Graco 313296F Warm Melt Supply Systems Instructions


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Graco 313296F Warm Melt Supply Systems Instructions | Manualzz

Instructions - Parts

Warm Melt Supply

Systems

313296F

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

D200S 6.5 inch dual post

200 liter (55 gallon)

125 psi (0.9 MPa, 9 bar) Maximum Air Inlet Pressure

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 4 for model information.

US Patent Pending

The Graco Control Architecture Electric Components are listed in Intertek’s Directory of Listed Products.

D200s (WM2179) Shown

2

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

System Description . . . . . . . . . . . . . . . . . . . . . . . . . 7

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . 7

Heat Control Zone Selection . . . . . . . . . . . . . . . . . . 7

Component Identification . . . . . . . . . . . . . . . . . . . . . . 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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Location Requirements . . . . . . . . . . . . . . . . . . . . . 17

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Set Values on Display Module . . . . . . . . . . . . . . . . 24

Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

System Heat Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 28

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Start and Adjust Ram . . . . . . . . . . . . . . . . . . . . . . . 28

Start and Adjust Pump . . . . . . . . . . . . . . . . . . . . . . 28

Automatic Crossover . . . . . . . . . . . . . . . . . . . . . . . 29

Manual Crossover . . . . . . . . . . . . . . . . . . . . . . . . . 29

Recirculate Function . . . . . . . . . . . . . . . . . . . . . . . 30

Depressurize Function . . . . . . . . . . . . . . . . . . . . . . 30

Change Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Replace Throat Seals . . . . . . . . . . . . . . . . . . . . . . 33

Platen Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 34

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . 35

Pump Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Diagnose Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Clear Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Alarm Codes and Troubleshooting . . . . . . . . . . . . 37

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 48

Disconnect Pump from Platen . . . . . . . . . . . . . . . . 50

Connect Pump to Platen . . . . . . . . . . . . . . . . . . . . 51

Replace Pump Heaters . . . . . . . . . . . . . . . . . . . . . 51

Replace Platen Heaters and Sensor . . . . . . . . . . . 52

Replace Platen Wipers . . . . . . . . . . . . . . . . . . . . . 54

Replace Ram Piston Rod Seals . . . . . . . . . . . . . . 54

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . 55

Display/User Interface . . . . . . . . . . . . . . . . . . . . . . 58

Replace Fluid Control Module . . . . . . . . . . . . . . . . 59

Replace Cable Track . . . . . . . . . . . . . . . . . . . . . . . 60

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . 61

Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 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

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Warm Melt Kits for D200 Systems . . . . . . . . . . . . . 76

Warm Melt Kits for D60 Systems . . . . . . . . . . . . . . 81

Electrical Enclosure Parts . . . . . . . . . . . . . . . . . . . 88

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Appendix A - User Interface Display . . . . . . . . . . . . 91

Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Display Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Setup Mode Screens . . . . . . . . . . . . . . . . . . . . . . . 93

Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . 98

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

D200 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

D60 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . 106

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . 106

313296F

Related Manuals

Manuals are available at www.graco.com.

Component Manuals in U.S. English:

Manual Description

313528 Tandem Supply Systems Operation

313529 Tandem Supply Systems Repair-Parts

313526 Supply Systems Operation

313527 Supply Systems Repair-Parts

312375

Check-Mate

®

Displacement Pumps

Instructions-Parts

Check-Mate

®

Pump Packages

Instruction-Parts 312376

312468

200 cc Check-Mate Displacement Pump

Repair Parts

311238 NXT

Air Motor Instructions-Parts

312374 Air Controls Instructions-Parts

3A0099

3A0100

Two-Zone Enclosure Expansion Kit

Instructions-Parts

Two-Zone and Four-Zone Enclosure

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

312396

Hotmelt/Warm Melt Heated Fluid Regulator Instructions-Parts

307517 Mastic Fluid Regulator Instructions-Parts

309133

309181

311209

310538

309376

312864

313138

Pressure Compensating Valve

Instructions-Parts

Heated Header and Manifold

Instructions-Parts

Hot Melt Dispense Guns

Instructions-Parts

Therm-O-Flow

®

Automatic Dispense

Valves Instructions-Parts

EnDure

Automatic Dispense Valves

Instructions-Parts

Communications Gateway Module

Instructions-Parts

Supply System Communications Gateway

Module Installation Kit Instructions-Parts

406681 Platen Cover Kit Instructions

313296F

Related Manuals

3

4

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.

ID

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.

TI11157A

WM

First and

Second Digit

29

Third and

Fourth Digit

7 9

TW

(Warm Melt

Tandem

Supply

System)

Pump Code

4

Y 3 in.

Fifth Digit

Ram Options

Size Style

3 in.

D60

D60i

DataTrak

Voltage Air Controls no volt

WM

(Warm Melt

Single Supply

System)

5 3 in.

D200 no volt

6 3 in D200i no volt

(See Table 1 for 2-digit

Pump Code)

7 6.5 in. D200s no volt

8 6.5 in. D200si no volt no volt

INT F

INT H

2-Button

Interlock L

INT R

2-Button

Interlock U

2-Button

Interlock Y

8

9

Sixth Digit

Platen and Seal Options

Platen

Size

Platen

Style

20 L

(5 Gal)

20 L

(5 Gal)

30 L

(8 Gal)

30 L

(8 Gal)

F, SW

F, DW

F, SW

F, DW

60 L

(16 Gal) F, SW

60 L

(16 Gal) F, DW

Platen

Material

SST

CS

SST

CS

SST

200 L

(55 Gal)

200 L

(55 Gal)

DR

DR

CS

PTFE coated

AL

AL

Seal

Material

PTFE coated

Polyurethane

PTFE coated

Polyurethane

PTFE coated

Polyurethane

EPDM

EPDM

Key:

D = Dual post ram i = 2-Button interlock s = 6.5 in. ram

INT = Integrated air controls

F = Flat

SW = Single wiper

DW = Dual wiper

DR = Dual o-ring

Table 1: Check-Mate Pump Identification Code/Part

Pump

Code

Pump Part No. (see manual 312376)

Pump

Code

Pump Part No. (see manual 312376)

NXT 2200/CM 200

21 P23LCS

22

26

P23LCM

P23LSM

NXT 3400/CM 200

29

2A

2G

P36LCS

P36LCM

P36LSM

NXT 6500/CM 200

2L P68LCS

2M

2U

P68LCM

P68LSM

313296F

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• 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:

• Use equipment only in well ventilated area.

• 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.

• Wait until equipment/fluid has cooled completely.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point 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.

313296F 5

Warnings

WARNING

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• 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.

• 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 splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

• If this equipment is used with isocyanate material, see additional information on isocyanates in Isocyanate 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 manufacturer’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:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

6 313296F

Overview

Overview

System Description

Warm melt supply systems are used for melting and pumping warm melt adhesives and high viscosity sealants.

The system consists of an air-powered ram that drives a

Check-Mate pump and a heated platen into a drum of material. The heated platen heats the material and the pump removes it from the drum. The material is then pushed through a supply hose to the applicator.

All features of the warm melt supply system are controlled 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.

Power Requirements

A 30A (minimum) - 60A (maximum) circuit breaker (not provided) must be installed on the incoming power sup-

ply. See Table 1, and Technical Data, page 104, for

more information regarding electrical requirements.

Table 1: Electrical Requirements

AC Panel

Voltage

240

HZ

50/60

Phase

1

Full Load

Amps

57.0

Heat Control Zone Selection

Warm melt supply systems have four heat zones (see

F IG . 1).

• Zones 1 and 2 are always used for the heated platen and the heated pump respectively.

• 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 with an 8-pin matching connector. Accessory cables are available for other possible combinations.

Valve 1

Hose 1

ZONE 1

Control

Platen

F IG . 1: Heat Control Zone Selection

ZONE 2

Control

ZONE 3

Control

ZONE 4

Control

1920 Watts max 1920 Watts max

Pump

313296F 7

Component Identification

Component Identification

Single Supply Systems

AF

D200s Ram Shown

S

Lift Locations

NOTE: Do not use air motor lift ring (S) to lift entire system.

C

H

AE

A

U

D

E

F

IG

. 2: Single Supply System

Key:

A Ram Assembly

C Air Motor

D Heated Check-Mate Displacement Pump

E Heated Platen

G Display Module

H Electrical Enclosure

J Integrated Air Controls (see F IG . 4)

K Fluid Control Module (inside shroud)

S Lift Ring (air motor)

T Platen Bleed Port

U Pump Outlet

8

V Platen Lift Rod

X Wet Cup

Z Main Air Line (not supplied)

AD Air Motor Solenoid

AE Junction Box

AF Cable Track

X

Z

T

313296F

V

AD

G

J

K

Component Identification

Tandem Supply Systems

D200s Rams Shown

Supply System A

H

S

AF A G F AD

V

B

Supply System B

N

C

J

K

AE

X

Z

To heated manifold

(243697)

U

D

E

F IG . 3: Tandem Supply System

Key:

A Ram A

B Ram B

C Air Motor

D Heated Check-Mate Displacement Pump (Ram A and B)

E Heated Platen (Ram A and B)

F Drum Empty Sensor (partially hidden; Ram A and B)

G Display Module (Ram A only)

H Electrical Enclosure (Ram A and B)

J

Integrated Air Controls (Ram A and B); see page 10

K Fluid Control Module (inside shroud, Ram A and B)

N CAN Communication Cable

S Lift Ring (Air Motor)

T Platen Bleed Port

U Pump Outlet

V Platen Lift Rod

X Wet Cup

Z Main Air Line (not supplied)

AD Air Motor Solenoid (Ram A and B)

AE Junction Box (Ram A and B)

AF Cable Track (Ram A and B) r_wm2179_313269_4a

313296F 9

Component Identification

NOTE:

See F IG

. 2 and F IG . 3. Before you install the system,

you should be familiar with the following components.

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 sensor (F), and fluid control module (K).

Only Ram A includes the display module (G).

• Drum empty sensor (F). Signals drum empty condition. See F IG . 11, page 19.

• Display module (G). Mounted on Ram A only. Provides Run Mode status screens, Setup screens, and

control keys. See F IG . 8, page 13.

• Fluid control module (K). See F IG

. 7, page 12.

• Integrated air controls (J). See F IG . 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. Recirculates fluid when Recirculate Mode is active.

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 pressure 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 relieves 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 (BG): turns air on and off to push the platen out of an empty drum.

BF

BE

To depressurize the system, press the Depressurize key on the display module and select 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 system will not depressurize the system.

BG

BA

F IG . 4. Integrated Air Controls ti10438a

BD

BC

BB

10 313296F

Component Identification

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.

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:

2-Button Module: See the Air Controls manual for information.

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.

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 Module Installation Kit manual for fieldbus parameter setup instructions and screen descriptions.

CGM Module Status LED Signals

Signal

Green on

Yellow

Red

Solid

*Red

(7 flashes)

Description

System is powered up

Internal communication in progress

CGM hardware failure

Data map load failure

Incorrect data map for fieldbus type

No data map loaded

Activation

Buttons ti10843a1

F IG . 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

* 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.

