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Graco 3A2175A User's Manual

1. 58 1in y 1476 mm 3 ti18219a 4 5 8 diameter anchor locations 1 2175 3A2175A Technical Data 95 Graco Standard VVarranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defecis 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 conditione
2. 5 DATAODOS DATADODO DATADODS UPLOAD O UPLOAD x 5 DVD Drive F M b DVD Drive F Fic 24 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 down loaded or uploaded In each DATAxxxx folder there is two log files They are formatted as csv comma sepa rated value files and can be opened by most text editors or data processing programs such as Excel 86 3A2175A Example LOG01 File The LOG0O file is the Errors and Events log file DO 4 01 OT o ul e 10 11 12 13 14 A E Error Log h FFFFFFFF Software Part Number 155457 Revision 0 086 007 3 23 2010 15 00 4 4 H LOGOL Example LOG02 File The LOGO file is the Shot Data Log file 1 2 3 4 5 m 9 10 11 12 15 14 15 16 17 15 19 20 21 22 7 Date A 1672010 1672010 3186 2010 316 2010 316 2010 310 2010 310 2010 310 2010 318 2010 318 2010 318 2010 318 2010 3 23 2010 3 23 2010 ORANAN B Running Shot Data Log SN FFFFFFFF Software Part Number 154457 Revision 0 086 007 3 23 2010 15 00 Time 10 38 12 10 38 28 10 38 38 10 38 44 10 38 45 10 38 49 10 38 56 10 39 02 10 39 18 10 39 23 10 38 28 10 38 47 10 03 35 10 03 36 10 02 49 4 4 H NLOGO2 3A2175A Inline Blue
3. Z0 a Navigate to System Screen 2 and select the MD2 dispense valve from the Dispense Valve drop down menu See System Screen 2 on page 62 b Set pressure relief valves SA SB to RELIEF c f dispense valve has a trigger safety lock engage the trigger safety lock Y LOCKED ti10442a1 d Connect gun to machine Verify gun is ready for operation See appropriate gun manual listed in Related Manuals on page 3 for detailed instructions e Verify airline is connected to the dispense valve then open bleed type master air line valve f Set PRESSURE RELIEF DISPENSE valves SA ti9877a1 solid green h Check fluid pressure display and adjust as nec essary 34 i lf equipped check fluid pressure gauges GA GB to ensure proper pressure balance If imbalanced reduce pressure of higher compo nent by slightly turning PRESSURE HELIEF DISPENSE valve for that component toward PRESSURE RELIEF CIRCULATION 47 until gauges shovv balanced pressures NOTE For systems vvithout gauges pressures can be monitored on the home screen of the ADM GA GB In this example B Blue side pressure is higher so use the B Blue side valve to balance pres sures o Z S ti9877a1 j If dispense valve has a trigger safety lock dis engage the trigger safety lock N J ti10441a1 UNLOCKED k Perform mix ratio test using two tared cups Weigh the cups an
4. 6 When the reservoir is flushed clean fill with fresh IsoGuard Select fluid 47 Maintenance 7 Thread the reservoir onto the cap assembly and place it in the bracket RB 8 Push the supply tube ST approximately 1 3 of the way into the reservoir 9 Push the return tube RT into the reservoir until it reaches the bottom NOTE The return tube must reach the bottom of the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube and returned to the pump Ca gt N IN v v TS Qn 4 A 24 352 313998 8e FIG 18 IsoGuard Select Fluid System Prime IsoGuard Select Fluid Cylinder Ensure that the IsoGuard Select fluid cylinder outlet faces upward for air to exhaust 1 Install IsoGuard Select fluid cylinder inlet fitting and inlet tube into bottom of cylinder The inlet tube is the tube with a check valve installed in it which points in the direction of flow towards the IsoGuard Select fluid cylinder 2 Install IsoGuard Select fluid cylinder outlet fitting and outlet tube into top of cylinder The outlet tube is the tube with a check valve installed in it which points in the direction of flow away from the Iso Guard Select fluid cylinder 3 Remove check valve from end of outlet tube 4 Use funnel to pour IsoGuard Select fluid into tube to fill cylinder 48 5 With check valve arrow pointing away from the Iso
5. REARO Night Mode Recirc On REBRO Night Mode Recirc Off REMOO System Pow The System was powered off ered Off REBOO Stop Button The Red stop button was pressed on the Advanced Display Module Executed RENNO Automatic RECA1 Red Mate i ifi RECB2 Blue Material The Blue materials specific gravity was SG Modified modified RENC1 Cal Point 1 A value for the first point in the three point calibration vvas entered Pressed fully completed Cat Performed rae win he Automat calraon_ Cal Performed terized with the Automatic calibration rial SG Modified modified Weight Entered three point calibration was entered RENC4 Cal Point 1 Weight Erased RENC5 Cal Point 2 Weight Erased RENDO Ratio Check Dispense REAOO Disp A dispense has occurred of the given REHOO Gel Timer The gel timer expired and the system Dispense RERO1 Shot Count Heset RERO2 Seq Posi tion Count Reset RERA1 Red Mate rial Volume Reset HERB 1 Blue Material Volume Reset RERA2 Red Mate rial Weight Reset Weight Entered i 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 automatically took the gel shot RENC2 Cal Point 2 The running average for point one of the three point calibration was erased A counter from the shot counters main A counter from the sequence counters The resettable totalizer for the Red The resetta
6. Troubleshooting Problem Material imbalance Inadequate flow from pump cavitation Increase fluid supply to proportioning pump Use 2 1 supply pump e Use minimum 3 4 in 19 mm ID supply hose as short as practical Fluid is too thick Consult your material supplier for the recommended fluid temperature to maintain a vis cosity of 250 to 1500 centipoise Clean inlet strainer screen VVorn pump inlet valve ball seat or gasket Pressure relief circulation valve leak Remove return line and determine if flow is present Erratic pump movement Pump cavitation Feed pump pressure is too low Adjust pressure to Pump output low Obstructed fluid hose or gun fluid Open clear use hose with larger ID Sn Ponet a Worn piston valve or intake valve in See pump manual 3A0019 x Inadequate feed pump pressure Check feed pump pressure and adjust to 100 psi 0 7 Power Supply System No power received from DC Defective power supply Check circuit breaker Check power supply Replace power supply power supply No power to MCM heat Circuit breaker is tripping Check circuit breaker for tripping and defects Diag zones or tanks nose cause of circuit breaker tripping before resetting it Replace defective parts if required 50 3A2175A Troubleshooting ADM Troubleshooting ti12363a1 CP Fic 19 ADM Component Identification Rear ADM Module Status LEDs CN Conditions Module Status LED Signal Descri
7. Use the following process to transfer system settings from one machine to another 1 Insert a high quality USB stick drive into the USB port on the system with the settings to be trans ferred Once the download is complete the SET TINGS TXT file will be located in the DOWNLOAD folder NOTICE The user should never attempt to modify the SET TINGS 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 88 NOTE Before the update begins the ADM automatically shuts down the system aborting any in progress dis pensing When the software is updating the system 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 Once this box appears it is safe to remove the drive before cycling power 6 When the software is done updating remove the USB stick drive from the ADM USB port and install in a computer 7 Navigate to the UPLOAD folder and remove the SETTINGS TXT file NOTE Immediately after uploading the settings remove the SETTINGS
8. only if required to balance the outlet pressures 5 If neither rule a or rule above are met by either material install an orifice valve in both orifice blocks to raise the pressure and allow pressure balancing 41 Operation NOTE In general the flovv area ratio of the orifice valves should be equal to the material ratio but it vvill also be influenced by differences betvveen A and B material viscosities and flow characteristics For flow able materials start with a smaller orifice combination to increase pressure For heavy viscosity paste materials start with a larger orifice combination It is desirable for the orifice to do the majority of the pressure adjustment as this will result in the most stable system Adjustments of the needle valve if used will require periodic adjust ment NOTICE Not properly maintaining the pressure differential between inlet and dispense pressures may cause inconsistent pump output Adjust the needle valves periodically to maintain pressures Available Orifice Flow Area Ratios Dia meter 0 073 0 086 20 8 28 9 o a ef D 5 O o D 7 7 9 T g D j D F D 2 o o D 7 7 DN Co ee e Doi SER SES Ol A ol o A NI c l po co AY lt 68 Flowrate Bua as Diameter increases gt Item included in kit 24E250 42 3A2175A Maintenance 2 Schedule
9. Con Fault Blue Chiller Con Fault Motor Controller Fault A general fault has occurred Cycle povver if the error persists the MCM vvill need to s Deviation Internal hardware failure within the MCM be replaced On the ADM go into the setup screens gt System gt Invalid The requested controlling System incorrectly setup land ensure that all pages have properly defined Setpoint value pressure or flow is Deviation values Request outside the limits of the system i Redefine shot with control parameters within the limits Shot incorrectly defined of the system Gel timer shot is below the minimum dispense amount or set for a The shot that was entered for invalid pressure flow the gel timer is not a valid shot Deviation The MCM has This must be fixed before the determined that the gel If you are certain that the shot is within parameters gel timer will function properly timer shot will not be able try running the Learn Mode routine found in the setup to be executed based screen Calibration If the error persists a gel shot with parameters entered in reduced control parameters is required the ADM Select a different shot or modify existing shot data Invalid Gel Timer Definition 3A2175A 83 Appendix E System Events Appendix E System Events RELO0 System Pow The System was powered on ered On REQU3 Language Downloaded Event Code and String REQU4 Language Uploaded REQU5 Logs Down loaded
10. Guard Select fluid cylinder install check valve in end of outlet tube 6 Install tubes into reservoir and install reservoir into holder Clean Orifice Valves Only for MD2 Valve using Orifice Block Kit 24E505 and an orifice NOTE 24E505 does not come with an orifice 1 Follow Pressure Relief Procedure in MD2 valve manual 2 Use 5 16 in nut driver to remove orifices NOTICE To prevent cross contamination of the orifices do not interchange A component and B component parts The A component orifice is marked vvith an A 3 Remove cap from orifice NOTE The cap is held in place with reverse threads 4 Remove needle from orifice Thoroughly inspect all o rings and replace if necessary 5 If necessary use drill bit that is the same size as the orifice to drill out the orifice Orifice size is marked on the orifice 6 Liberally lubricate all o rings 7 Reassemble in reverse order Torque orifices into fluid housing to 20 30 in Ib 2 26 3 39 Nem 3A2175A Troubleshooting Troubleshooting A Q Light Tower Optional Signal Description Green on only System is powered up and there are Before performing any troubleshooting procedure no error conditions present 1 Perform Pressure Relief Procedure on page 38 7700 Red flashing A deviation exists 2 Turn main power OFF Red on The system is shut down due to an alarm occurring 3 Allow e
11. Motor Over A software error has occurred Bad Motor Control Check for MCM software update load latest MCM A9C1 l Alarm Current commanding too much current Module code 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 Pumps are defined with the wrong size The requested dispense amount is below the minimum amount of the system 25 of Deviation the combined pump volumes is Small Shot Request Requested shot is belovv the capabilities of the current pump setup If the user has to be able to take the shot the system must be fitted vvith smaller pumps the minimum 3A2175A 75 Appendix D ADM Error Codes Error Error Code Error Description Type Cause Comm Error Comm Error Comm Error Blue Tank Comm Error Comm Error Mix Head 2 Comm Error Ratio Monitor Comm Error Red Blanket Comm Error Blue Blanket Comm Error Red nline Comm Error Blue nline Comm Error Comm Error Blue Hose Comm Error Red Chiller Comm Error Blue Chiller Loose broken connection Check connection Communication error Module not programmed Program the module Module missing power Check power supply connection Module bad Setpoint Not The set point was not reached Deviation Material restriction too Reduce lon TEBUGSE Reached and the pump was shutdown high for requeste
12. 1 5 33 1 Stain less Steel 5 5 Feed HFRS30 x HFR for Silicone 400 3 5 33 1 Stain HFRSO8 x HFR for Silicone 400 3 1 1 Stainless 77O7 5 Steel 5 5 Feed H 5 33 1 HFRS09 HFR for Silicone 230 1 4 1 Carbon Steel 55 55 Feed HFRS10 HFR for Silicone 230 1 4 1 Carbon Steel 55 5 Feed HFRS11 HFR for Silicone 230 1 4 1 Carbon Steel 5 5 Feed HFRS12 x HFR for Silicone 400 3 4 1 Carbon Steel 55 55 Feed HFRS13 x HFR for Silicone 400 3 4 1 Carbon Steel 55 5 Feed HFRS14 x HFH for Silicone 400 3 4 1 Carbon Steel 5 5 Feed HFRS15 HFR for Silicone 230 1 4 1 Stainless Steel 55 55 Feed HFRS16 HFR for Silicone 230 1 4 1 Stainless Steel 55 5 Feed HFRS17 HFR for Silicone 230 1 4 1 Stainless Steel 5 5 Feed HFRS18 HFH for Silicone 400 3 4 1 Stainless Steel 55 55 Feed HFRS19 x HFR for Silicone 400 3 4 1 Stainless Steel 55 5 Feed HFRS20 x HFR for Silicone 400 3 4 1 Stainless Steel 5 5 Feed HFRS43 x HFR for Silicone 400 3 6 1 Stainless HFRS21 HFR for Silicone 230 1 5 33 1 Carbon 25077 Steel 55 55 Feed HFRS44 x HFH for Silicone 400 3 6 1 Stainless HFRS22 HFR for Silicone 230 1 5 33 1 Carbon psp TOC Steel 55 5 Feed 3A2175A d FRS31 x HFR for Silicone 400 83 5 33 1 Stain less Steel 55 5 Feed HFRS32 x HFR for Silicone 400 3 5 33 1 Stain less Steel 5 5 Feed HFRS33 HFR for Silicone 230 1 6 1 Carbon Steel 55 55 Feed HFRS34 HFR fo
13. 1 67 1 50 30 Carbon Steel HFRL1 1 HFR for Lamination 230 1 1 86 1 160 86 Carbon Steel HFRL12 HFR for Lamination 230 1 2 00 1 50 25 Carbon Steel HFRL13 HFR for Lamination 230 1 2 15 1 86 40 Carbon Steel HFRL14 HFR for Lamination 230 1 2 40 1 60 25 Carbon Steel HFRL15 HFR for Lamination 230 1 2 5 1 50 20 Carbon Steel HFRL16 HFH for Lamination 400 3 1 00 1 80 80 Carbon Steel HFRL17 HFH for Lamination 400 3 1 08 1 86 80 Carbon Steel HFRL18 HFH for Lamination 400 3 1 16 1 100 86 Carbon Steel HFRL19 HFH for Lamination 400 3 1 20 1 60 50 Carbon Steel HFRL20 x HFH for Lamination 400 3 1 23 1 80 65 Carbon Steel HFRL21 Xx HFH for Lamination 400 3 1 33 1 80 60 Carbon Steel HFRL22 HFH for Lamination 400 3 1 50 1 60 40 Carbon Steel 3A2175A 5 HFRL26 xk HFH for Lamination 400 8 1 86 1 160 86 Carbon Steel HFRL27 HFH for Lamination 400 3 2 00 1 50 25 Carbon Steel HFRL28 Xx HFH for Lamination 400 8 2 15 1 86 40 Carbon Steel HFRL29 Xx HFH for Lamination 400 8 2 40 1 60 25 Carbon Steel HFRL30 HFR for Lamination 400 3 2 5 1 50 20 Carbon Steel Models HFR Silicone HFRS HFRS models are designed for use vvith high viscosity unheated silicone adhesives at flovv rates of up to 20 cc sec The equipment can be ran at up to 20 cycles per minute continuous duty Maximum Fluid VVorking
