Graco 3A2176J User Manual
Repair - Parts
3A2176J
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.
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
Operation ................................16
Shutdown .............................16
Pressure Relief Procedure ................16
Flushing .............................. 17
Repair ...................................18
Pumpline ..............................18
Hydraulic Power Pack Repair ..............25
Replace Power Supply ...................31
Replace Circuit Breaker ..................31
Parts ....................................32
HFRL Models .......................... 32
HFRS Models ..........................34
Base Module ........................... 40
Power Pack Module ...................... 44
Hydraulic DC Power Pack Module, 257442 .... 46
Power Modules, 24M034 & 24M035 ......... 48
Power Panels, 24M030 & 24M031 .......... 50
Fluid Outlet Modules, 24M167 & 24M168 ..... 52
Fluid Manifolds, 255629 & 289999 ..........54
Fluid Inlet Assembly, 24M129 (HFRL) ........56
Fluid Inlet Assemblies, 24M132 & 24M133 (HFRS)
58
Dispense Hose Assembly Kits ............. 60
Inlet Hose Assembly Kits ................. 62
Lubrication Kit, 24M154 .................. 63
Logic Drawings ...........................64
230V, 1 Phase .........................64
400V, 3 Phase ..........................65
DC Hydraulic Power Pack ................. 66
Motor Control Module (MCM) .............. 67
Accessories ..............................69
Technical Data ............................ 70
Motor Control Module Technical Data ........71
Graco Standard Warranty ...................72
Graco Information .........................72
2 3A2176J
Related Manuals
Manuals are available at www.graco.com.
Component manuals in U.S. English:
System Manuals
3A2175 HFRL and HFRS Setup-Operation
Pumpline Manuals
3A0019 Z-Series Chemical Pumps Instructions-Parts
3A0020
Feed System Manuals
3A0235 Feed Supply Kits Instructions-Parts
Dispense Valve Manuals
312185 MD2 Valve, Instructions-Parts
Accessory Manuals
HFR™Hydraulic Actuator Instructions-Parts
Related Manuals
3A1149 HFR Discrete Gateway Module Kits Manual
3A2176J 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) @ 1500 psi (10 MPa, 103 bar).
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
** 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 may be possible, but should be tested under application conditions.
B Pump
Size cc/cycle
Required cpm@
Flow**
Max Flow †
cc/sec (lb/min) @ 1500 psi (10 MPa, 103 bar) Ratio
1.86
30 (4)
† Dispense rate in excess of max flow and pressure may result in an elevated temperature of the hydraulic system,
resulting in a thermal shutdown (T4H1). Other system models are available for sustained flow rates and pressures
in excess of above.
4 3A2176J
Models
HFRL Models
Part Number Description
HFRL01 HFR for Lamination, 230/1, 1.00:1,
80/80, Carbon Steel
HFRL02 HFR for Lamination, 230/1, 1.08:1,
86/80, Carbon Steel
HFRL03 HFR for Lamination, 230/1, 1.16:1,
