Graco 313997ZAC - HFR Owner's Manual

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Graco 313997ZAC - HFR Owner's Manual | Manualzz

Setup - Operation

HFR

313997ZAC

EN

Hydraulic, Plural-Component, Fixed-Ratio Proportioner.

For pouring and dispensing sealants and adhesives and polyurethane foam.

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

Important Safety Instructions

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

See page 4 for model information and maximum

working pressure.

ti19598a

2

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Manual and Semi-Automatic Circulation Kits . . 16

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

Important Two-Component Material Information 20

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

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

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

20

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

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

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

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

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

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

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

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

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

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

Temperature Control Module (Heated HFR Only)

34

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

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

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

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

Advanced Display Module (ADM) Operation . . . 46

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

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

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

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

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

ADM - Battery Replacement and Screen Cleaning

54

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

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

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

IsoGuard Select

®

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

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

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

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

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

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

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

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

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

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

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

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

Appendix C - ADM Run Screens Overview . . . . . 83

Appendix D - ADM Error Codes . . . . . . . . . . . . . . 89

Appendix E - System Events . . . . . . . . . . . . . . . 101

Appendix F - USB Operation . . . . . . . . . . . . . . . . 103

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

USB Options . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Download Log Files . . . . . . . . . . . . . . . . . . . . . 103

Log Files, Folder Structure . . . . . . . . . . . . . . . 104

Transfer System Settings . . . . . . . . . . . . . . . . 106

Update Custom Language . . . . . . . . . . . . . . . . 107

Appendix G- Temperature . . . . . . . . . . . . . . . . . . 109

Temperature Displayed and Actual Material

Temperature . . . . . . . . . . . . . . . . . . . . . . . 109

Appendix H- Circulation . . . . . . . . . . . . . . . . . . . 110

Manual and Semi-Automatic Circulation Feature .

110

Manual Circulation Feature . . . . . . . . . . . . . . . 110

Semi-Automatic Circulation Feature . . . . . . . . 110

Circulation Feature Operation . . . . . . . . . . . . . 115

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Motor Control Module Technical Data . . . . . . . . 118

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 120

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 120

313997ZAC

Related Manuals

Related Manuals

Manuals are available at www.graco.com.

Component manuals in English:

System Manuals

313998 HFR Repair-Parts

Power Distribution Box Manual

3A0239 Power Distribution Boxes Instructions-Parts

Pumpline Manuals

3A0019

3A0020

Z-Series Chemical Pumps Instructions-Parts

HFR Hydraulic Actuator Instructions-Parts

Feed System Manuals

3A0238

3A0235

3A0395

3A1299

3A0237

Dispense Head Hydraulic Power

Pack Instructions-Parts

Feed Supply Kits

Instructions-Parts

Stainless Steel Tank Feed Systems Instructions-Parts

Carbon Steel Tank Feed Systems

Instructions-Parts

Heated Hoses and Applicator Kits,

Instructions-Parts

Dispense Valve Manuals

313872

313536

312185

312752

312753

309550

309856

312666

EP

Gun

GX-16, Operation

MD2 Valve, Instructions-Parts

S-Head Operation-Parts

L-Head Operation-Parts

Fusion

®

AP Gun

Fusion MP Gun

Fusion CS Gun

Accessory Manuals

3A1149

312864

3A1657

3A1244

3A2890

HFR Discrete Gateway Module

Kits Manual

HFR Communications Gateway

Module Instructions-Parts

HFR Flow Meter Kits

Instructions-Parts

Graco Control Architecture

Module Programming Manual

Mobile Pallet with Casters Kit Manual

313997ZAC 3

4

Models

Models

See

Product Configurator on page 5 for detailed product configuration information.

System

HFR,

Non-Heated

HFR,

Heated

Full Load

Peak

Amps Per

Phase*

55 A

29 A

Voltage

(phase)

230V (1)

Power Description

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

230V (3)

2 wire and PE

200-240VAC, 3 phase

Δ

, 50/60Hz, 3 wire and PE

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

55 A  400V (3)

116 A

73 A

230V (1)

230V (3)

2 wire and PE

200-240VAC, 3 phase

Δ

, 50/60Hz, 3 wire and PE

200-240VAC, 3 phase

Δ

, 50/60Hz, 3 wire and PE

System Watts †

Maximum

Fluid Working

Pressure ‡ psi (MPa, bar)

12, 650

11,340

12,650

26,680

28,600

3000

(20.7, 207)

3000

(20.7, 207)

63 A  400V (3)

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

2 wire and PE

28,600

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

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

 approved.

‡ The maximum fluid working pressure for the base machine without hoses is 3000 psi (20.7 MPa, 207 bar). If hoses rated at less than 3000 psi are installed, the system maximum fluid working pressure becomes the rating of the hoses. If 2000 psi hoses were purchased 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.

313997ZAC

Product Configurator

HFR - A -

Ref.: 1

-

2

-

3

-

4

-

5

-

6

Product Configurator

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

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

Ref.: 1 2 3 4 5 6

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

Ref. 1

1

2

Ref. 2

1

2

3

4

5

6

Part

Part

Base Unit

HFR Base Unit, Carbon Steel

HFR Base Unit, Stainless Steel

Voltage

230V, 1 phase;

No Heat

230V, 1 phase;

Maximum of Two 6 kW Primary Heater and One

Zone of Hose Heat

230V, 3 phase;

No Heat

230V, 3 phase;

Maximum of Two 6 kW Primary Heaters and Two

Zones of Hose Heat

400V, 3 phase;

No heat

400V, 3 phase;

Maximum of Two 6 kW Primary Heaters and Two

Zones of Hose Heat

Ref. 3

AQ

AS

AR

AT

AJ

AK

AL

AM

AE

AF

AG

AH

AA

AB

AC

AD

AU

AV

Part B (Blue) Pump †

L010S1 10 cc Stainless Steel

L015S1 15 cc Stainless Steel

L020S1 20 cc Stainless Steel

L025S1 25 cc Stainless Steel

L030S1 30 cc Stainless Steel

L040S1 40 cc Stainless Steel

L050S1 50 cc Stainless Steel

L060S1 60 cc Stainless Steel

L080S1 80 cc Stainless Steel

L100S1 100 cc Stainless Steel

L120S1 120 cc Stainless Steel

L160S1 160 cc Stainless Steel

L005S1 5 cc Stainless Steel

L086S1 86 cc Stainless Steel

L065S1 65 cc Stainless Steel

L035S1 35 cc Stainless Steel

L045S1 45 cc Stainless Steel

L105S1 105 cc Stainless Steel

Ref. 4 Part A (Red) Pump †

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

313997ZAC 5

Product Configurator

6

Ref. 5

A

B

C

D

E

F

G

Ref. 6

NN

AA

AB

AC

AD

AE

AF

AG

AH

BA

BB

BC

BD

BE

BF

BG

BH

CA

CB

CC

CD

CE

Part

Part

Primary/Hose Heat

No Heat

A (Red) and B (Blue) Primary Heaters

A (Red) and B (Blue) Primary Heaters, One Zone of Hose Heat

A (Red) and B (Blue) Primary Heaters, A (Red) and B (Blue) Hose Heat

A (Red) and B (Blue) Hose Heat, Carbon Steel

A (Red) and B (Blue) Hose Heat, Stainless Steel

B (Blue) Primary Heaters, B (Blue) Hose Heat

B (Blue) Applicator Hose or High Volume/

Low Volume Hose Bundle Assembly

-No Hose

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

† Pump size listed is the combined volume dispensed in one extending stroke and one retracting stroke.

313997ZAC

Product Configurator

Whip Hose Bundles

Part Description

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

Single Zone

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

Single Zone

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

Dual Zone

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

Dual Zone

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

Steel, Single Zone

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

Steel, Single Zone

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

Steel, Dual Zone

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

Steel, Dual Zone

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

Single Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Dual Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

Individual B (Blue) Heated Whip

Hose

Part Description

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

Single Zone, 3500 psi

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

Single Zone, 3500 psi

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

Dual Zone, 3500 psi

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

Dual Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

Individual A (Red) Heated Whip

Hose

Part Description

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

Single Zone, 3500 psi

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

Single Zone, 3500 psi

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

Dual Zone, 3500 psi

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

Dual Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

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

Single Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Dual Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Steel, Single Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

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

Steel, Dual Zone, 3500 psi

313997ZAC 7

8

Product Configurator

Hoses

Part Description

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

2000 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

B (Blue) Individual

Part Description

24E902 Heated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi

24E904 Heated Hose, 10 ft, 1/4, Carbon Steel, 3500 psi

24E906 Heated Hose, 25 ft, 1/4, Carbon Steel, 3500 psi

24E908 Heated Hose, 50 ft, 1/4, Carbon Steel, 3500 psi

24E910 Heated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi

24E912 Heated Hose, 10 ft, 3/8, Carbon Steel, 3500 psi

24E914 Heated Hose, 25 ft, 3/8, Carbon Steel, 3500 psi

24E916 Heated Hose, 50 ft, 3/8, Carbon Steel, 3500 psi

24E918 Heated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi

24E920 Heated Hose, 10 ft, 1/2, Carbon Steel, 3500 psi

24E922 Heated Hose, 25 ft, 1/2, Carbon Steel, 3500 psi

24E924 Heated Hose, 50 ft, 1/2, Carbon Steel, 3500 psi

24E926 Heated Hose, 5 ft, 1/4, Stainless Steel, 3500 psi

24E928 Heated Hose, 10 ft, 1/4, Stainless Steel, 3500 psi

24E930 Heated Hose, 25 ft, 1/4, Stainless Steel, 3500 psi

24E932 Heated Hose, 50 ft, 1/4, Stainless Steel, 3500 psi

24E934 Heated Hose, 5 ft, 3/8, Stainless Steel, 3500 psi

24E936 Heated Hose, 10 ft, 3/8, Stainless Steel, 3500 psi

24E938 Heated Hose, 25 ft, 3/8, Stainless Steel, 3500 psi

24E940 Heated Hose, 50 ft, 3/8, Stainless Steel, 3500 psi

24E942 Heated Hose, 5 ft, 1/2, Stainless Steel, 3500 psi

24E944 Heated Hose, 10 ft, 1/2, Stainless Steel, 3500 psi

24E946 Heated Hose, 25 ft, 1/2, Stainless Steel, 3500 psi

24E948 Heated Hose, 50 ft, 1/2, Stainless Steel, 3500 psi

262174 Unheated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi

262176 Unheated Hose, 10 ft, 1/4, Carbon Steel,

3500 psi

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

3500 psi

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

3500 psi

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

262184 Unheated Hose, 10 ft, 3/8, Carbon Steel,

3500 psi

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

3500 psi

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

3500 psi

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

262192 Unheated Hose, 10 ft, 1/2, Carbon Steel,

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

313997ZAC

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

A (Red) Individual

Part Description

24E901 Heated Hose, 5 ft, 1/4, Carbon Steel, 3500 psi

24E903 Heated Hose, 10 ft, 1/4, Carbon Steel, 3500 psi

24E905 Heated Hose, 25 ft, 1/4, Carbon Steel, 3500 psi

24E907 Heated Hose, 50 ft, 1/4, Carbon Steel, 3500 psi

24E909 Heated Hose, 5 ft, 3/8, Carbon Steel, 3500 psi

24E911 Heated Hose, 10 ft, 3/8, Carbon Steel, 3500 psi

24E913 Heated Hose, 25 ft, 3/8, Carbon Steel, 3500 psi

24E915 Heated Hose, 50 ft, 3/8, Carbon Steel, 3500 psi

24E917 Heated Hose, 5 ft, 1/2, Carbon Steel, 3500 psi

24E919 Heated Hose, 10 ft, 1/2, Carbon Steel, 3500 psi

24E921 Heated Hose, 25 ft, 1/2, Carbon Steel, 3500 psi

24E923 Heated Hose, 50 ft, 1/2, Carbon Steel, 3500 psi

24E925 Heated Hose, 5 ft, 1/4, Stainless Steel, 3500 psi

24E927 Heated Hose, 10 ft, 1/4, Stainless Steel, 3500 psi

24E929 Heated Hose, 25 ft, 1/4, Stainless Steel, 3500 psi

24E931 Heated Hose, 50 ft, 1/4, Stainless Steel, 3500 psi

24E933 Heated Hose, 5 ft, 3/8, Stainless Steel, 3500 psi

24E935 Heated Hose, 10 ft, 3/8, Stainless Steel, 3500 psi

24E937 Heated Hose, 25 ft, 3/8, Stainless Steel, 3500 psi

24E939 Heated Hose, 50 ft, 3/8, Stainless Steel, 3500 psi

24E941 Heated Hose, 5 ft, 1/2, Stainless Steel, 3500 psi

24E943 Heated Hose, 10 ft, 1/2, Stainless Steel, 3500 psi

24E945 Heated Hose, 25 ft, 1/2, Stainless Steel, 3500 psi

24E947 Heated Hose, 50 ft, 1/2, Stainless Steel, 3500 psi

313997ZAC

Product Configurator

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

262175 Unheated Hose, 10 ft, 1/4, Carbon Steel,

3500 psi

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

3500 psi

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

3500 psi

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

262183 Unheated Hose, 10 ft, 3/8, Carbon Steel,

3500 psi

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

3500 psi

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

3500 psi

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

262191 Unheated Hose, 10 ft, 1/2, Carbon Steel,

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

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

3500 psi

Hose Bundling Accessories

Description Part

24E953 Air Hose, 5 ft

15B280 Air Hose, 10 ft

15C624 Air Hose, 25 ft

15B295 Air Hose, 50 ft

9

Product Configurator

24E900 Signal Cable, 5 pin, Male/Female, 2.0 meter

24E899 Signal Cable, 5 pin, Male/Female, 4.0 meter

24E898 Signal Cable, 5 pin, Male/Female, 8.5 meter

24E897 Signal Cable, 5 pin, Male/Female, 16.0 meter

24E896 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 2.0 meter

24E895 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 3.0 meter

24E894 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 8.0 meter

24E893 Fluid Temperature Sensor Cable, 4 pin,

Male/Female, 15.7 meter

24E954 Scuff Guard, 1.75 in. (44 mm), 200 ft (61 m) Roll

24E961 Scuff Guard, 1.75 in. (44 mm), 200 ft (61 m) Roll

261821 Wire Connector, 6AWG (4.11 mm)

24E955 Hose Lacing, 1500 ft (457.2 m) Roll

15B679 Hose Safety Label

10

246100

247007

246101

247019

246102

247025

24D500

24D501

24D502

24D503

24D504

24K233

24K234

24E876

24E877

24E878

CS00RD

CS01RD

CS02RD

Part

24A084

24A085

24A086

24A090

24A092

24A093

24J187

24D505

24D509

24D510

24D511

24D512

24D513

24D514

Applicator

NOTE: When selecting an applicator, if an applicator is chosen which does not have a signal communicating to the HFR, then the sizes of the A and B pumps added together must be greater or equal to 120 cc. For example: A (red) pump size = 20 cc, B (blue) pump size =

100 cc, 20 cc + 100 cc = 120 cc. Since the pump sizes combined = 120 cc, an applicator may be selected which does not have a signal communicating to the

HFR.

