Graco HFRL Manual instruction

Setup - Operation
HFRL and HFRS 3A2175Z
EN
Hydraulic, Plural-Component, Fixed-Ratio Proportioner.
For pouring and dispensing laminates and silicones.
For professional use only. Not approved for use in explosive atmospheres or hazardous
locations.
See page 4 for model information and maximum
working pressure.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
ti18208a
Silicone unit shown.

2 3A2175Z
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HFR-Laminate (HFRL) . . . . . . . . . . . . . . . . . . . . . 4
HFR-Silicone (HFRS) . . . . . . . . . . . . . . . . . . . . . . 6
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Important Two-Component Material Information 14
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . 14
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 14
Keep Components A (Red) and B (Blue) Separate
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Moisture Sensitivity of Isocyanates . . . . . . . . . 14
Changing Materials . . . . . . . . . . . . . . . . . . . . . . 15
A (Red) and B (Blue) Components . . . . . . . . . . . . 15
Typical HFRS System . . . . . . . . . . . . . . . . . . . . . . 16
Typical HFRL System . . . . . . . . . . . . . . . . . . . . . . 17
Component Identification . . . . . . . . . . . . . . . . . . . 18
Hydraulic Power Pack . . . . . . . . . . . . . . . . . . . . 21
Motor Control Module (MCM) . . . . . . . . . . . . . . 22
Advanced Display Module (ADM) . . . . . . . . . . . 24
Fluid Control Module (FCM) . . . . . . . . . . . . . . . 27
Dispense Requests and Valves Overview . . . . . . 28
Dispense Request/Valve Connection . . . . . . . . 29
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Pressure Relief Procedure . . . . . . . . . . . . . . . . 40
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Adjusting Material Inlet Pressure Using the Material
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure Balancing Using the Orifice Valve
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 42
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ADM - Battery Replacement and Screen Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
MCM and TCM - Clean Heat Sink Fins . . . . . . . 45
Install Upgrade Tokens . . . . . . . . . . . . . . . . . . . 46
Programming Tokens/Updating System Software
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 48
Grease Cup Maintenance . . . . . . . . . . . . . . . . . 49
Clean Orifice Valves . . . . . . . . . . . . . . . . . . . . . 50
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . 51
Common Problems . . . . . . . . . . . . . . . . . . . . . . 51
ADM Troubleshooting . . . . . . . . . . . . . . . . . . . . 53
Motor Control Module . . . . . . . . . . . . . . . . . . . . 54
Fluid Control Module . . . . . . . . . . . . . . . . . . . . 56
Advanced Display Module (ADM) Operation . . . . 57
Appendix A - ADM Icons Overview . . . . . . . . . . . 58
Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . . 58
Run Screen Icons . . . . . . . . . . . . . . . . . . . . . . . 59
Appendix B - ADM Setup Screens Overview . . . . 60
Appendix C - ADM Run Screens Overview . . . . . 77
Appendix D - ADM Error Codes . . . . . . . . . . . . . . 84
Appendix E - System Events . . . . . . . . . . . . . . . . . 97
Appendix F - USB Operation . . . . . . . . . . . . . . . . . 98
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
USB Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Download Log Files . . . . . . . . . . . . . . . . . . . . . . 98
Log Files, Folder Structure . . . . . . . . . . . . . . . . 99
Transfer System Settings . . . . . . . . . . . . . . . . . 101
Update Custom Language . . . . . . . . . . . . . . . 102
Appendix G- Temperature . . . . . . . . . . . . . . . . . . 104
Temperature Displayed and Actual Material
Temperature . . . . . . . . . . . . . . . . . . . . . . . 104
Appendix H- Circulation . . . . . . . . . . . . . . . . . . . 105
Manual, Semi-Automatic and Fully Automatic
Circulation Features . . . . . . . . . . . . . . . . . 105
Manual Recirculation Feature . . . . . . . . . . . . . 105
Semi-Automatic Circulation Feature . . . . . . . . 105
Manual and Semi-Automatic Circulation Feature
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fully Automatic Circulation Feature Operation 111
Pressurize Before Opening DV Feature . . . . . . 113
Night Mode Capability . . . . . . . . . . . . . . . . . . . 114
Fully Automatic Circulation Shot Repeatability Test
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Appendix I - Communications Gateway Module
Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . 116
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Setup - Gateway Screens . . . . . . . . . . . . . . . . 117
Available Internal Data . . . . . . . . . . . . . . . . . . . 120
Run Screens Available Data. . . . . . . . . . . . . . . 122
I/O Signal Descriptions . . . . . . . . . . . . . . . . . . 123
Data Exchange Interface . . . . . . . . . . . . . . . . . 124
Data Exchange Interface Pointer Designation Table
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Error Number Tables: . . . . . . . . . . . . . . . . . . . 131
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Motor Control Module Technical Data . . . . . . . . 139
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
California Proposition 65 . . . . . . . . . . . . . . . . . . . 141
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 142
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 142

