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Graco 3A2797G User's Manual

1. Step 9c Step 9d Step 9e Step 9f KA ZZ Zo ZZ PA H LA KA F PA Pr ZZ 2295 E53 0 ZZZ H 597 j 5 i a ON Ey o Q 6 ni O 9 to 20 0 00 0 o 2 d 0 9 3A2797G 10 Connect Material Hoses A A NOTICE Avoid routing hoses in walkway areas to prevent operators from tripping on hoses running between system components This also prevents fittings from leaking NOTE Refer to Fic 15 on page 32 for visual clarity of the following steps a Ensure main power is OFF lt n b Ensure A Red and B Blue inlet valves on the HFR and the material supply ball valves on the tanks are closed c Remove reducer fitting from the A Red con nection of the HFR fluid manifold Install FTS in the A Red material supply line between main hose and whip hose Ensure the FTS is facing toward the fluid flow of material after installation See Heated Hose manual for instructions Refer to FIG 15 and FIG 16 3A2797G Setup d Remove reducer fitting from B Blue connection of the HFR fluid manifold Models 24N573 24N574 only Install the provided additional spacers near the location of the FTS for the remaining material lines Refer to Fic 15 and FIG 16 HFR material manifold Remove reducer Fic 16
2. 44 F USNINO z baie oe aa eels Sere 45 Mailmitenance aya a Bae oa oL Da b 46 Install Upgrade Tokens 47 IsoGuard Select System 48 Troubleshooting 49 Light Tovver Optional 49 Appendix A ADM Icons Overview 52 Setup Screen lcons 52 Run Screen Icons 53 Appendix B ADM Setup Screens Overview 54 Appendix C ADM Run Screens Overview 69 2 Appendix D ADM Error Codes 75 Appendix E System Events 87 Appendix F USB Operation 89 GVeTV M AA 89 USB OPLORS d lb hha buha 89 Download Log Files 89 Log Files Folder Structure 90 Transfer System Settings 92 Update Custom Language 93 Technical Data aa a bos Gos Sb 95 Motor Control Module Technical Data 96 Dimension Sanita hana 97 Graco Standard Warranty 98 Graco Information 98 3A2797G Related Manuals Manuals are available at www graco com Component manuals below are in English System Manuals 313998 HFR Repair Parts Power Distribution Box Manual 3A0239 Power Distribution Boxes Instruc tions Parts Pumpline Manuals 3A0019 Z Series Chemical Pumps Instruc tions Parts 3A0020 HFR Hydraulic Actuator
3. that flow meter is matched to nominal pump 7 defined limit not turning output N2D0 p Deviation Below Deviation Material Napo ispense Deviation 7 Material dispense is above the Cable unplugged loose Deviation P p ugg check for loose or disconnected wires or plugs defined limit power Material N4D0 Dispense Alarm Above Alarm 3A2797G 79 Appendix D ADM Error Codes Error Error Code Error Description Type Cause More 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 Hydraulic power pack failure Check to ensure the linear position sensor is properly connected to the MCM and the wiring has not be damaged Pump Failad The MCM attempted to move 777 Replace the linear position sensor N4A1 p the pump but no movement Deviation p to Move WAG dalaciad Motor no longer coupled Reset coupler per specifications and retighten set to hydraulic pump screws Supply tube from hydraulic pump to manifold is loose or broken 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 Thermal unsafe level due to thermal l ma Open the dispense valve manually or open the valves P400 Pressure expansion of materials All Deviation High pressure 75 to bleed pressure Rise
4. The custom language file was suc cessfully transferred from the USB drive to the ADM EQU5 R Logs Down The Error Event and Shot data logs loaded 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 circula tion mode and turned off all condition ing zones EWAO R Prepoly While in night mode the prepoly Refresh Cancelled refresh was cancelled REQU R Settings Uploaded EQU3 R Language Downloaded EQU4 R Language Uploaded EAO R Night Mode Recirc On EBRO R Night Mode Recirc Off 87 Appendix E System Events 88 3A2797G Appendix F USB Operation Appendix F USB Operation Overview There are 3 main uses for the USB on a GMS system e 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 e Ability to download modify and upload custom lan guage files e Ability to download and upload system configura tions e This data includes most user selectable and user configurable settings e 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 68 08 16 13 09 57 4 Con
5. a Connect the hydraulic hose to the hydraulic hose fittings A2 and B2 on the AC power pack Hydraulic Hydraulic Hydraulic Hose Hose Fitting Hoses Color Markings Material close Material open Green White A RI ROA AV NS Y NO 5 ti19515a Fic 14 Hydraulic Fittings on Hydraulic Housing b Hand tighten each fitting c Tighten each fitting 1 4 turn past hand tight 3A2797G Setup 7 Install GX 16 Fitting Adapter Kit 8 Install Flow Meter Kit Optional 2 Refer to HFR Flow Meter Kits Instruction Parts manual for installation and setup instructions 7 DOS a Remove the chemical fittings from the back of the GX 16 b Install JIC 4 fitting assembly into the B Supply port c Install JIC 6 fitting assembly into the B Return port d Install JIC 8 fitting assembly into both A Supply 9 Install PrePoly Refresh Kit Optional and A Return ports DO Refer to HFR for NVH Prepoly Refresh Kit Instruc ah tions Parts for installation and setup instructions vz KI ras A IL giv gt 3A2797G 31 Setup Step 9g Step 9h 22 SORES KS q SBR SRR IS 2 IKAN a NG NATALO NSO ISIS ISA IRS SSS PASS SS RRR RIS RRR ti19507a Fic 15 Material Hose Connections 32 s b NG s C A a Q ae 2 O Lu
6. e Use equipment only in well ventilated area e 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 e Ground all equipment in the work area See Grounding instructions e Use only grounded hoses e Hold gun firmly to side of grounded pail when triggering into pail e lf 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 ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material supplier for compatibility 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 e Follow the Pressure Relief Procedure
7. 2 A Red Primary Heat A Red Hose Heat o through 7 Not Used Lovv Povver Module mi Switch Settings 0 ors 4 e Used B Blue Tank Heater A Red Tank Heater B Blue Chiller A Red Chiller 3A2797G 3A2797G Component Identification 27 Setup Setup Perform this setup procedure to secure all necessary machine connections for machine operation 1 Locate system a Locate system on a level surface See Dimen sions on page 97 for space requirements b Do not expose system to rain 2 Electrical requirements See Models on page 4 for detailed electrical requirements information 3 Ground system ML This equipment must be grounded aA 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 4 in this setup procedure All electrical wiring must be done by a qualified electri cian and comply with all local codes and regulations 28 a System grounded through power cord See step 4 on page 28 b Fluid supply containers follow your local code c Object being dispensed into follow your local code d Solvent pails used when flushing follow your local code Use only metal pails which are con ductive placed on a grounded surface
8. Part Description 24K659 GX 16 Proximity Kit 3A2797G Additional Accessories Part 24C871 24C873 24F516 121728 255468 255244 24G389 24K344 24K348 24K346 24K223 123694 123226 123695 125113 248280 117792 0553 6 255468 24T182 241183 241180 241181 Flow meter electronics kit 24J318 is required for flow meter kit Description Hydraulic Power Pack Hydraulic Tank Fluid Level Sensor Hydraulic Power Pack Manifold Oil Temperature Sensor IsoGuard Select fluid 6 quarts Extension Cable for Advanced Display Module 4 meter Light Tower Foot Switch with Guard and 4 meter Cable Pneumatic Agitator for 20 gal 75 1 Carbon Steel Tank No Heat Pneumatic Agitator for 20 gal 75 1 Carbon Steel Tank Heat Pneumatic Agitator for 20 gal 75 Stainless Steel Tank No Heat Pneumatic Agitator for 20 gal 75 1 Stainless Steel Tank Heat Isolated Pistol Grip Adapter Straight Gun Cover 90 Gun Cover 12 ft 3 7 m Hose Cover Z Series Pump Cover Z Series Purp cover installation 3A2797G Accessories Communications Gateway Module CGM Part Description 24J415 CGM Mounting Kit VC for all applications CGMDNO GCA GCA Gateway Module DeviceNet Fieldbus 1 Module DeviceNet Fieldbus CGMEPO GCA Gateway Module EtherNet IP Fieldbus CGMPBO GCA Gateway Module PROFIBUS Fieldbus CGMPNO GCA Gateway Module PROFINET Fieldbus Bag Filter Kits Part
9. 4 11 2012 14 17 28 Mrl 2 308 7 Tis T Ready PI Example 3 SYSTEM File The 3 SYSTEM file is the Software Version log file A B C D E F G 1 System Software Log 2 S M 06201073 3 Software Part Number 16N420 4 Software Version 1 01 0072 4 23 2012 11 11 7 Date Time Node Software Version 8 4 23 2012 6 53 49 MCM Application Blue 1 01 108 9 4 23 2012 6 53 49 MCM Component Blue 1 09 001 10 4 23 2012 6 53 49 Blue Tank Monitor 1 01 001 11 4 23 2012 6 53 49 Red Primary Heat 1 05 0085 12 4 23 2012 6 53 49 Blue Hose Heat 1 05 0082 13 4 23 2012 6 53 49 USB Configuration 1 07 001 14 4 23 2012 6 53 49 Advanced Display 1 01 003 15 4 23 2012 6 53 50 Blue Primary Heat 1 05 0082 16 4 23 2012 6 53 51 Red Hose Heat 1 05 0085 17 4 23 2012 6 53 54 Red Primary Heat 1 05 0082 18 4 23 2012 6 53 56 Blue Primary Heat 1 05 008 19 20 21 w M 4 k HM 3 SYSTEM 2 ia T b Il 3A2797G 91 Appendix F USB Operation Transfer System Settings dr DOWNLOAD MEINS Back v 3 yy Search E Folders pa HAN Address 3 E GRACO FFFFFFFF DOWNLOAD v Go Folders x Name Size Type Date Modified 1G Desktop a 1 File Folder 1 12 2010 12 38 PM s by Gie 2 File Folder 1 12 2010 1 52 PM baTA0003 File Folder 1 12 2010 10 12 AM Local Disk C C3 DATAO004 File Folder 12 20 2004 12 00 AM ss DVD CD RW Drive D QDATA0005 File Folder 1 12 2010 10 17 AM DIESEL E DaTA0006 File Folder 1 13 2010
10. Press to enter the Conditioning Control screen 2 Use the arrows keys to navigate to the desired zone a Press FI to turn on the selected zone When a zone is on the button will be selected Press the button again to turn off the zone To turn on off all zones 1 Press to enter the Conditioning Control screen 2 Press the more zones are on the button will be selected Press the button again to turn off all zones All zones shown for reference Only four zones may be active at one time 3A2797G 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 49 fora detailed description of all of the system errors 03 10 10 15 34 LA Status Events Shot C Mo Active Errors Date Time Code ClassDescription OSANG 16 25 1122 Blue Low Material Level ONG 05 CACS A Comm Error Red Tank z n 15 05 P6B2 D Blue Pressure Sensor Fault 030910 16 05 PBATDI Red Pressure Sensor Fault OSf090 15 05 DBA Position Sensor Fault OS 0S10 G05 TAHI A Oil Temp Shutdown 16 05 TANTA Motor Temp Shutdown 00O NO 12 45 1122 Blue Low Material Level OYO 15 47 L122 L Blue Low Material Level OO NO T544 L122 D Blue Low Material Level Events Screens
11. This screen shows users a list of events that have occurred in the system Each event includes a descrip tion 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 49 for a detailed description of all of the system events 03 10 10 15 32 4 Errors Maintenance Shot mi No Active Errors Date Time Code ClassDescription 030910 10 05 EMOO R Systern Powered Off 1614 EOUT R Settings Downloaded 03000 1614 EQUS R Language Downloaded z n 1614 EQUS R Logs Downloaded z n 1613 00 Disp Occurred Shot z n 1613 EAQO R Disp Occurred Shot 5 1613 EAOO R Disp Occurred Shot 3 08 0 1613 EAQO R Disp Occurred Shot 5 1613 EAOO R Disp Occurred Shot 023 08 0 1613 EAQO R Disp Occurred Shot 3A2797G Appendix C ADM Run Screens Overview Maintenance Screen 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 mate rial usage counters units are displayed next to the vol ume weight indicator icons S To erase a batch counter press and navigate to the to erase that data point Alternatively amp 4 may be pressed to
12. into the open port on the solenoid valve Install the air tube from the refill valve to the solenoid valve 3A2797G Startup 7 ot it i O To reduce the risk of personal injury do not operate HFR without all covers and shrouds in place 1 Check that all machine connections are setup See Setup procedure page 28 2 Check level and condition of ISO lube daily see IsoGuard Select System on page 48 3 Verify both PRESSURE RELIEF DISPENSE valves m SA SB are set to DISPENSE SA SB 4 f dispense valve has a trigger safety lock engage the trigger safety lock LOCKED ti10442a1 5 Open system fluid inlet valves and ball valves found on the material tanks As applicable ball valves on the material tanks include material supply applica tor return and pressure relief Check for leaks 3A2797G ti9877a1 Startup Press to enable system LED should be solid green Navigate to Home Standby screen and press o to initiate auto startup Check that heat zones are on and temperatures are on target Check fluid pressure display Refer to Sta tus Screen on page 72 for more details If dispense valve has a trigger safety lock disen gage the trigger safety lock O ti10441a1 i Equipment is ready to dispense 43 Shutdown Shutdown Pressure Relief A An Procedure 9 1 Park pumps AT hy MAZ a
13. 130A 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 96 3A2797G Technical Data Dimensions A Height 76 in 193 cm 72 in 183 cm B Width C Length 58 in 147 cm 3A2797G 2 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
14. 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 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 62 The pressure imbalance setting is set from this screen Pressure imbalance is the allowable difference in pres sure between the two materials before an alarm is trig gered The input range is 145 2000 psi 1 14 MPa 10 138 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 The ratio displayed between chemicals can be changed between blue or red allowing either chemical to be dis played as aratio to 1 This screen allows the user to enter material specific gravities gal Calibration Maintenance C Mo Active Errors Label Specific Gravity Pressure 1 000 Imbalance Setting Pressure Imbalance Alarm psi Flowmeter Type Deviation Alarm Ratio Ratio 1 h r 61 Appendix B ADM Setup Screens Overview Keyboard Screen This screen is used to edit the A Red and B Blue labels on the ADM Use arrow keys to select
