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

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

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

Full Load Peak Amps

Per Phase*

System Description

24F226

VPM-25,

Heated

Heat

Platen

55 A 62 A 62 A 400 (3)

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)

✔

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

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

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

AG Boom Lift Lever AH Mixer AJ Main Power Switch AK Air Supply Inlet AL Electrical Enclosure

ti17693a

FIG. 1: Component Identification

10 313875J

VPM-25 shown

Component Identification

ti17702a

FIG. 2: Component Identification

313875J 11

Component Identification

VPM-12

ti17703a

FIG. 3

12 313875J

RAM Assembly

Component Identification

BA Vertical Hydraulic Driver BB Pump Lower BC Platen BD Integrated Air Controls BE Platen Bleed Port

BF Blowoff Air Supply Line Connector BG Platen Lift Rod BH Pump Bleeder Valve BJ Pump Wet Cup BK Material Line

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.

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

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

257442_313873-5_1t

Shown with shroud removed

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.

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.

FIG. 6: MCM Component Identification

r_257396_3b9905_01b

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

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

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

IG. 8: ADM Component Identification - Rear

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

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

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

ti12337a1

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

313875J 21

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

)

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

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

0.000001 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.

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).

257396_3B9905_04b

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

Startup

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.

1. Perform all required maintenance tasks. See Main- tenance on page 47.

2. Check for leaks.

3. Check hydraulic fluid levels.

4. Check pump wet cup fluid levels.

5. Check feed system fluid levels.

6. Turn Main Power Switch to the ON position. The splash screen will be displayed on the ADM until it is finished loading.

7. When the ADM is finished loading, press to

enable the ADM. The System Status Indicator Light

next to will illuminate green.

8. Press repeatedly to select a different operating

mode then press to accept.

NOTE: The Setup screens cannot be accessed when Disabled mode is the active operating mode. Also, certain machine functions and setup changes are disabled when Standby mode is selected.

28 313875J

Change 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.

Remove Drum

1. Open main air slider valve on the integrated air controls and set ram air regulator to 40 psi (0.28 MPa,

2.8 bar).

2. Set ram director valve handle to UP then immediately press and hold the blowoff air button until the platen is completely out of the drum. Use minimum amount of air pressure necessary to push the platen out of the drum.

3. Release the blowoff air button and allow the ram to rise to its full height.

Change Drum

7. Remove bleed stick from platen bleed port (J).

ti10543a

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

4. Remove drum.

Install Drum

1. If platen is inside a drum, perform Remove Drum procedure.

2. If the platen is not at its full height, set ram director valve handle to UP and allow the ram to rise to its full height.

3. Inspect platen and, if necessary, remove any remaining material or material build-up.

4. Lubricate the platen seals with grease or other lubricant compatible with the fluid you will pump.

NOTICE

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

5. Place full drum on the ram base, slide it back against the drum stops, and center it under the platen.

9. Set the director valve to DOWN and lower the ram until fluid appears at the top of the platen bleed port (J). Adjust ram air regulator as needed. 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.

10. Set the director valve to neutral and close the platen bleed port (J).

11. Perform Priming procedure, see page 30.

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

313875J 29

Priming

1. Place waste containers below both ratio check dispense valves.

NOTE: Both ratio check dispense valves will be open when dispensing in Prime Mode. Only one pump moves but material may drip from the other ratio check dispense valve when opened.

2. Verify RAM director valve is in the DOWN position and air pressure is applied to the RAM.

3. Press repeatedly to select Prime Mode then

press to accept.

4. Check the dispense settings shown at the bottom of the screen.

8. Continue dispensing until clean, air-free material is

dispensed from both sides then press to stop

dispensing.

9. Press to select the B (Blue) side.

10. Press to begin dispensing B (Blue) material.

11. Continue dispensing until clean, air-free material is

dispensed from both sides then press to stop

dispensing.

5. If desired, change the dispense settings.

a. Press to enter editing mode.

b. Use the left and right arrow keys to select the

item to change.

c. Use the numeric keypad to type the new value.

d. Press to accept the new value.

e. Press to exit editing mode.

6. Press to select the A (Red) side.

7. Press to begin dispensing A (Red) material.

30 313875J

Operation

ADM Operation Overview

NOTE: After startup, press to enable the ADM.

ADM Navigation Diagram

Run Screens

Operation

Shot #1

Shot #2

Shot #...

Home

Password

(if enabled)

Setup Screens

Sequences #1

Sequences #2

Sequences #...

Entry

Errors #1

Errors #2

Errors #...

Calibration

Events #1

Events #2

Events #...

System #1

System #2

System #3

Maintenance

Optional:

Diagnostic

Supply

Conditioning #1

Conditioning #2

Conditioning #3

Advanced #1

Advanced #2

Advanced #...

313875J 31

Operation

Navigation Overview

For all ADM screens to be accessible and functional, the ADM must be enabled and an operating mode other than Standby or Disabled must be selected.

NOTE: The optional Diagnostic screen can be enabled from Advanced #3 screen, see page 64.

To navigate between screens use the arrow keys on the ADM keypad. To access the Setup screens,

press . If the Setup screens password is turned on, use the ADM keypad to enter the password then

press . For Setup screens information, see Appen- dix B - ADM Setup Screens Overview on page 59. For Run screens information, see Appendix C - ADM Run

Screens Overview on page 65.

Change ADM Values

To edit information in a screen, such as a shot definition or a system setting like time or date format, follow this general process:

1. Press .

NOTE: Operator mode flow settings are edited using a slightly different process. To edit dispensing settings when in Operator mode, see Dispense in Operator Mode section on page 44.

2. Once in the screen, use the arrow keys to navigate to the desired item.

3. Edit the value:

• If the item has a drop-down list to select

from, press to display the dropdown list. Use the up and down arrow keys to highlight the

desired item then press to select the item.

• If the item is a numeric value, use the numeric

keypad on the ADM to type the new value then

press to accept the value.

• If the item is a select/deselect or enable/dis-

able checkbox option, press to toggle the value.

If a screen has been entered by pressing or if the system is in editing mode then navigating to a different screen will be disabled. As applicable, exit the screen and editing mode to re-enable screen navigation.

• If necessary, press to cancel editing.

4. Press .

32 313875J

Machine Operation Overview

Operation

Ramp Up Feature

The purpose of the ramp up feature is to enable dispensing at the correct ratio but at a reduced flow rate when materials are too thick to dispense at the correct flow rate. As the fluid warms up due to the friction of moving through the system, the Ramp Up feature will slowly increase the flow rate until the desired flow rate is achieved. After a period of idle time the system will cool down and the fluids will not be as warm while dispensing, which may result in the Ramp Up feature being activated.

While the system is dispensing, the ramp up feature monitors the torque supplied to the B (Blue) pump to verify it does not apply more torque than the pump can handle. If it does, it will reduce the flow rate in both pumps to maintain the required dispense ratio. As the system warms up and material thickness decreases, the ramp up feature will increase the flow rate until the desired flow rate is achieved.

NOTE: Because the B (Blue) side is the high volume side, it is closer to its maximum flow rate capacity than the A (Red) side pump.

Learning Mode

When a flow rate or dispense ratio is requested that the machine has not learned, the system will use the pump volume of each pump to estimate the pump velocities needed then Learn mode will be used to adjust them to the correct flow rates. The system will begin dispensing at the estimated pump velocity and each stroke performed will be used to gather information and adjust the velocity. After a number of strokes, the system will have sufficient data to accurately dispense at the desired setpoint and Learning mode will be exited.

When Learn mode is active, a “Learning New Set Point” advisory is generated and the yellow light on the light tower is illuminated. After Learn mode is complete, the advisory is cleared.

Because a base purge is done before the system is shut down, the first dispense after the system is turned on is always initiated at a reduced flow rate. The ramp up feature will then increase the flow rate as described in the previous paragraph. Also, after ten minutes of idle time the first dispense will be at a reduced flow rate followed by the flow rate ramp up.

When the ramp up feature reduces the flow rate, a “System Dispensing Below Requested Set Point” advisory is generated and the yellow advisory lamp on the light tower is illuminated. If the system is able to achieve the desired flow rate the advisory is cleared.

313875J 33

Operation

System Setup and Calibration

Perform this entire procedure if any of the following conditions are met:

• The machine is new

• One or both materials in the system have changed since last performing this procedure

• Flow rate, ratio, or ambient temperature has changed

If the software has been updated, verify all software settings in the first section of this procedure are still correct. If any incorrect software setting is found, perform this entire setup and calibration procedure.

Software Settings

1. With the machine on, press to enable the ADM. The LED next to the button should be green.

2. Press repeatedly to select Standby mode then

press to accept.

7. Navigate to the System 2 screen.

8. Select a base purge flow rate. A value of approximately 200 g/s or 200 cc/s is recommended.

9. If installed, check the “Supply Low Level Sensor” option.

10. Verify the correct Dispense Valve type is selected.

11. Navigate to the System 3 screen.

3. Press to enter the Setup screens.

4. Navigate to the System 1 screen.

5. Verify the correct pumps and pump sizes are selected. For the standard VPM system, the B (Blue) pump should be a Check-Mate 500 and the A (Red) pump should be a Check-Mate 250.

6. Select volume or weight for the dispense mode. Weight mode is recommended because it is easier to calibrate.

34 313875J

12. Select the flow meter types installed on your system. For VPM-25 systems, select “HG6000” for the A (Red) side and “SRZ-100” for the B (Blue) side. For VPM-12 systems, select “HG6000” for both sides. If no flow meters are installed, select the “Disable” option as indicated below and proceed to step 14.

13. Set the Ratio “Alarm %” to 0 to turn off ratio alarms and set the Ratio “Deviation %” to any number greater than or equal to 5%.