CB ti10846a

F IG . 6: Roller Switch and Bracket Actuator

313296F 11

Component Identification

Fluid Control Module

Connection

1

2

3

4

5

6

7

CAN communication cable 1

CAN communication cable 2

Ram

Ram A and Ram B

Ram A

Ram A + B not used

Table 2: FCM Sensor Connections

Ram A and Ram B not used

Ram A

Ram A

Ram A and Ram B

Sensor Description

Air motor solenoid (wire labeled 3), drum low (wire labeled 1), drum empty (wire labeled 2)

Light tower

Fluid depressurize/recirculate solenoid not used

Air motor reed switch, sensors not used

Filter pressure at inlet and outlet

From Ram A FCM to display module.

15 ft (4.57 m) from Ram A FCM to Ram B FCM.

3

4

CAN Cable 2

TI12337A

5

6

TI12336A

7

CAN Cable 1

F IG . 7: FCM Sensor Connections

12 313296F

Component Identification

User Interface

F IG . 8: Display Module

Button

On/Off

Cancel

Table 3: Display Module Button Functions

Function

Powers air motor solenoid ON and OFF from Ram Operation screen (F IG . 71, page 98).

• 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 (F IG . 72, page 99).

• When ON, the enabled heat zones are ON.

• When OFF, all heat zones are OFF.

Cancel a selection or number entry while in the process of entering a number or making a selection.

Setup

Enter

Toggle between run and setup screens.

• Setup changes can be made while system is operating.

• If setup screens are password protected, button toggles between run and password entry screen.

Opens 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 91, for more information.

Arrows Up/Down Navigate up or down within a screen or to a new screen.

• Move between selections within a drop-down menu.

• Increment or decrement the selected numerical field within a selection menu.

313296F 13

Component Identification

Button

Soft Key

Table 3: Display Module Button Functions

Function

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.

Icon

Depressurize

Pump Prime

Recirculate

Table 4: Display Soft Key Icons

Function

Depressurize relieves fluid pressure from the pump outlet to below the platen on the currently active ram.

If system is pressurized, press button.

• When prompted to depressurize the system, select

active ram will depressurize both rams.

or . Depressurizing the

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.

• When prompted to pressurize the system, select or .

Pump Prime

Tandem ram: if pump is off, activates the air solenoid 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;

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.

• When prompted to prime the ram, select to prime.

Press button to exit Prime Mode or to reset counter to the prime time.

• When prompted to exit Prime Mode, select to exit or to reset prime counter.

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.

or . Adjust motor air regulator to • When prompted to turn recirculation on, select obtain desired flow rate.

If system is in Recirculate Mode, press button.

• When prompted to turn recirculation off, select or .

14 313296F

Icon

Crossover

Setback

Jump In

Component Identification

Table 4: Display Soft Key Icons

Function

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 in single ram operation.

Press button.

• When prompted to initiate a crossover, select or .

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 94, and Heat

Run Screen, page 99.

In screens that have editable fields, press to access the fields and make changes. See

Appendix A - User Interface Display, page 91, 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.

313296F 15

Component Identification

User Interface Display

NOTE: For details regarding the user interface dis-

play see Appendix A - User Interface Display, page

91.

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

F IG . 9: Display Screen Components

16 313296F

Installation

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 assistance in designing a system to suit your particular needs.

Grounding

Ground the supply system as instructed here and in the individual component manuals.

Location Requirements

Refer to Dimensions, page 102, for ram mounting

and clearance dimensions.

• Install indoors only, and not near water or any other liquid that is sprayed.

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 equipment used or located in the dispensing area. All electrical wiring must be done by a qualified electrician and comply with local codes and regulations.

Location

NOTICE

Always lift supply system at proper lift locations (see

F IG . 2) to avoid equipment damage. Do not lift in any other way.

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

F IG . 10.

1.

Attach a lifting sling at the proper lift spots. Lift off the pallet using a crane or a forklift. See F IG . 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.

F IG . 10: Ground Pump ti8250a

Air and fluid hoses: use only electrically conductive hoses.

Air compressor: follow manufacturer’s recommendations.

Dispense valve: ground through connection to a properly grounded fluid hose and pump.

313296F 17

Installation

Fluid supply container: follow local code.

Object being sprayed: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or

relieving pressure: hold metal part of the dispense valve firmly to the side of a grounded metal pail, then trigger the valve.

Connect Power Source

The electrical enclosure comes already attached and wired to the ram; however, before the supply system becomes functional you must connect the electrical enclosure to a power source.

NOTE: See Power Requirements, page 7, for circuit

protection requirements.

1.

Open electrical enclosure door and locate power line filter.

2.

Have a qualified electrician perform the following steps: a.

Connect your plant power to the electrical enclosure power line filter according to local codes. A 1-3/8 in. (35 mm) diameter opening is provided on the side of the enclosure adjacent to the label. This opening is suitable for a 1 in. npt conduit or strain relief fitting (supplied).

b.

Connect a power protective ground to the center post on the line end of the power line filter.

NOTE: Install safety insulation boots (supplied) on the power line. Install 1/4 in. ring lugs (user supplied) on the power line and power protective ground line prior to connecting to the power line filter 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 313296F

Installation

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).

4.

Attach the sensor to the corresponding connector on the splitter cable. For drum low, attach the sensor to connector 1. For drum empty, attach the sensor 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.

D200 Shown

EA

EE

ED

EB

F IG . 11: Low or Empty Sensor Kit

3.

Replace the existing cable between the empty sensor (EE) and FCM connector (see F IG . 7, page 12) with the empty/low sensor splitter cable.

Light Tower Accessory

Order the 255468 Light Tower Accessory as a diagnostic indicator for supply systems. See T ABLE 5 for a description of light tower signals.

Table 5: Light Tower Signals

Signal Description

Yellow flashing A low priority error exists.

Yellow on

Red flashing

Red on

A medium priority error exists.

A high priority error exists.

The system is shut down due to error conditions.

313296F 19

Installation

Attach Drum Stops

Supply systems are shipped with drum stops in place to help position the drum on the ram. For replacement parts, order Kit 255477. The kit includes two each of capscrews (FA), lock washers (not shown), and drum stops (FB).

1.

Locate the correct set of mounting holes on the ram base.

2.

Using the capscrews (FA) and lock washers (not shown), attach the drum stops (FB) to the ram base.

D200 Shown

FB

F IG . 12: Attach Drum Stops

FA

55 gal (200 L)

30 gal (115 L)

8 gal (30 L)

5 gal (20 L)

F IG . 13: Drum Stop Location

20 313296F

Installation

Check Resistance

Check the Resistance Between the Supply

System and the True Earth Ground

The resistance between the supply system components 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 different 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.

Sensor Resistance Checks

Conduct these electrical checks with the main disconnect OFF.

NOTE: For dispense valve and hose sensor resistance 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 components.

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 temperature (63°– 77°F [17°– 25°C] ).

Table 6: RTD Sensor Resistance

Zone Component Connector Pin

1 Platen Pin 1 to 3

2 Fluid Pump Pin 1 to 3

Range (ohms)

1050-1100

Ω

1050-1100

Ω

F IG . 14: RTD Connector Pins

313296F 21

Installation

Heater Resistance Checks

Conduct these electrical checks with the main power disconnect OFF.

NOTE: For dispense valve and hose sensor resistance checks, refer to your dispense valve manual or hose manual.

To check heater 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 components. Refer to Table 7. Heater terminal pins are located on the back of the enclosure (H). See F IG . 2, page 8.

3.

Replace any parts whose resistance readings do not comply with the ranges listed in Table 7.

NOTE: Check resistance at ambient room temperature (63°– 77°F [17°– 25°C] ).

Table 7: Resistance Chart of All Heaters

Zone Component

1

2

3

Platen - D200

Platen - D60

Pump

Between

Terminals

1 and 3

1 and 3

L and N

Unit

Voltage

240

240

240

Range

(ohms)

15 +5/-5

80 +10/-10

37 +5/-5

1

3

L N

F IG . 15: Heater Terminal Pins

22 313296F

Installation

Hose Installation and Care

NOTE: The warm melt supply system requires Graco single-circuit material hoses rated at a maximum of

1920 Watts.

Hose Installation

1.

Connect heated hose to the pump outlet.

2.

Use two wrenches to tighten. Torque to 470-550 in-lbs (53.1-62.1 N•m).

Mechanical Setup

1.

Fill displacement pump wet cup 2/3 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 performance curves in the Check-Mate Pump Packages manual to determine your air supply flow requirements.

NOTE: Quick disconnects restrict flow for large air motors.

3.

Wrap exposed fittings on the pump outlet with

Nomex insulation and secure insulation using fiberglass tape.

4.

Connect hose adapter to green receptacle on junction box.

Overview of Temperature

Control Settings

Temperature controls are set in Setup mode. See Setup

Mode Screens on page 93 for information about setting

temperature controls.

See Run Mode Screens on page 98 for information on

controlling temperatures for each zone.

F IG . 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.

313296F 23

Setup

Setup

The pump was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating fluid with oil, flush the pump with a compatible sol-

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.

If the two substances are compatible, omit the remaining steps in this procedure and refer to the start up and operation instructions.

b.

If the two substances are incompatible, perform the remaining steps in this procedure to flush the system at ambient temperature.

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 one chemical are removed before introducing 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 recommended 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 approximately 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 93.

Use fluids that are chemically compatible with the equipment wetted parts. See the Technical Data sections in the equipment manuals.

24 313296F

Setup

Load Material

D200 Shown

J

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.

NOTE: Follow steps below for both rams if using a tandem warm melt supply system.

1.

Refer to F IG

. 2, F IG . 3, and F

IG . 4. Close all air regulators and air valves.

2.

Open main air slider valve (BA) and set ram air regulator (BB) to 40 psi (0.28 MPa, 2.8 bar). Set director 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

F IG . 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.

Put a 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

F IG . 17.

7.

If drum has a plastic liner, pull it over edge of drum.

Secure liner with tape wrapped around circumference of drum.

D

F IG . 17: Heated Platen

8.

Set the director valve (BC) to DOWN and lower the ram until fluid appears at the top of the platen bleed port (J). 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 has this feature, press and hold both buttons to start lowering the ram. See F IG . 5, page 11.

313296F 25

Setup

System Heat Up

Never pressurize warm melt supply system while using warm melt materials before turning on heat.

Many warm melt materials tend to expand when heating 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 pressure 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.

F IG . 18: Heat Run Screen - Ram A

26 313296F

Setup

Prime

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)

F IG . 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 dispenses from the dispense valve.

8.

Lock the dispense valve trigger lock.

NOTE: To exit Prime Mode before the timer expires, press the Pump Prime key . The display prompts the operator to confirm. See F IG . 22. Select

to exit prime.

F IG . 19: Ram Operation Screen - Tandem System

(Prime inactive ram - in Run Mode)

F IG . 22: Exit Prime Mode Confirmation

F IG . 20: Ram Operation Screen - Tandem System

4.

If using a manual dispense valve, unlock the dispense valve trigger and place dispense valve over a waste container.

5.

Press the Pump Prime key . The display prompts the operator to confirm. See F IG . 21. Select

to begin prime.

NOTE: To extend the prime time counter, select in F

IG

. 22. Display prompts operator to confirm. See

F

IG

. 23. Select to reset.

