Graco 313296A, Warm Melt Supply Systems Instructions


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Graco 313296A, Warm Melt Supply Systems Instructions | Manualzz

Instructions - Parts

Warm Melt Supply

Systems

313296A

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.

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

Check Connections . . . . . . . . . . . . . . . . . . . . . . 18

Adjust Drum Low/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

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

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Flush Before Using Equipment . . . . . . . . . . . . . 25

Set Values on Display Module . . . . . . . . . . . . . 25

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 . . . . . . . . . . . . . . . . . . . 29

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

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

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

Depressurize Function . . . . . . . . . . . . . . . . . . . 31

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

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

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

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

Platen Maintenance . . . . . . . . . . . . . . . . . . . . . . 33

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . 34

Pump Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Diagnose Alarms . . . . . . . . . . . . . . . . . . . . . . . . 36

Clear Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Alarm Codes and Troubleshooting . . . . . . . . . . 36

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Displacement Pump . . . . . . . . . . . . . . . . . . . . . 47

Disconnect Pump from Platen . . . . . . . . . . . . . . 48

Connect Pump to Platen . . . . . . . . . . . . . . . . . . 48

Replace Pump Heaters . . . . . . . . . . . . . . . . . . . 49

Replace Platen Heaters . . . . . . . . . . . . . . . . . . . 49

Replace Platen Wipers . . . . . . . . . . . . . . . . . . . 50

Replace Ram Piston Rod Seals . . . . . . . . . . . . 50

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . 51

Display/User Interface . . . . . . . . . . . . . . . . . . . . 54

Replace Fluid Control Module . . . . . . . . . . . . . . 55

Replace Cable Track . . . . . . . . . . . . . . . . . . . . . 56

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 58

Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 58

Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 58

Ram B Schematic . . . . . . . . . . . . . . . . . . . . . . . 59

Displacement Pump and Platen Schematics . . . 60

Junction Box Schematic . . . . . . . . . . . . . . . . . . 61

Cable Track Schematic . . . . . . . . . . . . . . . . . . . 62

Electrical Enclosure Schematic . . . . . . . . . . . . . 63

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Warm Melt Kits for D200 Systems . . . . . . . . . . . 65

Electrical Enclosures Parts . . . . . . . . . . . . . . . . 70

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Display Module Details . . . . . . . . . . . . . . . . . . . 73

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 84

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 84

313296A

Related Manuals

Manuals are available at www.graco.com.

Component Manuals in U.S. English:

Manual Description

313529 Tandem Supply Systems Repair-Parts

313526 Supply Systems Operation

313527 Supply Systems Repair-Parts

312375

Check-Mate

®

Displacement Pumps

Instructions-Parts

312376

Check-Mate

®

Pump Packages

Instruction-Parts

312468

200 cc Check-Mate Displacement Pump

Repair Parts

311238 NXT

Air Motor Instructions-Parts

312374 Air Controls Instructions-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

313296A

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

Pump Code

Fifth Digit

Ram Options

Size Style

DataTrak

Voltage Air Controls

WM

(Warm Melt

Single Supply

System)

5 3 in.

D200 no volt

(See Table 1 for 2-digit

Pump Code)

6 3 in D200i no volt

7 6.5 in. D200s no volt

TW

(Warm Melt

Tandem

Supply

System)

8 6.5 in. D200si no volt

INT

INT

2-Button

Interlock

8

2-Button

Interlock 9

A

9

Sixth Digit

Platen and Seal Options

Platen

Size

Platen

Style

DR

Platen

Material

PTFE coated

AL

200 L

(55 Gal)

200 L

(55 Gal)

200 L

(55 Gal)

DR

DR

AL

AL

Seal

Material

EPDM

EPDM

Neoprene

Key:

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

INT = Integrated air controls

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

22

P23LCS

P23LCM

26 P23LSM

NXT 3400/CM 200

29

2A

2G

P36LCS

P36LCM

P36LSM

NXT 6500/CM 200

2L

2M

2U

P68LCS

P68LCM

P68LSM

313296A

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.

313296A 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 313296A

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 temperatures in 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 83, for more

information regarding electrical requirements.

Table 1: Electrical Requirements

AC Panel

Voltage

240

HZ

50/60

Phase

1

Full Load

Amps

40.0

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

313296A 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 (behind rear 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

313296A

V

AD

G

J

K

Component Identification

Tandem Supply Systems

D200s Rams Shown

Supply System A

G F AD

H

AF A

J

AE

E

F IG . 3: Tandem Supply System

Key:

A Ram A

B Ram B

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 Control Panel (Ram A and B)

J

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

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

N CAN Communication Cable

AD Air Motor Solenoid (Ram A and B)

AE Junction Box (Ram A and B)

AF Cable Track (Ram A and B)

313296A

To heated manifold

(243697)

B

Supply System B

N

K r_wm2179_313269_4a

D

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.

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

Fluid control module (K). See page 12.

• Integrated air controls (J). See F IG . 4.

• Air motor solenoid (P). Solenoid is on when system 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. Turns on in Recirculate Mode.

The solenoid LED will illuminate when the solenoid is on.

• Depressurize/recirculate fluid valve (R). Depressurizes system when Depressurize Mode is active.

Recirculates fluid when Recirculate Mode is active.

Integrated Air Controls

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

BD

BC

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

BB

10 313296A

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

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.

CGM Module Status LED Signals

Signal

Green on

Yellow

Red

Solid

*Red

(5 flashes)

* ▼ Red

(7 flashes)

Description

System is powered up

Internal communication in progress

CGM hardware failure

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

313296A 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 313296A

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 . 68, page 79).

• When ON, the air motor solenoid is ON and 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 . 69, page 79).

• When ON, the enabled heat zones are ON.

• When OFF, the enabled 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 screens.

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.

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

• Move between field within a drop-down menu.

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

313296A 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:

• activates the air solenoid on the inactive ram of a tandem system, which enables you to purge air and prime the pump;

• clears the Pump Not Primed warning or alarm (depending on setup selection); and

• resets the drum volume remaining to the drum fill volume setpoint.

Press button when in Run Mode.

• 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.

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 313296A

Icon

Crossover

Setback

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 Heat Run screen (F IG . 69, page 79).

313296A 15

Component Identification

User Interface Display

NOTE:

For details regarding the user interface display see

Accessories, page 72.

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 313296A

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 82, 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. 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.

313296A 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.

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 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 top of the enclosure above the connections. This opening is suitable for a

1 in. npt conduit or strain relief fitting (supplied).

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.

Check Connections

Ensure RTD is installed correctly in block of pump heater

Check connections of electrical components on buss line in electrical enclosure

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 313296A

Installation

Adjust Drum Low/Empty Sensor

1.

Position ram at desired level (low or empty).

2.

If necessary, attach low/empty sensor bracket (EA) to mounting bracket (EB).

5.

Make precise adjustments by moving the sensor within the slot on the sensor bracket.

