Graco 3A2806C User's Manual
Contents
1. 10 Install Level Sensors 12 Install Light Tower 13 Setup nre ed ea en 14 Calibrate Barrel Style Level Sensors 14 Set the ADM to Recognize the Feed System Kit 14 Set the ADM to Recognize which Level Sensors are to Operate 15 Set the Level Sensors Output Function 15 St rtup o lil x E 16 Shutdown 1 2 4 EE 16 Pressure Relief Procedure 16 Maintenance 16 Drum Feed Kit Air Dryer 16 Drum Feed Kit Pump 17 Drum Feed Kit Changing Top Drums 17 Install Upgrade Tokens 18 Troubleshooting 19 Repair X TE RECS 20 Level Sensor and Well 20 Electrical Schematics 21 p a cL 22 Drum Feed System 24N816 22 Drum Feed Kit 24 767 24 Electric Panel 24N804 26 4 Drum Rack 01 0955 25 Optional 30 Appendix A ADM Setup Screens Overview 32 Appendix B ADM Run Screens Overview 35 Technical Data 37 Graco Standard Warranty 38 3A2806C Related Manuals Component manuals in English Manuals are available at www graco com Manual No Description 3A2175 HFRL and HFRS Se2. Active Errors _ Enable Diagnostic Screen 27 Low Material Disables Dispense Standby O Enable Downloading of USB Logs WI Enable USB Errors T Date of Last Download 2 Press 342806C Setup 3 Ifitis desired to stop dispensing when a low level is sensed select and check Low Material Disables Dispense NOTE Setting this option initiates a deviation condition and disables the machine from operation when there is a low level condition When a low level is sensed the machine will not cycle until the sensor see material A pop up screen on the ADM alerts the operator of the specific level condition 4 Ifitis not desired to stop dispense verify Low Mate rial Disables Dispense is unchecked NOTE This option is the default setting of the system and is set as a deviation condition When a deviation is issued the machine will continue to cycle and will not be affected by the deviation NOTE A low level condition generates a pop up mes sage on the ADM that can only be cleared by the opera tor If the Low Material Disables Dispense option is selected dispensing can resume with a remote start signal when material is replenished and the sensor sees material It is not necessary to clear the ADM to initiate a start unless the ADM is used as the start device 5 Press IJ 15 Startup Startup 1 See Load fluid with feed pumps in HFR operation manual
3. 0 5 28 ON 58 Sn TEF N WN 225 NAN gree WM Seu gt 0 Step 13 r_24n804 Panel view is shown rotated 180 from the installed position 11 Panel Install FlG 6 Install Electrical Panel 3A2806C Installation Install Level Sensors 9 NOTE Lower drum hardware must be installed in an empty drum and then installed on the lower drum rack The drum can then be filled from the cascade feed hose from a full upper drum NOTE There are two possible locations for the low level sensor depending on desired function Install both sen sors in the same location on each chemical side e Low Level Indication Located in the upper to lower drum feed hose Empty Indication Located in the drum to pump feed hose NOTICE Do avoid machine damage install one sensor on each chemical side only 1 Turn main power off 2 Drain drums below the lowest level sensor well NOTE For proper level sensor function the tip of the level sensor well must protrude at least 1 8 in into the tank 3 Route the level sensor wire through the correspond ing well nut CC See Fic 7 for level sensor assem bly view CA 4 cc a i s Wire gt wall 59 CD RC r4 r 24b969 3A0395a 7a 2 FiG 7 Level Sensor Assembly where the well is inserted Note these measure ments as they will be need later 5 Being c
4. 2 Open feed pump air regulator 3 Open feed pump bleed type master air valve 4 Adjust air to feed pump with needle valve NOTE e Cold viscous material may be difficult to prime Use needle valve to reduce air flow to motor e Do not plug or shut off pump fluid outlet when priming Fluid must be free to flow through pump to prime e To increase pump flow rate and reduce icing remove pump muffler This will increase exhaust noise 5 Never let pump run when drum is empty A dry pump can accelerate and damage itself If pump is running too fast stop it immediately Check and refill fluid supply or flush with compatible solvent Always prime entire system to remove any air Do not let material harden in pump 16 Shutdown See Shutdown in system operation manual Close feed pump bleed type master air valve Pressure Relief Procedure 1 If the optional drum feed kit is being used remove the air pressure from the Husky pump 2 See Pressure Relief Procedure in system opera tion manual Maintenance Wo Drum Feed Kit Air Dryer Replace silica gel units when the desiccant color or moisture indicator has changed color from Blue mean ing dry to Pink meaning wet There is a sight window on the side of the canister to allow viewing of the desiccant color 1 Loosen the clamp ring and remove the desiccant canister from the rubber housing 2 Apply tape over the both ends of th