F

IG

. 23: Reset Prime Time Counter Confirmation

313296F 27

Operation

Operation

Pressure Relief Procedure

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.

Lock the dispense valve trigger.

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 dispensing to prevent the gun from being triggered accidentally by hand or if dropped or bumped.

2.

Press On/Off key highlight . Select

. If system is On, display will

to turn off.

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.

F IG . 24: System Function Screen

3.

See F IG . 4, page 10. Close the air motor slider valve

(BF) and the main air slider valve (BA) on ram(s).

4.

Set the ram director valve to DOWN. The ram will slowly drop.

5.

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 dispense valve to relieve pressure.

8.

Lock the dispense valve trigger.

9.

Open all fluid drain valves on ram(s). Have a container ready to catch the drainage. Leave fluid drain valves open until ready to dispense again.

Start and Adjust Pump

NOTE: Follow steps below for both pumps if using a tandem warm melt supply system.

1.

Connect pump outlet fittings and hose (not supplied).

NOTE: Be sure all components are adequately sized and pressure rated to meet the system’s requirements.

2.

Be sure 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 F IG . 4, page 10.

28 313296F

3.

Press while in the Ram Operation screen.

Operation

Manual Crossover

(Tandem Warm Melt Supply System Only)

Manual crossover can only be initiated if the following conditions are met:

• inactive ram is not in the drum empty error condition.

• pump runaway and not primed alarms do not exist.

F

4.

IG . 25: Ram Operation Screen - Tandem System

When the confirmation screen appears with a prompt, select 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.

To initiate a manual crossover to the inactive ram:

1.

From the Ram Operation screen, press the Crossover key . The display prompts the operator to confirm.

2.

Select to confirm manual crossover operation or select to cancel.

Automatic Crossover

(Tandem Supply System Only)

Keep clear of the inactive ram, as automatic crossover may occur unexpectedly. To repair or adjust the

ram, first follow all steps of the Pressure Relief Pro-

cedure on page 28.

F IG . 26: Crossover Function Screen

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 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

101, for details.

NOTE: If the active ram has a pump runaway error or drum empty error, the system will attempt an automatic crossover.

313296F 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.

Set the motor air regulator to 30 psi (0.2 MPa, 2.1 bar).

2.

From the Ram Operation screen, press the Recirculate key confirm.

. The display prompts the operator to

3.

Select cancel.

to confirm recirculation or select

Depressurize Function

Follow the Pressure Relief Procedure on page 28.

Shutting off power or removing power from the system will not depressurize the system.

to

When the system is pressurized the depressurize function relieves fluid pressure from the pump outlet to below the platen on the currently active ram. However, when the system is depressurized pressing the depressurize key will restore fluid pressure.

Depressurize System

From the Ram Operation screen, press the Depressurize key . The display prompts the operator to confirm. Select to cancel.

to confirm depressurize or select

F IG . 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 used and the inactive ram cannot be primed.

F IG . 28: Depressurize Function Screen

To exit Recirculate Mode, press the Recirculate key

. The display prompts the operator to confirm.

Select

27.

to confirm or select to cancel. See F IG

NOTE:

You must exit Recirculate Mode before depressurizing or initiating a crossover.

.

30 313296F

Operation

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 again.

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.

Pressurize System

From the Ram Operation screen, press the Depressurize key . The display prompts the operator to confirm. Select to confirm pressurize or select cancel. See F IG . 28.

to

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 F IG . 4.

2.

Set ram 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 drum. Use minimum amount of air pressure necessary 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.

313296F 31

Operation

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

F IG . 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 the ram and adjust the position of the drum

relative to the platen. See Load Material on page

25.

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 independent 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 to confirm.

2.

Press while in the Heater Run screen to turn off the heaters. Select to confirm.

3.

Follow the Pressure Relief Procedure, page 28.

Many warm melt materials tend to expand when heating 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 313296F

Maintenance

Maintenance

3.

Remove Quick Coupler:

Remove clip (GC), and slide coupling cover (GB) up to remove coupling (GA).

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pres-

sure Relief procedure.

GB

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 of stroke.

2.

Follow the Pressure Relief Procedure on page 28.

GC

F IG . 29: Remove Quick Coupler

GA ti10508a

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).

313296F 33

Maintenance

Platen Maintenance

Remove and Reinstall Platen Wipers

Refer to Supply Units Repair-Parts manual for instructions.

If the platen does not come out of the pail easily when 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 raising it from the pail.

1.

Turn off main disconnect.

2.

Relieve pressure and disassemble air assist valve.

Refer to Supply Systems Repair-Parts manual.

3.

Clear air 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 through bleed relieve port (T) to remove material

residue. See F IG . 30.

5.

Remove platen covers. See F IG . 30.

a.

Remove platen cover fasteners (70) or nuts

(309).

b.

For 55 gallon platen (D200 3 in. and D200s 6.5

in. supply systems): Remove both platen covers

(49) and ground wire from platen.

Bleed

Stick

T

309

70

49

43

48 r_wm2179_313296_6a

309

For smaller platens (D60 3 in. supply systems):

Disconnect pump for the platen; see Discon-

nect Pump from Platen, page 50. Remove

screws (323) from upper heater plate (320).

Remove upper heater plate.

6.

Remove any excess fluid. Use a soft wire brush on

heater coils (48) or heater (319). See F IG . 30.

7.

Inspect platen heater blocks (43 or 320) or heater

(48 or 319) for burn or melt spots. Replace platen

heater blocks or heater if necessary. See F IG . 30.

8.

Check for loose connections and damaged wires.

9.

Follow steps in reverse order to reassemble platen.

NOTE: Torque platen cover fasteners (70) to 60 +/-

10 in-lbs (6.8 +/- 1.1 N•m) for 55 gallon platen.

Torque nuts (309) to 45 +/- 5 in-lbs (5.1 +/- 0.6 N•m) for smaller platens.

Bleed

Stick

T

F IG . 30: Remove Platen Covers and Heaters

323

320

319

34 313296F

Maintenance

Electrical Enclosure

1.

Turn the main disconnect on the electrical control panel door to the OFF position to disconnect power.

Check Ground Fault Circuit Interrupter

1.

With electrical enclosure door still open, switch main disconnect (421) back on.

Power is still connected to the power line filter (459) even after the main disconnect is open. Avoid contact with the power line filter.

2.

Open door of electrical enclosure.

459

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

421

419

F IG . 31: Inside View of Electrical Enclosure

3.

Check for damaged or loose wires. Check connections from cable track.

F IG . 32: Ground Fault Circuit Interrupter

4.

Switch main disconnect off.

313296F 35

Maintenance

Pump Heaters

1.

Turn the main disconnect on the electrical control panel door to the OFF position to disconnect power.

2.

Remove four screws (80 or 257) from back pump shroud (52 or 234).

4.

Check for damaged wires and connections.

5.

Ensure heaters (44 or 227) are secure so they cannot rotate on pump.

D200 Shown

D200 Shown

44 or 227

80 or 257

F IG . 34: Pump Heaters

F IG . 33: Remove Pump Shroud

3.

Remove pump heater front shroud (51 or 233).

36 313296F

Alarms

Alarms

Warm Melt alarms alert you to a problem and help prevent system shutdown or application errors. If an alarm occurs, operation may stop and the following occurs.

• Light tower indication changes (if equipped)

• Status bar on the display shows the alarm description

Diagnose Alarms

See Alarm Codes and Troubleshooting, page 37, for

causes and solutions to each alarm code.

Clear Alarms

Alarms are cleared by the solution(s) listed in the following table or from the screen in which they appear. Refer

to Alarm Codes and Troubleshooting, page 37, for

details.

Alarm Codes and Troubleshooting

Alarm

Code Alarm Problem

CB1X A - Communication Error -

Ram A Not Found

CB2X B - Communication Error -

Ram B Not Found

B61X

B62X

Crossover Error (Ram A)

Crossover Error (Ram B)

Cause Solution Clear Alarm

Fluid Control Module

Ram cannot communicate with

FCM A.

Verify that power is supplied.

Check that CAN cables are connected.

Verify that selector switch is set correctly.

Alarm automatically cleared by solution.

Ram cannot communicate with

FCM B.

Replace FCM A.

Verify that power is supplied.

Check that CAN cables are connected.

Alarm automatically cleared by solution.

Verify that selector switch is set correctly.

Replace FCM B

Inactive ram has a Not Primed alarm.

There is a Runaway alarm

Set inactive ram to Prime mode to automatically clear alarm.

Cleared from Ram Alarm

screen. See Appendix A -

User Interface Display, page 91.

Correct runaway condition and clear alarm on Status screen 1.

There is a Drum Empty alarm. Replace empty drum with full drum to clear.

313296F 37

Alarms

Alarm

Code

DA1X

DA2X

L11X

L12X

DB1X

DB2X

WJ1X

WJ2X

DK1X

DK2X

L21X

L22X

WK1X

WK2X

ML1X

ML2X

MA1X

MA2X

Alarm Problem

Pump Runaway A

Pump Runaway B

A - Drum Empty

Cause Solution

Fluid Control Module (continued)

Pump is running faster than set runaway limit due to:

Correct runaway condition and clear alarm.

Clear Alarm

Cleared from Ram Alarm

screen. See Appendix A -

User Interface Display, page 91.

• Increased air pressure.

• Increased fluid output.

• Exhausted fluid supply.

• Open fitting, hose, drain, or bleed valve.

Drum empty sensor has been activated.

Replace empty drum with full drum to clear.

Alarm automatically cleared by solution.

B - Drum Empty

A - Not Primed

B - Not Primed

The pump is not primed.

Set ram to Prime mode to automatically clear alarm, or manually clear alarm from Ram Alarm screen.

A - Air Solenoid Disconnected

Solenoid unplugged.

B - Air Solenoid Disconnected

A - Air Motor Sensor Error

Damaged solenoid / wires.

B - Air Motor Sensor Error

A - Drum Low Deviation

Check that solenoid cable is connected.

Inspect solenoid wires for damage.

System has seen multiple up strokes without a down stroke, or multiple down strokes without an up stroke.

Damaged or disconnected air motor sensors.

See air motor manual.

Drum low sensor has been activated.

Check that air motor sensors are connected.

Inspect air motor sensor harness for damage.

Replace empty drum with full drum to clear.

B - Drum Low Deviation

A - Fluid Solenoid Disconnected Deviation

B - Fluid Solenoid Disconnected Deviation

A - Rebuild Platen Seals

Solenoid unplugged.

Damaged solenoid wires.

Check that solenoid cable is connected.

Inspect solenoid cable for damage.

B - Rebuild Platen Seals

A - Rebuild Pump

B - Rebuild Pump

Cleared from Ram Alarm screen or Ram Operation

screen. See Appendix A -

User Interface Display, page 91.

Alarm automatically cleared by solution.

Alarm automatically cleared by solution.

Cleared from Ram Alarm

screen. See Appendix A -

User Interface Display, page 91.

Deviation automatically cleared by solution.

Deviation automatically cleared by solution.

Counter has reached programmed platen maintenance interval.

Perform platen maintenance; see Supply Systems Repair-Parts manual.

Counter has reached programmed pump maintenance interval.

Perform pump maintenance. See Check-Mate

Displacement Pump manual.

Cleared from Maintenance

screen. See Appendix A -

User Interface Display, page 91.

