Graco 313875J User Manual
Instructions
™
VPM
Hydraulic, Plural-Component, High-Viscosity, Variable-Ratio Proportioner.
For pouring and dispensing sealants and adhesives. For professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 4 for model information, including maximum working pressure and approvals.
313875J
EN
VPM-12 VPM-25
ti17692a
ti17693a
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Important Two-Component Material Information . 7
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7
Keep Components A (Red) and B (Blue) Separate 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8
A (Red) and B (Blue) Components . . . . . . . . . . . . . 8
Component Identification . . . . . . . . . . . . . . . . . . . 10
VPM-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic Power Pack . . . . . . . . . . . . . . . . . . . . 15
Motor Control Module (MCM) . . . . . . . . . . . . . . 16
Advanced Display Module (ADM) . . . . . . . . . . . 18
Fluid Control Module (FCM) . . . . . . . . . . . . . . . 21
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Initial Machine Setup . . . . . . . . . . . . . . . . . . . . . 22
Adjust Motor Control Module Selector Switch . . 27
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Change Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Remove Drum . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ADM Operation Overview . . . . . . . . . . . . . . . . . 31
Machine Operation Overview . . . . . . . . . . . . . . 33
System Setup and Calibration . . . . . . . . . . . . . . 34
Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Short-term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
End of Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 46
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Install Upgrade Tokens . . . . . . . . . . . . . . . . . . . 48
Advanced Display Module (ADM) . . . . . . . . . . . 49
Motor Control Module (MCM) . . . . . . . . . . . . . . 49
Fluid Control Module (FCM) . . . . . . . . . . . . . . . 49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . 51
Common Problems . . . . . . . . . . . . . . . . . . . . . . 51
ADM Troubleshooting . . . . . . . . . . . . . . . . . . . . 53
Motor Control Module . . . . . . . . . . . . . . . . . . . . 54
Fluid Control Module . . . . . . . . . . . . . . . . . . . . . 56
Appendix A - ADM Icons Overview . . . . . . . . . . . 57
Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . . 57
Home Screen Icons . . . . . . . . . . . . . . . . . . . . . 58
Appendix B - ADM Setup Screens Overview . . . . 59
Appendix C - ADM Run Screens Overview . . . . . 65
Optional Screens . . . . . . . . . . . . . . . . . . . . . . . . 68
Appendix D - ADM Event and Error Codes Overview
69
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Appendix E - USB Operation . . . . . . . . . . . . . . . . 80
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
USB Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Download Log Files . . . . . . . . . . . . . . . . . . . . . . 80
Log Files, Folder Structure . . . . . . . . . . . . . . . . 81
Transfer System Settings . . . . . . . . . . . . . . . . . . 83
Update Custom Language . . . . . . . . . . . . . . . . . 84
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 88
2 313875J
Related Manuals
Manuals are available at www.graco.com.
Component manuals in English:
System Manual
312764 VPM Repair-Parts
Power Distribution Box Manual
3A0239 Power Distribution Boxes Instruc-
tions-Parts
Pumpline Manuals
312375
3A0021 Vertical Hydraulic Driver
Val ve Manu als
Check-Mate
Pumps
Repair-Parts
®
Displacement
Related Manuals
310550 1/2 in. NPT Fluid Port Ball Seat
Applicator
310551 3/4 in. NPT Fluid Port Ball Seat
Applicator
3A1792 DV Series Dispense Valves
Flow Meter Manual
309834 Helical Gear Fluid Flow Meter
Accessories
3A1937 Heated Platen Kits
313875J 3
Models
Models
Full Load Peak Amps
Per Phase*
System Description
24F226
VPM-25,
1
No
Heated
Heat
Platen
55 A 62 A 62 A 400 (3)
2
Heated
Platen
Voltag e
(phase)
Boom
24F874 60 A 76 A 86 A 230 (3)
mounted
System
Watts
24,000
(No Heat)
Max Flow
Rate◆**
lb/min
(kg/min)
55 (25)
Approximat
e Output
per Cycle
(A+B)**
gal. (liter)
Hydraulic
Pressure
Ratio**
dispense
24F875
24J509
24J510 60 A 76 A 86 A 230 (3)
24J511
valve
VPM-12,
Mast
mounted
dispense
valve,
reduced
55 A 62 A 62 A 400 (3)
✔
55 A 62 A 62 A 400 (3)
55 A 62 A 62 A 400 (3)
✔
27,600
(1 Platen)
31,200
(2 Platens)
0.2 (0.76) 1.87
26 (12)
flow
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and
mix chamber sizes may be less.