5. 4 minutes Refill Sensor Type Low Temp Sensor Low Temp Sensor 32 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 Conditioning No Active Errors Date Format mmiddiyy fe Date 06 18 Time 11 07 Password 0000 Screen Saver _5 minutes O Silent Mode e Time formatted in 24 hour time Shots ta Language English v e Password Enables the setup screens to be pass word protected Entering 0000 disables the fea ture 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 06 18 12 11 07 Standby Conditioning m No Active Errors Volume Units Weight Units BE Pressure Units ps Te Temperature Units PF Flow Units Volume v Rate Units second v Shots 3A2806C Advanced Screen 3 06 18 12 11 07 4 Advanced 5 5 Standby m No Active Errors L Disable Dispensing From Display tal L Disable Modifying Temp Setpoint O Disable Operator Mode Adjustments L Temperature Alarm Disables D
6. Red flashing A deviation exists Red on The system is shut down due to an alarm occur ring Errors include advisories deviations or alarms so green will only be on when none of these occur A yellow light can be on atthe same time as red flashing or solid on when an advisory exists at the same time as a devi ation or alarm Messaging will be viewable on the ADM to determine the specific error code 3A2806C 7 Grounding Grounding El WAS The equipment must be grounded Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit Pump follow instructions in separate feed pump man ual supplied HFR see operation manual Fluid supply container follow local code Solvent pails used when flushing follow local code Use only conductive metal pails placed on a grounded surface Do not place the pail on a nonconductive sur face such as paper or cardboard which interrupts grounding continuity To maintain grounding continuity when flushing or relieving pressure hold metal part of the spray gun or dispense valve firmly to the side of a grounded metal pail then trigger the gun or valve Flush Pumps Before Using Aw Flush equipment only in a well ventilated area Do not spray flammable fluids Diaphragm pumps are factory tested with w
7. anchor the rack to the floor with 4 1 2 bolts pro vided by customer and verify all bolt assemblies are tightened before loading the drums onto the rack 3A2806C Ref Part Description Quantity 301 01 0955 A 99 SHELF rack 4 drum 2 302 01 0955 B 99 SUPPORT shelf rack 2 4 drum right 1 303 01 0955 C 99 SUPPORT shelf rack 2 4 drum left 1 304 01 0955 D 99 STRAP stabilizer rack 4 drum 2 305 01 0955 50 RACK 2 4 drum seal hardware 1 3A2806C Parts 31 Appendix A ADM Setup Screens Overview Appendix A ADM Setup Screens Overview For other screen not mentioned refer to the HFRL and HFRS Setup Operations manual 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 Activate at least 2 level sensors for each reservoir or the level sensor functions will be disabled For a single low sensor in each drum feed configure as shown below Activate mid and low sensors and set refill setting to monitor 2 11 09 L Conditioning Refill Setting Disabled Installed Monitor a Manual Auto Top Off Auto Full Volume 4 minutes Refill Sensor Type Low Temp Sensor Low Temp Sensor X X Conditioning Refill Setting Monitor v Refill Timeout _1 minutes
8. FCM HFRL stand enclosure and includes two fluid control Program token 16G584 is also provided modules r_24n804 Fic 2 Component Identification Electrical Panel AA Fluid Control Module A Red Tank AB Fluid Control Module B Blue Tank AC Ground Cable AD CAN Cable AE Flanged Hex Nuts 3x AF Wire Tie Anchor 3A2806C Component Identification Fluid Control Module FCM FiG 3 Component Identification FCM BD ti12336a BA Fluid Control Module FCM BB Base BC Module Connection Screws BD Access Cover BE Module Status LEDs BF CAN Connectors BG Level Sensor Input BH Fill Solenoid Signal Adjust Rotary Switch The rotary switch setting indicates which zone the fluid control module will control in the system The FCM uses a 16 position rotary switch to make selections Set the rotary switch to the specific selection according to the settings listed in the following table Rotary Switch ti12361a Fic 4 Adjust Rotary Switch Setting Zone 0 through 2 Not Used 3 B Blue Tank Level 4 A Red Tank Level 5 through F Not Used 3A2806C Component Identification Light Tower tower Fic 5 Component Identification Light Tower Signal Description Green on only System is powered up and there are no error con ditions present Yellow on An advisory exists Yellow flashing Material is at a low level condition