15. ADM Module Status LEDs CN Conditions Uploading software Red flashing slow Token error Remove token and upload software token again USB Module Status LEDs CL Conditions Module Status LED Signal Description Green flashing System is powered up Yellow on Downloading information to USB Green Yellow Flashing ADM is busy USB cannot transfer information when in this mode 3A2797G 21 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 Shutdown page 44 Current date and time Previous chapter Current chapter Next chapter Left Arrow Right Arrow Mode 06 05 12 15 50 4 Shots Calibration Faults Status standby m Active Errors Enter Exit screen Previous page Up Arrovv Current 0 Next page Function display 1 Down Arrow H i Fic 8 Main Display Components 22 3A2797G Component Identification Fluid Control Module FCM E ti12337a1 ti12336a1 D Fic 9 Fluid Control Module FCM Key A Fluid Control Module D Access Cover B Base E Module Status LEDs C Module Connection Screws F CAN Connectors Diagnostic nformation System is powered up Internal communication in progress Red solid FCM hardware failure Replace FCM Red flashing fast Uploading softwar
16. Blue Blanket 53 51 Bad heaters Measure resistance of heater Blue Inline 75 over current vvas detected Alarm Red Hose on the output Blue Hose Red Chiller High vollaqe es voltage across the disconnect switch Overcurrent Voltage should measure between 190 and 264 Vac Blue Chiller Shorted Temperature If temperature rises for a zone that has been disabled 7 0O Temperature Control Module High current has been Reo WING OI Replace a Motor Over ldetected on a phase and has Alam motor Overcurrent Current been shutdown to prevent Short circuit of motor Check wiring to the motor to ensure no bare wires are damage wiring touching and that no wires are shorted to ground Motor Over Too much current is being Low voltage from the wall Make sure the supply line is properly sized for the Alarm Current drawn from the wall during load load and is above the minimum voltage requirements Refer to AC Power Pack manual gt gt gt gt gt gt gt gt gt gt U U gt IN IN IN D D D D IN IN D NO O1 N ING W m IN I wD gt OD gt OW gt WD O I I I T T TI Co NS IS Po co O o a d co CO CO c CO Appendix D ADM Error Codes Error Error Code Eror Name enor Desoription Type cause Short circuit of motor Check wiring to the motor to ensure no bare wires are Unplug the directional valve so pressure will not build and try to move the motor
17. Do not place pail on a nonconductive surface such as paper or cardboard which interrupts grounding continuity e To maintain grounding 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 4 Connect electrical cord to system AM A NOTE See Power Line Voltage Surges information on page 29 NOTE Power cord is not supplied See the following table 3A2797G Table 2 Power Cord Requirements Cord Requirements AWG mm Heated system 4 21 2 4 wire ground 400V 3 phase Heated system 4 21 2 3 wire ground 230V 3 phase t Residual Current Device RCD must be rated at 300 MA if installed Electrical Cord Wires by Model 230V 3 phase L1 L2 L3 GND 400V 3 phase L1 L2 L3 N GND Use 5 32 or 4 mm hex allen wrench to connect the three power leads to L1 L2 L3 and Neutral as required Connect green to ground GND r 24C686 313998 1a Fic 13 400V 3 phase shown Power Line Voltage Surges Power conversion equipment can be sensitive to voltage fluctuations on incoming power The Motor Control Mod ule falls under the category of power conversion equip ment because energy is stored on a capacitive bus and then modulated to control a brushless motor Engi neered design takes this into account and withstands
18. For MCM location see reference MA in FIG 2 on page 14 When installed the end of the MCM with the If the Motor Control Module is replaced the selector power input connection 12 faces down and the end switch must be set prior to initial startup of the with the access cover A faces up Motor Control Module or damage may occur See HFR Repair manual for details see Related Manu The Motor Control Module uses an 8 position selector als on page 3 switch to set the system maximum working pressure 13 ALL r 257396 3b9905 03b FiG 5 MCM Component Identification 18 3A2797G Component Identification Ref Description Ce qes 2 Three way Splitter to Oil Low Level Sensor Dispense Valve Solenoid and Footswitch Oil Temperature Sensor Electric Motor Temperature Sensor 6 LVDT Position Sensor Three way Splitter to Hydraulic Directional Valve Oil Overtemperature Switch Pressure Transducer B Blue side Pressure Transducer A Red side 12 MOM Power input Connection Diagnostic Information Table 1 LED Ref B Status Signal System is powered up Internal communication in progress Red solid MCM hardware failure Replace MCM Red flas
19. Material Manifold e Install ball valves optional between main hose and whip hose Connect the main hose bundle to the whip hose bundle NOTE The ball valve kit is designed to fit in one orienta tion only NOTICE If using the ball valve kit ensure the FTS does not go through the ball valve Failure to do so will result in damage to the FTS and the inability to close the ball valve f Assemble the hydraulic hose sections together and place the assembled hose connection near the FTS area Refer to FIG 15 g Connect A Red and B Blue hoses to A Red and B Blue outlets on HFR fluid manifold FM Hoses are color coded solid red for component A solid blue for component B 33 Setup Connect cables Y 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 Connect the other end of the supply hoses solid color to the applicator See the applicator manual for fluid inlet identification Connect A Red and B Blue return hoses solid with white stripe to the applicator See the applicator manual for fluid outlet identifica tion NOTE The other end of the return hose will be con nected in step n on page 39 34 11 Connect GX 16 Hydraulic Lines AS a Navigate to the System Screen 2 and set the mode
20. Range 50 psi to 100 psi 345 kPa 3 4 bar to 0 7 MPa 7 bar Fluid Inlet Component A Red 1 2 npt f Fluid Inlet Component B Blue 3 4 npt f Fluid Outlet l Component A Red 8 1 2 in JIC 3 4 16 unf with 5 5 16 in JIC adapter Fluid Outlet Component B Blue 10 5 8 in JIC 7 8 14 unf with 6 3 8 in JIC adapter Fluid Circulation Ports 1 4 nosm m with plastic tubing 250 psi 1 75 MPa 17 5 bar maximum Line Voltage Requirement 400V 3 phase Models See 400 V Power Requirements on page 5 See Models on page 4 93 dB Heater Power 10 kW full load A Red and B Blue heaters total no hose 12 kW for 1 1 Models Only Hydraulic reservoir capacity 9 gal 34 liters Recommended hydraulic fluid Citgo A W Hydraulic Oil ISO Grade 46 Weight Units with 10 kW Heaters 868 Ib 394 kg Wetted Part 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 3A2797G 95 Technical Data Motor Control Module Technical Data Motor Control Module 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
21. Ratio Monitoring Flow Meters Fluid Control Module 3A2797G Maintenance 47 Maintenance IsoGuard Select System I of a m MING me 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 lsoGuard Select fluid 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 replacement due to discoloration should not be necessary more often than every 3 or 4 weeks To change pump IsoGuard Select fluid 1 Perform Pressure Relief Procedure on page 44 2 Remove fittings from IsoGuard Select fluid cylinder inlet and outlet ports Keep supply tube return tube and leak management tube connected to the fit tings 3 Carefully place ends of tubes with fittings still con nected into an empty pail to drain IsoGuard Select fluid 4 Lift the IsoGuard Select fluid reservoir out of the bracket and remove the container from the cap Holding the cap over a suitable container remove the inlet check valve and all
22. Red and B side Blue feed inlet valves on the system See FIG 2 on page 14 b Close A side Red material return ball valves on the material tank stand c Follow Pressure Relief Procedure on page 44 d Remove plugs from GX 16 e Install orifices provided Orifice A Side ti17747a 22 GX 16 Plug Location 40 16 Pressure check hose See hose manual Pressure check for leaks If no leaks wrap hose and electrical connections to protect from damage 17 Check hydraulic fluid level Hydraulic reservoir is filled at the factory Check fluid level before operating the first time and weekly thereaf ter See Technical Data on page 95 for specifications 3A2797G 18 IsoGuard Select Fluid System Setup Component A Red Pump Fill IsoGuard Select reser voir LR with IsoGuard Select fluid provided by Graco a Lift the reservoir LR out of the bracket RB and remove the container from the cap AT 4 LR ND 24C352 313998 8e 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
23. 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
24. 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 93 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 pns 0002000 0 80002002 0 680002005 0 80002004 Ox20002005 0 80002006 0 80002007 0002006 000200 0 80002002 Ox28000200d Ox2000200e 0 680002002 Ox80002010 Oxe0002011 Oxe0002015 0 50002019 xs z la Oxe000201b Ox00000030 Ox00000001 Ox00000000 Ox00000001 0 00000000 0 00000000 0 00000001 0 00000000 0 00002205 0 00000000 0 00000000 0 00000000 0 00000001 0 00000000 x n dcalic 0 000 1 0 00000000 0 00000000 0 0000 60 239 Blue Motor High Speed Blue Pump Failed to Move 1 1 Invalid Setpoint Request Small Shot Request Pressure Imbalance 244 Pumps Not Defined Invalid Learn Mode Data Blue Invalid Weight Cal Data Blue Position Sensor Fault Red Pressure Sensor Fault Blue Pressure Sensor Fault Blue Setpoint Not Reached Blue Setpoint Not Reached Blue Setpoint Exceeded 94 3A2797G Technical Data Technical Data HFR for NVH Foam Maximum fluid working pressure 2 4 MPa 138 bar Maximum Fluid Temperature 1 88 C Fluid Inlet Feed Pressure
25. again If this Motor rotor has become 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 Blanket Alemi Shorted Temperature lf temperature rises for a zone that has been disabled Control Module replace Temperature Control Module Current No Bed Inline Tripped circuit breaker Visually check circuit breaker for a tripped condition A8A3 Current 1 No Blue Inline 1 5 No current to the conditioning ASA No Red Hose n Alarm Current Measure voltage across input terminals on povver line No Blue Hose Low power filter Voltage should measure between 190 and 264 Current Vac 755 Cable unplugged loose A8B7 Chiller piugg Check for loose or disconnected wires or plugs A hardware current fault has occurred causing a system Alarm shutdown Motor Over Current A7A6 A7B5 Control Fault Unexpected current to A7A2 70 A7B4 A7A7 ATBB Gontrol Pau No Red Blanket Current A8A6 No Blue A8B5 power Current No Blue Chiller Current Motor Over A software error has occurred Bad Motor Control Check for MCM software update load latest MCM Alarm Current commanding too much current Module code software if problem persists contact Graco On the ADM go into the Setup screens to the System screens then make sure that the pump sizes are defined correctly Bad heater
26. approaching a level where damage is possible so the Advisory 570 the output to a safe level conditions are too hot Motor pump coupler may be rubbing on hydraulic pump Motor temperature is Reset coupler per specifications and retighten set SCrews 3A2797G Appendix D ADM Error Codes Error Error Code Error Description Type Cause Red Hose T4A2 High Fluid Red Inline T4A3 High Fluid T4A6 High Fluid Temp Red Chiller T4A7 High Fluid Temp Defective Temperature Control Module Replace Power Temperature Control Module Fluid temperature is above the defined high alarm limit Alarm Blue Inline T4B1 High Fluid Temp Blue Hose T4B4 High Fluid Temp Blue Tank T4B5 High Fluid Temp Blue Chiller T4B8 High Fluid Temp No power to fan Check cord to make sure fan has power Debris is fan or heatsink Clear debris from fan or heatsink The temperature the MCM has EE Try to stop fan by lightly pressing on the center with a reached a level where product 202 Motor Control f Low air volume from fan pencil eraser If the fan slows down easily it will need T4C1 life will be decreased Alarm High Temp to be replaced drastically and has been Motor may be damaged Oil Temp na Shutdown Debris is packed in the ela MCM s heat sink fins Clear debris from MCM heat sink fins Motor Temp an Shutdown No Power to Fan Check cord to make sure fan has power Debris in fan or fan gril
27. check of loose or disconnected wires or plugs Meter Blue power The type or size of the Red or On the ADM go into the setup screens gt System gt Pumps Not j Properly setup the Blue material pumps have not Alarm system then make sure that the pump type and size are set been defined not 140 Low Flow Alarm Cogs in flow meter are Check that flow meter is matched to nominal pump 2A0 Red Flow is below the defined low Deviation not turning output 1B0 limit Al 77109 Alarm cable Check for loose or disconnected wires or plugs 2B0 Blue Deviation power T N T 71 O O O O O O 69 JJ O TI O O O D D gt 0 T gt O J gt N m F4A0 High Flow Red Flow is above the defined low Deviation Cogs in flow meter are Check that flow meter is matched to nominal pump F4BO High Flow limit Alarm turning rapidly output F3B0 Blue Deviation ai Failure of the dispense the valve has a proper air supply and seals en the pump tried to stall to valve properly If not service the valve as necessary pressure the pump traveled F7D1 Pump Failed m reihan tensuleinm rmal i Deyil n Visually inspect the machine and hoses for sign of to Stall l Material leak leakage NOTE This error will display after 2 full operation only applies to piston strokes so the leak will be substantial dead headed system Out of material Fill tanks Liti eee Tan
28. conditioning zones have automatically been turned off 1 Red Pressure Dispense valve failed to Check to make sure the dispense valve is properly Shutdown open configured and connected to the MCM B Alarm ad dispense valve Replace dispense valve Blue P4B2 Pressure Shutdown The pressure difference Restriction in the Check to ensure there is no blockage material lines es betysenihe Bedand Blua too much on one or both when adjusted to the fully open position then adjust Make sure the requested pressure is within the max Imbalance l material is greater than the sides accordingly operating pressure which can be found on the setup defined amount m Relieve system pressure then remove the orifice from Debris in the orifice block nig ga the orifice block and inspect for debris in the cavity screen System 1 Relieve system pressure and remove the orifice from Dispense valve failed to Check to make sure the dispense valve is properly Dispense line is clogged 5 material lines On the ADM go into the setup screens gt System gt Pressure imbalance is land ensure the pressure imbalance value is the the orifice block and inspect for pack out Clean or replace as necessary installed and all wires are properly connected providing invalid no pressure Bad sensor pressure transducer defined too lovv maximum acceptable to prevent unnecessary alarms Pressure readings AH Sensor Fall No material in pump Fill tanks