100/86, Carbon Steel
HFRL04 HFR for Lamination, 230/1, 1.20:1,
60/50, Carbon Steel
HFRL05 HFR for Lamination, 230/1, 1.23:1,
80/65, Carbon Steel
HFRL06 HFR for Lamination, 230/1, 1.33:1,
80/60, Carbon Steel
HFRL07 HFR for Lamination, 230/1, 1.50:1,
60/40, Carbon Steel
HFRL08 HFR for Lamination, 230/1, 1.60:1,
80/50, Carbon Steel
HFRL09 HFR for Lamination, 230/1, 1.63:1,
65/40, Carbon Steel
HFRL10 HFR for Lamination, 230/1, 1.67:1,
50/30, Carbon Steel
HFRL11 HFR for Lamination, 230/1, 1.86:1,
160/86, Carbon Steel
HFRL12 HFR for Lamination, 230/1, 2.00:1,
50/25, Carbon Steel
HFRL13 HFR for Lamination, 230/1, 2.15:1,
86/40, Carbon Steel
HFRL14 HFR for Lamination, 230/1, 2.40:1,
60/25, Carbon Steel
HFRL15 HFR for Lamination, 230/1, 2.5:1,
50/20, Carbon Steel
HFRL16
★✖
HFRL17
★✖
HFRL18
★✖
HFRL19
★✖
HFRL20
★✖
HFRL21
★✖
HFRL22
★✖
HFR for Lamination, 400/3, 1.00:1,
80/80, Carbon Steel
HFR for Lamination, 400/3, 1.08:1,
86/80, Carbon Steel
HFR for Lamination, 400/3, 1.16:1,
100/86, Carbon Steel
HFR for Lamination, 400/3, 1.20:1,
60/50, Carbon Steel
HFR for Lamination, 400/3, 1.23:1,
80/65, Carbon Steel
HFR for Lamination, 400/3, 1.33:1,
80/60, Carbon Steel
HFR for Lamination, 400/3, 1.50:1,
60/40, Carbon Steel
Part Number
HFRL23
★✖
HFRL24
★✖
HFRL25
★✖
HFRL26
★✖
HFRL27
★✖
HFRL28
★✖
HFRL29
★✖
HFRL30
★✖
★ approved.
✖ See 400 V Power Requirements.
Description
HFR for Lamination, 400/3, 1.60:1,
80/50, Carbon Steel
HFR for Lamination, 400/3, 1.63:1,
65/40, Carbon Steel
HFR for Lamination, 400/3, 1.67:1,
50/30, Carbon Steel
HFR for Lamination, 400/3, 1.86:1,
160/86, Carbon Steel
HFR for Lamination, 400/3, 2.00:1,
50/25, Carbon Steel
HFR for Lamination, 400/3, 2.15:1,
86/40, Carbon Steel
HFR for Lamination, 400/3, 2.40:1,
60/25, Carbon Steel
HFR for Lamination, 400/3, 2.5:1,
50/20, Carbon Steel
400 V Power Requirements
• 400 V systems are intended for International voltage
requirements. Not for voltage requirements in North
America.
• If a 400 volt configuration is operated in North America, a special transformer rated for 400 V (“Y” configuration (4 wire)) may be required.
• North America mostly employs a 3 wire or Delta
configuration. The two configurations are not interchangeable.
3A2176J 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 (3 lb/min) @ 2500 psi (17 MPa, 172 bar). The equipment can be run at up to 20 cycles per minute
continuous duty.
A Pump
Size
10 100 110 11 5.6 20 10.00
15 80 95 12.5 4.8 20 5.33
40 40 80 15 4 20 1.00
10 60 70 17 3.6 20 6.00
20 40 60 20 3 20 2.00
10 40 50 20 2.5 16.7 4.00
10 10 20 12 1 4 1.00
** Cycle rate should be between 3 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 may be possible, but should be tested under application conditions.
† Flow rates are established @ 2500 psi (17 MPa, 172 bar). Dispense rate in excess of max flow and pressure may
result in an elevated temperature of the hydraulic system, resulting in a thermal shutdown (T4H1). Other system
models are available for sustained flow rates and pressures in excess of above.