** Values are dependent on installed pump size. Values shown are for largest available pump size.
Maximum
Fluid
Wor king
Pressure ‡
psi (MPa,
bar)
3000
(21, 207)
◆ Flow rate is independent of frequency 50/60 Hz.
❖ Flow rate increases with flow meters removed.
‡ The maximum fluid working pressure for the base machine without hoses is 3000 psi (21 MPa, 207 bar). If hoses
rated at less than 3000 psi are installed, the system maximum fluid working pressure becomes the rating of the
hoses. If 2000 psi hoses were purchased and installed by Graco, the working pressure for the machine is already
setup for the lower 2000 psi (14 MPa, 138 bar) working pressure by Graco. If the machine was purchased without
hoses and aftermarket hoses rated at or above 3000 psi are to be installed, see Adjust Motor Control Module
Selector Switch on page 27 for the procedure to setup the machine for higher rated hoses. The change in working pressure is made by changing a rotary switch setting in the Motor Control Module. The minimum pressure rating for hoses is 2000 psi. Do not install hoses with a pressure rating lower than 2000 psi.
Accessories
Heated Platen Kits
The Heated Platen kits convert the standard platen to a
heated platen to enable dispensing in lower temperature
environments.
Part Description
24E267 B (Blue) Side Kit
24E268
A (Red) Side Kit
Power Distribution Box Conversion Kits
These conversion kits convert the voltage and CE
approval of a system.
Part Description
24E269
24E272
400V Non-CE Conversion Kit
400V CE Conversion Kit
4 313875J
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
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 MSDSs 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 chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
+
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
313875J 5
Warnings
WARNING
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. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• 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 Da ta in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine 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.
MOVING PARTS HAZARD
Moving parts can pinch, cut 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 and disconnect all power sources.
6 313875J
Important Two-Component Material Information
WARNING
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.
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.
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Material Self-ignition
Keep Components A (Red) and B(Blue) Separate
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of
the equipment’s wetted parts, never interchange
component A (Red) and component B (Blue) parts.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
313875J 7
A (Red) and B (Blue) Components
Moisture Sensitivity of Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the pump wet cups filled with IsoGuard
®
Select
rier between the ISO and the atmosphere.
, part 24F516. The lubricant creates a bar-
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been contaminated from the other side.
• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Changing Materials
• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A (Red) side, but
some use ISO on the B (Blue) side. See the following section.
A (Red) and B (Blue) Components
IMPORTANT!
Material suppliers can vary in how they refer to plural
component materials.
Be aware that when standing in front of the manifold on
proportioner:
• Component A (Red) is on the left side.
• Component B (Blue) is on the right side.
For all machines:
• The A (Red) side is intended for ISO, hardeners,
and catalysts.
• The B (Blue) side is intended for polyols, resins, and
bases.
NOTE: For machines with material volume ratios other
than 1:1, the higher volume side is typically the B (Blue)
side.
