Setup - Operation HFR™ for NVH Foam - Cart 3A2797G EN Hydraulic, Plural-Component, Fixed-Ratio Proportioner. For dispensing NVH foam. 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.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 GX-16 Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . 6 B (Blue) and A (Red) Feed Tanks . . . . . . . . . . . 6 AC Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Manuals Related Manuals Manuals are available at www.graco.com.
Models Models Primary Heater Watts A (Red) System Full Load Peak Amps Per Phase* Voltage (phase) 24N569 90 230V (3) 24N570 ★✖ 68 400V (3) 24N571 90 230V (3) 24N572 ★✖ 68 400V (3) 24N573 90 230V (3) 24N574 ★✖ 68 400V (3) 24N575 90 230V (3) 24N576 ★✖ 68 400V (3) System 24N569 24N570 ★ 24N571 24N572 ★ 24N573 24N574 ★ 24N575 24N576 ★ System Primary Heater Watts B (Blue) Max Flow Rate◆ lb/min (kg/min) Approximate Output per Cycle (A+B) gal.
Models * Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less. ◆ Flow rate is independent of frequency 50/60 Hz. 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.
Accessories Accessories Applicator B (Blue) and A (Red) Feed Tanks Part Description 24J187 GX-16, 24:1, Straight, Machine Mount 24K233 GX-16, 24:1, Left, Machine Mount 24K234 GX-16, No Orifice, Left, Machine Mount 24E876 GX-16, No Orifice, Straight, Machine Mount 24E877 GX-16, 24:1, Right, Machine Mount 24E878 GX-16, No Orifice, Right, Machine Mount GX-16 Orifices Part Part 20 gal. (75 l) Stainless Steel Tank, No Agitation, Insulation, 3 Level Sensors, A-Side 24N595 20 gal.
Accessories Additional Accessories Part Description 24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level Sensor 24C873 Hydraulic Power Pack Manifold Oil Temperature Sensor 24F516 IsoGuard Select fluid, 6 quarts 121728 Extension Cable for Advanced Display Module, 4 meter, 255468 Light Tower 255244 Foot Switch with Guard and 4 meter Cable 24G389 Pneumatic Agitator for 20 gal. (75 l) Carbon Steel Tank, No Heat 24K344 Pneumatic Agitator for 20 gal.
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.
Warnings WARNING 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.
Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area.
A (Red) and B (Blue) Components Changing Materials • When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. • Always clean the fluid inlet strainers after flushing. • Check with your material manufacturer for chemical compatibility. • Most materials use ISO on the A (Red) side, but some use ISO on the B (Blue) side. See the following section.
Typical Installation Typical Installation C D A G H B J E F* ti19507a * Shown exposed for clarity. Wrap with tape during operation. FIG.
Component Identification Component Identification Key for FIG. 2 and FIG. 3.
Component Identification Fluid Manifold (FM) Detail SA GA Rear View TB GB SB TA MP FA LS FB BA BB HA HB ti9880a1 ti19510a Primary Heater (PHB) Detail, B (Blue) side shown Primary Heater (PHA) Detail, A (Red) side shown PO PI PS (In Enclosure) PR PI PS ti19511a ti19509a PO PR FIG.
Component Identification Main Power Switch Circuit Breakers Located on top of the power distribution box, see page 14. The main power switch turns power ON and OFF . The main power switch does not turn pumps or heat zones on. Most circuit breakers are located inside the power distribution box. The main block of circuit breakers in the power distribution box is shown below, with detailed information in the following table.
Component Identification HFR Hydraulic Power Pack DE DG DF DK DB DH DA DD ti19514a DL FIG.
Component Identification Motor Control Module (MCM) For MCM location, see reference MA in FIG. 2 on page 14. 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 (Position Sensor) 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
Component Identification Advanced Display Module (ADM) User Interface CB CC CD CA CE CF CF CH CG TI12362a1 FIG. 6: ADM Component Identification - Front Buttons Ref. Button Function CA System enable/ disable Enables/disables system. When system is disabled, temperature control and dispense operation are disabled. CB System Displays system status. See System Status Status Indicator (CB) Conditions on Indicator page 20 for details. Light CC Stop CD Soft Keys Defined by application using ADM.
Component Identification CJ CS CK CL CM CR CN CP r_24E451_3B9900_1a FIG. 7: ADM Component Identification - Rear Key: CJ CK CL CM Flat Panel Mount Model Number USB Module Interface CAN Cable Connections CN CP CR CS Module Status LEDs Accessory Cable Connections Token Access Cover Battery Access Cover 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.