Description

L-Head 6/10 With Calibration Orifice

L-Head 10/14 With Calibration Orifice

L-Head 13/20 With Calibration Orifice

S-Head 6-625 With Calibration Orifice

S-Head 6-500 L/S With Calibration Orifice

S-Head 6-625 L/S With Calibration Orifice

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

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

GX-16, No Orifice, Left, Machine Mount

GX-16, No Orifice, Straight, Machine Mount

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

GX-16, No Orifice, Right, Machine Mount

Fusion CS, 1:1 Only, 0.029

Fusion CS, 1:1 Only, 0.042

Fusion CS, 1:1 Only, 0.052

Fusion AP, 1:1 Only, 0.029

Fusion MP, 1:1 Only, 0.029

Fusion AP, 1:1 Only, 0.042

Fusion MP, 1:1 Only, 0.047

Fusion AP, 1:1 Only, 0.052

Fusion MP, 1:1 Only, 0.057

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

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

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

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

Applicator, MD2, 1:1, Soft, Stainless Steel, Electric

Applicator, MD2, 1:1, Soft, Stainless Steel, Lever

Applicator, MD2, 1:1, Hard, Carbon Steel

Applicator, MD2, 1:1, Hard, Carbon Steel, Electric

Applicator, MD2, 1:1, Hard, Carbon Steel, Lever

Applicator, MD2, 1:1, Hard, Carbon Steel, Pneumatic

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

Applicator, MD2, 1:1, Hard, Stainless Steel, Electric

313997ZAC

Product Configurator

24D526

24D530

24D531

24D532

24D533

24D534

24D535

24D536

24D537

LC0295

LC0296

LC0079

LC0080

LC0081

LC0086

LC0087

LC0088

24E505

257999

24C932

24C933

24C934

LC0058

LC0059

LC0060

24D515

24D516

24D521

24D522

24D523

24D524

24D525

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

Lever

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

Pneumatic

Applicator, MD2, 10:1, Soft, Carbon Steel

Applicator, MD2, 10:1, Soft, Carbon Steel, Electric

Applicator, MD2, 10:1, Soft, Carbon Steel, Lever

Applicator, MD2, 10:1, Soft, Stainless Steel

Applicator, MD2, 10:1, Soft, Stainless Steel, Electric

Applicator, MD2, 10:1, Soft, Stainless Steel,

Lever

Applicator, MD2, 10:1, Hard, Carbon Steel

Applicator, MD2, 10:1, Hard, Carbon Steel, Electric

Applicator, MD2, 10:1, Hard, Carbon Steel, Lever

Applicator, MD2, 10:1, Hard, Carbon Steel, Pneumatic

Applicator, MD2, 10:1, Hard, Stainless Steel

Applicator, MD2, 10:1, Hard, Stainless Steel,

Electric

Applicator, MD2, 10:1, Hard, Stainless Steel,

Lever

Applicator, MD2, 10:1, Hard, Stainless Steel,

Pneumatic

MD2 Orifice Adapter Kit

EP Pour Gun, Pistol Grip, 1/4 in. Purge Rod

EP Pour Gun, Machine mount, 1/4 in. Purge Rod

EP Pour Gun, Pistol Grip, 3/8 in. Purge Rod

EP Pour Gun, Machine Mount, 3/8 in. Purge Rod

Mixer Kit, (10) 3/8 in. x 24 Element with Shroud

Mixer Kit, (10) 3/8 in. x 36 Element with Shroud

Mixer Kit, (10) 3/8 in. Combo with Shroud

Mixer Kit, (10) 1/2 in. x 24 Element with Shroud

Mixer Kit, (10) 1/2 in. x 36 Element with Shroud

Mixer Pack, (50) 3/8 in. x 24 Element

Mixer Pack, (50) 3/8 in. x 24 Element

Mixer Pack, (50) 3/8 in. Combo Element

Mixer Pack, (250) 3/8 in. x 24 Element

Mixer Pack, (250) 3/8 in. x 36 Element

Mixer Pack, (250) 3/8 in. Combo Element

B (Blue) Applicator Orifice

S-Head and L-Head

1.2

1.25

1.3

1.4

1.5

1.6

1.65

1.7

0.25

0.45

0.5

0.75

0.8

0.85

1

1.1

1.75

1.8

1.9

4.20

4.50

5.00

5.50

6.00

6.50

7.00

Calibrate

1.70

1.80

1.90

2.00

2.50

3.00

3.50

4.00

Description Part

Calibrate 24A036

0.25

0.35

24A037

24A038

0.50

0.60

0.70

0.80

24A039

24A040

24A041

24A042

0.90

1.00

1.10

1.20

1.30

1.40

1.50

1.60

24A043

24A044

24A045

24A046

24A047

24A050

24A051

24A052

24A053

24A054

24A055

24A056

24A057

24A058

24A059

24A060

24A061

24A062

24A063

24A064

24A065

24A066

24A067

M0934A-4

247848

248858

247859

247860

247861

247862

247863

247864

247761

247762

247763

247764

247765

247766

247767

247811

247865

247866

247867

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

L-Head Only

For Use With Applicator:

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

S-Head Only

313997ZAC 11

Product Configurator

2

2.4

3.2

3.6

4.2

5

5.6

247868

247869

247870

247871

247872

247873

247874

GX-16

Description

257701

257702

257703

257704

257705

257706

257707

257708

257709

257710

257711

257712

257713

257714

257715

257716

257717

257718

257719

257720

257721

257722

257723

257724

24K682

Part

0.011 in. Orifice

0.013 in. Orifice

0.016 in. Orifice

0.018 in. Orifice

0.020 in. Orifice

0.022 in. Orifice

0.023 in. Orifice

0.024 in. Orifice

0.025 in. Orifice

0.026 in. Orifice

0.028 in. Orifice

0.029 in. Orifice

0.032 in. Orifice

0.035 in. Orifice

0.036 in. Orifice

0.038 in. Orifice

0.039 in. Orifice

0.040 in. Orifice

0.042 in. Orifice

0.043 in. Orifice

0.044 in. Orifice

0.049 in. Orifice

0.052 in. Orifice

0.061 in. Orifice

0.085 in. Orifice

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

L-Head Only

EP

Gun

Description

Orifice Kit

0.51 mm Poly

Orifice

0.79 mm Poly

Orifice

1.19 mm Poly

Orifice

1.52 mm Poly

Orifice

1.70mm Poly

Orifice

2.18 mm Poly

Orifice

0.41 mm Poly

Orifice

0.61 mm Poly

Orifice

Part

24E250

For Use With Applicator:

EP 250, 6 Blue, 6 Red

24C751 EP 250 Poly Side Orifice, Std

24C752 EP 250 Poly Side Orifice, Std

24C753 EP 250 Poly Side Orifice, Std

24C754 EP 250 Poly Side Orifice, Std

24C755 EP 250 Poly Side Orifice, Std

24C756 EP 250 Poly Side Orifice, Std

24C805 EP 250 Poly Side Orifice

24C806 EP 250 Poly Side Orifice

12

0.51 mm Poly

Orifice

0.79 mm Poly

Orifice

1.19 mm Poly

Orifice

1.52 mm Poly

Orifice

1.70 mm Poly

Orifice

2.18 mm Poly

Orifice

0.41 mm Poly

Orifice

0.61 mm Poly

Orifice

0.71 mm Poly

Orifice

0.89 mm Poly

Orifice

0.99 mm Poly

Orifice

1.07 mm Poly

Orifice

1.32 mm Poly

Orifice

1.40 mm Poly

Orifice

1.60 mm Poly

Orifice

1.85 mm Poly

Orifice

Orifice Kit

0.71 mm Poly

Orifice

0.89 mm Poly

Orifice

0.99 mm Poly

Orifice

1.07 mm Poly

Orifice

1.32 mm Poly

Orifice

1.40 mm Poly

Orifice

1.60 mm Poly

Orifice

1.85 mm Poly

Orifice

24C807 EP 250 Poly Side Orifice

24C808 EP 250 Poly Side Orifice

24C809 EP 250 Poly Side Orifice

24C810 EP 250 Poly Side Orifice

24C811 EP 250 Poly Side Orifice

24C812 EP 250 Poly Side Orifice

24C813 EP 250 Poly Side Orifice

24C815 EP 250 Poly Side Orifice

24E251

24C761

EP 375, 6 Blue, 6 Red

EP 375 Poly Side Orifice, Std

24C762 EP 375 Poly Side Orifice, Std

24C763 EP 375 Poly Side Orifice, Std

24C764 EP 375 Poly Side Orifice, Std

24C765 EP 375 Poly Side Orifice, Std

24C766 EP 375 Poly Side Orifice, Std

24C794 EP 375 Poly Side Orifice

24C795 EP 375 Poly Side Orifice

24C796 EP 375 Poly Side Orifice

24C797 EP 375 Poly Side Orifice

24C798 EP 375 Poly Side Orifice

24C799 EP 375 Poly Side Orifice

24C800 EP 375 Poly Side Orifice

24C801 EP 375 Poly Side Orifice

24C802 EP 375 Poly Side Orifice

24C804 EP 375 Poly Side Orifice

313997ZAC

Product Configurator

EP Gun

Description

0.51 mm Iso

Orifice

0.79 mm Iso

Orifice

1.19 mm Iso

Orifice

1.52 mm Iso

Orifice

1.70mm Iso

Orifice

2.18 mm Iso

Orifice

0.41 mm Iso

Orifice

0.61 mm Iso

Orifice

Iso A (Red) Applicator Orifice

S-Head and L-Head

The A (Red) applicator orifices for the S-Head and

L-Head are the same as the B (Blue) applicator orifices.

See page 11.

GX-16

Description

257701

257702

257703

257704

257705

257706

257707

257708

257709

257710

257711

257712

257713

257714

257715

257716

257717

257718

257719

257720

257721

257722

257723

257724

24K682

Part

0.011 in. Orifice

0.013 in. Orifice

0.016 in. Orifice

0.018 in. Orifice

0.020 in. Orifice

0.022 in. Orifice

0.023 in. Orifice

0.024 in. Orifice

0.025 in. Orifice

0.026 in. Orifice

0.028 in. Orifice

0.029 in. Orifice

0.032 in. Orifice

0.035 in. Orifice

0.036 in. Orifice

0.038 in. Orifice

0.039 in. Orifice

0.040 in. Orifice

0.042 in. Orifice

0.043 in. Orifice

0.044 in. Orifice

0.049 in. Orifice

0.052 in. Orifice

0.061 in. Orifice

0.085 in. Orifice

Part

24D223

For Use With Applicator:

EP 250 Iso Side Orifice, Std

24D224 EP 250 Iso Side Orifice, Std

24D225 EP 250 Iso Side Orifice, Std

24D226 EP 250 Iso Side Orifice, Std

24D227 EP 250 Iso Side Orifice, Std

24D228 EP 250 Iso Side Orifice, Std

24D229 EP 250 Iso Side Orifice

24D230 EP 250 Iso Side Orifice

0.51 mm Iso

Orifice

0.79 mm Iso

Orifice

1.19 mm Iso

Orifice

1.52 mm Iso

Orifice

1.70 mm Iso

Orifice

2.18 mm Iso

Orifice

0.41 mm Iso

Orifice

0.61 mm Iso

Orifice

0.71 mm Iso

Orifice

0.89 mm Iso

Orifice

0.99 mm Iso

Orifice

1.07 mm Iso

Orifice

1.32 mm Iso

Orifice

1.40 mm Iso

Orifice

1.60 mm Iso

Orifice

1.85 mm Iso

Orifice

0.71 mm Iso

Orifice

0.89 mm Iso

Orifice

0.99 mm Iso

Orifice

1.07 mm Iso

Orifice

1.32 mm Iso

Orifice

1.40 mm Iso

Orifice

1.60 mm Iso

Orifice

1.85 mm Iso

Orifice

24D231 EP 250 Iso Side Orifice

24D232 EP 250 Iso Side Orifice

24D233 EP 250 Iso Side Orifice

24D234 EP 250 Iso Side Orifice

24D235 EP 250 Iso Side Orifice

24D236 EP 250 Iso Side Orifice

24D237 EP 250 Iso Side Orifice

24D238 EP 250 Iso Side Orifice

24D239 EP 375 Iso Side Orifice, Std

24D240 EP 375 Iso Side Orifice, Std

24D241 EP 375 Iso Side Orifice, Std

24D242 EP 375 Iso Side Orifice, Std

24D243 EP 375 Iso Side Orifice, Std

24D244 EP 375 Iso Side Orifice, Std

24D245 EP 375 Iso Side Orifice

24D246 EP 375 Iso Side Orifice

24D247 EP 375 Iso Side Orifice

24D248 EP 375 Iso Side Orifice

24D249 EP 375 Iso Side Orifice

24D250 EP 375 Iso Side Orifice

24D251 EP 375 Iso Side Orifice

24D252 EP 375 Iso Side Orifice

24D253 EP 375 Iso Side Orifice

24D254 EP 375 Iso Side Orifice

313997ZAC 13

Product Configurator

AC Power Pack with

S-Head/L-Head Hoses, Optional

Boom

Part Description

24D829 230V, Boom, L-Head Hoses

24D830 230V, Boom, S-Head Hoses

24D834 400V, Boom, L-Head Hoses

24D835 400V, Boom, S-Head Hoses

24D831 230V, L-Head Hoses, No Boom

24D832 230V, S-Head Hoses, No Boom

24D836 400V, L-Head Hoses, No Boom

24D837 400V, S-Head Hoses, No Boom

24F297 230V, L-Head Application, No Boom, No Hoses

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

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

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

257798 Power Pack GX-16 Connection Kit

24E347 Hydraulic Power Pack Level Sensor Kit

24C872 Hydraulic Power Pack Pressure Gauge Kit

24E348 Hydraulic Power Pack Temperature Sensor

124217 Power Pack Accumulator Charging kit

Flow Meters

Flow Meter Electronics (Necessary)

Part Description

24J318 Flow Meter Electronics Kit

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

Part Description

24J319 S3000 Flow Meter Kit

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

(1 to 1000 cps)

24J320 G3000 Flow Meter Kit

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

(20 to 3000 cps)

24J321 G3000HR Flow Meter Kit

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

(20 to 3000 cps)

24J322 HG6000 Flow Meter Kit

(0.013 to 6.0 gpm, 50 to 22,700 cc per min)

(30 to 1,000,000 cps)

24J323 HG6000HR Flow Meter Kit

(0.007 to 2.0 gpm, 25 to 7571 cc per min)

(30 to 1,000,000,cps)

Dispense Valve Interface Kit

Part Description

24C757 MD2 Valve Solenoid, Machine Mount

24D160 MD2 Valve Solenoid, Remote Mount

24D161 Auto-Fusion Solenoid for Fusion Dispense Valve

24C067 Fusion Gun Pressure Adjust Kit

Flow Meter Calibration Kit (per applicator)

Part Description

24J324 L-Head Flow Meter Calibration Kit

24J325 S-Head Flow Meter Calibration Kit

24J326 P2 Flow Meter Calibration Kit

24J357 GX-16 Flow Meter Calibration Kit

24F227 EP/Fusion Flow Meter Calibration Kit

255247 MD2 1:1 Flow Meter Calibration Kit

255245 MD2 10:1 Flow Meter Calibration Kit

14 313997ZAC

Pump Feed Kits

Part Description

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

Pump Kit

246369 H515 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

246375 H716 (Air/Fluid) Carbon Steel Complete Supply

Pump Kit

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

Pump Kit

257769

High-Flo

®

(Air/Fluid) Carbon Steel Complete

Supply Pump Kit

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

Pump Kit

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

Pump Kit

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

Pump Kit

24D094 H1050 (Air/Fluid) Stainless Steel Complete Supply Pump Kit

24D095 5:1 Monarch 55G Stainless Steel Complete Supply Pump Kit

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

Pump Kit

257777 High-Flo Stainless Steel Complete Supply Pump

Kit

246366

Husky

515 Pump, Drum with Riser Tube

246367 Husky 716 Pump, Drum with Riser Tube

24D329 Husky 1050 Pump, Drum with Riser Tube

233052 Husky 515 Diaphragm Pump, Drum with Riser

Tube

233057 Husky 716 Diaphragm Pump, Drum with Riser

Tube

24D097 Husky 1050 SS Pump, Drum with Riser Tube

295616 2:1 (Air/Fluid) Stainless Steel Supply Pumps with

Riser Tubes

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

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

246481 Husky 515 Pump with Carbon Steel Fluid Plumbing

246482 Husky 716 Pump with Carbon Steel Fluid Plumbing

24D332 Husky 1050 Pump with Carbon Steel Fluid

Plumbing

246898 2:1 Supply Pump with Carbon Steel Fluid Plumbing

24D100 Husky 515 Pump with Stainless Steel Fluid

Plumbing

24D101 Husky 716 Pump with Stainless Steel Fluid

Plumbing

313997ZAC

Product Configurator

24D102 Husky 1050 Pump with Stainless Steel Fluid

Plumbing

24D103 2:1 Supply Pump with Stainless Steel Fluid

Plumbing

24D104 5:1 Monarch Pump with Stainless Steel Fluid

Plumbing

24D105 5:1 Monarch Pump with Stainless Steel Fluid

Plumbing

24E396 One 2:1 T-2 Pump, Carbon Steel

24E397 One 2:1 T-2 Pump, Stainless Steel

24E398 One Monarch 5:1 Pump, 5G

24E399 One Monarch 5:1 Pump, 55G

246419 Carbon Steel Riser Tube Assembly

246477 Carbon Steel Return Tube

246483 Air Supply for Feed Pump and Gun

247616 Desiccant Dryer

15C381 Desiccant Dryer Cartridge

233048 Drum Pump Accessory Kit

24D106 Stainless Steel Return Tube Accessory Kit

24D107 Stainless Steel Circulation Accessory

24E379 Carbon Steel Circulation Accessory Kit

244053 26 sq. in., 60 mesh, Stainless Steel Fluid Filter

116178 26 sq. in., 30 mesh, Stainless Steel Fluid Filter

Element

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

Element

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

Element

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

Element

213058 36 sq. in., 60 mesh, Carbon Steel Fluid Filter

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

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

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

Element

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

Element

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

Element

15

Product Configurator

B (Blue) and A (Red) Feed Tanks

Part Description

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

Level Sensors

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

Sensors

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

Level Sensors

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

Sensors

24D568 38L Tank, No Agitation, No Level Sensors

24D569 38L Tank, No Agitation, 2 Level Sensors

24D570 38L Tank, Agitation, 2 Level Sensors

24D571 38L Tank, Agitation, Slinger Plate, 2 Level Sensors

24D572 38L Tank, Agitation, Slinger Plate, Heat, Insulation, 2 Level Sensors

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

Sensors

24D574 75L Tank, No Agitation, No Level Sensors

24D575 75L Tank, No Agitation, 2 Level Sensors

24D576 75L Tank, Agitation, 2 Level Sensors

24D577 75L Tank, Agitation, Slinger Plate, 2 Level Sensors

24D578 75L Tank, Agitation, Slinger Plate, Heat, Insulation, 2 Level Sensors

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

Sensors

257757 Insulator Blanket for 38L Tank

257758 Insulator Blanket for 75L Tank

257770 Refill Kit For Customer Supplied Feed System

257778 Nitrogen Kit For 1 Tank

257779 Nitrogen Kit For 2 Tanks

257916 Vacuum Pump Kit, 6.9 cfm, 1st, 230V, 1 phase

24D271 3rd Level Sensor Prox Switch Option

LC0097 Desiccant Dryer, 3/8 in. Npt With Adapter And

Cartridge

LC0098 Desiccant Dryer Refill Cartridge

24G952 20gal (75L) Carbon Steel Tank, 2 Level Sensors

24G953 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Pneumatic Agitator

24G955 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Electric Agitator

24G956 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Chiller Control Valve, Heat Exchanger

24G957 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Pneumatic Agitator, Chiller Control Valve, Heat Exchanger

24G959 20gal (75L) Carbon Steel Tank, 2 Level Sensors,

Variable Speed Electric Agitator, Chiller Control

Valve, Heat Exchanger

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

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

Insulated

24J243 2gal (7.6L) Stainless Steel Tank

Manual and Semi-Automatic

Circulation Kits

Part Description

24D107 Manual Circulation Kit, Stainless Steel

24E379 Manual Circulation Kit, Carbon Steel

24N486 Semi-Automatic Circulation Kit, Component A

24N487 Semi-Automatic Circulation Kit, Component B

24N990 Solenoid Valve Kit, for Semi-Automatic Circulation.