14. 8 Connect air tubes from solenoid valve to MD2 R to relief fittings BA BB of both PRES SURE RELIEF DISPENSE valves Secure sup plied bleed tubes N in grounded sealed waste CLOSED 5 containers H See FIG 1 page 16 V Z OPEN ON RA C A 2 R LU o ti9880a1 BB NOTICE To avoid improper machine operation ensure the open and close ports of the MD2 are connected to the proper open and close ports of the valve a Route the airlines following the material hoses 32 3A2175A 9 Connect whip hose to MD2 valve component A Red and component B Blue fluid inlets 10 Pressure check hose Pressure check hoses for leaks If no leaks secure the hoses and airlines together to protect from damage 11 Ground system This equipment must be grounded a HFH grounded through power cord See step 3 on page 29 b Fluid supply containers follow your local code c Object being dispensedi follow your local code d Solvent pails used when flushing follow your local code Use only metal pails which are con ductive placed on a grounded surface Do not place pail on a nonconductive surface such as paper or cardboard which interrupts grounding continuity e To maintain grounding continuity when flushing or relieving pressure hold a metal part of dis pense gun firmly to the side of a grounded metal pail then trigger gun 12 Check hydraulic fluid level Hydrauli
15. BLLIE Pressure Imbalance Alarm psi 37 Operation Shutdown AX 1 Park pumps MA AZ a From the Home screen press 6 and select Standby mode gili Material will dispense Pump will park automatically Once pump is parked pump will stop moving If a dispense gun with a trigger is installed pulling the trigger will begin a park operation Material will dispense lay 2 Press the enable disable key on the ADM to disable the ADM 3 Turn main power switch MP to OFF position 4 Close A Red and B Blue fluid supply valves FV if equipped or remove fluid pressure at supply device ti9883a1 5 Perform Pressure Relief Procedure on page 38 6 Shut down feed pumps as required See feed pump manual 38 Pressure Relief Procedure A 1 Shut off feed pumps and agitator if used 2 Turn PRESSURE RELIEF DISPENSE valves SA NN SB to PRESSURE RELIEF CIRCULATION d Route fluid to waste containers or supply tanks Ensure gauges drop to O SB ti9879a1 3 For models with an dispense valve with a safety lock engage gun safety lock 4 Relieve pressure in dispense valve See dispense valve manual 3A2175A Operation Flushi ng e To maintain grounding continuity when flushing or relieving pressure hold a metal part of dispense gun firmly to the side of a grounded metal pail then AV trigger gun Flush equ
16. Error Codes Error Error Code Error Description Type Cause TSA7 E Alarm Tripped circuit breaker Visually check circuit breaker for a tripped condition Disconnect the valve and measure the voltage across the wires when the chiller is running to ensure 24V is No temperature decline Defective cooling valve l i T8B8 No Cooling Alani being delivered to the valve If so the cooling valve will likely need replacing Chilled water supply off Turn on chilled water supply Loose or bad connection Check RTD wiring Red Blanket Temp Cutoff Blue Blanket Defective RTD Replace RTD Temp Cutoff Heater overtemperature cutoff Defective High Power Temperature Control Replace High Power Temperature Control Module Module Blue Inline Loose connections Tighten connections Temp Cutoff Red Blanket Ctrl Shutdovvn Blue Blanket Ctrl Shutdovvn Red nline Ctrl Shutdown Blue Inline Ctrl Overheated Turn conditioning zone off Wait a few minutes If the Shutdown PCB over temperature Temperature Control condition does not clear or regenerates consistently Red Hose Ctrl Module replace heater module Shutdown Blue Hose Ctrl Shutdown Red Chiller Ctrl Shutdown Blue Chiller Ctrl Shutdown Motor Control The voltage to the MCM has performance is greatly affected low voltage minimum operating voltage Red Blanket Overvoltage Blue Blanket Overvoltage Red Inline Overvoltage Blue Inline Overvoltage
17. Fail M1 Cleanout ND Rod Shift Fail 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 0500 VVeight Cal Deviation Invalid data Re calibrate the machine The system will ignore the calibration data gathered and will use information gathered during dispenses If any messages appeared indicating why the Deviation ilnvalid data calibration failed attempt to fix the problem then re run the calibration Red Blanket Overcurrent Blue Blanket Red Inline Bad heaters Measure resistance of heater Blue Inline An over current was detected on the output Red Chiller ANA AA Measure voltage across the disconnect switch Overcurrent 9 9 Voltage should measure betvveen 190 and 264 Vac Blue Chiller Shorted Temperature If temperature rises for a zone that has been disabled Control Module replace Temperature Control Module High current has been Bad internal wiring of the Replace motor Motor Over detected on a phase and has motor Current been shutdown to prevent Short circuit of motor Check wiring to the motor to ensure no bare wires are damage wiring touching and that no wires are shorted to ground Motor Over Too much current is being Low voltage from the wall Make sure the supply line is properly sized for the A4M1 Alarm un Current drawn from the wall during load load and
18. Hose Blue Inline Red Hase Red Tank Blue Tank 24 09999 24 09999 25 T late Time Error Log 3272010 17 15 18 3172010 17 15 33 31772010 17 15 40 31772010 17 31 01 1 Comm 31772010 17 32 50 3172010 17 32 51 3172010 17 33 06 TANT A Motor T 99 29999 99 29999 5 99 9999 99 29999 39 29999 99 29999 99 29999 99 39999 99 299599 99 29999 995 N9999 155 19 5 1G 5 Event Lag EGLS R Logs Di EGLI3 R Langua EGLIT R Setting EMUL R Syster ELUU R System kl 26 19 09999 26 19 09999 m al Active Shot Mur Appendix F USB Operation 87 Appendix F USB Operation Transfer System Settings DOWNLOAD iP h c f JP search FP Folders X wv H Address C E GRACO FFFFFFFF DOWNLOAD v Go Folders X Name Size Type Date Modified JDATADOO01 File Folder 1 12 2010 12 38 PM 3 Desktop 8 BEA TO File Folder nenne 1 52 PM 3 18 My Computer C3OATAO003 File Folder 1 12 2010 10 12 AM BP tocal DIK CS CIDATAD004 File Folder 12 20 2004 12 00 AM a DVD CD RW Drive D CJDATADO005S File Folder 1 12 2010 10 17 AM 3 DIESEL E EJDATA0006 File Folder 1 13 2010 9 01 AM 3 GRACO DISPTEXT TXT 22KB TextDocument 1 13 2010 9 03 AM FFFFFFFF SETTINGS TXT 43 KB Text Document 1 13 2010 9 03 AM DOWNLOAD ED DATADD 1 2 C3 C3 DATA0004 5 06 C3 UPLOAD A DVD Drive F NG
19. Hydraulic Level Sensor L Hydraulic RTD Dispense Valve M2 Tv 62 Mix Head Operating Details Screen This screen allows the user to define the mix head oper ating parameters e Low Pressure Circulation The percentage of set point at which the system will run during low pres sure circulation Pre Dispense Circulation The time for which the system will circulate at high pressure prior to dis pensing when the dispense command is triggered while the system is in low pressure circulation Post Dispense Circulation The time duration that the system will remain in high pressure circulation after a dispense before dropping into low pressure circulation e Idle Position Applies to an L Head only The posi tion of the cleanout rod when the mix head is idle e Clean Out Open Applies to an L Head only The amount of time the cleanout rod will remain open immediately after the completion of a dispense e Clean Out Closed Applies to an L Head in a Nor mally Open configuration only The amount of time the cleanout rod will remain closed when it closes after the completion of a dispense after the clean out open time delay Anti Seize Delay Applies to an L Head in a Nor mally Closed configuration only After a shot occurs and the cleanout piston closes the first anti seize delay will count down then the cleanout piston will open and close to break loose from any curing material The second anti se
20. Size Size cc stroke Flow cc sec Ib min psi MPa bar Ratio 160 86 246 8 1 86 100 86 186 10 146 86 80 166 11 108 80 80 160 12 1 00 80 65 145 13 1 23 80 60 140 13 30 4 1 33 80 50 130 4 14 60 86 40 126 15 1500 10 103 2 15 60 50 110 17 1 20 65 40 105 18 1 63 60 40 100 19 8 150 60 25 85 20 28 3 7 2 40 50 30 80 20 26 3 5 1 67 50 25 75 20 25 3 3 2 00 50 20 70 20 23 3 1 250 Fullload amps with all devices operating at maximum capabilities Fuse requirements at various flow rates and mix chamber sizes may be less Cycle rate should be between 8 and 20 cycles per minute Max flow rate is determined for continuous service at 120 F 39 C at stated cpm and pressure Higher cycle rates are possible at lower temperatures pressures and intermittant use Lower cycle rates are possible but should be tested under application conditions 1 Dispense rate in excess of max flow and pressure may result in a machine shutdown due to elevated temperature of the hydraulic system resulting in a thermal shutdown T4H 1 C approved The maximum fluid working pressure for the base machine without hoses is 3000 psi 20 7 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 f 2000 psi hoses vvere purchased and installed by Graco the vvorking pr
21. Tank Feed Systems manual for information about install ing level sensors see Related Manuals on page 3 The user may select from the follovving refill settings Dis abled Monitor Manual Auto Top Off Auto Full Volume NOTE Use the Disabled setting if off board tanks are not installed The following describes system operation when each tank mode is selected e Disabled e Disables tank operation Monitor e The top sensor generates a high level deviation and the bottom sensor generates a low level alarm Refill is not supported no button is provided on the run screens to initiate refill e Errors will clear when the corresponding condi tion clears e Manual e The low level sensor will generate a low level alarm e A button is provided to the user on the run screens to instigate a manual refill operation at any time e Manual refill will run until either the high level sensor sees material the user aborts the refill via the refill button on the run screens or the refill time out expires e The low level alarm will clear when the condition clears Auto Top Off e The low level sensor will generate a low level alarm e When the high level sensor does not see mate rial automatic refill will begin and continue until either the high level sensor sees material or until the refill time out expires e The low level alarm will clear when the condition clears e A button is provided to the user on the run screens
22. Technical Data Technical Data Maximum Fluid VVorking Pressure 3000 psi 21MPa 207 bar See Models starting on page 4 for specific information Maximum Fluid Temperature 120 F 50 C Fluid Inlet Pressure at Inlet Fitting HFRL Models 50 psi 345 kPa 3 4 bar to 250 psi 1 8 MPa 18 bar HFRS Models 250 psi 1 8 MPa 18 bar to 3000 psi 21 MPa 207 bar HFRS Regulated Pressure 250 psi 1 8 MPa 18 bar to 1500 psi 10 MPa 103 bar Fluid Inlets Component A Red 3 4 nptff Component B Blue 3 4 npt f Fluid Outlets on Manifold Component A Red 1 2 in npt f Component B Blue 1 2 in npt f AI leti 2a ud d btts 1 4 NPS Air Inlet Pressure 40 psi 280 kPa 2 8 bar to 100 psi 0 7 MPa 7 bar Fluid Circulation Ports 1 4 npsm m with plastic tubing 250 psi 1 8 MPa 18 bar maximum Line Voltage Requirement 230V 1 phase 195 264V 50 60 Hz 400V 8 phase 360 440V 50 60 Hz Amperage Requirement See Models on page 4 Sound Povver 93 dB Hydraulic reservoir capacity 8 gal 30 liters Recommended hydraulic fluid Citgo A VV Hydraulic Oil ISO Grade 46 AG ea s PE 634 Ib 288 kg Not including supply pumps Wetted Parts Aluminum stainless steel zinc plated carbon steel brass carbide chrome fluoroelastomer PTFE ultra high molecular weight polyet
23. allovvs the user to set the language date format current date time setup screens passvvord screen saver delay and turn on or off silent mode 0112110 12 57 4 Conditioning Shot No Active Errors Z Date Format Date 01 H2 Time 12 Password Screen Saver 5 minutes Silent Mode Advanced Screen 2 This screen allows the user to set the units of measure Shots uk Volume Units Weight Units g Pressure Units psi Cr Temperature Units Flow Units Rate Units second v Advanced Screen 3 00 00 00 00 00 Conditioning standby mi No Active Errors Disable Dispensing From Display m Disable Modifying Temp Setpoint Disable Operator Mode Adjustments Low Heater Temp Disables Dispense m High Lhiller Temp Disables Dispense Enable Operator Mode Cavitation Alarm Complete Dispense With Setpoint Error Enable Downloading of USB Logs Date of Last Download This screen allows the user to control the availability of a few key system features e Disable Dispensing Check this box to disable dis pensing from the ADM A footswitch gun trigger or other external signal will be the only means with which to trigger a dispense 3A2175A Appendix B ADM Setup Screens Overview e Disable Modifying Temp Setpoint Check this box to disable modifying temperature setpoints from the Status run screen Disable Operator Mode Adjustments When this box is checked
24. dead headed system piston strokes so the leak will be substantial Out of material Fill tanks L111 Red LOW Deviation Tanks low on material Fill tanks with material Material Level L 122 If the tanks appear to have plenty of material check to Loose broken connection make sure the level sensor is connected to the proper port and that the cord is not damaged Bad level sensor Replace level sensor Red High L311 Ed 9 If the tanks appear to have plenty of material check to Material Levell i t l High material level in tanks Defective fill valve make sure the level sensor is connected to the proper Blue High i L322 i port and that the cord is not damaged Material Level Red Auto 2222 No material is actually LGA1 2 Make sure the feed pumps are operating properl Refill Timeout The tank stand has been filing being fed 9 property L6B2 Blue Low Low material level in tanks Deviation Material Level i sensor i i Blue Auto 2 X 7 7 Check for loose or disconnected wires or plugs ee expected connection Refill Timeout Bad level sensor Replace level sensor 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 properly connected to the MCM and that the wire has not been damaged Bad level sensor Replace sensor Inspect hydraulic driver end seals and early leak Leak in hydraulic driver detection tubing Replace se
25. edit the temperature setpoint and alarms for a partic ular component 1 Press the Enter Screen button and navigate to the component you wish to edit 2 Press the enter key to display the setpoint and alarm values associated with that component Supply Advanced mi No Active Errors O 1010 13 Standby Material MEH High p Low Alarm 111 F 3 Editthe setpoint and alarm values and then press the page back button to return to the previous screen 66 Conditioning Screen 3 This screen allovvs the user to configure Night Mode operation In Night Mode the system will cycle on and Off periodically Press the Enter Screen button and adiust the on and off durations as desired When the system is in Night Mode and in an On cycle the system will circulate in low pressure The installed conditioning zones will be on and controlling to their respective setpoints When the system is in Night Mode and in an Off cycle the system will be idle The system will not be circulating and the conditioning zones will not be actively controlling temperature When in Night Mode supply tanks will not fill NOTE Gray fields on this screen are items unavailable at this time Future product releases will incorporate these features 0112 10 10 17 Supply Advanced Operator mn Ha Active Errors Night Mode Conditionin On Duration minutes Off Duration minutes 3A2175A Advanced Screen 1 This screen