Cleared from Maintenance

screen. See Appendix A -

User Interface Display, page 91.

38 313296F

Alarms

T2A1

T2A2

T2A3

T2A4

T2A5

T2A6

T2A7

T2A8

T2A9

T2A10

T2A11

T2A12

T3A1

T3A2

T3A3

T3A4

T3A5

T3A6

T3A7

T3A8

T3A9

T3A10

T3A11

T3A12

Alarm

Code

DD1X

DD2X

Alarm Problem Cause Solution Clear Alarm

A - Pump Diving

B - Pump Diving

Fluid Control Module (continued)

Pump leak.

Worn valve or packings.

See Check-Mate Displacement Pump manual.

Ram air pressure set too low.

Increase air pressure to ram until diving stops.

Material flow rate exceeds ability of ram to feed pump.

Decrease pump air pressure to slow cycle rate.

Decrease pressure until diving stops.

Cleared from Ram Alarm

screen. See Appendix A -

User Interface Display, page 91.

Temperature Control Modules

The last digit in the temperature control module alarm codes identify the heat zone.

Alarm Above Setpoint RTD on wrong module.

Deviation Above Setpoint

Verify RTD wire and heater power cord is attached to correct heat module.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Shorted module.

Replace module.

Deviation Below Setpoint Tripped circuit breaker.

Low power.

Visually check circuit breaker for a tripped condition.

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 disconnected wires and plugs.

Circuit breaker not set for L2 and L3.

Visually check circuit breaker for proper setting of

L2 and L3.

Bad heaters.

GFCI has been tripped.

Measure resistance of heater.

Visually check GFCI for a tripped condition.

Customer supplied main circuit breaker tripped.

Measure voltage across the disconnect switch. Voltage should measure between

190 and 275 Vac.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

313296F 39

Alarms

A4A1

A4A2

A4A3

A4A4

A4A5

A4A6

A4A7

A4A8

A4A9

A4A10

A4A11

A4A12

Alarm

Code Alarm Problem

T6A1

T6A2

T6A3

T6A4

T6A5

T6A6

T6A7

T6A8

T6A9

T6A10

T6A11

T6A12

No Temp Rise

Over current

Cause Solution Clear Alarm

Temperature Control Modules (continued)

Tripped circuit breaker.

Visually check circuit breaker for a tripped condition.

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 disconnected wires and plugs.

Circuit breaker not set for L2 and L3.

Visually check circuit breaker for proper setting of

L2 and L3.

Bad heater(s).

GFCI has been tripped.

Measure resistance of heater(s).

Visually check GFCI for a tripped condition.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Customer supplied main circuit breaker tripped.

Measure voltage across the disconnect switch. Voltage should measure between

190 and 275 Vac.

Bad heaters.

Wrong zone type.

Measure resistance of heater.

Ensure zone is set for type of hardware connected to it.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

High voltage.

Shorted module.

Measure voltage across the disconnect switch. Voltage should measure between

190 and 275 Vac.

If temperature rises for a zone that has been disabled, replace heat module.

40 313296F

Alarms

Alarm

Code Alarm Problem

A1A1

A1A2

A1A3

A1A4

A1A5

A1A6

A1A7

A1A8

A1A9

A1A10

A1A11

A1A12

Undercurrent

Cause Solution Clear Alarm

Temperature Control Modules (continued)

Tripped circuit breaker.

Visually check circuit breaker for a tripped condition.

Over temperature protection is activated.

Low power.

Allow zone to cool down.

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 disconnected wires and plugs.

Circuit breaker not set for L2 and L3.

Visually check circuit breaker for proper setting of

L2 and L3.

Bad heaters.

GFCI has been tripped.

Measure resistance of heater.

Visually check GFCI for a tripped condition.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Customer supplied main circuit breaker tripped.

Wrong zone type.

Measure voltage across the disconnect switch. Voltage should measure between

190 and 250 Vac.

Ensure zone is set for type of hardware connected to it.

Shorted module.

If temperature rises for a zone that has been disabled, replace heat module.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

T6A1

T6A2

T6A3

T6A4

T6A5

T6A6

T6A7

T6A8

T6A9

T6A10

T6A11

T6A12

A7A1

A7A2

A7A3

A7A4

A7A5

A7A6

A7A7

A7A8

A7A9

A7A10

A7A11

A7A12

Unexpected Current

Invalid RTD Reading Bad RTD.

Bad RTD connection/loose wire.

Component not plugged in.

Measure resistance of RTD and verify it is within valid range.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Check for loose or disconnected wires and plugs.

Ensure a component is plugged into zone reporting error. If nothing is plugged in, disable zone.

313296F 41

Alarms

Alarm

Code Alarm Problem

PCB Overtemperature

V4I1

V4I2

V4I3

V4I4

V4I5

V4I6

V4I7

V4I8

V4I9

V4I10

V4I11

V4I12

V1M1

V1M2

V1M3

V1M4

V1M5

V1M6

V1M7

V1M8

V1M9

V1M10

V1M11

V1M12

V4M1

V4M2

V4M3

V4M4

V4M5

V4M6

V4M7

V4M8

V4M9

V4M10

V4M11

V4M12

T4C1

T4C2

T4C3

T4C4

T4C5

T4C6

T4C7

T4C8

T4C9

T4C10

T4C11

T4C12

High Line Voltage

No Line Voltage

Low Line Voltage

High DC Voltage

Cause Solution

Overheated Temperature Control Module.

Turn heat zone off. Wait a few minutes. If the condition does not clear on its own, replace heater module.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Incoming line voltage is too high.

Tripped circuit breaker.

GFCI has been tripped.

Visually check GFCI for a tripped condition.

Cable unplugged/loose wire.

Check for loose or disconnected wires and plugs.

Faulty DC power supply.

Measure voltage across disconnect switch. Voltage should measure between

190 and 250 Vac.

Visually check circuit breaker for a tripped condition.

Measure that DC supply output is 24V. If not, replace supply.

Clear Alarm

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

42 313296F

Alarms

Alarm

Code

A7C1

A7C2

A7C3

A7C4

A7C5

A7C6

A7C7

A7C8

A7C9

A7C10

A7C11

A7C12

A1C1

A1C2

A1C3

A1C4

A1C5

A1C6

A1C7

A1C8

A1C9

A1C10

A1C11

A1C12

A4C1

A4C2

A4C3

A4C4

A4C5

A4C6

A4C7

A4C8

A4C9

A4C10

A4C11

A4C12

V1I1

V1I2

V1I3

V1I4

V1I5

V1I6

V1I7

V1I8

V1I9

V1I10

V1I11

V1I12

Alarm Problem

Low DC Voltage

High Contactor Current

Low Contactor Current

Temperature Control Modules (continued)

Faulty DC power supply.

Broken Temperature Control

Module.

Broken contactor.

Broken contactor.

Disconnected or loose wire.

Broken Temperature Control

Module.

Cause

Unexpected Contactor Current

Broken Temperature Control

Module.

Solution

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.

Replace contactor.

Replace contactor.

Verify cable 15W902 from

High Power Temperature

Control Module is connected correctly.

Verify there is 24V between both wires on 15W902. If there is not 24V, replace

High Power Temperature

Control Module.

Turn heat zone for platen off. If there is still 24V across wires on 15W902, replace Temperature Control Module.

Clear Alarm

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

Cleared from Heat Run

screen. See Heat Run

Screen, page 99.

313296F 43

Troubleshooting

Troubleshooting

NOTE: Troubleshooting covered in this manual is specific to warm melt heat functions. Refer to Supply Systems Repair-Parts manual and/or Tandem

Supply Systems Repair-Parts manual for ram troubleshooting. Refer to Check-Mate Pump Packages manual for pump troubleshooting.

Problem

No power.

No graphics on screen.

1.

Follow Pressure Relief Procedure, page 28,

before disassembling any part of the warm melt supply system.

2.

3.

Disconnect all power to the warm melt supply system before repairing.

Check all possible problems before disassembling any part of the warm melt supply system.

Cause

Customer supplied main circuit breaker tripped.

GFCI has been tripped.

No graphics are shown on display screen.

Verification Solution

Measure voltage across disconnect switch; voltage should measure between

190 and 250 Vac.

Visually check GFCI for a tripped condition.

Determine cause of the tripped circuit breaker.

Then repair fault and reset main circuit breaker.

Determine fault that caused

GFCI to trip. Then repair fault and reset GFCI.

Verify green LED on bottom of display is illuminated.

If green LED is not illuminated:

Backlight does not power up.

3

24 Rtn

2

24 Vdc+

GCA cable end

1.

Check for DC power on the GCA cable at the display. Replace faulty cable/component.

2.

Replace faulty display module.

Can see display, but backlight is not illuminated when a button is pressed.

If green LED is illuminated, check red LED. If red LED is illuminated, replace display module.

Replace display module.

44 313296F

No heat.

Problem

313296F

Troubleshooting

Cause

Tripped circuit breaker.

Low power.

Cable unplugged/loose wire.

GFCI tripped.

Zone not enabled.

Incorrect temperature set point.

Bad heater.

Contactor not closing.

Verification

Visually check circuit breaker for a tripped condition.

Measure voltage across terminals 2T1 and 4T2 on main disconnect. Voltage should measure between

190 and 275 Vac.

Solution

Determine cause of tripped circuit breaker. Then repair fault and reset main circuit breaker.

1.

If voltage is lower than expected, use electrical schematic to locate faulty wiring or connection.

Check for loose or disconnected wires and plugs.

Visually check GFCI for a tripped condition.

2.

Have a qualified electrician service electrical components.

Attach plug/wire.

Verify zone is enabled on

Heat Run screen.

Verify zone has a correct temperature setting on

Heat Run screen.

Measure resistance of heater.

Determine fault that caused

GFCI to trip. Repair fault, and reset GFCI.

Enter Setup screen and enable correct zone.

Enter Setup and enter correct temperature.

1.

Unplug suspected heater zone from heater module.

2.

Follow Heater Resis-

tance Checks, page

22.

Turn on heat for zone A1 or

B1and ensure contactor closes.

3.

If resistance is outside allowable value, replace heater(s).

1.

Verify cable 15W902 from the high power

TCM is connected correctly.

2.

Verify that there are no other error conditions that would prevent heater from starting.

3.

Verify there is 24 Vdc between 2 wires on

15W902. If not, replace high power TCM. See

Alarms, page 37.

4.

Replace contactor.

45

Troubleshooting

Problem

Missing module.

Heating is slow.

Heating over shoots.

Does not crossover.

Cause

Modules not on network.

Verification

Verify attached modules through Advanced Setup screens 4 and 5.

Solution

Enter Setup screen and scroll to Advanced Setup screens 4 and 5. These screens lists all components corresponding software revision number on network.

Reconnect/replace faulty cable.

Cable disconnected.

Module with wrong rotary switch setting.

Verify all green LEDs are illuminated and yellow

LEDs are flashing.

Verify rotary switch is set correctly.

1.

Remove power from unit.

2.

Remove access cover and visually check rotary switch setting.

Heater defective.

Low power.

3.

If incorrect, set to correct setting. See

Upgrade Temperature Control Module

Software, page 56,

and Upgrade FCM

Software, page 59, for

selector switch locations.

