Setup - Operation HFR™ 313997W EN Hydraulic, Plural-Component, Fixed-Ratio Proportioner. For pouring and dispensing sealants and adhesives and polyurethane foam. For professional use only. Not for use in explosive atmospheres. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 4 for model information and maximum working pressure.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product Configurator . . . . . . . . . . . . . . . . . . . . . . . 5 Whip Hose Bundles . . . . . . . . . . . . . . . . . . . . . . 7 Individual B (Blue) Heated Whip Hose . . . . . . . . 7 Individual A (Red) Heated Whip Hose . . . . . . . . 7 B (Blue) Individual . . . . . . . . . . . . . . . . . . . . . . . . 8 A (Red) Individual . . . . . . . . . . .
Related Manuals Related Manuals Manuals are available at www.graco.com.
Models Models See Product Configurator on page 5 for detailed product configuration information.
Product Configurator Product Configurator HFR - A - - - - - 2 3 4 5 6 Voltage B (Blue) Pump A (Red) Pump Primary/Hose Heat High Volume/Low Volume Hose Bundle Assembly Configurator Revision 1 Base Ref.: - An example of the product configurator would be the following configurator code. HFR - A - 1 - 6 - AM - AM - D - AG 3 4 5 6 High Volume/Low Volume Primary/Hose Heat A (Red) Pump B (Blue) Pump 2 Voltage Configurator Revision 1 Base Ref.
Product Configurator Ref.
Product Configurator Whip Hose Bundles Part Description 24H076 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel, Single Zone 24H077 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel, Single Zone 24H078 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel, Dual Zone 24H079 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel, Dual Zone 24H080 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless Steel, Single Zone 24H081 10 ft (3 m) long, 3/8 in.
Product Configurator Hoses Part B (Blue) Individual Description Description 24E902 Heated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi 24E904 Heated Hose, 10 ft, 1/4, Carbon Steel, 3500 psi 24D115 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Stainless Steel, 3500 psi 24E906 Heated Hose, 25 ft, 1/4, Carbon Steel, 3500 psi 24E908 Heated Hose, 50 ft, 1/4, Carbon Steel, 3500 psi 24D119 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel, 3500 psi 24E910 Heated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi 24E912 Heated H
Product Configurator 262239 Unheated Hose, 10 ft, 1/4, Stainless Steel, 3500 psi 262173 Unheated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi 262241 Unheated Hose, 25 ft, 1/4, Stainless Steel, 3500 psi 262175 Unheated Hose, 10 ft, 1/4, Carbon Steel, 3500 psi 262243 Unheated Hose, 50 ft, 1/4, Stainless Steel, 3500 psi 262177 Unheated Hose, 25 ft, 1/4, Carbon Steel, 3500 psi 262245 Unheated Hose, 5 ft, 3/8, Stainless Steel, 3500 psi 262179 Unheated Hose, 50 ft, 1/4, Carbon Steel, 3500 psi 262247
Product Configurator 24E900 Signal Cable, 5 pin, Male/Female, 2.0 meter 24E899 Signal Cable, 5 pin, Male/Female, 4.0 meter 24E898 Signal Cable, 5 pin, Male/Female, 8.5 meter 24E897 Signal Cable, 5 pin, Male/Female, 16.0 meter 24E896 Fluid Temperature Sensor Cable, 4 pin, Male/Female, 2.0 meter 24E895 Fluid Temperature Sensor Cable, 4 pin, Male/Female, 3.0 meter 24E894 Fluid Temperature Sensor Cable, 4 pin, Male/Female, 8.0 meter 24E893 Fluid Temperature Sensor Cable, 4 pin, Male/Female, 15.
Product Configurator 24D516 24D521 24D522 Applicator, MD2, 1:1, Hard, Stainless Steel, Pneumatic 0.60 24A040 S-Head Only 0.70 24A041 S-Head Only Applicator, MD2, 10:1, Soft, Carbon Steel 0.80 24A042 S-Head Only 0.90 24A043 S-Head Only 1.00 24A044 S-Head Only 1.10 24A045 S-Head Only 1.20 24A046 S-Head Only 1.
Product Configurator GX-16 Description Part 1.32 mm Poly Orifice 24C811 EP 250 Poly Side Orifice 1.40 mm Poly Orifice 24C812 EP 250 Poly Side Orifice 1.60 mm Poly Orifice 24C813 EP 250 Poly Side Orifice 24C815 EP 250 Poly Side Orifice 257701 0.011 in. Orifice 257702 0.013 in. Orifice 257703 0.016 in. Orifice 257704 0.018 in. Orifice 257705 0.020 in. Orifice 1.85 mm Poly Orifice 257706 0.022 in. Orifice Orifice Kit 24E251 EP 375, 6 Blue, 6 Red 257707 0.023 in.