6.

Attach the sensor to the corresponding connector on the D-Sub harness of the remote DataTrak.

EA

EE

ED

EB

F IG . 11: Drum Low/Empty Sensor

NOTE: Follow step 3 only if necessary.

3.

To measure either drum low or drum empty, attach one sensor (EE) to the sensor bracket (EA).

4.

Attach the actuator (ED) to the ram piston rod, near the top, so it passes in front of the sensor (EE) at the desired level for drum low or drum empty. See

F IG . 11.

NOTE: Leave a space (0.13 in. maximum) between

the actuator and the sensor. See F IG . 12.

Space

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.

ED

F IG . 12: Space Between Actuator and Sensor

EE

313296A 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.

FB

F

IG

. 13: Attach Drum Stops

FA

55 gal (200 L)

30 gal (115 L)

8 gal (30 L)

5 gal (20 L)

F IG . 14: Drum Stop Location

20 313296A

Installation

Check Resistance

Check the Resistance Between the Supply

System and the True Earth Ground

Sensor Resistance Checks

Conduct these electrical checks with the main disconnect OFF.

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.

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

2 Fluid Pump

Pin 1 to 3

Pin 1 to 3

Range (ohms)

1000 +/- 2%

1000 +/- 2%

F IG . 15: RTD Connector Pins

313296A 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.

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

Platen

Pump

Between

Terminals

1 and 3

L and N

Unit

Voltage

240

240

Range

(ohms)

15 +5/-5

37 +5/-5

1

3

L

N

F IG . 16: Heater Terminal Pins

22 313296A

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).

Hose Care Guidelines

Refer to the Hotmelt/Warm Melt Heated Hose manual for details regarding hose care guidelines.

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 1/2 in. (13 mm) air line from an air source to the system air inlet, see F IG . 2 (page 8) letter (H) capable of delivering a minimum of 15 cfm (0.4 m

3

/m) at 100 psi (0.7 MPa, 7.0 bar). Do not use quick disconnects.

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 on page 74 for information about setting tempera-

ture controls.

See Run Mode on page 79 for information on control-

ling temperatures for each zone.

F IG . 17: 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.

313296A 23

Installation

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.

3.

Select a pail 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 pail 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 pail if purge material was used.

Use fluids that are chemically compatible with the

equipment wetted parts. See the Technical Data sec-

tions of all the equipment manuals.

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.

24 313296A

Setup

Setup

Flush Before Using Equipment

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 solvent before use. See pump manual for flushing directions.

Set Values on Display Module

Set desired values on display module Setup menus.

See Setup Mode, page 74.

Load Material

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).

7.

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

Secure liner with tape wrapped around circumference of drum.

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.

D

F IG . 18: Heated Platen

NOTE: Before loading material, ensure that there is a minimum overhead clearance of 82 in. (209 cm) and all air regulators are backed off to their full counterclockwise position.

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.

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.

313296A 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 Heater Run screen to turn on the heater.

26 313296A

Setup

Prime

NOTE: To exit Prime Mode before the timer expires, press the Pump Prime key . The display prompts the operator to confirm. See F IG . 20. Select

to exit prime.

1.

Make sure the system is at required temperature.

2.

To prime the inactive ram, ensure that the system is on and in Run Mode.

3.

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

4.

Press the Pump Prime key . The display prompts the operator to confirm. See F IG . 19. Select

to begin prime.

F IG . 20: Exit Prime Mode Confirmation

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

IG

. 20. Display will read “Reset the Prime Time

Counter?” See F

IG

. 21. Select to reset.

F

IG

. 19: Prime Confirmation

5.

Tandem Systems Only: When the timer expires the air motor solenoid LED will turn off.

6.

Prime the system until a smooth flow of material dispenses from the dispense valve.

7.

Lock the dispense valve trigger lock.

F IG . 21: Reset Prime Time Counter Confirmation

313296A 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.

2.

Tandem Systems Only: Press Pump On/Off key

. If system is On, display will highlight key

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.

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

. Select 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.

F IG . 22: System Function Screen

3.

See F IG . 4. 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.

1.

Refer to F IG . 4. Close all air regulators and air valves.

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

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, the ram will stop as it nears the top.

Press and hold both buttons to raise ram completely. See F IG . 5.

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.

28 313296A

Operation

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.

NOTE: To avoid damage to the platen seals, do not use a drum that is dented or damaged.

6.

Remove bleed stick from platen bleed port (J).

7.

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

Secure liner with tape wrapped around circumference of drum.

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.

4.

When new screen appears with prompt, select to start pump.

5.

Keep the director valve (BC) or elevator director valve (DD) 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.

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) or elevator director valve

(DD) to DOWN. Press the prime/flush key.

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 Procedure on page 28.

The automatic crossover feature allows continuous flow and prevents system shutdown. If the active ram encounters a pump runaway, drum empty, or air solenoid disconnected 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, air solenoid disconnected, or not primed alarm.

3.

Press while in the Ram Operation screen.

Manual Crossover

(Tandem Warm Melt Supply System Only)

Press the Crossover key to initiate a manual crossover to the inactive ram, provided the following conditions are met:

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

• air motor solenoid disconnected error does not exist.

• pump runaway and not primed alarms do not exist.

F IG . 23: Ram Operation Screen - Tandem System

313296A 29

Operation

In Ram Operation screen, press the Crossover key

. The display prompts the operator to confirm.

See F IG . 24. Select operation or select

to confirm manual crossover

to cancel.

NOTE:

If the active ram has a pump runaway error, drum empty error, or air motor solenoid disconnected error, the system will attempt an automatic crossover.

Recirculate Function

Use Recirculate Mode to pump fluid from the drum, through the pump, and back into the drum on the currently active ram.

To enter Recirculate Mode, set motor air regulator to 30 psi (0.2 MPa, 2.1 bar). Press the Recirculate key

The display prompts the operator to confirm. Adjust motor air regulator to obtain desired flow rate. See F IG .

25.

.

To exit Recirculate Mode, press the Recirculate key. The display prompts the operator to confirm.

NOTE:

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

F IG . 24: Crossover Function Screen

NOTE:

While in Recirculate Mode, the manual crossover function cannot be used and the inactive ram cannot be primed.

F IG . 25: Enter Recirculate Mode

30 313296A

Operation

Depressurize Function Change Drums

Follow the Pressure Relief Procedure on page 28.

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

NOTE: Follow this procedure to change the drum on a fully heated warm melt supply system.

Use the Depressurize function to relieve fluid pressure from the pump outlet to below the platen on the currently active ram.

NOTE: Follow this procedure for either ram if using a tandem warm melt supply system.

In Run Mode, press the Depressurize key . The display prompts the operator to confirm depressurize or pressurize (depending on current system status). See

F IG . 26.

NOTICE

Be sure to reload the empty supply system with a

full drum of material immediately. Do not raise the ram and remove the platen from the empty drum until you are ready to immediately install a new drum.

