Graco 3A2797G User Manual

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Setup - Operation

ti19507a

™

HFR

for NVH

3A2797G

Foam - Cart

Hydraulic, Plural-Component, Fixed-Ratio Proportioner. For dispensing NVH foam.

For professional use only. Not approved for use in explosive atmospheres or hazardous locations.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 4 for model information and maximum working pressure.

Patents Pending

Contents

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

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

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GX-16 Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . 6

B (Blue) and A (Red) Feed Tanks . . . . . . . . . . . 6

AC Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Refill Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GX-16 Shutoff Valve Kit . . . . . . . . . . . . . . . . . . . 6

Additional Accessories . . . . . . . . . . . . . . . . . . . . 7

Communications Gateway Module (CGM) . . . . . 7

Bag Filter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GX-16 Fitting Kits . . . . . . . . . . . . . . . . . . . . . . . . 7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Important Two-Component Material Information 11

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 11

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 11

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

Moisture Sensitivity of Isocyanates . . . . . . . . . . 11

Foam Resins with 245 fa Blowing Agents . . . . . 11

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 12

A (Red) and B (Blue) Components . . . . . . . . . . . . 12

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 13

Component Identification . . . . . . . . . . . . . . . . . . . 14

HFR Hydraulic Power Pack . . . . . . . . . . . . . . . . 17

Motor Control Module (MCM) . . . . . . . . . . . . . . 18

Advanced Display Module (ADM) . . . . . . . . . . . 20

Fluid Control Module (FCM) . . . . . . . . . . . . . . . 23

Temperature Control Module . . . . . . . . . . . . . . . 24

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 44

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Install Upgrade Tokens . . . . . . . . . . . . . . . . . . . 47

IsoGuard Select™ System . . . . . . . . . . . . . . . . 48

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

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

Appendix A - ADM Icons Overview . . . . . . . . . . . 52

Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . . 52

Run Screen Icons . . . . . . . . . . . . . . . . . . . . . . . 53

Appendix B - ADM Setup Screens Overview . . . 54

Appendix C - ADM Run Screens Overview . . . . . 69

Appendix D - ADM Error Codes . . . . . . . . . . . . . . 75

Appendix E - System Events . . . . . . . . . . . . . . . . 87

Appendix F - USB Operation . . . . . . . . . . . . . . . . . 89

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

USB Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Download Log Files . . . . . . . . . . . . . . . . . . . . . . 89

Log Files, Folder Structure . . . . . . . . . . . . . . . . 90

Transfer System Settings . . . . . . . . . . . . . . . . . . 92

Update Custom Language . . . . . . . . . . . . . . . . . 93

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Motor Control Module Technical Data . . . . . . . . 96

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 98

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 98

2 3A2797G

Related Manuals

Manuals are available at www.graco.com. Component manuals below are in English:

System Manuals

313998 HFR Repair-Parts

Power Distribution Box Manual

3A0239 Power Distribution Boxes Instruc-

tions-Parts

Pumpline Manuals

3A0019 Z-Series Chemical Pumps Instruc-

tions-Parts

3A0020 HFR Hydraulic Actuator Instruc-

tions-Parts

Feed System Manuals

3A0238 AC Hydraulic Power Pack Instruc-

tions-Parts

3A0235 Feed Supply Kits

Instructions-Parts

3A0395 Stainless Steel Tank Feed Sys-

tems Instructions-Parts

3A1299 Carbon Steel Tank Feed Systems

Instructions-Parts

3A0237 Heated Hoses and Applicator Kits,

Instructions-Parts

308495

Viscon® Heater Kit Manual

Related Manuals

Dispense Valve Manuals

313536 GX-16, Operation

Accessory Manuals

3A1149 HFR Discrete Gateway Module

Kits Manual

312864 HFR Communications Gateway

Module Instructions-Parts

3A1936 Agitator Kit

Instructions-Parts

3A1962 Agitator Kit with Heat Blanket

Instructions-Parts

3A1657 HFR Flow Meter Kits

Instructions-Parts

332544 HFR for NVH Prepoly Refresh Kit

Instructions-Parts

3A2797G 3

Models

Full Load

System

Peak Amps

Per Phase*

Voltage (phase)

24N569 90 230V (3)

24N570 ★✖ 68 400V (3)

24N571 90 230V (3)

24N572 ★✖ 68 400V (3)

24N573 90 230V (3)

24N574 ★✖ 68 400V (3)

24N575 90 230V (3)

24N576 ★✖ 68 400V (3)

System

Material

Ratio (A:B)

A (Red)

Pump

Size

B (Blue)

24N569

24:1 120 5 .061 .011

24N570 ★

24N571

16:1 160 10 .057 .014

24N572 ★

Pump

Size

Primary

Heater

Watts

A (Red)

6,000

A (Red)

Orifice

Primary

Heater

Watts

B (Blue)

Max Flow

Rate◆ lb/min

(kg/min)

Approximate

Output per

Cycle (A+B)

gal. (liter)

Hydraulic

Pressure

Ratio

18 (8.2) 0.033 (0.125) 1.9:1

4,000

24 (11) 0.045 (0.170) 1.4:1

6,000 17 (7.7) 0.032 (0.121) 3.7:1

4,000 18 (8.2) 0.033 (0.125) 1.9:1

B (Blue)

Orifice

25’ (7.6 m)

Chemical

Hose Bundle

10’ (3 m)

Chemical

Hose Bundle

24J290 24J316

Maximum

Fluid Working

Pressure ‡

psi (MPa, bar)

2000

(14, 138)

24N573

24N574 ★

24N575

24N576 ★

System

24N569

24N570 ★

24N571

24N572 ★

24N573

24N574 ★

24N575

24N576 ★

1:1 60 60 .039 .039 24N287 24N289

24:1 120 5 .085 .013 24K681

27.5’ (8.4 m) Hydraulic

Hose Bundle

10’ (3 m)

Hydraulic

Hose Bundle

24V197 24J177

4 3A2797G

Models

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and

mix chamber sizes may be less.

◆ Flow rate is independent of frequency 50/60 Hz.

★ approved.

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

hoses rated at less than 3000 psi are installed, the system maximum fluid working pressure becomes the rating of the hoses. 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 313998 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.

✖ See 400 V Power Requirements.

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.

3A2797G 5

Accessories

Applicator

Part Description

24J187 GX-16, 24:1, Straight, Machine Mount

24K233 GX-16, 24:1, Left, Machine Mount

24K234 GX-16, No Orifice, Left, Machine Mount

24E876 GX-16, No Orifice, Straight, Machine Mount

24E877 GX-16, 24:1, Right, Machine Mount

24E878 GX-16, No Orifice, Right, Machine Mount

GX-16 Orifices

Part Description

257701 0.011 in. Orifice

257702 0.013 in. Orifice

24N158 0.014 in. Orifice

257703 0.016 in. Orifice

257704 0.018 in. Orifice

257705 0.020 in. Orifice

257706 0.022 in. Orifice

257707 0.023 in. Orifice

257708 0.024 in. Orifice

257709 0.025 in. Orifice

257710 0.026 in. Orifice

257711 0.028 in. Orifice

257712 0.029 in. Orifice

257713 0.032 in. Orifice

257714 0.035 in. Orifice

257715 0.036 in. Orifice

257716 0.038 in. Orifice

257717 0.039 in. Orifice

257718 0.040 in. Orifice

257719 0.042 in. Orifice

257720 0.043 in. Orifice

257721 0.044 in. Orifice

257722 0.049 in. Orifice

257723 0.052 in. Orifice

24N159 0.057 in. Orifice

257724 0.061 in. Orifice

24K682 0.085 in. Orifice

B (Blue) and A (Red) Feed Tanks

Part Description

24N594 20 gal. (75 l) Stainless Steel Tank, No Agitation,

Insulation, 3 Level Sensors, A-Side

24N595 20 gal. (75 l) Stainless Steel Tank, No Agitation,

Insulation, 3 Level Sensors, B-Side

24N578 20 gal. (75 l) Carbon Steel Tank, No Agitation, 3

Level Sensors, A-Side

24N597 20 gal. (75 l) Carbon Steel Tank, No Agitation, 3

Level Sensors, B-Side

24N579 2 gal. (8 l) Stainless Steel Tank, No Agitation, 1

Level Sensor, B-Side

AC Power Pack

Part Description

24J912 230V, AC Power Pack

24J913 400V, AC Power Pack

24E347 Hydraulic Power Pack Level Sensor Kit

24C872 Hydraulic Power Pack Pressure Gauge Kit

24E348 Hydraulic Power Pack Temperature Sensor

124217 Power Pack Accumulator Charging Kit

Refill Kits

Part Description

24M418 Low Volume, 2 gal. (7.6 l) tank

24M419 High Volume, 20 gal. (76 l) tank

GX-16 Shutoff Valve Kit

Part Description

24M596 GX-16 Shutoff Valve Kit

For use with: 24N569, 24N570, 24N571, 24N572, 24N573, 24N574

24M368 GX-16 Shutoff Valve Kit

For use with: 24N575, 24N576

GX-16 Proximity Kit

Part Description

24K659 GX-16 Proximity Kit

6 3A2797G

Accessories

Additional Accessories

Part Description

24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level

Sensor

24C873 Hydraulic Power Pack Manifold Oil Temperature

Sensor

24F516 IsoGuard Select fluid, 6 quar ts

121728 Extension Cable for Advanced Display Module,

4 meter,

255468 Light Tower

255244 Foot Switch with Guard and 4 meter Cable

24G389 Pneumatic Agitator for 20 gal. (75 l) Carbon Steel

Tank, No Heat

24K344 Pneumatic Agitator for 20 gal. (75 l) Carbon Steel

Tank, Heat

24K348 Pneumatic Agitator for 20 gal. (75 l) Stainless

Steel Tank, No Heat

24K346 Pneumatic Agitator for 20 gal. (75 l) Stainless

Steel Tank, Heat

24K223 Isolated Pistol Grip Adapter

123694 Straight Gun Cover

123226 90° Gun Cover

123695 12 ft (3.7 m) Hose Cover

125236 Z-Series Pump Cover

125113 Gun Cover Handle Hole Cover

248280 3 oz. Quik Shot Grease Tube (10 Pack)

117792 3 oz. Grease Gun

0553-6 14 oz. Synthetic Grease Tube

255468 Light Tower Kit

24T182* Flow Meter Kit, NVH Cart, 24:1 and 16:1

24T183* Flow Meter Kit, NVH Cart, 1:1

24T180 PrePoly Refresh Kit, NVH Car t, with Autofill

24T181 PrePoly Refresh Kit, NVH Car t, without Autofill

* Flow meter electronics kit, 24J318, is required for flow meter kit

installation.

