Graco 313296J User Manual

Instructions - PartsWarm Melt Supply SystemsFor use with heated bulk supply of medium to high viscosity sealant and adhesive materials. Not for use in

Component Identification 10 313296JNOTE: See FIG. 2 and FIG. 3. Before you install the system, you should be familiar with the following compo-nents.

Appendix A - User Interface Display 100 313296JRun Mode ScreensRun mode screens are divided into six sections: ram operation, heat zone operation, cur

Appendix A - User Interface Display313296J 101Heat Run ScreenThe Heat Run screen displays information for four to six heat zones. See FIG. 72 for info

Appendix A - User Interface Display 102 313296JStatus ScreenThis screen displays the job totals and grand totals. If there is a filter or an error iss

Appendix A - User Interface Display313296J 103Alarm ScreenThe alarm screens display the type of alarm currently occurring on each ram. Once an alarm i

Dimensions 104 313296JDimensionsD200 ModelsD200s ShownCGEFDB(ram down)A(ram up)Ram ModelAin. (mm)Bin. (mm)Cin. (mm)Din. (mm)Ein. (mm)Fin. (mm)Gin. (mm

Dimensions313296J 105D60 ModelsCGEFDB(ram down)A(ram up)Ram ModelAin. (mm)Bin. (mm)Cin. (mm)Din. (mm)Ein. (mm)Fin. (mm)Gin. (mm)D6092.7 (2355) 62.7 (1

Technical Data 106 313296JTechnical DataMaximum Fluid Working Pressure and Flow Rate at Full Air Pressure (100 psi)WeightSee the identification plate

Technical Data313296J 107

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

Component Identification313296J 11Air Line AccessoriesSee Supply Systems Operation manual.• Air line drain valve. Not included.• Air line filter: remo

Component Identification 12 313296JFluid Control ModuleTable 2: FCM Sensor ConnectionsConnection Ram Sensor Description1 Ram A and Ram B Air motor sol

Component Identification313296J 13User InterfaceFIG. 8: Display ModuleTable 3: Display Module Button FunctionsButton FunctionOn/OffPowers air motor so

Component Identification 14 313296JSoft KeySoft keys activate the mode or action represented by the icon above each button in the LCD. See Table 4 for

Component Identification313296J 15Crossover Crossover key transitions the active ram to inactive, and inactive ram to active. Available on Warm Melt T

Component Identification 16 313296JUser Interface DisplayNOTE: For details regarding the user interface dis-play see Appendix A - User Interface Displ

Installation313296J 17InstallationAccessories are available from Graco. Make certain all accessories are adequately sized and pressure-rated to meet t

Installation 18 313296JFluid supply container: follow local code.Object being sprayed: follow local code.Solvent pails used when flushing: follow loca

Installation313296J 19Install/Adjust Drum Low or Empty Sensor1. Position ram at desired level (low or empty).NOTE: Follow Steps 2 through 4 only if in

2 313296JContentsRelated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Models . . . . . . . . . . . . . . . . . . . . .

Installation 20 313296JAttach Drum StopsSupply systems are shipped with drum stops in place to help position the drum on the ram. For replacement part

Installation313296J 21Check ResistanceCheck the Resistance Between the Supply System and the True Earth GroundHave a qualified electrician check the r

Installation 22 313296JHeater Resistance ChecksNOTE: For dispense valve and hose sensor resis-tance checks, refer to your dispense valve manual or hos

Installation313296J 23Hose Installation and CareNOTE: The warm melt supply system requires Graco single-circuit material hoses rated at a maxi-mum of

Setup 24 313296JSetupThe pump was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminat-ing fluid wit

Setup313296J 25Load MaterialNOTE: Before loading material, ensure that there is a minimum overhead clearance of 105 in. (267 cm) and all air regulator

Setup 26 313296JSystem Heat UpNOTE: Operate at the lowest temperature and pres-sure necessary for your application.1. Turn the main disconnect on the

Setup313296J 27Prime 1. Make sure the system is at required temperature.2. Tandem Systems Only: To prime the active ram, ensure that the system is not

Operation 28 313296JOperationPressure Relief ProcedureThis procedure describes how to relieve pressure for the supply system. Use this procedure whene

Operation313296J 293. Press while in the Ram Operation screen. 4. When the confirmation screen appears with a prompt, select to start the pump.5.

