Graco 3A2797J - HFR for NVH Foam Owner's Manual

Setup - Operation
HFR™ for NVH
Foam - Cart
3A2797J
EN
Hydraulic, Plural-Component, Fixed-Ratio Proportioner.
For dispensing NVH foam.
For professional use only. Not approved for use in explosive atmospheres or hazardous
locations.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 4 for model information and maximum
working pressure.
Patents Pending
ti19507a
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GX-16 Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B (Blue) and A (Red) Feed Tanks . . . . . . . . . . . 6
AC Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Refill Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GX-16 Shutoff Valve Kit . . . . . . . . . . . . . . . . . . . 6
Additional Accessories . . . . . . . . . . . . . . . . . . . . 7
Communications Gateway Module (CGM) . . . . . 7
Bag Filter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GX-16 Fitting Kits . . . . . . . . . . . . . . . . . . . . . . . . 7
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Important Two-Component Material Information 11
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 11
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 11
Keep Components A (Red) and B (Blue) Separate
11
Moisture Sensitivity of Isocyanates . . . . . . . . . . 11
Foam Resins with 245 fa Blowing Agents . . . . . 11
Changing Materials . . . . . . . . . . . . . . . . . . . . . . 12
A (Red) and B (Blue) Components . . . . . . . . . . . . 12
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Identification . . . . . . . . . . . . . . . . . . . 14
HFR Hydraulic Power Pack . . . . . . . . . . . . . . . 17
Motor Control Module (MCM) . . . . . . . . . . . . . . 18
Advanced Display Module (ADM) . . . . . . . . . . . 20
Fluid Control Module (FCM) . . . . . . . . . . . . . . . 23
Temperature Control Module . . . . . . . . . . . . . . 24
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 44
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Install Upgrade Tokens . . . . . . . . . . . . . . . . . . . 47
IsoGuard Select™ System . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Tower (Optional) . . . . . . . . . . . . . . . . . . .
Appendix A - ADM Icons Overview . . . . . . . . . . .
Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . .
Run Screen Icons . . . . . . . . . . . . . . . . . . . . . . .
Appendix B - ADM Setup Screens Overview . . .
Appendix C - ADM Run Screens Overview . . . . .
2
Appendix D - ADM Error Codes . . . . . . . . . . . . . . 75
Appendix E - System Events . . . . . . . . . . . . . . . . 87
Appendix F - USB Operation . . . . . . . . . . . . . . . . . 89
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
USB Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Download Log Files . . . . . . . . . . . . . . . . . . . . . . 89
Log Files, Folder Structure . . . . . . . . . . . . . . . . 90
Transfer System Settings . . . . . . . . . . . . . . . . . 92
Update Custom Language . . . . . . . . . . . . . . . . . 93
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Motor Control Module Technical Data . . . . . . . . 96
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 98
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 98
48
50
50
52
52
53
54
69
3A2797J
Related Manuals
Related Manuals
Manuals are available at www.graco.com. Component
manuals below are in English:
System Manuals
313998
HFR Repair-Parts
Power Distribution Box Manual
3A0239
Power Distribution Boxes Instructions-Parts
Pumpline Manuals
3A0019
Z-Series Chemical Pumps Instructions-Parts
3A0020
HFR Hydraulic Actuator Instructions-Parts
Feed System Manuals
3A0238
AC Hydraulic Power Pack Instructions-Parts
3A0235
Feed Supply Kits
Instructions-Parts
3A0395
Stainless Steel Tank Feed Systems Instructions-Parts
3A1299
Carbon Steel Tank Feed Systems
Instructions-Parts
3A0237
Heated Hoses and Applicator Kits,
Instructions-Parts
308495
Viscon® Heater Kit Manual
Dispense Valve Manuals
313536
GX-16, Operation
Accessory Manuals
3A1149
HFR Discrete Gateway Module
Kits Manual
312864
HFR Communications Gateway
Module Instructions-Parts
3A1936
Agitator Kit
Instructions-Parts
3A1962
Agitator Kit with Heat Blanket
Instructions-Parts
3A1657
HFR Flow Meter Kits
Instructions-Parts
332544
HFR for NVH Prepoly Refresh Kit
Instructions-Parts
3A2797J
3
Models
Models
Primary
Heater
Watts
A (Red)
System
Full Load
Peak Amps
Per Phase*
Voltage
(phase)
24N569
90
230V (3)
24N570 
68
400V (3)
24N571
90
230V (3)
24N572 
68
400V (3)
24N573
90
230V (3)
24N574 
68
400V (3)
24N575
90
230V (3)
24N576 
68
400V (3)
System
24N569
24N570 
24N571
24N572 
24N573
24N574 
24N575
24N576 
System
Primary
Heater
Watts
B (Blue)
Max Flow
Rate
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Maximum
Hydraulic Fluid Working
Pressure
Pressure ‡
Ratio
psi (MPa, bar)
18 (8.2)
0.033 (0.125)
1.9:1
24 (11)
0.045 (0.170)
1.4:1
4,000
2000
(14, 138)
6,000
6,000
17 (7.7)
0.032 (0.121)
3.7:1
4,000
18 (8.2)
0.033 (0.125)
1.9:1
Material
Ratio
(A:B)
A (Red)
Pump
Size
B (Blue)
Pump
Size
A (Red)
Orifice
B (Blue)
Orifice
24:1
120
5
.061
.011
16:1
160
10
.057
.014
1:1
60
60
.039
.039
24:1
120
5
.085
.013
25’ (7.6 m)
Chemical
Hose Bundle
10’ (3 m)
Chemical
Hose Bundle
24J290
24J316
24N287
24N289
24K681
27.5’ (8.4 m)
10’ (3 m)
Hydraulic
Hydraulic
Hose Bundle Hose Bundle
24N569
24N570 
24N571
24N572 
24N573
24V197
24J177
24N574 
24N575
24N576 
4
3A2797J
Models
*
Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and
mix chamber sizes may be less.
 Flow rate is independent of frequency 50/60 Hz.
approved.

‡ The maximum fluid working pressure for the base machine without hoses is 3000 psi (20.7 MPa, 207 bar). If
hoses rated at less than 3000 psi are installed, the system maximum fluid working pressure becomes the rating of
the hoses. If 2000 psi hoses were purchased and installed by Graco, the working pressure for the machine is
already setup for the lower 2000 psi (13.8 MPa, 138 bar) working pressure by Graco. If the machine was purchased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed, see instruction manual 313998 for the procedure to setup the machine for higher rated hoses. The change in working pressure is
made by changing a rotary switch setting in the Motor Control Module. The minimum pressure rating for hoses is
2000 psi. Do not install hoses with a pressure rating lower than 2000 psi.
 See 400 V Power Requirements.
400 V Power Requirements
•
400 V systems are intended for International voltage
requirements. Not for voltage requirements in North
America.
•
If a 400 volt configuration is operated in North America, a special transformer rated for 400 V (“Y” configuration (4 wire)) may be required.
•
North America mostly employs a 3 wire or Delta
configuration. The two configurations are not interchangeable.
3A2797J
5
Accessories
Accessories
Applicator
B (Blue) and A (Red) Feed Tanks
Part
Description
24J187
GX-16, 24:1, Straight, Machine Mount
24K233
GX-16, 24:1, Left, Machine Mount
24K234
GX-16, No Orifice, Left, Machine Mount
24E876
GX-16, No Orifice, Straight, Machine Mount
24E877
GX-16, 24:1, Right, Machine Mount
24E878
GX-16, No Orifice, Right, Machine Mount
GX-16 Orifices
Part
Part
24N595 20 gal. (75 l) Stainless Steel Tank, No Agitation,
Insulation, 3 Level Sensors, B-Side
24N578 20 gal. (75 l) Carbon Steel Tank, No Agitation, 3
Level Sensors, A-Side
24N597 20 gal. (75 l) Carbon Steel Tank, No Agitation, 3
Level Sensors, B-Side
24N579 2 gal. (8 l) Stainless Steel Tank, No Agitation, 1
Level Sensor, B-Side
Description
AC Power Pack
257701
0.011 in. Orifice
257702
0.013 in. Orifice
24N158
0.014 in. Orifice
Part
257703
0.016 in. Orifice
24J912
230V, AC Power Pack
257704
0.018 in. Orifice
24J913
400V, AC Power Pack
257705
0.020 in. Orifice
24E347
Hydraulic Power Pack Level Sensor Kit
257706
0.022 in. Orifice
257707
0.023 in. Orifice
257708
0.024 in. Orifice
257709
0.025 in. Orifice
257710
0.026 in. Orifice
257711
0.028 in. Orifice
257712
0.029 in. Orifice
257713
0.032 in. Orifice
257714
0.035 in. Orifice
257715
0.036 in. Orifice
257716
0.038 in. Orifice
257717
0.039 in. Orifice
257718
0.040 in. Orifice
257719
0.042 in. Orifice
257720
0.043 in. Orifice
257721
0.044 in. Orifice
257722
0.049 in. Orifice
257723
0.052 in. Orifice
24N159
0.057 in. Orifice
257724
0.061 in. Orifice
24K682
0.085 in. Orifice
Description
24C872 Hydraulic Power Pack Pressure Gauge Kit
24E348
Hydraulic Power Pack Temperature Sensor
124217
Power Pack Accumulator Charging Kit
Refill Kits
Part
Description
24M418 Low Volume, 2 gal. (7.6 l) tank
24M419 High Volume, 20 gal. (76 l) tank
GX-16 Shutoff Valve Kit
Part
Description
24M596 GX-16 Shutoff Valve Kit
For use with: 24N569, 24N570, 24N571, 24N572,
24N573, 24N574
24M368 GX-16 Shutoff Valve Kit
For use with: 24N575, 24N576
GX-16 Proximity Kit
Part
24K659
6
Description
24N594 20 gal. (75 l) Stainless Steel Tank, No Agitation,
Insulation, 3 Level Sensors, A-Side
Description
GX-16 Proximity Kit
3A2797J
Accessories
Additional Accessories
Part
Description
24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level
Sensor
24C873 Hydraulic Power Pack Manifold Oil Temperature
Sensor
24F516
IsoGuard Select fluid, 6 quarts
121728
Extension Cable for Advanced Display Module,
4 meter,
255468
Light Tower
255244
Foot Switch with Guard and 4 meter Cable
24G389 Pneumatic Agitator for 20 gal. (75 l) Carbon Steel
Tank, No Heat
24K344
Pneumatic Agitator for 20 gal. (75 l) Carbon Steel
Tank, Heat
24K348
Pneumatic Agitator for 20 gal. (75 l) Stainless
Steel Tank, No Heat
24K346
Pneumatic Agitator for 20 gal. (75 l) Stainless
Steel Tank, Heat
24K223
Isolated Pistol Grip Adapter
123694
Straight Gun Cover
123226
90° Gun Cover
123695
12 ft (3.7 m) Hose Cover
125236
Z-Series Pump Cover
125113
Gun Cover Handle Hole Cover
248280
3 oz. Quik Shot Grease Tube (10 Pack)
117792
3 oz. Grease Gun
0553-6
14 oz. Synthetic Grease Tube
255468
Light Tower Kit
Communications Gateway
Module (CGM)
Part
24J415
Description
CGM Mounting Kit
(Required for all applications)
CGMDN0 GCA Gateway Module, DeviceNet Fieldbus
CGMEP0 GCA Gateway Module, EtherNet/IP Fieldbus
CGMPB0 GCA Gateway Module, PROFIBUS Fieldbus
CGMPN0 GCA Gateway Module, PROFINET Fieldbus
Bag Filter Kits
Part
Description
24J312
High Volume Filter Kit (40 Mesh)
24P095
Low Volume Filter Kit (100 Mesh)
125147
40 Mesh Filter Replacement
125148
100 Mesh Filter Replacement
0135-4.30x.313 TEV O-Ring for Lid Seal
0131-4.30x.313 EP O-Ring for Lid Seal
GX-16 Fitting Kits
The following kit is for Models 24N575 and 24N576 only.
Part
24N435
Description
Gun Fitting Kit
24T182* Flow Meter Kit, NVH Cart, 24:1 and 16:1
24T183* Flow Meter Kit, NVH Cart, 1:1
*
24T180
PrePoly Refresh Kit, NVH Cart, with Autofill
24T181
PrePoly Refresh Kit, NVH Cart, without Autofill
Flow meter electronics kit, 24J318, is required for flow meter kit
installation.
3A2797J
The following kits are for all other Models.
Part
Description
24K672
Right Orientation, 90° Fitting Adapter Kit
24K674
Left Orientation, 90° Fitting Adapter Kit
7
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
•
•
•
Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
Connect only to grounded power source.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•
Read MSDSs to know the specific hazards of the fluids you are using.
•
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
•
Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
•
•
Protective eyewear, and hearing protection.
Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
+
•
Do not point dispensing device at anyone or at any part of the body.
•
Do not put your hand over the fluid outlet.
•
Do not stop or deflect leaks with your hand, body, glove, or rag.
•
8
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.
3A2797J
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:
•
•
•
•
Use equipment only in well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
Keep work area free of debris, including solvent, rags and gasoline.
Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•
Ground all equipment in the work area. See Grounding instructions.
•
Use only grounded hoses.
•
Hold gun firmly to side of grounded pail when triggering into pail.
•
•
If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
Keep a working fire extinguisher in the work area.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or
property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
•
3A2797J
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.
9
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•
Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
•
Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
•
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•
Do not alter or modify equipment.
•
Use equipment only for its intended purpose. Call your distributor for information.
•
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•
Do not kink or over bend hoses or use hoses to pull equipment.
•
Keep children and animals away from work area.
•
Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
•
Keep clear of moving parts.
•
Do not operate equipment with protective guards or covers removed.
•
Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
•
10
Do not touch hot fluid or equipment.
3A2797J
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Material Self-ignition
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Keep Components A (Red) and
B (Blue) Separate
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of
the equipment’s wetted parts, never interchange
component A (Red) and component B (Blue) parts.
3A2797J
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
To prevent exposing ISO to moisture:
•
Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
•
Keep the ISO lube pump reservoir (if installed) filled
with IsoGuard Select™, part 24F516. The lubricant
creates a barrier between the ISO and the atmosphere.
•
Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
•
Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
•
Never use solvent on one side if it has been contaminated from the other side.
•
Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
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.
11
A (Red) and B (Blue) Components
Changing Materials
•
When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
•
Always clean the fluid inlet strainers after flushing.
•
Check with your material manufacturer for chemical
compatibility.
•
Most materials use ISO on the A (Red) side, but
some use ISO on the B (Blue) side. See the following section.
A (Red) and B (Blue) Components
IMPORTANT!
For all machines:
Material suppliers can vary in how they refer to plural
component materials.
•
•
Be aware that when standing in front of the manifold on
proportioner:
•
•
•
12
Component A (Red) is on the left side.
Component B (Blue) is on the right side.
The A (Red) side is intended for ISO, hardeners,
and catalysts.
If one of the materials being used is moisture-sensitive, that material should always be in the A (Red)
side.
The B (Blue) side is intended for polyols, resins, and
bases.
3A2797J
Typical Installation
Typical Installation
C
D
A
G
H
B
J
E
F*
ti19507a
* Shown exposed for clarity.
Wrap with tape during operation.
FIG. 1: Typical Installation
Key:
A
B
C
D
E
F
G
H
J
Tank Stand - A (Red)
Tank Stand - B (Blue)
AC Power Pack
HFR Power Pack
Dispense Gun
Fluid Temperature Sensor (FTS)
Manifold
Main Hose Bundle
Whip Hose Bundle
3A2797J
13
Component Identification
Component Identification
Key for FIG. 2 and FIG. 3.