Product Configurator Iso A (Red) Applicator Orifice S-Head and L-Head The A (Red) applicator orifices for the S-Head and L-Head are the same as the B (Blue) applicator orifices. See page 11. GX-16 Description Part 257701 0.011 in. Orifice 257702 0.013 in. Orifice 257703 0.016 in. Orifice 257704 0.018 in. Orifice 257705 0.020 in. Orifice 257706 0.022 in. Orifice 257707 0.023 in. Orifice 257708 0.024 in. Orifice 257709 0.025 in. Orifice 257710 0.026 in. Orifice 257711 0.028 in.
Product Configurator AC Power Pack with S-Head/L-Head Hoses, Optional Boom Flow Meters Flow Meter Electronics (Necessary) Part Part Description 24J318 Description Flow Meter Electronics Kit 24D829 230V, Boom, L-Head Hoses 24D830 230V, Boom, S-Head Hoses “A” and “B” Side Flow Meter (One for each side) 24D834 400V, Boom, L-Head Hoses 24D835 400V, Boom, S-Head Hoses 24D831 230V, L-Head Hoses, No Boom Part 24J319 S3000 Flow Meter Kit (0.01 to 0.
Product Configurator Pump Feed Kits Part Description 246081 2:1 (Air/Fluid) Carbon Steel Complete Supply Pump Kit 246369 H515 (Air/Fluid) Carbon Steel Complete Supply Pump Kit 246375 H716 (Air/Fluid) Carbon Steel Complete Supply Pump Kit 24D328 H1050 (Air/Fluid) Carbon Steel Complete Supply Pump Kit 24D102 Husky 1050 Pump with Stainless Steel Fluid Plumbing 24D103 2:1 Supply Pump with Stainless Steel Fluid Plumbing 24D104 5:1 Monarch Pump with Stainless Steel Fluid Plumbing 24D105 5:1 Monarch Pump
Product Configurator B (Blue) and A (Red) Feed Tanks Part Description 24D562 38L Tank, No Agitation, Chiller, Desiccant, 2 Level Sensors 24J209 20gal (75L) Stainless Steel Tank, 3 Level Sensors, Insulated 24J707 20gal (75L) Carbon Steel Tank, 3 Level Sensors, Insulated 24J243 2gal (7.
Product Configurator Additional Accessories Discrete Gateway Module (DGM) Miscellaneous Part Description 24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level Sensor 24C873 Hydraulic Power Pack Manifold Oil Temperature Sensor 24P090 Mobile Pallet Base with Casters 24F516 IsoGuard Select fluid, 6 quarts 121728 Extension Cable for Advanced Display Module, 4 meter, The HFR Discrete Gateway Module allows the user to control an HFR through multiple external control devices such as contact blocks or re
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable. WARNING ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: • • • • Use equipment only in well ventilated area. Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). Keep work area free of debris, including solvent, rags and gasoline.
Important Two-Component Material Information WARNING MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • • • Keep clear of moving parts. Do not operate equipment with protective guards or covers removed. Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. BURN HAZARD Equipment surfaces and fluid that’s heated can become very hot during operation.
A (Red) and B (Blue) Components Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.
A (Red) and B (Blue) Components 22 313997W
Typical Installation Typical Installation B (Blue) Side Supply Detail A (Red) Side Supply Detail K K M G L K G ti7821a3 ti7821a2 K A P J F N H D J E H P C* * Shown exposed for clarity. Wrap with tape during operation. B ti14720a FIG. 1 Key: A B C D E F G H J HFR Unit (see FIG.
Component Identification Component Identification Key for FIG. 2.
Component Identification MA MP HP FM PD AA PB HT FT PA FP FV FT FS PH LR FS FP 24C352_313998_3g CO Primary Heater (PH) Detail, B (Blue) side shown Fluid Manifold (FM) Detail SA GA TA PO GB SB FA Rear View PI TB LS FB PR BA PS HA BB HB ti9880a1 24C327_313998_1e 24C352_313998_4e FIG.
Component Identification Main Power Switch Located on top of the power distribution box, see page 25. The main power switch turns power ON and OFF . The main power switch Additional circuit breakers for protection of the secondary side of the heated hose transformer are located inside the frame. See the parts list for the installed primary/hose heat option. See Ref. 5 of the product configurator code for your machine to determine which primary/hose heat option is installed.
Component Identification Hydraulic Power Pack DK DG DB DF DE DH DA DD 24C352_313998_2g FIG.
Component Identification Motor Control Module (MCM) For MCM location, see reference MA in FIG. 2 on page 25. When installed, the end of the MCM with the power input connection (12) faces down and the end with the access cover (A) faces up. NOTICE If the Motor Control Module is replaced, the selector switch must be set prior to initial startup of the Motor Control Module or damage may occur. See HFR Repair manual for details, see Related Manuals on page 3.
