1. Manuals
  2. Brands
  3. Graco Manuals
  4. Industrial Equipment
  5. HVR
  6. Instructions manual

Graco HVR Instructions Manual

Hydraulic, plural-component, variable-ratio proportioner
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Instructions
HVR
Hydraulic, Plural-Component, Variable-Ratio Proportioner.
For pouring and dispensing sealants and adhesives. For professional use only.
Not approved to European explosive atmosphere requirements.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 4 for model information, including max-
imum working pressure and approvals.
313873B
ENG
24F391_313873_4d

Advertisement

Table of Contents
loading

Related Manuals for Graco HVR

Summary of Contents for Graco HVR

  • Page 1 Instructions 313873B Hydraulic, Plural-Component, Variable-Ratio Proportioner. For pouring and dispensing sealants and adhesives. For professional use only. Not approved to European explosive atmosphere requirements. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 4 for model information, including max- imum working pressure and approvals.

  • Page 2: Table Of Contents

    Fluid Control Module (FCM) ....19 Graco Standard Warranty ....76 Setup .

  • Page 3: Related Manuals

    Related Manuals Related Manuals Manuals are available at www.graco.com. Component manuals in U.S. English: System Manuals 313874 HVR Repair-Parts Power Distribution Box Manual 3A0239 Power Distribution Boxes Instruc- tions-Parts Pumpline Manuals 3A0022 U-Cup Dura-Flo Lowers 3A0021 Vertical Hydraulic Driver Repair-Parts...

  • Page 4: Models

    ◆ Flow rate is independent of frequency 50/60 Hz. ‡ If a motor control module is replaced, see the Adjust Motor Control Module Selector Switch in the HVR repair manual to set the machine to the proper maximum fluid working pressure.

  • Page 5: Warnings

    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.
  • Page 6 Warnings WARNING 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: • Use equipment only in well ventilated area. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
  • Page 7 Warnings WARNING MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equip- ment, follow the Pressure Relief Procedure and disconnect all power sources.

  • Page 8: Important Two-Component Material Information

    Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture Spraying or dispensing materials containing isocya- (such as humidity) to form small, hard, abrasive crystals, nates creates potentially harmful mists, vapors, and which become suspended in the fluid.

  • Page 9: Changing Materials

    Component B (Blue) is on the right side. side. NOTE: On the HVR system, A (Red) is on the left side of the base unit and B (Blue) is on the right side of the base unit. The sides switch when going to the dispense...

  • Page 10: Component Identification

    Component Identification Component Identification AA Advanced Display Module (see page 16) AJ Pump Wet Cup AB Hydraulic Power Pack AK Main Power Switch AC Vertical Hydraulic Driver AL Air Supply Inlet AD Pump Lower AM Electrical Enclosure AE Flow Meter AN Ratio Check Dispense Valves/Ports AF Power Distribution Box AP Material Line...
  • Page 11 Component Identification 24F391_313873_3d 24F391_313873_5d . 2: Component Identification 313873B...
  • Page 12 Component Identification Circuit Breakers Most circuit breakers are located inside the power distri- bution box. The main block of circuit breakers in the power distribution box is shown below, with detailed information in the following table. See the power distri- bution box manual for more information.

  • Page 13: Hydraulic Power Pack

    Component Identification Hydraulic Power Pack 257442_313873-5_1t 257442_313873-5_2t Shown with shroud removed Key: 8 Gallon Hydraulic Oil Reservoir (see Technical Data on Motor Control Module (see page 14) page 75 for specifications) Electric Motor Hydraulic Oil Filter Dipstick Hydraulic Fluid Drain Port Hydraulic Housing 313873B...

  • Page 14: Motor Control Module (Mcm)

    Component Identification Motor Control Module (MCM) The MCM is located in the Hydraulic Power Pack. NOTICE If the Motor Control Module is replaced, the selec- When installed, the end of the MCM with the power tor switch must be set prior to initial startup of the input connection (12) faces down and the end with the Motor Control Module or damage may occur.
  • Page 15 Component Identification Description Access Cover Module Status LEDs Warning Label A (Red) MCM only: ADM, Power Distribution Box 1A, 1B B (Blue) MCM only: FCM, Power Distribution Box NOTE: 1A and 1B are interchangeable. Three-way Splitter to: Oil Low Level Sensor, Dispense Valve Solenoid, Footswitch Oil Temperature Sensor...