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 Shutdown, page 44. Current date and time Mode Previous chapter (Left Arrow) Current chapter Next chapter (Right Arrow) Faults, Status Enter/Exit screen Previous page (Up Arrow) Current page Function display Next page (Down Arrow) FIG.
Component Identification Fluid Control Module (FCM) A C E ti12337a1 B ti12336a1 F D FIG. 9: Fluid Control Module (FCM) Key: A B C Fluid Control Module Base Module Connection Screws D E F Access Cover Module Status LEDs CAN Connectors Diagnostic Information Module Status LED (Ref E) 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.
Component Identification Temperature Control Module LED Signals 2 5 1 7 3 ti12352a1 6 ti12353a1 4 FIG. 10: 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 5 1 2 LED Signals 6 3 ti12356a1 ti12357a1 4 7 FIG.
Component Identification 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 fast Uploading software. Red flashing slow Token error. Remove token and upload software token again. Blue light off (High Power Module only) Temperature control module is off.
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 a 16-position rotary switch. Setting Zone 0 Not Used 1 B (Blue) Primary Heat 2 B (Blue) Hose Heat Set the rotary switch (S) to the specific selection according to the settings listed in the following tables.
Component Identification 3A2797G 27
Setup Setup Perform this setup procedure to secure all necessary machine connections for machine operation. 3. Ground system 1. Locate system. a. Locate system on a level surface. See Dimensions on page 97 for space requirements. b. Do not expose system to rain. 2. Electrical requirements. See Models on page 4 for detailed electrical requirements information. Installing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.
Setup Table 2: Power Cord Requirements Cord Requirements AWG (mm2) Model Heated system, 230V, 3 phase 4 (21.2), 3 wire + ground Heated system, 400V, 3 phase 4 (21.2), 4 wire + ground † † Residual Current Device (RCD) must be rated at 300 mA if installed. Electrical Cord Wires by Model 230V, 3 phase: L1, L2, L3, GND 400V, 3 phase: L1, L2, L3, N, GND The MAX-HOLD feature on a multimeter can be used to determine peak DC voltage on the line.
Setup 5. Connect HFR Proximity Cables to the GX-16. 6. Connect Hydraulic Lines to the system. NOTE: Refer to the HFR and GX-16 manuals for more details for the following procedures. NOTE: The cable is indicated by a green stripe. a. Connect the GX-16 proximity sensor to the proximity cable. b. c. Connect the 10 ft (3 m) hydraulic whip hose cable to the 25 ft (7.6 m) chemical hose cable. Connect the other end of the cable to the electrical connector found near the fluid manifold on the HFR.
Setup 7. Install GX-16 Fitting Adapter Kit (Models 24N575 and 24N576 Only). 8. Install Flow Meter Kit (Optional). Refer to HFR Flow Meter Kits, Instruction-Parts manual for installation and setup instructions. a. Remove the chemical fittings from the back of the GX-16. b. Install JIC #4 fitting assembly into the B Supply port. c. Install JIC #6 fitting assembly into the B Return port. d. Install JIC #8 fitting assembly into both A Supply and A Return ports. 3A2797G 9.
Setup Step 9g, Step 9h Step 9i, Step 9j Step 9c, Step 9d, Step 9e, Step 9f ti19507a FIG.
Setup 10. Connect Material Hoses d. Remove reducer fitting from B (Blue) connection of the HFR fluid manifold (Models 24N573, 24N574 only). Install the provided additional spacers near the location of the FTS for the remaining material lines. Refer to FIG. 15 and FIG. 16. NOTICE HFR material manifold Avoid routing hoses in walkway areas to prevent operators from tripping on hoses running between system components. This also prevents fittings from leaking. A B Remove reducer NOTE: Refer to FIG.
Setup h. Connect cables (Y). Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape. See Heated Hose manual for heated hose connection details and illustrations for the various types of heated hoses. 11. Connect GX-16 Hydraulic Lines a. Navigate to the System Screen 2 and set the mode to run as straight head: prox dispense valve. Y Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts. b.
Setup together. This creates a hydraulic fluid circulation loop. NOTE: The hydraulic hose marked with both green and white stripe is for the open port of the gun. The hydraulic hose marked with only a green stripe is for the close port of the gun. ti14495a FIG. 18: Hydraulic Loop ti14496a FIG. 19: Hydraulic Connections e. Turn on the power pack by navigating to the Home Screen, Standby Mode and press . Circulate oil for 3 minutes to purge air from hydraulic hoses. j.
