Graco 313296J User Manual

Page 1

Instructions - Parts

Warm Melt Supply

313296J

Systems

For use with heated bulk supply of medium to high viscosity sealant and adhesive materials. Not for use in hazardous locations. Intended for indoor use only.

D60 3 inch dual post

60 liter (16 gallon), 30 liter (8 gallon), and 20 liter (5 gallon) sizes

150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure

D200 3 inch dual post

200 liter (55 gallon)

150 psi (1.0 MPa, 10 bar) Maximum Air Inlet Pressure

D200S 6.5 inch dual post

200 liter (55 gallon)

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

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 4 for model information.

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

D200s (WM2179) Shown

Page 2

Contents

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

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

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

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

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

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

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

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 8

Single Supply Systems . . . . . . . . . . . . . . . . . . . . . . . . . 8

Tandem Supply Systems . . . . . . . . . . . . . . . . . . . . . . .9

Integrated Air Controls . . . . . . . . . . . . . . . . . . . . . . . . 10

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-Button Interlock Air Controls . . . . . . . . . . . . . . . . . . 11

Communications Gateway Module . . . . . . . . . . . . . . . 11

Fluid Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . 12

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

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

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

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Connect Power Source . . . . . . . . . . . . . . . . . . . . . . . . 18

Install/Adjust Drum Low or Empty Sensor . . . . . . . . . 19

Light Tower Accessory . . . . . . . . . . . . . . . . . . . . . . . . 19

Attach Drum Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Check Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Hose Installation and Care . . . . . . . . . . . . . . . . . . . . . 23

Overview of Temperature Control Settings . . . . . . . . . 23

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Replace Throat Seals . . . . . . . . . . . . . . . . . . . . . . . . . 32

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

D200 Single Ram Schematic . . . . . . . . . . . . . . . . . . . 61

D200 Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . 62

D200 Ram B Schematic . . . . . . . . . . . . . . . . . . . . . . . 63

D200 Displacement Pump and Platen Schematics . . 64

D200 Junction Box Schematic . . . . . . . . . . . . . . . . . . 65

D200 Cable Track Schematic . . . . . . . . . . . . . . . . . . . 66

D60 Single Ram Schematic . . . . . . . . . . . . . . . . . . . . 67

D60 Ram A Schematic . . . . . . . . . . . . . . . . . . . . . . . . 68

D60 Ram B Schematic . . . . . . . . . . . . . . . . . . . . . . . . 69

D60 Pump and Platen Schematic . . . . . . . . . . . . . . . . 70

D60 Junction Box Schematic . . . . . . . . . . . . . . . . . . . 71

D60 Cable Harness Schematic . . . . . . . . . . . . . . . . . 72

Electrical Enclosure Schematic . . . . . . . . . . . . . . . . . 73

Electrical Enclosure Schematic . . . . . . . . . . . . . . . . . 74

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Warm Melt Kits for D200 Systems . . . . . . . . . . . . . . . 78

Warm Melt Kits for D60 Systems . . . . . . . . . . . . . . . . 83

Electrical Enclosure Parts . . . . . . . . . . . . . . . . . . . . . . 90

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Appendix A - User Interface Display . . . . . . . . . . . . . . . 93

Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Display Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Setup Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . . 95

Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

D200 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

D60 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . 108

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

2 313296J

Page 3

Related Manuals

Manuals are available at www.graco.com.

Component Manuals in U.S. English:

Manual Description

313528 Tandem Supply Systems Operation 313529 Tandem Supply Systems Repair-Parts 313526 Supply Systems Operation 313527 Supply Systems Repair-Parts

Check-Mate

312375

Instructions-Parts

Check-Mate

312376

312468

311238 NXT

Instruction-Parts 200 cc Check-Mate Displacement Pump

Repair Parts

™

312374 Air Controls Instructions-Parts

3A0099

3A0100

Two-Zone Enclosure Expansion Kit Instructions-Parts

Two-Zone and Four-Zone Enclosure Accessory Kits Instructions-Parts

3A0135 Bracket Mounting Kits Parts

Displacement Pumps

Pump Packages

Air Motor Instructions-Parts

Related Manuals

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

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 Gate-

313138

way Module Installation Kit Instructions-Parts

406681 Platen Cover Kit Instructions

313296J 3

Page 4

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 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.

displacement

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.

WM 29 7

First and

Second Digit

(Warm Melt

Single Supply

System)

(Warm Melt

Tandem

Supply

System)

Third and

Fourth Digit Fifth Digit

Ram Options

DataTra

Pump Code

Size Style

Voltage Air Controls

4 3 in. D60 no volt INT

5 3 in. D200 no volt INT

6 3 in D200i no volt

(See Table 1

for 2-digit

Pump Code)

7 6.5 in. D200s no volt INT

8 6.5 in. D200si no volt

Y 3 in. D60i no volt

2-Button Interlock

TI11157A

Sixth Digit

Platen and Seal Options

Platen

Size

20 L

(5 Gal) F, SW SST

20 L

(5 Gal) F, DW CS

30 L

(8 Gal) F, SW SST

30 L

(8 Gal) F, DW CS

60 L

(16 Gal) F, SW SST

60 L

(16 Gal) F, DW CS

200 L

(55 Gal) DR

200 L

(55 Gal) DR AL EPDM

Platen

Style

Platen

Material

PTFE

coated

AL EPDM

Seal

Material

PTFE

coated

Polyure-

thane PTFE

coated

Polyure-

thane PTFE

coated

Polyure-

thane

Key:

D = Dual post ram i = 2-Button interlock s = 6.5 in. ram INT = Integrated air controls F = Flat SW = Single wiper DW = Dual wiper DR = Dual o-ring

4 313296J

Table 1: Check-Mate Pump Identification Code/Part

Pump

Code

NXT 2200/CM 200 NXT 6500/CM 200

NXT 3400/CM 200

Pump Part No. (see

manual 312376)

21 P23LCS 2L P68LCS 22 P23LCM 2M P68LCM 26 P23LSM 2U P68LSM

29 P36LCS 2A P36LCM 2G P36LSM

Pump

Code

Pump Part No. (see

manual 312376)

Page 5

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.

313296J 5

Page 6

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 313296J

Page 7

Overview

System Description

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

The system consists of an air-powered ram that drives a Check-Mate pump and a heated platen into a drum of material. The heated platen heats the material and the pump removes it from the drum. The material is then pushed through a supply hose to the applicator.

All features of the warm melt supply system are controlled by Graco Control Architecture components: Fluid Control Module (FCM), Temperature Control Modules (TCM), and the display module. The FCM controls the motor and pump, and the TCMs control the heaters. The display module provides the user interface for the entire warm melt supply system.

Power Requirements

A 30A (minimum) - 60A (maximum) circuit breaker (not provided) must be installed on the incoming power supply. See Table 1, and Technical Data, page 106, for more information regarding electrical requirements.

Table 1: Electrical Requirements

AC Panel

Voltage HZ Phase

240 50/60 1 57.0

Full Load

Amps

Heat Control Zone Selection

Warm melt supply systems have four heat zones (see F

. 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.

ZONE 1

Control

Platen

FIG. 1: Heat Control Zone Selection

ZONE 2

Control

Pump

Valve 1

ZONE 3

Control

1920 Watts max

Hose 1

ZONE 4

Control

1920 Watts max

313296J 7

Page 8

Component Identification

Single Supply Systems

D200s Ram Shown

Lift Locations

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

FIG. 2: Single Supply System

Key:

ARam 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 K Fluid Control Module (inside shroud) S Lift Ring (air motor) T Platen Bleed Port U Pump Outlet

8 313296J

. 4)

V Platen Lift Rod XWet Cup Z Main Air Line (not supplied) AD Air Motor Solenoid AE Junction Box AF Cable Track

Page 9

Tandem Supply Systems

D200s Rams Shown

Component Identification

Supply System A

Supply System B

To heated

manifold (243697)

FIG. 3: Tandem Supply System

Key:

ARam A BRam B C Air Motor D Heated Check-Mate Displacement Pump (Ram A and B) E Heated Platen (Ram A and B) F Drum Empty Sensor (partially hidden; Ram A and B) G Display Module (Ram A only) H Electrical Enclosure (Ram A and B) J Integrated Air Controls (Ram A and B); see page 10 K Fluid Control Module (inside shroud, Ram A and B) N CAN Communication Cable S Lift Ring (Air Motor) T Platen Bleed Port U Pump Outlet V Platen Lift Rod

r_wm2179_313269_4a

XWet Cup Z Main Air Line (not supplied) AD Air Motor Solenoid (Ram A and B) AE Junction Box (Ram A and B) AF Cable Track (Ram A and B)

313296J 9

Page 10

Component Identification

NOTE: See F

. 2 and FIG. 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 condi-

tion. See F

. 11, page 19.

• Display module (G). Mounted on Ram A only. Pro-

vides Run Mode status screens, Setup screens, and control keys. See F

• Fluid control module (K). See F

• Integrated air controls (J). See F

. 8, page 13.

. 7, page 12.

. 4.

• Air motor solenoid (AD). Solenoid is on when the

selected ram is on and in Run Mode, Recirculate Mode, or Prime Mode. Solenoid is off when system is shut off or when in Depressurize Mode, or the ram is in an Inactive Ready Mode. The solenoid LED will illuminate when the solenoid is on.

• Depressurize/recirculate fluid valve. Depressurizes

system when Depressurize Mode is active. Recirculates fluid when Recirculate Mode is active.

Integrated Air Controls

D60, D200, and D200s Models

The integrated air controls include:

• Main air slider valve (BA): turns air on and off to the system. When closed, the valve relieves pressure downstream.

• Ram air regulator (BB): controls ram up and down pressure and blowoff pressure.

• Ram director valve (BC): controls ram direction.

• Exhaust port with muffler (BD)

• Air motor regulator (BE): Controls air pressure to motor.

• Air motor slider valve (BF): turns air on and off to the air motor. When closed, the valve relieves air trapped between it and the air motor. Push the valve in to shutoff. The air solenoid (AD), the air motor valve (BF), and the main air slider valve (BA) must be open for air to flow.

• Blowoff button (BG): turns air on and off to push the platen out of an empty drum.

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.

ti10438a

FIG. 4. Integrated Air Controls

10 313296J

Page 11

Component Identification

Air Line Accessories

See Supply Systems Operation manual.

• Air line drain valve. Not included.

• Air line filter: removes harmful dirt and moisture from compressed air supply. Not included.

• Second bleed-type air valve isolates air line accessories and supply system for servicing. Locate upstream from all other air line accessories. Not included.

• Air relief valve: automatically relieves excessive pressure. Not included.

2-Button Interlock Air Controls

D60i, D200i, and D200si Models

Systems that have 2-Button Interlock controls have the following additional components:

Communications Gateway Module

The Communications Gateway Module (CGM) provides a control link between Graco Control Architecture based systems and a selected fieldbus. This provides the means for remote monitoring and control by external automation systems.

Data provided by the CGM to the fieldbus depends on which Graco Control Architecture based system and fieldbus are connected. A data map supplied on a map token is defined for this pairing. Once the data map has been loaded into the CGM, it is stored internally, and the map token is no longer required for operation.

See the Supply System Communications Gateway Module Installation Kit manual for fieldbus parameter setup instructions and screen descriptions.

CGM Module Status LED Signals

Signal Description

• 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.

Activation Buttons

ti10843a1

. 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.

Green on System is powered up

Yellow Internal communication in progress

Red Solid

*Red (7 flashes)

* 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.

CGM hardware failure

Data map load failure

Incorrect data map for fieldbus type

No data map loaded

ti10846a

. 6: Roller Switch and Bracket Actuator

313296J 11

Page 12

Component Identification

Fluid Control Module

Table 2: FCM Sensor Connections

Connection Ram Sensor Description

1 Ram A and Ram B Air motor solenoid (wire labeled 3), drum low (wire labeled 1),

drum empty (wire labeled 2)

2 Ram A Light tower

3 Ram A + B Fluid depressurize/recirculate solenoid

4 not used not used

5 Ram A and Ram B Air motor reed switch, sensors

6 not used not used

7 Ram A Filter pressure at inlet and outlet

CAN communication cable 1

CAN communication cable 2

Ram A From Ram A FCM to display module.

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

CAN Cable 1

FIG. 7: FCM Sensor Connections

CAN Cable 2

TI12337A

TI12336A

12 313296J

Page 13

User Interface

FIG. 8: Display Module

Button Function

On/Off

Powers air motor solenoid ON and OFF from Ram Operation screen (F

• When ON, the air motor solenoid is ON and the pump of the active ram is pressurized.

Table 3: Display Module Button Functions

Component Identification

. 71, page 100).

Cancel

Setup

Enter

Arrows Left/Right

• 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

• When ON, the enabled heat zones are ON.

• When OFF, all heat zones are OFF.

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

Toggle between run and setup screens.

• Setup changes can be made while system is operating.

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

Opens drop down menus on Setup fields. Press to enter changes and make a selection.

Navigate left or right to a new screen. Navigate left or right within a screen while in Jump In mode. See Appendix A - User Interface Display, page 93, for more information.

. 72, page 101).

Arrows Up/Down

313296J 13

Navigate up or down within a screen or to a new screen.

• Move between selections within a drop-down menu.

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

Page 14

Component Identification

Table 3: Display Module Button Functions

Button Function

Soft Key

Soft keys activate the mode or action represented by the icon above each button in the LCD. See Table 4 for soft key modes and actions.

Table 4: Display Soft Key Icons

Icon Function

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

active ram.

If system is pressurized, press button.

Pump Prime

• When prompted to depressurize the system, select or .

active ram will depressurize both rams.

Depressurizing the

NOTE: If additional user-supplied check valves have been added to the system, only the

active ram will be depressurized. You must perform manual crossover and select depressurize again to depressurize both rams. See Crossover section of this table on page 15.

If system is depressurized, press button.

• When prompted to pressurize the system, select or .

Pump Prime

•

Tandem ram:

•

Tandem ram:

if pump is off, activates the air solenoid on the active ram; if pump is on, activates the air solenoid on the inactive ram which enables you

to purge air and prime the pump;

•

Single ram:

activates air solenoid whether or not pump is on;

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

• resets the drum volume remaining to the drum fill volume setpoint for pump being primed. Press button.

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

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

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

Recirculate Recirculate Mode pumps fluid from the drum, through the pump, and back into the drum on the

currently active ram.

Set motor air regulator to 30 psi (0.2 MPa, 2.1 bar) before pressing Recirculate key.

If system is not in Recirculate Mode, press button.

• When prompted to turn recirculation on, select or . Adjust motor air regulator to

obtain desired flow rate.

If system is in Recirculate Mode, press button.

• When prompted to turn recirculation off, select or .

14 313296J

Page 15

Component Identification

Table 4: Display Soft Key Icons

Icon Function

Crossover 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

Setback transitions the heaters into setback mode. The setpoint for each zone will be decreased by the setback amount. See Heater System Setup Screen, page 95, and Heat Run Screen, page 101.

Jump In

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

Appendix A - User Interface Display, page 93, for more information.

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

313296J 15

Page 16

Component Identification

User Interface Display

NOTE: For details regarding the user interface display see Appendix A - User Interface Display, page

93.

Display Screen Components

The following figure calls out the navigational, status, and general informational components of each display screen.

Current Date and Time

Displays soft keys that are active for particular screen

Soft Keys

. 9: Display Screen Components

Navigation

Status

Mode

Function Display

16 313296J

Page 17

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.

Location Requirements

•Refer to Dimensions, page 104, for ram mounting and clearance dimensions.

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

Location

NOTICE

Always lift supply system at proper lift locations (see F

. 2) to avoid equipment damage. Do not lift in any

other way.