Related Manuals313296J 3Related ManualsManuals are available at www.graco.com.Component Manuals in U.S. English:Manual Description313528 Tandem Supply

Operation 30 313296JRecirculate FunctionRecirculate mode pumps fluid from the drum, through the pump, and back into the drum on the currently active r

Operation313296J 31NOTE: Depressurizing the active ram will depressurize both rams. However, if additional user-supplied check valves have been added

Maintenance 32 313296JShutdownFollow the procedure below for normal system shut down, such as at the end of the work day.NOTE: The ram up/down and blo

Maintenance313296J 33Platen MaintenanceIf the platen does not come out of the pail easily when the pump is being raised, the air assist tube or check

Maintenance 34 313296JElectrical Enclosure1. Turn the main disconnect on the electrical control panel door to the OFF position to disconnect power.2.

Maintenance313296J 35Pump Heaters1. Turn the main disconnect on the electrical control panel door to the OFF position to disconnect power.2. Remove fo

Alarms 36 313296JAlarmsWarm Melt alarms alert you to a problem and help pre-vent system shutdown or application errors. If an alarm occurs, operation

Alarms313296J 37Fluid Control Module (continued)DA1XDA2XPump Runaway APump Runaway BPump is running faster than set runaway limit due to:•Increased ai

Alarms 38 313296JFluid Control Module (continued)DA1XDA2XPump Runaway APump Runaway BPump is running faster than set runaway limit due to:•Increased a

Alarms313296J 39Fluid Control Module (continued)DD1XDD2XA - Pump Diving B - Pump Diving Pump leak. Worn valve or packings. See Check-Mate Displace-men

Models 4 313296JModelsCheck the identification plate (ID) for the 6-digit part number of your warm melt supply system. Use the following matrix to def

Alarms 40 313296JTemperature Control Modules (continued)T6A1T6A2T6A3T6A4T6A5T6A6T6A7T6A8T6A9T6A10T6A11T6A12No Temp Rise Tripped circuit breaker. Visua

Alarms313296J 41Temperature Control Modules (continued)A1A1A1A2A1A3A1A4A1A5A1A6A1A7A1A8A1A9A1A10A1A11A1A12Undercurrent Tripped circuit breaker. Visual

Alarms 42 313296JT4C1T4C2T4C3T4C4T4C5T4C6T4C7T4C8T4C9T4C10T4C11T4C12PCB Overtemperature Overheated Temperature Control Module.Turn heat zone off. Wait

Alarms313296J 43Temperature Control Modules (continued)V1I1V1I2V1I3V1I4V1I5V1I6V1I7V1I8V1I9V1I10V1I11V1I12Low DC Voltage Faulty DC power supply. Measu

Troubleshooting 44 313296JTroubleshootingNOTE: Troubleshooting covered in this manual is specific to warm melt heat functions. Refer to Sup-ply System

Troubleshooting313296J 45No heat. Tripped circuit breaker. Visually check circuit breaker for a tripped condi-tion.Determine cause of tripped circuit

Troubleshooting 46 313296JMissing module. Modules not on network. Verify attached modules through Advanced Setup screens 4 and 5.Enter Setup screen an

Repair313296J 47RepairAir MotorRemove Air MotorRemove junction box.For 55 gallon platen (D200 and D200s supply systems): Remove two screws (61) securi

Repair 48 313296JInstall Air Motor1. See Supply System repair manual for air motor installation instructions.2. Reinstall junction box.For 55 gallon p

Repair313296J 49D60 Supply System1. Disconnect air hose and ground wire from air motor.2. See Disconnect Displacement Pump in Check-Mate Pump Packages

Warnings313296J 5WarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point s

Repair 50 313296JDisconnect Pump from PlatenThe pump is mounted to the platens by mounting Kit 255392.55 Gallon Platen1. Disconnect displacement pump

