Graco 3A2175A User Manual

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Setup - Operation

3A2175A

HFRL and HFRS

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.

Patent Pending

ti18208a

Silicone unit shown.

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

HFR-Laminate (HFRL) . . . . . . . . . . . . . . . . . . . . 4

HFR-Silicone (HFRS) . . . . . . . . . . . . . . . . . . . . . 6

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Important Two-Component Material Information 14

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 14

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 14

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

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 Display Module (ADM) . . . . . . . . . . . 24

Fluid Control Module (FCM) . . . . . . . . . . . . . . . 27

Dispense Valve Overview . . . . . . . . . . . . . . . . . . . 28

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Pressure Relief Procedure . . . . . . . . . . . . . . . . 38

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Adjusting Material Inlet Pressure Using the Material

Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Pressure Balancing Using the Orifice Valve

Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 41

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Advanced Display Module (ADM) . . . . . . . . . . . 44

Motor Control Module (MCM) . . . . . . . . . . . . . . 45

Fluid Control Module (FCM) . . . . . . . . . . . . . . . 46

Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 46

IsoGuard Select

Clean Orifice Valves . . . . . . . . . . . . . . . . . . . . . 48

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . 49

Common Problems . . . . . . . . . . . . . . . . . . . . . . 49

ADM Troubleshooting . . . . . . . . . . . . . . . . . . . . 51

Motor Control Module . . . . . . . . . . . . . . . . . . . . 52

Fluid Control Module . . . . . . . . . . . . . . . . . . . . . 54

Advanced Display Module (ADM) Operation . . . . 55

™

System . . . . . . . . . . . . . . . . 47

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 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Download Log Files . . . . . . . . . . . . . . . . . . . . . . 85

Log Files, Folder Structure . . . . . . . . . . . . . . . . 86

Transfer System Settings . . . . . . . . . . . . . . . . . . 88

Update Custom Language . . . . . . . . . . . . . . . . . 89

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Motor Control Module Technical Data . . . . . . . . 93

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 96

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 96

2 3A2175A

Related Manuals

Manuals are available at www.graco.com.

Component manuals listed below 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

Related Manuals

3A1149 HFR Discrete Gateway Module Kits Manual

3A2175A 3

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 lb/min).

Maximum Fluid Working

Full Load Peak

Amps Per Phase*

Voltage (phase) System Watts

Pressure ‡

psi (MPa, bar)

55 A 230V (1)

55 A ★ 400V (3)

A Pump

Size

160 86 246 8 100 86 186 10 1.16

86 80 166 11 1.08 80 80 160 12 1.00 80 65 145 13 1.23 80 60 140 13 1.33 80 50 130 14 1.60 86 40 126 15 2.15 60 50 110 17 1.20 65 40 105 18 1.63 60 40 100 19 1.50 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) 2.50

B Pump

Size

cc/stroke

12,650

Required cpm@

Flow**

3000

(20.7, 207)

Max Flow †

cc/sec (lb/min)

30 (4)

Max Dispense Pressure

psi (MPa, bar)**

1500 (10, 103)

Ratio

1.86

* 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 intermittant use. Lower cycle rates are possible, but should be tested under application conditions.

† 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 (T4H1).

★ 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, 138 bar) working pressure by Graco. If the machine was purchased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed, see instruction manual 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

HFRL Models

Part Number

HFRL01 HFR for Lamination, 230/1, 1.00:1,

HFRL02 HFR for Lamination, 230/1, 1.08:1,

HFRL03 HFR for Lamination, 230/1, 1.16:1,

HFRL04 HFR for Lamination, 230/1, 1.20:1,

HFRL05 HFR for Lamination, 230/1, 1.23:1,

HFRL06 HFR for Lamination, 230/1, 1.33:1,

HFRL07 HFR for Lamination, 230/1, 1.50:1,

HFRL08 HFR for Lamination, 230/1, 1.60:1,

HFRL09 HFR for Lamination, 230/1, 1.63:1,

HFRL10 HFR for Lamination, 230/1, 1.67:1,

HFRL11 HFR for Lamination, 230/1, 1.86:1,

HFRL12 HFR for Lamination, 230/1, 2.00:1,

HFRL13 HFR for Lamination, 230/1, 2.15:1,

HFRL14 HFR for Lamination, 230/1, 2.40:1,

HFRL15 HFR for Lamination, 230/1, 2.5:1,

HFRL16 ★ HFR for Lamination, 400/3, 1.00:1,

HFRL17 ★ HFR for Lamination, 400/3, 1.08:1,

HFRL18 ★ HFR for Lamination, 400/3, 1.16:1,

HFRL19 ★ HFR for Lamination, 400/3, 1.20:1,

HFRL20 ★ HFR for Lamination, 400/3, 1.23:1,

HFRL21 ★ HFR for Lamination, 400/3, 1.33:1,

HFRL22 ★ HFR for Lamination, 400/3, 1.50:1,

Description

80/80, Carbon Steel

86/80, Carbon Steel

100/86, Carbon Steel

60/50, Carbon Steel

80/65, Carbon Steel

80/60, Carbon Steel

60/40, Carbon Steel

80/50, Carbon Steel

65/40, Carbon Steel

50/30, Carbon Steel

160/86, Carbon Steel

50/25, Carbon Steel

86/40, Carbon Steel

60/25, Carbon Steel

50/20, Carbon Steel

80/80, Carbon Steel

86/80, Carbon Steel

100/86, Carbon Steel

60/50, Carbon Steel

80/65, Carbon Steel

80/60, Carbon Steel

60/40, Carbon Steel

Part Number

Description

HFRL23 ★ HFR for Lamination, 400/3, 1.60:1,

80/50, Carbon Steel

HFRL24 ★ HFR for Lamination, 400/3, 1.63:1,

65/40, Carbon Steel

HFRL25 ★ HFR for Lamination, 400/3, 1.67:1,

50/30, Carbon Steel

HFRL26 ★ HFR for Lamination, 400/3, 1.86:1,

160/86, Carbon Steel

HFRL27 ★ HFR for Lamination, 400/3, 2.00:1,

50/25, Carbon Steel

HFRL28 ★ HFR for Lamination, 400/3, 2.15:1,

86/40, Carbon Steel

HFRL29 ★ HFR for Lamination, 400/3, 2.40:1,

60/25, Carbon Steel

HFRL30 ★ HFR for Lamination, 400/3, 2.5:1,

50/20, Carbon Steel

★ approved.

3A2175A 5

Models

HFR-Silicone (HFRS)

HFRS models are designed for use with high viscosity, unheated silicone adhesives at flow rates of up to 20 cc/sec. The equipment can be ran at up to 20 cycles per minute continuous duty.

Maximum Fluid Working

Full Load Peak

Amps Per Phase*

Voltage (phase)

System Watts

Pressure ‡

psi (MPa, bar)

55 A 230V (1)

12,650

55 A ★ 400V (3)

A Pump

Size

B Pump

Size

cc/stroke

Required cpm@

Flow**

15 80 95 11.3-12.5 18-20

3000

(20.7, 207)

Max Flow †

cc/sec

Max Dispense Pressure

psi (MPa, bar)**

Ratio

5.33 5 50 55 20 18.3 10.00 5 30 35 20 11.7 6.00 5 20 25 20 8.3 4.00

2500 (17, 172)

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.

† 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 (T4H1).

★ approved.

‡ The maximum fluid working pressure for the base machine without hoses is 3000 psi (20.7 MPa, 207 bar). If