B Pump
Size cc/cycle
Required cpm@
Maximum Flow**
Minimum Flow †
cc/sec
Maximum Flow †
cc/sec Ratio
6 3A2176J
Models
HFRS Models
Part Number Description
HFRS01 HFR for Silicone, 230/1, 1:1, Carbon
Steel, 55/55 Feed, (10/10 pumps)
HFRS02 HFR for Silicone, 230/1, 1:1, Carbon
Steel, 5/5 Feed, (10/10 pumps)
HFRS03
★✖
HFRS04
★✖
HFRS05 HFR for Silicone, 230/1, 1:1, Stainless
HFRS06 HFR for Silicone, 230/1, 1:1, Stainless
HFRS07
★✖
HFRS08
★✖
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
★✖
HFRS13
★✖
HFRS14
★✖
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
★✖
HFRS19
★✖
HFRS20
★✖
HFRS21 HFR for Silicone, 230/1, 5.33:1, Carbon
HFRS22 HFR for Silicone, 230/1, 5.33:1, Carbon
HFR for Silicone, 400/3, 1:1, Carbon
Steel, 55/55 Feed, (10/10 pumps)
HFR for Silicone, 400/3, 1:1, Carbon
Steel, 5/5 Feed, (10/10 pumps)
Steel, 55/55 Feed, (10/10 pumps)
Steel, 5/5 Feed, (10/10 pumps)
HFR for Silicone, 400/3, 1:1, Stainless
Steel, 55/55 Feed, (10/10 pumps)
HFR for Silicone, 400/3, 1:1, Stainless
Steel, 5/5 Feed, (10/10 pumps)
Steel, 55/55 Feed
Steel, 55/5 Feed
Steel, 5/5 Feed
HFR for Silicone, 400/3, 4:1, Carbon
Steel, 55/55 Feed
HFR for Silicone, 400/3, 4:1, Carbon
Steel, 55/5 Feed
HFR for Silicone, 400/3, 4:1, Carbon
Steel, 5/5 Feed
Steel, 55/55 Feed
Steel, 55/5 Feed
Steel, 5/5 Feed
HFR for Silicone, 400/3, 4:1, Stainless
Steel, 55/55 Feed
HFR for Silicone, 400/3, 4:1, Stainless
Steel, 55/5 Feed
HFR for Silicone, 400/3, 4:1, Stainless
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
★✖
HFRS25
★✖
HFRS26
★✖
HFR for Silicone, 400/3, 5.33:1, Carbon
Steel, 55/55 Feed
HFR for Silicone, 400/3, 5.33:1, Carbon
Steel, 55/5 Feed
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
★✖
HFRS31
★✖
HFRS32
★✖
HFR for Silicone, 400/3, 5.33:1, Stainless Steel, 55/55 Feed
HFR for Silicone, 400/3, 5.33:1, Stainless Steel, 55/5 Feed
HFR for Silicone, 400/3, 5.33:1, Stainless 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
★✖
HFRS37
★✖
HFRS38
★✖
HFR for Silicone, 400/3, 6:1, Carbon
Steel, 55/55 Feed
HFR for Silicone, 400/3, 6:1, Carbon
Steel, 55/5 Feed
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
★✖
HFRS43
★✖
HFRS44
★✖
HFR for Silicone, 400/3, 6:1, SS 55/55
Feed
HFR for Silicone, 400/3, 6:1, Stainless
Steel, 55/5 Feed
HFR for Silicone, 400/3, 6:1, Stainless
Steel, 5/5 Feed
3A2176J 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
★✖
HFRS49
★✖
HFRS50
★✖
HFR for Silicone, 400/3, 10:1, Carbon
Steel, 55/55 Feed
HFR for Silicone, 400/3, 10:1, Carbon
Steel, 55/5 Feed
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
★✖
HFRS55
★✖
HFRS56
★✖
HFR for Silicone, 400/3, 10:1, Stainless
Steel, 55/55 Feed
HFR for Silicone, 400/3, 10:1, Stainless
Steel, 55/5 Feed
HFR for Silicone, 400/3, 10:1, Stainless
Steel, 5/5 Feed
HFRS57 HFR for Silicone, 230/1, 2:1, Carbon
Steel, 55/55 Feed
HFRS58
★✖
HFR for Silicone, 230/1, 2:1, Carbon
Steel, 55/5 Feed
