 5 in suppl
98. one chemical are removed before introduc ing a second chemical 3 Select a container of material that can eliminate the factory test oil from the system If necessary check with Graco or the material supplier for a recom mended solvent 4 Before purging ensure the entire system and waste container are properly grounded NOTE Remove any dispense valve orifices before purging Reinstall after purging has been completed 5 Purge the material through the system for approxi mately 1 to 2 minutes 6 Remove the container if purge material was used Set Values on Display Module Set desired values on display module Setup menus See Setup Mode Screens page 95 313296J Setup Load Material D200 Shown Hx 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 NOTICE Do not use a drum of material that has been dented or otherwise damaged damage to the platen wiper can result NOTE Before loading material ensure that there is a minimum overhead clearance of 105 in 267 cm and all air regulators are backed off to their full counterclockwise position 8 Set the director valve BC to DOWN and lower the ram until fluid appears at the top of the platen bleed port J
99. ons pass word system setup heat zone setup maintenance setup hardware setup and advanced setup Password Screen While in Run mode press the Setup 2 button If the password is not set to 0000 the Password screen will appear Enter the password to continue to Setup mode NOTE Upon the first system startup the System Setup screen will display Otherwise the last setup screen viewed will display Set Password To set the password press to enter the screen Press to select digit to change Press to set value for each digit Press again to enter the password 0 22 00 2321 FiG 61 Password Screen Heater System Setup Screen This screen enables users to set parameters for each heat zone Press to scroll through each heat zone When the desired heat zone displays press to access the fields to make changes Press to exit edit mode 313296J Appendix A User Interface Display System Setup The System Setup screen enables users to configure system settings for the ram s Press to access the fields and make changes Press to exit edit mode Select tandem operation ram A only oper ation or ram B only operation Select if a Not Primed event will issue an A alarm or deviation Set number of minutes 1 9 for priming Set pump cycles per minute that will issue a pump runaway alarm Set between 0 and 99 default setting is 60 cycles 00 setting disables th
100. ontroller software part number and ver sion Display software part number and version Fieldbus gateway software part number T and version Temperature controller software part num 0000 ber and version Den en SMETI SMETI oao 1 04 0101 Fic 70 Advanced Setup Screens 4 and 5 99 Appendix A User Interface Display Run Mode Screens Run mode screens are divided into six sections ram operation heat zone operation current system status preventative maintenance schedule current alarms and error reports The system starts in Run mode If the sys tem is in Setup mode press 2 to enter Run mode Ram Operation Screen The Ram Operation screen displays which ram A or B is active and how much volume remains in each drum This screen also displays the flow rate of the active ram When the fluid line is shown filled the system is on Depending on the current system status users can per form the following procedures from the Ram Operation Screen e turn the air motor on and off e Qdepressurize and pressurize the system e recirculate fluid within the active ram prime the pump s perform a manual crossover on tandem sys tems 100 See Operation page 28 for instructions on all of these procedures Fluid line shown filled when system is Run Mode Active ram is Flow highlighted rate 07 15209 DESDE ik Vol ume Remai
101. placement pump Service displacement pump as needed See Check Mate Displacement Pump manual for instructions 313296J D60 Supply System 1 Disconnect air hose and ground wire from air motor 2 See Disconnect Displacement Pump in Check Mate Pump Packages manual 3 Follow steps 1 4 of Replace Platen Heaters and Sensor section page 52 to remove pump heater shrouds 233 234 pump heaters 227 and RTD sensor 229 zZ Ate 5 227 JINE D 5 gt 229 wei 227 5 4 233 CL Q Fic 39 D60 Pump Heater Shrouds 4 Seeto Disconnect Pump from Platen on page 50 to disconnect displacement pump from platen 5 Raise ram assembly to lift air motor away from dis placement pump 6 Remove displacement pump and service as needed See Check Mate Displacement Pump manual 313296J Repair Install Displacement Pump D200 and D200s Supply Systems 1 Install displacement pump on platen See Connect Pump to Platen page 51 Lower air motor Use wrench on nut EA to lower air motor Reinstall pump heater shrouds 51 52 Secure with screws 80 See Reconnect Displacement Pump in Check Mate Pump Packages manual Reconnect air hose and ground wire to air motor Fic 40 Reconnect Air Hose and Ground Wire D60 Supply System 1 2 Raise ram to install displacement pump to platen Connect displacement pump to platen See Con nec