9. Drum Feed Kit US Metric Maximum fluid working pressure 125 psi 0 86 MPa 8 6 bar Maximum air input pressure 125 psi 0 86 MPa 8 6 bar Noise dBa Maximum sound pressure te Maximum sound power Inlet Outlet Sizes Air inlet size 1 2 NPTF Materials of Construction Wetted materials Carbon steel PTFE Stainless Steel PE Aluminum Nylon Weight 24N816 16 Ib 7 3 kg 24N767 Optional 69 Ib 31 kg 01 0955 25 Optional 209 Ib 95 kg Notes 1 For additional technical data regarding the HFRL and HFRS systems refer to manual For additional technical data regarding the Husky 1050 Air Operated Diaphragm Pump refer to manual 3A2806C 37 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 impr
10. components are not included 2 Refer to Husky 1050 Air Operated Diaphragm Pump Operation manual for instructions Installation Install Electrical Panel 1 10 Perform HFR shutdown procedure See HFRL oper ation manual for detailed instructions Disconnect the power supply to the machine Turn the disconnect switch on the rear base cover of the machine to the OFF position Remove the cover to allow access into the base cube Install the pre assembled panel on the left side of the cube directly opposite of the main control panel Note the locations of the 3 studs One in each top corner and one in the bottom center a Orient the panel so the mounting holes match the stud locations of the cube b Insert the panel into the base cube c Orient the top of the panel such that the studs in the cube wall extend through the holes in the top corners of the panel d Fasten the panel to the studs with the 3 flanged hex nuts provided Tighten the nuts Connect the cable labeled 121002 extending from the panel to the yellow cable splitter located on the lower left side of the main machine control panel a Remove the two screws to free the splitter from the panel b Insert the cable end into the open port on the splitter and tighten Note that the plug is keyed and only fits in the splitter in one orientation c Reattach the splitter to the panel If there is no available con
11. 969 BUSHING reducing 1 127 94 0451 2 99 CLAMP hose 1 3 4 3 4 ms 4 128 94 0414 99 CLAMP hose 2 1 4 1 5 16 ms 4 129 94 0397 M 99 BUSHING 1nptx3 4npt mf ms prox 1 130 102726 PLUG pipe headles 2 A Replacement Danger and Warning labels tags and cards are available at no cost Either the upper or lower plug can be removed and replaced with a level sensor assembly Only one sensor per chemical side can be used Both material sides should utilize the same upper or lower sensor position 3A2806C Parts 25 Parts Electric Panel 24N804 parts1 r 24n804 3A2806C 26 342806C 222 lt 221 223 adim ATTI ee Parts M UUU L an 225 D LE r 24n804 parts2 27 Parts Ref Part Description Quantity 201 15Y917 PANEL electric heat 1 202 115942 NUT hex flange head 3 203 289697 MODULE GCA cube base 2 204 24C476 HARNESS wire ground term 1 205 102063 WASHER lock ext 2 206 114993 SCREW mach pan wash hd 2 207 102598 SCREW cap socket head 8 208 289696 MODULE GCA cube FCM 2 209 277674 ENCLOSURE cube door 2 210 100021 SCREW cap hex hd 1 211 100015 NUT hex mscr 2 212 100028 WASHER lock 3 213 123452 HOLDER anchor wire tie n
12. Instructions Parts G GRACO Level Detection Module and Drum Feed Kit nn Installation kit to provide low level sensors in both chemical sides of an HFRL or HFRS plural component proportioner being fed from 55 gallon 208 liter drums Not for use with standard configured HFR units For professional use only Not approved for use in explosive atmospheres or hazardous locations Important Safety Instructions Read all warnings and instructions in the HFRL and HFRS Setup Operations manual Save all instructions See page 3 for model information 125 psi 0 86 MPa 8 6 bar Maximum Fluid Working Pressure 125 psi 0 86 MPa 8 6 bar Maximum Air Input Pressure d ti19596a PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Models Yu Se ee AR 3 Component Identification 4 Complete Feed System 4 Electrical Panel Components 5 Fluid Control Module FCM 6 Light 7 Grounding eee a 8 Flush Pumps Before Using 8 Installation 9 Install 4 Drum Rack Optional 9 Refer to 4 Drum Rack 01 0955 25 Optional on page 30 for visual clarity 9 Position Drums 9 Install Drum Feed 9 Connect Feed Pump 9 Install Electrical