Setup 12. Setup the Advanced Display Module (ADM) Perform the following tasks to fully setup your system. 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. Enter Setup Mode by pressing the button. a. Define shots. See Shots Screen, page 55 for more detail. b. Define sequences. See Sequences Screen, page 58 for more detail. c. Calibrate HFR, page 37.
Setup 13. Calibrate HFR • Set temperatures: NOTE: Machine is calibrated from the factory. Only perform the following steps when changing or rebuilding pumps. 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.
Setup a. Navigate to System Screen 3. b. Press c. Navigate to the pressure imbalance field. to enter the screen. d. Type the desired pressure imbalance setting then press 14. Flush the System . e. Press and input the specific gravity (SG) of each material into the ADM. NOTE: System components will contain testing oil from the factory. Perform the following procedure when the machine is initially installed. Both supply and pressure relief must be flushed. a.
Setup 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 75 psi (517 kPa, 5.2 bar). Maintain A (Red) and B (Blue) feed pressures within 10% of each other. l. Stop dispensing by pushing Standby Screen. from the m. Close feed inlet valve and the material supply ball valve on the system. n. Connect the applicator return hose to the fluid inlet fitting on the system. FP ti10006a1 g. Turn HFR main power ON . h.
Setup 15. Install GX-16 Orifices 16. Pressure check hose See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage. a. Close both A side (Red) and B side (Blue) feed inlet valves on the system. See FIG. 2 on page 14. b. Close A side (Red) material return ball valves on the material tank stand. c. Follow Pressure Relief Procedure on page 44. 17. Check hydraulic fluid level Hydraulic reservoir is filled at the factory.
Setup 18. IsoGuard Select Fluid System Setup 19. Install High Volume Fill Kit (Optional). Component A (Red) Pump: Fill IsoGuard Select reservoir (LR) with IsoGuard Select fluid (provided by Graco). a. Lift the reservoir (LR) out of the bracket (RB) and remove the container from the cap. RB LR r_24m419_3a1961_1a FIG. 23: High Volume Refill Kit 24C352_313998_8e b. c. a. Perform Pressure Relief Procedure, page 44. Fill with fresh fluid.
Setup 20. Install Low Volume Fill Kit (Optional). r_24m418_3a1961_1a FIG. 24: Low Volume Refill Kit a. Perform Pressure Relief Procedure, page 44. b. Close the ball valves located on the day tanks. c. Remove the swivel fitting from the day tank inlet port ball valve. d. Insert the refill valve onto the ball valve. e. Install the swivel fitting onto the refill valve assembly. f. Remove the air tube fitting installed on the solenoid valve located inside the tank stand base cube. g.
Startup Startup To reduce the risk of personal injury, do not operate HFR without all covers and shrouds in place. 1. Check that all machine connections are setup. See Setup procedure, page 28. 2. Check level and condition of ISO lube daily, see IsoGuard Select™ System on page 48. 3. Verify both PRESSURE RELIEF/DISPENSE valves (SA, SB) are set to DISPENSE . SB SA 6. Press green. to enable system. LED should be solid 7. Navigate to Home Standby screen and press to initiate auto startup. 8.
Shutdown Shutdown Pressure Relief Procedure 1. Park pumps. a. From the Home screen, press Standby mode. and select 1. Press to disable the ADM. 2. Shut off feed pumps and agitator, if used. 3. Turn PRESSURE RELIEF/DISPENSE valves (SA, b. Press . Material will not dispense. Pump will park automatically. Once pump is parked, pump will stop moving. 2. Press SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0. to disable the ADM. 3.
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. Heaters must be off and cool when solvent is in the system. • 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 Task Schedule Check hoses for wear Task Schedule Change break-in oil in a new unit After first 250 hours of operation or within 3 months, whichever comes first Inspect hydraulic and fluid lines for leaks Inspect IsoGuard Select™ fluid level and condition, refill or replace as needed, page 48 Daily Daily Check hydraulic fluid level Weekly Grease circulation valves with Fusion® grease (117773) Weekly Verify operation of air drying system to prevent isocyanate crystallizati
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 IsoGuard Select™ System 9. Push the return tube 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 44. 2. Turn main power OFF. 3. Allow equipment to cool.
Troubleshooting PROBLEM Material does not maintain temperature while spraying Material temperature exceeds setpoint Erratic material temperature CAUSE Ambient temperature is too cold Flow too high Faulty RTD connections Faulty RTD connection FTS not installed correctly Material does not heat FTS failed or is not contacting correctly FTS not installed correctly Temperature control alarm Proportioning System Proportioning pump does not Pump piston or intake valve leaking hold pressure when stalled Mat
Troubleshooting 3A2797G 51
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 Technical Data on page 95. FIG. 27 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 flow units selection. Shots are defined by flow rate and weight or time (duration). See Home Screen, Shot Mode on page 70 for information on how to use predefined shots. NOTE: 100 shot definitions are available across ten pages.
