Graco HFR Setup And Operation Manual

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Page 1

Setup - Operation

ti19598a

™

313997ZAA

HFR

Hydraulic, Plural-Component, Fixed-Ratio Proportioner. For pouring and dispensing sealants and adhesives and polyurethane foam.

For professional use only. Not for use in explosive atmospheres.

Important Safety Instructions

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

See page 4 for model information and maximum working pressure.

Page 2

Contents

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

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

Product Configurator . . . . . . . . . . . . . . . . . . . . . . . 5

Whip Hose Bundles . . . . . . . . . . . . . . . . . . . . . . 7

Individual B (Blue) Heated Whip Hose . . . . . . . . 7

Individual A (Red) Heated Whip Hose . . . . . . . . 7

B (Blue) Individual . . . . . . . . . . . . . . . . . . . . . . . . 8

A (Red) Individual . . . . . . . . . . . . . . . . . . . . . . . . 9

Hose Bundling Accessories . . . . . . . . . . . . . . . . 9

Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B (Blue) Applicator Orifice . . . . . . . . . . . . . . . . . 11

Iso A (Red) Applicator Orifice . . . . . . . . . . . . . . 13

AC Power Pack with S-Head/L-Head Hoses,

Optional Boom . . . . . . . . . . . . . . . . . . . . . . 14

Dispense Valve Interface Kit . . . . . . . . . . . . . . 14

Flow Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pump Feed Kits . . . . . . . . . . . . . . . . . . . . . . . . 15

B (Blue) and A (Red) Feed Tanks . . . . . . . . . . 16

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Important Two-Component Material Information 20

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 20

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 20

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

Moisture Sensitivity of Isocyanates . . . . . . . . . . 21

Foam Resins with 245 fa Blowing Agents . . . . . 21

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 21

A (Red) and B (Blue) Components . . . . . . . . . . . . 21

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 23

Component Identification . . . . . . . . . . . . . . . . . . . 24

Hydraulic Power Pack . . . . . . . . . . . . . . . . . . . . 27

Motor Control Module (MCM) . . . . . . . . . . . . . . 28

Advanced Display Module (ADM) . . . . . . . . . . . 30

Fluid Control Module (FCM) . . . . . . . . . . . . . . . 33

Temperature Control Module (Heated HFR Only)

Dispense Valves Overview . . . . . . . . . . . . . . . . . . 37

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Vacuum De-gas . . . . . . . . . . . . . . . . . . . . . . . . 44

Vacuum De-gas and Vacuum Manual Refill . . . 45

Advanced Display Module (ADM) Operation . . . 46

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 51

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ADM - Battery Replacement and Screen Cleaning

MCM and TCM - Clean Heat Sink Fins . . . . . . . 54

Install Upgrade Tokens . . . . . . . . . . . . . . . . . . . 55

Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 56

IsoGuard Select

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . 58

Common Problems . . . . . . . . . . . . . . . . . . . . . . 58

ADM Troubleshooting . . . . . . . . . . . . . . . . . . . . 61

Motor Control Module . . . . . . . . . . . . . . . . . . . . 62

Fluid Control Module . . . . . . . . . . . . . . . . . . . . . 64

Temperature Control Module . . . . . . . . . . . . . . . 65

Appendix A - ADM Icons Overview . . . . . . . . . . . 66

Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . . 66

Run Screen Icons . . . . . . . . . . . . . . . . . . . . . . . 67

Appendix B - ADM Setup Screens Overview . . . . 68

Appendix C - ADM Run Screens Overview . . . . . 82

Appendix D - ADM Error Codes . . . . . . . . . . . . . . 88

Appendix E - System Events . . . . . . . . . . . . . . . 100

Appendix F - USB Operation . . . . . . . . . . . . . . . . 102

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

USB Options . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Download Log Files . . . . . . . . . . . . . . . . . . . . . 102

Log Files, Folder Structure . . . . . . . . . . . . . . . 103

Transfer System Settings . . . . . . . . . . . . . . . . 105

Update Custom Language . . . . . . . . . . . . . . . . 106

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Motor Control Module Technical Data . . . . . . . . 109

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 112

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 112

System . . . . . . . . . . . . . . . . . 57

2 313997ZAA

Page 3

Related Manuals

Manuals are available at www.graco.com. Component manuals 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 Dispense Head Hydraulic Power

Pack Instructions-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

Accessory Manuals

3A1149 HFR Discrete Gateway Module

Kits Manual

312864 HFR Communications Gateway

Module Instructions-Parts

3A1657 HFR Flow Meter Kits

Instructions-Parts

3A1244

3A2890 Mobile Pallet with Casters Kit Man

Graco Control Architecture ule Programming Manual

ual

™

Mod

Dispense Valve Manuals

313872 313536 GX-16, Operation

312185 MD2 Valve, Instructions-Parts 312752 S-Head Operation-Parts 312753 L-Head Operation-Parts 309550

309856 Fusion MP Gun 312666 Fusion CS Gun

™

Gun

Fusion

AP Gun

313997ZAA 3

Page 4

Models

See Product Configurator on page 5 for detailed product configuration information.

System

Full Load Peak Amps Per Phase*

Voltage (phase) Power Description System Watts †

Maximum Fluid Working Pressure ‡ psi (MPa, bar)

200-240VAC, 1 phase, 50/60Hz,

55 A 230V (1)

12, 650

2 wire and PE

HFR, Non-Heated

29 A 230V (3)

200-240VAC, 3 phase

wire and PE

Δ, 50/60Hz, 3

11,340

3000

(20.7, 207)

380-415VAC, 3 phase Y, 50/60Hz,

55 A  400V (3)

12,650

2 wire and PE

116 A 230V (1)

200-240VAC, 3 phase

Δ, 50/60Hz, 3

26,680

wire and PE

HFR, Heated

73 A 230V (3)

200-240VAC, 3 phase

wire and PE

Δ, 50/60Hz, 3

28,600

3000

(20.7, 207)

380-415VAC, 3 phase Y, 50/60Hz,

63 A  400V (3)

28,600

2 wire and PE

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

mix chamber sizes may be less.

† 210 ft (64 m) maximum heated hose length, including whip hose.

 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 an d insta lled by Gr aco , th e wor kin g pr es su re for th e ma ch in e is already setup for the lower 2000 psi (13.8 MPa, 138 bar) working pressure by Graco. If the machine was pur chased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed, see instruction man ual 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 Cont rol 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 Amer ica, a special transformer rated for 400 V (“Y” con figuration (4 wire)) may be required.

• North America mostly employs a 3 wire or Delta configuration. The two configurations are not inter changeable.

4 313997ZAA

Page 5

Product Configurator

HFR-A------

Product Configurator

Ref.: 12345 6

Configurator Revision

Base

Voltage

B (Blue) Pump

A (Red) Pump

Primary/Hose Heat

Hose Bundle Assembly

An example of the product configurator would be the following configurator code.

HFR - A - 1 - 6 - AM - AM - D - AG

Ref.: 123456

Configurator Revision

Base

Voltage

B (Blue) Pump

A (Red) Pump

Primary/Hose Heat

High Volume/Low Volume

The following part number fields apply for the HFR part numbering configurator fields.

Ref. 1 Part Base Unit

1 HFR Base Unit, Carbon Steel 2 HFR Base Unit, Stainless Steel

Ref. 2 Part Voltage

1 230V, 1 phase;

No Heat

2 230V, 1 phase;

Maximum of Two 6 kW Primary Heater and One Zone of Hose Heat

3 230V, 3 phase;

No Heat

4 230V, 3 phase;

Maximum of Two 6 kW Primary Heaters and Two Zones of Hose Heat

5 400V, 3 phase;

No heat

6 400V, 3 phase;

Maximum of Two 6 kW Primary Heaters and Two Zones of Hose Heat

Ref. 3 Part B (Blue) Pump †

AA L010S1 10 cc Stainless Steel

AB L015S1 15 cc Stainless Steel AC L020S1 20 cc Stainless Steel AD L025S1 25 cc Stainless Steel

AE L030S1 30 cc Stainless Steel

AF L040S1 40 cc Stainless Steel AG L050S1 50 cc Stainless Steel AH L060S1 60 cc Stainless Steel

AJ L080S1 80 cc Stainless Steel AK L100S1 100 cc Stainless Steel AL L120S1 120 cc Stainless Steel

AM L160S1 160 cc Stainless Steel AQ L005S1 5 cc Stainless Steel

AS L086S1 86 cc Stainless Steel

AR L065S1 65 cc Stainless Steel

L035S1 35 cc Stainless Steel

L045S1 45 cc Stainless Steel

L105S1 105 cc Stainless Steel

Ref. 4 Part A (Red) Pump †

Code, Part, and Description for Ref. 4 are the same as Ref. 3

313997ZAA 5

Page 6

Product Configurator

Ref. 5 Part Primary/Hose Heat

A No Heat B A (Red) and B (Blue) Primary Heaters C A (Red) and B (Blue) Primary Heaters, One Zone

of Hose Heat

D A (Red) and B (Blue) Primary Heaters, A (Red)

E A (Red) and B (Blue) Hose Heat, Carbon Steel F A (Red) and B (Blue) Hose Heat, Stainless Steel G B (Blue) Primary Heaters, B (Blue) Hose Heat

Ref. 6 Part

NN AA

24D108 Dual Hose, 2:1, 1/4 x 3/8, 5 ft, Stainless Steel,

24D109 Dual Hose, 2:1, 1/4 x 3/8, 10 ft, Stainless Steel,

24D110 Dual Hose, 2:1, 1/4 x 3/8, 25 ft, Stainless Steel,

24D111 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Stainless Steel,

24D112 Dual Hose, 1:1, 3/8 x 3/8, 5 ft, Stainless Steel,

24D113 Dual Hose, 1:1, 3/8 x 3/8, 10 ft, Stainless Steel,

24D114 Dual Hose, 1:1, 3/8 x 3/8, 25 ft, Stainless Steel,

24D115 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Stainless Steel,

24D116 Dual Hose, 2:1, 1/4 x 3/8, 5 ft, Stainless Steel,

24D117 Dual Hose, 2:1, 1/4 x 3/8, 10 ft, Carbon Steel,

24D118 Dual Hose, 2:1, 1/4 x 3/8, 25 ft, Carbon Steel,

24D119 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

24D120 Dual Hose, 1:1, 3/8 x 3/8, 5 ft, Carbon Steel,

24D121 Dual Hose, 1:1, 3/8 x 3/8, 10 ft, Carbon Steel,

24D122 Dual Hose, 1:1, 3/8 x 3/8, 25 ft, Carbon Steel,

24D123 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

24E968 Single Hose, 1:1, 1/4 x 1/4, 10 ft, Carbon Steel,

24E963 Single Hose, 1:1, 1/4 x 1/4, 25 ft, Carbon Steel,

24E964 Single Hose, 1:1, 1/4 x 1/4, 50 ft, Carbon Steel,

24D124 Single Hose, 2:1, 1/4 x 3/8, 25 ft, Carbon Steel,

24D125 Single Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

and B (Blue) Hose Heat

B (Blue) Applicator Hose or High Volume/

Low Volume Hose Bundle Assembly

-- No Hose

3500 psi

2000 psi

24E969 Single Hose, 1:1, 3/8 x 3/8, 10 ft, Carbon Steel,

2000 psi

24D126 Single Hose, 1:1, 3/8 x 3/8, 25 ft, Carbon Steel,

2000 psi

24D127 Single Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

2000 psi

24E965 Single Hose, 1:1, 1/2 x 1/2, 50 ft, Carbon Steel,

2000 psi

24E966 Single Hose, 1:1, 1/4 x 1/4, 50 ft, Carbon Steel,

3500 psi

24D129 Single Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

3500 psi

24D131 Single Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

3500 psi

24E967 Single Hose, 1:1, 1/2 x 1/2, 50 ft, Carbon Steel,

3500 psi

† Pump size listed is the combined volume dispensed

in one extending stroke and one retracting stroke.