HFRS59 HFR for Silicone, 230/1, 2:1, Carbon
Steel, 5/5 Feed
HFRS60
★✖
HFR for Silicone, 400/3, 2:1, Carbon
Steel, 55/55 Feed
HFRS61 HFR for Silicone, 400/3, 2:1, Carbon
Steel, 55/5 Feed
HFRS62
★✖
HFR for Silicone, 400/3, 2:1, Carbon
Steel, 5/5 Feed
HFRS63 HFR for Silicone, 230/1, 2:1, Stainless
Steel, 55/55 Feed
HFRS64
★✖
HFR for Silicone, 230/1, 2:1, Stainless
Steel, 55/5 Feed
HFRS65 HFR for Silicone, 230/1, 2:1, Stainless
Steel, 5/5 Feed
HFRS66
★✖
HFR for Silicone, 400/3, 2:1, Stainless
Steel, 55/55 Feed
Part Number
Description
HFRS67 HFR for Silicone, 400/3, 2:1, Stainless
Steel, 55/5 Feed
HFRS68
★✖
HFR for Silicone, 400/3, 2:1, Stainless
Steel, 5/5 Feed
HFRS69 HFR for Silicone, 230/1, 1:1, Carbon
Steel, No Feed, (10/10 pumps)
HFRS70
★✖
HFR for Silicone, 400/3, 1:1, Carbon
Steel, No Feed, (10/10 pumps)
HFRS71 HFR for Silicone, 230/1, 1:1, Stainless
Steel, No Feed, (10/10 pumps)
HFRS72
★✖
HFR for Silicone, 400/3, 1:1, Stainless
Steel, No Feed, (10/10 pumps)
HFRS73 HFR for Silicone, 230/1, 2:1, Carbon
Steel, No Feed
HFRS74
★✖
HFR for Silicone, 400/3, 2:1, Carbon
Steel, No Feed
HFRS75 HFR for Silicone, 230/1, 2:1, Stainless
Steel, No Feed
HFRS76
★✖
HFR for Silicone, 400/3, 2:1, 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, 5.33:1, Carbon
Steel, No Feed
HFRS82
★✖
HFR for Silicone, 400/3, 5.33:1, Carbon
Steel, No Feed
HFRS83 HFR for Silicone, 230/1, 5.33:1, Stain-
less Steel, No Feed
HFRS84
★✖
HFR for Silicone, 400/3, 5.33:1, 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 3A2176J
Models
Part Number
HFRS89 HFR for Silicone, 230/1, 10:1, Carbon
HFRS90
★✖
HFRS91 HFR for Silicone, 230/1, 10:1, Stainless
HFRS92
★✖
HFRS93 HFR for Silicone, 230/1, 1:1, Carbon
HFRS94 HFR for Silicone, 230/1, 1:1, Carbon
HFRS95
★✖
HFRS96
★✖
HFRS97 HFR for Silicone, 230/1, 1:1, Stainless
HFRS98 HFR for Silicone, 230/1, 1:1, Stainless
HFRS99
★✖
HFRSA0
★✖
HFRSA1 HFR for Silicone, 230/1, 1:1, Carbon
HFRSA2
★✖
HFRSA3 HFR for Silicone, 230/1, 1:1, Stainless
HFRSA4
★✖
Description
Steel, No Feed
HFR for Silicone, 400/3, 10:1, Carbon
Steel, No Feed
Steel, No Feed
HFR for Silicone, 400/3, 10:1, Stainless
Steel, No Feed
Steel, 55/55 Feed, (40/40 pumps)
Steel, 5/5 Feed, (40/40 pumps)
HFR for Silicone, 400/3, 1:1, Carbon
Steel, 55/55 Feed, (40/40 pumps)
HFR for Silicone, 400/3, 1:1, Carbon
Steel, 5/5 Feed, (40/40 pumps)
Steel, 55/55 Feed, (40/40 pumps)
Steel, 5/5 Feed, (40/40 pumps)
HFR for Silicone, 400/3, 1:1, Stainless
Steel, 55/55 Feed, (40/40 pumps)
HFR for Silicone, 400/3, 1:1, Stainless
Steel, 5/5 Feed, (40/40 pumps)
Steel, No Feed, (40/40 pumps)
HFR for Silicone, 400/3, 1:1, Carbon
Steel, No Feed, (40/40 pumps)
Steel, No Feed, (40/40 pumps)
HFR for Silicone, 400/3, 1:1, Stainless
Steel, No Feed, (40/40 pumps)
400 V Power Requirements
• 400 V systems are intended for International voltage
requirements. Not for voltage requirements in North
America.