26. material amounts for the setpoint provided during the process If a weight dispense operation uses a setpoint significantly different from the setpoint used in during calibration an advisory will be provided to inform the user that the dis pense accuracy may be degraded Set system control and dispense modes See System Screen 1 on page 61 4 Set pump sizes See System Screen 1 on page 61 3A2175A Operation 5 Define Shot Recipes a Navigate to the Shots screen b Press to enter the screen c Use the directional keypad to navigate to the shot detail column for the desired shot number d Type the desired setting for that item then press Repeat the previous two steps for all desired shot numbers D 6 Change pressure imbalance setting optional The pressure imbalance function detects conditions that can cause off ratio dispense such as loss of feed pres sure supply pump seal failure clogged fluid inlet filter or a fluid leak The pressure imbalance default is factory set at 500 psi 3 4 MPa 34 bar For tighter ratio error detection select a lower value For looser detection or to avoid nuisance alarms input a higher value a Navigate to System Screen 3 b Press a to enter the screen c Navigate to the pressure imbalance field d Type the desired pressure imbalance setting then press Enter Maintenance 0120 15 53 4 Sustem Hu Active Errors Red Label Blue Label
27. nent A Red and component B Blue parts i Prime material regulators with fluid Refer to Adjusting Material Inlet Pressure Using the Material Regulator on page 40 j Use feed pumps to load system k Hold MD2 valve nose piece without a mixer installed over two grounded waste containers Leave mixer off and trigger gun until both fluids flow freely from the nose piece without any air To prime the pump cycle the pump a few times or until air free fluid dispenses 35 Operation 2 Calibrate HFR The HFR calibration procedure is a two step process The first step Learn Mode must be performed when ever 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 follow the Learn Mode procedure The Learn Mode procedure will teach the system the mechanical limits of travel Learn Mode Procedure a Navigate to the Calibration screen b Place a waste container below the dispense valve The next steps will cause the machine to dispense material c Press the go right button E2 and then the dis pense button I The pump will travel to the right most extreme position d After the pump stops moving press the go left button and then press the dispe
28. the user will not be able to adjust the dispense setpoint in Operator Mode e Low Heater Temp Disables Dispense When this box is checked the system will reject dispense requests on system power up until all enabled heat zones have reached their setpoint High Chiller Temp Disables Dispense When this box is checked the system will disable dispensing on system power up until all enabled chiller zones have reached their setpoint e Operator Mode Cavitation Alarm Check this box to enable cavitation alarms in Operator Mode Clear this box to disable cavitation alarms in Operator Mode e Enable Downloading of USB Logs When this box is checked USB logs will be automatically down loaded when a USB drive is inserted into the ADM e Complete Dispense with Setpoint Error When this box is checked the shot will continue dispens ing even if the system never reaches the desired setpoint The screen displays the date of the last USB log down load When downloading logs only data recorded since the displayed date will be downloaded To reset the date and force a download of the USB logs in their entirety press the Erase Single button next to the Date of Last Download label The next time a USB drive is inserted into the ADM the complete USB logs will be down loaded See Appendix F USB Operation on page 85 for a complete explanation 67 Appendix C ADM Run Screens Overview Appendix C ADM Run Screens Overview Run screens a
29. to instigate an automatic refill operation at any time this button can also be used to abort a refill operation 3A2175A Auto Full Volume e The low level sensor will initiate an automatic refill when it does not see material e Automatic refill will continue until either the high level sensor sees material or until the refill time out expires e The low level alarm will clear when the condition clears e A button is provided to the user on the run screens to instigate an automatic refill operation at any time this button can also be used to abort a refill operation If a refill setting other than Disabled is selected the user must set at least two level sensor locations as installed by checking the check box on the screen If all three locations are set to installed the system will default to the Auto Top Off refill setting and operate as follows e The low level sensor will generate a low level alarm e The high level sensor will generate a high level devi ation and abort any automatic refill operation e When the middle sensor is not satisfied automatic refill will begin and will run until either the middle sensor is satisfied the high level sensor generates a deviation if the middle sensor fails or the refill time out expires The low level alarm and the high level deviation will clear when the condition clears A button is provided to the user on the Run screens to instigate an automatic refill operation at an
30. will automatically begin updating NOTE Before the update begins the ADM automatically shuts down the system aborting any in progress dis pensing When the software is updating the system 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 Once this box appears it is safe to remove the drive before cycling power 8 When the software is done updating remove the USB stick drive from the ADM USB port and install in a computer 9 Navigate to the UPLOAD folder and remove the DISPTEXT TXT file 3A2175A Appendix F USB Operation 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 port the software will try to update the ADM 89 Appendix F USB Operation Example SETTINGS TXT File Example DISPTEXT TXT File NOTICE A B D i English Custom The user should never attempt to modify the SET TINGS TXT file in any way Graco is not responsible for damages caused by an improperly modified gt setup file 3 A 10 15 20 25 pns 30 0002000 0 00000030 0 80002002 0 00000001 40 0 800020
31. 03 Ox00000000 50 0 80002004 0 00000001 0 80002005 0 00000000 an 0x80002006 0 00000000 100 0 80002007 0 00000001 0002008 0 00000000 120 000200 00002205 145 Ox2000200c Ox00000000 160 0 80002002 0 00000000 90 Ox8000200e Ox8000200f Ox80002010 0002011 0002015 0 50002019 0 5000201 000201 0 00000000 0 00000001 0 00000000 0 00042 1 0 00042 1 0 00000000 0 00000000 0 0000 60 Accessories Part No Description 24M154 IsoGuard Select Assembly with 32 oz reservoir Included on HFRL units 24F516 lsoGuard Select Fluid 6 Quarts 255244 Footswitch with Guard and 4 meter cable HFR Discrete Gateway Module DGM Kits Single DGM Kit 24F843 Dual DGM Kit 24F844 DGM only 246830 The HFR Discrete Gateway Module DGM allows the user to control an HFR through an external control device such as a PLC The DGM operates in conjunc tion with the existing Advanced Display Module ADM such that both devices can be used to control the machine See HFR Discrete Gateway Module manual 3A1149 for more information Secondary Supply Pump to Create a Tandem Unit HFRS Equipment Only Drum Ram Size gallon liter Type Displacement 24M0028 5 19 Carbon Steel 24M0026 55 208 60 cc 20 1 24M0029 5 19 Stainless Steel 24M0027 55 208 3A2175A Accessories 91
32. 2 weeks or more often if the machine is used during more than one full shift a day 3A2175A Download Log Files If the Enable Downloading of USB Logs is checked the user can use a USB stick drive 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 DISP TEXT TXT and the system settings SETTINGS TXT The status of the download will be shown in the Status bar 85 Appendix F USB Operation Log Files Folder Structure n DOWNLOAD m jp DATA0006 Back 4 y Search ie Folders BAN Back 7 3 4 Search Kes Folders x Address 9 E GRACO FFFFFFFF DOWNLOAD v EJ co Address E GRACO FFFFFFFF BOWNLOAD DATAOD v 4 Go Folders Name Folders X Name 01 564 1 01 5 2 Deskto E 7 iB R 2 G 7 EQLOG02 csv y Computer C3DATAO003 Y My Computer Local Disk C 4 45 Local Disk C d DVD CD RW Drive D 5 z DVD CD RW Drive D 3 w DIESEL E C DATADOD06 DIESEL E GRACO DISPTEXT TXT GRACO La FFFFFFFF i SETTINGS TXT CD FFFFFFFF 3 C3 DOWNLOAD 3 B DOWNLOAD G DATADOD1 23 DATAODO1 G DATADOO2 DATADO02 O DATAODO3 CJ DATAODO4 G DATADOD4 i
33. 211a O CO 00 5 AA HG ks 2 A ex SC NG 77 Jey Fluid Manifold FM Detail 19 Fic 4 Component Identification shown with shrouds removed 3A2175A Component Identification Main Power Switch Located on rear of machine VID OLA The main power switch turns power ON and OFF The main power switch does not turn pumps on 20 Circuit Breakers AM A The circuit breakers are located on the panel assembly mounted directly behind the disconnect switch panel on the right side of the enclosure For more information about items on the power distribution panel see manual 3A2176 ti18215a 230V 1 phase 400V 3 phase Component 3A2175A Hydraulic Power Pack DB DE Component Identification KI wz FIG 5 Key DA 8 Gallon Hydraulic Oil Reservoir see Accessories on page 91 for specifications DB Electric Motor DC Dipstick not shown located at rear left of hydraulic tank DD Hydraulic Housing 3A2175A 2 200 gt KA 24C 3R2 313998 208 DE Directional Valve DF Motor Control Module see page 22 DG Fan DH Filter DJ Shroud not shown removed for clarity 21 Component ldentification Motor Control Module MCM NOTICE For MCM location see reference MA in FIG 4 on page 19 VVhen installed
34. 230 1 5 33 1 Stain less Steel No Feed HFRS69 HFR for Silicone 230 1 6 1 Carbon Steel No Feed HFRS70 x HFR for Silicone 400 3 6 1 Carbon Steel No Feed HFRS71 HFR for Silicone 230 1 6 1 Stainless Steel No Feed HFHS72 x HFH for Silicone 400 3 6 1 Stainless Steel No Feed HFRS73 HFR for Silicone 230 1 10 1 Carbon Steel No Feed HFRS58 x HFR for Silicone 400 1 1 1 Carbon Steel No Feed HFRS59 HFR for Silicone 230 1 1 1 Stainless Steel No Feed HFRS60 x HFR for Silicone 400 8 1 1 Stainless Steel No Feed HFRS61 HFR for Silicone 230 1 4 1 Carbon Steel No Feed HFRS62 x HFR for Silicone 400 3 4 1 Carbon Steel No Feed HFRS63 HFH for Silicone 230 1 4 1 Stainless Steel No Feed HFRS64 HFR for Silicone 400 3 4 1 Stainless Steel No Feed HFRS81 HFR for Silicone 230 1 5 1 Carbon Steel No Feed HFRS82 x HFH for Silicone 400 3 5 1 Carbon Steel No Feed HFRS83 HFH for Silicone 230 1 5 1 Stainless Steel No Feed HFRS84 x HFH for Silicone 400 3 5 1 Stainless Steel No Feed HFRS85 HFR for Silicone 230 1 6 1 Carbon Steel No Feed HFRS86 x HFR for Silicone 400 83 6 1 Carbon Steel No Feed HFRS65 HFR for Silicone 230 1 5 33 1 Carbon HFRS87 HFR for Silicone 230 1 6 1 Stainless Steel No Feed Steel No Feed HFRS66 x HFH for Silicone 400 3 5 33 1 Carbon HFRS88 x HFR for Silicone 400 3 6 1 Stainless Steel No Feed Steel No Feed g 3A2175A HFRS7
35. 38 bar working pressure by Graco If the machine was pur chased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed see instruction man ual 3A1276 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 6 3A2175A Models HFRS Models Part Num ber Description HFRS01 HFH for Silicone 230 1 1 1 Carbon Steel 55 55 Feed HFRS02 HFR for Silicone 230 1 1 1 Carbon Steel 5 5 Feed Part Num ber Description HFRS23 HFR for Silicone 230 1 5 33 1 Carbon Steel 5 5 Feed HFRS24 x HFH for Silicone 400 3 5 33 1 Carbon Steel 55 55 Feed HFRS25 x 1 HFH for Silicone 400 3 5 33 1 Carbon Steel 55 5 Feed HFRS26 x HFH for Silicone 400 3 5 33 1 Carbon Steel 5 5 Feed HFRSO3 Xx HFR for Silicone 400 3 1 1 Carbon Steel 55 55 Feed HFRS04 HFR for Silicone 400 3 1 1 Carbon Steel 5 5 Feed HFRS05 HFR for Silicone 230 1 1 1 Stainless Steel 55 55 Feed HFRS06 HFR for Silicone 230 1 1 1 Stainless Steel 5 5 Feed l HFRS27 HFR for Silicone 230 1 5 33 1 Stain less Steel 55 55 Feed HFRS07 x HFR for Silicone 400 3 1 1 Stainless Steel 55 55 Feed HFRS28 HFR for Silicone 230 1 5 33 1 Stain less Steel 55 5 Feed HFRS29 HFR for Silicone 230
36. 4 x HFH for Silicone 400 3 10 1 Carbon Steel No Feed HFRS75 HFR for Silicone 230 1 10 1 Stainless Steel No Feed H HFRS57 HFR for Silicone 230 1 1 1 Carbon Steel No Feed FRS76 HFR for Silicone 400 3 10 1 Stainless Steel No Feed HFRS77 HFR for Silicone 230 1 4 1 Carbon Steel No Feed HFRS78 x HFH for Silicone 400 3 4 1 Carbon Steel No Feed HFRS79 HFR for Silicone 230 1 4 1 Stainless Steel No Feed HFRS80 x HFR for Silicone 400 3 4 1 Stainless Steel No Feed HFRS68 x HFR for Silicone 400 3 5 33 1 Stain less Steel No Feed Models Part Num ber Description HFRS89 HFR for Silicone 230 1 10 1 Carbon Steel No Feed HFRS90 x HFR for Silicone 400 3 10 1 Carbon Steel No Feed HFRS91 HFR for Silicone 230 1 10 1 Stainless Steel No Feed HFRS92 x HFR for Silicone 400 3 10 1 Stainless Steel No Feed C approved 3A2175A Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 2 10 ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause elec tric shock Turn off and di
37. After first 250 hours of opera tion or within 3 months which ever comes first Inspect hydraulic and fluid lines Daily for leaks If equipped inspect fluid inlet Daily strainer screens page 46 If equipped inspect IsoGuard Daily Select fluid level and condition Check hydraulic fluid level Weekly 7 or replace as needed page Grease circulation valves vvith VVeekly Change break in oil in a nevv unit Fusion grease 117773 Verify operation of air drying sys VVeekly tem to prevent isocyanate crystal lization Inspect air filter part 24H018 clean or replace as necessary Monthly Use compressed air to remove dust buildup on control boards fan motor under shield and hydraulic oil coolers Clean up all hydraulic leaks iden As needed tify and repair cause of leak Clean dispense valve mix cham See dispense ber ports regularly see dispense valve manual valve manual Clean dispense valve check valve screens see dispense valve manual See dispense valve manual 3A2175A Maintenance Change Break in Oil After initial break in see Table 5 for recommended fre quency of oil changes Table 2 Frequency of Oil Changes Ambient Recommended Temperature Frequency O to 90 F 1000 hours or 12 months 17 to 32 C whichever comes first 90 F and above 500 hours or 6 months 32 C and above whichever comes first Grease Circulation Valves With Fusion Grease 117773 ti9879
38. E The material pressure regulator is not self relieving Reducing the material pressure at the regulator will not effect the pressure reading until the accumu lated down stream pressure is relieved Perform Pressure Relief Procedure on page 38 3A2175A Pressure Balancing Using the Orifice Valve Assemblies Nia bar PS1 AD The MD2 valve for HFRL and HFRS systems is provided with orifice valve blocks on both of the inlet ports The orifice blocks are assembled at the factory with no ori fices installed An orifice kit is provided with a range of orifice sizes to balance pressures The orifice size is etched on the side of the orifice body and there are two orifices provided in each size One of the orifices in each size will be stamped on the hex end with an A Use the orifices stamped with the A in the RED side orifice block The orifices with no letter etched on the hex end are to be used on the BLUE side L HAN B ORIFICE 4 JA m AN R A KA Pa S A ORIFICE SIZE LOCATION ADJUSTMENT Orifices can be installed in one or both orifice blocks as a tool to increase the outlet pressure in the correspond ing material hose The orifice valves are equipped with a needle valve that can be adjusted with the provided allen wrench 3A2175A Operation 1 Before installing insert the allen wrench into the hex end of the orifice valve to adjust the needle position 2 Verify the needle val
39. Full Load Peak Voltage Pressure t Amps Per Phase phase System Watts psi MPa bar 55 A k 400V 3 20 7 207 APump B Pump Required cpm e Max Flow 7 Max Dispense Pressure Size Size cc stroke Flow cc sec psi MPa bar Ratio 15 80 95 11 3 12 5 18 20 5 33 5 50 55 20 18 3 10 00 2 11 7 6 00 2 2d 2500 17 172 5 20 25 20 8 3 4 00 10 10 20 20 6 7 1 00 5 10 15 20 5 2 00 Full load amps with all devices operating at maximum capabilities Fuse requirements at various flow rates and mix chamber sizes may be less Cycle rate should be between 8 and 20 cycles per minute Max flow rate is determined for continuous service at 120 F 39 C at stated cpm and pressure Higher cycle rates are possible at lower temperatures pressures and intermittent use Lower cycle rates are possible but should be tested under application conditions 1 Dispense rate in excess of max flow and pressure may result in a machine shutdown due to elevated temperature of the hydraulic system resulting in a thermal shutdown T4H 1 C approved The maximum fluid working pressure for the base machine without hoses is 3000 psi 20 7 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 13 8 MPa 1