16 313997ZAC

Product Configurator

Additional Accessories

Miscellaneous

Part Description

24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level

Sensor

24C873 Hydraulic Power Pack Manifold Oil Temperature

Sensor

24P090 Mobile Pallet Base with Casters

24F516 IsoGuard Select fluid, 6 quarts

121728 Extension Cable for Advanced Display Module,

4 meter,

255244 Foot Switch with Guard and 4 meter Cable

24F227 EP and Fusion Gun Ratio Check

24F235 25 ft hose extensions for L-Head applicator; material, hydraulic, and signal cables

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

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

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

24K206 Nip Sensor Kit

24H019 Air Inlet Filter for Hydraulic Power Pack

255468 Light Tower Kit

Communications Gateway Module (CGM)

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

Part Description

24J415 CGM Mounting KIt (Required)

CGMDN0 GCA Gateway Module, DeviceNet Fieldbus

CGMEP0 GCA Gateway Module, EtherNet/IP Fieldbus

CGMPB0 GCA Gateway Module, PROFIBUS Fieldbus

CGMPN0 GCA Gateway Module, PROFINET Fieldbus

Discrete Gateway Module (DGM)

The HFR Discrete Gateway Module allows the user to control an HFR through multiple external control devices such as contact blocks or relays. The DGM operates in conjunction with the existing Advanced Display Module

(ADM) such that both devices can be used to control the machine. See HFR Communication Gateway Module manual for more information

Part Description

24F843 Single DGM Cube with Board

24F844 Two DGM Cubes with Board

24G830 Single DGM Cube

313997ZAC 17

Warnings

+

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

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

• Tighten all fluid connections before operating the equipment.

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

18 313997ZAC

Warnings

313997ZAC

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

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

• Use only grounded hoses.

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

• If there is static sparking or you feel a shock, stop operation immediately.

Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

PRESSURIZED EQUIPMENT HAZARD

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

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

• Tighten all fluid connections before operating the equipment.

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

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

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

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

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving 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.

19

Important Two-Component Material Information

WARNING

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

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

BURN HAZARD

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

• Do not touch hot fluid or equipment.

Important Two-Component Material Information

Isocyanate Conditions Keep Components A (Red) and

B (Blue) Separate

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

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.

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

20 313997ZAC

A (Red) and B (Blue) Components

Moisture Sensitivity of

Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture

(such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE: The amount of film formation and rate of 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.

Changing Materials

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

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

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

A (Red) and B (Blue) Components

IMPORTANT!

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

Be aware that when standing in front of the manifold on proportioner:

• Component A (Red) is on the left side.

• Component B (Blue) is on the right side.

For all machines:

• The A (Red) side is intended for ISO, hardeners, and catalysts.

• If one of the materials being used is moisture-sensitive, that material should always be in the A (Red) side.

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

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

313997ZAC 21

A (Red) and B (Blue) Components

22 313997ZAC

Typical Installation

Typical Installation

K

B (Blue) Side Supply Detail

A (Red) Side Supply Detail

K M

G

G

K

L ti7821a3

P

A ti7821a2

J

K

F

D

J

N

H

H

B

F IG . 1

Key:

A

HFR Unit (see F IG . 2, page 25)

B Hose

C Fluid Temperature Sensor (FTS); 2x, 1 for each hose

D Whip Hose

E Dispense Gun

F Gun Air Supply Hose

G Feed Pump Air Supply Lines

H Waste Container

J Fluid Supply Lines

313997ZAC

K Feed Pumps

L Agitator

M Desiccant Dryer

N Bleed Lines

P Fluid Manifold

E

P

C*

* Shown exposed for clarity.

Wrap with tape during operation.

ti14720a

23

Component Identification

Component Identification

Key for F IG . 2.

AA Advanced Display Module (see page 30)

BA Component A (Red) Pressure Relief Outlet

BB Component B (Blue) Pressure Relief Outlet

CO Base and Casters (Optional)

FA Component A (Red) Fluid Manifold Inlet (on left side of manifold block)

FB Component B (Blue) Fluid Manifold Inlet

FM HFR Fluid Manifold

FP Feed Inlet Pressure Gauge

FS Feed Inlet Strainer (standard filter size is 20 mesh)

FT Feed Inlet Temperature Gauge (heated models only)

FV Feed Inlet Valve (A (Red) side shown)

GA Component A (Red) Outlet Pressure Gauge

GB Component B (Blue) Outlet Pressure Gauge

HA Component A (Red) Hose Connection (from feed to gun or mix head)

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

HP Hydraulic Power Pack Assembly

HT Hydraulic Tank

LR IsoGuard Select Fluid Reservoir

LS Pumpline Linear Sensor

MA Motor Control Module, see page 28

MP Main Power Switch

PA Component A (Red) Pump

PB Component B (Blue) Pump

PD Power Distribution Box

PH Primary Heater

PI Primary Heater Fluid Inlet

PO Primary Heater Fluid Outlet

PR Primary Heater RTD

PS Primary Heater Overtemperature Switch

SA Component A (Red) PRESSURE RELIEF/DISPENSE

Valve

SB Component B (Blue) PRESSURE RELIEF/DISPENSE

Valve

TA Component A (Red) Pressure Transducer

TB Component B (Blue) Pressure Transducer

TC High Power Temperature Control Module (not shown, see

page 34)

24 313997ZAC

Component Identification

MP MA

HP

FM

LR

FS

FP

CO

FV

FT

PH

PD

AA

HT

PA

24C352_313998_3g

FS

PB

FT

FP

FA

SA

Fluid Manifold (FM) Detail

GA

GB

SB

FB

Primary Heater (PH) Detail,

B (Blue) side shown

PO

PI

LS

Rear View

TA

TB

PR

BA

PS

HA

HB

BB ti9880a1

24C327_313998_1e

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

24C352_313998_4e

313997ZAC 25

Component Identification

Main Power Switch

Located on top of the power distribution box, see page

25

. The main power switch turns power

ON and OFF . The main power switch does not turn pumps or heat zones on.

Circuit Breakers

Additional circuit breakers for protection of the secondary side of the heated hose transformer are located inside the frame. See the parts list for the installed primary/hose heat option. See Ref. 5 of the product configurator code for your machine to determine which primary/hose heat option is installed. See

Product Configurator on page 5.

B (Blue)

Left Side from Rear View

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 for more information.

CB1 CB3

CB5 CB4

CB2

CB9

CB7 CB6

CB8

CB579

24C332_313998_3f

A (Red)

Right Side from Rear View

24C681_313998_1e

Ref.

CB1

CB2

CB3

CB4

CB5

CB6

CB7

CB8

CB9

Size

230V/

1 phase,

400V/

3 phase

63A

40A

15A

40A

5A

5A

40A

15A

40A

230V/

3 phase

30A

40A

15A

40A

5A

5A

40A

15A

40A

Component

Motor Control Module

Primary Heater A

Tank Heat A

Hose Heat A

Miscellaneous

Miscellaneous

Hose Heat B

Tank Heat B

Primary Heater B

24C332_313998_6f

26

CB718

313997ZAC

Component Identification

Hydraulic Power Pack

DK

DB

DE

DG

DF

DH

DA

DD

24C352_313998_2g

F IG . 3

Key:

DA 8 Gallon Hydraulic Oil Reservoir (see Technical Data

on

page 117 for specifications)

DB Electric Motor

DC Dipstick (not shown, located at rear left of hydraulic tank)

DD Hydraulic Housing

DE Directional Valve

DF Motor Control Module (see page 28)

DG Fan

DH Oil Filter

DJ Shroud (not shown, removed for clarity)

DK Air Inlet Filter

313997ZAC 27

Component Identification

Motor Control Module (MCM)

NOTICE

If the Motor Control Module is replaced, the selector switch must be set prior to initial startup of the

Motor Control Module or damage may occur. See

HFR Repair manual for details, see

Related Manuals on page 3.

B

A

For MCM location, see reference MA in F IG . 2 on page 25. When installed, the end of the MCM with the

power input connection (12) faces down and the end with the access cover (A) faces up.

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

C

12

F IG . 4: MCM Component Identification

28

1A

10

1B

2

3 r_257396_3b9905_01b

6

8

9

11

5 r_257396_3b9905_03b

13

7

313997ZAC

8

9

10

11

12

13

Ref

A

B

C

1A, 1B

2

3

5

6

7

Description

Access Cover

LEDs

Warning Label

CAN Connections

Three-way Splitter to: Oil Low Level

Sensor, Dispense Valve Solenoid, and

Footswitch

Oil Temperature Sensor

Electric Motor Temperature Sensor

LVDT

Three-way Splitter to:

Hydraulic Directional Valve,

Oil Overtemperature Switch

Pressure Transducer B (Blue) side

Pressure Transducer A (Red) side

Not used

Motor Position Sensor

MCM Power Input Connection

Motor Power Connection

Component Identification

313997ZAC 29

Component Identification

Advanced Display Module (ADM)

User Interface

CB

CA

CC

CD

CE

CF

CH

CG

TI12362a1

F IG . 5: ADM Component Identification - Front

Buttons

Ref.

Button Function

CA System enable/ disable

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

CB System

Status

Indicator

Light

Displays system status. See System

Status Indicator (CB) Conditions on page 31 for details.

CC Stop Stops all system processes.

Ref.

Button Function

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

CG Lock/Set up

Acknowledge changing a value or making a selection.

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

CH Navigation

Navigate within a screen or to a new screen.

30 313997ZAC

CS

Component Identification

CJ

CK

CR

F IG . 6: ADM Component Identification - Rear

Key:

CJ Flat Panel Mount

CK Model Number

CL USB Module Interface

CM CAN Cable Connections

System Status Indicator (CB) Conditions

Green Solid - Run Mode, System On

Green Flashing - Setup Mode, System On

Yellow Solid - Run Mode, System Off

Yellow Flashing - Setup Mode, System Off

CP

CN

CL

CM r_24E451_3B9900_1a

CN Module Status LEDs

CP Accessory Cable Connections

CR Token Access Cover

CS Battery Access Cover

313997ZAC 31

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 Advanced Display Module (ADM) Operation , page 46.

Current date and time Previous screen Current screen Next screen

Mode

Faults, Status

Enter/Exit screen

Previous screen no.

Current screen no.

Next screen no.

Function display

F IG . 7: Main Display Components

32 313997ZAC

Fluid Control Module (FCM)

A

C

E

B

F

IG

. 8:

Key:

A Fluid Control Module

B Base

C Module Connection Screws

D Access Cover

E Module Status LEDs

F CAN Connectors

F ti12337a1

D

Component Identification ti12336a1

313997ZAC 33

Component Identification

Temperature Control Module (Heated HFR Only)

2

LED

Signals

5

1

7

3 ti12352a1

6

F

IG

. 9: High Power Temperature Control Module Sensor Connections

Key:

1 Overtemperature Switch Connection (primary heaters only)

2 RTD Temperature Sensor Connection

3 Output Power Connection

4

4 DC Output Connection

5 Input Power Connection

6 CAN Connections

7 Rotary Selector Switch, Token Access ti12353a1

1

2

5

6

3 ti12356a1

F IG . 10: Low Power Module Cable Connections

1 Overtemperature Switch Connection

2 RTD Temperature Sensor Connection

3 Output Power Connection

4

7

4 DC Output Connection

5 Input Power Connection

6 CAN Connections

7 Base ti12357a1

34 313997ZAC

Heat Control Zone Selection

(Heated models only)

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

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

Left Side from

Rear View

24C332_313998_3f

Primary Heater A (Red) Hose Heater A (Red)

Right Side from

Rear View

24C332_313998_6f

313997ZAC

Component Identification

35

Component Identification

Adjust Rotary Switch

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

The low power module uses a16-position rotary switch.

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

High Power Module Rotary Switch Location

S ti12360a

Low Power Module Rotary Switch Location

High Power Module Rotary Switch Settings

Setting

0

1

2

5

6

3

4

7

Zone

Not Used

B (Blue) Primary Heat

B (Blue) Hose Heat

A (Red) Primary Heat

A (Red) Hose Heat

Not Used

Not Used

Not Used

Low Power Module Rotary Switch Settings

B

C

D

E

F

9

A

7

8

Setting

0

1

2

5

6

3

4

Zone

Not Used

Not Used

Not Used

Not Used

Not Used

B (Blue) Tank Heater

A (Red) Tank Heater

B (Blue) Chiller

A (Red) Chiller

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

S ti12361a

F IG . 11

36 313997ZAC

Dispense Valves Overview

Three types of dispense valves can be used with the

HFR system:

• Stall-at-pressure

• Solenoid controlled

• Hydraulically actuated and recirculating

The P2 Gun and Fusion Gun are examples of stall-at-pressure dispense valves. When not dispensing, the fluid in the chemical lines are fully pressurized.

When using a stall-to-pressure dispense valve, a footswitch cannot be used. Any signals sent from a footswitch will be ignored.

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

The L-Head, S-Head, and GX-16 are examples of hydraulically actuated, recirculating dispense valves.

When not dispensing, material is recirculated to maintain temperature and pressure. Opening and closing the valve is controlled hydraulically which leads to faster actuation and more accurate dispenses.

Dispense Valves Overview

313997ZAC 37

Setup

Setup

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

1.

Locate HFR.

a.

Locate HFR on a level surface. See

Dimensions on page 119 for space requirements.

b.

Anchor the HFR to the floor (suggested anchors: McMaster Carr anchor, 92403A400).

See

Dimensions , page 119, for bolt locations.

If machine mobility is required, purchase Mobile

Pallet Base with Casters Kit, 24P090.

NOTICE

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

c.

Do not expose HFR to rain.

NOTICE

Bolt HFR to original shipping pallet before lifting.

2.

Electrical requirements. See Models on page 4

for detailed electrical requirements information.

Installing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power

switch terminals, see step 3 in this setup procedure.

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

NOTICE

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

3.

Connect electrical cord.

NOTE:

See Power Line Voltage Surges information on page 39.

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

Table 1: Power Cord Requirements

Model

Non-Heated HFR,

230V, 1 phase

Non-Heated HFR,

230V, 3 phase

Non-Heated HFR,

400V, 3 phase

Heated HFR,

230V, 1 phase

Heated HFR,

230V, 3 phase

Heated HFR,

400V, 3 phase

Cord Requirements

AWG (mm

2

)

6 (13.3), 2 wire + ground

8 (8.4), 3 wire + ground

6 (13.3), 4 wire + ground †

1 (42.4), 2 wire + ground

4 (21.2), 3 wire + ground

4 (21.2), 4 wire + ground †

† Residual Current Device (RCD) must be rated at

300 mA if installed.

Electrical Cord Wires by Model

230V, 1 phase: L1, L2, GND

230V, 3 phase: L1, L2, L3, GND

400V, 3 phase: L1, L2, L3, N, GND

Typical Voltage Readings

230V, 1 phase:

L1-L2: 230V

L1 or L2-G: 115V

230V, 3 phase (delta high leg):

L1-L2, L2-L3, L3-L1: 230V

L1-G, L3-G: 115V

L2-G: 208V

400V, 3 phase (Y / wye):

L1-L2, L2-L3, L3-L1: 400V

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

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

38 313997ZAC

Setup

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

Connect green to ground (GND).

