Graco EFR User Manual Download

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3A6165J

Instructions - Parts

EFR

Electric Fixed-Ratio Proportioner

For use with two-component sealant and adhesive materials. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

2000 psi (13.8 MPa, 138 bar) Maximum Fluid Inlet Pressure
3500 psi (24.1 MPa, 241 bar) Maximum Fluid Outlet Pressure

See page 3 for model information.

Important Safety Instructions

Read all warnings and instructions in this
manual and in related manuals before
using the equipment. Save these instruc

tions.

Summary of Contents for EFR

Page 1: ...oved for use in explosive atmospheres or hazardous locations 2000 psi 13 8 MPa 138 bar Maximum Fluid Inlet Pressure 3500 psi 24 1 MPa 241 bar Maximum Fluid Outlet Pressure See page 3 for model informa...

Page 2: ...it 42 Inlet Regulator Kits 42 Inlet Fittings 42 Outlet Fittings 42 Additional Accessories 42 Advanced Display Module ADM Operation 44 ADM Screen Overview 45 Home Screen 45 Voltex Dynamic Mix Valve Run...

Page 3: ...umps EFR First Second and Third Digits Digit 4 Digit 5 Digit 6 Digit 7 Digit 8 System Designator Voltage Options Control Options A Side Pump B Side Pump Inlet Outlet Fitting Options EFR Electric Fixed...

Page 4: ...ific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more th...

Page 5: ...static sparking 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 cl...

Page 6: ...rn 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 replace...

Page 7: ...be in the B Blue side Cross contamination can result in cured material in fluid lines which could cause serious injury or damage equipment To prevent cross contamination Never interchange component A...

Page 8: ...M Driver Communication and I O Connectors N Lift Ring P Pressure Relief Drain Tubes R A Side Outlet Drain Relief Valve S B Side Outlet Drain Relief Valve Required components supplied with the system...

Page 9: ...sories not supplied with the proportioner Optional accessories not supplied with the proportioner FIG 2 Typical Installation WL D Dispense Valve A Supply System B Supply System Power Cord with User Su...

Page 10: ...Sys tem Status Indicator AB Condi tions on page 11 for details AC Stop Stop all system processes Is not a safety or emergency stop AD Soft Keys Defined by application using ADM AE Cancel Cancel a sele...

Page 11: ...Off Yellow Flashing Setup Mode System Off ADM Module Status LEDs AN Conditions USB Module Status LEDs AL Conditions FIG 4 ADM Component Identification Rear AR AK AJ AL AP AN AM AS ti12363a1 Module St...

Page 12: ...ircuit protected with a circuit breaker Connect Power 1 Cut power cord wires to the following lengths Ground wire 6 5 inches 16 5 cm Power wires 3 0 inches 7 6 cm Add ferrules as necessary See FIG 5 2...

Page 13: ...between the power disconnect switch and the electric driver See Wiring Diagrams on page 65 NOTE Do not attach the ground wire to the grounding lug locknut on the outside of the electric driver See Gro...

Page 14: ...ory pre filled with oil The temporary unvented cap PX prevents oil leaks during shipment This temporary cap must be replaced with the vented oil cap PY supplied with the equipment before use NOTE Prio...

Page 15: ...age 36 The B pump larger volume should be located on the side of the driver electrical con nections Use spring clamps 106 provided with pumps to couple the pump to yoke adapt ers 216 d Install adapter...

Page 16: ...outlet hoses together to protect them from damage Flushing Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing new fluid Use the lowest possible pre...

Page 17: ...h C to the OFF posi tion 2 Perform the Pressure Relief Procedure on page 20 3 Loosen the four screws and remove the pump yoke shroud F 4 Verify the correct pumps are mounted for your mix ratio by volu...

Page 18: ...n the adapter rod DA then use the supplied tool DT to loosen the serrated yoke nut DB above the yoke DC 5 Loosen the three nuts D2 below the driver tie rods 6 Grab the output shaft and slide the posit...

Page 19: ...y systems to load the system h To prime the pump cycle the pump a few times or until air free fluid dispenses See Home Screen on page 45 for instructions on priming the pump through the ADM i Hold the...

Page 20: ...your materials for compatibility with zinc plating and sulfur before reusing any material that passed through them as it may inhibit curing 1 Press the enable disable key on the ADM to disable the EFR...

Page 21: ...al viscosity and flow rate 9 Once material is flowing from the drain hose slowly decrease pressure on the inlet regulator until flow stops 10 Gradually increase pressure to the inlet regulator until m...

Page 22: ...ar the halfway point of the sight glass when the sprayer is not running If oil is low open fill cap FB and add Graco Part No 16W645 ISO 220 silicone free synthetic EP gear oil See FIG 11 The oil capac...