Operation

16. Press .

17. Enter the specific gravities for the two materials in the system.

NOTE: The specific gravities do not need to be exact but should be close.

18. Press to exit the Setup screens.

NOTE: The “Alarm %” can be turned back on after this setup and calibration procedure is completed.

14. Set the “Pressure Imbalance Alarm” to 2000 psi (137.9 bar, 13.8 MPa).

15. Navigate to the main Calibration screen.

Prime the Machine

Refer to Priming section on page 30.

Piston Position Learning

19. Navigate to the Calibration screen.

20. Perform Learn Mode.

NOTE: Learn Mode will teach the system the mechanical limits of piston travel. It must be performed whenever the pump line is rebuilt or if any other maintenance is performed that may affect the mechanical tolerances in the pump line. If the machine does not appear to be utilizing the full extent of the pump stroke, or if the machine appears to be contacting the end of the hydraulic cylinder, perform the Learn Mode procedure.

a. From the Calibration screen, press to

access the Learn Mode screen.

313875J 35

Operation

b. Place a waste container below the ratio check

valves. The next steps will cause the machine to dispense material.

c. Press then . The pump will travel to

bottom-most position.

d. After the pump stops moving, press then

press . The pump will travel to the top-most position.

NOTE: During this process, the system learned the mechanical limits of piston travel. If the pump did not reach either piston mechanical travel limit for any reason, repeat the procedure.

Flow Rate and Ratio Learning

25. At the main Calibration screen, press to erase

all learned data.

NOTE: This will not affect the weight calibration that was just completed.

26. Press to exit the Setup screens.

21. Press to exit the Setup screens.

22. Press repeatedly to select Operator mode

then press to accept.

23. Press to enter the Setup screens then press

left or right to navigate to the main Calibration screen.

Flow Meter / No Flow Meter Calibration

24. If flow meters are installed, refer to Flow Meter or Flow/Ratio Calibration starting on page 39. If flow meters are not installed, refer to No Flow Meter Machine Calibration starting on page 40.

27. Press repeatedly to select Shot mode then

press to accept.

28. Select a defined shot that will provide a 10 second or longer dispense at the flow rate and ratio intended to be used during normal system operation.

NOTE: If the ambient temperature is significantly below 68°F (20°C) then the flow rate for the machine will need to be decreased. For most materials at 68°F (20°C) at a 2:1 to 3:1 ratio, a maximum flow rate of 335 g/s or 335 cc/s can be expected. The machine should not be operated much below 120 g/s or 120 cc/s at a 2:1 to 3:1 ratio.

36 313875J

Operation

29. On the main run screen, verify the ratio check valve

button is not active.

NOTE: This verifies material dispenses through the static mixer.

30. Place bucket under the end of the static mixer.

31. Press to begin dispensing then write down the A (Red) and B (Blue) dispense pressures shown on the ADM.

NOTE: During the dispense an off-ratio deviation may be generated and that is ok.

32. Repeat the previous step until the “System Learning New Setpoint” advisory turns off and the light tower yellow lights turns from yellow to green.

NOTE: Continue base purge until clean material comes out of the end of the mixer.

d. When all mixed material is pushed out of the

mixer, press to stop dispensing.

34. Press repeatedly to select Shot Mode then

press to accept.

35. Press to activate the ratio check valves.

NOTE: Be ready to adjust ratio check valves immediately after performing the following step.

36. With buckets below the ratio check valves,

press to begin dispensing.

37. While dispensing, adjust the ratio check opening adjustment screws until both material line pressures are approximately equal to the pressures recorded in step 31.

NOTE: If adjusting the ratio check opening screws after a ratio check dispense, the pressure difference due to the adjustment will not be shown until the next dispense.

NOTE: After the ratio check dispense pressures are properly adjusted a ratio check dispense can be performed. The ratio check dispense should be at least 10 seconds.

33. Base purge the mixer to clear mixer of mixed mate-

38. If the pressures are correctly adjusted prior to com-

rial:

pleting the shot, press to stop dispensing.

NOTE: A base purge will dispense only the B (Blue) material to push all mixed material out of the mixer. Base purge settings are defined on the System #2

39. If the pressures were not correctly adjusted prior to the shot finishing, go to step 36 to repeat.

screen, see page 61.

Ratio Check

a. Press repeatedly to select Standby Mode

NOTE: In the following steps, the weight of the dispensed materials is used to calibrate the flow meters.

then press to accept.

This works regardless of whether the selected dispense mode is weight or volume.

b. Press .

40. With active and with pre-weighed buckets

c. Press to begin dispensing.

below the ratio check valves, press to begin dispensing a ratio check dispense.

313875J 37

Operation

41. Weigh the two buckets and use the net weight of each dispensed material to calculate the actual ratio of the dispensed material.

42. If the calculated ratio of the weighed materials does not match the ratios displayed on the ADM, go to step 1 to re-calibrate the flow meters.

43. If the calculated ratio of the weighed materials matches the ratio displayed on the ADM, then navigate to the System 3 screen and change the ratio alarm percentage to the desired percentage.

44. If at any point in the future the ratio, flow rate, or ambient temperature changes from what was used while performing this procedure, go to step 1.

NOTE: If the ratio or flow rate is changed to a ratio or flow rate that has not been calibrated by performing this procedure, the system will generate a “Learning New Setpoint” advisory. The system usually produces a good dispense ratio during the learning process however the advisory is generated to inform the user of the condition. The system can store calibration data in its memory for up to five different flow rates and ratios.

NOTE: If the ambient temperature changes significantly from the ambient temperature seen while performing this calibration procedure, the system will need to “learn” the new temperature and the flow rate may need to be decreased. If the original flow rate was 325 g/s at 68°F (20°C) and the temperature is now 46°F (8°C), the user may want to select a flow rate of 150 g/s or 150 cc/s. The machine will not automatically be aware of the temperature change but it will try to find the correct dispensing properties to compensate for the new temperature. If the ambient temperature changes significantly, go to step 1. It is important for the system to learn the new temperature because typical paste materials increase viscosity significantly as the temperature decreases below 68°F (20°C).

38 313875J

Operation

Flow Meter or Flow/Ratio Calibration

1. At the main Calibration screen, press to erase

any previously learned flow meter calibration data.

NOTE: At this point, the “Learning New Set Point” advisory will be generated.

2. Select to enter the flow meter calibration

screen.

8. Weigh both buckets and enter the net weight of each material dispensed in the last two fields provided on the screen.

NOTE: After the weights are entered the K-factor will be shown to the right of the weights. The previous K-factor is shown to the left of the weight entry fields.

9. Repeat steps 5-8 until the new K-factor shown is within 1% of the previous K-factor.

NOTE: If the new K-factor is not within 1% of the previous K-factor the machine may need further priming to remove any trapped air in the material lines.

NOTE: The ratio of the weights entered may not match the requested ratio. This is ok for now.

10. Select to exit the flow meter calibration screen.

3. On the flow meter calibration screen, enter the flow rate and ratio that will be used during normal operation.

NOTE: It is recommended to use approximately 200 g/s or 200 cc/s and a ratio of approximately 2.0:1.

4. If either K-Factor value is 0, enter 3000 if an HG6000 flow meter is installed in that side and 700 if the SRZ-100 flow meter is installed in that side.

NOTE: In the following steps, the weight of the dispensed materials is used to calibrate the flow meters. This works regardless of whether the selected dispense mode is weight or volume.

5. Weigh two buckets and record the weight of each then place below the ratio check valves.

6. With two buckets in place to catch material dis-

pensed from the ratio check valves, press to begin dispensing.

7. After dispensing for at least 10 seconds, press to stop dispensing.

NOTE: If available, a footswitch can also be used.

313875J 39

Operation

No Flow Meter Machine Calibration

It is highly recommended that the user operate the machine in weight mode when flow meters are not installed or have been disabled.

NOTE: In weight mode, the ratio displayed is a weight ratio and should not be considered as volumetric ratio.

1. Press to enter the Setup screens then press

left or right to navigate to Advanced #3 screen. Turn off the “Enable Ratio Check Weight Mode Entry” option.

3. Press to exit the setup screen and verify the

ratio check option is not selected.

4. Place a waste container under the mixer.

Press to begin dispensing and record the average A (Red) and B (Blue) pressures shown on the ADM.

NOTE: The dispense can be aborted early after record-

2. Press and navigate to the shot definition screen. Define a shot which is 10 times larger than

the desired flow rate selected. This will set approximately a 10 second dispense time.

Example: If the dispense rate is 300 grams/second, set the amount to 3000 grams.

ing by pressing .

5. Select Standby mode and perform a base purge.

NOTE: A base purge will dispense only the B (Blue) material to push all mixed material out of the mixer. Base purge settings are defined on the System #2 screen, see page 61.

a. Press .

b. Press to begin dispensing.

c. When all mixed material is pushed out of the

mixer, press to stop dispensing.

NOTE: Approximately 1 to 2 liters of base material will need to be dispensed.

6. Select Shot mode and select the ratio check option

by pressing .

40 313875J

Operation

7. Place waste containers below the ratio check nozzles and start a ratio check dispense. Adjust the ratio check opening screws until the pressures displayed are near the values previously recorded when dispensing through the mixer (step 4).

8. Press to enter the Setup screens then press

left or right to navigate to Advanced #3 screen. Turn on the “Enable Ratio Check Weight Mode Entry” option.

NOTE: After entering the net weight of B (Blue) material, the ADM will inform the user how close the respective flow of the pump was to the desire rate.

11. Press to accept the information.

NOTE: The ADM will respond by generating a “System Learning Setpoint” advisory and the corresponding advisory light will be illuminated on the machine light tower (if installed).

9. Press to exit the setup screen and verify the

ratio check option is selected.

10. With new waste containers below the ratio check nozzles, start the dispense by pressing the foot-

switch or . At the end of the dispense, enter the A (Red) and B (Blue) material weights into the prompt boxes. Enter the weight of each bucket for both materials.

