Graco 3A2806C User Manual
Instructions - Parts
Level Detection Module
3A2806C
and Drum Feed Kit
Installation kit to provide low level sensors in both chemical sides of an HFRL or HFRS
plural-component proportioner being fed from 55 gallon (208 liter) drums. Not for use with
standard configured HFR units. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Important Safety Instructions
Read all warnings and instructions in the HFRL and HFRS
Setup-Operations manual. Save all instructions.
EN
See page 3 for model information.
125 psi (0.86 MPa, 8.6 bar) Maximum Fluid Working Pressure
125 psi (0.86 MPa, 8.6 bar) Maximum Air Input Pressure
ti19596a
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 4
Complete Feed System . . . . . . . . . . . . . . . . . . . . 4
Electrical Panel Components . . . . . . . . . . . . . . . 5
Fluid Control Module (FCM) . . . . . . . . . . . . . . . . 6
Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flush Pumps Before Using . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install 4 Drum Rack (Optional) . . . . . . . . . . . . . . 9
Refer to 4 Drum Rack, 01/0955/25 (Optional) on
page 30 for visual clarity. . . . . . . . . . . . . . . . 9
Position Drums . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install Drum Feed Kit . . . . . . . . . . . . . . . . . . . . . . 9
Connect Feed Pump . . . . . . . . . . . . . . . . . . . . . . 9
Install Electrical Panel . . . . . . . . . . . . . . . . . . . . 10
Install Level Sensors . . . . . . . . . . . . . . . . . . . . . 12
Install Light Tower . . . . . . . . . . . . . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Calibrate Barrel Style Level Sensors . . . . . . . . . 14
Set the ADM to Recognize the Feed System Kit 14
Set the ADM to Recognize which Level Sensors are
to Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Set the Level Sensors Output Function . . . . . . 15
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drum Feed Kit - Air Dryer . . . . . . . . . . . . . . . . . 16
Drum Feed Kit, Pump . . . . . . . . . . . . . . . . . . . . 17
Drum Feed Kit, Changing Top Drums . . . . . . . . 17
Install Upgrade Tokens . . . . . . . . . . . . . . . . . . . 18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Level Sensor and Well . . . . . . . . . . . . . . . . . . . . 20
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 21
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drum Feed System, 24N816 . . . . . . . . . . . . . . . 22
Drum Feed Kit, 24N767 . . . . . . . . . . . . . . . . . . . 24
Electric Panel, 24N804 . . . . . . . . . . . . . . . . . . . 26
4 Drum Rack, 01/0955/25 (Optional) . . . . . . . . . 30
Appendix A - ADM Setup Screens Overview . . . . 32
Appendix B - ADM Run Screens Overview . . . . . 35
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 38
2 3A2806C
Related Manuals
Component manuals in English. Manuals are available
at www.graco.com.
Manual No. Description
3A2175 HFRL and HFRS, Setup-Operations
3A2176 HFRL and HFRS, Repair-Parts
312877 Husky 1050 Air-Operated Diaphragm Pump, Operation
3A0235 Feed Supply Kits, Instructions-Parts
406987 GCA CAN Cables, Reference (Extension Cables)
Models
NOTE: Not for use with standard HFR units.
Related Manuals
Part
24N816
24N767
01/0955/25 4 Drum rack (Optional)
Description
KIT, low level, stack light, HFRL (Required):
- (2) low level sensors - (1) sensor per chemical side
- (1) control panel for level sensors
- (1) indicator stack light
Carbon steel drum feed kit with Husky pump (Optional):
- Kit is to add a drum feed to (1) chemical side
3A2806C 3
Component Identification
Component Identification
Complete Feed System
Figure Shown With:
(1) Level Kit
(2) Drum Feed Kit Options
(1) 4 Drum Rack Option
G
F
D
E
B
C
A
ti19596a
KJ H
FIG. 1: Component Identification - Feed System
Key:
A Auxiliary Control Panel (Mounted in Machine Base)
Refer to F
B Level Sensor - Low Level Indication
C Level Sensor - Empty Indication
D Indicator Stack Light
E Drum Feed / Pump Kit for One Chemical (Optional)
F 4 Drum Rack (Optional)
G Upper to Lower Drum Feed Hose
4 3A2806C
IG. 2
H Drum to Pump Feed Hose, 6 ft (1.8 m)
J Husky Pump
K HFR Supply Hose
Electrical Panel Components
Component Identification
The electrical panel will be located on the inside of the
HFRL stand enclosure, and includes two fluid control
modules.