40. Overview Home Screen Disabled Mode When this mode is selected the machine will not be able to dispense or condition heat cool material The setup screens cannot be accessed while in Disabled mode Use the Select mode button to exit Disabled mode 3A2175A 71 Appendix C ADM Run Screens Overview Status Screen The status screen provides all of the operational func tionality 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 condi tioning information and control 24544 24402 49036 cc 72 Status Screen Conditioning Control This screen allows users to turn on and off heat zones individually or all at once The grey circles indicate that a zone is off and green circles indicate that a zone is on When a zone is on it is actively controlling temperature To turn a single zone on off 1 Press to enter the Conditioning Control screen 2 Usethe arrows keys to navigate to the desired zone 3 Press FI to turn the selected zone on When a zone is on the button will be selected Press the button again to turn the zone off To turn all zones on off 1 Press to enter the Conditioning Control screen are on the button will be selected Press the button again to turn all zones off All
41. Powered Off 1614 EQUT E Settings Downloaded 1614 EQLIS E Language Downloaded 1614 EQU5 E Logs Downloaded 1615 00 Disp Occurred Shot 1613 EAOQO R Disp Occurred Shot 1613 EAOO F Disp Occurred Shot 1613 EAOQO R Disp Occurred Shot 1613 EAOO F Oise Occurred Shot 1613 EAGO R Disp Occurred Shot 3A2175A Appendix C ADM Run Screens Overview Maintenance Screen 1 This screen displays historical information for each pump in the system The Batch counters are resettable and count both material usage and pump cycles The Total counters are not resettable by the user They also count both material usage and pump cycles For mate rial usage counters units are displayed next to the vol ume weight indicator icons To erase a batch counter press the Enter Screen button and navigate to the field to be erased Press the Erase Single button to erase that data point Alternatively the Erase All button may be pressed to erase all of the batch data points simultaneously AA GA Maintenance BEEN sequence C Mo Active Errors l l c IN 519589 Ci 23737 23737 m Ba 241550175 270756665 21 25959 26959 NOTE In a circulation system the pumpline must be stopped to erase counters 73 Appendix D ADM Error Codes Appendix D ADM Error Codes MBH3 Head Oil Low P1H3 Accumulator Pressure Refer to AC Power Pack manual High P4H3 Accumulator Pressure M1 Material Rod Shift
42. Red Hose Overvoltage Blue Hose Overvoltage Blue Chiller Red Inline Temp Cutoff Incoming line voltage is Measure voltage across disconnect switch Voltage should measure between 190 and 264 Vac High line voltage Red Chiller Overvoltage Blue Chiller Overvoltage 3A2175A 81 Appendix D ADM Error Codes Error Error Code Error Description Type Cause The voltage to the MCM has V4HO Motor Control reached an unsafe level and WOUO Overvoltage has been shutdown in an VVBH1 Supply lines providing Check incoming voltage to ensure it is below the high voltage maximum operating voltage System Settings file is Replace the system settings file with a backup or new corrupt file Alarm attempt to prevent damage USB Update The ADM tried to upload a system settings file but failed System Settings file is Ensure that the first line in the settings txt file contains intended for another the text GMS If not replace the file with the proper system system update file Failing sensors If error persists the motor will need to be replaced An error has been detected on p p Encoder Faultithe motor position sensor Ensure the d sub connector to the motor is connected Loose connection aa and the wiring is intact Make sure the directional valve has povver valve Alarm Make sure the cord to the directional valve is connected to the correct port and the cord is not damaged Dir
43. Setup Operation G g GRACO HFRL and HFRS 3A2175A Hydraulic Plural Component Fixed Ratio Proportioner For pouring and dispensing laminates and silicones For professional use only Not approved for use in explosive atmospheres or hazardous locations Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 4 for model information and maximum working pressure EC LAP CERT EN eal Bl eae m y 17 gt NI i Brat DN m Patent Pending ti18208a Silicone unit shovvn PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Models 2 1 3 x c t deos aban e MARE n e 4 HFR Laminate HFRL 4 HFR Silicone HERS 6 vuarn nds uerum xe tet pr rad EE 10 Important Two Component Material Information 14 Isocyanate Conditions 14 Material Self ignition 14 Keep Components A Red and B Blue Separate 14 Moisture Sensitivity of Isocyanates 14 Changing Materials 15 A Red and B Blue Components 15 Typical HFRS System 16 Typical HFRL System 17 Component Identification 18 Hydraulic Power Pack 21 Motor Control Module MCM 22 Advanced D
44. TXT file from the UPLOAD folder to pre vent 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 try to update the ADM 3A2175A Update Custom Language Use the follovving process to customize the text on the ADM The language file DISPTEXT TXT can be modi fied 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 USB port on the system vvith the settings to be trans ferred Once the dovvnload is complete the DISP TEXT 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 to your computer 5 Use any data processing software such as Excel to edit the DISPTEXT TXT file When done editing save the file as the Unicode Text format See Example DISPTEXT TXT File on page 90 a In the first column locate the string to change b Inthe second column of the same row enter the new string c Savethe 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 install it into the ADM USB port The software
45. a1 Check Hydraulic Fluid Level Check hydraulic fluid level on dipstick Fluid level must be between indent marks IM on dipstick Refill as required with approved hydraulic fluid see Accessories on page 91 If fluid is dark in color change fluid and fil ENA S SG a 4 ET by y y 2 ACA TS N ti18218a 43 Maintenance Advanced Display Module ADM AA Replace Battery A lithium battery maintains the ADM clock when power is not connected To replace the battery 1 Disconnect power to the ADM NOTE This can be done by removing the CAN cable from the bottom of the ADM 2 Remove rear access panel 3 Remove the old battery and replace with a new CR2032 battery 4 Properly dispose the old lithium battery according to local codes 5 Replace rear access panel 6 Connect the power to the ADM and reset the clock through Advanced Screen 1 Refer to Appendix B ADM Setup Screens Overview for more detail 44 Install Upgrade Token To install software upgrades 1 Use software token 16H821 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 soft ware versions may not be compatible All data in the module System Settings USB Logs Recipes M
46. age weight for the calibration point 3A2175A 57 Appendix B ADM Setup Screens Overview Appendix B ADM Setup Screens Overview The ADM will start in the Run screens at the Home screen From the Run screens press E to access the Setup screens If the Setup screens password is turned on use the ADM keypad to enter the password then 4 press TERE mc mn Active Errors Standby Password il z2 Calibration 77 System 1 FIG 22 Setup Screens Navigation Diagram 58 From the Setup screens press a to access the Run screens For Run screens information see Appendix C ADM Run Screens Overview on page 68 FIG 22 shows the flow of the Setup screens N z2 Maintenance z Supply 2 Conditioning 1 N Conditioning 2 N 3A2175A Shots Screen This screen allovvs the user to edit shot definitions The contents of this screen change based on the Dispense and Control Mode selections Shots may be defined by pressure or flovv rate depending upon the Control Mode selection and by time duration volume or weight depending upon the Dispense Mode selection See Sys tem Screen 1 for Control and Dispense Mode options See Home Screen Shot Mode on page 69 for informa tion on how to use predefined shots NOTE 100 shot definition are available across ten pages To edit a shot definition 1 Press the Enter screen button then use the arrow keys to navigate to the desi
47. aintenance 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 The latest software version for each system can be found at www graco com 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 3A2175A Motor Control Module MCM aA 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 Fic 14 Clean Heat Sink Fins 3A2175A Maintenance Install Upgrade Token NOTE The MCM connection to the system is temporar ily disabled during the installation of upgrade tokens 1 Use software token 16H821 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 soft ware 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 The latest software version for each system can be found at www g
48. als as necessary and replace lost oil The volume of oil in the tank is below the minimum level needed for the system to properly operate MBH1 Low Oil Level Alarm Leak in the hydraulic Inspect the hydraulic reservoir fittings and filter for reservoir heat leaks Repair or replace as necessary and replace exchanger lost oil The motor magnetism has If error persists and performance can no longer Low Motor Prolonged exposure to l MBN1 decreased to the point where satisfy the user requirements the motor vvill need to Performance i heat or high voltage performance is greatly reduced be replaced 3A2175A 77 Appendix D ADM Error Codes Error Error Code Error Description Type Cause Motor failure 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 Hydraulic power pack failure Check to ensure the linear position sensor is properly connected to the MCM and the wiring has not be damaged Failure of the linear The MCM attempted to move eee ei Replace the linear position sensor position sensor the pump but movement Deviation Motor no longer coupled Reset coupler per specifications and retighten set vvas detected to hydraulic pump screws Supply tube from hydraulic pump to Loose bad connection to the linear position sensor Retighten or replace supp
49. amination of the A side screen NOTE Clean the A side screen only during daily startup This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations 1 Perform Pressure Relief Procedure on page 38 2 Close the fluid inlet valve at the pump inlet and shut Off the appropriate feed pump This prevents mate rial from being pumped while cleaning the screen 3 Place a container under the strainer manifold 59d to catch fluid Remove the strainer plug 59j 4 Remove the screen 599 from the strainer manifold Thoroughly flush the screen with compatible solvent and shake it dry Inspect the screen If more than 2596 of the mesh is blocked replace the screen Inspect the gasket 59h and replace as required 5 Ensure the pipe plug 59k is screwed into the strainer plug 59j Install the strainer plug with the screen 599 and gasket 59h in place and tighten Do not overtighten Let the gasket make the seal 3A2175A 6 Open the fluid inlet valve ensure that there are no leaks and vvipe the equipment clean Proceed with operation ti9886a1 FIG 17 Fluid Inlet Strainer 3A2175A Maintenance TM IsoGuard Select System Not included on HFRS systems a 4 Na LF i AR ez Li illi 6 NOTE The IsoGuard Select system is included on all HFRL systems t is available separately for HFRS systems as kit 24M154 C
50. anifold Inlet on left side of manifold block Component B Blue Fluid Manifold Inlet HFR Fluid Manifold Feed Inlet Pressure Gauge Feed Inlet Strainer standard filter size is 20 mesh Feed Inlet Valve A Red side shown Component A Red Outlet Pressure Gauge Component B Blue Outlet Pressure Gauge Component A Red Hose Connection from feed to gun or mix head Component B Blue Hose Connection from feed to gun or mix head Hydraulic Power Pack Assembly Hydraulic Tank BS BT BU BV BW BX BY BZ CA CB CC CD CE IsoGuard Select Fluid Reservoir included on all HFRL available separately as kit 24M154 for HFRS Pumpline Linear Sensor Motor Control Module see page 22 Main Power Switch Component A Red Pump Component B Blue Pump Power Distribution Box Component A Red PRESSURE RELIEF DISPENSE Valve Component B Blue PRESSURE RELIEF DISPENSE Valve Component A Red Pressure Transducer Component B Blue Pressure Transducer Material Pressure Regulator Component A Red Power Distribution Box 3A2175A Component Identification HFRS Material Inlet HFRL Material Inlet ti18212a 24C352 313998 4e A 73 KA B NED 2 i NAR NA CN PING EN AG Q Rear View NI An CUN VD KN Ta e O 7 N G YA ve z 3000 psi Max 4 yy SONO M 7 SN N TY BI py b LA A J O LY IN CU sg BJ ti18
51. ble totalizer for the Blue The resettable totalizer for the Red RERB2 Blue Material The resettable totalizer for the Blue Weight Reset RERA3 Red Cycle Count Reset RERB3 Blue Cycle Count Reset REQU1 Settings Downloaded material weight was reset to zero The resettable cycle counter for the Hed pump was reset to zero The resettable cycle counter for the Blue pump was reset to zero The system settings were successfully transferred from the ADM to a USB drive The system settings file was success fully transferred from the USB drive to the ADM HEQU2 Settings Uploaded 84 Event Code and String Triggers The custom language file was suc cessfully transferred from the ADM to a USB drive The custom language file was suc cessfully 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 While in night mode the system has automatically entered a low recircula tion mode and attempted to turn on all enabled conditioning zones While in night mode the system has automatically stopped the low recircu lation mode and turned off all condi tioning zones 3A2175A Appendix F USB Operation Appendix F USB Operation Overvievv There are 3 main uses for the USB on a GMS system e Ability to download a log of the past 50 000 errors and events and a shot log that can contain over 250 000 snapshots of critical dispense i
52. c reservoir is filled at the factory Check fluid level before operating the first time and weekly thereaf ter See Accessories on page 91 for specifications 13 IsoGuard Select Fluid system setup Not included on HFRS models Component A Red Pump Fill IsoGuard Select reser voir ER with IsoGuard Select fluid provided by Graco 3A2175A Setup a Liftthe reservoir LR out of the bracket RB and remove the container from the cap HG C 24C352 313998 8e b Fill with fresh fluid Thread the reservoir onto the cap assembly and place it in the bracket RB c Push the supply tube approximately 1 3 of the way into the reservoir The supply tube is the tube with the check valve with an arrow pointing in the direction of flow towards the IsoGuard Select fluid cylinder d Push the return tube into the reservoir until it reaches the bottom The return tube is the tube with the check valve with an arrow pointing in the direction of flow away from the IsoGuard Select fluid cylinder NOTE The return tube must reach the bottom of the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube and returned to the pump 14 Prime IsoGuard Select fluid cylinder The IsoGuard Select fluid cylinder must be primed when replacing IsoGuard Select fluid See IsoGuard Select System on page 47 for instructions 33 Setup 15 Install dispense valve