Measure resistance of heater.

Measure voltage across terminals 2T1 and 4T2 on main disconnect. Voltage should measure between

190 and 275 Vac.

4.

Replace access cover.

Follow Heater Resistance

Checks, page 22.

1.

If voltage is lower than expected, use electrical schematic to locate faulty wiring or connection.

RTD on wrong module.

Verify for given zone that temperature does not increase when zone is disabled.

Shorted module.

Alternate ram has an empty sensor activated.

Verify ram has material.

Alternate pump is not primed.

Alternate pump has an active alarm.

Verify alternate ram is ready to run.

See Alarm Codes and

Troubleshooting, page 37.

2.

Have a qualified electrician service electrical components.

Verify RTD wire or heater power cord is attached to correct heat module.

Replace module.

Replace empty drum.

Prime pump.

See Alarm Codes and

Troubleshooting, page 37.

46 313296F

Repair

Repair

To reduce the risk of serious injury, follow the Pres-

sure Relief Procedure and the Load Material pro-

cedure prior to performing repair procedures.

Air Motor

Remove Air Motor

Remove junction box.

For 55 gallon platen (D200 and D200s supply systems):

Remove two screws (61) securing junction box to air motor. Remove junction box and temporarily secure to platen rod.

For smaller platens (D60 3 in. supply systems):

Remove junction box. Remove screws (278) from junction box (255), and remove cover (271). Remove junction box from bracket (258).

42

258

255

F IG . 36: Remove D60 Junction Box

271

3.

See Disconnect Displacement Pump in

Check-Mate Pump Packages manual.

278

61

71

96

90, 91

F

IG

. 35: Remove D200 and D200s Junction Box

12

To reduce the risk of serious injury or damage to equipment, make sure the main disconnect is off before continuing with this procedure.

4.

See Supply System repair manual for air motor removal instructions.

313296F 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. Reinstall junction box to air motor using move two

screws (61). See F IG . 35.

For smaller platens (D60 3 in. supply systems):

Reinstall junction box (255) onto bracket (258). Use

screws (278) to attach cover (271). See F IG . 36.

shrouds (51, 52), pump heaters (44), and RTD sensor (46).

51

44

46

44

52

Displacement Pump

F IG . 37: D200 and D200s Pump Heater Shrouds

Remove Displacement Pump

This procedure must be done while the system is still warm. The material and equipment may still be hot.

Refer 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

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.

HC

HA

HB

HD

TI10648A

F IG . 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 displacement pump. Service displacement pump as needed. See

Check-Mate Displacement Pump manual for instructions.

48 313296F

Repair

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).

227

229

227

Install Displacement Pump

D200 and D200s Supply Systems

1.

Install displacement pump on platen. See Connect

Pump to Platen, page 51.

2.

Lower air motor. Use wrench on nut (EA) to lower air motor.

3.

Reinstall pump heater shrouds (51, 52). Secure with screws (80).

4.

See Reconnect Displacement Pump in

Check-Mate Pump Packages manual.

5.

Reconnect air hose and ground wire to air motor.

233

F IG . 39: D60 Pump Heater Shrouds

TI10515A

F IG . 40: Reconnect Air Hose and Ground Wire

4.

See to Disconnect Pump from Platen on page 50

to disconnect displacement pump from platen.

5.

Raise ram assembly to lift air motor away from displacement pump.

6.

Remove displacement pump, and service as needed. See Check-Mate Displacement Pump manual.

D60 Supply System

1.

Raise ram to install displacement pump to platen.

2.

Connect displacement pump to platen. See Con-

nect Pump to Platen, page 51.

3.

Reinstall pump heater shrouds (233, 234). Secure with screws (257).

4.

See Reconnect Displacement Pump in

Check-Mate Pump Packages manual.

5.

Reconnect air hose and ground wire to air motor.

313296F 49

Repair

Disconnect Pump from Platen

The pump is mounted to the platens by mounting Kit

255392.

55 Gallon Platen

1.

Disconnect displacement pump from air motor. See

Check-Mate Pump Packages manual.

2.

Raise air motor. See Remove Displacement

Pump, page 48.

3.

Remove four screws (103a) and four clamps (103b).

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

Pump, page 48.

3.

Remove screws (308) from platen.

103a

103b

308

F IG . 42: 20, 30, 60 Liter Mounting

103c

F IG . 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.

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 necessary.

50 313296F

Repair

Connect Pump to Platen Replace Pump Heaters

55 Gallon Platen

1.

Use two people to set pump onto platen.

2.

Secure pump to platen with screws (103a) and clamps (103b). See F IG . 41.

3.

Lower air motor.

4.

See Reconnect Displacement Pump in

Check-Mate Pump Packages manual.

20, 30, and 60 Liter Platen

NOTE: Before installing a 20, 30, or 60 liter platen to a pump with an intake adapter, install adapter and o-ring.

1.

Place o-ring on pump intake. See F IG . 42.

2.

Use two people to set pump onto platen.

3.

Secure pump to platen with screws (308).

4.

Lower air motor.

5.

See Reconnect Displacement Pump in

Check-Mate Pump Packages manual.

1.

Turn off main disconnect.

2.

Remove screws (80 or 257) from back pump heater shroud (52 or 234).

D200 Shown

80 or 257

F IG . 43: Remove Pump Shroud

3.

Remove ground wires.

4.

Remove pump heater front shroud (51 or 233).

52 or

234

313296F 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.

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.

70

49

44 or 227

45 or 228

46 or 229,

110

43

44 or 227

59

11

64 ti17720a

F IG . 44: Remove 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 correct location.

7.

Reinstall RTD sensor and tighten screw on sensor support.

NOTE: Ensure RTD is flush to pump before tightening screw.

8.

Reinstall pump heater front shroud.

9.

Reinstall ground wires.

10. Reinstall back pump heater shroud, and secure with screws.

109

58

82 ti18061a

F IG . 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.

b.

Remove screws (12) from junction box cover

(96). Loosen strain relief nut (91), and remove junction box cover.

c.

Disconnect four platen heater wires (labeled A dn B) and RTD sensor connector in the terminal

box. See Electrical Schematics, page 61.

52 313296F

Repair d.

Remove screws (58) and washers (82).

Remove platen heater blocks (43) and RTD sensor (46).

5.

Install new platen heaters and RTD sensor. Secure

RTD sensor with screw and washer. Secure platen heater blocks with nuts and washers.

6.

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.

7.

Reinstall junction box cover. Secure with screws and tighten strain relief nut.

8.

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

N•m)

9.

Reconnect displacement pump using screws and clamps.

20, 30, and 60 Liter Platen Heater

1.

Disconnect pump from platen.

2.

Remove platen heater block (320).

a.

Remove screws (278) from junction box cover

(271), and remove junction box cover. See page

84.

b.

Remove strain relief nut (265) from junction box

to allow space for wires. See page 84.

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.

F IG . 46: Replace Platen Heaters ti17717b

324

323

320

319

318

309

Air Fitting

Assembly

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 lower heater plate

(318). Install upper heater plate (320). 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-lbs (5.1 +/- 0.6 N•m).

7.

Reconnect displacement pump using screws and clamps.

8.

Reinstall junction box cover and strain relief nut.

Secure cover with screws.

313296F 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) connecting electrical enclosure (13 or 14) to ram piston rod and cable track (42, if applicable).

42

13 or 14

50 or 232

F IG . 47: Replace Rod Seals

3.

For 55 gallon platen (D200 and D200s 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 enclosure.

54 313296F

Repair

Electrical Enclosure

Prior to repairing any component of the electrical enclosure (13 or 14), turn the main disconnect on the electrical control panel door to the OFF position to disconnect power.

Power is still connected to the power line filter (459) even after the main disconnect is open. Avoid contact with the power line filter.

408

Outbound

Power

RTD

411

Outbound

Power

RTD

F IG . 49: Back View of Electrical Enclosure

Replace Low Power Temperature Control

Module(s)

1.

Open enclosure door (402). Disconnect the following cables from low power TCM (408):

• incoming power supply cable (430)

outbound power supply cable (see F IG . 49)

• RTD cable

2.

Loosen both captive screws (409) holding low power

TCM (408) to base (407); remove low power TCM.

See F IG . 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.

459

Captive

Screw

430

408

Captive

Screw

411

431

429

432

F IG . 48: Internal View of Electrical Enclosure

428

313296F 55

Repair

Replace Base

1.

Remove low power TCM. See Replace Low 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

• “5” for TCM labeled “2” on Ram B

• “6” for TCM labeled “3” on Ram B

• “7” for TCM labeled “4” on Ram B

NOTE: Reuse brackets (412, 413) to install new high power TCM.

6.

Upload the correct TCM software from kit 16C027.

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.

Selector

Switch

TI12360a

F IG . 51: Set Selector Switch

Selector

Switch

F IG . 50: Set Selector Switch

TI12361a

Upgrade Temperature Control Module

Software

NOTE: Order kit 16C027 for an upgrade token. See

Graco Control Architecture

Module Programming manual for instructions.

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 TCM

(411). See F IG . 49.

2.

Remove electrical enclosure side panel (436). See

Electrical Enclosure Parts on page 88.

3.

Disconnect all four incoming cables (432, 428, 429,

431) from high power TCM. See F IG . 48.

4.

Remove both screws (415) that secure brackets

(412, 413) of high power TCM to electrical enclo-

sure. Remove high power TCM. See Electrical

Enclosure Parts on page 88.

5.

Follow steps in reverse order to install new high power TCM.

56 313296F

Repair

Replace Circuit Breakers

1.

Open enclosure door (402). Disconnect wires from circuit breaker (417, 419).

2.

Push in circuit breaker tab and pull out breaker.

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

11 or 201,

12 or 202

417

50 or 232

13 or 14

419

417 39 or 222

F IG . 53: Replace Electrical Enclosure

F IG . 52: Circuit Breakers

3.

Replace with new circuit breaker. Use tabs on bottom 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 disconnected.

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).

5.

Lift enclosure off and replace with new enclosure.

6.

Secure new electrical enclosure to bottom and side brackets with screws and washers.

7.

Reconnect heater and RTD cables to each TCM.

8.

Reconnect power to power line filter.

Have a qualified electrician reinstall main incoming power to system and electrical enclosure.

313296F 57

Repair

Display/User Interface

Upgrade Display Software

NOTICE

To avoid damaging 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 313296F

Repair

Replace Fluid Control Module

1.

Disconnect power to system.

2.

Remove front shroud (16 or 204) and back shroud

(17 or 205).

D200 Shown

41 or 224

Captive

Screws

16 or 204

17 or 205

F IG . 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).

30 or

217

36 or

220

33 or

219

28 or 215

F

IG

. 55: Remove FCM

6.

Replace with new FCM, and secure with screws.

7.

Reconnect cables to FCM.

8.

Load the correct FCM software for the system. Fol-

low the steps in Upgrade FCM Software on page

59.

Replace Base

1.

Disconnect power to system.

2.

Remove FCM (36 or 220). See Replace Fluid Con-

trol Module.

3.

Disconnect CAN cable(s) from FCM (36 or 220).

4.

Remove screws (28 or 215) and ground screw (30

or 217) from base (33 or 219). See F IG . 55.

5.