29. 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 Defective RTD Replace RTD Alarm Defective cooling valve No temperature decline Heater overtemperature cutoff Defective High Power Temperature Control Replace High Power Temperature Control Module Module Loose connections Tighten connections Appendix D ADM Error Codes Error Error Code Error Description Type Cause Vj Motor Control The voltage to the MCM has kam Gan circuit breaker isually check circuit breaker for a tripped condition Undervoltage dropped to a level where Supply lines providing incoming voltage to ensure it is above the low voltage minimum operating voltage performance is greatly affected VAA6 Red Blanket Overvoltage Red Chiller Overvoltage V4B5 Blue Blanket Overvoltage Hi hine iiitaas Alana Incoming line voltage is Measure voltage across disconnect switch Voltage 9 9 i should measure between 190 and 264 Vac Blue Chiller Overvoltage V4A3 Red nline Overvoltage 1 Blue Inline Overvoltage The voltage to the MCM has Motor Control reached an unsafe level and Supply lines providing Check incoming voltage to ensure it is below the V4H0 Alarm i i Overvoltage has been shutdown in an high voltage maximum operating voltage attempt to prevent damage V4A2 Red Hose Overvolta
30. 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 soecial 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 dacti
31. s Measure resistance of heater s The requested dispense Pumps are defined with amount is below the minimum the wrong size amount of the system 25 of the combined pump volumes is If the user has to be able to take the shot the system Small Shot the minimum the capabilities ofthe ust be fitted with smaller pumps Requested shot is below Request Deviation 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 uy o gt gt gt gt gt to Co Co N P O O O WO o gt Z C0 IN 6 3A2797G Appendix D ADM Error Codes Error Error Code Error Description Type Cause Comm Error m CAA2 Module missing power power supply connection Module not programmed Program the module Alarm Module bad Replace module Comm Error Red Inline PLC is not maintaining ae l heartbeat Ensure PLC is triggering the heartbeat Alarm Comm Error Comm Error Ratio Monitor Comm Error Gateway Comm Error DGM Comm Error O gt O N CACN O JJ JJ D 3 O D Pendant CUCN _ Heartbeat Heartbeat Error Comm Error pone Red Blanket Comm Error TAN Red Chiller CABI Comm Error Blue Inline Module missing power power supply connection Module not programmed Program the module Module Bad Replace module Comm Error Comm Error Cang Blue
32. same environment as gun Verify FTS installation Material does not heat FTS failed or is not contacting cor Check FTS rectly FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Verify FTS installation Temperature control alarm See Advanced Display Module ADM on page 20 Proportioning System Proportioning pump does not Pump piston or intake valve leaking Observe gauges to determine which pump is los hold pressure when stalled ing pressure Determine in which direction the pump has stalled by observing which directional valve indi cator light is on Repair the valve Material imbalance 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 vis cosity of 250 to 1500 centipoise Clean inlet strainer screen Worn pump inlet valve ball seat or gasket Pressure relief circulation valve leak Remove return line and determine if flow is present Erratic pump movement Pump cavitation Feed pump pressure is too low Adjust pressure to Pump output low Obstructed fluid hose or gun fluid Open clear use hose with larger ID sum VVorn piston valve or intake valve in See pump manual 3A0019 displacement pump Inadequate feed pump pressure Check feed pump pressure and adjust to 100 psi 0 7 MPa 7 bar minimum 50 3A2797G Tr
33. service the orifices As Needed and filters Check Accumulator Pre Charge Weekly Check tightness of all clamps and Weekly am fittings 46 3A2797G 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 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 compo nents FiG 25 Remove Access Cover The software version history for each system can be viewed in the technical support section at www graco com 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
34. start up process 70 Home Screen Shot Mode This mode allows the user to select one of 100 pre defined shot numbers See Shots Screen on page 55 for information about editing shot definitions To use a predefined shot 1 2 Enter shot mode Press m and use the numeric keypad to enter the desired shot number Press to select the shot number 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 61 expires NOTE There is a three second delay after a dispense before another dispense can be initiated Target Flow Target recipe time Ratio Press Bbl to switch between low and high pressure modes without dispensing During a dispense press Ki to abort the dispense See Home Screen Standby Mode on page 70 for other button functions 3A2797G 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 58 for information about editing sequence defini tions NOTE There is a three second delay after a dispense before another dispense can be initiated 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 betwee
35. the desired letter and press to accept the letter 01 25 12 10 22 Calibration Maintenance mi Hu Active Errors Red Label RED is mizin nini Standby fale pnmo umana Pe eehm 1 Use arrow keys to select the desired letter and press Bili to accept the letter To erase all text press To delete one letter press To move the cursor one letter to the left press Mia cursor one letter to the right press Ml To toggle m the letters from upper lower case press 2 When finished entering the new label press AS 62 Maintenance Screen This screen shows shot number sequence position and 1 dispense valve counters Press and navigate to the drop down box Press and scroll to a range of count 4 1 ers to view Press M again to select the range of counters and display them on the screen Counters may be erased individually Navigate to the PAYA counter you want to erase and press Alternatively each counter displayed on the page may be erased simultaneously by pressing E44 x 3 3 DO Fa om Mom 1 2 3 4 J 7 8 g 10 3A2797G 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 install ing level sensors se
36. to set the units of measure Volume Units ec r Weight Units Tel Pressure Units psi Temperature Units F Cr Flow Units Weight v Rate Units second 3A2797G Appendix B ADM Setup Screens Overview Advanced Screen 3 6 19 11 13 39 Conditioning Shots Standby ray Dispensing Disabled Low Temp mi Disable Dispensing From Display Disable Modifying Temp Setpoint Disable Operator Mode Adjustments Temperature Alarm Disables Dispense Enable Operator Mode Cavitation Alarm Complete Dispense With Setpoint Error J Enable shot aborted notification 2x Trigger For Dispense Dispense From Home Position This screen allows the user to control the availability of some key system features e 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 e 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 e Disable Operator Mode Adjustments When this box is checked the user will not be able to adjust the dispense settings in Operator Mode e 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 e Enable Opera
37. 2 il ie Calibration EYE Inlet psi Type B 50 Inlet psi Type 60 160 Size 60 Size 60 System Screen 2 This screen allows the user to set which items are installed on the machine 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 ispressed 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 61 O 06b 14 1175 O Calibration Maintenance shot sd No Active Errors Enable Gel Timer Pump Line Miz Head Hydraulic Level Sensor Hydraulic RTD Post Dispense Shot Disable seconds Dispense Valve D2 seconds 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 applica ble for P2 Fusion Dispense Valves This feature can not be active if the Pre Dispense Delay feature is active Pre Dispense Delay Pre Dispense Delay is a feature where the HFR can delay the start of a dispense until the user has pressed a
38. 30 F Low Alarm 111 7F 3 Edit the setpoint and alarm values and then press 5 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 3A2797G 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 vvill circulate in lovv 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 Periodic Night Mode Conditioning Screen This screen allows the user to set the on and off times of the machine in one minute intervals 08 16 13 09 56 le Supply Advanced Standby mi Active Errors Night Conditionin scheme Prepoly Material F Prepoly Timeout minutes Outlet Pressure psi On Duration minutes Off Duration minutes 65 Appendix B ADM Setup Screens Overview Time Based Night Mode Conditioning Screen This screen allows the user to set a speci
39. 9 01 AM 3 GRACO DISPTEXT TXT 22 KB Text Document 1 13 2010 9 03 AM 3 FFFFFFFF SETTINGS TXT 43 KB Text Document 1 13 2010 9 03 AM C DOWNLOAD 1 2 C DATA0004 C DATAON05 B 06 UPLOAD DVD Drive F x 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 trans ferred 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 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 92 NOTE Before the update begins the ADM automatically shuts down the system aborting any in progress dis pensing When the software is updating the system a pop up box will appear to inform the user of the update an
40. 97G Typical Installation 2 ad 0 gt 8 5 on MCC 9 LUE A O WN EN se os 6 Shown exposed for clarity AS 0 WE 2 We sg KO NG KG NG Q 54 NG NG NG NG 2 KG SS 9 KG Ny YQ 42 2 442 ag res 4 res KO res x Ko gt NS 4 ates NU Q 5 gt 8 res KO 44 4 4 4 NO 2 KS 54 4 lS 59 o gt KZ 54 o KZ KZ o o Q Q 54 KS NG 54 4 4 KO 4 o lS V NG QO 4 O 2 44 4 4 2 54 S 5 lS 5 o ti19507a 5 OO 54 55 4 4 KI 5 2 lS No gt 4 4 O KO res 4 2 KIS 254 Ng KS O oO 42 5 RD 5 ni O KS OO A
41. Advanced Sequences 23 I 05 16 13 09 45 ie mi No Active Errors 5 2 3 4 5 6 7 8 9 Fi 1 516 NOTE Depending on the dispensed volume average the column may be either a positive or negative value 56 Volume VVeight Based Example A 75 cc s shot is defined to dispense for 75 cc 00 16 13 0946 e Advanced Sequences standby mi Active Errors gt dani pi C CETT 1 Dispense 5 shots into 5 separate containers 2 Measure the dispensed amount and record the data Example 3 Dispensed Volume cc 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 3A2797G Appendix B ADM Setup Screens Overview d o Enter the calculated value in the column 2 Press E then use the arrow keys to navigate to the Example 3 Enable Range Calibration option OB 1 17 15 ie Advanced Sec HeNc 3 Press to activate the option standby mi Mo Active Errors icc To edit a shot definition Ba 1 Navigate to Shots Screen mn Mo Active Errors 4 1 Gl Shot Calibration Table This screen allows the user to set the offset 2 g for a calculated range of shot sizes based on pump sizes and material specific gravity 7 NOTE This table is only available whe
42. Blanket Setpoint Not The set point was not reached Deviation Material restriction too tow request Reached and the pump was shutdown high for requested flow q The maximum cycles per Comm Error SABS Blue Chiller Motor minute of the pump has been Deviation exceeded Comm Error Communication error Pump cannot reach the a Setpoint Not eures ed oresoua Increase restriction in the system The set point was not reached Deviation q P Restriction for the pump is not sufficient Setpoint Increase the restriction or lower the set point Exceeded Comm Error 55 Red Tank Comm Error BACs Blue Tank Reached Pump cannot reach the BAS Decrease restriction in the system requested flow System underwent a Comm Error change that caused a Erase learned System Data found in the setup large drop in restriction screens under calibration such as new orifices mahaba Make sure the material lines are open and have No material in pumps proper feed pressure Setpoint The set point was exceeded Deviation Exceeded 3 ge STS gt gt gt gt O O 3A2797G 77 Appendix D ADM Error Codes Error Error Code Eror Nam enor Desoription Type cause OOO This calibration lets the MGM know where the ends of the L bad ii Check to ensure the pressure transducer is properly pump are If the data gathered AA orn installed and all wires are properly connected nvalid Learn Devi
43. Description 24J312 High Volume Filter Kit 40 Mesh 24P095 Low Volume Filter Kit 100 Mesh GX 16 Fitting Kits The following kit is for Models 24N575 and 24N576 only Part Description 24N435 Gun Fitting Kit The following kits are for all other Models Part Description 24K672 Right Orientation 90 Fitting Adapter Kit Left Orientation 90 Fitting Adapter Kit 24K674 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 Q ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause elec tric shock e Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source e All electrical wiring must be done by a qualified electrician and comply with all local codes and reg ulations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if solashed in the eyes or on skin inhaled or swallowed e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispos
44. Display Module see page 20 Component A Red Pressure Relief Outlet Component B Blue Pressure Relief Outlet Component A Red Fluid Manifold Inlet on left side of manifold block Component B Blue Fluid Manifold Inlet HFR Fluid Manifold Feed Inlet Pressure Gauge Feed Inlet Temperature Gauge Component A Red Outlet Pressure Gauge Component B Blue Outlet Pressure Gauge Component A Red Hose Connection from feed to gun or mix head Component B Blue Hose Connection from feed to gun or mix head Hydraulic Power Pack Assembly Hydraulic Tank Pumpline Linear Sensor AA FM PA WAG FP QI PB 3 MA Motor Control Module see page 18 MP Main Povver Svvitch PA PB PD Component A Red Pump Component B Blue Pump Povver Distribution Box PHB Primary Heater B Side PHA Primary Heater A Side SB TA TB TC Primary Heater Fluid Inlet Primary Heater Fluid Outlet Primary Heater RTD Primary Heater Overtemperature Switch Component A Red PRESSURE RELIEF DISPENSE Valve Component B Blue PRESSURE RELIEF DISPENSE Valve Component A Red Pressure Transducer Component B Blue Pressure Transducer High Power Temperature Control Module not shown see page 24 MA Ly HP PD WU UM UI NNNNNNN i FT FP ti19508a Fic 2 C
45. From the Home screen press 6 and select 1 Press O to disable the ADM Standby mode 2 Shut off feed pumps and agitator if used 3 Turn PRESSURE RELIEF DISPENSE valves SA b geli Material will not dispense Pump will park automatically Once pump is parked SB to PRESSURE RELIEF CIRCULATION ri pump will stop moving Route fluid to waste containers or supply tanks Ensure gauges drop to 0 l 2 Press to disable the ADM 3 Turn main power switch MP to OFF position SA 4 Close A Red and B Blue fluid supply valves ti9879a1 OY 4 For models with a dispense valve with a safety 7 lock engage gun safety lock 5 Relieve pressure in dispense valve See dispense valve manual 5 Perform Pressure Relief Procedure on page 44 6 Shut down feed pumps as required See feed pump manual 44 3A2797G Flushing A M Pd Flush equipment only in a well ventilated area Do not dispense flammable fluids Do not turn on heaters while flushing with flammable solvents Heaters must be off and cool when solvent is in the system 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 Run Screen Icons on pa