102. rce 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 gun at anyone or at any part of the body Do not put your hand over the dispense outlet Do not stop or deflect leaks with your hand body glove or rag Follow Pressure Relief Procedure in this manual when you stop dispensing and before cleaning checking or servicing equipment 3132965 5 Warnings MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply 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 TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if solashed in the eyes or on skin inhaled or swallowed e Read MSDS s 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 impervious gloves when spraying or cleaning equipment e If this equipment i
103. rchaser 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 of 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
104. reaker GFCI has been tripped Visually check GFCI fora Determine fault that caused tripped condition GFCI to trip Then repair fault and reset GFCI No graphics on screen No graphics are shown on Verify green LED on bottom green LED is not illumi display screen of display is illuminated nated 1 Checkfor DC power on the cable at the display Replace faulty cable component 2 24 Vdc faulty displa cable end P module If green LED is illuminated check red LED If red LED is illuminated replace dis play module Backlight does not power Can see display but back Replace display module up light is not illuminated when a button is pressed 44 313296J Troubleshooting wee VeWkaion No heat Tripped circuit breaker Visually check circuit Determine cause of tripped breaker for a tripped condi circuit breaker Then repair tion fault and reset main circuit breaker Low power Measure voltage across If voltage is lower than terminals 2T1 and 4T2 on expected use electrical main disconnect Voltage schematic to locate should measure between faulty wiring or connec 190 and 275 Vac tion Have a qualified electri cian service electrical components Visually check GFCl fora Determine fault that caused tripped condition GFCI to trip Repair fault and reset GFCI Incorrect temperature set Verify zone has a corre
105. ro vides Run Mode status screens Setup screens and control keys See FIG 8 page 13 Fluid control module See FIG 7 page 12 Integrated air controls J See FIG 4 Air motor solenoid AD Solenoid is on when the selected ram is on and in Run Mode Recirculate Mode or Prime Mode Solenoid is off when system is shut off or when in Depressurize Mode or the ram is in an Inactive Ready Mode The solenoid LED will illuminate when the solenoid is on Depressurize recirculate fluid valve Depressurizes system when Depressurize Mode is active Recircu lates fluid when Recirculate Mode is active To depressurize the system press the Depressurize key on the display module and select T d 0 when asked if you want to depressurize the system Follow the Pressure Relief Procedure on page 28 Shutting off power or removing power from the sys tem will not depressurize the system 10 Integrated Air Controls D60 D200 and D200s Models The integrated air controls include Main air slider valve BA turns air on and off to the system When closed the valve relieves pres sure downstream Ram air regulator BB controls ram up and down pressure and blowoff pressure Ram director valve BC controls ram direction Exhaust port with muffler BD Air motor regulator BE Controls air pressure to motor Air motor slider valve BF turns air on and off to the air motor When closed the valve reli
106. rranty 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 English MM 313296 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2009 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised January 2015