Communications Gateway Module (CGM)

Part Description

24J415 CGM Mounting Kit

(Required for all applications)

CGMDN0 GCA Gateway Module, DeviceNet Fieldbus

CGMEP0 GCA Gateway Module, EtherNet/IP Fieldbus

CGMPB0 GCA Gateway Module, PROFIBUS Fieldbus

CGMPN0 GCA Gateway Module, PROFINET Fieldbus

Bag Filter Kits

Part Description

24J312 High Volume Filter Kit (40 Mesh)

24P095 Low Volume Filter Kit (100 Mesh)

125147 40 Mesh Filter Replacement

125148 100 Mesh Filter Replacement

0135-4.30x.313 TEV O-Ring for Lid Seal

0131-4.30x.313 EP O-Ring for Lid Seal

GX-16 Fitting Kits

The following kit is for Models 24N575 and 24N576 only.

Part Description

24N435 Gun Fitting Kit

The following kits are for all other Models.

Part Description

24K672 Right Orientation, 90° Fitting Adapter Kit

24K674 Left Orientation, 90° Fitting Adapter Kit

3A2797G 7

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.

8 3A2797G

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 ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

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.

3A2797G 9

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. 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.

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.

10 3A2797G

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

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures

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.

3A2797G 11

above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

A (Red) and B (Blue) Components

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• Most materials use ISO on the A (Red) side, but some use ISO on the B (Blue) side. See the following section.

A (Red) and B (Blue) Components

IMPORTANT!

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

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.

12 3A2797G

Typical Installation

* Shown exposed for clarity.

Wrap with tape during operation.

ti19507a

Typical Installation

FIG. 1: Typical Installation

Key:

A Tank Stand - A (Red) B Tank Stand - B (Blue) C AC Power Pack D HFR Power Pack E Dispense Gun F Fluid Temperature Sensor (FTS) G Manifold H Main Hose Bundle J Whip Hose Bundle

3A2797G 13

Component Identification

ti19508a

Component Identification

Key for FIG. 2 and FIG. 3.

AA Advanced Display Module (see page 20) BA Component A (Red) Pressure Relief Outlet BB Component B (Blue) Pressure Relief Outlet FA Component A (Red) Fluid Manifold Inlet (on left side of

manifold block) FB Component B (Blue) Fluid Manifold Inlet FM HFR Fluid Manifold FP Feed Inlet Pressure Gauge FT Feed Inlet Temperature Gauge GA Component A (Red) Outlet Pressure Gauge GB Component B (Blue) Outlet Pressure Gauge HA Component A (Red) Hose Connection (from feed to gun

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

or mix head) HP Hydraulic Power Pack Assembly HT Hydraulic Tank LS Pumpline Linear Sensor

MA Motor Control Module, see page 18 MP Main Power Switch PA Component A (Red) Pump PB Component B (Blue) Pump PD Power Distribution Box PHB Primary Heater - B Side PHA Primary Heater - A Side PI Primary Heater Fluid Inlet PO Primary Heater Fluid Outlet PR Primary Heater RTD PS Primary Heater Overtemperature Switch SA Component A (Red) PRESSURE RELIEF/DISPENSE

Valve

SB Component B (Blue) PRESSURE RELIEF/DISPENSE

Valve TA Component A (Red) Pressure Transducer TB Component B (Blue) Pressure Transducer TC High Power Temperature Control Module (not shown, see

page 24)

FIG. 2: Component Identification, Heated Model shown with shrouds removed

14 3A2797G

Component Identification

ti9880a1

Fluid Manifold (FM) Detail

Rear View

Primary Heater (PHA)

Detail, A (Red) side shown

ti19509a

ti19510a

Primary Heater (PHB)

Detail, B (Blue) side shown

ti19511a

(In Enclosure)

FIG. 3: Component Identification, Continued

3A2797G 15

Component Identification

CB1

CB5

CB2

CB9

CB6

CB11

400V/ 3 phase

230V/ 3 phase

ti19512a

ti19513a

Main Power Switch

Located on top of the power distribution box, see page14. The main power switch turns power

ON and OFF . The main power switch

does not turn pumps or heat zones on.

Circuit Breakers

Most circuit breakers are located inside the power distribution box. The main block of circuit breakers in the power distribution box is shown below, with detailed information in the following table. For more information about items in the power distribution box, see power distribution box manual.

Size

400V/

Ref.

3 phase

CB1 63A 30A Motor Control Module

CB2 40A 40A Primary Heater A

CB5 5A 5A Miscellaneous

CB6 5A 5A Miscellaneous

230V/

3 phase

Component

CB9 40A 40A Primary Heater B

CB11 30A 30A AC Power Pack

16 3A2797G

HFR Hydraulic Power Pack

ti19514a

Component Identification

FIG. 4: HFR Hydraulic Power Pack

Key:

DA 9 Gallon Hydraulic Oil Reservoir (see Technical Data on

page 95 for specifications) DB Electric Motor DD Hydraulic Housing DE Directional Valve DF Motor Control Module (see page 18)

DG Fan DH Oil Filter DJ Shroud (not shown, removed for clarity) DK 3 Way Splitter DL Oil Level Sensor (Optional)

3A2797G 17

Component Identification

r_257396_3b9905_01b

r_257396_3b9905_03b

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 Manu- als on page 3.

For MCM location, see reference MA in FIG. 2 on page 14. When installed, the end of the MCM with the power input connection (12) faces down and the end with the access cover (A) faces up.

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

FIG. 5: MCM Component Identification

18 3A2797G

Ref Description

A Access Cover

B LEDs

C Warning Label

1A, 1B CAN Connections

2 Three-way Splitter to: Oil Low Level

Sensor, Dispense Valve Solenoid, and Footswitch

3 Oil Temperature Sensor

5 Electric Motor Temperature Sensor

6 LVDT (Position Sensor)

7 Three-way Splitter to:

Hydraulic Directional Valve, Oil Overtemperature Switch

8 Pressure Transducer B (Blue) side

9 Pressure Transducer A (Red) side

10 Not used

11 Motor Position Sensor

12 MCM Power Input Connection

13 Motor Power Connection

Component Identification

Diagnostic Information

Table 1: LED (Ref B) Status Signal

Module Status LED Signal Description

Green on System is powered up.

Yellow on Internal communication in progress.

Red solid MCM hardware failure. Replace MCM.

Red flashing fast Uploading software.

Red flashing slow Token error. Remove token and upload

software token again.

3A2797G 19

Component Identification

TI12362a1

Advanced Display Module (ADM)

User Interface

FIG. 6: ADM Component Identification - Front

Buttons

Ref. Button Function

CA System

enable/ disable

CB System

Status Indicator Light

CC Stop Stop all system processes.

CD Soft Keys Defined by application using ADM.

CE Cancel Cancel a selection or number entry

CF Enter Acknowledge changing a value or

CG Setup Toggle between run and setup

CH Naviga-

tion

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

Displays system status. See System Status Indicator (CB) Conditions on page 20 for details.

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

making a selection.

screens or password screen if setup screens are password protected.

Navigate within a screen or to a new screen.

System Status Indicator (CB) Conditions

Green Solid - Run Mode, System On Green Flashing - Setup Mode, System On

Yellow Solid - Run Mode, System Off

20 3A2797G

Component Identification

r_24E451_3B9900_1a

FIG. 7: ADM Component Identification - Rear

Key:

CJ Flat Panel Mount CK Model Number CL USB Module Interface CM CAN Cable Connections

CN Module Status LEDs CP Accessory Cable Connections CR Token Access Cover CS Battery Access Cover

ADM Module Status LEDs (CN) Conditions

Module Status LED Signal Description

Green on System is powered up.

Yellow on Communication in progress.

Red solid ADM hardware failure.

Red flashing fast Uploading software.

Red flashing slow Token error. Remove token and upload

software token again.

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

3A2797G 21

Component Identification

Current date and time Current chapter

Enter/Exit screen

Previous chapter

(Left Arrow)

Next chapter (Right Arrow)

Function display

Current page

Next page (Down Arrow)

Previous page (Up Arrow)

Mode

Faults, Status

Main Display Components

The following figure calls out the navigational, status, and general informational components of each screen. For details regarding the user interface display see Shutdown, page 44.

FIG. 8: Main Display Components

22 3A2797G

Fluid Control Module (FCM)

ti12337a1

ti12336a1

Component Identification

FIG. 9: Fluid Control Module (FCM)

Key:

A Fluid Control Module B Base C Module Connection Screws

D Access Cover E Module Status LEDs F CAN Connectors

Diagnostic Information

Module Status LED (Ref E) Signal Diagnosis

Green on System is powered up

Yellow Internal communication in progress

Red solid FCM hardware failure. Replace FCM.

Red flashing fast Uploading software.

Red flashing slow Token error. Remove token and

upload software token again.

3A2797G 23

Component Identification

LED Signals

ti12352a1

ti12353a1

ti12356a1

ti12357a1

LED Signals

Temperature Control Module

FIG. 10: High Power Temperature Control Module Sensor Connections

Key:

1 Overtemperature Switch Connection (primary heaters

only) 2 RTD Temperature Sensor Connection 3 Output Power Connection

4 DC Output Connection 5 Input Power Connection 6 CAN Connections 7 Rotary Selector Switch, Token Access

FIG. 11: Low Power Temperature Control Module Cable Connections

1 Overtemperature Switch Connection 2 RTD Temperature Sensor Connection 3 Output Power Connection

4 DC Output Connection 5 Input Power Connection 6 CAN Connections 7 Base

24 3A2797G

Component Identification

Primary Heater B (Blue)

Primary Heater A (Red)

Right Side from

Rear View

Left Side from

Rear View

ti17748a

ti17749a

Material Temperature

FTS - (Red)

Temperature Control Module Diagnostic Information

Module Status LEDs

Signal Description

Green on Temperature control module is

powered up.

Yellow on Internal communication in prog-

ress.

Red solid Temperature control module failure.

See Troubleshooting table.

Red flashing fast

Red flashing slow

Blue light off (High Power Module only)

Blue flashing (High Power Module only)

Uploading software.

Token error. Remove token and upload software token again.

Temperature control module is off. See Troubleshooting table.

Length of flashes indicates amount of power running through temperature control module.

Heat Control Zone Selection

The HFR unit supports four independent temperature control zones and two independent temperature monitoring zones. The high power temperature control modules are located inside the frame below the hydraulic power pack.

3A2797G 25

Component Identification

High Power Module Rotary Switch Location

Low Power Module Rotary Switch Location

ti12360a

ti12361a

Adjust Rotary Switch

The rotary switch setting indicates which zone the temperature control module will control in the system. The high power module uses an 8-position rotary switch. The low power module uses a 16-position rotary switch.

Set the rotary switch (S) to the specific selection according to the settings listed in the following tables.

High Power Module Rotary Switch Settings

Setting Zone

0 Not Used

1 B (Blue) Primary Heat

2 B (Blue) Hose Heat

3 A (Red) Primary Heat

4 A (Red) Hose Heat

5 through 7 Not Used

Low Power Module Rotary Switch Settings

Setting Zone

0 through 4 Not Used

5 B (Blue) Tank Heater

6 A (Red) Tank Heater

7 B (Blue) Chiller

8 A (Red) Chiller

9 through F Not Used

FIG. 12: Rotary Switch

26 3A2797G

Component Identification

3A2797G 27

Setup

Perform this setup procedure to secure all necessary machine connections for machine operation.