6 313997ZAA

Page 7

Product Configurator

Whip Hose Bundles

Part Description

24H076 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone

24H077 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Single Zone

24H078 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone

24H079 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Dual Zone

24H080 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Single Zone

24H081 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone

24H082 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Dual Zone

24H083 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone

Individual B (Blue) Heated Whip Hose

Part Description

24E950 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24E952 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24H086 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H088 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H090 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H092 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H094 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H096 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H225 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24H227 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Carbon

Steel, Single Zone, 3500 psi

24H229 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H231 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Carbon

Steel, Dual Zone, 3500 psi

24H233 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H235 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H237 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H239 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

Individual A (Red) Heated Whip Hose

Part Description

24E949 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24E951 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24H085 10 ft (3 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H087 10 ft (3 m) long, 3/8 in. (10 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H089 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H091 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H093 10 ft (3 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H095 10 ft (3 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H224 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Single Zone, 3500 psi

24H226 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Carbon

Steel, Single Zone, 3500 psi

24H228 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Carbon Steel,

Dual Zone, 3500 psi

24H230 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Carbon

Steel, Dual Zone, 3500 psi

24H232 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H234 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Single Zone, 3500 psi

24H236 5 ft (1.5 m) long, 1/4 in. (6 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

24H238 5 ft (1.5 m) long, 3/8 in. (10 mm) ID, Stainless

Steel, Dual Zone, 3500 psi

313997ZAA 7

Page 8

Product Configurator

Hoses B (Blue) Individual

Part Description

24D111 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Stainless Steel,

3500 psi

24D115 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Stainless Steel,

3500 psi

24D119 Dual Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

3500 psi

24D123 Dual Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

3500 psi

24E964 Single Hose, 1:1, 1/4 x 1/4, 50 ft, Carbon Steel,

2000 psi

24D125 Single Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

2000 psi

24D127 Single Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

2000 psi

24E965 Single Hose, 1:1, 1/2 x 1/2, 50 ft, Carbon Steel,

2000 psi

24E966 Single Hose, 1:1, 1/4 x 1/4, 50 ft, Carbon Steel,

3500 psi

24D129 Single Hose, 2:1, 1/4 x 3/8, 50 ft, Carbon Steel,

3500 psi

24D131 Single Hose, 1:1, 3/8 x 3/8, 50 ft, Carbon Steel,

3500 psi

24E967 Single Hose, 1:1, 1/2 x 1/2, 50 ft, Carbon Steel,

3500 psi

Part Description

24E902 Heated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi 24E904 Heated Hose, 10 ft, 1/4, Carbon Steel, 3500 psi 24E906 Heated Hose, 25 ft, 1/4, Carbon Steel, 3500 psi 24E908 Heated Hose, 50 ft, 1/4, Carbon Steel, 3500 psi 24E910 Heated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi 24E912 Heated Hose, 10 ft, 3/8, Carbon Steel, 3500 psi 24E914 Heated Hose, 25 ft, 3/8, Carbon Steel, 3500 psi 24E916 Heated Hose, 50 ft, 3/8, Carbon Steel, 3500 psi 24E918 Heated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi 24E920 Heated Hose, 10 ft, 1/2, Carbon Steel, 3500 psi 24E922 Heated Hose, 25 ft, 1/2, Carbon Steel, 3500 psi 24E924 Heated Hose, 50 ft, 1/2, Carbon Steel, 3500 psi 24E926 Heated Hose, 5 ft, 1/4, Stainless Steel, 3500 psi 24E928 Heated Hose, 10 ft, 1/4, Stainless Steel, 3500 psi 24E930 Heated Hose, 25 ft, 1/4, Stainless Steel, 3500 psi 24E932 Heated Hose, 50 ft, 1/4, Stainless Steel, 3500 psi 24E934 Heated Hose, 5 ft, 3/8, Stainless Steel, 3500 psi 24E936 Heated Hose, 10 ft, 3/8, Stainless Steel, 3500 psi 24E938 Heated Hose, 25 ft, 3/8, Stainless Steel, 3500 psi 24E940 Heated Hose, 50 ft, 3/8, Stainless Steel, 3500 psi 24E942 Heated Hose, 5 ft, 1/2, Stainless Steel, 3500 psi 24E944 Heated Hose, 10 ft, 1/2, Stainless Steel, 3500 psi 24E946 Heated Hose, 25 ft, 1/2, Stainless Steel, 3500 psi 24E948 Heated Hose, 50 ft, 1/2, Stainless Steel, 3500 psi 262174 Unheated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi 262176 Unheated Hose, 10 ft, 1/4, Carbon Steel,

3500 psi

262178 Unheated Hose, 25 ft, 1/4, Carbon Steel,

3500 psi

262180 Unheated Hose, 50 ft, 1/4, Carbon Steel,

3500 psi 262182 Unheated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi 262184 Unheated Hose, 10 ft, 3/8, Carbon Steel,

3500 psi 262186 Unheated Hose, 25 ft, 3/8, Carbon Steel,

3500 psi 262188 Unheated Hose, 50 ft, 3/8, Carbon Steel,

3500 psi 262190 Unheated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi 262192 Unheated Hose, 10 ft, 1/2, Carbon Steel,

3500 psi 262194 Unheated Hose, 25 ft, 1/2, Carbon Steel,

3500 psi 262196 Unheated Hose, 50 ft, 1/2, Carbon Steel,

3500 psi 262237 Unheated Hose, 5 ft, 1/4, Stainless Steel,

3500 psi

8 313997ZAA

Page 9

Product Configurator

262239 Unheated Hose, 10 ft, 1/4, Stainless Steel,

3500 psi

262241 Unheated Hose, 25 ft, 1/4, Stainless Steel,

3500 psi

262243 Unheated Hose, 50 ft, 1/4, Stainless Steel,

3500 psi

262245 Unheated Hose, 5 ft, 3/8, Stainless Steel,

3500 psi

262247 Unheated Hose, 10 ft, 3/8, Stainless Steel,

3500 psi

262249 Unheated Hose, 25 ft, 3/8, Stainless Steel,

3500 psi

262251 Unheated Hose, 50 ft, 3/8, Stainless Steel,

3500 psi

262253 Unheated Hose, 5 ft, 3/8, Stainless Steel,

3500 psi

262255 Unheated Hose, 10 ft, 3/8, Stainless Steel,

3500 psi

262257 Unheated Hose, 25 ft, 3/8, Stainless Steel,

3500 psi

262259 Unheated Hose, 50 ft, 3/8, Stainless Steel,

3500 psi

A (Red) Individual

Part Description

24E901 Heated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi 24E903 Heated Hose, 10 ft, 1/4, Carbon Steel, 3500 psi 24E905 Heated Hose, 25 ft, 1/4, Carbon Steel, 3500 psi 24E907 Heated Hose, 50 ft, 1/4, Carbon Steel, 3500 psi 24E909 Heated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi 24E911 Heated Hose, 10 ft, 3/8, Carbon Steel, 3500 psi 24E913 Heated Hose, 25 ft, 3/8, Carbon Steel, 3500 psi 24E915 Heated Hose, 50 ft, 3/8, Carbon Steel, 3500 psi 24E917 Heated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi 24E919 Heated Hose, 10 ft, 1/2, Carbon Steel, 3500 psi 24E921 Heated Hose, 25 ft, 1/2, Carbon Steel, 3500 psi 24E923 Heated Hose, 50 ft, 1/2, Carbon Steel, 3500 psi 24E925 Heated Hose, 5 ft, 1/4, Stainless Steel, 3500 psi 24E927 Heated Hose, 10 ft, 1/4, Stainless Steel, 3500 psi 24E929 Heated Hose, 25 ft, 1/4, Stainless Steel, 3500 psi 24E931 Heated Hose, 50 ft, 1/4, Stainless Steel, 3500 psi 24E933 Heated Hose, 5 ft, 3/8, Stainless Steel, 3500 psi 24E935 Heated Hose, 10 ft, 3/8, Stainless Steel, 3500 psi 24E937 Heated Hose, 25 ft, 3/8, Stainless Steel, 3500 psi 24E939 Heated Hose, 50 ft, 3/8, Stainless Steel, 3500 psi 24E941 Heated Hose, 5 ft, 1/2, Stainless Steel, 3500 psi 24E943 Heated Hose, 10 ft, 1/2, Stainless Steel, 3500 psi 24E945 Heated Hose, 25 ft, 1/2, Stainless Steel, 3500 psi 24E947 Heated Hose, 50 ft, 1/2, Stainless Steel, 3500 psi

262173 Unheated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi 262175 Unheated Hose, 10 ft, 1/4, Carbon Steel,

3500 psi

262177 Unheated Hose, 25 ft, 1/4, Carbon Steel,

3500 psi

262179 Unheated Hose, 50 ft, 1/4, Carbon Steel,

3500 psi 262181 Unheated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi 262183 Unheated Hose, 10 ft, 3/8, Carbon Steel,

3500 psi 262185 Unheated Hose, 25 ft, 3/8, Carbon Steel,

3500 psi 262187 Unheated Hose, 50 ft, 3/8, Carbon Steel,

3500 psi 262189 Unheated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi 262191 Unheated Hose, 10 ft, 1/2, Carbon Steel,

3500 psi 262193 Unheated Hose, 25 ft, 1/2, Carbon Steel,

3500 psi 262195 Unheated Hose, 50 ft, 1/2, Carbon Steel,

3500 psi 262236 Unheated Hose, 5 ft, 1/4, Stainless Steel,

3500 psi 262238 Unheated Hose, 10 ft, 1/4, Stainless Steel,

3500 psi 262240 Unheated Hose, 25 ft, 1/4, Stainless Steel,

3500 psi 262242 Unheated Hose, 50 ft, 1/4, Stainless Steel,

3500 psi 262244 Unheated Hose, 5 ft, 3/8, Stainless Steel,

3500 psi 262246 Unheated Hose, 10 ft, 3/8, Stainless Steel,

3500 psi 262248 Unheated Hose, 25 ft, 3/8, Stainless Steel,

3500 psi 262250 Unheated Hose, 50 ft, 3/8, Stainless Steel,

3500 psi 262252 Unheated Hose, 5 ft, 1/2, Stainless Steel,

3500 psi 262254 Unheated Hose, 10 ft, 1/2, Stainless Steel,

3500 psi 262256 Unheated Hose, 25 ft, 1/2, Stainless Steel,

3500 psi 262258 Unheated Hose, 50 ft, 1/2, Stainless Steel,

3500 psi

Hose Bundling Accessories

Part Description

24E953 Air Hose, 5 ft 15B280 Air Hose, 10 ft 15C624 Air Hose, 25 ft 15B295 Air Hose, 50 ft

313997ZAA 9

Page 10

Product Configurator

24E900 Signal Cable, 5 pin, Male/Female, 2.0 meter 24E899 Signal Cable, 5 pin, Male/Female, 4.0 meter 24E898 Signal Cable, 5 pin, Male/Female, 8.5 meter 24E897 Signal Cable, 5 pin, Male/Female, 16.0 meter 24E896 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 2.0 meter

24E895 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 3.0 meter

24E894 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 8.0 meter

24E893 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 15.7 meter 24E954 Scuff Guard, 1.75 in. (44 mm), 200 ft (61 m) Roll 24E961 Scuff Guard, 1.75 in. (44 mm), 200 ft (61 m) Roll

261821 Wire Connector, 6AWG (4.11 mm) 24E955 Hose Lacing, 1500 ft (457.2 m) Roll 15B679 Hose Safety Label

Applicator

NOTE: When selecting an applicator, if an applicator is

chosen which does not have a signal communicating to the HFR, then the sizes of the A and B pumps added together must be greater or equal to 120 cc. For exam ple: A (red) pump size = 20 cc, B (blue) pump size = 100 cc, 20 cc + 100 cc = 120 cc. Since the pump sizes combined = 120 cc, an applicator may be selected which does not have a signal communicating to the HFR.

Part Description

24A084 L-Head 6/10 With Calibration Orifice 24A085 L-Head 10/14 With Calibration Orifice 24A086 L-Head 13/20 With Calibration Orifice 24A090 S-Head 6-625 With Calibration Orifice 24A092 S-Head 6-500 L/S With Calibration Orifice 24A093 S-Head 6-625 L/S With Calibration Orifice 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 CS00RD Fusion CS, 1:1 Only, 0.029 CS01RD Fusion CS, 1:1 Only, 0.042 CS02RD Fusion CS, 1:1 Only, 0.052

246100 Fusion AP, 1:1 Only, 0.029

247007 Fusion MP, 1:1 Only, 0.029

246101 Fusion AP, 1:1 Only, 0.042

247019 Fusion MP, 1:1 Only, 0.047

246102 Fusion AP, 1:1 Only, 0.052

247025 Fusion MP, 1:1 Only, 0.057

24D500 Applicator, MD2, 1:1, Soft, Carbon Steel

24D501 Applicator, MD2, 1:1, Soft, Carbon Steel, Electric

24D502 Applicator, MD2, 1:1, Soft, Carbon Steel, Lever

24D503 Applicator, MD2, 1:1, Soft, Stainless Steel

24D504 Applicator, MD2, 1:1, Soft, Stainless Steel, Elec

tric 24D505 Applicator, MD2, 1:1, Soft, Stainless Steel, Lever 24D509 Applicator, MD2, 1:1, Hard, Carbon Steel 24D510 Applicator, MD2, 1:1, Hard, Carbon Steel, Elec

tric 24D511 Applicator, MD2, 1:1, Hard, Carbon Steel, Lever 24D512 Applicator, MD2, 1:1, Hard, Carbon Steel, Pneu

matic 24D513 Applicator, MD2, 1:1, Hard, Stainless Steel 24D514 Applicator, MD2, 1:1, Hard, Stainless Steel, Elec

tric

10 313997ZAA

Page 11

Product Configurator

24D515 Applicator, MD2, 1:1, Hard, Stainless Steel,

Lever

24D516 Applicator, MD2, 1:1, Hard, Stainless Steel,

Pneumatic 24D521 Applicator, MD2, 10:1, Soft, Carbon Steel 24D522 Applicator, MD2, 10:1, Soft, Carbon Steel, Elec

tric 24D523 Applicator, MD2, 10:1, Soft, Carbon Steel, Lever 24D524 Applicator, MD2, 10:1, Soft, Stainless Steel 24D525 Applicator, MD2, 10:1, Soft, Stainless Steel, Elec

tric 24D526 Applicator, MD2, 10:1, Soft, Stainless Steel,

Lever 24D530 Applicator, MD2, 10:1, Hard, Carbon Steel 24D531 Applicator, MD2, 10:1, Hard, Carbon Steel, Elec

tric 24D532 Applicator, MD2, 10:1, Hard, Carbon Steel, Lever 24D533 Applicator, MD2, 10:1, Hard, Carbon Steel, Pneu

matic 24D534 Applicator, MD2, 10:1, Hard, Stainless Steel 24D535 Applicator, MD2, 10:1, Hard, Stainless Steel,