Grounding

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

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.

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

. 10.

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

. 2 for

ti8250a

. 10: Ground Pump

Air and fluid hoses: use only electrically conductive

hoses.

Air compressor: follow manufacturer’s recommendations.

Dispense valve: ground through connection to a prop-

erly grounded fluid hose and pump.

313296J 17

Page 18

Installation

Fluid supply container: follow local code.

Object being sprayed: follow local code.

Solvent pails used when flushing: follow local code.

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

To maintain grounding continuity when flushing or relieving pressure: hold metal part of the dispense

valve firmly to the side of a grounded metal pail, then trigger the valve.

Connect Power Source

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

enclosure to a power source.

NOTE: See Power Requirements, page 7, for circuit protection requirements.

1. Open electrical enclosure door and locate power line filter.

2. Have a qualified electrician perform the following steps:

a. Connect your plant power to the electrical

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

b. Connect a power protective ground to the cen-

ter post on the line end of the power line filter.

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

Have a qualified electrician connect power according to national, state, and local safety and fire codes.

NOTE: Required voltage and amperage is noted on the electrical enclosure label. Also see Table 1. Before running power to the unit, make sure the plant electrical service meets the supply system’s electrical requirements.

18 313296J

Page 19

Installation

Install/Adjust Drum Low or Empty Sensor

1. Position ram at desired level (low or empty).

NOTE: Follow Steps 2 through 4 only if installing the low sensor.

2. Attach the low sensor to the existing sensor bracket (EA), above the existing empty sensor (EE).

D200 Shown

. 11: Low or Empty Sensor Kit

4. Attach the sensor to the corresponding connector on the splitter cable. For drum low, attach the sensor to connector 1. For drum empty, attach the sensor to connector 2.

5. Power system on.

6. Make precise adjustments by moving the sensor within the slot on the sensor bracket. Use the yellow indicator on the sensor cable to indicate a drum low or empty condition.

Light Tower Accessory

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

Table 5: Light Tower Signals

Signal Description

Yellow flashing A low priority error exists.

Yellow on A medium priority error exists.

Red flashing A high priority error exists.

Red on The system is shut down due to

error conditions.

ABLE

5 for a

3. Replace the existing cable between the empty sensor (EE) and FCM connector (see F with the empty/low sensor splitter cable.

. 7, page 12)

313296J 19

Page 20

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).

D200 Shown

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.

. 12: Attach Drum Stops

55 gal (200 L)

30 gal (115 L)

8 gal (30 L)

5 gal (20 L)

. 13: Drum Stop Location

20 313296J

Page 21

Installation

Check Resistance

Check the Resistance Between the Supply System and the True Earth Ground

The resistance between the supply system components and true earth ground must be less than 0.25 ohms.

Have a qualified electrician check the resistance between each supply system component and the true earth ground. The resistance must be less than 0.25 ohms. If the resistance is greater than 0.25 ohms a different ground site may be required. Do not operate the system until the problem is corrected.

NOTE: Use a meter that is capable of measuring resistance at this level.

Sensor Resistance Checks

Conduct these electrical checks with the main disconnect OFF.

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

The supply system includes a heat sensor and controller for each of the four heated zones. To check sensor resistance:

1. Make sure the power is off and that the disconnect switch is in the OFF position.

2. Make electrical resistance checks for the components.

3. Replace any parts that have resistance readings that do not comply with the ranges listed in Table 6.

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

Table 6: RTD Sensor Resistance

Zone Component Connector Pin Range (ohms)

1 Platen Pin 1 to 3

2 Fluid Pump Pin 1 to 3

FIG. 14: RTD Connector Pins

1050-1100

313296J 21

Page 22

Installation

Heater Resistance Checks

Conduct these electrical checks with the main power disconnect OFF.

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

To check heater resistance:

1. Make sure the power is off and that the disconnect switch is in the OFF position.

2. Make electrical resistance checks for the components. Refer to Table 7. Heater terminal pins are located on the back of the enclosure (H). See F page 8.

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

. 2,

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

Table 7: Resistance Chart of All Heaters

Between

Zone Component

1 Platen - D200 1 and 3 240 15 +5/-5 2 Platen - D60 1 and 3 240 80 +10/-10 3 Pump L and N 240 37 +5/-5

Terminals

Unit Voltage

Range (ohms)

FIG. 15: Heater Terminal Pins

22 313296J

Page 23

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).

3. Wrap exposed fittings on the pump outlet with Nomex insulation and secure insulation using fiberglass tape.

Mechanical Setup

1. Fill displacement pump wet cup 2/3 full with Graco Throat Seal Liquid (TSL).

2. Turn all air regulators to their full counterclockwise position.

3. Connect a 3/4 in. (19 mm) air line from an air source to the system air inlet. Refer to the pump performance curves in the Check-Mate Pump Packages manual to determine your air supply flow requirements.

NOTE: Quick disconnects restrict flow for large air motors.

Overview of Temperature Control Settings

Temperature controls are set in Setup mode. See Setup Mode Screens on page 95 for information about setting

temperature controls.

See Run Mode Screens on page 100 for information on controlling temperatures for each zone.

4. Connect hose adapter to green receptacle on junction box.

FIG. 16: Connect Hose to Junction Box

5. Securely tighten the 16-pin electrical connectors on long heated hose leads into 16-socket receptacles on the end of the hose adapter.

6. Securely tighten the 8-socket electrical connectors on short heated hose leads into 8-pin receptacle located on the dispense valves.

Hose Care Guidelines

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

313296J 23

Page 24

Setup

The pump was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating fluid with oil, flush the pump with a compatible solvent before use. See Purge System, step 2.

Purge System

Purging the system before the initial use can prevent material contamination, which may cause the material to fail or perform poorly.

NOTICE

Purge the system before performing the initial material loading procedure. The system was factory-tested

using a light soluble oil, a soybean oil, or some other oil as tagged. Flush the system to avoid contaminating the material that has been designated for initial material loading.

To purge the system perform the following procedure:

This equipment should not be used with more than one type of fluid due to potential compatibility issues that could result in an unpredictable reaction. Graco recommends using new hoses when chemicals are changed or care must be taken to assure that all traces of one chemical are removed before introducing a second chemical.

3. Select a container of material that can eliminate the factory-test oil from the system. If necessary, check with Graco or the material supplier for a recommended solvent.

4. Before purging ensure the entire system and waste container are properly grounded.

NOTE: Remove any dispense valve orifices before purging. Reinstall after purging has been completed.

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.

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

5. Purge the material through the system for approximately 1 to 2 minutes.

6. Remove the container if purge material was used.

Set Values on Display Module

Set desired values on display module Setup menus. See Setup Mode Screens, page 95.

24 313296J

Page 25

Setup

Load Material

Moving parts can pinch or amputate fingers. When the pump is operating and when raising or lowering the ram, keep fingers and hands away from the pump intake, platen, and lip of the drum.

NOTICE

Do not use a drum of material that has been dented or otherwise damaged; damage to the platen wiper can result.

NOTE: Before loading material, ensure that there is a minimum overhead clearance of 105 in. (267 cm) and all air regulators are backed off to their full counterclockwise position.

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

1. Refer to F lators and air valves.

. 2, FIG. 3, and FIG. 4. Close all air regu-

D200 Shown

FIG. 17: Heated Platen

8. Set the director valve (BC) to DOWN and lower the ram until fluid appears at the top of the platen bleed port (J). Adjust ram air regulator (BB) as needed. Set the director valve (BC) to neutral and close the platen bleed port (J). 2-Button Interlock: If system has this feature, press and hold both buttons to start lowering the ram. See F

. 5, page 11.

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

. 5 on page 11.

3. Lubricate the platen seals (D) with grease or other lubricant compatible with the fluid you will pump.

4. Remove the drum cover and smooth the surface of the fluid with a straightedge.

5. Put a full drum of fluid on the ram base, slide it back against the drum stops, and center it under the platen (D). An optional drum roller kit is available to make it easier to load the drum on the base. Order Kit 255627.

6. Remove bleed stick from platen bleed port (J). See F

. 17.

7. If drum has a plastic liner, pull it over edge of drum. Secure liner with tape wrapped around circumference of drum.

313296J 25

Page 26

Setup

System Heat Up

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

Many warm melt materials tend to expand when heating and may cause a heated hose to burst. Avoid the potential of bursting a hose by opening the dispense valve during system heat up and lock the dispense valve trigger open every time you shut the system down.

NOTE: Operate at the lowest temperature and pressure necessary for your application.

1. Turn the main disconnect on the electrical control panel door to the ON position.

2. Press while in the Heat Run screen to turn the

heaters on for enabled heat zones.

. 18: Heat Run Screen - Ram A

26 313296J

Page 27

Setup

Prime

1. Make sure the system is at required temperature.

2. Tandem Systems Only: To prime the active ram, ensure that the system is not in Run Mode. To prime the inactive ram, ensure that the system is on and in Run Mode.

3. Single Systems Only: To prime the ram, ensure that the system is on. The system may or may not

be in Run Mode.

(Prime active ram - not Run Mode)

FIG. 21: Prime Confirmation

6. When the timer expires the air motor solenoid LED will turn off.

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

8. Lock the dispense valve trigger lock.

NOTE: To exit Prime Mode before the timer expires,

press the Pump Prime key . The display

prompts the operator to confirm. See F

. 22. Select

to exit prime.

FIG. 19: Ram Operation Screen - Tandem System

(Prime inactive ram - in Run Mode)

. 20: Ram Operation Screen - Tandem System

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

5. Press the Pump Prime key . The display

prompts the operator to confirm. See F

. 21. Select

. 22: Exit Prime Mode Confirmation

NOTE: To extend the prime time counter, select

in F

. 22. Display prompts operator to confirm.

See F

. 23. Select to reset.

to begin prime.

. 23: Reset Prime Time Counter Confirmation

313296J 27

Page 28

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. Press On/Off key . If system is On, display will

highlight . Select to turn off.

If you suspect that the dispense tip/nozzle or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.

Trigger Lock

Always engage the trigger lock when you stop dispensing to prevent the gun from being triggered accidentally by hand or if dropped or bumped.

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.

FIG. 24: System Function Screen

3. See F

4. Set the ram director valve to DOWN. The ram will

5. Jog the director valve up and down to bleed air from

6. Unlock the dispense valve trigger.

7. Hold a metal part of the dispense valve firmly to the

8. Lock the dispense valve trigger.

9. Open all fluid drain valves on ram(s). Have a con-

. 4, page 10. Close the air motor slider valve

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

slowly drop.

ram cylinders.

side of a grounded metal pail, and trigger the dispense valve to relieve pressure.

tainer ready to catch the drainage. Leave fluid drain valves open until ready to dispense again.

To start and adjust the ram(s), follow the Load Material procedure on page 25.

Start and Adjust Pump

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

1. Connect pump outlet fittings and hose (not supplied).

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

2. Be sure the pump air valve is closed. Then set the ram air regulator (BB) to 50 psi (0.35 MPa, 3.5 bar). Set the director valve (BC) to DOWN. See F page 10.

. 4,

28 313296J

Page 29

Operation

3. Press while in the Ram Operation screen.

. 25: Ram Operation Screen - Tandem System

4. When the confirmation screen appears with a

prompt, select to start the pump.

5. Open the pump air valve (BF) and keep the director valve (BC) set to DOWN while pump is operating.

NOTE: Increase air pressure to the ram if the pump does not prime properly with heavier fluids. Decrease air pressure if fluid is forced out around the top seal or platen.

Manual Crossover

(Tandem Warm Melt Supply System Only)

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

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

• pump runaway and not primed alarms do not exist.

To initiate a manual crossover to the inactive ram:

1. From the Ram Operation screen, press the Cross-

over key . The display prompts the operator

to confirm.

2. Select to confirm manual crossover operation

or select to cancel.

Automatic Crossover

(Tandem Supply System Only)

Keep clear of the inactive ram, as automatic crossover may occur unexpectedly. To repair or adjust the ram, first follow all steps of the Pressure Relief Pro- cedure on page 28.

The automatic crossover feature allows continuous flow and prevents system shutdown. If the active ram encounters a pump runaway or drum empty alarm, it will attempt an automatic crossover to the inactive ram.

The system will generate a crossover error if the active ram attempts an automatic crossover while the inactive ram has a pump runaway, drum empty, or not primed alarm. If this occurs, correct the error and clear the alarm from the Alarm screen. See Alarm Screen, page 103, for details.

FIG. 26: Crossover Function Screen

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

313296J 29

Page 30

Operation

Recirculate Function

Recirculate mode pumps fluid from the drum, through the pump, and back into the drum on the currently active ram.

To enter Recirculate mode:

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

2. From the Ram Operation screen, press the Recircu-

late key . The display prompts the operator to

confirm.

3. Select to confirm recirculation or select to

cancel.

Depressurize Function

Follow the Pressure Relief Procedure on page 28. Shutting off power or removing power from the system will not depressurize the system.

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

Depressurize System

From the Ram Operation screen, press the Depressur-

ize key . The display prompts the operator to con-

firm. Select to confirm depressurize or select

to cancel.

. 27: Enter Recirculate Mode

4. Adjust motor air regulator to obtain desired flow rate.

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

To exit Recirculate Mode, press the Recirculate key

. The display prompts the operator to confirm.

Select to confirm or select to cancel. See F

27.

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

. 28: Depressurize Function Screen

30 313296J

Page 31

Operation

NOTE: Depressurizing the active ram will depressurize both rams. However, if additional user-supplied check valves have been added to the system, only the active ram will be depressurized.

To depressurize both rams perform manual crossover (see Manual Crossover, page 29), and then

press the Depressurize key again.

Pressurize System

From the Ram Operation screen, press the Depressur-

ize key . The display prompts the operator to con-

firm. Select to confirm pressurize or select to

cancel. See F

. 28.

Change Drums

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.

3. Once the platen clears the drum, release the blow-off air button (BG) and allow the ram to rise to its full height. 2-Button Interlock: If system has this feature, the ram will stop as it nears the top. Press and hold both buttons to raise ram completely. See F

. 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.

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

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

NOTICE

Do not use a drum of material that has been dented or otherwise damaged; damage to the platen wiper can result.

1. Push in the air motor slider valve (BF) to stop the pump. See F

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

. 4.

7. Lower the ram and adjust the position of the drum relative to the platen. See Load Material on page

25.

313296J 31

Page 32

Maintenance

Shutdown

Follow the procedure below for normal system shut down, such as at the end of the work day.

NOTICE

Turning the system OFF relieves pressure from the pump motor; however, it does not depressurize the fluid pressure. Follow the Pressure Relief Procedure, page

28.

NOTE: The ram up/down and blowoff air is 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

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).

off the heaters. Select to confirm.

3. Follow the Pressure Relief Procedure, page 28.

. 29: Remove Quick Coupler

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

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

ti10508a

32 313296J

Page 33

Maintenance

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. Turn off main disconnect.

2. Relieve pressure and disassemble air assist valve. Refer to Supply Systems Repair-Parts manual.

3. Clear air assist tube in platen. Clean all parts of valve and reassemble. Refer to Supply Systems Repair-Parts manual.

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

5. Remove platen covers. See F

. 30.

Remove and Reinstall Platen Wipers

Refer to Supply Units Repair-Parts manual for instructions.

Bleed Stick

r_wm2179_313296_6a

a. Remove platen cover fasteners (70) or nuts

(309).

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

in. supply systems):

Remove both platen covers

(49) and ground wire from platen.

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

Disconnect pump for the platen; see Discon- nect Pump from Platen, page 50. Remove screws (323) from upper heater plate (320). Remove upper heater plate.