53. cal HFRS System Typical HFRS System TS m EK iL il DY T f il del HA HU x gt e CD SW af ti18208a E FIG 1 HFR Silicone System Key A HFR Unit Silicone H Dispense Gun B Power Module J Orifice Block Blue Pump K Orifice 1 4 A Red Pump L Supply Unit B Side E Outlet Module M Supply Unit A Side F B Hose Kit N Supply Hose G A Hose Kit P Inlet Regulator 16 3A2175A Typical HFRL System Typical HFRL System AA AE A Y SVM ZA CLG oc 4 Ta Q Q b AJ AK SS mp MEX 7 IDD AH ti18209a FIG 2 HFR Laminate System E ar o mo OST Eu 6 a 0 5940 J 0 0 GH 2 IN JS o o o O Eooo SSEES J0 oOnRn y qv Sys 9 D lt O p o2 0422 Bc I Irmom UIMODULO 4 17 2175 Component ldentification Component Identification BP BF BX CE BV Located on opposite side of machine FIG 3 Component Identification shown with shrouds removed Key for Fic 4 BA BB BC BD BE BF BG BH BJ BK BL BM BN BP BR 18 Advanced Display Module see page 24 Component A Red Pressure Relief Outlet Component B Blue Pressure Relief Outlet Component A Red Fluid M
54. ch other 250 psi max inlet pressure pressure gauge 1 37 3000 psi max inlet pressure 3A2175A Setup b Ensure A Red and B Blue inlet valves FV are closed C ti9883a1 Adjust the fluid pressure regulator so the pres sure gauge reads zero NOTE Supply hoses from feed pumps should be 3 4 in 19 mm ID minimum d e Connect and tighten component B Blue supply hose to the 3 4 npt f swivel on the component B Blue inlet assembly Connect and tighten component A Red supply hose to the 3 4 NPT f swivel on the component A Red inlet assembly 31 Setup 6 Connect pressure relief lines R 7 Connect hose MS a Turn main power OFF Do not install shutoffs downstream of the PRESSURE RELIEF DISPENSE valve outlets BA BB The b Assemble fluid supply hose sections and whip valves function as overpressure relief valves when set hose mu to DISPENSE Lines must be open so valves can automatically relieve pressure when machine is c Connect A Red and B Blue hoses to A Red and B Blue outlets on HFR fluid manifold FM operating If circulating fluid back to the supply drums use high Hoses are color coded red for component A pressure hose rated to withstand the maximum work blue for component B Fittings are sized to pre ing pressure of this equipment vent connection errors a Recommended Connect high pressure hose
55. cord to make sure fan has power Debris is fan or fan grill Clear debris from fan fan grill Try to stop fan by lightly pressing on the center with a Low air volume from fan pencil eraser If the fan slows down easily it will need Motor Control reached a level where product High Temp Motor temperature is too high Motor Temp land system has been Shutdown shutdown to prevent possible mal to be replaced damage j j 9 Ambient environmental Move machine to an area below 120 F conditions are too hot Motor may be damaged Motor may need to be replaced Red Tank RTD Fault Blue Tank RTD Fault Red nline RTD Fault Blue nline RTD Fault RTD 1 is giving no or invalid Red Hose data FTS Fault Blue Hose FTS Fault Red Chiller RTD Fault BE Red Blanket RTD Fault Blue Blanket RTD Fault RTD 2 is giving no or invalid Red Chiller data RTD Fault pe No Heat Red Tank No Heat Blue Tank No Heat Red Inline Loose or bad connection Check RTD wiring Loose or bad connection Check RTD wiring Tripped circuit breaker Visually check circuit breaker for a tripped condition No temperature rise Measure voltage across input terminals on power line No Heat Blue Low Power filter Voltage should measure between 190 and 264 Inline Vac 77 2 Check for loose or disconnected wires or plugs Hose povver 7 a Bad heater s Measure resistance of heater s 80 3A2175A Appendix D ADM
56. d and B Blue Separate CI MN Cross contamination can result in cured material in fluid lines which could cause serious injury or dam age equipment To prevent cross contamination of the equipment s wetted parts never interchange component A Red and component B Blue parts 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 crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Keep the ISO lube pump reservoir if installed filled with IsoGuard Select part 24F516 The lubricant creates a barrier between the ISO and the atmo sphere e 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 e Never use solvent on one side if it
57. d divide the weights to verify the mix ratio by weight See Ratio Checking section in the dispense valve manual for more information Equipment is ready to dispense 3A2175A Operation Startup MING E1 Do not operate HFH vvithout all covers and shrouds in place 1 Use feed pumps to load fluid NOTE The HFR is tested vvith oil at the factory Flush out the oil vvith a compatible solvent before dispensing See Flushing on page 39 a Check that all machine connections are setup See Setup procedure page 29 b Verify both feed supply systems and the HFR are connected to an air supply c Verify the machine is ON d f applicable check that inlet screens are clean before daily startup see page 46 NOTE There are no inlet screens on systems equipped with fluid pressure regulators e f equipped check level and condition of ISO lube daily see IsoGuard Select System on page 47 f Turn both PRESSURE RELIEF DISPENSE m valves SA SB to DISPENSE SA SB ti9877a1 g Start feed pumps 3A2175A Operation h Open fluid inlet valves FV if equipped Check for leaks ti10002a1 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 compo
58. d flow q Pump cannot reach the Increase restriction in the system requested pressure Deviation Pump cannot reach the Decrease restriction in the system requested flow System underwent a change that caused a D2A1 D3A1 D5A1 D6A1 DDA1 DDB2 76 Exceeded Invalid Learn Mode Data Blue Pump Cavitation The set point vvas not reached Erase learned System Data found in the setup large drop in restriction screens under calibration such as new orifices Make sure the material lines are open and have No material in pumps proper feed pressure Recalibrate the machine Rerun the learn mode calibration AA NA Check to ensure the pressure transducer is properly installed and all wires are properly connected Bad linear position sensor Loose bad connection to Check to ensure the linear position sensor is properly linear position sensor installed and all wires are properly connected Alarm 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 Deviation of normal parameters the machine will operate with a greatly reduced stroke Verify pump moves to limits if problem persists replace linear position sensor The linear position sensor is returning data that should not be possible during normal operation Bad linear position Replace linear position sensor sensor Linear positi
59. d 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
60. e Shots Screen on page 59 for information about editing shot definitions To use a predefined shot 1 Enter shot mode 2 Press m and use the numeric keypad to enter the desired shot number 3 Press the Enter button to select the shot num ber 4 Press the dispense button to begin dispensing Target Flov Pressure Target dispense amount time vol Ratio ume weight depending on Dis pense Mode 69 Appendix C ADM Run Screens Overview Home Screen Sequence Mode This mode allows the user to select one of five sequences A E The progress bar on the bottom of the screen shows the progress of a shot dispensing from the selected sequence See Sequences Screen on page 59 for information about editing sequence defini tions To use a predefined sequence 1 Ensure that the machine is in Sequence Mode 2 Press the sequence letter position selection button 3 Use the left and right arrows to toggle between letter and position selection When selecting a sequence letter A E use the up and down arrow keys to scroll through the available letters When selecting a sequence position type in the desired position with the numeric keypad The system will reject invalid letter position selections 4 Press the enter key to accept the sequence let ter position 5 Press the Dispense button to begin dispensing Flow Pressure i i arget dispense amount time vol ume weight depending on Dis Ratio pe
61. e without notice Original instructions This manual contains English MM 3A2175 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2011 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com
62. ect mode zi Press a second time to turn off insti AII other screens gated system action Begin Dispense Lock Dispense Valve Closed Press to lock the valved closed during Press to enter the Conditioning Control a dispense Used to circulate through screen the material manifold back to the tank the Pressure Relief Dispense Valves will need to be in the relief position Red and B Blue refill button Press to start abort refill Jump in to select sequence letter and position Skip the next shot in selected sequence Only available when the sys tem is not dispensing Set system in park icon vvill be selected when system is parked 56 3A2175A Appendix A ADM lcons Overview Icon Function Tank Blanket Heater H Primary Heater D Heated Hose Current and setpoint temperature for primary heater Not displayed if heat zone is not enabled Current and setpoint temperatures for ial MG heated hose Not displayed if heat zone is not enabled ep Current and setpoint temperatures for b l ALs tank blanket Not displayed if heat zone is not enabled Current and setpoint temperatures for chiller Not displayed if heat zone is not enabled A Shot Number m 41 Sequence Position e Pressure Ar Flow 21 Cycles m 5 Time Duration d li Volume Amount of material moved through pump volume tracking VVeight Aver
63. ectional valve failure The directional valve will need to be replaced The hydraulic power pack will need repair Defective encoder Replace encoder Motor no longer coupled GC a coupler per specifications and retighten set to hydraulic pump screws Retighten or replace supply tube Bad directional valve connection The motor has reached a speed that should not be High Motor Speed reached in normal operation and was shutdovn to prevent possible damage manifold is loose or broken Broken motor shaft Replace motor Red Tank Con Fault Blue Tank Con Fault Red nline Con Fault Blue nline Con Fault Red Hose Con Fault Blue Hose Con Fault Red Chiller Con Fault High current to relay 1 Broken contactor Replace contactor Blue Chiller Con Fault Red Blanket High Temp Defective RTD Replace RTD Defective High Povver Temperature Control Replace High Povver Temperature Control Module Tank blanket is above the Blue Blanket defined high alarm limit High Temp Alarm Module Loose connections Tighten connections 82 3A2175A Appendix D ADM Error Codes Error Error Code Error Description Type Cause Red Tank Con Fault Blue Tank Con Fault Red nline Con Fault Blue nline Con Fault If temperature is being affected by a zone that has EM Unexpected current to relay 1 Shorted module ee 7 7 5 Con Fault Blue Hose Con Fault Red Chiller
64. essure for the machine is already setup for the lower 2000 psi 13 8 MPa 138 bar working pressure by Graco If the machine was pur chased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed see instruction man ual 3A1276 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 4 3A2175A Models Part Num ber Description HFRL23 Xx HFH for Lamination 400 3 1 60 1 80 50 Carbon Steel HFRL24 Xx HFH for Lamination 400 3 1 63 1 65 40 Carbon Steel HFRL25 Xx HFH for Lamination 400 8 1 67 1 50 30 Carbon Steel HFRL Models Part Num ber Description HFRLO1 HFR for Lamination 230 1 1 00 1 80 80 Carbon Steel HFRLO2 HFR for Lamination 230 1 1 08 1 86 80 Carbon Steel HFRLOS HFR for Lamination 230 1 1 16 1 100 86 Carbon Steel 104 HFR Lamination 230 1 1 20 1 60 50 Carbon Steel HFRLO5 HFR for Lamination 230 1 1 23 1 80 65 Carbon Steel HFRLO6 HFR for Lamination 230 1 1 33 1 80 60 Carbon Steel HFRLO7 HFR for Lamination 230 1 1 50 1 60 40 Carbon Steel HFRLO8 HFR for Lamination 230 1 1 60 1 80 50 Carbon Steel HFRLO9 HFR for Lamination 230 1 1 63 1 k C approved 65 40 Carbon Steel HFRL10 HFR for Lamination 230 1
65. g ADM system is disabled temperature Cancel a selection or number entry control and dispense operation are while in the process of entering a disabled number or making a selection System TDisplays system status See Sys IT Acknowledge changing a value or i nl a selection safety or emergency stop betvveen run and passvvord entry screen Naviga Navigate within a screen or to a tion nevv screen i ms Toggle between run and setup screens If setup screens are pass Stop all system processes Is not a word protected button toggles 24 3A2175A ES ER FIG 8 ADM Component Identification Rear Key EJ Flat Panel Mount EK Model Number EL USB Module Interface EM CAN Cable Connections System Status Indicator CB Conditions Green Solid Run Mode System On Green Flashing Setup Mode System On Yellow Solid Run Mode System Off Yellow Flashing Setup Mode System Off 3A2175A Component Identification EL ti12363a1 EN Module Status LEDs EP Accessory Cable Connections ER Token Access Cover ES Battery Access Cover 25 Component ldentification Main Display Components The following figure calls out the navigational status and general informational components of each screen For details regarding the user interface display see Advanced Display Module ADM Operation page 55 Current date and time Previous screen Current screen Next screen Mode sesi Sequences RZ r F
66. has been contam inated from the other side e Always lubricate threaded parts with ISO pump oil or grease when reassembling 3A2175A Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A Red side but some use ISO on the B Blue side See the follow ing 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 e Component A Red is on the left side e Component B Blue is on the right side For all machines e The A Red side is intended for ISO hardeners and catalysts f one of the materials being used is moisture sensi tive that material should alvvays be in the A Red side e The B Blue side is intended for polyols resins and bases For HFRS Systems The high volume material is typically the ISO and is located on the A Red side Some material chemistries may have an ISO which is the low volume material The ISO must always be in the A Red side containing the Isolube For HFRL Systems The high volume material will always be the B Blue side Typical Installation 3A2175A A Hed and B Blue Components 15 Typi
67. heck the condition of the A Red pump IsoGuard Select fluid daily Change the fluid if it becomes a gel its color darkens or it becomes diluted vvith isocyanate Gel formation is due to moisture absorption by the pump IsoGuard Select fluid The interval between changes depends on the environment in which the equipment is operating The pump lubrication system minimizes exposure to moisture but some contamination is still possible Fluid discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation If the packings are operating properly Iso Guard Select fluid replacement due to discoloration should not be necessary more often than every 3 or 4 weeks To change pump IsoGuard Select fluid 1 Perform Pressure Relief Procedure on page 38 2 Remove fittings from IsoGuard Select fluid cylinder inlet and outlet ports Keep supply tube ST return tube RT and leak management tube LT con nected to the fittings 3 Carefully place ends of tubes with fittings still con nected into an empty pail to drain IsoGuard Select fluid 4 Liftthe IsoGuard Select fluid reservoir LR out of the bracket RB and remove the container from the cap Holding the cap over a suitable container remove the inlet check valve and allow the IsoGuard Select fluid to drain Reattach the check valve to the inlet hose See FIG 18 5 Drain the reservoir and flush it with clean IsoGuard Select fluid