F IG

N L3 L2 L1

. 12: 400V, 3 phase shown

GND r_24C686_313998_1a

Power Line Voltage Surges

Power conversion equipment can be sensitive to voltage fluctuations on incoming power. The Motor Control Module falls under the category of power conversion equipment because energy is stored on a capacitive bus and then modulated to control a brushless motor. Engineered design takes this into account and withstands a wide range of conditions, but it is possible for supplied power to occasionally fall outside the tolerable range in industrial plants with high-amperage reactive pulsed loads such as welding equipment. If the tolerable range is exceeded, an overvoltage condition is flagged and the system will shut down in an alarm state to protect itself and alert the user of unstable power. Excessive or repeated overvoltage may permanently damage hardware.

The MAX-HOLD feature on a multimeter can be used to determine peak DC voltage on the line. DC is the proper setting, as opposed to AC, because peak voltage is the critical parameter that affects the DC voltage level stored on the capacitive bus in power conversion equipment. Reading should not regularly exceed approximately 400VDC to avoid tripping the 420VDC alarm level in the Motor Control Module. If power quality is suspect, power conditioning or isolation of the device(s) causing poor power quality is recommended. Consult a qualified electrician if there are any concerns about the available power supply.

Power Line Test Steps with Multimeter a.

Set multimeter to “DC voltage”.

b.

Connect multimeter probes to supplied power line.

c.

Press “Min Max” successively to show the peak positive and negative DC voltages.

d.

Confirm readings do not exceed 400VDC

(Motor Control Module alarm issued at

420VDC).

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

Maximum Permissible Transient Voltage Surges

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

1400

1200

1000

800

1200Vac, 1697Vdc

<--1 MW Max Surge Power

600

400

200

480Vac, 679Vdc

<--150 KW Max Surge Power

336Vac, 475Vdc

<--50 KW Max Surge Power

288Vac, 407Vdc

0

0.000001 0.00001 0.0001 0.001 0.01

Time (seconds)

0.1

<--No Power Limit

264Vac, 373Vdc

1 10

313997ZAC 39

Setup

4.

Connect feed lines a.

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

and B (Blue) supply drums. See F IG

. 1 and F IG .

2, pages 23 and 25.

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

3.5 bar) is required at both feed inlet pressure gauges

(FP). Maximum feed pressure is 250 psi (1.75 MPa,

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

FP

5.

Connect pressure relief lines

Do not install shutoffs downstream of the PRESSURE

RELIEF/DISPENSE valve outlets (BA, BB). The valves function as overpressure relief valves when set to DISPENSE . Lines must be open so valves can automatically relieve pressure when machine is operating.

If circulating fluid back to the supply drums, use high pressure hose rated to withstand the maximum working pressure of this equipment.

ti10006a1 a.

Recommended : Connect high pressure hose

(R) to relief fittings (BA, BB) of both PRES-

SURE RELIEF/DISPENSE valves. Route hose back to component A (Red) and B (Blue) drums.

See F IG . 1, page 23.

b.

Seal component A (Red) drum and use desiccant dryer (M) in vent.

c.

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

d.

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

SA

SB

BA

R ti9880a1

R

BB

FV ti9883a1

NOTE:

Supply hoses from feed pumps should be 3/4 in.

(19 mm) ID minimum.

e.

Connect and tighten component B (Blue) supply hose to the 3/4 npt(f) swivel on the component

B (Blue) inlet valve.

f.

Connect and tighten component A (Red) supply hose to the 1/2 npt(f) swivel on the component

A (Red) inlet valve.

b.

Alternately: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See

F

IG

. 1, page 23.

6.

For Heated HFR models only, install Fluid Temperature Sensor (FTS) a.

Install FTS between main hose and whip hose.

See Heated Hose manual for instructions.

40 313997ZAC

Setup

7.

Connect heated hose monitor zones

NOTE: For Heated HFR models only, see Heated Hose manual for detailed instructions on connecting heated hoses.

NOTICE

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

d.

For Heated HFR Models only, connect cables (Y). Connect electrical connectors (V).

Be sure cables have slack when hose bends.

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

Y a.

Turn main power OFF .

V b.

For Heated HFR Models only, assemble heated hose sections, FTS, and whip hose. See

Heated Hose manual 3A0237 for heated hose connection details and illustrations for the various types of heated hoses.

For Non-Heated HFR Models only, assemble fluid supply hose sections and whip hose. c.

Connect A (Red) and B (Blue) hoses to A (Red) and B (Blue) outlets on HFR fluid manifold (FM).

Hoses are color coded: red for component A, blue for component B. Fittings are sized to prevent connection errors.

NOTE: Gun fluid manifold hose adapters allow use of

1/4 in. and 3/8 in. ID fluid hoses. To use 1/2 in. (13 mm)

ID fluid hoses, remove adapters from gun fluid manifold and install as needed to connect hose.

ti2411a1 ti9881a1

8.

For systems with a gun fluid manifold, close gun fluid manifold valves A (Red) and B (blue).

313997ZAC 41

Setup

9.

For models with an MD2 valve, connect whip hose to MD2 valve component A (Red) and component B (Blue) fluid inlets.

For models with a dispense gun, connect whip hose to gun fluid manifold. Do not connect man-

ifold to gun. See F IG . 13.

F IG . 13 ti2417a1 pense gun firmly to the side of a grounded metal pail, then trigger gun.

12.

Check hydraulic fluid level

Hydraulic reservoir is filled at the factory. Check fluid level before operating the first time, and weekly thereafter. See

Technical Data on page 117 for specifications.

13.

IsoGuard Select Fluid system setup

Component A (Red) Pump: Fill IsoGuard Select reservoir (LR) with IsoGuard Select fluid (24F516).

a.

Lift the reservoir (LR) out of the bracket (RB) and remove the container from the cap.

10.

Pressure check hose

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

11.

Ground system

LR

RB

This equipment must be grounded.

a.

HFR:

grounded through power cord. See step 3 on page 38.

b.

EP Gun or Dispense Valve : If supplied, connect whip hose ground wire to FTS, see step 6 on page 40. Do not disconnect wire or dispense without whip hose. c.

Fluid supply containers : follow your local code.

d.

Object being dispensed : follow your local code.

e.

Solvent pails used when flushing : follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

f.

To maintain grounding continuity when flushing or relieving pressure, hold a metal part of dis-

24C352_312998_8g b.

Fill with fresh fluid. Thread the reservoir onto the cap assembly and place it in the bracket (RB).

c.

Push the supply tube approximately 1/3 of the way into the reservoir. The supply tube is the tube with the check valve with an arrow pointing in the direction of flow towards the IsoGuard

Select fluid cylinder.

d.

Push the return tube into the reservoir until it reaches the bottom. The return tube is the tube with the check valve with an arrow pointing in the direction of flow away from the IsoGuard

Select fluid cylinder.

NOTE: The return tube must reach the bottom of the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube and returned to the pump.

42 313997ZAC

14. Prime IsoGuard Select fluid cylinder

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

IsoGuard Select

®

System on page 57 for instructions.

15. Install dispense valve a.

Navigate to System Screen 2 and select the appropriate dispense valve from the “Dispense

Valve” dropdown menu. See System Screen 2 on page 73.

b.

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

c.

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

LOCKED ti10442a1 d.

Connect gun to machine. Verify gun is ready for operation. See appropriate gun manual listed in

Related Manuals on page 3 for detailed

instructions. e.

If gun has pneumatics, verify air line is connected then open bleed-type master air line valve.

f.

Set PRESSURE RELIEF/DISPENSE valves

(SA, SB) to DISPENSE .

SA

SB

Setup g.

Press to enable system. LED should be solid green.

h.

Check that heat zones are on and temperatures are on target, see Status Screen on page 86.

i.

Check fluid pressure display and adjust as necessary.

j.

For MD2 and Auto-Fusion dispense valves, perform Connect Solenoid Kit procedure. See

Heated Hoses and Applicator Kits manual for procedure.

k.

Check fluid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning PRESSURE RELIEF/DIS-

PENSE valve for that component toward PRES-

SURE RELIEF/CIRCULATION gauges show balanced pressures.

, until

GA

GB

In this example, B (Blue) side pressure is higher, so use the B (Blue) side valve to balance pressures.

ti9877a1 l.

For MD2 and Auto-Fusion dispense valves, perform Connect Solenoid Kit procedure. See

Heated Hoses and Applicator Kits manual for procedure.

m.

If dispense valve has a trigger safety lock, disengage the trigger safety lock. ti9877a1 UNLOCKED ti10441a1

313997ZAC 43

Setup n.

For EP Gun and GX-16, perform a test pour into a waste container. Adjust pressure and temperature to get desired results. Equipment is ready to dispense.

o.

For all dispense valves other than the EP Gun, perform mix ratio test using two tared cups.

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

p.

For Fusion dispense valves, perform DC Power

Pack Hydraulic Pressure Setup. See HFR

Repair manual for procedure.

q.

Equipment is ready to dispense.

Vacuum De-gas

NOTE: This procedure is for assemblies with vacuum tree manifold and no agitator or auto-refill.

1.

Disable machine movement by pressing the

Machine Disable Mode key ( ).

2.

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

3.

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

4.

Close the fill port ball valve.

5.

If the tank lid requires a desiccant dryer or nitrogen pump installed, install one into the top ball valve of the vacuum tree manifold.

6.

Close the top ball valve of the vacuum tree manifold.

7.

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

8.

Turn on the vacuum pump.

9.

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

10. Close bottom ball valve of the vacuum tree manifold.

11. Turn off the vacuum pump.

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

NOTICE

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

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

44 313997ZAC

Setup

Vacuum De-gas and Vacuum

Manual Refill

NOTE: This procedure is for assemblies with a vacuum tree manifold, agitator, and auto-refill.

12. Close bottom ball valve of the vacuum tree manifold).

13. Turn off the vacuum pump.

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

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

NOTICE

1.

Press the Select Operating Mode button ( ) repeatedly to select Shot, Sequence, or Operator

(Manual) mode.

2.

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

3.

If the tank lid requires a desiccant dryer or nitrogen pump installed, install one into the top ball valve of the vacuum tree manifold).

4.

Close the top ball valve of the vacuum tree manifold.

5.

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

6.

Turn on the vacuum pump.

7.

Turn on agitator.

8.

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

9.

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

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

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

)

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

NOTICE

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

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

313997ZAC 45

Advanced Display Module (ADM) Operation

Advanced Display Module (ADM) Operation

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

To begin using the ADM, the machine must be on and enabled. To verify the machine is enabled, verify the

System Status Indicator Light (CB) is illuminated green,

see F IG . 5 on page 30. 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.

7.

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

8.

Define level sensors and refill settings. See Supply

Screen , page 76.

9.

Enable/disable temperature conditioning components. See Conditioning Screen 1 , page 77.

10. Define temperature conditioning setpoints. See

Conditioning Screen 2 , page 78.

11.

If Night mode will be used, define Night mode set-

tings. See Conditioning Screen 3 , page 79.

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

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

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

15. If desired, view/reset counters. See Maintenance

Screen , page 76.

If the machine is in the Disabled mode screen press

repeatedly to select a different operating mode.

Perform the following tasks to fully setup your system.

1.

Set general system settings. See Advanced

Screen 1 , page 80.

2.

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

3.

Enable/disable system features. See

Advanced

Screen 3 , page 81.

4.

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

5.

Define dispense valve and other system settings.

See System Screen 2 , page 73.

6.

Define labels and other system settings. See System Screen 3 , page 75.

46 313997ZAC

Startup

Startup

g.

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

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

FV

1.

Use feed pumps to load fluid

NOTE:

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

Flushing on page 52.

a.

Check that all machine connections are setup.

See Setup procedure, page 38.

b.

Check that inlet screens are clean before daily

startup, see page 56.

c.

Check level and condition of ISO lube daily, see

IsoGuard Select

®

System on page 57.

d.

Turn on component B (Blue) and component A

(Red) agitators, if used.

SA e.

Turn both PRESSURE RELIEF/DISPENSE valves (SA, SB) to DISPENSE .

SB ti10002a1

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. h.

Use feed pumps to load system. i.

For models with an EP, Fusion, or P2 gun only, hold gun fluid manifold over two grounded waste containers. Open gun fluid valves A

(Red) and B (Blue) until clean, air-free fluid comes from valves. Close valves.

f.

Start feed pumps.

313997ZAC ti9877a1 ti2484a1 j.

For models with an MD2 Valve only, hold

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

k.

To prime the pump, cycle the pump a few times or until air-free fluid dispenses.

47

Startup

2.

Calibrate HFR

The HFR calibration procedure is a two step process.

The first step, Learn Mode, must be performed whenever the pump line is rebuilt, if any other maintenance is performed that may affect the mechanical tolerances in the pump line, or the MCM module is replaced. If the machine does not appear to be utilizing the full extent of the pump stroke, or if the machine appears to be contacting the end of the hydraulic cylinder, follow the Learn

Mode procedure. The Learn Mode procedure will teach the system the mechanical limits of travel.

Learn Mode Procedure: a.

Navigate to the Calibration screen.

b.

Press the Learn Mode Calibration button and set the mode to run as the dispense applicator that is installed on the system.

c.

If not a full circulation system, place a waste container below the dispense valve. The next steps will cause the machine to dispense material for all other settings.

3.

Set temperatures (Heated models only)

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

• Do not touch hot fluid or equipment.

• Allow equipment to cool completely before 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 78 for details. For minor adjustments to the temperature setpoint once the machine has been initially configured, see the Status

Screen on page 86.

4.

Set system control and dispense modes: See

System Screen 1 on page 73.

5.

Set pump sizes: See System Screen 1 on page 73.

6.

Define Shot Recipes a.

Navigate to the Shots screen.

d.

Press the go right button and then the dispense button . The pump will travel to the right most extreme position.

e.

After the pump stops moving, press the go left button and then press the dispense button . The pump will travel to the left most extreme position.

f.

After the pump stops moving, press the continue button to go on to the next step in the calibration process or the page back button to return to the main Calibration screen.

NOTE: During this process, the system learned the mechanical limits of travel. If the pump did not reach both the left and right extreme limits for any reason, repeat the procedure.

b.

Press to enter the screen.

c.

Use the directional keypad to navigate to the shot detail column for the desired shot number.

d.

Type the desired setting for that item then press . e.

Repeat the previous two steps for all desired shot numbers.

48 313997ZAC

7.

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.

a.

Navigate to System Screen 3.

b.

Press to enter the screen.

c.

Navigate to the pressure imbalance field. d.

Type the desired pressure imbalance setting then press Enter .

Startup

313997ZAC 49

Shutdown

Shutdown

1.

Park pumps.

a.

From the Home screen, press

Standby mode.

and select b.

Press . Material will dispense for non circulation systems. Pump will park automatically.

Once pump is parked, pump will stop moving.

If a dispense gun with a trigger is installed, pulling the trigger will begin a park operation.

Material will dispense for non circulation systems. c.

For models with an EP, Fusion, or P2 gun only, turn diversion valves to tank then press

Park . Pressure must be below 400 psi

(2.8 MPa, 28 bar).

2.

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

to

3.

Turn main power switch (MP) to OFF position.

4.

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

FV ti9883a1

5.

Perform

Pressure Relief Procedure on page 51.

6.

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

50 313997ZAC

Pressure Relief Procedure

1.

Shut off feed pumps and agitator, if used.

2.

Turn PRESSURE RELIEF/DISPENSE valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

Route fluid to waste containers or supply tanks.

Ensure gauges drop to 0.

.

SA

SB ti9879a1

3.

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

4.

Relieve pressure in dispense valve. See dispense valve manual.

Pressure Relief Procedure

313997ZAC 51

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.

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

• Use the lowest possible pressure when flushing.

• All fluid components are compatible with common solvents. Use only moisture-free solvents. See

Technical Data on page 117 for list of wetted com-

ponents 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/DIS-

PENSE valves (SA, SB) to PRESSURE

• To maintain grounding continuity when flushing or relieving pressure, hold a metal part of dispense gun firmly to the side of a grounded metal pail, then trigger gun.

RELIEF/CIRCULATION lines (N).

SA

. Flush through bleed

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 20.

• Solvent pails used when flushing : follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

52 313997ZAC

Maintenance

Maintenance

Task

Change break-in oil in a new unit

Inspect hydraulic and fluid lines for leaks

Inspect fluid inlet strainer

screens, page 56

Inspect IsoGuard Select fluid level and condition, refill or

replace as needed, page 57

Check hydraulic fluid level

Grease circulation valves with

Fusion grease (117773)

Verify operation of air drying system to prevent isocyanate crystallization

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

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

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

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

Clean dispense valve mix chamber ports regularly, see dispense valve manual

Clean dispense valve check valve screens, see dispense valve manual

Schedule

After first 250 hours of operation or within 3 months, whichever comes first

Daily

Daily

Daily

Weekly

Weekly

Weekly

Weekly

Daily

Monthly

As needed

See dispense valve manual

See dispense valve manual

Change Break-in Oil

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

Table 2: Frequency of Oil Changes

Ambient

Temperature

Recommended

Frequency

0 to 90°F

(-17 to 32°C)

1000 hours or 12 months, whichever comes first

90°F and above

(32°C and above)

500 hours or 6 months, whichever comes first

Grease Circulation Valves With Fusion

Grease (117773)

ti9879a1

Check Hydraulic Fluid Level

Check hydraulic fluid level on dipstick (DS). Fluid level must be between indent marks (IM) on dipstick. Refill as required with approved hydraulic fluid; see

Technical

Data on page 117. If fluid is dark in color, change fluid

and filter.