Component Identification Ref Description A Access Cover B LEDs C Warning Label 1A, 1B CAN Connections 2 Three-way Splitter to: Oil Low Level Sensor, Dispense Valve Solenoid, and Footswitch 3 Oil Temperature Sensor 5 Electric Motor Temperature Sensor 6 LVDT 7 Three-way Splitter to: Hydraulic Directional Valve, Oil Overtemperature Switch 8 Pressure Transducer B (Blue) side 9 Pressure Transducer A (Red) side 10 Not used 11 Motor Position Sensor 12 MCM Power Input Connection 13 M
Component Identification Advanced Display Module (ADM) User Interface CB CC CA CD CE CF CH CG TI12362a1 FIG. 5: ADM Component Identification - Front Buttons Ref. Button Function Ref. CA System enable/ disable Enables/disables system. When system is disabled, temperature control and dispense operation are disabled. CD Soft Keys Defined by application using ADM. CE Cancel Cancel a selection or number entry while in the process of entering a number or making a selection.
Component Identification CJ CS CK CL CM CR CN CP r_24E451_3B9900_1a FIG.
Component Identification 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 46. Current date and time Mode Previous screen Current screen Next screen Faults, Status Enter/Exit screen Previous screen no. Current screen no. Function display Next screen no. FIG.
Component Identification Fluid Control Module (FCM) A C E ti12337a1 B F ti12336a1 D FIG.
Component Identification Temperature Control Module (Heated HFR Only) LED Signals 2 5 1 7 3 ti12352a1 6 ti12353a1 4 FIG. 9: High Power Temperature Control Module Sensor Connections Key: 1 2 3 Overtemperature Switch Connection (primary heaters only) RTD Temperature Sensor Connection Output Power Connection 4 5 6 7 DC Output Connection Input Power Connection CAN Connections Rotary Selector Switch, Token Access 1 5 2 6 3 ti12356a1 ti12357a1 4 7 FIG.
Component Identification Heat Control Zone Selection (Heated models only) The HFR unit supports 4 independent temperature control zones. The high power temperature control modules are located inside the frame below the hydraulic power pack.
Component Identification Adjust Rotary Switch High Power Module Rotary Switch Settings The rotary switch setting indicates which zone the temperature control module will control in the system. The high power module uses an 8-position rotary switch. The low power module uses a16-position rotary switch. Set the rotary switch (S) to the specific selection according to the settings listed in the following tables.
Dispense Valves Overview Dispense Valves Overview Three types of dispense valves can be used with the HFR system: • • • Stall-at-pressure Solenoid controlled Hydraulically actuated and recirculating The P2 Gun and Fusion Gun are examples of stall-at-pressure dispense valves. When not dispensing, the fluid in the chemical lines are fully pressurized. When using a stall-to-pressure dispense valve, a footswitch cannot be used. Any signals sent from a footswitch will be ignored.
Setup Setup Perform this setup procedure to secure all necessary machine connections for machine operation. 3. Connect electrical cord. 1. Locate HFR. a. Locate HFR on a level surface. See Dimensions on page 110 for space requirements. b. Anchor the HFR to the floor (suggested anchors: McMaster Carr anchor, 92403A400). See Dimensions, page 110, for bolt locations. If machine mobility is required, purchase Mobile Pallet Base with Casters Kit, 24P090.
Setup c. 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). Press “Min Max” successively to show the peak positive and negative DC voltages. d. Confirm readings do not exceed 400VDC (Motor Control Module alarm issued at 420VDC).
Setup 4. Connect feed lines 5. Connect pressure relief lines a. Install feed pumps (K) in component A (Red) and B (Blue) supply drums. See FIG. 1 and FIG. 2, pages 23 and 25. NOTE: A minimum feed pressure of 50 psi (0.35 MPa, 3.5 bar) is required at both feed inlet pressure gauges (FP). Maximum feed pressure is 250 psi (1.75 MPa, 17.5 bar). Maintain A (Red) and B (Blue) feed pressures within 10% of each other. FP Do not install shutoffs downstream of the PRESSURE RELIEF/DISPENSE valve outlets (BA, BB).
Setup 7. Connect heated hose monitor zones NOTE: For Heated HFR models only, see Heated Hose manual for detailed instructions on connecting heated hoses. NOTICE For Heated HFR models only, the FTS (C) and whip hose (D) must be used with heated hose. See step 6 on page 40 for FTS installation. Hose length, including whip hose, must be 10 ft (3 m) minimum. d. For Heated HFR Models only, connect cables (Y). Connect electrical connectors (V). Be sure cables have slack when hose bends.
Setup 9. For models with an MD2 valve, connect whip hose to MD2 valve component A (Red) and component B (Blue) fluid inlets. For models with a dispense gun, connect whip hose to gun fluid manifold. Do not connect manifold to gun. See FIG. 13. pense gun firmly to the side of a grounded metal pail, then trigger gun. 12. Check hydraulic fluid level Hydraulic reservoir is filled at the factory. Check fluid level before operating the first time, and weekly thereafter.