Repair313296J 51Connect Pump to Platen55 Gallon Platen1. Use two people to set pump onto platen.2. Secure pump to platen with screws (103a) and clamps

Repair 52 313296J5. Remove pump heater bands (44 or 227):a. Remove screws from both pump heaters.b. Pry heater bands apart and remove from pump.c. Dis

Repair313296J 53d. Remove screws (58) and washers (82). Remove platen heater blocks (43) and RTD sensor (46). 5. Install new platen heaters and RTD se

Repair 54 313296JReplace Platen WipersRefer to Supply Systems Repair-Parts manual for instructions.Replace Ram Piston Rod Seals1. Support electrical e

Repair313296J 55Electrical EnclosurePrior to repairing any component of the electrical enclo-sure (13 or 14), turn the main disconnect on the electri-

Repair 56 313296JReplace Base1. Remove low power TCM. See Replace Low Power Temperature Control Module(s).2. Disconnect two CAN cables from base (407)

Repair313296J 57Replace Circuit Breakers1. Open enclosure door (402). Disconnect wires from circuit breaker (417, 419).2. Push in circuit breaker tab

Repair 58 313296JDisplay/User InterfaceUpgrade Display SoftwareNOTE: Order kit 16C027 for an upgrade token. See Graco Control Architecture™ Module Pro

Repair313296J 59Replace Fluid Control Module1. Disconnect power to system.2. Remove front shroud (16 or 204) and back shroud (17 or 205).3. Disconnect

Warnings 6 313296JMOVING PARTS HAZARDMoving parts can pinch or amputate fingers and other body parts.• Keep clear of moving parts.• Do not operate equ

Repair 60 313296JReplace Cable TrackD200 and D200S Supply Systems OnlyNOTE: Order Kit 257163 for replacement.1. Disconnect power to system.2. Disconne

Electrical Schematics313296J 61Electrical SchematicsWarm Melt EnclosurePower (1)Low Sensor (2)Common (3)1(2) N/C(3) Motor Reed Up(5) Motor Reed Com5(7

Electrical Schematics 62 313296JWarm Melt EnclosurePower (1)Low Sensor (2)Common (3)1(2) N/C(3) Motor Reed Up(5) Motor Reed Com5(7) Linear Com-24Vdc (

Electrical Schematics313296J 63-24Vdc (3)+24Vdc (2)CAN_H (4)CAN_L (5)SHLD (1)-24Vdc (3)+24Vdc (2)CAN_H (4)CAN_L (5)SHLD (1)FLUID CONTROLMODULERAM “B”C

Electrical Schematics 64 313296JD200 Displacement Pump and Platen SchematicsPlatenDisplacement Pump

Electrical Schematics313296J 65D200 Junction Box Schematic

Electrical Schematics 66 313296JD200 Cable Track Schematic

Electrical Schematics313296J 67Warm Melt EnclosurePower (1)Low Sensor (2)Common (3)1(2) N/C(3) Motor Reed Up(5) Motor Reed Com5(7) Linear Com-24Vdc (3

Electrical Schematics 68 313296JWarm Melt EnclosurePower (1)Low Sensor (2)Common (3)1(2) N/C(3) Motor Reed Up(5) Motor Reed Com5(7) Linear Com-24Vdc (

Electrical Schematics313296J 69-24Vdc (3)+24Vdc (2)CAN_H (4)CAN_L (5)SHLD (1)-24Vdc (3)+24Vdc (2)CAN_H (4)CAN_L (5)SHLD (1)FLUID CONTROLMODULERAM “B”C

Overview313296J 7OverviewSystem DescriptionWarm melt supply systems are used for melting and pumping warm melt adhesives and high viscosity seal-ants.