DS

24C352_313998_1

S

IM ti7861a1

313997ZAC 53

Maintenance

ADM - Battery Replacement and

Screen Cleaning

MCM and TCM - Clean Heat Sink

Fins

Battery Replacement

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

To replace the battery:

1.

Disconnect power to the ADM.

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

2.

Remove rear access panel.

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

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

Heat

Sink Fins r_257396_3b9905_02b ti12364a1

3.

Remove the old battery and replace with a new

CR2032 battery.

4.

Properly dispose the old lithium battery according to local codes.

5.

Replace rear access panel.

6.

Connect the power to the ADM and reset the clock through Advanced Screen 1

. Refer to Appendix B

- ADM Setup Screens Overview

for more detail.

Cleaning

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

Heat Sink Fins ti12357a1

F IG . 14: Clean Heat Sink Fins ti12353a1

54 313997ZAC

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.

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.

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

r_257396_3b9905_04b ti12358a1 ti12334a1

F

IG

. 15: Remove Access Cover

Token Application

16H821 HFR :

- Advanced Display Module

- Motor Control Module

- High Power Temperature Control Module

- Fluid Control Module (AC Power Pack)

- Discrete Gateway Module

- Communication Gateway Module

16G584 Tank Stand:

- Fluid Control Module

- Low Power Temperature Control Module

16G407 Ratio Monitoring (Flow Meters) :

- Fluid Control Module ti12354a1

313997ZAC 55

Maintenance

Fluid Inlet Strainer Screen

6.

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

59d

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

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

NOTE:

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

1.

Perform

Pressure Relief Procedure on page 51.

2.

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

3.

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

4.

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

5.

Ensure the pipe plug (59k) is screwed into the strainer plug (59j). Install the strainer plug with the screen (59g) and gasket (59h) in place and tighten.

Do not overtighten. Let the gasket make the seal.

F IG . 16. Fluid Inlet Strainer

59g*

59h

59j

59k ti9886a1

56 313997ZAC

Maintenance

IsoGuard Select

®

System

Check the condition of the A (Red) pump IsoGuard

Select fluid daily. Change the fluid if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by the pump

IsoGuard Select fluid (24F516). The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible.

Fluid discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly,

IsoGuard Select fluid (24F516) replacement due to discoloration should not be necessary more often than every 3 or 4 weeks.

To change pump IsoGuard Select fluid (24F516):

1.

Perform

Pressure Relief Procedure on page 51.

2.

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

3.

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

4.

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

Select fluid to drain. Reattach the check valve to the

inlet hose. See F IG . 17.

5.

Drain the reservoir and flush it with clean IsoGuard

Select fluid (24F516).

6.

When the reservoir is flushed clean, fill with fresh

IsoGuard Select fluid (24F516).

7.

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

8.

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

9.

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

NOTE:

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

24C352_313998_8e

F IG . 17: IsoGuard Select Fluid System

Prime IsoGuard Select Fluid Cylinder

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

1.

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

Select fluid cylinder.

2.

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

IsoGuard Select fluid cylinder.

3.

Remove check valve from end of outlet tube.

4.

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

5.

With check valve arrow pointing away from the

IsoGuard Select fluid cylinder, install check valve in end of outlet tube.

6.

Install tubes into reservoir and install reservoir into holder.

313997ZAC 57

Troubleshooting

Troubleshooting

Before performing any troubleshooting procedure:

1.

Perform

Pressure Relief Procedure on page 51.

2.

Turn main power OFF.

3.

Allow equipment to cool.

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.

Light Tower (Optional)

Signal Description

Green on only System is powered up and there are no error conditions present

Yellow on

Red flashing

Red on

An advisory exists

A deviation exists

The system is shut down due to an alarm occurring.

Errors include advisories, deviations, or alarms, so green will only be on when none of these occur. A yellow light can be on at the same time as red (flashing or solid on) when an advisory exists at the same time as a deviation or alarm.

Common Problems

Problem

General

Display Module completely dark

No or incorrect amount of material dispensed from either side

Significant material leaking from pump seal

Material dispensed not correct weight

Cause

No Power

Thrown Breaker

Loose Connection

Bad Display Module

Ball Valve closed (if Installed)

Tank Empty

Tank Clogged

Air In Material

Pump shaft worn and/or shaft seal worn

Specific gravity of one or more of the two materials has changed since calibration

Check valve malfunction

Piston worn or broken

A (Red) and B (Blue) Primary Heaters

Control of primary heat is abnormal; high temperature overshoots

Dirty RTD connection

RTD not contacting heater element

Failed heater element

Signal failure from RTD

RTD wired incorrectly

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.

58 313997ZAC

Troubleshooting

Problem

Hose Heat System

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

Hose does not maintain temperature while spraying

Hose temperature exceeds setpoint

Erratic hose temperature

Hose does not heat

Hoses near system are warm, but hoses downstream are cold

Cause

Ambient temperature is too cold

FTS failed or not installed correctly

Low supply voltage

A and B setpoints too low

Ambient temperature is too cold

Flow too high

Hose was not fully preheated

Low supply voltage

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

Faulty RTD connections

Faulty RTD connection

FTS not installed correctly

FTS failed or is not contacting correctly

FTS not installed correctly

Temperature control alarm

Shorted connection or failed hose heating element

Solution

Use auxiliary hose system.

Check FTS

Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths.

Increase A (Red) and B (Blue) setpoints. Hose is designed to maintain temperature, not to increase it.

Increase A (Red) and B (Blue) setpoints to increase fluid temperature and keep it steady

Use smaller mix chamber. Decrease pressure.

Wait for hose to heat to correct temperature before spraying

Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths.

Check primary heaters for either an RTD problem or a failed element attached to thermocouple

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

Appendix D - ADM Error Codes on page 89

With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between connectors at each section of hose.

Voltage should drop incrementally for each section of hose further from the system. Use safety precautions when hose heat is turned on.

Proportioning System

Proportioning pump does not hold pressure when stalled

Pump piston or intake valve leaking 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.

313997ZAC 59

Troubleshooting

Problem

Material imbalance.

Erratic pump movement

Pump output low

Cause Solution

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

Pressure relief/circulation valve leaking back to supply

Pump cavitation

• 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 Obstructed fluid hose or gun; fluid hose ID too small

Worn piston valve or intake valve in displacement pump

Inadequate feed pump pressure

See pump manual

Check feed pump pressure and adjust to 100 psi (0.7

MPa, 7 bar) minimum.

60 313997ZAC

ADM Troubleshooting

CS

CJ

CK

Troubleshooting

CR

CP

F IG . 18: ADM Component Identification - Rear

ADM Module Status LEDs (CN) Conditions

Module Status LED Signal

Green on

Yellow on

Red solid

Red flashing

Description

System is powered up.

Communication in progress.

ADM hardware failure.

Uploading software.

USB Module Status LEDs (CL) Conditions

Module Status LED Signal

Green flashing

Yellow on

Green/Yellow Flashing

Description

System is powered up.

Downloading information to USB

ADM is busy, USB cannot transfer information when in this mode

CN

CL

CM r_24E451_3B9900_1a

313997ZAC 61

Troubleshooting

Motor Control Module

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

7

Diagnostic Information

Table 3: LED Status Signal

Module Status LED Signal

Green on

Yellow on

Red solid

Red flashing fast

Red flashing slow

Description

System is powered up.

Internal communication in progress.

MCM hardware failure. Replace MCM.

Uploading software.

Token error. Remove token and upload software token again.

F

IG

. 19: LED Signals

LED

Signals

62 r_257396_3b9905_07b

313997ZAC

Acceptable Size and Duration of Power Line Voltage Fluctuations

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

Maximum Permissible Transient Voltage Surges

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

1400

1200

1000

800

1200Vac, 1697Vdc

<--1 MW Max Surge Power

600

400

480Vac, 679Vdc

<--150 KW Max Surge Power

336Vac, 475Vdc

<--50 KW Max Surge Power

288Vac, 407Vdc

200

0

0.000001 0.00001 0.0001 0.001 0.01

Time (seconds)

0.1

<--No Power Limit

264Vac, 373Vdc

1 10

Troubleshooting

313997ZAC 63

Troubleshooting

Fluid Control Module

Diagnostic Information

Module Status LED Signal

Green on

Yellow

Red solid

Red flashing fast

Red flashing slow

Diagnosis

System is powered up

Internal communication in progress

FCM hardware failure. Replace FCM.

Uploading software

Token error. Remove token and upload software token again.

Module Status LEDs ti12337a1

F IG . 20:

64 313997ZAC

Temperature Control Module

Diagnostic Information

Module Status LEDs

Signal

Green on

Yellow on

Red solid

Red flashing

Blue light off

(High Power

Module only)

Blue flashing

(High Power

Module only)

Description

Temperature control module is powered up.

Internal communication in progress.

Temperature control module failure. See Troubleshooting table.

Software is updating.

Temperature control module is off.

See Troubleshooting table.

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

LED

Signals ti12353a1

F IG . 21: LED Signals ti12357a1

LED

Signals

Troubleshooting

313997ZAC 65

Appendix A - ADM Icons Overview

Appendix A - ADM Icons Overview

Setup Screen Icons

Icon Description

Enter Screen

Icon Description

Erase All Counters on Page

Access Flowmeter Calibration

Exit Screen

On Learn Mode Calibration screen:

Move pump

All other screens:

Begin Dispense

Stop Dispense

Abort Changing the Label

Select left direction

Select right direction

Valve Details

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

Pressure

Shot Number

Sequence Position

Flow

Time (Duration)

Tank Blanket Heater

Backspace

Back to main calibration screen from learn mode calibration screen or

Back to system screen 2 from mix head operating details screen

Access Learn Mode Calibration screen

Run MCM Learn Mode

Proceed to next step in calibration procedure

On Main Calibration screen:

Calibrate Weight Dispense or Enter

Specific Gravity Information

On Flow Meter Calibration screen:

Use Dispensed Material Weight to

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

Erase Selected Item or Control Data

Primary Heater

Heated Hose

Chiller

Move Cursor to the Left

Move Cursor to the Right

Upper/Lower Case Letters

Positive / Negative

66 313997ZAC

Appendix A - ADM Icons Overview

Run Screen Icons

Icon

OR

Description

Select mode.

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

Open, Close Valve

A (Red) and B (Blue) refill button

(Press to start/abort refill)

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

Press a second time to turn off instigated system action.

If Green:

Allowed to Dispense

If Red:

Not Allowed to Dispense

Stop Dispense

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

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

Abort sequence and reset to first valid position

Edit Operator Dispense Setting

Press to enter the Conditioning Control screen

Turn on or off the highlighted zone.

Turn on or off all zones.

Erase a single batch

Erase all batch data points

Manual or Semi-Automatic Circulation

Option (Not displayed for Full Circulation Systems).

313997ZAC

Icon Description

Sets machine to low pressure

Sets machine to high pressure

Current and setpoint temperature for primary heater. Not displayed if heat zone is not enabled.

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

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

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

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

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

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

Amount of material moved through pump (volume tracking)

Cycles

67

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

Appendix C

- ADM Run Screens Overview on page 83. F

IG . 22 shows the flow of the Setup screens.

Shot #1

Shot #2

Sequences #1

Sequences #2

Shot #...

Sequences #...

Calibration System #1

System #2

System #3

Maintenance Supply Conditioning #1

Conditioning #2

Conditioning #3

Advanced #1

Advanced #2

Advanced #...

F IG . 22: Setup Screens Navigation Diagram

68 313997ZAC

Appendix B - ADM Setup Screens Overview

Shots Screen

This screen allows the user to edit shot definitions. The contents of this screen change based on the Dispense and Control Mode selections. Shots may be defined by pressure or flow rate depending upon the Control Mode selection and by time (duration), volume, or weight depending upon the Dispense Mode selection. See System Screen #1 for Control and Dispense Mode options.

See Home Screen, Shot Mode on page 84 for information on how to use predefined shots.

NOTE: 100 shot definition are available across ten pages.

To edit a shot definition:

1.

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

Due to variation in material properties, the

column gives the ability to adjust the shot time/volume/weight for each defined shot.

NOTE: If the

column is used, it is recommended that a minimum of 5 shots are dispensed, measured and averaged for each dispense before entering a value for the

column.

Time Based Example:

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

2.

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

3.

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

4.

Repeat step 2 as required.

1.

Dispense 5 shots into 5 separate containers.

2.

Measure the dispensed amount and record the data.

Shot

1

2

3

4

5

Example 1

Dispensed Volume

(cc)

146.2

146.4

145.6

145.8

146.0

Example 2

Dispensed Volume

(cc)

156.2

156.4

155.6

155.8

156.0

3.

Calculate the average of the 5 shots.

Example 1 = 146cc

Example 2 = 156cc

313997ZAC 69

Appendix B - ADM Setup Screens Overview

4.

Use the following formula to calculate the

column value.

((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

Volume/Weight Based Example:

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

5.

Enter the calculated value in the

Example 1:

Example 2:

column.

1.

Dispense 5 shots into 5 separate containers.

2.

Measure the dispensed amount and record the data.

Shot

3

4

1

2

5

Example 3

Dispensed Volume

(cc)

72.2

72.4

72.6

72.8

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.

70 313997ZAC

5.

Enter the calculated value in the

column.

Example 3:

Appendix B - ADM Setup Screens Overview

Sequences Screen

This screen allows the user to edit sequence information. The contents of this screen change based on the

Dispense and Control Mode selections.

Dispense detail is shown as volume, time, or weight depending on which Dispense Mode is selected. See

System Screen 1 on page 73 for Dispense Mode

options. See Home Screen, Sequence Mode on page 85 for information on how to use predefined

sequences.

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

To edit a sequence:

1.

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

2.

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

313997ZAC 71

Appendix B - ADM Setup Screens Overview

Calibration Screen, Main

This screen shows calibration information for the system and provides access to other calibration screens. See

Calibrate HFR on page 48 for how to use the calibration

screens to calibrate the machine.

The date next to each key represents the last time that calibration was performed.

The “Cal. Min” and “Cal. Max” values are the system recognized extreme ends of piston travel. See Calibration Screen, Learn Mode .

Calibration Screen, Learn Mode

This screen allows the user to calibrate piston position.

The piston can be moved to the left and right to obtain

the full range of motion. See Calibrate HFR on page 48

for how to use this screen to calibrate the machine.

Current position

Previously saved left position

Previously saved right position

Press to the left.

and then to move the pump all the way

Press to go to the Calibration Screen, Learn

Mode screen.

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

Press to the right.

and then to move the pump all the way

Press to return to the Calibration Screen, Main .

This saves the new left and right numbers.

72 313997ZAC

Appendix B - ADM Setup Screens Overview

System Screen 1

NOTE: Not all of the following modes may be available depending on the dispense valve selected.

This screen allows the user to set important system settings specific to what dispense applicator has been selected. Control Mode can be set to Pressure or Flow.

With Control Mode set to Pressure, the machine will adjust dispense flow rate in order to maintain the requested pressure. With Control Mode set to Flow, the machine will dispense at a continuous flow rate regardless of pressure fluctuations unless pressure alarm conditions occur.

Dispense Mode can be set to Time, Volume, or Weight.

Dispense Mode controls how displayed amounts are measured. If Dispense Mode is set to Weight, then the machine dispenses until the desired weight of material is dispensed. See

Calibrate HFR on page 48 for more

information.

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

If pump sizes and inlet pressures are not entered properly, system performance will be affected. The inlet pressure must be set to the maximum feed pressure that will be seen by that side of the machine.

The maximum working pressure for the machine is displayed on this screen. The maximum working pressure is dependent on the installed hoses and dispense valve.

The maximum working pressure is set to the lowest rated system component. If 2000 psi hoses are installed and the maximum working pressure displayed is not

2000 psi, see HFR repair/parts manual for instructions to set the maximum working pressure for hoses. If the installed dispense valve rating is below the maximum working pressure shown here, verify the correct dispense valve is selected on System Screen 2.

System Screen 2

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

When enabling the Gel Timer, the user must select one of the 100 available shot definitions to use as the Gel

Shot. This shot will be dispensed when the Idle Period expires. The Idle Period will begin after a dispense is completed. Any dispense operation in the middle of the timer countdown will reset the Idle Period counter. The system will generate an audible alarm based upon the user Alarm setting. The alarm will sound the user-entered number of seconds before the Idle Period expires.

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

Select the dispense valve installed in the system. This selection is critical to ensure proper operation of the machine. When a mix head is selected, button will become active when the is pressed. When active, pressing this button will open a screen used to define the mix head operating parameters. See the Mix Head

Operating Details Screen on page 74.