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14. ZIN S ZIW MOSN3S 13431 S z n Nid 38 n Si WNOIS IVNSIS vil VNOS lt M NOS gi O O s O VNI Bu gt lt lt 604 901 901 SS3NMVH SS3NNVH gt NVL 8 E XNVL 034 V 201 l too two NO Low evi Z WOO NYO 1 WOO NYO WOO NY9 WOO NVO e 6 1 Nid 8N Nid 8 vel sel 9 vOvZ xS A 621 5 O O re T 021 gt gt d Wollo8 d WoLLog an LW MOSN3S 13431 ORGS WNOIS lt Paz 2 gt TWN TWN 3wWii YA 801 S ZIN S 21 Nid S S ZIN 8 ZIN S ZIN 101 vol f NOUISod OL HOLMS ANVLON 138 v NOUISod OL HOLIMS ANVLON l3S 17921 col JINON TO4LNOD GQlIn 14 FINION lOMINOO GIANT ot j AND 21 Drum Feed Kit 24N813 ti16632b Fic 10 3A2806C Parts Parts Drum Feed System 24N816 003 004 001 005 3A2806C 22 Parts Ref Part Description Quantity 001 24N804 PANEL assy fluid control HFRL 1 Inside Enclosure Refer to F c 2 page 5 003 255468 KIT acc light tower TC ram 004 124003 CABLE CAN male female 5 0m 005 24N767 KIT drum feed carbon Optional 006 01 0955 25 RACK 4 drum Optional Items are optional Shown for clarity a A Replacement Danger a
15. areful to not cross threads thread assem bled level sensor CB into well housing until it bot toms out against the bottom of the well The bottom of the level sensor will be slightly visible through the bottom of the well NOTE In the following step do not allow PTFE paste or tape to cover the tip of the level sensor well If paste comes in contact with the tip of the level sensor well thoroughly wipe it clean 6 Apply PTFE paste and PTFE tape to the male threads of the level sensor well housing 7 Being careful to not cross threads thread the level sensor well CA into the corresponding drum feed port and lightly tighten with a crescent wrench Do not pressurize tank with level sensor removed from sensor well Doing so will rupture the level sen sor well 4 Measure the length of the level sensor well housing and then measure the depth of the hole in the fitting 12 8 The protrusion length must be at least 1 8 in 8 2 mm If not remove the level sensor well and restart at step 4 9 Rotate level sensor such that the cord is pointing vertical and the sensing face is pointing down 10 Plug the sensor connector CD into the level sen sors a Route the sensor wires from the control panel through the bushing that was installed with the level sensor panel steps 8 and 9 11 Plug the sensor connector into the connector on the FCM 12 Calibrate the sensor See Calibrate Barrel Style Level Sensor
16. ater Thoroughly flush pumps before using to prevent moisture contamination when pumping moisture sensitive materials 3A2806C Installation Install 4 Drum Rack Optional To avoid machine damage or personal injury anchor the rack to the floor with 4 1 2 bolts pro vided by customer and verify all bolt assemblies are tightened before loading the drums onto the rack Refer to 4 Drum Rack 01 0955 25 Optional on page 30 for visual clarity Position Drums Place component A red and component B blue drums as desired Air hose connecting feed pumps is 15 ft 4 57 m long Fluid hose connecting feed pumps to systems are 10 ft 3 05 m long Install Drum Feed Kit To avoid machine damage or personal injury do not supply pressure to drums 1 Complete Setup instructions in the pump manual before installing in drum feed kit To avoid improper operation the diaphragm pump must be floor mounted 2 If applicable locate drum rack to allow access for top drum change 3 Dry fit all hose and fitting components to ensure components are located properly and will reach the HFRL Refer to F c 1 page 4 NOTE Drum to pump feed hose length can be reduced if necessary Refer to FIG 1 page 4 item 3A2806C Installation 4 Tighten all connections Connect Feed Pump 1 Supply clean dry filtered air to feed pumps NOTE Air supply
17. e canister 3 Discard used canister 4 Remove sticky tabs from the ends of the new canis ter to allow airflow 5 Install canister into the rubber housing to allow view ing of the sight window NOTE Make sure the arrows found on the canister point into the rubber housing 6 Tighten the clamp ring 3A2806C Drum Feed Kit Pump NOTE See supplied pump manual for maintenance repair and parts information Tighten pump clamps and external fasteners periodi cally See pump manual Drum Feed Kit Changing Top Drums en Wo To prevent cross contamination of fluid when changing drums complete changing one compo nent before changing second component 1 See Shutdown page 16 2 Close ball valves on top drum outlet assembly closed_ballvalves a 2 ER 3 Place a container underneath the CAM lock fitting to catch chemicals 4 Disconnect the CAM lock fitting from the system 5 Remove the empty drum from the rack if applica ble and place it vertically on the floor 6 Remove the air dryer assembly ball valve assembly from the empty drum 7 Inspect and clean the threads of the full drum and removed fitting assemblies 8 Apply thread sealant to threads of the removed assemblies 9 Install the ball valve assembly 3A2806C Maintenance 10 Install dryer assembly NOTE To prevent contamination of the desiccant in the dryer canister caused by slo