Page 23: ...e halfway point of the sight glass The oil capacity is approximately 2 0 2 2 quarts 1 9 2 1 liters Do not overfill 5 Reinstall the fill cap Bearing Pre Load See FIG 11 The bearing pre loads FD are fac...

Page 24: ...to the OFF position 13 Couple the pumps to the yoke adapter using the spring clamps removed previously 14 Replace the pump yoke shroud F 15 Turn the power disconnect switch C to the ON position and re...

Page 25: ...Display Modlule No or incorrect amount of material dispensed from either side Ball Valve closed if Installed Open supply ball valve Supply Empty Add fluid Air in Material Prime the machine Significant...

Page 26: ...sket Erratic pump movement Pump cavitation Feed pump pressure is too low Adjust pressure to maintain 100 psi 0 7 MPa 7 bar minimum Pump output low Obstructed fluid hose or dispense valve fluid hose ID...

Page 27: ...Tank Stand Verify CAN cable is plugged in Remove and reconnect CAN cable taking care not to cross thread the connector nut CACA Comm Error Advanced Display System is unable to communicate with Advanc...

Page 28: ...ify host is communicating DDDA Pump Cavitation A Out of material Verify A material supply Check valve not working properly Inspect and clean A side check valve Check for leaking seals or damage to the...

Page 29: ...aking Bad level sensor Replace level sensor L6TA Red Auto Refill Timeout No material is actually being fed Make sure the feed pumps are operating properly Loose level sensor connection Check for loose...

Page 30: ...let A Pressure A is below user defined dispense pressure limit Check feed system for low or empty material Increase dispense rate Check pressure settings on setup screen P1DB Low Pressure Alarm Outlet...

Page 31: ...eck feed system for low or empty material Check feed system filters for blockage if installed Check for blockage in feed system Check pressure settings on setup screen P3FA High Pressure Deviation Inl...

Page 32: ...dispense pressure limit Inspect for hardened material or obstructions to flow Attempt to purge material at a reduced flow rate Reduce operating pressure by reducing flow rate and or restriction in th...

Page 33: ...flow rate Reduce operating pressure by reducing flow rate and or restriction in the hose and valve P4DC High Pressure Alarm Outlet A Pressure A exceeds user defined dispense pressure limit Inspect fo...

Page 34: ...or connection to Motor Control Module Check to make sure that the pressure sensor is properly connected to the connector 6 of the Fluid Control Module FCM Faulty sensor Replace the Pressure Sensor P6F...

Page 35: ...e Motor AC voltage is too low Check wire connections and verify line voltage is within specification V4NX High Voltage Motor AC voltage is too high Verify line voltage is within specification WBNX Enc...

Page 36: ...Parts 36 3A6165J Parts EFR Common System Parts 119 125 121 122 131 132 128 123...

Page 37: ...Parts 3A6165J 37 Fluid Section 106 110 112 117 116 115 114 113 103 108 107 109 107 104 116 115 114 113 117 A Side Pump B Side Pump 208 105 105 219...

Page 38: ...3 ft lbs Torque to 67 81 N m 50 60 ft lbs Torque adapters to 122 135 N m 90 100 ft lbs Torque to 196 210 N m 145 155 ft lbs Press fit bushings into sleeve until flush Orient yoke group as shown for as...

Page 39: ...1 25N520 DRIVER 1 202 17E535 TIE ROD 3 203 25E099 FRAME 1 204 PLATE 1 205 112395 SCREW 4 206 RATIO PLATE 1 207 154636 WASHER 3 208 113980 NUT 9 209 262468 ROD tie 14 25 long 4 210 16D450 ADAPTER 1 211...

Page 40: ...E103 1 221 SCREW 114182 4 114182 8 222 JUNCTION BOX 1 1 223 SCREW 117080 4 117080 4 224 SWITCH disconnect 40A 123970 1 123970 1 225 COVER junction box 1 1 226 SCREW 113768 4 113768 4 227 KNOB disconne...

Page 41: ...il able at no cost 231 CORD GRIP strain relief 3 4 14 NPT male cable range 0 35 0 63 in 8 9 16 mm 121171 1 121171 1 232 BUSHING strain relief 1 126881 1 233 LABEL safety danger 25E178 1 234 NUT strain...

Page 42: ...08 m Stainless Steel 15M863 3 4 NPT m x JIC 12 m Stainless Steel 124315 3 4 NPT m x JIC 16 m Stainless Steel Part Description 158683 90 1 2 NPT m x 1 2 NPT f Steel 100206 1 2 NPT m x 1 4 NPT f Steel...

Page 43: ...ateway Module allows the user to control an EFR through an external control device such as a PLC See EFR Communication Gate way Module manual for more information Part Description 25B127 DeviceNet CGM...

Page 44: ...Light is not green press the ADM Power On Off AA button The System Status Indicator Light will illu minate yellow if the machine is disabled Perform the following tasks to fully setup your system 1 Se...