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

313997ZAC

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.

73

Appendix B - ADM Setup Screens Overview

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

P2/Fusion Dispense Valve applications. This feature can not be active if the Post Dispense Shot Disable feature is active.

Mix Head Operating Details Screen

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

• Low Pressure Circulation: The percentage of setpoint 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.

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

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

• Clean Out Closed: Applies to an L-Head in a Normally Open configuration only. The amount of time the clean out rod will remain closed when it closes after the completion of a dispense (after the clean out open time delay).

• Anti-Seize Delay: Applies to an L-Head in a Normally Closed configuration only. After a shot occurs and the cleanout piston closes, the first anti-seize delay will count down then the cleanout piston will open and close to break loose from any curing material. The second anti-seize timer will then begin counting down and the cleanout piston will open and close again to break loose from any remaining curing material. If a shot occurs before both anti-seize timers elapse, the anti-seize timers restart.

74

Press to go back to the System Screen 2 .

313997ZAC

Appendix B - ADM Setup Screens Overview

System Screen 3

This screen allows the user to edit the labels for the A

(Red) and B (Blue) sides of the machine. The labels set for the A (Red) and B (Blue) sides of the machine are displayed throughout the screens. Labels are limited to five characters.

To edit a label:

Keyboard Screen

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

1.

Press .

2.

To edit the A (Red) label, press .

To edit the B (Blue) label, press the down arrow then press . The keyboard will appear on the screen. See Keyboard Screen on page 75.

3.

Use arrow keys to select the desired letter and press to accept the letter. To erase all text, press the Eraser softkey. To go back one letter, press the Back Arrow softkey.

4.

When finished entering the new label, press the button twice.

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

17-138 bar).

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

This screen allows the user to enter material specific gravities.

1.

Use arrow keys to select the desired letter and press press move the cursor one letter to the right, press .

To toggle the letters from upper/lower case, press

.

to accept the letter. To erase all text,

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

. To

. To

2.

When finished entering the new label, press

Flow Meter Calibration

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

.

Pressure

Imbalance

Setting

313997ZAC 75

Appendix B - ADM Setup Screens Overview

Maintenance Screen

This screen shows shot number, sequence position, and dispense valve counters. Press 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 .

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

Supply Screen

This screen allows the user to specify the operating parameters for off-board, integrated tanks and indicate which positions have level sensors installed. See the

Tank Feed Systems manual for information about installing level sensors, see

Related Manuals

on

page 3. The user may select from the following refill set-

tings: Disabled, Monitor, Manual, Auto Top-Off, Auto

Full-Volume.

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

76

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

• Disabled

• Disables tank operation

• Monitor

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

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

• Errors will clear when the corresponding condition clears

• Manual

• The low level sensor will generate a low level alarm

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

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

• The low level alarm will clear when the condition clears

• Auto Top-Off

• The low level sensor will generate a low level alarm

313997ZAC

Appendix B - ADM Setup Screens Overview

• 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

• The low level alarm will clear when the condition clears

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

• Auto Full-Volume

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

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

• The low level alarm will clear when the condition clears

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

Refill Setting

If a refill setting other than Disabled is selected, the user must set at least two level sensor locations as installed by checking the check box on the screen. If all three locations are set to installed, the system will default to the Auto-Top Off refill setting and operate as follows:

• 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 instigate an automatic refill operation at any time.

This button can also be used to abort a refill operation.

Refill Timeout

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

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 may be selected. A maximum of four components and two monitoring zones may be selected.

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Appendix B - ADM Setup Screens Overview

Conditioning Screen 2

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

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

2.

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

NOTE: All components are shown installed for reference only. Only 4 components can be installed at one time.

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

3.

Edit the setpoint and alarm values and then press to return to Conditioning Screen 2 .

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

1.

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

78 313997ZAC

Appendix B - ADM Setup Screens Overview

Conditioning Screen 3

This screen allows the user to configure Night Mode operation. In Night Mode, the system will cycle on and off periodically or turn on at a preset time. Press and select periodic or time schemes.

When the system is in Night Mode and in an “On” cycle, the system will circulate in low pressure. The installed conditioning zones will be on and controlling to their respective setpoints. When the system is in Night Mode and in an “Off” cycle, the system will be idle. The system will not be circulating, and the conditioning zones will not be actively controlling temperature. When in Night

Mode, supply tanks will not fill.

Time Based Night Mode Conditioning Screen

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

Friday where each day has the same on or off times, or

Sunday through Saturday where each day has the same on or off times. The days can be selected by pressing the left or right arrow keys once entered into the screen.

313997ZAC

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.

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

Description

Machine is ON

Machine is OFF

6.

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

79

Appendix B - ADM Setup Screens Overview

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

Cold Start Up Mode

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

Auto High Pressure

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

Calender Time Based Night Mode Conditioning

Screen

This screen shows a summary of Time Based Night

Mode on or off times that were set by the Time Based

Night Mode Conditioning Screen .

Advanced Screen 1

This screen allows the user to set the language, date format, current date, time, setup screens password, screen saver delay, and turn on or off silent mode.

• Language: Available languages are English, Spanish, French, German, Chinese, Japanese, Korean,

Russian, and Italian.

• 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.

Advanced Screen 2

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

80 313997ZAC

Advanced Screen 3

Appendix B - ADM Setup Screens Overview

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

Advanced Screen 4

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

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

• Disable Modifying Temp Setpoint: Check this box to disable modifying temperature setpoints from the

Run screens. This is only applicable if temperature control items are installed and enabled.

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

• Temperature Alarm Disables Dispense: When this box is checked, and temperature zones are enabled, the HFR will not dispense until the material temperature reaches the set temperatures of the zones.

• 2x Trigger for Dispense: When this box is checked, the dispense valve trigger handle or footswitch assembly will require the user to tap the switch twice before the HFR will acknowledge the dispense request (Shot and Sequence Modes

Only). Likewise, the same double tap sequence will require the user to cancel an active dispense using the switch device. The described double tap does not apply when requesting a dispense from the

ADM.

• Dispense from Home Position: Only applicable for full circulation type systems in Shot or Sequence

Modes. If the machine is active, wait until the HFR reaches a certain position on the pump going a given direction before starting a dispense after a request is issued. This configuration typically provides the most consistent material amounts, but will provide inconsistent dispense delays after a dispense request is issued.

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

Mode.

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

• Enable Diagnostic Screen: Check this box to enable the optional ADM screens, enabling USB log downloading, and erasing USB logs. For more information about USB operation, see

Appendix F -

USB Operation on page 103. For more information

about the optional screens, see Diagnostic screen on page 88.

• 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.

Advanced Screen 5

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

This screen displays software information.

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Appendix B - ADM Setup Screens Overview

Advanced Screen 6

As indicated in the HFR setup Advanced #6 screen, additional manual or semi-automatic circulation related features are available. All of these check box options will be disabled if the HFR is a full circulation type system

(GX16, GX16 w/ Prox, L-Head). Refer to the Manual

and Semi-Automatic Circulation section, page 110, for

more details.

1.

HFR Circulation Valves Installed - Activate this feature if the Semi-Automatic Circulation Kits are installed. If checked, the hydraulic level sensor option provided on Setup System Screen #2 will not be available. Do NOT check this box if air driven circulation valves are not installed (default).

2.

Auto Pressurize After Circulation - If turned ON, the HFR will automatically stall to the last dispense pressure monitored after commanded out of circulation mode (“ ” key off). This will enable the next dispense out of the dispense valve to start at the correct dispense pressure. Since P2/Fusion DV type HFR will stall to pressure by pressing the green dispense key, this option is disabled if the dispense valve option is selected.

3.

Maximum Circulation Pressure - The user can configure the system to generate a warning (deviation) if any of the two pump pressures exceed the entered amount while in circulation. If excessive pressure exists, a “High Circulation Pressure” deviation will be generated and logged for the user. If this feature is NOT desired, enter a large pressure value.

82 313997ZAC

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

Errors #2

Errors #...

Events #1

Events #2

Events #...

Maintenance

F IG . 23: Run Screens Navigation Diagram

Home Screen

The Home screen is the first screen that displays in the

Run screens. It shows the current fluid pressure on the

A (Red) and B (Blue) fluid outlets of the pump and if there are any active errors. If tanks are installed in the system, the fill level is shown on each tank. The ratio is also displayed as either Red:1 or Blue:1 depending on which display has been setup.

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

Alternately, press the Select Mode button and use the up and down arrow keys until the desired mode is shown, then press the Enter button to select the mode. The available operating modes are operator, sequence, shot, standby, night, and disabled.

Home Screen, Disabled Mode

When this mode is selected, the machine will not be able to dispense or condition (heat/cool) material. The setup screens cannot be accessed while in Disabled mode. Use the Select mode button to exit Disabled mode.

* Supply tanks shown for reference only. Your system may not include supply tanks.

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Appendix C - ADM Run Screens Overview

Home Screen, Standby Mode

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

NOTE: The following screen is for a full circulation type

HFR system (GX16, GX16 w/ Prox, L-Head).

Press to open or close the dispense valve when the HFR is idle.

Home Screen, Shot Mode

This mode allows the user to select one of 100 predefined shot numbers. See Shots Screen on page 69 for information about editing shot definitions.

To use a predefined shot:

1.

Enter shot mode.

2.

Press and use the numeric keypad to enter the desired shot number.

3.

Press to select the shot number.

Press to change operating modes.

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

4.

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

Details Screen on page 74, expires.

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.

NOTE: The following screen is for all other HFR systems and is not present in full circulation HFR systems.

Target Flow

Ratio

Target recipe time

Press to perform a park operation with the dispense valve closed.

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 84 for

other button functions.

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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 71 for information about editing sequence defini-

tions.

To use a predefined sequence:

1.

Enter Sequence Mode.

2.

Press the sequence letter/position selection button.

3.

Use the left and right arrows to toggle between letter and position selection. When selecting a sequence letter (A-E), use the up and down arrow keys to scroll through the available letters. When selecting a sequence position, type in the desired position with the numeric keypad. The system will reject invalid letter/position selections.

Home Screen, Operator Mode

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

1.

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

Ratio

Operator

Setting

4.

Press to accept the sequence letter/position.

5.

Press the Dispense button to begin dispensing.

A (Red) resettable material counter

B (Blue) resettable material counter

Total of resettable material counters

Target

Flow/Pressure

Ratio

Target dispense amount

(time/volume/weight depending on Dispense Mode)

2.

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

Details Screen on page 74, expires. Press the to stop the dispense.

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

3.

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

4.

See Home Screen, Shot Mode on page 84 for other button functions.

6.

Press to skip to the next sequence position.

7.

Press to abort the sequence.

8.

See Home Screen, Shot Mode on page 84 for other button functions.

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Appendix C - ADM Run Screens Overview

Home Screen, Night Mode

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

Conditioning Screen 3 on page 79.

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.

 No setpoint box will be displayed if selected as monitor zone.

86 313997ZAC

Appendix C - ADM Run Screens Overview

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

Black

Grey

Yellow

Green

Definition

Dispense Disabled

Dispense Allowed

Dispense Disabled

Dispense Allowed

Errors Screens

This screen shows users a list of errors that have occurred in the system. Each error entry includes a description and error code along with a date and time stamp. There are 5 pages, each holding 10 errors. The

50 most recent errors are shown.

Refer to the Troubleshooting section on page 58 for a

detailed description of all of the system errors.

To turn a single zone on/off:

1.

Press to enter the Conditioning Control screen.

2.

Use the arrows keys to navigate to the desired zone.

3.

1.

2.

Press zone is on, the button will be selected. Press the button again to turn the zone off.

To turn all zones on/off:

Press

Press the

to turn the selected zone on. When a

to enter the Conditioning Control screen.

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

Press the button again to turn all zones off.

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 58 for a

detailed description of all of the system events.

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

 No setpoint box will be displayed if selected as monitor zone.

313997ZAC 87

Appendix C - ADM Run Screens Overview

Maintenance Screen 1

This screen displays historical information for each pump in the system. The Batch counters are resettable and count both material usage and pump cycles. The

Total counters are not resettable by the user. They also count both material usage and pump cycles. For material usage counters, units are displayed next to the volume/weight indicator icons.

To erase a batch counter, press the Enter Screen button and navigate to the field to be erased. Press the Erase

Single button to erase that data point. Alternatively, the

Erase All button may be pressed to erase all of the batch data points simultaneously.

Optional Screens

The optional Diagnostic screen can be enabled in the

Advanced Screen 4 screen, see page 81.

Diagnostic

The Diagnostic screen shows status information for various system components.

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

88 313997ZAC

Appendix D - ADM Error Codes

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

P4H3

P1H3

T4H3

MBH3

DEH3

A4H3

WDF1

WDF1

WDD3

A4A6

A4B5

A4A3

A4B1

A4A2

A4B4

A4A7

A4B8

A4H1

A4M1

A4N1

High

Accumulator

Pressure

Low

Accumulator

Pressure

High Mix

Head Oil

Temp.

Low Mix

Head Oil

Level

Soft Stop

Asserted

AC Power Pack pressure too high

AC Power Pack pressure too low, or failed to reach desired pressure.

AC Power Pack temperature too high.

Oil level in AC Power Pack too low.

Soft Stop on AC Power Pack has been pressed.

Error

Type

Alarm

Alarm

Alarm

Alarm

Alarm

Cause

Accumulator Directional

Valve stuck in charge position.

Accumulator Directional

Valve will not shift to charge position.

Solution

Check control line to Directional Valve. Replace

Directional Valve.

Check control line to Directional Valve. Replace

Directional Valve.

RTD Sensor option turned ON without RTD installed. Oil temperature is excessively hot.

If oil is not hot, replace sensor.

Add oil.

Level Sensor bad.

Function turned ON without sensor installed.

User has pressed the

Red Soft Stop Button on

AC Power Pack.

Pull out Soft Stop button.

Short circuit within AC

Power Pack Motor.

Replace motor.

Mix Head

Motor

Overload

Excessive Current to AC

Power Pack Motor.

Alarm

M1 Material

Extend Fault

M1 Material

Extend Fault

M1 Cleanout

Extend Fault

Material Rod in dispense valve failed to close. Pump halted.

Material rod in dispense valve failed to open during a dispense.

Alarm Material Rod failed to close. Pump movement halted.

Hydraulic lines installed backwards. + DC voltage shorted to the Valve Control Line.

Deviation Material Rod stuck closed. Shot duration too problem.

short.

Take a long shot to determine if it corrects the

Clean-Out Rod in dispense

Alarm Clean-Out Rod Valve faulty.

Check control line to Clean-Out Valve. Replace

Hydraulic Valve.

valve (“L-Head”) failed to move.

Red Blanket

Overcurrent

Blue Blanket

Overcurrent

Red Inline

Overcurrent

Blue Inline

Overcurrent

Red Hose

Overcurrent

Blue Hose

Overcurrent

Red Chiller

Overcurrent

Blue Chiller

Overcurrent

An over current was detected on the output

Alarm

Bad heaters Measure resistance of heater

Motor Over

Current

Motor Over

Current

Motor Over

Current

High current has been detected on a phase and has been shutdown to prevent damage

Too much current is being drawn from the wall

A hardware current fault has occurred causing a system shutdown

Alarm

Alarm

Alarm

High voltage

Shorted Temperature

Control Module

Measure voltage across the disconnect switch.

Voltage should measure between 190 and 264 Vac.

If temperature rises for a zone that has been disabled, replace Temperature Control Module

Bad internal wiring of the

Replace motor motor

Short circuit of motor wiring

Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground

Low voltage from the wall Make sure the supply line is properly sized for the during load load and is above the minimum voltage requirements

Short circuit of motor wiring

Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground

Motor rotor has become locked

Unplug the directional valve (so pressure will not build) and try to move the motor again. If this succeeds then the power pack may need to be replaced. If the motor is still unable to move, the bearings or hydraulic pump have likely failed in the motor and will need to be replaced.