46. Instruc tions Parts Feed System Manuals 3A0238 AC Hydraulic Power Pack Instruc tions Parts 3A0235 Feed Supply Kits Instructions Parts 3A0395 Stainless Steel Tank Feed Sys tems Instructions Parts 3A1299 Carbon Steel Tank Feed Systems Instructions Parts 3A0237 Heated Hoses and Applicator Kits Instructions Parts 308495 Viscon Heater Kit Manual Dispense Valve Manuals 313536 GX 16 Operation Accessory Manuals 3A1149 HFR Discrete Gateway Module Kits Manual 312864 HFR Communications Gateway Module Instructions Parts 3A1936 Agitator Kit Instructions Parts 3A1962 Agitator Kit with Heat Blanket Instructions Parts 3A1657 HFR Flow Meter Kits Instructions Parts 332544 HFR for NVH Prepoly Refresh Kit Instructions Parts 3A2797G Related Manuals Models Models Primary Primary Max Flow Approximate Maximum Full Load Heater Heater Rate Output per Hydraulic Fluid Working Peak Amps Watts Watts Ib min Cycle A B Pressure Pressure Per Phase B Blue kg min gal liter Ratio _ psi MPa bar 24N569 90 1230 3 18 8 2 0 033 0 125 1 9 1 24N570 x 68 400V 3 24N571 90 1 230V 3 24 11 0 045 0 170 1 4 1 24N5724w 68 400V 3 ka 2000 24N573 230V 3 14 138 EA kaa a ud 4 000 18 8 2 0 033 0 125 aans ew e A00 0 Lawas o av Material A Red B Blue 25 7 6 m 10 3 m Ratio Pump Pump A Red B Blue Chemical Chemical System A B Size S
47. Loose bad connection to the linear position sensor Retighten or replace supply tube Over pressure valve dumping to tank The material pump pressure exceeded the maximum operating pressure as defined in the setup screens Invalid maximum pressure defined which will abort dispenses Orifice blocks closed off Verify that one or both of the orifice blocks dispense P4DO Alarm Material fillers may have packed out in an orifice 80 3A2797G Appendix D ADM Error Codes Error Error Code Error Description Type Cause 100 Low Ratio Alarm Alarm RADO High Ratio Alarm Ratio monitor has detected an Material A to Material B l 5 l Check feed system R2D0 7 77 of ratio condition is out of ratio Deviation ae High Ratio Deviation Deviation Red Tank T1A6 Low Fluid Temp Blue Tank T1B5 Low Fluid Temp Red Inline T1A3 Low Fluid Tripped circuit breaker Visually check circuit breaker for a tripped condition Temp Blue Inline T1B1 Lovv Fluid Temp Fluid temperature is below the Red Hose defined lovv alarm limit T1A2 Low Fluid Temp Blue Hose Measure voltage across input terminals on power line T1B4 Lovv Fluid Lovv povver filter Voltage should measure betvveen 190 and 264 Temp Vac Red Chiller Low Fluid Temp Blue Chiller Low Fluid Bad heater s Measure resistance of heater s Temp Dispensing Disabled Low Temp Dispensing disabled because Temperature is out of Dispensing lof tem
48. N KG 4 KS ag l OY KO 42 9 Q 2 9 2 NG 4 res KI x 2 54 KS gt KO S Q O KS o Q HO O82 5282 252 Ny 2 o 2 o KG NG KZ 54 442 K gt K2 x l Sx KI 4 4 KO SS 4 9 4 54 4 o 595 o KS HG 546 SOK KS KO KIS o 54 54 22 6 KS 54 KG 55 Q Ks 9 5 KO KO 2 54 4 res l KG NG 4 KS KG KG KS 5 NG KG NG KO res 4 54 KG RS 54 54 54 SS O o K2 oS 13 Wrap with tape during operation lon Typical Installation Installat Typica FIG 1 Fluid Temperature Sensor FTS B Tank Stand B Blue A Tank Stand A Red C AC Power Pack HFR Power Pack E Dispense Gun F H Main Hose Bundle G Manifold J Key Whip Hose Bundle 3A2797G Component Identification Component Identification Key for Fic 2 and FIG 3 AA BA BB FA FB FM FP FT GA GB HA HB HP HT LS Advanced
49. PENSE for the corresponding material side ti9877a1 j Open feed inlet valve and the material supply ball valve on the system k Navigate to the Standby Screen and push to start pumps NOTE Material will dispense into the container from the applicator material hose at this time Continue to dis pense fluid until no material contamination is noticed NOTE If necessary navigate to Operator Mode to adjust the flowrate 3A2797G Setup Stop dispensing by pushing from the Standby Screen m Close feed inlet valve and the material supply ball valve on the system n Connect the applicator return hose to the fluid inlet fitting on the system gt nas Gal A lz P ell NG UNG p H FIG 21 Return Lines AS Do not install shutoffs downstream of the PRESSURE RELIEF DISPENSE valve outlets BA BB The valves function as overpressure relief valves when set ma 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 work ing pressure of this equipment o Ensure all material hose connections are tight p Open the RETURN ball valves on the tank stand q Repeat steps j thru p for A side Red 39 Setup 15 Install GX 16 Orifices Q Ar a Close both A side
50. ROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 MOGE S z a d NA AWA 4 ACCeSSOT eS vu n ab tied OR ee aks 6 ABD ICA OT s NN LANG al 6 GX ONNCES se z b attain b l s b 6 B Blue and A Red Feed Tanks 6 AC Povver Pack 6 Reiki LL 6 GX 16 Shutoff Valve Kit 6 Additional Accessories 7 Communications Gateway Module CGM 7 Ba Filter KIIS sia ce is eaten Sd asta dala SUZ l l Ka 7 52 16 Fillin S E a 7 Vuarn n s z l b 8 Important Two Component Material Information 11 Isocyanate Conditions 11 Material Self ignition 11 Keep Components A Red and B Blue Separate 11 Moisture Sensitivity of Isocyanates 11 Foam Resins with 245 fa Blowing Agents 11 Changing Materials 12 A Red and B Blue Components 12 Typical Installation 13 Component Identification 14 HFR Hydraulic Power Pack 17 Motor Control Module MCM 18 Advanced Display Module ADM 20 Fluid Control Module FCM 23 Temperature Control Module 24 SOUD aan ba Gn 28 SIAMUD a 43 hUlGOV z o Dey z 44 Pressure Relief Procedure
51. SB 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 89 Appendix F USB Operation Log Files Folder Structure L DOWNLOAD End Fil Edit View Favorites Tools Help G Back 3 IG Search ep rates Address V E GRACOWS620 1073 DOWNLOAD F Se TEM PRELOAD Ci 4 DVO CD Rw Drive D Sa Removable Disk E1 T CanSolarData K Car_Search china Trip fMyCamera E K GRACO T 06200799 5 Z 06201073 T L CO 2 H rini man KA NT ES lt Fic 29 DOWNLOAD DATAxxxx Folders F ir iii Fark Qj 3 K Search gt Folders Address E GRACO 06201073 DOWNLOAD DATADNNZ Folders x DATADO Folders El DISPTEXT TXT E Desktop iz o My Documents E l My Documents O Computer mi Bu Se TEM PRELOAD C11 LA DVD CD Ruv Drive Do tag Removable Disk E CO CanSolarData Search CO China Trip K GRACO T 06200799 z 06201073 EZ DOWNLOAD 2 002 IPL man II x ZL 1 ERROR C
52. SV f sl E 2 yoB Csv E6 3 5YSTEM CSY 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 are 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 A B C 1 Error Log 2 S N 06201073 3 Software Part Number 16N420 4 Software Version 1 01 002 5 4 23 2012 11 09 6 7 Date Time Error Log 8 4 11 2012 14 12 17 No Active Errors 9 4 11 2012 14 13 26 No Active Errors 10 4 11 2012 14 14 14 No Active Errors 11 4 11 2012 14 15 00 No Active Errors 12 4 11 2012 14 17 11 P4D0 A Pressure Imbalance 13 4 11 2012 14 17 17 Error Cleared P4D0 A Pressure Imbalance 14 4 11 2012 14 17 31 DDA1 D Red Pump Cavitation 15 4 11 2012 14 17 44 DDB2 D Blue Pump Cavitation 16 4 11 2012 14 20 18 Error Cleared DDA1 D Red Pump Cavitation 17 4 11 2012 14 20 18 Error Cleared DDB2 D Blue Pump Cavitation 18 4 11 2012 14 20 46 P4D0 A Pressure Imbalance 19 4 11 2012 14 20 52 Error Cleared PADO A Pressure Imbalance 20 4 11 2012 14 23 59 No Active Errors 21 4 11 2012 14 24 00 No Active Errors 22 4 11 2012 14 48 47 No Active Errors 23 4 11 2012 14 48 48 No Active Errors 24 4 11 2012 14 50 03 No A
53. Setup Operation GRACO HFR for Foam Cart Hydraulic Plural Component Fixed Ratio Proportioner For dispensing NVH foam For professional use only Not approved for use in explosive atmospheres or hazardous locations Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 4 for model information and maximum working pressure GIG KAKA HAAN AA KKK NATAN NATN SORKRKRKK KR KKK RRND SRK KR KR KKK KKK KD RRKRKKRK e SRKRKRKS SRR II SRS HO RRS atone SKS SERA 3n KIKO LSS S KRAS KS SRS KN KS KKK PO RS IS SRKKKD SIY NLA KS Nagtatago AO RRS AS RRS natatago SKS talata sas 4565 S505 HS KI natatae IS 2x5 95 RS KS SRS taganas KO SKK Pato tato SRS HRS a 25299A KS aa SS tatto 2456 agta tot 44 SRKXS atasan SxS 26299 KO KA 1545 RRS atraso KS taganas SKS NGA ttr KOS KA IG SXRD IA REKKKRKR SKK KKK REX KKK NG 7 GG YAAN 00 0 6 0 0 0 0 0 0 0 0 0 0 0 0 0 Pa en S Pend ng KKK KKK ti19507a P
54. 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 hard ware 3A2797G Setup 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 equip ment Reading should not regularly exceed approxi mately 400VDC to avoid tripping the 420VDC alarm level in the Motor Control Module If power quality is sus pect 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 duratio
55. able safety regulations Nam MOVING PARTS HAZARD 4 Moving parts can pinch cut or amputate fingers and other body parts e Keep clear of moving parts Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equip ment follow the Pressure Relief Procedure and disconnect all power sources vf BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment 10 3A2797G Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocya nates 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 ventila tion 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 per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition Jj Some materials m
56. acre 81 63 CB 5 SA 2 400 B5 SA 169 441 HIHI o l a LL ai il il ilo 119512 11 230V 3 phase l Ty FT FT Hi WALA 2 ti19513a 400V 230V 3 phase 3 phase Component 30A Motor Control Module Primary Heater A Primary Heater B AC Power Pack 68A 30A 0 a MGA A 5 5A Miscellaneous El BA 4 SA 1 HOA 30A 30A 16 3A2797G Component Identification HFR Hydraulic Power Pack DE DG Kat DF Q ZA 4 2 R 2 E675 5 H R Ta DB o M 4 DH LU ae O N O 6 NG 1 L 2 5 DD Ba o 419514 DL Fic 4 HFR Hydraulic Power Pack Key DA 9 Gallon Hydraulic Oil Reservoir see Technical Data on DG Fan page 95 for specifications DH Oil Filter DB Electric Motor DJ Shroud not shown removed for clarity DD Hydraulic Housing DK 3 Way Splitter DE Directional Valve DL Oil Level Sensor Optional DF Motor Control Module see page 18 3A2797G 17 Component Identification Motor Control Module MCM NOTICE
57. ar gloves if fluid temperature exceeds 110 F 43 C For detailed temperature adjustments including alarm levels or upon initial machine configuration see Condi tioning Screen 2 on page 64 for details For minor adjustments to the temperature setpoint once the machine has been initially configured see the Status Screen on page 72 e Set system control and dispense modes See Sys tem Screen 1 on page 60 e Set pump sizes See System Screen 1 on page 60 e Define Shot Recipes a Navigate to the Shots screen 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 5 e Repeat the previous two steps for all desired shot numbers e Change pressure imbalance setting optional The pressure imbalance function detects conditions that can cause off ratio dispense such as loss of feed pres sure 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 37 Setup 38 Navigate to System Screen 3 Press cal to enter the screen Navigate to the pressure imbalance field Type the desired pressure imbalance setting then press Press ita
58. ation D5A1 during this process is outside of normal parameters the machine will operate with a greatly reduced stroke Mode Data n Bad linear position Verify pump moves to limits if problem persists sensor replace linear position sensor Bad linear position Ra The linear position sensor is Replace linear position sensor Position returning data that should not Sensor Fault be possible during normal operation Red Pump Cavitation Blue Pump Cavitation sensor Linear position sensor may be loose where attached to pump housing Insufficient material Verify that incoming ball valves are open being supplied or Deviation Re tighten the sensor and re calibrate the machine Loose bad connection to Check to ensure the linear position sensor is properly linear position sensor installed and all wires are properly connected Alarm Cavitation was detected on the given pump pressure on feed system Inspect filter for debris of filler packout and clean or incoming fluid filter replace as necessary Pump Not Parked The pump failed to reach the park position Hose blocked Clear or replace hose as necessary Dispense valve failed to Check to make sure the dispense valve is properly open configured and connected to the MCM Check Flow Cogs in flow meter are that flow meter is matched to nominal pump 151 Flow Meter has caused a fault Deviation uu Check Flow Cable unplugged loose l
59. aulic hose marked with both green and white stripe is for the open port of the gun The hydraulic hose marked with only a green stripe is for the close port of the gun Fic 19 Hydraulic Connections j Attach trigger switch cable if applicable to gun and HFR ti14494a Fic 20 Cable Connections 35 Setup 12 Setup the Advanced Display Module ADM 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 FIG 6 on page 20 If the System Status Indicator Light is not green press the ADM Power On Off CA button The System Status Indicator Light will illu minate yellow if the machine is disabled The blue token 24M560 must be installed to enable cold start up temperature monitor zones and shot times less than one second NOTICE To ensure proper machine operation the blue token must remain installed in the ADM during operation If the machine is in the Disabled mode screen press repeatedly to select standby mode Navigation e Press or to navigate to new screens e Press or to navigate to new screens or to move between fields e Press to activate the desired field or to acti vate deactivate an op
60. ay become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS Keep Components A Red and B Blue Separate ey Cross contamination can result in cured material in fluid lines which could cause serious injury or dam age equipment To prevent cross contamination of the equipment s wetted parts never interchange component A Red and component B Blue parts 3A2797G 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 crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Keep the ISO lube pump reservoir if installed filled with IsoGuard Select part 24F516 The lubricant creates a barrier between the ISO and the atmo sphere e Use moisture proof hoses specifically designed for ISO such as those supplied with your system N