Setup 14. Prime IsoGuard Select fluid cylinder g. Press The IsoGuard Select fluid cylinder must be primed when replacing IsoGuard Select fluid. See IsoGuard Select® System on page 57 for instructions. to enable system. LED should be solid green. h. Check that heat zones are on and temperatures are on target, see Status Screen on page 85. 15. Install dispense valve a. Navigate to System Screen 2 and select the appropriate dispense valve from the “Dispense Valve” dropdown menu.
Setup n. For EP Gun and GX-16, perform a test pour into a waste container. Adjust pressure and temperature to get desired results. Equipment is ready to dispense. o. p. For all dispense valves other than the EP Gun, perform mix ratio test using two tared cups. Weigh the cups and divide the weights to verify the mix ratio by weight. See Ratio Checking section in the dispense valve manual for more information. For Fusion dispense valves, perform DC Power Pack Hydraulic Pressure Setup.
Setup Vacuum De-gas and Vacuum Manual Refill 12. Close bottom ball valve of the vacuum tree manifold). 13. Turn off the vacuum pump. NOTE: This procedure is for assemblies with a vacuum tree manifold, agitator, and auto-refill. 1. Press the Select Operating Mode button ( 14. Open the top ball valve of the vacuum tree manifold.
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. 7. If L-Head is installed, define L-Head control details. See Mix Head Operating Details Screen, page 74. 8. Define level sensors and refill settings. See Supply Screen, page 76. 9. Enable/disable temperature conditioning components.
Startup Startup g. Open fluid inlet valves (FV). Check for leaks. Do not operate HFR without all covers and shrouds in place. FV 1. Use feed pumps to load fluid ti10002a1 NOTE: The HFR is tested with oil at the factory. Flush out the oil with a compatible solvent before dispensing. See Flushing on page 52. Keep Components A (Red) and B (Blue) Separate a. Check that all machine connections are setup. See Setup procedure, page 38. b. Check that inlet screens are clean before daily startup, see page 56.
Startup 2. Calibrate HFR The HFR calibration procedure is a two step process. The first step, Learn Mode, must be performed whenever the pump line is rebuilt or if any other maintenance is performed that may affect the mechanical tolerances in the pump line. If the machine does not appear to be utilizing the full extent of the pump stroke, or if the machine appears to be contacting the end of the hydraulic cylinder, follow the Learn Mode procedure.
Startup 3. Set temperatures (Heated models only) This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns: • Do not touch hot fluid or equipment. • Allow equipment to cool completely before touching it. • Wear gloves if fluid temperature exceeds 110°F (43°C). For detailed temperature adjustments, including alarm levels, or upon initial machine configuration, see Conditioning Screen 2 on page 78 for details.
Shutdown Shutdown 1. Park pumps. a. From the Home screen, press Standby mode. and select b. Press . Material will dispense for non circulation systems. 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 for non circulation systems. c. For models with an EP, Fusion, or P2 gun only, turn diversion valves to tank then press Park .
Pressure Relief Procedure Pressure Relief Procedure 1. Shut off feed pumps and agitator, if used. 2. Turn PRESSURE RELIEF/DISPENSE valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0. SA 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.
Flushing Flushing • Flush equipment 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. • Use the lowest possible pressure when flushing. • All fluid components are compatible with common solvents. Use only moisture-free solvents.
Maintenance Maintenance Change Break-in Oil After initial break-in, see Table 5 for recommended frequency of oil changes.
Maintenance ADM - Battery Replacement and Screen Cleaning MCM and TCM - Clean Heat Sink Fins Battery Replacement Keep heat sink fins clean at all times. Clean them using compressed air. A lithium battery maintains the ADM clock when power is not connected. To replace the battery: NOTE: Do not use conductive cleaning solvents on the module. 1. Disconnect power to the ADM. NOTE: This can be done by removing the CAN cable from the bottom of the ADM. Heat Sink Fins 2. Remove rear access panel.
Maintenance Install Upgrade Tokens NOTE: The Motor Control Module, Fluid Control Module, and Temperature Control Module connection to the system is temporarily disabled during the installation of upgrade tokens. To install software upgrades: 1. Use correct software token stated in the table. See Graco Control Architecture™ Module Programming manual for instructions.
Maintenance Fluid Inlet Strainer Screen 6. Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation. 59d 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 required. The standard strainer is 20 mesh. 59g* 59h 59j Use clean chemicals and follow proper storage, transfer, and operating procedures, to minimize contamination of the A-side screen.
Maintenance IsoGuard Select® System 9. Push the return tube (RT) into the reservoir until it reaches the bottom. NOTE: Check 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 with isocyanate. 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.
Troubleshooting Troubleshooting Light Tower (Optional) Signal Description Green on only System is powered up and there are no error conditions present Yellow on An advisory exists Red flashing A deviation exists Red on The system is shut down due to an alarm occurring. Before performing any troubleshooting procedure: 1. Perform Pressure Relief Procedure on page 51. 2. Turn main power OFF. 3. Allow equipment to cool.