  • Page 16: Advanced Display Module (Adm)

    Component Identification Advanced Display Module (ADM) User Interface TI12362a1 . 5: ADM Component Identification - Front Buttons Call Call Button Function Button Function Softkeys Defined by icon next to softkey Enable/disable ADM Enable/ Abort Abort current operation Disable Enter Accept change, acknowledge error, System Displays system status select item, toggle selected item...
  • Page 17 Component Identification ti12902a . 6: ADM Component Identification - Rear Key: Flat Panel Mount Module Status LEDs Model Number Identification Label Accessory Cable Connection USB Interface (see Appendix E - USB Operation Software Token Access Cover beginning on page 69) Battery Access Cover CAN Cable Connection to MCM See ADM Troubleshooting on page 41 for LED status information.
  • Page 18 Component Identification ADM Screen Components See the ADM appendix sections beginning with Appendix A - ADM Icons Overview on page 45 for more informa- tion. Current date and time Previous screen Current screen Next screen Operating Mode Faults, Status Enter/Exit screen Previous screen no.

  • Page 19: Fluid Control Module (Fcm)

    Component Identification Fluid Control Module (FCM) The fluid control module is located inside the electrical enclosure. ti12337a1 ti12336a1 . 9: Key: Module Connection Screws Access Cover Module Status LEDs CAN Connectors (one is connected to MCM, other is unused) 313873B...

  • Page 20: Setup

    Setup Setup Initial Machine Setup Electrical Cord Requirements NOTE: Power cord is not supplied. See the following Perform this setup procedure to prepare the machine for table. initial operation. Table 1: Power Cord Requirements Cord Requirements Model AWG (mm The machine is not properly grounded until this setup procedure is performed.
  • Page 21 Consult a qualified electrician if there are any concerns about the a. HVR: grounded through power cord. See Con- available power supply. nect Electrical Cord, step #2 on page 20.
  • Page 22 Setup 4. Install feed system. Check hydraulic fluid levels. NOTE: This step only connects the feed system. Do not The hydraulic reservoirs are filled at the factory. See allow fluid to flow into the system in this step. Technical Data on page 75 for hydraulic fluid specifica- tions.
  • Page 23 Setup d. Navigate to System #1 screen then define con- trol mode, dispense mode, and pump informa- tion. See page 49. e. Navigate to System #2 screen then define dis- pense valve details and other system settings. See page 49. Navigate to System #3 screen then define labels, pressure imbalance, and flow meter details.

  • Page 24: Startup

    Startup Startup 1. Perform all required maintenance tasks. See Main- tenance on page 35. 2. Check for leaks. 3. Check hydraulic fluid levels. 4. Check pump wet cup fluid levels. 5. Check feed system fluid levels. 6. Turn Main Power Switch to the ON position. The splash screen will be displayed on the ADM until it is finished loading.

  • Page 25: Priming

    Priming Priming 1. Place waste containers below both ratio check dis- 7. Continue dispensing until clean, air-free material is pense valves. dispensed from both sides then press to stop NOTE: Both ratio check dispense valves will be open dispensing. when dispensing in Prime Mode. Only one pump moves but material may drip from the other ratio check dis- 8.

  • Page 26: Operation

    Operation Operation ADM Operation Overview ADM Navigation Diagram Run Screens Optional: Home Errors #1 Events #1 Maintenance Diagnostic Errors #2 Events #2 Errors #... Events #... Password Entry (if enabled) Setup Screens Calibration Shot #1 Sequences #1 System #1 Maintenance Supply Conditioning #1 Advanced #1...
  • Page 27 Operation Navigation Overview 2. Once in the screen, use the arrow keys to navigate to the desired item. For all ADM screens to be accessible and functional, the ADM must be enabled and an operating mode other 3. Edit the value: than Standby or Disabled must be selected.

  • Page 28: Calibration

    Operation Calibration NOTE: During this process, the system learned the mechanical limits of piston travel. If the pump did not reach either piston mechanical travel limit for any rea- The entire calibration procedure does not always need son, repeat the procedure. to be performed.

  • Page 29: Flow Meter Calibration

    Operation Flow Meter Calibration Ratio Check NOTE: The ratio check ports have a needle valve that NOTE: The ratio check ports have a needle valve that can be adjusted to change dispensing pressure so that can be adjusted to change dispensing pressure so that it matches normal operating dispensing pressure.