68. hulie Status J zi Active Errors Enter Exit screen Previous Wa screen no Current screen no Next reen no Function display screen no I I I I i I I i Fic 9 Main Display Components 26 3A2175A Component Identification Fluid Control Module FCM FA FC ti12337a1 ti12336a1 FB FD Fic 10 FA Fluid Control Module FB Base FC Module Connection Screws FD Access Cover FE Module Status LEDs FF CAN Connectors 3A2175A 27 Dispense Valve Overview Dispense Valve Overview The HFRL and HFRS systems will be provided exclu sively with MD2 dispense valves The MD2 dispense valve is an example of a solenoid controlled dispense valve VVhen the trigger is pulled the signal requests the dispense to start When the machine sees the signal fluid rises to dispensing pressure and the valve is opened to begin dispensing When the trig ger is released the solenoid signals that the dispense is finished 28 3A2175A Setup Perform this setup procedure to secure all necessary machine connections for machine operation 1 Locate HFR a Locate HFR on a level surface See Dimen sions on page 94 for space requirements b Do not expose HFR to rain To avoid machine damage and personal injury ensure the machine is securely strapped to the pallet to prevent tipping before lifting 2 Electrical requiremen
69. hylene chemically resistant o rings All other brand names or marks are used for identification purposes and are trademarks of their respective owners 92 3A2175A Technical Data Motor Control Module Technical Data Input Specifications Input Line Voltage 0 264 Vac line to line Input Line Phaslflg susce bx ER Single or Three Phase Input Line Frequency 50 60 Hz Input Current per Phase 25A three phase 50A single phase Maximum Branch Circuit Protection Rating 30A three phase 63A single phase Short Circuit Current Rating 5 kA Output Specifications Output Line Voltage 0 264 Vac Output Line Phasing Three Phase Output GUITent a kdo REUS Pande beaten qos 0 30A Output Overload 20096 for 0 2 seconds C Power SUDDIY us irai ch E dede Rob beca ea 24 Vdc Class 2 Graco provided power supply ENCIOSUIC uu eA PS as AO bed ae n Type 1 Max Ambient Temperature 50 C 122 F Overtemperature protection is provided to protect from motor overload Current limit set via the software is provided as a secondary protection from motor overload All installations and wiring must comply with NEC and local electrical codes 3A2175A 93 Technical Data Dimensions 51 8 in 1316 mm 24 in ER mr 127 mm
70. ipment only in a well ventilated area Do not dispense flammable fluids Do not turn on heaters while flushing with flammable solvents Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing new fluid e Use the lowest possible pressure when flushing All fluid components are compatible with common solvents Use only moisture free solvents See Accessories on page 91 for list of wetted compo nents to verify compatibility of solvent with wetted materials See solvent manufacturers information for material compatibility e To flush feed hoses pumps and heaters separately from heated hoses set PRESSURE RELIEF DIS PENSE valves SA SB to PRESSURE HELIEF CIRCULATION d Flush through bleed lines N ti9880a1 e To flush entire system circulate through gun fluid manifold with manifold removed from gun e To prevent moisture from reacting with isocyanate always leave the system dry or filled with a mois ture free plasticizer or oil Do not use water See Important Two Component Material Information on page 14 Solvent pails used when flushing follow your local code Use only metal pails which are conductive placed on a grounded surface Do not place pail on a nonconductive surface such as paper or card board which interrupts grounding continuity 3A2175A 39 Operation Adjusting Material Inlet Pressure Using the Mate
71. is above the minimum voltage requirements 74 3A2175A Appendix D ADM Error Codes Error Error Code enor Name ror Dosoription Tyee Cause Souton 00000 Short circuit of motor Check vviring to the motor to ensure no bare vvires are Unplug the directional valve so pressure will not Motor Over A hardvvare current fault has AAN1 occurred causing a system Alarm build and try to move the motor agaln f this Motor rotor has become isucceeds 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 shutdown Hed Blanket Control Fault Blue Blanket Control Fault Hed Inline Control Fault Blue Inline Control Fault Unexpected current to Shorted Temperature If temperature rises for a zone that has been disabled heater chiller Control Module replace Temperature Control Module Control Fault Blue Hose Control Fault Red Chiller Control Fault Blue Chiller Control Fault No Red Inline Tripped circuit breaker Visually check circuit breaker for a tripped condition No Blue Inline Current No current to the conditionin No Red Hose g zone Measure voltage across input terminals on power line Low power filter Voltage should measure between 190 and 264 Vac No Blue Hose Cable unplugged loose Check for loose or disconnected wires or plugs Bad heater s Measure resistance of heater s
72. isplay Module ADM 24 Fluid Control Module FCM 27 Dispense Valve Overview 28 SE D m 29 Operation so bacon beau at e da 35 ari erc 35 Ka gde xas PA 38 Pressure Relief Procedure 38 FIOSAN cas mo as b do S ud m 39 Adjusting Material Inlet Pressure Using the Material REGULATOR 40 Pressure Balancing Using the Orifice Valve Assemblies cat 4 4 d e te Aa 41 Maintenance ooa dob Lara par oe er he CR 43 Advanced Display Module ADM 44 Motor Control Module MCM 45 Fluid Control Module FCM 46 Fluid Inlet Strainer Screen 46 IsoGuard Select System 47 Clean Orifice Valves 48 Troubleshooting 49 Light Tovver Optional 49 Common Problems 49 ADM Troubleshooting 51 Motor Control Module 52 Fluid Control Module 54 Advanced Display Module ADM Operation 55 Appendix A ADM Icons Overview 56 Appendix B ADM Setup Screens Overview 58 Appendix C ADM Run Screens Overview 68 Appendix D ADM Error Codes 74 Appendix E System Events 84 Appendix F USB Operation 85 Overview 85 USB ODHOFLIS 9 vata que S
73. ize timer will then begin counting down and the cleanout piston will open and close again to break loose from any remaining cur ing material If a shot occurs before both anti seize timers elapse the anti seize timers restart uu System Standby mi Ho Active Errors Head Control Low Pressure Circulation Pre Dispense Lirculation seconds Maintenance Post Dispense Circulation seconds Idle Position Normally Open Clean Rut Open seconds Clean Out Closed 5 0 seconds Anti Seize Anti Seize Delay seconds Anti Seize Secondary Delay seconds 3A2175A System Screen 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 To edit a label 1 Press 2 To edit the A Red label press To edit the B Blue label press the dovvn arrovv then press The keyboard will appear on the screen See Keyboard Screen on page 63 3 Use arrow keys to select the desired letter and par press to accept the letter To erase all text press the Eraser softkey To go back one letter press the Back Arrovv softkey 4 VVhen finished entering the nevv label press the button twice The pressure imbalance setting may be set from this screen Pressure imbalance is the allowable difference in pressure between
74. ly tube manifold is loose Or broken Broken motor shaft Replace motor Verify that no outside forces are stopping the pump from moving then inspect over pressure valve for damage or debris Over pressure valve dumping to tank N4A1 Pump Failed to Move Red Pressure 5 Shutdown P4B2 Pressure The pressure difference Pressure has risen to an unsafe level due to thermal expansion of materials All Deviation High pressure conditioning zones have automatically been turned off Open the dispense valve manually or open the valves to bleed pressure Alarm Dispense valve failed to Check to make sure the dispense valve is properly open configured and connected to the MCM Bad dispense valve Replace dispense valve Restriction in the 3 70 Check to ensure there is no blockage The material pump pressure material lines exceeded the maximum Make sure the requested pressure is within the max operating pressure as defined operating pressure vvhich can be found on the setup in the setup screens screen System 1 Orifices blocked Clear blockage Hose blocked Clear blockage or replace hose as necessary Dispense valve failed to Check to make sure the dispense valve is properly open configured and connected to the MCM i Ensure the material flovv is equally restricted on both Dispense line is clogged material lines On the ADM go into the setup screens gt System gt Pressure imbalance is land ensure the pressure imbala
75. more than 3000 psi 21 MPa 207 bar material pressure to the inlet regulator assembly 7 Place a container at the outlet of the relief lines from the manifold assembly and secure the lines in place 40 8 Place the pressure relief valve on the manifold into the recirculation position 9 Slowly increase the air pressure on the material reg ulator to allow material to flow though the pump and out the bleed hose The required material pressure will vary depending on the material viscosity and flow rate 10 Once material is flowing from the bleed hose slowly decrease pressure on the material regulator until flow stops 11 Gradually increase pressure to the material regula tor until material begins to flow again 12 When material begins to flow out of the bleed port close the pressure relief valve NOTE Record the material pressure gauge reading Use this pressure as a starting point for adjusting the material feed pressure to meet application require ments NOTE As a general rule for high viscosity materials the dispense pressure must exceed the material inlet pres sure by 2 to 3 times Therefore if the maximum dis pense pressure is 2500 psi 17 MPa 172 bar the inlet pressure should be no more than 1250 psi 9 MPa 86 bar For lower viscosity flowable materials the dis pense pressure should exceed the inlet pressure by 3 4 times Use only enough feed pressure to adequately feed the HFR pumps NOTIC
76. n Temp Blue Inline Low Fluid Fluid temperature is below the defined low alarm limit Low Fluid Temp Blue Hose Measure voltage across input terminals on power line Low Fluid Low power filter Voltage should measure between 190 and 264 Temp Vac Red Chiller Cable unplugged loose power Low Fluid Temp Blue Chiller Low Fluid Bad heater s Measure resistance of heater s Temp Check for loose or disconnected wires or plugs The hydraulic oil temperature No power to fan Check cord to make sure fan has power is approaching a level where Debris is fan or fan grill Clear debris from fan fan grill Oil Temp damage is possible so the ode E P Deviation Try to stop fan by lightly pressing on the center with a Cutback Motor Control Module is L i i If the f d ilv it wil d limiting the output to a safe ow air volume from fan pencil eraser e fan slows down easily it will nee to be replaced level No power to fan Check cord to make sure fan has power Debris is fan or fan grill clear debris from fan fan grill Try to stop fan by lightly pressing on the center with a Low air volume from fan pencil eraser If the fan slows down easily it will need T3H1 Motor temperature is approaching a level where Motor Temp damage is possible so the Advisory to be replaced Cutback eer motor control module is limiting Move machine to an area below 120 F the output to a safe level conditions are too h
77. nce value is the defined too lovv maximum acceptable to prevent unnecessary alarms which will abort dispenses Orifice blocks closed off Verify that one or both of the orifice blocks dispense Pressure between the Red and Blue too much on one or both when adjusted to the fully open position then adjust Imbalance X material is greater than the sides accordingly defined amount me ue Helieve system pressure then remove the orifice from Debris in the orifice block M 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 Out of material Fill tanks vvith material Feed system defective Replace defective item Red Pressure i Check to ensure the pressure transducer is properly P6A1 Alarm Loose bad connection Sensor Fault The pressure sensor is installed and all wires are properly connected Blue providing invalid no pressure Replace pressure transducer Alarm P6B2 P readings ressure g No material in pump Fill tanks Invalid maximum Alarm pressure defined P4D0 Material fillers may have packed out in an orifice Sensor Fault 78 3A2175A Appendix D ADM Error Codes Error Error Code Error Description Type Cause Red Tank Low Fluid Temp Blue Tank Low Fluid Temp Red Inline Low Fluid Tripped circuit breaker Visually check circuit breaker for a tripped conditio
78. nformation e Ability to download modify and upload custom lan guage files e Ability to download and upload system configura tions e This data includes most user selectable and user configurable settings e 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 Screen 2 see page 67 00 00 00 t Conditioning Shots standby mi No Active Errors Disable Dispensing From Display m Disable Modifying Temp Setpoint Disable Operator Mode Adjustments Low Heater Temp Disables Dispense m High Chiller Temp Disables Dispense Enable Operator Mode Cavitation Alarm m Complete Dispense With Setpoint Error Enable Downloading of USE Logs Date of Last Download The first option is a checkbox that enables or disables the dovvnloading of the Error Event and Shot Data log files The Shot Data log runs during all recirculation shots and operator modes The second option is the Erase icon which will reset the last dovvnload date to a time vvhere all logs can be downloaded 10 01 09 This will allow the user to down load all the USB log entries which may take over 2 hours if the log files are full Currently the ADM does not monitor the USB logs and alert the user when data may be overwritten so in order to minimize download times and the risk of losing data it is recommended that the user download the logs every
79. nse button Ol The pump will travel to the left most extreme position e After the pump stops moving press the con tinue button to go on to the next step in the calibration process or the page back button to return to the main Calibration screen NOTE During this process the system learned the mechanical limits of travel If the pump did not reach both the left and right extreme limits for any reason repeat the procedure 36 If the system is to be used in a Time or Volume Dis pense Mode system calibration is complete after the Learn Mode procedure described above Hovvever if the system is to be used in VVeight Dispense mode and the application requires that the dispense amount be accu rate and consistent then the weight calibration proce dure belovv must be follovved VVeight Calibration Procedure NOTE Only perform Weight Calibration procedure if the system will be run in Weight Dispense mode The VVeight Calibration procedure must be run vvith the system production ready Orifice sizes and hose lengths must be finalized material should be at temperature and any conditioning zones that will be on during production should be turned on Any variation in system setup between when this procedure is run and the production environment will result in a decrease in system dispense accuracy a Navigate to the Weight Calibration screen rel b Navigate to the Cal Setpoint text box then enter the desired set point