Troubleshooting Problem Cause Hose Heat System Hose heats but heats slower Ambient temperature is too cold than usual or it does not FTS failed or not installed correctly reach temperature Low supply voltage Solution Use auxiliary hose system. Check FTS Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths. Hose does not maintain tem- A and B setpoints too low Increase A (Red) and B (Blue) setpoints.
Troubleshooting Problem Material imbalance. Cause Solution Inadequate flow from pump; cavitation Increase fluid supply to proportioning pump: • • Erratic pump movement Pump output low 60 Pressure relief/circulation valve leaking back to supply Pump cavitation Obstructed fluid hose or gun; fluid hose ID too small Worn piston valve or intake valve in displacement pump Inadequate feed pump pressure Use 2:1 supply pump Use minimum 3/4 in. (19 mm) ID supply hose, as short as practical Fluid is too thick.
Troubleshooting ADM Troubleshooting CJ CS CK CL CM CR CN CP r_24E451_3B9900_1a FIG. 18: ADM Component Identification - Rear ADM Module Status LEDs (CN) Conditions Module Status LED Signal Description Green on System is powered up. Yellow on Communication in progress. Red solid ADM hardware failure. Red flashing Uploading software. USB Module Status LEDs (CL) Conditions Module Status LED Signal Description Green flashing System is powered up.
Troubleshooting Motor Control Module For MCM location, see reference MA in FIG. 2 on page 25. Diagnostic Information 7 Table 3: LED Status Signal Module Status LED Signal Description Green on System is powered up. Yellow on Internal communication in progress. Red solid MCM hardware failure. Replace MCM. Red flashing fast Uploading software. Red flashing slow Token error. Remove token and upload software token again. LED Signals r_257396_3b9905_07b FIG.
Troubleshooting Acceptable Size and Duration of Power Line Voltage Fluctuations The Motor Control Module is designed to withstand voltage fluctuations from the incoming power supply. If the incoming power supply goes outside of the tolerable range, an over-voltage condition is flagged and the system shuts down in an alarm state. Excessive or repeated over-voltage may permanently damage hardware. The chart below shows the permissible magnitude and duration of temporary over-voltage events.
Troubleshooting Fluid Control Module Diagnostic Information Module Status LED Signal Diagnosis Green on System is powered up Yellow Internal communication in progress Red solid FCM hardware failure. Replace FCM. Red flashing fast Uploading software Red flashing slow Token error. Remove token and upload software token again. Module Status LEDs ti12337a1 FIG.
Troubleshooting Temperature Control Module Diagnostic Information Module Status LEDs Signal Description Green on Temperature control module is powered up. Yellow on Internal communication in progress. Red solid Temperature control module failure. See Troubleshooting table. Red flashing Software is updating. Blue light off (High Power Module only) Temperature control module is off. See Troubleshooting table.
Appendix A - ADM Icons Overview Appendix A - ADM Icons Overview Setup Screen Icons Icon Description Icon Description Enter Screen Erase All Counters on Page Exit Screen Access Flowmeter Calibration On Learn Mode Calibration screen: Move pump Valve Details All other screens: Begin Dispense Selects all shots to be changed to the same user specific value Stop Dispense Abort Changing the Label Pressure Shot Number Sequence Position Select left direction Flow Select right direction Time (Duration
Appendix A - ADM Icons Overview Run Screen Icons Icon Description Description Select mode. Sets machine to low pressure Set system in park (icon will be selected when system is parked) Sets machine to high pressure Open, Close Valve A (Red) and B (Blue) refill button (Press to start/abort refill) With a mix head installed: Turns on the mix head hydraulics and puts the machine in low pressure circulation. Press a second time to turn off instigated system action.
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 to access the Setup screens. If the Setup screens password is turned on, use the ADM keypad to enter the password then press From the Setup screens, press to access the Run screens. For Run screens information, see Appendix C - ADM Run Screens Overview on page 82. FIG. 22 shows the flow of the Setup screens. .
Appendix B - ADM Setup Screens Overview Shots Screen This screen allows 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 flow rate depending upon the Control Mode selection and by time (duration), volume, or weight depending upon the Dispense Mode selection. See System Screen #1 for Control and Dispense Mode options.
Appendix B - ADM Setup Screens Overview 4. Use the following formula to calculate the Δ column value. Volume/Weight Based Example: A 75 cc/s shot is defined to dispense for 75 cc. ((Flow Rate x Time) - Average Volume) Flow Rate Example 1: ((75cc/sec x 2sec) - 146cc) 75 cc/sec = 0.053 sec Example 2: ((75cc/sec x 2sec) - 156cc) 75 cc/sec = -0.08 sec 5. Enter the calculated value in the Δ column. Example 1: 1. Dispense 5 shots into 5 separate containers. 2.
Appendix B - ADM Setup Screens Overview 5. Enter the calculated value in the Δ column. Example 3: Sequences Screen This screen allows the user to edit sequence information. 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 73 for Dispense Mode options. See Home Screen, Sequence Mode on page 84 for information on how to use predefined sequences.