8 313875J
A (Red) and B (Blue) Components
313875J 9
Component Identification
Component Identification
AA Advanced Display Module (see page 18)
AB Hydraulic Power Pack
AC Vertical Hydraulic Driver
AD RAM Assembly
AE Ratio Check Dispense Valves/Ports
AF Power Distribution Box
VPM-25 shown
AE
AH
AE
AG Boom Lift Lever
AH Mixer
AJ Main Power Switch
AK Air Supply Inlet
AL Electrical Enclosure
AB
AD
AG
AK
ti17693a
AL
AA
FIG. 1: Component Identification
10 313875J
VPM-25 shown
Component Identification
AF
AD
AC
AJ
ti17702a
AL
FIG. 2: Component Identification
313875J 11
Component Identification
VPM-12
AH
AK
AL
AB
AD
AE
AD
AC
AC
AJ
AF
ti17703a
AL
FIG. 3
AA
12 313875J
RAM Assembly
Component Identification
BA Vertical Hydraulic Driver
BB Pump Lower
BC Platen
BD Integrated Air Controls
BE Platen Bleed Port
BA
BK
BJ
BF Blowoff Air Supply Line Connector
BG Platen Lift Rod
BH Pump Bleeder Valve
BJ Pump Wet Cup
BK Material Line
BD
BB
BC
BF
BH
BG
BE
ti17705a
313875J 13
Component Identification
Integrated Air Controls
The integrated air controls include:
• Main air slider valve (CA): turns air on and off to
the ram system. When closed, the valve relieves
pressure downstream.
• Ram air regulator (CB): controls ram up and down
pressure and blowoff pressure.
• Ram director valve (CC): controls ram direction.
• Exhaust port with muffler (CD)
• Blowoff button (CE): turns air on and off to push
the platen out of an empty drum.
CD
CC
CE
CB
Circuit Breakers
Most circuit breakers are located inside the power distribution box. The main block of circuit breakers in the
power distribution box is shown below, with detailed
information in the following table. See the power distribution box manual for more information.
CB1 CB5 CB10CB6
24C687_313873-5_1c
Size
CA
F
IG. 4: Component Identification
Ref.
230V/
3 phase
400V/
3 phase
Component
CB1 30A 63A Motor Control Module
CB5 5A 5A Miscellaneous
CB6 5A 5A Miscellaneous
CB10 30A 63A Motor Control Module
14 313875J
Hydraulic Power Pack
Component Identification
F
B
257442_313873-5_1t
Shown with shroud removed
E
C
G
A
D
H
257442_313873-5_2t
FIG. 5
Key:
A 8 Gallon Hydraulic Oil Reservoir (see Technical Data on
page 87 for specifications)
B Electric Motor
C Dipstick
D Hydraulic Housing
313875J 15
E Motor Control Module (see page 16)
FFan
G Hydraulic Oil Filter
H Hydraulic Fluid Drain Port
Component Identification
Motor Control Module (MCM)
NOTICE
If the Motor Control Module is replaced, the selector switch must be set prior to initial startup of the
Motor Control Module or damage may occur. See
Adjust Motor Control Module Selector Switch
on page 27.
B
A
The MCM is located in the Hydraulic Power Pack.
When installed, the end of the MCM with the power
input connection (12) faces down and the end with the
access cover (A) faces up.
The Motor Control Module uses an 8-position selector
switch to set the system maximum working pressure.
C
12
FIG. 6: MCM Component Identification
1A
10
1B
3
2
r_257396_3b9905_01b
6
8
9
11
7
13
5
r_257396_3b9905_03b
16 313875J
Ref Description
A Access Cover
B Module Status LEDs
C Warning Label
A (Red) MCM only:
ADM,
Power Distribution Box
Component Identification
1A, 1B
B (Blue) MCM only:
FCM,
Power Distribution Box
NOTE: 1A and 1B are interchangeable.
2 Three-way Splitter to:
Oil Low Level Sensor,
Dispense Valve Solenoid,
Footswitch
3 Oil Temperature Sensor
5 Electric Motor Temperature Sensor
6LVDT
7 A (Red) MCM only:
Three-way Splitter to:
Hydraulic Directional Valve,
Oil Overtemperature Switch,
Ratio Check Solenoid Valve
B (Blue) MCM only:
Three-way Splitter to:
Hydraulic Directional Valve,
Oil Overtemperature Switch
(Third connection is not used)
8 Pressure Transducer (for material side
controlled by the MCM)
9 Not used
10 MCM to MCM Analog Connection
11 Motor Position Sensor
12 MCM Power Input Connection
13 Motor Power Connection
313875J 17
Component Identification
Advanced Display Module (ADM)
User Interface
A
B
C
D
E
H
G
FIG. 7: ADM Component Identification - Front
Buttons
Call
out Button Function
AADM
Enable/
Disable
B System
Status
Indicator
LED
C Stop Stop all system processes
Enable/disable ADM
Displays system status
F
TI12362a1
Call
out Button Function
D Softkeys Defined by icon next to softkey
E Abort Abort current operation
F Enter Accept change, acknowledge error,
select item, toggle selected item
GRun/
Setup
Toggle between Run and Setup
screens
Screens
Toggle
HArrow
Keys
Navigate within a screen or to a new
screen
18 313875J
Component Identification
J
S
K
L
M
N
R
F
IG. 8: ADM Component Identification - Rear
P
ti12902a
Key:
J Flat Panel Mount
K Model Number Identification Label
L USB Interface (see Appendix E - USB Operation
beginning on page 80
M CAN Cable Connection to MCM
)
N Module Status LEDs
P Accessory Cable Connection
R Software Token Access Cover
S Battery Access Cover
See ADM Troubleshooting on page 53 for LED status information.