12. Press to accept the advisory. Repeat steps 10 through 11 until the percentages approach zero and the advisory is removed.

NOTE: The machine will be calibrated for the flow and ratio selected once the advisory is removed.

13. If the user needs to operate at a second flow or ratio, repeat the calibration process for the second desired flow or ratio.

NOTE: The machine will store the necessary control data for both calibration points.

313875J 41

Operation

NOTE: It is recommended that the user calibrate the machine at the extreme rates where it will be used. Example: If the machine is to be used at mixed flows between 300 & 500 grams/second (at 3:1 ratio), calibrate the machine at the two 300 and 500 grams/ second extremes, then stop the calibration process. The machine will be very close to all requested flows and ratios in between.

14. Turn off the “Enable Ratio Check Weight Mode Entry” option in the Advanced #3 screen. The user can verify the machine calibration by performing a ratio check dispense and weighing the A (Red) and B (Blue) materials.

42 313875J

Operation

Dispensing

Dispense in Shot Mode

To dispense in Shot mode, at least one shot number must be defined. Shots are defined on the Shots screen, see page 59.

1. Navigate to the Home screen.

2. Press repeatedly to select Shot Mode then

press to accept.

3. If desired, change the selected shot.

a. Press .

b. Use numeric keypad to type the desired shot

number.

c. Press to accept. The shot number defini-

tion details will be shown on the bottom of the screen.

NOTE: Only defined shot numbers can be entered. If an undefined shot number is entered, it will be ignored.

Dispense in Sequence Mode

Sequences can be defined on the Sequences screen. Sequences are defined on the Sequences screen, see page 60.

1. Navigate to the Home screen.

2. Press repeatedly to select Sequence Mode

then press to accept.

3. If desired, changed the selected sequence.

a. Press once.

b. Press the right arrow key on the ADM keypad

once.

c. Use the up and down arrow keys to select a

sequence.

d. Press to accept.

4. If desired, press to skip to the next defined

shot position in the sequence. Repeat as desired. To go to the first defined position in the sequence,

4. Press to begin dispensing the active shot. To

abort the shot at any time, press or . The

shot will continue until the predefined amount has been dispensed.

5. Check the ADM for errors and pop-up notifications

that could indicate a faulty dispense. Press to acknowledge any displayed errors.

press .

5. Press to begin dispensing the active shot.

NOTE: To abort the shot at any time, press or

. If the shot is not aborted, material will continue to

dispense until the predefined amount has been dispensed. The next position in the Sequence will automatically be selected upon completion of the shot.

6. Check the ADM for errors and pop-up notifications

that could indicate a faulty dispense. Press to acknowledge any displayed errors.

313875J 43

Operation

Dispense in Operator Mode

Operator Mode begins dispensing when is pressed and stops when it is pressed again.

NOTE: If a footswitch is used, press and hold to dispense. Release to stop dispensing.

1. Navigate to the Home screen.

2. Press repeatedly to select Operator Mode

then press to accept.

3. Check the dispense settings shown at the bottom of the screen.

7. Check the ADM for errors and pop-up notifications

that could indicate a faulty dispense. Press to acknowledge any displayed errors.

4. If desired, change the dispense settings.

a. Press to enter editing mode.

b. Use the left and right arrow keys to select the

item to change.

c. Use the numeric keypad to type the new value.

d. Press to accept the new value.

e. Press to exit editing mode.

5. Press to begin dispensing.

6. Press to stop dispensing.

44 313875J

Shutdown

Short-term

1. Place container under mixer.

2. If using a moisture-sensitive material, park pumps.

a. Navigate to the Home screen.

b. Press repeatedly to select Standby Mode

then press to accept.

c. Press to park pump. Material will dis-

pense. when the pumps are in the parked position, they will stop moving.

3. Allow material to drain completely from the mixer prior to base purge.

4. Perform base purge.

NOTE: A base purge will dispense only the B (Blue) material to push all mixed material out of the mixer. Base purge settings are defined on the System #2 screen, see page 61.

7. Place container under the mixer and allow mixer to drain completely.

NOTICE

Preventing material from draining from the mixer may cause material in the mixer to harden and damage the dispense block.

8. Turn Main Power Switch to the OFF position.

9. Close air inlet ball valve.

End of Shift

1. Perform Short-term Shutdown procedure.

2. Remove, disassemble, and flush mixer.

a. Press .

b. Press to begin dispensing.

c. When all mixed material is pushed out of the

mixer, press to stop dispensing.

NOTE: The user can disable changing the flow, ratio, or both on the Advanced #3 setup screen.

NOTE: Approximately 1 to 2 liters of base material will need to be dispensed.

5. Press to park pumps again.

6. Press .

313875J 45

Pressure Relief Procedure

1. Perform Shutdown procedure.

2. Set the ram director valve to neutral position.

3. Place a waste container below each ratio check valve.

In the following step, any pressure in the lines will be instantly relieved which may lead to material spraying out of the valve and splashing in the bucket. Use appropriate protective wear to prevent contact with materials.

4. Press the red override button on top of the pneumatic valve nearest the mixer. This will open the ratio check valves and relieve any residual pressure in the fluid lines.

ti17709a

46 313875J

Maintenance

Check all sub-component manuals for maintenance schedule and procedures.

Task Schedule

Replace hydraulic oil and filter See table

Inspect fluid lines for leaks and signs of wear

Check wet cup fluid level, add IsoGuard Select fluid as necessary

Check hydraulic fluid level Weekly

Verify vent holes on bottom of hydraulic power pack shroud are clear and unobstructed

Check all fittings and connections, tighten as necessary

Daily

Weekly

Weekly (more often in dusty environ-

ments)

As necessary

Maintenance

Change Hydraulic Oil and Filter

Change break-in oil in a new unit after the first 250 hours of operation or within 3 months, whichever comes first. After initial break-in, see the following table for recommended oil and filter change schedule.

Table 2: Frequency of Oil Changes

Ambient Tem peratu re

0 to 90°F (-17 to 32°C)

90°F and above (32°C and above)

Recommended Frequency

1000 hours or 12 months, whichever comes first

500 hours or 6 months, whichever comes first

Check Hydraulic Fluid Level

Check hydraulic fluid level on dipstick (A). Fluid level must be between indent marks (B) on dipstick. Refill as required with approved hydraulic fluid; see Technical Data on page 87. If fluid is dark in color, change fluid and filter.

Use compressed air to remove dust buildup on control boards, fan, motor (under shield), hydraulic oil coolers, and component heat sink fins

Monthly

ti7861a1

257442_313873-5_2t

313875J 47

Maintenance

Install Upgrade Tokens

NOTE: The Motor Control Module, Fluid Control Mod-

ule, and Temperature Control Module connection to the system is temporarily disabled during the installation of upgrade tokens.

To install software upgrades:

1. Use correct software token stated in the table. See Graco Control Architecture

™

Module Programming

manual for instructions.

NOTE: Upgrade all modules in the system to the software version on the token, even if you are replacing only one or two modules. Different software versions may not be compatible.

All data in the module (System Settings, USB Logs, Recipes, Maintenance Counters) may be reset to factory default settings. Download all settings and user preferences to a USB before the upgrade, for ease of restoring them following the upgrade.

See manuals for locations of specific GCA components.

The software version history for each system can be viewed in the technical support section at www.graco.com.

Token Application

16G365 VPM:

- Advanced Display Module

- Motor Control Module

- High Power Temperature Control Module

- Communication Gateway Module

16G407 Ratio Monitoring (Flow Meters):

- Fluid Control Module

r_257396_3b9905_04b

ti12334a1

FIG. 14: Remove Access Cover

ti12354a1

48 313875J

Maintenance

Advanced Display Module (ADM)

Replace Battery

A lithium battery maintains the ADM clock when power is not connected.

To replace the battery:

1. Disconnect power to the ADM.

2. Remove rear access panel.

Motor Control Module (MCM)

Keep heat sink fins clean at all times. Clean them using compressed air.

NOTE: Do not use conductive cleaning solvents on the module.

Heat Sink Fins

r_257396_3b9905_02b

FIG. 15: Clean Heat Sink Fins

Install Upgrade Token

ti12903a

3. Remove the old battery and replace with a new CR2032 battery.

4. Replace rear access panel.

Install Upgrade Token

See Install Upgrade Tokens on page 48.

Cleaning

Use any alcohol-based household cleaner, such as glass cleaner, to clean the ADM. Spray on the rag then wipe ADM. Do not directly spray the ADM.

See Install Upgrade Tokens on page 48.

Fluid Control Module (FCM)

Install Upgrade and Key Tokens

See Install Upgrade Tokens on page 48.

313875J 49

Maintenance

50 313875J

Troubleshooting

For information about ADM error and event codes see Appendix D - ADM Event and Error Codes Overview, page 69.

Before performing any troubleshooting procedure:

1. Perform Pressure Relief Procedure on page 46.

2. Turn Main Power Switch to the OFF position.

3. Allow equipment to cool.

Try the recommended solutions in the order given for each problem to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.

Troubleshooting

Light Tower (Optional)

Signal Description

Green on only System is powered up and there are

no error conditions present

Yellow on An advisory exists

Red flashing A deviation exists

Red on The system is shut down due to an

alarm occurring.

Errors include advisories, deviations, or alarms, so green will only be on when none of these occur. A yellow light can be on at the same time as red (flashing or solid on) when an advisory exists at the same time as a deviation or alarm.