18. e in the fitting where the well is inserted Note these measure ments as they will be needed later 8 Being careful to not cross threads thread assem bled level sensor CB into well housing until it bot toms out against the bottom of the well The bottom of the level sensor will be slightly visible through the bottom of the well 20 NOTE In the following step do not allow PTFE paste or tape to cover the tip of the level sensor well If paste comes in contact with the tip of the level sensor well thoroughly wipe it clean 9 Apply PTFE paste and PTFE tape to the male threads of the level sensor well housing 10 Being careful to not cross threads thread the level sensor well into the tank C and lightly tighten with a crescent wrench 11 Measure the amount of the level sensor well hous ing that is visible beyond the day tank hole then perform the following equation P L1 L2 L3 P Protrusion length inside of day tank L1 Length of level sensor well A10 L2 Visible length of level sensor well L3 Length of well threads in fitting 12 The protrusion length must be at least 1 8 in 3 2 mm If not remove the level sensor well and restart at step 7 Level sensor must be oriented with the sensing face pointing down Alternate orientations could result in material pooling on the sensor face resulting in a false reading 3A2806C Electrical Schematics Electrical Schematics JINGOW AMOS
19. ispense O Enable Operator Mode Cavitation Alarm Complete Dispense With Setpoint Error L Enable Shot Aborted Notification L Enable Ratio Check Weight Mode Entry L 2x Trigger For Dispense 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 settings in Operator Mode Temperature Alarm Disables Dispense When this box is checked the system will reject dispense requests when any enabled heat chiller zones are below above their setpoint Enable Operator Mode Cavitation Alarm Check this box to enable cavitation alarms in Operator Mode Clear this box to disable cavitation alarms in Operator Mode Complete Dispense with Setpoint Error When this box is checked the shot will continue dispens ing even if the system never reaches the desired setpoint Enable Shot Aborted Notification When this box is checked a pop up notification will be displayed when a shot is aborted 2x Trigger For Dispense When thi
20. n the sensor well rotate the sen SOr a Loosen the sensor well nut CC 2 Press j b Rotate sensor until the calibration punan can be 3 For the appropriate chemical side select Monitor seen through one of the four holes in the sensor within the Refill Setting selection box well housing NOTE Select Disabled if the level system is not being c Tighten sensor well nut used d Press and hold the button down with the ball end of an allen wrench for two seconds The light will flash slowly and then go out 3 Test for proper sensor function a Loosen the sensor well nut b Back the sensor out of the well The sensor should sense the housing wall 14 3A2806C Set the ADM to Recognize which Level Sensors are to Operate NOTE Two sensors must be selected for each material with a level sensor regardless if there is only one low level sensor installed 1 Remain within the ADM Refill Screen I Supply No Active Errors 06 18 12 11 06 Standby Conditioning Refill Setting L Refill Timeout a _1 minutes 4 minutes Refill Sensor Type Low Temp Sensor Low Temp Sensor X X 2 For the appropriate chemical side select and check the middle sensor 3 Forthe appropriate chemical side select and check the bottom sensor 4 Press N Set the Level Sensors Output Function 1 Navigate to the ADM Advanced Screen 4