  • Page 30: Dispensing

    Operation Dispensing Dispense in Sequence Mode Sequences can be defined on the Sequences screen. Sequences are defined on the Sequences screen, see Dispense in Shot Mode page 48. To dispense in Shot mode, at least one shot number must be defined. Shots are defined on the Shots 1.
  • Page 31 Operation Dispense in Operator Mode 7. Check the ADM for errors and pop-up notifications that could indicate a faulty dispense. Press acknowledge any displayed errors. Operator Mode begins dispensing when is pressed and stops when it is pressed again. NOTE: If a footswitch is used, press and hold to dis- pense.

  • Page 32: Flushing

    Flushing Flushing 9. To maintain grounding continuity when flushing or relieving pressure, hold a metal part of dispense valve firmly to the side of a grounded metal pail, then press . Continue to dispense until the sys- tem is thoroughly flushed then press to stop Flush equipment only in a well-ventilated area.

  • Page 33: Shutdown

    Shutdown Shutdown Short-term 7. Place container under the mixer and allow mixer to drain completely. 1. Place container under mixer. NOTICE 2. If using a moisture-sensitive material, park pumps. Preventing material from draining from the mixer may cause material in the mixer to harden and dam- a.

  • Page 34: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 1. Perform Shutdown procedure. 2. Place a waste container below each ratio check valve. In the following step, any pressure in the lines will be instantly relieved which may lead to material spraying out of the valve and splashing in the bucket. Use appropriate protective wear to prevent contact with materials.

  • Page 35: Maintenance

    Maintenance Maintenance Change Hydraulic Oil and Filter Change break-in oil in a new unit after the first 250 hours of operation or within 3 months, whichever comes first. After initial break-in, see the following table for rec- Check all sub-component manuals for maintenance ommended oil and filter change schedule.

  • Page 36: Motor Control Module (Mcm)

    Maintenance Motor Control Module (MCM) 3. Insert and press token (T) firmly into slot. NOTE: There is no preferred orientation of the token. Keep heat sink fins clean at all times. Clean them using compressed air. NOTE: Do not use conductive cleaning solvents on the module.

  • Page 37: Advanced Display Module (Adm)

    Maintenance Advanced Display Module (ADM) 2. Remove token access panel. Replace Battery A lithium battery maintains the ADM clock when power is not connected. To replace the battery: 1. Disconnect power to the ADM. ti12904a 2. Remove rear access panel. 3.

  • Page 38: Fluid Control Module (Fcm)

    Maintenance Fluid Control Module (FCM) 4. Press and hold the push button (M) for three sec- onds and then release. The red LED (L) flashes until the software is uploaded. See F . 15. 5. Remove token (T) when software has successfully uploaded.

  • Page 39: Troubleshooting

    Troubleshooting Troubleshooting Light Tower (Optional) Signal Description Green on only System is powered up and there are For information about ADM error and event codes see no error conditions present Appendix D - ADM Event and Error Codes Overview, Yellow on An advisory exists page 58.
  • Page 40 Troubleshooting Problem Cause Solution Material imbalance Inadequate flow from pump; cavitation Clean inlet strainer screen Worn pump inlet valve ball/seat or gasket, repair as necessary Erratic pump movement Pump cavitation Feed pump pressure is too low, adjust pressure to within required range Pump output low Obstructed fluid hose or mixer;...

  • Page 41: Adm Troubleshooting

    Troubleshooting ADM Troubleshooting ti12902a ti12362a1 . 16: ADM Component Identification - Rear ADM System Status LEDs (B) Conditions Module Status LED Signal Description Green on Run mode, System on Green flashing Setup mode, System on Yellow on Run Mode, System off ADM Module Status LEDs (N) Conditions Module Status LED Signal...

  • Page 42: Motor Control Module

    Troubleshooting Motor Control Module Diagnostic Information Table 3: LED Status Signal Module Status LED Signal Description Green on System is powered up Yellow on Internal communication in progress Red solid MCM hardware failure. Replace MCM Red flashing fast Uploading software Red flashing slow Token error, remove token and upload software token again...
  • Page 43 Troubleshooting Acceptable Size and Duration of Power Line Voltage Fluctuations The Motor Control Module is designed to withstand volt- age fluctuations from the incoming power supply. If the incoming power supply goes outside of the tolerable range, an over-voltage condition is flagged and the sys- tem shuts down in an alarm state.

  • Page 44: Fluid Control Module

    Troubleshooting Fluid Control Module Diagnostic Information Module Status LED Signal Diagnosis Green on System is powered up Yellow Internal communication in progress Red solid FCM hardware failure. Replace FCM. Red flashing fast Uploading software Red flashing slow Token error. Remove token and upload software token again.