Replace with new base, and secure with screws.

6.

Reconnect CAN cable(s).

7.

Set selector switch to “A” for Ram A or “B” for Ram

B. See F IG . 55.

8.

Reinstall FCM. 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.

313296F 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).

4.

Remove screws (12) from junction box cover (96) and junction box (78).

5.

Loosen strain relief nut (90), and remove junction box cover.

6.

Disconnect all wires in junction box. Pull wires out of strain relief.

7.

Remove mounting screws (71), washer (72), and nut (73) securing cable track assembly (42) to junction box.

42

72

73

61

F IG . 56: Back View of Electrical Enclosure

3.

Remove screws (71) from bracket (50) that connect cable track (42) to electrical enclosure (13 or 14) and ram.

96

91

90

F IG . 58: Junction Box

50

42

13 or 14

F IG

71

. 57: Cable Track Bracket

71

12

8.

Lift out cable track assembly and cables.

9.

Replace with new cable track kit. Secure new cable track to junction box using mounting screws.

10. Run wires through strain relief and reconnect all

wires in junction box. See D200 Junction Box

Schematic, page 65.

11. Reinstall strain relief nut and junction box cover.

Secure junction box using screws.

12. Reattach cable track to bracket. Use screws to secure bracket holding cable track to electrical enclosure and ram.

13. Reconnect all 10 cables to back of electrical enclosure.

14. Reconnect power to system.

60 313296F

Electrical Schematics

D200 Single Ram Schematic

Electrical Schematics

MEMBRAN E SW IT CH

D ISPL AY

313296F 61

Electrical Schematics

D200 Ram A Schematic

MEMBRAN E SW IT CH

D ISPL AY

62 313296F

D200 Ram B

Schematic

Electrical Schematics

313296F 63

Electrical Schematics

D200 Displacement Pump and Platen Schematics

Ground Wire P/N 16A574

RTD SENSOR P/N 16D383

GROUND SCREW P/N 116343

64 313296F

D200 Junction Box Schematic

Electrical Schematics

313296F 65

Electrical Schematics

D200 Cable Track Schematic

66 313296F

D60 Single Ram Schematic

Electrical Schematics

MEMBRAN E SW IT CH

D ISPL AY

313296F 67

Electrical Schematics

D60 Ram A Schematic

MEMBRAN E SW IT CH

D ISPL AY

68 313296F

D60 Ram B

Schematic

Electrical Schematics

313296F 69

Electrical Schematics

D60 Pump and Platen Schematic

70 313296F

D60 Junction Box Schematic

Electrical Schematics

313296F 71

Electrical Schematics

D60 Cable Harness Schematic

72 313296F

Electrical Enclosure

Schematic

Electrical Schematics

313296F 73

3

6

4

Parts

Parts

D200s Rams Shown

13

Single Supply System or Supply System A

5

7

14

Supply System B

5

7

2

15

3

4

6

2

16

74 313296F

Parts

NOTE: See Component Identification, starting on page 8, to identify the components included in your

Warm Melt supply system.

Ref. Part

2

3

Description

RAM ASSEMBLY, D60, 3 in.

RAM ASSEMBLY, D60i, 3 in.

RAM ASSEMBLY, D200s, 6.5 in.

RAM ASSEMBLY, D200si, 6.5 in.

RAM ASSEMBLY, D200, 3 in.

RAM ASSEMBLY, D200i, 3 in.

PUMP, Check-Mate; see manual

312375 for parts

4 24D066 PLATEN, 20 liter, double wiper, cst, polyurethane

24D069 PLATEN, 20 liter, double wiper, sst, polyurethane

24D067 PLATEN, 30 liter, double wiper, cst, polyurethane

24D070 PLATEN, 30 liter, double wiper, sst, polyurethane

24D068 PLATEN, 60 liter, double wiper, cst, polyurethane

24D071 PLATEN, 60 liter, double wiper, sst, polyurethane

257748 PLATEN, 55 gal., PTFE-coated o-ring, EPDM

257749 PLATEN, 55 gal., o-ring, EPDM

257750 PLATEN, 55 gal., o-ring, neoprene

5  257623 KIT, mounting, pump; 3 in.; 20 liter; for NXT 2200 air motors

257624 KIT, mounting, pump; 3 in.; 20 liter; for NXT 3400 and 6500 air motors

255305 KIT, mounting, pump; 3 in.; 55 gal.

255315 KIT, mounting, pump; 6.5 in.; 55 gal.

6  255392 KIT, mounting; Check-Mate pump

7  VALVE, safety relief; located out of view, on back side of air controls

103347 For systems with pumps: P23xxx or

P36xxx

108124 For systems with pumps: P68xxx

Qty.

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

1 or 2

Ref. Part Description

ENCLOSURE, electrical (see Elec-

trical Enclosure Parts, page 88)

13 257158 For single systems and Ram A

14 257291 For Ram B

15 KIT, warm melt, with display (see

Warm Melt Kits for D200 Systems,

16

page 76, or Warm Melt Kits for D60

Systems, page 81)

24D010 D60 and D60i conversion kit, Ram A

24D013 D200 and D200i conversion kit,

Ram A

24D016 D200s and D200si conversion kit,

Ram A

24D009 D60 and D60i conversion kit, single system

24D012 D200 and D200i conversion kit, single system

24D015 D200s and D200si conversion kit, single system

KIT, warm melt, with no display (see

Warm Melt Kits for D200 Systems,

page 76, or Warm Melt Kits for D60

Systems, page 81)

24D011 D60 and D60i conversion kit, Ram B

24D014 D200 and D200i conversion kit,

Ram B

24D017 D200s and D200si conversion kit,

Ram B

 See Supply Systems Repair-Parts manual for parts.

Qty.

1

1

1

1

1

1

1

1

1

1

1

313296F 75

Parts

Warm Melt Kits for D200 Systems

Kit 24D012 with Display for D200 and D200i Systems

Kit 24D015 with Display for D200s and D200si Systems

Kit 24D013 with Display for Ram A of Tandem D200 and D200i Systems

Kit 24D014 without Display for Ram B of Tandem D200 and D200i Systems

Kit 24D016 with Display for Ram A of Tandem D200s and D200si Systems

Kit 24D017 without Display for Ram B of Tandem D200s and D200si Systems

Kit 24D016 Shown

20

12

11 23

65

26

27

60

15

13

14

22

105

16

24

21

47

66

38

81

19

12

11

32

37

35

34

36

41

33

30

28

76

50

71, 72, 73

18

11

12

75

76

17 r_wm_2179_313296_5a

313296F

86

52

78

61, 62

101

80

313296F

42

72, 73

Parts

101

88

39

83, 84, 85

11, 12

40

11, 26, 58, 59

71

54, 55

53 r_wm_2179_313296_12a

77

Parts

45, 79

46

107(x2), 108(x2), 110

51

87

1

Torque to 60 +/- 10 in-lbs (6.8

+/- 1.1 N•m)

49

78

43

107

108

109

46, 56, 82

44

68, 69, 97, 98

103a

103b

103c

57, 99 ti17719a

70

63

64

11

59

1

48

57, 97, 100, 102 ti17718a

313296F

Parts

12

11

78

68, 97, 99

96

90

93

92

91

94 95

89

11

59 r_wm_2179_313296_11a

D200 Warm Melt Kits

Ref.

Part

11

12

13 

100016

101682

Description

WASHER, lock

SCREW, cap, sch

SCREW, cap, hex hd; 7/16-14 unc

WASHER, top hat

SUPPORT, hose hanger

COVER, shroud front

Qty.

29

15

1

1

1

1

14 

15  15G347

16

†277589

 277591

17

†277590

 277592

18

†255383

 15R108

19 

20  24F493

21 

22 

23  121250

24  102040

25 

‡123328

 15X968

16C377

26  110755

27  121253

28 114417

COVER, shroud rear

BRACKET, light tower

WASHER, plain

MODULE, display

BRACKET, pendant pivot

BRACKET, mounting, assy

SCREW, cap, sch; 1/4-20 unc

NUT, lock, hex

CABLE, splitter, FCM3

WASHER, plain

KNOB, display

SCREW, self tap, pan hd

1

1

5

1

4

1

1

1

1

2

1

1

Ref.

29 

30

31 

Part

121070

Description

SUPPRESSOR, ferrite bead

SCREW, machine; #8-32 x 1

3/8

CABLE, CAN, female/female;

0.5 m

Qty.

1

1

1

121001

121228

32  101213

33 289697

34*‡  122716

35*‡ 

36  289696

37*‡ 

38

39

15R121

†  15W703

 15W704

40

†  16A566

 15W366

41  277674

42 257163

43  15V429

44  121980

45  C03507

46  16D383

47  119832

48  15V427

49 

Kits 24D014 and 24D017 only

NUT, full, hex

MODULE, cube, base

SENSOR, inductive, M12

BRACKET, sensor, low/empty

MODULE, fluid control 1

ACTUATOR, sensor, low/empty 1

LABEL

BRACKET, mounting, bottom

BRACKET, mounting

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

COVER, platen front, assy.

1

1

1

1

1

1

1

2

1

2

1

2

2

1

1

2

313296F 79

Parts

73

75

76

78

79 C31012

80 110637

81  119958

82

83 

84  121456

85 

86  15J075

87  15H668

88

93

94

95

96

89

90

91

92

Ref.

Part

50

†  15W959

 15W705

51  15W706

52  15W707

53

54

55

56

57

58

117026

116343

100643

100058

59 100015

60  100023

100575 61

62 

63 

64 176692

65  100307

66  C34132

68 194988

15B090 69

70 

71

72

97

98

99

120223

100020

100179

121255

15W708

15J076

24B810

102794

15X538

111640

100166

100

101  189930

102

C19208

Description

BRACKET, mounting, top

ENCLOSURE, pump, front

ENCLOSURE, pump, rear

CONDUIT; 12.9 mm

COUPLER, conduit

NUT, split

SCREW, shcs; m5 x 12

SCREW, ground

SCREW, cap, hex hd

3 in. ram

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

WIRE, grounding, panel

WIRE, grounding, door

FASTENER, platen, cover

SCREW, machine, flat hd

WASHER, lock

NUT, hex mscr

COVER

SCREW, countersunk; 6-32 x

0.38

BRACKET, junction box

CLAMP

SCREW, machine, pan hd

SPRING, hose hanger

WASHER

O-RING

CONNECTOR, power, female,

3 pin

COVER, connector

LABEL, warning

LABEL, warning

LABEL, read manual

RAIL, din, assy.

BUSHING, strain relief; m40

NUT, strain relief; m40

CONNECTOR, bulkhead; 15 pin

SCREW, socket hd cap

WASHER, lock

NUT, hex

COVER, junction box

WASHER, lock

NUT, full hex

WIRE, ground

WIRE, ground

LABEL, caution

WIRE, ground

Qty.

1

1

2

4

4

4

1

1

4

12

2

2

6

1

1

1

1

1

1

1

4

1

1

1

1

1

1

1

2

1

1

5

5

1

2

4

1

4

4

4

4

2

2

1

1

6

2

4

1

2

Ref.

103

Part

255392

103a 102637

103b 276025

103c 109495

104 

105 

106  15Y051

107 124131

108 103187

109 15B137

110 16K094

Description Qty.