21. nd Warning labels tags and cards are available at no cost 3A2806C 23 Parts Drum Feed Kit 24N767 100 r_24n767_parts 3A2806C 24 Ref Part Description Quantity 101 109505 BUSHING 1 102 108209 NIPPLE pipe close 2 103 94 0906 R2 99 VALVE ball 2w 1 1 2npt f 1500ps 1 104 121443 FITTING tee 1 1 2npt 1 105 94 1045 M 99 BUSHING 1 5nptx3 4npt mf ms prox 1 106 94 0910 98 FITTING barb 1 1 2x1 1 2npt m ss 2 107 647673 PUMP 1050a ss ss pt a 1 108 94 0398 99 FITTING elbw strt 90 1npt mf ms 2 2 109 160022 FITTING union adapter 1 110 94 0758 99 FITTING npl hex 1 x3 4npt mm ms 2k 1 111 94 0433 99 FITTING nipple hex 1npt mm 4 5k 1 112 123250 FITTING coupling 1 5nptxinpt cs 1 114 123890 FITTING tee 1nptxinptxinptf fff c 1 115 94 0909 99 FITTING nipple barb 1 x1 npt m ms 2 116 94 0459 99 BUSHING 2nptx1npt mf blk 150 1 117 94 0456 99 FITTING nipple inpt mm blk sch40 1 118 94 0904 R2 99 VALVE bal 2w 1 npt f 2000psi ms 2 119 94 0912 99 FITTING qd 1 npt m cam dfk ms 1 120 94 0915 99 FITTING qd 1 npt f cam dfk ms 1 121 247616 DRYER desiccant option 1 122 94 0550 99 SWIVEL 3 4npsx1npt fm ms 4k 1 123 61 0055 88 HOSE hose chem pe 1 200psi 6 124 61 0056 88 HOSE chem pe 1 1 2 6 125 217382 HOSE coupled 10 ft 1 126 104
22. nection on the splitter an alternate CAN connection will need to be used The alternate location may require a different gendered cord 122487 is provided for this purpose Consult the system manual in finding an alternate connec tion location 8 Remove one of the hole plugs located on the top of the base cube directly over the disconnect panel that was just removed NOTE There are three holes on the top edge of the base cube The plug can be easily pushed out from inside the cube 9 Replace the removed plug with the provided plastic edge bushing a The bushing will snap into place by aligning the smaller diameter end of the bushing on top of the hole and pressing the bushing down through the hole from outside the cube Insert the male ends of the sensor cords labeled FCM1A and FCM2B through the bushing and into the base cube Connect the cord labeled FCM1A to port 1 Refer to FiG 2 page 5 on the FCM labeled FCM1 Connect the cord labeled FCM2B to port 1 Refer to FIG 2 page 5 on the FCM labeled FCM2 Attached the wire anchor to the inside face of the base by inserting the provided screw through the anchor and the weld nut indicated in Fic 6 Secure in place by tightening the hex nut on the screw from the outside of the base Secure the cords to the panel and the base cube by using wire ties not provided and the installed plas tic anchors 3A2806C Installation
23. nsor is triggered When the level condition is acknowledged by the opera tor by hitting the enter key but not cleared the audible alarm will stop and the pop up window will disappear The active error display will still indicate a low level con dition and the stack light will continue to flash yellow unless the low level condition has been corrected n 10 0 582 931 Bcc 160 1 35 Appendix B ADM Run Screens Overview 1513 cc When a low level on the BLUE side is sensed the pop up error code appears and the active error display reads Red Low Material Level The light stack will flash yel low and the audible alarm will sound When this error occurs the machine will continue to dispense when a start is initiated unless the Low Material Disables Dis pense flag is set Refer to Advanced Screen 3 to configure the machine to stop dispensing when a low level sensor is triggered When the level condition is acknowledged by the opera tor by hitting the enter key but not cleared the audible alarm will stop and the pop up window will disappear The active error display will still indicate a low level con dition and the stack light will continue to flash yellow unless the low level condition has been corrected 160 1 1513 cc 36 3A2806C Technical Data Technical Data Level Detection Module and
24. onsequential 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc d
25. oper 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 c
26. or 16A206 101001 101001 06 18 12 13 59 Conditioning S Mode It vom Advanced Display 16 122 112 004 USB Configuration 166102 108 001 MCM Application Blue 15Y820 110 077 MCM Component Blue 16C014 109 001 342806C Appendix B ADM Run Screens Overview Appendix B ADM Run Screens Overview For other screen not mentioned refer to the HFRL and HFRS Setup Operations manual Home Screen Refill Disabled 06 18 12 13 56 Diagnostic Operator m No Active Errors NY RED BUE gt CH o gt 0 psi 0 psi t Uh 10 0 amp 160 1 582 931 Bcc If refill is Disabled the home screen will show a graphic display of the reservoirs Home Screen Refill Enabled 10 0 642 1027 1669 cc When the level sensors are active and both reservoirs have material the display looks as above The stack light will illuminate a solid green Unless another error is present 3A2806C 10 0 cc 160 1 582 931 Bcc When alow level on the RED side is sensed the pop up error code appears and the active error display reads Red Low Material Level The light stack will flash yel low and the audible alarm will sound When this error occurs tne machine will continue to dispense when a start is initiated unless the Low Material Disables Dis pense flag is set Refer to Advanced Screen 3 to configure the machine to stop dispensing when a low level se