Electric 24D536 Applicator, MD2, 10:1, Hard, Stainless Steel,

Lever 24D537 Applicator, MD2, 10:1, Hard, Stainless Steel,

Pneumatic 24E505 MD2 Orifice Adapter Kit 257999 EP Pour Gun, Pistol Grip, 1/4 in. Purge Rod 24C932 EP Pour Gun, Machine mount, 1/4 in. Purge Rod 24C933 EP Pour Gun, Pistol Grip, 3/8 in. Purge Rod 24C934 EP Pour Gun, Machine Mount, 3/8 in. Purge Rod LC0058 Mixer Kit, (10) 3/8 in. x 24 Element with Shroud LC0059 Mixer Kit, (10) 3/8 in. x 36 Element with Shroud LC0060 Mixer Kit, (10) 3/8 in. Combo with Shroud LC0295 Mixer Kit, (10) 1/2 in. x 24 Element with Shroud LC0296 Mixer Kit, (10) 1/2 in. x 36 Element with Shroud LC0079 Mixer Pack, (50) 3/8 in. x 24 Element LC0080 Mixer Pack, (50) 3/8 in. x 24 Element LC0081 Mixer Pack, (50) 3/8 in. Combo Element LC0086 Mixer Pack, (250) 3/8 in. x 24 Element LC0087 Mixer Pack, (250) 3/8 in. x 36 Element LC0088 Mixer Pack, (250) 3/8 in. Combo Element

B (Blue) Applicator Orifice

S-Head and L-Head

Description Part For Use With Applicator:

Calibrate 24A036 S-Head Only

0.25 24A037 S-Head Only

0.35 24A038 S-Head Only

0.50 24A039 S-Head Only

0.60 24A040 S-Head Only

0.70 24A041 S-Head Only

0.80 24A042 S-Head Only

0.90 24A043 S-Head Only

1.00 24A044 S-Head Only

1.10 24A045 S-Head Only

1.20 24A046 S-Head Only

1.30 24A047 S-Head Only

1.40 24A050 S-Head Only

1.50 24A051 S-Head Only

1.60 24A052 S-Head Only

1.70 24A053 S-Head Only

1.80 24A054 S-Head Only

1.90 24A055 S-Head Only

2.00 24A056 S-Head Only

2.50 24A057 S-Head Only

3.00 24A058 S-Head Only

3.50 24A059 S-Head Only

4.00 24A060 S-Head Only

4.20 24A061 S-Head Only

4.50 24A062 S-Head Only

5.00 24A063 S-Head Only

5.50 24A064 S-Head Only

6.00 24A065 S-Head Only

6.50 24A066 S-Head Only

7.00 24A067 S-Head Only

Calibrate M0934A-4 L-Head Only

0.25 247761 L-Head Only

0.45 247762 L-Head Only

0.5 247763 L-Head Only

0.75 247764 L-Head Only

0.8 247765 L-Head Only

0.85 247766 L-Head Only 1 247767 L-Head Only

1.1 247811 L-Head Only

1.2 247848 L-Head Only

1.25 248858 L-Head Only

1.3 247859 L-Head Only

1.4 247860 L-Head Only

1.5 247861 L-Head Only

1.6 247862 L-Head Only

1.65 247863 L-Head Only

1.7 247864 L-Head Only

1.75 247865 L-Head Only

1.8 247866 L-Head Only

1.9 247867 L-Head Only

313997ZAA 11

Page 12

Product Configurator

2 247868 L-Head Only

2.4 247869 L-Head Only

3.2 247870 L-Head Only

3.6 247871 L-Head Only

4.2 247872 L-Head Only 5 247873 L-Head Only

5.6 247874 L-Head Only

GX-16

Description Part

257701 0.011 in. Orifice 257702 0.013 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 257724 0.061 in. Orifice 24K682 0.085 in. Orifice

™

Gun

Description Part For Use With Applicator:

Orifice Kit 24E250 EP 250, 6 Blue, 6 Red

0.51 mm Poly Orifice

0.79 mm Poly Orifice

1.19 mm Poly Orifice

1.52 mm Poly Orifice

1.70mm Poly Orifice

2.18 mm Poly Orifice

0.41 mm Poly Orifice

0.61 mm Poly Orifice

24C751 EP 250 Poly Side Orifice, Std

24C752 EP 250 Poly Side Orifice, Std

24C753 EP 250 Poly Side Orifice, Std

24C754 EP 250 Poly Side Orifice, Std

24C755 EP 250 Poly Side Orifice, Std

24C756 EP 250 Poly Side Orifice, Std

24C805 EP 250 Poly Side Orifice

24C806 EP 250 Poly Side Orifice

0.71 mm Poly Orifice

0.89 mm Poly Orifice

0.99 mm Poly Orifice

1.07 mm Poly Orifice

1.32 mm Poly Orifice

1.40 mm Poly Orifice

1.60 mm Poly Orifice

1.85 mm Poly Orifice

Orifice Kit 24E251 EP 375, 6 Blue, 6 Red

0.51 mm Poly Orifice

0.79 mm Poly Orifice

1.19 mm Poly Orifice

1.52 mm Poly Orifice

1.70 mm Poly Orifice

2.18 mm Poly Orifice

0.41 mm Poly Orifice

0.61 mm Poly Orifice

0.71 mm Poly Orifice

0.89 mm Poly Orifice

0.99 mm Poly Orifice

1.07 mm Poly Orifice

1.32 mm Poly Orifice

1.40 mm Poly Orifice

1.60 mm Poly Orifice

1.85 mm Poly Orifice

24C807 EP 250 Poly Side Orifice

24C808 EP 250 Poly Side Orifice

24C809 EP 250 Poly Side Orifice

24C810 EP 250 Poly Side Orifice

24C811 EP 250 Poly Side Orifice

24C812 EP 250 Poly Side Orifice

24C813 EP 250 Poly Side Orifice

24C815 EP 250 Poly Side Orifice

24C761 EP 375 Poly Side Orifice, Std

24C762 EP 375 Poly Side Orifice, Std

24C763 EP 375 Poly Side Orifice, Std

24C764 EP 375 Poly Side Orifice, Std

24C765 EP 375 Poly Side Orifice, Std

24C766 EP 375 Poly Side Orifice, Std

24C794 EP 375 Poly Side Orifice

24C795 EP 375 Poly Side Orifice

24C796 EP 375 Poly Side Orifice

24C797 EP 375 Poly Side Orifice

24C798 EP 375 Poly Side Orifice

24C799 EP 375 Poly Side Orifice

24C800 EP 375 Poly Side Orifice

24C801 EP 375 Poly Side Orifice

24C802 EP 375 Poly Side Orifice

24C804 EP 375 Poly Side Orifice

12 313997ZAA

Page 13

Product Configurator

Iso A (Red) Applicator Orifice

S-Head and L-Head

The A (Red) applicator orifices for the S-Head and L-Head are the same as the B (Blue) applicator orifices. See page 11.

GX-16

Description Part

EP Gun

Description Part For Use With Applicator:

0.51 mm Iso Orifice

0.79 mm Iso Orifice

1.19 mm Iso Orifice

1.52 mm Iso Orifice

1.70mm Iso Orifice

2.18 mm Iso Orifice

0.41 mm Iso Orifice

0.61 mm Iso Orifice

24D223 EP 250 Iso Side Orifice, Std

24D224 EP 250 Iso Side Orifice, Std

24D225 EP 250 Iso Side Orifice, Std

24D226 EP 250 Iso Side Orifice, Std

24D227 EP 250 Iso Side Orifice, Std

24D228 EP 250 Iso Side Orifice, Std

24D229 EP 250 Iso Side Orifice

24D230 EP 250 Iso Side Orifice

0.71 mm Iso Orifice

0.89 mm Iso Orifice

0.99 mm Iso Orifice

1.07 mm Iso Orifice

1.32 mm Iso Orifice

1.40 mm Iso Orifice

1.60 mm Iso Orifice

1.85 mm Iso Orifice

0.51 mm Iso Orifice

0.79 mm Iso Orifice

1.19 mm Iso Orifice

1.52 mm Iso Orifice

1.70 mm Iso Orifice

2.18 mm Iso Orifice

0.41 mm Iso Orifice

0.61 mm Iso Orifice

0.71 mm Iso Orifice

0.89 mm Iso Orifice

0.99 mm Iso Orifice

1.07 mm Iso Orifice

1.32 mm Iso Orifice

1.40 mm Iso Orifice

1.60 mm Iso Orifice

1.85 mm Iso Orifice

24D231 EP 250 Iso Side Orifice

24D232 EP 250 Iso Side Orifice

24D233 EP 250 Iso Side Orifice

24D234 EP 250 Iso Side Orifice

24D235 EP 250 Iso Side Orifice

24D236 EP 250 Iso Side Orifice

24D237 EP 250 Iso Side Orifice

24D238 EP 250 Iso Side Orifice

24D239 EP 375 Iso Side Orifice, Std

24D240 EP 375 Iso Side Orifice, Std

24D241 EP 375 Iso Side Orifice, Std

24D242 EP 375 Iso Side Orifice, Std

24D243 EP 375 Iso Side Orifice, Std

24D244 EP 375 Iso Side Orifice, Std

24D245 EP 375 Iso Side Orifice

24D246 EP 375 Iso Side Orifice

24D247 EP 375 Iso Side Orifice

24D248 EP 375 Iso Side Orifice

24D249 EP 375 Iso Side Orifice

24D250 EP 375 Iso Side Orifice

24D251 EP 375 Iso Side Orifice

24D252 EP 375 Iso Side Orifice

24D253 EP 375 Iso Side Orifice

24D254 EP 375 Iso Side Orifice

313997ZAA 13

Page 14

Product Configurator

AC Power Pack with S-Head/L-Head Hoses, Optional Boom

Part Description

24D829 230V, Boom, L-Head Hoses 24D830 230V, Boom, S-Head Hoses 24D834 400V, Boom, L-Head Hoses 24D835 400V, Boom, S-Head Hoses 24D831 230V, L-Head Hoses, No Boom 24D832 230V, S-Head Hoses, No Boom 24D836 400V, L-Head Hoses, No Boom 24D837 400V, S-Head Hoses, No Boom 24F297 230V, L-Head Application, No Boom, No Hoses

24J912 230V, S-Head Application, No Boom, No Hoses

24F298 400V, L-Head Application, No Boom, No Hoses

24J913 230V, S-Head Application, No Boom, No Hoses

257798 Power Pack GX-16 Connection Kit 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

Flow Meters

Flow Meter Electronics (Necessary)

Part Description

24J318 Flow Meter Electronics Kit

“A” and “B” Side Flow Meter (One for each side)

Part Description

24J319 S3000 Flow Meter Kit

(0.01 to 0.53 gpm, 50 to 2000 cc per min) (1 to 1000 cps)

24J320 G3000 Flow Meter Kit

(0.02 to 1.0 gpm, 75 to 3800 cc per min) (20 to 3000 cps)

24J321 G3000HR Flow Meter Kit

(0.01 to 0.5 gpm, 38 to 1900 cc per min) (20 to 3000 cps)

24J322 HG6000 Flow Meter Kit

(0.013 to 6.0 gpm, 50 to 22,700 cc per min) (30 to 1,000,000 cps)

24J323 HG6000HR Flow Meter Kit

(0.007 to 2.0 gpm, 25 to 7571 cc per min) (30 to 1,000,000,cps)

Dispense Valve Interface Kit

Part Description

24C757 MD2 Valve Solenoid, Machine Mount 24D160 MD2 Valve Solenoid, Remote Mount 24D161 Auto-Fusion Solenoid for Fusion Dispense Valve 24C067 Fusion Gun Pressure Adjust Kit

Flow Meter Calibration Kit (per applicator)

Part Description

24J324 L-Head Flow Meter Calibration Kit 24J325 S-Head Flow Meter Calibration Kit 24J326 P2 Flow Meter Calibration Kit 24J357 GX-16 Flow Meter Calibration Kit 24F227 EP/Fusion Flow Meter Calibration Kit 255247 MD2 1:1 Flow Meter Calibration Kit 255245 MD2 10:1 Flow Meter Calibration Kit

14 313997ZAA

Page 15

Product Configurator

Pump Feed Kits

Part Description

246081 2:1 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

246369 H515 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

246375 H716 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

24D328 H1050 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

257769

24D091 2:1 (Air/Fluid) Stainless Steel Complete Supply

24D092 H515 (Air/Fluid) Stainless Steel Complete Supply

24D093 H716 (Air/Fluid) Stainless Steel Complete Supply

24D094 H1050 (Air/Fluid) Stainless Steel Complete Sup

24D095 5:1 Monarch 55G Stainless Steel Complete Sup

24D096 5:1 Monarch 5G Stainless Steel Complete Supply

257777 High-Flo Stainless Steel Complete Supply Pump

246366 246367 Husky 716 Pump, Drum with Riser Tube

24D329 Husky 1050 Pump, Drum with Riser Tube 233052 Husky 515 Diaphragm Pump, Drum with Riser

233057 Husky 716 Diaphragm Pump, Drum with Riser

24D097 Husky 1050 SS Pump, Drum with Riser Tube 295616 2:1 (Air/Fluid) Stainless Steel Supply Pumps with