Do not use a drum of material that has been

dented or otherwise damaged; damage to the platen wiper can result.

F IG . 26: Depressurize Function Screen

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.

313296A 31

Operation

3.

Once the platen clears the drum, release the blowoff 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 313296A

Maintenance

Maintenance

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

sure Relief procedure.

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.

3.

Remove Quick Coupler:

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

Platen Maintenance

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.

Relieve pressure and disassemble air assist valve.

Refer to Supply Systems Repair-Parts manual.

2.

Clear air assist tube in platen. Clean all parts of valve and reassemble. Refer to Supply Systems

Repair-Parts manual.

3.

Remove bleed stick from platen. Push bleed stick through bleed relieve port (T) to remove material residue.

4.

Remove platen covers.

a.

Remove both platen cover fasteners (70).

b.

Remove both platen covers (49) and ground wire from platen.

70

GB

49

GC

F IG . 27: Remove Quick Coupler

GA ti10508a

Bleed

Stick

43

48

4.

Remove Threaded Coupler: (not shown)

Loosen and remove coupling nut as described in

Check-Mate Pump Packages manual.

5.

Lift air motor rod to bring rod to top of stroke.

6.

Remove wet cup and packing cartridge according to instructions in displacement pump manual(s).

r_wm2179_313296_6a

F IG . 28: Remove Platen Covers and Heaters

313296A 33

Maintenance

5.

Remove excess fluid. Use a soft wire brush on heater coils (48).

6.

Inspect platen heater blocks (43) for burn or melt spots. Replace platen heater blocks if necessary.

7.

Check for loose connections and damaged wires.

8.

Follow steps in reverse order to reassemble platen.

NOTE: Torque platen cover bolts to 60 in-lbs +/- 10 in-lbs.

Remove and Reinstall Platen Wipers

Refer to Supply Units Repair-Parts manual for instructions.

3.

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

Check GFCI Circuit Breaker

1.

With electrical enclosure door still open, switch main disconnect (321) back on.

Have a qualified electrician restore power to main disconnect while electrical enclosure door is open.

Electrical Enclosure

1.

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

2.

Press Test button on GFCI circuit breaker (319). 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.

Power is still connected to the power line filter (359) even after the power is disconnected to the electrical enclosure. Avoid contact with the power line filter.

2.

Open door of electrical enclosure.

359

319

319

321

F IG . 30: GFCI Circuit Breaker

4.

Switch main disconnect off.

F IG . 29: Inside View of Electrical Enclosure

34 313296A

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) from back pump shroud

(52).

5.

Check for damaged wires and connections.

6.

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

80

F IG . 31: Remove Pump Shroud

3.

Remove ground wires.

4.

Remove pump heater front shroud (51).

44

F IG . 32: Pump Heaters

313296A 35

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 36, 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 36, for

details.

Alarm Codes and Troubleshooting

Alarm

Code

MGDX

Alarm Problem

Filter Pressure Drop High

Filter Pressure Drop Low

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

Pressure drop from filter inlet to outlet is above or below maximum drop setpoint for 10 consecutive cycles. Filter is clogged or open.

Remove, inspect, and clean filter. Reset on Filter screen.

Cleared from Status

Screen 2 (Filter). See

Appendix A, page 73.

Ram cannot communicate with

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.

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.

Set inactive ram to Prime mode to automatically clear alarm.

Cleared from Ram Alarm

screen. See Appendix A, page 73.

There is a Runaway alarm Correct runaway condition and clear alarm on Status screen 1.

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

36 313296A

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

Cause Solution

Fluid Control Module (continued)

Pump is running faster than set runaway limit due to:

Correct runaway condition and clear alarm on Status screen 1.

• 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.

Clear Alarm

Cleared from Ram Alarm

screen. See Appendix A, page 73.

Alarm automatically cleared by solution.

A - Drum Empty

B - Drum Empty

A - Not Primed

B - Not Primed

A - Air Solenoid Disconnected

The pump is not primed.

Solenoid unplugged.

Damaged solenoid / wires.

Set inactive ram to Prime mode to automatically clear alarm, or manually clear alarm on Status screen 1.

Cleared from Ram Alarm screen or Ram Operation

screen. See Appendix A, page 73.

Check that solenoid cable is connected.

Inspect solenoid wires for damage.

Alarm automatically cleared by solution.

Alarm automatically cleared by solution.

B - Air Solenoid Disconnected

A - Air Motor Sensor Error

B - Air Motor Sensor Error

A - Drum Low Warning

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.

Check that air motor sensors are connected.

Inspect air motor sensor harness for damage.

Drum low sensor has been activated.

Replace empty drum with full drum to clear.

Cleared from Ram Alarm

screen. See Appendix A, page 73.

Alarm automatically cleared by solution.

B - Drum Low Warning

A - Fluid Solenoid Disconnected Warning

Solenoid unplugged.

Check that solenoid cable is connected.

Inspect solenoid cable for damage.

Alarm automatically cleared by solution.

B - Fluid Solenoid Disconnected Warning

A - Rebuild Platen Seals

Damaged solenoid wires.

B - Rebuild Platen Seals

A - Rebuild Pump

B - Rebuild Pump

Counter has reached selected platen maintenance interval.

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

Counter has reached selected pump maintenance interval.

Perform pump maintenance. See Check-Mate

Displacement Pump manual.

Cleared from Maintenance

screen. See Appendix A, page 73.

Cleared from Maintenance

screen. See Appendix A, page 73.

313296A 37

Alarms

Alarm

Code

DD1X

DD2X

T4AX

T1AX

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.

Temperature Control Modules

Deviation Above Setpoint RTD on wrong module.

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

Shorted module.

Deviation Below Setpoint Tripped circuit breaker.

Replace module.

Visually check circuit breaker for a tripped condition.

Low power.

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.

Measure voltage across terminals 2 and 4. Voltage should measure between

190 and 250 Vac.

GFCI has been tripped.

Measure resistance of heater.

Visually check GFCI for a tripped condition.

Main circuit breaker tripped.

Measure voltage across the disconnect switch. Voltage should measure between

190 and 275 Vac.

Cleared from Ram Alarm

screen. See Appendix A, page 73.

Cleared from Heat Run

screen. See Appendix A, page 73.

Cleared from Heat Run

screen. See Appendix A, page 73.

38 313296A

Alarms

Alarm

Code Alarm Problem

T6AX No Temp Rise

A4AX 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 terminals 2 and 4. 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.

Main circuit breaker tripped.

Bad heaters.

Wrong zone type.

High voltage.

Shorted module.

Cleared from Heat Run

screen. See Appendix A, page 73.

Measure voltage across the disconnect switch. Voltage should measure between 190 and 275 Vac.

Measure resistance of heater.

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

Cleared from Heat Run

screen. See Appendix A, page 73.

Measure voltage across the disconnect switch. Voltage should measure between

190 and 275 Vac.