Common Problems

Problem Cause Solution General

Display Module completely dark

No or incorrect amount of material dispensed from either side

Significant material leaking from pump seal

Material dispensed not correct weight

Proportioning System

Proportioning pump does not hold pressure when stalled

No power Verify main power switch is ON Thrown circuit breaker Check machine breakers and reset Loose connection Tighten 5-pin cable on Advanced Display Module Bad display module Replace Advanced Display Module Tank empty Install new drum of fluid Air in material Prime the machine

Pump shaft worn and/or shaft seal worn

Specific gravity of one or more of the two materials has changed since calibration

Check valve malfunction Remove check valve; clean or replace as necessary Piston worn or broken Replace piston

Pump piston or intake valve leaking 1. Observe gauges to determine which pump is los-

Remove pump shaft assembly and reinstall, see pump manual for instructions and rebuild kit

Perform calibration procedure

ing pressure.

2. Determine in which direction the pump has stalled by observing which directional valve indicator light is on.

3. Repair the valve.

313875J 51

Troubleshooting

Problem Cause Solution

Material imbalance Inadequate flow from pump; cavitation Increase fluid supply to proportioning pump

Worn pump inlet valve ball/seat or gasket, repair as necessary

Erratic pump movement Pump cavitation Feed pump pressure is too low, adjust pressure to

within required range

Pump output low Obstructed fluid hose or mixer; fluid

hose ID too small Worn piston valve or intake valve in

displacement pump Inadequate feed pump pressure Check feed pump pressure and adjust to within

Open, clear; use hose with larger ID

See pump manual for appropriate repair procedure

required range

52 313875J

ADM Troubleshooting

Troubleshooting

FIG. 16: ADM Component Identification - Rear

ti12362a1

ADM System Status LEDs (B) Conditions

Module Status

LED Signal Description

Green on Run mode, System on

Green flashing Setup mode, System on

Yellow on Run Mode, System off

ti12902a

ADM Module Status LEDs (N) Conditions

Module Status

LED Signal Description

Green on System is powered up

Yellow on Communication in progress

Red solid ADM hardware failure

Red flashing Uploading software

USB Module Status LEDs (L) Conditions

Module Status

LED Signal Description

Green flashing System is powered up

Yellow on Downloading information to USB

Green/Yellow Flashing

313875J 53

ADM is busy, USB cannot transfer information when in this mode

Troubleshooting

Motor Control Module

Diagnostic Information

Table 3: LED Status Signal

Module Status LED Signal Description

Green on System is powered up

Yellow on Internal communication in progress

Red solid MCM hardware failure. Replace MCM

Red flashing fast Uploading software

Red flashing slow Token error, remove token and upload

software token again

LED Signals

FIG. 17: LED Signals

54 313875J

r_257396_3b9905_07b

Acceptable Size and Duration of Power Line Voltage Fluctuations

The Motor Control Module is designed to withstand voltage fluctuations from the incoming power supply. If the incoming power supply goes outside of the tolerable range, an over-voltage condition is flagged and the system shuts down in an alarm state. Excessive or repeated over-voltage may permanently damage hardware. The chart below shows the permissible magnitude and duration of temporary over-voltage events. Consult a qualified electrician if there are any concerns about the available power supply.

Maximum Permissible Transient Voltage Surges

* Constructed from ITIC 1996 curve, referenced by IEC 61000-2-4

1400

Troubleshooting

1200

1000

800

600

400

Voltage (Volts RMS)

200

0.000001 0.00001 0.0001 0.001 0.01 0.1 1 10

1200Vac, 1697Vdc

<--1 MW Max Surge Power

480Vac, 679Vdc

336Vac, 475Vdc

<--150 KW Max Surge Power

<--50 KW Max Surge Power

288Vac, 407Vdc

<--No Power Limit

264Vac, 373Vdc

Time (seconds)

313875J 55

Troubleshooting

Fluid Control Module

Diagnostic Information

Module Status LED Signal Diagnosis

Green on System is powered up

Yellow Internal communication in progress

Red solid FCM hardware failure. Replace FCM.

Red flashing fast Uploading software

Red flashing slow Token error. Remove token and

upload software token again.

FIG. 18:

Module Status LEDs

ti12337a1

56 313875J

Appendix A - ADM Icons Overview

Setup Screen Icons

Icon Description

Enter Screen

Exit Screen

Erase Selected Item

Erase All Items Shown

Change Multiple Values

(see Using the button on

page 59)

Ratio Calculator

(see Using the button on

page 59)

Icon Description

Learn Top-Most Piston Position

Go to Next Calibration Screen

Begin Weight Calibration Shot

Dispense Valve Details

Shot Number

Sequence

Flow

Weight

Volume

Return to Previous/Main Screen

Calibrate Piston Position

On Main Calibration screen:

Calibrate Weight Dispense

On Flow Meter Calibration screen:

Use Dispensed Material Weight to Calibrate Flow Meters

Use Dispensed Material Volume to Calibrate Flow Meters

Calibrate Flow Meters

Learn Bottom-Most Piston Position

Duration

Ratio

Calculated Ratio

Tank/Tank Heater

Primary Heater

Heated Hose

Chiller

313875J 57

Appendix A - ADM Icons Overview

Home Screen Icons

Icon Description

Select Operating Mode

Initiate Dispense

Dispense Disabled

Ratio Check

Park Piston

Park Piston Disabled

Close Dispense Valve

Icon Description

Prime A (Red) Side

Prime B (Blue) Side

Enter Screen

Exit Screen

Erase Selected Item

Erase All Items Shown

Weight

Perform Base Purge

Selected Shot Number

No Shot Number Selected

Selected Sequence and Sequence Position

No Sequence Selected

Skip to Next Shot in Sequence

Abort Sequence

Volume

Duration

Piston Cycles

Edit Operator Mode Flow Properties

58 313875J

Appendix B - ADM Setup Screens Overview

Setup Screens Navigation Diagram

Shot #1

Shot #2

Shot #...

Sequences #1

Sequences #2

Sequences #...

Calibration

System #1

System #2

System #3

Shots

This screen allows the user to edit shot definitions. The contents of this screen change based on the Dispense Mode. Shots may be defined by flow rate and by time (duration), volume, or weight depending on the Dispense Mode selection. See System #1 on page 61 for Dispense Mode options.

Maintenance

Supply

Conditioning #1

Conditioning #2

Conditioning #3

Advanced #1

Advanced #2

Advanced #...

4. Type the new value then press enter. All values below the selected shot will change to the new value.

5. Repeat the previous two steps as desired.

6. Press to deactivate.

Using the button

The button can be used to calculate an x:1 ratio

from a non x:1 ratio. For example, if the desired ratio is

5:2, the button can be used to convert 5:2 to 2.5:1.

1. From the Shots screen, press .

2. Navigate to the column.

Using the button

The button can be used to change multiple shot

definitions at once.

3. Press .

4. Enter the non x:1 ratio in the column. The calculated x:1 ratio will automatically be displayed in

the column and in the shot definition.

1. From the Shots screen, press .

5. Press .

2. Press .

3. Navigate to a shot definition value.

313875J 59

Appendix B - ADM Setup Screens Overview

Sequences

This screen allows the user to edit sequence definitions. The contents of this screen change based on the Dispense mode.

Dispense detail is shown as volume, time, or weight depending on which Dispense Mode is selected. See

System #1 on page 61 for Dispense Mode options.

NOTE: 5 sequences with 20 positions each are avail-

able across 10 pages.

Calibration - Learn Mode

This screen is for learning the mechanical limits for piston travel.

Calibration - Weight

Calibration - Main

This screen shows calibration data for the system and provides access to the individual calibration screens. See System Setup and Calibration on page 34 for how to use the calibration screens.

The date next to each key represents the last time that function was performed.

The “Cal. Min” and “Cal. Max” values are the system recognized extreme ends of piston travel.

This screen is for calibrating weight.

Calibration - Flow Meters

This screen is for calibrating the flow meters.

60 313875J

Appendix B - ADM Setup Screens Overview

System #1

This screen allows the user to set mechanical system settings and the Dispense Mode setting.

Dispense mode can be set to volume or weight. Dispense mode controls how dispense quantities are measured. Dispensing must be calibrated, see System Setup and Calibration on page 34 for more information.

Pump sizes and inlet pressures must be entered on this screen. The inlet pressure is the minimum allowable fluid inlet pressure. If the inlet pressure is below this value, dispensing is disabled. If pump sizes and inlet pressures are not entered properly, system performance will be affected.

The maximum working pressure for the machine is displayed on this screen. The maximum working pressure is dependent on the installed hoses and is set to the lowest rated system component. If 2000 psi hoses are installed and the maximum working pressure displayed is not 2000 psi, see Adjust Motor Control Module Selector Switch on page 27 for instructions to set the maximum working pressure for hoses.

System #2

This screen allows the user to set the Gel Timer properties and set which items are installed on the machine.

NOTICE

The correct dispense valve option must be selected. Selecting an incorrect dispense valve option will lead to erratic machine performance.

When enabling the Gel Timer, the user must select one of the 100 available shot definitions to use as the Gel Shot. This shot will be dispensed when the Idle Period expires. The Idle Period will begin after a dispense is completed. Any dispense operation in the middle of the timer countdown will reset the Idle Period counter. The system will generate an audible alarm that will begin the user-entered number of seconds before the Idle Period expires.

The hydraulic level sensor and hydraulic RTD for the pump line must be enabled when installed in the system. If the sensors are not marked as enabled, they will be ignored.

313875J 61

Appendix B - ADM Setup Screens Overview

System #3

This screen allows the user to edit the labels for the A (Red) and B (Blue) sides of the machine. The labels set for the A (Red) and B (Blue) sides of the machine are displayed throughout the screens. Labels are limited to five characters.

The pressure imbalance alarm can also be set. This is the difference between the A (Red) and B (Blue) side material pressures before an alarm occurs.

Maintenance

This screen shows shot number and sequence position counters. Use the Counters dropdown menu to select which set of counters to view.