  • Page 45: Appendix A - Adm Icons Overview

    Appendix A - ADM Icons Overview Appendix A - ADM Icons Overview Setup Screen Icons Icon Description Icon Description Learn Top-Most Piston Position Enter Screen Go to Next Calibration Screen Exit Screen Begin Weight Calibration Shot Erase Selected Item Dispense Valve Details Erase All Items Shown Shot Number Change Multiple Values...

  • Page 46: Home Screen Icons

    Appendix A - ADM Icons Overview Home Screen Icons Icon Description Icon Description Prime A (Red) Side Select Operating Mode Prime B (Blue) Side Initiate Dispense Enter Screen Dispense Disabled Exit Screen Ratio Check Erase Selected Item Park Piston Erase All Items Shown Park Piston Disabled Weight Close Dispense Valve...

  • Page 47: Appendix B - Adm Setup Screens Overview

    Appendix B - ADM Setup Screens Overview Appendix B - ADM Setup Screens Overview Setup Screens Navigation Diagram Calibration Shot #1 Sequences #1 System #1 Maintenance Supply Conditioning #1 Advanced #1 Shot #2 Sequences #2 System #2 Conditioning #2 Advanced #2 Shot #...
  • Page 48 Appendix B - ADM Setup Screens Overview Sequences Calibration - Learn Mode This screen is for learning the mechanical limits for pis- This screen allows the user to edit sequence definitions. ton travel. The contents of this screen change based on the Dis- pense mode.
  • Page 49 Appendix B - ADM Setup Screens Overview System #1 System #2 This screen allows the user to set the Gel Timer proper- This screen allows the user to set mechanical system ties and set which items are installed on the machine. settings and the Dispense Mode setting.
  • Page 50 Appendix B - ADM Setup Screens Overview System #3 This screen allows the user to edit the labels for the 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.
  • Page 51 Maintenance Conditioning #1 This screen shows shot number and sequence position NOTE: The HVR does not use temperature condition- counters. Use the Counters dropdown menu to select ing. Do not check any of the boxes on this screen. which set of counters to view.
  • Page 52 Conditioning #3 Advanced #2 This screen allows the user to set the units of measure. NOTE: The HVR does not use Night mode conditioning. Do not enable night mode. Advanced #3 This screen allows the user to configure Night Mode operation.
  • Page 53 Appendix B - ADM Setup Screens Overview • Operator Mode Cavitation Alarm: Check this box Advanced #5 to enable cavitation alarms in Operator Mode. Clear this box to disable cavitation alarms in Operator Mode. • Complete Dispense with Setpoint Error: When this box is checked, the shot will continue dispens- ing even if the system never reaches the desired setpoint.

  • Page 54: Appendix C - Adm Run Screens Overview

    Appendix C - ADM Run Screens Overview Appendix C - ADM Run Screens Overview Run Screens Navigation Diagram Optional: Home Errors #1 Events #1 Maintenance Diagnostic Errors #2 Events #2 Errors #... Events #... Home Screens Disabled The Home screen is the first screen that displays when the machine is started and when switching from the Setup screens to the Run screens.
  • Page 55 Appendix C - ADM Run Screens Overview Shot Operator This mode allows the user to dispense using one of the This mode allows users to dispense without using pre- defined shots. See Shots screen on page 47. Shot defi- defined shot numbers or sequences. Use to set nition including flow, ratio, progress, and size is shown at the bottom of the screen.
  • Page 56 Appendix C - ADM Run Screens Overview Errors Screen Maintenance The Errors screens display the 50 most recent system This screen displays historical information for each errors. Each error entry includes a description and error pump including material usage and pump cycles. The code along with a date and time stamp.

  • Page 57: Optional Screens

    Appendix C - ADM Run Screens Overview Optional Screens The optional Diagnostic screen can be enabled in the Advanced #4 screen, see page 53. Diagnostic The Diagnostic screen shows status information for vari- ous system components. 313873B...

  • Page 58: Appendix D - Adm Event And Error Codes Overview

    Appendix D - ADM Event and Error Codes Overview Appendix D - ADM Event and Error Codes Overview Event Codes Event Code and String Triggers Event Code and EQU1-R: Settings The system settings were successfully String Triggers Downloaded transferred from the ADM to a USB EAA0-R: Base Purge Base purge performed drive.