AA
BA
BB
FA
FB
FM
FP
FT
GA
GB
HA
HB
HP
HT
LS
Advanced Display Module (see page 20)
Component A (Red) Pressure Relief Outlet
Component B (Blue) Pressure Relief Outlet
Component A (Red) Fluid Manifold Inlet (on left side of
manifold block)
Component B (Blue) Fluid Manifold Inlet
HFR Fluid Manifold
Feed Inlet Pressure Gauge
Feed Inlet Temperature Gauge
Component A (Red) Outlet Pressure Gauge
Component B (Blue) Outlet Pressure Gauge
Component A (Red) Hose Connection (from feed to gun
or mix head)
Component B (Blue) Hose Connection (from feed to gun
or mix head)
Hydraulic Power Pack Assembly
Hydraulic Tank
Pumpline Linear Sensor
MA Motor Control Module, see page 18
MP Main Power Switch
PA Component A (Red) Pump
PB Component B (Blue) Pump
PD Power Distribution Box
PHB Primary Heater - B Side
PHA Primary Heater - A Side
PI Primary Heater Fluid Inlet
PO Primary Heater Fluid Outlet
PR Primary Heater RTD
PS Primary Heater Overtemperature Switch
SA Component A (Red) PRESSURE RELIEF/DISPENSE
Valve
SB Component B (Blue) PRESSURE RELIEF/DISPENSE
Valve
TA Component A (Red) Pressure Transducer
TB Component B (Blue) Pressure Transducer
TC High Power Temperature Control Module (not shown, see
page 24)
MA
HP
AA
FM
PD
PA
HT
FP
PB
FT
FP
ti19508a
FIG. 2: Component Identification, Heated Model shown with shrouds removed
14
3A2797J
Component Identification
Fluid Manifold (FM) Detail
SA
GA
Rear View
TB
GB
SB
TA
MP
FA
LS
FB
BA
HA
BB
HB
ti9880a1
ti19510a
Primary Heater (PHB)
Detail, B (Blue) side shown
Primary Heater (PHA)
Detail, A (Red) side shown
PO
PI
PS
(In Enclosure)
PR
PI
PS
ti19511a
ti19509a
PO
PR
FIG. 3: Component Identification, Continued
3A2797J
15
Component Identification
Main Power Switch
Circuit Breakers
Located on top of the power distribution box, see
page 14. The main power switch turns power
ON
and OFF
. The main power switch
does not turn pumps or heat zones on.
Most circuit breakers are located inside the power distribution box. The main block of circuit breakers in the
power distribution box is shown below, with detailed
information in the following table. For more information
about items in the power distribution box, see power distribution box manual.
400V/ 3 phase
ti19512a
CB11
CB1
CB2
CB6
CB9
CB5
230V/ 3 phase
ti19513a
Size
400V/
3 phase
230V/
3 phase
Component
CB1
63A
30A
Motor Control Module
CB2
40A
40A
Primary Heater A
CB5
5A
5A
Miscellaneous
CB6
5A
5A
Miscellaneous
CB9
40A
40A
Primary Heater B
CB11
30A
30A
AC Power Pack
Ref.
16
3A2797J
Component Identification
HFR Hydraulic Power Pack
DE
DG
DF
DK
DB
DH
DA
DD
ti19514a
DL
FIG. 4: HFR Hydraulic Power Pack
Key:
DA 9 Gallon Hydraulic Oil Reservoir (see Technical Data on
page 95 for specifications)
DB Electric Motor
DD Hydraulic Housing
DE Directional Valve
DF Motor Control Module (see page 18)
3A2797J
DG
DH
DJ
DK
DL
Fan
Oil Filter
Shroud (not shown, removed for clarity)
3 Way Splitter
Oil Level Sensor (Optional)
17
Component Identification
Motor Control Module (MCM)
For MCM location, see reference MA in FIG. 2 on
page 14. When installed, the end of the MCM with the
power input connection (12) faces down and the end
with the access cover (A) faces up.
NOTICE
If the Motor Control Module is replaced, the selector
switch must be set prior to initial startup of the Motor
Control Module or damage may occur. See HFR
Repair manual for details, see Related Manuals on
page 3.
The Motor Control Module uses an 8-position selector
switch to set the system maximum working pressure.
B
A
3
1A
C
10
1B
r_257396_3b9905_01b
2
6
8
9
11
7
12
13
5
r_257396_3b9905_03b
FIG. 5: MCM Component Identification
18
3A2797J
Component Identification
Ref
Description
A
Access Cover
B
LEDs
C
Warning Label
1A, 1B
CAN Connections
2
Three-way Splitter to: Oil Low Level
Sensor, Dispense Valve Solenoid, and
Footswitch
3
Oil Temperature Sensor
5
Electric Motor Temperature Sensor
6
LVDT (Position Sensor)
7
Three-way Splitter to:
Hydraulic Directional Valve,
Oil Overtemperature Switch
8
Pressure Transducer B (Blue) side
9
Pressure Transducer A (Red) side
10
Not used
11
Motor Position Sensor
12
MCM Power Input Connection
13
Motor Power Connection
Diagnostic Information
Table 1: LED (Ref B) Status Signal
7
Module Status LED Signal
Description
Green on
System is powered up.
Yellow on
Internal communication in progress.
Red solid
MCM hardware failure. Replace MCM.
Red flashing fast
Uploading software.
Red flashing slow
Token error. Remove token and upload
software token again.
3A2797J
19
Component Identification
Advanced Display Module (ADM)
User Interface
CB
CC
CD
CA
CE
CF
CF
CH
CG
TI12362a1
FIG. 6: ADM Component Identification - Front
Buttons
Ref. Button
CA
CB
CC
System
enable/
disable
Function
Ref. Button
Function
Enables/disables system. When system is disabled, temperature control
and dispense operation are disabled.
CD
Soft
Keys
Defined by application using ADM.
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
Setup
Toggle between run and setup
screens or password screen if setup
screens are password protected.
CH
Navigation
Navigate within a screen or to a new
screen.
System Displays system status. See System
Status Indicator (CB) Conditions on
Status
Indicator page 20 for details.
Light
Stop
Stop all system processes.
System Status Indicator (CB) Conditions
Green Solid - Run Mode, System On
Green Flashing - Setup Mode, System On
Yellow Solid - Run Mode, System Off
20
3A2797J
Component Identification
CJ
CS
CK
CL
CM
CR
CN
CP
r_24E451_3B9900_1a
FIG. 7: ADM Component Identification - Rear
Key:
CJ
CK
CL
CM
Flat Panel Mount
Model Number
USB Module Interface
CAN Cable Connections
CN
CP
CR
CS
Module Status LEDs
Accessory Cable Connections
Token Access Cover
Battery Access Cover
ADM Module Status LEDs (CN) Conditions
Module Status LED Signal
Description
Green on
System is powered up.
Yellow on
Communication in progress.
Red solid
ADM hardware failure.
Red flashing fast
Uploading software.
Red flashing slow
Token error. Remove token and upload
software token again.
USB Module Status LEDs (CL) Conditions
Module Status LED Signal
Description
Green flashing
System is powered up.
Yellow on
Downloading information to USB
Green/Yellow Flashing
ADM is busy, USB cannot transfer
information when in this mode
3A2797J
21
Component Identification
Main Display Components
The following figure calls out the navigational, status, and general informational components of each screen. For
details regarding the user interface display see Shutdown, page 44.
Current date and time
Mode
Previous chapter
(Left Arrow)
Current chapter
Next chapter
(Right Arrow)
Faults, Status
Enter/Exit screen
Previous
page
(Up Arrow)
Current
page
Function display
Next
page
(Down Arrow)
FIG. 8: Main Display Components
22
3A2797J
Component Identification
Fluid Control Module (FCM)
A
C
E
ti12337a1
B
ti12336a1
F
D
FIG. 9: Fluid Control Module (FCM)
Key:
A
B
C
Fluid Control Module
Base
Module Connection Screws
D
E
F
Access Cover
Module Status LEDs
CAN Connectors
Diagnostic Information
Module Status LED (Ref E) Signal
Diagnosis
Green on
System is powered up
Yellow
Internal communication in progress
Red solid
FCM hardware failure. Replace FCM.
Red flashing fast
Uploading software.
Red flashing slow
Token error. Remove token and
upload software token again.
3A2797J
23
Component Identification
Temperature Control Module
LED
Signals
2
5
1
7
3
ti12352a1
6
ti12353a1
4
FIG. 10: High Power Temperature Control Module Sensor Connections
Key:
1
2
3
Overtemperature Switch Connection (primary heaters
only)
RTD Temperature Sensor Connection
Output Power Connection
4
5
6
7
DC Output Connection
Input Power Connection
CAN Connections
Rotary Selector Switch, Token Access
5
1
2
LED
Signals
6
3
ti12356a1
ti12357a1
4
7
FIG. 11: Low Power Temperature Control Module Cable Connections
1
2
3
24
Overtemperature Switch Connection
RTD Temperature Sensor Connection
Output Power Connection
4
5
6
7
DC Output Connection
Input Power Connection
CAN Connections
Base
3A2797J
Component Identification
Temperature Control Module Diagnostic
Information
Module Status LEDs
Signal
Description
Green on
Temperature control module is
powered up.
Yellow on
Internal communication in progress.
Red solid
Temperature control module failure. See Troubleshooting table.
Red flashing
fast
Uploading software.
Red flashing
slow
Token error. Remove token and
upload software token again.
Blue light off
(High Power
Module only)
Temperature control module is off.
See Troubleshooting table.
Blue flashing
(High Power
Module only)
Length of flashes indicates amount
of power running through temperature control module.
Heat Control Zone Selection
The HFR unit supports four independent temperature
control zones and two independent temperature monitoring zones. The high power temperature control modules are located inside the frame below the hydraulic
power pack.
Primary Heater B (Blue)
Left Side from
Rear View
ti17748a
Material Temperature
Primary Heater A (Red)
FTS - (Red)
Right Side from
Rear View
ti17749a
3A2797J
25
Component Identification
Adjust Rotary Switch
High Power Module Rotary Switch Settings
The rotary switch setting indicates which zone the temperature control module will control in the system. The
high power module uses an 8-position rotary switch.
The low power module uses a 16-position rotary switch.
Setting
Zone
0
Not Used
1
B (Blue) Primary Heat
2
B (Blue) Hose Heat
Set the rotary switch (S) to the specific selection according to the settings listed in the following tables.
3
A (Red) Primary Heat
4
A (Red) Hose Heat
5 through 7
Not Used
High Power Module Rotary Switch Location
Low Power Module Rotary Switch Settings
S
Setting
Zone
0 through 4
Not Used
5
B (Blue) Tank Heater
6
A (Red) Tank Heater
7
B (Blue) Chiller
8
A (Red) Chiller
9 through F
Not Used
ti12360a
Low Power Module Rotary Switch Location
S
ti12361a
FIG. 12: Rotary Switch
26
3A2797J
Component Identification
3A2797J
27
Setup
Setup
Perform this setup procedure to secure all necessary
machine connections for machine operation.
3. Ground system
1. Locate system.
a. Locate system on a level surface. See Dimensions on page 97 for space requirements.
b. Do not expose system to rain.
2. Electrical requirements. See Models on page 4
for detailed electrical requirements information.
This equipment must be grounded.
a. System: grounded through power cord. See
step 4 on page 28.
b. Fluid supply containers: follow your local code.
c.
Installing this equipment requires access to parts
which may cause electric shock or other serious injury
if work is not performed properly. Have a qualified
electrician connect power and ground to main power
switch terminals, see step 4 in this setup procedure.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
Object being dispensed into: follow your local
code.
d. Solvent pails used when flushing: follow your
local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not
place pail on a nonconductive surface, such as
paper or cardboard, which interrupts grounding
continuity.
e. To maintain grounding continuity when flushing
or relieving pressure, hold a metal part of dispense gun firmly to the side of a grounded metal
pail, then trigger gun.
4. Connect electrical cord to system.
NOTE: See Power Line Voltage Surges information on
page 29.
NOTE: Power cord is not supplied. See the following
table.
28
3A2797J
Setup
Table 2: Power Cord Requirements
Cord Requirements
AWG (mm2)
Model
Heated system,
230V, 3 phase
4 (21.2), 3 wire + ground
Heated system,
400V, 3 phase
4 (21.2), 4 wire + ground †
† Residual Current Device (RCD) must be rated at
300 mA if installed.
Electrical Cord Wires by Model
230V, 3 phase: L1, L2, L3, GND
400V, 3 phase: L1, L2, L3, N, GND
The MAX-HOLD feature on a multimeter can be used to
determine peak DC voltage on the line. DC is the proper
setting, as opposed to AC, because peak voltage is the
critical parameter that affects the DC voltage level
stored on the capacitive bus in power conversion equipment. Reading should not regularly exceed approximately 400VDC to avoid tripping the 420VDC alarm
level in the Motor Control Module. If power quality is
suspect, power conditioning or isolation of the device(s)
causing poor power quality is recommended. Consult a
qualified electrician if there are any concerns about the
available power supply.
Power Line Test Steps with Multimeter
a. Set multimeter to “DC voltage”.
Use 5/32 or 4 mm hex allen wrench to connect the three
power leads to L1, L2, L3, and Neutral (as required).
Connect green to ground (GND).
b. Connect multimeter probes to supplied power
line.
c.
N L3 L2 L1
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).
GND
The chart below shows the permissible magnitude and
duration of temporary over-voltage events:
r_24C686_313998_1a
FIG. 13: 400V, 3 phase shown
Maximum Permissible Transient Voltage Surges
* Constructed from ITIC 1996 curve, referenced by IEC 61000-2-4
Power conversion equipment can be sensitive to voltage
fluctuations on incoming power. The Motor Control Module falls under the category of power conversion equipment because energy is stored on a capacitive bus and
then modulated to control a brushless motor. Engineered design takes this into account and withstands a
wide range of conditions, but it is possible for supplied
power to occasionally fall outside the tolerable range in
industrial plants with high-amperage reactive pulsed
loads such as welding equipment. If the tolerable range
is exceeded, an overvoltage condition is flagged and the
system will shut down in an alarm state to protect itself
and alert the user of unstable power. Excessive or
repeated overvoltage may permanently damage hardware.
3A2797J
1200
<--1 MW Max Surge Power
1200Vac, 1697Vdc
1000
Voltage (Volts RMS)
Power Line Voltage Surges
1400
800
600
480Vac, 679Vdc
400
<--150 KW Max Surge Power
336Vac, 475Vdc
<--50 KW Max Surge Power
288Vac, 407Vdc
200
<--No Power Limit
264Vac, 373Vdc
0
0.000001
0.00001
0.0001
0.001
0.01
0.1
1
10
Time (seconds)
29
Setup
5. Connect HFR Proximity Cables to the GX-16.
6. Connect Hydraulic Lines to the system.
NOTE: Refer to the HFR and GX-16 manuals for more
details for the following procedures.
NOTE: The cable is indicated by a green stripe.
a. Connect the GX-16 proximity sensor to the
proximity cable.
b. Connect the 10 ft (3 m) hydraulic whip hose
cable to the 25 ft (7.6 m) chemical hose cable.
c.
Connect the other end of the cable to the electrical connector found near the fluid manifold on
the HFR.
NOTICE
Damage can occur to the directional valve if the
hydraulic hose diameter is larger than 3/8 in.
(9.5 mm).
To prevent damage to the applicator or directional
valves, do not allow any dirt or foreign matter to
enter the lines, when connecting the hose kit to the
applicator and hydraulic power pack.
a. Connect the hydraulic hose to the hydraulic
hose fittings (A2 and B2) on the AC power pack.
Hydraulic
Hose Fitting
Hydraulic
Hoses
Hydraulic Hose
Color Markings
A2
B2
Material close
Material open
Green
Green/White
NOTE: The electrical connector will be indicated by a
green stripe and labeled “PG-MPO”.
B2
A2
ti19515a
FIG. 14: Hydraulic Fittings on Hydraulic Housing
b. Hand tighten each fitting.
c.