Supply

The flowmeter types are defined on this screen. The available flow meter types are Disabled, HG6000, or SRZ-100. The ratio deviation value is the allowable percentage before the machine displays a pop-up notification. The ratio alarm value is the allowable percentage difference before the machine will stop a dispense.

Keyboard Screen

This screen is used to edit the A (Red) and B (Blue) labels on the ADM. Use arrow keys to select the desired

Do not use the check-boxes on this screen. If a low level sensor is used, check the box for the Supply Low Level Sensor option on the System #2 screen, see page 61.

letter and press to accept the letter. Press to exit the keyboard.

62 313875J

Appendix B - ADM Setup Screens Overview

Conditioning #1

NOTE: Platen heaters are available as an option on the

VPM system.

Conditioning #2

Advanced #1

This screen allows the user to set the language, date format, current date, time, setup screens password, screen saver delay, and turn on or off silent mode.

Advanced #2

NOTE: Platen heaters are available as an option on the

VPM system.

This screen allows the user to set the units of measure.

Conditioning #3

NOTE: The VPM does not use Night mode conditioning.

Do not enable night mode.

313875J 63

Appendix B - ADM Setup Screens Overview

Advanced #3

This screen allows the user to control the availability of some key system features.

• Disable Dispensing From Display: Check this box to disable dispensing from the ADM. A footswitch, dispense valve trigger, or other external signal will be the only way to initiate a dispense.

• Disable Modifying Temp Setpoint: Check this box to disable modifying temperature setpoints from the Run screens. This is only applicable if temperature control items are installed and enabled.

• Disable Operator Mode Flow Adjustments: When checked, the user will not be able to change the flow on operator mode Home Run screen.

• Disable Operator Mode Ratio Adjustments: When checked, the user will not be able to change the ratio on operator mode Home Run screen.

• Temperature Alarm Disables Dispense: When checked, any active alarm from any temperature zone will disable dispensing.

• Complete Dispense with Setpoint Error: When this box is checked, the shot will continue dispensing even if the system never reaches the desired setpoint.

• Enable Shot Aborted Notification: When this box is checked, a pop-up notification will be displayed when a shot is aborted.

• Enable Ratio Check Weight Mode Entry: This option is for machines without flow meters. When this box is checked, after any ratio check shot a popup window will appear asking the user to enter the dispensed weights. Press the Cancel button to abort the entry or press the Enter button to record the new values.

Advanced #4

This screen is for enabling the optional Diagnostic screen and for enabling USB log downloading and USB errors. For more information about USB operation, see Appendix E - USB Operation on page 80. For more information about the optional screens, see Diagnostic

Screen screen on page 68.

Advanced #5

Numbers shown are for reference only and may be different on your system.

This screen displays software information.

64 313875J

Appendix C - ADM Run Screens Overview

Run Screens Navigation Diagram

Home Events #1

Errors #1

Errors #2

Errors #...

Events #2

Events #...

Home Screens

The Home screen is the first screen that displays when the machine is started and when switching from the Setup screens to the Run screens. The Home screen shows the current fluid pressure at the pump outlets.

The operating mode can be selected from the Home screen. The available operating modes are Operator, Sequence, Shot, Standby, Night, and Disabled.

System Off

Maintenance

Optional:

Diagnostic

Disabled

In Disabled mode, machine operation is disabled and the setup screens cannot be accessed.

Standby

This operating mode is only used at initial startup and

when is pressed.

In Standby mode, the user can park the pumps, perform a base purge, and close the dispense valve. See Shut- down on page 45 for base purge and parking the pumps procedure.

313875J 65

Appendix C - ADM Run Screens Overview

Shot

This mode allows the user to dispense using one of the defined shots. See Shots screen on page 59. Shot definition including flow, ratio, progress, and size is shown at the bottom of the screen. The user can also dispense a ratio check shot.

Sequence

Operator

This mode allows users to dispense without using pre-

defined shot numbers or sequences. Use to set

flow rate and ratio. The user can also dispense a ratio check shot.

Prime

This mode allows the user to dispense using one of the

This mode allows users to prime each pump individually. defined sequences. See Sequences on page 60. The shot definition for the shot used in the current sequence position is shown at the bottom of the screen. Shot definition information shown includes flow, ratio, progress, and size.

66 313875J

Appendix C - ADM Run Screens Overview

Errors Screen

The Errors screens display the 50 most recent system errors. Each error entry includes a description and error code along with a date and time stamp. There are 5 pages displaying 10 errors each.

See the Troubleshooting section beginning on page 51 for a detailed description of all system errors.

Events Screen

Maintenance

This screen displays historical information for each pump including material usage and pump cycles. The

material usage units are shown next to the , , or

icons and depend on the selected Dispense mode. The batch counters are resettable but the total counters are not.

The Events screens display the 200 most recent events. Each event includes a description and event code along with a date and time stamp. There are 20 pages displaying 10 events each.

See the Troubleshooting section beginning on page 51 for a detailed description of all system events.

313875J 67

Appendix C - ADM Run Screens Overview

Optional Screens

Diagnostic Screen

The optional Diagnostic screen can be enabled in the Advanced #4 screen, see page 64.

The Diagnostic screen shows status information for various system components.

Status Screen

The status screen provides all of the operational functionality of the Home screen except for operating mode selection. Refer to the Home screen and operating mode descriptions for information on this functionality.

In addition to the functionality provided by the Home screen, the Status screen also provides material conditioning information and control.

68 313875J

Appendix D - ADM Event and Error Codes Overview

Event Codes

Event Code and String Triggers

EAA0-R: Base Purge Base purge performed EAD0-R: Pump(s)

Parked EA10-R: Red Pump

Prime EA20-R: Blue Pump

Prime EA00-R: Disp.

Occurred (Shot #) EAR0-R: Night Mode

Recirc On

EB00-R: Stop Button Pressed

EBR0-R: Night Mode Recirc Off

EBR1-R: Setup values changed

ECA1-R: Red Material SG Modified

ECB2-R: Blue Material SG Modified

ECH0-R: Learn Mode Executed

EH00-R: Gel Timer Dispense

EL00-R: System Powered On

EM00-R: System Powered Off

ENC1-R: Cal. Point 1 Weight Entered

ENC2-R: Cal. Point 2 Weight Entered

ENC4-R: Cal. Point 1 Weight Erased

ENC5-R: Cal. Point 2 Weight Erased

END0-R: Ratio Check Dispense

ENN0-R: Automatic Cal. Performed

One or both pumps were parked

The red pump has been primed

The blue pump has been primed

A dispense has occurred of the given shot number.

While in night mode the system has automatically entered a low recirculation mode and attempted to turn on all enabled conditioning zones.

The Red stop button was pressed on the Advanced Display Module.

While in night mode the system has automatically stopped the low recirculation mode and turned off all conditioning zones.

One or more of the setup values has changed.

The Red materials specific gravity was modified.

The Blue materials specific gravity was modified.

A learn mode calibration was successfully completed.

The gel timer expired and the system automatically took the gel shot.

The System was powered on.

The System was powered off.

A value for the first point in the three point calibration was entered.

A value for the second point in the three point calibration was entered.

The running average for point one of the three point calibration was erased.

The running average for point two of the three point calibration was erased.

A ratio check shot was dispensed from the ratio check calibration screen.

The system was successfully characterized with the Automatic calibration.

Event Code and String Triggers

EQU1-R: Settings Downloaded

EQU2-R: Settings Uploaded

EQU3-R: Language Downloaded

EQU4-R: Language Uploaded

EQU5-R: Logs Downloaded

ER01-R: Shot Count Reset

ER02-R: Seq. Position Count Reset

ERA1-R: Red Material Volume Reset

ERA2-R: Red Material Weight Reset

ERA3-R: Red Cycle Count Reset

ERB1-R: Blue Material Volume Reset

ERB2-R: Blue Material Weight Reset

ERB3-R: Blue Cycle Count Reset

The system settings were successfully transferred from the ADM to a USB drive.

The system settings file was successfully transferred from the USB drive to the ADM.

The custom language file was successfully transferred from the ADM to a USB drive.

The custom language file was successfully transferred from the USB drive to the ADM.

The Error/Event and Shot data logs were successfully transferred from the ADM to a USB drive.

A counter from the shot counters maintenance page was erased

A counter from the sequence counters maintenance page was erased

The resettable totalizer for the Red material volume was reset to zero.

The resettable totalizer for the Red material weight was reset to zero.

The resettable cycle counter for the Red pump was reset to zero.

The resettable totalizer for the Blue material volume was reset to zero.

The resettable totalizer for the Blue material weight was reset to zero.

The resettable cycle counter for the Blue pump was reset to zero.

313875J 69

Appendix D - ADM Event and Error Codes Overview

Error Codes

Error Code Error Name Error Description

The three point calibration data is invalid, system will operate in weight mode but will attempt to volumetrically calculate weight. This will lead to consistent shots which will be offset for the desired dispense amount.