Appendix B - ADM Setup Screens Overview 4. Use the following formula to calculate the ? 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 ? 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 ? column. Example 3: 2. Press then use the arrow keys to navigate to the “Enable Range Calibration” option. 3. Press to activate the option. To edit a shot definition: 1. Navigate to Shots Screen. Shot Calibration Table This screen allows the user to set the offset, ?(g), for a calculated range of shot sizes based on pump sizes and material specific gravity. NOTE: This table is only available when defining the shot by weight.
Appendix B - ADM Setup Screens Overview Weight Based Example Using Shot Calibration Table: NOTE: The offset needs to be determined for each range and may need to be modified if the flow rate changes. Visit www.graco.com and search for PKE “Shot Calibration Table Worksheet” to assist in the calculations for the following procedure. NOTE: Offset ranges are dependant on material ratio and material specific gravity. The values shown are for reference only. 1.
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 37 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 This screen allows the user to set important system settings. Control Mode can be set to Flow. With Control Mode set to Flow, the machine will dispense at a continuous flow rate regardless of pressure fluctuations unless pressure alarm conditions occur. This screen allows the user to set which items are installed on the machine. Dispense Mode can be set to Time, Volume, and Weight.
Appendix B - ADM Setup Screens Overview Mix Head Operating Details Screen System Screen 3 This screen allows the user to define the mix head operating parameters. 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.
Appendix B - ADM Setup Screens Overview Keyboard Screen Maintenance Screen This screen is used to edit the A (Red) and B (Blue) labels on the ADM. Use arrow keys to select the desired This screen shows shot number, sequence position, and dispense valve counters. Press letter and press and navigate to the to accept the letter. drop down box. Press and scroll to a range of count- ers to view. Press again to select the range of counters and display them on the screen.
Appendix B - ADM Setup Screens Overview Supply Screen • 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. NOTE: Use the “Disabled” setting if off-board tanks are not installed.
Appendix B - ADM Setup Screens Overview Refill Timeout Conditioning Screen 2 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 sensor 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 triggered, the refill will abort. A refill must be manually started to enable auto refills again.
Appendix B - ADM Setup Screens Overview Conditioning Screen 3 2. Press to display the setpoint and alarm values associated with that component. 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.
Appendix B - ADM Setup Screens Overview Time Based Night Mode Conditioning Screen This screen allows the user to set a specific time each day to turn the machine on or off. The times can be set on or off by either each day separately, Monday through Friday where each day has the same on or off times, or Sunday through Saturday where each day has the same on or off times. 6. To erase times, repeat steps 1 thru 3 and press once the desired time duration has been selected.
Appendix B - ADM Setup Screens Overview Advanced Screen 1 Advanced Screen 3 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. This screen allows the user to control the availability of some key system features. • • • • Time: formatted in 24 hour time. Password: Enables the setup screens to be password protected. Entering “0000” disables the feature.
Appendix B - ADM Setup Screens Overview Advanced Screen 4 • Enable PrePoly Refresh: Check this box to enable Prepoly Refresh. A Prepoly refresh will initiate a cold start, heat the system to a specified temperature (Conditioning Screen 3), empty the prepoly tank to the low level sensor and refill the tank. When enabled, either the user may initiate a refresh manually or through a scheduled task.
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. 28: 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 55 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 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 58 for information about editing sequence definitions. NOTE: There is a three second delay after a dispense before another dispense can be initiated. 8. See Home Screen, Shot Mode on page 70 for other button functions.
Appendix C - ADM Run Screens Overview Home Screen, Night Mode In Night Mode, the system will cycle on and off periodically or turn on at a preset time. Entering night mode will turn pumps and all conditioning zones off. The circulation on/off cycle begins automatically upon entering Night Mode. See Conditioning Screen 3 on page 65. Status Screen, Conditioning Control This screen allows users to turn on and off heat zones individually or all at once.
Appendix C - ADM Run Screens Overview Errors Screens Maintenance Screen 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. The 50 most recent errors are shown. This screen displays historical information for each pump in the system. The Batch counters are resettable and count both material usage and pump cycles.
Appendix C - ADM Run Screens Overview Optional Screens The optional Diagnostic screen can be enabled in the Advanced Screen 4 screen, see page 68. Diagnostic The Diagnostic screen shows status information for various components in the Motor Control Module.