30
Tighten each fitting 1/4 turn past hand tight.
3A2797J
Setup
7. Install GX-16 Fitting Adapter Kit
(Models 24N575 and 24N576 Only).
8. Install Flow Meter Kit (Optional).
Refer to HFR Flow Meter Kits, Instruction-Parts manual
for installation and setup instructions.
a. Remove the chemical fittings from the back of
the GX-16.
b. Install JIC #4 fitting assembly into the B Supply
port.
c.
Install JIC #6 fitting assembly into the B Return
port.
d. Install JIC #8 fitting assembly into both A Supply
and A Return ports.
3A2797J
9. Install PrePoly Refresh Kit (Optional).
Refer to HFR for NVH Prepoly Refresh Kit, Instructions-Parts for installation and setup instructions.
31
Setup
Step 9g,
Step 9h
Step 9i,
Step 9j
Step 9c,
Step 9d,
Step 9e,
Step 9f
ti19507a
FIG. 15: Material Hose Connections
32
3A2797J
Setup
10. Connect Material Hoses
d. Remove reducer fitting from B (Blue) connection of the HFR fluid manifold (Models 24N573,
24N574 only). Install the provided additional
spacers near the location of the FTS for the
remaining material lines. Refer to FIG. 15 and
FIG. 16.
NOTICE
HFR material
manifold
Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components. This also prevents fittings from
leaking.
A
B
Remove
reducer
NOTE: Refer to FIG. 15 on page 32 for visual clarity of
the following steps.
a. Ensure main power is OFF
.
b. Ensure A (Red) and B (Blue) inlet valves on the
HFR and the material supply ball valves on the
tanks are closed.
FIG. 16: Material Manifold
e. Install ball valves (optional) between main hose
and whip hose. Connect the main hose bundle
to the whip hose bundle.
NOTE: The ball valve kit is designed to fit in one orientation only.
NOTICE
If using the ball valve kit, ensure the FTS does not
go through the ball valve. Failure to do so will result
in damage to the FTS and the inability to close the
ball valve.
f.
c.
3A2797J
Remove reducer fitting from the A (Red) connection of the HFR fluid manifold. Install FTS in
the A (Red) material supply line between main
hose and whip hose. Ensure the FTS is facing
toward the fluid flow of material after installation.
See Heated Hose manual for instructions. Refer
to FIG. 15 and FIG. 16.
Assemble the hydraulic hose sections together
and place the assembled hose connection near
the FTS area. Refer to FIG. 15.
g. Connect A (Red) and B (Blue) hoses to A (Red)
and B (Blue) outlets on HFR fluid manifold (FM).
Hoses are color coded: solid red for component
A, solid blue for component B.
33
Setup
h. Connect cables (Y). Be sure cables have slack
when hose bends. Wrap cable and electrical
connections with electrical tape. See Heated
Hose manual for heated hose connection
details and illustrations for the various types of
heated hoses.
11. Connect GX-16 Hydraulic Lines
a. Navigate to the System Screen 2 and set the
mode to run as straight head: prox dispense
valve.
Y
Trapped air can cause the pump to cycle unexpectedly,
which could result in serious injury from splashing or
moving parts.
b. Verify the mixhead hydraulic power pack is not
active by verifying the gauge is at 0.
i.
Connect the other end of the supply hoses
(solid color) to the applicator. See the applicator
manual for fluid inlet identification.
j.
Connect A (Red) and B (Blue) return hoses
(solid with white stripe) to the applicator. See
the applicator manual for fluid outlet identification.
NOTE: The other end of the return hose will be connected in step n on page 39.
FIG. 17: Gauge
c.
Check the hydraulic fluid level. See Technical
Data on page 95 for specifications.
d. Use the supplied 7/16 in. JIC male-male
adapter at the gun end to connect hoses
34
3A2797J
Setup
together. This creates a hydraulic fluid circulation loop.
NOTE: The hydraulic hose marked with both green and
white stripe is for the open port of the gun. The hydraulic
hose marked with only a green stripe is for the close port
of the gun.
ti14495a
FIG. 18: Hydraulic Loop
ti14496a
FIG. 19: Hydraulic Connections
e. Turn on the power pack by navigating to the
Home Screen, Standby Mode and press
.
Circulate oil for 3 minutes to purge air from
hydraulic hoses.
j.
Attach trigger switch cable (if applicable) to gun
and HFR.
NOTE: Pressure should not increase while air is purged
from hoses.
f.
Turn off the power pack by pressing
. Look
at the gauge to verify no pressure exists in the
hydraulic hoses and the AC Power Pack.
g. Remove the 7/16 in. JIC male-male adapter
connecting the hydraulic hoses.
ti14494a
NOTICE
To prevent air from entering the hydraulic hoses, do
not spill oil while disassembling the adapter connection. If spilling occurs, replace the lost fluid by manually filling the hoses with hydraulic fluid.
h. Fill both open and close gun chambers with
hydraulic fluid.
i.
3A2797J
Attach hydraulic hoses to the gun. Tighten each
fitting 1/4 turn past hand tight.
FIG. 20: Cable Connections
35
Setup
12. Setup the Advanced Display Module (ADM)
Perform the following tasks to fully setup your system.
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.
Enter Setup Mode by pressing the
button.
a. Define shots. See Shots Screen, page 55 for
more detail.
b. Define sequences. See Sequences Screen,
page 58 for more detail.
c.
Calibrate HFR, page 37. See Calibration
Screen, Main, page 59 for more detail.
d. Define pump information. See
System Screen 1, page 60 for more detail.
To begin using the ADM, the machine must be on and
enabled. To verify the machine is enabled, verify the
System Status Indicator Light (CB) is illuminated green,
see FIG. 6 on page 20. If the System Status Indicator
Light is not green, press the ADM Power On/Off (CA)
button
. The System Status Indicator Light will illuminate yellow if the machine is disabled.
The blue token (24M560) must be installed to enable
cold start up, temperature monitor zones, and shot
times less than one second.
NOTICE
e. Define dispense valve and other system settings. See System Screen 2, page 60 for more
detail.
f.
g. If desired, view/reset counters. See Maintenance Screen, page 62 for more detail.
h. Define level sensors and refill settings. See
Supply Screen, page 63 for more detail.
i.
Enable/disable temperature conditioning components. See Conditioning Screen 1, page 64
for more detail.
j.
Define temperature conditioning setpoints. See
Conditioning Screen 2, page 64 for more
detail.
k.
If Night mode will be used, define Night mode
settings. See Conditioning Screen 3, page 65
for more detail.
l.
Set general system settings. See Advanced
Screen 1, page 67 for more detail.
To ensure proper machine operation, the blue token
must remain installed in the ADM during operation.
If the machine is in the Disabled mode screen press
repeatedly to select standby mode.
Navigation
•
Press
or
to navigate to new screens.
•
Press
or
to navigate to new screens or
to move between fields.
•
36
Press
to activate the desired field or to activate/deactivate an option.
Define labels and other system settings. See
System Screen 3, page 61 for more detail.
m. Set units of measure. See Advanced Screen 2,
page 67 for more detail.
n. Enable/disable system features. See
Advanced Screen 3, page 67 for more detail.
3A2797J
Setup
13. Calibrate HFR
• Set temperatures:
NOTE: Machine is calibrated from the factory. Only perform the following steps when changing or rebuilding
pumps.
The HFR calibration procedure is a two step process.
The first step, Learn Mode, must be performed whenever the pump line is rebuilt or if any other maintenance
is performed that may affect the mechanical tolerances
in the pump line. If the machine does not appear to be
utilizing the full extent of the pump stroke, or if the
machine appears to be contacting the end of the
hydraulic cylinder, follow the Learn Mode procedure.
The Learn Mode procedure will teach the system the
mechanical limits of travel.
• Learn Mode Procedure:
a. Ensure the dispense valve is set up as either
straight head or straight head prox.
This equipment is used with heated fluid, which can
cause equipment surfaces to become very hot. To
avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
• Wear gloves if fluid temperature exceeds 110°F
(43°C).
For detailed temperature adjustments, including alarm
levels, or upon initial machine configuration, see Conditioning Screen 2 on page 64 for details. For minor
adjustments to the temperature setpoint once the
machine has been initially configured, see the Status
Screen on page 72.
b. Navigate to the Calibration screen.
• Set system control and dispense modes: See System Screen 1 on page 60.
c.
• Set pump sizes: See System Screen 1 on page 60.
Press
d. Press
and then
. The pump will travel to
the right most extreme position.
e. After the pump stops moving, press
and
then press
. The pump will travel to the left
most extreme position.
f.
After the pump stops moving, press
return to the main Calibration screen.
to
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.
• Define Shot Recipes
a. Navigate to the Shots screen.
b. Press
c.
to enter the screen.
Use the directional keypad to navigate to the
shot detail column for the desired shot number.
d. Type the desired setting for that item then
press
.
e. Repeat the previous two steps for all desired
shot numbers.
• Change pressure imbalance setting (optional)
The pressure imbalance function detects conditions that
can cause off-ratio dispense, such as loss of feed pressure/supply, pump seal failure, clogged fluid inlet filter,
or a fluid leak.
The pressure imbalance default is factory-set at 500 psi
(3.5 MPa, 35 bar). For tighter ratio error detection, select
a lower value. For looser detection or to avoid nuisance
alarms, input a higher value.
3A2797J
37
Setup
a. Navigate to System Screen 3.
b. Press
c.
to enter the screen.
Navigate to the pressure imbalance field.
d. Type the desired pressure imbalance setting
then press
14. Flush the System
.
e. Press
and input the specific gravity (SG) of
each material into the ADM.
NOTE: System components will contain testing oil from
the factory. Perform the following procedure when the
machine is initially installed. Both supply and pressure
relief must be flushed.
a. Close both A side (Red) and B side (Blue) feed
inlet valves on the system. See FIG. 2 on page
14.
b. Close A side (Red) and B side (Blue) material
return ball valves on the system.
c.
Close both A side (Red) and B side (Blue) material supply ball valves on the system.
d. Place the applicator return hoses into a container.
NOTICE
To prevent cross contamination, keep components
A (Red) and B (Blue) in separate containers.
e. Fill tank A (Red) with approximately 5 gal. (19 l)
of material and tank B (Blue) with approximately
2 gal. (8 l) of material.
f.
38
Pressurize both material tanks.
3A2797J
Setup
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 75 psi (517 kPa, 5.2 bar).
Maintain A (Red) and B (Blue) feed pressures within
10% of each other.
l.
Stop dispensing by pushing
Standby Screen.
from the
m. Close feed inlet valve and the material supply
ball valve on the system.
n. Connect the applicator return hose to the fluid
inlet fitting on the system.
FP
ti10006a1
g. Turn HFR main power ON
.
h. Navigate to the System Setup Screen. Set the
low pressure dispense to 25%.
NOTE: The following steps are referring to the B side
(Blue) components of the system.
i.
Set PRESSURE RELIEF/DISPENSE valve (SA,
SB) to DISPENSE
material side.
for the corresponding
FIG. 21: Return Lines
SA
SB
Do not install shutoffs downstream of the PRESSURE
RELIEF/DISPENSE valve outlets (BA, BB). The
valves function as overpressure relief valves when set
ti9877a1
j.
Open feed inlet valve and the material supply
ball valve on the system.
k.
Navigate to the Standby Screen and push
to start pumps.
NOTE: Material will dispense into the container from the
applicator material hose at this time. Continue to dispense fluid until no material contamination is noticed.
to DISPENSE
. Lines must be open so valves
can automatically relieve pressure when machine is
operating.
If circulating fluid back to the supply drums, use high
pressure hose rated to withstand the maximum working pressure of this equipment.
o. Ensure all material hose connections are tight.
p. Open the RETURN ball valves on the tank
stand.
q. Repeat steps j thru p for A side (Red).
NOTE: If necessary, navigate to Operator Mode to
adjust the flowrate
3A2797J
39
Setup
15. Install GX-16 Orifices
16. Pressure check hose
See hose manual. Pressure check for leaks. If no leaks,
wrap hose and electrical connections to protect from
damage.
a. Close both A side (Red) and B side (Blue) feed
inlet valves on the system. See FIG. 2 on page
14.
b. Close A side (Red) material return ball valves
on the material tank stand.
c.
17. Check hydraulic fluid level
Hydraulic reservoir is filled at the factory. Check fluid
level before operating the first time, and weekly thereafter. See Technical Data on page 95 for specifications.
Follow Pressure Relief Procedure on page 44.
d. Remove plugs from GX-16.
e. Install orifices provided.
Orifice
(A) Side
ti17747a
FIG. 22: GX-16 Plug Location
40
3A2797J
Setup
18. IsoGuard Select Fluid System Setup
19. Install High Volume Fill Kit (Optional).
Component A (Red) Pump: Fill IsoGuard Select
reservoir (LR) with IsoGuard Select fluid (provided by
Graco).
a. Close air supply ball valve (RA) to Husky
Diaphragm pump.
LR
RC
RA
r_24m419_3a1961_1a
FIG. 23: High Volume Refill Kit
RB
a. Perform Pressure Relief Procedure, page 44.
b. Open reservoir lid (LR) and fill with fresh
IsoGuard.
c.
Open air supply ball valve (RA) to Husky
Diaphragm pump.
d. Set Husky Diaphragm pump regulator (RB) to 35
psi. The pump will begin to cycle and fill the
IsoGuard Select fluid cylinder. Verify the cylinder
is full and that the IsoGuard fluid returns from the
top port of the reservoir (RC).
e. Top off fluid level just below top of bag filter
(below return port, RC) with IsoGuard fluid. An
empty system will require 2 to 2 1/2 quarts of
IsoGuard fluid.
f.
b. Close the ball valves located on the day tanks.
c.
Insert the refill valve onto the ball valve.
d. Connect the air tube from the “open” port on the
refill valve to the fitting on the solenoid valve that
is located inside the tank stand base cube.
e. Remove the plug from other port on the solenoid
valve and install the air tube fitting.
f.
Connect the air tube from the “close” port on the
refill valve to the fitting installed in step e above.
Close reservoir lid (LR).
3A2797J
41
Setup
20. Install Low Volume Fill Kit (Optional).
r_24m418_3a1961_1a
FIG. 24: Low Volume Refill Kit
a. Perform Pressure Relief Procedure, page 44.
b. Close the ball valves located on the day tanks.
c.
Remove the swivel fitting from the day tank inlet
port ball valve.
d. Insert the refill valve onto the ball valve.
e. Install the swivel fitting onto the refill valve
assembly.
f.
Remove the air tube fitting installed on the solenoid valve located inside the tank stand base
cube.
g. Install the air tube fitting provided with the kit
into the open port on the solenoid valve.
h. Install the air tube from the refill valve to the
solenoid valve.
42
3A2797J
Startup
Startup
To reduce the risk of personal injury, do not operate
HFR without all covers and shrouds in place.
1. Check that all machine connections are setup. See
Setup procedure, page 28.
2. Check level and condition of ISO lube daily, see
IsoGuard Select™ System on page 48.
3. Verify both PRESSURE RELIEF/DISPENSE valves
(SA, SB) are set to DISPENSE
.
SB
SA
6. Press
green.
to enable system. LED should be solid
7. Navigate to Home Standby screen and press
to initiate auto startup.
8. Check that heat zones are on and temperatures are
on target. Check fluid pressure display. Refer to
Status Screen on page 72 for more details.
9. If dispense valve has a trigger safety lock, disengage the trigger safety lock.
ti9877a1
4. If dispense valve has a trigger safety lock, engage
the trigger safety lock.
UNLOCKED
i.
LOCKED
ti10441a1
Equipment is ready to dispense.
ti10442a1
5. Open system fluid inlet valves and ball valves found
on the material tanks. As applicable, ball valves on
the material tanks include material supply, applicator return, and pressure relief. Check for leaks.