Locate system.

a. Locate system on a level surface. See Dimen-

sions on page 97 for space requirements.

b. Do not expose system to rain.

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 4 in this setup procedure. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Ground system

This equipment must be grounded.

a. System: grounded through power cord. See

step 4 on page 28.

b. Fluid supply containers: follow your local code.

c. Object being dispensed into: 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.

Connect electrical cord to system.

NOTE: See Power Line Voltage Surges information on

page 29.

NOTE: Power cord is not supplied. See the following table.

28 3A2797G

Setup

r_24C686_313998_1a

L1L2L3N

GND

Maximum Permissible Transient Voltage Surges

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

1200Vac, 1697Vdc

264Vac, 373Vdc

336Vac, 475Vdc

288Vac, 407Vdc

480Vac, 679Vdc

<--1 MW Max Surge Power

<--150 KW Max Surge Power

<--50 KW Max Surge Power

<--No Power Limit

200

400

600

800

1000

1200

1400

Time (seconds)

Voltage (Volts RMS)

Table 2: Power Cord Requirements

Cord Requirements

Model

Heated system,

4 (21.2), 3 wire + ground

AWG (mm2)

230V, 3 phase

Heated system,

4 (21.2), 4 wire + ground †

400V, 3 phase

† Residual Current Device (RCD) must be rated at

300 mA if installed.

Electrical Cord Wires by Model 230V, 3 phase: L1, L2, L3, GND 400V, 3 phase: L1, L2, L3, N, GND

Use 5/32 or 4 mm hex allen wrench to connect the three power leads to L1, L2, L3, and Neutral (as required). Connect green to ground (GND).

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.

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).

FIG. 13: 400V, 3 phase shown

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.

3A2797G 29

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

Setup

ti19515a

Connect HFR Proximity Cables to the GX-16.

Connect Hydraulic Lines to the system.

NOTE: Refer to the HFR and GX-16 manuals for more

details for the following procedures.

NOTE: The cable is indicated by a green stripe.

a. Connect the GX-16 proximity sensor to the

proximity cable.

b. Connect the 10 ft (3 m) hydraulic whip hose

cable to the 25 ft (7.6 m) chemical hose cable.

c. Connect the other end of the cable to the electri-

cal connector found near the fluid manifold on the HFR.

NOTE: The electrical connector will be indicated by a green stripe and labeled “PG-MPO”.

NOTICE

Damage can occur to the directional valve if the hydraulic hose diameter is larger than 3/8 in. (9.5 mm).

To prevent damage to the applicator or directional valves, do not allow any dirt or foreign matter to enter the lines, when connecting the hose kit to the applicator and hydraulic power pack.

a. Connect the hydraulic hose to the hydraulic

hose fittings (A2 and B2) on the AC power pack.

Hydraulic

Hose Fitting

Hydraulic

Hoses

Hydraulic Hose Color Markings

A2 Material close Green B2 Material open Green/White

FIG. 14: Hydraulic Fittings on Hydraulic Housing

b. Hand tighten each fitting.

c. Tighten each fitting 1/4 turn past hand tight.

30 3A2797G

Install GX-16 Fitting Adapter Kit (Models 24N575 and 24N576 Only).

a. Remove the chemical fittings from the back of

the GX-16.

b. Install JIC #4 fitting assembly into the B Supply

port.

c. Install JIC #6 fitting assembly into the B Return

port.

d. Install JIC #8 fitting assembly into both A Supply

and A Return ports.

Setup

Install Flow Meter Kit (Optional).

Refer to HFR Flow Meter Kits, Instruction-Parts manual for installation and setup instructions.

Install PrePoly Refresh Kit (Optional).

Refer to HFR for NVH Prepoly Refresh Kit, Instructions-Parts for installation and setup instructions.

3A2797G 31

Setup

ti19507a

Step 9g, Step 9h

Step 9c, Step 9d, Step 9e, Step 9f

Step 9i, Step 9j

FIG. 15: Material Hose Connections

32 3A2797G

Setup

HFR material

manifold

Remove reducer

10.

Connect Material Hoses

NOTICE

Avoid routing hoses in walkway areas to prevent operators from tripping on hoses running between system components. This also prevents fittings from leaking.

NOTE: Refer to FIG. 15 on page 32 for visual clarity of the following steps.

a. Ensure main power is OFF .

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

HFR and the material supply ball valves on the tanks are closed.

d. Remove reducer fitting from B (Blue) connection

of the HFR fluid manifold (Models 24N573, 24N574 only). Install the provided additional spacers near the location of the FTS for the remaining material lines. Refer to FIG. 15 and FIG. 16.

FIG. 16: Material Manifold

e. Install ball valves (optional) between main hose

and whip hose. Connect the main hose bundle to the whip hose bundle.

NOTE: The ball valve kit is designed to fit in one orientation only.

c. Remove reducer fitting from the A (Red) con-

nection of the HFR fluid manifold. Install FTS in the A (Red) material supply line between main hose and whip hose. Ensure the FTS is facing toward the fluid flow of material after installation. See Heated Hose manual for instructions. Refer to FIG. 15 and FIG. 16.

NOTICE

If using the ball valve kit, ensure the FTS does not go through the ball valve. Failure to do so will result in damage to the FTS and the inability to close the ball valve.

f. Assemble the hydraulic hose sections together

and place the assembled hose connection near the FTS area. Refer to FIG. 15.

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

and B (Blue) outlets on HFR fluid manifold (FM). Hoses are color coded: solid red for component A, solid blue for component B.

3A2797G 33

Setup

h. Connect cables (Y). Be sure cables have slack

when hose bends. Wrap cable and electrical connections with electrical tape. See Heated Hose manual for heated hose connection details and illustrations for the various types of heated hoses.

i. Connect the other end of the supply hoses

(solid color) to the applicator. See the applicator manual for fluid inlet identification.

11.

Connect GX-16 Hydraulic Lines

a. Navigate to the System Screen 2 and set the

mode to run as straight head: prox dispense valve.

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

b. Verify the mixhead hydraulic power pack is not

active by verifying the gauge is at 0.

j. Connect A (Red) and B (Blue) return hoses

(solid with white stripe) to the applicator. See the applicator manual for fluid outlet identification.

NOTE: The other end of the return hose will be connected in step n on page 39.

FIG. 17: Gauge

c. Check the hydraulic fluid level. See Technical

Data on page 95 for specifications.

d. Use the supplied 7/16 in. JIC male-male

adapter at the gun end to connect hoses

34 3A2797G

Setup

ti14495a

ti14496a

ti14494a

together. This creates a hydraulic fluid circulation loop.

FIG. 18: Hydraulic Loop

e. Turn on the power pack by navigating to the

Home Screen, Standby Mode and press . Circulate oil for 3 minutes to purge air from hydraulic hoses.

NOTE: The hydraulic hose marked with both green and white stripe is for the open port of the gun. The hydraulic hose marked with only a green stripe is for the close port of the gun.

FIG. 19: Hydraulic Connections

j. Attach trigger switch cable (if applicable) to gun

and HFR.

NOTE: Pressure should not increase while air is purged from hoses.

f. Turn off the power pack by pressing . Look

at the gauge to verify no pressure exists in the hydraulic hoses and the AC Power Pack.

g. Remove the 7/16 in. JIC male-male adapter

connecting the hydraulic hoses.

NOTICE

To prevent air from entering the hydraulic hoses, do not spill oil while disassembling the adapter connection. If spilling occurs, replace the lost fluid by manually filling the hoses with hydraulic fluid.

h. Fill both open and close gun chambers with

hydraulic fluid.

i. Attach hydraulic hoses to the gun. Tighten each

fitting 1/4 turn past hand tight.

FIG. 20: Cable Connections

3A2797G 35

Setup

12.

Setup the Advanced Display Module (ADM)

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 FIG. 6 on page 20. 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.

The blue token (24M560) must be installed to enable cold start up, temperature monitor zones, and shot times less than one second.

Perform the following tasks to fully setup your system.

Enter Setup Mode by pressing the button.

a. Define shots. See Shots Screen, page 55 for

more detail.

b. Define sequences. See Sequences Screen,

page 58 for more detail.

c. Calibrate HFR, page 37. See Calibration

Screen, Main, page 59 for more detail.

d. Define pump information. See

System Screen 1, page 60 for more detail.

e. Define dispense valve and other system set-

tings. See System Screen 2, page 60 for more detail.

f. Define labels and other system settings. See

System Screen 3, page 61 for more detail.

g. If desired, view/reset counters. See Mainte-

nance Screen, page 62 for more detail.

h. Define level sensors and refill settings. See

Supply Screen, page 63 for more detail.

NOTICE

To ensure proper machine operation, the blue token must remain installed in the ADM during operation.

If the machine is in the Disabled mode screen press

repeatedly to select standby mode.

Navigation

• Press or to navigate to new screens.

• Press or to navigate to new screens or

to move between fields.

• Press to activate the desired field or to acti-

vate/deactivate an option.

i. Enable/disable temperature conditioning com-

ponents. See Conditioning Screen 1, page 64 for more detail.

j. Define temperature conditioning setpoints. See

Conditioning Screen 2, page 64 for more detail.

k. If Night mode will be used, define Night mode

settings. See Conditioning Screen 3, page 65 for more detail.

l. Set general system settings. See Advanced

Screen 1, page 67 for more detail.

m. Set units of measure. See Advanced Screen 2,

page 67 for more detail.

n. Enable/disable system features. See Advanced

Screen 3, page 67 for more detail.

36 3A2797G

Setup

13.

Calibrate HFR

NOTE: Machine is calibrated from the factory. Only per-

form the following steps when changing or rebuilding pumps.

The HFR calibration procedure is a two step process. The first step, Learn Mode, must be performed whenever the pump line is rebuilt or if any other maintenance is performed that may affect the mechanical tolerances in the pump line. 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. Ensure the dispense valve is set up as either

straight head or straight head prox.

b. Navigate to the Calibration screen.

• Set temperatures:

This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns:

• Do not touch hot fluid or equipment.

• Allow equipment to cool completely before touching it.

• Wear gloves if fluid temperature exceeds 110°F (43°C).

For detailed temperature adjustments, including alarm levels, or upon initial machine configuration, see Condi- tioning Screen 2 on page 64 for details. For minor adjustments to the temperature setpoint once the machine has been initially configured, see the Status

Screen on page 72.

• Set system control and dispense modes: See System Screen 1 on page 60.

c. Press

d. Press and then . The pump will travel to

the right most extreme position.

e. After the pump stops moving, press and

then press . The pump will travel to the left most extreme position.

f. After the pump stops moving, press 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.

• Set pump sizes: See System Screen 1 on page 60.

• 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.

