Instructions - Parts Level Detection Module and Drum Feed Kit 3A2806C EN Installation kit to provide low level sensors in both chemical sides of an HFRL or HFRS plural-component proportioner being fed from 55 gallon (208 liter) drums. Not for use with standard configured HFR units. For professional use only. Not approved for use in explosive atmospheres or hazardous locations. Important Safety Instructions Read all warnings and instructions in the HFRL and HFRS Setup-Operations manual.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component Identification . . . . . . . . . . . . . . . . . . . . 4 Complete Feed System . . . . . . . . . . . . . . . . . . . . 4 Electrical Panel Components . . . . . . . . . . . . . . . 5 Fluid Control Module (FCM) . . . . . . . . . . . . . . . . 6 Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Grounding . . . . . . . . . .
Related Manuals Related Manuals Component manuals in English. Manuals are available at www.graco.com. Manual No. Description 3A2175 HFRL and HFRS, Setup-Operations 3A2176 HFRL and HFRS, Repair-Parts 312877 Husky 1050 Air-Operated Diaphragm Pump, Operation 3A0235 Feed Supply Kits, Instructions-Parts 406987 GCA CAN Cables, Reference (Extension Cables) Models NOTE: Not for use with standard HFR units.
Component Identification Component Identification Complete Feed System Figure Shown With: (1) Level Kit (2) Drum Feed Kit Options (1) 4 Drum Rack Option F G D E B C A ti19596a K J H FIG. 1: Component Identification - Feed System Key: A B C D E F G 4 Auxiliary Control Panel (Mounted in Machine Base) Refer to FIG.
Component Identification Electrical Panel Components The electrical panel will be located on the inside of the HFRL stand enclosure, and includes two fluid control modules. Software is loaded on Fluid Control Modules (FCM). Program token 16G584 is also provided. AF AD AE AC AA AB r_24n804 FIG.
Component Identification Fluid Control Module (FCM) BA BC BH BG ti12337a ti12336a BE BF BD BB FIG. 3: Component Identification - FCM Key: BA BB BC BD BE BF BG BH Fluid Control Module (FCM) Base Module Connection Screws Access Cover Module Status LEDs CAN Connectors Level Sensor Input Fill Solenoid Signal Adjust Rotary Switch The rotary switch setting indicates which zone the fluid control module will control in the system. The FCM uses a 16-position rotary switch to make selections.
Component Identification Light Tower tower FIG. 5: Component Identification - Light Tower Signal Description Green on only System is powered up and there are no error conditions present Yellow on An advisory exists Yellow flashing Material is at a low level condition Red flashing A deviation exists Red on The system is shut down due to an alarm occurring. Errors include advisories, deviations, or alarms, so green will only be on when none of these occur.
Grounding Grounding The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit. Pump: follow instructions in separate feed pump manual, supplied. HFR: see operation manual. Flush Pumps Before Using Flush equipment only in a well-ventilated area. Do not spray flammable fluids. NOTICE Diaphragm pumps are factory tested with water.
Installation Installation Install 4 Drum Rack (Optional) NOTICE To avoid machine damage or personal injury, anchor the rack to the floor with (4) 1/2” bolts (provided by customer) and verify all bolt assemblies are tightened before loading the drums onto the rack. 4. Tighten all connections. Connect Feed Pump 1. Supply clean, dry, filtered air to feed pumps. NOTE: Air supply components are not included. 2. Refer to Husky 1050 Air-Operated Diaphragm Pump, Operation manual for instructions.
Installation Install Electrical Panel 1. Perform HFR shutdown procedure. See HFRL operation manual for detailed instructions. 2. Disconnect the power supply to the machine. 3. Turn the disconnect switch on the rear base cover of the machine to the “OFF” position 4. Remove the cover to allow access into the base cube. 5. Install the pre-assembled panel on the left side of the cube, directly opposite of the main control panel.
Installation NOTE: Mounting location for panel is only available on HFRL and HFRS models. This location is used for other control components on standard HFR models. Step 5 Step 5 Step 6 r_24n804 Panel view is shown rotated 180° from the installed position. Step 8, Step 9 Step 6 Step 13 Panel Install FIG.
Installation Install Level Sensors where the well is inserted. Note these measurements as they will be need later. NOTE: Lower drum hardware must be installed in an empty drum and then installed on the lower drum rack. The drum can then be filled from the cascade feed hose from a full upper drum. NOTE: There are two possible locations for the low level sensor, depending on desired function. Install both sensors in the same location on each chemical side.
Installation Install Light Tower NOTE: Install the light tower in a suitable location for clear viewing. 1. Create the hole pattern below to match the light tower base. Ø 1.57 Bolt Circle Ø 0.90 3x 8-32 UNC 2B Equally Spaced Mount Pattern 2. Use the provided screws to attach the light tower to the mounting bracket. 3. Route the light tower cord as needed towards the ADM. NOTICE To prevent damage to the cord, ensure it will not be pinched during normal machine operation after routing. 4.
Setup Setup Set the ADM to Recognize the Feed System Kit Calibrate Barrel Style Level Sensors 1. Navigate to the ADM Supply Screen. 1. Locate the calibration button on the sensor (11) closest to the electrical connector through one of the four holes of the sensor well housing (CA). 2. If the calibration button cannot be seen through one of the four holes in the sensor well, rotate the sensor. a. Loosen the sensor well nut (CC). b.
Setup Set the ADM to Recognize which Level Sensors are to Operate 3. If it is desired to stop dispensing when a low level is sensed, select and check “Low Material Disables Dispense”. NOTE: Two sensors must be selected for each material with a level sensor, regardless if there is only one low level sensor installed. NOTE: Setting this option initiates a deviation condition and disables the machine from operation when there is a low level condition.
Startup Startup Shutdown 1. See Load fluid with feed pumps in HFR operation manual. See Shutdown in system operation manual. Close feed pump bleed-type master air valve. 2. Open feed pump air regulator. 3. Open feed pump bleed-type master air valve. 4. Adjust air to feed pump with needle valve. Pressure Relief Procedure NOTE: • Cold, viscous material may be difficult to prime. Use needle valve to reduce air flow to motor. • Do not plug or shut off pump fluid outlet when priming.
Maintenance Drum Feed Kit, Pump 10. Install dryer assembly. NOTE: See supplied pump manual for maintenance, repair, and parts information. NOTE: To prevent contamination of the desiccant in the dryer canister caused by sloshing material, it is recommended that the tape is temporarily placed over the air inlet on the dryer canister. The tape should be removed after the drum is installed. Tighten pump clamps and external fasteners periodically. See pump manual. Drum Feed Kit, Changing Top Drums 11.
Maintenance Install Upgrade Tokens NOTE: The Motor Control Module, Fluid Control Module, 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.
Troubleshooting Troubleshooting Problem Level sensor is not sensing material when material is present. Cause Level sensors out of calibration. Solution Calibrate level sensor. Replace level sensor. Intermittent electrical connections. Ensure the system main power is ON. Ensure all electrical connections to the level sensor are secure. See electrical schematic in either the HFR or VRM Repair-Parts manual. FCM errors. Check FCM. A red LED indicates a problem with the module.
Repair Repair Level Sensor and Well NOTE: For proper level sensor function, the tip of the level sensor well must protrude at least 1/8 in. into the reservoir. NOTE: In the following step, do not allow PTFE paste or tape to cover the tip of the level sensor well. If paste comes in contact with the tip of the level sensor well, thoroughly wipe it clean. 9. Apply PTFE paste and PTFE tape to the male threads of the level sensor well housing. CA CB CC CD 10.
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 3A2806C 4 3 2 M12 5 PIN MALE (122487) FEMALE (121002) 1 2 3 4 5 1 2 3 4 5 M12 5 PIN FEMALE CAN COM 1 SIGNAL SIGNAL COMMON SIGNAL 24VDC 1 2 3 1 1 4 2 2 3 3 4 4 5 5 CAN COM 1 1 2 3 4 M8 4 PIN FEMALE 1 2 3 4 M8 4 PIN F
Parts Parts Drum Feed System, 24N816 006 005 003 004 001 005 22 3A2806C
Parts Ref 001 Part 24N804 003 004 005* 006* * Description PANEL, assy, fluid control, HFRL (Inside Enclosure - Refer to FIG. 2, page 5) 255468 KIT, acc., light tower, TC ram 124003 CABLE, CAN, male-female, 5.0m 24N767 KIT, drum feed, carbon (Optional) 01/0955/25 RACK, 4 drum (Optional) Quantity 1 1 1 1 1 Items are optional. Shown for clarity. Replacement Danger and Warning labels, tags, and cards are available at no cost.