24D098 5:1 Monarch, 5G, Stainless Steel Supply Pumps

24D099 5:1 Monarch, 55G, Stainless Steel Supply Pumps

246481 Husky 515 Pump with Carbon Steel Fluid Plumb

246482 Husky 716 Pump with Carbon Steel Fluid Plumb

24D332 Husky 1050 Pump with Carbon Steel Fluid

246898 2:1 Supply Pump with Carbon Steel Fluid Plumb

24D100 Husky 515 Pump with Stainless Steel Fluid

24D101 Husky 716 Pump with Stainless Steel Fluid

High-Flo Supply Pump Kit

Pump Kit

ply Pump Kit

Pump Kit

Kit Husky

Tube

Riser Tubes

with Riser Tubes

ing

Plumbing

ing

Plumbing

(Air/Fluid) Carbon Steel Complete

™

515 Pump, Drum with Riser Tube

24D102 Husky 1050 Pump with Stainless Steel Fluid

Plumbing

24D103 2:1 Supply Pump with Stainless Steel Fluid

Plumbing

24D104 5:1 Monarch Pump with Stainless Steel Fluid

Plumbing

24D105 5:1 Monarch Pump with Stainless Steel Fluid

Plumbing 24E396 One 2:1 T-2 Pump, Carbon Steel 24E397 One 2:1 T-2 Pump, Stainless Steel 24E398 One Monarch 5:1 Pump, 5G 24E399 One Monarch 5:1 Pump, 55G 246419 Carbon Steel Riser Tube Assembly 246477 Carbon Steel Return Tube 246483 Air Supply for Feed Pump and Gun 247616 Desiccant Dryer 15C381 Desiccant Dryer Cartridge 233048 Drum Pump Accessory Kit 24D106 Stainless Steel Return Tube Accessory Kit 24D107 Stainless Steel Circulation Accessory 24E379 Carbon Steel Circulation Accessory Kit 244053 26 sq. in., 60 mesh, Stainless Steel Fluid Filter 116178 26 sq. in., 30 mesh, Stainless Steel Fluid Filter

Element 116179 26 sq. in., 60 mesh, Stainless Steel Fluid Filter

Element 116180 26 sq. in., 100 mesh, Stainless Steel Fluid Filter

Element 116181 26 sq. in., 200 mesh, Stainless Steel Fluid Filter

Element 213058 36 sq. in., 60 mesh, Carbon Steel Fluid Filter 108106 36 sq. in., 30 mesh, Carbon Steel Fluid Filter Ele

ment 108107 36 sq. in., 60 mesh, Carbon Steel Fluid Filter Ele

ment 108108 36 sq. in., 100 mesh, Carbon Steel Fluid Filter

Element 108109 36 sq. in., 150 mesh, Carbon Steel Fluid Filter

Element 108110 36 sq. in., 200 mesh, Carbon Steel Fluid Filter

Element

313997ZAA 15

Page 16

Product Configurator

B (Blue) and A (Red) Feed Tanks

Part Description

24D562 38L Tank, No Agitation, Chiller, Desiccant, 2

Level Sensors

24D564 38L Tank, Agitation, Chiller, Desiccant, 2 Level

Sensors

24D565 75L Tank, No Agitation, Chiller, Desiccant, 2

Level Sensors

24C317 75L Tank, Agitation, Chiller, Desiccant, 2 Level

Sensors 24D568 38L Tank, No Agitation, No Level Sensors 24D569 38L Tank, No Agitation, 2 Level Sensors 24D570 38L Tank, Agitation, 2 Level Sensors 24D571 38L Tank, Agitation, Slinger Plate, 2 Level Sen

sors 24D572 38L Tank, Agitation, Slinger Plate, Heat, Insula

tion, 2 Level Sensors 24D573 38L Tank, Agitation, Heat, Insulation, 2 Level

Sensors 24D574 75L Tank, No Agitation, No Level Sensors 24D575 75L Tank, No Agitation, 2 Level Sensors 24D576 75L Tank, Agitation, 2 Level Sensors 24D577 75L Tank, Agitation, Slinger Plate, 2 Level Sen

sors 24D578 75L Tank, Agitation, Slinger Plate, Heat, Insula

tion, 2 Level Sensors 24D579 75L Tank, Agitation, Heat, Insulation, 2 Level

Sensors

257757 Insulator Blanket for 38L Tank 257758 Insulator Blanket for 75L Tank 257770 Refill Kit For Customer Supplied Feed System 257778 Nitrogen Kit For 1 Tank 257779 Nitrogen Kit For 2 Tanks

257916 Vacuum Pump Kit, 6.9 cfm, 1st, 230V, 1 phase 24D271 3rd Level Sensor Prox Switch Option LC0097 Desiccant Dryer, 3/8 in. Npt With Adapter And

Cartridge LC0098 Desiccant Dryer Refill Cartridge 24G952 20gal (75L) Carbon Steel Tank, 2 Level Sensors 24G953 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Pneumatic Agitator 24G955 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Electric Agitator 24G956 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Chiller Control Valve, Heat Exchanger 24G957 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Pneumatic Agitator, Chiller Con

trol Valve, Heat Exchanger 24G959 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Electric Agitator, Chiller Control

Valve, Heat Exchanger

24J209 20gal (75L) Stainless Steel Tank, 3 Level Sen

sors, Insulated

24J707 20gal (75L) Carbon Steel Tank, 3 Level Sensors,

Insulated

24J243 2gal (7.6L) Stainless Steel Tank

16 313997ZAA

Page 17

Additional Accessories

Product Configurator

Miscellaneous

Part Description

24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level

Sensor

24C873 Hydraulic Power Pack Manifold Oil Temperature

Sensor 24P090 Mobile Pallet Base with Casters 24F516 IsoGuard Select fluid, 6 quarts 121728 Extension Cable for Advanced Display Module,

4meter, 255244 Foot Switch with Guard and 4 meter Cable 24F227 EP and Fusion Gun Ratio Check 24F235 25 ft hose extensions for L-Head applicator;

material, hydraulic, and signal cables 24F236 50 ft hose extensions for L-Head applicator;

material, hydraulic, and signal cables 24F237 25 ft hose extensions for S-Head applicator;

material, hydraulic, and signal cable 24F238 50 ft hose extensions for S-Head applicator;

material, hydraulic, and signal cable 24K206 Nip Sensor Kit 24H019 Air Inlet Filter for Hydraulic Power Pack 255468 Light Tower Kit

Discrete Gateway Module (DGM)

The HFR Discrete Gateway Module allows the user to control an HFR through multiple external control devices such as contact blocks or relays. The DGM operates in conjunction with the existing Advanced Display Module (ADM) such that both devices can be used to control the machine. See HFR Communication Gateway Module manual for more information

Part Description

24F843 Single DGM Cube with Board 24F844 Two DGM Cubes with Board 24G830 Single DGM Cube

Communications Gateway Module (CGM)

The HFR Communication Gateway Module allows the user to control an HFR through an external control device such as a PLC. The CGM operates in conjunc tion with the existing Advanced Display Module (ADM) such that both devices can be used to control the machine. See HFR Communication Gateway Module manual for more information

Part Description

24J415 CGM Mounting KIt (Required)

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

313997ZAA 17

Page 18

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama tion point symbol alerts you to a general warning and the ha zard symbol refe rs to procedure-sp ecific 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 elec tric 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 reg ulations.

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, inhala tion 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 manufac turer.

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.

18 313997ZAA

Page 19

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To he lp pre vent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot ligh ts, cigaret te s , po rt ab le ele ct ric lam p s, and pla s tic 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 fla mmable fu mes are present.

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

• Use only ground ed ho se s.

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

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

• Keep a working fire extinguisher in the work area.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured comp onents can splash in the eyes or on skin and cause serious injury.

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

• Tighten all fluid connections before operating the equipment.

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

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

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

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

• Do not leave the work area while equipment is energized or under pressu re . Turn off all e qui pme nt 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 manu facturer’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.

313997ZAA 19

Page 20

Important Two-Component Material Information

WARNING

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

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

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during ope ration. To avoid severe burns:

• Do not touch hot fluid or equipment.

Important Two-Component Material Information

Isocyanate Conditions

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

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

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventila tion 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 per sonal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-ignition

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

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

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

20 313997ZAA

Page 21

A (Red) and B (Blue) Components

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 crystal lization 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 atmo sphere.

• 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 con taminated from the other side.

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

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

Changing Materials

• When changing materials, flush the equipment mul tiple 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 follow ing 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-sensi tive, that material should always be in the A (Red) side.

• The B (Blue) side is intended for polyols, resins, and bases.

NOTE: For machines with material volume ratios other than 1:1, the higher volume side is typically the B (Blue) side.

313997ZAA 21

Page 22

A (Red) and B (Blue) Components

22 313997ZAA

Page 23

Typical Installation

ti7821a3

* Shown exposed for clarity.

Wrap with tape during operation.

B (Blue) Side Supply Detail

A (Red) Side Supply Detail

ti7821a2

ti14720a

Typical Installation

FIG. 1

Key:

A HFR Unit (see FIG. 2, page 25) BHose

C Fluid Temperature Sensor (FTS); 2x, 1 for each hose D Whip Hose E Dispense Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines H Waste Container J Fluid Supply Lines

313997ZAA 23

K Feed Pumps L Agitator M Desiccant Dryer N Bleed Lines P Fluid Manifold

Page 24

Component Identification

Key for FIG. 2.

AA Advanced Display Module (see page 30) BA Component A (Red) Pressure Relief Outlet BB Component B (Blue) Pressure Relief Outlet CO Base and Casters (Optional) 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 In let Pressure Gauge FS Feed Inlet Strai ner (standard filter size is 20 mesh) FT Feed Inlet Temperature Gauge (heated models only) FV Feed Inlet Valve (A (Red) side shown) 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 LR IsoGuard Se lect Fluid Reservoir LS Pumpline Linear Sensor MA Motor Control Module, see page 28 MP Main Power Switch PA Component A (Red) Pump PB Component B (Blue) Pump PD Power Distribution Box PH Primary Heater 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 34)

24 313997ZAA

Page 25

Component Identification

ti9880a1

Fluid Manifold (FM) Detail

Rear View

Primary Heater (PH) Detail,

B (Blue) side shown

24C352_313998_3g

24C327_313998_1e

24C352_313998_4e

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

313997ZAA 25

Page 26

Component Identification

CB1

CB5

CB4

CB2CB3

CB9

CB7

CB6

CB8

24C681_313998_1e

CB579

CB718

B (Blue)

Left Side from Rear View

A (Red)

Right Side from Rear View

24C332_313998_3f

24C332_313998_6f

Main Power Switch

Located on top of the power distribution box, see

25. The main power switch turns power

page

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 distri bution 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 d is tribution box manual for more information.

Additional circuit breakers for protection of the second ary side of the heated hose transformer are loc ate d inside the frame. See the parts list for the installed pri mary/hose heat option. See Ref. 5 of the product config urator code for your machine to determine which primary/hose heat option is installed. See Product Con

figurator on page 5.

Size

230V/

1 phase,

Ref.

400V/

3 phase

230V/

3 phase

Component

CB1 63A 30A Motor Control Module CB2 40A 40A Primary Heater A CB3 15A 15A Tank Heat A CB4 40A 40A Hose Heat A CB5 5A 5A Miscellaneous CB6 5A 5A Miscellaneous CB7 40A 40A Hose Heat B CB8 15A 15A Tank Heat B CB9 40A 40A Primary Heater B

26 313997ZAA

Page 27

Hydraulic Power Pack

24C352_313998_2g

Component Identification

FIG. 3

Key:

DA 8 Gallon Hydraulic Oil Reservoir (see Tech nical Data on

page 108 for specifications) DB Electric Motor DC Dipstick (not shown, located at rear left of hydraulic tank) DD Hydraulic Housing DE Directional Valve

DF Motor Control Module (see page 28) DG Fan DH Oil Filter DJ Shroud (not shown, removed for clarity) DK Air Inlet Filter

313997ZAA 27

Page 28

Component Identification

r_257396_3b9905_01b

r_257396_3b9905_03b

Motor Control Module (MCM)

NOTICE

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

For MCM location, see reference MA in FIG. 2 on page 25. 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 workin g pre ssu re .

FIG. 4: MCM Component Identification

28 313997ZAA

Page 29

Ref Description

A Access Cover BLEDs C Warning Label

1A, 1B CAN Connections

2 Three-way Splitter to: Oil Low Level

Sensor, Dispense Valve Solenoid, and

Footswitch 3 Oil Temperature Sensor 5 Electric Motor Temperature Sensor 6LVDT 7 Three-way Splitter to:

Hydraulic Directional Valve,

Oil Overtemperature Switch 8 Pressure Transducer B (Blue) side 9 Pressure Transducer A (Red) side

10 Not used 11 Motor Position Sensor 12 MCM Power Input Connection 13 Motor Power Connection

Component Identification

313997ZAA 29

Page 30

Component Identification

TI12362a1

Advanced Display Module (ADM)

User Interface

FIG. 5: ADM Component Identification - Front

Buttons

Ref. Button Function

CA System

enable/ disable

CB System

Status Indicator Light

CC Stop Stops all system processes.

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

Displays system status. See System Status Indicator (CB) Conditions on page 31 for details.

Ref. Button Function

CD Soft

Defined by application using ADM.

Keys

CE Cancel Cancel a selection or number entry

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

CF Enter Acknowledge changing a value or

making a selection.

CG Lock/SetupToggle between run and setup

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

CH Naviga

tion

Navigate within a screen or to a new screen.

30 313997ZAA

Page 31

Component Identification

r_24E451_3B9900_1a

IG. 6: ADM Component Identification - Rear

Key:

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

System Status Indicator (CB) Conditions

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

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

313997ZAA 31

Page 32

Component Identification

Current date and time Current screen

Enter/Exit screen

Previous screen Next screen

Function display

Current screen no.

Next screen no.

Previous screen no.

Mode

Faults, Status

Main Display Components

The following figure calls out the navigational, status, and general infor mational components of each screen. For details regarding the user interface display see Advanced Display Module (ADM) Operation, page 46.