The system will ignore the calibration data gathered and will use information gathered during dispenses

An over current was detected on the output

High current has been detected on a phase and has been shutdown to prevent damage

Too much current is being drawn from the wall

A hardware current fault has occurred causing a system shutdown

Unexpected current to heater/chiller

0500

05A1

A4A6

A4B5

A4A3

A4B1

A4A2

A4B4

A4A7

A4B8

A4H1

A4M1

A4N1

A7A6

A7B5

A7A3

A7B1

A7A2

A7B4

A7A7

A7B8

Invalid Weight Cal. Data

Invalid Auto Cal. Data

Red Blanket Overcurrent Blue Blanket Overcurrent Red Inline Overcurrent Blue Inline Overcurrent Red Hose Overcurrent Blue Hose Overcurrent Red Chiller Overcurrent Blue Chiller Overcurrent

Motor Over Current

Red Blanket Control Fault Blue Blanket Control Fault Red Inline Control Fault Blue Inline Control Fault Red Hose Control Fault Blue Hose Control Fault Red Chiller Control Fault Blue Chiller Control Fault

Error Type Cause Solution

Deviation Invalid data Re-calibrate the machine

If any messages appeared indicating why the

Deviation Invalid data

Alarm

Bad heaters Measure resistance of heater

Alarm

Alarm High voltage

Alarm

Shorted Temperature Control Module Bad internal wiring of the motor Short circuit of motor wiring Low voltage from the wall during load Short circuit of motor wiring

Motor rotor has become locked

Shorted Temperature Control Module

calibration failed attempt to fix the problem then re-run the calibration

Measure voltage across the disconnect switch. Voltage should measure between 190 and 264 Vac. If temperature rises for a zone that has been disabled, replace Temperature Control Module

Replace motor

Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground Make sure the supply line is properly sized for the load and is above the minimum voltage requirements Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground Unplug the directional valve (so pressure will not build) and try to move the motor again. If this succeeds then the power pack may need to be replaced. If the motor is still unable to move, the bearings or hydraulic pump have likely failed in the motor and will need to be replaced.

If temperature rises for a zone that has been disabled, replace Temperature Control Module

70 313875J

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

No Red

A8A6

Blanket Current

No Blue

A8B5

Blanket Current No Red Inline

A8A3

Current No Blue Inline

A8B1

A8A2

A8B4

A8B7

A8B8

A9C1

B9C0

CAC1

CAC3

CAC4

CAC5

CAC6

CAC7

CAA6

CAB5

CAA3

CAB1

CAA2

CAB4

CAA7

CAB8

D1A1

Current No Red Hose Current

No Blue Hose Current

No Red Chiller Current

No Blue Chiller Current

Motor Over Current

Small Shot Request

Comm. Error Motor Comm. Error Red Tank Comm. Error Blue Tank Comm. Error Mix Head Comm. Error Mix Head 2 Comm. Error Ratio Monitor Comm. Error Red Blanket Comm. Error Blue Blanket Comm. Error Red Inline Comm. Error Blue Inline Comm. Error Red Hose Comm. Error Blue Hose Comm. Error Red Chiller Comm. Error Blue Chiller Setpoint Not Reached

No current to the conditioning zone

A software error has occurred commanding too much current

The requested dispense amount is below the minimum amount of the system (25% of the combined pump volumes is the minimum)

Communication error

The set point was not reached and the pump was shutdown

Error Type Cause Solution

Alarm

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Alarm

Measure voltage across input terminals on power line

Alarm Low power

Alarm

Alarm Bad heater(s) Measure resistance of heater(s)

Alarm

Deviation

Alarm

Alarm Module not programmed Program the module

Alarm Module missing power Check power supply connection

Alarm Module bad Replace module

Deviation

Cable unplugged/loose power

Bad Motor Control Module code

Pumps are defined with the wrong size

Requested shot is below the capabilities of the current pump setup

Loose/broken connection Check connection

Material restriction too high for requested flow

filter. Voltage should measure between 190 and 264 Vac

Check for loose or disconnected wires or plugs

Check for MCM software update, load latest MCM software, if problem persists contact Graco

On the ADM go into the Setup screens to the System screens then make sure that the pump sizes are defined correctly

If the user has to be able to take the shot the system must be fitted with smaller pumps

Reduce flow request

313875J 71

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

D2A1

D3A1

D5A1

D6A1

DDA1

DDB2

DFA1

DSC0

F7D1

L111

L122

L311

L322

L6A1

L6B2

Setpoint Not Reached

Setpoint Exceeded

Invalid Learn Mode Data

Position Sensor Fault

Red Pump Cavitation

Blue Pump Cavitation

Pump Not Parked

Pumps Not Defined

Pump Failed to Stall

Red Low Material Level

Blue Low Material Level

Red High Material Level

Blue High Material Level

Red Auto Refill Timeout

Blue Auto Refill Timeout

The set point was not reached Deviation

The set point was exceeded Deviation

This calibration lets the MCM know where the ends of the pump are. If the data gathered during this process is outside of normal parameters the machine will operate with a greatly reduced stroke.

The linear position sensor is returning data that should not be possible during normal operation

Cavitation was detected on the given pump

The pump failed to reach the park position

The type or size of the Red or Blue material pumps have not been defined

When the pump tried to stall to pressure the pump traveled more than it should in normal operation (only applies to dead-headed system)

Low material level in tanks

High material level in tanks

The tank stand has been filing for a time greater than expected

Error Type Cause Solution

Pump cannot reach the requested pressure Pump cannot reach the requested flow System underwent a change that caused a large drop in restriction (such as new orifices)

No material in pumps

Recalibrate the machine Rerun the learn mode calibration

Loose/bad connection

Deviation

Bad linear position sensor

Loose/bad connection to linear position sensor

Bad linear position

Alarm

Deviation

Deviation Verify that feed pumps are supplying material

Deviation

Alarm

Deviation

Deviation Tanks low on material Fill tanks with material

Deviation Loose/broken connection

Deviation

sensor Linear position sensor

may be loose where attached to pump housing

Insufficient material being supplied or insufficient material pressure on feed system

Debris or packout in the incoming fluid filter

Orifices blocked Clear blockage Hose blocked Clear or replace hose as necessary Dispense valve failed to open

Properly setup the system

Failure of the dispense valve

Material leak

Out of material Fill tanks

Bad level sensor Replace level sensor

Defective fill valve

No material is actually being fed

Loose level sensor connection

Bad level sensor Replace level sensor

Increase restriction in the system

Decrease restriction in the system

Erase learned System Data, found in the setup screens under calibration

Make sure the material lines are open and have proper feed pressure

Check to ensure the pressure transducer is properly installed and all wires are properly connected

Verify pump moves to limits, if problem persists replace linear position sensor

Check to ensure the linear position sensor is properly installed and all wires are properly connected

Replace linear position sensor

Re-tighten the sensor and re-calibrate the machine

Verify that incoming ball valves are open

Inspect filter for debris of filler packout and clean or replace as necessary

Check to make sure the dispense valve is properly configured and connected to the MCM On the ADM go into the setup screens -> System-> then make sure that the pump type and size are set (not --) Ensure the valve has a proper air supply and seals properly. If not, service the valve as necessary. Visually inspect the machine and hoses for sign of leakage. NOTE: This error will display after 2 full piston strokes so the leak will be substantial.

If the tanks appear to have plenty of material check to make sure the level sensor is connected to the proper port and that the cord is not damaged

Make sure the feed pumps are operating properly

Check for loose or disconnected wires or plugs

72 313875J

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

The volume of oil in the tank is

MBH1 Low Oil Level

Low Motor

MBN1

Performance

Pump Failed

N4A1

to Move

Thermal

P400

Pressure Rise

Red Pressure

P4A1

Shutdown

Blue

P4B2

Pressure Shutdown

below the minimum level needed for the system to properly operate

The motor magnetism has decreased to the point where performance is greatly reduced

The MCM attempted to move the pump but no movement was detected

Pressure has risen to an unsafe level due to thermal expansion of materials. All conditioning zones have automatically been turned off.

The material pump pressure exceeded the maximum operating pressure as defined in the setup screens

Error Type Cause Solution

Low oil level Check oil level and if low add more hydraulic fluid

Check to ensure the hydraulic oil level sensor is

Loose/bad connection

Bad level sensor Replace sensor

Alarm

Leak in hydraulic driver

Leak in the hydraulic reservoir, heat exchanger

Advisory

Deviation

Deviation High pressure

Alarm

Prolonged exposure to heat or high voltage

Motor failure

Hydraulic power pack failure

Loose/bad connection to the linear position sensor

Failure of the linear position sensor Motor no longer coupled to hydraulic pump Supply tube from hydraulic pump to manifold is loose or broken Broken motor shaft Replace motor

Over-pressure valve dumping to tank

Dispense valve failed to open Bad dispense valve Replace dispense valve

Restriction in the material lines

Invalid maximum pressure defined

Orifices blocked Clear blockage Hose blocked Clear blockage or replace hose as necessary Dispense valve failed to

open

properly connected to the MCM and that the wire has not been damaged

Inspect hydraulic driver end seals and early leak detection tubing. Replace seals as necessary and replace lost oil. Inspect the hydraulic reservoir fittings and filter for leaks. Repair or replace as necessary and replace lost oil.

If error persists and performance can no longer satisfy the user requirements the motor will need to be replaced

Visually check to ensure the pump is moving, if not ensure the motor is wired properly If motor is moving but pump is not and pressure is not building they hydraulic power pack may need servicing Check to ensure the linear position sensor is properly connected to the MCM and the wiring has not be damaged

Replace the linear position sensor

Reset coupler per specifications and retighten set screws

Retighten or replace supply tube

Verify that no outside forces are stopping the pump from moving, then inspect over-pressure valve for damage or debris

Open the dispense valve manually or open the valves to bleed pressure

Check to make sure the dispense valve is properly configured and connected to the MCM

Check to ensure there is no blockage

Make sure the requested pressure is within the max operating pressure, which can be found on the setup screen System 1

Check to make sure the dispense valve is properly configured and connected to the MCM

313875J 73

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

The pressure difference

P4D0

P6A1

P6B2

T1A6

T1B5

T1A3

T1B1

T1A2

T1B4

T1A7

T1B8

T3H1

T3N1

Pressure Imbalance

Red Pressure Sensor Fault Blue Pressure Sensor Fault Red Tank Low Fluid Temp. Blue Tank Low Fluid Temp.

Red Inline Low Fluid Temp.

Blue Inline Low Fluid Temp. Red Hose Low Fluid Temp.

Blue Hose Low Fluid Temp.

Red Chiller Low Fluid Temp. Blue Chiller Low Fluid Temp.