313997ZAC 89

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

A7A6

A7B5

Red Blanket

Control Fault

Blue Blanket

Control Fault

A7A3

A7B1

A7A2

A7B4

Red Inline

Control Fault

Blue Inline

Control Fault

Red Hose

Control Fault

Blue Hose

Control Fault

Unexpected current to heater/chiller

A7A7

A7B8

A8A6

A8B5

A8A3

A8B1

A8A2

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

No current to the conditioning zone

Current

Error

Type

Alarm

Alarm

A8B4

A8B7

A8B8

A9C1

B9C0

B9C1

Cause

Shorted Temperature

Control Module

Tripped circuit breaker

Solution

If temperature rises for a zone that has been disabled, replace Temperature Control Module

Visually check circuit breaker for a tripped condition

No Blue Hose

Current

No Red

Chiller

Current

No Blue

Chiller

Current

Motor Over

Current

Small Shot

Request

Low power

Cable unplugged/loose power

Bad heater(s)

Measure voltage across input terminals on power line filter. Voltage should measure between 190 and 264

Vac

Check for loose or disconnected wires or plugs

Measure resistance of heater(s)

A software error has occurred commanding too much current

Alarm

The requested dispense amount is below the minimum amount of the system (25% of the combined pump volumes is the minimum)

Deviation

Bad Motor Control

Module code

Check for MCM software update, load latest MCM software, if problem persists contact Graco

Pumps are defined with the wrong size

On the ADM go into the Setup screens to the System screens then make sure that the pump sizes are defined correctly

Requested shot is below the capabilities of the

If the user has to be able to take the shot the system must be fitted with smaller pumps current pump setup

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

90 313997ZAC

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

CAA2

CAA3

Comm. Error

Red Hose

Comm. Error

Red Inline

CAA6

CAA7

CAB1

CAB4

Comm. Error

Red Blanket

Comm. Error

Red Chiller

Comm. Error

Blue Inline

Comm. Error

Blue Hose

CAB5

CAB8

CAC1

CAC2

CAC3

CAC4

CAC5

CAC6

CAC7

CACN

CACP

CACR

Comm. Error

Blue Blanket

Comm. Error

Blue Chiller

Comm. Error

Motor

Comm. Error

MCM

Communication error

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

CUCN

D1A1

D4A1

Gateway

Heartbeat

Error

Setpoint Not

Reached

Setpoint

Exceeded

Error

Type

Alarm

Cause

Module missing power

Solution

Module not programmed Program the module

Module bad

Check power supply connection

Replace module

Heartbeat Error Alarm

The set point was not reached

Deviation and the pump was shutdown

The maximum cycles per minute of the pump has been exceeded

Deviation

PLC is not maintaining heartbeat

Module missing power Check power supply connection

Module not programmed Program the module

Module Bad

Material restriction too high for requested flow

Ensure PLC is triggering the heartbeat

Replace module

Reduce flow request

Restriction for the pump is not sufficient

Increase the restriction or lower the set point

D2A1

D3A1

Setpoint Not

Reached

Setpoint

Exceeded

The set point was not reached Deviation

The set point was exceeded Deviation

Pump cannot reach the requested pressure

Pump cannot reach the requested flow

System underwent a change that caused a large drop in restriction

(such as new orifices)

Increase restriction in the system

Decrease restriction in the system

Erase learned System Data, found in the setup screens under calibration

No material in pumps

Make sure the material lines are open and have proper feed pressure

313997ZAC 91

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

D5A1

Error

Type

Invalid Learn

Mode Data

This calibration lets the MCM know where the ends of the pump are. If the data gathered during this process is outside Deviation of normal parameters the machine will operate with a greatly reduced stroke.

Cause

Bad linear position sensor

Solution

Recalibrate the machine Rerun the learn mode calibration

Loose/bad connection

Check to ensure the pressure transducer is properly installed and all wires are properly connected

Verify pump moves to limits, if problem persists replace linear position sensor

D6A1

DDA1

DDB2

DFA1

DR6A

DR6B

Position

Sensor Fault

Red Pump

Cavitation

Blue Pump

Cavitation

Pump Not

Parked

Check Flow

Meter Red

Check Flow

Meter Blue

The linear position sensor is returning data that should not be possible during normal operation

Cavitation was detected on the given pump

The pump failed to reach the park position

Alarm

Deviation

Deviation

Flow Meter has caused a fault Deviation

Loose/bad connection to Check to ensure the linear position sensor is properly linear position sensor installed and all wires are properly connected

Bad linear position sensor

Linear position sensor may be loose where attached to pump housing

Replace linear position sensor

Re-tighten the sensor and re-calibrate the machine

Insufficient material being supplied or insufficient material pressure on feed system

Debris or packout in the incoming fluid filter

Orifices blocked

Hose blocked

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

Dispense valve failed to open

Cogs in flow meter are not turning

Cable unplugged/loose power

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

Properly setup the system

On the ADM go into the setup screens -> System-> then make sure that the pump type and size are set

(not --)

DSC0

Pumps Not

Defined

F1A0 Low Flow

F2A0 Red

F1B0 Low Flow

F2B0 Blue

F4A0 High Flow

F3A0 Red

F4B0 High Flow

F3B0 Blue

F7D1

L111

L122

L311

L322

L6A1

L6B2

The type or size of the Red or

Blue material pumps have not been defined

Alarm

Flow is below the defined low limit

Flow is above the defined low limit

Alarm

Deviation

Alarm

Deviation

Alarm

Deviation

Alarm

Deviation

Cogs in flow meter are not turning

Cable unplugged/loose power

Cogs in flow meter are turning rapidly

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

Pump Failed to Stall

When the pump tried to stall to pressure the pump traveled more than it should in normal operation (only applies to dead-headed system)

Deviation

Failure of the dispense valve

Material leak

Out of material

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

Red Low

Material Level

Tanks low on material Fill tanks with material

Blue Low

Material Level

Low material level in tanks Deviation

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

Blue High

Material Level

Deviation Defective fill valve

Red Auto

Refill Timeout The tank stand has been filing for a time greater than

Blue Auto expected

Refill Timeout

Deviation

No material is actually being fed

Loose level sensor connection

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

92 313997ZAC

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

L8A1

DR6B

Red Tank

Sensor

Failure

Blue Tank

Sensor

Failure

A level sensor had ceased working

Error

Type Cause

Deviation Bad level sensor

Solution

Replace level sensor

MBH1 Low Oil Level

MBN1

MMUX

N1D0

N2D0

N3D0

N4D0

N4A1

P400

Low Motor

Performance

USB Logs

Full

Thermal

Pressure

Rise

The volume of oil in the tank is below the minimum level needed for the system to

Alarm properly operate

The motor magnetism has decreased to the point where performance is greatly reduced

USB log has reached the maximum entries

Advisory

Material

Dispense

Below Alarm

Material

Dispense

Below

Deviation

Material

Dispense

Above

Deviation

Material

Dispense

Above Alarm

Material dispense is below the defined limit

Material dispense is above the defined limit

Alarm

Deviation

Deviation

Alarm

Cogs in flow meter are not turning

Cable unplugged/loose power

Check that flow meter is matched to nominal pump output check for loose or disconnected wires or plugs

Pump Failed to Move

The MCM attempted to move the pump but no movement was detected

Deviation

Motor failure

Hydraulic power pack failure

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

If motor is moving but pump is not and pressure is not building they hydraulic power pack may need servicing

Loose/bad connection to

Check to ensure the linear position sensor is properly the linear position sensor connected to the MCM and the wiring has not be damaged

Failure of the linear position sensor

Replace the linear position sensor

Motor no longer coupled to hydraulic pump

Reset coupler per specifications and retighten set screws

Supply tube from hydraulic pump to manifold is loose or broken

Retighten or replace supply tube

Broken motor shaft

Over-pressure valve dumping to tank

Replace motor

Verify that no outside forces are stopping the pump from moving, then inspect over-pressure valve for damage or debris

Pressure has risen to an unsafe level due to thermal expansion of materials. All conditioning zones have automatically been turned off.

Advisory

Low oil level

Loose/bad connection

Bad level sensor

Leak in hydraulic driver

Check oil level and if low add more hydraulic fluid

Check to ensure the hydraulic oil level sensor is properly connected to the MCM and that the wire has not been damaged

Replace sensor

Inspect hydraulic driver end seals and early leak detection tubing. Replace seals as necessary and replace lost oil.

Leak in the hydraulic reservoir, heat exchanger

Prolonged exposure to heat or high voltage

Inspect the hydraulic reservoir fittings and filter for leaks. Repair or replace as necessary and replace lost oil.

If error persists and performance can no longer satisfy the user requirements the motor will need to be replaced

USB logs have not been downloaded

Download USB logs to a memory stick

Uncheck the Enable USB errors on Advanced screen

4

Deviation High pressure

Open the dispense valve manually or open the valves to bleed pressure

313997ZAC 93

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

P4A1

P4B2

P4D0

P6A1

P6B2

R1D0

R4D0

R2D0

R3D0

Red Pressure

Shutdown

Blue

Pressure

Shutdown

Pressure

Imbalance

The material pump pressure exceeded the maximum operating pressure as defined in the setup screens

The pressure difference between the Red and Blue material is greater than the defined amount

Error

Type

Alarm

Alarm

Cause

Dispense valve failed to open

Bad dispense valve

Restriction in the material lines

Solution

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

Invalid maximum pressure defined

Orifices blocked

Hose blocked

Dispense valve failed to open

Dispense line is clogged

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 material lines

Pressure imbalance is defined too low

On the ADM go into the setup screens -> System-> and ensure the pressure imbalance value is the maximum acceptable to prevent unnecessary alarms which will abort dispenses

Orifice blocks closed off too much on one or both sides

Verify that one or both of the orifice blocks dispense when adjusted to the fully open position then adjust accordingly

Debris in the orifice block

Relieve system pressure then remove the orifice from the orifice block and inspect for debris in the cavity

Material fillers may have packed out in an orifice

Relieve system pressure and remove the orifice from the orifice block and inspect for pack out. Clean or replace as necessary.

Out of material Fill tanks with material

Feed system defective Replace defective item

Loose/bad connection

Bad sensor

Check to ensure the pressure transducer is properly installed and all wires are properly connected

Replace pressure transducer

Red Pressure

Sensor Fault The pressure sensor is

Blue

Pressure providing invalid/no pressure readings

Sensor Fault

Low Ratio

Alarm

High Ratio

Alarm

Low Ratio

Deviation

High Ratio

Deviation

Ratio monitor has detected an out of ratio condition

Alarm

Alarm

Alarm

Deviation

No material in pump

Material A to Material B is out of ratio

Fill tanks

Check feed system

94 313997ZAC

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

T1A6

T1B5

Red Tank

Low Fluid

Temp.

Blue Tank

Low Fluid

Temp.

T1A3

T1B1

T1A2

T1B4

Red Inline

Low Fluid

Temp.

Blue Inline

Low Fluid

Temp.

Red Hose

Low Fluid

Temp.

Blue Hose

Low Fluid

Temp.

Fluid temperature is below the defined low alarm limit

Error

Type

Alarm

T1A7

T1B8

T20X

T30X

Red Chiller

Low Fluid

Temp.

Blue Chiller

Low Fluid

Temp.

Dispensing

Disabled Low

Temp

Dispensing

Disabled High

Dispensing disabled because of temperature

Temp

Advisory

Cause

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Low power

Cable unplugged/loose power

Bad heater(s)

Temperature is out of alarm limits

Solution

Measure voltage across input terminals on power line filter. Voltage should measure between 190 and 264

Vac

Check for loose or disconnected wires or plugs

Measure resistance of heater(s)

Check temperature alarm limits

313997ZAC 95

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

T2AA

T2AE

Red Hose

Low Fluid

Temp.

Red Tank

Low Fluid

Temp.

T2AF

T2BC

T2BD

T2BG

Red Chiller

Low Fluid

Temp.

Blue Hose

Low Fluid

Temp.

Blue tank Low

Fluid Temp.

Blue Chiller

Low Fluid

Temp.

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

Error

Type

Deviation

T3AA

T3AE

T3AF

T3BC

Red Hose

High Fluid

Temp.

Red Tank

High Fluid

Temp.

Red Chiller

High Fluid

Temp.

Blue Hose

High Fluid

Temp.

Fluid temperature for a monitor zone is above the defined high alarm limit

T3BD

T3BG

Blue Tank

High Fluid

Temp.

Blue Chiller

High Fluid

Temp.

T3H1

Oil Temp.

Cutback

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

Deviation

Cause

Temperature is out of alarm limits

Cable unplugged/loose power

Low air volume from fan

Solution

Check temperature alarm limits

Check for loose or disconnected wires or plugs

Inline heater is not turned on

Turn on inline heater

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 pencil eraser. If the fan slows down easily it will need to be replaced

T3N1

Motor Temp.

Cutback

Motor temperature is approaching a level where damage is possible so the motor control module is limiting the output to a safe level

Advisory

No power to fan Check cord to make sure fan has power

Debris is fan or fan grill clear debris from fan/fan grill

Low air volume from fan

Try to stop fan by lightly pressing on the center with a pencil eraser. If the fan slows down easily it will need to be replaced

Ambient environmental conditions are too hot

Move machine to an area below 120°F

Motor/pump coupler may be rubbing on hydraulic

Reset coupler per specifications and retighten set screws pump

96 313997ZAC

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

T4A2

T4A3

Red Hose

High Fluid

Temp.

Red Inline

High Fluid

Temp.

T4A6

T4A7

T4B1

T4B4

T4B5

T4B8

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.

Fluid temperature is above the defined high alarm limit

Error

Type

Alarm

Cause

Defective Temperature

Control Module

Defective RTD

Solution

Replace Power Temperature Control Module

Replace RTD

T4C1

T4H1

T4N1

The temperature the MCM has

Motor Control reached a level where product life will be decreased

High Temp.

drastically and has been

Alarm

Oil Temp.

Shutdown

Motor Temp.

Shutdown shutdown for protection

The hydraulic oil is at a temperature where performance is impacted significantly and has resulted in a system shutdown

Motor temperature is too high and system has been shutdown to prevent possible damage

Alarm

Alarm

Loose connections Tighten connections

No power to fan Check cord to make sure fan has power

Debris is fan or heatsink Clear debris from fan or heatsink

Low air volume from fan

Try to stop fan by lightly pressing on the center with a pencil eraser. If the fan slows down easily it will need to be replaced

Motor may be damaged Replace motor

Debris is packed in the

MCM’s heat sink fins

No Power to Fan

Clear debris from MCM heat sink fins

Check cord to make sure fan has power

Debris in fan or fan grill Clear debris from fan/fan grill

Low air volume from fan

Try to stop fan by lightly pressing on the center with a pencil eraser. If the fan slows down easily it will need to be replaced

Check cord to make sure fan has power No power to fan

Debris is fan or fan grill Clear debris from fan/fan grill

Low air volume from fan

Try to stop fan by lightly pressing on the center with a pencil eraser. If the fan slows down easily it will need to be replaced

Ambient environmental conditions are too hot

Move machine to an area below 120°F

Motor may be damaged Motor may need to be replaced

T6A6

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

RTD 1 is giving no or invalid data

Alarm

Loose or bad connection Check RTD wiring

Bad RTD Replace RTD

313997ZAC 97

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

T6C6

T6C5

Red Blanket

RTD Fault

Blue Blanket

RTD Fault RTD 2 is giving no or invalid data

T6C7

T6C8

Red Chiller

RTD Fault

Blue Chiller

RTD Fault

T8A6

T8B5

T8A3

T8B1

No Heat Red

Tank

No Heat Blue

Tank

No Heat Red

Inline

No Heat Blue

No temperature rise

Inline

T8A2

T8B4

T8A7

No Heat Red

Hose

No Heat Blue

Hose

No Cooling

Red Chiller

Error

Type

Alarm

Alarm

T8B8

No Cooling

Blue Chiller

No temperature decline Alarm

Cause

Loose or bad connection Check RTD wiring

Bad RTD

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Low Power

Bad heater(s)

Solution

Replace RTD

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

Measure resistance of heater(s)

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Defective cooling valve

Disconnect the valve and measure the voltage across the wires when the chiller is running to ensure 24V is being delivered to the valve. If so, the cooling valve will likely need replacing.

Chilled water supply off Turn on chilled water supply

Loose or bad connection Check RTD wiring

T9A6

T9B5

T9A3

Red Blanket

Temp. Cutoff

Blue Blanket

Temp. Cutoff

Red Inline

Temp. Cutoff

Heater overtemperature cutoff Alarm

T9B1

T9C6

T9C5

T9C3

T9C1

T9C2

T9C4

T9C7

T9C8

Blue Inline

Temp. Cutoff

Red Blanket

Ctrl

Shutdown

Blue Blanket

Ctrl

Shutdown

Red Inline

Ctrl

Shutdown

Blue Inline

Ctrl

Shutdown

Red Hose Ctrl

Shutdown

Blue Hose

Ctrl

Shutdown

Red Chiller

Ctrl

Shutdown

Blue Chiller

Ctrl

Shutdown

PCB over temperature Alarm

Defective RTD

Defective High Power

Temperature Control

Module

Loose connections

Overheated

Temperature Control

Module

Replace RTD

Replace High Power Temperature Control Module

Tighten connections

Turn conditioning zone off. Wait a few minutes. If the condition does not clear or regenerates consistently, replace heater module

98 313997ZAC

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

V1H1

V4A6

V4B5

V4A3

V4B1

V4A2

V4B4

V4A7

V4B8

V4H0

Error

Type

Motor Control

The voltage to the MCM has

Undervoltage dropped to a level where performance is greatly affected

Alarm

Red Blanket

Overvoltage

Blue Blanket

Overvoltage

Red Inline

Overvoltage

Blue Inline

Overvoltage

Red Hose

Overvoltage

Blue Hose

Overvoltage

High line voltage Alarm

Red Chiller

Overvoltage

Blue Chiller

Overvoltage

The voltage to the MCM has

Motor Control reached an unsafe level and

Overvoltage has been shutdown in an attempt to prevent damage

Alarm

Cause Solution

Tripped circuit breaker Visually check circuit breaker for a tripped condition

Supply lines providing low voltage

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.

