Graco HORIZON Instructions-Parts List Manual
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Graco HORIZON Instructions-Parts List Manual

Fluid management systems
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INSTRUCTIONS-PARTS LIST
308–607
Rev. B
This manual contains important
Supersedes A
warnings and information.
First choice when
READ AND KEEP FOR REFERENCE.
quality counts.
INSTRUCTIONS
Fluid Management Systems
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

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  • Page 1 Supersedes A warnings and information. First choice when READ AND KEEP FOR REFERENCE. quality counts. INSTRUCTIONS Fluid Management Systems GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1997, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    To Clean the Solenoid Valve ....fluid at the same time. The Horizon allows up to 12 Horizon System Components ....

  • Page 3: Symbols

    This equipment is for professional use only. Read all instruction manuals, tags, and labels before operating the equipment. Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco distributor. Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

  • Page 4: Pre-Installation Checklist

    Floor Plan, purchase order, and packing slip 3. Verify that all Horizon system components are marked in their proper loca- Floor Plan tions on the Floor Plan. 4. Assign a name and number to all the control modules in the system. Record Floor Plan the control module numbers on the Floor Plan.
  • Page 5 1 to 6. Record the port number and whether it is an air or fluid solenoid on the Floor Plan. NOTE: Air and fluid solenoids can be inter- mixed on the Horizon ports. b. For each meter attached to the control module, assign one port number, from 7 to 12.

  • Page 6: Installation Checklist

    Installation Checklist After completing the Pre-installation Checklist on page 4, use the following installation checklist to guide you through the steps of the system installation. Hardware Installation Installation Steps Reference 1. Flush all fluid lines to remove the debris and avoid clogs in the meters. 2.
  • Page 7 Page 15 display a revision screen and then the HOME screen. The printer should print “WELCOME TO HORIZON...” If the HOME screen is not displayed and/or there is no print-out, see Troubleshooting, page 38. 15. Using the Administrative Keypad, which is connected to the Master Control Page 15 Module, access the Setup screens.

  • Page 8: Hardware Installation

    The OFF position A Pressure Relief Kit is required in the indicates a basic keypad is connected. The ON Horizon system to reduce the risk of position indicates an enhanced or administrative serious injury, caused by splashing fluid keypad is connected.

  • Page 9: To Change From 120 Vac To 240 Vac

    Hardware Installation 3. Set Control Module Addresses and 4. To Change from 120 VAC to 240 VAC Label the Boxes (continued) WARNING Address Switch FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Setting Setting To reduce the risk of fire, explosion, and electric shock all wiring must be done by a qualified electrician.

  • Page 10: Mount The Control Module And Keypad Bracket

    Hardware Installation 5. Mount the Control Module and Keypad Keypad Bracket Bracket See Fig. 4 for the mounting hole layout. Control Module The control module(s) should be mounted near the hose reels. Control modules can be mounted on the wall or at ceiling level. Locate the control module(s) as directed in the floor plan, being sure to follow the cable length and other configuration requirements.

  • Page 11: Cable Routing And Connection

    AC power supply, 120 VAC or 240 VAC; 240 VAC operation requires modification of transformer connections inside control Ground the Horizon system by connecting the module. See page 9. electrical power cable to a true earth ground. Leave green ground wire 2 inches (50.8 mm) longer than the two AC wires.

  • Page 12: Route The Solenoid And Meter Cables

    Cable Routing and Connection 7. Route the Solenoid and Meter Cables Solenoid Connection to their Assigned Control Module P8 or P9 8. Connect the Solenoid and Meter Cables a. Connect the solenoid cables as shown in Fig. 6. The cables connect at the solenoid end with wire nuts.
  • Page 13 Cable Routing and Connection 9. Connect the Control Modules to the Control Module Connectors CAN (Controller Area Network) WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD To reduce the risk of fire, explosion, and electric shock all wiring must be done by a qualified electrician.