Page 45: ...icon will enter the home screen and allow you to select the active sequence the number of times a sequence is repeated and the purge flow You can also pause stop or start an active sequence once the h...

Page 46: ...prime icon will prime the unit The sequence that will run when the prime icon is pressed depends on the pressure preset set by the user See Setup Screen 2 on page 51 for information on setting the Pre...

Page 47: ...acceleration Example 500ms half a second to get to the RPM setpoint of 4400 RPM 4 B Valve Status Icon turns green when the dispensing system turns on the valve signal Icon turns grey when dispensing...

Page 48: ...tions available for the shot size including operator mode volume mass weight and seconds NOTE If the user selects seconds for the shot size cal ibration will no longer be an option for the selected sh...

Page 49: ...box Once the external trigger is received the EFR will proceed through the sequence If the user enters the home screen while a sequence including a checked shot size is selected as the active sequence...

Page 50: ...e mode rate units pressure units pressure imbalance alarm and the pump line size and specific gravity of the A and B pumps Dispense Mode The dispense mode can be set to either volume or weight If the...

Page 51: ...own on the home screen or one of the other sequences listed in the drop down menu for the pressure preset Running the pressure preset allows the EFR to learn the running pressure and prime the system...

Page 52: ...otor Speed The RPM s that the motor will run at The Motor RPM Setpoint can be locked out using a pass word Motor Ramp Up Time This changes the amount of time in milliseconds the motor takes to get to...

Page 53: ...e until either the high level sensor sees material or until the refill time out expires The low level deviation will clear when the condition clears An icon is shown on the Run screens to initiate an...

Page 54: ...uage date and time shown on the ADM The user can also set up a password and change the screen saver here Advanced Screen 2 This screen allows the user to view and upgrade soft ware installed on the sy...

Page 55: ...ycles exceeds the number entered in the second column limit field If a non zero number is entered in that field and the corresponding pump or valve cycles exceeds that value the EFR will generate and...

Page 56: ...t recent events are shown 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 sta...

Page 57: ...on USB Plug In Screen This screen will appear when a USB device is plugged into the ADM Here the user can select dates to download data from the ADM to the USB device by pressing the left and right ar...

Page 58: ...rientation of token 5 Turn the power disconnect switch C to the ON position NOTE When the ADM display turns on you may see the following screens 6 Remove token TK 7 Replace token access panel BK 8 Ins...

Page 59: ...4V is ON 0V is OFF System Enable When this digital input pin is ON the EFR system will be active and when this digital input pin is OFF the EFR system will be inactive 4 6 Analog Input 0 10V Analog Ra...

Page 60: ...ollowing table shows the wire color codes for the M12 8 pin bare leads 13 1 ft 4 m pigtail cable 128441 supplied with the EFR for I O integration from EFR connector 4 Connector 3 Connector 4 Pin Color...

Page 61: ...em can also be put into the active state by turning the system enable I O pin ON Once the system is in the active state dispense com mands can be sent over the I O pins This can be seen in the diagram...

Page 62: ...e sequence Automation Inputs EFR Outputs System Ready Alarm Active Valve Signal Automation Outputs EFR Inputs Trigger Signal Foot Switch System Enable Sequence Select Bits optional command EFR State S...

Page 63: ...nding the sequence select bits is optional If the sequence select bits are not sent the EFR will use the current selected sequence Automation Inputs EFR Outputs System Ready Alarm Active Valve Signal...

Page 64: ...desired connect cable 17Z431 to connector 4 of the EFR Sequence Number Selected Sequence Selection BIT0 Conn 1 Pin 1 Sequence Selection BIT1 Conn 1 Pin 2 Sequence Selection BIT2 Conn 1 Pin 4 Sequence...

Page 65: ...Wiring Diagrams NOTE See the APD20 Advanced Precision Driver Instructions manual for driver internal wiring Power Wiring X5 H5 X4 H4 X1 X3 X6 X9 H1 H3 H6 H9 Customer Ground Customer Power In Customer...

Page 66: ...Machine Mounting Holes 21 5 in 55 cm For 3 8 in 10mm Mounting Fasteners B Machine Mounting Holes 21 1 in 54 cm C Total Machine Height 22 in 56 cm D Total Machine Length 50 in 127cm E Total Machine Wi...

Page 67: ...t hoses is 3500 psi 24 1 MPa 241 bar If hoses valves or accessories rated at less than 3500 psi are installed the system maxi mum fluid working pressure becomes the rating of the hoses The minimum pre...

Page 68: ...Technical Specifications 68 3A6165J California Proposition 65 CALIFORNIA RESIDENTS WARNING Cancer and reproductive harm www P65warnings ca gov...

Page 69: ...Technical Specifications 3A6165J 69...

Page 70: ...ade 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...

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