Appendix B - ADM Setup Screens Overview Calibration Screen, Main Calibration Screen, Learn Mode This screen shows calibration information for the system and provides access to other calibration screens. See Calibrate HFR on page 48 for how to use the calibration screens to calibrate the machine. 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.
Appendix B - ADM Setup Screens Overview System Screen 1 System Screen 2 NOTE: Not all of the following modes may be available depending on the dispense valve selected. This screen allows the user to set the Gel Timer properties and set which items are installed on the machine. This screen allows the user to set important system settings specific to what dispense applicator has been selected. Control Mode can be set to Pressure or Flow.
Appendix B - ADM Setup Screens Overview Pre Dispense Delay is a feature where the HFR can delay the start of a dispense until the user has pressed and held the foot switch for the duration entered. For example, if the user enters a five second duration, the footswitch must be held on continuously for five seconds before the HFR will start a dispense. This feature is not available for recirculation systems or applicable for P2/Fusion Dispense Valve applications.
Appendix B - ADM Setup Screens Overview System Screen 3 Keyboard Screen 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. 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. To edit a label: 1. Press . 2.
Appendix B - ADM Setup Screens Overview Maintenance Screen Supply Screen This screen shows shot number, sequence position, and This screen allows the user to specify the operating parameters for off-board, integrated tanks and indicate which positions have level sensors installed. See the Tank Feed Systems manual for information about installing level sensors, see Related Manuals on page 3. The user may select from the following refill settings: Disabled, Monitor, Manual, Auto Top-Off, Auto Full-Volume.
Appendix B - ADM Setup Screens Overview • • When the high level sensor does not see material, automatic refill will begin and continue until either the high level sensor sees material or until the refill time-out expires • The low level alarm will clear when the condition clears • 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 Auto Full-Volume • The low level sensor will initiate an autom
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. 2. Press to display the setpoint and alarm values associated with that 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. 3.
Appendix B - ADM Setup Screens Overview Conditioning Screen 3 This screen allows the user to configure Night Mode operation. In Night Mode, the system will cycle on and off periodically or turn on at a preset time. Press and select periodic or time schemes. 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.
Appendix B - ADM Setup Screens Overview NOTE: If times are entered in the weekly schedule, individual days can not be erased. Cold Start Up Mode Advanced Screen 1 This screen allows the user to set the language, date format, current date, time, setup screens password, screen saver delay, and turn on or off silent mode. Allows the user to select what mode the machine will enter once the cold start-up is complete.
Appendix B - ADM Setup Screens Overview Advanced Screen 3 Advanced Screen 4 This screen allows the user to control the availability of some key system features. • Limit Rate on Stall to Pressure: Check this box to allow the HFR to increase to stalling pressure at a slower, more controlled rate. • Enable Diagnostic Screen: Check this box to enable the optional ADM screens, enabling USB log downloading, and erasing USB logs.
Appendix C - ADM Run Screens Overview Appendix C - ADM Run Screens Overview Run screens are 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. Home Status Errors #1 Events #1 Errors #2 Events #2 Errors #... Events #... Maintenance FIG. 23: Run Screens Navigation Diagram Home Screen Home Screen, Disabled Mode The Home screen is the first screen that displays in the Run screens.
Appendix C - ADM Run Screens Overview Home Screen, Standby Mode Home Screen, Shot Mode In Standby Mode, the user can enable heating, park the pumps, refill the tanks, circulate materials. This mode allows the user to select one of 100 predefined shot numbers. See Shots Screen on page 69 for information about editing shot definitions. To use a predefined shot: 1. Enter shot mode. 2. Press and use the numeric keypad to enter the desired shot number. 3. Press Press to change operating modes.
Appendix C - ADM Run Screens Overview Home Screen, Sequence Mode Home Screen, Operator 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 71 for information about editing sequence definitions. This mode allows users to set a pressure or flow rate to dispense material without using predefined shot information.
Appendix C - ADM Run Screens Overview 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 79. Status Screen The status screen provides all of the operational functionality of the Home screen except for operating mode selection. Refer to the Home screen and operating mode descriptions for information on this functionality.
Appendix C - ADM Run Screens Overview Status Screen, Conditioning Control Errors Screens This screen allows users to turn on and off heat zones individually or all at once. When a zone is on it is actively controlling temperature. Refer to the table below for color code definitions. This screen shows users a list of errors that have occurred in the system. Each error entry includes a description and error code along with a date and time stamp. There are 5 pages, each holding 10 errors.
Appendix C - ADM Run Screens Overview Maintenance Screen 1 Optional Screens 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 material usage counters, units are displayed next to the volume/weight indicator icons.