27. s page 14 3A2806C Install Light Tower NOTE Install the light tower in a suitable location for clear viewing 1 Create the hole pattern below to match the light tower base Bolt Circle 7 0 90 3x 8 32 UNC 2B dee Equally Spaced Mount Pattern 2 Use the provided screws to attach the light tower to the mounting bracket 3 Route the light tower cord as needed towards the ADM To prevent damage to the cord ensure it will not be pinched during normal machine operation after routing 4 Connect the cable to the port labeled 1 on the base of the ADM Refer to F c 1 page 4 NOTE A 5 m 16 ft cable is provided with the level con trol kit If extension cables are necessary refer to GCA CAN Cables Reference manual 3A2806C Installation 13 Setup Setup Set the ADM to Recognize the Feed System Kit Calibrate Barrel Style Level 1 Navigate to the ADM Supply Screen Senso rs PLE Supply Standby jal Comm Error Blue MCM Az 1 Locate the calibration button the sensor 11 closest to the electrical connector through one of the four holes of the sensor well housing CA Refill Setting Disabled M Disabled Refill Tirneout _1minutes _1 minutes Refill Sensor Type Low Temp Sensor w Low Temp Sensor 2 Ifthe calibration button cannot be seen through one of the four holes i
28. s box is checked the machine will require a double trigger pull to initiate dispensing in shot or sequence mode 3A2806C Appendix A ADM Setup Screens Overview e Dispense from Home Position When this box is checked the machine will be required to reach a defined home position before dispensing in shot or sequence mode Advanced Screen 4 _ Enable Diagno Low Material Disables Dispense L Enable Downloading of USB Logs _ Enable USB Errors Date of Last Download SN es a This screen is for enabling the optional ADM screens enabling USB log downloading and erasing USB logs To enable the machine to automatically stop dispensing when a reservoir is low place an X beside the Low Material Disables Dispense check box When this fea ture is active the machine will not cycle unless material is present in the monitored reservoirs 33 Appendix A ADM Setup Screens Overview Advanced Screen 5 e Conditioning ES No Ac 06 18 12 11 08 Standby Blue Tank Monitor 16A206 This screen displays software information If the level controls are present but not active the tank monitor program will not appear in the advanced 5 screen as shown below Im No Active Errors 34 Mode MIN UMS Advanced Display 16 122 112 004 USB Configuration 16G102 108 001 MCM Application Blue 000000 Component Red Tank Monit
29. shing material it is recom mended that the tape is temporarily placed over the air inlet on the dryer canister The tape should be removed after the drum is installed 11 Place drum on top rack and orient it so that the air dryer assembly is on top and outlet is on the bottom ti19596a we D 12 Perform Drum Feed Kit Air Dryer page 16 as required 13 Connect CAM lock fittings from lower drum securely to ball valve assembly on upper drum and lock in place NOTE CAM levers on either side of female CAM recep tacle should be perpendicular to the receptacle to mate and parallel to body to lock 14 Open both ball valves on top drum outlet assembly to fill bottom the drum See Load fluid with feed pumps in GMS operation manual 17 Maintenance Install Upgrade Tokens NOTE The Motor Control Module Fluid Control Mod ule 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 soft ware versions may not be compatible All data in the module System Settings USB Logs Recipes Maintenance Counters may be reset to factory defa
30. sing material when material is not present Level sensors out of calibration Calibrate level sensor Replace level sensor Level sensors blocked inside reser voir Check inside reservoir to ensure there is nothing blocking the level sensor Intermittent electrical connections Ensure the system main power is ON Ensure all electrical connections to the level sensor are secure See electrical schematic in either the HFR Repair Parts manual FCM errors Check FCM circuit breaker in base cube to see if it has tripped See electrical sche matic in either the HFR or VRM Repair Parts manual Check FCM A red LED indicates a problem with the module See electrical schematic in either the HFR or VRM Repair Parts man ual Replace FCM 3A2806C 19 Repair Repair Level Sensor and Well NOTE For proper level sensor function the tip of the level sensor well must protrude at least 1 8 in into the reservoir r 24b969 3A0395a 7a 2 Fic 9 Level Sensor Assembly 1 Turn main power off 2 Close ball valves on the drum outlets 3 Drain drums to below level sensor well 4 Unscrew level sensor harness cable CD from level sensor well housing CA 5 Use a crescent wrench to remove level sensor well housing from tank C 6 Remove the old level sensor CB from well housing 7 Measure the length of the level sensor well housing and then measure the depth of the hol