• 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 (3.5 MPa, 35 bar). For tighter ratio error detection, select a lower value. For looser detection or to avoid nuisance alarms, input a higher value.

3A2797G 37

Setup

a. Navigate to System Screen 3.

b. Press to enter the screen.

c. Navigate to the pressure imbalance field.

d. Type the desired pressure imbalance setting

then press .

e. Press and input the specific gravity (SG) of

each material into the ADM.

14.

Flush the System

NOTE: System components will contain testing oil from

the factory. Perform the following procedure when the machine is initially installed. Both supply and pressure relief must be flushed.

a. Close both A side (Red) and B side (Blue) feed

inlet valves on the system. See FIG. 2 on page

14.

b. Close A side (Red) and B side (Blue) material

return ball valves on the system.

c. Close both A side (Red) and B side (Blue) mate-

rial supply ball valves on the system.

d. Place the applicator return hoses into a con-

tainer.

NOTICE

To prevent cross contamination, keep components A (Red) and B (Blue) in separate containers.

e. Fill tank A (Red) with approximately 5 gal. (19 l)

of material and tank B (Blue) with approximately 2 gal. (8 l) of material.

f. Pressurize both material tanks.

38 3A2797G

NOTE: A minimum feed pressure of 50 psi (0.35 MPa,

ti10006a1

ti9877a1

3.5 bar) is required at both feed inlet pressure gauges (FP). Maximum feed pressure is 75 psi (

517 kPa, 5.2 bar)

Maintain A (Red) and B (Blue) feed pressures within 10% of each other.

g. Turn HFR main power ON .

h. Navigate to the System Setup Screen. Set the

low pressure dispense to 25%.

Setup

l. Stop dispensing by pushing from the

Standby Screen.

m. Close feed inlet valve and the material supply

ball valve on the system.

n. Connect the applicator return hose to the fluid

inlet fitting on the system.

NOTE: The following steps are referring to the B side (Blue) components of the system.

i. Set PRESSURE RELIEF/DISPENSE valve (SA,

SB) to DISPENSE for the corresponding material side.

j. Open feed inlet valve and the material supply

ball valve on the system.

k. Navigate to the Standby Screen and push

to start pumps.

FIG. 21: Return Lines

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.

o. Ensure all material hose connections are tight.

NOTE: Material will dispense into the container from the applicator material hose at this time. Continue to dispense fluid until no material contamination is noticed.

stand.

q. Repeat steps j thru p for A side (Red).

NOTE: If necessary, navigate to Operator Mode to adjust the flowrate

3A2797G 39

p. Open the RETURN ball valves on the tank

Setup

ti17747a

Orifice (A) Side

15.

Install GX-16 Orifices

16.

Pressure check hose

See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage.

a. Close both A side (Red) and B side (Blue) feed

inlet valves on the system. See FIG. 2 on page

14.

b. Close A side (Red) material return ball valves

on the material tank stand.

c. Follow Pressure Relief Procedure on page 44.

d. Remove plugs from GX-16.

e. Install orifices provided.

17.

Check hydraulic fluid level

Hydraulic reservoir is filled at the factory. Check fluid level before operating the first time, and weekly thereafter. See Technical Data on page 95 for specifications.

FIG. 22: GX-16 Plug Location

40 3A2797G

18.

24C352_313998_8e

r_24m419_3a1961_1a

IsoGuard Select Fluid System Setup

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

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

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

and remove the container from the cap.

19.I

nstall High Volume Fill Kit (Optional).

FIG. 23: High Volume Refill Kit

Setup

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.

a. Perform Pressure Relief Procedure, page 44.

b. Close the ball valves located on the day tanks.

c. Insert the refill valve onto the ball valve.

d. Connect the air tube from the “open” port on the

refill valve to the fitting on the solenoid valve that is located inside the tank stand base cube.

e. Remove the plug from other port on the sole-

noid valve and install the air tube fitting.

f. Connect the air tube from the “close” port on the

refill valve to the fitting installed in step e above.

3A2797G 41

Setup

r_24m418_3a1961_1a

20.I

nstall Low Volume Fill Kit (Optional).

FIG. 24: Low Volume Refill Kit

a. Perform Pressure Relief Procedure, page 44.

b. Close the ball valves located on the day tanks.

c. Remove the swivel fitting from the day tank inlet

port ball valve.

d. Insert the refill valve onto the ball valve.

e. Install the swivel fitting onto the refill valve

assembly.

f. Remove the air tube fitting installed on the sole-

noid valve located inside the tank stand base cube.

g. Install the air tube fitting provided with the kit

into the open port on the solenoid valve.

h. Install the air tube from the refill valve to the

solenoid valve.

42 3A2797G

Startup

ti9877a1

ti10442a1

LOCKED

ti10441a1

UNLOCKED

To reduce the risk of personal injury, do not operate HFR without all covers and shrouds in place.

Startup

1. Check that all machine connections are setup. See Setup procedure, page 28.

2. Check level and condition of ISO lube daily, see IsoGuard Select™ System on page 48.

3. Verify both PRESSURE RELIEF/DISPENSE valves

(SA, SB) are set to DISPENSE .

4. If dispense valve has a trigger safety lock, engage the trigger safety lock.

6. Press to enable system. LED should be solid green.

7. Navigate to Home Standby screen and press

to initiate auto startup.

8. Check that heat zones are on and temperatures are on target. Check fluid pressure display. Refer to Sta- tus Screen on page 72 for more details.

9. If dispense valve has a trigger safety lock, disengage the trigger safety lock.

i. Equipment is ready to dispense.

5. Open system fluid inlet valves and ball valves found on the material tanks. As applicable, ball valves on the material tanks include material supply, applicator return, and pressure relief. Check for leaks.

3A2797G 43

Shutdown

ti9879a1

Shutdown

1. Park pumps.

a. From the Home screen, press and select

Standby mode.

b. Press . Material will not dispense. Pump

will park automatically. Once pump is parked, pump will stop moving.

2. Press to disable the ADM.

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

4. Close A (Red) and B (Blue) fluid supply valves.

Pressure Relief Procedure

1. Press to disable the ADM.

2. Shut off feed pumps and agitator, if used.

3. Turn PRESSURE RELIEF/DISPENSE valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0.

5. Perform Pressure Relief Procedure on page 44.

6. Shut down feed pumps as required. See feed pump manual.

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

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

44 3A2797G

Flushing

ti9880a1

Flush equipment only in a well-ventilated area. Do not dispense flammable fluids. Do not turn on heaters while flushing with flammable solvents. Heaters must be off and cool when solvent is in the system.

• Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid.

• Use the lowest possible pressure when flushing.

• All fluid components are compatible with common solvents. Use only moisture-free solvents. See Run Screen Icons on page 53 for list of wetted components to verify compatibility of solvent with wetted materials. See solvent manufacturers information for material compatibility.

Flushing

• 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.

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

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

• 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 11.

• 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.

3A2797G 45

Maintenance

ti9879a1

Maintenance

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

Inspect IsoGuard Select™ fluid level and condition, refill or replace as needed, page 48

Check hydraulic fluid level Weekly

Grease circulation valves with Fusion® grease (117773)

Daily

Weekly

Task Schedule

Check hoses for wear Monthly

Check hydraulic fluid and filter 6 months

Grease (115982) high volume refill valve, if equipped

Monthly

Change Break-in Oil

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

Table 3: Frequency of Oil Changes

Ambient Temperature

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

Verify operation of air drying system to prevent isocyanate crystallization

Verify vent holes on bottom of electrical cabinet are clear and unobstructed

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

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

Inspect the gun, fluid lines, trigger switch cable and proximity switch cable for wear or damage

Grease (117773 or 0553-6) the gun

Clean and service the orifices and filters

Weekly

Daily

Monthly

As needed

Daily

Weekly or every

15,000 shots

As Needed

Grease Circulation Valves With Fusion Grease (117773)

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 Run Screen Icons on page 53. If fluid is dark in color, change fluid and filter.

Check Accumulator Pre-Charge Weekly

Check tightness of all clamps and fittings

46 3A2797G

Weekly

Install Upgrade Tokens

r_257396_3b9905_04b

ti12334a1

ti12358a1

ti12354a1

NOTE: The Motor Control Module, Fluid Control Module, and Temperature Control Module connection to the system is temporarily disabled during the installation of upgrade tokens.

To install software upgrades:

1. Use correct software token stated in the table. See Graco Control Architecture™ Module Programming

manual for instructions.

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.

Maintenance

See manuals for locations of specific GCA components.

The software version history for each system can be viewed in the technical support section at www.graco.com.

16H821 HFR:

16G584 Tank Stand:

16G407 Ratio Monitoring (Flow Meters):

FIG. 25: Remove Access Cover

Token Application

- Advanced Display Module

- Motor Control Module

- High Power Temperature Control Module

- Fluid Control Module (AC Power Pack)

- Discrete Gateway Module

- Communication Gateway Module

- Fluid Control Module

- Low Power Temperature Control Module

- Fluid Control Module

3A2797G 47

Maintenance

24C352_313998_8e

IsoGuard Select™ System

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.

9. Push the return tube 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.

To change pump IsoGuard Select fluid:

1. Perform Pressure Relief Procedure on page 44.

2. Remove fittings from IsoGuard Select fluid cylinder inlet and outlet ports. Keep supply tube, return tube, and leak management tube 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 out of the bracket 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 FIG. 26.

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.

FIG. 26: IsoGuard Select Fluid System

Prime IsoGuard Select Fluid Cylinder

Ensure that the IsoGuard Select fluid cylinder outlet faces upward for air to exhaust.

1. Remove check valve from end of inlet tube.

2. Cut tip of IsoGuard bottle and fill the reservoir through the tube.

3. With check valve arrow pointing towards the IsoGuard Select fluid cylinder, install check valve in end of inlet tube.

4. Install tubes into reservoir and install reservoir into holder.

7. Thread the reservoir onto the cap assembly and place it in the bracket.

8. Push the supply tube approximately 1/3 of the way into the reservoir.

48 3A2797G

Troubleshooting

Before performing any troubleshooting procedure:

1. Perform Pressure Relief Procedure on page 44.

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.

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

A (Red) and B (Blue) Primary Heaters

Control of primary heat is abnormal; high temperature overshoots

Hose System

Material heats but heats slower than usual or it does not reach temperature

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

Dirty RTD connection Unplug and re-plug RTD wires. RTD not contacting heater element Loosen ferrule nut, push in RTD so tip contact heater

Failed heater element Replace Signal failure from RTD Check connections RTD wired incorrectly Check connections. Power up zones one at a time

Ambient temperature is too cold Use auxiliary hose system. FTS failed or not installed correctly Check FTS

Remove pump shaft assembly and reinstall read pump rebuild kit

Run calibration

element. Holding RTD tip against heater element, tighten ferrule nut 1/4 turn past tight.

and verify that temperature for each zone rises.