Appendix D - ADM Error Codes Appendix D - ADM Error Codes Error Code A4H3 DEH3 MBH3 P1H3 P4H3 T4H3 WDF3 WDD3 0500 02D0 A4A6 A4B5 A4A3 A4B1 A4A2 A4B4 A4A7 A4B8 A4H1 A4M1 88 Error Error Name Error Description Type Cause Solution Mix Head Motor Overload Soft Stop Asserted Low Mix Head Oil Level Low Accumulator Pressure Refer to AC Power Pack manual High Accumulator Pressure High Mix Head Oil Temp.
Appendix D - ADM Error Codes Error Code A4N1 A7A6 A7B5 A7A3 A7B1 A7A2 A7B4 A7A7 A7B8 A8A6 A8B5 A8A3 A8B1 A8A2 A8B4 A8B7 A8B8 A9C1 Error Type Error Name Error Description Motor Over Current A hardware current fault has occurred causing a system shutdown Alarm Unexpected current to heater/chiller Alarm Red Blanket Control Fault Blue Blanket Control Fault Red Inline Control Fault Blue Inline Control Fault Red Hose Control Fault Blue Hose Control Fault Red Chiller Control Fault Blue Chiller Contr
Appendix D - ADM Error Codes Error Code CAA2 CAA3 CAA6 CAA7 CAB1 CAB4 CAB5 CAB8 CAC1 CAC2 CAC3 CAC4 CAC5 CAC6 CAC7 CACN CACP CACR Error Name Error Description Comm. Error Red Hose Comm. Error Red Inline Comm. Error Red Blanket Comm. Error Red Chiller Comm. Error Blue Inline Comm. Error Blue Hose Comm. Error Blue Blanket Comm. Error Blue Chiller Comm. Error Motor Comm. Error Communication error MCM Comm. Error Red Tank Comm. Error Blue Tank Comm. Error Mix Head Comm. Error Mix Head 2 Comm.
Appendix D - ADM Error Codes Error Code D5A1 Error Error Description Type This calibration lets the MCM know where the ends of the pump are. If the data gathered Invalid Learn during this process is outside Deviation Mode Data of normal parameters the machine will operate with a greatly reduced stroke.
Appendix D - ADM Error Codes Error Code Error Name Red Tank L8A1 Sensor Failure Blue Tank DR6B Sensor Failure Error Description A level sensor had ceased working Error Type Cause Deviation Bad level sensor Solution 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 The volume of oil in the tank is Bad level sensor Replace s
Appendix D - ADM Error Codes Error Code P4A1 Error Name Error Description Red Pressure Shutdown P4B2 Blue Pressure Shutdown P4D0 Pressure Imbalance P6A1 P6B2 R1D0 R4D0 R2D0 R3D0 Red Pressure Sensor Fault Blue Pressure Sensor Fault Low Ratio Alarm High Ratio Alarm Low Ratio Deviation High Ratio Deviation 313997W Error Type The material pump pressure exceeded the maximum Alarm operating pressure as defined in the setup screens The pressure difference between the Red and Blue material is greater th
Appendix D - ADM Error Codes Error Code T1A6 T1B5 T1A3 T1B1 T1A2 T1B4 T1A7 T1B8 T20X T30X 94 Error Name Red Tank Low Fluid Temp. Blue Tank Low Fluid Temp. Red Inline Low Fluid Temp. Blue Inline Low Fluid Temp. Red Hose Low Fluid Temp. Blue Hose Low Fluid Temp. Red Chiller Low Fluid Temp. Blue Chiller Low Fluid Temp.
Appendix D - ADM Error Codes Error Code Error Name Red Hose T2AA Low Fluid Temp. Red Tank T2AE Low Fluid Temp. Red Chiller T2AF Low Fluid Temp. Blue Hose T2BC Low Fluid Temp. Blue tank Low T2BD Fluid Temp. Blue Chiller T2BG Low Fluid Temp. Red Hose T3AA High Fluid Temp. Red Tank T3AE High Fluid Temp. Red Chiller T3AF High Fluid Temp. Blue Hose T3BC High Fluid Temp. Blue Tank T3BD High Fluid Temp. Blue Chiller T3BG High Fluid Temp. T3H1 Oil Temp.
Appendix D - ADM Error Codes Error Code T4A2 T4A3 T4A6 T4A7 T4B1 T4B4 T4B5 T4B8 T4C1 Error Name Red Hose High Fluid Temp. Red Inline High Fluid Temp. Red Tank High Fluid Temp. Red Chiller High Fluid Temp. Blue Inline High Fluid Temp. Blue Hose High Fluid Temp. Blue Tank High Fluid Temp. Blue Chiller High Fluid Temp. Error Description Error Type The temperature the MCM has reached a level where product Motor Control Alarm life will be decreased High Temp.