3A2797J
43
Shutdown
Shutdown
Pressure Relief
Procedure
1. Park pumps.
a. From the Home screen, press
Standby mode.
and select
1. Press
to disable the ADM.
2. Shut off feed pumps and agitator, if used.
3. Turn PRESSURE RELIEF/DISPENSE valves (SA,
b. Press
. Material will not dispense. Pump
will park automatically. Once pump is parked,
pump will stop moving.
2. Press
SB) to PRESSURE RELIEF/CIRCULATION
.
Route fluid to waste containers or supply tanks.
Ensure gauges drop to 0.
to disable the ADM.
3. Turn main power switch (MP) to OFF position.
4. Close A (Red) and B (Blue) fluid supply valves.
SA
SB
ti9879a1
4. For models with a dispense valve with a safety
lock, engage gun safety lock.
5. Relieve pressure in dispense valve. See dispense
valve manual.
5. Perform Pressure Relief Procedure on page 44.
6. Shut down feed pumps as required. See feed pump
manual.
44
3A2797J
Flushing
Flushing
•
Flush equipment only in a well-ventilated area. Do not
dispense flammable fluids. Do not turn on heaters
while flushing with flammable solvents. Heaters must
be off and cool when solvent is in the system.
•
Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent before introducing
new fluid.
•
Use the lowest possible pressure when flushing.
•
All fluid components are compatible with common
solvents. Use only moisture-free solvents. See Run
Screen Icons on page 53 for list of wetted components to verify compatibility of solvent with wetted
materials. See solvent manufacturers information
for material compatibility.
•
To flush feed hoses, pumps, and heaters separately
from heated hoses, set PRESSURE RELIEF/DISPENSE valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).
To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of dispense
gun firmly to the side of a grounded metal pail, then
trigger gun.
. Flush through bleed
SA
SB
N
N
ti9880a1
•
To flush entire system, circulate through gun fluid
manifold (with manifold removed from gun).
•
To prevent moisture from reacting with isocyanate,
always leave the system dry or filled with a moisture-free plasticizer or oil. Do not use water. See
Important Two-Component Material Information
on page 11.
•
Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place pail on
a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.
3A2797J
45
Maintenance
Maintenance
Task
Schedule
Check tightness of all clamps and
fittings
Weekly
Task
Schedule
Check hoses for wear
Monthly
Change break-in oil in a new unit
After first 250
hours of operation or within 3
months, whichever comes first
Replace hydraulic filter
6 months
Grease (115982) high volume
refill valve, if equipped
Monthly
Change hydraulic fluid
Yearly
Inspect hydraulic and fluid lines
for leaks
Daily
Replace IsoGuard Select filter
(125148)
Monthly
Inspect IsoGuard Select™ fluid
level and condition, refill or
replace as needed, page 48
Weekly
Change IsoGuard Select fluid
Bi-Monthly
Check hydraulic fluid level
Weekly
Grease circulation valves with
Fusion® grease (117773)
Weekly
Verify operation of air drying system to prevent isocyanate crystallization
Weekly
Verify vent holes on bottom of
electrical cabinet are clear and
unobstructed
Weekly
Check Hydraulic Fluid Level
Inspect HFR Powerpack air filter
(part 24H018), clean or replace
as necessary,
Weekly
Check hydraulic fluid level on dipstick. Fluid level must
be between indent marks (IM) on dipstick. Refill as
required with approved hydraulic fluid; see Run Screen
Icons on page 53. If fluid is dark in color, change fluid
and filter.
Use compressed air to remove
dust buildup on control boards,
fan, motor (under shield), and
hydraulic oil coolers
Monthly
ti9879a1
Clean up all hydraulic leaks; identify and repair cause of leak
As needed
Inspect the gun, fluid lines, trigger
switch cable and proximity switch
cable for wear or damage
Daily
Grease (117773 or 0553-6) the
gun
Clean and service the orifices
and filters
Check Accumulator Pre-Charge
46
Grease Circulation Valves With Fusion
Grease (117773)
Weekly or every
15,000 shots
IM
As Needed
Monthly
3A2797J
Maintenance
Install Upgrade Tokens
NOTE: The Motor Control Module, Fluid Control Module, and Temperature Control Module connection to the
system is temporarily disabled during the installation of
upgrade tokens.
To install software upgrades:
1. Use correct software token stated in the table. See
Graco Control Architecture™ Module Programming
manual for instructions.
r_257396_3b9905_04b
ti12334a1
NOTE: Upgrade all modules in the system to the
software version on the token, even if you are
replacing only one or two modules. Different software versions may not be compatible.
All data in the module (System Settings, USB Logs,
Recipes, Maintenance Counters) may be reset to
factory default settings. Download all settings and
user preferences to a USB before the upgrade, for
ease of restoring them following the upgrade.
See manuals for locations of specific GCA components.
ti12358a1
ti12354a1
FIG. 25: Remove Access Cover
The software version history for each system can be
viewed in the technical support section at
www.graco.com.
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
3A2797J
47
Maintenance
IsoGuard Select™ System
2. Close air supply ball valve (RA) to Husky
Diaphragm pump.
LR
Check the condition of the IsoGuard Select filter and
fluid weekly. Replace the filter if it becomes clogged with
debris or gel. 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
IsoGuard Select fluid.
The interval between filter replacement and fluid change
depend on the environment in which the equipment is
operating and equipment run time. The pump lubrication
system minimizes exposure to moisture, but some
contamination is still possible.
Fluid discoloration is due to seepage of small amounts
of isocyanate past the pump packings during operation.
if the packings are operating properly, IsoGuard Select
fluid replacement due to discoloration should not be
necessary more often than every other month.
To replace IsoGuard Select filter:
1. Perform Pressure Relief Procedure on page 44.
2. Close air supply ball valve (RA) to Husky
Diaphragm pump.
3. Open IsoGuard Select reservoir lid (LR).
4. Remove bag filter. A hook may be used to grab the
bag filter strap.
5. Replace bag filter (Part 125148). Cleaning and
reusing the filter bag is not recommended.
RC
RA
RB
RD
FIG. 26: IsoGuard Select Fluid Reservoir and Air
Controls
3. Place waste container below IsoGuard Select
reservoir drain (RD).
4. Open the IsoGuard Select reservoir lid (LR).
5. Remove drain plug and open drain valve (RD) which
will drain the IsoGuard reservoir.
6. Remove bag filter and discard.
7. Remove filter basket and clean thoroughly. Clean
IsoGuard reservoir thoroughly.
8. Remove pump outlet line (RE) from the Husky
Diaphragm pump and place in a waste container.
This will drain the remaining IsoGuard fluid from the
IsoGuard Select fluid cylinder. See FIG. 26.
6. Close IsoGuard Select reservoir lid (LR) and open
air supply ball valve (RA). Verify the Husky
Diaphragm pump regulator (RB) is set to 35 psi.
This will return the IsoGuard Select system to circulation mode.
To change the IsoGuard Select fluid:
1. Perform Pressure Relief Procedure on page 44.
48
3A2797J
Maintenance
RE
FIG. 27: IsoGuard Select Fluid Husky Diaphragm
Pump
9. Install removed line (RE) back to Husky Diaphragm
pump outlet.
10. Close drain valve (RD) and install drain plug.
11. Replace the filter basket and install a new IsoGuard
filter (Part 125148). Fill reservoir with fresh
IsoGuard Select fluid.
12. Open air supply ball valve (RA) to Husky Diaphragm
pump. Verify pump air regulator (RB) is set to 35
psi. This will return the IsoGuard Select system to
circulation mode.
13. Top off fluid level just below top of bag filter (below
return port, RC) with IsoGuard fluid. An empty
system will require 2 to 2 1/2 quarts of IsoGuard
fluid.
14. Make sure the reservoir cover gasket groove is
clean and free of debris and close reservoir lid (LR).
3A2797J
49
Troubleshooting
Troubleshooting
Light Tower (Optional)
Before performing any troubleshooting procedure:
1. Perform Pressure Relief Procedure on page 44.
2. Turn main power OFF.
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.
3. Allow equipment to cool.
Try the recommended solutions in the order given for
each problem, to avoid unnecessary repairs. Also,
determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.
PROBLEM
General
Display Module completely
dark
Errors include advisories, deviations, or alarms, so
green will only be on when none of these occur. A yellow light can be on at the same time as red (flashing or
solid on) when an advisory exists at the same time as a
deviation or alarm.
CAUSE
No Power
Thrown Breaker
Loose Connection
Bad Display Module
No or incorrect amount of
Ball Valve closed (if Installed)
material dispensed from
Tank Empty
either side
Tank Clogged
Air In Material
Significant material leaking
Pump shaft worn and/or shaft seal
from pump seal
worn
Material dispensed not corSpecific gravity of one or more of the
rect weight
two materials has changed since calibration
Check valve malfunction
Piston worn or broken
A (Red) and B (Blue) Primary Heaters
Control of primary heat is
Dirty RTD connection
abnormal; high temperature RTD not contacting heater element
overshoots
Failed heater element
Signal failure from RTD
RTD wired incorrectly
Hose System
Material heats but heats
slower than usual or it does
not reach temperature
50
Ambient temperature is too cold
FTS failed or not installed correctly
SOLUTION
Verify AC Power switch is ON
Check Machines Breakers and Reset
Tighten 5-pin cable on Advanced Display Module
Replace Advanced Display Module
Open tank ball valve.
Add fluid
Clean tank
Prime the machine
Remove pump shaft assembly and reinstall read
pump rebuild kit
Run calibration
Remove check valve; clean or replace as necessary
Replace Piston
Unplug and re-plug RTD wires.
Loosen ferrule nut, push in RTD so tip contact heater
element. Holding RTD tip against heater element,
tighten ferrule nut 1/4 turn past tight.
Replace
Check connections
Check connections. Power up zones one at a time
and verify that temperature for each zone rises.
Use auxiliary hose system.
Check FTS
3A2797J
Troubleshooting
PROBLEM
Material does not maintain
temperature while spraying
Material temperature
exceeds setpoint
Erratic material temperature
CAUSE
Ambient temperature is too cold
Flow too high
Faulty RTD connections
Faulty RTD connection
FTS not installed correctly
Material does not heat
FTS failed or is not contacting correctly
FTS not installed correctly
Temperature control alarm
Proportioning System
Proportioning pump does not Pump piston or intake valve leaking
hold pressure when stalled
Material imbalance.
SOLUTION
Increase A (Red) and B (Blue) setpoints to increase
fluid temperature and keep it steady
Use smaller mix chamber. Decrease pressure.
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.
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 should be installed close to end of hose in same
environment as gun. Verify FTS installation.
Check FTS
FTS should be installed close to end of hose in same
environment as gun. Verify FTS installation.
See Advanced Display Module (ADM) on page 20
1.
Observe gauges to determine which pump is losing pressure.
2.
Determine in which direction the pump has
stalled by observing which directional valve indicator light is on.
3. Repair the valve.
Inadequate flow from pump; cavitation Increase fluid supply to proportioning pump:
•
•
Erratic pump movement
Pump output low
3A2797J
Pressure relief/circulation valve leaking back to supply
Pump cavitation
Obstructed fluid hose or gun; fluid
hose ID too small
Worn piston valve or intake valve in
displacement pump
Inadequate feed pump pressure
Use 2:1 supply pump
Use minimum 3/4 in. (19 mm) ID supply hose, as
short as practical
Fluid is too thick. Consult your material supplier for
the recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise.
Clean inlet strainer screen
Worn pump inlet valve ball/seat or gasket
Remove return line and determine if flow is present
while in SPRAY mode
Feed pump pressure is too low. Adjust pressure to
maintain 100 psi (0.7 MPa, 7 bar) minimum.
Open, clear; use hose with larger ID
See pump manual 3A0019
Check feed pump pressure and adjust to 100 psi (0.7
MPa, 7 bar) minimum.
51
Appendix A - ADM Icons Overview
Appendix A - ADM Icons Overview
Setup Screen Icons
Icon
Description
Icon
Description
Enter Screen
Erase All Counters on Page
Exit Screen
Access Flowmeter Calibration
On Learn Mode Calibration screen:
Move pump
Valve Details
All other screens:
Begin Dispense
Selects all shots to be changed to the
same user specific value
Stop Dispense
Abort Changing the Label
Pressure
Shot Number
Sequence Position
Select left direction
Flow
Select right direction
Time (Duration)
Backspace
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
Primary Heater
Heated Hose
Chiller
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.
Move Cursor to the Left
Move Cursor to the Right
Upper/Lower Case Letters
Positive / Negative
Erase Selected Item or Control Data
52
3A2797J
Appendix A - ADM Icons Overview
Run Screen Icons
Icon
Description
Description
Select mode.
Sets machine to low pressure
Set system in park (icon will be
selected when system is parked)
Sets machine to high pressure
Open, Close Valve
A (Red) and B (Blue) refill button
(Press to start/abort refill)
With a mix head installed: Turns on
the mix head hydraulics and puts the
machine in low pressure circulation.
Press a second time to turn off instigated system action.
If Green:
Allowed to Dispense
If Yellow:
System is in a pre-dispense state
If Red:
Not Allowed to Dispense
Stop Dispense
OR
Icon
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
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 monitor. Not displayed if heat zone is not
enabled.
Amount of material moved through
pump (volume tracking)
Cycles
Edit Operator Dispense Setting
Press to enter the Conditioning Control screen
Activates the PrePoly Refresh
Turn on or off the highlighted zone.
Turn on or off all zones.
Erase a single batch
Erase all batch data points
3A2797J
53
Appendix B - ADM Setup Screens Overview
Appendix B - ADM Setup Screens Overview
The ADM will start in the Run screens at the “Home”
screen. From the Run screens, press
to access
the Setup screens. If the Setup screens password is
turned on, use the ADM keypad to enter the password
then press
From the Setup screens, press
to access the Run
screens. For Run screens information, see Technical
Data on page 95. FIG. 28 shows the flow of the Setup
screens.
.
Home
Status
Errors #1
Events #1
Errors #2
Events #2
Errors #...
Events #...
Maintenance
* Gateway screen will automatically be enabled when a CGM is installed on the system
FIG. 28: Setup Screens Navigation Diagram
54
3A2797J
Appendix B - ADM Setup Screens Overview
Shots Screen
This screen allows the user to edit shot definitions. The
contents of this screen change based on the flow units
selection. Shots are defined by flow rate and weight or
time (duration). See Home Screen, Shot Mode on
page 70 for information on how to use predefined shots.
NOTE: 100 shot definitions are available across ten
pages.
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 the ?
column.
Time Based Example:
To edit a shot definition:
1. Press
then use the arrow keys to navigate to the
desired value.
A 75 cc/s shot is defined to dispense for 2 seconds.
1. Dispense 5 shots into 5 separate containers.
2. Measure the dispensed amount and record the
data.
2. Type the new value then press
new value.
to accept the
3. If desired, press
to quickly enter the same value
for the rate and time/volume/weight.
4. Repeat step 2 as required.
3A2797J
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 average of the 5 shots.
Example 1 = 146cc
Example 2 = 156cc
55
Appendix B - ADM Setup Screens Overview
4. Use the following formula to calculate the ? column
value.
Volume/Weight Based Example:
A 75 cc/s shot is defined to dispense for 75 cc.
((Flow Rate x Time) - Average Volume)
Flow Rate
Example 1:
((75cc/sec x 2sec) - 146cc)
75 cc/sec
= 0.053 sec
Example 2:
((75cc/sec x 2sec) - 156cc)
75 cc/sec
= -0.08 sec
5. Enter the calculated value in the ? column.
Example 1:
Example 2:
1. Dispense 5 shots into 5 separate containers.
2. Measure the dispensed amount and record the
data.