3A2797G 49

Troubleshooting

PROBLEM CAUSE SOLUTION

Material does not maintain temperature while spraying

Material temperature exceeds setpoint

Erratic material temperature Faulty RTD connection Verify that all FTS connections are snug and that pins

Material does not heat FTS failed or is not contacting cor-

Proportioning System

Proportioning pump does not hold pressure when stalled

Ambient temperature is too cold Increase A (Red) and B (Blue) setpoints to increase

fluid temperature and keep it steady Flow too high Use smaller mix chamber. Decrease pressure. Faulty RTD connections Verify that all FTS connections are snug and that pins

of connectors are snug and that pins of connects are

clean. Examine connection of thermocouples to long

green plug on heater control board. Unplug and

re-plug RTD wires, cleaning off any debris. Unplug

and re-plug long green connector on heater control

board.

of connectors are clean. Examine connection of RTD

to long green plug on heater control board. Unplug

and re-plug RTD wires, cleaning off any debris.

Unplug and re-plug long green connector. FTS not installed correctly FTS should be installed close to end of hose in same

environment as gun. Verify FTS installation.

Check FTS rectly

FTS not installed correctly FTS should be installed close to end of hose in same

environment as gun. Verify FTS installation. Temperature control alarm See Advanced Display Module (ADM) on page 20

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

ing pressure.

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

3. Repair the valve.

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

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.

50 3A2797G

Troubleshooting

3A2797G 51

Appendix A - ADM Icons Overview

Setup Screen Icons

Icon Description

Enter Screen

Exit Screen

On Learn Mode Calibration screen:

Move pump

All other screens:

Begin Dispense

Stop Dispense

Abort Changing the Label

Select left direction

Select right direction

Backspace

Icon Description

Erase All Counters on Page

Access Flowmeter Calibration

Valve Details

Selects all shots to be changed to the same user specific value

Pressure

Shot Number

Sequence Position

Flow

Time (Duration)

Tank Blanket Heater

Back to main calibration screen from learn mode calibration screen or Back to system screen 2 from mix head operating details screen

Access Learn Mode Calibration screen

Run MCM Learn Mode

Proceed to next step in calibration procedure

On Main Calibration screen:

Calibrate Weight Dispense or Enter Specific Gravity Information

On Flow Meter Calibration screen:

Use Dispensed Material Weight to Calibrate Flow Meters. If pressed, icon will change and units are changed to volume units.

Erase Selected Item or Control Data

Primary Heater

Heated Hose

Chiller

Move Cursor to the Left

Move Cursor to the Right

Upper/Lower Case Letters

Positive / Negative

52 3A2797G

Run Screen Icons

Appendix A - ADM Icons Overview

Icon Description

Select mode.

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

Open, Close Valve

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

With a mix head installed: Turns on the mix head hydraulics and puts the machine in low pressure circulation.

Press a second time to turn off instigated system action.

If Green:

Allowed to Dispense

If Yellow:

System is in a pre-dispense state

If Red:

Not Allowed to Dispense

Icon Description

Sets machine to low pressure

Sets machine to high pressure

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 temperatures for heated hose monitor. Not displayed if heat zone is not enabled.

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

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

Stop Dispense

Jump in and use the key pad to select a shot number.

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

Abort sequence and reset to first valid position

Edit Operator Dispense Setting

Press to enter the Conditioning Control screen

Turn on or off the highlighted zone.

Turn on or off all zones.

Erase a single batch

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

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

Amount of material moved through pump (volume tracking)

Cycles

Activates the PrePoly Refresh

Erase all batch data points

3A2797G 53

Appendix B - ADM Setup Screens Overview

Calibration

Maintenance

Shot #1

Shot #2

Shot #...

Sequences #1

Sequences #2

Sequences #...

Advanced #1

Advanced #2

Advanced #...

System #1

System #2

System #3

Supply

Conditioning #1

Conditioning #2

Conditioning #3

* Gateway screen will automatically be enabled when a CGM is installed on the system

Appendix B - ADM Setup Screens Overview

The ADM will start in the Run screens at the “Home”

screen. From the Run screens, press to access the Setup screens. If the Setup screens password is turned

on, use the ADM keypad to enter the password then

press .

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

Data on page 95. FIG. 27 shows the flow of the Setup screens.

FIG. 27: Setup Screens Navigation Diagram

54 3A2797G

Appendix B - ADM Setup Screens Overview

Shots Screen

This screen allows the user to edit shot definitions. The contents of this screen change based on the flow units selection. Shots are defined by flow rate and weight or time (duration). See Home Screen, Shot Mode on page 70 for information on how to use predefined shots.

NOTE: 100 shot definitions are available across ten pages.

To edit a shot definition:

1. Press then use the arrow keys to navigate to the desired value.

Due to variation in material properties, the ? column gives the ability to adjust the shot time/volume/weight for each defined shot.

NOTE: If the ? column is used, it is recommended that a minimum of 5 shots are dispensed, measured and aver-

aged for each dispense before entering a value for the ? column.

Time Based Example:

A 75 cc/s shot is defined to dispense for 2 seconds.

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

3. If desired, press to quickly enter the same value for the rate and time/volume/weight.

4. Repeat step 2 as required.

1. Dispense 5 shots into 5 separate containers.

2. Measure the dispensed amount and record the data.

Shot

Example 1

Dispensed Volume

(cc)

Example 2

Dispensed Volume

(cc)

1 146.2 156.2

146.4 156.4

3 145.6 155.6

145.8 155.8

5 146.0 156.0

3. Calculate the average of the 5 shots. Example 1 = 146cc Example 2 = 156cc

3A2797G 55

Appendix B - ADM Setup Screens Overview

((Flow Rate x Time) - Average Volume)

Flow Rate

Example 1:

= 0.053 sec

Example 2:

((75cc/sec x 2sec) - 146cc)

75 cc/sec

= -0.08 sec

((75cc/sec x 2sec) - 156cc)

75 cc/sec

Example 1:

Example 2:

(Requested Amount - Actual Amount)

Example 3:

(75cc - 72.5cc = 2.5cc)

4. Use the following formula to calculate the ? column value.

5. Enter the calculated value in the ? column.

Volume/Weight Based Example:

A 75 cc/s shot is defined to dispense for 75 cc.

1. Dispense 5 shots into 5 separate containers.

2. Measure the dispensed amount and record the data.

Example 3

Dispensed Volume

Shot

(cc)

NOTE: Depending on the dispensed volume average,

the ? column may be either a positive or negative value.

1 72.2

72.4

3 72.6

72.8

5 72.5

3. Calculate the average of the 5 shots. Example 3 = 72.5cc

4. Use the following formula to calculate the ? column value.

56 3A2797G

Appendix B - ADM Setup Screens Overview

Example 3:

5. Enter the calculated value in the ? column.

Shot Calibration Table

This screen allows the user to set the offset, ?(g), for a calculated range of shot sizes based on pump sizes and material specific gravity.

NOTE: This table is only available when defining the shot by weight.

2. Press then use the arrow keys to navigate to the “Enable Range Calibration” option.

3. Press to activate the option.

To edit a shot definition:

1. Navigate to Shots Screen.

2. Press to enter the screen.

3. Press to show the shot calibration table.

To enable the shot calibration table:

1. Navigate to Advanced Screen 4.

4. Press then use the arrow keys to navigate to the desired value.

5. Type the new value then press to accept the new value.

6. Repeat as required for other ranges.

3A2797G 57

Appendix B - ADM Setup Screens Overview

(Shot1 + Shot2 + Shot3 + Shot4 + Shot5)

Target Shot Size - Average Shot Size

Weight Based Example Using Shot Calibration Table:

NOTE: The offset needs to be determined for each

range and may need to be modified if the flow rate changes. Visit www.graco.com and search for PKE “Shot Calibration Table Worksheet” to assist in the calculations for the following procedure.

NOTE: Offset ranges are dependant on material ratio and material specific gravity. The values shown are for reference only.

1. Dispense five shots into separate containers for an average range.

2. Measure the amount for each shot size and record the data.

3. Repeat steps 1 and 2 for all twelve ranges.

4. Calculate the average for each range and record the data.

Example:

Step

Ref.

Shot

Number

Range: 11-15g

Target Shot Size: 13g

1,2 Shot 1 11.600 1,2 Shot 2 12.200 1,2 Shot 3 12.400 1,2 Shot 4 11.900 1,2 Shot 5 12.000

4 Average

12.02

Shot Size

5 Offset 0.98

Sequences Screen

This screen allows the user to edit sequence information.

See Home Screen, Sequence Mode on page 71 for information on how to use predefined sequences.

NOTE: Five sequences with 20 positions each are available across 10 pages.

5. Calculate the offset of each shot size and record the data.

6. Enter the offset into the table.

7. Repeat steps 1 through 6 for more precise offsets.

NOTE: Sequence positions are made from shots defined in the Shots Screen.

To edit a sequence:

1. Press then use the arrow keys to navigate to the desired value.

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

58 3A2797G

Appendix B - ADM Setup Screens Overview

Previously saved left position

Previously saved right position

Current position

Calibration Screen, Main

This screen shows calibration information for the system and provides access to other calibration screens. See Calibrate HFR on page 37 for how to use the calibration screens to calibrate the machine.

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 37 for how to use this screen to calibrate the machine.

Press to go to the Calibration Screen, Learn Mode screen.

Press to erase the motor control database in the motor control module.

Press and then to move the pump all the way to the left.

Press and then to move the pump all the way to the right.

Press to return to the Calibration Screen, Main. This saves the new left and right numbers.

3A2797G 59

Appendix B - ADM Setup Screens Overview

System Screen 1

This screen allows the user to set important system settings. Control Mode can be set to Flow. With Control Mode set to Flow, the machine will dispense at a continuous flow rate regardless of pressure fluctuations unless pressure alarm conditions occur.

Dispense Mode can be set to Time, Volume, and Weight. Dispense Mode controls how displayed amounts are measured. See Calibrate HFR on page 37 for more information.

Pump sizes and inlet pressures must be entered on this screen.

NOTICE

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.

System Screen 2

This screen allows the user to set which items are installed on the machine.

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, button will

become active when the is pressed. 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 61.

Post Dispense Shot Disable is a feature where the user can disable shot requests for zero to five seconds after the completion of a dispense. This feature is not applicable for P2/Fusion Dispense Valves. This feature can not be active if the Pre Dispense Delay feature is active.

Pre Dispense Delay is a feature where the HFR can delay the start of a dispense until the user has pressed and held the foot switch for the duration entered. For example, if the user enters a five second duration, the footswitch must be held on continuously for five seconds before the HFR will start a dispense. This feature is not available for recirculation systems or applicable for P2/Fusion Dispense Valve applications. This feature can not be active if the Post Dispense Shot Disable feature is active.

60 3A2797G

Appendix B - ADM Setup Screens Overview

Pressure Imbalance Setting

Mix Head Operating Details Screen

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

• Low Pressure Circulation: The percentage of setpoint, 10%-90%, 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. Entering “0” disables the post-dispense time.

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 62.

The pressure imbalance setting is 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 145-2000 psi (1-14 MPa, 10-138 bar).

Press to go back to the System Screen 2.

The flowmeter types are defined on this screen. The ratio deviation value is the allowable percentage before the machine displays a pop-up notification. The ratio alarm value is the allowable percentage difference before the machine will stop a dispense.

The ratio displayed between chemicals can be changed between blue or red, allowing either chemical to be displayed as a ratio to 1.

This screen allows the user to enter material specific gravities.

3A2797G 61

Appendix B - ADM Setup Screens Overview

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.

1. Use arrow keys to select the desired letter and

press to accept the letter. To erase all text, press

. To delete one letter, press . To move the

Maintenance Screen

This screen shows shot number, sequence position, and

dispense valve counters. Press and navigate to the

drop down box. Press and scroll to a range of count-

ers to view. Press again to select the range of counters and display them on the screen.

Counters may be erased individually. Navigate to the

counter you want to erase and press . Alternatively, each counter displayed on the page may be erased

simultaneously by pressing .

cursor one letter to the left, press . To move the

cursor one letter to the right, press . To toggle

the letters from upper/lower case, press .

2. When finished entering the new label, press .

62 3A2797G

Appendix B - ADM Setup Screens Overview

Supply Screen

This screen allows the user to specify the operating parameters for off-board, integrated tanks and indicate which positions have level sensors installed. See the Tank Feed Systems manual for information about installing level sensors, see Related Manuals on page 3. The user may select from the following refill settings: Disabled, Monitor, Manual, Auto Top-Off, Auto Full-Volume.

NOTE: Use the “Disabled” setting if off-board tanks are not installed.

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

• Disabled

• Disables tank operation

• Monitor (2 Sensors)

• 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 (2 Sensors)

• The top sensor generates a high level deviation and the bottom sensor generates a low level alarm

• A button is provided to the user on the run screens to initiate 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 (2 or 3 Sensors)

• Automatically selected with three level sensors selected

• The low level sensor will generate a low level alarm

• Two level sensors installed: 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

• Three level sensors installed: When the middle level sensor does not see material, automatic refill will begin and continue until either the middle 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 initiate an automatic refill operation at any time, this button can also be used to abort a refill operation

• Auto Full-Volume (2 Sensors)

• 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 initiate an automatic refill operation at any time, this button can also be used to abort a refill operation

Refill Setting

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 initiate an automatic refill operation at any time. This button can also be used to abort a refill operation.

3A2797G 63

Appendix B - ADM Setup Screens Overview

Refill Timeout

The refill time-out setting may be set by the user as a means to abort the refill in the case of a high level sensor failure. When an automatic refill begins, the time-out counter will begin to count down. If the timer expires before the high level sensor is triggered, the refill will abort. A refill must be manually started to enable auto refills again.

Refill Sensor Type

The Low-Temp Sensor setting limits tank temperatures to 150°F (66°C). And the High-Temp Sensor setting limits tank temperatures to 190°F (88°C).

NOTICE

If you are using low temperature sensors and select the High-Temp Sensor setting and set the temperature above 150°F (66°C), damage to the level sensors will occur.

Conditioning Screen 1

This screen allows the user to select which temperature conditioning components are installed in the system.

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.

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 and two monitoring zones may be selected.

To edit the temperature setpoint and alarms for a particular component:

1. Press then use the arrow keys to navigate to the component you wish to edit.

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Appendix B - ADM Setup Screens Overview

Conditioning Screen 3

2. Press to display the setpoint and alarm values associated with that component.

3. Edit the setpoint and alarm values and then press

to return to Conditioning Screen 2.

NOTE: The high alarm and low alarm values must be at least +/-9°F (5°C) than the material temperature value.

This screen allows the user to configure Night Mode operation. In Night Mode, the system will cycle on and

off periodically or turn on at a preset time. Press and select periodic or time schemes.

When the system is in Night Mode and in an “On” cycle, the system will circulate in low pressure. The installed conditioning zones will be on and controlling to their respective setpoints. 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.

Periodic Night Mode Conditioning Screen

This screen allows the user to set the on and off times of the machine in one minute intervals.

3A2797G 65

Appendix B - ADM Setup Screens Overview

Time Based Night Mode Conditioning Screen

This screen allows the user to set a specific time each day to turn the machine on or off. The times can be set on or off by either each day separately, Monday through Friday where each day has the same on or off times, or Sunday through Saturday where each day has the same on or off times.

To set the on/off machine times:

1. Press to enter the screen

2. Press left or right arrow keys to highlight the day selection column. Continue to press the left or right arrow keys to select the desired day, work week (Monday thru Friday), or full week (Sunday thru Saturday) duration.

6. To erase times, repeat steps 1 thru 3 and press once the desired time duration has been selected.

NOTE: If times are entered in the weekly schedule, individual days can not be erased.

NOTE: Set the Prepoly Timeout one minute beyond the time it takes for the material to reach the middle sensor.

Cold Start Up Mode

Allows the user to select what mode the machine will enter once the cold start-up is complete. Selecting no change will leave the machine in either standby or night modes circulating at the set low pressure percentage.

Auto High Pressure

Changes the machine to high pressure circulation when the mode is changed from either standby or night modes.

Calender Time Based Night Mode Conditioning Screen

This screen shows a summary of Time Based Night Mode on or off times that were set by the Time Based Night Mode Conditioning Screen.

3. Press the up or down arrow keys to select the desired hour to schedule the on or off machine times.

4. Press to enter the selected hour and select the desired time (15 minute increments) for either machine on or off to occur.

5. Press and select either on or off for the time duration selected.

Bar Color Description

Green Machine is ON Red Machine is OFF Blue Machine PrePoly Refresh Start

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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.

• Time: formatted in 24 hour time.

• Password: Enables the setup screens to be pass- word protected. Entering “0000” disables the feature.

• Screen Saver: Enter the amount of time until the backlight turns off. Entering “0” leave it constantly on.

• Silent Mode: Check this box to turn off the buzzer for key presses.

Advanced Screen 2

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

Advanced Screen 3

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

• Disable Dispensing From Display: Check this box to disable dispensing from the ADM. A footswitch, dispense valve trigger, or other external signal will be the only way to initiate a dispense.

• Disable Modifying Temp Setpoint: Check this box to disable modifying temperature setpoints from the Run screens. This is only applicable if temperature control items are installed and enabled.

• Disable Operator Mode Adjustments: When this box is checked, the user will not be able to adjust the dispense settings in Operator Mode.

• Temperature Alarm Disables Dispense: When this box is checked, the system will reject dispense requests when any enabled heat/chiller zones are below/above their setpoint.

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

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

• Enable Shot Aborted Notification: When this box is checked, a pop-up notification will be displayed when a shot is aborted.

• 2x Trigger For Dispense: When this box is checked, the machine will require a double trigger pull to initiate dispensing in shot or sequence mode.

• Dispense from Home Position: When this box is checked, the machine will be required to reach a defined home position before dispensing in shot or sequence mode.

3A2797G 67

Appendix B - ADM Setup Screens Overview

Numbers shown are for reference only and may be different on your system.

Advanced Screen 4

• Enable Diagnostic Screen: Check this box to enable the optional ADM screens, enabling USB log downloading, and erasing USB logs. For more information about USB operation, see Appendix F - USB Operation on page 89. For more information about the optional screens, see Diagnostic screen on page 74.

• Low Material Disables Dispense: When this box is checked, the current dispense will terminate and prevent additional dispenses when the supply system indicates a low level.

• Limit Rate on Stall to Pressure: Check this box to enable Limit Rate on Stall to Pressure. This will slow the rate of pressure rise on a stall to pressure system.

• Enable PrePoly Refresh: Check this box to enable Prepoly Refresh. A Prepoly refresh will initiate a cold start, heat the system to a specified temperature (Conditioning Screen 3), empty the prepoly tank to the low level sensor and refill the tank. When enabled, either the user may initiate a refresh manually or through a scheduled task.

• Night Mode, Disabled, or Standby Modes:

Automatic refills are disabled. If the material level drops below the low level sensor, a low level alarm is thrown.

• Shot, Operator or Sequence Modes: The sys-

tem will monitor the amount of automatic refills requested after the last shot has been taken. If the system sees two refills without dispensing, the system will generate a leak detection warning and disable the system. The system must be completely powered down to clear the error.

• Enable Leak Detection: Check this box to enable Leak Detection. Leak detection is intended for catastrophic leaks only. It requires a Graco auto fill control to be enabled and working. Leak detection is not active during dispense.

Advanced Screen 5

• Enable Range Calibration: Check this box to enable Range Calibration. This creates a range of shot offsets in a table based on the size of the shot. The user must calibrate each range at the specified flow rate. If the flow rate is changed, the table must be recalibrated.

This screen displays software information.

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Appendix C - ADM Run Screens Overview

Maintenance

Home Status Events #1

Events #2

Events #...

Errors #1

Errors #2

Errors #...

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.

FIG. 28: Run Screens Navigation Diagram

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. The ratio is also displayed as either Red:1 or Blue:1 depending on which display has been setup. See System Screen 3 on page 61.

To select an operating mode, press repeatedly until

the desired mode is shown then press to select the

mode. Alternately, press and use the up and down arrow keys until the desired mode is shown, then press

to select the mode. The available operating modes are operator, sequence, shot, standby, night, and disabled.

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.

3A2797G 69

Appendix C - ADM Run Screens Overview

Target Flow

Ratio

Target recipe time

Home Screen, Standby Mode

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

Press to change operating modes.

Press to move the pumps all the way to the left and turns the hydraulic power pack off.

Home Screen, Shot Mode

This mode allows the user to select one of 100 predefined shot numbers. See Shots Screen on page 55 for information about editing shot definitions.

To use a predefined shot:

1. Enter shot mode.

2. Press and use the numeric keypad to enter

the desired shot number.

3. Press to select the shot number.

4. Press to initiate a dispense. The system will go to high pressure mode and dispense a shot after the pre-dispense timer, see Mix Head Operating

Details Screen on page 61, expires.

NOTE: There is a three second delay after a dispense

before another dispense can be initiated

Press or to initiate a tank refill. If a tank is filling, pressing either button will abort the filling operation.

Press to stop or start the hydraulic power pack and run the start-up process.

5. Press to switch between low and high pressure modes without dispensing.

6. During a dispense, press to abort the dispense.

7. See Home Screen, Standby Mode on page 70 for other button functions.

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Appendix C - ADM Run Screens Overview

Target

Flow/Pressure

Ratio

Target dispense amount (time/vol-

ume/weight depending on Dis-

pense Mode)

Total of resettable material counters

B (Blue) resettable material counter

A (Red) resettable material counter

Operator

Setting

Ratio

Home Screen, Sequence Mode

This mode allows the user to select one of five sequences (A-E). The progress bar on the bottom of the screen shows the progress of a shot dispensing from the selected sequence. See Sequences Screen on page 58 for information about editing sequence definitions.