See Maintenance section beginning on page 47 for battery replacement and software update procedures.
313875J 19
Component Identification
ADM Screen Components
See the ADM appendix sections beginning with Appendix A - ADM Icons Overview on page 57 for more informa-
tion.
Current date and time Current screen
Previous screen Next screen
Operating Mode
Enter/Exit screen
Settings Detail
F
IG. 9: Main Display Components - Typical Setup Screen
Faults, Status
Previous
screen no.
Current
screen no.
Next
screen no.
Current date and time Current screen
Previous screen Next screen
Operating Mode
Change Operating
Mode
Dispense Details
F
IG. 10: Main Display Components - Home Screen (Shot mode shown)
Faults, Status
Initiate Dispense
Initiate Ratio
Check Dispense
20 313875J
Fluid Control Module (FCM)
The fluid control module is located inside the electrical
enclosure.
Component Identification
A
C
ti12337a1
D
FIG. 11:
Key:
A Module Connection Screws
B Access Cover
C Module Status LEDs
D CAN Connectors (one is connected to MCM, other is
unused)
ti12336a1
B
313875J 21
Setup
Setup
Initial Machine Setup
Perform this setup procedure to prepare the machine for
initial operation.
The machine is not properly grounded until this setup
procedure is performed. To prevent risk of electric
shock, do not start the machine until this setup procedure is completed.
1. Locate the machine.
NOTICE
To prevent machine damage, do not expose system
to rain.
NOTICE
If lifting the machine is required, use a forklift at the
base of the machine. Do not lift the machine by placing forks at the top of the RAM assembly frame.
a. Locate the machine on a level surface. See
Dimensions on page 87 for space requirements.
b. Connect air line on boom to boom director valve
located on boom support.
c. Install mixer onto boom.
d. Connect electrical cables from base to boom.
e. Connect fluid lines from base to boom.
3. VPM-12 systems only: If the mast
was shipped disassembled, install
the mast.
a. Use four bolts and washers to install mast onto
base.
ti17706a1
b. Connect air line on mast to mast director valve.
b. Lock the wheels once the machine is in place.
2. VPM-25 systems only: Install the
c. Install mixer onto mast.
d. Connect electrical cables from base to mast.
boom.
e. Connect fluid lines from base to mast.
ti17706a
a. Install boom into support.
22 313875J
Setup
4. Fill pump wet cups 2/3 full with
IsoGuard Select fluid.
ti17707a
5. Back-off air regulators to their full
pointed up and the sensor is on the outlet side
(top, as shown) of the flow meter.
B (Blue) Side
b. Hand tighten flow meter fittings to allow proper
positioning of the entire assembly.
c. Install the output plumbing hand-tight. The out-
let plumbing includes the pressure sensor and
pressure gauge.
A (Red) Side
counterclockwise position and
close all shutoff valves.
6. Install Flow Meters
NOTE: This system ships with the flow meters removed.
The illustrations below shows what the flow meters will
look like after they are installed.
B (Blue) Side A (Red) Side
NOTICE
To prevent damage, be careful when handling the
pressure sensor and pressure gauge assembly
because the pressure sensor cable is attached.
B (Blue) Side A (Red) Side
d. Align the flow meter assembly and fully tighten
all fittings.
a. Place the flow meter in position as shown in the
illustration below. The flow direction arrow is
313875J 23
Setup
e. Connect the flow meter cable.
B (Blue) Side A (Red) Side
7. Connect 1/2 in. NPT female air
supply to air inlet.
NOTICE
To prevent machine damage, supplied air must be
dried and filtered.
Electrical Cord Requirements
NOTE: Power cord is not supplied. See the following
table.
Table 1: Power Cord Requirements
Cord Requirements
Model
AWG (mm
2
)
230V, 3 phase 8 (8.4), 3 wire + ground
400V, 3 phase 6 (13.3), 4 wire + ground †
† Residual Current Device (RCD) must be rated at
300 mA if installed.
Electrical Cord Wires by Model
230V, 3 phase: L1, L2, L3, GND
400V, 3 phase: L1, L2, L3, N, GND
Electrical Requirements
See Models on page 4 for detailed electrical requirements information.
ti17708a
8. Connect electrical cord.
Installing this equipment requires access to parts
which may cause electric shock or other serious injury
if work is not performed properly. Have a qualified
electrician connect power and ground to main power
switch terminals. All electrical wiring must be done by
a qualified electrician and comply with all local codes
and regulations.
a. Use 5/32 in. or 4 mm hex allen wrench to con-
nect the power leads to L1, L2, L3, and N as
applicable.
b. Connect green wire to ground (GND).
L1L2L3N
GND
r_24C686_313998_1a
F
IG. 12: 400V, 3 phase shown
24 313875J
Setup
Power Line Voltage Surges
Power conversion equipment can be sensitive to voltage
fluctuations on incoming power. The Motor Control Module falls under the category of power conversion equipment because energy is stored on a capacitive bus and
then modulated to control a brushless motor. Engineered design takes this into account and withstands a
wide range of conditions, but it is possible for supplied
power to occasionally fall outside the tolerable range in
industrial plants with high-amperage reactive pulsed
loads such as welding equipment. If the tolerable range
is exceeded, an overvoltage condition is flagged and the
system will shut down in an alarm state to protect itself
and alert the user of unstable power. Excessive or
repeated overvoltage may permanently damage hardware.
The MAX-HOLD feature on a multimeter can be used to
determine peak DC voltage on the line. DC is the proper
setting, as opposed to AC, because peak voltage is the
critical parameter that affects the DC voltage level
stored on the capacitive bus in power conversion equipment. Reading should not regularly exceed approximately 400VDC to avoid tripping the 420VDC alarm
level in the Motor Control Module. If power quality is suspect, power conditioning or isolation of the device(s)
causing poor power quality is recommended. Consult a
qualified electrician if there are any concerns about the
available power supply.
The chart below shows the permissible magnitude and
duration of temporary over-voltage events:
Maximum Permissible Transient Voltage Surges
* Constructed from ITIC 1996 curve, referenced by IEC 61000-2-4
1400
1200
1200Vac, 1697Vdc
1000
800
600
400
Voltage (Volts RMS)
200
0
0.000001 0.00001 0.0001 0.001 0.01 0.1 1 10
<--1 MW Max Surge Power
480Vac, 679Vdc
<--150 KW Max Surge Power
336Vac, 475Vdc
Time (seconds)
<--50 KW Max Surge Power
288Vac, 407Vdc
<--No Power Limit
264Vac, 373Vdc
9. Ground the system.
This equipment must be grounded.
a. VPM: grounded through power cord. See Con-
nect Electrical Cord, step #8 on page 24.
Power Line Test Steps with Multimeter
i. Set multimeter to “DC voltage”.
ii. Connect multimeter probes to supplied power line.
iii. Press “Min Max” successively to show the peak
positive and negative DC voltages.
iv. Confirm readings do not exceed 400VDC (Motor
Control Module alarm issued at 420VDC).
b. Dispense Valve: follow your local code.
c. Fluid supply containers: follow your local code.
d. Dispensing target/container: follow your local
code.
e. To maintain grounding continuity when flushing
or relieving pressure, hold grounded metal pail
firmly to a metal part of dispense valve then initiate a dispense.