6 3A2175A

Models

HFRS Models

Part Number

HFRS01 HFR for Silicone, 230/1, 1:1, Carbon

HFRS02 HFR for Silicone, 230/1, 1:1, Carbon

HFRS03 ★ HFR for Silicone, 400/3, 1:1, Carbon

HFRS04 ★ HFR for Silicone, 400/3, 1:1, Carbon

HFRS05 HFR for Silicone, 230/1, 1:1, Stainless

HFRS06 HFR for Silicone, 230/1, 1:1, Stainless

HFRS07 ★ HFR for Silicone, 400/3, 1:1, Stainless

HFRS08 ★ HFR for Silicone, 400/3, 1:1, Stainless

HFRS09 HFR for Silicone, 230/1, 4:1, Carbon

HFRS10 HFR for Silicone, 230/1, 4:1, Carbon

HFRS11 HFR for Silicone, 230/1, 4:1, Carbon

HFRS12 ★ HFR for Silicone, 400/3, 4:1, Carbon

HFRS13 ★ HFR for Silicone, 400/3, 4:1, Carbon

HFRS14 ★ HFR for Silicone, 400/3, 4:1, Carbon

HFRS15 HFR for Silicone, 230/1, 4:1, Stainless

HFRS16 HFR for Silicone, 230/1, 4:1, Stainless

HFRS17 HFR for Silicone, 230/1, 4:1, Stainless

HFRS18 ★ HFR for Silicone, 400/3, 4:1, Stainless

HFRS19 ★ HFR for Silicone, 400/3, 4:1, Stainless

HFRS20 ★ HFR for Silicone, 400/3, 4:1, Stainless

HFRS21 HFR for Silicone, 230/1, 5.33:1, Carbon

HFRS22 HFR for Silicone, 230/1, 5.33:1, Carbon

Description

Steel, 55/55 Feed

Steel, 5/5 Feed

Steel, 55/55 Feed

Steel, 5/5 Feed

Steel, 55/55 Feed

Steel, 5/5 Feed

Steel, 55/55 Feed

Steel, 5/5 Feed

Steel, 55/55 Feed

Steel, 55/5 Feed

Steel, 5/5 Feed

Steel, 55/55 Feed

Steel, 55/5 Feed

Steel, 5/5 Feed

Steel, 55/55 Feed

Steel, 55/5 Feed

Steel, 5/5 Feed

Steel, 55/55 Feed

Steel, 55/5 Feed

Steel, 5/5 Feed

Steel, 55/55 Feed

Steel, 55/5 Feed

Part Number

Description

HFRS23 HFR for Silicone, 230/1, 5.33:1, Carbon

Steel, 5/5 Feed

HFRS24 ★ HFR for Silicone, 400/3, 5.33:1, Carbon

Steel, 55/55 Feed

HFRS25 ★ HFR for Silicone, 400/3, 5.33:1, Carbon

Steel, 55/5 Feed

HFRS26 ★ HFR for Silicone, 400/3, 5.33:1, Carbon

Steel, 5/5 Feed

HFRS27 HFR for Silicone, 230/1, 5.33:1, Stain-

less Steel, 55/55 Feed

HFRS28 HFR for Silicone, 230/1, 5.33:1, Stain-

less Steel, 55/5 Feed

HFRS29 HFR for Silicone, 230/1, 5.33:1, Stain-

less Steel, 5/5 Feed

HFRS30 ★ HFR for Silicone, 400/3, 5.33:1, Stain-

less Steel, 55/55 Feed

HFRS31 ★ HFR for Silicone, 400/3, 5.33:1, Stain-

less Steel, 55/5 Feed

HFRS32 ★ 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 for Silicone, 230/1, 6:1, Carbon

Steel, 55/5 Feed

HFRS35 HFR for Silicone, 230/1, 6:1, Carbon

Steel, 5/5 Feed

HFRS36 ★ HFR for Silicone, 400/3, 6:1, Carbon

Steel, 55/55 Feed

HFRS37 ★ HFR for Silicone, 400/3, 6:1, Carbon

Steel, 55/5 Feed

HFRS38 ★ HFR for Silicone, 400/3, 6:1, Carbon

Steel, 5/5 Feed

HFRS39 HFR 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 ★ HFR for Silicone, 400/3, 6:1, SS 55/55

Feed

HFRS43 ★ HFR for Silicone, 400/3, 6:1, Stainless

Steel, 55/5 Feed

HFRS44 ★ HFR for Silicone, 400/3, 6:1, Stainless

Steel, 5/5 Feed

3A2175A 7

Models

Part Number

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 ★ HFR for Silicone, 400/3, 10:1, Carbon

Steel, 55/55 Feed

HFRS49 ★ HFR for Silicone, 400/3, 10:1, Carbon

Steel, 55/5 Feed

HFRS50 ★ 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 ★ HFR for Silicone, 400/3, 10:1, Stainless

Steel, 55/55 Feed

HFRS55 ★ HFR for Silicone, 400/3, 10:1, Stainless

Steel, 55/5 Feed

HFRS56 ★ HFR for Silicone, 400/3, 10:1, Stainless

Steel, 5/5 Feed

HFRS57 HFR for Silicone, 230/1, 1:1, Carbon

Steel, No Feed

HFRS58 ★ HFR for Silicone, 400/1, 1:1, Carbon

Steel, No Feed

HFRS59 HFR for Silicone, 230/1, 1:1, Stainless

Steel, No Feed

HFRS60 ★ HFR for Silicone, 400/3, 1:1, Stainless

Steel, No Feed

HFRS61 HFR for Silicone, 230/1, 4:1, Carbon

Steel, No Feed

HFRS62 ★ HFR for Silicone, 400/3, 4:1, Carbon

Steel, No Feed

HFRS63 HFR for Silicone, 230/1, 4:1, Stainless

Steel, No Feed

HFRS64 ★ HFR for Silicone, 400/3, 4:1, Stainless

Steel, No Feed

HFRS65 HFR for Silicone, 230/1, 5.33:1, Carbon

Steel, No Feed

HFRS66 ★ HFR for Silicone, 400/3, 5.33:1, Carbon

Steel, No Feed

Part Number

Description

HFRS67 HFR for Silicone, 230/1, 5.33:1, Stain-

less Steel, No Feed

HFRS68 ★ HFR for Silicone, 400/3, 5.33:1, Stain-

less Steel, No Feed

HFRS69 HFR for Silicone, 230/1, 6:1, Carbon

Steel, No Feed

HFRS70 ★ HFR for Silicone, 400/3, 6:1, Carbon

Steel, No Feed

HFRS71 HFR for Silicone, 230/1, 6:1, Stainless

Steel, No Feed

HFRS72 ★ HFR for Silicone, 400/3, 6:1, Stainless

Steel, No Feed

HFRS73 HFR for Silicone, 230/1, 10:1, Carbon

Steel, No Feed

HFRS74 ★ HFR for Silicone, 400/3, 10:1, Carbon

Steel, No Feed

HFRS75 HFR for Silicone, 230/1, 10:1, Stainless

Steel, No Feed

HFRS76 ★ HFR for Silicone, 400/3, 10:1, Stainless

Steel, No Feed

HFRS77 HFR for Silicone, 230/1, 4:1, Carbon

Steel, No Feed

HFRS78 ★ HFR for Silicone, 400/3, 4:1, Carbon

Steel, No Feed

HFRS79 HFR for Silicone, 230/1, 4:1, Stainless

Steel, No Feed

HFRS80 ★ HFR for Silicone, 400/3, 4:1, Stainless

Steel, No Feed

HFRS81 HFR for Silicone, 230/1, 5:1, Carbon

Steel, No Feed

HFRS82 ★ HFR for Silicone, 400/3, 5:1, Carbon

Steel, No Feed

HFRS83 HFR for Silicone, 230/1, 5:1, Stainless

Steel, No Feed

HFRS84 ★ HFR for Silicone, 400/3, 5:1, Stainless

Steel, No Feed

HFRS85 HFR for Silicone, 230/1, 6:1, Carbon

Steel, No Feed

HFRS86 ★ HFR for Silicone, 400/3, 6:1, Carbon

Steel, No Feed

HFRS87 HFR for Silicone, 230/1, 6:1, Stainless

Steel, No Feed

HFRS88 ★ HFR for Silicone, 400/3, 6:1, Stainless

Steel, No Feed

8 3A2175A

Part Number

Description

HFRS89 HFR for Silicone, 230/1, 10:1, Carbon

Steel, No Feed

HFRS90 ★ HFR for Silicone, 400/3, 10:1, Carbon

Steel, No Feed

HFRS91 HFR for Silicone, 230/1, 10:1, Stainless

Steel, No Feed

HFRS92 ★ HFR for Silicone, 400/3, 10:1, Stainless

Steel, No Feed

★ approved.

Models

3A2175A 9

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

10 3A2175A

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

3A2175A 11

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 Da ta in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

12 3A2175A

Warnings

3A2175A 13

Important Two-Component Material Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-ignition

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Keep Components A (Red) and

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO lube pump reservoir (if installed) filled

with IsoGuard Select creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

™

, part 24F516. The lubricant

B(Blue) Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (Red) and component B (Blue) parts.

14 3A2175A

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.

A (Red) and B (Blue) Components

IMPORTANT!

Material suppliers can vary in how they refer to plural component materials.

A (Red) and B (Blue) Components

Be aware that when standing in front of the manifold on proportioner:

• Component A (Red) is on the left side.

• Component B (Blue) is on the right side.

For all machines:

• The A (Red) side is intended for ISO, hardeners, and catalysts.

• If one of the materials being used is moisture-sensitive, that material should always be in the A (Red) side.

• 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 15

Typical HFRS System

ti18208a

J, K

FIG. 1: HFR Silicone System

Key:

A HFR Unit (Silicone) B Power Module CB “Blue” Pump D A ”Red” Pump E Outlet Module F B Hose Kit G A Hose Kit

16 3A2175A

H Dispense Gun J Orifice Block K Orifice, 1/4” L Supply Unit, B Side M Supply Unit, A Side N Supply Hose P Inlet Regulator

Typical HFRL System

AJ, AK

FIG. 2: HFR Laminate System

Key:

AA HFR Unit (Laminate) AB Power Module AC B “Blue” Pump AD A “Red” Pump AE Outlet Module AF B Hose Kit AG A Hose Kit

ti18209a

AH Dispense Gun AJ Orifice Block AK Orifice, 1/4” AL Inlet Assembly AM Isolube Kit (not shown)

3A2175A 17

Component Identification

(Located on opposite side of machine)

ti18210a

FIG. 3: Component Identification, shown with shrouds removed

Key for FIG. 4.

BA Advanced Display Module (see page 24) BB Component A (Red) Pressure Relief Outlet BC Component B (Blue) Pressure Relief Outlet BD Component A (Red) Fluid Manifold Inlet (on left side of manifold

block) BE Component B (Blue) Fluid Manifold Inlet BF HFR Fluid Manifold BG Feed Inlet Pressure Gauge BH Feed Inlet Strainer (standard filter size is 20 mesh) BJ Feed Inlet Valve (A (Red) side shown) BK Component A (Red) Outlet Pressure Gauge BL Component B (Blue) Outlet Pressure Gauge BM Component A (Red) Hose Connection (from feed to gun or mix

head) BN Component B (Blue) Hose Connection (from feed to gun or mix

head) BP Hydraulic Power Pack Assembly BR Hydraulic Tank

BS IsoGuard

available separately as kit 24M154 for HFRS) BT Pumpline Linear Sensor BU Motor Control Module, see page 22 BV Main Power Switch BW Component A (Red) Pump BX Component B (Blue) Pump BY Power Distribution Box BZ Component A (Red) PRESSURE RELIEF/DISPENSE Valve CA Component B (Blue) PRESSURE RELIEF/DISPENSE Valve CB Component A (Red) Pressure Transducer CC Component B (Blue) Pressure Transducer CD Material Pressure Regulator Component A (Red) CE Power Distribution Box

18 3A2175A

™

Select Fluid Reservoir (included on all HFRL,

Component Identification

HFRL Material Inlet

(250 psi Max)

Fluid Manifold (FM) Detail

ti18211a

HFRS Material Inlet

(3000 psi Max)

Rear View

ti18212a

BZBD CABLBK BE

BMBB BCBN

ti9880a1

FIG. 4: Component Identification, shown with shrouds removed

24C352_313998_4e

3A2175A 19

Component Identification

Main Power Switch

Located on rear of machine.

ti18213a

The main power switch turns power ON and

Circuit Breakers

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

ti18214a

OFF . The main power switch does not turn

pumps on.