KIT, mounting, displacement 1 pump

SCREW, cap

CLAMP

O-RING

STUD

CAP, plug

CABLE

SCREW

WASHER, lock

SWITCH, thermal

SWITCH, overtemp, horizontal 1

4

1

1

4

6

1

4

4

1

 Not shown.

 Replacement Danger and Warning labels, tags, and cards are available at no cost.

Kit 24D012 only.

 Kit 24D015 only.

 Kits 24D013 and 24D016 only in tandem supply systems.

 Parts included in Hose Hanger Kit 234966 (purchase separately).

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. Ram 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).

 Replacement electronic components do not have

Warm Melt specific software installed. Therefore, use software upgrade token 16C027 to install software before use.

80 313296F

Parts

Warm Melt Kits for D60 Systems

Kit 24D009 with Display for D260 and D60i Systems

Kit 24D010 with Display for Ram A of Tandem D60 and D60i Systems

Kit 24D011 without Display for Ram B of Tandem D60 and D60i Systems

201

Kit 24D010 Shown

209

202 210

207

203

204

221

211

213

208

214

281

224

219

215

217

220

202

201

279

280

206

201

202

313296F

205

254

253 r_wm29yy_31329b6_5

81

Parts

82

257

258

233 r_wm_2179_313296_12a

259,

260,

261

237

236

235

313296F

282, 283, 284

234

262

201, 202

232

313296F

201, 202, 222 ti17721a

Parts

227

256

249, 272,

273

228,

229

227

239,

274

223

201, 213, 240, 241

83

Parts

265

248, 272, 273

255

241

201

258

268

278

276

264

241

201

266

270

269

267

271 r_wm29yy_313296b_8

D60 Warm Melt Kits

Ref.

Part Description Qty.

201

202

203

204

100016 WASHER, lock

101682 SCREW, cap, sch

288543 BRACKET, hose spring

277589 COVER, shroud front

205 277590 COVER, shroud rear

206 255383 BRACKET, light tower

207  24F493 MODULE, display

208  BRACKET, pendant pivot

209  BRACKET, mounting, assy

210  121250 SCREW, shcs; 1/4 unc x 4.25

211  102040 NUT, lock, hex

212 

CABLE, M12; 24D009 only

123328 CABLE, splitter, FCM empty/air;

24D010 and 24D011 only

213  110755 WASHER, plain

214  121253 KNOB, display

215

216 

114417 SCREW, self tap, pan hd

SUPPRESSOR, ferrite bead

217 121070 SCREW, machine; #8-32 x 1 3/8 1

218  121001 CABLE, CAN, female / female; 1m 1

219 289697 MODULE, base

220  289696 MODULE, fluid control

4

1

1

1

221 15R121 LABEL

222  15W703 BRACKET, mounting, bottom

223  16A566 BRACKET, mounting

224 277674 ENCLOSURE, cube door

5

1

1

1

1

1

1

1

1

1

1

1

23

13

1

1

1

1

1

Ref.

Part Description

225  16C430 HARNESS

227  121980 HEATER, pump; 725 watt

228  C03507 SUPPORT, sensor

229  16D383 SENSOR, RTD, shielded

232  BRACKET, mounting,

Qty.

accessory box

233  15W706 ENCLOSURE, pump, front

234  15W707 ENCLOSURE, pump, rear

235 CONDUIT; 12.9 mm

236

237

239

240

241

247 

COUPLER, conduit

NUT, split

116343 SCREW, ground

100058 SCREW, cap, hex hd

100015 NUT, hex mscr

15Y051 CABLE, M12, 8 pin, f/m

248

249

WIRE, grounding, panel

16A574 WIRE, grounding, door

253 COVER 1

254 121255 SCREW, countersunk, 6-32 x 0.38

2

255  16A539 BOX, junction box 1

256 C31012 CLAMP 1

1

2

8

1

2

4

3

3

257 110637 SCREW, mach, pan head

258

259 

BRACKET, mount

O-RING

260  121456 CONNECTOR, power,

1

1

2

1

1

4

1 female, 3 pin

1

1

1

1

2

84 313296F

Parts

Ref.

Part Description

261  COVER, connector

262  15J075 LABEL, warning

263  15H668 LABEL, warning

264 RAIL, din, assy

265 BUSHING, strain relief; M40

266

267

268

269

270

271

272 thread

NUT, strain relief; M40 thread

24B810 CONNECTOR, bulkhead, 15 pin

SCREW, cap, sch

C19208 WASHER, lock

102794 NUT, hex

COVER, junction box

111640 WASHER, lock, internal

273 100166 NUT, full hex

274 16A355 WIRE, ground

276  196548 LABEL, caution

278

279*‡ 

112788 SCREW, cap, sch

BRACKET, sensor, low/empty

280*‡  122716 SENSOR, inductive, M12

281*‡  ACTUATOR, sensor, low/empty

282 124131 SCREW

283

284

103187 WASHER, lock

16K094 SWITCH, overtemp, horizontal

Qty.

1

1

1

1

1

1

2

1

2

2

1

1

4

3

1

1

3

4

4

1

1

4

 Not shown.

 Replacement Danger and Warning labels, tags, and cards are available at no cost.

* Standard only on tandem supply systems.

 Kits 24D009 and 24D010.

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. Ram Bracket Mounting Kit

24C628 (purchase separately).

 Parts included in Pump Heater Kit 24C495 (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 software before use.

313296F 85

Parts

Heated Platens - 20L, 30L, and 60L

Platen 24D066 (20L) Shown

337

3 311

4

331, 332

321

333

334

335

328, 329, 330

303

1

Torque to 45 +/- 5 in-lbs (5.1 +/- 0.6 N•m)

2

Apply sealant to all non-swiveling pipe threads.

3

Add lubricant to threads.

4

Ground RTD sleeve to screw (332).

302

310

327

325, 326

309 1 3

324

323 ti17717b

320

319

318

317

301

308 3

309 1

307

3

313 2

304, 305

86 313296F

Parts

Parts Used on all Heated Platens

Ref.

Part Description

301

305

BASE

PLATE, bottom

306 121829 O-RING

309 NUT, keps, hex hd

311 257697 HANDLE, bleed, sst, assy

312 109482 O-RING

313 C20350 ELBOW, 90 deg.

317 GASKET, heat transfer

318

319

320

321

PLATE, heater, lower

HEATER

PLATE, heater, upper

HOLDER, RTD sensor

322 16D383 SENSOR, RTD, 1k ohm, shielded

323 NUT, barrel, binding screw

324

325

GUARD, heat shield

COUPLER, conduit

326 CONDUIT, ID 12.9mm

327 189930 LABEL, caution

328 111640 WASHER, lock, internal

329 100166 NUT, full hex

330 WIRE, ground

331 16A574 WIRE, ground

332 111593 SCREW, grounding

333 124131 SCREW

334 103187 WASHER, lock

335 15B137 SWITCH, thermal

337 15K616 LABEL, safety

Qty.

1

2

1

1

36

1

1

1

2

1

1

1

1

1

4

1

1

1

1

1

1

1

1

1

8

1

1

Parts that Vary by Heated Platen Model

Heated Platen Models

Ref. Description

302 SPACER, dual wiper

303 WIPER, main

304 WIPER, support

307 PLATE, top

308 SCREW, set, sch

310 VALVE, check

24D066, 20L

Platen, CS

24D067, 30L

Platen, CS

24D068, 60L

Platen, CS

24D069, 20L

Platen, SST

24D070, 30L

Platen, SST

257694

257678

257681

257686

100421

122056

257695

257679

257682

257687

100421

122056

257696

257680

257683

257688

100421

122056

257694

257678

257681

257686

109477

501867

257695

257679

257682

257687

109477

501867

24D071, 60L

Platen, SST

Qty

257696

257680

257683

257688

109477

501867

1

1

1

2

2

1

313296F 87

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

443, 458

441 440

401

451

436

437

442

438

446

439

439

439

439

Side View

445

444

402, 403, 404, 405

452

433, 434, 435

407

427

457

415, 426

425, 453

456

408, 409, 410

430

429

412

415

426

414

417

420, 454

318

460

413

422

415, 426

411

432

428

431

88

459

406

461

415

416

419

417

421

423

424

313296F

Parts

Electrical Enclosure Parts

Ref.

Part Description Qty.

401

402

ENCLOSURE

DOOR, enclosure

403 101682 SCREW, cap, sch

404 100016 WASHER, lock

405 100015 NUT, hex, mscr

406 15X754 BRACKET, mounting, electrical

407 289697 MODULE, cube, base

408  256270 MODULE, low power temp

409 114417 SCREW, self tap, pan hd

410 121070 SCREW, machine, pan hd

411  255774 MODULE, high power temp

412 15U651 BRACKET, high power temp module

413 15R535 BRACKET, mounting, high power temp module

414 117831 SCREW, machine, pan hd

415 100035 SCREW, machine, pan hd

416 122148 BAR, buss, smissline; 17.125 in.

417 122124 CIRCUIT, breaker, smissline; 8A

1

(257291 includes qty. of 3)

418 122129 COVER, buss bar

419 122128 CIRCUIT, breaker

420 16A573 WIRE, power

421 122122 SWITCH, disconnect

422 122317 ROD, connecting, on/off

423 122125 RELAY, contactor

424 123141 CIRCUIT, breaker, smissline; 25A

425 111640 WASHER, lock, internal

426 157021 WASHER, lock, internal

427 KIT, bar, ground

428 257341 HARNESS, wiring, high power temp module

429 121597 CABLE, CAN, 90 female/90 female 3

430 15V999 CABLE; 14 in.

3

431 CABLE; M8, male/ferrules 1

432 121000 CABLE, CAN, female/female; 0.5 m 1

433 100023 WASHER, flat

434 100133 WASHER, lock

4

4

435 100307 NUT, hex

436 PANEL, side, 3 low power heat

4

1

1

1

1

1

1

1

2

2

10

1

1

437

438

439

440 modules, 1 hp

GASKET, low power heat module

GASKET, high power heat module

LABEL, junction box

CORD, grip; PG-7

441 GRIP, cord

442 121612 CONNECTOR, thru; M12, m x f

443 112788 SCREW, cap, socket hd

444 LATCH, quarter turn

445 15W905 HANDLE, selector, on/off

446 190774 LABEL

451 SEAL, hole, plug; 0.5 in.

452 194337 WIRE, grounding, door

453 100166 NUT, full hex

454

455 

INSULATOR, boot

WIRE, chassis, ground

456 277674 ENCLOSURE, cube door

4

20

1

4

1

3

2

5

1

1

1

1

6

2

1

1

1

1

3

1

3

3

4

1

4

4

1

1

12

3

1

1

Ref.

Part Description

457 186620 LABEL, ground

458 112905 WASHER, plain

459 123373 FILTER, power line; single phase

460 123374 SUPPLY, power; 24Vdc, 2.5A, 60W

461

(included in only 257158)

COVER, buss bar, single

Qty.

1

1

1

6

1

 Not shown.

 Replacement Danger and Warning labels, tags, and cards are available at no cost.

 Replacement electronic components do not have

Warm Melt specific software installed. Therefore, use software upgrade token 16C027 to install software before use.