IG. 7: Main Display Components

32 313997ZAA

Page 33

Fluid Control Module (FCM)

ti12337a1

ti12336a1

Component Identification

FIG. 8:

Key:

A Fluid Control Module BBase C Module Connection Screws D Access Cover E Module Status LEDs F CAN Connectors

313997ZAA 33

Page 34

Component Identification

LED Signals

ti12352a1

ti12353a1

ti12356a1

ti12357a1

Temperature Control Module (Heated HFR Only)

FIG. 9: High Power Temperature Control Module Sensor Connections

Key:

1 Overtemperature Switch Connection (primary heaters

only) 2 RTD Temperature Sensor Connection 3 Output Power Connection

FIG. 10: Low Power 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 Rotary Selector Switch, Token Access

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

34 313997ZAA

Page 35

Heat Control Zone Selection

Hose Heater B (Blue) Primary Heater B (Blue)

Hose Heater A (Red)

Primary Heater A (Red)

Right Side from

Rear View

Left Side from

Rear View

24C332_313998_3f

24C332_313998_6f

(Heated models only)

The HFR unit supports 4 independent temperature con trol zones. The high power temperature control modules are located inside the frame below the hydraulic power pack.

Component Identification

313997ZAA 35

Page 36

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 tem perature control module will control in the system. The high power module uses an 8-position rotary switch. The low power module uses a16-position rotary switch.

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

High Power Module Rotary Switch Settings

Setting Zone

0Not Used 1 B (Blue) Primary Heat 2 B (Blue) Hose Heat 3 A (Red) Primary Heat 4 A (Red) Hose Heat 5Not Used 6Not Used 7Not Used

Low Power Module Rotary Switch Settings

Setting Zone

0Not Used 1Not Used 2Not Used 3Not Used 4Not Used 5 B (Blue) Tank Heater 6 A (Red) Tank Heater 7 B (Blue) Chiller 8 A (Red) Chiller

9Not Used ANot Used BNot Used CNot Used DNot Used ENot Used FNot Used

IG. 11

36 313997ZAA

Page 37

Dispense Valves Overview

Three types of dispense valves can be used with the HFR system:

• Stall-at-pressure

• Solenoid controlled

• Hydraulically actuated and recirculating The P2 Gun and Fusion Gun are examples of

stall-at-pressure dispense valves. When not dispensing, the fluid in the chemical lines are fully pressurized. When using a stall-to-pressure dispense valve, a footswitch cannot be used. Any signals sent from a footswitch will be ignored.

The EP Gun and MD2 Valve are examples of solenoid controlled dispense valves. When the trigger is pulled the signal requests the dispense to start. When the machine sees the signal, fluid rises to dispensing pres sure and the valve is opened to begin dispensing. When the trigger is released, the solenoid signals that the dis pense is finished.

Dispense Valves Overview

The L-Head, S-Head, and GX-16 are examples of hydraulically actuated, recirculating dispense valves. When not dispensing, material is recirculated to main tain temperature and pressure. Opening and closing the valve is controlled hydraulically which leads to faster actuation and more accurate dispenses.

313997ZAA 37

Page 38

Setup

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

1. Locate HFR.

a. Locate HFR on a level surface. See Dimen

sions on page 110 for space requirements.

b. Anchor the HFR to the floor (suggested

anchors: McMaster Carr anchor, 92403A400). See Dimensions, page 110, for bolt locations. If machine mobility is required, purchase Mobile Pallet Base with Casters Kit, 24P090.

NOTICE

To avoid tipping the machine and personal injury, do not attach wheels directly to the standard HFR mounting brackets.

c. Do not expose HFR to rain.

NOTICE

Bolt HFR to original shipping pallet before lifting.

2. Electrical requirements. See Models on page 4

for detailed electrical requirements information.

3. Connect electrical cord.

NOTE: See Power Line Voltage Surges informati on on

page 39. NOTE: Power cord is not supplied. See the following

table.

Table 1: Power Cord Requirements

Cord Requirements

Model

Non-Heated HFR, 230V, 1 phase

Non-Heated HFR, 230V, 3 phase

Non-Heated HFR, 400V, 3 phase

Heated HFR, 230V, 1 phase

Heated HFR, 230V, 3 phase

Heated HFR, 400V, 3 phase

AWG (mm

6 (13.3), 2 wire + ground

8 (8.4), 3 wire + ground

6 (13.3), 4 wire + ground †

1 (42.4), 2 wire + ground

4 (21.2), 3 wire + ground

4 (21.2), 4 wire + ground †

)

† Residual Current Device (RCD) must be rated at

300 mA if installed.

Installing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals, see step 3 in this setup procedure. All electrical wiring must be done by a qualified electri cian and comply with all local codes and regulations.

NOTICE

Never connect to 480V, 3 phase power. Severe equipment damage will occur.

38 313997ZAA

Electrical Cord Wires by Model 230V, 1 phase: L1, L2, GND 230V, 3 phase: L1, L2, L3, GND 400V, 3 phase: L1, L2, L3, N, GND

Typical Voltage Readings 230V, 1 phase:

L1-L2: 230V L1 or L2-G: 115V

230V, 3 phase (delta high leg):

L1-L2, L2-L3, L3-L1: 230V L1-G, L3-G: 115V L2-G: 208V

400V, 3 phase (Y / wye):

L1-L2, L2-L3, L3-L1: 400V L1-N, L2-N, L3-N: 230V L1-G, L2-G, L3-G: 230V

Page 39

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)

0.000001 0.00001 0.0001 0.001 0.01 0.1 1 10

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

IG. 12: 400V, 3 phase shown

Power Line Voltage Surges

Power conversion equipment can be sensitive to voltage fluctuations on incoming power. The Motor Control Mod ule falls under the category of power conversion equip ment because energy is stored on a capacitive bus and then modulated to control a brushless motor. Engi neered 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 hard ware.

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).

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

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 equip ment. Reading should not regularly exceed approxi mately 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.

313997ZAA 39

Page 40

Setup

ti10006a1

ti9883a1

ti9880a1

4. Connect feed lines

a. Install feed pumps (K) in component A (Red)

and B (Blue) supply drums. See F 2, pages 23 and 25.

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

3.5 bar) is required at both feed inlet pressure gauges (FP). Maximum feed pressure is 250 psi (1.75 MPa,

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

b. Seal component A (Red) drum and use desic

cant dryer (M) in vent.

c. Install agitator (L) in component B (Blue) drum,

if necessary.

IG. 1 and FIG.

5. Connect pressure relief 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 work ing pressure of this equipment.

a. Recommended: Connect high pressure hose

(R) to relief fittings (BA, BB) of both PRES SURE RELIEF/DISPENSE valves. Route hose back to component A (Red) and B (Blue) drums.

IG. 1, page 23.

See F

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

are closed.

NOTE:

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

e. Connect and tighten component B (Blue) supply

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

f. Connect and tighten component A (Red) supply

hose to the 1/2 npt(f) swivel on the component A (Red) inlet valve.

b. Alternately: Secure supplied bleed tubes (N) in

grounded, sealed waste containers (H). See

IG. 1, page 23.

6. For Heated HFR models only, install Fluid Tem

perature Sensor (FTS)

a. Install FTS between main hose and whip hose.

See Heated Hose manual for instructions.

40 313997ZAA

Page 41

Setup

ti9881a1

ti2411a1

7. Connect heated hose monitor zones

NOTE: For Heated HFR models only, see Heated Hose

manual for detailed instructions on connecting heated hoses.

NOTICE

For Heated HFR models only, the FTS (C) and whip hose (D) must be used with heated hose. See step 6 on page 40 for FTS installation. Hose length, including whip hose, must be 10 ft (3 m) minimum.

a. Turn main power OFF .

b. For Heated HFR Models only, assemble

heated hose sections, FTS, and whip ho se. See Heated Hose manual 3A0237 for heated hose connection details and illustrations for the vari ous types of heated hoses. For Non-Heated HFR Models only, assemble fluid supply hose sections and whip hose.

d. For Heated HFR Models only, connect

cables (Y). Connect electrical connectors (V). 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.

8. For systems with a gun fluid manifold, close gun

fluid manifold valves A (Red) and B (blue).

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

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

NOTE: Gun fluid manifold hose adapters allow use of 1/4 in. and 3/8 in. ID fluid hoses. To use 1/2 in. (13 mm) ID fluid hoses, remove adapters from gun fluid manifold and install as needed to connect hose.

313997ZAA 41

Page 42

Setup

ti2417a1

24C352_312998_8g

9. For models with an MD2 valve, connect whip

hose to MD2 valve component A (Red) and com ponent B (Blue) fluid inlets. For models with a dispense gun, connect whip hose to gun fluid manifold. Do not connect man ifold to gun. See F

IG. 13

IG. 13.

10.Pressure check hose

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

11.Ground system

pense gun firmly to the side of a grounded metal pail, then trigger gun.

12.Check hydraulic fluid level

Hydraulic reservoir is filled at the factory. Check fluid level before operating the first time, and weekly thereaf ter. See Technical Data on page 108 for specifications.

13.IsoGuard Select Fluid system setup

Component A (Red) Pump: Fill IsoGuard Select reser

voir (LR) with IsoGuard Select fluid (24F516).

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

and remove the container from the cap.

This equipment must be grounded.

a. HFR: grounded through power cord. See step 3

on page 38.

b. EP Gun or Dispense Valve: If supplied, connect

whip hose ground wire to FTS, see step 6 on page 40. Do not disconnect wire or dispense without whip hose.

c. Fluid supply containers: follow your local code.

d. Object being dispensed: follow your local code.

e. Solvent pails used when flushing: follow your

local code. Use only metal pails, which are con ductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

f. To maintain grounding continuity when flushing

or relieving pressure, hold a metal part of dis

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.

42 313997ZAA

Page 43

Setup

ti10442a1

LOCKED

ti9877a1

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

valve to balance pres

sures.

ti9877a1

ti10441a1

UNLOCKED

14. Prime IsoGuard Select fluid cylinder

The IsoGuard Select fluid cylinder must be primed when replacing IsoGuard Select fluid. See IsoGuard Select

System on page 57 for instructions.

15. Install dispense valve

a. Navigate to System Screen 2 and select the

appropriate dispense valve from the “Dispense Valve” dropdown menu. See System Screen 2 on page 73.

b. Set pressure relief valves (SA, SB) to RELIEF.

c. If dispense valve has a trigger safety lock,

engage the trigger safety lock.

g. Press to enable system. LED should be

solid green.

h. Check that heat zones are on and temperatures

are on target, see Status Screen on page 85.

i. Check fluid pressure display and adjust as nec

essary.

j. For MD2 and Auto-Fusion dispense valves, per

form Connect Solenoid Kit procedure. See Heated Hoses and Applicator Kits manual for procedure.

k. Check fluid pressure gauges (GA, GB) to

ensure proper pressure balance. If im balanced , reduce pressure of higher component by slightly turning PRESSURE RELIEF/DIS PENSE valve for that component toward PRES

SURE RELIEF/CIRCULATION , until gauges show balanced pressures.

d. Connect gun to machine. Verify gun is ready for

operation. See appropriate gun manual listed in Related Manuals on page 3 for detailed instructions.

e. If gun has pneumatics, verify air line is con

nected then open bleed-type master air line valve.

f. Set PRESSURE RELIEF/DISPENSE valves

(SA, SB) to DISPENSE .

313997ZAA 43

l. For MD2 and Auto-Fusion dispense valves, per

form Connect Solenoid Kit procedure. See Heated Hoses and Applicator Kits manual for procedure.

m. If dispense valve has a trigger safety lock, dis

engage the trigger safety lock.

Page 44

Setup

n. For EP Gun and GX-16, perform a test pour into

a waste container. Adjust pressure and tem perature to get desired results. Equipment is ready to dispense.

o. For all dispense valves other than the EP Gun,

perform mix ratio test using two tared cups. Weigh the cups and divide the weights to verify the mix ratio by weight. See Ratio Checking section in the dispense valve manual for more information.

p. For Fusion dispense valves, perform DC Power

Pack Hydraulic Pressure Setup. See HFR Repair manual for procedure.

q. Equipment is ready to dispense.

Vacuum De-gas

NOTE: This procedure is for assemblies with vacuum

tree manifold and no agitator or auto-refill.

1. Disable machine movement by pressing the Machine Disable Mode key ( ).

2. Close the shut-off ball valves at the base of the tanks.

3. If the tank lid has a fill port, turn off any systems that might refill the tank during the vacuum de-gas pro cedure.

4. Close the fill port ball valve.

5. If the tank lid requires a desic can t dr ye r or nitroge n pump installed, install one into the top ball valve of the vacuum tree manifold.

6. Close the top ball valve of the vacuum tree mani fold.

7. Attach vacuum pump to the bottom ball valve of the vacuum tree manifold then open the ball valve.

8. Turn on the vacuum pump.

9. Continue to de-gas for sufficient time to de-gas the material.

10. Close bottom ball valve of the vacuum tree mani fold.

11. Turn off the vacuum pump.

12. Open the top ball valve of the vacuum tree manifold.

NOTICE

Operating the tank after the vacuum de-gas proce dure without the top ball valve open will result in pump cavitation, off-ratio conditions, and possible collapse of the tank.

13. Open the shutoff valves at the base of the tanks.

44 313997ZAA

Page 45

Setup

Vacuum De-gas and Vacuum Manual Refill

NOTE: This procedure is for assemblies with a vacuum

tree manifold, agitator, and auto-refill.

1. Press the Select Operatin g M od e butt on ( ) repeatedly to select Shot, Sequence, or Operator

(Manual) mode.