NOTE: There is a three second delay after a dispense before another dispense can be initiated.

To use a predefined sequence:

1. Enter 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.

8. See Home Screen, Shot Mode on page 70 for other button functions.

Home Screen, Operator Mode

This mode allows users to set a flow rate to dispense material without using predefined shot information.

1. To edit the flow rate, press . The value to change will now be highlighted. Type the new value

then press to accept it.

4. Press to accept the sequence letter/position.

5. Press the Dispense button to begin dispensing.

6. Press to skip to the next sequence position.

7. Press to abort the sequence.

2. Press to initiate a dispense. The system will go to high pressure mode and dispense a shot after the pre-dispense timer, see Mix Head Operating

Details Screen on page 61, expires. Press the to stop the dispense.

NOTE: There is a three second delay after a dispense before another dispense can be initiated.

3. If an external trigger is used, press an hold the trigger to initiate a dispense. Release the trigger to stop the dispense.

4. See Home Screen, Shot Mode on page 70 for other button functions.

3A2797G 71

Appendix C - ADM Run Screens Overview

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

Home Screen, Night Mode

In Night Mode, the system will cycle on and off periodically or turn on at a preset time. Entering night mode will turn pumps and all conditioning zones off. The circulation on/off cycle begins automatically upon entering Night Mode. See Conditioning Screen 3 on page 65.

Status Screen

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.

Status Screen, Conditioning Control

This screen allows users to turn on and off heat zones individually or all at once. When a zone is on it is actively controlling temperature. Refer to the table below for color code definitions.

Zone

Setting Color Definition

Black Dispense Disabled

OFF

Grey Dispense Allowed

Yellow Dispense Disabled

Green Dispense Allowed

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 on the selected zone. When a zone is on, the button will be selected. Press the

button again to turn off the zone.

To turn on/off all zones:

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

1. Press to enter the Conditioning Control screen.

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

Press the button again to turn off all zones.

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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.

Maintenance Screen

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 and navigate to the

field to be erased. Press to erase that data point.

Alternatively, may be pressed to erase all of the batch data points simultaneously.

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

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

3A2797G 73

Appendix C - ADM Run Screens Overview

Optional Screens

The optional Diagnostic screen can be enabled in the Advanced Screen 4 screen, see page 68.

Diagnostic

The Diagnostic screen shows status information for various components in the Motor Control Module.

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

A4H3

DEH3

MBH3

P1H3

P4H3

T4H3

WDF3

WDD3

0500

02D0

A4A6

A4B5

A4A3

A4B1

A4A2

A4B4

A4A7

A4B8

A4H1

A4M1

Mix Head Motor Overload Soft Stop Asserted Low Mix Head Oil Level

Low Accumulator Pressure

High Accumulator Pressure High Mix Head Oil Temp.

M1 Material Rod Shift Fail

M1 Cleanout Rod Shift Fail

Invalid Weight Cal. Data

Low Flow Advisory

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

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.

Pump velocity is too low. Advisory

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

Error Type Cause Solution

Refer to AC Power Pack manual

Deviation Invalid data Re-calibrate the machine

Pump flow setpoint is

Alarm

lower than one eighth of the total pump volumes

Bad heaters Measure resistance of heater

High voltage

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

Increase the pump flow setpoint

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

3A2797G 75

Appendix D - ADM Error Codes

Error Code Error Name Error Description

A4N1

A7A6

A7B5

A7A3

A7B1

A7A2

A7B4

A7A7

A7B8

A8A6

A8B5

A8A3

A8B1

A8A2

A8B4

A8B7

A8B8

A9C1

B9C0

B9C1 The requested dispense

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

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)

amount (time/volume/weight) is below the minimum amount of the system

Error Type Cause Solution

Alarm

Deviation

Short circuit of motor wiring

Motor rotor has become locked

Shorted Temperature Control Module

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Low power

Cable unplugged/loose power

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

Bad Motor Control Module code

Pumps are defined with the wrong size

Requested shot is below the capabilities of the current pump setup

Short shot size Increase the time/volume/weight of the shot

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

76 3A2797G

Appendix D - ADM Error Codes

Error Code Error Name Error Description

CAA2

CAA3

CAA6

CAA7

CAB1

CAB4

CAB5

CAB8

CAC1

CAC2

CAC3

CAC4

CAC5

CAC6

CAC7

CACN

CACP

CACR

CUCN

D1A1

D4A1

D2A1

D3A1

Comm. Error Red Hose

Comm. Error Red Inline

Comm. Error Red Blanket

Comm. Error Red Chiller

Comm. Error Blue Inline

Comm. Error Blue Hose

Comm. Error Blue Blanket

Comm. Error Blue Chiller

Comm. Error Motor

Comm. Error MCM

Comm. Error Red Tank

Comm. Error Blue Tank

Comm. Error Mix Head

Comm. Error Mix Head 2

Comm. Error Ratio Monitor

Comm. Error Gateway

Comm. Error DGM

Comm. Error Remote Pendant

Gateway Heartbeat Error

Setpoint Not Reached

Setpoint Exceeded

Setpoint Not Reached

Setpoint Exceeded

Communication error Alarm

Heartbeat Error Alarm

The set point was not reached and the pump was shutdown The maximum cycles per minute of the pump has been exceeded

The set point was not reached Deviation

The set point was exceeded Deviation

Error Type Cause Solution

Module missing power Check power supply connection

Module not programmed Program the module

Module bad Replace module

Deviation

PLC is not maintaining heartbeat Module missing power Check power supply connection Module not programmed Program the module Module Bad Replace module Material restriction too high for requested flow

Restriction for the pump is not sufficient

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

Ensure PLC is triggering the heartbeat

Reduce flow request

Increase the restriction or lower the set point

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

3A2797G 77

Appendix D - ADM Error Codes

Error Code Error Name Error Description

This calibration lets the MCM know where the ends of the

D5A1

D6A1

DDA1

DDB2

DFA1

DR6A

DR6B

DSC0

F1A0 F2A0 Deviation F1B0 F2B0 Deviation F4A0 F3A0 Deviation F4B0 F3B0 Deviation

F7D1

L111

L122

L311

L322

L6A1

L6B2

Invalid Learn Mode Data

Position Sensor Fault

Red Pump Cavitation

Blue Pump Cavitation

Pump Not Parked

Check Flow Meter Red Check Flow Meter Blue

Pumps Not Defined

Low Flow Red

Low Flow Blue

High Flow Red

High Flow Blue

Pump Failed to Stall

Red Low Material Level

Blue Low Material Level

Red High Material Level Blue High Material Level Red Auto Refill Timeout

Blue Auto Refill Timeout

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

The pump failed to reach the park position

Flow Meter has caused a fault Deviation

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

Flow is below the defined low limit

Flow is above the defined low limit

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 Deviation

High material level in tanks Deviation Defective fill valve

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

Error Type Cause Solution

Deviation

Alarm

Deviation

Alarm

Deviation

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

Orifices blocked Clear blockage Hose blocked Clear or replace hose as necessary Dispense valve failed to open Cogs in flow meter are not turning Cable unplugged/loose power

Properly setup the system

Cogs in flow meter are not turning

Cable unplugged/loose power

Cogs in flow meter are turning rapidly

Failure of the dispense valve

Material leak

Out of material Fill tanks

Tanks low on material Fill tanks with material

Loose/broken connection

Bad level sensor Replace level sensor

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

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

Verify that feed pumps are supplying material

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

Check to make sure the dispense valve is properly configured and connected to the MCM Check that flow meter is matched to nominal pump output

check of loose or disconnected wires or plugs

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

Check that flow meter is matched to nominal pump output

Check for loose or disconnected wires or plugs

Check that flow meter is matched to nominal pump output

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

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

L8A1

DR6B

L9AX

L9BX

L9A0

MBH1 Low Oil Level

MBN1

MMUX

N1D0

N2D0

N3D0

N4D0

Red Tank Sensor Failure Blue Tank Sensor Failure

Red Tank Leak Detected

Blue Tank Leak Detected

Prepoly Refresh Time Expired

Low Motor Performance

USB Logs Full

Material Dispense Below Alarm Material Dispense Below Deviation Material Dispense Above Deviation Material Dispense Above Alarm

A level sensor had ceased working

A tank or material line is leaking

Prepoly refresh took longer to complete than normal

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

USB log has reached the maximum entries

Material dispense is below the defined limit

Material dispense is above the defined limit

Error Type Cause Solution

Deviation Bad level sensor Replace level sensor

Alarm

Advisory

Alarm

Deviation

Alarm

Two tank refills occur without a dispense

No material is sensed by the second level sensor within an allotted amount of time 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

USB logs have not been downloaded

Cogs in flow meter are not turning

Cable unplugged/loose power

Check all hoses and pumps for material leaks

Check for an obstructions within the material supply line

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

Download USB logs to a memory stick Uncheck the Enable USB errors on Advanced screen 4

Check that flow meter is matched to nominal pump output

check for loose or disconnected wires or plugs

3A2797G 79

Appendix D - ADM Error Codes

Error Code Error Name Error Description

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

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

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

80 3A2797G

Appendix D - ADM Error Codes

Error Code Error Name Error Description

R1D0

R4D0

R2D0

R3D0

T1A6

T1B5

T1A3

T1B1

T1A2

T1B4

T1A7

T1B8

T20X

T30X

Low Ratio Alarm

High Ratio Alarm

Low Ratio Deviation

High Ratio Deviation

Red Tank Low Fluid Temp. Blue Tank Low Fluid Temp.

Red Inline Low Fluid Temp.

Blue Inline Low Fluid Temp. Red Hose Low Fluid Temp.

Blue Hose Low Fluid Temp.

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

Dispensing Disabled Low Temp

Dispensing Disabled High Temp

Ratio monitor has detected an out of ratio condition

Fluid temperature is below the defined low alarm limit

Dispensing disabled because of temperature

Error Type Cause Solution

Alarm

Deviation

Alarm

Advisory

Material A to Material B is out of ratio

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Low power

Cable unplugged/loose power

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

Temperature is out of alarm limits

Check feed system

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 temperature alarm limits

3A2797G 81

Appendix D - ADM Error Codes

Error Code Error Name Error Description

T2AA

T2AE

T2AF

T2BC

T2BD

T2BG

T3AA

T3AE

T3AF

T3BC

T3BD

T3BG

T3H1

T3N1

Red Hose Low Fluid Temp. Red Tank Low Fluid Temp.

Red Chiller Low Fluid Temp.

Blue Hose Low Fluid Temp. Blue tank Low Fluid Temp. Blue Chiller Low Fluid Temp.

Red Hose High Fluid Temp.

Red Tank High Fluid Temp. Red Chiller High Fluid Temp.

Blue Hose High Fluid Temp.

Blue Tank High Fluid Temp. Blue Chiller High Fluid Temp.