Appendix D - ADM Error Codes Error Code T6C6 T6C5 T6C7 T6C8 T8A6 T8B5 T8A3 T8B1 T8A2 T8B4 T8A7 T8B8 T9A6 T9B5 T9A3 T9B1 T9C6 T9C5 T9C3 T9C1 T9C2 T9C4 T9C7 T9C8 Error Name Error Description Red Blanket RTD Fault Blue Blanket RTD Fault RTD 2 is giving no or invalid data Red Chiller RTD Fault Blue Chiller RTD Fault No Heat Red Tank No Heat Blue Tank No Heat Red Inline No temperature rise No Heat Blue Inline Error Type No temperature decline Loose or bad connection Check RTD wiring Alarm Heater ov
Appendix D - ADM Error Codes Error Code V1H1 V4A6 V4B5 V4A3 V4B1 V4A2 V4B4 V4A7 V4B8 V4H0 W0U0 Error Error Description Type The voltage to the MCM has Motor Control dropped to a level where Alarm Undervoltage performance is greatly affected Red Blanket Overvoltage Blue Blanket Overvoltage Red Inline Overvoltage Blue Inline Overvoltage High line voltage Alarm Red Hose Overvoltage Blue Hose Overvoltage Red Chiller Overvoltage Blue Chiller Overvoltage The voltage to the MCM has Motor Control reached an uns
Appendix D - ADM Error Codes Error Code WM06 WM05 WM03 WM01 WM02 WM04 WM07 WM08 WMA6 Error Name Red Tank Con. Fault Blue Tank Con. Fault Red Inline Con. Fault Blue Inline Con. Fault Red Hose Con. Fault Blue Hose Con. Fault Red Chiller Con. Fault Blue Chiller Con. Fault Red Blanket High Temp.
Appendix E - System Events Appendix E - System Events Event Code and String REL00: System Powered On REM00: System Powered Off REB00: Stop Button Pressed RECH0: Learn Mode Executed RENN0: Automatic Cal. Performed RECA1: Red Material SG Modified RECB2: Blue Material SG Modified RENC1: Cal. Point 1 Weight Entered RENC2: Cal. Point 2 Weight Entered RENC4: Cal. Point 1 Weight Erased RENC5: Cal. Point 2 Weight Erased REND0: Ratio Check Dispense Triggers The System was powered on. The System was powered off.
Appendix E - System Events 313997W 101
Appendix F - USB Operation Appendix F - USB Operation Overview Download Log Files There are 3 main uses for the USB on a GMS™ system If the “Enable Downloading of USB Logs” is checked, the user can use a USB stick-drive to download the log files. • • • Ability to download a log of up to the past 50,000 errors, events, or jobs that can contain over 150,000 snapshots of critical dispense information.
Appendix F - USB Operation Log Files, Folder Structure FIG. 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 downloaded or uploaded. In each DATAxxxx folder there is three log files. They are formatted as .csv (comma separated value) files and can be opened by most text editors or data processing programs such as Excel.
Appendix F - USB Operation Example 2-JOB File The 2-JOB file is the Shot Data Log file. Example 3-SYSTEM File The 3-SYSTEM file is the Software Version log file.
Appendix F - USB Operation Transfer System Settings NOTICE Low-quality USB stick drives may lead to burning out the USB port on the ADM. Use only high-quality USB stick-drives with the ADM USB port. 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 transferred. Once the download is complete the SETTINGS.TXT file will be located in the “DOWNLOAD” folder.
Appendix F - USB Operation Update Custom Language NOTICE Low-quality USB stick drives may lead to burning out the USB port on the ADM. Use only high-quality USB stick-drives with the ADM USB port. Use the following process to customize the text on the ADM. The language file DISPTEXT.TXT can be modified in Excel but must be saved as a Unicode Text file with the extension .TXT in order for it to properly import. 1.
Appendix F - USB Operation Example SETTINGS.TXT File Example DISPTEXT.TXT File NOTICE The user should never attempt to modify the SETTINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified setup file.
Technical Data Technical Data Maximum Fluid Working Pressure . . . Maximum Fluid Temperature . . . . . . . Fluid Inlet Feed Pressure Range . . . . Fluid Inlets . . . . . . . . . . . . . . . . . . . . . Fluid Outlets. . . . . . . . . . . . . . . . . . . . Fluid Circulation Ports . . . . . . . . . . . . Line Voltage Requirement . . . . . . . . . Amperage Requirement. . . . . . . . . . . Sound Power . . . . . . . . . . . . . . . . . . .
Motor Control Module Technical Data Motor Control Module Technical Data Input Specifications Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Line Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Line Frequency . . . . . . . . . . . . . . . . . . . . . . . . . Input Current per Phase. . . . . . . . . . . . . . . . . . . . . . . Maximum Branch Circuit Protection Rating: . . . . . . . Short Circuit Current Rating. . . . . . . . . . . . . . . . . . . .
Motor Control Module Technical Data Dimensions 34.1 in. (870 mm) 47.5 in. (1210 mm) 59.8 in. (1520 mm) D Bolt Mounting Pattern and Dimensions Type of Base E Right Front 110 Ref No Pallet Pallet D 24 in. 32.4 in. (610 mm) (823 mm) E 15 in. 30.3 in.
Motor Control Module Technical Data 313997W 111
Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