80. nse Mode 70 Home Screen Operator Mode This mode allows users to set a pressure or flow rate to dispense material vvithout using predefined shot infor mation Pressure or flow rate availability is dependent on the Control Mode selection see System Screen 2 on page 62 To edit the pressure or flovv rate press the button The value to change will now be highlighted Type the nevv value then press the Enter button to accept it The machine will begin dispensing at the set pressure or flow rate when the dispense button is pressed and will stop dispensing when it is pressed again If a foot switch is installed the machine will dispense and continue to dispense until the foot svvitch is released f the foot switch is used with a Mix Head installed a foot switch press will start the pre dispense timer and dispense material when the timer expires Another foot switch press will terminate the dispense and start the post dis pense timer 01 12 10 10 17 Maintenance Operator No Active Errors Ratio Operator Setting 24344 23482 49056 Total of resetta ble material counters A Red resetta ble material counter B Blue reset table material counter 3A2175A Home Screen Night Mode In Night Mode the system will cycle on and off periodically The recirculation on off cycle begins automatically upon entering Night Mode See Conditioning Screen 3 on page 66 Appendix C ADM Run Screens
81. o Motor pump coupler may be rubbing on hydraulic pump T3N1 Reset coupler per specifications and retighten set screws Blue Tank High Fluid Temp Red Inline High Fluid Temp Blue Inline Defective RTD Replace RTD Fluid temperature is above the defined high alarm limit Defective High Power Temperature Control Replace High Power Temperature Control Module Module Loose connections Tighten connections 3A2175A 79 Appendix D ADM Error Codes Error Error Code Error Description Type Cause No povver to fan Check cord to make sure fan has povver Debris is fan or heatsink Clear debris from fan or heatsink The temperature the MCM has T4C1 Try to stop fan by lightly pressing on the center with a Low air volume from fan pencil eraser If the fan slows down easily it will need life will be decreased Alarm drastically and has been to be replaced shutdown for protection Motor be damaged Replace motor Debris is packed in the i ee MCMs heat sink fins Clear debris from MCM heat sink fins The hydraulic oil is at a No Power to Fan Check cord to make sure fan has power temperature where Debris in fan or fan grill Clear debris from fan fan grill performance is impacted Alarm Try to stop fan by lightly pressing on the center with a significantly and has resulted Low air volume from fan pencil eraser If the fan slows down easily it will need in a system shutdown to be replaced No power to fan Check
82. ody 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 3A2175A 3A2175A Warnings 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 e 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 PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury Follow the P
83. on sensor may be loose where Re tighten the sensor and re calibrate the machine Insufficient material axan being supplied or Verify that incoming ball valves are open Verify that feed pumps are supplying material insufficient material pressure on feed system Debris or packout in the Inspect filter for debris of filler packout and clean or incoming fluid filter replace as necessary Cavitation vvas detected on the Deviation given pump 3A2175A Appendix D ADM Error Codes Error Error Code Error Description Type Cause Orifices blocked Clear blockage DFA1 The pump failed to reach the D viation Hose blocked Clear or replace hose as necessary park position Dispense valve failed to Check to make sure the dispense valve is properly open configured and connected to the MCM On the ADM go into the setup screens gt System gt Pumps Not The type or size of the Red or Bund sd ike DSCO Blue material pumps have not Alarm Pery P then make sure that the pump type and size are set RUNS been defined BAGU not Vibe ied Failure of the dispense the valve has a proper air supply and seals nn valve properly If not service the valve as necessary pressure the pump traveled F7D1 Pump Failed Aore anormal Deal Visually inspect the machine and hoses for sign of to Stall i i Material leak leakage NOTE This error will display after 2 full operation only applies to
84. power The Motor Control Mod ule falls under the category of power conversion equip ment because energy is stored on a capacitive bus and then modulated to control a brushless motor Engi neered 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 hard ware 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 equip ment Reading should not regularly exceed approxi mately 400VDC to avoid tripping the 420VDC alarm level in the Motor Control Module If power quality is sus pect povver 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 Power Line Test Steps with Multimeter a Set multimeter to DC voltage b Connect multimeter probes to supplied power line c Press Min Ma
85. pressure or flow based on selected Control Mode d Puta waste container under the dispense valve e Press or the footswitch to start the system characterization process The pump will start to operate at the entered setpoint until it learns the proper control parameters then repeat the pro cess at 60 of that value When it is complete the icon will change back to O again to deactivate g Select the Cal Point 1 of 2 text box under the scale graphic h With a waste container under the dispense valve press or the footswitch to dispense a Cal 1 shot Discard the dispensed material 3A2175A i Select the Cal 1 Shot Average field then press ra to erase the value j Select the Cal Point 1 of 2 text box k Press or the footswitch to dispense a Cal 1 shot Weight the material dispensed and enter the weight in the text box m Repeat the previous two steps three more times The logic will automatically average the readings and provide the result in the second text box in the row n Select the Cal Point 2 of 2 text box under the scale graphic o Press or the footsvvitch to dispense a Cal 2 shot p Weight the dispensed material and enter the weight in the text box q Repeat the previous two steps three more times The logic will automatically average the readings and provide the result in the second text box in the row r Press i The system is now able to dispense accurate
86. ption Grenon T Systems powered up Communication in progress Red solid ADM hardware failure Red flashing Uploading software USB Module Status LEDs CL Conditions Green flashing System is powered up Downloading information to USB Green Yellow Flashing ADM is busy USB cannot transfer information when in this mode 3A2175A 51 Troubleshooting Motor Control Module For MCM location see reference MA in FIG 4 on page 19 Diagnostic nformation Table 3 LED Status Signal Red flashing slovv Token error Remove token and upload softvvare token again TALL r 257396 3b9905 01b Fic 20 LED Signals 52 3A2175A Acceptable Size and Duration of Povver Line Voltage Fluctuations The Motor Control Module is designed to withstand volt age 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 sys tem shuts down in an alarm state Excessive or repeated over voltage may permanently damage hard ware 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 Troubleshooting Maximum Permissible Transient Voltage Surges Constructed from ITIC 1996 cu
87. quipment to cool 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 devi ation or alarm Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum ing there is a problem Common Problems Problem U case Sotion O Gem 2 Display Module completely dark No or incorrect amount o material dispensed from Air In Material Prime the machine Significant material leaking Pump shaft worn and or shaft seal Remove pump shaft assembly and reinstall read from pump seal worn pump rebuild kit Material dispensed not cor Specific gravity of one or more of the Run calibration rect weight two materials has changed since cali bration Check valve malfunction Remove check valve clean or replace as necessary Piston worn or broken Replace Piston Proportioning System Proportioning pump does not Pump piston or intake valve leaking Observe gauges to determine which pump is los hold pressure when stalled ing pressure Determine in which direction the pump has stalled by observing which directional valve indi cator light is on Repair the valve 2175 49
88. r RE Dd eee aid 85 Download Log Files 85 Log Files Folder Structure 86 Transfer System Settings 88 Update Custom Language 89 ACCeSSOLIGS ue d qo t a CR C ee 91 Technical Data 23 25 Tack ux Re XR erras 92 Motor Control Module Technical Data 93 DIMENSIONS xac ios Seco opo aoe MAGA aces 94 Graco Standard Warranty 96 Graco Information 96 3A2175A Related Manuals Manuals are available at www graco com Component manuals listed belovv are in English System Manuals 3A2176 HFRL and HFRS Repair Parts Pumpline Manuals 3A0019 Z Series Chemical Pumps Instructions Parts 3A0020 HFR Hydraulic Actuator Instructions Parts Feed System Manuals for HFRL Systems 3A0235 Feed Supply Kits Instructions Parts Dispense Valve Manuals 312185 MD2 Valve Instructions Parts Accessory Manuals 3A1149 HFR Discrete Gateway Module Kits Manual 3A2175A Related Manuals Models Models HFR Laminate HFRL HFRL models are designed for use with low viscosity unheated urethane laminating adhesives at flow rates of up to 30 cc sec 4 Ib min Maximum Fluid Working Full Load Peak Voltage Pressure t Amps Per Phase phase System Watts psi MPa bar 3000 sax lov o g z 207 A Pump B Pump Required cpm e Max Flow Max Dispense Pressure
89. r Silicone 230 1 6 1 Carbon Steel 55 5 Feed HFRS35 HFR for Silicone 230 1 6 1 Carbon Steel 5 5 Feed HFRS36 x HFH for Silicone 400 3 6 1 Carbon Steel 55 55 Feed HFRS37 x HFR for Silicone 400 3 6 1 Carbon Steel 55 5 Feed HFRS38 x HFR for Silicone 400 3 6 1 Carbon Steel 5 5 Feed HFRS39 HFH for Silicone 230 1 6 1 Stainless Steel 55 55 Feed HFRS40 HFR for Silicone 230 1 6 1 Stainless Steel 55 5 Feed HFRS41 HFR for Silicone 230 1 6 1 Stainless Steel 5 5 Feed HFRS42 x HFR for Silicone 400 3 6 1 SS 55 55 Feed Models Part Num ber Description HFRS45 HFR for Silicone 230 1 10 1 Carbon Steel 55 55 Feed HFRS46 HFR for Silicone 230 1 10 1 Carbon Steel 55 5 Feed HFRS47 HFR for Silicone 230 1 10 1 Carbon Steel 5 5 Feed HFRS48 HFH for Silicone 400 3 10 1 Carbon Steel 55 55 Feed HFRS49 x 1 HFH for Silicone 400 3 10 1 Carbon Steel 55 5 Feed HFRS50 x HFR for Silicone 400 3 10 1 Carbon Steel 5 5 Feed HFRS51 HFR for Silicone 230 1 10 1 Stainless Steel 55 55 Feed HFRS52 HFR for Silicone 230 1 10 1 Stainless Steel 55 5 Feed HFRS53 HFR for Silicone 230 1 10 1 Stainless Steel 5 5 Feed HFRS54 x HFH for Silicone 400 3 10 1 Stainless Steel 55 55 Feed HFRS55 x HFH for Silicone 400 3 10 1 Stainless Steel 55 5 Feed HFRS56 x HFH for Silicone 400 3 10 1 Stainless Steel 5 5 Feed Part Num ber Description HFRS67 HFR for Silicone
90. raco com r 257396 3b9905 04b FiG 15 Remove Access Cover 45 Maintenance Fluid Control Module FCM MA Install Upgrade and Key Tokens NOTE FCM connection to system is temporarily dis abled during the installation of upgrade or key tokens 1 Use software token 16H821 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 soft ware 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 The latest software version for each system can be found at www graco com ti12334a1 FIG 16 46 Fluid Inlet Strainer Screen Not included on HFRS systems xos The inlet strainers filter out particles that can plug the pump inlet check valves Inspect the screens daily as part of the startup routine and clean as requlred The standard strainer is 20 mesh Use clean chemicals and follovv proper storage transfer and operating procedures to minimize cont
91. re divided into five major sections status errors events and maintenance The following diagram demonstrates the flow of the Run screens beginning with the Home screen Tn 22 Home 22 Status 2 Errors 1 Tn Errors 2 N Events 1 z Maintenance 2 N Events 2 N Errors N N Events N FIG 23 Run Screens Navigation Diagram Home Screen The Home screen is the first screen that displays in the Run screens It shows the current fluid pressure on the A Red and B Blue fluid outlets of the pump and if there are any active errors If tanks are installed in the system the fill level is shown on each tank To select an operating mode press the Select Mode button Ki repeatedly until the desired mode is shown then press the Enter button to select the mode Alternately press the Select Mode button and use the up and down arrow keys until the desired mode is Supply tanks shown for reference only Your sys shown then press the Enter button to select the mode The available operating modes are operator sequence shot standby night and disabled 68 tem may not include supply tanks 3A2175A Home Screen Standby Mode In Standby Mode the user can enable heating park the pumps refill the tanks circulate materials 3A2175A Appendix C ADM Run Screens Overview Home Screen Shot Mode This mode allows the user to select one of 100 pre defined shot numbers Se
92. red value 2 Type the new value then press the Enter button to accept the new value E r1 1 2 3 4 J B gt B g 10 ele eTo 3A2175A Appendix B ADM Setup Screens Overview Sequences Screen This screen allows the user to edit sequence informa tion The contents of this screen change based on the Dispense and Control Mode selections Dispense detail is shown as volume time or weight depending on which Dispense Mode is selected See System Screen 1 on page 61 for Dispense Mode options See Home Screen Sequence Mode on page 70 for information on how to use predefined sequences NOTE 5 sequences with 20 positions each are avail able across 10 pages To edit a sequence 1 Press the Enter screen button then use the arrow keys to navigate to the desired value 2 Type the new value then press the Enter button to accept the nevv value 11 15 10 12 41 e Shots Prime mi Active Errors 0 0 1 59 Appendix B ADM Setup Screens Overview Calibration Screen Main This screen shows calibration information for the system and provides access to other calibration screens See Calibrate HFR on page 36 for how to use the calibration screens to calibrate the machine The date next to each key represents the last time that calibration was performed The Cal Min and Cal Max values are the system recognized extreme end
93. regardless of pressure fluctuations unless pressure alarm conditions occur Dispense Mode can be set to Time Volume or Weight Dispense Mode controls hovv displayed amounts are measured If Dispense Mode is set to Weight then the machine dispenses until the desired weight of material is dispensed See Calibrate HFR on page 36 for more information Pump sizes and inlet pressures must be entered on this screen If pump sizes and inlet pressures are not entered prop erly system performance will be affected The inlet pres sure must be set to the maximum feed pressure that vvill be seen by that side of the machine The maximum vvorking pressure for the machine is dis played on this screen The maximum vvorking pressure is dependent on the installed hoses and dispense valve The maximum working pressure 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 manual 313998 for instructions to set the maximum working pressure for hoses If the installed dispense valve rating is below the maximum working pressure shown here verify the correct dispense valve is selected on System Screen 2 Maintenance 001 mn mi No Active Errors Control Mode Pressure w Dispense Mode Tie Masimum Working Pressure 2000 psi D fog BE Inlet 200 psi Inlet psi Size v Size l 61 Appendix B ADM Setup Screens Overview S
94. ressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately 11 Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals 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 manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Houte 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 wi