Oil Temp. Cutback

Motor Temp. Cutback

Fluid temperature for a monitor zone is below the defined low alarm limit

Fluid temperature for a monitor zone is above the defined high 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

Error Type Cause Solution

Deviation

Advisory

Temperature is out of alarm limits

Cable unplugged/loose power

Inline heater is not turned on

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

Check temperature alarm limits

Check for loose or disconnected wires or plugs

Turn on inline heater

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

82 3A2797G

Appendix D - ADM Error Codes

Error Code Error Name Error Description

T4A2

T4A3

T4A6

T4A7

T4B1

T4B4

T4B5

T4B8

T4C1

T4H1

T4N1

T6A6

T6B5

T6A3

T6B1

T6A2

T6B4

T6A7

T6B8

Red Hose High Fluid Temp. Red Inline High Fluid Temp.

Red Tank High Fluid Temp.

Red Chiller High Fluid Temp. Blue Inline High Fluid Temp.

Blue Hose High Fluid Temp.

Blue Tank High Fluid Temp. Blue Chiller High Fluid Temp.

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

Fluid temperature is above the defined high alarm limit

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

Error Type Cause Solution

Alarm

Defective Temperature Control Module

Defective RTD Replace RTD

Loose connections Tighten connections

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

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

Bad RTD Replace RTD

Replace Power Temperature Control Module

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

3A2797G 83

Appendix D - ADM Error Codes

Error Code Error Name Error Description

T6C6

T6C7

T6C8

T8A6

T8A3

T8B1

T8A2

T8B4

T8A7

T8B8

T9A6

T9B5

T9A3

T9B1

T9C6

T9C5

T9C3

T9C1

T9C2

T9C4

T9C7

T9C8

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 No Cooling Red Chiller

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

RTD 2 is giving no or invalid data

No temperature rise Deviation

No temperature decline Deviation

Heater overtemperature cutoff Alarm

PCB over temperature Alarm

Error Type Cause Solution

Loose or bad connection Check RTD wiringT6C5

Alarm

Bad RTD Replace RTD

Tripped circuit breaker Visually check circuit breaker for a tripped conditionT8B5

Low Power

Cable unplugged/loose power

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

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Defective cooling valve

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

Defective RTD Replace RTD

Defective High Power Temperature Control Module

Loose connections Tighten connections

Overheated 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

Disconnect the valve and measure the voltage across 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

84 3A2797G

Appendix D - ADM Error Codes

Error Code Error Name Error Description

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

High line voltage Alarm

The voltage to the MCM has 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 material rod failed to move on a straight head

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

V1H1

V4A6

V4B5

V4A3

V4B1

V4A2

V4B4

V4A7

V4B8

V4H0

W0U0

WBH1

WDF1

WKH1

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

Motor Control Overvoltage

USB Update Failed

Motor Encoder Fault

M1 Material Rod Shift Fail

High Motor Speed

Error Type Cause Solution

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Alarm

Supply lines providing low voltage

Incoming line voltage is too high

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

Stuck material rod Check that material rod is able to freely move No power to directional

valve 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

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.

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

3A2797G 85

Appendix D - ADM Error Codes

Error Code Error Name Error Description

WM06

WM05

WM03

WM01

WM02

WM04

WM07

WM08

WMA6

WMB5

WMC6

WMC5

WMC3

WMC1

WMC2

WMC4

WMC7

WMC8

WMH1

WSC0

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.

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

Motor Controller Fault

Invalid Setpoint Request

Invalid Gel Timer Definition

High current to relay 1 Alarm Broken contactor Replace contactor

Tank blanket is above the defined high alarm limit

Unexpected current to relay 1 Alarm Shorted module

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

Defective RTD Replace RTD

Alarm

Deviation Internal hardware failure

Deviation

Defective High Power Temperature Control Module Loose connections Tighten connections

System incorrectly setup

Shot incorrectly defined

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

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

Replace High Power Temperature Control Module

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.

86 3A2797G

Appendix E - System Events

Event Code and String Triggers

EAA0-R: Prepoly Refresh Started

EBA0-R: Prepoly Refresh Complete

EL00-R: System Powered On

EM00-R: System Powered Off

EB00-R: Stop Button Pressed

ECH0-R: Learn Mode Executed

ENN0-R: Automatic Cal. Performed

ECA1-R: Red Material SG Modified

ECB2-R: Blue Material SG Modified

ENC1-R: Cal. Point 1 Weight Entered

ENC2-R: Cal. Point 2 Weight Entered

ENC4-R: Cal. Point 1 Weight Erased

ENC5-R: Cal. Point 2 Weight Erased

END0-R: Ratio Check Dispense

EA00-R: Disp. Occurred (Shot #)

EH00-R: Gel Timer Dispense

ER01-R: Shot Count Reset

ER02-R: Seq. Position Count Reset

ERA1-R: Red Material Volume Reset

ERB1-R: Blue Material Volume Reset

ERA2-R: Red Material Weight Reset

ERB2-R: Blue Material Weight Reset

ERA3-R: Red Cycle Count Reset

ERB3-R: Blue Cycle Count Reset

While in night mode, the prepoly refresh started.

While in night mode, the prepoly refresh completed successfully.

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.

Event Code and String Triggers

EQU1-R: Settings Downloaded

REQU-R: Settings Uploaded

EQU3-R: Language Downloaded

EQU4-R: Language Uploaded

EQU5-R: Logs Downloaded

EA0-R: Night Mode Recirc On

EBR0-R: Night Mode Recirc Off

EWA0-R: Prepoly Refresh Cancelled

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.

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 circulation mode and attempted to turn on all enabled conditioning zones.

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

While in night mode, the prepoly refresh was cancelled

3A2797G 87

Appendix E - System Events

88 3A2797G

Appendix F - USB Operation

Overview

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

• Ability to download a log of up to the past 50,000 errors, events, or jobs that can contain over 150,000 snapshots of critical dispense information.

• 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 4, see page 68.

The third option is a checkbox that enables or disables the ability to record errors associated with the USB logs.

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.

NOTICE

Low-quality USB stick drives may lead to burning out the USB port on the ADM. Use only high-quality USB stick-drives with the ADM USB port.

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 circulation, 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. 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.

3A2797G 89

Appendix F - USB Operation

Log Files, Folder Structure

FIG. 29: DOWNLOAD, DATAxxxx Folders

Each time a stick-drive is inserted into the ADM USB port, a new folder named DATAxxxx is created. The number at the end of the folder name is incremented each time a stick-drive is inserted and data is downloaded or uploaded. In each DATAxxxx folder there are three log files. They are formatted as .csv (comma separated value) files and can be opened by most text editors or data processing programs such as Excel.

Example 1-ERROR File

The 1-ERROR file is the Errors and Events log file.

90 3A2797G

Example 2-JOB File

The 2-JOB file is the Shot Data Log file.

Appendix F - USB Operation

Example 3-SYSTEM File

The 3-SYSTEM file is the Software Version log file.

3A2797G 91

Appendix F - USB Operation

Transfer System Settings

NOTICE

Low-quality USB stick drives may lead to burning out the USB port on the ADM. Use only high-quality USB stick-drives with the ADM USB port.

Use the following process to transfer system settings from one machine to another.

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

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.

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.

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.

92 3A2797G

Update Custom Language

NOTICE

Low-quality USB stick drives may lead to burning out the USB port on the ADM. Use only high-quality USB stick-drives with the ADM USB port.

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 94.

a. In the first column, locate the string to change.

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.

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.

3A2797G 93

Appendix F - USB Operation

Example SETTINGS.TXT File

NOTICE

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

Example DISPTEXT.TXT File

94 3A2797G

Technical Data

HFR for NVH Foam

US Metric

Maximum fluid working pressure 2000 psi 14 MPa, 138 bar Maximum Fluid Temperature 190°F 88°C Fluid Inlet Feed Pressure Range 50 psi to 100 psi 345 kPa, 3.4 bar to Fluid Inlet:

Component A (Red)

Fluid Inlet:

Component B (Blue)

Fluid Outlet:

Component A (Red)

Fluid Outlet:

Component B (Blue)

Fluid Circulation Ports 1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum Line Voltage Requirement:

230V / 3 phase Models

Line Voltage Requirement:

400V / 3 phase Models

Amperage Requirement See Models on page 4 Sound Power 93 dB Heater Power

(A (Red) and B (Blue) heaters total, no hose) Hydraulic reservoir capacity 9 gal. (34 liters) Recommended hydraulic fluid Citgo A/W Hydraulic Oil, ISO Grade 46 Weight:

Units with 10 kW Heaters

Wetted Part Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide,

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

#10 (5/8 in.) JIC (7/8-14 unf), with #6 (3/8 in.) JIC adapter

chrome, fluoroelastomer, PTFE, ultra-high molecular weight polyethylene,

#8 (1/2 in.) JIC (3/4-16 unf), with #5 (5/16 in.) JIC adapter

See 400 V Power Requirements on page 5

(12 kW for 1:1 Models Only)

chemically resistant o-rings

1/2 npt(f)

3/4 npt(f)

195-264V, 50/60 Hz

360-440V, 50/60 Hz

10 kW full load

868 lb (394 kg)

0.7 MPa, 7 bar

3A2797G 95

Technical Data

Motor Control Module Technical Data

Motor Control Module

US Metric

Input Specifications:

Input Line Voltage 0-264 Vac, line-to-line Input Line Phasing Single or Three Phase Input Line Frequency 50/60 Hz Input Current per Phase 25A (three-phase), 50A (single-phase) Maximum Branch Circuit Protection Rating 30A (three-phase), 63A (single-phase) Short Circuit Current Rating 5 kA

Output Specifications:

Output Line Voltage 0-264 Vac Output Line Phasing Three Phase Output Current 0-30A

Output 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.

96 3A2797G

Dimensions

ti19519a

Dimensions

A (Height) 76 in. (193 cm)

B (Width) 72 in. (183 cm)

C (Length) 58 in. (147 cm)

Technical Data

3A2797G 97

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 par t 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 parts. 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. Toll Free: 1-800-746-1334 or Fax: 330-966-3006

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.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 3A2797

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised November 2014

Graco 3A2797G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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Refill Kits

GX-16 Shutoff Valve Kit

Additional Accessories

Communications Gateway Module (CGM)

Bag Filter Kits

GX-16 Fitting Kits

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Foam Resins with 245 fa Blowing Agents

A (Red) and B (Blue) Components

Changing Materials

Typical Installation

Component Identification

HFR Hydraulic Power Pack

Motor Control Module (MCM)

Advanced Display Module (ADM)

Fluid Control Module (FCM)

Temperature Control Module

Setup

Startup

Shutdown

Pressure Relief Procedure

Flushing

Maintenance

Install Upgrade Tokens

IsoGuard Select™ System

Troubleshooting

Light Tower (Optional)

Appendix A - ADM Icons Overview

Setup Screen Icons

Run Screen Icons

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

Technical Data

Motor Control Module Technical Data

Dimensions

Graco Standard Warranty

Graco Information