107. rts included in Pump Heater Kit 24C495 purchase separately Parts included in Stainless Steel Pump Heater Kit 24K669 purchase separately Parts only available in Display Mounting Kit 24C653 purchase separately Parts only available in Cover Connector Kit 256883 purchase separately Replacement electronic components do not have Warm Melt specific software installed Therefore use software upgrade token 16C027 to install soft ware before use 87 Parts Heated Platens 20L 30L and 60L Platen 24D066 20L Shown 327 395 2 8 325 326 UT MT gi 39 A A 324 323 A 311 320 319 318 niin ud 301 a oN 333 308 3 334 309 N A 336 328 329 330 313 A 303 304 305 ti17717b 302 A Torque to 45 5 in Ibs 5 1 0 6 Nem A Apply sealant to all non swiveling pipe threads A Add lubricant to threads A Ground RTD sleeve to screw 332 88 313296J Parts Parts Used on all Heated Platens Ref Part Description Qty Ref Part Description Qty 322 16D383 SENSOR RTD 1k ohm 1 1 BASE ol 1 shielded sl 0 1 323 NUT barrel binding screw 4 306 121829 O RING 1 324 GUARD heat shield 1 309 NUT keps hex hd 12 or 20 2 COUFLER conduit 311 257697 HANDLE bleed sst assy 1 326 CONDUIT ID 12 9mm 36 312 109482 O RING 1 327 189930 LABEL caution 1 313 C20350 ELBOW 90 deg 1 328 38163 WASHER lock external 1 317 GASKET heat
108. s used with isocyanate material see additional information on isocyanates in Iso cyanate Conditions Section of this manual EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure in this manual 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 modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recom
109. t Pump to Platen page 51 Reinstall pump heater shrouds 233 234 Secure with screws 257 See Reconnect Displacement Pump in Check Mate Pump Packages manual Reconnect air hose and ground wire to air motor 49 Repair Disconnect Pump from Platen 20 30 and 60 Liter Platens 1 Disconnect displacement pump from air motor See Check Mate Pump Packages manual 2 Raise air motor See Remove Displacement The pump is mounted to the platens by mounting Kit Pump page 48 255392 3 Remove screws 308 from platen 55 Gallon Platen y 1 Disconnect displacement pump from air motor See 2 Check Mate Pump Packages manual 7 UD gt 2 Haise air motor See Remove Displacement Pump page 48 8 3 Remove four screws 103a and four clamps 103b 1222 103a ES LE gt 103b 308 Fic 42 20 30 60 Liter Mounting 4 Use two people to carefully lift pump from platen If using a pump with an intake adapter remove screws adapter and o rings from pump inlet 5 Inspect o ring for damage Replace o ring if neces sary 41 55 Gallon Mounting Kit 4 Use two people to carefully lift pump from platen 5 Inspect o ring 103c for damage Replace o ring if necessary 50 3132965 Repair Connect Pump to Platen Replace Pump Heaters
110. t for each pump A rebuild pump error is issued when maintenance is required See Alarm Codes and Troubleshooting on page 36 6 20 09 15 02 TER HATIA 9C H coro 3800 Fic 64 Maintenance Setup 313296J Appendix A User Interface Display Hardware Setup Screens Monitor the filter pressure readings through the normal range of flow with a clean filter to establish the initial limit The Hardware Setup screens enable users to specify if settings specific hardware is installed on the system and to adjust hardware settings Press to scroll JE 25 n8 15 11 EC Tan through the Hardware Setup screens Once in the desired Hardware Setup screen press to access p screens P the fields to make changes Press to exit edit 2000 psi mode NOTE Must exit edit mode to scroll through the Hardware Setup screens 65 Hardware Setup Screen 1 Filter Hardware Setup Screen 1 This screen enables users to specify if a fluid filter moni Hardware Setup Screen 2 tor is installed and set the high and low limits for the pressure drop across the filter This screen enables users to specify if a fluid solenoid is installed and if a drum low sensor is installed The fluid solenoid controls the depressurize recirculate valve Select if fluid solenoid is installed on sys raises above the high limit Select to tem Set for and B rams disable