W0U0

WBH1

WDF1

WKH1

USB Update

Failed

Motor

High Motor

Speed

The ADM tried to upload a system settings file but failed

An error has been detected on

Alarm

Encoder Fault the motor position sensor

M1 Material

Rod Shift Fail

The material rod failed to move

Alarm on a straight head

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

Alarm

Alarm

Supply lines providing high voltage

Check incoming voltage to ensure it is below the maximum operating voltage

System Settings file is corrupt

System Settings file is intended for another system

Replace the system settings file with a backup or new file

Ensure that the first line in the settings.txt file contains the text GMS

. If not replace the file with the proper system update file.

Failing sensors

Loose connection

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 Stuck material rod

No power to directional valve

No power to directional valve

Make sure the directional valve has power

Make sure the directional valve has power

Bad directional valve connection

Make sure the cord to the directional valve is connected to the correct port and the cord is not damaged

Directional valve failure The directional valve will need to be replaced

Hydraulic power pack failure

The hydraulic power pack will need repair

Defective encoder Replace encoder

Motor no longer coupled to hydraulic pump

Reset coupler per specifications and retighten set screws

Supply tube from hydraulic pump to manifold is loose or broken

Broken motor shaft

Retighten or replace supply tube

Replace motor

313997ZAC 99

Appendix D - ADM Error Codes

Error

Code Error Name Error Description

WM06

WM05

Red Tank

Con. Fault

Blue Tank

Con. Fault

WM03

WM01

WM02

WM04

Red Inline

Con. Fault

Blue Inline

Con. Fault

Red Hose

Con. Fault

Blue Hose

Con. Fault

High current to relay 1

WM07

WM08

WMA6

WMB5

Red Chiller

Con. Fault

Blue Chiller

Con. Fault

Red Blanket

High Temp.

Blue Blanket

High Temp.

Tank blanket is above the defined high alarm limit

Error

Type

Alarm

Cause

Broken contactor

Defective RTD

Solution

Replace contactor

Replace RTD

WSC0

Invalid

Setpoint

Request

Invalid Gel

Timer

Definition

Alarm

Defective High Power

Temperature Control

Module

Loose connections

Replace High Power Temperature Control Module

Tighten connections

WMC6

WMC5

WMC3

WMC1

WMC2

WMC4

WMC7

WMC8

WMH1

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

Unexpected current to relay 1 Alarm

A general fault has occurred within the MCM

Shorted module

Deviation Internal hardware failure

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

The requested controlling value (pressure or flow) is outside the limits of the system

Deviation

The shot that was entered for the gel timer is not a valid shot.

Deviation

This must be fixed before the gel timer will function properly

System incorrectly setup

Shot incorrectly defined

On the ADM go into the setup screens -> System-> and ensure that all pages have properly defined values

Redefine shot with control parameters within the limits of the system

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

Select a different shot or modify existing shot data

The MCM has determined that the gel timer shot will not be able

If you are certain that the shot is within parameters, try running the Learn Mode routine found in the setup to be executed based parameters entered in the ADM screen Calibration. If the error persists, a gel shot with reduced control parameters is required.

100 313997ZAC

Appendix E - System Events

Appendix E - System Events

Event Code and

String

REL00: System Powered On

Triggers

The System was powered on.

REM00: System Powered Off

The System was powered off.

REB00: Stop Button

Pressed

RECH0: Learn Mode

Executed

The Red stop button was pressed on the Advanced Display Module.

A learn mode calibration was successfully completed.

RENN0: Automatic

Cal. Performed

The system was successfully characterized with the Automatic calibration.

RECA1: Red Material

SG Modified

The Red materials specific gravity was modified.

RECB2: Blue Material

SG Modified

The Blue materials specific gravity was modified.

RENC1: Cal. Point 1

Weight Entered

RENC2: Cal. Point 2

Weight Entered

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.

RENC4: Cal. Point 1

Weight Erased

RENC5: Cal. Point 2

Weight Erased

REND0: Ratio Check

Dispense

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.

REA00: Disp.

Occurred (Shot #)

REH00: Gel Timer

Dispense

A dispense has occurred of the given shot number.

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

RER01: Shot Count

Reset

RER02: Seq. Position Count Reset

A counter from the shot counters maintenance page was erased

A counter from the sequence counters maintenance page was erased

RERA1: Red Material

Volume Reset

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

RERB1: Blue Material

Volume Reset

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

RERA2: Red Material

Weight Reset

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

RERB2: Blue Material

Weight Reset

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

RERA3: Red Cycle

Count Reset

RERB3: Blue Cycle

Count Reset

REQU1: Settings

Downloaded

The resettable cycle counter for the

Red pump was reset to zero.

The resettable cycle counter for the

Blue pump was reset to zero.

The system settings were successfully transferred from the ADM to a

USB drive.

Event Code and

String

REQU2: Settings

Uploaded

REQU3: Language

Downloaded

REQU4: Language

Uploaded

REQU5: Logs Downloaded

REAR0: Night Mode

Recirc On

REBR0: Night Mode

Recirc Off

Triggers

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

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

The custom language file was successfully transferred from the USB drive to the ADM.

The Error/Event and Shot data logs were successfully transferred from the

ADM to a USB drive.

While in night mode the system has automatically entered a low circulation mode and attempted to turn on all enabled conditioning zones.

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

313997ZAC 101

Appendix E - System Events

102 313997ZAC

Appendix F - USB Operation

Appendix F - USB Operation

Overview

There are 3 main uses for the USB on a GMS

system

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

• Ability to download, modify, and upload custom language files

• Ability to download and upload system configurations

• This data includes most user selectable and user configurable settings.

• This data does not include pump counters, error and event logs, shot and sequence counters

USB Options

The only options for USB on the ADM are in

Advanced

Screen 4 , see page 81.

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 (DISP-

TEXT.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.

313997ZAC 103

Appendix F - USB Operation

Log Files, Folder Structure

F IG . 24: 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 is 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.

104 313997ZAC

Example 2-JOB File

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

Appendix F - USB Operation

Example 3-SYSTEM File

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

313997ZAC 105

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 SET-

TINGS.TXT file will be located in the “DOWNLOAD” folder.

NOTICE

The user should never attempt to modify the SET-

TINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified setup file.

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.

2.

Plug the USB stick-drive into a computer.

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.

106 313997ZAC

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 DISP-

TEXT.TXT file will be located in the “DOWNLOAD” folder.

2.

Plug the USB stick-drive into a computer.

3.

Navigate to the DOWNLOAD folder.

4.

Copy the DISPTEXT.TXT file from the DOWNLOAD to your computer.

5.

Use any data processing software such as Excel to edit the DISPTEXT.TXT file. When done editing save the file as the “Unicode Text” format. See

Example DISPTEXT.TXT File on page 108.

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.

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.

313997ZAC 107

Appendix F - USB Operation

Example SETTINGS.TXT File

NOTICE

The user should never attempt to modify the SET-

TINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified setup file.

Example DISPTEXT.TXT File

108 313997ZAC

Appendix G- Temperature

Temperature Displayed and

Actual Material Temperature

For HFR systems which have heat zones installed

(Inline, tank or Hose heaters), to prevent excessive material temperatures when the material flow is 0 (not moving), the zone temperature sensors are installed near or touching the heating elements of the respective zone. Because of this, the temperature reading displayed on the HFR ADM module may be affected by the heating element of the zone, especially if the machine is idle or stalled to pressure. For these situations, the temperature displayed (on the ADM run Status Screen), may be higher than the actual material temperature. If the ADM displayed material temperature accuracy is critical for the respective manufacturing process, it is recommended that a manual or semi-automatic circulation system be added to a stall to pressure type HFR

(P2/Fusion, MD2, EP, Auto-Fusion, … dispense valve options).

Appendix G- Temperature

313997ZAC 109

Appendix H- Circulation

Appendix H- Circulation

Manual and Semi-Automatic

Circulation Feature

A manual or Semi-Automatic circulation feature has been added to HFR product which allows the user to circulate the materials back to the tank at low pressure, hence enabling the system to heat or material condition the 2 component materials prior to a dispense. The feature can also be used to lower the pressure in the dispense hoses when the machine is put into the circulation mode. The feature is intended to be used for HFR systems which use standard non-recirculating dispense valve options

(MD2, P2/ Fusion, Auto-Fusion, EP, …). The feature is available on HFR systems with logic versions 1.10.001 or later.

Two circulation kit options are available with the standard

HFR product; A Manual and Semi-automatic version.

Manual Circulation Feature

This version uses the Graco circulation kits. Part numbers 24D107, 24E379, or equivalent hardware is recommended. The circulation kits will provide a return fluid path from the HFR output manifold back to the corresponding material tanks.

This method puts the system into circulation mode by manually putting the over pressure/ circulation valves on the dispense manifold into the circulation position (as indicated below), to divert the blue and red materials back to their supplies.

Semi-Automatic Circulation

Feature

This version uses the Graco circulation kits, part numbers 24N486, 24N487. These kits contain externally controlled valves, and the valve control solenoid kit part number 24N990. These circulation kits are intended to recirculate the two material paths from the dispense valve back to the material supplies. This method keeps

the F IG . 25 Manifold valves in the dispense positions.

This method allows the user switch between dispense and circulation modes using the ADM, or an external robot or PLC control.

If Semi-Automatic circulation kits are installed to recirculate from the dispense valve back to the supplies, the user will need to add the corresponding insulated return path hoses, which are not part of the kits.

If this method is used, the “HFR Circulation Valves

Installed” check box option on setup Advanced #6 screen

will need checked, as indicated in F

IG

. 26.

F IG . 26: HFR Setup Advanced #6 Screen - Circulation

Options

F IG . 25: HFR Manifold Valves in the Manual

Circulation Positions

110 313997ZAC

Appendix H- Circulation

Semi-Automatic Circulation Kit - 24N486, 24N487

207

206

210

211

212

205

215

216

4

201

202

2 Apply pipe sealant to all male threads as needed prior to assembly.

4

Torque to 8 ft-lb (11 N•m).

F IG . 27:

203

204

208

209 ti19957a

313997ZAC 111

Appendix H- Circulation

Ref Part

201 556762

202 16C509

203 6308-28

204 103475

205 24P005

206 158683

207 100206

208 6310-200

Description

CONNECTOR, #4 jic 1/4 pm

HOSE, assy, ss brd, 1/4 x 24, ss

FITTING, elbw, 90°, jic 04 x 1/2 npt, mm, m

FITTING, tee, pipe

VALVE, endure, amb or temp cond, 1

FITTING, elbow, 90 deg

BUSHING, pipe

ADAPTER, jic(05) x 1/2 npt, m ms

94/0653/99 ADAPTER, jic06 x 1/2 npt, mm, ms, 3k

209 262175

262176

HOSE, A, 10 ft (3 m), 1/4, moisture-lok, ms

HOSE, B, 10 ft (3 m), 1/4, moisture-lok, ms

210 122963

117506

211 124281

212 246477

215 124313

216 100016

ADAPTER, swivel, jic05 x 1/4 npt, fm, ms, 6

FITTING, swivel, 1/4 npt x #6 jic

FITTING, cplg, 1/2 npt x 1/4 npt, ff, ms

KIT, accessory, return tube

SCREW, shcs, m6-1 x 16 mm, sst

WASHER, lock

Quantity

24N486, KIT, circulation, cs, pu, a

24N487, KIT, circulation, cs, pu, b

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

4

1

1

1

4

4

112 313997ZAC

Appendix H- Circulation

Solenoid Valve (Manual) - 24N990

316

312

302

312

315

305

306

313 ti19958a

1

Apply pipe sealant to all male threads prior to assembly.

308

309

301

307

303

F IG . 28: HFR Semi-Automatic Valve Kit

313997ZAC

304

113

Appendix H- Circulation

Ref Part

301 120900

302 108638

303 114158

304 121022

305 121021

306 123395

307 112698

308 115968

309 GC2107

312 114339

313 124876

315 120953

316 299971

Description

VALVE, solenoid, 3 way

FITTING, pipe, tee

FITTING, adapter, y

FITTING, elbow, male, 1/4 npt

MUFFLER, 1/4 npt

HARNESS, pwr valve, tank

ELBOW, male, swivel

SCREW, cap, socket head

WASHER, lock, spring, #8

FITTING, union, swivel, 1/4 npt, sst

SPACER, standoff, 1.5 lg, 8-32 thrd

CONNECTOR, splitter

HOSE, 1/4 x 2 ft (0.6 m) (msf) air

Quantity

3

3

2

2

1

4

3

1

1

1

1

2

2

114 313997ZAC

Appendix H- Circulation

Circulation Feature Operation

To implement the feature, a soft key option on the main

Operator mode run screen has been added (“ illustrated below.

”), as

If recirculating the material is desired, the user will need to stop the dispense, then press the l circulation option

(“ ”). If selected, the user will be given the option to select a flow rate for the circulation dispense, as indicated below. The manual circulation feature will only operate in flow mode, regardless if the user is dispensing in constant pressure or flow.

F IG . 29: Main Operator Mode Run Screen, with

Circulation Option.

F IG . 31: Main Operator Mode Run Screen, with

Circulation Option Selected.

As illustrated in F IG . 29, the HFR is configured to dis-

pense in constant pressure mode, which while dispensing will appear something like the following:

F IG . 30: Main Operator Mode Run Screen,

Dispensing in Constant Pressure Mode.

After the desired flow rate is entered in the field indicated, if the full manual configuration is used, the circulation valves on the dispense manifold will need to be

put into the circulation position, as indicated in F IG . 25. If

the HFR has the semi-Automatic kit installed, the HFR will configure the circulation valves to the circulation position automatically after the “ ” key is selected.

The user can now circulate the material by pressing the dispense key (“ ”), pressing the footswitch, and requesting dispense from either the CGM or DGM interface. A manual circulation dispense will circulate the materials, apply heat (if necessary), and not command the dispense valve to open.

Furthermore, corresponding error generation logic is turned off (cavitation, pressure imbalance, off ratio, etc.) since material is not being dispensed. Also, material counters are not incremented since material is not being dispensed.

313997ZAC 115

Appendix H- Circulation

While the pumps are moving material in circulation mode, the main run screen will appears like the following:

F IG . 32: Operator Mode Run Screen while Manually

Circulating Material.

Just like any Operator mode dispense, the user has the option to change the rate of circulation, without stopping the pumps. The user simply has the change the flow rate set point value, as indicated below.

F IG . 33: Changing Flow Rate for a Manual Circulation

Dispense

116 313997ZAC

Technical Data

Technical Data

Maximum Fluid Working Pressure . . . 3000 psi (20.7 MPa, 207 bar)

Maximum Fluid Temperature . . . . . . . 190°F (88°C)

Fluid Inlet Feed Pressure Range . . . . 50 psi (0.35 MPa, 3.5 bar) to 250 psi (1.75 MPa, 17.5 bar)

Fluid Inlets . . . . . . . . . . . . . . . . . . . . .

Component A (Red): 1/2 npt(f)

Component B (Blue): 3/4 npt(f)

Fluid Outlets . . . . . . . . . . . . . . . . . . . .

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

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

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

Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . 1/4 nps

Air Inlet Pressure . . . . . . . . . . . . . . . . 40 psi (280 KPa, 2.8 bar) to 100 psi (0.7 MPa, 7 bar)

Line Voltage Requirement . . . . . . . . .

230V / 1 phase and 230V / 3 phase Models: 195-264V, 50/60 Hz

400V / 3 phase: 360-440V, 50/60 Hz; see

400 V Power Requirements , page 4

Amperage Requirement . . . . . . . . . . . See

Models on page 4

Sound Power . . . . . . . . . . . . . . . . . . . 93 dB

Heater Power

(A (Red) and B (Blue) heaters total, no hose, Heated HFR Models only) . . 12 kW

Hydraulic reservoir capacity . . . . . . . . 9 gal. (34 liters)

Recommended hydraulic fluid . . . . . . Citgo A/W Hydraulic Oil, ISO Grade 46

Weight . . . . . . . . . . . . . . . . . . . . . . . .

Units with 12 kW Heaters: 868 lb (394 kg)

Units without heaters: 634 lb (288 kg)

Wetted Parts . . . . . . . . . . . . . . . . . . . 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.

313997ZAC 117

Motor Control Module Technical Data

Motor Control Module Technical Data

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.

118 313997ZAC

Dimensions

47.5 in.

(1210 mm)

59.8 in.

(1520 mm)

Motor Control Module Technical Data

34.1 in.

(870 mm)

313997ZAC

E

D

Front

Right

Bolt Mounting Pattern and

Dimensions

Ref

D

E

Type of Base

No Pallet

24 in.

(610 mm)

15 in.

(381 mm)

Pallet

32.4 in.

(823 mm)

30.3 in.

(770 mm)

119

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 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 313997

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision ZAC, August 2016

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