Graco 3A2175A User Manual
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.
EN
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
14
Moisture Sensitivity of Isocyanates . . . . . . . . . . 14
Changing Materials . . . . . . . . . . . . . . . . . . . . . . 15
A (Red) and B (Blue) Components . . . . . . . . . . . . 15
Typical HFRS System . . . . . . . . . . . . . . . . . . . . . . 16
Typical HFRL System . . . . . . . . . . . . . . . . . . . . . . 17
Component Identification . . . . . . . . . . . . . . . . . . . 18
Hydraulic Power Pack . . . . . . . . . . . . . . . . . . . . 21
Motor Control Module (MCM) . . . . . . . . . . . . . . 22
Advanced 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
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
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.
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
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
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
Typical HFRS System
M
N
A
L
E
C
D
P
G
F
B
N
ti18208a
P
J,
K
J,
K
H
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
Typical HFRL System
AG
AF
AL
AD
AB
AE
AA
AC
AJ,
AK
AH
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
AL
AH Dispense Gun
AJ Orifice Block
AK Orifice, 1/4”
AL Inlet Assembly
AM Isolube Kit (not shown)
3A2175A 17
Component Identification
Component Identification
BP
BF
BA
BR
BY
BJ
BS
BH
BG
BX
BH
BG
CE
BV
(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
BJ
BH
HFRL Material Inlet
(250 psi Max)
BG
Fluid Manifold (FM) Detail
ti18211a
BJ
BJ
CD
HFRS Material Inlet
(3000 psi Max)
BG
Rear View
ti18212a
BZBD CABLBK BE
BT
BMBB BCBN
ti9880a1
FIG. 4: Component Identification, shown with shrouds removed
CB
CC
BU
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
DB
DE
Component Identification
DG
DF
DH
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
DA
DD
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.
B
A
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.
C
12
FIG. 6: MCM Component Identification
1A
10
1B
3
2
5
r_257396_3b9905_01b
6
8
9
11
7
13
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
EA
EB
EC
ED
EE
EH
EG
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.
EF
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
ES
Component Identification
EJ
EK
EL
EM
EN
ER
F
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
EP
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
F
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
FA
FC
E
FB
FIG. 10
Key:
FA Fluid Control Module
FB Base
FC Module Connection Screws
FD Access Cover
FE Module Status LEDs
FF CAN Connectors
FF
ti12337a1
ti12336a1
FD
3A2175A 27
Dispense Valve Overview
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
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
2
)
FIG. 13: Grounding Lug
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