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

313296A 39

Alarms

Alarm

Code

A1AX

A7AX

T9AX

Alarm Problem

Undercurrent

Unexpected Current

Invalid RTD Reading

T4CX PCB Overtemperature

V4AX

V8AX

High Line Voltage

No Line Voltage

Cause Solution Clear Alarm

Temperature Control Modules (continued)

Tripped circuit breaker.

Visually check circuit breaker for a tripped condition.

Low power.

Measure voltage across terminals 2 and 4. 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.

Main circuit breaker tripped.

Wrong zone type.

Shorted module.

Bad RTD.

Bad RTD connection/loose wire.

Component not plugged in.

Cleared from Heat Run

screen. See Appendix A, page 73.

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.

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

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

Check for loose or disconnected wires and plugs.

Cleared from Heat Run

screen. See Appendix A, page 73.

Cleared from Heat Run

screen. See Appendix A, page 73.

Overheated Temperature Control Module.

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

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 Appendix A, page 73.

Incoming line voltage is too high.

Tripped circuit breaker.

Measure voltage across disconnect switch. Voltage should measure between

190 and 250 Vac.

Visually check circuit breaker for a tripped condition.

GFCI has been tripped.

Visually check GFCI for a tripped condition.

Cable unplugged/loose wire.

Check for loose or disconnected wires and plugs.

Cleared from Heat Run

screen. See Appendix A, page 73.

Cleared from Heat Run

screen. See Appendix A, page 73.

40 313296A

Alarms

Alarm

Code Alarm Problem Cause Solution Clear Alarm

V4MX

V1MX

A4CX

A1CX

High DC Voltage

Low DC Voltage

High Contactor Current

Low Contactor Current

A7CX Unexpected Contactor Current

Temperature Control Modules (continued)

Faulty DC power supply.

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

Cleared from Heat Run

screen. See Appendix A, page 73.

Faulty DC power supply.

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

Cleared from Heat Run

screen. See Appendix A, page 73.

Broken Temperature Control

Module.

Broken contactor.

Broken contactor.

Disconnected or loose wire.

Broken Temperature Control

Module.

Broken Temperature Control

Module.

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.

Cleared from Heat Run

screen. See Appendix A, page 73.

Cleared from Heat Run

screen. See Appendix A, page 73.

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.

Cleared from Heat Run

screen. See Appendix A, page 73.

313296A 41

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.

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

3.

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

Cause Verification Solution

Main circuit breaker tripped. Measure voltage across disconnect switch; voltage

GFCI has been tripped.

No graphics are shown on display screen.

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.

1.

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

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

2.

Replace faulty display.

Replace display module.

42 313296A

No heat.

Problem

313296A

Troubleshooting

Cause

Tripped circuit breaker.

Low power.

Cable unplugged/loose wire.

Circuit breaker not set for

L2 and L3.

Zone not enabled.

Incorrect temperature set point.

Bad heater.

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.

2.

Have a qualified electrician service electrical components.

Attach plug/wire.

Check for loose or disconnected wires and plugs.

Visually check circuit breaker for proper setting of

L2 and L3.

1.

Disconnect incoming power.

2.

Remove wires from circuit breaker.

3.

Remove circuit breaker from base.

4.

Pull white tab to allow white piece to slide into correct location.

5.

Install circuit breaker onto base.

Verify zone is enabled on

Run screen.

6.

Install wires in circuit breaker.

Enter Setup screen and enable correct zone.

Verify zone has a correct temperature setting on Run screen.

Measure resistance of heater.

Enter Setup and enter correct temperature.

1.

Unplug suspected heater zone from heater module. Follow

Heater Resistance

Checks, page 22.

2.

Measure resistance of heater and compare to resistance chart under

Heater Resistance

Checks, page 22.

3.

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

43

Troubleshooting

Problem

No heat (continued).

Missing module.

Cause

Contactor not closing.

Modules not on network.

Cable disconnected.

Module with wrong rotary switch setting.

Verification Solution

Turn on heat for zone A1 or

B1and ensure contactor closes.

1.

Verify cable 15W902 from the high power

TCM is connected correctly.

Verify attached modules through Setup Version screen.

Verify all green LEDs are illuminated and yellow

LEDs are flashing.

Verify rotary switch is set correctly.

2.

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

See F IG . 71.

3.

Verify there is 24 Vdc between 2 wires on

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

Alarms, page 36.

4.

Replace contactor.

Enter Setup screen and scroll to component list page. This screen lists all components corresponding software revision number on network.

Reconnect/replace faulty cable.

1.

Remove power from unit.

2.

Remove access cover and visually check rotary switch setting.

3.

If incorrect, set to correct setting. See

Upgrade Temperature Control Module

Software, page 52,

and Upgrade FCM

Software, page 56.

4.

Replace access cover.

44 313296A

Problem

Heating is slow.

Heating over shoots.

Does not crossover.

Troubleshooting

Cause

Heater defective.

Low power.

Verification

Measure resistance of heater.

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

190 and 275 Vac.

Solution

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.

Shorted module.

Alternate ram has an empty sensor activated.

Alternate pump is not primed.

Alternate pump has an active alarm.

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

Verify ram has material.

Verify alternate ram is ready to run.

See Alarm Codes and

Troubleshooting, page 36.

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 36.

313296A 45

Repair

Repair

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

sure Relief Procedure and the Flush Before Using

Equipment procedure prior to performing repair pro-

cedures.

Air Motor

Remove Air Motor

1.

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

2.

See Disconnect Displacement Pump in

Check-Mate Pump Packages manual.

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

3.

Disconnect air hose and ground wire from air motor.

4.

Disconnect air motor: a.

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

in. supply systems): Loosen nut (HB) below crossbar. Use wrench to hold lift ring adapter

(HD) in place and loosen threaded rod (HC) above crossbar with another wrench.

HC

5.

Using a capable hoist, secure air motor to hoist and remove air motor.

6.

Refer to NXT Air Motor manual for repair instructions.

Install Air Motor

D200 3 in. and D200s 6.5 in. Supply Systems

55 Gallon Platen:

1.

Using a capable hoist, insert tie rods into displacement pump and secure air motor to pump.

a.

See Reconnect Displacement Pump in

Check-Mate Pump Packages manual.

b.

Install threaded rod (HC) through center hole in the crossbar. Install lock washers (HE) and nuts

(HA, HB) onto threaded rod (HC), both above and below crossbar. Use wrench to hold lift ring adapter (HD) and tighten threaded rod (HC) into

lift ring adapter using another wrench. See F IG .

34.

c.

Tighten nut (HB) below crossbar to 25 ft-lb (34

N•m) maximum.

d.

Tighten nut (HA) above crossbar to lock motor in place.

HA

HE

HC

HA

HB

HD

HB

HD

TI10649A

F IG . 34: 55 Gallon Platen - Install Air Motor

2.

Connect air hose and ground to wire to motor.