• If a 400 volt configuration is operated in North America, a special transformer rated for 400 V (“Y” configuration (4 wire)) may be required.
• North America mostly employs a 3 wire or Delta
configuration. The two configurations are not interchangeable.
★ approved.
✖ See 400 V Power Requirements.
3A2176J 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 3A2176J
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.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine 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 par ts, 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.
3A2176J 11
Warnings
WARNING
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
12 3A2176J
Warnings
3A2176J 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™, part 24F516. The lubricant
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.
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 3A2176J
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.
NOTE: For HFRL Systems:
The high volume material will always be the B (Blue)
side.Typical Installation
3A2176J 15
Operation
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.
Pressure Relief Procedure
NOTICE
The fittings on the pressure relief hoses are zinc
plated carbon steel. The hose cores are cured with
sulfur. Check your materials for compatibility with
zinc plating and sulfur before reusing any material
that passed through them, as it may inhibit curing.
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.
3. Turn main power switch (MP) to OFF position.
4. Close A (Red) and B (Blue) fluid supply valves (FV),
if equipped, or remove fluid pressure at supply
device.
FV
ti9883a1
5. Perform Pressure Relief Procedure on page 16.
6. Shut down feed pumps as required. See feed pump
manual.
SA
SB
ti9879a1
3. For models with an dispense valve with a safety
lock, engage gun safety lock.
4. Relieve pressure in dispense valve. See dispense
valve manual.
16 3A2176J
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
Technical Data on page 70 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).
SA
SB
N
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.
3A2176J 17
Repair
Repair
Pumpline
See Z-Series Chemical Pumps manual, HFR Hydraulic
Driver manuals for more detailed pumpline repair information.
Remove Chemical Pumps
This procedure removes the chemical pumps so that
replacement parts can be installed. See Z-Series Chemical Pumps manual for replacement parts installation
procedure.
1. Flush system, see page 17.
2. Perform Operation, see page 16.
3. Remove the front pump shroud.
4. Disconnect the chemical pump inlet and outlet fluid
lines. Do not disconnect the fluid manifold inlet line
or the fluid line connections at the heater.
Fluid Manifold Inlet
Pump Outlet
Pump Inlet
24C352_313998_4g1
18 3A2176J
Repair
5. Unthread smaller cylinder from hydraulic driver and
slide inside larger cylinder. Use punch slots in lube
cylinder to aid rotation if necessary. See FIG.1.
Lube Cylinder Outlet Fitting
Punch Slot (same on opposite side)
24C352_313998_2g1
Lube Cylinder Inlet Fitting (behind cylinder)
7. Remove coupler from the A and B side pump shafts.
See FIG.2.
8. Unscrew LVDT sensor assembly and spool assembly from pump outlet housing. Wipe off spool
assembly. See F
IG.2.
9. Remove three nuts securing pump to tie rods. See
F
IG.2.
FIG. 1: Lube Cylinder
6. Remove two shoulder bolts from LVDT collar then
remove collar from B side pump shaft. See FIG.2.
Pump Outlet Housing
LVDT Sensor Assembly
(behind pump)
LVDT Spool Assembly
24C352_313998_2g1
LVDT Collar
Coupler
Nuts
FIG.2
3A2176J 19
Repair
Install Chemical Pumps
Reconnect or install a different size chemical pump to
achieve desired ratio.
1. Install ISO lube cylinder on A side pump. Apply light
coating of lubricant on o-rings on outside of small
cylinder.
2. Install nuts on tie rods after the pumps have been
installed. Torque to 50-60 ft-lb (68-81 N•m).
3. Install coupler on A and B side pump shafts.
4. Install LVDT Assembly.
a. Apply a very light coat of hydraulic oil on LVDT
sensor tube and install through pump outlet
housing. Install spool assembly.
b. Install LVDT collar on coupler and pump shaft.