CB5

CB1

ti18215a

230V/ 1 phase,

Ref.

400V/ 3 phase Component

CB1 63A Motor Control Module

CB5 5A Miscellaneous

20 3A2175A

Hydraulic Power Pack

Component Identification

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

DE Directional Valve DF Motor Control Module (see page 22) DG Fan DH Filter DJ Shroud (not shown, removed for clarity)

3A2175A 21

Component Identification

Motor Control Module (MCM)

NOTICE

If the Motor Control Module is replaced, the selector switch must be set prior to initial startup of the Motor Control Module or damage may occur. See HFR Repair manual for details, see Related Man- uals on page 3.

For MCM location, see reference MA in FIG. 4 on page 19. When installed, the end of the MCM with the power input connection (12) faces down and the end with the access cover (A) faces up.

The Motor Control Module uses an 8-position selector switch to set the system maximum working pressure.

FIG. 6: MCM Component Identification

r_257396_3b9905_01b

r_257396_3b9905_03b

22 3A2175A

Ref Description

A Access Cover

BLEDs

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

6LVDT

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 Motor Power Connection

Component Identification

3A2175A 23

Component Identification

Advanced Display Module (ADM)

User Interface

FIG. 7: ADM Component Identification - Front

Buttons

Callout Button Function

EA System

enable/ disable

EB System

Status Indicator Light

EC Stop Stop all system processes. Is not a

Enables/disables system. When system is disabled, temperature control and dispense operation are disabled.

Displays system status. See Sys-

tem Status Indicator (CB) Conditions on page 25 for details.

safety or emergency stop.

TI12362a1

Callout Button Function

ED Soft Keys Defined by application using ADM.

EE Cancel Cancel a selection or number entry

while in the process of entering a number or making a selection.

EF Enter Acknowledge changing a value or

making a selection.

EG Lock/SetupToggle between run and setup

screens. If setup screens are password protected, button toggles between run and password entry screen.

EH Naviga-

tion

Navigate within a screen or to a new screen.

24 3A2175A

Component Identification

IG. 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

EN Module Status LEDs EP Accessory Cable Connections ER Token Access Cover ES Battery Access Cover

ti12363a1

3A2175A 25

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 55.

Current date and time Current screen

Mode

Enter/Exit screen

Function display

IG. 9: Main Display Components

Previous screen Next screen

Faults, Status

Previous screen no.

Current screen no.

Next screen no.

26 3A2175A

Fluid Control Module (FCM)

Component Identification

FIG. 10

Key:

FA Fluid Control Module FB Base FC Module Connection Screws FD Access Cover FE Module Status LEDs FF CAN Connectors

ti12337a1

ti12336a1

3A2175A 27

Dispense Valve Overview

The HFRL and HFRS systems will be provided exclusively with MD2 dispense valves.

The MD2 dispense valve is an example of a solenoid controlled dispense valve. When 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 trigger 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.

NOTICE

To avoid machine damage and personal injury, ensure the machine is securely strapped to the pallet to prevent tipping before lifting.

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. 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 electrician and comply with all local codes and regulations.

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

L1 L2 L3

FIG. 11: 230V, 1 phase shown

L1 L2 L3N

3. Connect electrical cord.

FIG. 12: 400V, 3 phase shown

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

Model

230V, 1 phase 6 (13.3), 2 wire + ground

400V, 3 phase 6 (13.3), 4 wire + ground †

† Residual Current Device (RCD) must be rated at

3A2175A 29

AWG (mm

)

FIG. 13: Grounding Lug

Setup

Power Line Voltage Surges

Power conversion equipment can be sensitive to voltage fluctuations on incoming power. The Motor Control Module falls under the category of power conversion equipment because energy is stored on a capacitive bus and then modulated to control a brushless motor. Engineered design takes this into account and withstands a wide range of conditions, but it is possible for supplied power to occasionally fall outside the tolerable range in industrial plants with high-amperage reactive pulsed loads such as welding equipment. If the tolerable range is exceeded, an overvoltage condition is flagged and the system will shut down in an alarm state to protect itself and alert the user of unstable power. Excessive or repeated overvoltage may permanently damage hardware.

The MAX-HOLD feature on a multimeter can be used to determine peak DC voltage on the line. DC is the proper setting, as opposed to AC, because peak voltage is the critical parameter that affects the DC voltage level stored on the capacitive bus in power conversion equipment. Reading should not regularly exceed approximately 400VDC to avoid tripping the 420VDC alarm level in the Motor Control Module. If power quality is suspect, power conditioning or isolation of the device(s) causing poor power quality is recommended. Consult a qualified electrician if there are any concerns about the available power supply.

The chart below shows the permissible magnitude and duration of temporary over-voltage events:

Maximum Permissible Transient Voltage Surges

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

1400

1200

1200Vac, 1697Vdc

1000

800

600

400

Voltage (Volts RMS)

200

0.000001 0.00001 0.0001 0.001 0.01 0.1 1 10

<--1 MW Max Surge Power

480Vac, 679Vdc

336Vac, 475Vdc

Time (seconds)

<--150 KW Max Surge Power

<--50 KW Max Surge Power

288Vac, 407Vdc

<--No Power Limit

264Vac, 373Vdc

Power Line Test Steps with Multimeter

a. Set multimeter to “DC voltage”.

b. Connect multimeter probes to supplied power

line.

c. 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).

30 3A2175A

Setup

4. Connect regulator assemblies (If Equipped)

NOTE: Systems equipped with a fluid regulator on the

material inlet will 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 F 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 10% of each other.

IG. 1 and FIG. 4,

b. Ensure A (Red) and B (Blue) inlet valves (FV)

are closed.

ti9883a1

c. Adjust the fluid pressure regulator so the pres-

sure gauge reads zero.

ti18217a

250 psi max inlet pressure

pressure gauge

ti18216a

3000 psi max inlet pressure

NOTE: Supply hoses from feed pumps should be 3/4 in. (19 mm) ID minimum.

d. Connect and tighten component B (Blue) supply

hose to the 3/4 npt(f) swivel on the component B (Blue) inlet assembly.

e. Connect and tighten component A (Red) supply

hose to the 3/4 NPT(f) swivel on the component A (Red) inlet assembly.

3A2175A 31

Setup

6. Connect pressure relief lines (R)

Do not install shutoffs downstream of the PRESSURE RELIEF/DISPENSE valve outlets (BA, BB). The valves function as overpressure relief valves when set

to DISPENSE . Lines must be open so valves can automatically relieve pressure when machine is operating. If circulating fluid back to the supply drums, use high pressure hose rated to withstand the maximum working pressure of this equipment.

a. Recommended: Connect high pressure hose

(R) to relief fittings (BA, BB) of both PRESSURE RELIEF/DISPENSE valves. Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See F

IG. 1, page 16.

7. Connect hose

a. Turn main power OFF .

b. Assemble fluid supply hose sections and whip

hose.

c. Connect A (Red) and B (Blue) hoses to A (Red)

and B (Blue) outlets on HFR fluid manifold (FM). Hoses are color coded: red for component A, blue for component B. Fittings are sized to prevent connection errors.

8. Connect air tubes from solenoid valve to MD2.

CLOSED

OPEN

ti9880a1

OPEN

CLOSED

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

Setup

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. HFR: grounded through power cord. See step 3

on page 29.

b. Fluid supply containers: follow your local code.

c. Object being dispensed: follow your local code.

d. 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 cardboard, which interrupts grounding continuity.

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 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. See Accessories on page 91 for specifications.

13.IsoGuard Select Fluid system setup

(Not included on HFRS models)

a. Lift the reservoir (LR) out of the bracket (RB)

and remove the container from the cap.

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.

™

Component A (Red) Pump: Fill IsoGuard Select reser-

voir (LR) with IsoGuard Select fluid (provided by Graco).

3A2175A 33

Setup

15. Install dispense valve

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. If dispense valve has a trigger safety lock,

engage the trigger safety lock.

LOCKED

ti10442a1

i. If equipped, check fluid pressure gauges (GA,

GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning PRESSURE RELIEF/DISPENSE valve for that component toward PRESSURE RELIEF/CIRCULATION

, until gauges show balanced pressures.

NOTE: For systems without gauges, pressures can be monitored on the home screen of the ADM.

In this example, B (Blue) side pressure is higher,

so use the B (Blue) side

valve to balance pres-

sures.

ti9877a1

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, SB) to DISPENSE .

ti9877a1

g. Press to enable system. LED should be

solid green.

j. If dispense valve has a trigger safety lock, dis-

engage the trigger safety lock.

UNLOCKED

ti10441a1

k. 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.

l. Equipment is ready to dispense.

h. Check fluid pressure display and adjust as nec-

essary.

34 3A2175A

Operation

Startup

Do not operate HFR without all covers and shrouds in place.