95. rial Regulator o Pa bar PSI AX NOTICE Care must be taken when applying pressure to sys tems equipped with a material pressure regulator on the inlet assembly Read both operation and ser vice manuals for the pump ram supply system and the material pressure regulator prior to loading material to the HFR system Use the following procedure to adjust the material pres sure to the system This process assumes that the sup ply system consisting of a supply pump and outlet hose has already been loaded and primed and is ready to provide material to the pump inlet 1 Verify the air pressure is provided to the material regulators and that the air gauge on both regulators are functioning properly 2 Adjust the air pressure on both material regulators so that there is no air pressure on them and that the regulator pressure gauge reads zero 3 Verify that the material supply pump does not pro vide material pressure in excess of 3000 psi 21 MPa 207 bar NOTICE Although the material regulator itself is rated for 5000 psi 35 MPa 345 bar the assembly pro vided is only rated for do not exceed 3000 psi 21 MPa 207 bar 4 Verify that there is no pressure in the material sup ply pump 5 Connect the feed hose from material supply system to the inlet assembly and make sure all fittings are fluid tight 6 Gradually increase the air pressure to the supply pump to provide no
96. rve referenced by IEC 61000 2 4 1400 1200 lt 1 MW Max Surge Power 1200Vac 1697Vdc 1000 E T 800 O 600 B 480Vac 679Vdc lt 150 KW Max Surge Power 5 nue 50 KW Max S P 336Vac 475Vdc WI 2707577 No Power Limit 0 0 000001 0 00001 0 0001 0 001 0 01 0 1 1 10 Time seconds 3A2175A 53 Troubleshooting Fluid Control Module Diagnostic nformation System is povvered up 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 Module Status LEDs ti12337a1 FIG 21 54 3A2175A Advanced Display Module ADM Operation Advanced Display Module ADM Operation When main power is turned on by turning the main power switch MP to the ON position the splash screen will be displayed until communication and initialization is complete 4 GRACO 2 To begin using the the machine must be on and enabled To verify the machine is enabled verify the System Status Indicator Light CB is illuminated green see FIG 7 on page 24 If the System Status Indicator Light is not green press the ADM Power On Off CA button O The System Status Indicator Light will illu minate yellow if the machine is disabled If the machine is in the Disabled mode screen press 6 repeatedl
97. s of piston travel See Calibra tion Screen Learn Mode 05 10 10 15 47 m Sequences No Active Errors Previous i Lua Cal Mac ad Cal Mir Range 10900 1900 Range 2300 3300 x Previous A Erase Learned Data 60 Calibration Screen Learn Mode This screen allows the user to calibrate piston position The piston can be moved to the left and right to obtain the full range of motion See Calibrate HFR on page 36 for how to use this screen to calibrate the machine Current position Previously saved left position Previously saved right position 3A2175A Calibration Screen Specific Gravity This screen allovvs the user to enter material specific gravities and perform weight calibration shots See Cali brate HFR on page 36 for how and when to use this screen to calibrate the machine 03 10 10 1549 Sequences System EH No Active Errors Specific Gravity RED BEH Specific Gravity BLUE 11 000 Cal Setpoint O psi l x Cal Point 1 of 2 0 000 g Cal Point 2 of 2 0 000 g 3A2175A Appendix B ADM Setup Screens Overview System Screen 1 This screen allows the user to set important system set tings Control Mode can be set to Pressure or Flow With Control Mode set to Pressure the machine will adjust dispense flow rate in order to maintain the requested pressure With Control Mode set to Flow the machine will dispense at a continuous flow rate
98. sconnect 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 reg ulations 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 e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e 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 inhala tion of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection e 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 b
99. th 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 e Pressurized equipment can start without warning Before checking moving or servicing equip ment follow the Pressure Relief Procedure and disconnect all power sources 12 3A2175A 3A2175A Warnings 13 Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocya nates creates potentially harmful mists vapors and atomized particulates Head 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 ventila tion 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 per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS Keep Components A Re
100. the end of the MCM vvith the If the Motor Control Module is replaced the selec power input connection 12 faces down and the end tor switch must be set prior to initial startup of the with the access cover A faces up Motor Control Module or damage may occur See HFR Repair manual for details see Related Man The Motor Control Module uses an 8 position selector uals on page 3 switch to set the system maximum working pressure 11 13 UL r 257396 3b9905 03b FIG 6 MCM Component Identification 22 3A2175A Description 9808 C wema Three vvay Splitter to Oil Lovv Level Sensor Dispense Valve Solenoid and Footsvvitch Oil Temperature Sensor Electric Motor Temperature Sensor Hydraulic Directional Valve Oil Overtemperature Svvitch Pressure Transducer B HO side e Pressure Transducer A Red sde ER UN SO _ UN Three way Splitter to to 3A2175A Component Identification 23 Component ldentification Advanced Display Module ADM User interface EC EA ED EE EF EH TI12362a1 FiG 7 ADM Component Identification Front Buttons System Enables disables system When Keys Defined by application usin
101. the two materials before an alarm is triggered The input range is 250 2000 psi 2 14 MPa 17 138 bar MESA System Maintenance Mo Active Errors Pressure Red Label Imbalance Blue Label BLUE Setting Pressure Imbalance Alarm psi 3A2175A Appendix B ADM Setup Screens Overview 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 letter and press to accept the letter 01 14 10 1407 Susten Standby mn No Active Errors S Maintenance fo pure per a a als OF em zx pe Wve 010 63 Appendix B ADM Setup Screens Overview Maintenance Screen This screen shows shot number and sequence position counters Press the Enter Screen button and navigate to the drop down box Press the enter key and scroll to a range of counters to view Press the enter key again to select the range of counters and display them on the screen Counters may be erased individually Navigate to the counter you want to erase and press the Erase Individ ual button Alternatively each counter displayed on the page may be erased simultaneously by pressing the Erase All button A 2 c 1 2 3 4 J B T 8 9 10 64 Supply Screen This screen allovvs the user to specify the operating parameters for off board integrated tanks and indicate which positions have level sensors installed See the
102. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any tim
103. ts See Models on page 4 for detailed electrical requirements information aA 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 see step 3 in this setup procedure All electrical wiring must be done by a qualified electri cian and comply with all local codes and regulations 3 Connect electrical cord Aw A NOTE See Power Line Voltage Surges information on page 30 NOTE Power cord is not supplied See the following table Table 1 Power Cord Requirements Cord Requirements AWG mm 230V 1 phase 6 13 3 2 wire ground 400V 3 phase 6 13 3 4 wire ground T f Residual Current Device RCD must be rated at 3A2175A Setup 300 mA if installed Electrical Cord Wires by Model 230V 1 phase L1 L2 GND 400V 3 phase L1 L2 L3 N GND Use 5 32 or 4 mm hex allen wrench to connect the two or three power leads to L1 L2 and L3 as applicable Connect green to ground GND Electrical Cord Wires by Model 230V 1phase L1 L2 L3 No Connection GND 400V 3 phase L1 L2 L3 N GND FIG 12 400V 3 Sion si Shown FiG 13 Grounding Lug 29 Setup Povver Line Voltage Surges Power conversion equipment can be sensitive to voltage fluctuations on incoming
104. ve is in the fully open position by turning counter clockwise until rotation stops After installation the needle valve can be turned clockwise to further increase pressure NOTE Always run the material first at the desired flow rate with no orifice valves installed to evaluate the dis pense pressures generated for each material NOTE Appropriate orifice valve selection is essentially done by trial The following can help determine if it is necessary to increase the outlet pressure and help select an orifice a The outlet pressure for heavy paste viscosity materials should be at least 2 times higher than the z pump feed pressure as determined by the material pressure regulator Max outlet pres sure is equal to 3000 psi 21 MPa 207 bar and the feed pressure should be below 1500 psi 10 MPa 103 bar b The outlet pressure for lower viscosity flovvable materials should be 3 4 times higher than the z pump feed pressure Dispense pressures for this viscosity range should be in the 750 psi b MPa 52 bar to 1000 psi 7 MPa 69 bar range C The outlet pressures of both material hoses should be as close as possible to each other and within a suggested range of 1096 See Sys tem Screen 3 page 63 3 Install orifice valves only if the outlet pressure needs to be increased See Maintenance starting on page 43 for details 4 frule a and b above are met by both materials install an orifice valve in the lower pressure side
105. x successively to show the peak positive and negative DC voltages d Confirm readings do not exceed 400VDC Motor Control Module alarm issued at 420VDC 30 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 lt 1 MW Max Surge Power 1200Vac 1697Vdc 480Vac 679Vdc lt 150 KW Max Surge Power Voltage Volts RMS 50 KW Max S P 336Vac 475Vdc SA AM T NEC No Power Limit 288Vac 407Vdc 0 000001 0 00001 0 0001 0 001 0 01 0 1 1 10 Time seconds 3A2175A 4 Connect regulator assemblies If Equipped NOTE Systems equipped with a fluid regulator on the material inlet vvill not be fully assembled due to shipping The regulator assembly will be detached and boxed separately a Attach the male nipple located on the regulator assembly to the female swivel located on the end of the pump assembly b Connect the air tube to the tee fitting on the power valve assembly located on the right side of the machine 5 Connect feed pumps HFRL a Install feed pumps in component A Red and B Blue supply drums See FIG 1 and FIG 4 pages 16 and 19 NOTE A minimum feed pressure of 50 psi 0 35 MPa 3 5 bar is required at both feed inlet pressure gauges FP Maintain A Red and B Blue feed pressures within 1076 of ea
106. y time This button can also be used to abort a refill opera tion The refill time out setting may be set by the user as a means to abort the refill in the case of a high level sen sor failure When an automatic refill begins the time out counter will begin to count down If the timer expires before the high level sensor is satisfied the refill will abort 01 12 10 10 17 Eo Operator C Mo Active Errors Refill Setting Auta Top Off Md Conditioning Refill Timeout i minutes Installed 3 X 3A2175A Appendix B ADM Setup Screens Overview Conditioning Screen 1 This screen allows the user to select which temperature conditioning components are installed in the system Check the box next to the component type for the appro priate side of the system to indicate that a component is installed A maximum of four components may be selected 65 Appendix B ADM Setup Screens Overview Conditioning Screen 2 This screen shows the fluid path for the temperature conditioning components and temperature setpoints for each component NOTE If tank blanket heaters or inline heaters are installed along with hose heat the hose heat setting will be limited to at or below the inline or tank heat setting D1 12 10 10 17 e Sup E NG Ac Operator fy leer 122 ke Let CT E ES ES NOTE All components are shown installed for refer ence only Only 4 components can be installed at one time To
107. y to select a different operating mode Perform the follovving tasks to fully setup your system 1 Set general system settings See Advanced Screen 1 page 67 2 Set units of measure See Advanced Screen 2 page 67 3 Enable disable system features See Advanced Screen 3 page 67 4 Define control mode dispense mode and pump information See System Screen 1 page 61 5 Define dispense valve and other system settings See System Screen 2 page 62 6 Define labels and other system settings See Sys tem Screen 3 page 63 3A2175A 7 If L Head is installed define L Head control details See Mix Head Operating Details Screen page 62 Define level sensors and refill settings See Supply Screen page 64 If Night mode will be used define Night mode set tings See Conditioning Screen 3 page 66 Calibrate machine See Calibration Screen Main page 60 Define shots See Shots Screen page 59 Define sequences See Sequences Screen page 59 If desired view reset counters See Maintenance Screen page 64 55 Appendix A ADM lcons Overview Appendix A ADM Icons Overview Icon Function Access Weight Calibration and Material al Move L Head Cleanout Rod Specific Gravity Entry screen VVith a mix head installed Turns on Pump Graphic the mix head hydraulics and puts the Move pump Icon Function Access Learn Mode Calibration screen Sel
108. ystem Screen 2 This screen allows the user to set the Gel Timer proper ties and set which items are installed on the machine 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 based upon the user Alarm setting The alarm will sound the user entered number of seconds before the Idle Period expires The hydraulic level sensor and hydraulic RTD for both the pump line and mix head must be marked as enabled when installed in the system If the sensors are not marked as enabled they will be ignored by the machine controls Select the dispense valve installed in the system This selection is critical to ensure proper operation of the machine When a mix head is selected the Dispense Valve Details button will become active When active pressing this button will open a screen used to define the mix head operating parameters See the Mix Head Operating Details Screen on page 62 Selecting the dispense valve will limit the system maxi mum working pressure to the maximum working pres sure of the dispense valve See System Screen 1 on page 61 HEEHUEEZE L System Maintenance No Active Errors Pump Line Head
109. zones shown for reference Only four zones may be active at one time 3A2175A Errors Screens This screen shovvs users a list of errors that have occurred in the system Each error entry includes a description and error code along vvith a date and time stamp There are 5 pages each holding 10 errors The 50 most recent errors are shovvn Refer to the Troubleshooting section on page 49 for a detailed description of all of the system errors 03 10 10 15 34 e Status Event Shot mi No Active Errors late Time Code ClassDescription 050910 16 35 LT22 Dx Blue Low Material Level z n 15 05 CACS A Comm Error Red Tank 030910 16 05 P6B2 D Blue Pressure Sensor Fault 0535 0970 15 05 Red Pressure Sensor Fault 0370900 1505 D6ATLD Position Sensor Fault 03709070 15 05 TAHA Gil Temp Shutdown 0310900 16 05 TAMTA Motor Temp Shutdown 0370900 1548 LT22 Dx Blue Low Material Level Osa T847 LT22 Dr Blue Low Material Level O0900 T844 LT22 Dx Blue Low Material Level Events Screens This screen shows users a list of events that have occurred in the system Each event includes a descrip tion and event code along with a date and time stamp There are 20 pages each holding 10 events The 200 most recent events are shown Refer to the Troubleshooting section on page 49 for a detailed description of all of the system events 03 10 10 15 32 e Errors Maintenance Shot mi Mo Active Errors 10 05 EMOO R System

Graco 3A2175A User's Manual

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