Ensure that the split on the LVDT collar does not
ride in the spool assembly.
c. Apply thread sealant to shoulder bolts then
install in LVDT collar. Torque to 40-50 in-lb
(4.5-5.6 N•m).
Prime IsoGuard Select™Cylinder
24C352_313998_8g1
FIG. 3: IsoGuard Select System
NOTE: The IsoGuard Select cylinder is installed on all
HFRL systems and is available separately as kit
24M154 for HFRS systems.
5. After the IsoGuard Select cylinder has been
installed on the A side pump, apply pipe sealant on
cylinder outlet fitting.
6. Perform Prime IsoGuard Select™Cylinder procedure, see page 20.
7. Reconnect inlet and outlet fluid lines.
Ensure that the IsoGuard Select cylinder outlet faces
upward for air to exhaust.
1. Install IsoGuard Select 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
cylinder.
2. Install IsoGuard Select 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
cylinder.
3. Remove check valve from end of outlet tube.
4. Use funnel to pour IsoGuard Select into tube to fill
cylinder.
5. With check valve arrow pointing away from the
IsoGuard Select cylinder, install check valve in end
of outlet tube.
6. Install tubes into reservoir and install reservoir into
holder.
20 3A2176J
Repair
Remove HFR Hydraulic Driver
D88
24C352_313998_5g1
FIG.4
4. See FIG.4. Remove four nuts (D88) securing
hydraulic driver to hydraulic power pack. This will
also loosen manifold plate (MP) from hydraulic
driver. Remove manifold plate. Remove hydraulic
driver.
Install HFR Hydraulic Driver
MP
This procedure installs the hydraulic driver after replacement parts have been installed and actuator has been
reassembled. See HFR Hydraulic Driver manual for
replacement parts installation procedure.
1. Hang the hydraulic driver on the studs. Verify o-rings
between driver and hydraulic power pack are
installed and lubricated. Secure the driver with nuts
and washer at bottom-left and top-right corners.
2. Install manifold bracket. Secure at top-left and bottom-right corners.
3. Install pump support brackets, torque to 300 in-lb
(33.9 N•m). This will also install manifold plate (MP)
to hydraulic driver.
4. Connect fluid manifold inlet lines.
This procedure removes the HFR Hydraulic Driver so
replacement parts can be installed. See HFR Hydraulic
Driver manual for replacement parts installation procedure.
1. Perform Remove Chemical Pumps procedure, see
page 18.
2. Disconnect the fluid manifold inlet lines. Do not disconnect the fluid line connections at the heater.
Fluid Manifold Inlet
24C352_313998_4e1
5. Perform Install Chemical Pumps procedure, see
page 20.
3. Remove pump support brackets. Each bracket is
secured with three screws at the base frame and
two screws at the manifold bracket.
3A2176J 21
Repair
Remove PowerHouse Pumpline
The Hydraulic Power Pack must be removed to perform
some Hydraulic Power Pack repair procedures. In order
to remove the Hydraulic Power Pack, the PowerHouse
pumpline must be removed. See Hydraulic Power
Pack Repair starting on page 25 for more information.
1. Perform Operation procedure, see page 16.
2. Flush the system, see page 17.
3. Disconnect the chemical pump inlet, pump outlet,
and fluid manifold inlet lines. Do not disconnect the
fluid line connections at the heater.
Fluid Manifold Inlet
Pump Outlet
4. Remove lube cylinder inlet and outlet fittings. Let
cylinder drain.
Punch Slot (same on opposite side)
Lube Cylinder Outlet Fitting
24C352_313998_8e1
Lube Cylinder Inlet Fitting
FIG. 5: Lube Cylinder, Viewed from Rear Left of
Machine
Pump Inlet
5. See FIG.6. Remove four screws securing pumpline
to hydraulic power pack. This will also loosen manifold plate (MP) from hydraulic driver.
MP
24C352_313998_4e1
24C352_313998_5g1
FIG.6
22 3A2176J
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