1. Use feed pumps to load fluid

NOTE: The HFR is tested with oil at the factory. Flush

out the oil with 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. If 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.

h. Open fluid inlet valves (FV), if equipped. Check

for leaks.

ti10002a1

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

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.

e. If equipped, check level and condition of ISO

lube daily, see IsoGuard Select page 47.

f. Turn both PRESSURE RELIEF/DISPENSE

valves (SA, SB) to DISPENSE .

g. Start feed pumps.

3A2175A 35

™

System on

ti9877a1

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.

l. To prime the pump, cycle the pump a few times

or until air-free fluid dispenses.

Operation

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. 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.

If the system is to be used in a Time or Volume Dispense Mode, system calibration is complete after the Learn Mode procedure described above. However, if the system is to be used in Weight Dispense mode and the application requires that the dispense amount be accurate and consistent then the weight calibration procedure below must be followed.

Weight Calibration Procedure:

NOTE: Only perform Weight Calibration procedure if the

system will be run in Weight Dispense mode.

The Weight Calibration procedure must be run with 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 .

c. Press the go right button and then the dis-

pense button . 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 dispense

button . 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.

b. Navigate to the Cal. Setpoint text box then enter

the desired set point (pressure or flow, based on selected Control Mode).

c. Press .

d. Put a 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 process at 60% of that value. When it is complete,

the icon will change back to .

f. Press 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.

36 3A2175A

Operation

i. Select the Cal. 1 Shot Average field then press

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.

l. 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 footswitch 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.

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 .

e. Repeat the previous two steps for all desired

shot numbers.

6. Change pressure imbalance setting (optional)

The pressure imbalance function detects conditions that can cause off-ratio dispense, such as loss of feed pressure/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 to enter the screen.

r. Press .

The system is now able to dispense accurate 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 dispense accuracy may be degraded.

c. Navigate to the pressure imbalance field.

d. Type the desired pressure imbalance setting

then press Enter .

3. 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 37

Operation

Shutdown

1. Park pumps.

a. From the Home screen, press and select

Standby mode.

b. Press . 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.

2. Press the enable/disable key on the ADM to disable the ADM.

3. Turn main power switch (MP) to OFF position.

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.

ti9879a1

3. For models with an dispense valve with a safety lock, engage gun safety lock.

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.

4. Relieve pressure in dispense valve. See dispense valve manual.

38 3A2175A

Operation

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. See Accessories on page 91 for list of wetted components to verify compatibility of solvent with wetted materials. See solvent manufacturers information for material compatibility.

• To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/DISPENSE valves (SA, SB) to PRESSURE

• 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 trigger gun.

RELIEF/CIRCULATION . Flush through bleed lines (N).

ti9880a1

• To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).

• To prevent moisture from reacting with isocyanate, always leave the system dry or filled with a moisture-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 cardboard, which interrupts grounding continuity.

3A2175A 39

Operation

Adjusting Material Inlet Pressure Using the Material Regulator

NOTICE

Care must be taken when applying pressure to systems equipped with a material pressure regulator on the inlet assembly. Read both operation and service 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 pressure to the system. This process assumes that the supply 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 provide 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 provided is only rated for do not exceed 3000 psi (21 MPa, 207 bar)

8. Place the pressure relief valve on the manifold into the recirculation position.

9. Slowly increase the air pressure on the material regulator 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 regulator 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 requirements.

NOTE: As a general rule for high viscosity materials, the dispense pressure must exceed the material inlet pressure by 2 to 3 times. Therefore, if the maximum dispense 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 dispense pressure should exceed the inlet pressure by 3-4 times. Use only enough feed pressure to adequately feed the HFR pumps.

NOTICE

The material pressure regulator is not self relieving. Reducing the material pressure at the regulator will not effect the pressure reading until the accumulated down stream pressure is relieved. Perform Pressure Relief Procedure on page 38.

4. Verify that there is no pressure in the material supply 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 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 3A2175A

Operation

Pressure Balancing Using the Orifice Valve Assemblies

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 orifices 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.

B ORIFICE

1. Before installing, insert the allen wrench into the hex end of the orifice valve to adjust the needle position.

2. Verify the needle valve 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 dispense 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 pressure is equal to 3000 psi (21 MPa, 207 bar) and the feed pressure should be below 1500 psi (10 MPa, 103 bar).

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 corresponding material hose. The orifice valves are equipped with a needle valve that can be adjusted with the provided allen wrench.

b. The outlet pressure for lower viscosity-flowable

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 (5 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 10%. 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. If rule a and b above are met by both materials, install an orifice valve in the lower pressure side, 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.

3A2175A 41

Operation

NOTE: In general, the flow area ratio of the orifice valves should be equal to the material ratio, but it will also be influenced by differences between "A" and "B" material viscosities and flow characteristics. For flowable 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 adjustment.

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

0.016

0.020*

0.024

0.028

0.031 *

0.035

0.039

0.042

0.047 *

0.052

0.055

0.060 *

0.063

0.067 *

0.016 1.0 1.6 2.3 3.1 3.8 4.8 5.9 6.9 8.6 10.6 11.8 14.1 15.5 17.5 20.8 28.9

0.020* 1.6

0.024 2.3 1.4

0.028 3.1

0.031* 3.8 2.4 1.7 1.2

0.035 4.8 3.1 2.1 1.6 1.3

0.039 5.9 3.8 2.6 1.9 1.6 1.2

0.042 6.9 4.4 3.1 2.3 1.8 1.4 1.2

0.047* 8.6 5.5 3.8 2.8 2.3 1.8 1.5 1.3

0.052 10.6 6.8 4.7 3.4 2.8 2.2 1.8 1.5 1.2

0.055 11.8 7.6 5.3 3.9 3.1 2.5

0.060* 14.1 9.0 6.3 4.6 3.7 2.9 2.4

0.063 15.5 9.9 6.9 5.1 4.1 3.2 2.6 2.3 1.8 1.5 1.3 1.1

0.067* 17.5 11.2 7.8 5.7 4.7 3.7

0.073 20.8 13.3 9.3 6.8 5.5 4.4 3.5

1.0 1.4 2.0 2.4 3.1 3.8 4.4 5.5 6.8 7.6 9.0 9.9 11.2 13.3 18.5

1.0 1.4 1.7 2.1 2.6 3.1 3.8 4.7 5.3 6.3 6.9 7.8 9.3 12.8

2.0 1.4 1.0 1.2 1.6 1.9 2.3 2.8 3.4 3.9 4.6 5.1 5.7 6.8 9.4

1.0 1.3 1.6 1.8 2.3 2.8 3.1 3.7 4.1 4.7 5.5 7.7

1.0 1.2 1.4 1.8 2.2 2.5 2.9 3.2 3.7 4.4 6.0

1.01.21.51.82.0 2.4 2.6 3.0 3.5 4.9

1.0 1.3 1.5 1.7 2.0 2.3 2.5 3.0 4.2

1.0 1.2 1.4 1.6 1.8 2.0 2.4 3.3

1.0 1.1 1.3 1.5 1.7 2.0 2.7

2.01.71.41.11.0 1.2 1.3 1.5 1.8 2.4

2.0 1.6 1.3 1.2 1.01.11.21.52.1

1.0 1.1 1.3 1.9

3.0 2.5 2.0 1.7 1.5 1.2 1.1 1.0 1.2 1.6

3.0 2.4 2.0 1.8 1.5 1.3 1.2 1.0 1.4

0.086* 28.9 18.5 12.8 9.4 7.7 6.0 4.9 4.2 3.3 2.7 2.4 2.1 1.9 1.6 1.4 Flowrate Increases as Diameter Increases =>

0.086 *

Flowrate Increases as Diameter Increases=>

0.073

1.0

* Item included in kit 24E250

42 3A2175A

Maintenance

Change Break-in Oil

After initial break-in, see Table 5 for recommended frequency of oil changes.

Task Schedule

Change break-in oil in a new unit After first 250

hours of opera-

tion or within 3

months, which-

ever comes first

Inspect hydraulic and fluid lines for leaks

If equipped, inspect fluid inlet strainer screens, page 46

If equipped, inspect IsoGuard

™

Select refill or replace as needed, page 47

Check hydraulic fluid level Weekly

Grease circulation valves with Fusion grease (117773)

Verify operation of air drying system to prevent isocyanate crystallization

Inspect air filter (part 24H018), clean or replace as necessary,

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

fluid level and condition,

Daily

Weekly

Daily

Monthly

Table 2: Frequency of Oil Changes

Ambient Tem peratu re

0 to 90°F (-17 to 32°C)

90°F and above (32°C and above)

Recommended Frequency

1000 hours or 12 months, whichever comes first

500 hours or 6 months, whichever comes first

Grease Circulation Valves With Fusion Grease (117773)

ti9879a1

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 filter.

Clean up all hydraulic leaks; identify and repair cause of leak

Clean dispense valve mix chamber ports regularly, see dispense valve manual

Clean dispense valve check valve screens, see dispense valve manual

3A2175A 43

As needed

See dispense

valve manual

See dispense

valve manual

ti18218a

Maintenance

Advanced Display Module (ADM)

Replace Battery

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

To replace the battery:

1. Disconnect power to the ADM.

NOTE: This can be done by removing the CAN cable from the bottom of the ADM.

2. Remove rear access panel.

Install Upgrade Token

To install software upgrades:

1. Use software token 16H821. See Graco Control

Architecture instructions.

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

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

The latest software version for each system can be found at www.graco.com.

™

Module Programming manual for

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.

ti12364a1

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 3A2175A

Maintenance

Motor Control Module (MCM)

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

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

Heat Sink Fins

r_257396_3b9905_02b

FIG. 14: Clean Heat Sink Fins

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 instructions.