Shot
Example 3
Dispensed Volume
(cc)
1
72.2
2
72.4
3
72.6
4
72.8
5
72.5
3. Calculate the average of the 5 shots.
Example 3 = 72.5cc
4. Use the following formula to calculate the ? column
value.
(Requested Amount - Actual Amount)
Example 3:
(75cc - 72.5cc = 2.5cc)
NOTE: Depending on the dispensed volume average,
the ? column may be either a positive or negative value.
56
3A2797J
Appendix B - ADM Setup Screens Overview
5. Enter the calculated value in the ? column.
Example 3:
2. Press
then use the arrow keys to navigate to the
“Enable Range Calibration” option.
3. Press
to activate the option.
To edit a shot definition:
1. Navigate to Shots Screen.
Shot Calibration Table
This screen allows the user to set the offset, ?(g), for a
calculated range of shot sizes based on pump sizes and
material specific gravity.
NOTE: This table is only available when defining the
shot by weight.
2. Press
to enter the screen.
3. Press
to show the shot calibration table.
4. Press
then use the arrow keys to navigate to the
desired value.
To enable the shot calibration table:
1. Navigate to Advanced Screen 4.
5. Type the new value then press
new value.
to accept the
6. Repeat as required for other ranges.
3A2797J
57
Appendix B - ADM Setup Screens Overview
Weight Based Example Using Shot Calibration
Table:
NOTE: The offset needs to be determined for each
range and may need to be modified if the flow rate
changes. Visit www.graco.com and search for PKE
“Shot Calibration Table Worksheet” to assist in the calculations for the following procedure.
NOTE: Offset ranges are dependant on material ratio
and material specific gravity. The values shown are for
reference only.
1. Dispense five shots into separate containers for an
average range.
2. Measure the amount for each shot size and record
the data.
3. Repeat steps 1 and 2 for all twelve ranges.
4. Calculate the average for each range and record the
data.
(Shot1 + Shot2 + Shot3 + Shot4 + Shot5)
5
5. Calculate the offset of each shot size and record the
data.
Target Shot Size - Average Shot Size
6. Enter the offset into the table.
Example:
Step
Ref.
Shot
Number
Range: 11-15g
Target Shot Size: 13g
1,2
1,2
1,2
1,2
1,2
4
Shot 1
Shot 2
Shot 3
Shot 4
Shot 5
Average
Shot Size
Offset
11.600
12.200
12.400
11.900
12.000
12.02
5
0.98
Sequences Screen
This screen allows the user to edit sequence information.
See Home Screen, Sequence Mode on page 71 for
information on how to use predefined sequences.
NOTE: Five sequences with 20 positions each are available across 10 pages.
NOTE: Sequence positions are made from shots
defined in the Shots Screen.
To edit a sequence:
1. Press
then use the arrow keys to navigate to the
desired value.
2. Type the new value then press
new value.
to accept the
7. Repeat steps 1 through 6 for more precise offsets.
58
3A2797J
Appendix B - ADM Setup Screens Overview
Calibration Screen, Main
Calibration Screen, Learn Mode
This screen shows calibration information for the system
and provides access to other calibration screens. See
Calibrate HFR on page 37 for how to use the calibration
screens to calibrate the machine.
This screen allows the user to calibrate piston position.
The piston can be moved to the left and right to obtain
the full range of motion. See Calibrate HFR on page 37
for how to use this screen to calibrate the machine.
Current position
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 Calibration Screen, Learn Mode.
Previously saved left
position
Press
to go to the Calibration Screen, Learn
Mode screen.
Press
to erase the motor control database in the
motor control module.
Previously saved right
position
Press
and then
to the left.
to move the pump all the way
Press
and then
to the right.
to move the pump all the way
Press
to return to the Calibration Screen, Main.
This saves the new left and right numbers.
3A2797J
59
Appendix B - ADM Setup Screens Overview
System Screen 1
System Screen 2
This screen allows the user to set important system settings. Control Mode can be set to Flow. With Control
Mode set to Flow, the machine will dispense at a continuous flow rate regardless of pressure fluctuations unless
pressure alarm conditions occur.
This screen allows the user to set which items are
installed on the machine.
Dispense Mode can be set to Time, Volume, and
Weight. Dispense Mode controls how displayed
amounts are measured. See Calibrate HFR on page 37
for more information.
Pump sizes and inlet pressures must be entered on this
screen.
NOTICE
If pump sizes and inlet pressures are not entered
properly, system performance will be affected.
The hydraulic level sensor and hydraulic RTD for both
the pump line and mix head must be marked as enabled
when installed in the system. If the sensors are not
marked as enabled, they will be ignored by the machine
controls.
Select the dispense valve installed in the system. This
selection is critical to ensure proper operation of the
machine. When a mix head is selected,
button will
become active when the
is pressed. When active,
pressing this button will open a screen used to define
the mix head operating parameters. See the Mix Head
Operating Details Screen on page 61.
The inlet pressure must be set to the maximum feed
pressure that will be seen by that side of the machine.
The maximum working pressure for the machine is displayed on this screen. The maximum working pressure
is dependent on the installed hoses and dispense valve.
The maximum working pressure is set to the lowest
rated system component. If 2000 psi hoses are installed
and the maximum working pressure displayed is not
2000 psi, see manual 313998 for instructions to set the
maximum working pressure for hoses. If the installed
dispense valve rating is below the maximum working
pressure shown here, verify the correct dispense valve
is selected on System Screen 2.
Post Dispense Shot Disable is a feature where the user
can disable shot requests for zero to five seconds after
the completion of a dispense. This feature is not applicable for P2/Fusion Dispense Valves. This feature can not
be active if the Pre Dispense Delay feature is active.
Pre Dispense Delay is a feature where the HFR can
delay the start of a dispense until the user has pressed
and held the foot switch for the duration entered. For
example, if the user enters a five second duration, the
footswitch must be held on continuously for five seconds
before the HFR will start a dispense. This feature is not
available for recirculation systems or applicable for
P2/Fusion Dispense Valve applications. This feature
can not be active if the Post Dispense Shot Disable feature is active.
60
3A2797J
Appendix B - ADM Setup Screens Overview
Mix Head Operating Details Screen
System Screen 3
This screen allows the user to define the mix head operating parameters.
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.
•
•
•
Low Pressure Circulation: The percentage of setpoint, 10%-90%, at which the system will run during
low pressure circulation.
Pre-Dispense Circulation: The time for which the
system will circulate at high pressure prior to dispensing when the dispense command is triggered
while the system is in low pressure circulation.
Post-Dispense Circulation: The time duration that
the system will remain in high pressure circulation
after a dispense before dropping into low pressure
circulation. Entering “0” disables the post-dispense
time.
To edit a label:
1. Press
.
2. To edit the A (Red) label, press
.
To edit the B (Blue) label, press the down arrow
then press
. The keyboard will appear on the
screen. See Keyboard Screen on page 62.
The pressure imbalance setting is set from this screen.
Pressure imbalance is the allowable difference in pressure between the two materials before an alarm is triggered. The input range is 145-2000 psi (1-14 MPa,
10-138 bar).
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.
Press
to go back to the System Screen 2.
The ratio displayed between chemicals can be changed
between blue or red, allowing either chemical to be displayed as a ratio to 1.
This screen allows the user to enter material specific
gravities.
Pressure
Imbalance
Setting
3A2797J
61
Appendix B - ADM Setup Screens Overview
Keyboard Screen
Maintenance Screen
This screen is used to edit the A (Red) and B (Blue)
labels on the ADM. Use arrow keys to select the desired
This screen shows shot number, sequence position, and
dispense valve counters. Press
letter and press
and navigate to the
to accept the letter.
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
.
1. Use arrow keys to select the desired letter and
press
to accept the letter. To erase all text,
press
. To delete one letter, press
. To
move the cursor one letter to the left, press
. To
move the cursor one letter to the right, press
.
To toggle the letters from upper/lower case, press
.
2. When finished entering the new label, press
62
.
3A2797J
Appendix B - ADM Setup Screens Overview
Supply Screen
•
This screen allows the user to specify the operating
parameters for off-board, integrated tanks and indicate
which positions have level sensors installed. See the
Tank Feed Systems manual for information about
installing level sensors, see Related Manuals on
page 3. The user may select from the following refill settings: Disabled, Monitor, Manual, Auto Top-Off, Auto
Full-Volume.
NOTE: Use the “Disabled” setting if off-board tanks are
not installed.
•
The following describes system operation when each
tank mode is selected.
•
•
•
Disabled
• Disables tank operation
Monitor (2 Sensors)
• The top sensor generates a high level deviation
and the bottom sensor generates a low level
alarm
• Refill is not supported, no button is provided on
the run screens to initiate refill
• Errors will clear when the corresponding condition clears
Manual (2 Sensors)
• The top sensor generates a high level deviation
and the bottom sensor generates a low level
alarm
• A button is provided to the user on the run
screens to initiate a manual refill operation at
any time
• Manual refill will run until either the high level
sensor sees material, the user aborts the refill
via the refill button on the run screens, or the
refill time-out expires
• The low level alarm will clear when the condition
clears
3A2797J
Auto Top-Off (2 or 3 Sensors)
• Automatically selected with three level sensors
selected
• The low level sensor will generate a low level
alarm
• Two level sensors installed: When the high level
sensor does not see material, automatic refill
will begin and continue until either the high level
sensor sees material or until the refill time-out
expires
• Three level sensors installed: When the middle
level sensor does not see material, automatic
refill will begin and continue until either the middle level sensor sees material or until the refill
time-out expires
• The low level alarm will clear when the condition
clears
• A button is provided to the user on the run
screens to initiate an automatic refill operation
at any time, this button can also be used to
abort a refill operation
Auto Full-Volume (2 Sensors)
• The low level sensor will initiate an automatic
refill when it does not see material
• Automatic refill will continue until either the high
level sensor sees material or until the refill
time-out expires
• The low level alarm will clear when the condition
clears
• A button is provided to the user on the run
screens to initiate an automatic refill operation
at any time, this button can also be used to
abort a refill operation
Refill Setting
If a refill setting other than Disabled is selected, the user
must set at least two level sensor locations as installed
by checking the check box on the screen. If all three
locations are set to installed, the system will default to
the Auto-Top Off refill setting and operate as follows:
•
•
•
•
•
The low level sensor will generate a low level alarm.
The high level sensor will generate a high level deviation and abort any automatic refill operation.
When the middle sensor is not satisfied, automatic
refill will begin and will run until either the middle
sensor is satisfied, the high level sensor generates
a deviation (if the middle sensor fails), or the refill
time-out expires.
The low level alarm and the high level deviation will
clear when the condition clears.
A button is provided to the user on the Run screens
to initiate an automatic refill operation at any time.
This button can also be used to abort a refill operation.
63
Appendix B - ADM Setup Screens Overview
Refill Timeout
Conditioning Screen 2
The refill time-out setting may be set by the user as a
means to abort the refill in the case of a high level sensor failure. When an automatic refill begins, the time-out
counter will begin to count down. If the timer expires
before the high level sensor is triggered, the refill will
abort. A refill must be manually started to enable auto
refills again.
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.
Refill Sensor Type
The Low-Temp Sensor setting limits tank temperatures
to 150°F (66°C). And the High-Temp Sensor setting limits tank temperatures to 190°F (88°C).
NOTICE
If you are using low temperature sensors and select
the High-Temp Sensor setting and set the temperature above 150°F (66°C), damage to the level sensors will occur.
Conditioning Screen 1
This screen allows the user to select which temperature
conditioning components are installed in the system.
Check the box next to the component type for the appropriate side of the system to indicate that a component is
installed. A maximum of four components and two monitoring zones may be selected.
64
NOTE: All components are shown installed for reference only. Only 4 components and two monitoring
zones can be installed at one time.
To edit the temperature setpoint and alarms for a particular component:
1. Press
then use the arrow keys to navigate to
the component you wish to edit.
3A2797J
Appendix B - ADM Setup Screens Overview
Conditioning Screen 3
2. Press
to display the setpoint and alarm values
associated with that component.
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.
3. Edit the setpoint and alarm values and then press
to return to Conditioning Screen 2.
Periodic Night Mode Conditioning Screen
This screen allows the user to set the on and off times of
the machine in one minute intervals.
NOTE: The high alarm and low alarm values must be at
least +/-9°F (5°C) than the material temperature value.
3A2797J
65
Appendix B - ADM Setup Screens Overview
Time Based Night Mode Conditioning Screen
This screen allows the user to set a specific time each
day to turn the machine on or off. The times can be set
on or off by either each day separately, Monday through
Friday where each day has the same on or off times, or
Sunday through Saturday where each day has the same
on or off times.
6. To erase times, repeat steps 1 thru 3 and press
once the desired time duration has been selected.
NOTE: If times are entered in the weekly schedule, individual days can not be erased.
NOTE: Set the Prepoly Timeout one minute beyond the
time it takes for the material to reach the middle sensor.
Cold Start Up Mode
Allows the user to select what mode the machine will
enter once the cold start-up is complete. Selecting no
change will leave the machine in either standby or night
modes circulating at the set low pressure percentage.
Auto High Pressure
Changes the machine to high pressure circulation when
the mode is changed from either standby or night
modes.
To set the on/off machine times:
1. Press
to enter the screen
2. Press left or right arrow keys to highlight the day
selection column. Continue to press the left or right
arrow keys to select the desired day, work week
(Monday thru Friday), or full week (Sunday thru Saturday) duration.
Calender Time Based Night Mode Conditioning
Screen
This screen shows a summary of Time Based Night
Mode on or off times that were set by the Time Based
Night Mode Conditioning Screen.
3. Press the up or down arrow keys to select the
desired hour to schedule the on or off machine
times.
4. Press
to enter the selected hour and select the
desired time (15 minute increments) for either
machine on or off to occur.
5. Press
and select either on or off for the time
duration selected.
Bar Color
Green
Red
Blue
66
Description
Machine is ON
Machine is OFF
Machine PrePoly Refresh Start
3A2797J
Appendix B - ADM Setup Screens Overview
Advanced Screen 1
Advanced Screen 3
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.
This screen allows the user to control the availability of
some key system features.
•
•
•
•
Time: formatted in 24 hour time.
Password: Enables the setup screens to be password protected. Entering “0000” disables the feature.
Screen Saver: Enter the amount of time until the
backlight turns off. Entering “0” leave it constantly
on.
Silent Mode: Check this box to turn off the buzzer
for key presses.
•
Disable Dispensing From Display: Check this box
to disable dispensing from the ADM. A footswitch,
dispense valve trigger, or other external signal will
be the only way to initiate a dispense.
•
Disable Modifying Temp Setpoint: Check this box
to disable modifying temperature setpoints from the
Run screens. This is only applicable if temperature
control items are installed and enabled.
•
Disable Operator Mode Adjustments: When this
box is checked, the user will not be able to adjust
the dispense settings in Operator Mode.
•
Temperature Alarm Disables Dispense: When
this box is checked, the system will reject dispense
requests when any enabled heat/chiller zones are
below/above their setpoint.
•
Enable Operator Mode Cavitation Alarm: Check
this box to enable cavitation alarms in Operator
Mode. Clear this box to disable cavitation alarms in
Operator Mode.
•
Complete Dispense with Setpoint Error: When
this box is checked, the shot will continue dispensing even if the system never reaches the desired
setpoint.
•
Enable Shot Aborted Notification: When this box
is checked, a pop-up notification will be displayed
when a shot is aborted.
•
2x Trigger For Dispense: When this box is
checked, the machine will require a double trigger
pull to initiate dispensing in shot or sequence mode.
•
Dispense from Home Position: When this box is
checked, the machine will be required to reach a
defined home position before dispensing in shot or
sequence mode.
Advanced Screen 2
This screen allows the user to set the units of measure.