61. ch temperature conditioning components are installed in the system Check the box next to the component type for the appro priate side of the system to indicate that a component is installed A maximum of four components and two moni toring zones may be selected ON11 11 09 51 e Supply Advanced di Red Pressure Sensor Fault Monitor R aj 64 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 01 12 10 10 17 Sup mi Ha Ac ber atar xx PP OF 1222 7 KAT NOTE All components are shown installed for refer ence only Only 4 components and two monitoring zones can be installed at one time To edit the temperature setpoint and alarms for a partic ular component 1 Press then use the arrow keys to navigate to the component you wish to edit 01 12 10 10 17 e Supply Advanced Operator mi No Active Errors RED BLUE same 22 F 122 F er 22 F 7 I G i Napa F 22 F 1 3A2797G 4 2 Press to display the setpoint and alarm values associated with that component 031010 15 49 4 Supply Advanced Standby mi No Active Errors Material MEH F High Alarm 1
62. ctive Errors 25 4 11 2012 14 50 10 No Active Errors 26 4 11 2012 14 50 18 No Active Errors 27 4 12 2012 7 51 33 No Active Errors 28 4 12 2012 7 52 35 DDA1 D Red Pump Cavitation 29 4112 2912 7 52 39 DDR2 N Blue Pumn Cavitation M b bl 1 ERROR 3 90 Event Log ECOX R Setup Values Changed ECOX R Setup Values Changed ECOX R Setup Values Changed ECOX R Setup Values Changed No Event No Event No Event No Event No Event No Event No Event No Event EM00 R System Powered Off EL00 R System Powered On EM00 R System Powered Off ELOO R System Powered On EM00 R System Powered Off ELOO R System Powered On EM00 R System Powered Off ELOO R System Powered On No Event No Event 4 Active Shot Number 2 3A2797G Example 2 JOB File The 2 JOB file is the Shot Data Log file Appendix F USB Operation A B D F G H l J K 1 Job Log 2 S N 06201073 3 Software Part Number 16N420 4 Software Version 1 01 002 5 4 23 2012 11 09 6 Requested Requested Requested Requested Tank Bl Inline Blue Inline Blue Hose Blue Hose Blue Inline Red Inline Red Hose Red FTS Hose Red Materia 7 Date Time RTD Temp Temp FT5 Temp Temp RTD Temp Temp Temp Temp Temp 8 4 11 2012 14 16 52 9 4 11 2012 14 16 54 10 4 11 2012 14 16 56 11 4 11 2012 14 16 58 12 4 11 2012 14 17 00 2 13 4 11 2012 14 17 02 14 4 11 2012 14 17 04 15 4 11 2012 14 17 07 16 4 11 2012 14 17 09 17 4 11 2012 14 17 11 18
63. d by poy Prepoly refresh took longer to the second level sensor Check for an obstructions within the material supply 9 Refresh Time Alarm 5 complete than normal vvithin an allotted amount line pres of time Low oil level Check oil level and if low add more hydraulic fluid Check to ensure the hydraulic oil level sensor is Loose bad connection 8 properly connected to the MCM and that the wire has pa not been damaged The volume of oil in the tank is a Bad level sensor below the minimum level MBH1 Alarm Replace level sensor Low Oil Level needed for the system to m Inspect hydraulic driver end seals and early leak Leak in hydraulic driver detection tubing Replace seals as necessary and properly operate replace lost oil Leak in the hydraulic Inspect the hydraulic reservoir fittings and filter for reservoir heat leaks Repair or replace as necessary and replace exchanger lost oil Low Motor Te motor magnetism has Prolonged exposure to error persists and performance can no longer MBN1 decreased to the point where Advisory 9 p satisfy the user requirements the motor will need to x performance is greatly reduced be replaced Download USB logs to a memory stick MMUX USB Logs USB log has reached the porn logs have not been Full ean downloaded 77 the Enable USB errors on Advanced screen Material N1D0 Dispense Alarm Below Alarm 7 Material dispense is belovv the Cogs in flow meter are
64. d 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 pre vent 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 3A2797G Update Custom Language 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 modi fied 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 trans ferred 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
65. ditioning Shots standby mi No Active Errors _ Enable Diagnostic Screen Low Material Disables Dispense Limit Rate on Stall to Pressure Enable Range Calibration Enable Prepoly Refresh _ Enable Leak Detection Enable Downloading of USB Logs 7 Enable USB Errors Date of Last Download 081613 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 overwrit ten 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 3A2797G The third option is a checkbox that enables or disables the ability to record errors associated with the USB logs 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 U
66. e Red flashing slow Token error Remove token and upload software token again 3A2797G 23 Component Identification Temperature Control Module Nik 4a ti12353a1 Fic 10 High Power Temperature Control Module Sensor Connections Key 1 Overtemperature Switch Connection primary heaters only 2 RTD Temperature Sensor Connection 3 Output Power Connection DC Output Connection Input Power Connection CAN Connections Rotary Selector Switch Token Access NOOA ti12356a1 ti12357a1 Fic 11 Low Power Temperature Control Module Cable Connections 1 Overtemperature Switch Connection 4 Output Connection 2 RTD Temperature Sensor Connection 5 Input Power Connection 3 Output Power Connection 6 CAN Connections 7 Base 24 3A2797G Temperature Control Module Diagnostic Information Module Status LEDs Signal Description Green on Temperature control module is powered up Yellow on Internal communication in prog ress Red solid Temperature control module failure See Troubleshooting table Red flashing Uploading software fast Red flashing Token error Remove token and slow upload software token again Blue light off High Power Module only Temperature control module is off See Troubleshooting table Blue flashing High Power Module only Length of flashes indicates amount of power running through tempera ture control module 3A2797G Component Identification Heat Control Zo
67. e time it takes for the material to reach the middle sensor 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 11 10 29 Supply Advanced 3A2797G 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 08 18 11 10 53 Conditioning Shots mi Mo Active Errors Language English Date Format mmizidi Date 08 151 11 Time 53 Password Screen Saver 5 minutes Silent Mede e Time formatted in 24 hour time e Password Enables the setup screens to be pass word protected Entering 0000 disables the fea ture e Screen Saver Enter the amount of time until the backlight turns off Entering O 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
68. e Related Manuals on page 3 The user may select from the following refill settings Dis abled Monitor Manual Auto Top Off Auto Full Volume NOTE Use the Disabled setting if off board tanks are not installed 2411 15154 Ell Supply Conditioning Standby ry Corn Error Blue M M Refill Setting Disabled Disabled Refill Timeout ilminute ilminute Refill Sensor Type The following describes system operation when each tank mode is selected e Disabled Disables tank operation Monitor 2 Sensors e The top sensor generates a high level deviation and the bottom sensor generates a low level alarm e Refill is not supported no button is provided on the run screens to initiate refill e Errors will clear when the corresponding condi tion clears e Manual 2 Sensors e The top sensor generates a high level deviation and the bottom sensor generates a low level alarm e A button is provided to the user on the run screens to initiate a manual refill operation at any time e 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 e The low level alarm will clear when the condition clears 3A2797G Appendix B ADM Setup Screens Overview e Auto Top Off 2 or 3 Sensors e Automatically selected with three level sensors selected e The low level sensor will generate a low level alarm Two
69. e of it according to applicable guidelines e 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 inhala tion of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection e 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 8 3A2797G Warnings 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
70. ements 3A2797G 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 Amer ica a special transformer rated for 400 V Y con figuration 4 wire may be required North America mostly employs a 3 wire or Delta configuration The two configurations are not inter changeable Accessories Accessories Applicator Part Description 24J187 GX 16 24 1 Straight Machine Mount 24K233 GX 16 24 1 Left Machine Mount GX 16 Orifices Part Description B Blue and A Red Feed Tanks Part Description 24N594 120 gal 75 1 Stainless Steel Tank No Agitation Insulation 3 Level Sensors A Side 24N595 120 gal 75 1 Stainless Steel Tank No Agitation Insulation 3 Level Sensors B Side 24N578 120 gal 75 1 Carbon Steel Tank No Agitation 3 Level Sensors A Side 24N597 120 gal 751 Carbon Steel Tank No Agitation 3 Level Sensors B Side 24N579 12 gal 8 1 Stainless Steel Tank No Agitation 1 Level Sensor B Side AC Power Pack Part Description Refill Kits Part Description 24M418 Low Volume 2 gal 7 6 1 tank 24M419 High Volume 20 gal 76 tank GX 16 Shutoff Valve Kit Description 24M596 GX 16 Shutoff Valve Kit For use with 24N569 24N570 24N571 24N572 24N573 24N574 24M368 GX 16 Shutoff Valve Kit For use with 24N575 24N576 GX 16 Proximity Kit
71. eparate containers for an average range 2 Measure the amount for each shot size and record the data 3 Repeat steps 1 and 2 for all twelve ranges 4 Calculate the average for each range and record the data Shot1 Shot2 Shot3 Shot4 Shot5 5 5 Calculate the offset of each shot size and record the data Target Shot Size Average Shot Size 6 Enter the offset into the table 00 16 13 09 53 Advanced SecLences mi Mo Active Errors Standby Setpoint ceis shot Size Offset Shot Size Offset 1115 73 106 16 16 f 107 145 18 27 1 148 127 28 41 180 280 42 54 251 354 55 72 355 7 Repeat steps 1 through 6 for more precise offsets 58 Example Step Shot Range 11 15g Ref Number Target Shot Size 13g 1 2 Shot 1 11 600 1 2 Shot 2 12 200 1 2 Shot 3 12 400 1 2 Shot 4 11 900 1 2 Shot 5 12 000 Average 12 02 Shot Size Offset 0 98 Sequences Screen This screen allows the user to edit sequence informa tion See Home Screen Sequence Mode on page 71 for information on how to use predefined sequences NOTE Five sequences with 20 positions each are avail able across 10 pages NOTE Sequence positions are made from shots defined in the Shots Screen To edit a sequence 1 Press then use the arrow keys to navigate to the desired value 2 Type the new value then press to accept the new value 06 08 17 15 50 Shots Calibration standb
72. erase all of the batch data points simultaneously Batch l l EE 519589 Ci 23737 23737 i fel 6 22650175 270756665 21 26959 26959 NOTE In a circulation system the pumpline must be stopped to erase counters 73 Appendix C ADM Run Screens Overview Optional Screens The optional Diagnostic screen can be enabled in the Advanced Screen 4 screen see page 68 Diagnostic a Capacitor Motor Hydraulic g7 y Current Amps BUS Phase 1 Phase 2 Phase 3 0 0 0 0 0 0 0 0 Voltage Volts Speed RP BUS Motor Motor Motor 335 O 0 The Diagnostic screen shows status information for vari ous components in the Motor Control Module 74 3A2797G Appendix D ADM Error Codes Appendix D ADM Error Codes Code Error Name ror eserption Type cause OOOO Mix Head Motor Overload Soft Stop Low Mix Head Oil Level Low Accumulator Pressure High Accumulator Pressure High Mix Head Oil Temp M1 Material M1 Cleanout The three point calibration data is invalid system will operate Invalid in weight mode but will attempt Weight Cal 111117 Call Deviation lnvalid data Re calibrate the machine Data weight This will lead to consistent shots which will be offset for the desired dispense amount Low Flow Pump flow setpoint is Advisory Plmpbvelociiy 1S t00 10W Advisory lower than one eighth of Increase the pump flow setpoint the total pump volumes Red Blanket
73. erform Pressure Relief Procedure on page 44 neue oa 02 Red flashing A deviation exists 2 Turn main power OFF Red on The system is shut down due to an alarm occurring 3 Allow equipment to cool Errors include advisories deviations or alarms so Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum ation or alarm ing there is a problem PROBLEM CAUSE SOLUTION Display Module completely Verify AC Power switch is ON Very AC PowerswichisON dark material dispensed from a Air In Material Prime the machine Significant material leaking Pump shaft worn and or shaft seal Remove pump shaft assembly and reinstall read from pump seal worn pump rebuild kit Material dispensed not cor Specific gravity of one or more of the Run calibration rect weight two materials has changed since cali bration Check valve malfunction Remove check valve clean or replace as necessary Piston worn or broken Replace Piston A Red and B Blue Primary Heaters Control of primary heat is Dirty RTD connection Unplug and re plug RTD wires abnormal high temperature RTD not contacting heater element Loosen ferrule nut push in RTD so tip contact heater overshoots element Holding RTD tip against heater element tighten ferrule nut 1 4 turn past tight Failed heate
74. erial Disables Dispense VVhen this box is checked the current dispense vvill terminate and prevent additional dispenses when the supply sys tem indicates a low level Limit Rate on Stall to Pressure Check this box to enable Limit Rate on Stall to Pressure This will slow the rate of pressure rise on a stall to pressure sys tem Enable Range Calibration Check this box to enable Range Calibration This creates a range of shot offsets in a table based on the size of the shot The user must calibrate each range at the specified flow rate If the flow rate is changed the table must be recalibrated Enable PrePoly Refresh Check this box to enable Prepoly Refresh A Prepoly refresh will initiate a cold start heat the system to a specified tempera ture Conditioning Screen 3 empty the prepoly tank to the low level sensor and refill the tank When enabled either the user may initiate a refresh manu ally or through a scheduled task e Night Mode Disabled or Standby Modes Automatic refills are disabled If the material level drops below the low level sensor a low level alarm is thrown Shot Operator or Sequence Modes The sys tem will monitor the amount of automatic refills requested after the last shot has been taken If the system sees two refills without dispensing the system will generate a leak detection warn ing and disable the system The system must be completely powered down to clear the error Enable Leak Detec