Related Manuals
3A2175Z 3
Related Manuals
Manuals are available at www.graco.com.
Component manuals listed below are in English:
System Manuals
3A2176 HFRL and HFRS Repair-Parts
Pumpline Manuals
3A0019 Z-Series Chemical Pumps Instructions-Parts
3A0020 HFR™ Hydraulic Actuator Instructions-Parts
Feed System Manuals for HFRL Systems
3A0235 Feed Supply Kits Instructions-Parts
Dispense Valve Manuals
312185 MD2 Valve, Instructions-Parts
Accessory Manuals
3A1149 HFR Discrete Gateway Module Kits Manual
3A1244 Graco Control Architecture™ Module Pro-
gramming Manual
U82706 Small Dispense Kit
Operation-Maintenance
3A8115 Voltex™ Dynamic Mix Valve and Controllers

Models
4 3A2175Z
Models
HFR-Laminate (HFRL)
HFRL models are designed for use with low viscosity, unheated urethane laminating adhesives at flow rates of up to
30 cc/sec (4 lb/min) @ 1500 psi (10 MPa, 103 bar).
** Cycle rate should be between 8 and 20 cycles per minute. Max flow rate is determined for continuous service at
120°F (39°C) at stated cpm and pressure. Higher cycle rates are possible at lower temperatures/pressures and
intermittent use. Lower cycle rates may be possible, but should be tested under application conditions.
†Dispense rate in excess of max flow and pressure may result in an elevated temperature of the hydraulic system,
resulting in a thermal shutdown (T4H1). Other system models are available for sustained flow rates and pressures
in excess of above.
A Pump
Size
B Pump
Size cc/cycle
Required cpm@
Flow**
Max Flow †
cc/sec (lb/min) @ 1500 psi (10 MPa, 103 bar) Ratio
160 86 246 8
30 (4)
1.86
100 86 186 10 1.16
86 80 166 11 1.08
80 80 160 12 1.00
80 65 145 13 1.23
80 60 140 13 1.33
80 50 130 14 1.60
86 40 126 15 2.15
60 50 110 17 1.20
65 40 105 18 1.63
60 40 100 19 1.50
60 25 85 20 28 (3.7) 2.40
50 30 80 20 26 (3.5) 1.67
50 25 75 20 25 (3.3) 2.00
50 20 70 20 23 (3.1) 2.50

Models
3A2175Z 5
HFRL Models
★ approved.
✖See 400 V Power Requirements.
400 V Power Requirements
• 400 V systems are intended for International volt-
age requirements. Not for voltage requirements in
North America.
• If a 400 volt configuration is operated in North
America, a special transformer rated for 400 V (“Y”
configuration (4 wire)) may be required.
• North America mostly employs a 3 wire or Delta
configuration. The two configurations are not inter-
changeable.
Part Number Description
HFRL01 HFR for Lamination, 230/1, 1.00:1,
80/80, Carbon Steel
HFRL02 HFR for Lamination, 230/1, 1.08:1,
86/80, Carbon Steel
HFRL03 HFR for Lamination, 230/1, 1.16:1,
100/86, Carbon Steel
HFRL04 HFR for Lamination, 230/1, 1.20:1,
60/50, Carbon Steel
HFRL05 HFR for Lamination, 230/1, 1.23:1,
80/65, Carbon Steel
HFRL06 HFR for Lamination, 230/1, 1.33:1,
80/60, Carbon Steel
HFRL07 HFR for Lamination, 230/1, 1.50:1,
60/40, Carbon Steel
HFRL08 HFR for Lamination, 230/1, 1.60:1,
80/50, Carbon Steel
HFRL09 HFR for Lamination, 230/1, 1.63:1,
65/40, Carbon Steel
HFRL10 HFR for Lamination, 230/1, 1.67:1,
50/30, Carbon Steel
HFRL11 HFR for Lamination, 230/1, 1.86:1,
160/86, Carbon Steel
HFRL12 HFR for Lamination, 230/1, 2.00:1,
50/25, Carbon Steel
HFRL13 HFR for Lamination, 230/1, 2.15:1,
86/40, Carbon Steel
HFRL14 HFR for Lamination, 230/1, 2.40:1,
60/25, Carbon Steel
HFRL15 HFR for Lamination, 230/1, 2.5:1,
50/20, Carbon Steel
HFRL16 ★✖ HFR for Lamination, 400/3, 1.00:1,
80/80, Carbon Steel
HFRL17 ★✖ HFR for Lamination, 400/3, 1.08:1,
86/80, Carbon Steel
HFRL18 ★✖ HFR for Lamination, 400/3, 1.16:1,
100/86, Carbon Steel
HFRL19 ★✖ HFR for Lamination, 400/3, 1.20:1,
60/50, Carbon Steel
HFRL20 ★✖ HFR for Lamination, 400/3, 1.23:1,
80/65, Carbon Steel
HFRL21 ★✖ HFR for Lamination, 400/3, 1.33:1,
80/60, Carbon Steel
HFRL22 ★✖ HFR for Lamination, 400/3, 1.50:1,
60/40, Carbon Steel
HFRL23 ★✖ HFR for Lamination, 400/3, 1.60:1,
80/50, Carbon Steel
HFRL24 ★✖ HFR for Lamination, 400/3, 1.63:1,
65/40, Carbon Steel
HFRL25 ★✖ HFR for Lamination, 400/3, 1.67:1,
50/30, Carbon Steel
HFRL26 ★✖ HFR for Lamination, 400/3, 1.86:1,
160/86, Carbon Steel
HFRL27 ★✖ HFR for Lamination, 400/3, 2.00:1,
50/25, Carbon Steel
HFRL28 ★✖ HFR for Lamination, 400/3, 2.15:1,
86/40, Carbon Steel
HFRL29 ★✖ HFR for Lamination, 400/3, 2.40:1,
60/25, Carbon Steel
HFRL30 ★✖ HFR for Lamination, 400/3, 2.5:1,
50/20, Carbon Steel
Part Number Description