  • Page 14: Connect The Keypad Cable

    10. Connect the Keypad Cable 12. Visually Check the Wire Connections Route and connect the keypad cables between the NOTE: The Horizon hardware installation is now keypads and control module connectors. If using the complete. The Checklist Steps 1 to 12, page 6, Administrative or Enhanced Keypad, be sure to con- should be checked off.
  • Page 15 Instructions Screens Startup Screen STARTUP Screen HORIZON REV X.XX This screen is displayed for four seconds after the GRACO INC system is turned on, then the Mode Selection screen COPYRIGHT XXXX (or Home screen) appears.
  • Page 16 System Setup – Startup Instructions Screens 3. Type of Setup SETUP Screens a. SETUP screen appears. _ _ _ _ _ _ _ _ _ _ SETUP _ _ _ _ _ _ _ _ _ _ b. Cursor is on ENABLE CAN. ENABLE CAN c.
  • Page 17 System Setup – Modify or New Instructions Screens 5. Modify Setup Options _ _ _ _ _ _ _ _ _ _ SETUP _ _ _ _ _ _ _ _ _ _ ENABLE CAN a. With the cursor at MODIFY SETUP, press MODIFY SETUP ENTER on the keypad.
  • Page 18 System Setup – Clear Setup Instructions Screens 7. Clear Setup Options _ _ _ _ _ _ _ _ _ _ SETUP _ _ _ _ _ _ _ _ _ _ MODIFY SETUP CAUTION NEW SETUP CLEAR SETUP Clearing the OPERATOR PASSWORDS or ALL MEMORY will delete all passwords, including the CLEAR OPTIONS Screen password the system is supplied with, which allows...
  • Page 19 System Setup – Print Setup 8. Print Setup Options _ _ _ _ _ _ _ _ _ _ SETUP _ _ _ _ _ _ _ _ _ _ NEW SETUP NOTE: Only the information for the control module the CLEAR SETUP keypad is connected to is printed.
  • Page 20 System Setup – Update Tables Instructions Screens 9. Update Tables Options _ _ _ _ _ _ _ _ _ _ SETUP _ _ _ _ _ _ _ _ _ _ CLEAR SETUP a. Move the cursor to UPDATE TABLES using PRINT SETUP key.
  • Page 21 Pressing any key will return the cursor to the DIAGNOSTICS ABOUT Screen screen. g. The SOLENOIDS screen allows you to check HORIZON X.XX the operation of the solenoids by turning them FIRMWARECKSUM: XXXX off and on. DATA...
  • Page 22 System Setup – Diagnostics Instructions Screens 10. Diagnostics (continued) METERS Screens _ _ _ _ _ _ _ _ _ _ METERS _ _ _ _ _ _ _ _ _ _ h. The METERS screen appears with the cursor MONITOR METERS at the MONITOR METERS option.
  • Page 23 System Setup – Diagnostics Instructions Screens 10. Diagnostics (continued) KEYPAD Screen KEYPAD MODEL: The KEYPAD screen appears with the cursor ADMIN/ENHANCED at the first line, which should show the type of PRESS ENTER KEY TO keypad you are using right now. ADMIN/ CHANGE ENHANCED or BASIC are the two choice.
  • Page 24 NOTE: Only the Master Control Module can access the TIME AND DATE screen. 15:50:08 1. With the cursor in the TIME field, type in the time. Notice that the Horizon has a 24 hour clock. TIME (HH:MM) 15:50 2. Press ENTER on the keypad.
  • Page 25 System Setup – Save Setup Instructions Screens Save Setup SAVE SETUP: NOTE: WARNING: SAVE WILL CANCEL Any active or waiting jobs will be canceled when ACTIVE JOBS you save the setup options. The Master Control Module will update the copied setup files in each Slave Control Module.
  • Page 26 System Setup – Fluids Instructions Screens Enter Fluid Data FLO1 NAME: UNITS: QUARTS 1. Cursor is in the fluid number (FL01) field. ORDER: 01 2. The fluid number will automatically increment up EXIT DELETE by 1 as you add fluids or you can type the number identification of the fluid.
  • Page 27 System Setup – Dispense Areas Instructions Screens Define Dispense Areas DAO1 NAME: 1. Cursor is in the dispense area number (DA01) field. EXIT DELETE 2. The dispense area number will automatically incre- ment up by 1 as you add areas or you can type the number identification of the area.
  • Page 28 System Setup – Connection Assignments Instructions Screens Assign Connections ASSGN CONN: DA01 FL01 AIR SOL: CM 01 PORT0 1. The dispense area and fluid number appear in the FLD SOL: CM 01 PORT0 first row. MTR#: 000 MORE EXIT NOTE: The combined designation of the dispense area and fluid number is called the dispense point.
  • Page 29 System Setup – Meter Calibration Instructions Screens Set Meter Calibration METER NUMBER: 001 CM# 01 PORT# 07 1. Cursor is in the METER NUMBER field. 0001 PULSES PER QT 2. The meter number will display according to the MORE EXIT order they were entered while assigning connec- tions (page 28).
  • Page 30 System Setup – Inventory Instructions Screens Set Inventory Levels FL#01 QT 10W30 00010 GL REORDER PT. 1. Cursor is in the fluid number (FL#01) field. 00100.0 GL TANK LVL 2. The meter number will automatically increment up MORE EXIT by 1, based on the fluids entered while entering the fluid data (page 26).
  • Page 31 System Setup – Report Options Not implemented in this software version. System Setup – Run Options Instructions Screens Set Run Options RUN OPTIONS: 1. Cursor is on YES in the PASSWORD? field in the PASSWORD? JOB NUMBER? RUN OPTIONS screen. 2.
  • Page 32 Run Mode – Dispensing Instructions Screens Startup Screen STARTUP Screen HORIZON This screen is displayed for four seconds after the REV X.XX system is turned on, then the Mode Selection screen GRACO INC (or HOME screen) appears. If the system was turned COPYRIGHT XXXX on previously, you will not see this startup screen.
  • Page 33 Run Mode – Dispensing Instructions Screens 4. Enter Vehicle Data NOTE: The job number, vehicle ID, and the custom _ _ _ _ _ _ _ _ RUN NEW JOB _ _ _ _ _ _ _ input field are optional. What is necessary to enter is JOB NUMBER: _ _ _ _ _ _ _ determined during setup.
  • Page 34 Run Mode – Dispensing Instructions Screens 6. Preset Dispense PRESET DISPENSE Screen NOTE: The unit of measurement (in this example, QT SEL FL:02 PENNZ5W20 SEL DA:03 BAY3 or quart) is entered during the System Setup. There are four units of measurement available: quarts, liters, PRESET AMOUNT?: YES gallons, and pints.
  • Page 35 Run Mode – Dispensing Instructions Screens 9. Dispense DISPENSE ACCEPTED Screen a. After the dispense is confirmed, if the system DISPENSE ACCEPTED: does not detect any problems, it will turn on STATUS: READY the correct air and fluid solenoids, enable the meter pulse count, and start the time out clock.
  • Page 36 Run Mode – Review Jobs Instructions Screens Startup Screen STARTUP Screen HORIZON This screen is displayed for four seconds after the REV 1.00.001 system is turned on, then the Mode Selection screen GRACO INC (or HOME screen) appears. If the system was turned COPYRIGHT 1996 on previously, you will not see this startup screen.
  • Page 37 Run Mode – Review Jobs Instructions Screens 4. Review Jobs REVIEW Screens Active Screen a. The oldest job in the system is displayed. ACTIVE in line one indicates that the ACTIVE12:01 solenoids have been activated and the 004.0 QT PENNZ5W20 system is ready to dispense.
  • Page 38 Troubleshooting Problem Cause Solution Keypad screen completely 1. No power to control module 1. Verify power is on blank 2. Keypad cable disconnected 2. Reconnect cable and cycle power to control module 3. Keypad malfunction 3. Replace keypad 4. Control module malfunction 4.
  • Page 39 Extraction Tool To Install New Software 1. Turn off the electrical power to the Horizon system. Fig. 14 2. Remove the cover from each of the control mod- ules. 3. Identify the new memory chips included with the software upgrade.
  • Page 40 Shutdown Procedure on 1.4 N m). page 39 before servicing any part of the Horizon system and before checking for loose or 5. Connect the pulse meter wires to the cable, follow- shorted wires. ing the original wiring polarity.
  • Page 41 6. Dispense fluid at the dispensing valve controlled by page 39 before servicing any part of the the cleaned or replaced solenoid valve until all air Horizon system and before checking for loose or is purged from the system. shorted wires.
  • Page 42 It continuously tracks the time and date. Part No. 238–625, Slave Control Module Control Module Specifications: The Horizon system consists of a number of control There can be a total of 40 control modules in a modules that are connected by cables to form a net- system, 1 Master plus 39 Slaves.
  • Page 43 Horizon System Components Control Module 06799 Control Module Component Identification NOTE: See page 48 for more information about sys- 6. Power Supply tem cables. Converts AC input power for use by control module 7. Power Supply Connector 1. Cable Port Holes...
  • Page 44 Horizon System Components Keypads Enhanced Keypad with Bar Code Reader The Enhanced Keypad provides all the functionality of Part No. 113–551, Basic Keypad the Basic Keypad, with the added functionality of a bar code reader. Part No. 113–552, Enhanced Keypad with Bar Code Reader Part No.
  • Page 45 Horizon System Components Administrative Keypad Keypad Specifications: This keypad is needed to set up and make changes to There can only be one Administrative Keypad in the the system parameters. It can only be connected to the system, and it can only be connected to the Master Master Control Module.
  • Page 46 Horizon System Components Fluid Solenoid Valves Air Solenoid Valves Part No. 215–407, Air Solenoid Valve; Low Flow Part No. 218–588, Fluid Solenoid Valve For low-air-flow requirement pump models, such as the Eagle and Fire-Ball 0 to 3 gpm (0–11.4 liter/min.), with Ready Light; See manual 307–696 for more information...

  • Page 47: Pulse Meters

    Sends 10 pulses per quart (9 pulses per liter) of fluid through it. During the setup of the Horizon software, each pulse meter is defined, including the number of pulses per unit of fluid. This pulse constant can be input for differ-...

  • Page 48: System Cables

    System Cables Keypad/Computer Cables (with connector) For Keypad, Computer, or Printer Connections These cables connect keypads to control modules or (include connectors) can connect the Horizon output port to a computer serial connector for data transfer. Part No. Length 191–393 Keypad or 25 ft.
  • Page 49 Horizon System Components Solenoid Cable (bulk) Network Cable (bulk) Control modules are linked together with 2-conductor, These cables connect the air and fluid solenoids to the 22 AWG shielded cable, which is available in bulk control modules. They are 2-conductor, 18 AWG spools of 500 or 1000 ft.

  • Page 50: Pressure Relief Kit

    1–1/2” npt (m x f) Printer Printer The Horizon system printer can print out individual job tickets after each dispense transaction is completed. It uses a roll of thermal paper and prints a 40-column- width ticket, similar to a cash register receipt. These...

  • Page 51: Appendix

    Appendix 308–607...

  • Page 52: Horizon Software Features

    Horizon system; there is no jobs or jobs that are waiting in queue. physical tank-level-monitoring device. Current levels...

  • Page 53: System Configuration

    (15.3 m) total wire length from the control module. Pages 54 to 66 show examples of system design Vertical distance, routing around pipes and beams, and how to complete and use the Horizon Forms to and other factors must be considered. For this setup the system.

  • Page 54: System Configuration Examples

    System Configuration System Configuration Examples Example 1 Parts List Qty. Component Example 1 Configuration 3 fluids Master Control Module All 3 fluids dispensed in each of 3 bays Slave Control Module No simultaneous dispensing of the same fluid Keypad (could be Administrator Keypad for One keypad in the office setup, or Basic Keypad for normal operation) Printer in the office for output...
  • Page 55 System Configuration Example 2 Configuration Example 2 Parts List 3 fluids Qty. Component All 3 fluids dispensed in each of 3 bays Master Control Module Simultaneous dispensing of all fluids to all bays One keypad in the office, plus a keypad in each bay Slave Control Module Printer in the office for output Keypads (could be 1 Administrator Keypad...
  • Page 56 Horizon Form #1 Graco, Inc. Horizon Horizon User Name, PIN Number and Access Level ACCESS LEVEL (check one) Name on System PIN Number Run & Run, Invt. User Name (4 characters max) (4 characters max) Inventory & Setup John Doe...
  • Page 57 Horizon Form #1 The following Horizon Form pages show examples of NOTE: Use the keys to move the cursor to how to complete and use the forms to setup the sys- DELETE if you need to delete operator entrees. tem. The example forms are filled out according to the system design shown on page 55 and are based on 5.
  • Page 58 Horizon Form #2 Graco, Inc. Graco, Inc. Horizon Horizon Control Module & Fluid Names & Numbers t l M d l & Fl id N & N CM Name in Software Map Control Module Location (10 Characters max) Master – Near Office/Pumps...
  • Page 59 Horizon Form #2 Use Form #2 as a guide for inputting the control mod- MASTER CONTROL MODULE Screen ule and fluid names. NAME CONTROL MODULES CM#01 (MASTER CM) Name the Master Control Module NAME: OFFICE _ _ _ _ NOTE: The first screen you access will be the Master EXIT Control Module screen CM#01.
  • Page 60 Horizon Form #3 Graco, Inc. Graco, Inc. Horizon Horizon Dispense Area Names & Numbers & N Dispense Area Name in Software Map Dispense Area Location (10 Characters max) Service Bay #1 Service Bay #2 Service Bay #3 308–607...
  • Page 61 Horizon Form #3 Use Form #3 as a guide for inputting the names of the 8. If there are more dispense areas to add, press dispense areas. ENTER. 9. When all the dispense areas have been entered, You also define which fluids are available at each...
  • Page 62 Horizon Form #4 Graco, Inc. FLUIDS Name Name Name Name Name Name Name Name Name Name Connection Assignments Record the Control Module # and port # for 5/30 10/30 each solenoid (ports 1–6); number each me- ter consecutively (1,2,...) Example: CM1/3...
  • Page 63 Horizon Form #4 Use Form #4 as a guide for inputting which solenoids 13. Press ENTER on the keypad. to turn on and which meter counts the pulses when 14. When the cursor is at MORE, press ENTER to dispensing specified fluids at specified dispense points.
  • Page 64 Horizon Form #5 Graco, Inc. Horizon Horizon Meter Calibration Chart No. Location Fluid CM # Port # Pulses Per Unit Bay #1 5/30 Oil Bay #1 10/30 Oil Bay #1 Bay #2 5/30 Oil Bay #2 10/30 Oil Bay #2...
  • Page 65 Horizon Form #5 Use Form #5 as a guide for inputting the meter con- If using P/N 238–618 Meter (for oil), set nection address and to set the calibration (pulses per calibration at: unit) for each meter. 100 pulses per pint,...
  • Page 66 Horizon Form #6 Horizon Fluid Management Systems Warranty Registration and Checkout Form 1. Site Identification 2. Installer Identification Customer Name: Bob’s Service Garage Company Name: Pumps ’R Us Address: 123 Main Street Address: 9876 Elm Street City/State/Zip: Anytown, USA 12345 City/State/Zip: Anytown, USA 12345 Phone Number: (612) 555–1234...

  • Page 67: System Dynamics And Design Factors

    A Pressure Relief Kit (A) is required in NOTE: Each control module has a DIP switch that can the Horizon system to reduce the risk of be used to turn on all the solenoids connected to it. serious injury, caused by splashing fluid See page 8 for more information.
  • Page 68 F can be used to isolate the meter and/or solenoid for service. Change the hose reel connection from connector D to connec- tor E to bypass Horizon system. Cap the connector that is not being used. Fig. 20 Fig. 21...

  • Page 69: Avoiding Pulsation

    (B), and valve com- binations are actively dispensing. See Fig. 22. A Pressure Relief Kit is required in the Horizon system to reduce the risk of These false readings occur when one or more reels serious injury, caused by splashing fluid...

  • Page 70: Technical Data

    Technical Data System Specifications 40 maximum Control Modules in a system (1 Master only, plus 39 Slave) 40 maximum Keypads in a system (1 keypad per Control Module; Administrators Keypad must be connected to the Master Control Module) 240 maximum Solenoids in a system (40 Control Modules, 6 ports each) 240 maximum Meters in a system (40 Control Modules, 6 ports each)
  • Page 71 Notes 308–607...

  • Page 72: Graco Warranty And Limitation Of Liability

    Graco distributor to the original purchaser for use. Graco will, for a period of twenty-four months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

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