TI11169A

F IG . 33: 55 Gallon Platen - Remove Air Motor

46 313296A

Repair

Displacement Pump

Remove Displacement Pump

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

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

HD

HA

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 46.

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 section, page 49, to remove pump heater shrouds (51,

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

HB

F IG . 36: Raise Air Motor

TI10648A

5.

See Disconnect Pump from Platen, page 48, 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.

51

44

46

44

52

F IG . 35: Remove Pump Heater Shrouds

313296A 47

Repair

Install Displacement Pump

D200 and D200s Supply Systems

1.

Insert displacement pump on platen. See Connect

Pump to Platen, page 48.

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.

3.

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

103a

103b

103c

F IG . 38: 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.

Connect Pump to Platen

TI10515A

F IG . 37:

Disconnect Pump from Platen

The pump is mounted to the platens by mounting Kit

255392 or Kit 257630.

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 47.

55 Gallon Platen

1.

Use two people to set pump onto platen.

2.

Secure pump to platen with screws (xxx) and clamps (xxx). See F IG . 38.

3.

Lower air motor.

4.

See Reconnect Displacement Pump in

Check-Mate Pump Packages manual.

48 313296A

Repair

Replace Pump Heaters

1.

Remove screws (80) from back pump heater shroud

(52).

2.

Remove ground wires.

3.

Remove pump heater front shroud (51).

4.

Remove pump heater bands (44): 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 58.

d.

Remove RTD sensor (46). Loosen screw on sensor support (45) and slide RTD out.

5.

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.

6.

Reinstall RTD sensor and tighten screw on sensor support.

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

7.

Reinstall pump heater front shroud.

8.

Reinstall ground wires.

9.

Reinstall back pump heater shroud, and secure with screws.

Replace Platen Heaters

44

1.

Remove both platen cover fasteners (70).

2.

Remove both platen covers (49) and ground wire from platen.

70

45

46

49

44

59

11

64

F IG . 39: Remove Pump Heaters

43

313296A

58

82

F IG . 40: Replace Platen Heaters r_wm2179_313296_6a

49

Repair

3.

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 wires on top of terminal box.

See Electrical Schematics, page 58.

d.

Remove screws (58) and washers (82).

Remove platen heater blocks and RTD sensors

(46) together.

4.

Install new platen heater blocks and RTD sensors.

Secure RTD sensors with screws and washers.

Secure platen heater blocks with nuts and washers.

5.

Reconnect four wires on top of terminal block.

6.

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

7.

Reconnect ground wire, and install platen covers.

Secure platen covers with fasteners. Torque platen cover fasteners to 60 in-lbs +/- 10 in-lbs.

8.

Reconnect displacement pump using screws and clamps.

Replace Ram Piston Rod Seals

1.

Support electrical enclosure (7) using a loop and a hoist.

2.

Remove screws from bracket (50) connecting electrical enclosure (7) to ram piston rod and cable track

(42).

42

7

50

Replace Platen Wipers

Refer to Supply Systems Repair-Parts manual for instructions.

F IG . 41: Replace Rod Seals

3.

Gently move cable track and bracket to side.

4.

See Supply Systems Repair-Parts manual for replacement instructions.

50 313296A

Repair

Electrical Enclosure

Prior to repairing any component of the electrical enclosure (7), 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 (359) even after the power is disconnected to the electrical enclosure. Avoid contact with the power line filter.

308

Outbound

Power

RTD

311

Outbound

Power

RTD

F IG . 43: Back View of Electrical Enclosure

Replace Low Power Temperature Control

Module(s)

1.

Open enclosure door (302). Disconnect the following cables from low power TCM (308):

• incoming power supply cable (330)

• outbound power supply cable

• RTD cable

359

330

308

2.

Remove both screws (309) holding low power TCM

to base (308). See Electrical Enclosures Parts, page 70.

3.

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

Replace Base

1.

Remove low power TCM. See Replace Low Power

Temperature Control Module(s).

2.

Disconnect two CAN cables from base (307).

3.

Remove four screws (309) and ground screw 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

311

Selector

Switch

TI12361a

329

331

322

F IG . 42: Internal View of Electrical Enclosure

328

F IG . 44: Set Selector Switch

7.

Reinstall low power TCM. See Replace Low Power

Temperature Control Module(s).

313296A 51

Repair

Replace High Power Temperature Control

Module

1.

Open enclosure door (302). Disconnect outbound power supply and RTD cables from high power TCM

(311). See F IG . 43.

2.

Remove electrical enclosure panel (336).

3.

Disconnect all four incoming cables (322, 328, 329,

331) from high power TCM. See F IG . 42.

4.

Remove both screws (315) that secure brackets

(312, 313) of high power TCM to electrical enclo-

sure. Remove high power TCM. See Electrical

Enclosures Parts, page 70.

5.

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

NOTE: Reuse brackets (312, 313) to install new high power TCM.

6.

Remove cover of new high power TCM and set selector switch to “0” for Ram A or “1” for Ram B.

Upgrade Temperature Control Module

Software

1.

Open enclosure door (302). Remove access cover from module(s).

Token

Access

Cover

TI12358a

Access

Cover

F IG . 45: Set Selector Switch

Selector

Switch

TI12360a

TI12354a

F IG . 46: Access Cover and Token

2.

Insert and press token firmly into slot.

NOTE: There is no preferred orientation of token.

3.

Turn on power to electrical enclosure (7). The token automatically downloads the new software if an older version is detected. The red indicator light will flash up to three seconds after the software is uploaded.

4.

Turn power to electrical enclosure off, and then back on.

5.

Remove token.

6.

Replace access cover.

7.

Close enclosure door.

52 313296A

Repair

Replace Circuit Breakers

1.

Open enclosure door (302). Disconnect wires from circuit breaker (317, 319).

2.

Push in circuit breaker tab and pull out breaker.

4.

Remove screws (12) and washers (11) from bottom bracket (39) and side bracket (50) of enclosure.

11, 12

317

50

7

319

39

F IG . 48: Replace Electrical Enclosure

317

F IG . 47: 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.

Insert loop and hoist into lift ring at top of electrical enclosure (7).

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.

313296A 53

Repair

Display/User Interface

Upgrade Software

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.

Remove four screws and then access cover.

Replace Display

NOTE: Order Kit 257165 for replacement.

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 both CAN cables.

4.

Replace with new display. Reconnect both CAN cables.

5.

Snap display into bracket and reconnect power.

Screws

Access

Cover

Indicator

Light

Token r_xm1a00_312359_313289_2a

F IG . 49: Upgrade Display Software

4.

Insert and press token firmly into slot.

NOTE: There is no preferred orientation of token.

5.

Turn power on.

6.

The red indicator light will flash until new software is completely loaded. After the software load is complete the yellow light will constantly flash.

7.

Turn power off.

8.

Remove token.

9.

Reassemble access cover and screws.