75. ever use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been contam inated from the other side e 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 83 C when not under pressure especially if agitated To reduce frothing minimize preheating in a circulation system 11 A Red and B Blue Components Changing Materials When changing materials flush the equipment mul tiple 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 follow ing 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 12 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 sensi tive that material should always be in the A Red side The B Blue side is intended for polyols resins and bases 3A27
76. fic 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 05 16 13 09 56 Fe Supply Advanced standby C Mo Active Errors Night Mode Conditionin Scheme Time gt Prepoly Material F Prepoly Timeout minutes Max Outlet Pressure psi Cold Start Up Mode No Change w Auto High Pressure 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 Sat urday duration 3 Press the up or down arrow keys to select the desired hour to schedule the on or off machine times 43 4 Press E to enter the selected hour and select the desired time 15 minute increments for either machine on or off to occur 4 5 Press and select either on or off for the time duration selected Green Machine is ON Red Machine is OFF Blue PrePoly Refresh Start 66 6 To erase times repeat steps 1 thru 3 and press once the desired time duration has been selected NOTE If times are entered in the weekly schedule indi vidual days can not be erased NOTE Set the Prepoly Timeout one minute beyond th
77. 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 94 a Inthe first column locate the string to change b Inthe 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 dis pensing 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 3A2797G Appendix F USB Operation 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
78. ge System Settings file is Replace the system settings file with a backup or new USB Update The ADM tried to upload 7 5 VVOUO pdate e trie to upload a Alar system settings file but failed V4B4 Blue Hose Overvoltage System Settings file is that the first line in the settings txt file contains intended for another the text GMS If not replace the file with the proper system system update file Failin nsor If error persists the motor will need to be replaced An error has been detected on inal Ka If error persists the motor will need to be replaced VVBH1 Alarm Ensure the d sub connector to the motor is connected Loose connection L M and the vviring is intact AA AA rad failed ANA Stuck material rod Check that material rod is able to freely move VVDF1 Alarm Encoder Fault the motor position sensor Rod Shift Fail lon a straight head No povver to directional p Make sure the directional valve has power valve No power to directional i p Make sure the directional valve has power valve Alarm 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 7577 The hydraulic power pack will need repair Defective encoder Replace encoder Motor no longer coupled Reset coupler per specifications and retighten set to hydraulic pump screws Supply tube from
79. ge 53 for list of wetted compo nents 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 RELIEF CIRCULATION Oy Flush through bleed lines N SA 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 mois ture free plasticizer or oil Do not use water See Important Two Component Material Information on page 11 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 card board which interrupts grounding continuity 3A2797G Flushing 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 45 Maintenance Maintenance DAN ame Check hoses for wear Monthly Check hydraulic fluid and filter Grease 115982 high volume Monthly Change break in oil ina new unit After first 250 refill valve if equipped hours of opera tion or within 3 Change Break in Oil months which eve
80. he pump all the way to the right Press to return to the Calibration Screen Main This saves the new left and right numbers 59 Appendix B ADM Setup Screens Overview System Screen 1 This screen allows the user to set important system set tings Control Mode can be set to Flow With Control Mode set to Flow the machine will dispense at a contin uous flow rate regardless of pressure fluctuations unless pressure alarm conditions occur Dispense Mode can be set to Time Volume and Weight Dispense Mode controls how displayed amounts are measured See Calibrate HFR on page 37 for more information Pump sizes and inlet pressures must be entered on this screen NOTICE 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 dis played 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 manual 313998 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
81. he 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 See System Screen 3 on page 61 To select an operating mode press repeatedly until the desired mode is shown then press to select the mode Alternately press Ki and use the up and down arrow keys until the desired mode is shown then press to select the mode The available operating modes are operator sequence shot standby night and dis abled 3A2797G Events 1 Events 2 Maintenance 2 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 1 12 10 10 17 m Ac 69 Appendix C ADM Run Screens Overview Home Screen Standby Mode In Standby Mode the user can enable heating park the pumps refill the tanks circulate materials 3 41 e Maintenance KI Dispensing NAG Press Q to change operating modes Press to move the pumps all the way to the left and turns the hydraulic power pack off Press to initiate a tank refill If a tank is fill ing pressing either button will abort the filling operation Press to stop or start the hydraulic power pack and run the
82. heater Not displayed if heat A Red and B Blue refill button zone is not enabled Press to start abort refill With a mix head installed Turns on the mix head hydraulics and puts the machine in low pressure circulation Open Close Valve 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 Press a second time to turn off insti gated system action Allowed to Dispense Current and setpoint temperatures for tank blanket Not displayed if heat If Yellow Zone is not enabled System is in a pre dispense state Current temperatures for tank blanket lf Red monitor Not displayed if heat zone is Not Allowed to Dispense not enabled Stop Dispense Current and setpoint temperatures for chiller Not displayed if heat zone is Jump in and use the key pad to select not enabled a shot number Current temperatures for chiller moni tor Not displayed if heat zone is not enabled Skip the next shot in selected sequence Only available when the system is not dispensing Abort sequence and reset to first valid position d Amount of material moved through pump volume tracking Edit Operator Dispense Setting te Activates the PrePoly Refresh Press to enter the Conditioning Con trol screen dil Turn on or off the highlighted zone a ah Turn on or off all zone
83. hing fast Uploading software Red flashing slow Token error Remove token and upload software token again 3A2797G 19 Component Identification Advanced Display Module ADM User Interface CB CC CE CF CF CH CG 1112362a1 Fic 6 ADM Component Identification Front Buttons Ref Button Function System Status Indicator CB Conditions CA System Enables disables system When sys tem is disabled temperature control Green Solid Run Mode System On disable land dispense operation are disabled Green Flashing Setup Mode System On Displays system status See System Yellow Solid Run Mode System Off Status Indicator CB Conditions on Indicator page 20 for details Light Stop all system processes 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 Acknowledge changing a value or making a selection G Setup Toggle between run and setup screens or password screen if setup screens are password protected CH Naviga Navigate within a screen or to a new tion screen No 0 3A2797G Component Identification CP r 24E451 3B9900 1a Fic 7 ADM Component Identification Rear Key CJ Flat Panel Mount CN Module Status LEDs CK Model Number CP Accessory Cable Connections CL USB Module Interface CR Token Access Cover CM CAN Cable Connections CS Battery Access Cover
84. hydraulic pump to Bad directional valve connection The motor has reached a speed that should not be reached in normal operation and was shutdown to prevent possible damage Retighten or replace supply tube manifold is loose or broken Broken motor shaft Replace motor 3A2797G 85 Appendix D ADM Error Codes Error Error Code Error Description Type Cause Red Tank MOG Con Fault Blue Tank yee Con Fault Red Inline Con Fault 211 High current to relay 1 Alarm Broken contactor Replace contactor VVMO2 Red Hose Con Fault Blue Hose ene Con Fault Red Chiller Con Fault Blue Chiller Con Fault WM08 Red Blanket High Temp Tank blanket is above the Blue Blanket defined high alarm limit High Temp Red Tank Blue Tank Red Inline VVMC Blue Inline Con Fault If temperature is being affected by a zone that has Unexpected current to relay 1 Alarm Shorted module Red Hose been disabled replace heat module WMC2 Con Fault Blue Hose we Con Fault WMC7 Red Chiller Defective High Power Temperature Control Replace High Power Temperature Control Module Module Loose connections Tighten connections VVMB5 Defective RTD Replace RTD Alarm Con Fault Blue Chiller 2 Con Fault Motor WMH1 Controller A general fault has occurred pan mera hardware Cycle power if the error persists the MCM will need to Fault within the MCM be replaced On the ADM g
85. ize Orifice Orifice Hose Bundle Hose Bundle 24N570 x 24J290 241316 24N572 x 24N287 24N289 24N574 x pra 24K681 24N576 x 27 5 8 4 m 10 3 m Hydraulic Hydraulic 7 Hose Bundle Hose Bundle 24N569 7 x ku bia k Ka bak 24N576 24V197 2441177 4 3A2797G Models Full load amps with all devices operating at maximum capabilities Fuse requirements at various flow rates and mix chamber sizes may be less Flow rate is independent of frequency 50 60 Hz C approved x 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 pur chased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed see instruction man ual 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 Requir
86. ks low on material Fill tanks with material Material Level If the tanks appear to have plenty of material check to Lovv material level in tanks Deviation l L122 Blue Low 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 pa x High material level in tanks Deviation Defective fill valve L322 Blue High Material Level Red Auto Refill Timeout The tank stand has been filing for a time greater than Blue Auto al gipalorina expected Material Level 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 Loose level sensor i Check for loose or disconnected wires or plugs connection Bad level sensor Replace level sensor Refill Timeout No material is actually being fed Make sure the feed pumps are operating properly Deviation N Co rep op So N 3A2797G Appendix D ADM Error Codes Error Error Code Error Description Type Cause L8A1 A level sensor had ceased Deviation Bad level sensor Blue Tank working DR6B Sensor Failure Red Tank L9AX Leak Det SEPT AT 5 a tank or material line is Alarm Two tank d l Check all hoses and pumps for material leaks Blue Tank leaking vvithout a dispense L9BX Leak Detected Prepol No material is sense
87. l Clear debris from fan fan grill Alarm Red Tank TER RTD Fault Blue Tank RTD Fault Try to stop fan by lightly pressing on the center vvith a Low air volume from fan pencil eraser If the fan slows down easily it will need Red Inline H RTD Fault Blue Inline T6B1 most fe Fault RTD 1 is giving no or invalid to be replaced No power to fan Check cord to make sure fan has power Alarm Red Hose data HA FTS Fault Blue Hose b FTS Fault Debris is fan or fan grill Clear debris from fan fan grill Motor may be damaged Motor may need to be replaced Red Chiller ba RTD Fault Try to stop fan by lightly pressing on the center with a Loose or bad connection Check RTD wiring Alarm Blue Chiller T6B8 RTD Fault Bad RTD Replace RTD Low air volume from fan pencil eraser If the fan slows down easily it will need 3A2797G 83 Defective RTD Replace RTD Loose connections Tighten connections shutdown for protection The hydraulic oil is ata 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 to be replaced Su ehvironinelitat Move machine to an area below 120 F conditions are too hot Appendix D ADM Error Codes Error Error Code Error Description Type Cause Red Blanket T6C6 ETD Fault Blue Blanket T recs Fault RTD 2 is giving no or invalid Ala
88. l and input the specific gravity SG of each material into the ADM 14 Flush the System 9 NOTE System components will contain testing oil from the factory Perform the following procedure when the machine is initially installed Both supply and pressure relief must be flushed a Close both A side Red and B side Blue feed inlet valves on the system See FIG 2 on page 14 Close A side Red and B side Blue material return ball valves on the system Close both A side Red and B side Blue mate rial supply ball valves on the system Place the applicator return hoses into a con tainer NOTICE To prevent cross contamination keep components A Red and B Blue in separate containers Fill tank A Red with approximately 5 gal 19 1 of material and tank B Blue with approximately o gal 8 1 of material Pressurize both material tanks 3A2797G 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 75 psi 517 kPa 5 2 bar Maintain A Red and B Blue feed pressures within 10 of each other ti10006a1 g Turn HFR main power ON 11 h Navigate to the System Setup Screen Set the low pressure dispense to 25 NOTE The following steps are referring to the B side Blue components of the system i Set PRESSURE RELIEF DISPENSE valve SA nr SB to DIS
89. level alarm high level sensor will generate a high level devi ation 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 e A button is provided to the user on the Run screens to initiate an automatic refill operation at any time This button can also be used to abort a refill opera tion 63 Appendix B ADM Setup Screens Overview 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 sen sor 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 triggered the refill will abort A refill must be manually started to enable auto refills again Refill Sensor Type The Low Temp Sensor setting limits tank temperatures to 150 F 66 C And the High Temp Sensor setting lim its 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 tempera ture above 150 F 66 C damage to the level sen sors will occur Conditioning Screen 1 This screen allows the user to select whi