6. Remove any excess fluid. Use a soft wire brush on heater coils (48) or heater (319). See F

. 30.

7. Inspect platen heater blocks (43 or 320) or heater (48 or 319) for burn or melt spots. Replace platen heater blocks or heater if necessary. See F

. 30.

8. Check for loose connections and damaged wires.

9. Follow steps in reverse order to reassemble platen.

309

Bleed Stick

FIG. 30: Remove Platen Covers and Heaters

309

323

320

319

NOTE: Torque platen cover fasteners (70) to 60 +/10 in-lbs (6.8 +/- 1.1 N•m) for 55 gallon platen. Torque nuts (309) to 45 +/- 5 in-lbs (5.1 +/- 0.6 N•m) for smaller platens.

313296J 33

Page 34

Maintenance

Electrical Enclosure

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

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

2. Open door of electrical enclosure.

459

419

Check Ground Fault Circuit Interrupter

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

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

2. Press Test button on ground fault circuit interrupter (419). The blue switch should flip to the middle or opposite side.

NOTE: Do not perform this test while the system is in operation.

3. Press blue switch back into place to reset breaker.

419

421

. 31: Inside View of Electrical Enclosure

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

. 32: Ground Fault Circuit Interrupter

4. Switch main disconnect off.

34 313296J

Page 35

Maintenance

Pump Heaters

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

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

D200 Shown

80 or 257

4. Check for damaged wires and connections.

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

D200 Shown

44 or 227

. 34: Pump Heaters

. 33: Remove Pump Shroud

3. Remove pump heater front shroud (51 or 233).

313296J 35

Page 36

Alarms

Warm Melt alarms alert you to a problem and help pre-

Diagnose Alarms

vent system shutdown or application errors. If an alarm occurs, operation may stop and the following occurs.

See Alarm Codes and Troubleshooting, page 36, for causes and solutions to each alarm code.

• Light tower indication changes (if equipped)

• Status bar on the display shows the alarm description

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 Alarm Problem Cause Solution Clear Alarm

Fluid Control Module

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)

Ram cannot communicate with FCM A.

Ram cannot communicate with FCM B.

Inactive ram has a Not Primed alarm.

There is a Runaway alarm Correct runaway condition

There is a Drum Empty alarm. Replace empty drum with

Verify that power is supplied.

Check that CAN cables are connected.

Verify that selector switch is set correctly.

Replace FCM A.

Verify that power is supplied.

Check that CAN cables are connected.

Verify that selector switch is set correctly.

Replace FCM B

Set inactive ram to Prime mode to automatically clear alarm.

and clear alarm on Status screen 1.

full drum to clear.

Alarm automatically cleared by solution.

Cleared from Ram Alarm screen. See Appendix A - User Interface Display, page 93.

36 313296J

Page 37

Alarm

Code Alarm Problem Cause Solution Clear Alarm

Fluid Control Module (continued)

DA1X

DA2X

L11X

L12X

DB1X

DB2X

WJ1X

WJ2X

DK1X

DK2X

L21X

L22X

WK1X

WK2X

ML1X

ML2X

MA1X

MA2X

Pump Runaway A

Pump Runaway B

A - Drum Empty

B - Drum Empty

A - Not Primed

B - Not Primed

A - Air Solenoid Disconnected

B - Air Solenoid Disconnected

A - Air Motor Sensor Error

B - Air Motor Sensor Error

A - Drum Low Deviation

B - Drum Low Deviation

A - Fluid Solenoid Disconnected Deviation

B - Fluid Solenoid Disconnected Deviation

A - Rebuild Platen Seals

B - Rebuild Platen Seals

A - Rebuild Pump

B - Rebuild Pump

Pump is running faster than set runaway limit due to:

•

Increased air pressure.

•

Increased fluid output.

•

Exhausted fluid supply.

•

Open fitting, hose, drain, or bleed valve.

Drum empty sensor has been activated.

The pump is not primed. Set ram to Prime mode to

Solenoid unplugged. Check that solenoid cable

Damaged solenoid / wires. Inspect solenoid wires for

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

Damaged or disconnected air motor sensors.

Drum low sensor has been activated.

Solenoid unplugged. Check that solenoid cable

Damaged solenoid wires. Inspect solenoid cable for

Counter has reached programmed platen maintenance interval.

Counter has reached programmed pump maintenance interval.

Correct runaway condition and clear alarm.

Replace empty drum with full drum to clear.

automatically clear alarm, or manually clear alarm from Ram Alarm screen.

is connected.

damage.

See air motor manual. Cleared from Ram Alarm

Check that air motor sensors are connected.

Inspect air motor sensor harness for damage.

Replace empty drum with full drum to clear.

is connected.

damage.

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

Perform pump maintenance. See Check-Mate Displacement Pump manual.

Cleared from Ram Alarm screen. See Appendix A - User Interface Display, page 93.

Alarm automatically cleared by solution.

Cleared from Ram Alarm screen or Ram Operation screen. See Appendix A - User Interface Display, page 93.

Alarm automatically cleared by solution.

screen. See Appendix A - User Interface Display, page 93.

Deviation automatically cleared by solution.

Cleared from Maintenance screen. See Appendix A - User Interface Display, page 93.

Alarms

313296J 37

Page 38

Alarms

Alarm

Code Alarm Problem Cause Solution Clear Alarm

Fluid Control Module (continued)

DA1X

DA2X

L11X

L12X

DB1X

DB2X

WJ1X

WJ2X

DK1X

DK2X

L21X

L22X

WK1X

WK2X

ML1X

ML2X

MA1X

MA2X

Pump Runaway A

Pump Runaway B

A - Drum Empty

B - Drum Empty

A - Not Primed

B - Not Primed

A - Air Solenoid Disconnected

B - Air Solenoid Disconnected

A - Air Motor Sensor Error

B - Air Motor Sensor Error

A - Drum Low Deviation

B - Drum Low Deviation

A - Fluid Solenoid Disconnected Deviation

B - Fluid Solenoid Disconnected Deviation

A - Rebuild Platen Seals

B - Rebuild Platen Seals

A - Rebuild Pump

B - Rebuild Pump

Pump is running faster than set runaway limit due to:

•

Increased air pressure.

•

Increased fluid output.

•

Exhausted fluid supply.

•

Open fitting, hose, drain, or bleed valve.

Drum empty sensor has been activated.

The pump is not primed. Set ram to Prime mode to

Solenoid unplugged. Check that solenoid cable

Damaged solenoid / wires. Inspect solenoid wires for

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

Damaged or disconnected air motor sensors.

Drum low sensor has been activated.

Solenoid unplugged. Check that solenoid cable

Damaged solenoid wires. Inspect solenoid cable for

Counter has reached programmed platen maintenance interval.

Counter has reached programmed pump maintenance interval.

Correct runaway condition and clear alarm.

Replace empty drum with full drum to clear.

automatically clear alarm, or manually clear alarm from Ram Alarm screen.

is connected.

damage.

See air motor manual. Cleared from Ram Alarm

Check that air motor sensors are connected.

Inspect air motor sensor harness for damage.

Replace empty drum with full drum to clear.

is connected.

damage.

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

Perform pump maintenance. See Check-Mate Displacement Pump manual.

Cleared from Ram Alarm screen. See Appendix A - User Interface Display, page 93.

Alarm automatically cleared by solution.

Cleared from Ram Alarm screen or Ram Operation screen. See Appendix A - User Interface Display, page 93.

Alarm automatically cleared by solution.

screen. See Appendix A - User Interface Display, page 93.

Deviation automatically cleared by solution.

Cleared from Maintenance screen. See Appendix A - User Interface Display, page 93.

38 313296J

Page 39

Alarm

Code Alarm Problem Cause Solution Clear Alarm

Fluid Control Module (continued)

DD1X

DD2X

A - Pump Diving

B - Pump Diving

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.

Temperature Control Modules

Decrease pump air pressure to slow cycle rate. Decrease pressure until diving stops.

Cleared from Ram Alarm screen. See Appendix A - User Interface Display, page 93.

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

T3A1 T3A2 T3A3 T3A4 T3A5 T3A6 T3A7 T3A8 T3A9 T3A10 T3A11 T3A12

T2A1 T2A2 T2A3 T2A4 T2A5 T2A6 T2A7 T2A8 T2A9 T2A10 T2A11 T2A12

Alarm Above Setpoint

Deviation Above Setpoint

Deviation Below Setpoint Tripped circuit breaker. Visually check circuit

RTD on wrong module. Verify RTD wire and heater

power cord is attached to correct heat module.

Shorted module. Replace module.

breaker for a tripped condition.

Low power. Measure voltage across

input terminals on power line filter. Voltage should measure between 190 and 250 Vac.

Cable unplugged/loose wire. Check for loose or discon-

nected wires and plugs.

Circuit breaker not set for L2 and L3.

Bad heaters. Measure resistance of

GFCI has been tripped. Visually check GFCI for a

Customer supplied main circuit breaker tripped.

Visually check circuit breaker for proper setting of L2 and L3.

heater.

tripped condition.

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

Cleared from Heat Run screen. See Heat Run Screen, page 101.

Alarms

313296J 39

Page 40

Alarms

Alarm

Code Alarm Problem Cause Solution Clear Alarm

Temperature Control Modules (continued)

T6A1 T6A2 T6A3 T6A4 T6A5 T6A6 T6A7 T6A8 T6A9 T6A10 T6A11 T6A12

A4A1 A4A2 A4A3 A4A4 A4A5 A4A6 A4A7 A4A8 A4A9 A4A10 A4A11 A4A12

No Temp Rise Tripped circuit breaker. Visually check circuit

breaker for a tripped condition.

Low power. Measure voltage across

input terminals on power line filter. Voltage should measure between 190 and 250 Vac

Cable unplugged/loose wire. Check for loose or discon-

nected wires and plugs.

Circuit breaker not set for L2 and L3.

Bad heater(s). Measure resistance of

GFCI has been tripped. Visually check GFCI for a

Customer supplied main circuit breaker tripped.

Over current Bad heaters. Measure resistance of

Wrong zone type. Ensure zone is set for type

High voltage. Measure voltage across the

Shorted module. If temperature rises for a

Visually check circuit breaker for proper setting of L2 and L3.

heater(s).

tripped condition.

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

heater.

of hardware connected to it.

disconnect switch. Voltage should measure between 190 and 275 Vac.

zone that has been disabled, replace heat module.

Cleared from Heat Run screen. See Heat Run Screen, page 101.

40 313296J

Page 41

Alarm

Code Alarm Problem Cause Solution Clear Alarm

Temperature Control Modules (continued)

A1A1 A1A2 A1A3 A1A4 A1A5 A1A6 A1A7 A1A8 A1A9 A1A10 A1A11 A1A12

A7A1 A7A2 A7A3 A7A4 A7A5 A7A6 A7A7 A7A8 A7A9 A7A10 A7A11 A7A12

T6A1 T6A2 T6A3 T6A4 T6A5 T6A6 T6A7 T6A8 T6A9 T6A10 T6A11 T6A12

Undercurrent Tripped circuit breaker. Visually check circuit

breaker for a tripped condition.

Over temperature protection is activated.

Low power. Measure voltage across

Cable unplugged/loose wire. Check for loose or discon-

Circuit breaker not set for L2 and L3.

Bad heaters. Measure resistance of

GFCI has been tripped. Visually check GFCI for a

Customer supplied main circuit breaker tripped.

Wrong zone type. Ensure zone is set for type

Unexpected Current Shorted module. If temperature rises for a

Invalid RTD Reading Bad RTD. Measure resistance of RTD

Bad RTD connection/loose wire.

Component not plugged in. Ensure a component is

Allow zone to cool down.

input terminals on power line filter. Voltage should measure between 190 and 250 Vac.

nected wires and plugs.

Visually check circuit breaker for proper setting of L2 and L3.

heater.

tripped condition.

Measure voltage across the disconnect switch. Voltage should measure between 190 and 250 Vac.

of hardware connected to it.

zone that has been disabled, replace heat module.

and verify it is within valid range.

Check for loose or disconnected wires and plugs.

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

Cleared from Heat Run screen. See Heat Run Screen, page 101.

Alarms

313296J 41

Page 42

Alarms

Alarm

Code Alarm Problem Cause Solution Clear Alarm

T4C1 T4C2 T4C3 T4C4 T4C5 T4C6 T4C7 T4C8 T4C9 T4C10 T4C11 T4C12

V4M1 V4M2 V4M3 V4M4 V4M5 V4M6 V4M7 V4M8 V4M9 V4M10 V4M11 V4M12

V1M1 V1M2 V1M3 V1M4 V1M5 V1M6 V1M7 V1M8 V1M9 V1M10 V1M11 V1M12

V4I1 V4I2 V4I3 V4I4 V4I5 V4I6 V4I7 V4I8 V4I9 V4I10 V4I11 V4I12

PCB Overtemperature Overheated Temperature

Control Module.

High Line Voltage Incoming line voltage is too

high.

No Line Voltage Low Line Voltage

High DC Voltage Faulty DC power supply. Measure that DC supply

Tripped circuit breaker. Visually check circuit

GFCI has been tripped. Visually check GFCI for a

Cable unplugged/loose wire. Check for loose or discon-

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

Measure voltage across disconnect switch. Voltage should measure between 190 and 250 Vac.

breaker for a tripped condition.

tripped condition.

nected wires and plugs.

output is 24V. If not, replace supply.

Cleared from Heat Run screen. See Heat Run Screen, page 101.

42 313296J

Page 43

Alarm

Code Alarm Problem Cause Solution Clear Alarm

Temperature Control Modules (continued)

V1I1 V1I2 V1I3 V1I4 V1I5 V1I6 V1I7 V1I8 V1I9 V1I10 V1I11 V1I12

A4C1 A4C2 A4C3 A4C4 A4C5 A4C6 A4C7 A4C8 A4C9 A4C10 A4C11 A4C12

A1C1 A1C2 A1C3 A1C4 A1C5 A1C6 A1C7 A1C8 A1C9 A1C10 A1C11 A1C12

A7C1 A7C2 A7C3 A7C4 A7C5 A7C6 A7C7 A7C8 A7C9 A7C10 A7C11 A7C12

Low DC Voltage Faulty DC power supply. Measure that DC supply

output is 24V. If not, replace supply.

Broken Temperature Control Module.

High Contactor Current Broken contactor. Replace contactor. Cleared from Heat Run

Low Contactor Current Broken contactor. Replace contactor. Cleared from Heat Run

Disconnected or loose wire. Verify cable 15W902 from

Broken Temperature Control Module.

Unexpected Contactor Current

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.

High Power Temperature Control Module is connected correctly.

Verify there is 24V between both wires on 15W902. If there is not 24V, replace High Power Temperature Control Module.

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

Cleared from Heat Run screen. See Heat Run Screen, page 101.

screen. See Heat Run Screen, page 101.

Cleared from Heat Run screen. See Heat Run Screen, page 101.

Alarms

313296J 43

Page 44

Troubleshooting

1. Follow Pressure Relief Procedure, page 28, before disassembling any part of the warm melt supply system.

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 Cause Verification Solution

No power. Customer supplied main

circuit breaker tripped.

GFCI has been tripped. Visually check GFCI for a

No graphics on screen. No graphics are shown on

display screen.

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.

Measure voltage across disconnect switch; voltage should measure between 190 and 250 Vac.

tripped condition.

Verify green LED on bottom of display is illuminated.

24 Rtn

24 Vdc+

GCA cable end

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.

If green LED is not illuminated:

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

2. Replace faulty display module.

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

Backlight does not power up.

44 313296J

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

Replace display module.