Oil Temp. Cutback

Motor Temp. Cutback

between the Red and Blue material is greater than the defined amount

The pressure sensor is providing invalid/no pressure readings

Fluid temperature is below the defined low alarm limit

The hydraulic oil temperature is approaching a level where damage is possible so the Motor Control Module is limiting the output to a safe level

Motor temperature is approaching a level where damage is possible so the motor control module is limiting the output to a safe level

Error Type Cause Solution

Dispense line is clogged

Pressure imbalance is defined too low

Orifice blocks closed off

Alarm

Alarm Loose/bad connection

Alarm

Alarm Low power

Alarm

Alarm Bad heater(s) Measure resistance of heater(s)

Deviation

Advisory

too much on one or both sides

Debris in the orifice block

Material fillers may have packed out in an orifice

Out of material Fill tanks with material Feed system defective Replace defective item

Bad sensor Replace pressure transducer

No material in pump Fill tanks

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Cable unplugged/loose power

No power to fan Check cord to make sure fan has power Debris in fan or fan grill Clear debris from fan/fan grill

Low air volume from fan

No power to fan Check cord to make sure fan has power Debris in fan or fan grill clear debris from fan/fan grill

Low air volume from fan

Ambient environmental conditions are too hot

Motor/pump coupler may be rubbing on hydraulic pump

Ensure the material flow is equally restricted on both material lines On the ADM go into the setup screens -> System-> and ensure the pressure imbalance value is the maximum acceptable to prevent unnecessary alarms which will abort dispenses Verify that one or both of the orifice blocks dispense when adjusted to the fully open position then adjust accordingly Relieve system pressure then remove the orifice from the orifice block and inspect for debris in the cavity Relieve system pressure and remove the orifice from the orifice block and inspect for pack out. Clean or replace as necessary.

Check to ensure the pressure transducer is properly installed and all wires are properly connected

Measure voltage across input terminals on power line filter. Voltage should measure between 190 and 264 Vac

Check for loose or disconnected wires or plugs

Try to stop fan by lightly pressing on the center with a pencil eraser. If the fan slows down easily it will need to be replaced

Move machine to an area below 120°F

Reset coupler per specifications and retighten set screws

74 313875J

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

Blue Tank

T4B5

High Fluid Temp.

Red Inline

T4A3

High Fluid Temp. Blue Inline

T4B1

High Fluid Temp.

T4A2

T4B4

T4A7

T4B8

T4C1

T4H1

T4N1

T6A6

T6B5

T6A3

T6B1

T6A2

T6B4

T6A7

T6B8

Red Hose High Fluid Temp.

Blue Hose High Fluid Temp.

Red Chiller High Fluid Temp. Blue Chiller High Fluid Temp.

Motor Control High Temp.

Oil Temp. Shutdown

Motor Temp. Shutdown

Red Tank RTD Fault

Blue Tank RTD Fault

Red Inline RTD Fault

Blue Inline RTD Fault

Red Hose FTS Fault

Blue Hose FTS Fault

Red Chiller RTD Fault

Blue Chiller RTD Fault

Fluid temperature is above the defined high alarm limit

The temperature the MCM has reached a level where product life will be decreased drastically and has been shutdown for protection

The hydraulic oil is at a temperature where performance is impacted significantly and has resulted in a system shutdown

Motor temperature is too high and system has been shutdown to prevent possible damage

RTD 1 is giving no or invalid data

Error Type Cause Solution

Alarm

Alarm Loose connections Tighten connections

Alarm

Alarm Bad RTD Replace RTD

Defective RTD Replace RTD

Defective High Power Temperature Control Module

No power to fan Check cord to make sure fan has power Debris in fan or heatsink Clear debris from fan or heatsink

Low air volume from fan

Motor may be damaged Replace motor Debris is packed in the

MCM’s heat sink fins No Power to Fan Check cord to make sure fan has power Debris in fan or fan grill Clear debris from fan/fan grill

Low air volume from fan

No power to fan Check cord to make sure fan has power Debris in fan or fan grill Clear debris from fan/fan grill

Low air volume from fan

Ambient environmental conditions are too hot Motor may be damaged Motor may need to be replaced

Loose or bad connection Check RTD wiring

Replace High Power Temperature Control Module

Try to stop fan by lightly pressing on the center with a pencil eraser. If the fan slows down easily it will need to be replaced

Clear debris from MCM heat sink fins

Try to stop fan by lightly pressing on the center with a pencil eraser. If the fan slows down easily it will need to be replaced

Move machine to an area below 120°F

313875J 75

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

Red Blanket

T6C6

RTD Fault Blue Blanket

T6C7

T6C8

T8A6

T8A3

T8B1

T8A2

T8B4

T8A7

T8B8

T9A6

T9B5

T9A3

T9B1

RTD Fault Red Chiller RTD Fault Blue Chiller RTD Fault No Heat Red Tank No Heat Blue Tank No Heat Red Inline

No Heat Blue Inline

No Heat Red Hose

No Heat Blue Hose

No Cooling Red Chiller

No Cooling Blue Chiller

Red Blanket Temp. Cutoff Blue Blanket Temp. Cutoff

Red Inline Temp. Cutoff

Blue Inline Temp. Cutoff

RTD 2 is giving no or invalid data

No temperature rise

No temperature decline

Heater overtemperature cutoff

Error Type Cause Solution

Alarm

Alarm Bad RTD Replace RTD

Alarm

Alarm Low Power

Alarm

Alarm Bad heater(s) Measure resistance of heater(s)

Alarm Tripped circuit breaker Visually check circuit breaker for a tripped condition

Alarm

Alarm Loose connections Tighten connections

Loose or bad connection Check RTD wiringT6C5

Tripped circuit breaker Visually check circuit breaker for a tripped conditionT8B5

Measure voltage across input terminals on power line filter. Voltage should measure between 190 and 264 Vac

Cable unplugged/loose power

Defective cooling valve

Chilled water supply off Turn on chilled water supply Loose or bad connection Check RTD wiring

Defective RTD Replace RTD

Defective High Power Temperature Control Module

Check for loose or disconnected wires or plugs

Disconnect the valve and measure the voltage across the wires when the chiller is running to ensure 24V is being delivered to the valve. If so, the cooling valve will likely need replacing.

Replace High Power Temperature Control Module

76 313875J

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

Red Blanket

T9C6

Ctrl Shutdown

Blue Blanket

T9C5

Ctrl Shutdown Red Inline

T9C3

Ctrl Shutdown Blue Inline

T9C1

Ctrl

T9C2

T9C4

T9C7

T9C8

V1H1

V4A6

V4B5

V4A3

V4B1

V4A2

V4B4

V4A7

V4B8

V4H0

W0U0

WBH1

Shutdown Red Hose Ctrl

Shutdown Blue Hose

Ctrl Shutdown Red Chiller Ctrl Shutdown Blue Chiller Ctrl Shutdown

Motor Control Undervoltage

Red Blanket Overvoltage Blue Blanket Overvoltage Red Inline Overvoltage Blue Inline Overvoltage Red Hose Overvoltage Blue Hose Overvoltage Red Chiller Overvoltage Blue Chiller Overvoltage

Motor Control Overvoltage

USB Update Failed

Motor Encoder Fault

PCB over temperature

The voltage to the MCM has dropped to a level where performance is greatly affected

High line voltage

The voltage to the MCM has reached an unsafe level and has been shutdown in an attempt to prevent damage

The ADM tried to upload a system settings file but failed

An error has been detected on the motor position sensor

Error Type Cause Solution

Alarm

Overheated Temperature Control Module

Tripped circuit breaker Visually check circuit breaker for a tripped condition Supply lines providing low voltage

Incoming line voltage is too high

Supply lines providing high voltage

System Settings file is corrupt

System Settings file is intended for another system

Failing sensors If error persists the motor will need to be replaced

Loose connection

Turn conditioning zone off. Wait a few minutes. If the condition does not clear or regenerates consistently, replace heater module

Check incoming voltage to ensure it is above the minimum operating voltage

Measure voltage across disconnect switch. Voltage should measure between 190 and 264 Vac.

Check incoming voltage to ensure it is below the maximum operating voltage

Replace the system settings file with a backup or new file

Ensure that the first line in the settings.txt file contains the text GMS. If not replace the file with the proper system update file.

Ensure the d-sub connector to the motor is connected and the wiring is intact

313875J 77

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

The motor has reached a

WKH1

WM06

WM05

WM03

WM01

WM02

WM04

WM07

WM08

WMA6

WMB5

WMC6

WMC5

WMC3

WMC1

WMC2

WMC4

WMC7

WMC8

WMH1

High Motor Speed

Red Tank Con. Fault Blue Tank Con. Fault Red Inline Con. Fault Blue Inline Con. Fault Red Hose Con. Fault Blue Hose Con. Fault Red Chiller Con. Fault Blue Chiller Con. Fault Red Blanket High Temp.

Blue Blanket High Temp.