90. level sensors installed 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 e Three level sensors installed When the middle level sensor does not see material automatic refill will begin and continue until either the mid dle level sensor sees material or until the refill time out expires e The low level alarm will clear when the condition clears e A button is provided to the user on the run screens to initiate an automatic refill operation at any time this button can also be used to abort a refill operation Auto Full Volume 2 Sensors e The low level sensor will initiate an automatic refill when it does not see material e Automatic refill will continue until either the high level sensor sees material or until the refill time out expires e The low level alarm will clear when the condition clears e A button is provided to the user on the run screens to initiate 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 e The low level sensor will generate a low
91. lumn is used it is recommended that a page 70 for information on how to use predefined shots minimum of 5 shots are dispensed measured and aver aged for each dispense before entering a value for the NOTE 100 shot definitions are available across ten column pages Time Based Example To edit a shot definition A 75 cc s shot is defined to dispense for 2 seconds 1 Press then use the arrow keys to navigate to the desired value B 15 13 09 43 El Advanced Sequences standby mi No Active Errors 05 16 13 09 55 mi Advanced Sequences standby mn No Active Errors dani ETE Ee 1 Dispense 5 shots into 5 separate containers No Active Errors 2 Measure the dispensed amount and record the data Example 1 Example 2 Dispensed Volume Dispensed Volume cc cc 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 3 Calculate the average of the 5 shots Example 1 146cc 4 Repeat step 2 as required Example 2 156cc 3A2797G 55 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 5 Enter the calculated value in the column Example 1 05 16 13 08 44 te
92. materials specific gravity was ECB2 R Blue Mate The Blue materials specific gravity was ENC1 R Cal Point 1 A value for the first point in the three ENC2 R Cal Point 2 A value for the second point in the ENC4 R Cal Point 1 The running average for point one of ENC5 R Cal Point 2 The running average for point two of Dispense the ratio check calibration screen EAOO R Disp Occurred Shot EHOO R Gel Timer Dispense ER01 R Shot Count A counter from the shot counters main Reset tenance page was erased A dispense has occurred of the given shot number The gel timer expired and the system automatically took the gel shot ER02 R Seq Posi tion Count Reset A counter from the sequence counters ERA1 R Red Mate The resettable totalizer for the Red ERB1 R Blue Mate The resettable totalizer for the Blue ERA2 R Red Mate The resettable totalizer for the Red ERB2 R Blue Mate The resettable totalizer for the Blue ERA3 R Red Cycle The resettable cycle counter for the ERB3 R Blue Cycle The resettable cycle counter for the Blue pump was reset to zero 3A2797G Appendix E System Events Event Code and String Triggers EQU1 R Settings Downloaded The system settings were successfully transferred from the ADM to a USB drive The system settings file was success fully transferred from the USB drive to the ADM The custom language file was suc cessfully transferred from the ADM to a USB drive
93. n changing or rebuilding pumps The HFR calibration procedure is a two step process The first step Learn Mode must be performed when ever the pump line is rebuilt or if any other maintenance is performed that may affect the mechanical tolerances in the pump line 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 e Learn Mode Procedure a Ensure the dispense valve is set up as either straight head or straight head prox b Navigate to the Calibration screen c Press d Press ki and then KO The pump will travel to the right most extreme position e After the pump stops moving press i then press 5 The pump will travel to the left most extreme position f After the pump stops moving press 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 3A2797G Setup e Set temperatures A m 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 e Allow equipment to cool completely before touch ing it e We
94. n defining the 2 Press M to enter the screen shot by weight 0815613 09 50 mi Advanced Sequences 3 Press to show the shot calibration table standby mi No Active Errors 4 Press then use the arrow keys to navigate to the desired value 00 16 13 09 53 Advanced Sequences standby mn No Active Errors Setpoint TO Shot Size Offset Shot Size Offset Setpoint EL Shot Size Offset Shot Size Offset To enable the shot calibration table 1 Navigate to Advanced Screen 4 08 16 13 09 51 Conditioning Sh standby mi No Active Errors Enable Diagnostic Screen Low Material Disables Dispense 2 Limit Rate on Stall to Pressure 6 Repeat as required for other ranges Enable Range Calibration 4 m Enable Prepoly Refresh _ Enable Leak Detection 5 Type the new value then press to accept the new value Enable Downloading of USB Logs _ Enable USB Errors Date of Last Download Qo BTS 3A2797G 27 Appendix B ADM Setup Screens Overview Weight Based Example Using Shot Calibration Table NOTE The offset needs to be determined for each range and may need to be modified if the flow rate changes Visit www graco com and search for PKE Shot Calibration Table Worksheet to assist in the cal culations for the following procedure NOTE Offset ranges are dependant on material ratio and material specific gravity The values shown are for reference only 1 Dispense five shots into s
95. n 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 4 4 Press to accept the sequence letter position 5 Press the Dispense button to begin dispensing 0516 13 10 20 El Maintenance mn Target Flow Pressure Target dispense amount time vol ume weight depending on Dis pense Mode Ratio 6 Press to skip to the next sequence position 7 Press to abort the sequence 3A2797G Appendix C ADM Run Screens Overview 8 See Home Screen Shot Mode on page 70 for other button functions Home Screen Operator Mode This mode allows users to set a flow rate to dispense material without using predefined shot information 1 To edit the flow rate press EY The value to change will now be highlighted Type the new value then press to accept it 0 16 13 10 21 El Maintenance fay Red Ratio Operator Setting Total of resetta ble material counters A Red resetta ble material counter B Blue reset table material counter 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 61 expires Press the to stop the dispense NOTE There is a th
96. n of temporary over voltage events Maximum Permissible Transient Voltage Surges Constructed from ITIC 1996 curve referenced by IEC 61000 2 4 1400 1200 lt 1 MW Max Surge Power 1200Vac 1697Vdc 1000 800 600 480Vac 679Vdc lt 150 KW Max Surge Power Voltage Volts RMS 400 336Vac 475Vdc lt 50 KW Max Surge Power 288Vac 407Vdc 200 0 0 000001 0 00001 0 0001 0 001 0 01 0 1 1 10 Time seconds 29 Setup 5 Connect HFR Proximity Cables to the GX 16 aA NOTE Refer to the HFR and GX 16 manuals for more details for the following procedures NOTE The cable is indicated by a green stripe a Connect the GX 16 proximity sensor to the proximity cable b Connect the 10 ft 8 m hydraulic whip hose cable to the 25 ft 7 6 m chemical hose cable c Connect the other end of the cable to the electri cal connector found near the fluid manifold on the HFR NOTE The electrical connector will be indicated by a green stripe and labeled PG MPO 30 6 Connect Hydraulic Lines to the system os NOTICE Damage can occur to the directional valve if the hydraulic hose diameter is larger than 3 8 in 9 5 mm To prevent damage to the applicator or directional valves do not allow any dirt or foreign matter to enter the lines when connecting the hose kit to the applicator and hydraulic power pack
97. nd 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 recirculation systems or applicable for P2 Fusion Dispense Valve applications This feature can not be active if the Post Dispense Shot Disable feature is active 3A2797G Mix Head Operating Details Screen This screen allows the user to define the mix head oper ating parameters e Low Pressure Circulation The percentage of set point 10 90 at which the system will run during low pressure circulation e Pre Dispense Circulation The time for which the system will circulate at high pressure prior to dis pensing when the dispense command is triggered while the system is in low pressure circulation e Post Dispense Circulation The time duration that the system will remain in high pressure circulation after a dispense before dropping into low pressure circulation Entering O disables the post dispense time 08 19 11 13 33 Calibration Maintenance Standby Dispensing Disabled Low Temp Miz Head Control Low Pressure Circulation Bill 4 Pre Dispense Circulation seconds Post Disperse Circulation R seconds Press to go back to the System Screen 2 3A2797G Appendix B ADM Setup Screens Overview System Screen 3 This screen allows the user to edit the labels for the
98. ne Selection The HFR unit supports four independent temperature control zones and two independent temperature moni toring zones The high power temperature control mod ules are located inside the frame below the hydraulic power pack Primary Heater B Blue Left Side from Rear View EAP m l qz N ti17748a Material Temperature Primary Heater A Red X Right Side from Rear Vievv o 2 2 KIO JO KO PO O OJO O O O o ti17749a 25 Component Identification Adjust Rotary Switch The rotary switch setting indicates which zone the tem perature control module will control in the system The high power module uses an 8 position rotary switch The low power module uses a 16 position rotary switch Set the rotary switch S to the specific selection accord ing to the settings listed in the following tables High Power Module Rotary Switch Location gt pi Z Z O ti12360a Low Power Module Rotary Switch Location Fic 12 Rotary Switch 26 ti12361a High Power Module Rotary Switch Settings Not Used B Blue Primary Heat B Blue Hose Heat
99. o into the setup screens gt System gt Invalid The requested controlling System incorrectly setup land ensure that all pages have properly defined Setpoint value pressure or flow is Deviation values Request outside the limits of the system Redefine shot vvith control parameters vvithin the limits Shot incorrectly defined of the system Gel timer shot is belovv Select a different shot or modify existing shot data amount or set fora The shot that vvas entered for invalid pressure flow Invalid Gel l Timer the gel timer is not a valid shot Deviation The MCM has This must be fixed before the determined that the gel you are certain that the shot is within parameters Definition gel timer will function properly timer shot will not be able try running the Learn Mode routine found in the setup to be executed based screen Calibration If the error persists a gel shot with parameters entered in reduced control parameters is required the ADM 2 g 5 F 86 3A2797G Appendix E System Events Event Code and EAAO R Prepoly While in night mode the prepoly EBAO R Prepoly While in night mode the prepoly ELOO R System Pow The System was powered on EM00 R System The System was powered off ex EB00 R Stop Button The Red stop button was pressed on ECHO R Learn Mode A learn mode calibration was success ENNO R Automatic The system was successfully charac ECA1 R Red Mate The Red
100. omponent Identification Heated Model shown with shrouds removed 14 3A2797G 47 NA KY a 7 YS 7 EU 2 SLOT Sal EN ae TIL ji ATI NG OS ti19510a 15 Component Identification Rear View Fluid Manifold FM Detail LINEAR sis Se ti9880a1 Primary Heater PHB Detail B Blue side shown Primary Heater PHA Detail A Red side shown o 5 wn O O LU c ti19511a ti19509a Continued FiG 3 Component Identification 3A2797G Component Identification Main Power Switch Circuit Breakers AM A Most circuit breakers are located inside the power distri does not turn pumps or heat zones on bution 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 dis tribution box manual Located on top of the power distribution box see page 14 The main power switch turns power ON and OFF The main power switch 400V 3 phase Bi ARH m kala CI Las mb c2 ols 0122 o ka 5 2 2 ox m 8 H 4
101. on du pr sente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intentes a la suite de ou en rapport directement ou indirectement avec les proc dures 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 Toll Free 1 800 746 1334 or 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 3A2797 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O 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 2014
102. oubleshooting 3A2797G 51 Appendix A ADM Icons Overview Appendix A ADM Icons Overview Setup Screen Icons rs Access Flowmeter Calibration On Learn Mode Calibration screen Valve Details Move pump Selects all shots to be changed to the same user specific value Shot Number Sequence Position Time Duration Tank Blanket Heater Primary Heater j Access Learn Mode Calibration gt screen iy Chiller Run MCM Learn Mode AEC Move Cursor to the Left Proceed to next step in calibration procedure On Main Calibration screen Move Cursor to the Right Calibrate Weight Dispense or Enter Specific Gravity Information Upper Lower Case Letters Positive Negative m m a o Hi D All other screens Begin Dispense Stop Dispense Abort Changing the Label Select left direction Select right direction LAX er Back to main calibration screen from learn mode calibration screen Back to system screen 2 from mix head operating details screen 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 52 3A2797G Appendix A ADM Icons Overview Run Screen Icons VAZ Select mode fa Sets machine to low pressure Set system in park icon will be selected when system is parked Sets machine to high pressure Current and setpoint temperature for primary
103. ow the IsoGuard Select fluid to drain Reattach the check valve to the inlet hose See FIG 26 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 reservoir onto the cap assembly and place it in the bracket 8 Push the supply tube approximately 1 3 of the way into the reservoir 48 9 Push the return tube 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 bot tom and not be siphoned into the supply tube and returned to the pump Cine 240352 313998 8e Fic 26 IsoGuard Select Fluid System Prime IsoGuard Select Fluid Cylinder Ensure that the IsoGuard Select fluid cylinder outlet faces upward for air to exhaust 1 Remove check valve from end of inlet tube 2 Cut tip of IsoGuard bottle and fill the reservoir through the tube 3 With check valve arrow pointing towards the IsoGuard Select fluid cylinder install check valve in end of inlet tube 4 Install tubes into reservoir and install reservoir into holder 3A2797G Troubleshooting Troubleshooting A i O 4 Light Tower Optional Tat Signal Description Green on only System is powered up and there are Before performing any troubleshooting procedure no error conditions present 1 P