10. Snap display back into bracket and reconnect power.

54 313296A

Replace Fluid Control Module

Repair

5.

Loosen both screws from FCM and pull FCM off base (33).

1.

Disconnect power to system.

2.

Remove front shroud (16) and back shroud (17).

16

41

Screws

17

F

IG

. 50: Remove Shrouds

3.

Disconnect all cables from FCM (36).

4.

Remove access door (41).

31

36

33

28

F IG . 51: Remove FCM

6.

Replace with new FCM, and secure with screws.

7.

Reconnect cables to FCM.

8.

Reassemble front and back shrouds.

9.

Reconnect power to system.

Replace Base

1.

Disconnect power to system.

2.

Remove FCM (36). See Replace Fluid Control

Module.

3.

Disconnect both CAN cables.

4.

Remove screws (28) and ground screw (31) from

base (33). See F IG . 51.

5.

Replace with new base, and secure with screws.

6.

Reconnect both CAN cables.

7.

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

B. See F IG . 52.

8.

Reinstall FCM. See Replace Fluid Control Mod-

ule.

313296A 55

Repair

Upgrade FCM Software

1.

Disconnect power to system.

2.

Remove front shroud (16) and back shroud (17).

3.

Remove access cover (41) from FCM (36).

4.

Insert and press token firmly into slot.

NOTE: There is no preferred orientation of token.

5.

Turn on power. The token automatically downloads the new software if an older version is detected. The red indicator light will flash up to three seconds after the software is uploaded.

Replace Cable Track

NOTE: Order Kit 257163 for replacement.

1.

Disconnect power to system.

2.

Disconnect all 10 cables from back of electrical enclosure (7). Cables can hang to side of electrical enclosure.

Indicator

Light

Selector

Switch

F

IG

. 52: FCM - Update Software

Token

TI12335A

6.

Turn power off, and then back on.

7.

Remove token and replace access cover.

8.

Reinstall front and back shrouds.

F IG . 53: Back View of Electrical Enclosure

3.

Remove screws (71) from bracket (50) that connect cable track (42) to electrical enclosure (7) and ram.

50

42

71

7

F

IG

. 54: Cable Track Bracket

56 313296A

Repair

4.

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

5.

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

6.

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

7.

Remove mounting screws (71) securing cable track assembly (42) to junction box.

42

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.

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 on back of electrical enclosure.

14. Reconnect power to system.

61

96

90, 91

F IG . 55: Junction Box

71

12

313296A 57

Electrical Schematics

Electrical Schematics

Ram A Schematic

W IT CH

D I S PL AY

58 313296A

Ram B Schematic

Electrical Schematics

313296A 59

Electrical Schematics

Displacement Pump and Platen Schematics

60 313296A

Junction Box Schematic

Electrical Schematics

313296A 61

Electrical Schematics

Cable Track Schematic

62 313296A

Electrical Enclosure Schematic

Electrical Schematics

313296A 63

Parts

Parts

D200s Rams Shown

Single Supply System or Supply System A

4

7

6

7

Supply System B

4

6

8

2

8

2

5

1

3

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

Warm Melt supply system.

Ref. Part

1 ❄

Description

RAM ASSEMBLY, D200s, 6.5 in.

RAM ASSEMBLY, D200si, 6.5 in.

RAM ASSEMBLY, D200, 3 in.

RAM ASSEMBLY, D200i, 3 in.

2 see Table PUMP, Check-Mate; see manual

1, page 7 312375 for parts

3 ❄ 257748 PLATEN, 55 gal., PTFE-coated o-ring, EPDM

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

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

4 ❄ 255305 KIT, mounting, pump; 3 in.; 55 gal.

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

5 ❄ 255392 KIT, mounting; Check-Mate pump

6 ❄ 103347 VALVE, safety relief; located out of view, on back side of air controls

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

3

5

Ref. Part

7

8

9

Description

ENCLOSURE, electrical (see Elec-

trical Enclosures Parts, page 70)

257158 For single systems and Ram A

257291 For Ram B

KIT, warm melt, with display (see

Warm Melt Kits for D200 Systems, page 65)

24C489 For D200 and D200i Ram A

24C491 For D200s and D200si Ram A

257316 For D200 and D200i single systems

257317 For D200s and D200si single systems

KIT, warm melt, with no display (see

Warm Melt Kits for D200 Systems, page 65)

24C490 For D200 and D200i Ram B

24C492 For D200s and D200si Ram B

❄ See Supply Systems Repair-Parts manual for parts.

Qty.

1

1

1

1

1

1

1

1

64 313296A

Parts

Warm Melt Kits for D200 Systems

Kit 257316 with Display for D200 and D200i Systems

Kit 257317 with Display for D200s and D200si Systems

Kit 24C489 with Display for Ram A of Tandem D200 and D200i Systems

Kit 24C490 without Display for Ram B of Tandem D200 and D200i Systems

Kit 24C491 with Display for Ram A of Tandem D200s and D200si Systems

Kit 24C492 without Display for Ram B of Tandem D200s and D200si Systems

Kit 257317 Shown

20

12

11 23

65

26

27

60

15

13

14

22

24

16

21

47

66

38

81

19

12

11

32

37

35

34

36

41

33

30

28

313296A

50

71, 72, 73

18

11

12

75

76

17 r_wm_2179_313296_5a

65

Parts

66

86

52

78

61, 62

101

80

42

72, 73

101

88

83, 84, 85

11, 12

39

40

11, 26, 58, 59

71

54, 55

53 r_wm_2179_313296_12a

313296A

51

87

46

45, 79

1

Torque to 12 ft-lbs (16.2 N•m)

49

48

43

46, 56, 82

313296A

Parts

44

103c

68, 69, 97, 98

67, 99

103a

103b

70

63

64

11

59

1

57, 97, 100, 102

67

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

14

15 ❖ 15G347

16

†277589

◆ 277591

17

†277590

◆ 277592

18

†255383

◆ 15R108

19 ❖

20

257165

21 ✿✓

22

✿✓

23 ✿ 121250

24 ✿ 102040

25 ★

‡123328

✖ 15X968

26

110755

27 ✿ 121253

28

29 ★

114417

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

17

1

1

1

1

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

SUPPRESSOR, ferrite bead

1

1

4

4

5

1

1

1

1

1

2

1

1

Ref.

30

31 ★

Part

121070

Description

SCREW, machine; #8-32 x 1

3/8

CABLE, CAN, female/female;

0.5 m

Qty.

1

1

121001

121228

32 ❖ 101213

33 289697

34‡ ✖ 122716

35‡

257915 36

37‡

38 15R121

39

† ❋ 15W703

◆✠

15W704

40

16A566

◆✠ 15W366

41

277674

42 257163

43

15V429

44 ✛ 121980

45

C03507

46 ●✛ 15R347

47

119832

48 ● 15V427

49 ◗●

Kits 24C490 and 24C492 only

NUT, full, hex

MODULE, cube, base

SENSOR, inductive, M12

BRACKET, sensor, low/empty

MODULE, fluid control

ACTUATOR, sensor, low/empty

LABEL

BRACKET, mounting, bottom

BRACKET, mounting

ENCLOSURE, cube door

CABLE, track

CONDUCTOR, block, heater

HEATER, pump, 725 watt

SUPPORT, sensor

SENSOR, RTD; 1k ohm

BOLT, eye, 3/8-14 x 6

HEATER, coil

COVER, platen front, assy.