313296F 89

Accessories

Accessories

Platen Cover, 255691

Two platen covers. See manual 406681 for more information.

Two-Zone Expansion Kit, 24C223

For adding two zones of heat to a Warm Melt Supply

System. 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 systems.

90 313296F

Appendix A - User Interface Display

Appendix A - User Interface Display

Display Overview

The user interface display is divided into two main functions: 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 parameters;

• schedule maintenance parameters;

• configure system hardware settings;

• set and change display units and format for all other screens;

• set pump size and drum fill volume;

• and view software information for each system component.

Run Mode Functions

The run mode functions enable users to:

• view current flow rate and drum volume;

• 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.

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 communication with other components in the system.

F IG . 59: Power Up Screen

Menu Bar

The menu bar appears at the top of the screen, and consists of the following components.

F IG . 60: Menu Bar

Date and Time

The date and time are always displayed in one of the following formats. The time is always displayed as a

24-hour clock.

• DD/MM/YY HH:MM

• 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.

313296F 91

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:

Navigation within Screens

Press screens. Also, press selection.

to open drop-down menus on Setup

to enter changes or make a

Press to navigate to new screens and to navigate left and right within a screen. Also press

select digits within a field to change.

Icon

No Icon

Function

No information or no error has occurred

Advisory

Deviation

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.

Alarm

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.

92 313296F

Appendix A - User Interface Display

Setup Mode Screens

Setup mode screens are divided into six sections: password, system setup, heat zone setup, maintenance setup, hardware setup, and advanced setup.

Password Screen

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.

While in Run mode, press the Setup 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.

Icon Function

Select tandem operation, ram A only operation, or ram B only operation.

Select if a Not Primed event will issue an 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 this function.

F IG . 62: System Setup

F IG . 61: Password Screen

313296F 93

Appendix A - User Interface Display

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.

NOTE: Must exit edit mode to scroll through the heat zones.

Icon Function

Displays selected heat zone. Press

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 deviation is issued.

Select to enable the heat zone; leave blank to disable the heat zone.

Shared zone. Select to enable zone for both ram A and ram B.

Maintenance Setup Screen

The Maintenance Setup screen enables users to set maintenance intervals for rebuilding platen seals and rebuilding the pump.

Icon Function

Set the number of drums (0-9999) between platen seal maintenance. Setting the number of pump cycles to 0 disables this function. 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 37.

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, set for each pump. A rebuild pump error is issued

when maintenance is required. See Alarm

Codes and Troubleshooting on page 37.

F IG . 64: Maintenance Setup

F IG . 63: Heater System Setup Screen

94 313296F

Appendix A - User Interface Display

Hardware Setup Screens

The Hardware Setup screens enable users to specify if specific hardware is installed on the system and to adjust hardware settings. Press to scroll through the Hardware Setup screens. Once in the desired Hardware Setup screen, press to access the fields to make changes. Press mode.

to exit edit

NOTE: Must exit edit mode to scroll through the

Hardware Setup screens.

Monitor the filter pressure readings through the normal range of flow with a clean filter to establish the initial limit settings.

F IG . 65: Hardware Setup Screen 1 (Filter)

Hardware Setup Screen 1

This screen enables users to specify if a fluid filter monitor is installed, and set the high and low limits for the pressure drop across the filter.

Icon Function

Select what type of error will be issued if filter pressure drops below the low limit or raises above the high limit. Select to disable filter monitoring or if there is no filter installed on the system.

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.

Hardware Setup Screen 2

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.

Icon Function

Select if fluid solenoid is installed on system. Set for A and B rams.

Select if drum low sensor is installed on system. Set for A and B rams.

F IG . 66: Hardware Setup Screen 2

313296F 95

Appendix A - User Interface Display

Advanced Setup Screens

The Advanced Setup screens enable users to set units, adjust values, set formats, and view software information 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 mode.

to exit edit

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 accessory kit, only and settings are available.

Icon Function

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.

Set units of measurement for temperature.

Select between °F and °C.

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 Operation screen to be accurate.

Icon Function

Set pump size (cc/cycle) for each ram.

Select between, 60, 100, 200, 250, and

500).

Set fill volume for each drum. Use digits

1-9999.

F IG . 68: Advanced Setup Screen 2

F

IG

. 67: Advanced Setup Screen 1

96 313296F

Advanced Setup Screen 3

This screen enables users to set the date, time, and date format.

Icon Function

Set date format. Select between

MM-DD-YYYY and DD-MM-YYYY.

Set current date.

Set current time.

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.

Icon Function

Controller software part number and version.

Display software part number and version.

Fieldbus gateway software part number and version.

Temperature controller software part number and version.

F IG . 69: Advanced Setup Screen 3

F IG . 70: Advanced Setup Screens 4 and 5

313296F 97

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 system is in Setup mode, press to enter Run mode.

See Operation, page 28, for instructions on all of these

procedures.

Active ram is highlighted

Flow rate

Fluid line shown filled when system is 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 perform the following procedures from the Ram Operation screen:

• turn the air motor on and off;

• depressurize and pressurize the system;

• recirculate fluid within the active ram;

• prime the pump(s);

• and perform a manual crossover on tandem systems.

Volume

Remain

-ing

Current mode

F IG . 71: Ram Operation Screen - Tandem System

The Ram Operation screen will display the appropriate icon and highlight the corresponding soft key if the system is:

• depressurized ,

• in Recirculate mode ,

• or if a ram is in Prime mode .

98 313296F

Appendix A - User Interface Display

Heat Run Screen

The Heat Run screen displays information for four to six heat zones. See F IG . 72 for information about each zone. For each zone, the icon on the upper right is present 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 deviation.

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.

From the Heat Run screen, users can view heat zone 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 scroll through the Heat Run screens.

to

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 94.

Zone

Number

A5

A6

B1

B2

A1

A2

A3

A4

B3

B4

B5

B6

Temperature Control

Module Alarm Code

7

8

5

6

3

4

1

2

9

10

11

12

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.

System component being heated

Zone set point

Zone number

Current zone temperature

F IG . 72: Heat Run Screen - Ram A

313296F 99

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

Status screens.

to scroll to through the

Icon Function

Job total column; indicates pump cycle count total for a single job.

Grand total column; indicates pump cycle count total for all jobs.

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 system for a single job and all jobs.

Maintenance Screen

The maintenance screen enables operators to establish a preventive maintenance schedule based on the system application and repair history. This screen displays the number of maintenance units remaining before preventive maintenance is due for the platen seals and pump.

NOTE: If a maintenance interval is set to 0, the display will be a series of dashes.

Icon Function

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 in the Advanced Setup screen 1. The example shown in F IG . 74 is set to units of

1000 pump cycles .

F IG . 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

. When prompted, press to confirm. If the job total is reset, A and B totals will also be reset. Press

to exit edit mode.

F IG . 74: Maintenance Screen

To reset a counter, press gate to the value, and press press to confirm. Press

to access the fields, navi-

. When prompted,

to exit edit mode.

NOTE: Grand totals cannot be reset.

100 313296F

Appendix A - User Interface Display

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 information regarding alarms. See

Alarms on page 37.

Icon

Alarm

Code Function

B61X

B62X

DA1X

DA2X

DB1X

DB2X

DK1X

KD2X

DD1X

DD2X

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.

Press screens.

Report Screens

The five Report screens display a chronological list of

the most recent 20 errors. See Alarm Codes and Trou-

bleshooting, page 37, for details regarding each alarm

code.

Icon Function

Chronological order of errors as they occur.

Date when error occurred.

Time when error occurred.

Error code.

to scroll through the five report

L11X

L12X

Drum Empty

Drum for ram A or ram B is empty.

F IG . 76: Report Screen

F IG . 75: Ram Alarm Screen

To clear an alarm, press to access the fields, navigate to the alarm icon, and press prompted, press mode.

. When

to confirm. Press to exit edit

313296F 101

Dimensions

Dimensions

D200 Models

D200s Shown

G

B

(ram down)

A

(ram up)

C

D

F

E

Ram

Model

A in. (mm)

D200 102.3 (2599)

D200s 104.9 (2665)

B in. (mm)

72.6 (1844)

74.3 (1887)

C in. (mm)

21.0 (533)

23.0 (584)

D in. (mm)

25.0 (635)

25.0 (635)

E in. (mm)

38.0 (965)

45.0 (1143)

F in. (mm)

42.0 (1067)

48.0 (1219)

G in. (mm)

56.4 (1433)

64.6 (1641)

102 313296F

Dimensions

D60 Models

G

B

(ram down)

A

(ram up)

C

D

F

E

Ram

Model

D60

A in. (mm)

92.7 (2355)

B in. (mm)

62.7 (1593)

C in. (mm)

14.0 (356)

D in. (mm)

18.0 (457)

E in. (mm)

24.0 (610)

F in. (mm)

28.0 (711)

G in. (mm)

47.0 (1194)

313296F 103

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. (115 L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 psi (1.0 MPa, 10 bar)

D200 - 3 in. dual post, 55 gal. (200 L) . . . . . . . . . . . . 150 psi (1.0 MPa, 10 bar)

D200s - 6.5 in. dual post, 55 gal. (200 L). . . . . . . . . . 125 psi (0.9 MPa, 9 bar)

Max fluid and air working pressure . . . . . . . . . . . . . . . . . See table below.

Wetted parts and weight (displacement pump) . . . . . . . . See Check-Mate Displacement Pump manual 312375.

Platen Codes (see page 4): Part number; Wetted parts

F: 257729, 5 gal. (20 L)

L: 257734, 8 gal. (30 L)

U: 257738, 16 gal. (60 L). . . . . . . . . . . . . . . . . . . . . .

H: 257731, 5 gal. (20 L)

R: 257736, 8 gal. (30 L)

Y: 257741, 16 gal. (60 L) . . . . . . . . . . . . . . . . . . . . . .

8: 255662, 55 gal. (200 L) . . . . . . . . . . . . . . . . . . . . .

9: 255663, 55 gal. (200 L) . . . . . . . . . . . . . . . . . . . . .

Stainless steel, polyurethane, PTFE coated nitrile, polyethylene, nitrile, PTFE, 303 sst, 304 sst, 316 sst,

17-4PH sst

Electroless nickel, aramind reinforced elastomer, rubber-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

Maximum operating temperature (supply system) 158°F (70°C)

Sound data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See NXT Air Motor manual 311238.

External power supply requirements

AC power units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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)

Ratio

Maximum Air Inlet

Pressure psi (MPa, bar)

Maximum Fluid Working

Pressure psi (MPa, bar)

23

36

68

100 (0.7, 7.0)

100 (0.7, 7.0)

91 (0.64, 6.4)

2300 (16.1, 161)

3600 (25.2, 252)

6200 (43.4, 434)

Motor

NXT2200

NXT3400

NXT6500

Displacement

Pump

(cc per cycle)

200

200

200

Flow Rate gpm (lpm)

30 cpm 60 cpm

1.6 (6.0) 3.2 (12.0)

1.6 (6.0) 3.2 (12.0)

1.6 (6.0) 3.2 (12.0)

Weight

See the identification plate (ID) for the weight of your supply system.

ID ti11157a

104 313296F

Technical Data

313296F 105

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

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

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification 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 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 warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

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

Graco 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.

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 11/2011

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