104. perature alarm limits Disabled High Temp Cable unplugged loose power Check for loose or disconnected wires or plugs Check temperature alarm limits 3A2797G 81 Appendix D ADM Error Codes Error Error Code Error Description Type Cause Red Hose T2AA Low Fluid Red Tank T2AE Low Fluid Red Chiller Low Fluid Motor Temp Cutback 82 Temperature is out of alarm limits Check temperature alarm limits Fluid temperature for a monitor zone is below the defined low alarm limit Cable unplugged loose power Deviation Check for loose or disconnected wires or plugs Fluid temperature for a monitor Zone is above the defined high alarm limit Inline heater is not turned pa Turn on inline heater The hydraulic oil temperature No power to fan Check cord to make sure fan has power is approaching a level where Debris is fan or fan grill Clear debris from fan fan grill damage is possible so the 9 p Deviation Try to stop fan by lightly pressing on the center with a Motor Control Module is L l i i if the f ilv it will d limiting the output to a safe ow air volume from fan pencil eraser e fan slows down easily it will nee to be replaced level 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 i Low air volume from fan pencil eraser If the fan slows down easily it will need
105. r comes first After initial break in see Table 5 for recommended fre quency of oil changes Inspect hydraulic and fluid lines Daily Ambient Recommended Inspect IsoGuard Select fluid d level and condition refill or 0 to 90 F 1000 hours or 12 months 17 to 32 C whichever comes first Check hydraulic fluid level Weekly replace as needed page 48 90 F and above 500 hours or 6 months Grease circulation valves with Weekly 32 C and above whichever comes first Fusion grease 117773 Weekly Grease Circulation Valves With Fusion Grease 117773 Verify operation of air drying sys tem to prevent isocyanate crystal lization Verify vent holes on bottom of electrical cabinet are clear and unobstructed Weekly Inspect air filter part 24H018 Daily clean or replace as necessary ti9879a1 Use compressed air to remove Monthly Check Hydraulic dust buildup on contro boards Check hydraulic fluid level on dipstick Fluid level must 75 77 ane be between indent marks IM on dipstick Refill as y required with approved hydraulic fluid see Run Screen Clean up all hydraulic leaks iden As needed Icons on page 53 If fluid is dark in color change fluid tify and repair cause of leak and filter Inspect the gun fluid lines trigger Daily switch cable and proximity switch cable for wear or damage Grease 117773 or 0553 6 the Weekly or every gun 15 000 shots Clean and
106. r element Signal failure from RTD Check connections and verify that temperature for each zone rises Hose System Material heats but heats slower than usual or it does FTS failed or not installed correctly 8 Check FTS not reach temperature 3A2797G 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 devi 49 Troubleshooting PROBLEM CAUSE SOLUTION Material does not maintain Ambient temperature is too cold Increase A Red and B Blue setpoints to increase temperature while spraying fluid temperature and keep it steady Flow too high Use smaller mix chamber Decrease pressure Material temperature Faulty RTD connections Verify that all FTS connections are snug and that pins exceeds setpoint 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 Erratic material temperature Faulty RTD 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 cleaning off any debris Unplug and re plug long green connector FTS not installed correctly FTS should be installed close to end of hose in
107. ree second delay after a dispense before another dispense can be initiated 3 If an external trigger is used press an hold the trig ger to initiate a dispense Release the trigger to stop the dispense 4 See Home Screen Shot Mode on page 70 for other button functions 71 Appendix C ADM Run Screens Overview Home Screen Night Mode In Night Mode the system will cycle on and off periodically or turn on at a preset time Entering night mode will turn pumps and all conditioning zones off The circulation on off cycle begins automatically upon entering Night Mode See Conditioning Screen 3 on page 65 OB 19 11 13 43 le Status No Active Errors Status Screen The status screen provides all of the operational func tionality 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 condi tioning information and control 24544 24492 49036 72 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 Dispense Disabled Dispense Allowed Dispense Disabled Dispense Allowed To turn a single zone on off
108. rm T6C7 Red Chiller data RTD Fault Blue Chiller Topa RTD Fault No Heat Red No Heat Blue T8A3 No Heat Red Inline T8B1 No Heat Blue Inline TSA No Heat Red Hose T8B4 No Heat Blue Hose No Cooling 1527 Red Chiller No Cooling Blue Chiller Red Blanket Temp Cutoff Blue Blanket Temp Cutoff Red Inline T9A3 Hemp Cutoff Blue Inline Temp Cutoff Red Blanket T9C6 Ctrl Shutdown Blue Blanket T9C5 Ctrl Shutdown Red Inline T9C3 Ctrl Shutdown Blue Inline T9C1 Ctrl Overheated Turn conditioning zone off Wait a few minutes If the Shutdown PCB over temperature Alarm Temperature Control condition does not clear or regenerates consistently 205177 Module replace heater module T9C2 Shutdown Blue Hose T9C4 Ctrl Shutdown Red Chiller T9C7 Ctrl Shutdown Blue Chiller T9C8 Ctrl Shutdown 84 3A2797G Loose or bad connection Check RTD wiring Bad RTD Replace RTD Tripped circuit breaker Visually check circuit breaker for a tripped condition No temperature rise Deviation Measure voltage across input terminals on power line Low Power filter Voltage should measure between 190 and 264 Vac Check for loose or disconnected wires or plugs power Bad heater s Measure resistance of heater s Tripped circuit breaker Visually check circuit breaker for a tripped condition Deviation Disconnect the valve and measure the voltage across the wires when the chiller is running to ensure 24V is being
109. s Erase a single batch Erase all batch data points 3A2797G 53 Appendix B ADM Setup Screens Overview Appendix B ADM Setup Screens Overview The ADM will start in the Run screens at the Home Password i N iH Sequences 1 z Calibration 77 System 1 N 14 Sequences 2 N Sequences N TIN System 2 System 3 From the Setup screens press O to access the Run screen From the Run screens press JJ to access the screens For Run screens information see Technical Setup screens If the Setup screens password is turned Data on page 95 FIG 27 shows the flow of the Setup on use the ADM keypad to enter the password then press 011310 1437 mc standby C Active Errors screens N lin 22 Maintenance z Supply 2 Conditioning 1 N Conditioning 2 Conditioning 3 Gateway screen will automatically be enabled when a CGM is installed on the system 27 Setup Screens Navigation Diagram 54 3A2797G Appendix B ADM Setup Screens Overview Shots Screen Due to variation in material properties the column This screen allows the user to edit shot definitions The 0975 the ability to adjust the shot time volume weight for contents of this screen change based on the flow units each defined shot selection Shots are defined by flow rate and weight or time duration See Home Screen Shot Mode on NOTE If the co
110. tion 36 Perform the following tasks to fully setup your system Enter Setup Mode by pressing the E button a Define shots See Shots Screen page 55 for more detail b Define sequences See Sequences Screen page 58 for more detail c Calibrate HFR page 37 See Calibration Screen Main page 59 for more detail d Define pump information See System Screen 1 page 60 for more detail e Define dispense valve and other system set tings See System Screen 2 page 60 for more detail f Define labels and other system settings See System Screen 3 page 61 for more detail g If desired view reset counters See Mainte nance Screen page 62 for more detail h Define level sensors and refill settings See Supply Screen page 63 for more detail i Enable disable temperature conditioning com ponents See Conditioning Screen 1 page 64 for more detail Define temperature conditioning setpoints See Conditioning Screen 2 page 64 for more detail k If Night mode will be used define Night mode settings See Conditioning Screen 3 page 65 for more detail Set general system settings See Advanced Screen 1 page 67 for more detail m Set units of measure See Advanced Screen 2 page 67 for more detail n Enable disable system features See Advanced Screen 3 page 67 for more detail 3A2797G 13 Calibrate HFR NOTE Machine is calibrated from the factory Only per form the following steps whe
111. tion Check this box to enable Leak Detection Leak detection is intended for cata strophic leaks only It requires a Graco auto fill con trol to be enabled and working Leak detection is not active during dispense Advanced Screen 5 06 15 11 13 40 le Conditioning Shots standby fay Dispensing Disabled Low Temp Module software Part Software umber Version Advanced Display 162122 108 069 USB Configuration 166102 105 011 Application Blue 15620 105 016 Component Blue 16 014 103 001 Red Primary Heat Thar 105 005 Blue Primary Heat Thar 105 005 Red Hose Heat EMG 71 105 008 Red Chiller Bhar 105 006 Mix Head Power Pack 164029 105 057 Red Tank Monitor 164206 101 001 Blue Tank Monitor 1 206 101 001 Numbers shown are for reference only and may be different on your system This screen displays software information 3A2797G 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 N Errors 1 N Errors 2 22 Home 22 Status z Tt Events N N Errors N FiG 28 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 t
112. to run as straight head prox dispense valve Trapped air can cause the pump to cycle unexpectedly which could result in serious injury from splashing or moving parts b Verify the mixhead hydraulic power pack is not active by verifying the gauge is at 0 c Check the hydraulic fluid level See Technical Data on page 95 for specifications d Use the supplied 7 16 in JIC male male adapter at the gun end to connect hoses 3A2797G together This creates a hydraulic fluid circula tion loop ti14495a Fic 18 Hydraulic Loop e Turn on the power pack by navigating to the Home Screen Standby Mode and press Ed Circulate oil for 3 minutes to purge air from hydraulic hoses NOTE Pressure should not increase vvhile air is purged from hoses f Turn off the power pack by pressing El Look at the gauge to verify no pressure exists in the hydraulic hoses and the AC Power Pack g Remove the 7 16 in JIC male male adapter connecting the hydraulic hoses NOTICE To prevent air from entering the hydraulic hoses do not spill oil while disassembling the adapter connec tion If spilling occurs replace the lost fluid by man ually filling the hoses with hydraulic fluid h Fill both open and close gun chambers with hydraulic fluid i Attach hydraulic hoses to the gun Tighten each fitting 1 4 turn past hand tight 3A2797G Setup NOTE The hydr
113. tor Mode Cavitation Alarm Check this box to enable cavitation alarms in Operator Mode Clear this box to disable cavitation alarms in Operator Mode e 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 e 2x Trigger For Dispense When this box is checked the machine will require a double trigger pull to initiate dispensing in shot or sequence mode 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 67 Appendix B ADM Setup Screens Overview Advanced Screen 4 00 16 13 09 57 4 Conditioning Shots mi Mo Active Errors Enable Diagnostic Screen Low Material Disables Dispense Limit Rate on Stall to Pressure Enable Range Calibration m Enable Prepoly Refresh _ Enable Leak Detection Enable Downloading of USB Logs E _ Enable USB Errors Date of Last Download 0665 Enable Diagnostic Screen Check this box to enable the optional ADM screens enabling USB log downloading and erasing USB logs For more infor mation about USB operation see Appendix F USB Operation on page 89 For more information about the optional screens see Diagnostic screen on page 74 Lovv Mat
114. when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately 3A2797G g Warnings C EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol 7 e 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 manu facturer 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 applic
115. 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 3A2797G Setup 19 Install High Volume Fill Kit Optional m r 24m419 3a1961 1a High Volume Refill Kit Perform Pressure Relief Procedure page 44 Close the ball valves located on the day tanks Insert the refill valve onto the ball valve Connect the air tube from the open port on the refill valve to the fitting on the solenoid valve that is located inside the tank stand base cube Remove the plug from other port on the sole noid valve and install the air tube fitting Connect the air tube from the close port on the refill valve to the fitting installed in step e above 41 Setup 20 Install Low Volume Fill Kit Optional r 24m418 3a1961 1a Fic 24 Low Volume Refill Kit 42 Perform Pressure Relief Procedure page 44 Close the ball valves located on the day tanks Remove the swivel fitting from the day tank inlet port ball valve Insert the refill valve onto the ball valve Install the swivel fitting onto the refill valve assembly Remove the air tube fitting installed on the sole noid valve located inside the tank stand base cube Install the air tube fitting provided with the kit
116. y mi Mo Active Errors 0 3A2797G Calibration Screen Main This screen shows calibration information for the system and provides access to other calibration screens See Calibrate HFR on page 37 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 Calibra tion Screen Learn Mode 06 06 12 09 59 ie Sequences mi Mo Active Errors Previous Ol Cal 8000 RABB Cal Min 3500 Range 10500 T1900 Range 2300 3300 Erase Control Data 2 Press 4 to go to the Calibration Screen Learn Mode screen Press 2 to erase the motor control database in the motor control module 3A2797G Appendix B ADM Setup Screens Overview 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 37 for how to use this screen to calibrate the machine Current position Do 16 11 06 16 Sequence Calibration BAG Previously saved left position Previously saved right position Press and then to move the pump all the vvay to the left uli Press and then to move t

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