AF
AD
Software is loaded on Fluid Control Modules (FCM).
Program token 16G584 is also provided.
AE
AA
FIG. 2: Component Identification - Electrical Panel
Key:
AA Fluid Control Module - A (Red) Tank
AB Fluid Control Module - B (Blue) Tank
AC Ground Cable
AD CAN Cable
AE Flanged Hex Nuts (3x)
AF Wire Tie Anchor
AC
AB
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3A2806C 5
Component Identification
Fluid Control Module (FCM)
BA
BC
BH
BG
BE
ti12337a
BF
BB
FIG. 3: Component Identification - FCM
Key:
BA Fluid Control Module (FCM)
BB Base
BC Module Connection Screws
BD Access Cover
BE Module Status LEDs
BF CAN Connectors
BG Level Sensor Input
BH Fill Solenoid Signal
Adjust Rotary Switch
The rotary switch setting indicates which zone the fluid
control module will control in the system. The FCM uses
a 16-position rotary switch to make selections.
Set the rotary switch to the specific selection according
to the settings listed in the following table.
ti12336a
BD
Setting Zone
0 through 2 Not Used
3 B (Blue) Tank Level
4 A (Red) Tank Level
5 through F Not Used
Rotary Switch
ti12361a
FIG. 4: Adjust Rotary Switch
6 3A2806C
Light Tower
Component Identification
FIG. 5: Component Identification - Light Tower
Signal Description
Green on only System is powered up and there are no error con-
ditions present
Yellow on An advisory exists
Yellow flashing Material is at a low level condition
Red flashing A deviation exists
Red on The system is shut down due to an alarm occur-
ring.
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.
Messaging will be viewable on the ADM to determine
the specific error code.
tower
3A2806C 7
Grounding
Grounding
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
Pump: follow instructions in separate feed pump manual, supplied.
HFR: see operation manual.
Fluid supply container: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray gun or
dispense valve firmly to the side of a grounded metal
pail, then trigger the gun or valve.
Flush Pumps Before
Using
Flush equipment only in a well-ventilated area. Do
not spray flammable fluids.
NOTICE
Diaphragm pumps are factory tested with water.
Thoroughly flush pumps before using to prevent
moisture contamination when pumping moisture
sensitive materials.
8 3A2806C
Installation
Installation
Install 4 Drum Rack (Optional)
NOTICE
To avoid machine damage or personal injury,
anchor the rack to the floor with (4) 1/2” bolts (provided by customer) and verify all bolt assemblies
are tightened before loading the drums onto the
rack.
Refer to 4 Drum Rack, 01/0955/25 (Optional) on
page 30 for visual clarity.
Position Drums
Place component A (red) and component B (blue)
drums as desired. Air hose connecting feed pumps is
15 ft (4.57 m) long.
Fluid hose connecting feed pumps to systems are
10 ft (3.05 m) long.
4. Tighten all connections.
Connect Feed Pump
1. Supply clean, dry, filtered air to feed pumps.
NOTE: Air supply components are not included.
2. Refer to Husky 1050 Air-Operated Diaphragm
Pump, Operation manual for instructions.
Install Drum Feed Kit
NOTICE
To avoid machine damage or personal injury, do not
supply pressure to drums.
1. Complete Setup instructions in the pump manual
before installing in drum feed kit.
NOTICE
To avoid improper operation, the diaphragm pump
must be floor mounted.
2. If applicable, locate drum rack to allow access for
top drum change.
3. Dry fit all hose and fitting components to ensure
components are located properly and will reach the
HFRL. Refer to F
NOTE: Drum to pump feed hose length can be reduced
if necessary. Refer to F
IG. 1, page 4.
IG. 1, page 4, item H.
3A2806C 9
Installation
Install Electrical Panel
1. Perform HFR shutdown procedure. See HFRL operation manual for detailed instructions.
2. Disconnect the power supply to the machine.
3. Turn the disconnect switch on the rear base cover of
the machine to the “OFF” position
4. Remove the cover to allow access into the base
cube.
5. Install the pre-assembled panel on the left side of
the cube, directly opposite of the main control panel.
Note the locations of the 3 studs; One in each top
corner, and one in the bottom center.
a. Orient the panel so the mounting holes match
the stud locations of the cube.
b. Insert the panel into the base cube.
8. Remove one of the hole plugs located on the top of
the base cube directly over the disconnect panel
that was just removed.