3A2797J
67
Appendix B - ADM Setup Screens Overview
Advanced Screen 4
•
Enable PrePoly Refresh: Check this box to enable
Prepoly Refresh. A Prepoly refresh will initiate a
cold start, heat the system to a specified temperature (Conditioning Screen 3), empty the prepoly
tank to the low level sensor and refill the tank. When
enabled, either the user may initiate a refresh manually or through a scheduled task.
•
•
•
Enable Diagnostic Screen: Check this box to
enable the optional ADM screens, enabling USB log
downloading, and erasing USB logs. For more information about USB operation, see Appendix F USB Operation on page 89. For more information
about the optional screens, see Diagnostic screen
on page 74.
•
Low Material Disables Dispense: When this box is
checked, the current dispense will terminate and
prevent additional dispenses when the supply system indicates a low level.
•
Limit Rate on Stall to Pressure: Check this box to
enable Limit Rate on Stall to Pressure. This will slow
the rate of pressure rise on a stall to pressure system.
•
Enable Range Calibration: Check this box to
enable Range Calibration. This creates a range of
shot offsets in a table based on the size of the shot.
The user must calibrate each range at the specified
flow rate. If the flow rate is changed, the table must
be recalibrated.
•
Night Mode, Disabled, or Standby Modes:
Automatic refills are disabled. If the material
level drops below the low level sensor, a low
level alarm is thrown.
Shot, Operator or Sequence Modes: The system will monitor the amount of automatic refills
requested after the last shot has been taken. If
the system sees two refills without dispensing,
the system will generate a leak detection warning and disable the system. The system must
be completely powered down to clear the error.
Enable Leak Detection: Check this box to enable
Leak Detection. Leak detection is intended for catastrophic leaks only. It requires a Graco auto fill control to be enabled and working. Leak detection is not
active during dispense.
Advanced Screen 5
Numbers shown are for reference only and may
be different on your system.
This screen displays software information.
68
3A2797J
Appendix C - ADM Run Screens Overview
Appendix C - ADM Run Screens Overview
Run screens are divided into five major sections: status,
errors, events, and maintenance. The following diagram
demonstrates the flow of the Run screens beginning
with the Home screen.
Home
Status
Errors #1
Events #1
Errors #2
Events #2
Errors #...
Events #...
Maintenance
FIG. 29: Run Screens Navigation Diagram
Home Screen
Home Screen, Disabled Mode
The Home screen is the first screen that displays in the
Run screens. It shows the current fluid pressure on the
A (Red) and B (Blue) fluid outlets of the pump and if
there are any active errors. If tanks are installed in the
system, the fill level is shown on each tank. The ratio is
also displayed as either Red:1 or Blue:1 depending on
which display has been setup. See System Screen 3
on page 61.
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.
To select an operating mode, press
the desired mode is shown then press
repeatedly until
to select the
mode. Alternately, press
and use the up and down
arrow keys until the desired mode is shown, then press
to select the mode. The available operating modes
are operator, sequence, shot, standby, night, and disabled.
3A2797J
69
Appendix C - ADM Run Screens Overview
Home Screen, Standby Mode
Home Screen, Shot Mode
In Standby Mode, the user can enable heating, park the
pumps, refill the tanks, circulate materials.
This mode allows the user to select one of 100 predefined shot numbers. See Shots Screen on page 55
for information about editing shot definitions.
To use a predefined shot:
1. Enter shot mode.
2. Press
and use the numeric keypad to enter
the desired shot number.
3. Press
Press
to change operating modes.
Press
to move the pumps all the way to the left and
turns the hydraulic power pack off.
to select the shot number.
4. Press
to initiate a dispense. The system will go
to high pressure mode and dispense a shot after the
pre-dispense timer, see Mix Head Operating
Details Screen on page 61, expires.
NOTE: There is a three second delay after a dispense
before another dispense can be initiated
Press
or
to initiate a tank refill. If a tank is filling, pressing either button will abort the filling operation.
Press
to stop or start the hydraulic power pack and
run the start-up process.
Target Flow
Target recipe time
Ratio
5. Press
to switch between low and high pressure
modes without dispensing.
6. During a dispense, press
to abort the dispense.
7. See Home Screen, Standby Mode on page 70 for
other button functions.
70
3A2797J
Appendix C - ADM Run Screens Overview
Home Screen, Sequence Mode
This mode allows the user to select one of five
sequences (A-E). The progress bar on the bottom of the
screen shows the progress of a shot dispensing from
the selected sequence. See Sequences Screen on
page 58 for information about editing sequence definitions.
NOTE: There is a three second delay after a dispense
before another dispense can be initiated.
To use a predefined sequence:
8. See Home Screen, Shot Mode on page 70 for
other button functions.
Home Screen, Operator Mode
This mode allows users to set a flow rate to dispense
material without using predefined shot information.
1. To edit the flow rate, press
. The value to
change will now be highlighted. Type the new value
then press
to accept it.
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.
5. Press the Dispense button to begin dispensing.
Ratio
Operator
Setting
A (Red) resettable material
counter
B (Blue) resettable material
counter
Total of resettable material
counters
2. Press
to initiate a dispense. The system will go
to high pressure mode and dispense a shot after the
pre-dispense timer, see Mix Head Operating
Details Screen on page 61, expires. Press the
to stop the dispense.
NOTE: There is a three second delay after a dispense
before another dispense can be initiated.
Target
Flow/Pressure
Ratio
3. If an external trigger is used, press an hold the trigger to initiate a dispense. Release the trigger to stop
the dispense.
Target dispense amount
(time/volume/weight depending
on Dispense Mode)
6. Press
to skip to the next sequence position.
7. Press
to abort the sequence.
3A2797J
4. See Home Screen, Shot Mode on page 70 for
other button functions.
71
Appendix C - ADM Run Screens Overview
Home Screen, Night Mode
In Night Mode, the system will cycle on and off
periodically or turn on at a preset time. Entering night
mode will turn pumps and all conditioning zones off. The
circulation on/off cycle begins automatically upon
entering Night Mode. See Conditioning Screen 3 on
page 65.
Status Screen, 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
OFF
ON
Color
Definition
Black
Dispense Disabled
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.
Status Screen
The status screen provides all of the operational functionality of the Home screen except for operating mode
selection. Refer to the Home screen and operating
mode descriptions for information on this functionality.
In addition to the functionality provided by the Home
screen, the Status screen also provides material conditioning information and control.
3. Press
to turn on the selected zone. When a
zone is on, the button will be selected. Press the
button again to turn off the zone.
To turn on/off all zones:
1. Press
to enter the Conditioning Control screen.
2. Press the
to turn on all zones. When one or
more zones are on, the button will be selected.
Press the button again to turn off all zones.
All zones shown for reference. Only four zones may
be active at one time.
72
3A2797J
Appendix C - ADM Run Screens Overview
Errors Screens
Maintenance Screen
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.
This screen displays historical information for each
pump in the system. The Batch counters are resettable
and count both material usage and pump cycles. The
Total counters are not resettable by the user. They also
count both material usage and pump cycles. For material usage counters, units are displayed next to the volume/weight indicator icons.
Refer to the Troubleshooting section on page 50 for a
detailed description of all of the system errors.
To erase a batch counter, press
field to be erased. Press
and navigate to the
to erase that data point.
Alternatively,
may be pressed to erase all of the
batch data points simultaneously.
Events Screens
This screen shows users a list of events that have
occurred in the system. Each event includes a description and event code along with a date and time stamp.
There are 20 pages, each holding 10 events. The 200
most recent events are shown.
Refer to the Troubleshooting section on page 50 for a
detailed description of all of the system events.
3A2797J
NOTE: In a circulation system, the pumpline must be
stopped to erase counters.
73
Appendix C - ADM Run Screens Overview
Optional Screens
The optional Diagnostic screen can be enabled in the
Advanced Screen 4 screen, see page 68.
Diagnostic
The Diagnostic screen shows status information for various components in the Motor Control Module.
74
3A2797J
Appendix D - ADM Error Codes
Appendix D - ADM Error Codes
Error
Code
A4H3
DEH3
MBH3
P1H3
P4H3
T4H3
WDF3
WDD3
0500
02D0
A4A6
A4B5
A4A3
A4B1
A4A2
A4B4
A4A7
A4B8
A4H1
A4M1
Error
Error Name Error Description
Type
Cause
Solution
Mix Head
Motor
Overload
Soft Stop
Asserted
Low Mix
Head Oil
Level
Low
Accumulator
Pressure
Refer to AC Power Pack manual
High
Accumulator
Pressure
High Mix
Head Oil
Temp.
M1 Material
Rod Shift Fail
M1 Cleanout
Rod Shift Fail
The three point calibration data
is invalid, system will operate
in weight mode but will attempt
Invalid
to volumetrically calculate
Deviation Invalid data
Re-calibrate the machine
Weight Cal.
weight. This will lead to
Data
consistent shots which will be
offset for the desired dispense
amount.
Pump flow setpoint is
Low Flow
Pump velocity is too low.
Advisory lower than one eighth of Increase the pump flow setpoint
Advisory
the total pump volumes
Red Blanket
Overcurrent
Blue Blanket
Overcurrent
Red Inline
Overcurrent
Bad heaters
Measure resistance of heater
Blue Inline
Overcurrent An over current was detected
Alarm
on the output
Red Hose
Overcurrent
Blue Hose
Overcurrent
Measure voltage across the disconnect switch.
Red Chiller
High voltage
Voltage should measure between 190 and 264 Vac.
Overcurrent
Blue Chiller
Shorted Temperature
If temperature rises for a zone that has been disabled,
Overcurrent
Control Module
replace Temperature Control Module
Bad internal wiring of the
High current has been
Replace motor
motor
Motor Over detected on a phase and has
Alarm
been shutdown to prevent
Current
Short circuit of motor
Check wiring to the motor to ensure no bare wires are
damage
wiring
touching and that no wires are shorted to ground
Low voltage from the wall Make sure the supply line is properly sized for the
Motor Over Too much current is being
Alarm
during load
load and is above the minimum voltage requirements
Current
drawn from the wall
3A2797J
75
Appendix D - ADM Error Codes
Error
Code
A4N1
A7A6
A7B5
A7A3
A7B1
A7A2
A7B4
A7A7
A7B8
A8A6
A8B5
A8A3
A8B1
A8A2
A8B4
A8B7
A8B8
A9C1
Error Description
Motor Over
Current
A hardware current fault has
occurred causing a system
shutdown
Alarm
Unexpected current to
heater/chiller
Alarm
Red Blanket
Control Fault
Blue Blanket
Control Fault
Red Inline
Control Fault
Blue Inline
Control Fault
Red Hose
Control Fault
Blue Hose
Control Fault
Red Chiller
Control Fault
Blue Chiller
Control Fault
No Red
Blanket
Current
No Blue
Blanket
Current
No Red Inline
Current
No Blue Inline
Current
No Red Hose
Current
76
Cause
Short circuit of motor
wiring
Solution
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
Motor rotor has become succeeds then the power pack may need to be
replaced. If the motor is still unable to move, the
locked
bearings or hydraulic pump have likely failed in the
motor and will need to be replaced.
Shorted Temperature
Control Module
If temperature rises for a zone that has been disabled,
replace Temperature Control Module
Tripped circuit breaker
Visually check circuit breaker for a tripped condition
Low power
Measure voltage across input terminals on power line
filter. Voltage should measure between 190 and 264
Vac
Cable unplugged/loose
power
Check for loose or disconnected wires or plugs
Bad heater(s)
Measure resistance of heater(s)
Bad Motor Control
Module code
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
No current to the conditioning
Alarm
zone
No Blue Hose
Current
No Red
Chiller
Current
No Blue
Chiller
Current
Motor Over
Current
A software error has occurred
Alarm
commanding too much current
Small Shot
Request
Pumps are defined with
The requested dispense
the wrong size
amount is below the minimum
amount of the system (25% of
Requested shot is below
the combined pump volumes is
If the user has to be able to take the shot the system
the capabilities of the
the minimum)
must be fitted with smaller pumps
Deviation current pump setup
B9C0
B9C1
Error
Type
Error Name
The requested dispense
amount (time/volume/weight)
is below the minimum amount
of the system
Short shot size
Increase the time/volume/weight of the shot
3A2797J
Appendix D - ADM Error Codes
Error
Code
CAA2
CAA3
CAA6
CAA7
CAB1
CAB4
CAB5
CAB8
CAC1
CAC2
CAC3
CAC4
CAC5
CAC6
CAC7
CACN
CACP
CACR
CUCN
D1A1
D4A1
D2A1
D3A1
Error Name Error Description
Comm. Error
Red Hose
Comm. Error
Red Inline
Comm. Error
Red Blanket
Comm. Error
Red Chiller
Comm. Error
Blue Inline
Comm. Error
Blue Hose
Comm. Error
Blue Blanket
Comm. Error
Blue Chiller
Comm. Error
Motor
Comm. Error Communication 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
Error
Type
Cause
Solution
Module missing power
Check power supply connection
Module not programmed Program the module
Alarm
Module bad
PLC is not maintaining
heartbeat
Module missing power
Heartbeat Error
Alarm
Module not programmed
Module Bad
Material restriction too
Setpoint Not The set point was not reached
Deviation
high for requested flow
Reached
and the pump was shutdown
The maximum cycles per
Restriction for the pump
Setpoint
minute of the pump has been Deviation
is not sufficient
Exceeded
exceeded
Pump cannot reach the
requested pressure
Setpoint Not
The set point was not reached Deviation
Reached
Pump cannot reach the
requested flow
System underwent a
change that caused a
large drop in restriction
Setpoint
The set point was exceeded
Deviation
(such as new orifices)
Exceeded
Gateway
Heartbeat
Error
No material in pumps
3A2797J
Replace module
Ensure PLC is triggering the heartbeat
Check power supply connection
Program the module
Replace module
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
77
Appendix D - ADM Error Codes
Error
Code
D5A1
D6A1
DDA1
DDB2
DFA1
DR6A
DR6B
DSC0
F1A0
F2A0
F1B0
F2B0
F4A0
F3A0
F4B0
F3B0
F7D1
L111
L122
L311
L322
L6A1
L6B2
78
Error
Error Description
Type
This calibration lets the MCM
know where the ends of the
pump are. If the data gathered
Invalid Learn
during this process is outside Deviation
Mode Data
of normal parameters the
machine will operate with a
greatly reduced stroke.
Error Name
Cause
Solution
Recalibrate the machine Rerun the learn mode calibration
Check to ensure the pressure transducer is properly
Loose/bad connection
installed and all wires are properly connected
Bad linear position
sensor
Loose/bad connection to
linear position sensor
Bad linear position
The linear position sensor is
sensor
returning data that should not
Position
Alarm
Sensor Fault be possible during normal
Linear position sensor
operation
may be loose where
attached to pump
housing
Insufficient material
Red Pump
being supplied or
Cavitation
insufficient material
Cavitation was detected on the
Deviation
pressure on feed system
given pump
Blue Pump
Cavitation
Debris or packout in the
incoming fluid filter
Orifices blocked
Hose blocked
Pump Not
The pump failed to reach the
Deviation
Parked
park position
Dispense valve failed to
open
Check Flow
Cogs in flow meter are
Meter Red
not turning
Flow Meter has caused a fault Deviation
Cable unplugged/loose
Check Flow
Meter Blue
power
The type or size of the Red or
Properly setup the
Pumps Not
Blue material pumps have not Alarm
system
Defined
been defined
Alarm
Low Flow
Cogs in flow meter are
Red
Flow is below the defined low Deviation not turning
limit
Alarm
Low Flow
Cable unplugged/loose
Blue
Deviation power
Alarm
High Flow
Red
Flow is above the defined low Deviation Cogs in flow meter are
limit
turning rapidly
Alarm
High Flow
Blue
Deviation
Failure of the dispense
When the pump tried to stall to
valve
pressure the pump traveled
Pump Failed
more than it should in normal Deviation
Material leak
to Stall
operation (only applies to
dead-headed system)
Out of material
Red Low
Tanks low on material
Material Level
Blue Low
Material Level
Low material level in tanks
Deviation
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
Clear blockage
Clear or replace hose 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.