2. Close the shut-off ball valves at th e ba se of the tanks.

3. If the tank lid requires a desicc an t dr ye r or nit ro gen pump installed, install one into the top ball valve of the vacuum tree manifold).

4. Close the top ball valve of the vacuum tree mani fold.

5. Attach vacuum pump to the bottom ball valve of the vacuum tree manifold then open the ball valve.

6. Turn on the vacuum pump.

12. Close bottom ball valve of the vacuum tree mani fold).

13. Turn off the vacuum pump.

14. Open the top ball valve of the vacuum tree manifold.

NOTICE

Operating the tank after the vacuum de-gas proce dure without the top ball valve open will result in pump cavitation, off-ratio conditions, and possible collapse of the tank.

15. Open the shutoff valves at the base of the tanks.

7. Turn on agitator.

8. Select Manual Refill mode. See operation manual referenced at the beginning of this manual for more information.

9. Press the appropriate Auto-Refill Tank Select button or buttons ( and/or ) to select the tanks to

refill.

10. If necessary, press the Abort/Cancel button ( ) to cancel auto-refill.

If an auto-refill is aborted or times out, the software will not initiate a new auto-refill until a manually initi ated auto-refill has completed. To complete a man ually initiated auto-refill after an aborted or timed out auto-refill, restart at step 2.

NOTICE

If an auto-refill is stopped and not restarted as described in the previous note, the pumps may be run dry and chemical crossover at the valve may occur.

11. Continue to de-gas for sufficient time to de-gas the material.

313997ZAA 45

Page 46

Advanced Display Module (ADM) Operation

When main power is turned on by turning the main power switch (MP) to the ON position, the splash screen will be displayed until communication and initialization is complete.

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

IG. 5 on page 30. If the System Status Indicator

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

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

7. If L-Head is installed, define L-Head contr ol details. See Mix Head Operating Details Screen, page 74.

8. Define level sensors and refill settings. See Supply Screen, page 76.

9. Enable/disable temperature conditioning compo nents. See Conditioning Screen 1, page 77.

10. Define temperature conditioning setpoints. See Conditioning Screen 2, page 78.

11. If Night mode will be used, define Night mode set tings. See Conditioning Screen 3, page 79.

12. Calibrate machine. See Calibration Screen, Main, page 72.

13. Define shots. See Shots Screen, page 69.

14. Define sequences. See Sequences Screen, page 71.

15. If desired, view/reset counters. See Maintenance Screen, page 76.

If the machine is in the Disabled mode screen press

repeatedly to select a different operating mode.

Perform the following tasks to fully setup your system.

1. Set general system settings. See Advanced Screen 1, page 80.

2. Set units of measure. See Advanced Screen 2, page 80.

3. Enable/disable syste m fe atu r es. See Advanced Screen 3, page 81.

4. Define control mode, dispense mode, and pump information. See System Screen 1, page 73.

5. Define dispense valve an d ot he r sys te m se ttin gs . See System Screen 2, page 73.

6. Define labels and other system settings. See Sys tem Screen 3, page 75.

46 313997ZAA

Page 47

Startup

ti9877a1

ti10002a1

ti2484a1

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

1. Use feed pumps to load fluid

NOTE:

The HFR is tested with oil at the factory. Flush out the oil with a compatible solvent before dispensing. See Flush ing on page 52.

a. Check that all machine connections are setup.

See Setup procedure, page 38.

b. Check that inlet screens are clean before daily

startup, see page 56.

Startup

g. Open fluid inlet valves (FV). Check for leaks.

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

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

c. Check level and condition of ISO lube daily, see

IsoGuard Select

System on page 57.

d. Turn on component B (Blue) and component A

(Red) agitators, if used.

e. Turn both PRESSURE RELIEF/DISPENSE

valves (SA, SB) to DISPENSE .

f. Start feed pumps.

h. Use feed pumps to load system.

i. For models with an EP, Fusion, or P2 gun

only, hold gun fluid manifold over two gr ounded waste containers. Open gun fluid valves A (Red) and B (Blue) until clean, air-free fluid comes from valves. Close valves.

j. For models with an MD2 Valve only, hold

MD2 valve nose piece, without a mixer installed, over two grounded waste containers. Leave mixer off and trigger gun until both fluids flow freely from the nose piece without any air.

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

or until air-free fluid dispenses.

313997ZAA 47

Page 48

Startup

2. Calibrate HFR

The HFR calibration procedure is a two step process. The first step, Learn Mode, must be performed when ever the pump line is rebuilt or if any other maintenance is performed that may affect the mechanical tolerances in the pump line. If the machine does not appear to be utilizing the full extent of the pump stroke, or if the machine appears to be contacting the end of the hydraulic cylinder, follow the Learn Mode procedure. The Learn Mode procedure will teach the system the mechanical limits of travel.

Learn Mode Procedure:

a. Navigate to the Calibration screen.

b. Press the Learn Mode Calibration button

and set the mode to run as the dispense appli cator that is installed on the system.

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.

NOTE: For circulation systems, set the mode as either EP or MD2 valves. These settings will not dispense material.

c. Place a waste container below the dispense

valve. The next steps will cause the machine to dispense material for all other settings.

d. Press the go right button and then the dis

pense button . The pump will travel to the right most extreme position.

e. After the pump stops moving, press the go left

button and then press the dispense button . The pump will travel to the left most

extreme position.

f. After the pump stops moving, press the con

tinue button to go on to the next step in the calibration process or the page back button

to return to the main Calibration screen.

48 313997ZAA

Page 49

Startup

3. Set temperatures (Heated models only)

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 touch ing 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 78 for details. For minor adjustments to the temperature setpoint once the machine has been initially configured, see the Status

Screen on page 85.

4. Set system control and dispense modes: See

System Screen 1 on page 73.

7. Change pressure imbalance setting (optional)

The pressure imbalance function detects conditions that can cause off-ratio dispense, such as loss of feed pres sure/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.

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 Enter .

5. Set pump sizes: See System Screen 1 on

page 73.

6. 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.

313997ZAA 49

Page 50

Shutdown

ti9883a1

Shutdown

1. Park pumps.

a. From the Home screen, press and select

Standby mode.

b. Press . Material will dispense for non cir

culation systems. Pump will park automatically. Once pump is parked, pump will stop moving. If a dispense gun with a trigger is installed, pulling the trigger will begin a park operation. Material will dispense for non circulation sys tems.

c. For models with an EP, Fusion, or P2 gun

only, turn diversion valves to tank then press

Park . Pressure must be below 400 psi (2.8 MPa, 28 bar).

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

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

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

5. Perform Pressure Relief Procedure on page 51.

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

50 313997ZAA

Page 51

Pressure Relief Procedure

ti9879a1

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

2. Turn PRESSURE RELIEF/DISPENSE valves (SA,

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

Pressure Relief Procedure

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

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

313997ZAA 51

Page 52

Flushing

ti9880a1

Flushing

Flush equipment only in a well-ventilated area. Do not dispense flammable fluids. Do not turn on heaters while flushing with flammable solvents.

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

• Use the lowest possible pressure when flushing.

• All fluid components are compatible with common solvents. Use only moisture-free solvents. See Technical Data on page 108 for list of wetted com ponents to verify compatibility of solvent with wetted materials. See solvent manufacturers information for material compatibility.

• To maintain grounding continuity when flushi ng 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/DIS PENSE 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 mois ture-free plasticizer or oil. Do not use water. See Important Two-Component Material Information on page 20.

• 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 card board, which interrupts grounding continuity.

52 313997ZAA

Page 53

Maintenance

ti9879a1

ti7861a1

24C352_313998_1

Maintenance

Change Break-in Oil

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

Task Schedule

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

hours of opera

tion or within 3

months, which

ever comes first

Inspect hydraulic and fluid lines for leaks

Inspect fluid inlet strainer screens, page 56

Inspect IsoGuard Select fluid level and condition, refill or replace as needed, page 57

Check hydraulic fluid level Weekly Grease circulation valves with

Fusion grease (117773) Verify operation of air drying sys

tem to prevent isocyanate crystal lization

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

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

Daily

Weekly

Daily

Table 2: 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

Grease Circulation Valves With Fusion Grease (117773)

Check Hydraulic Fluid Level

Check hydraulic fluid level on dipstick (DS). Fluid level must be between indent marks (IM) on dipstick. Refill as required with approved hydraulic fluid; see Technical Data on page 108. If fluid is dark in color, change fluid and filter.

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

Clean up all hydraulic leaks; iden tify and repair cause of leak

Clean dispense valve mix cham ber ports regularly, see dispense

valve manual Clean dispense valve check

valve screens, see dispense valve manual

313997ZAA 53

Monthly

As needed

See dispense

valve manual

See dispense

valve manual

Page 54

Maintenance

ti12364a1

r_257396_3b9905_02b

Heat Sink Fins

ti12353a1

ti12357a1

Heat Sink Fins

ADM - Battery Replacement and Screen Cleaning

Battery Replacement

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

To replace the battery:

1. Disconnect power to the ADM.

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

2. Remove rear access panel.

MCM and TCM - Clean Heat Sink Fins

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

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

3. Remove the old battery and replace with a new CR2032 battery.

4. Properly dispose the old lithium battery according to local codes.

5. Replace rear access panel.

6. Connect the power to the ADM and reset the clock through Advanced Screen 1. Refer to Appendix B

- ADM Setup Screens Overview for more detail.

Cleaning

Use any alcohol-based household cleaner, such as glass cleaner, to clean the ADM. Spray on the rag then wipe ADM. Do not directly spray the ADM.

FIG. 14: Clean Heat Sink Fins

54 313997ZAA

Page 55

Install Upgrade Tokens

r_257396_3b9905_04b

ti12334a1

ti12358a1

ti12354a1

NOTE: The Motor Control Module, Fluid Control Mod ule, 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 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 soft ware 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.

Module Programming

Maintenance

See manuals for locations of specific GCA compo nents.

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

FIG. 15: Remove Access Cover

Token Application

16H821 HFR:

- Advanced Display Module

- Motor Control Module

- High Power Temperature Control Module

- Fluid Control Module (AC Power Pack)

- Discrete Gateway Module

- Communication Gateway Module

16G584 Tank Stand:

- Fluid Control Module

- Low Power Temperature Control Module

16G407 Ratio Monitoring (Flow Meters):

- Fluid Control Module

313997ZAA 55

Page 56

Maintenance

59g* 59h

59j 59k

ti9886a1

59d

Fluid Inlet Strainer Screen

The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required. The standard strainer is 20 mesh.

Use clean chemicals and follow proper storage , transfer, and operating procedures, to minimize contamination of the A-side screen.

NOTE:

Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flush ing out any isocyanate residue at the start of dispensing operations.

1. Perform Pressure Relief Procedure on page 51.

2. Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents mate rial from being pumped while cleaning the screen.

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

FIG. 16. Fluid Inlet Strainer

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

4. Remove the screen (59g) from the strainer mani fold. Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket (59h) and replace as required.

5. Ensure the pipe plug (59k) is screwed into the strainer plug (59j). Install the strainer plug with the screen (59g) and gasket (59h) in place and tighten. Do not overtighten. Let the gasket make the seal.

56 313997ZAA

Page 57

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 (24F516). The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamina tion 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 (24F516) replacement due to dis coloration should not be necessary more often than every 3 or 4 weeks.

9. Push the return tube (RT) into the reservoir until it reaches the bottom.

NOTE:

The return tube must reach the bottom of the reservoir, to ensure that isocyanate crystals will settle to the bot tom and not be siphoned into the supply tube and

returned to the pump.

To change pump IsoGuard Select fluid (24F516):

1. Perform Pressure Relief Procedure on page 51.

2. Remove fittings from IsoGuard Select fluid cylinder inlet and outlet ports. Keep supply tube (ST), return tube (RT), and leak management tube (LT) con nected to the fittings.

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

4. Lift the IsoGuard Select fluid reservoir (LR) out of the bracket (RB) and remove the container from the cap. Holding the cap over a suitable container, remove the inlet check valve and allow the IsoGuard Select fluid to drain. Reattach the check valve to the inlet hose. See F

IG. 17.

5. Drain the reservoir and flush it with clean IsoGuard Select fluid (24F516).

6. When the reservoir is flushed clean, fill with fresh IsoGuard Select fluid (24F516).

FIG. 17: IsoGuard Select Fluid System

Prime IsoGuard Select Fluid Cylinder

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

1. Install IsoGuard Select fluid cylinder inlet fitting and inlet tube into bottom of cylinder. The inlet tube is the tube with a check valve installed in it which points in the direction of flow towards the IsoGuard Select fluid cylinder.

2. Install IsoGuard Select fluid cylinder outlet fitting and outlet tube into top of cylinder. The outlet tube is the tube with a check valve installed in it which points in the direction of flow away from the IsoGuard Select fluid cylinder.

3. Remove check valve from end of outlet tube.

4. Use funnel to pour IsoGuard Select fluid (24F516) into tube to fill cylinder.

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

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

313997ZAA 57

5. With check valve arrow pointing away from the IsoGuard Select fluid cylinder, install check valve in end of outlet tube.

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

Page 58

Troubleshooting

Before performing any troubleshooting procedure:

1. Perform Pressure Relief Procedure on page 51.

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 con trols are properly set and wiring is correct before assum ing there is a problem.

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, deviation s, or alar m s, so green will only be on when none of these occur. A yel low light can be on at the same time as red (flashing or solid on) when an advisory exists at the same time as a deviation or alarm.