Page 45

Troubleshooting

Problem Cause Verification Solution

No heat. Tripped circuit breaker. Visually check circuit

breaker for a tripped condition.

Low power. Measure voltage across

terminals 2T1 and 4T2 on main disconnect. Voltage should measure between 190 and 275 Vac.

Cable unplugged/loose wire.

Check for loose or disconnected wires and plugs.

GFCI tripped. Visually check GFCI for a

tripped condition.

Zone not enabled. Verify zone is enabled on

Heat Run screen.

Incorrect temperature set point.

Verify zone has a correct temperature setting on Heat Run screen.

Bad heater. Measure resistance of

heater.

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.

Determine fault that caused GFCI to trip. Repair fault, and reset GFCI.

Enter Setup screen and enable correct zone.

Enter Setup and enter correct temperature.

1. Unplug suspected heater zone from heater module.

Contactor not closing. Turn on heat for zone A1 or

B1and ensure contactor closes.

2. Follow Heater Resis- tance Checks, page

22.

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

1. Verify cable 15W902 from the high power TCM is connected correctly.

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

3. Verify there is 24 Vdc between 2 wires on 15W902. If not, replace high power TCM. See Alarms, page 36.

4. Replace contactor.

313296J 45

Page 46

Troubleshooting

Problem Cause Verification Solution

Missing module. Modules not on network. Verify attached modules

through Advanced Setup screens 4 and 5.

Cable disconnected. Verify all green LEDs are

illuminated and yellow LEDs are flashing.

Module with wrong rotary switch setting.

Verify rotary switch is set correctly.

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

Reconnect/replace faulty cable.

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 56, and Upgrade FCM Software, page 59, for

selector switch locations.

Heating is slow. Heater defective. Measure resistance of

heater.

Low power. Measure voltage across

terminals 2T1 and 4T2 on main disconnect. Voltage should measure between 190 and 275 Vac.

Heating over shoots. RTD on wrong module. Verify for given zone that

temperature does not increase when zone is dis-

Shorted module. Replace module.

Does not crossover. Alternate ram has an empty

abled.

Verify ram has material. Replace empty drum.

sensor activated.

Alternate pump is not primed.

Alternate pump has an active alarm.

Verify alternate ram is ready to run.

See Alarm Codes and Troubleshooting, page

36.

4. Replace access cover.

Follow Heater Resistance Checks, page 22.

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

2. Have a qualified electrician service electrical components.

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

Prime pump.

See Alarm Codes and Troubleshooting, page

36.

46 313296J

Page 47

Repair

To reduce the risk of serious injury, follow the Pressure Relief Procedure and the Load Material pro-

cedure prior to performing repair procedures.

Air Motor

Remove Air Motor

Remove junction box.

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

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

platen rod.

Repair

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

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

90, 91

. 35: Remove D200 and D200s Junction Box

258

. 36: Remove D60 Junction Box

3. 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.

4. See Supply System repair manual for air motor removal instructions.

255

271

278

313296J 47

Page 48

Repair

Install Air Motor

1. See Supply System repair manual for air motor installation instructions.

2. Reinstall junction box.

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

Remove junction box from platen rod. Reinstall junction box to air motor using move two screws (61). See F

. 35.

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

Reinstall junction box (255) onto bracket (258). Use screws (278) to attach cover (271). See F

. 36.

Displacement Pump

Remove Displacement Pump

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

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

46 44

r_wm2179_313296_7a

FIG. 37: D200 and D200s Pump Heater Shrouds

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.

Refer to your Check-Mate Displacement Pump manual to repair the displacement pump.

If the air motor does not require servicing, leave it attached to its mounting. If the air motor does need to be removed, see Remove Air Motor, page 47.

D200 and D200s Supply Systems

1. Disconnect air hose and ground wire from air motor.

2. See Disconnect Displacement Pump in Check-Mate Pump Packages manual.

3. Follow steps 1- 4 of Replace Platen Heaters and Sensor section, page 52, to remove pump heater

TI10648A

. 38: Raise Air Motor

5. See Disconnect Pump from Platen, page 50, to disconnect the displacement pump from the platen.

6. Use two people to carefully lift out the displacement pump. Service displacement pump as needed. See Check-Mate Displacement Pump manual for instructions.

48 313296J

Page 49

Repair

D60 Supply System

1. Disconnect air hose and ground wire from air motor.

2. See Disconnect Displacement Pump in Check-Mate Pump Packages manual.

3. Follow steps 1- 4 of Replace Platen Heaters and Sensor section, page 52, to remove pump heater shrouds (233, 234), pump heaters (227), and RTD sensor (229).

227

229

227

r_wm29yy_313296b_3

233

Install Displacement Pump

D200 and D200s Supply Systems

1. Install displacement pump on platen. See Connect Pump to Platen, page 51.

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

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

4. See Reconnect Displacement Pump in Check-Mate Pump Packages manual.

5. Reconnect air hose and ground wire to air motor.

. 39: D60 Pump Heater Shrouds

4. See to Disconnect Pump from Platen on page 50 to disconnect displacement pump from platen.

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

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

TI10515A

. 40: Reconnect Air Hose and Ground Wire

D60 Supply System

1. Raise ram to install displacement pump to platen.

2. Connect displacement pump to platen. See Con- nect Pump to Platen, page 51.

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

4. See Reconnect Displacement Pump in Check-Mate Pump Packages manual.

5. Reconnect air hose and ground wire to air motor.

313296J 49

Page 50

Repair

Disconnect Pump from Platen

The pump is mounted to the platens by mounting Kit

255392.

55 Gallon Platen

1. Disconnect displacement pump from air motor. See Check-Mate Pump Packages manual.

2. Raise air motor. See Remove Displacement Pump, page 48.

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

103a

103b

20, 30, and 60 Liter Platens

1. Disconnect displacement pump from air motor. See Check-Mate Pump Packages manual.

2. Raise air motor. See Remove Displacement Pump, page 48.

3. Remove screws (308) from platen.

308

103c

FIG. 41: 55 Gallon Mounting Kit

4. Use two people to carefully lift pump from platen.

5. Inspect o-ring (103c) for damage. Replace o-ring if necessary.

. 42: 20, 30, 60 Liter Mounting

4. Use two people to carefully lift pump from platen. If using a pump with an intake adapter, remove screws, adapter, and o-rings from pump inlet.

5. Inspect o-ring for damage. Replace o-ring if necessary.

50 313296J

Page 51

Repair

Connect Pump to Platen

55 Gallon Platen

1. Use two people to set pump onto platen.

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

3. Lower air motor.

4. See Reconnect Displacement Pump in Check-Mate Pump Packages manual.

20, 30, and 60 Liter Platen

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

1. Place o-ring on pump intake. See F

. 41.

. 42.

Replace Pump Heaters

1. Turn off main disconnect.

2. Remove screws (80 or 257) from back pump heater

shroud (52 or 234).

D200 Shown

52 or

80 or 257

234

2. Use two people to set pump onto platen.

3. Secure pump to platen with screws (308).

4. Lower air motor.

5. See Reconnect Displacement Pump in Check-Mate Pump Packages manual.

FIG. 43: Remove Pump Shroud

3. Remove ground wires.

4. Remove pump heater front shroud (51 or 233).

313296J 51

Page 52

Repair

5. Remove pump heater bands (44 or 227):

a. Remove screws from both pump heaters.

b. Pry heater bands apart and remove from pump.

c. Disconnect wires from heater bands. Inspect

wires for damage, and replace with new wires (included with pump heaters) if necessary. See Electrical Schematics, page 61.

d. Remove RTD sensor (46 or 229). Loosen screw

on sensor support (45 or 228) and slide RTD out.

44 or 227

45 or 228

46 or 229,

110

44 or 227

Replace Platen Heaters and Sensor

55 Gallon Platen Heater and Sensor

1. Turn off main disconnect.

2. Remove both platen cover fasteners (70).

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

ti17720a

. 44: Remove Pump Heaters

6. Install new pump heater bands and secure with screws.

NOTE: To ease pump heater band installation, first install heater bands on middle of displacement pump. Then slide heater band up or down into correct location.

7. Reinstall RTD sensor and tighten screw on sensor support.

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

8. Reinstall pump heater front shroud.

9. Reinstall ground wires.

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

109

58 82

FIG. 45: Replace Platen Heaters and RTD Sensor

4. Remove platen heater blocks (43).

a. Use a hex wrench to remove three nuts (59)

and washers (11, 64) from each heater block.

b. Remove screws (12) from junction box cover

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

c. Disconnect four platen heater wires (labeled A

dn B) and RTD sensor connector in the terminal box. See Electrical Schematics, page 61.

ti18061a

52 313296J

Page 53

d. Remove screws (58) and washers (82).

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

5. Install new platen heaters and RTD sensor. Secure RTD sensor with screw and washer. Secure platen heater blocks with nuts and washers.

Repair

324

323

6. Label platen heater wires A and B as shown on page 64. Reroute platen heater wires and platen RTD sensor through the conduit to the junction box. Reconnect the four wires to the appropriate terminal block A and B. Reconnect the platen RTD sensor.

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

8. Reconnect ground wire, and install platen covers. Secure platen covers with fasteners. Torque platen cover fasteners to 60 in-lbs +/- 10 in-lbs (6.8 +/- 1.1 N•m)

9. Reconnect displacement pump using screws and clamps.

20, 30, and 60 Liter Platen Heater

1. Disconnect pump from platen.

2. Remove platen heater block (320).

a. Remove screws (278) from junction box cover

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

86.

Air Fitting Assembly

ti17717b

. 46: Replace Platen Heaters

3. Remove platen heater (319).

a. Disconnect two platen heater wires (labeled A

and B) in the terminal box. See D60 Junction Box Schematic, page 71.

b. Remove platen and heater (319).

320

319

318

309

b. Remove strain relief nut (265) from junction box

to allow space for wires. See page 86.

4. Install new platen heater (319) to lower heater plate (318). Install upper heater plate (320). Reconnect ground wire, and secure with screws.

c. Remove air fitting assembly from platen.

5. Label platen heater wires A and B as shown on

d. Remove nuts (309) from the heat shield guard

(324).

page page 70. Reroute platen heater wires through the conduit to the junction box. Reconnect the two wires to the appropriate terminal block A and B.

e. Remove screws (323) from upper heater plate

(320). Remove upper heater plate and ground

6. Reinstall heat shield guard. Secure with nuts. Torque nuts to 45 +/- 5 in-lbs (5.1 +/- 0.6 N•m).

wire.

7. Reconnect displacement pump using screws and clamps.

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

313296J 53

Page 54

Repair

Replace Platen Wipers

Refer to Supply Systems Repair-Parts manual for instructions.

Replace Ram Piston Rod Seals

1. Support electrical enclosure (13 or 14) using a loop and a hoist.

2. Remove screws from bracket (50 or 232) connecting electrical enclosure (13 or 14) to ram piston rod and cable track (42, if applicable).

13 or 14

50 or 232

FIG. 47: Replace Rod Seals

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

(50) to side.

For smaller platens (D60 supply systems):

bracket (232).

Gently move cable track (42) and bracket

Remove

4. See Supply Systems Repair-Parts manual for replacement instructions.

5. Follow steps in reverse order to reinstall bracket, cable track (if applicable), and the electrical enclosure.

54 313296J

Page 55

Repair

Electrical Enclosure

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

power.

Replace Low Power Temperature Control Module(s)

1. Open enclosure door (402). Disconnect the follow-

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

ing cables from low power TCM (408):

• incoming power supply cable (430)

• outbound power supply cable (see F

• RTD cable

. 49)

408

Outbound Power

RTD

411

Outbound Power

RTD

FIG. 49: Back View of Electrical Enclosure

2. Loosen both captive screws (409) holding low power TCM (408) to base (407); remove low power TCM. See F

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

4. Upload the correct TCM software for the system. See Upgrade Temperature Control Module Soft- ware, page 56, for instructions.

. 48.

459

Captive Screw

430

408

Captive Screw

411

431

429

428

432

. 48: Internal View of Electrical Enclosure

313296J 55

Page 56

Repair

Replace Base

1. Remove low power TCM. See Replace Low Power Temperature Control Module(s).

2. Disconnect two CAN cables from base (407).

3. Remove four screws (409) and ground screw (410) from base.

4. Replace with new base and secure with screws.

5. Reconnect two CAN cables to base.

6. Set selector switch to:

• “0” for TCM labeled “2” on Ram A

• “1” for TCM labeled “3” on Ram A

• “2” for TCM labeled “4” on Ram A

• “5” for TCM labeled “2” on Ram B

• “6” for TCM labeled “3” on Ram B

• “7” for TCM labeled “4” on Ram B

Selector Switch

TI12361a

. 50: Set Selector Switch

7. Reinstall low power TCM. See Replace Low Power Temperature Control Module(s).

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

6. Upload the correct TCM software from kit 16C027. See Upgrade Temperature Control Module Soft- ware, page 56, for instructions.

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

Selector Switch

TI12360a

. 51: Set Selector Switch

Upgrade Temperature Control Module Software

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

Graco Control Architecture manual for instructions.

™

Module Programming

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

Replace High Power Temperature Control Module

1. Open enclosure door (402). Disconnect outbound power supply and RTD cables from high power TCM (411). See F

2. Remove electrical enclosure side panel (436). See Electrical Enclosure Parts on page 90.

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

431) from high power TCM. See F

4. Remove both screws (415) that secure brackets (412, 413) of high power TCM to electrical enclosure. Remove high power TCM. See Electrical Enclosure Parts on page 90.

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

. 49.

. 48.

56 313296J

Page 57

Repair

Replace Circuit Breakers

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

2. Push in circuit breaker tab and pull out breaker.

417

4. Remove screws (12 or 202) and washers (11 or

201) from bottom bracket (39 or 222) and side bracket (50 or 232) of enclosure.

D200 Shown

plug

11 or 201, 12 or 202

50 or 232

13 or 14

419

417

. 52: Circuit Breakers

3. Replace with new circuit breaker. Use tabs on bottom of breaker to select L2 and L3.

4. Snap new circuit breaker into place and reconnect wires.

Replace Electrical Enclosure

1. Ensure power to electrical enclosure is disconnected.

2. Disconnect heater and RTD cables from each TCM.

3. Remove plug and use lift ring (not included) at top of electrical enclosure (13 or 14).

39 or 222

. 53: Replace Electrical Enclosure

5. Lift enclosure off and replace with new enclosure.

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

7. 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.

313296J 57

Page 58

Repair

Display/User Interface

Upgrade Display Software

NOTICE

To avoid damaging circuit board, wear a grounding strap.

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

™

Graco Control Architecture manual for instructions.

Replace Display

NOTE: Order Kit 24F493 for replacement. Software token 16C027 is required to install software before use.

NOTICE

To avoid damaging circuit board, wear a grounding strap.

Module Programming

1. Disconnect power.

2. Pull display (20) out of bracket (22) clips to remove it.

3. Disconnect CAN cable(s) from display (20).

4. Replace with new display. Reconnect CAN cable(s).

5. Load the correct display software for the system. Follow the steps in Upgrade Display Software on page 58.

NOTE: Token is not included with display and must be ordered separately.

58 313296J

Page 59

Replace Fluid Control Module

Repair

41 or 224

1. Disconnect power to system.

2. Remove front shroud (16 or 204) and back shroud (17 or 205).

200 Shown

16 or 204

Captive Screws

36 or 220

28 or 215

. 55: Remove FCM

6. Replace with new FCM, and secure with screws.

7. Reconnect cables to FCM.

8. Load the correct FCM software for the system. Follow the steps in Upgrade FCM Software on page

59.