NOTE: There are three holes on the top edge of the
base cube. The plug can be easily pushed out from
inside the cube.
9. Replace the removed plug with the provided plastic
edge bushing
a. The bushing will snap into place by aligning the
smaller diameter end of the bushing on top of
the hole and pressing the bushing down through
the hole from outside the cube.
10. Insert the male ends of the sensor cords labeled
FCM1A and FCM2B through the bushing and into
the base cube.
11. Connect the cord labeled FCM1A to port “1” (Refer
to F
IG. 2, page 5) on the FCM labeled FCM1.
12. Connect the cord labeled FCM2B to port “1” (Refer
to F
IG. 2, page 5) on the FCM labeled FCM2.
c. Orient the top of the panel such that the studs in
the cube wall extend through the holes in the
top corners of the panel.
d. Fasten the panel to the studs with the (3)
flanged hex nuts provided. Tighten the nuts.
6. Connect the cable (labeled 121002) extending from
the panel to the yellow cable splitter located on the
lower left side of the main machine control panel.
a. Remove the two screws to free the splitter from
the panel.
b. Insert the cable end into the open port on the
splitter and tighten. Note that the plug is keyed
and only fits in the splitter in one orientation.
c. Reattach the splitter to the panel.
7. If there is no available connection on the splitter, an
alternate CAN connection will need to be used. The
alternate location may require a different gendered
cord (122487 is provided for this purpose). Consult
the system manual in finding an alternate connection location.
13. Attached the wire anchor to the inside face of the
base by inserting the provided screw through the
anchor and the weld nut indicated in F
IG. 6. Secure
in place by tightening the hex nut on the screw from
the outside of the base.
14. Secure the cords to the panel and the base cube by
using wire ties (not provided) and the installed plastic anchors.
10 3A2806C
Step 6
Step 5
Installation
NOTE: Mounting location for panel is
only available on HFRL and HFRS
models. This location is used for
other control components on standard HFR models.
Step 5
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Panel view is shown rotated 180°
from the installed position.
Step 13
Step 8,
Step 9
Step 6
Panel Install
FIG. 6: Install Electrical Panel
3A2806C 11
Installation
Install Level Sensors
NOTE: Lower drum hardware must be installed in an
empty drum and then installed on the lower drum rack.
The drum can then be filled from the cascade feed hose
from a full upper drum.
NOTE: There are two possible locations for the low level
sensor, depending on desired function. Install both sensors in the same location on each chemical side.
• Low Level Indication: Located in the upper to
lower drum feed hose
• Empty Indication: Located in the drum to pump
feed hose.
NOTICE
Do avoid machine damage, install one sensor on
each chemical side only.
where the well is inserted. Note these measurements as they will be need later.
5. Being careful to not cross-threads, thread assembled level sensor (CB) into well housing until it bottoms out against the bottom of the well. The bottom
of the level sensor will be slightly visible through the
bottom of the well.
NOTE: In the following step, do not allow PTFE
paste or tape to cover the tip of the level sensor
well. If paste comes in contact with the tip of the
level sensor well, thoroughly wipe it clean.
6. Apply PTFE paste and PTFE tape to the male
threads of the level sensor well housing.
7. Being careful to not cross-threads, thread the level
sensor well (CA) into the corresponding drum feed
port and lightly tighten with a crescent wrench.
NOTICE
Do not pressurize tank with level sensor removed
from sensor well. Doing so will rupture the level sensor well.
1. Turn main power off.
2. Drain drums below the lowest level sensor well.
NOTE: For proper level sensor function, the tip of
the level sensor well must protrude at least 1/8 in.
into the tank.
3. Route the level sensor wire through the corresponding well nut (CC). See F
IG. 7 for level sensor assem-
bly view.
CA
CB
CC
Wire
CD
8. The protrusion length must be at least 1/8 in.
(3.2 mm). If not, remove the level sensor well and
restart at step 4.
9. Rotate level sensor such that the cord is pointing
vertical and the sensing face is pointing down.
10. Plug the sensor connector (CD) into the level sensors.
a. Route the sensor wires from the control panel
through the bushing that was installed with the
level sensor panel (steps 8 and 9).
11. Plug the sensor connector into the connector on the
FCM.
12. Calibrate the sensor. See Calibrate Barrel Style
Level Sensors, page 14.
r_24b969_3A0395a_7a-2
FIG. 7: Level Sensor Assembly
4. Measure the length of the level sensor well housing,
and then measure the depth of the hole in the fitting
12 3A2806C
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