Fill tanks
Fill tanks with material
If the tanks appear to have plenty of material check to
Loose/broken connection make sure the level sensor is connected to the proper
port and that the cord is not damaged
Bad level sensor
Replace level sensor
Red High
Material Level
High material level in tanks
Deviation Defective fill valve
Blue High
Material Level
No material is actually
Red Auto
being fed
Refill Timeout The tank stand has been filing
for a time greater than
Deviation Loose level sensor
Blue Auto
connection
expected
Refill Timeout
Bad level sensor
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
Replace level sensor
3A2797J
Appendix D - ADM Error Codes
Error
Code
L8A1
DR6B
L9AX
L9BX
L9A0
MBH1
MBN1
MMUX
N1D0
N2D0
N3D0
N4D0
Error Name
Red Tank
Sensor
Failure
Blue Tank
Sensor
Failure
Red Tank
Leak
Detected
Blue Tank
Leak
Detected
Error Description
Error
Type
Cause
A level sensor had ceased
working
Deviation Bad level sensor
A tank or material line is
leaking
Alarm
Two tank refills occur
without a dispense
Solution
Replace level sensor
Check all hoses and pumps for material leaks
No material is sensed by
the second level sensor Check for an obstructions within the material supply
within an allotted amount line
of time
Low oil level
Check oil level and if low add more hydraulic fluid
Check to ensure the hydraulic oil level sensor is
Loose/bad connection
properly connected to the MCM and that the wire has
not been damaged
The volume of oil in the tank is
Bad level sensor
Replace sensor
below the minimum level
Alarm
Low Oil Level
Inspect hydraulic driver end seals and early leak
needed for the system to
Leak in hydraulic driver detection tubing. Replace seals as necessary and
properly operate
replace lost oil.
Inspect the hydraulic reservoir fittings and filter for
Leak in the hydraulic
leaks. Repair or replace as necessary and replace
reservoir, heat
lost oil.
exchanger
If error persists and performance can no longer
The motor magnetism has
Prolonged exposure to
Low Motor
satisfy the user requirements the motor will need to
decreased to the point where Advisory
heat or high voltage
Performance
be replaced
performance is greatly reduced
Download USB logs to a memory stick
USB logs have not been
USB Logs
USB log has reached the
Advisory
Uncheck the Enable USB errors on Advanced screen
downloaded
Full
maximum entries
4
Material
Alarm
Dispense
Below Alarm
Cogs in flow meter are Check that flow meter is matched to nominal pump
Material dispense is below the
Material
not turning
output
defined limit
Dispense
Deviation
Below
Deviation
Material
Dispense
Deviation
Above
Material dispense is above the
Cable unplugged/loose
Deviation
check for loose or disconnected wires or plugs
defined limit
power
Material
Dispense
Alarm
Above Alarm
Prepoly
Prepoly refresh took longer to
Alarm
Refresh Time
complete than normal
Expired
3A2797J
79
Appendix D - ADM Error Codes
Error
Code
Error Name
Error Description
N4A1
The MCM attempted to move
Pump Failed
the pump but no movement
to Move
was detected
P400
Thermal
Pressure
Rise
P4A1
P4B2
P4D0
P6A1
P6B2
80
Error
Type
Cause
Solution
Visually check to ensure the pump is moving, if not
Motor failure
ensure the motor is wired properly
If motor is moving but pump is not and pressure is not
Hydraulic power pack
building they hydraulic power pack may need
failure
servicing
Check to ensure the linear position sensor is properly
Loose/bad connection to
connected to the MCM and the wiring has not be
the linear position sensor
damaged
Failure of the linear
Replace the linear position sensor
position sensor
Deviation
Motor no longer coupled Reset coupler per specifications and retighten set
to hydraulic pump
screws
Supply tube from
hydraulic pump to
Retighten or replace supply tube
manifold is loose or
broken
Broken motor shaft
Replace motor
Verify that no outside forces are stopping the pump
Over-pressure valve
from moving, then inspect over-pressure valve for
dumping to tank
damage or debris
Pressure has risen to an
unsafe level due to thermal
Deviation High pressure
expansion of materials. All
conditioning zones have
automatically been turned off.
Dispense valve failed to
Red Pressure
open
Shutdown
Bad dispense valve
Restriction in the
material lines
The material pump pressure
exceeded the maximum
Invalid maximum
Alarm
Blue
operating pressure as defined
pressure defined
Pressure
in the setup screens
Shutdown
Orifices blocked
Hose blocked
Dispense valve failed to
open
Pressure
Imbalance
The pressure difference
between the Red and Blue
material is greater than the
defined amount
Red Pressure
Sensor Fault The pressure sensor is
providing invalid/no pressure
Blue
readings
Pressure
Sensor Fault
Alarm
Alarm
Alarm
Open the dispense valve manually or open the valves
to bleed pressure
Check to make sure the dispense valve is properly
configured and connected to the MCM
Replace dispense valve
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
Clear blockage
Clear blockage or replace hose as necessary
Check to make sure the dispense valve is properly
configured and connected to the MCM
Ensure the material flow is equally restricted on both
Dispense line is clogged
material lines
On the ADM go into the setup screens -> System->
and ensure the pressure imbalance value is the
Pressure imbalance is
maximum acceptable to prevent unnecessary alarms
defined too low
which will abort dispenses
Orifice blocks closed off Verify that one or both of the orifice blocks dispense
too much on one or both when adjusted to the fully open position then adjust
accordingly
sides
Relieve system pressure then remove the orifice from
Debris in the orifice block
the orifice block and inspect for debris in the cavity
Relieve system pressure and remove the orifice from
Material fillers may have
the orifice block and inspect for pack out. Clean or
packed out in an orifice
replace as necessary.
Out of material
Fill tanks with material
Feed system defective Replace defective item
Check to ensure the pressure transducer is properly
Loose/bad connection
installed and all wires are properly connected
Bad sensor
Replace pressure transducer
No material in pump
Fill tanks
3A2797J
Appendix D - ADM Error Codes
Error
Code
R1D0
R4D0
R2D0
R3D0
T1A6
T1B5
T1A3
T1B1
T1A2
T1B4
T1A7
T1B8
T20X
T30X
Error Name
Low Ratio
Alarm
High Ratio
Alarm
Low Ratio
Deviation
High Ratio
Deviation
Red Tank
Low Fluid
Temp.
Blue Tank
Low Fluid
Temp.
Red Inline
Low Fluid
Temp.
Blue Inline
Low Fluid
Temp.
Red Hose
Low Fluid
Temp.
Blue Hose
Low Fluid
Temp.
Red Chiller
Low Fluid
Temp.
Blue Chiller
Low Fluid
Temp.
Dispensing
Disabled Low
Temp
Dispensing
Disabled High
Temp
3A2797J
Error Description
Error
Type
Cause
Solution
Material A to Material B
is out of ratio
Check feed system
Tripped circuit breaker
Visually check circuit breaker for a tripped condition
Low power
Measure voltage across input terminals on power line
filter. Voltage should measure between 190 and 264
Vac
Cable unplugged/loose
power
Check for loose or disconnected wires or plugs
Bad heater(s)
Measure resistance of heater(s)
Alarm
Ratio monitor has detected an
out of ratio condition
Deviation
Fluid temperature is below the
Alarm
defined low alarm limit
Temperature is out of
Dispensing disabled because
Advisory
alarm limits
of temperature
Check temperature alarm limits
81
Appendix D - ADM Error Codes
Error
Code
T2AA
T2AE
T2AF
T2BC
T2BD
T2BG
T3AA
T3AE
T3AF
T3BC
T3BD
T3BG
T3H1
Error Name
Red Hose
Low Fluid
Temp.
Red Tank
Low Fluid
Temp.
Red Chiller
Low Fluid
Temp.
Blue Hose
Low Fluid
Temp.
Blue tank Low
Fluid Temp.
Blue Chiller
Low Fluid
Temp.
Red Hose
High Fluid
Temp.
Red Tank
High Fluid
Temp.
Red Chiller
High Fluid
Temp.
Blue Hose
High Fluid
Temp.
Blue Tank
High Fluid
Temp.
Blue Chiller
High Fluid
Temp.
Oil Temp.
Cutback
Error Description
Error
Type
Cause
Solution
Temperature is out of
alarm limits
Check temperature alarm limits
Cable unplugged/loose
power
Check for loose or disconnected wires or plugs
Fluid temperature for a monitor
zone is below the defined low
alarm limit
Deviation
Fluid temperature for a monitor
zone is above the defined high
alarm limit
Inline heater is not turned
Turn on inline heater
on
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
No power to fan
Debris is fan or fan grill
Deviation
Check cord to make sure fan has power
Clear debris from fan/fan grill
Try to stop fan by lightly pressing on the center with a
Low air volume from fan pencil eraser. If the fan slows down easily it will need
to be replaced
No power to fan
Debris is fan or fan grill
T3N1
82
Check cord to make sure fan has power
clear debris from fan/fan grill
Try to stop fan by lightly pressing on the center with a
Motor temperature is
Low air volume from fan pencil eraser. If the fan slows down easily it will need
approaching a level where
to be replaced
Motor Temp.
Advisory
damage is possible so the
Cutback
Ambient
environmental
motor control module is limiting
Move machine to an area below 120°F
conditions are too hot
the output to a safe level
Motor/pump coupler may
Reset coupler per specifications and retighten set
be rubbing on hydraulic
screws
pump
3A2797J
Appendix D - ADM Error Codes
Error
Code
T4A2
T4A3
T4A6
T4A7
T4B1
T4B4
T4B5
T4B8
T4C1
Error Name
Red Hose
High Fluid
Temp.
Red Inline
High Fluid
Temp.
Red Tank
High Fluid
Temp.
Red Chiller
High Fluid
Temp.
Blue Inline
High Fluid
Temp.
Blue Hose
High Fluid
Temp.
Blue Tank
High Fluid
Temp.
Blue Chiller
High Fluid
Temp.
Error Description
Error
Type
The temperature the MCM has
reached a level where product
Motor Control
Alarm
life will be decreased
High Temp.
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
Oil Temp.
Shutdown
T4N1
Motor temperature is too high
Motor Temp. and system has been
Alarm
shutdown to prevent possible
Shutdown
damage
T6B5
T6A3
T6B1
T6A2
T6B4
T6A7
T6B8
Red Tank
RTD Fault
Blue Tank
RTD Fault
Red Inline
RTD Fault
Blue Inline
RTD Fault
Red Hose
FTS Fault
Blue Hose
FTS Fault
Red Chiller
RTD Fault
Blue Chiller
RTD Fault
3A2797J
Solution
Defective Temperature
Control Module
Replace Power Temperature Control Module
Defective RTD
Replace RTD
Loose connections
Tighten connections
Fluid temperature is above the
Alarm
defined high alarm limit
T4H1
T6A6
Cause
RTD 1 is giving no or invalid
data
Alarm
No power to fan
Check cord to make sure fan has power
Debris is fan or heatsink Clear debris from fan or heatsink
Try to stop fan by lightly pressing on the center with a
Low air volume from fan pencil eraser. If the fan slows down easily it will need
to be replaced
Motor may be damaged Replace motor
Debris is packed in the
Clear debris from MCM heat sink fins
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
Try to stop fan by lightly pressing on the center with a
Low air volume from fan pencil eraser. If the fan slows down easily it will need
to be replaced
No power to fan
Check cord to make sure fan has power
Debris is fan or fan grill Clear debris from fan/fan grill
Try to stop fan by lightly pressing on the center with a
Low air volume from fan pencil eraser. If the fan slows down easily it will need
to be replaced
Ambient environmental
Move machine to an area below 120°F
conditions are too hot
Motor may be damaged Motor may need to be replaced
Loose or bad connection Check RTD wiring
Alarm
Bad RTD
Replace RTD
83
Appendix D - ADM Error Codes
Error
Code
T6C6
T6C5
T6C7
T6C8
T8A6
T8B5
T8A3
T8B1
T8A2
T8B4
T8A7
T8B8
T9A6
T9B5
T9A3
T9B1
T9C6
T9C5
T9C3
T9C1
T9C2
T9C4
T9C7
T9C8
84
Error Name Error Description
Red Blanket
RTD Fault
Blue Blanket
RTD Fault
RTD 2 is giving no or invalid
data
Red Chiller
RTD Fault
Blue Chiller
RTD Fault
No Heat Red
Tank
No Heat Blue
Tank
No Heat Red
Inline
No temperature rise
No Heat Blue
Inline
Error
Type
No temperature decline
Loose or bad connection Check RTD wiring
Replace RTD
Tripped circuit breaker
Visually check circuit breaker for a tripped condition
Low Power
Measure voltage across input terminals on power line
filter. Voltage should measure between 190 and 264
Vac
Cable unplugged/loose
power
Check for loose or disconnected wires or plugs
Bad heater(s)
Measure resistance of heater(s)
Tripped circuit breaker
Visually check circuit breaker for a tripped condition
Disconnect the valve and measure the voltage across
the wires when the chiller is running to ensure 24V is
Deviation Defective cooling valve
being delivered to the valve. If so, the cooling valve
will likely need replacing.
Chilled water supply off Turn on chilled water supply
Loose or bad connection Check RTD wiring
Heater overtemperature cutoff Alarm
Blue Inline
Temp. Cutoff
Red Blanket
Ctrl
Shutdown
Blue Blanket
Ctrl
Shutdown
Red Inline
Ctrl
Shutdown
Blue Inline
Ctrl
Shutdown
PCB over temperature
Red Hose Ctrl
Shutdown
Blue Hose
Ctrl
Shutdown
Red Chiller
Ctrl
Shutdown
Blue Chiller
Ctrl
Shutdown
Bad RTD
Deviation
Red Blanket
Temp. Cutoff
Blue Blanket
Temp. Cutoff
Red Inline
Temp. Cutoff
Solution
Alarm
No Heat Red
Hose
No Heat Blue
Hose
No Cooling
Red Chiller
No Cooling
Blue Chiller
Cause
Alarm
Defective RTD
Replace RTD
Defective High Power
Temperature Control
Module
Replace High Power Temperature Control Module
Loose connections
Tighten connections
Overheated
Temperature Control
Module
Turn conditioning zone off. Wait a few minutes. If the
condition does not clear or regenerates consistently,
replace heater module
3A2797J
Appendix D - ADM Error Codes
Error
Code
V1H1
V4A6
V4B5
V4A3
V4B1
V4A2
V4B4
V4A7
V4B8
V4H0
W0U0
Error
Error Description
Type
The voltage to the MCM has
Motor Control
dropped to a level where
Alarm
Undervoltage
performance is greatly affected
Red Blanket
Overvoltage
Blue Blanket
Overvoltage
Red Inline
Overvoltage
Blue Inline
Overvoltage
High line voltage
Alarm
Red Hose
Overvoltage
Blue Hose
Overvoltage
Red Chiller
Overvoltage
Blue Chiller
Overvoltage
The voltage to the MCM has
Motor Control reached an unsafe level and
Alarm
Overvoltage has been shutdown in an
attempt to prevent damage
Error Name
USB Update The ADM tried to upload a
Failed
system settings file but failed
Alarm
WBH1
Motor
An error has been detected on
Alarm
Encoder Fault the motor position sensor
WDF1
M1 Material The material rod failed to move
Alarm
Rod Shift Fail on a straight head
Cause
Tripped circuit breaker
Supply lines providing
low voltage
Solution
Visually check circuit breaker for a tripped condition
Check incoming voltage to ensure it is above the
minimum operating voltage
Incoming line voltage is
too high
Measure voltage across disconnect switch. Voltage
should measure between 190 and 264 Vac.