Electrical Schematics 70 313296JD60 Pump and Platen Schematic

Electrical Schematics313296J 71D60 Junction Box Schematic

Electrical Schematics 72 313296JD60 Cable Harness Schematic

Electrical Schematics313296J 73Electrical Enclosure Schematic4-Zone Medium Enclosure

Electrical Schematics 74 313296JElectrical Enclosure Schematic4-Zone RAM ‘B’ Enclosure

Electrical Schematics313296J 75

Parts 76 313296JPartsD200s Rams ShownSingle Supply System or Supply System ASupply System B55436161577141336422

Parts313296J 77NOTE: See Component Identification, starting on page 8, to identify the components included in your Warm Melt supply system.❄See Supply

Parts 78 313296JWarm Melt Kits for D200 SystemsKit 24D012 (CST), 24K675 (SST) with Display for D200 and D200i SystemsKit 24D015 (CST), 24K678 (SST) wi

Parts313296J 79421018883, 84, 8511, 123911, 26, 58, 594053547180528610161, 6272, 7378TI19984a

Component Identification 8 313296JComponent IdentificationSingle Supply Systems Key:ARam AssemblyC Air MotorD Heated Check-Mate Displacement PumpE Hea

Parts 80 313296J4457, 99518770634968, 69, 97, 984645, 79484359641157, 97, 100, 10246, 56, 82103a103b103c1Torque to 60 +/- 10 in-lbs (6.8 +/- 1.1 N•m)1

Parts313296J 81D200 Warm Melt KitsUBFB9392949591115910111659119011368, 97, 98891171121159Ref. Part Description Qty.11✓ 100016 WASHER, lock 2912

Parts 82 313296J★Not shown.▲Replacement Danger and Warning labels, tags, and cards are available at no cost.†Kit 24D012 only.◆Kit 24D015 only.✿Kits 24

Parts313296J 83Warm Melt Kits for D60 SystemsKit 24D009 (CST), 24K670 (SST) with Display for D60 and D60i SystemsKit 24D010 (CST), 24K671 (SST) with D

Parts 84 313296Jr_wm_2179_313296_12a258257235237236259,260,261233

Parts313296J 85234262239,227228, 201, 202, 222201, 202256227229274249, 272,273223232201, 213, 240, 241ti17721a282, 283, 284

Parts 86 313296JD60 Warm Melt KitsUBFB268267269270266201241276278241201265258248, 272, 273264271255201241Ref. Part Description Qty.201 100016 WA

Parts313296J 87★Not shown.▲Replacement Danger and Warning labels, tags, and cards are available at no cost.* Standard only on tandem supply systems.✿K

Parts 88 313296JHeated Platens - 20L, 30L, and 60L325, 326324308317318319320323311304, 305310313321309303302301307309Platen 24D066 (20L) ShownTorque t

Parts313296J 89Parts Used on all Heated Platens▲Replacement Danger and Warning labels, tags, and cards are available at no cost.Parts that Vary by Hea

Component Identification313296J 9Tandem Supply SystemsKey:ARam ABRam BC Air MotorD Heated Check-Mate Displacement Pump (Ram A and B)E Heated Platen (R

Parts 90 313296JElectrical Enclosure Parts257158 for single supply systems and ram A of tandem supply systems257291 for ram B of tandem supply systems

Parts313296J 91Electrical Enclosure Parts★Not shown.▲Replacement Danger and Warning labels, tags, and cards are available at no cost. Replacement elec

Accessories 92 313296JAccessoriesPlaten Cover, 255691Two platen covers. See manual 406681 for more infor-mation for D200 platens.Two-Zone Expansion Ki

Appendix A - User Interface Display313296J 93Appendix A - User Interface DisplayDisplay OverviewThe user interface display is divided into two main fu

Appendix A - User Interface Display 94 313296JStatusThe current system status is displayed on the right of the menu bar. If there is an error, an even

Appendix A - User Interface Display313296J 95Setup Mode ScreensSetup mode screens are divided into six sections: pass-word, system setup, heat zone se

Appendix A - User Interface Display 96 313296JNOTE: Must exit edit mode to scroll through the heat zones.Maintenance Setup ScreenThe Maintenance Setup

Appendix A - User Interface Display313296J 97Hardware Setup ScreensThe Hardware Setup screens enable users to specify if specific hardware is installe

Appendix A - User Interface Display 98 313296JAdvanced Setup ScreensThe Advanced Setup screens enable users to set units, adjust values, set formats,

Appendix A - User Interface Display313296J 99Advanced Setup Screen 3This screen enables users to set the date, time, and date format.Advanced Setup Sc