Red Tank Con. Fault Blue Tank Con. Fault Red Inline Con. Fault Blue Inline Con. Fault Red Hose Con. Fault Blue Hose Con. Fault Red Chiller Con. Fault Blue Chiller Con. Fault Motor Controller Fault

speed that should not be reached in normal operation and was shutdown to prevent possible damage

High current to relay 1

Tank blanket is above the defined high alarm limit

Unexpected current to relay 1

A general fault has occurred within the MCM

Error Type Cause Solution

No power to directional valve

Bad directional valve connection

Directional valve failure The directional valve will need to be replaced Hydraulic power pack

Alarm

Alarm Defective RTD Replace RTD

Alarm

Deviation Internal hardware failure

failure Defective encoder Replace encoder Motor no longer coupled to hydraulic pump Supply tube from hydraulic pump to manifold is loose or

broken Broken motor shaft Replace motor

Broken contactor Replace contactor

Defective High Power Temperature Control Module Loose connections Tighten connections

Shorted module

Make sure the directional valve has power

Make sure the cord to the directional valve is connected to the correct port and the cord is not damaged

The hydraulic power pack will need repair

Reset coupler per specifications and retighten set screws

Retighten or replace supply tube

Replace High Power Temperature Control Module

If temperature is being affected by a zone that has been disabled, replace heat module

Cycle power, if the error persists the MCM will need to be replaced

78 313875J

Appendix D - ADM Event and Error Codes Overview

Error Code Error Name Error Description

The requested controlling value (pressure or flow) is outside the limits of the system

The shot that was entered for the gel timer is not a valid shot. This must be fixed before the gel timer will function properly

WSC0

WSD0

Invalid Setpoint Request

Invalid Gel Timer Definition

Error Type Cause Solution

On the ADM go into the setup screens -> System->

Deviation

System incorrectly setup

Shot incorrectly defined

Gel timer shot is below the minimum dispense amount or set for a invalid pressure/flow

The MCM has determined that the gel timer shot will not be able to be executed based parameters entered in the ADM

and ensure that all pages have properly defined values

Redefine shot with control parameters within the limits of the system

Select a different shot or modify existing shot data

If you are certain that the shot is within parameters, try running the Learn Mode routine found in the setup screen Calibration. If the error persists, a gel shot with reduced control parameters is required.

313875J 79

Appendix E - USB Operation

NOTICE

Low-quality USB stick drives may lead to burning out the USB port on the ADM. Use only high-quality USB stick-drives.

Overview

There are 3 main uses for the USB.

• Ability to download a log of up to the past 50,000 errors, events, or jobs that can contain over 150,000 snapshots of critical dipsense information.

• Download, modify, and upload custom language files

• Download and upload system configurations

• This data includes most user-selectable and

user-configurable settings.

• This data does not include pump counters, error

and event logs, shot and sequence counters

USB Options

The only options for USB on the ADM are in Advanced #4, see page 64.

The second option is the Erase icon which will reset the last download date to a time where all logs can be downloaded. This will allow the user to download all USB log entries, which may take over 2 hours if the log files are full. The ADM does not monitor the USB logs to alert the user when data may be overwritten. In order to minimize download times and the risk of losing data it is recommended that the user download the logs every 2 weeks or more often if the machine is used during more than one full shift a day.

Download Log Files

If the “Enable Downloading of USB Logs” option is checked, a USB stick-drive can be used to download the log files.

To download the log files, insert a high-quality USB stick-drive into the USB port in the bottom of the ADM. The ADM will automatically begin downloading the log files as well as the custom language file (DISPTEXT.TXT) and the system settings file (SETTINGS.TXT). The status of the download will be shown in the Status bar. If an error occurs during download, remove the USB stick-drive then re-insert.

The first option is a checkbox that enables or disables the downloading of the Error Event and Shot Data log files. The Shot Data log runs during all operating modes.

80 313875J

Log Files, Folder Structure

Appendix E - USB Operation

IG. 19: DOWNLOAD, DATAxxxx Folders

Each time a stick-drive is inserted into the ADM USB port, a new folder named DATAxxxx is created. The number at the end of the folder name is incremented each time a stick-drive is inserted and data is transferred through the USB. In each DATAxxxx folder there are three log files. They are formatted as .csv (comma separated value) files and can be opened by most text editors or data processing programs such as Excel.

Example 1-ERROR File

The 1-ERROR file is the Errors and Events log file.

313875J 81

Appendix E - USB Operation

Example 2-JOB File

The 2-JOB file is the Shot Data log file.

Example 3-SYSTEM File

The 3-SYSTEM file is the Software Version log file.

82 313875J

Transfer System Settings

Appendix E - USB Operation

Use the following process to transfer system settings from one machine to another.

1. Insert a high-quality USB stick-drive into the ADM USB port on the system with the settings to be transferred. Once the download is complete the SETTINGS.TXT file will be located in the “DOWNLOAD” folder.

NOTICE

The user should never attempt to modify the SETTINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified setup file.

2. Plug the USB stick-drive into a computer.

3. Navigate to the DOWNLOAD folder.

4. Copy the SETTINGS.TXT file from the DOWNLOAD folder into the UPLOAD folder.

5. Remove the USB stick-drive from the computer and install it into the ADM USB port for the second machine. The software will automatically begin updating.

NOTE: Before the update begins the ADM automatically shuts down the system, aborting any in-progress dispensing. When the software is updating a pop-up box will appear to inform the user of the update and the system will lock. Once the update is complete the ADM will tell the user to cycle power to apply the updates.

6. When the software is done updating, remove the USB stick-drive.

7. Turn the Main Power Switch to the OFF position then back to the ON position.

8. Plug the USB stick-drive into a computer.

9. Navigate to the UPLOAD folder and remove the SETTINGS.TXT file.

NOTE: Immediately after uploading the settings, remove the SETTINGS.TXT file from the UPLOAD folder to prevent accidental loss of data the next time the USB stick-drive is inserted into the ADM USB port. If there is a SETTINGS.TXT file in the UPLOAD folder when the USB stick-drive is inserted into the ADM USB port the software will automatically begin updating.

313875J 83

Appendix E - USB Operation

Update Custom Language

Use the following process to customize the text on the ADM. The language file DISPTEXT.TXT can be modified in Excel but must be saved as a Unicode Text file with the extension .TXT in order for it to properly import.

1. Insert a high-quality USB stick-drive into the ADM USB port on the system with the settings to be transferred. Once the download is complete the DISPTEXT.TXT file will be located in the “DOWNLOAD” folder.

2. Plug the USB stick-drive into a computer.

3. Navigate to the DOWNLOAD folder.

4. Copy the DISPTEXT.TXT file from the DOWNLOAD folder to your computer.

5. Use any data processing software such as Excel to edit the DISPTEXT.TXT file.

a. In the first column, locate the string to change.

b. In the second column of the same row, enter the

new string.

NOTE: Immediately following uploading the language file, remove the DISPTEXT.TXT file from the UPLOAD folder to prevent accidental loss of data the next time the USB stick-drive is inserted into the ADM USB port. If there is a DISPTEXT.TXT file in the UPLOAD folder when the USB stick-drive is inserted into the ADM USB the software will automatically begin updating.

c. Save the file as a Unicode Text file. The name

must remain “DISPTEXT.TXT”.

6. Copy the edited DISPTEXT.TXT file into the UPLOAD folder.

7. Remove the USB stick-drive from the computer and insert it into the ADM USB port. The software will automatically begin updating.

8. When the software is done updating, remove the USB stick-drive.

9. Turn the Main Power Switch to the OFF position then back to the ON position.

10. Plug the USB stick-drive into a computer.

11. Navigate to the UPLOAD folder and remove the DISPTEXT.TXT file.

84 313875J

Appendix E - USB Operation

Example SETTINGS.TXT File Example DISPTEXT.TXT File

NOTICE

The user should never attempt to modify the SETTINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified setup file.

313875J 85

Appendix E - USB Operation

86 313875J

Technical Data

Air Inlet Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-100 psi (0.59-0.69 MPa, 5.9-6.9 bar)

Wetted Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless steel, UHMW, carbon steel

Fluid Viscosity Range . . . . . . . . . . . . . . . . . . . . . . . . . . Paste

Fluid Flow Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VPM-25: 12-25 kg/min (26-55 lb/min)

VPM-12: 10-12 kg/min (22-26 lb/min)

Hydraulic Reservoir Capacity . . . . . . . . . . . . . . . . . . . . 8 gal. (30 liters) each

Recommended Hydraulic Fluid . . . . . . . . . . . . . . . . . . . Citgo A/W Hydraulic Oil, ISO Grade 46

Dimensions

The dimensions of the machine vary by machine layout.

Ref VPM-25 VPM-12

A (Height) Ram in the lowered position:

9 ft 3 in.

(2.82 m)

Ram in the raised position:

11 ft 4 in.

(3.45 m)

B (Width) 7 ft 8 in.

(2.34 m)

C (Depth) 15 ft 10 in.

(4.83 m)

Ram in the lowered position:

9 ft 3 in. (2.82 m)

Ram in the raised position:

11 ft 4 in.

(3.45 m)

7 ft 8 in. (2.34 m)

6 ft 1 in. (1.86 m)

Technical Data

VPM-25 Shown

313875J 87

ti17693a

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

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

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

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

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 313875

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised November 2012

Graco 313875J User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Models

Accessories

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Keep Components A (Red) and B(Blue) Separate

A (Red) and B (Blue) Components

Moisture Sensitivity of Isocyanates

Changing Materials

Component Identification

VPM-12

Hydraulic Power Pack

Motor Control Module (MCM)

Advanced Display Module (ADM)

Fluid Control Module (FCM)

Setup

Initial Machine Setup

Adjust Motor Control Module Selector Switch

Startup

Change Drum

Remove Drum

Install Drum

Priming

Operation

ADM Operation Overview

Machine Operation Overview

System Setup and Calibration

Dispensing

Shutdown

Short-term

End of Shift

Pressure Relief Procedure

Maintenance

Install Upgrade Tokens

Advanced Display Module (ADM)

Motor Control Module (MCM)

Fluid Control Module (FCM)

Troubleshooting

Light Tower (Optional)

Common Problems

ADM Troubleshooting

Motor Control Module

Fluid Control Module

Appendix A - ADM Icons Overview

Setup Screen Icons

Home Screen Icons

Appendix B - ADM Setup Screens Overview

Appendix C - ADM Run Screens Overview

Optional Screens

Appendix D - ADM Event and Error Codes Overview

Event Codes

Error Codes

Appendix E - USB Operation

Overview

USB Options

Download Log Files

Log Files, Folder Structure

Transfer System Settings

Update Custom Language

Technical Data

Dimensions

Graco Standard Warranty