Supply lines providing
high voltage
Check incoming voltage to ensure it is below the
maximum operating voltage
System Settings file is
corrupt
Replace the system settings file with a backup or new
file
Ensure that the first line in the settings.txt file contains
System Settings file is
intended for another
system
Failing sensors
Loose connection
Stuck material rod
No power to directional
valve
No power to directional
valve
Bad directional valve
connection
WKH1
High Motor
Speed
3A2797J
The motor has reached a
speed that should not be
Alarm
reached in normal operation
and was shutdown to prevent
possible damage
Directional valve failure
Hydraulic power pack
failure
Defective encoder
Motor no longer coupled
to hydraulic pump
Supply tube from
hydraulic pump to
manifold is loose or
broken
Broken motor shaft
the text GMS™. If not replace the file with the proper
system update file.
If error persists the motor will need to be replaced
Ensure the d-sub connector to the motor is connected
and the wiring is intact
Check that material rod is able to freely move
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 directional valve will need to be replaced
The hydraulic power pack will need repair
Replace encoder
Reset coupler per specifications and retighten set
screws
Retighten or replace supply tube
Replace motor
85
Appendix D - ADM Error Codes
Error
Code
WM06
WM05
WM03
WM01
WM02
WM04
WM07
WM08
WMA6
WMB5
WMC6
WMC5
WMC3
WMC1
WMC2
WMC4
WMC7
WMC8
WMH1
Error Name
Red Tank
Con. Fault
Blue Tank
Con. Fault
Red Inline
Con. Fault
Blue Inline
Con. Fault
Red Hose
Con. Fault
Blue Hose
Con. Fault
Red Chiller
Con. Fault
Blue Chiller
Con. Fault
Red Blanket
High Temp.
Error
Type
Cause
Solution
High current to relay 1
Alarm
Broken contactor
Replace contactor
Defective RTD
Replace RTD
Tank blanket is above the
Blue Blanket defined high alarm limit
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
WSC0
Invalid Gel
Timer
Definition
86
Error Description
Alarm
Unexpected current to relay 1 Alarm
A general fault has occurred
within the MCM
Defective High Power
Temperature Control
Module
Loose connections
Shorted module
Deviation Internal hardware failure
Replace High Power Temperature Control Module
Tighten connections
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->
System incorrectly setup and ensure that all pages have properly defined
The requested controlling
values
value (pressure or flow) is
Deviation
outside the limits of the system
Redefine shot with control parameters within the limits
Shot incorrectly defined
of the system
Gel timer shot is below
the minimum dispense
Select a different shot or modify existing shot data
amount or set for a
invalid pressure/flow
The shot that was entered for
the gel timer is not a valid shot.
The MCM has
Deviation
This must be fixed before the
determined that the gel If you are certain that the shot is within parameters,
gel timer will function properly
timer shot will not be able try running the Learn Mode routine found in the setup
screen Calibration. If the error persists, a gel shot with
to be executed based
reduced control parameters is required.
parameters entered in
the ADM
3A2797J
Appendix E - System Events
Appendix E - System
Events
Event Code and
String
EAA0-R: Prepoly
Refresh Started
EBA0-R: Prepoly
Refresh Complete
EL00-R: System
Powered On
EM00-R: System
Powered Off
EB00-R: Stop Button
Pressed
ECH0-R: Learn Mode
Executed
ENN0-R: Automatic
Cal. Performed
ECA1-R: Red Material SG Modified
ECB2-R: Blue Material SG Modified
ENC1-R: Cal. Point 1
Weight Entered
ENC2-R: Cal. Point 2
Weight Entered
ENC4-R: Cal. Point 1
Weight Erased
ENC5-R: Cal. Point 2
Weight Erased
END0-R: Ratio Check
Dispense
EA00-R: Disp.
Occurred (Shot #)
EH00-R: Gel Timer
Dispense
ER01-R: Shot Count
Reset
ER02-R: Seq. Position Count Reset
ERA1-R: Red Material Volume Reset
ERB1-R: Blue Material Volume Reset
ERA2-R: Red Material Weight Reset
ERB2-R: Blue Material Weight Reset
ERA3-R: Red Cycle
Count Reset
ERB3-R: Blue Cycle
Count Reset
3A2797J
Triggers
While in night mode, the prepoly
refresh started.
While in night mode, the prepoly
refresh completed successfully.
The System was powered on.
The System was powered off.
The Red stop button was pressed on
the Advanced Display Module.
A learn mode calibration was successfully completed.
The system was successfully characterized with the Automatic calibration.
The Red materials specific gravity was
modified.
The Blue materials specific gravity was
modified.
A value for the first point in the three
point calibration was entered.
A value for the second point in the
three point calibration was entered.
The running average for point one of
the three point calibration was erased.
The running average for point two of
the three point calibration was erased.
A ratio check shot was dispensed from
the ratio check calibration screen.
A dispense has occurred of the given
shot number.
The gel timer expired and the system
automatically took the gel shot.
A counter from the shot counters maintenance page was erased
A counter from the sequence counters
maintenance page was erased
The resettable totalizer for the Red
material volume was reset to zero.
The resettable totalizer for the Blue
material volume was reset to zero.
The resettable totalizer for the Red
material weight was reset to zero.
The resettable totalizer for the Blue
material weight was reset to zero.
The resettable cycle counter for the
Red pump was reset to zero.
The resettable cycle counter for the
Blue pump was reset to zero.
Event Code and
String
EQU1-R: Settings
Downloaded
Triggers
The system settings were successfully
transferred from the ADM to a USB
drive.
REQU-R: Settings
The system settings file was successUploaded
fully transferred from the USB drive to
the ADM.
EQU3-R: Language The custom language file was sucDownloaded
cessfully transferred from the ADM to
a USB drive.
EQU4-R: Language The custom language file was sucUploaded
cessfully transferred from the USB
drive to the ADM.
EQU5-R: Logs Down- The Error/Event and Shot data logs
loaded
were successfully transferred from the
ADM to a USB drive.
EA0-R: Night Mode
While in night mode the system has
Recirc On
automatically entered a low circulation
mode and attempted to turn on all
enabled conditioning zones.
EBR0-R: Night Mode While in night mode the system has
Recirc Off
automatically stopped the low circulation mode and turned off all conditioning zones.
EWA0-R: Prepoly
While in night mode, the prepoly
Refresh Cancelled
refresh was cancelled
87
Appendix E - System Events
88
3A2797J
Appendix F - USB Operation
Appendix F - USB Operation
Overview
The third option is a checkbox that enables or disables
the ability to record errors associated with the USB logs.
There are 3 main uses for the USB on a GMS system
•
•
•
Ability to download a log of up to the past 50,000
errors, events, or jobs that can contain over 150,000
snapshots of critical dispense information.
Ability to download, modify, and upload custom language files
Ability to download and upload system configurations
• This data includes most user selectable and
user configurable settings.
• This data does not include pump counters, error
and event logs, shot and sequence counters
USB Options
The only options for USB on the ADM are in Advanced
Screen 4, see page 68.
Download Log Files
If the “Enable Downloading of USB Logs” is checked,
the user can use a USB stick-drive to download the log
files.
NOTICE
Low-quality USB stick drives may lead to burning
out the USB port on the ADM. Use only high-quality
USB stick-drives with the ADM USB port.
To download the log files, insert a high-quality USB
stick-drive into the USB port in the bottom of the ADM.
The ADM will automatically begin downloading the log
files as well as the custom language file (DISPTEXT.TXT) and the system settings (SETTINGS.TXT).
The status of the download will be shown in the Status
bar.
The first option is a checkbox that enables or disables
the downloading of the Error Event and Shot Data log
files. The Shot Data log runs during all circulation, shots,
and operator modes.
The second option is the Erase icon which will reset the
last download date to a time where all logs can be
downloaded. This will allow the user to download all the
USB log entries, which may take over 2 hours if the log
files are full. Currently the ADM does not monitor the
USB logs and alert the user when data may be overwritten so in order to minimize download times and the risk
of losing data it is recommended that the user download
the logs every 2 weeks or more often if the machine is
used during more than one full shift a day.
3A2797J
89
Appendix F - USB Operation
Log Files, Folder Structure
FIG. 30: DOWNLOAD, DATAxxxx Folders
Each time a stick-drive is inserted into the ADM USB port, a new folder named DATAxxxx is created. The number at
the end of the folder name is incremented each time a stick-drive is inserted and data is downloaded or uploaded. In
each DATAxxxx folder there are three log files. They are formatted as .csv (comma separated value) files and can be
opened by most text editors or data processing programs such as Excel.
Example 1-ERROR File
The 1-ERROR file is the Errors and Events log file.
90
3A2797J
Appendix F - USB Operation
Example 2-JOB File
The 2-JOB file is the Shot Data Log file.
Example 3-SYSTEM File
The 3-SYSTEM file is the Software Version log file.
3A2797J
91
Appendix F - USB Operation
Transfer System Settings
NOTICE
Low-quality USB stick drives may lead to burning
out the USB port on the ADM. Use only high-quality
USB stick-drives with the ADM USB port.
Use the following process to transfer system settings
from one machine to another.
1. Insert a high-quality USB stick-drive into the USB
port on the system with the settings to be transferred. Once the download is complete the SETTINGS.TXT file will be located in the “DOWNLOAD”
folder.
NOTICE
The user should never attempt to modify the SETTINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified
setup file.
2. Plug the USB stick-drive into a computer.
NOTE: Before the update begins the ADM automatically
shuts down the system, aborting any in-progress dispensing. When the software is updating the system a
pop-up box will appear to inform the user of the update
and the system will lock. Once the update is complete
the ADM will tell the user to cycle power to apply the
updates. Once this box appears it is safe to remove the
drive before cycling power.
6. When the software is done updating, remove the
USB stick-drive from the ADM USB port and install
in a computer.
7. Navigate to the UPLOAD folder and remove the
SETTINGS.TXT file.
NOTE: Immediately after uploading the settings,
remove the SETTINGS.TXT file from the UPLOAD
folder to prevent accidental loss of data the next time
the USB stick-drive is inserted into the ADM USB port. If
there is a SETTINGS.TXT file in the UPLOAD folder
when the USB stick-drive is inserted into the ADM USB
port the software will try to update the ADM.
3. Navigate to the DOWNLOAD folder.
4. Copy the SETTINGS.TXT file from the DOWNLOAD
folder into the UPLOAD folder.
5. Remove the USB stick-drive from the computer and
install it into the ADM USB port for the second
machine. The software will automatically begin
updating.
92
3A2797J
Appendix F - USB Operation
Update Custom Language
NOTICE
Low-quality USB stick drives may lead to burning
out the USB port on the ADM. Use only high-quality
USB stick-drives with the ADM USB port.
Use the following process to customize the text on the
ADM. The language file DISPTEXT.TXT can be modified in Excel but must be saved as a Unicode Text file
with the extension .TXT in order for it to properly import.
1. Insert a high-quality USB stick-drive into the USB
port on the system with the settings to be transferred. Once the download is complete the DISPTEXT.TXT file will be located in the “DOWNLOAD”
folder.
2. Plug the USB stick-drive into a computer.
3. Navigate to the DOWNLOAD folder.
8. When the software is done updating, remove the
USB stick-drive from the ADM USB port and install
in a computer.
9. Navigate to the UPLOAD folder and remove the
DISPTEXT.TXT file.
NOTE: Immediately following uploading the language
file, remove the DISPTEXT.TXT file from the UPLOAD
folder to prevent accidental loss of data the next time
the USB stick-drive is inserted into the ADM USB port. If
there is a DISPTEXT.TXT file in the UPLOAD folder
when the USB stick-drive is inserted into the ADM USB
port the software will try to update the ADM.
4. Copy the DISPTEXT.TXT file from the DOWNLOAD
to your computer.
5. Use any data processing software such as Excel to
edit the DISPTEXT.TXT file. When done editing
save the file as the “Unicode Text” format. See
Example DISPTEXT.TXT File on page 94.
a. In the first column, locate the string to change.
b. In the second column of the same row, enter the
new string.
c.
Save the file as a Unicode Text file. The name
must remain “DISPTEXT.TXT”.
6. Copy the edited DISPTEXT.TXT file into the
UPLOAD folder.
7. Remove the USB stick-drive from the computer and
install it into the ADM USB port. The software will
automatically begin updating.
NOTE: Before the update begins the ADM automatically
shuts down the system, aborting any in-progress dispensing. When the software is updating the system a
pop-up box will appear to inform the user of the update
and the system will lock. Once the update is complete
the ADM will tell the user to cycle power to apply the
updates. Once this box appears it is safe to remove the
drive before cycling power.
3A2797J
93
Appendix F - USB Operation
Example SETTINGS.TXT File
NOTICE
The user should never attempt to modify the SETTINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified
setup file.
Example DISPTEXT.TXT File
94
3A2797J
Technical Data
Technical Data
HFR for NVH Foam
Maximum fluid working pressure
Maximum Fluid Temperature
Fluid Inlet Feed Pressure Range
Fluid Inlet:
Component A (Red)
Fluid Inlet:
Component B (Blue)
Fluid Outlet:
Component A (Red)
Fluid Outlet:
Component B (Blue)
Fluid Circulation Ports
Line Voltage Requirement:
230V / 3 phase Models
Line Voltage Requirement:
400V / 3 phase Models
Amperage Requirement
Sound Power
Heater Power
(A (Red) and B (Blue) heaters total, no hose)
Hydraulic reservoir capacity
Recommended hydraulic fluid
Weight:
Units with 10 kW Heaters
Wetted Part
US
2000 psi
190°F
50 psi to 100 psi
Metric
14 MPa, 138 bar
88°C
345 kPa, 3.4 bar to 0.7 MPa, 7 bar
1/2 npt(f)
3/4 npt(f)
#8 (1/2 in.) JIC (3/4-16 unf), with #5 (5/16 in.) JIC adapter
#10 (5/8 in.) JIC (7/8-14 unf), with #6 (3/8 in.) JIC adapter
1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum
195-264V, 50/60 Hz
360-440V, 50/60 Hz
See 400 V Power Requirements on page 5
See Models on page 4
93 dB
10 kW full load
(12 kW for 1:1 Models Only)
9 gal. (34 liters)
Citgo A/W Hydraulic Oil, ISO Grade 46
868 lb (394 kg)
Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide,
chrome, fluoroelastomer, PTFE, ultra-high molecular weight polyethylene,
chemically resistant o-rings
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
3A2797J
95
Technical Data
Motor Control Module Technical Data
Motor Control Module
US
Metric
Input Specifications:
Input Line Voltage
0-264 Vac, line-to-line
Input Line Phasing
Single or Three Phase
Input Line Frequency
50/60 Hz
Input Current per Phase
25A (three-phase), 50A (single-phase)
Maximum Branch Circuit Protection Rating 30A (three-phase), 63A (single-phase)
Short Circuit Current Rating
5 kA
Output Specifications:
Output Line Voltage
0-264 Vac
Output Line Phasing
Three Phase
Output Current
0-30A
Output Overload
200% for 0.2 seconds
DC Power Supply
24 Vdc, Class 2, Graco-provided power supply
Enclosure
Type 1
Max Ambient Temperature
50°C (122°F)
Overtemperature protection is provided to protect from motor overload.
Current limit, set via the software, is provided as a secondary protection from motor overload.
All installations and wiring must comply with NEC and local electrical codes.
96
3A2797J
Technical Data
Dimensions
A
ti19519a
B
C
Dimensions
A (Height)
76 in. (193 cm)
B (Width)
72 in. (183 cm)
C (Length)
58 in. (147 cm)
3A2797J
97
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs
will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-746-1334 or Fax: 330-966-3006
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 3A2797
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision J, January 2016