30 or 217

33 or 219

Replace Base

17 or 205

FIG. 54: Remove Shrouds

3. Disconnect all cables from FCM (36 or 220).

4. Remove access door (41 or 224).

5. Loosen both captive screws from FCM and pull FCM off base (33 or 219).

1. Disconnect power to system.

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

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

4. Remove screws (28 or 215) and ground screw (30 or 217) from base (33 or 219). See F

5. Replace with new base, and secure with screws.

6. Reconnect CAN cable(s).

7. Set selector switch to “A” for Ram A or “B” for Ram B. See F

8. Reinstall FCM. See Replace Fluid Control Mod- ule.

. 55.

Upgrade FCM Software

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

™

Graco Control Architecture manual for instructions.

Module Programming

313296J 59

Page 60

Repair

Replace Cable Track

D200 and D200S Supply Systems Only

NOTE: Order Kit 257163 for replacement.

1. Disconnect power to system.

2. Disconnect all 10 cables from back of electrical enclosure (13 or 14).

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

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

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

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

72 73

FIG. 56: Back View of Electrical Enclosure

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

and ram.

13 or 14

. 57: Cable Track Bracket

. 58: Junction Box

8. Lift out cable track assembly and cables.

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

10. Run wires through strain relief and reconnect all wires in junction box. See D200 Junction Box Schematic, page 65.

11. Reinstall strain relief nut and junction box cover. Secure junction box using screws.

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

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

14. Reconnect power to system.

60 313296J

Page 61

Electrical Schematics

D200 Single Ram Schematic

(1) Power

(3) COM

(2) Unused

DRUM EMPTY

(1)

(3)

(4)

(2)

DRUM LOW or EMPTY OPTION

Cable Splitter

(1)

(4) SIGNAL

(2)

(3)

(1) Solenoid signal

(2) Solenoid RTN

(1)

(2)

(4)

(5)

P/N 121235

AIR SOLENOID

DRUM EMPTY

DRUM LOW and EMPTY OPTION

(2) Unused

(1) Power

(4) SIGNAL

(3) COM

DRUM LOW

(1)

(3)

(4)

(2)

Cable Splitter

(1)

(1) Power

(2) Unused

(1)

(2)

213

(2)

(3)

(3) COM

(3)

(4)

(4) SIGNAL

(4)

(5)

(1) Solenoid signal

(1)

AIR SOLENOID

(2) Solenoid RTN

(2)

Electrical Schematics

Warm Melt

Standard Ram

63A

Warm Melt Enclosure

GFCI

Line Filter

FLUID

Motor Pigtail

(1)

RAM A

MODULE

CONTROL

Cable 8 Pin

(2)

(3)

(4)

(5)

C/B

8 Amp

24 Vdc P/S

(2) N/C

(3) Motor Reed Up

(1) Linear Input

(1)

(2)

(3)

(1)

(2)

(3)

(1)

(2)

(3)

(1)

Sensor Reed Switch

Top Switch 1

(5) Motor Reed Com5(7) Linear Com

(4) Motor Reed Down

(6) Linear Power

(8) Drain

(4)

(5)

(6)

(7)

(4)

(5)

(6)

(7)

(4)

(5)

(6)

(7)

(2)

(3)

(4)

(2)

(3)

(4)

Top Switch 2

Bottom Switch 1

Bottom Switch 2

LPTCM

Power

Heater

(8)

8 Amp

Circuit

Heater

Power

Fluid Filter Monitor Option

Breaker

Cable

RTD

Input

Cable Splitter

(1)

(2)

(3)

Power (1)

Unused (2)

Common (3)

Fluid Pressure Sensor

Cable

LPTCM

Cable 15 Meter

(4)

Press Signal (4)

Power

Heater

332

(1) Power

(2) Filter Inlet Press.

(3) Common

(4) Filter Outlet Press.

(1)

(2)

(3)

(4)

(5)

(1)

(2)

(3)

(4)

(1)

(2)

(3)

(4)

Fluid Pressure Sensor

8 Amp

Circuit

Breaker

Cable

Heater

Power

Fluid Solenoid

Depres/Recirc Option

Wire Harness

(5) Drain

(5) (5)

(1)

(2)

(3)

(4)

Power (1)

Unused (2)

Common (3)

Press Signal (4)

RTD

Input

(1) Signal

(1)

(2)

Drain (2)

Unused (1)

Cable

(2) Common

(GND) Unused

(2)

(3)

(4)

Signal (4)

Common (3)

Cable

AIR SOLENOID

(1)

Power (1)

(1) Solenoid signal

(2) Solenoid RTN

(1)

(2)

(5)

(2)

(3)

(4)

Common (3)

Low Sensor (2)

Air Solenoid (5)

Empty Sensor (4)

SHLD (1)

+24Vdc (2)

-24Vdc (3)

+24Vdc (2)

Ferrite Bead

CAN_L (5)

CAN_H (4)

CAN_L (5)

Ferrite Bead

SHLD (1)

-24Vdc (3)

CAN_H (4)

CAN_L (5)

+24Vdc (2)

Module

Gateway

Gateway Option

Ferrite Bead

-24Vdc (3)

+24Vdc (2)

CAN_L (5)

CAN_H (4)

Light Tower Option

Light Tower

(1) Unused

(2) Amber

(1)

(2)

Amber (2)

Unused (1)

(3) Common

(4) Green

(3)

(4)

Green (4)

Common (3)

(5) Red

(5)

Red (5)

Fieldbus

BRAN

DISPLAY

MODULE

LAY

50A

8 Amp

Circuit

Breaker

Cable

LPTCM

Heater

Power

RTD

Input

Power

Heater

CONTACTOR

Circuit

25 Amp

Cable

Breaker

Cable

HPTCM

Cable

Heater

Power

CONTROL

RTD

Input

Power

Heater

SHLD (1)

Cable

+24Vdc (2)

-24Vdc (3)

Cable

-24Vdc (3)

CAN_H (4)

CAN_L (5)

CAN_H (4)

CAN_L (5)

CAN_H (4)

CAN_L (5)

24 Vdc+

24 Rtn

Cable, Volex

J-BOX CABLE TRACK

Cable, Extension

Cable, Volex

Cable, Extension

Cable, Volex

Cable, Extension

Black

Cable,10AWG

Cable, Extension

GRN/YEL

Cable,10AWG

Cable, CAN

SHIELDED CABLE

BUSS BAR

KEY

HOSE

GUN

PUMP

PLATEN

313296J 61

Page 62

Electrical Schematics

D200 Ram A Schematic

FLUID

RAM A

MODULE

CONTROL

(2) N/C

(3) Motor Reed Up

(5) Motor Reed Com5(7) Linear Com

(1) Linear Input

(4) Motor Reed Down

(6) Linear Power

(8) Drain

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(5)

(6)

(7)

(8)

(1)

(2)

(3)

(4)

Cable 8 Pin

(5)

(6)

(7)

(8)

(1)

(2)

(3)

(4)

Fluid Filter Monitor Option

Ram “A”

Warm Melt

Motor Pigtail

(1)

(2)

(3)

(1)

(2)

(3)

(4)

(5)

(1)

(2)

(3)

(4)

Sensor Reed Switch

Top Switch 1

Top Switch 2

Bottom Switch 1

Bottom Switch 2

Fluid Pressure Sensor

Cable Splitter

(1)

(2)

Power (1)

Unused (2)

Cable 15 Meter

(3)

(4)

Common (3)

Press Signal (4)

(1) Power

(2) Filter Inlet Press.

(1)

(2)

(1)

(2)

(1)

(2)

Fluid Pressure Sensor

Depres/Recirc Option

(3) Common

(4) Filter Outlet Press.

(5) Drain

(3)

(4)

(5)

(3)

(4)

(3)

(4)

(5) (5)

(1)

(2)

Power (1)

Unused (2)

Fluid Solenoid

Wire Harness

(3)

(4)

Common (3)

Press Signal (4)

AIR SOLENOID

DRUM EMPTY

(2) Unused

(1) Power

(4) SIGNAL

(3) COM

(1)

(3)

(4)

(2)

DRUM LOW and EMPTY OPTION

(1) Solenoid signal

(2) Solenoid RTN

(2) Unused

(1) Power

(4) SIGNAL

(3) COM

DRUM LOW

(1)

(3)

(4)

(2)

(1)

(2)

Cable Splitter

213

(1)

(2)

(3)

(4)

(5)

“B”

To Ram

Option

|OR|

(2) Unused

(1) Power

(4) SIGNAL

(3) COM

DRUM EMPTY

(2)

(1)

(3)

(4)

(1) Solenoid signal

Cable Splitter

(1)

(2)

Power (1)

Low Sensor (2)

(1)

(5)

(3)

(4)

Common (3)

Empty Sensor (4)

(2) Solenoid RTN

AIR SOLENOID

(2)

Air Solenoid (5)

SHLD (1)

+24Vdc (2)

-24Vdc (3)

Ferrite Bead

CAN_L (5)

CAN_H (4)

CAN_L (5)

Ferrite Bead

SHLD (1)

-24Vdc (3)

CAN_H (4)

CAN_L (5)

+24Vdc (2)

Module

Gateway

Gateway Option

Ferrite Bead

+24Vdc (2)

-24Vdc (3)

Ferrite Bead

CAN_L (5)

CAN_H (4)

Light Tower

(1) Unused

(2) Amber

(3) Common

(4) Green

(1) Signal

(2) Common

(GND) Unused

(3)

(4)

Signal (4)

Common (3)

Light Tower Option

(1)

(2)

(1)

(2)

Drain (2)

Unused (1)

(5) Red

(5)

(1)

(2)

(3)

(4)

Red (5)

Green (4)

Amber (2)

Unused (1)

Common (3)

Fieldbus

DISPLAY

MODULE

SPL

SHLD (1)

Cable

+24Vdc (2)

-24Vdc (3)

CAN_H (4)

CAN_L (5)

CAN_H (4)

CAN_L (5)

24 Vdc+

24 Rtn

63A

GFCI

Warm Melt Enclosure

Line Filter

8 Amp

24 Vdc P/S

50A

C/B

8 Amp

Circuit

Breaker

Cable

LPTCM

Heater

Power

RTD

Input

Power

Heater

Cable, Volex

Cable, Extension

8 Amp

Circuit

Breaker

Cable

LPTCM

Heater

Power

RTD

Input

Power

Heater

332

Cable, Volex

Cable, Extension

8 Amp

Circuit

Breaker

Cable

LPTCM

Heater

Power

RTD

Input

Power

Heater

Cable, Volex

Cable, Extension

J-BOX CABLE TRACK

CONTACTOR

Circuit

25 Amp

Cable

P/N 255774

Heater

Black

Cable,10AWG

Power

CONTROL

Breaker

Heater

Power

RTD

Input

Cable, Extension

Cable

GRN/YEL

Cable,10AWG

SHLD (1)

Cable, CAN

Cable

-24Vdc (3)

+24Vdc (2)

CAN_H (4)

CAN_L (5)

SHIELDED CABLE

BUSS BAR

Cable

HPTCM

KEY

HOSE

GUN

PUMP

PLATEN

62 313296J

Page 63

Electrical Schematics

D200 Ram B Schematic

Warm Melt

Ram “B” Option

63A

GFCI

Cable

Warm Melt Enclosure

Line Filter

J-BOX CABLE TRACK

LPTCM

Power

Heater

Cable, Volex

50A

CONTACTOR

Circuit

25 Amp

8 Amp

Circuit

Breaker

Cable

Heater

Power

RTD

Input

Cable, Extension

8 Amp

Circuit

LPTCM

Power

Heater

332

Cable, Volex

Heater

Breaker

Power

Cable

RTD

Input

Cable, Extension

Cable

HOSE

8 Amp

Circuit

Breaker

Heater

Cable

Power

RTD

Input

Cable, Extension

Cable

HPTCM

Cable,10AWG

Cable

LPTCM

Power

Heater

Cable, Volex

PUMP

Breaker

Heater

Power

RTD

Input

Cable, Extension

Cable

GRN/YEL

Cable,10AWG

SHLD (1)

-24Vdc (3)

+24Vdc (2)

CAN_H (4)

CAN_L (5)

Cable, CAN

Cable

Control

Power

Heater

Black

PLATEN

GUN

DRUM LOW and EMPTY OPTION

DRUM LOW

(1)

Cable Splitter

DRUM EMPTY

(1) Power

(2) Unused

(2)

(3) COM

(3)

(1) Power

(1)

(4) SIGNAL

(4)

(1)

(2) Unused

(2)

213

(2)

(3)

(3) COM

(3)

(4)

(4) SIGNAL

(4)

(5)

AIR SOLENOID

(1) Solenoid signal

(2) Solenoid RTN

(1)

(2)

(2) Unused

(1) Power

(4) SIGNAL

(3) COM

DRUM EMPTY

(1)

(3)

(4)

(2)

(1) Solenoid signal

(2) Solenoid RTN

Cable Splitter

(1)

(2)

Power (1)

Low Sensor (2)

(1)

(3)

(4)

(5)

Common (3)

Air Solenoid (5)

Empty Sensor (4)

(2)

AIR SOLENOID

SHLD (1)

-24Vdc (3)

+24Vdc (2)

-24Vdc (3)

+24Vdc (2)

CAN_L (5)

CAN_H (4)

CAN_L (5)

Ferrite Bead

Cable, CAN 15m

SHIELDED CABLE

BUSS BAR

KEY

FLUID

CONTROL

Motor Pigtail

(1)

RAM “B”

MODULE

Cable 8 Pin

(2)

(3)

(4)

(5)

(2) N/C

(3) Motor Reed Up

(1) Linear Input

(1)

(2)

(3)

(1)

(2)

(3)

(1)

(2)

(3)

(1)

Top Switch (1)

(5) Motor Reed Com

(4) Motor Reed Down

(6) Linear Power

(8) Drain

(7) Linear Com

(4)

(5)

(6)

(7)

(8)

(4)

(5)

(6)

(7)

(8)

(4)

(5)

(6)

(7)

(8)

(2)

(3)

(4)

(2)

(3)

(4)

Sensor Reed Switch

Top Switch (2)

Bottom Switch (1)

Bottom Switch (2)

Fluid Solenoid

Depress/Recirc Option

Wire Harness

(1) Signal

(1)

(2)

Drain (2)

Unused (1)

(2) Common

(GND) Unused

(2)

(3)

(4)

Signal (4)

Common (3)

To Ram “A”

313296J 63

Page 64

Electrical Schematics

D200 Displacement Pump and Platen Schematics

Platen

Displacement Pump

64 313296J

Page 65

D200 Junction Box Schematic

Electrical Schematics

313296J 65

Page 66

Electrical Schematics

D200 Cable Track Schematic

66 313296J

Page 67

D60 Single Ram Schematic

(2) Unused

(1) Power

(3) COM

DRUM EMPTY

(2)

(1)

(3)

DRUM LOW or EMPTY OPTION

Cable Splitter

(1)

(4) SIGNAL

(4)

(2)

(1) Solenoid signal

(1)

(3)

(4)

(5)

(2) Solenoid RTN

AIR SOLENOID

(2)

DRUM EMPTY

(1) Power

(1)

DRUM LOW and EMPTY OPTION

(2) Unused

(1) Power

(4) SIGNAL

(3) COM

DRUM LOW

(1)

(3)

(4)

(2)

Cable Splitter

(1)

(2) Unused

(3)

(2)

213

(2)

(3)

(3) COM

(4)

(4) SIGNAL

(4)

(5)

(1) Solenoid signal

(1)

AIR SOLENOID

(2) Solenoid RTN

(2)

Electrical Schematics

Motor Pigtail

Warm Melt

D60 Standard Ram

63A

GFCI

Warm Melt Enclosure

Line Filter

FLUID

CONTROL

(1)

(2)

8 Amp

24 Vdc P/S

RAM A

MODULE

(3)

(4)

(5)

C/B

Cable 8 Pin

(2) N/C

(3) Motor Reed Up

(1) Linear Input

(1)

(2)

(3)

(1)

(2)

(3)

(1)

(2)

(3)

(1)

Sensor Reed Switch

Top Switch 1

(5) Motor Reed Com5(7) Linear Com

(4) Motor Reed Down

(6) Linear Power

(8) Drain

(4)

(5)

(6)

(7)

(5)

(6)

(7)

(4)

(5)

(6)

(7)

(4)

(2)

(3)

(4)

(2)

(3)

(4)

Top Switch 2

Bottom Switch 1

Bottom Switch 2

LPTCM

Power

Heater

(8)

8 Amp

Circuit

Heater

Power

Fluid Filter Monitor Option

Breaker

Cable

RTD

Input

Cable Splitter

(1)

(2)

(3)

Power (1)

Unused (2)

Common (3)

Fluid Pressure Sensor

Cable

LPTCM

Cable 15 Meter

(4)

Press Signal (4)

Power

Heater

332

(1) Power

(2) Filter Inlet Press.