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

The latest software version for each system can be found at www.graco.com.

™

Module Programming manual for

r_257396_3b9905_04b

IG. 15: Remove Access Cover

3A2175A 45

Maintenance

Fluid Control Module (FCM)

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 instructions.

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

The latest software version for each system can be found at www.graco.com.

™

Module Programming manual for

Fluid Inlet Strainer Screen

(Not included on HFRS systems)

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.

Use clean chemicals and follow proper storage, transfer, and operating procedures, to minimize contamination 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 material from being pumped while cleaning the screen.

3. Place a container under the strainer manifold (59d) to catch fluid. Remove the strainer plug (59j).

FIG. 16

ti12334a1

4. Remove the screen (59g) from the strainer manifold. Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. If more than 25% 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 (59g) and gasket (59h) in place and tighten. Do not overtighten. Let the gasket make the seal.

46 3A2175A

Maintenance

6. Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.

59d

59g*

59h

59j

59k

ti9886a1

IG. 17. Fluid Inlet Strainer

IsoGuard Select™ System

(Not included on HFRS systems)

NOTE: The IsoGuard Select system is included on all HFRL

systems. It is available separately for HFRS systems as kit 24M154.

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.

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, IsoGuard 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) connected to the fittings.

3. Carefully place ends of tubes with fittings still connected into an empty pail to drain IsoGuard Select fluid.

4. Lift the 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 F

IG. 18.

5. Drain the reservoir and flush it with clean IsoGuard Select fluid.

6. When the reservoir is flushed clean, fill with fresh IsoGuard Select fluid.

3A2175A 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.

5. With check valve arrow pointing away from the IsoGuard 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 with an A.

24C352_313998_8e

IG. 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 IsoGuard Select fluid cylinder.

3. Remove check valve from end of outlet tube.

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-lb (2.26-3.39 N•m).

4. Use funnel to pour IsoGuard Select fluid into tube to fill cylinder.

48 3A2175A

Troubleshooting

Before performing any troubleshooting procedure:

1. Perform Pressure Relief Procedure on page 38.

2. Turn main power OFF.

3. Allow equipment to cool.

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

Troubleshooting

Light Tower (Optional)

Signal Description

Green on only System is powered up and there are

no error conditions present

Yellow on An advisory exists

Red flashing A deviation exists

Red on The system is shut down due to an

alarm occurring.

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

Common Problems

Problem Cause Solution General

Display Module completely dark

No or incorrect amount of material dispensed from either side

Significant material leaking from pump seal

Material dispensed not correct weight

Proportioning System

Proportioning pump does not hold pressure when stalled

No Power Verify AC Power switch is ON Thrown Breaker Check Machines Breakers and Reset Loose Connection Tighten 5-pin cable on Advanced Display Module Bad Display Module Replace Advanced Display Module Ball Valve closed (if Installed) Open tank ball valve. Tank Empty Add fluid Tank Clogged Clean tank Air In Material Prime the machine Pump shaft worn and/or shaft seal

worn Specific gravity of one or more of the

two materials has changed since calibration

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

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

Remove pump shaft assembly and reinstall read pump rebuild kit

Run calibration

ing pressure.

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

3. Repair the valve.

3A2175A 49

Troubleshooting

Problem Cause Solution

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

• Use 2:1 supply pump

• 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 viscosity of 250 to 1500 centipoise.

Clean inlet strainer screen Worn pump inlet valve ball/seat or gasket

Pressure relief/circulation valve leaking back to supply

Erratic pump movement Pump cavitation Feed pump pressure is too low. Adjust pressure to

Pump output low Obstructed fluid hose or gun; fluid

hose ID too small Worn piston valve or intake valve in

displacement pump Inadequate feed pump pressure Check feed pump pressure and adjust to 100 psi (0.7

Power Supply System

No power received from DC power supply

No power to MCM, heat zones, or tanks

Defective power supply Check circuit breaker. Check power supply. Replace

Circuit breaker is tripping Check circuit breaker for tripping and defects. Diag-

Remove return line and determine if flow is present while in SPRAY mode

maintain 100 psi (0.7 MPa, 7 bar) minimum. Open, clear; use hose with larger ID

See pump manual 3A0019

MPa, 7 bar) minimum

power supply.

nose cause of circuit breaker tripping before resetting it. Replace defective parts if required.

50 3A2175A

ADM Troubleshooting

Troubleshooting

FIG. 19: ADM Component Identification - Rear

ti12363a1

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.

Yellow on 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 Information

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

Table 3: LED Status Signal

software token again.

FIG. 20: LED Signals

LED Signals

r_257396_3b9905_01b

52 3A2175A

Acceptable Size and Duration of Power Line Voltage Fluctuations

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

Maximum Permissible Transient Voltage Surges

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

1400

Troubleshooting

1200

1000

800

600

400

Voltage (Volts RMS)

200

0.000001 0.00001 0.0001 0.001 0.01 0.1 1 10

1200Vac, 1697Vdc

<--1 MW Max Surge Power

480Vac, 679Vdc

336Vac, 475Vdc

<--150 KW Max Surge Power

<--50 KW Max Surge Power

288Vac, 407Vdc

<--No Power Limit

264Vac, 373Vdc

Time (seconds)

3A2175A 53

Troubleshooting

Fluid Control Module

Diagnostic Information

Module Status LED Signal Diagnosis

Green on System is powered up

Yellow Internal communication in progress

Red solid FCM hardware failure. Replace FCM.

Red flashing fast Uploading software

Red flashing slow Token error. Remove token and

upload software token again.

FIG. 21:

Module Status LEDs

ti12337a1

54 3A2175A

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.

To begin using the ADM, the machine must be on and enabled. To verify the machine is enabled, verify the System Status Indicator Light (CB) is illuminated green, see F

IG. 7 on page 24. If the System Status Indicator

Light is not green, press the ADM Power On/Off (CA)

button . The System Status Indicator Light will illuminate yellow if the machine is disabled.

7. If L-Head is installed, define L-Head control details. See Mix Head Operating Details Screen, page 62.

8. Define level sensors and refill settings. See Supply Screen, page 64.

9. If Night mode will be used, define Night mode settings. See Conditioning Screen 3, page 66.

10. Calibrate machine. See Calibration Screen, Main, page 60.

11. Define shots. See Shots Screen, page 59.

12. Define sequences. See Sequences Screen, page 59.

13. If desired, view/reset counters. See Maintenance Screen, page 64.

If the machine is in the Disabled mode screen press

repeatedly to select a different operating mode.

Perform the following 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 55

Appendix A - ADM Icons Overview

Icon Function

Access Learn Mode Calibration screen

Access Weight Calibration and Material Specific Gravity Entry screen

Pump Graphic

Calibration Screen, Learn Mode:

Move pump

All other screens:

Begin Dispense

Stop Dispense

Press to enter the Conditioning Control screen

Select left direction

Select right direction

Proceed to next step in calibration procedure

Back to main calibration screen

Icon Function

Select mode

Move L-Head Cleanout Rod

With a mix head installed: Tur ns o n the mix head hydraulics and puts the machine in low pressure circulation.

Press a second time to turn off instigated system action.

Edit Operator Dispense Setting

Lock Dispense Valve Closed (Press to lock the valved closed during a dispense. Used to circulate through the material manifold back to the tank (the Pressure Relief/Dispense Valves will need to be in the relief position).

Open, Close Valve

A (Red) and B (Blue) refill button (Press to start/abort refill)

Jump in to select sequence letter and

position.

Run MCM Learn Mode

Erase Individual Data

Erase All Data

Abort Changing the Label

Backspace

Turn on or off the highlighted zone.

Turn on or off all zones.

56 3A2175A

Skip the next shot in selected sequence. Only available when the system is not dispensing.

Abort sequence and reset to first valid position

Set system in park (icon will be selected when system is parked)

Icon Function

Tank Blanket Heater

Primary Heater

Heated Hose

Chiller

Current and setpoint temperature for primary heater. Not displayed if heat zone is not enabled.

Current and setpoint temperatures for heated hose. Not displayed if heat zone is not enabled.

Current and setpoint temperatures for tank blanket. Not displayed if heat zone is not enabled.

Current and setpoint temperatures for chiller. Not displayed if heat zone is not enabled.

Appendix A - ADM Icons Overview

Shot Number

Sequence Position

Pressure

Flow

Cycles

Time (Duration)

Volume

Amount of material moved through pump (volume tracking)

Weight

Average weight for the calibration point

3A2175A 57

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 .

Shot #1

Sequences #1

Calibration

System #1

From the Setup screens, press to access the Run screens. For Run screens information, see Appendix C

- ADM Run Screens Overview on page 68. F

IG. 22

shows the flow of the Setup screens.

Maintenance

Supply

Conditioning #1

Advanced #1

Shot #2

Shot #...

Sequences #2

Sequences #...

System #2

System #3

FIG. 22: Setup Screens Navigation Diagram

Conditioning #2

Conditioning #3

Advanced #2

Advanced #...

58 3A2175A

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. See Home Screen, Shot Mode on page 69 for information 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 desired value.

2. Type the new value then press the Enter button to accept the new value.

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 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 available 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 new value.

3A2175A 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 ends of piston travel. See Calibra-

tion Screen, Learn Mode.

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

60 3A2175A

Appendix B - ADM Setup Screens Overview

Calibration Screen, Specific Gravity

This screen allows 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.

System Screen 1

This screen allows the user to set important system settings. 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 regardless of pressure fluctuations unless pressure alarm conditions occur.

Dispense Mode can be set to Time, Volume, or Weight. Dispense Mode controls how 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 properly, system performance will be affected. The inlet pressure must be set to the maximum feed pressure that will be seen by that side of the machine.

The maximum working pressure for the machine is displayed on this screen. The maximum working 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.

3A2175A 61

Appendix B - ADM Setup Screens Overview

System Screen 2

This screen allows the user to set the Gel Timer properties 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 maximum working pressure to the maximum working pressure of the dispense valve. See System Screen 1 on page 61.

Mix Head Operating Details Screen

This screen allows the user to define the mix head operating parameters.

• Low Pressure Circulation: The percentage of setpoint at which the system will run during low pressure circulation.

• Pre-Dispense Circulation: The time for which the system will circulate at high pressure prior to dispensing 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.

• Idle Position: Applies to an L-Head only. The position of the cleanout rod when the mix head is idle.

• 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.

• Clean Out Closed: Applies to an L-Head in a Normally 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 Normally 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-seize timer will then begin counting down and the cleanout piston will open and close again to break loose from any remaining curing material. If a shot occurs before both anti-seize timers elapse, the anti-seize timers restart.

62 3A2175A

Appendix B - ADM Setup Screens Overview

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 down arrow

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

press to accept the letter. To erase all text, press the Eraser softkey. To go back one letter, press the Back Arrow softkey.

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.

4. When finished entering the new label, press

the button twice.

The pressure imbalance setting may be set from this screen. Pressure imbalance is the allowable difference in pressure between the two materials before an alarm is triggered. The input range is 250-2000 psi (2-14 MPa, 17-138 bar).

Pressure Imbalance Setting

3A2175A 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 Individual button. Alternatively, each counter displayed on the page may be erased simultaneously by pressing the Erase All button.

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.

The following describes system operation when each tank mode is selected.

• Disabled

• Disables tank operation

• Monitor

• 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

• Errors will clear when the corresponding condition clears

• Manual

• The low level sensor will generate a low level alarm

• A button is provided to the user on the run screens to instigate a manual refill operation at any time

• 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

• The low level alarm will clear when the condition clears

• Auto Top-Off

• The low level sensor will generate a low level alarm

• 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

64 3A2175A

Appendix B - ADM Setup Screens Overview

• Auto Full-Volume

• The low level sensor will initiate an automatic refill when it does not see material

• Automatic refill will 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

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:

• The low level sensor will generate a low level alarm.

• The high level sensor will generate a high level deviation and abort any automatic refill operation.

• 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 any time. This button can also be used to abort a refill operation.

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 appropriate side of the system to indicate that a component is installed. A maximum of four components may be selected.

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 satisfied, the refill will abort.

3A2175A 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.

OTE: All components are shown installed for refer-

nce only. Only 4 components can be installed at one

ime.

Conditioning Screen 3

This screen allows the user to configure Night Mode operation. In Night Mode, the system will cycle on and off periodically. Press the Enter Screen button and adjust 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.

To edit the temperature setpoint and alarms for a particular 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.

3. Edit the setpoint and alarm values and then press the page back button to return to the previous screen.

66 3A2175A

Appendix B - ADM Setup Screens Overview

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.

Advanced Screen 2

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

• 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, the user will not be able to adjust the dispense setpoint in Operator Mode.

• 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.

• Operator Mode Cavitation Alarm: Check this box to enable cavitation alarms in Operator Mode. Clear this box to disable cavitation alarms in Operator Mode.

• Enable Downloading of USB Logs: When this box is checked, USB logs will be automatically downloaded when a USB drive is inserted into the ADM.

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

Advanced Screen 3

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

• Disable Dispensing: Check this box to disable dispensing from the ADM. A footswitch, gun trigger, or other external signal will be the only means with which to trigger a dispense.

The screen displays the date of the last USB log download. 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 downloaded. See Appendix F - USB Operation on page 85 for a complete explanation.

3A2175A 67

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 Events #1

IG. 23: Run Screens Navigation Diagram

Errors #1

Errors #2

Errors #...

Events #2

Events #...

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 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

shown, then press the Enter button to select the mode. The available operating modes are operator, sequence, shot, standby, night, and disabled.

Maintenance

* Supply tanks shown for reference only. Your sys-

tem may not include supply tanks.

68 3A2175A

Appendix C - ADM Run Screens Overview

Home Screen, Standby Mode

In Standby Mode, the user can enable heating, park the pumps, refill the tanks, circulate materials.

Home Screen, Shot Mode

This mode allows the user to select one of 100 predefined shot numbers. See Shots Screen on page 59 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 the Enter button to select the shot number.

4. Press the dispense button to begin dispensing.

Target

Flow/Pressure

Ratio

Target dispense amount (time/vol-

ume/weight depending on Dis-

pense Mode)

3A2175A 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 definitions.

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 letter/position.

5. Press the Dispense button to begin dispensing.

Home Screen, Operator Mode

This mode allows users to set a pressure or flow rate to dispense material without using predefined shot information. Pressure or flow rate availability is dependent on the Control Mode selection, see System Screen 2 on page 62.

To edit the pressure or flow rate, press the button. The value to change will now be highlighted. Type the

new 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 switch is released. If 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 dispense timer.

Ta rg et

Flow/Pressure

Ratio

Target dispense amount (time/vol-

ume/weight depending on Dis-

pense Mode)

Ratio

Operator

Setting

A (Red) resettable material counter

B (Blue) resettable material counter

Total of resettable material counters

70 3A2175A

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 66.

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 functionality of the Home screen except for operating mode selection. Refer to the Home screen and operating mode descriptions for information on this functionality.

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

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. Use the arrows keys to navigate to the desired zone.

3. Press 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.

2. Press the to turn on all zones. When all zones are on, the button will be selected. Press the button

again to turn all zones off.

All zones shown for reference. Only four zones may be active at one time.

72 3A2175A

Appendix C - ADM Run Screens Overview

Errors Screens

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.

Refer to the Troubleshooting section on page 49 for a detailed description of all of the system errors.

Events Screens

This screen shows users a list of events that have occurred in the system. Each event includes a description 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.

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 material usage counters, units are displayed next to the volume/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.

NOTE: In a circulation system, the pumpline must be stopped to erase counters.

3A2175A 73

Appendix D - ADM Error Codes

Error Code Error Name Error Description

Mix Head

A4H3

Motor Overload

Soft Stop

DEH3

Asserted Low Mix

MBH3

Head Oil Level Low

P1H3

Accumulator Pressure High

P4H3

Accumulator Pressure

High Mix

T4H3

Head Oil Temp. M1 Material

WDF3

Rod Shift Fail M1 Cleanout

WDD3

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 amount.

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

An over current was detected on the output

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

Too much current is being drawn from the wall

0500

05A1

A4A6

A4B5

A4A3

A4B1

A4A2

A4B4

A4A7

A4B8

A4H1

A4M1

Invalid Weight Cal. Data

Invalid Auto Cal. Data

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

Motor Over Current

Error Type Cause Solution

Refer to AC Power Pack manual

Deviation Invalid data Re-calibrate the machine

If any messages appeared indicating why the

Deviation Invalid data

Alarm

Bad heaters Measure resistance of heater

Alarm

Alarm High voltage

Alarm

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

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

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

Replace motor

Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground Make sure the supply line is properly sized for the load and is above the minimum voltage requirements

74 3A2175A

Appendix D - ADM Error Codes

Error Code Error Name Error Description

A hardware current fault has occurred causing a system shutdown

Unexpected current to heater/chiller

No current to the conditioning zone

A software error has occurred commanding too much current

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

A4N1

A7A6

A7B5

A7A3

A7B1

A7A2

A7B4

A7A7

A7B8

A8A6

A8B5

A8A3

A8B1

A8A2

A8B4

A8B7

A8B8

A9C1

B9C0

Motor Over Current

Red Blanket Control Fault

Blue Blanket Control Fault

Red Inline Control Fault

Blue Inline Control Fault

Red Hose Control Fault

Blue Hose Control Fault

Red Chiller Control Fault

Blue Chiller Control Fault No Red Blanket Current

No Blue Blanket Current

No Red Inline Current No Blue Inline Current No Red Hose Current

No Blue Hose Current

No Red Chiller Current

No Blue Chiller Current

Motor Over Current

Small Shot Request

Error Type Cause Solution

Short circuit of motor wiring

Alarm

Alarm Low power

Alarm

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

Alarm

Deviation

Motor rotor has become locked

Shorted Temperature Control Module

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Cable unplugged/loose power

Bad Motor Control Module code

Pumps are defined with the wrong size

Requested shot is below the capabilities of the current pump setup

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

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

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

Check for loose or disconnected wires or plugs

Check for MCM software update, load latest MCM software, if problem persists contact Graco On the ADM go into the Setup screens to the System screens then make sure that the pump sizes are defined correctly

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

3A2175A 75

Appendix D - ADM Error Codes

Error Code Error Name Error Description

Comm. Error

CAC1

Motor Comm. Error

CAC3

Red Tank Comm. Error

CAC4

Blue Tank Comm. Error

CAC5

Mix Head Comm. Error

CAC6

Mix Head 2 Comm. Error

CAC7

Ratio Monitor Comm. Error

CAA6

CAB5

CAA3

CAB1

CAA2

CAB4

CAA7

CAB8

D1A1

D2A1

D3A1

D5A1

D6A1

DDA1

DDB2

Red Blanket Comm. Error Blue Blanket Comm. Error Red Inline Comm. Error Blue Inline Comm. Error Red Hose Comm. Error Blue Hose Comm. Error Red Chiller Comm. Error Blue Chiller Setpoint Not Reached

Setpoint Not Reached

Setpoint Exceeded

Invalid Learn Mode Data

Position Sensor Fault

Red Pump Cavitation

Blue Pump Cavitation

Communication error

The set point was not reached and the pump was shutdown

The set point was not reached Deviation

The set point was exceeded Deviation

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

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

Cavitation was detected on the given pump

Error Type Cause Solution

Alarm

Alarm Module not programmed Program the module

Alarm Module missing power Check power supply connection

Alarm Module bad Replace module

Deviation

Alarm

Deviation

Deviation Verify that feed pumps are supplying material

Loose/broken connection Check connection

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

No material in pumps

Recalibrate the machine Rerun the learn mode calibration

Loose/bad connection

Bad linear position sensor

Loose/bad connection to linear position sensor Bad linear position sensor Linear position sensor may be loose where attached to pump housing Insufficient material being supplied or insufficient material pressure on feed system

Debris or packout in the incoming fluid filter

Reduce flow request

Increase restriction in the system

Decrease restriction in the system

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

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

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

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

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

Replace linear position sensor

Re-tighten the sensor and re-calibrate the machine

Verify that incoming ball valves are open

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

76 3A2175A

Appendix D - ADM Error Codes

Error Code Error Name Error Description

Pump Not

DFA1

Parked

Pumps Not

DSC0

Defined

Pump Failed

F7D1

to Stall

Red Low

L111

Material Level

Blue Low

L122

Material Level

Red High

L311

Material Level Blue High

L322

Material Level Red Auto

L6A1

Refill Timeout

Blue Auto

L6B2

Refill Timeout

MBH1 Low Oil Level

Low Motor

MBN1

Performance

The pump failed to reach the park position

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

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

Low material level in tanks

High material level in tanks

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

The volume of oil in the tank is below the minimum level needed for the system to properly operate

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

Error Type Cause Solution

Orifices blocked Clear blockage

Deviation

Alarm

Deviation

Deviation Tanks low on material Fill tanks with material

Deviation Loose/broken connection

Deviation

Alarm

Advisory

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

open

Properly setup the system

Failure of the dispense valve

Material leak

Out of material Fill tanks

Bad level sensor Replace level sensor

Defective fill valve

No material is actually being fed Loose level sensor connection Bad level sensor Replace level sensor

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

Loose/bad connection

Bad level sensor Replace sensor

Leak in hydraulic driver

Leak in the hydraulic reservoir, heat exchanger

Prolonged exposure to heat or high voltage

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

On the ADM go into the setup screens -> System-> then make sure that the pump type and size are set (not --)

Ensure the valve has a proper air supply and seals properly. If not, service the valve as necessary. Visually inspect the machine and hoses for sign of leakage. NOTE: This error will display after 2 full piston strokes so the leak will be substantial.

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

Make sure the feed pumps are operating properly

Check for loose or disconnected wires or plugs

Check to ensure the hydraulic oil level sensor is properly connected to the MCM and that the wire has not been damaged

Inspect hydraulic driver end seals and early leak detection tubing. Replace seals as necessary and replace lost oil.

Inspect the hydraulic reservoir fittings and filter for leaks. Repair or replace as necessary and replace lost oil.

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

3A2175A 77

Appendix D - ADM Error Codes

Error Code Error Name Error Description

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

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

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

The pressure difference between the Red and Blue material is greater than the defined amount

The pressure sensor is providing invalid/no pressure readings

N4A1

P400

P4A1

P4B2

P4D0

P6A1

P6B2

Pump Failed to Move

Thermal Pressure Rise

Red Pressure Shutdown

Blue Pressure Shutdown

Pressure Imbalance

Red Pressure Sensor Fault Blue Pressure Sensor Fault

Error Type Cause Solution

Motor failure

Hydraulic power pack failure

Loose/bad connection to the linear position sensor

Failure of the linear

Deviation

Deviation High pressure

Alarm

Alarm Loose/bad connection

Alarm

position sensor Motor no longer coupled to hydraulic pump Supply tube from hydraulic pump to manifold is loose or

broken Broken motor shaft Replace motor

Over-pressure valve dumping to tank

Dispense valve failed to open Bad dispense valve Replace dispense valve Restriction in the material lines

Invalid maximum pressure defined

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

open

Dispense line is clogged

Pressure imbalance is defined too low

Orifice blocks closed off too much on one or both sides

Debris in the orifice block

Material fillers may have packed out in an orifice

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

Bad sensor Replace pressure transducer

No material in pump Fill tanks

Visually check to ensure the pump is moving, if not ensure the motor is wired properly If motor is moving but pump is not and pressure is not building they hydraulic power pack may need servicing

Check to ensure the linear position sensor is properly connected to the MCM and the wiring has not be damaged

Replace the linear position sensor

Reset coupler per specifications and retighten set screws

Retighten or replace supply tube

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

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

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

Check to ensure there is no blockage

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

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

Ensure the material flow is equally restricted on both material lines

On the ADM go into the setup screens -> System-> and ensure the pressure imbalance value is the maximum acceptable to prevent unnecessary alarms which will abort dispenses

Verify that one or both of the orifice blocks dispense when adjusted to the fully open position then adjust accordingly

Relieve system pressure then remove the orifice from the orifice block and inspect for debris in the cavity

Relieve system pressure and remove the orifice from the orifice block and inspect for pack out. Clean or replace as necessary.

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

78 3A2175A

Appendix D - ADM Error Codes

Error Code Error Name Error Description

Red Tank

T1A6

Low Fluid Temp.

Blue Tank

T1B5

Low Fluid Temp. Red Inline

T1A3

Low Fluid Temp. Blue Inline

T1B1

Low Fluid

T1A2

T1B4

T1A7

T1B8

T3H1

T3N1

T4B5

T4A3

T4B1

T4A2

T4B4

T4A7

T4B8

Temp. Red Hose

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

Blue Chiller Low Fluid Temp.

Oil Temp. Cutback

Motor Temp. Cutback

Blue Tank High Fluid Temp. Red Inline High Fluid Temp.

Blue Inline High Fluid Temp.

Red Hose High Fluid Temp. Blue Hose High Fluid Temp.

Red Chiller High Fluid Temp.

Blue Chiller High Fluid Temp.

Fluid temperature is below the defined low alarm limit

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

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

Fluid temperature is above the defined high alarm limit

Error Type Cause Solution

Alarm

Alarm Low power

Alarm

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

Deviation

Advisory

Alarm

Alarm Loose connections Tighten connections

Tripped circuit breaker Visually check circuit breaker for a tripped condition

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

Cable unplugged/loose power

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

Low air volume from fan

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

Low air volume from fan

Ambient environmental conditions are too hot

Motor/pump coupler may be rubbing on hydraulic pump

Defective RTD Replace RTD

Defective High Power Temperature Control Module

Check for loose or disconnected wires or plugs

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

Move machine to an area below 120°F

Reset coupler per specifications and retighten set screws

Replace High Power Temperature Control Module

3A2175A 79

Appendix D - ADM Error Codes

Error Code Error Name Error Description

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

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

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

RTD 1 is giving no or invalid data

RTD 2 is giving no or invalid data

No temperature rise

T4C1

T4H1

T4N1

T6A6

T6B5

T6A3

T6B1

T6A2

T6B4

T6A7

T6B8

T6C6

T6C7

T6C8

T8A6

T8A3

T8B1

T8A2

T8B4

Motor Control High Temp.

Oil Temp. Shutdown

Motor Temp. Shutdown

Red Tank RTD Fault

Blue Tank RTD Fault Red Inline RTD Fault Blue Inline RTD Fault Red Hose FTS Fault Blue Hose FTS Fault Red Chiller RTD Fault Blue Chiller RTD Fault Red Blanket RTD Fault Blue Blanket RTD Fault Red Chiller RTD Fault Blue Chiller RTD Fault No Heat Red Tank No Heat Blue Tank No Heat Red Inline

No Heat Blue Inline

No Heat Red Hose

No Heat Blue Hose

Error Type Cause Solution

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

Alarm

Alarm Bad RTD Replace RTD

Alarm

Alarm Bad RTD Replace RTD

Alarm

Alarm Low Power

Alarm

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

Low air volume from fan

Motor may be damaged Replace motor Debris is packed in the

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

Low air volume from fan

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

Low air volume from fan

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

Loose or bad connection Check RTD wiring

Loose or bad connection Check RTD wiringT6C5

Tripped circuit breaker Visually check circuit breaker for a tripped conditionT8B5

Cable unplugged/loose power

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

Clear debris from MCM heat sink fins

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

Move machine to an area below 120°F

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

Check for loose or disconnected wires or plugs

80 3A2175A

Appendix D - ADM Error Codes

Error Code Error Name Error Description

No Cooling

T8A7

Red Chiller

No temperature decline

Heater overtemperature cutoff

PCB over temperature

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

High line voltage

T8B8

T9A6

T9B5

T9A3

T9B1

T9C6

T9C5

T9C3

T9C1

T9C2

T9C4

T9C7

T9C8

V1H1

V4A6

V4B5

V4A3

V4B1

V4A2

V4B4

V4A7

V4B8

No Cooling Blue Chiller

Red Blanket Temp. Cutoff Blue Blanket Temp. Cutoff

Red Inline Temp. Cutoff

Blue Inline Temp. Cutoff

Red Blanket Ctrl Shutdown

Blue Blanket Ctrl Shutdown Red Inline Ctrl Shutdown Blue Inline Ctrl Shutdown

Red Hose Ctrl Shutdown

Blue Hose Ctrl Shutdown

Red Chiller Ctrl Shutdown Blue Chiller Ctrl Shutdown

Motor Control Undervoltage

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

Error Type Cause Solution

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

Disconnect the valve and measure the voltage across

Defective cooling valve

Alarm

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

Alarm

Defective RTD Replace RTD

Alarm

Defective High Power

Alarm

Alarm Loose connections Tighten connections

Alarm

Temperature Control Module

Overheated Temperature Control Module

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

Incoming line voltage is too high

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

Replace High Power Temperature Control Module

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

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

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

3A2175A 81

Appendix D - ADM Error Codes

Error Code Error Name Error Description

The voltage to the MCM has

V4H0

W0U0

WBH1

WKH1

WM06

WM05

WM03

WM01

WM02

WM04

WM07

WM08

WMA6

WMB5

Motor Control Overvoltage

USB Update Failed

Motor Encoder Fault

High Motor Speed

Red Tank Con. Fault

Blue Tank Con. Fault

Red Inline Con. Fault

Blue Inline Con. Fault

Red Hose Con. Fault

Blue Hose Con. Fault

Red Chiller Con. Fault

Blue Chiller Con. Fault

Red Blanket High Temp.