111. ters schedule maintenance parameters configure system hardware settings set and change display units and format for all other screens e set pump size and drum fill volume e view software information for each system component Run Mode Functions The run mode functions enable users to e view current flow rate and drum volume e view temperature for heat zones view system job totals and grand totals and reset totals view current pressures view and reset maintenance counters view and clear individual alarms and view the alarm log 313296J Display Details Power Up Screen The following screen appears when the display module is powered up It remains on while the display module runs through initialization and establishes communica tion with other components in the system 8 GRACO FiG 59 Power Up Screen Menu Bar The menu bar appears at the top of the screen and consists of the following components 5 1 18 09 16 401494 Fic 60 Menu Bar Date and Time The date and time are always displayed in one of the fol lowing formats The time is always displayed as a 24 hour clock e DD MM YY HH MM e MM DD YY HH MM Navigation The navigation section which is to the right of the date and time indicates the active screen with the center highlighted icon The left and right arrows indicate there are more screens that can be accessed within a mode
112. tion regarding alarms See Alarms on page 36 Crossover Error A crossover to a pump with an error was attempted Pump Runaway Pump is running faster than the runaway limit Pump Not Primed A new drum has not been primed Air Motor Sensor Error Air motor sensor detects a fault in the pump motion Pump Diving Pump leak or ram air pressure is too low Drum Empty Drum for ram A or ram B is empty Fic 75 Ram Alarm Screen To clear an alarm press to access the fields navi gate to the alarm icon and press m When prompted press d to confirm Press to exit edit mode 313296J Appendix A User Interface Display Report Screens The five Report screens display a chronological list of the most recent 20 errors See Alarm Codes and Trou bleshooting page 36 for details regarding each alarm code Chronological order of errors as they occur Date when error occurred Time when error occurred Error code Press to scroll through the five report SCreens 17 15 09 08 514 3 Bl mu d a 1 7 15 08 08 49 TS87 2 0771409 16 26 3 07 14 09 1523 4 07 1409 16 21 DAW Fic 76 Report Screen 103 D D200 Models ERST NI 4 m g NN
113. tivated full drum to clear L22X B Drum Low Deviation WK1X A Fluid Solenoid Discon Solenoid unplugged Check that solenoid cable Deviation automatically nected Deviation is connected cleared by solution WKOX B Fluid Solenoid Discon Damaged solenoid wires Inspect solenoid cable for on damage nected Deviation ML1X Rebuild Platen Seals Counter has reached pro Perform platen mainte Cleared from Maintenance grammed platen maintenance nance see Supply Sys screen See Appendix A ML2X Deviation automatically cleared by solution B Rebuild Platen Seals interval tems Repair Parts manual User Interface Display page 93 MA1X Rebuild Pump Counter has reached pro Perform pump mainte Cleared from Maintenance grammed pump maintenance nance See Check Mate screen See Appendix A MA2X Rebuild Pump interval Displacement Pump man User Interface Display ual page 93 38 3132965 Alarms Alarm Code Alarm Problem Cause Clear Alarm Fluid Control Module continued DD1X A Pump Diving Pump leak Worn valve or packings Cleared from Ram Alarm See Check Mate Displace screen See Appendix A ment Pump manual User Interface Display Ram air pressure set too low Increase air pressure to page 93 ram until diving stops Material flow rate exceeds Decrease pump air pres ability of ram to feed pump sure to slow cycle rate Decrease pressure until diving stops DD2X
114. y systems Remove both platen covers 323 49 and ground wire from platen 320 For smaller platens D60 3 in supply systems 319 Disconnect pump for the platen see Discon Bleed nect Pump from Platen page 50 Remove Stick screws 323 from upper heater plate 320 Remove upper heater plate 6 Remove any excess fluid Use a soft wire brush on T heater coils 48 or heater 319 See FIG 30 7 Inspect platen heater blocks 43 or 320 or heater 48 or 319 for burn or melt spots Replace platen a ET heater blocks or heater if necessary See FIG 30 CF 8 Check for loose connections and damaged wires 30 Remove Platen Covers and Heaters 9 Follow steps in reverse order to reassemble platen NOTE Torque platen cover fasteners 70 to 60 10 in Ibs 6 8 1 1 Nem for 55 gallon platen Torque nuts 309 to 45 5 in Ibs 5 1 0 6 Nem for smaller platens 3132965 33 Maintenance Electrical Enclosure 1 Turn the main disconnect on the electrical control panel door to the OFF position to disconnect power aA Power is still connected to the power line filter 459 even after the main disconnect is open Avoid con tact with the power line filter 2 Open door of electrical enclosure 459

Graco 313296J User's Manual

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