Common Problems

Problem Cause Solution General

Display Module completely dark

No or incorrect amount of material dispensed from either side

Significant material leaking from pump seal

Material dispensed not cor rect weight

A (Red) and B (Blue) Primary Heaters

Control of primary heat is abnormal; high temperature overshoots

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 cali bration

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

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.

58 313997ZAA

Page 59

Troubleshooting

Problem Cause Solution Hose Heat System

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

Ambient temperature is too cold Use auxiliary hose system. FTS failed or not installed correctly Check FTS Low supply voltage Verify line voltage. Low line voltage significantly

reduces power available to hose heat system, affect ing longer hose lengths.

Hose does not maintain tem perature while spraying

A and B setpoints too low Increase A (Red) and B (Blue) setpoints. Hose is

designed to maintain temperature, not to increase it.

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. Hose was not fully preheated Wait for hose to heat to correct temperature before

spraying Low supply voltage Verify line voltage. Low line voltage significantly

reduces power available to hose heat system, affect

ing longer hose lengths.

Hose temperature exceeds setpoint

A (Red) and/or B (Blue) primary heat ers are overheating material

Check primary heaters for either an RTD problem or a

failed element attached to thermocouple 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.

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

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.

Hose does not heat FTS failed or is not contacting cor

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 Appendix D - ADM Error Codes on page 88

Hoses near system are warm, but hoses downstream are cold

Shorted connection or failed hose heating element

With hose heat on and temperature setpoint above

displayed hose zone temperature, verify voltage

between connectors at each section of hose.

Proportioning System

Proportioning pump does not

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

hold pressure when stalled

313997ZAA 59

Voltage should drop incrementally for each section of

hose further from the system. Use safety precautions

when hose heat is turned on.

ing pressure.

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

3. Repair the valve.

Page 60

Troubleshooting

Problem Cause Solution

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

• Use 2:1 supply pump

• Use minimum 3/4 in. (19 mm) ID supply hose, as

short as practical

Fluid is too thick. Consult your material supplier for the recommended fluid temperature to maintain a vis cosity of 250 to 1500 centipoise.

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

Pressure relief/circulation valve leak ing 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

MPa, 7 bar) minimum.

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Page 61

ADM Troubleshooting

r_24E451_3B9900_1a

Troubleshooting

FIG. 18: ADM Component Identification - Rear

ADM Module Status LEDs (CN) Conditions

Module Status LED Signal Description

Green on System is powered up. Yellow on Communication in progress. Red solid ADM hardware failure. Red flashing Uploading software.

USB Module Status LEDs (CL) Conditions

Module Status LED Signal Description

Green flashing System is powered up. Yellow on Downloading information to USB Green/Yellow Flashing ADM is busy, USB cannot transfer

information when in this mode

313997ZAA 61

Page 62

Troubleshooting

LED Signals

r_257396_3b9905_07b

Motor Control Module

For MCM location, see reference MA in FIG. 2 on page 25.

Diagnostic Information

Module Status LED Signal Description

Green on System is powered up. Yellow on Internal communication in progress. Red solid MCM hardware failure. Replace MCM. Red flashing fast Uploading software. Red flashing slow Token error. Remove token and upload

Table 3: LED Status Signal

software token again.

FIG. 19: LED Signals

62 313997ZAA

Page 63

Acceptable Size and Duration of Power Line Voltage Fluctuations

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)

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

Troubleshooting

313997ZAA 63

0.000001 0.00001 0.0001 0.001 0.01 0.1 1 10

Page 64

Troubleshooting

ti12337a1

Module Status LEDs

Fluid Control Module

Diagnostic Information

Module Status LED Signal Diagnosis

Green on System is powered up Yellow Internal communication in progress Red solid FCM hardware failure. Replace FCM. Red flashing fast Uploading software Red flashing slow Token error. Remove token and

upload software token again.

FIG. 20:

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Page 65

Temperature Control Module

LED Signals

ti12353a1

ti12357a1

LED Signals

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 fail

ure. See Troubleshooting table. Red flashing Software is updating. Blue light off

(High Power Module only)

Blue flashing (High Power Module only)

Temperature control module is off.

See Troubleshooting table.

Length of flashes indicates amount

of power running through tempera

ture control module.

Troubleshooting

IG. 21: LED Signals

313997ZAA 65

Page 66

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

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Page 67

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 insti gated system action.

If Green:

Allowed to Dispense

If Red:

Not Allowed to Dispense 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 Con trol screen

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.

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

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

Amount of material moved through pump (volume tracking)

Cycles

Turn on or off the highlighted zone.

Turn on or off all zones.

Erase a single batch

Erase all batch data points

313997ZAA 67

Page 68

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

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 Appendix C

- ADM Run Screens Overview on page 82. F

IG. 22

shows the flow of the Setup screens.

FIG. 22: Setup Screens Navigation Diagram

68 313997ZAA

Page 69

Appendix B - ADM Setup Screens Overview

Shots Screen

This screen allows the user to edit shot definitions. The contents of this screen change based on the Dispense and Control Mode selections. Shots may be defined by pressure or flow rate depending upon the Control Mode selection and by time (duration), volume, or weight depending upon the Dispense Mode selection. See Sys tem Screen #1 for Control and Dispense Mode options. See Home Screen, Shot Mode on page 83 for informa tion on how to use predefined shots.

NOTE: 100 shot definition 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 averaged for each dispense before entering a value for

∆ column.

the

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 sepa ra te con ta ine rs.

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 2

146.4 156.4

3 145.6 155.6 4

145.8 155.8

5 146.0 156.0

3. Calculate the averag e of the 5 sh ot s. Example 1 = 146cc Example 2 = 156cc

313997ZAA 69

Page 70

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 sepa ra te con ta ine rs.

2. Measure the dispensed amount and record the data.

Example 3

Dispensed Volume

Shot

(cc)

NOTE: Depending on the dispensed volume average,

∆ column may be either a positive or negative

the value.

1 72.2 2 3 72.6 4 5 72.5

3. Calculate the averag e of the 5 sh ots . Example 3 = 72.5cc

4. Use the following formula to calculate the value.

72.4

72.8

∆ column

70 313997ZAA

Page 71

Appendix B - ADM Setup Screens Overview

Example 3:

5. Enter the calculated value in the ∆ column.

Sequences Screen

This screen allows the user to edit sequence informa tion. The contents of this screen change based on the Dispense and Control Mode selections.

Dispense detail is shown as volume, time, or weight depending on which Dispense Mode is selected. See System Screen 1 on page 73 for Dispense Mode options. See Home Screen, Sequence Mode on page 84 for information on how to use predefined sequences.

NOTE: Five sequences with 20 positions each ar e avail able across 10 pages.

To edit a sequence:

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

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

313997ZAA 71

Page 72

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 48 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 48 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.

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Appendix B - ADM Setup Screens Overview

System Screen 1 NOTE: Not all of the following modes may be available

depending on the dispense valve selected. This screen allows the user to set important system set

tings specific to what dispense applicator has been selected. Control Mode can be set to Pressure or Flow. With Control Mode set to Pressure, the machine will adjust dispense flow rate in order to maintain the requested pressure. With Control Mode set to Flow, the machine will dispense at a continuous flow rate regard less of pressure fluctuations unless pressure alarm con ditions occur.

Dispense Mode can be set to Time, Volume, or Weight. Dispense Mode controls how displayed amounts are measured. If Dispense Mode is set to Weight, then the machine dispenses until the desired weight of material is dispensed. See Calibrate HFR on page 48 for more information.

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

If pump sizes and inlet pressures are not entered prop erly, 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 dis played 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 HFR repair/parts manual 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 dis pense valve is selected on System Screen 2.

System Screen 2

This screen allows the user to set the Gel Timer proper ties and set which items are installed on the machine.

When enabling the Gel Timer, the user must select one of the 100 available shot definitions to use as the Gel Shot. This shot will be dispensed when the Idle Period expires. The Idle Period will begin after a dispense is completed. Any dispense operation in the middle of the timer countdown will reset the Idle Period counter. The system will generate an audible alarm based upon the user Alarm setting. The alarm will sound the user-entered number of seconds before the Idle Period expires.

The hydraulic level sensor and hydraulic RTD for both the pump line and mix head must be marked as enabled when installed in the system. If the sensors are not marked as enabled, they will be ignored by the machine controls.

Select the dispense valve installed in the system. This selection is critical to ensure proper operation of the

machine. When a mix head is selected, 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 74.

Selecting the dispense valve will limit the system maxi mum working pressure to the maximum working pres sure of the dispense valve. See System Screen 1 on page 73.

313997ZAA 73

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 applica ble for P2/Fusion Dispense Valves. This feature can not be active if the Pre Dispense Delay feature is active.

Page 74

Appendix B - ADM Setup Screens Overview

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 application s. T his fe at ur e can not be active if the Post Dispense Shot Disable fea ture is active.

Mix Head Operating Details Screen

This screen allows the user to define the mix head oper ating parameters.

• Low Pressure Circulation: The percentage of set point at which the system will run during low pres sure circulation.

• Pre-Dispense Circulation: The time for which the system will circulate at high pressure prior to dis pensing when the dispense command is triggered while the system is in low pressure circulation.

• Post-Dispense Circulation: The time duration that the system will remain in high pressure circulation after a dispense before dropping into low pressure circulation.

• Idle Position: Applies to an L-Head only. The posi tion of the clean out rod when the mix head is idle.

• Clean Out Open: Applies to an L-Head only. The amount of time the clean out rod will remain open immediately after the completion of a dispense.

• Clean Out Closed: Applies to an L-Head in a Nor mally Open configuration only. The amount of time the clean out rod will remain closed when it closes after the completion of a dispense (after the clean out open time delay).

• Anti-Seize Delay: Applies to an L-Head in a Nor mally Closed configuration only. After a shot occurs and the cleanout piston closes, the first anti-seize delay will count down then the cleanout piston will open and close to break loose from any curing material. The second anti-seize timer will then begin counting down and the cleanout piston will open and close again to break loose from any remaining cur ing material. If a shot occurs before both anti-seize timers elapse, the anti-seize timers restart.

74 313997ZAA

Press to go back to the System Screen 2.

Page 75

Appendix B - ADM Setup Screens Overview

Pressure Imbalance Setting

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 75.

3. Use arrow keys to select the desired letter and press to accept the letter. To erase all text,

press the Eraser softkey. To go back one letter, press the Back Arrow softkey.

Keyboard Screen

This screen is used to edit the A (Red) and B (Blue) labels on the ADM. Use arrow keys to select the desired

letter and press to accept the letter.

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

4. When finished enterin g the ne w lab el, pre ss the button twice.

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

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.

This screen allows the user to enter material specific gravities.

move the 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 .

Flow Meter Calibration

Refer to the HFR Flow Meter Kits manual for instruc tions on how to calibrate the flow meters.

313997ZAA 75

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Appendix B - ADM Setup Screens Overview

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 .

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 set tings: Disabled, Monitor, Manual, Auto Top-Off, Auto Full-Volume.

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

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

• Disabled

• Disables tank operation

• Monitor

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

• Refill is not supported, no button is provided on the run screens to initiate refill

• Errors will clear when the corresponding condi tion clears

• Manual

• The low level sensor will generate a low level alarm

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

• Manual refill will run until either the high level sensor sees material, the user aborts the refill via the refill button on the run screens, or the refill time-out expires

• The low level alarm will clear when the condition clears

• Auto Top-Off

• The low level sensor will generate a low level alarm

76 313997ZAA

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Appendix B - ADM Setup Screens Overview

• When the high level sensor does not see mate rial, automatic refill will begin and continue until either the high level sensor sees material or until the refill time-out expires

• The low level alarm will clear when the condition clears

• A button is provided to the user on the run screens to instigate an automatic refill operation at any time, this button can also be used to abort a refill operation

• Auto Full-Volume

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

• Automatic refill will continue until either the high level sensor sees material or until the refill time-out expires

• The low level alarm will clear when the condition clears

• A button is provided to the user on the run screens to instigate an automatic refill operation at any time, this button can also be used to abort a refill operation

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:

Refill Sensor Type

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

its 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.

Check the box next to the component type for the appro priate side of the system to indicate that a component is installed. A maximum of four components may be selected. A maximum of four components and two mon itoring zones may be selected.

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

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

• When the middle sensor is not satisfied, automatic refill will begin and will run until either the middle sensor is satisfied, the high level sensor generates a deviation (if the middle sensor fails), or the refill time-out expires.

• The low level alarm and the high level deviation will clear when the condition clears.

• A button is provided to the user on the Run screens to instigate an automatic refill operation at any time. This button can also be used to abort a refill opera tion.

Refill Timeout

The refill time-out setting may b e set by the user as a means to abort the refill in the case of a high level sen sor failure. When an automatic refill begins, the time-out counter will begin to count down. If the timer expires before the high level sensor is satisfied, the refill will abort.

313997ZAA 77

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Appendix B - ADM Setup Screens Overview

Conditioning Screen 2

This screen shows the fluid path for the temperature conditioning components and temperature setpoints for each component.

NOTE: If tank blanket heaters or inline heaters are installed along with hose heat, the hose heat setting will be limited to at or below the inline or tank heat setting.

To edit the temperature setpoint and alarms for a partic ular component:

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 m ust be at least +/-9°F (5°C) than the material temperature value.

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

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.

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. The days can be selected by pressing the left or right arrow keys once entered into the screen.

To set the on/off machine times:

1. Press to ente r th e scre e n

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 Sat urday) duration.

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

313997ZAA 79

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

Page 80

Appendix B - ADM Setup Screens Overview

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

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.

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.