(3) Common

(4) Filter Outlet Press.

(1)

(2)

(3)

(4)

(5)

(1)

(2)

(3)

(4)

(1)

(2)

(3)

(4)

Fluid Pressure Sensor

8 Amp

Circuit

Breaker

Cable

Heater

Power

Fluid Solenoid

Depres/Recirc Option

Wire Harness

(5) Drain

(5) (5)

(1)

(2)

(3)

(4)

Power (1)

Unused (2)

Common (3)

Press Signal (4)

RTD

Input

(1) Signal

(1)

(2)

Drain (2)

Unused (1)

Cable

(2) Common

(GND) Unused

(2)

(3)

(4)

Signal (4)

Common (3)

Light Tower Option

Light Tower

(1) Unused

(1)

(2)

Amber (2)

Unused (1)

(2) Amber

(3)

Common (3)

(3) Common

(4) Green

(5) Red

(5)

(4)

Red (5)

Green (4)

AIR SOLENOID

(1) Solenoid signal

(2) Solenoid RTN

(1)

(2)

Cable

SHLD (1)

+24Vdc (2)

-24Vdc (3)

+24Vdc (2)

Ferrite Bead

CAN_L (5)

CAN_H (4)

CAN_L (5)

Ferrite Bead

SHLD (1)

-24Vdc (3)

CAN_H (4)

CAN_L (5)

+24Vdc (2)

Module

Gateway

Gateway Option

Ferrite Bead

-24Vdc (3)

+24Vdc (2)

CAN_L (5)

CAN_H (4)

(5)

(1)

(2)

(3)

(4)

Power (1)

Common (3)

Low Sensor (2)

Air Solenoid (5)

Empty Sensor (4)

Fieldbus

BRAN

DISPLAY

MODULE

LAY

50A

8 Amp

Circuit

Breaker

Cable

LPTCM

Heater

Power

RTD

Input

Power

Heater

CONTACTOR

Circuit

25 Amp

Cable

Breaker

Cable

HPTCM

Cable

Heater

Power

CONTROL

RTD

Input

Power

Heater

SHLD (1)

Cable

-24Vdc (3)

+24Vdc (2)

-24Vdc (3)

+24Vdc (2)

Cable

-24Vdc (3)

+24Vdc (2)

CAN_H (4)

CAN_L (5)

CAN_H (4)

CAN_L (5)

CAN_H (4)

CAN_L (5)

24 Vdc+

24 Rtn

Cable, Volex

J-BOX CABLE HARNESS

Cable, Extension

Cable, Volex

Cable, Extension

Cable, Volex

Cable, Extension

Black

Cable,10AWG

Cable, Extension

GRN/YEL

Cable,10AWG

Cable, CAN

SHIELDED CABLE

BUSS BAR

KEY

HOSE

GUN

PUMP

PLATEN

313296J 67

Page 68

Electrical Schematics

D60 Ram A Schematic

FLUID

RAM A

MODULE

CONTROL

(2) N/C

(3) Motor Reed Up

(5) Motor Reed Com5(7) Linear Com

(1) Linear Input

(4) Motor Reed Down

(6) Linear Power

(8) Drain

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(5)

(6)

(7)

(8)

(1)

(2)

(3)

(4)

Cable 8 Pin

(5)

(6)

(7)

(8)

(1)

(2)

(3)

(4)

Fluid Filter Monitor Option

Warm Melt

D60 Ram “A”

Motor Pigtail

(1)

(2)

(3)

(5)

(1)

(2)

(3)

Sensor Reed Switch

Top Switch 1

Top Switch 2

Bottom Switch 1

(4)

Bottom Switch 2

(1)

(2)

(3)

(4)

Cable Splitter

Fluid Pressure Sensor

(1)

(2)

Power (1)

Unused (2)

Cable 15 Meter

(3)

(4)

Common (3)

Press Signal (4)

(1) Power

(2) Filter Inlet Press.

(3) Common

(4) Filter Outlet Press.

(1)

(2)

(3)

(4)

(1)

(2)

(3)

(4)

(1)

(2)

(3)

(4)

Fluid Pressure Sensor

Fluid Solenoid

Depres/Recirc Option

Wire Harness

(1)

Unused (1)

(5) Drain

(5)

(5) (5)

(1)

(2)

(3)

(4)

Power (1)

Unused (2)

Common (3)

Press Signal (4)

(1) Signal

(2) Common

(1)

(2)

Drain (2)

(GND) Unused

(3)

(4)

Signal (4)

Common (3)

Light Tower Option

DISPLAY

MODULE

Light Tower

(1) Unused

(2) Amber

(1)

(2)

Amber (2)

Unused (1)

(3) Common

(4) Green

(3)

(4)

Green (4)

Common (3)

DRUM LOW and EMPTY OPTION

DRUM LOW

Cable Splitter

(5) Red

(5)

Red (5)

BRAN

SPL

DRUM EMPTY

(2) Unused

(1) Power

(3) COM

(1)

(3)

(2)

(1) Power

DRUM EMPTY

(1)

Cable Splitter

(1) Power

(1)

(4) SIGNAL

(4)

(1)

(2)

(2) Unused

(3) COM

(3)

(2)

Power (1)

(4) SIGNAL

(3) COM

(2) Unused

(3)

(4)

(2)

213

(3)

(4)

(5)

(4) SIGNAL

(4)

(1)

(2)

(3)

(4)

Common (3)

Low Sensor (2)

Empty Sensor (4)

AIR SOLENOID

(1) Solenoid signal

(2) Solenoid RTN

(1)

(2)

(1) Solenoid signal

(2) Solenoid RTN

AIR SOLENOID

(1)

(2)

(5)

Air Solenoid (5)

SHLD (1)

+24Vdc (2)

-24Vdc (3)

+24Vdc (2)

Cable

-24Vdc (3)

+24Vdc (2)

-24Vdc (3)

+24Vdc (2)

To Ram

|OR|

Ferrite Bead

CAN_L (5)

CAN_H (4)

CAN_L (5)

Ferrite Bead

CAN_H (4)

CAN_L (5)

CAN_H (4)

CAN_L (5)

“B”

Option

Ferrite Bead

SHLD (1)

CAN_L (5)

-24Vdc (3)

CAN_H (4)

CAN_L (5)

Module

Gateway

+24Vdc (2)

CAN_H (4)

Gateway Option

Ferrite Bead

Fieldbus

24 Vdc+

24 Rtn

50A

CONTACTOR

Circuit

25 Amp

Cable

HPTCM

Cable,10AWG

Breaker

Cable

Heater

Power

CONTROL

RTD

Input

Power

Heater

Black

Cable, Extension

GRN/YEL

Cable,10AWG

+24Vdc (2)

SHLD (1)

Cable, CAN

-24Vdc (3)

CAN_H (4)

CAN_L (5)

SHIELDED CABLE

BUSS BAR

63A

GFCI

Warm Melt Enclosure

Line Filter

C/B

8 Amp

24 Vdc P/S

LPTCM

Cable, Volex

J-BOX CABLE TRACK

8 Amp

Circuit

Breaker

Cable

Heater

Power

RTD

Input

Power

Heater

Cable, Extension

8 Amp

Circuit

LPTCM

Cable, Volex

Heater

Power

Heater

332

Breaker

Cable

RTD

Cable, Extension

Input

Cable

8 Amp

Circuit

LPTCM

Heater

Cable, Volex

Breaker

Cable

Heater

Power

RTD

Input

Power

Cable, Extension

Cable

KEY

HOSE

GUN

PUMP

PLATEN

68 313296J

Page 69

D60 Ram B

Electrical Schematics

Schematic

Warm Melt

D60 Ram “B” Option

63A

GFCI

Cable

Warm Melt Enclosure

Line Filter

J-BOX CABLE TRACK

LPTCM

Cable, Volex

50A

CONTACTOR

Circuit

25 Amp

8 Amp

Circuit

Breaker

Cable

Heater

Power

RTD

Input

Power

Heater

Cable, Extension

8 Amp

Circuit

Breaker

Cable

LPTCM

Cable, Volex

Heater

Power

Heater

332

Cable

Power

Cable, Extension

RTD

Input

HOSE

8 Amp

Circuit

Breaker

Heater

Power

Cable, Extension

Cable

HPTCM

RTD

Input

Cable,10AWG

Cable

LPTCM

Power

Heater

Cable, Volex

PUMP

Breaker

Cable

Control

Power

Heater

Black

Cable, Extension

Cable

Heater

Power

RTD

Input

GRN/YEL

Cable,10AWG

SHLD (1)

-24Vdc (3)

+24Vdc (2)

CAN_H (4)

CAN_L (5)

Cable, CAN

PLATEN

GUN

DRUM LOW and EMPTY OPTION

DRUM LOW

Cable Splitter

(1) Power

(1)

(2) Unused

(2)

DRUM EMPTY

(1) Power

(1)

(4) SIGNAL

(3) COM

(3)

(4)

(1)

(2) Unused

(3) COM

(3)

(2)

213

(2)

(3)

(4)

(4) SIGNAL

(4)

(5)

AIR SOLENOID

(1) Solenoid signal

(2) Solenoid RTN

(1)

(2)

(2) Unused

(1) Power

(4) SIGNAL

(3) COM

DRUM EMPTY

(1)

(3)

(4)

(2)

(1) Solenoid signal

(2) Solenoid RTN

Cable Splitter

(1)

(2)

Power (1)

Low Sensor (2)

(1)

(3)

(4)

(5)

Common (3)

Air Solenoid (5)

Empty Sensor (4)

(2)

AIR SOLENOID

SHLD (1)

-24Vdc (3)

+24Vdc (2)

-24Vdc (3)

+24Vdc (2)

CAN_L (5)

CAN_H (4)

CAN_L (5)

Ferrite Bead

Cable, CAN 15m

SHIELDED CABLE

BUSS BAR

KEY

FLUID

CONTROL

Motor Pigtail

(1)

RAM “B”

MODULE

(2)

(3)

(4)

(5)

Cable 8 Pin

(2) N/C

(3) Motor Reed Up

(1) Linear Input

(1)

(2)

(3)

(1)

(2)

(3)

(1)

(2)

(3)

(1)

Top Switch (1)

(5) Motor Reed Com

(4) Motor Reed Down

(6) Linear Power

(8) Drain

(7) Linear Com

(4)

(5)

(6)

(7)

(8)

(4)

(5)

(6)

(7)

(8)

(4)

(5)

(6)

(7)

(8)

(2)

(3)

(4)

(2)

(3)

(4)

Sensor Reed Switch

Top Switch (2)

Bottom Switch (1)

Bottom Switch (2)

Fluid Solenoid

Depress/Recirc Option

Wire Harness

Unused (1)

(1)

(1) Signal

(1)

(2) Common

(2)

(3)

Drain (2)

Common (3)

(GND) Unused

(3)

(4)

Signal (4)

To Ram “A”

313296J 69

Page 70

Electrical Schematics

D60 Pump and Platen Schematic

70 313296J

Page 71

D60 Junction Box Schematic

Electrical Schematics

313296J 71

Page 72

Electrical Schematics

D60 Cable Harness Schematic

72 313296J

Page 73

Electrical Enclosure Schematic

Electrical Schematics

4-Zone Medium Enclosure

313296J 73

Page 74

Electrical Schematics

Electrical Enclosure Schematic

4-Zone RAM ‘B’ Enclosure

74 313296J

Page 75

Electrical Schematics

313296J 75

Page 76

Parts

D200s Rams Shown

Single Supply System or Supply System A

Supply System B

76 313296J

Page 77

Parts

NOTE: See Component Identification, starting on page 8, to identify the components included in your Warm Melt supply system.

Ref. Part Description Qty.

2❄ RAM ASSEMBLY, D60, 3 in. 1

RAM ASSEMBLY, D60i, 3 in. 1 RAM ASSEMBLY, D200s, 6.5 in. 1 RAM ASSEMBLY, D200si, 6.5 in. 1 RAM ASSEMBLY, D200, 3 in. 1 RAM ASSEMBLY, D200i, 3 in. 1

3 PUMP, Check-Mate; see manual

312375 for parts

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

polyurethane

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

polyurethane

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

polyurethane

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

polyurethane

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

polyurethane

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

polyurethane

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

EPDM 257749 PLATEN, 55 gal., o-ring, EPDM 1 257750 PLATEN, 55 gal., o-ring, neoprene 1

5❄ 257623 KIT, mounting, pump; 3 in.; 20 liter; for

NXT 2200 air motors 257624 KIT, mounting, pump; 3 in.; 20 liter; for

NXT 3400 and 6500 air motors 255305 KIT, mounting, pump; 3 in.; 55 gal. 1 255315 KIT, mounting, pump; 6.5 in.; 55 gal. 1

6❄ 255392 KIT, mounting; Check-Mate pump 1 7❄ VALVE, safety relief; located out of

view, on back side of air controls 103347 For systems with pumps: P23xxx or

P36xxx 108124 For systems with pumps: P68xxx

Ref. Part Description Qty.

ENCLOSURE, electrical (see Electrical Enclosure Parts, page 90)

13 257158 For single systems and Ram A 1 14 257291 For Ram B 1 15 KIT, warm melt, with display (see Warm

Melt Kits for D200 Systems, page 78, or Warm Melt Kits for D60 Systems,

page 83) 24D009 D60, Ram, WMxxxx Models 1 24D010 D60, Ram A, TWxxxx Models 1

24D012 D200, 3 in. Ram, WMxxxx Models 1 24D013 D200, 3 in. Ram A, TWxxxx Models 1 24D015 D200, 6.5 in. Ram, WMxxxx Models 1 24D016 D200, 6.5 in. Ram A, TWxxxx Models 1

16 KIT, warm melt, with no display (see

Warm Melt Kits for D200 Systems,

page 78, or Warm Melt Kits for D60

24D011 D60, Ram B, TWxxxx Models 1 24D014 D200, 3 in. Ram B, TWxxxx Models 1 24D017 D200, 6.5 in. Ram B, TWxxxx Models 1

❄

See Supply Systems Repair-Parts manual for parts.

Systems, page 83)

Stainless Steel Ram Conversion Kits

For converting carbon steel Ram to stainless steel.

24K670 D60, Ram, WMxxxx Models

24K671 D60, Ram A, TWxxxx Models 24K673 D60, Ram B, TWxxxx Models 24K675 D200, 3 in. Ram, WMxxxx Models 24K676 D200, 3 in. Ram A, TWxxxx Models 24K677 D200, 3 in. Ram B, TWxxxx Models

24K678 D200, 6.5 in. Ram, WMxxxx Models 24K679 D200, 6.5 in. Ram A, TWxxxx Models 24K680 D200, 6.5 in. Ram B, TWxxxx Models

313296J 77

Page 78

Parts

Warm Melt Kits for D200 Systems

Kit 24D012 (CST), 24K675 (SST) with Display for D200 and D200i Systems Kit 24D015 (CST), 24K678 (SST) with Display for D200s and D200si Systems Kit 24D013 (CST), 24K676 (SST) with Display for Ram A of Tandem D200 and D200i Systems Kit 24D014 (CST), 24K677 (SST) without Display for Ram B of Tandem D200 and D200i Systems Kit 24D016 (CST), 24K679 (SST) with Display for Ram A of Tandem D200s and D200si Systems Kit 24D017 (CST), 24K680 (SST) without Display for Ram B of Tandem D200s and D200si Systems

Kit 24D016 Shown

105

71, 72, 73

78 313296J

r_wm_2179_313296_5a

Page 79

72, 73

Parts

61, 62

101

83, 84, 85

11, 12

11, 26, 58, 59

101

TI19984a

313296J 79

Page 80

Parts

45, 79

107(x2), 108(x2), 110

Torque to 60 +/- 10 in-lbs (6.8 +/- 1.1 N•m)

103c

103a

103b

57, 99

68, 69, 97, 98

ti17719a

107

108

109

57, 97, 100, 102

46, 56, 82

80 313296J

ti17718a

Page 81

Parts

116

101

117

112

68, 97, 98

1159

113

UBFB

D200 Warm Melt Kits

Ref. Part Description Qty.

11✓ 100016 WASHER, lock 29 12 121112 SCREW, cap, sch 15 13❖ 115827 SCREW, cap, hex hd; 7/16-14

unc 14❖ 15X270 WASHER, top hat 1 15❖ 15G347 SUPPORT, hose hanger 1 16 COVER, shroud front 1

†277589 - for 3 in. Ram

◆277591 - for 6.5 in. Ram

17 COVER, shroud rear 1

†277590 - for 3 in. Ram

◆277592 - for 6.5 in. Ram 1

18 BRACKET, light tower 1

†255383 - for 3 in. Ram

◆15R108 - for 6.5 in. Ram 19❖ 100696 WASHER, plain 2 20✿■ 24F493 MODULE, display 1 21✿✓ BRACKET, pendant pivot 1 22✿✓ BRACKET, mounting, assy 1 23✿✓ SCREW, cap, sch; 1/4-20 unc 1 24✿ 102040 NUT, lock, hex 1 25★ ‡123328 CABLE, splitter, FCM,

empty/air ✖15X968 CABLE, FCM, low/hi/air 1 16C377 CABLE, M12, DIN 1

26✿ 110755 WASHER, plain 5 27✿ 121253 KNOB, display 1 28 114417 SCREW, self tap, pan hd 4

Ref. Part Description Qty.

29★ SUPPRESSOR, ferrite bead 1 30 121070 SCREW, machine; #8-32 x 1

3/8

31★ CABLE, CAN, female/female;

0.5 m 121001 121228 Kits 24D014 and 24D017 only

32❖ 101213 NUT, full, hex 1 33 289697 MODULE, cube, base 1 34*‡✖ 122716 SENSOR, inductive, M12 1 35*‡✖ BRACKET, sensor, low/empty 1 36■ 289696 MODULE, fluid control 1 37*‡✖ ACTUATOR, sensor,

low/empty

39 BRACKET, mounting, bottom 1

†❋ - for 3 in. Ram

◆✠ - for 6.5 in. Ram

40 BRACKET, mounting 1

†❋ - for 3 in. Ram

◆✠

- for 6.5 in. Ram

41❖ 277674 ENCLOSURE, cube door 1 42✓ 257163 CABLE, track 1 43● CONDUCTOR, block, heater 2

44✛✓★ 121980 HEATER, pump, 725 watt 2 45✛★ 16J890 SUPPORT, sensor 1 46●✛✓✖16D383 SENSOR, RTD, shielded 2

47❖ 119832 BOLT, eye, 3/8-14 x 6 1 48●✓ 15V427 HEATER, coil 2

313296J 81

Page 82

Parts

Ref. Part Description Qty.

49◗●✓✖ COVER, platen front, assy. 2 50 BRACKET, mounting, top 1

†❋ - 3 in. Ram

◆✠ - 6.5 in. Ram 51✛✓ ★ 15W706 ENCLOSURE, pump, front 1 52✛✓ ★ 15W707 ENCLOSURE, pump, rear 1 53 CONDUIT; 12.9 mm 4 54 COUPLER, conduit 4 56 117026 SCREW, shcs; m5 x 12 1 57✓★ 116343 SCREW, ground 2 58 SCREW, cap, hex hd 4

100014 - for 3 in. ram

100058 - for 6.5 in. ram 59✓ 100015 NUT, hex mscr 12 60❖ 100133 WASHER, flat 2 61 C19837 SCREW, cap, hex hd 2 62● STUD, 3/8-16 x 1.25 6 63◗● PLUG, finishing; 13/16 in.,

nickel plated 64 176692 WASHER, flat 6 65❖ 100307 NUT, hex 2 66❖ C34132 HANGER 1 67 15Y051 CABLE, M12 1 68 123507 WIRE, grounding 1 69 16H441 WIRE, grounding 1 70◗● FASTENER, platen, cover 2 71 120223 SCREW, machine, flat hd 4 72 100020 WASHER, lock 4 73 100179 NUT, hex mscr 4 74 111218 CAP, tube 1 75 COVER 1 76 121255 SCREW, countersunk; 6-32 x

0.38 78 16M941 BRACKET, cable and rack 1 79 C31012 CLAMP 1 80 110637 SCREW, machine, pan hd 4 81❖ 119958 SPRING, hose hanger 1 82 110170 WASHER 1 83❂ O-RING 1 84❂ CONNECTOR, power, female,

3 pin 85❂ COVER, connector 1 86▲ 15J075 LABEL, warning 2 87▲ 15H668 LABEL, warning 1 89✓ RAIL, din, assy. 1 90 BUSHING, strain relief; m40 1 91 NUT, strain relief; m40 1 92✓ 24B810 CONNECTOR, bulkhead; 15

pin 93 113970 SCREW, socket hd cap 4 94 C19208 WASHER, lock 4 95 102794 NUT, hex 4 97 111640 WASHER, lock 6 98 100166 NUT, full hex 5 99✓ 16A355 WIRE, ground, pump 1 100✓✖ 16A356 WIRE, ground, platen 1 101▲ 196548 LABEL, caution 1 102✓✖ 16A574 WIRE, ground 4

Ref. Part Description Qty.

103 255392 KIT, mounting, displacement

pump 103a 102637 SCREW, cap 4 103b 276025 CLAMP 4 103c 109495 O-RING 1

104★ STUD 6 106★ 15Y051 CABLE 1 107 124131 SCREW 4 108 103187 WASHER, lock 4 109✓★ 15B137 SWITCH, thermal 1 110✓★ 16K094 SWITCH, overtemp, horizontal 1 111★ 114958 STRAP TIE 7 112 16A539 JUNCTION BOX 1 113 16A543 BRACKET 1 114 299653 SHRINK TUBE 1 115 C33037 TAPE, fiberglass 1 116 112788 SCREW 4

117 16A541 COVER, junction box 1

★

Not shown.

▲

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

†

Kit 24D012 only.

◆

Kit 24D015 only.

✿

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

❖

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

‡

Parts included in Low or Empty Sensor Kit 255469 (purchase separately).

✖

Parts included in Drum Low and Empty Sensor Kit 24C530 (purchase separately).

❋

Parts included in 3 in. Ram Bracket Mounting Kit 24C628 (purchase separately).

✠

Parts included in 6.5 in. Ram Bracket Mounting Kit 24C660 (purchase separately).

●

Parts included in Platen Heater Kit 24C493 (purchase separately).

✛

Parts included in Pump Heater Kit 24C495 (purchase separately).

◗

Parts included in Platen Cover Kit 255691 (purchase separately).

✓

Parts only available in Display Mounting Kit 24C653 (purchase separately).

❂

Parts only available in Cover Connector Kit 256883 (purchase separately).

■

Replacement electronic components do not have Warm Melt specific software installed. Therefore, use software upgrade token 16C027 to install software before use.

82 313296J

Page 83

Warm Melt Kits for D60 Systems

Kit 24D009 (CST), 24K670 (SST) with Display for D60 and D60i Systems Kit 24D010 (CST), 24K671 (SST) with Display for Ram A of Tandem D60 and D60i Systems Kit 24D011 (CST), 24K673 (SST) without Display for Ram B of Tandem D60 and D60i Systems

Parts

Kit 24D010 Shown

204

207

211

281

213

208

209

214

202

210

201

203

202

201

279

280

206

201

202

224

219

215

217

220

205

254

253

r_wm29yy_31329b6_5

313296J 83

Page 84

Parts

258

233

257

r_wm_2179_313296_12a

259, 260, 261

237

236

235

84 313296J

Page 85

282, 283, 284

234

Parts

227

256

249, 272, 273

228, 229

227

262

239, 274

ti17721a

201, 202

232

223

201, 213, 240, 241

201

202, 222

313296J 85

Page 86

Parts

278

276

271

265

241

201

241

201

264

255

266

248, 272, 273

270

201241

258

268

269

267

UBFB

D60 Warm Melt Kits

Ref. Part Description Qty.

201 100016 WASHER, lock 31 202 121112 SCREW, cap, sch 23 203 288543 BRACKET, hose spring 1 204 277589 COVER, shroud front 1 205 277590 COVER, shroud rear 1 206 255383 BRACKET, light tower 1 207✿■ 24F493 MODULE, display 1 208✿✓ BRACKET, pendant pivot 1 209✿✓ BRACKET, mounting, assy 1 210✿✓ SCREW, shcs; 1/4 unc x 4.25 1 211✿✓ 102040 NUT, lock, hex 1 212★

16C377 CABLE, M12;

Kits 24D009/24K670 only

15X968 CABLE, splitter, FCM empty/air;

Kits 24D010. 24D011, 24K671,

24K673 only 213✿✓ 110755 WASHER, plain 1 214✿✓ 121253 KNOB, display 1 215 114417 SCREW, self tap, pan hd 4 216★ 123375 SUPPRESSOR, ferrite bead 1 217 121070 SCREW, machine; #8-32 x 1 3/8 1 218★ 121001 CABLE, CAN, female / female; 1m 1 219 289697 MODULE, base 1 220■ 289696 MODULE, fluid control 1 222❋ BRACKET, mounting, bottom 1 223❋ BRACKET, mounting 1

Ref. Part Description Qty.

224 277674 ENCLOSURE, cube door 1 225★ 16C430 HARNESS 1 227✛ 121980 HEATER, pump; 725 watt 2 228✛ 16J890 SUPPORT, sensor 1 229✛ 16D383 SENSOR, RTD, shielded 1 232❋ BRACKET, mounting,

accessory box

233✛ 15W706 ENCLOSURE, pump, front 1

◆ 16K771 ENCLOSURE, pump, front, SST

234✛ 15W707 ENCLOSURE, pump, rear 1

◆ 16K772 ENCLOSURE, pump, rear SST 235 CONDUIT; 12.9 mm 2 ft 236 COUPLER, conduit 3 239 116343 SCREW, ground 1

240 100014 SCREW, cap, hex hd 4 241 100015 NUT, hex mscr 8

247★ 15Y051 CABLE, M12, 8 pin, f/m 1 248 123507 WIRE, grounding, panel 1 249 16A574 WIRE, grounding, door 2 250 16H441 WIRE, grounding 1 253 COVER 1 254 121255 SCREW, countersunk, 6-32 x 0.38 2 255✛ 16A539 BOX, junction box 1 256 C31012 CLAMP 1 257 110637 SCREW, mach, pan head 4 258 BRACKET, mount 1 259❂ O-RING 1 260

❂ CONNECTOR, power,

female, 3 pin

86 313296J

Page 87

Ref. Part Description Qty.

261❂ COVER, connector 1 262▲ 15J075 LABEL, warning 1 263★▲ 15H668 LABEL, warning 1 264 RAIL, din, assy 1 265 BUSHING, strain relief; M40

thread 266 NUT, strain relief; M40 thread 1 267 24B810 CONNECTOR, bulkhead, 15 pin 1 268 113970 SCREW, cap, sch 4 269 C19208 WASHER, lock 4 270 102794 NUT, hex 4 271 COVER, junction box 1 272 111640 WASHER, lock, internal 4 273 100166 NUT, full hex 4 274 16A355 WIRE, ground 1 276▲ 196548 LABEL, caution 1 277★ 114958 STRAP, tie 7 278 112788 SCREW, cap, sch 4 279*‡✖ BRACKET, sensor, low/empty 1 280*‡✖ 122716 SENSOR, inductive, M12 2 281*‡✖ ACTUATOR, sensor, low/empty 1 282 124131 SCREW 2 283 103181 WASHER, lock 2 284 16K094 SWITCH, overtemp, horizontal 1 285 C33037 TAPE, fiberglass 1 286 106245 SCREW 1 287 157974 WASHER 1 288 16K066 CLAMP, support 1

★

Not shown.

▲

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

* Standard only on tandem supply systems.

✿

Kits 24D009, 24D010, 24K670, and 24K671.

‡

Parts included in Low or Empty Sensor Kit 255469 (purchase separately).

✖

Parts included in Drum Low and Empty Sensor Kit 24C530 (purchase separately).

❋

Parts included in 3 in. Ram Bracket Mounting Kit 24C628 (purchase separately).

✛

Parts included in Pump Heater Kit 24C495 (purchase separately).

◆

Parts included in Stainless Steel Pump Heater Kit 24K669 (purchase separately).

✓

Parts only available in Display Mounting Kit 24C653 (purchase separately).

❂

Parts only available in Cover Connector Kit 256883 (purchase separately).

■

Replacement electronic components do not have Warm Melt specific software installed. Therefore, use software upgrade token 16C027 to install software before use.

Parts

313296J 87

Page 88

Parts

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

Platen 24D066 (20L) Shown

311

335

327

325, 326

309

324

323

320

322

321

333

334 336

328, 329, 330

303

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

Apply sealant to all non-swiveling pipe threads.

Add lubricant to threads.

302

310

ti17717b

319

318

317

304, 305

301

308

309

307

313

Ground RTD sleeve to screw (332).

88 313296J

Page 89

Parts

Parts Used on all Heated Platens

Ref. Part Description Qty.

301 BASE, platen 1 305 PLATE, bottom 1 306 121829 O-RING 1 309 NUT, keps, hex hd 12 or 20 311 257697 HANDLE, bleed, sst, assy 1 312 109482 O-RING 1 313 C20350 ELBOW, 90 deg. 1 317 GASKET, heat transfer 1 318 PLATE, heater, lower 1 319 HEATER (includes wiring to

switch 336) 320 PLATE, heater, upper 1 321 HOLDER, RTD sensor 1

Ref. Part Description Qty.

322 16D383 SENSOR, RTD, 1k ohm,

shielded 323 NUT, barrel, binding screw 4 324 GUARD, heat shield 1 325 COUPLER, conduit 1 326 CONDUIT, ID 12.9mm 36 327 189930 LABEL, caution 1 328 C38163 WASHER, lock, external 1 329 100166 NUT, full hex 1 330 16A356 WIRE, ground 1 331 16H441 WIRE, ground 1 332 111593 SCREW, grounding 1 335 15K616 LABEL, safety 1 336 15B137 SWITCH, thermal 1 337 104714 SCREW, machine

338 103181 WASHER, lock

Replacement Danger and Warning labels, tags, and

▲

cards are available at no cost.

Parts that Vary by Heated Platen Model

Heated Platen Models

24D066, 20L

Ref. Description

302

SPACER, dual wiper

303

WIPER, main

304

WIPER, support

307

PLATE, top

308

SCREW, set, sch

310

VALVE, check

333

WIPER, support

334 SPACER, nylon, 3/4 in. --- --- --- 16J835 16J835 16J835 1

Platen, CS

257694 257695 257696 262873 262874 257684 1

257678 257679 257680 257675 257676 257677 2

257681 257682 257683 257681 257682 257683 1

257686 257687 257688 257698 257699 257725 1

100421 100421 100421 109477 109477 109477 2

122056 122056 122056 501867 501867 501867 1

--- --- --- 15V442 15V443 15V444 1

24D067, 30L

Platen, CS

24D068, 60L

Platen, CS

24D069, 20L

Platen, SST

24D070, 30L

Platen, SST

24D071, 60L

Platen, SST

Qty

313296J 89

Page 90

Parts

Electrical Enclosure Parts

257158 for single supply systems and ram A of tandem supply systems 257291 for ram B of tandem supply systems

257158 Shown

441

445

444

402, 403, 404, 405

436

443, 458

442

433, 434, 435

452

425, 453

407

440

427

457

415, 426

438

437

401

Side View

439

451

439

459

406

461

415

456

417

466

414

415, 426

420

318

460

422

413

431

415 426

412

432

429

428

408, 409, 410

430

411

90 313296J

416

419

417

421

423

424

Page 91

Parts

Electrical Enclosure Parts

Qty

Ref. Part Description

401 ENCLOSURE 1 402 DOOR, enclosure 1 403 101682 SCREW, cap, sch 4 404 100016 WASHER, lock 4 405 100015 NUT, hex, mscr 4 406 15X754 BRACKET, mounting, electrical 1 407★ 289697 MODULE, cube, base 3 408■★ 256270 MODULE, low power temp 3 409 114417 SCREW, self tap, pan hd 12 410 121070 SCREW, machine, pan hd 3 411■★ 255774 MODULE, high power temp 1 412 15U651 BRACKET, high power temp mod-

ule

413 15R535 BRACKET, mounting, high power

temp module 414 117831 SCREW, machine, pan hd 4 415 100035 SCREW, machine, pan hd 20 416★ 122148 BAR, buss, smissline; 17.125 in. 1 417★ 122619 CIRCUIT, breaker, smissline; 10A

(257291 includes qty. of 3) 418 122129 COVER, buss bar 1 419★ 122128 CIRCUIT, breaker 1 420★ 16A573 WIRE, power 2 421★ 122122 SWITCH, disconnect 1 422 122317 ROD, connecting, on/off 1 423★ 122125 RELAY, contactor 1 424★ 123141 CIRCUIT, breaker, smissline; 25A 1 425 111640 WASHER, lock, internal 2 426 157021 WASHER, lock, internal 10 427★ KIT, bar, ground 1 428 257341 HARNESS, wiring, high power

temp module 429★ 121597 CABLE, CAN, 90 female/90 female 2 430★ 15V999 CABLE; 14 in. 3 431★ CABLE; M8, male/ferrules 1 432★ 121000 CABLE, CAN, female/female; 0.5 m 1 433 100023 WASHER, flat 4 434 100133 WASHER, lock 4 435 100307 NUT, hex 4 436 PANEL, side, 3 low power heat

modules, 1 hp 437 GASKET, low power heat module 3 438 GASKET, high power heat module 1 439 LABEL, junction box 1 440 CORD, grip; PG-7 1 441 GRIP, cord 1 442★ 121612 CONNECTOR, thru; M12, m x f 1 443 112788 SCREW, cap, socket hd 6 444 LATCH, quarter turn 2 445 15W905 HANDLE, selector, on/off 1 451 SEAL, hole, plug; 0.5 in. 1 452 16H441 WIRE, grounding, door 1 453 100166 NUT, full hex 2 454 123507 WIRE, ground 1 456 277674 ENCLOSURE, cube door 3 457 186620 LABEL, ground 1

Ref. Part Description

458 112905 WASHER, plain 6

459★ 123373 FILTER, power line; single phase 1 460★ 123374 SUPPLY, power; 24Vdc, 2.5A,

60W

(included in only 257158) 461 COVER, buss bar, single 1 466 125789 CABLE, CAN, female/female 1 467 123615 TERMINAL, bus bar, L3 (257291

only)

★

Not shown.

▲

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

■

Replacement electronic components do not have Warm Melt specific software installed. Therefore, use software upgrade token 16C027 to install software before use.

Qty

313296J 91

Page 92

Accessories

Platen Cover, 255691

Two platen covers. See manual 406681 for more information for D200 platens.

Two-Zone Expansion Kit, 24C223

For adding two zones of heat to a Warm Melt Supply System. The two extra zones are controlled through the Warm Melt display.

Two-Zone Accessory Kit, 24C222

Controls two zones of heat; up to 212°F (100°C).

Four-Zone Accessory Kit, 24C526

Controls four zones of heat; up to 212°F (100°C).

Light Tower Accessory Kit, 255468

For use with Warm Melt or Tandem Supply Systems.

Low and Empty Sensor Kit, 24C530

Indicates when the drum is low and empty. Includes two sensors: one to be used as a low sensor, and one to be used as an empty sensor. For use with Warm Melt (to add a low sensor), Ambient, and Tandem supply systems.

92 313296J

Page 93

Appendix A - User Interface Display

Display Overview

The user interface display is divided into two main functions: Setup mode and Run mode.

Setup Mode Functions

The setup mode functions enable users to:

• set and change the password;

• configure system parameters;

• set heat zone parameters;

• schedule maintenance parameters;

• configure system hardware settings;

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

• set pump size and drum fill volume;

• and view software information for each system component.

Run Mode Functions

The run mode functions enable users to:

• view current flow rate and drum volume;

• view temperature for heat zones;

• view system job totals and grand totals, and reset totals;

• view current pressures;

• view and reset maintenance counters;

• view and clear individual alarms;

• and view the alarm log.

Display Details

Power Up Screen

The following screen appears when the display module is powered up. It remains on while the display module runs through initialization and establishes communication with other components in the system.

. 59: Power Up Screen

Menu Bar

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

. 60: Menu Bar

Date and Time

The date and time are always displayed in one of the following formats. The time is always displayed as a 24-hour clock.

• DD/MM/YY HH:MM

• MM/DD/YY HH:MM

Navigation

The navigation section, which is to the right of the date and time, indicates the active screen with the center, highlighted icon. The left and right arrows indicate there are more screens that can be accessed within a mode.

313296J 93

Page 94

Appendix A - User Interface Display

Status

The current system status is displayed on the right of the menu bar. If there is an error, an event icon and either a text description of the event or the standard error code for the event is displayed. If there are no errors or deviations, nothing is displayed.

Mode

The mode section displays the current system mode. The current mode is highlighted.

Error

The current system error is displayed in the menu bar. There are four possibilities:

Icon Function

No Icon

No information or no error has occurred

Advisory

Deviation

Alarm

Navigation within Screens

Press to open drop-down menus on Setup

screens. Also, press to enter changes or make a

selection.

Press to navigate to new screens and to

navigate left and right within a screen. Also press

select digits within a field to change.

Press to navigate to new screens and to

navigate up and down within a screen. Also press

to move between fields within a drop-down

menu, and to increment or decrement numbers within a field.

Soft Keys

Icons above the soft keys indicate which mode or action is associated with each soft key. Soft keys that do not have an icon above them are not active in the current screen.

Jump In/Jump Out

In screens that have editable fields, press to

access the fields and make changes. When changes

are complete press to exit edit mode.

94 313296J

Page 95

Setup Mode Screens

Appendix A - User Interface Display

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

Password Screen

While in Run mode, press the Setup button. If the

password is not set to 0000, the Password screen will appear. Enter the password to continue to Setup mode.

NOTE: Upon the first system startup, the System Setup screen will display. Otherwise, the last setup screen viewed will display.

Set Password

To set the password, press to enter the screen.

Press to select digit to change. Press

to set value for each digit. Press

again to enter the password.

System Setup

The System Setup screen enables users to configure

system settings for the ram(s). Press to access the

fields and make changes. Press to exit edit mode.

Icon Function

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

Select if a Not Primed event will issue an alarm or deviation.

Set number of minutes (1-9) for priming.

Set pump cycles per minute that will issue a pump runaway alarm. Set between 0 and 99; default setting is 60 cycles; 00 setting disables this function.

. 62: System Setup

. 61: Password Screen

Heater System Setup Screen

This screen enables users to set parameters for each

heat zone. Press to scroll through each

heat zone. When the desired heat zone displays, press

to access the fields to make changes. Press

to exit edit mode.

313296J 95

Page 96

Appendix A - User Interface Display

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

Icon Function

Displays selected heat zone. Press

to scroll through each heat

zone. Set the temperature setpoint for each heat

zone.

Set the number of degrees the setpoint will be decreased by when the heat zone is in setback mode.

Set the number of degrees the heat zone can go above the setpoint before an alarm is issued.

Set the number of degrees the heat zone can go above the setpoint before a deviation is issued.

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

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

Maintenance Setup Screen

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

rebuilding the pump.

Icon Function

Set the number of drums (0-9999) between platen seal maintenance. Setting the number of pump cycles to 0 disables this function. If using a tandem system, set for each ram. A rebuild platen seals error is issued when maintenance is required. See Alarm Codes and Troubleshooting on page 36.

Set the number of pump cycles (0-9999) between pump maintenance. Setting the number of pump cycles to 0 disables this function. If using a tandem system, set for each pump. A rebuild pump error is issued when maintenance is required. See Alarm

Codes and Troubleshooting on page 36.

. 64: Maintenance Setup

. 63: Heater System Setup Screen

96 313296J

Page 97

Appendix A - User Interface Display

Hardware Setup Screens

The Hardware Setup screens enable users to specify if specific hardware is installed on the system and to

adjust hardware settings. Press to scroll

through the Hardware Setup screens. Once in the

desired Hardware Setup screen, press to access

the fields to make changes. Press to exit edit

mode.

NOTE: Must exit edit mode to scroll through the Hardware Setup screens.

Hardware Setup Screen 1

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

pressure drop across the filter.

Icon Function

Select what type of error will be issued if filter pressure drops below the low limit or

raises above the high limit. Select to

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

FIG. 65: Hardware Setup Screen 1 (Filter)

Hardware Setup Screen 2

This screen enables users to specify if a fluid solenoid is installed, and if a drum low sensor is installed. The fluid

solenoid controls the depressurize/recirculate valve.

Icon Function

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

disable filter monitoring or if there is no filter installed on the system.

Set low limit (0-1000 psi) for pressure drop that will issue an error. Set the low limit to detect a filter element collapse or a missing element.

Set high limit (0-5000 psi) for pressure drop that will issue an error. Set the high limit to detect a clogged filter.

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

. 66: Hardware Setup Screen 2

313296J 97

Page 98

Appendix A - User Interface Display

Advanced Setup Screens

The Advanced Setup screens enable users to set units, adjust values, set formats, and view software informa-

tion for each component. Press to scroll

through the Advanced Setup screens. Once in the

desired Advanced Setup screen, press to access

the fields to make changes. Press to exit edit

mode.

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.

NOTE: Must exit edit mode to scroll through the Advanced Setup screens.

Advanced Setup Screen 1

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

NOTE: On two-zone and four-zone enclosure acces-

sory kit, only and settings are available.

Icon Function

Select units of measurement for volume. Select between cycles/gal. gal., oz., and liters/cc.

Set units of measurement for maintenance intervals. Select between cycles, drums, gal., and liters.

Set units of measurement for pressure. Select between psi and bar.

Set the password. Use digits 0-9999; 0000 = no password.

Icon Function

Set pump size (cc/cycle) for each ram. Check-Mate: Select between 60, 100, 200, 250, and 500. Dura-Flo: Select between 145, 180, 220, 290, 430, 580, and 1000.

Set fill volume for each drum. Use digits 1-9999.

Change between a Check-Mate or Dura-Flo pump.

Set units of measurement for temperature. Select between °F and °C.

. 67: Advanced Setup Screen 1

98 313296J

. 68: Advanced Setup Screen 2

Page 99

Appendix A - User Interface Display

Advanced Setup Screen 3

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

Icon Function

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

Set current date.

Set current time.

Advanced Setup Screens 4 and 5

These screens display the software part number and version information for the system components. Only system components that are detected via the system

data bus will be displayed on these screens.

Icon Function

Controller software part number and version.

Display software part number and version.

Fieldbus gateway software part number and version.

Temperature controller software part number and version.

. 69: Advanced Setup Screen 3

. 70: Advanced Setup Screens 4 and 5

313296J 99

Page 100

Appendix A - User Interface Display

Run Mode Screens

Run mode screens are divided into six sections: ram operation, heat zone operation, current system status, preventative maintenance schedule, current alarms, and error reports. The system starts in Run mode. If the sys-

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

Ram Operation Screen

The Ram Operation screen displays which ram (A or B) is active, and how much volume remains in each drum. This screen also displays the flow rate of the active ram. When the fluid line is shown filled the system is on.

Depending on the current system status, users can perform the following procedures from the Ram Operation screen:

• turn the air motor on and off;

• depressurize and pressurize the system;

• recirculate fluid within the active ram;

• prime the pump(s);

• and perform a manual crossover on tandem systems.

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

Active ram is highlighted

Volume Remain

Current mode

Flow rate

Fluid line shown filled when system is Run Mode

FIG. 71: Ram Operation Screen - Tandem System

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

• depressurized ,

• in Recirculate mode ,

• or if a ram is in Prime mode .

100 313296J

Graco 313296J User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Models

Warnings

Overview

System Description

Power Requirements

Heat Control Zone Selection

Component Identification

Single Supply Systems

Tandem Supply Systems

Integrated Air Controls

Air Line Accessories

2-Button Interlock Air Controls

Communications Gateway Module

Fluid Control Module

User Interface

Installation

Location Requirements

Location

Grounding

Connect Power Source

Install/Adjust Drum Low or Empty Sensor

Light Tower Accessory

Attach Drum Stops

Check Resistance

Hose Installation and Care

Overview of Temperature Control Settings

Setup

Purge System

Set Values on Display Module

Load Material

System Heat Up

Prime

Operation

Pressure Relief Procedure

Trigger Lock

Start and Adjust Ram

Start and Adjust Pump

Manual Crossover

Automatic Crossover

Recirculate Function

Depressurize Function

Change Drums

Maintenance

Shutdown

Replace Throat Seals

Platen Maintenance

Electrical Enclosure

Pump Heaters

Alarms

Diagnose Alarms

Clear Alarms

Alarm Codes and Troubleshooting

Troubleshooting

Repair

Air Motor

Displacement Pump

Disconnect Pump from Platen

Connect Pump to Platen

Replace Pump Heaters

Replace Platen Heaters and Sensor

Replace Platen Wipers

Replace Ram Piston Rod Seals

Electrical Enclosure

Display/User Interface

Replace Fluid Control Module

Replace Cable Track

Electrical Schematics

D200 Ram A Schematic

D200 Ram B Schematic

D200 Displacement Pump and Platen Schematics

D200 Junction Box Schematic

D200 Cable Track Schematic

D60 Single Ram Schematic

D60 Ram A Schematic

D60 Pump and Platen Schematic