1

1

1

1

1

1

1

1

1

1

2

1

2

2

2

2

1

1

68 313296A

Parts

73

75

76

78

79

89

90

91

92

93

94

95

96

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

120223

100020

80 110637

81

119958

82

83

84 ❂ 121456

85

86 ▲ 15J075

87

15H668

88 15J076

97

98

99

100179

121255

15W708

C31012

24B810

C19208

102794

15X538

100028

100166

100

101

189930

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

Qty.

1

1

1

4

4

4

1

1

4

12

4

2

6

1

1

1

1

1

1

1

4

1

1

1

1

1

1

1

2

1

1

6

5

2

4

1

4

4

4

4

1

2

1

2

6

2

4

1

2

Ref.

102

Part

103 255392

Description

WIRE, ground

KIT, mounting, displacement pump

SCREW, cap

CLAMP

O-RING

Qty.

2

1

130a 102637

103b 276025

103c 109495

★ Not shown.

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

Kit 257316 only.

◆ Kit 257317 only.

✿ Kits 24C489 and 24C491 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).

4

4

1

313296A 69

Parts

Electrical Enclosures Parts

257158 for single supply systems and ram A of tandem supply systems

257291 for ram B of tandem supply systems

257158 Shown

343, 358

341 340

301

351

336

337

342

338

346

339

339

339

339

Side View

345

344

302, 303, 304, 305

352

333, 334, 335

307

327

357

315, 326

325, 353

356

308, 309, 310

330

329

312

315

326

314

317

320, 354

318

360

313

322

315, 326

311

332

328

331

70

359

306

361

315

316

319

317

321

323

324

313296A

Parts

Electrical Enclosure Parts

Ref.

Part Description Qty.

301

302

ENCLOSURE

DOOR, enclosure

303 101682 SCREW, cap, sch

304 100016 WASHER, lock

305 100015 NUT, hex, mscr

306 15X754 BRACKET, mounting, electrical

307 289697 MODULE, cube, base

308 256270 MODULE, low power temp

309 114417 SCREW, self tap, pan hd

310 121070 SCREW, machine, pan hd

311 255774 MODULE, high power temp

312 15U651 BRACKET, high power temp module

313 15R535 BRACKET, mounting, high power temp module

314 117831 SCREW, machine, pan hd

315 100035 SCREW, machine, pan hd

316 122148 BAR, buss, smissline; 17.125 in.

317 122124 CIRCUIT, breaker, smissline; 8A

1

(257291 includes qty. of 3)

318 122129 COVER, buss bar

319 122128 CIRCUIT, breaker

320 16A573 WIRE, power

321 122122 SWITCH, disconnect

322 122317 ROD, connecting, on/off

323 122125 RELAY, contactor

324 123141 CIRCUIT, breaker, smissline; 25A

325 111640 WASHER, lock, internal

326 157021 WASHER, lock, internal

327 KIT, bar, ground

328 257341 HARNESS, wiring, high power temp module

329 121597 CABLE, CAN, 90 female/90 female 3

330 15V999 CABLE; 14 in.

3

331 CABLE; M8, male/ferrules 1

332 121000 CABLE, CAN, female/female; 0.5 m 1

333 100023 WASHER, flat

334 100133 WASHER, lock

4

4

335 100307 NUT, hex

336 PANEL, side, 3 low power heat

4

1

1

1

1

1

1

1

2

2

10

1

1

337

338

339

340 modules, 1 hp

GASKET, low power heat module

GASKET, high power heat module

LABEL, junction box

CORD, grip; PG-7

341 GRIP, cord

342 121612 CONNECTOR, thru; M12, m x f

343 112788 SCREW, cap, socket hd

344 LATCH, quarter turn

345 15W905 HANDLE, selector, on/off

346 190774 LABEL

351 SEAL, hole, plug; 0.5 in.

352 194337 WIRE, grounding, door

353 100166 NUT, full hex

354

355

INSULATOR, boot

WIRE, chassis, ground

356 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

357 186620 LABEL, ground

358 112905 WASHER, plain

359 123373 FILTER, power line; single phase

360 123374 SUPPLY, power; 24Vdc, 2.5A, 60W

361

(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.

313296A 71

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 F (100 C).

Four-Zone Accessory Kit, 24C526

Controls two zones of heat; up to F (100 C).

Light Tower Accessory Kit, 255468

For use with Warm Melt or Tandem Supply Systems.

Low or Empty Sensor Kit, 24C530

Indicates when the drum is empty or low. Includes only one sensor that can be used as either an empty sensor or low sensor. For use with Warm Melt, Ambient, and

Tandem Supply Systems with DataTrak.

72 313296A

Appendix A

Appendix A

Display Module 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.

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 warnings, nothing is displayed.

Mode

The mode section displays the current system mode.

The current mode is highlighted.

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, users must select

to access those fields to make changes.

F IG . 56: Power Up Screen

Menu Bar

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

Navigation within Screens

Press to open drop-down menus on Setup screens. Also, press make a selection.

to enter your changes or

F IG . 57: 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.

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

select digits within a field to change.

Press to navigate to new screens and to navigate up and down within a screen. Also press to move between fields within a drop-down menu, and to increment or decrement numbers within a field.

313296A 73

Appendix A

Setup Mode

Setup mode enables users to set system parameters.

Password Screen

In Run Mode, press the Setup key . If the password is not set to 0000, the Password screen will appear.

Enter the password to continue in Setup Mode.

System Setup

This screen enables users to change system setup parameters.

To set or change the password, press screen. Press

Press

to enter the

to select digit to change.

to set value for each digit. Press

again to save the new password.

F IG . 59: System Setup

F IG . 58: Password Screen

Table 8: System Setup Parameters

Parameter Icon

Operating

Mode

Not

Primed

Event

Prime

Time

Units

Tandem, Ram

A, Ram B

Warning,

Alarm

Minutes

Range

Select as desired

Select as desired

1 - 9

Pump

Runaway

Limit

Cycles per

Minute

0 - 99 (Default is 60; 00 disables)

74 313296A

Heater System Setup Screen

This screen enables users to set the parameters for each heater zone.

Appendix A

Maintenance Setup Screen 1

This screen enables users to change system and platen seal maintenance intervals.