• Language: Available languages are English, Span ish, French, German, Chinese, Japanese, Korean, Russian, and Italian.

• Time: formatted in 24 hour time.

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

• 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.

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Appendix B - ADM Setup Screens Overview

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

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.

• Low Heater Temp Disables Dispense: When this box is checked, the system will reject dispense requests when any enabled heat zones are below their setpoint.

• High Chiller Temp Disables Dispense: When this box is checked, the system will disable dispensing when any enabled chiller zones are above their set point.

• 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 dispens ing 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.

• Enable Ratio Check Weight Mode Entry: This option is for machines without flow meters. When this box is checked, after any ratio check shot a popup window will appear asking the user to enter the dispensed weights. Press the Cancel button to abort the entry or press the Enter button to record the new values.

Advanced Screen 4

• Limit Rate on Stall to Pressure: Check this box to allow the HFR to increase to stalling pressure at a slower, more controlled rate.

• Enable Diagnostic Screen: Check this box to enable the optional ADM screens, enabling USB log downloading, and erasing USB logs. For more infor mation about USB operation, see Appendix F - USB Operation on page 102. For more information about the optional screens, see Diagnostic screen on page 87.

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

Advanced Screen 5

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 #...

* Supply tanks shown for reference only. Your sys

tem may not include supply tanks.

Appendix C - ADM Run Screens Overview

Run screens are divided into five major sections: status, errors, events, and maintenance. The following diag ram demonstrates the flow of the Run screens beginning with the Home screen.

IG. 23: 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.

To select an operating mode, press the Select Mode button repeatedly until the desired mode is shown then press the Enter button to select the mode.

Alternately, press the Select Mode button and use the up and down arrow keys until the desired mode is

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

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.

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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 pre defined shot numbers. See Shots Screen on page 69 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 74, 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 fill ing, 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 83 for other button functions.

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Appendix C - ADM Run Screens Overview

Target

Flow/Pressure

Ratio

Target dispense amount

(time/volume/weight depending

on Dispense Mode)

Total of resetta ble material counters

B (Blue) reset table material counter

A (Red) resetta ble 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 71 for information about editing sequ ence defini tions.

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.

4. Press to accept the sequence letter/position.

Home Screen, Operator Mode

This mode allows users to set a pressure or flow rate to dispense material without using predefined shot infor mation. Pressure or flow rate availability is dependent on the Control Mode selection, see System Screen 2 on page 73.

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

then press to accept it.

5. Press the Dispense button to begin dispensing.

6. Press to skip to the next sequence position.

7. Press to abort the sequence.

8. See Home Screen, Shot Mode on page 83 for other button functions.

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 74, 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 trig ger to initiate a dispense. Release the trigger to stop the dispense.

4. See Home Screen, Shot Mode on page 83 for other button functions.

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Appendix C - ADM Run Screens Overview

Home Screen, Night Mode

In Night Mode, the system will cycle on and off periodically. The recirculation on/off cycle begins automatically upon entering Night Mode. See

Conditioning Screen 3 on page 79.

Home Screen, Disabled Mode

Status Screen

The status screen provides all of the operational func tionality of the Home screen except for operating mode selection. Refer to the Home screen and operating mode descriptions for information on this functionality.

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

 No setpoint box will be displayed if selected as moni

tor zone.

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Appendix C - ADM Run Screens Overview

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

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

button again to turn the zone off.

To turn all zones on/off:

1. Press to enter the Conditioning Control screen.

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 58 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 descrip tion 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.

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 all zones off.

 No setpoint box will be displayed if selected as moni

tor zone.

Refer to the Troubleshooting section on page 58 for a detailed description of all of the system events.

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Appendix C - ADM Run Screens Overview

Maintenance Screen 1

This screen displays historical information for each pump in the system. The Batch counters are resettable and count both material usage and pump cycles. The Total counters are not resettable by the user. They also count both material usage and pump cycles. For mate rial usage counters, units are displayed next to the vol ume/weight indicator icons.

To erase a batch counter, press the Enter Screen button and navigate to the field to be erased. Press the Erase Single button to erase that data point. Alternatively, the Erase All button may be pressed to erase all of the batch data points simultaneously.

Optional Screens

The optional Diagnostic screen can be enabled in the Advanced Screen 4 screen, see page 81.

Diagnostic

The Diagnostic screen shows status information for var ious system components.

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

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Mix Head

A4H3

Motor Overload

Soft Stop

DEH3

Asserted Low Mix

MBH3

Head Oil Level Low

P1H3

Accumulator Pressure High

P4H3

Accumulator Pressure

High Mix

T4H3

Head Oil Temp. M1 Material

WDF3

Rod Shift Fail M1 Cleanout

WDD3

Rod Shift Fail

The three point calibration data is invalid, system will operate in weight mode but will attempt to volumetrically calculate weight. This will lead to consistent shots which will be offset for the desired dispense amount.

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

0500

02D0

A4A6

A4B5

A4A3

A4B1

A4A2

A4B4

A4A7

A4B8

A4H1

A4M1

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

Motor Over

ent

Curr

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

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Motor Over

A4N1

Current

Red Blanket

A7A6

Control Fault Blue Blanket

A7B5

Control Fault Red Inline

A7A3

Control Fault Blue Inline

A7B1

Control Fault Red Hose

A7A2

Control Fault Blue Hose

A7B4

Control Fault Red Chiller

A7A7

Control Fault Blue Chiller

A7B8

Control Fault No Red

A8A6

Blanket Current

No Blue

A8B5

Blanket Current No Red Inline

A8A3

Current No Blue Inline

A8B1

Current No Red Hose

A8A2

Current No Blue Hose

A8B4

Current No Red

A8B7

Chiller Current

No Blue

A8B8

Chiller Current Motor Over

A9C1

Current

B9C0

Small Shot Request

B9C1 The requested dispense

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

equested dispense

The r amount is be 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

low the minimum

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

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Comm. Error

CAA2

Red Hose Comm. Error

CAA3

Red Inline Comm. Error

CAA6

Red Blanket Comm. Error

CAA7

Red Chiller Comm. Error

CAB1

Blue Inline Comm. Error

CAB4

Blue Hose Comm. Error

CAB5

Blue Blanket Comm. Error

CAB8

Blue Chiller Comm. Error

CAC1

Motor

CAC2

CAC3

CAC4

CAC5

CAC6

CAC7

CACN

CACP

CACR

CUCN

D1A1

D4A1

D2A1

D3A1

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 und change that caused a la

rge drop in restriction

(such as new orifices) No material in pumps

erwent a

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

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

This calibration lets the MCM know where the ends of the

Invalid Learn

D5A1

Mode Data

Position

D6A1

Sensor Fault

Red Pump

DDA1

Cavitation

Blue Pump

DDB2

Cavitation

Pump Not

DFA1

Parked

Check Flow

DR6A

Meter Red Check Flow

DR6B

Meter Blue Pumps Not

DSC0

Defined

F1A0

Low Flow Red

F2A0 Deviation F1B0

Low Flow Blue

F2B0 Deviation F4A0

High Flow Red

F3A0 Deviation F4B0

High Flow Blue

F3B0 Deviation

Pump Failed

F7D1

to Stall

Red Low

L111

Material Level

Blue Low

L122

Material Level

Red High

L311

Material Level Blue High

L322

Material Level Red Auto

L6A1

Refill Timeout Blue Auto

L6B2

Refill Timeout

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 not tur

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

meter are

ning

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

Red Tank

L8A1

Sensor Failure

Blue Tank

DR6B

Sensor Failure

MBH1 Low Oil Level

Low Motor

MBN1

Performance

USB Logs

MMUX

Full Material

N1D0

Dispense Below Alarm Material Dispense

N2D0

Below Deviation Material Dispense

N3D0

Above Deviation

Material

N4D0

Dispense Above Alarm

Pump Failed

N4A1

to Move

Thermal

P400

Pressure Rise

A level sensor had ceased working

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

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.

Error Type Cause Solution

Deviation Bad level sensor Replace level sensor

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

Loose/bad connection

Bad level sensor Replace sensor

Alarm

Leak in hydraulic driver

Leak in the hydraulic reservoir, heat exchanger

Advisory

Alarm

Deviation

Alarm

Deviation

Deviation High pressure

Prolonged exposure to heat or high voltage

USB logs have not been downloaded

Cogs in flow meter are not turning

Cable unplugged/loose power

Motor failure

Hydraulic pow failure

Loose/bad connection to the linear position sensor

Failure of the linear 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

er pack

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

Visually check to ensure the pump is moving, if not ensure the motor is wired properly If motor is moving 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

but pump is not and pressure is not

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Red Pressure

P4A1

Shutdown

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

Ratio monitor has detected an out of ratio condition

P4B2

P4D0

P6A1

P6B2

R1D0

R4D0

R2D0

R3D0

Blue Pressure Shutdown

Pressure Imbalance

Red Pressure Sensor Fault Blue Pressure Sensor Fault Low Ratio Alarm High Ratio Alarm Low Ratio Deviation High Ratio Deviation

Error Type Cause Solution

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

Alarm

Alarm Loose/bad connection

Alarm

Deviation

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

Material A to Material B is out of ratio

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

Check feed system

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Red Tank

T1A6

Low Fluid Temp.

Blue Tank

T1B5

Low Fluid Temp. Red Inline

T1A3

Low Fluid Temp. Blue Inline

T1B1

Low Fluid

T1A2

T1B4

T1A7

T1B8

T20X

T30X

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

Fluid temperature is below the defined low alarm limit

Dispensing disabled because of temperature

Error Type Cause Solution

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Alarm

Measure voltage across input terminals on power line

Advisory

Low power

Cable unplugged/loose power

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

Temperature is out of alarm limits

filter. Voltage should measure between 190 and 264 Vac

Check for loose or disconnected wires or plugs

Check temperature alarm limits

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Red Hose

T2AA

Low Fluid Temp.

Red Tank

T2AE

Low Fluid Temp. Red Chiller

T2AF

T2BC

T2BD

T2BG

T3AA

T3AE

T3AF

T3BC

T3BD

T3BG

T3H1

T3N1

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

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Red Hose

T4A2

High Fluid Temp.

Red Inline

T4A3

High Fluid Temp. Red Tank

T4A6

High Fluid Temp. Red Chiller

T4A7

High Fluid

T4B1

T4B4

T4B5

T4B8

T4C1

T4H1

T4N1

T6A6

T6B5

T6A3

T6B1

T6A2

T6B4

T6A7

T6B8

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

S F

FT 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

ault

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

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Red Blanket

T6C6

RTD Fault Blue Blanket

T6C7

T6C8

T8A6

T8A3

T8B1

T8A2

T8B4

T8A7

T8B8

T9A6

T9B5

T9A3

T9B1

T9C6

T9C5

T9C3

T9C2

T9C4

T9C7

T9C8

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 In 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 Alarm

No temperature decline Alarm

Heater overtemperature cutoff Alarm

line

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

Measure voltage across input terminals on power line

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

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

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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

Bad directional valve connection

Directional valve failure The directional valve will nee d 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 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 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

™

. If not replace the file with the proper

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Appendix D - ADM Error Codes

Error Code Error Name Error Description

Red Tank

WM06

Con. Fault Blue Tank

WM05

Con. Fault Red Inline

WM03

Con. Fault Blue Inline

WM01

WM02

WM04

WM07

WM08

WMA6

WMB5

WMC6

WMC5

WMC3

WMC1

WMC2

WMC4

WMC7

WMC8

WMH1

WSC0

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 Inter nal 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

mined that the gel

deter timer shot will not be able to be executed based para

meters 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.

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Appendix E - System Events

Event Code and String Triggers

REL00: System Pow ered On

REM00: System Pow ered Off

REB00: Stop Button Pressed

RECH0: Learn Mode Executed

RENN0: Automatic Cal. Performed

RECA1: Red Material SG Modified

RECB2: Blue Material SG Modified

RENC1: Cal. Point 1 Weight Entered

RENC2: Cal. Point 2 Weight Entered

RENC4: Cal. Point 1 Weight Erased

RENC5: Cal. Point 2 Weight Erased

REND0: Ratio Check Dispense

REA00: Disp. Occurred (Shot #)

REH00: Gel Timer Dispense

RER01: Shot Count Reset

RER02: Seq. Posi tion Count Reset

RERA1: Red Material Volume Reset

RERB1: Blue Material Volume Reset

RERA2: Red Material Weight Reset

RERB2: Blue Material Weight Reset

RERA3: Red Cycle Count Reset

RERB3: Blue Cycle Count Reset

REQU1: Settings Downloaded

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 suc cessfully completed.

The system was successfully charac terized with the Automatic calibration.

The Red materials specific gravity was modified.

The Blue materials specific gravity was modified.

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

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

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

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

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

A dispense has occurred of the given shot number.

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

A counter from the shot counters maintenance page was erased

A counter from the sequence counters maintenance page was erased

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

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

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

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

The resettable cycle counter for the Red pump was reset to zero.

The resettable cycle counter for the Blue pump was reset to zero.

The system settings were success fully transferred from the ADM to a USB drive.

Event Code and String Triggers

REQU2: Settings Uploaded

REQU3: Language Downloaded

REQU4: Language Uploaded

REQU5: Logs Down loaded

REAR0: Night Mode Recirc On

REBR0: Night Mode Recirc Off

The system settings file was success fully transferred from the USB drive to the ADM.

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

The custom language file was suc cessfully 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 recircula tion mode and attempted to turn on all enabled conditioning zones.

While in night mode the system has automatically stopped the low recircu lation mode and turned off all condi tioning zones.

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Graco HFR Setup And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual