Graco HFR Setup And Operation Download

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313997A

ENG

Setup - Operation

HFR

™

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

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

See page 4 for model information and maximum
working pressure.

Patent Pending

Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.

24C352_313998_7e

Summary of Contents for HFR

Page 1: ...ng sealants and adhesives and polyurethane foam For professional use only Not for use in explosive atmospheres See page 4 for model information and maximum working pressure Patent Pending Important Sa...

Page 2: ...y Module ADM 26 Fluid Control Module FCM 29 Temperature Control Module Heated HFR Only 30 Setup 33 EP Gun 37 MD2 Valve 37 Vacuum De gas 38 Vacuum De gas and Vacuum Auto Fill 39 Advanced Display Module...

Page 3: ...3A0020 HFR Hydraulic Actuator Instruc tions Parts Feed System Manuals 3A0238 Dispense Head Hydraulic Power Pack Instructions Parts 3A0235 Feed Supply Kits Instructions Parts 3A0395 Feed Tanks Instruct...

Page 4: ...e is already setup for the lower 2000 psi 13 8 MPa 138 bar working pressure by Graco If the machine was pur chased without hoses and aftermarket hoses rated less than 3000 psi are to be installed see...

Page 5: ...Steel Ref 2 Part Voltage 1 24C680 230V 1 phase No Heat 2 24C681 230V 1 phase Maximum of Two 6 kW Primary Heater and One Zone of Hose Heat 3 24C682 230V 3 phase No Heat 4 24C684 230V 3 phase Maximum o...

Page 6: ...4D129 Single Hose 1 1 3 8 x 3 8 10 ft Carbon Steel 3500 psi CG 24D130 Single Hose 1 1 3 8 x 3 8 25 ft Carbon Steel 3500 psi CH 24D131 Single Hose 1 1 3 8 x 3 8 50 ft Carbon Steel 3500 psi DA 262126 He...

Page 7: ...eel 3500 psi GG 262249 Hose 25 ft 1 4 in Stainless Steel 3500 psi GH 262251 Hose 50 ft 1 4 in Stainless Steel 3500 psi GJ 262253 Hose 5 ft 1 4 in Stainless Steel 3500 psi GK 262255 Hose 10 ft 1 4 in S...

Page 8: ...el 262247 Unheated Hose 10 ft 3 8 Stainless Steel 262182 Unheated Hose 5 ft 3 8 Mild Steel 262184 Unheated Hose 10 ft 3 8 Mild Steel 262253 Unheated Hose 5 ft 1 2 Stainless Steel 262255 Unheated Hose...

Page 9: ...ion MP 1 1 Only 0 057 CS02RD Fusion CS 1 1 Only 0 052 24D500 Applicator MD2 1 1 Soft Carbon Steel 24D501 Applicator MD2 1 1 Soft Carbon Steel Electric 24D502 Applicator MD2 1 1 Soft Carbon Steel Lever...

Page 10: ...ly 2 247868 L Head Only 2 4 247869 L Head Only 3 2 247870 L Head Only 3 6 247871 L Head Only 4 2 247872 L Head Only 5 247873 L Head Only 5 6 247874 L Head Only Description Part For Use With Applicator...

Page 11: ...EP 250 Iso Side Orifice 0 71 mm Iso Orifice 24D231 EP 250 Iso Side Orifice 0 89 mm Iso Orifice 24D232 EP 250 Iso Side Orifice 0 99 mm Iso Orifice 24D233 EP 250 Iso Side Orifice 1 07 mm Iso Orifice 24...

Page 12: ...Flow Meter with 90 degree sensor 0 02 to 1 0 gpm 75 to 3800 cc per min 289814 One G3000HR Flow Meter with 90 degree sensor 0 02 to 1 0 gpm 75 to 3800 cc per min 244039 One Coriolis Flow Meter 0 01 to...

Page 13: ...mp with Carbon Steel Fluid Plumbing 246898 2 1 Supply Pump with Carbon Steel Fluid Plumb ing 248825 5 1 Monarch Pump with Carbon Steel Fluid Plumbing 24D100 Husky 515 Pump with Stainless Steel Fluid P...

Page 14: ...nsulation 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...

Page 15: ...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 equ...

Page 16: ...l 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 n...

Page 17: ...tially 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 isoc...

Page 18: ...ver use solvent on one side if it has been contam inated from the other side Always lubricate threaded parts with ISO pump oil or grease when reassembling Foam Resins with 245 fa Blowing Agents Some f...

Page 19: ...ispense Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines H Waste Container J Fluid Supply Lines K Feed Pumps L Agitator M Desiccant Dryer N Bleed Lines P Fluid Manifold FIG 1 B C D E F K J ti782...

Page 20: ...ent 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 Hy...

Page 21: ...odel shown with shrouds removed ti9880a1 GA GB SB FB BB HB HA BA FA SA Fluid Manifold FM Detail LR PA PB FV FT FP FS AA HP FM PD HT MA FS FP FT MP PH TA TB LS PI PO PR PS Rear View Primary Heater PH D...

Page 22: ...eakers for protection of the second ary side of the heated hose transformer are located inside the frame See the parts list for the installed pri mary hose heat option See Ref 5 of the product config...

Page 23: ...echnical Data on page 93 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 24...

Page 24: ...n see reference MA in FIG 2 on page 21 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 FIG 4 MCM Component Identification A...

Page 25: ...ensor Dispense Valve Solenoid and Footswitch 3 Oil Temperature Sensor 5 Electric Motor Temperature Sensor 6 LVDT 7 Three way Splitter to Hydraulic Directional Valve Oil Overtemperature Switch 8 Pressu...

Page 26: ...Light Displays system status CC Stop Stop all system processes Is not a safety or emergency stop CD Soft Keys Defined by application using ADM CE Cancel Cancel a selection or number entry while in th...

Page 27: ...atus LEDs CP Accessory Cable Connections CR Token Access Cover CS Battery Access Cover System Status Indicator CB Conditions Green Solid Run Mode System On Green Flashing Setup Mode System On Yellow S...

Page 28: ...ational components of each screen For details regarding the user interface display see Advanced Display Module ADM Operation page 40 FIG 7 Main Display Components Current date and time Current screen...

Page 29: ...ent Identification 313997A 29 Fluid Control Module FCM Key A Fluid Control Module B Base C Module Connection Screws D Access Cover E Module Status LEDs F CAN Connectors FIG 8 ti12337a1 ti12336a1 A E B...

Page 30: ...t Power Connection 6 CAN Connections 7 Rotary Selector Switch Token Access 1 Overtemperature Switch Connection 2 RTD Temperature Sensor Connection 3 Output Power Connection 4 DC Output Connection 5 In...

Page 31: ...independent temperature con trol 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 Hose Heater A Red...

Page 32: ...ollowing tables High Power Module Rotary Switch Settings Low Power Module Rotary Switch Settings FIG 11 High Power Module Rotary Switch Location Low Power Module Rotary Switch Location S S ti12360a ti...

Page 33: ...3 as applicable Connect green to ground GND NOTICE Bolt HFR to original shipping pallet before lifting Installing this equipment requires access to parts which may cause electric shock or other seriou...

Page 34: ...to the 1 2 npt f swivel on the component A Red inlet valve 5 Connect pressure relief lines a Recommended Connect high pressure hose R to relief fittings BA BB of both PRES SURE RELIEF DISPENSE valves...

Page 35: ...vent connection errors NOTE Gun fluid manifold hose adapters allow use of 1 4 in and 3 8 in ID fluid hoses To use 1 2 in 13 mm ID fluid hoses remove adapters from gun fluid manifold and install as ne...

Page 36: ...ding continuity when flushing or relieving pressure hold a metal part of dis pense gun firmly to the side of a grounded metal pail then trigger gun 12 Check hydraulic fluid level Hydraulic reservoir i...

Page 37: ...system LED should be solid green 6 Check that heat zones are on and temperatures are on target see Status Screen on page 54 7 Check fluid pressure display and adjust as neces sary 8 Check fluid press...

Page 38: ...is ready to dispense Vacuum De gas 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...

Page 39: ...buttons and or to select the tanks to refill 11 Press the Initiate Auto Refill button or the Enter button to confirm 12 If necessary press the Abort Cancel button to cancel auto refill 13 Continue to...

Page 40: ...On Off CA button The System Status Indicator Light will illu minate yellow if the machine is disabled Setup Screens The ADM will start in the Run screens at the Home screen From the Run screens press...

Page 41: ...Mode selections If manual mode is selected shot number and dispense detail columns are shown If Automatic mode is selected a fourth col umn appears for editing the delay before the next sequence posit...

Page 42: ...ows 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 63 for how to use this screen to calibrate the mach...

Page 43: ...n page 63 for more information Pump sizes and inlet pressures must be entered on this screen If pump sizes and inlet pressures are not entered prop erly system performance will be affected The inlet p...

Page 44: ...n used to define the mix head operating parameters See the Mix Head Operating Details Screen on page 44 Selecting the dispense valve will limit the system maxi mum working pressure to the maximum work...

Page 45: ...w 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...

Page 46: ...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 When the high level sensor is not sat...

Page 47: ...e 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 Setting the refill time out to a va...

Page 48: ...on and off periodically Press the Enter Screen button and adjust the on and off durations as desired When the system is in Night Mode and in an on duration the system will circulate in low pressure T...

Page 49: ...he system will disable dispensing on system power up until all enabled chiller zones have reached their setpoint Operator Mode Cavitation Alarm Check this box to enable cavitation alarms in Operator M...

Page 50: ...ve errors If tanks are installed in the system the fill level is shown on each tank To select an operating mode press the Select Mode button repeatedly until the desired mode is shown then press the E...

Page 51: ...ton to begin dispensing Icon Function 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 Move L Head...

Page 52: ...allows users to set a pressure or flow rate to dispense material without using predefined shot infor mation Pressure or flow rate availability is dependent on the Control Mode selection see System Scr...

Page 53: ...t Operator Dispense Setting Lock Dispense Valve Closed Press to lock the valved closed during a dispense Used to circulate through the material manifold back to the tank the Pressure Relief Dispense V...

Page 54: ...urn the zone off To turn all zones on off 1 Press to enter the Conditioning Control screen 2 Press the to turn on all zones When all zones are on the button will be selected Press the button again to...

Page 55: ...for a detailed description of all of the system events Maintenance Screen 1 This screen displays historical information for each pump in the system The Batch counters are resettable and count both mat...

Page 56: ...to a time where all logs can be downloaded probably the launch date 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 AD...

Page 57: ...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 two log files They are formatted as csv com...

Page 58: ...USB Operation 58 313997A Example LOG01 File The LOG01 file is the Errors and Events log file Example LOG02 File The LOG02 file is the Shot Data Log file...

Page 59: ...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 powe...

Page 60: ...older 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...

Page 61: ...7A 61 Example SETTINGS TXT File Example DISPTEXT 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...

Page 62: ...gun only hold gun fluid manifold over two grounded waste contain ers Open gun fluid valves A Red and B Blue until clean air free fluid comes from valves Close valves j For models with an MD2 Valve onl...

Page 63: ...Dis pense Mode system calibration is complete after the Learn Mode procedure described above However if the system is to be used in a Weight Dispense Mode the Weight Calibration procedure must be fol...

Page 64: ...avigate 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 7 Change pressure imbalan...

Page 65: ...a trigger is installed pulling the trigger will begin a park operation Material will dispense Continue pulling the trig ger until the pump stops moving 2 Press the enable disable key on the ADM to dis...

Page 66: ...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 3 For models with an dispense valve with a safety l...

Page 67: ...system circulate through gun fluid manifold with manifold removed from gun To prevent moisture from reacting with isocyanate always leave the system dry or filled with a mois ture free plasticizer or...

Page 68: ...el and condition refill or replace as needed page 74 Daily Check hydraulic fluid level Weekly Grease circulation valves with Fusion grease 117773 Weekly Verify operation of air drying sys tem to preve...

Page 69: ...tware upgrades 1 Turn off system power at main power switch MP 2 Remove token access panel 3 Insert and press token T firmly into slot There is no preferred orientation of the token 4 Turn system powe...

Page 70: ...1 Ensure system is inactive 2 Remove access cover D 3 Insert and press token T firmly into slot NOTE There is no preferred orientation of the token 4 Turn power on The red LED L will flash until the s...

Page 71: ...tton M for three sec onds and then release The red LED L until the software is uploaded See FIG 22 5 Remove token T when software has successfully uploaded or key token is no longer required NOTE Upgr...

Page 72: ...er switch MP 2 Remove token access panel 3 Insert and press token T firmly into slot There is no preferred orientation of the token 4 Turn on system power at main power switch MP The red indicator lig...

Page 73: ...e at the pump inlet and shut off the appropriate feed pump This prevents mate rial from being pumped while cleaning the screen 3 Place a container under the strainer manifold 59d to catch fluid Remove...

Page 74: ...eck valve to the inlet hose See FIG 27 5 Drain the reservoir and flush it with clean IsoGuard Select fluid 6 When the reservoir is flushed clean fill with fresh IsoGuard Select fluid 7 Thread the rese...

Page 75: ...Material dispensed not cor rect weight Specific gravity of one or more of the two materials has changed since cali bration Run 3 point calibration Check valve malfunction Remove check valve clean or r...

Page 76: ...ouple connection Verify that all FTS connections are snug and that pins of connectors are clean Examine connection of RTD to long green plug on heater control board Unplug and re plug RTD wires cleani...

Page 77: ...et valve ball seat or gasket Pressure relief circulation valve leak ing back to supply Remove return line and determine if flow is present while in SPRAY mode Erratic pump movement Pump cavitation Fee...

Page 78: ...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...

Page 79: ...r high voltage If error persists and performance can no longer satisfy the user requirements the motor will need to be replaced WKH1 High Motor Speed The motor has reached a speed that should not be r...

Page 80: ...rial pumps have not been defined Alarm 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 D5A1 Invalid Learn Mode Data This ca...

Page 81: ...rly configured and connected to the MCM F7D1 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...

Page 82: ...ls on power line filter Voltage should measure between 190 and 264 Vac A8B7 No Red Chiller Current Alarm Cable unplugged loose power Check for loose or disconnected wires or plugs A8B8 No Blue Chiller...

Page 83: ...ld measure between 190 and 264 Vac V4B5 Blue Blanket Overvoltage Alarm V4A3 Red Inline Overvoltage Alarm V4B1 Blue Inline Overvoltage Alarm V4A2 Red Hose Overvoltage Alarm V4B4 Blue Hose Overvoltage A...

Page 84: ...tive High Power Temperature Control Module Replace High Power Temperature Control Module Loose connections Tighten connections T1A6 Red Tank Low Fluid Temp Fluid temperature is below the defined low a...

Page 85: ...valve will likely need replacing Chilled water supply off Turn on chilled water supply Loose or bad connection Check RTD wiring T6A6 Red Tank RTD Fault RTD 1 is giving no or invalid data Alarm Loose o...

Page 86: ...ial Fill tanks with material L122 Blue Low Material Level Deviation Loose broken connection If the tanks appear to have plenty of material check to make sure the level sensor is connected to the prope...

Page 87: ...AB4 Comm Error Blue Hose Alarm Module not programmed Program the module CAA7 Comm Error Red Chiller Alarm Module missing power Check power supply connection CAB8 Comm Error Blue Chiller Alarm Module b...

Page 88: ...ook the gel shot RER01 Shot Count Reset A counter from the shot counters main tenance page was erased RER02 Seq Posi tion Count Reset A counter from the sequence counters maintenance page was erased R...

Page 89: ...CM CS ti12363a1 Module Status LED Signal Description Green on System is powered up Yellow on Communication in progress Red solid ADM hardware failure Red flashing Uploading software Module Status LED...

Page 90: ...LED Status Signal Module Status LED Signal Description Green on System is powered up Yellow on Internal communication in progress Red solid MCM hardware failure Replace MCM Red flashing fast Uploading...

Page 91: ...LED Signal Diagnosis Green on System is powered up Yellow Internal communication in progress Red solid FCM hardware failure Replace FCM Red flashing fast Uploading software Red flashing slow Token er...

Page 92: ...prog ress Red solid Temperature control module failure See Troubleshooting table Red flashing Software is updating Blue light off High Power Module only Temperature control module is off See Troublesh...

Page 93: ...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 Line Voltage Requirement 230V 1 phase and 230V 3 phase Models 195 264V 50 60 Hz 400V 3 pha...

Page 94: ...ations 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...

Page 95: ...Motor Control Module Technical Data 313997A 95 Dimensions 48 in 122 cm 34 in 87 cm 59 150 24C352_1 24C352_3...

Page 96: ...epairs 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 IN...

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Graco HFR, Setup And Operation

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