  • Page 59: Error Codes

    Appendix D - ADM Event and Error Codes Overview Error Codes Error Error Code Error Name Error Description Type Cause Solution The three point calibration data is invalid, system will operate in weight mode but will attempt Invalid to volumetrically calculate 0500 Weight Cal.
  • Page 60 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 Pumps are defined with The requested dispense screens then make sure that the pump sizes are...
  • Page 61 Appendix D - ADM Event and Error Codes Overview Error Error Code Error Name Error Description Type Cause Solution Pump cannot reach the Increase restriction in the system requested pressure Setpoint Not D2A1 The set point was not reached Deviation Reached Pump cannot reach the Decrease restriction in the system...
  • Page 62 Appendix D - ADM Event and Error Codes Overview Error Error Code Error Name Error Description Type Cause Solution 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 properly connected to the MCM and that the wire has not been damaged...
  • Page 63 Appendix D - ADM Event and Error Codes Overview Error Error Code Error Name Error Description Type Cause Solution Ensure the material flow is equally restricted on both Dispense line is clogged material lines On the ADM go into the setup screens -> System-> Pressure imbalance is and ensure the pressure imbalance value is the defined too low...
  • Page 64 Appendix D - ADM Event and Error Codes Overview Error Error Code Error Name Error Description Type Cause Solution Blue Tank T4B5 High Fluid Alarm Temp. Red Inline T4A3 High Fluid Alarm Temp. Blue Inline T4B1 High Fluid Alarm Defective RTD Replace RTD Temp.
  • Page 65 Appendix D - ADM Event and Error Codes Overview Error Error Code Error Name Error Description Type Cause Solution Red Blanket T6C6 Alarm RTD Fault Blue Blanket T6C5 Alarm Loose or bad connection Check RTD wiring RTD Fault RTD 2 is giving no or invalid data Red Chiller T6C7...
  • Page 66 Appendix D - ADM Event and Error Codes Overview Error Error Code Error Name Error Description Type Cause Solution Red Blanket T9C6 Ctrl Alarm Shutdown Blue Blanket T9C5 Ctrl Alarm Shutdown Red Inline T9C3 Ctrl Alarm Shutdown Blue Inline T9C1 Ctrl Alarm Overheated...
  • Page 67 Appendix D - ADM Event and Error Codes Overview Error Error Code Error Name Error Description Type Cause Solution No power to directional Make sure the directional valve has power valve Make sure the cord to the directional valve is Bad directional valve connected to the correct port and the cord is not connection...
  • Page 68 Appendix D - ADM Event and Error Codes Overview Error Error Code Error Name Error Description Type Cause Solution On the ADM go into the setup screens -> System-> System incorrectly setup and ensure that all pages have properly defined Invalid The requested controlling values...

  • Page 69: Appendix E - Usb Operation

    Appendix E - USB Operation Appendix E - USB Operation The second option is the Erase icon which will reset the NOTICE last download date to a time where all logs can be Low-quality USB stick drives may lead to burning downloaded.

  • Page 70: Log Files, Folder Structure

    Appendix E - USB Operation Log Files, Folder Structure . 19: DOWNLOAD, DATAxxxx Folders 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 trans- ferred through the USB.
  • Page 71 Appendix E - USB Operation Example LOG01 File The LOG01 file is the Errors and Events log file. Example LOG02 File The LOG02 file is the Shot Data log file. 313873B...

  • Page 72: Transfer System Settings

    7. Turn the Main Power Switch to the OFF position The user should never attempt to modify the SET- then back to the ON position. TINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified 8. Plug the USB stick-drive into a computer.

  • Page 73: Update Custom Language

    Appendix E - USB Operation Update Custom Language Use the following process to customize the text on the NOTE: Immediately following uploading the language ADM. The language file DISPTEXT.TXT can be modi- file, remove the DISPTEXT.TXT file from the UPLOAD fied in Excel but must be saved as a Unicode Text file folder to prevent accidental loss of data the next time the with the extension .TXT in order for it to properly import.
  • Page 74 Appendix E - USB Operation Example SETTINGS.TXT File Example DISPTEXT.TXT File NOTICE The user should never attempt to modify the SET- TINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified setup file. 313873B...

  • Page 75: Technical Data

    Technical Data Technical Data Air Inlet Pressure ......85-100 psi (0.59-0.69 MPa, 5.9-6.9 bar) Wetted Parts .

  • Page 76: Graco Standard Warranty

    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.

Table of Contents