10.Check hydraulic fluid levels.
The hydraulic reservoirs are filled at the factory. See
Technical Data on page 87 for hydraulic fluid specifications.
313875J 25
Setup
11.If applicable, attach and adjust
drum low/empty sensor.
NOTE: An optional kit can be purchased to indicate
either when the drum is low or when it is empty.
ti10916a
a. Position ram at desired level (low or empty).
b. Attach low/empty sensor bracket (A) to mount-
ing bracket (B).
c. Attach the actuator (D) to the ram piston rod,
near the top, so it passes in front of the
sensor (E) at the correct level for drum low or
drum empty.
b. Navigate to Advanced #2 screen then set units
of measure. See page 63.
c. Navigate to Advanced #3 screen then
enable/disable system features. See page 64.
d. Navigate to System #1 screen then define con-
trol mode, dispense mode, and pump information. See page 61.
A
E
D
B
e. Navigate to System #2 screen then define dis-
pense valve details and other system settings.
See page 61.
f. Navigate to System #3 screen then define
labels, pressure imbalance, and flow meter
details. See page 62.
g. Navigate to Shots screen then define shots.
See page 59.
h. Navigate to Sequences screen then define
sequences. See page 60.
i. If desired, navigate to Maintenance screen
then reset counters. See page 62.
15.Perform System Setup and Calibration procedure on page 34.
12.Install material drums. See Install
Drum procedure, page 29.
13.Perform Startup procedure,
page 28.
14.Perform ADM setup.
NOTE: All ADM setup items are located in the Setup
screens. See Appendix B - ADM Setup Screens Overview beginning on page 59 for more information.
See ADM Operation Overview on page 31 for help with
operating the ADM including how to modify settings.
a. Navigate to Advanced #1 screen then set gen-
eral system settings. See page 63.
26 313875J
Adjust Motor Control Module Selector Switch
NOTICE
If the Motor Control Module is replaced, the selector
switch must be set prior to initial startup of the
Motor Control Module or damage may occur.
The Motor Control Module uses an 8-position selector
switch (S) to set system maximum working pressure.
See F
IG. 13.
The system can be configured to run in two pressure
ranges:
• 0-3000 psi (0-20.7 MPa, 0-207 bar): For systems
with all components rated to 3000 psi maximum
working pressure or higher.
• Do not install components rated to less than the
highest pressure in the selected pressure range.
For example, if the 0-2000 psi range is selected do
not install items rated less than 2000 psi. If the
0-3000 psi range is selected do not install items
rated less than 3000 psi. Doing so may lead to
overpressurization and ruptured components.
• High-pressure fluid from ruptured components will
pierce skin. This may look like just a cut, but it is a
serious injury that can result in amputation. Get
immediate surgical treatment.
Setup
• 0-2000 psi (0-13.8 MPa, 0-138 bar): For systems
with one or more component rated less than
3000 psi maximum working pressure. For example,
if the hoses are rated to 2500 psi, then the
0-2000 psi range must be used.
See the following table for MCM selector switch (S) position setting for each maximum working pressure.
Switch Position
MCM
2000 psi MWP 3000 psi MWP
B (Blue) 1 3
A (Red) 2 4
The factory setting for the Motor Control Module selector
switch is 2000 psi if the machine is shipped with no
hoses or hoses rated to 2000 psi maximum working
pressure. If the machine is shipped with hoses rated to
3000 psi maximum working pressure or higher then the
factory setting for the selector switch is 3000 psi.
The selector switch position will be properly set at the
factory for new systems. When a motor control module
is replaced, the selector switch must be set to the correct setting by the user prior to initial startup.
To set the Motor Control Module selector switch:
1. Turn machine power off.
2. Remove the access cover (D). See F
IG. 13.
3. Set the selector switch (S).
4. Install access cover (D).
D
S
257396_3B9905_04b
F
IG. 13
To change the maximum working pressure rating of the
system in the field, all outlet components including
hoses and dispense valve must be rated at or above the
new system maximum working pressure rating. For
example, if the new system rating will be 3000 psi, all
system components must be rated to at least 3000 psi
maximum working pressure.
313875J 27
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