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 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 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 Control Fault No Red Blanket
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 CUCN D1A1 D4A1 D2A1 D3A1 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.
Appendix D - ADM Error Codes Error Code D5A1 D6A1 DDA1 DDB2 DFA1 DR6A DR6B DSC0 F1A0 F2A0 F1B0 F2B0 F4A0 F3A0 F4B0 F3B0 F7D1 L111 L122 L311 L322 L6A1 L6B2 78 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 L8A1 DR6B L9AX L9BX L9A0 MBH1 MBN1 MMUX N1D0 N2D0 N3D0 N4D0 Error Name Red Tank Sensor Failure Blue Tank Sensor Failure Red Tank Leak Detected Blue Tank Leak Detected Error Description Error Type Cause A level sensor had ceased working Deviation Bad level sensor A tank or material line is leaking Alarm Two tank refills occur without a dispense Solution Replace level sensor Check all hoses and pumps for material leaks No material is sensed by t
Appendix D - ADM Error Codes Error Code Error Name Error Description N4A1 The MCM attempted to move Pump Failed the pump but no movement to Move was detected P400 Thermal Pressure Rise P4A1 P4B2 P4D0 P6A1 P6B2 80 Error Type Cause Solution Visually check to ensure the pump is moving, if not Motor failure ensure the motor is wired properly If motor is moving but pump is not and pressure is not Hydraulic power pack building they hydraulic power pack may need failure servicing Check to ensure the
Appendix D - ADM Error Codes Error Code R1D0 R4D0 R2D0 R3D0 T1A6 T1B5 T1A3 T1B1 T1A2 T1B4 T1A7 T1B8 T20X T30X Error Name Low Ratio Alarm High Ratio Alarm Low Ratio Deviation High Ratio Deviation 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 T2AA T2AE T2AF T2BC T2BD T2BG T3AA T3AE T3AF T3BC T3BD T3BG T3H1 Error Name Red Hose Low Fluid Temp. Red Tank Low Fluid Temp. Red Chiller Low Fluid Temp. Blue Hose Low Fluid Temp. Blue tank Low Fluid Temp. Blue Chiller Low Fluid Temp. Red Hose High Fluid Temp. Red Tank High Fluid Temp. Red Chiller High Fluid Temp. Blue Hose High Fluid Temp. Blue Tank High Fluid Temp. Blue Chiller High Fluid Temp. 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 84 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 Replace RTD
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 WMB5 WMC6 WMC5 WMC3 WMC1 WMC2 WMC4 WMC7 WMC8 WMH1 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 EAA0-R: Prepoly Refresh Started EBA0-R: Prepoly Refresh Complete EL00-R: System Powered On EM00-R: System Powered Off EB00-R: Stop Button Pressed ECH0-R: Learn Mode Executed ENN0-R: Automatic Cal. Performed ECA1-R: Red Material SG Modified ECB2-R: Blue Material SG Modified ENC1-R: Cal. Point 1 Weight Entered ENC2-R: Cal. Point 2 Weight Entered ENC4-R: Cal. Point 1 Weight Erased ENC5-R: Cal.
Appendix E - System Events 88 3A2797G
Appendix F - USB Operation Appendix F - USB Operation Overview The third option is a checkbox that enables or disables the ability to record errors associated with the USB logs. There are 3 main uses for the USB on a GMS system • • • 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. 29: 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 are three log files. They are formatted as .csv (comma separated value) files and can be opened by most text editors or data processing programs such as Excel.
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 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. Example DISPTEXT.
Technical Data Technical Data HFR for NVH Foam Maximum fluid working pressure Maximum Fluid Temperature Fluid Inlet Feed Pressure Range Fluid Inlet: Component A (Red) Fluid Inlet: Component B (Blue) Fluid Outlet: Component A (Red) Fluid Outlet: Component B (Blue) Fluid Circulation Ports Line Voltage Requirement: 230V / 3 phase Models Line Voltage Requirement: 400V / 3 phase Models Amperage Requirement Sound Power Heater Power (A (Red) and B (Blue) heaters total, no hose) Hydraulic reservoir capacity Recomm
Technical Data Motor Control Module Technical Data Motor Control Module US Metric Input Specifications: Input Line Voltage 0-264 Vac, line-to-line Input Line Phasing 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 Current 0-30A Output Overl
Technical Data Dimensions A ti19519a B C Dimensions A (Height) 76 in. (193 cm) B (Width) 72 in. (183 cm) C (Length) 58 in.
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.