F IG . 60: Heater System Setup Screen

Table 9: Heater System Setup Parameters

Parameter Icon

Setpoint

Units

Degrees

Range

Set as desired

Enable/

Disable

Zone

Alarm

Temperature

Warning

Temperature

Set back

Temperature

Shared

Zone

Enabled or disabled

Select as desired

Degrees above setpoint

Degrees above setpoint

Offset from setpoint

0 - 30° C

0 - 25° C

< setpoint

Enabled or disabled

Select as desired

F

IG

. 61: Maintenance Setup

Table 10: Maintenance Setup Parameters

Parameter Icon

Rebuild

Platen

Seals

(A and B)

Rebuild

Pump

(A and B)

Units

Drums

Range

0 - 9999

(0 disables)

User Settable 0 - 999

(0 disables)

313296A 75

Appendix A

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.

NOTE: Set the low limit to detect a filter element collapse or a missing element.

NOTE: Set the high limit to detect a clogged filter.

For more information regarding fluid filter pressure, Also

see Status Screen 2. Monitor the filter pressure read-

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

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.

F IG . 62: Hardware Setup Screen 1 (Filter)

Table 11: Hardware Setup Screen 1 Parameters

Parameter Icon

Filter Mode

Units Range

Disabled

Monitor warning

Select warning or alarm as desired

User Settable 0 - 1000 Filter

Monitor

Low Limit

Filter

Monitor

High Limit

User Settable 0 - 5000

F

IG

. 63: Hardware Setup Screen 2

Table 12: Hardware Setup Screen 2 Parameters

Parameter Icon

Fluid

Solenoid

Installed

Drum Low

Sensor

Installed

Units

Enable or disable for Ram

A and Ram B

Enable or disable for Ram

A and Ram B

Range

Select as desired

Select as desired

76 313296A

Advanced Setup Screen 1

This screen enables users to set units that display on other screens.

Appendix A

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.

F

IG

. 64: Advanced Setup Screen 1

Table 13: Advanced Setup Screen 1 Parameters

Parameter Icon

Volume

Unit

Maintenance Unit

Pressure

Unit

Units cycles/gal.

(US), gal. (UK), oz

(US), oz (UK), liters/cc

Range

Select as desired

1000 cycles, drums,

1000 gal. (US),

1000 gal. (UK),

1000 liters psi, bar

Select as desired

Select as desired

Password

Temperature Units

Digits

°F, °C

0 - 9999

0000 = no password

Select as desired

F IG . 65: Advanced Setup Screen 2

Table 14: Advanced Setup Screen 2 Parameters

Parameter Icon

Pump Size

(A and B)

Units cc/cycle

Range

_ _ _

(60, 100,

200, 250, or

500)

User Settable 1 - 9999 Drum Fill

Volume

(A and B)

313296A 77

Appendix A

Advanced Setup Screen 3

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

Advanced Setup Screens 4 and 5

These screens contain software part number and version information for system components.

F IG . 66: Advanced Setup Screen 3

Table 15: Advanced Setup Screen 3 Parameters

Parameter Icon

Date format

Current date

Details

Set date format. Select between MM-DD-YYYY or

DD-MM-YYYY

Set current date

Current time Set current time

F IG . 67: Advanced Setup Screens 4 and 5

Table 16: Advanced Setup Screen 4 and 5

Parameters

Parameter Icon

Controller software

Details

Software part number and version

Display software

Fieldbus software

Software part number and version

Software part number and version

78 313296A

Appendix A

Run Mode

The Run screens display information related to system operation.

Ram Operation Screen

The Ram Operation screen displays which ram (A or B) is active and how much volume is remaining in each drum. When the fluid line is shown filled the system is on.

This screen also displays the flow rate of the active ram.

Heat Run Screen

The Heat Run screen displays information for the four

heater zones. See F IG . 69 for information about 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.

System component being heated

Zone set point

Active ram is highlighted

Volume

Units

Fluid line shown filled when system is ON

Zone number

F IG . 69: Heat Run Screen - Ram A

Zone temperature

Current screen

F IG . 68: Ram Operation Screen - Tandem System

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

• depressurized

• in Recirculate Mode

• or if the inactive ram is in Prime Mode

313296A 79

Appendix A

Status Screens

NOTE: Press

Status screens.

to navigate among the

Status Screen 1

This screen displays the job totals and grand totals.

Status Screen 2

NOTE: Status screen 2 is only available if the filter

option is enabled. See Hardware Setup Screen 2, page 76.

This screen displays the fluid filter inlet pressure, outlet pressure, and the pressure drop across the filter.

F IG . 71: Status Screen 2 (Filter)

F IG . 70: Status Screen 1

To reset a job total for a single ram (A or B), 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.

NOTE: Grand totals cannot be reset.

Table 17: Status Screen 1 Parameters

Parameter Icon

Job Total

Details

Indicates pump cycle count total for a single job.

Grand Total

Ram A

Ram B

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.

• Filter Pressure Drop Low Warning will appear if the pressure drop is below the setpoint for 10 consecutive pump cycles.

• Filter Pressure Drop High Warning will appear if the pressure drop is above the setpoint for 10 consecutive pump cycles.

NOTE: To clear a warning, navigate to the warning and press . When prompted, press to confirm.

Table 18: Status Screen 2 Parameters

Parameter

Fluid Filter Inlet

Pressure

Icon Units psi psi Fluid Filter Outlet

Pressure

Pressure Drop psi

80 313296A

Appendix A

Maintenance Screen

The maintenance screens enable users 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.

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

Alarm Screens

The alarm screens display the type of alarm currently occurring on each ram.

F IG . 72: Maintenance Screen

To reset the counter to, navigate to the counter and press . When prompted press to confirm.

Table 19: Maintenance Screen Parameters

Parameter

Platen

Maintenance

Pump

Maintenance

Unit

Measurement

Pump Cycle

Measurement

Icon Details

Current count for when platen requires maintenance

Current count for when pump requires maintenance

Number of drums used before platen requires maintenance

Number of pump cycles before pump requires maintenance

F IG . 73: Ram Alarm Screen

Report Screens

The Report screens display a chronological list of the

most recent 20 errors. See Alarm Codes and Trouble-

shooting, page 36, for details regarding each alarm

code.

NOTE: Press report screens.

to scroll through the three

F IG . 74: Report Screen

Parameter

Error Number

Icon

Date

Time

Table 20: Report Screen Parameters

Error Code

Details

Chronological order of errors as they occur

Date on which error occurred

Time at which error occurred

Error code

313296A 81

Dimensions

Dimensions

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)

82 313296A

Technical Data

Technical Data

Max air input pressure (supply system)

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

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

PTFE, EPDM, PTFE coated aluminum, zinc plated carbon steel, 316 sst

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

EPDM, aluminum, zinc plated carbon steel, 316 sst

A: 255664, 55 gal. (200 L) . . . . . . . . . . . . . . . . . . . . .

PTFE, neoprene, 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, 40 amps max draw

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

313296A 83

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.

This manual contains English. MM 313296

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2009, Graco Inc. is registered to ISO 9001 www.graco.com

07/2009

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