Troubleshooting. Graco 313997P - HFR

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Troubleshooting. Graco 313997P - HFR | Manualzz

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 313997P

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

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

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

Hoses near system are warm, but hoses downstream are cold

Temperature control alarm

Shorted connection or failed hose heating element

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 88

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.

313997P 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 313997P

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

313997P 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

313997P

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

313997P 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 313997P

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

313997P 65

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