Parts Drum Feed Kit, 24N767 100 117 121 116 118 119 118 115 127 120 110 129, 130 114 125 101 115 127 123 105, 130 126 122 125 128 107 108 124 124 102 128 103 102 104 106 106 112 109 111 r_24n767_parts 108 24 3A2806C
Parts Ref 101 102 103 104 105 106 107 108 109 110 111 112 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130* Part 109505 108209 94/0906-R2/99 121443 94/1045-M/99 94/0910/98 647673 94/0398/99 160022 94/0758/99 94/0433/99 123250 123890 94/0909/99 94/0459/99 94/0456/99 94/0904-R2/99 94/0912/99 94/0915/99 247616 94/0550/99 61/0055/88 61/0056/88 217382 104969 94/0451-2/99 94/0414/99 94/0397-M/99 102726 Description BUSHING NIPPLE, pipe close VALVE, ball, 2w, 1-1/2npt, f, 1500ps FITTING, tee,
Parts Electric Panel, 24N804 210 211 212 204 212 202 215 212 204, 215 211 205 206 201 203 224 or 225 215 213 214 204 219 220 220 208, 209 208, 209 26 207 233, 234 r_24n804_parts1 3A2806C
Parts 222 221 223 225 220 224 218 214 213 216 217 r_24n804_parts2 3A2806C 27
Parts Ref Part 201 15Y917 202 115942 203 289697 204 24C476 205 102063 206 114993 207 102598 208 289696 209 277674 210 100021 211 100015 212 100028 213 123452 214 116610 215 24H240 216 100020 217 100166 218 123679 219 121597 220 126413 221 121511 222 16A511 223 15U978 224 121002 225 122487 226 16D656 227 070408 228 16H821 229 16E530 230 24N813 233 15A721 Description PANEL, electric, heat NUT, hex, flange head MODULE, GCA, cube, base HARNESS, wire, ground, term WASHER, lock, ext SCREW, mach, pan wash hd
Parts 3A2806C 29
Parts 4 Drum Rack, 01/0955/25 (Optional) 305 (Typical Installation - 9 Places) 305 304 305 305 305 303 A 301 D C 302 F 305 E B Rack Dimensions: A (Height): 60-1/2 in. (154 cm) B (Length): 36-1/2 in. (93 cm) C (Width): 60-1/2 in. (154 cm) Anchor Locations: D (Width): 57-1/2 in. (146 cm) E (Length): 33-1/2 in. (85 cm) F (Diameter): Ø 0.56 in. (1.
Parts Ref 301 302 303 304 305 Part 01/0955-A/99 01/0955-B/99 01/0955-C/99 01/0955-D/99 01/0955/50 3A2806C Description SHELF, rack, 4 drum SUPPORT, shelf, rack, 2/4 drum, right SUPPORT, shelf, rack, 2/4 drum, left STRAP, stabilizer, rack, 4 drum RACK, 2/4 drum, seal, hardware Quantity 2 1 1 2 1 31
Appendix A - ADM Setup Screens Overview Appendix A - ADM Setup Screens Overview For other screen not mentioned, refer to the HFRL and HFRS, Setup-Operations manual. Supply Screen 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.
Appendix A - ADM Setup Screens Overview Advanced Screen 3 • Dispense from Home Position: When this box is checked, the machine will be required to reach a defined home position before dispensing in shot or sequence mode. Advanced Screen 4 This screen allows the user to control the availability of some key system features. • Disable Dispensing From Display: Check this box to disable dispensing from the ADM.
Appendix A - ADM Setup Screens Overview Advanced Screen 5 This screen displays software information. If the level controls are present but not active, the tank monitor program will not appear in the advanced 5 screen as shown below.
Appendix B - ADM Run Screens Overview Appendix B - ADM Run Screens Overview For other screen not mentioned, refer to the HFRL and HFRS, Setup-Operations manual. Home Screen, Low Level - A (Red) Side Home Screen, Refill Disabled If refill is Disabled, the home screen will not show a graphic display of the reservoirs. Home Screen, Refill Enabled When a low level on the RED side is sensed, the pop up error code appears and the active error display reads “Red Low Material Level”.
Appendix B - ADM Run Screens Overview Home Screen, Low Level - B (Blue) Side When a low level on the BLUE side is sensed, the pop up error code appears and the active error display reads “Red Low Material Level”. The light stack will flash yellow, and the audible alarm will sound. When this error occurs, the machine will continue to dispense when a start is initiated, unless the “Low Material Disables Dispense” flag is set.
Technical Data Technical Data Level Detection Module and Drum Feed Kit US Maximum fluid working pressure Maximum air input pressure Noise (dBa) Maximum sound pressure Maximum sound power Inlet/Outlet Sizes Air inlet size 125 psi 125 psi Metric 0.86 MPa, 8.6 bar 0.86 MPa, 8.6 bar † † 1/2 NPTF Materials of Construction Wetted materials Carbon steel, PTFE, Stainless Steel, PE, Aluminum, Nylon Weight 24N816 16 lb 7.
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.