Blue Blanket High Temp.

reached an unsafe level and has been shutdown in an attempt to prevent damage

The ADM tried to upload a system settings file but failed

An error has been detected on the motor position sensor

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

High current to relay 1

Tank blanket is above the defined high alarm limit

Error Type Cause Solution

Alarm

Alarm Defective RTD Replace RTD

Alarm

Supply lines providing high voltage

System Settings file is corrupt System Settings file is intended for another system Failing sensors If error persists the motor will need to be replaced

Loose connection

No power to directional valve

Bad directional valve connection

Directional valve failure The directional valve will need to be replaced Hydraulic power pack failure Defective encoder Replace encoder Motor no longer coupled

to hydraulic pump Supply tube from

hydraulic pump to manifold is loose or broken

Broken motor shaft Replace motor

Broken contactor Replace contactor

Defective High Power Temperature Control Module

Loose connections Tighten connections

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

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

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

Make sure the directional valve has power

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

The hydraulic power pack will need repair

Reset coupler per specifications and retighten set screws

Retighten or replace supply tube

Replace High Power Temperature Control Module

82 3A2175A

Appendix D - ADM Error Codes

Error Code Error Name Error Description

Red Tank

WMC6

Con. Fault Blue Tank

WMC5

Con. Fault Red Inline

WMC3

Con. Fault Blue Inline

WMC1

WMC2

WMC4

WMC7

WMC8

WMH1

WSC0

WSD0

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

Fault

Invalid Setpoint Request

Invalid Gel Timer Definition

Unexpected current to relay 1

A general fault has occurred within the MCM

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

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

Error Type Cause Solution

Alarm

Shorted module

Alarm

Deviation Internal hardware failure

System incorrectly setup

Deviation

Shot incorrectly defined

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

Deviation

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

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

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

On the ADM go into the setup screens -> System-> and ensure that all pages have properly defined values

Redefine shot with control parameters within the limits of the system

Select a different shot or modify existing shot data

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

3A2175A 83

Appendix E - System Events

Event Code and String Triggers

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

REA00: Disp. Occurred (Shot #)

REH00: Gel Timer Dispense

RER01: Shot Count Reset

RER02: Seq. Position Count Reset

RERA1: Red Material Volume Reset

RERB1: Blue Material Volume Reset

RERA2: Red Material Weight Reset

RERB2: Blue Material Weight Reset

RERA3: Red Cycle Count Reset

RERB3: Blue Cycle Count Reset

REQU1: Settings Downloaded

REQU2: Settings Uploaded

The System was powered on.

The System was powered off.

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

A learn mode calibration was successfully completed.

The system was successfully characterized with the Automatic calibration.

The Red materials specific gravity was modified.

The Blue materials specific gravity was modified.

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

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

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

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

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

A dispense has occurred of the given shot number.

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

A counter from the shot counters maintenance page was erased

A counter from the sequence counters maintenance page was erased

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

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

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

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

The resettable cycle counter for the Red 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 successfully transferred from the USB drive to the ADM.

Event Code and String Triggers

REQU3: Language Downloaded

REQU4: Language Uploaded

REQU5: Logs Downloaded

REAR0: Night Mode Recirc On

REBR0: Night Mode Recirc Off

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

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

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

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

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

84 3A2175A

Appendix F - USB Operation

Overview

There are 3 main uses for the USB on a GMS system

• 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 information

• Ability to download, modify, and upload custom language files

• Ability to download and upload system configurations

• This data includes most user selectable and

user configurable settings.

• This data does not include pump counters, error

and event logs, shot and sequence counters

USB Options

The only options for USB on the ADM are in Advanced Screen 2, see page 67.

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 (DISPTEXT.TXT) and the system settings (SETTINGS.TXT). The status of the download will be shown in the Status bar.

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

The second option is the Erase icon which will reset the last download date to a time where all logs can be downloaded, 10/01/09. This will allow the user to download 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 2 weeks or more often if the machine is used during more than one full shift a day.

3A2175A 85

Appendix F - USB Operation

Log Files, Folder Structure

IG. 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 two 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.

86 3A2175A

Example LOG01 File

The LOG01 file is the Errors and Events log file.

Appendix F - USB Operation

Example LOG02 File

The LOG02 file is the Shot Data Log file.

3A2175A 87

Appendix F - USB Operation

Transfer System Settings

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.

NOTICE

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

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

3. Navigate to the DOWNLOAD folder.

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

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

NOTE: Before the update begins the ADM automatically shuts down the system, aborting any in-progress dispensing. When the software is updating 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.TXT file from the UPLOAD folder to prevent accidental loss of data the next time the USB stick-drive is inserted into the ADM USB port. If there is a SETTINGS.TXT file in the UPLOAD folder when the USB stick-drive is inserted into the ADM USB port the software will try to update the ADM.

88 3A2175A

Update Custom Language

Appendix F - USB Operation

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

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

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

3. Navigate to the DOWNLOAD folder.

4. Copy the DISPTEXT.TXT file from the DOWNLOAD 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.

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.

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

new string.

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

must remain “DISPTEXT.TXT”.

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

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

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 89

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.

90 3A2175A

Accessories

Part No. Description

24M154

24F516

255244 Footswitch with Guard and 4 meter cable

IsoGuard (Included on HFRL units)

IsoGuard

HFR Discrete Gateway Module (DGM) Kits

Single DGM Kit, 24F843 Dual DGM Kit, 24F844 DGM only, 24G830

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 conjunction 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.

Select Assembly with 32 oz reservoir

Select Fluid, 6 Quarts

Accessories

Secondary Supply Pump to Create a Tandem Unit (HFRS Equipment Only)

Drum/Ram

Size

Part No.

24M0028 5 (19)

24M0026 55 (208)

24M0029 5 (19)

24M0027 55 (208)

gallon (liter)

Type Displacement Ratio

Carbon Steel

60 cc 20:1

Stainless Steel

3A2175A 91

Technical Data

Maximum Fluid Working 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 npt(f)

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)

Air Inlet. . . . . . . . . . . . . . . . . . . . . . . . 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 / 3 phase: 360-440V, 50/60 Hz

Amperage Requirement. . . . . . . . . . . See Models on page 4

Sound Power . . . . . . . . . . . . . . . . . . . 93 dB

Hydraulic reservoir capacity. . . . . . . . 8 gal. (30 liters)

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

Weight . . . . . . . . . . . . . . . . . . . . . . . . 634 lb (288 kg) (Not including supply pumps)

Wetted Parts . . . . . . . . . . . . . . . . . . . Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome,

fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, 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 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 Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200% for 0.2 seconds

DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Vdc, Class 2, Graco-provided power supply

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

(610 mm)*

5 in.

(127 mm)*

15 in.

(381 mm)*

37.2 in.

(945 mm)

58.1 in.

(1476 mm)

ti18219a

* (4) 5/8” diameter anchor locations

94 3A2175A

Technical Data

3A2175A 95

Graco Standard Warranty

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

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

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

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

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

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

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

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

FOR GRACO CANADA CUSTOMERS

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

Graco Information

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

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

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

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

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

Original instructions. This manual contains English. MM 3A2175

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Graco 3A2175A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Models

HFR-Laminate (HFRL)

HFR-Silicone (HFRS)

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Changing Materials

A (Red) and B (Blue) Components

Typical HFRS System

Typical HFRL System

Component Identification

Hydraulic Power Pack

Motor Control Module (MCM)

Advanced Display Module (ADM)

Fluid Control Module (FCM)

Dispense Valve Overview

Setup

Operation

Startup

Shutdown

Pressure Relief Procedure

Flushing

Adjusting Material Inlet Pressure Using the Material Regulator

Pressure Balancing Using the Orifice Valve Assemblies

Maintenance

Advanced Display Module (ADM)

Motor Control Module (MCM)

Fluid Control Module (FCM)

Fluid Inlet Strainer Screen

IsoGuard Select™ System

Clean Orifice Valves

Troubleshooting

Light Tower (Optional)

Common Problems

ADM Troubleshooting

Motor Control Module

Fluid Control Module

Advanced Display Module (ADM) Operation

Appendix A - ADM Icons Overview

Appendix B - ADM Setup Screens Overview

Appendix C - ADM Run Screens Overview

Appendix D - ADM Error Codes

Appendix E - System Events

Appendix F - USB Operation

Overview

USB Options

Download Log Files

Log Files, Folder Structure

Transfer System Settings

Update Custom Language

Accessories

Technical Data

Motor Control Module Technical Data

Dimensions

Graco Standard Warranty

Graco Information