31. tup Operations 3A2176 HFRL and HFRS Repair Parts 312877 Husky 1050 Air Operated Diaphragm Pump Operation 3A0235 Feed Supply Kits Instructions Parts 406987 GCA CAN Cables Reference Extension Cables Models NOTE Not for use with standard HFR units Part Description KIT low level stack light HFRL Required 24N816 2 low level sensors 1 sensor per chemical side 1 1 control panel for level sensors indicator stack light 24N767 Kitis to add a drum feed to 1 chemical side 01 0955 25 4 Drum rack Optional Carbon steel drum feed kit with Husky pump Optional 3A2806C Related Manuals Component Identification Component Identification Complete Feed System Figure Shown With 1 Level Kit 2 Drum Feed Kit Options 1 4 Drum Rack Option FiG 1 Component Identification Feed System ti19596a Key A Auxiliary Control Panel Mounted in Machine Base Refer to FIG 2 Level Sensor Low Level Indication Level Sensor Empty Indication Indicator Stack Light Drum Feed Pump Kit for One Chemical Optional 4 Drum Rack Optional Upper to Lower Drum Feed Hose c Drum to Pump Feed Hose 6 ft 1 8 m Husky Pump HFR Supply Hose 3A2806C Component Identification Electrical Panel Components The electrical panel will be located on the inside of the Software is loaded on Fluid Control Modules
32. ult 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 compo nents The software version history for each system can be viewed in the technical support section at WWW graco com Token Application 16H821 HFR Advanced Display Module Motor Control Module High Power Temperature Control Module Fluid Control Module AC Power Pack Discrete Gateway Module Communication Gateway Module 16G584 Tank Stand Fluid Control Module Low Power Temperature Control Module 16G407 Ratio Monitoring Flow Meters Fluid Control Module 18 EI ti12358a1 TET Fic 8 Remove Access Cover 3A2806C Troubleshooting wA rN en Troubleshooting Problem Cause Solution Level sensor is not sensing material when material is present Level sensors out of calibration Calibrate level sensor Replace level sensor Intermittent electrical connections Ensure the system main power is ON Ensure all electrical connections to the level sensor are secure See electrical schematic in either the HFR or VRM Repair Parts man ual FCM errors Check FCM A red LED indicates a problem with the module See electrical schematic in either the HFR or VRM Repair Parts man ual Replace FCM Level sensor is sen
33. ures concern es Graco Information For the latest information about Graco products visit www graco com 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 For patent information see www graco com patents Original Instructions This manual contains English MM 3A2806 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2012 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised November 2013
34. ylon 3 214 116610 SCREW mach phil pan 10 3 215 24H240 HARNESS wire ground term 9 1 216 100020 WASHER lock 1 217 100166 NUT full hex 1 218 123679 BUSHING wire protector 1 3 8 od 1 219 121597 CABLE CAN 90 female 90 female 1 220 126413 HARNESS m12xm12 5px4p mxf 10m 2 221 121511 SENSOR capacitive 18mm qck disc 2 222 16A511 HOUSING well prox efector 2 223 15U978 CAP well prox PR70 2 224 121002 CABLE CAN female female 1 5m 1 225 122487 CABLE CAN male female 1 5m 1 226A 16D656 LABEL identification electronics 1 227 070408 SEALANT pipe sst 1 228 16H821 TOKEN GCA upgrade ADM32 1 229 16E530 SOFTWARE GCA tank stand 1 230 24N813 CONTROL panel HFRL low levels 1 233 15A721 LABEL designation 1 A Replacement Danger and Warning labels tags and cards are available at no cost 28 3A2806C Parts 3A2806C 29 Parts 4 Drum Rack 01 0955 25 Optional 305 303 Typical Installation 9 Places Rack Dimensions A Height 60 1 2 in 154 cm B Length 36 1 2 in 93 cm C Width 60 1 2 in 154 cm Anchor Locations D Width 57 1 2 in 146 cm E Length 33 1 2 in 85 cm F Diameter 0 56 in 1 4 cm 30 305 01_0955_25 To avoid machine damage or personal injury
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