Models
6 3A2175Z
HFR-Silicone (HFRS)
HFRS models are designed for use with high viscosity, unheated silicone adhesives at flow rates of up to
20 cc/sec (3 lb/min) @ 2500 psi (17 MPa, 172 bar). The equipment can be run at up to 20 cycles per minute
continuous duty.
** Cycle rate should be between 3 and 20 cycles per minute. Max flow rate is determined for continuous service at
120°F (39°C) at stated cpm and pressure. Higher cycle rates are possible at lower temperatures/pressures and
intermittent use. Lower cycle rates may be possible, but should be tested under application conditions.
†Flow rates are established @ 2500 psi (17 MPa, 172 bar). Dispense rate in excess of max flow and pressure may
result in an elevated temperature of the hydraulic system, resulting in a thermal shutdown (T4H1). Other system
models are available for sustained flow rates and pressures in excess of above.
A Pump
Size
B Pump
Size cc/cycle
Required cpm@
Maximum Flow**
Minimum Flow †
cc/sec
Maximum Flow †
cc/sec Ratio
10 100 110 11 5.6 20 10.00
15 80 95 12.5 4.8 20 5.33
40 40 80 15 4 20 1.00
10 60 70 17 3.6 20 6.00
20 40 60 20 3 20 2.00
10 40 50 20 2.5 16.7 4.00
10 10 20 12 1 4 1.00

Models
3A2175Z 7
HFRS Models
Part Num-
ber Description
HFRS01 HFR for Silicone, 230/1, 1:1, Carbon
Steel, 55/55 Feed, (10/10 pumps)
HFRS02 HFR for Silicone, 230/1, 1:1, Carbon
Steel, 5/5 Feed, (10/10 pumps)
HFRS03 ★HFR for Silicone, 400/3, 1:1, Carbon
Steel, 55/55 Feed, (10/10 pumps)
HFRS04 ★HFR for Silicone, 400/3, 1:1, Carbon
Steel, 5/5 Feed, (10/10 pumps)
HFRS05 HFR for Silicone, 230/1, 1:1, Stainless
Steel, 55/55 Feed, (10/10 pumps)
HFRS06 HFR for Silicone, 230/1, 1:1, Stainless
Steel, 5/5 Feed, (10/10 pumps)
HFRS07 ★HFR for Silicone, 400/3, 1:1, Stainless
Steel, 55/55 Feed, (10/10 pumps)
HFRS08 ★HFR for Silicone, 400/3, 1:1, Stainless
Steel, 5/5 Feed, (10/10 pumps)
HFRS09 HFR for Silicone, 230/1, 4:1, Carbon
Steel, 55/55 Feed
HFRS10 HFR for Silicone, 230/1, 4:1, Carbon
Steel, 55/5 Feed
HFRS11 HFR for Silicone, 230/1, 4:1, Carbon
Steel, 5/5 Feed
HFRS12 ★HFR for Silicone, 400/3, 4:1, Carbon
Steel, 55/55 Feed
HFRS13 ★HFR for Silicone, 400/3, 4:1, Carbon
Steel, 55/5 Feed
HFRS14 ★HFR for Silicone, 400/3, 4:1, Carbon
Steel, 5/5 Feed
HFRS15 HFR for Silicone, 230/1, 4:1, Stainless
Steel, 55/55 Feed
HFRS16 HFR for Silicone, 230/1, 4:1, Stainless
Steel, 55/5 Feed
HFRS17 HFR for Silicone, 230/1, 4:1, Stainless
Steel, 5/5 Feed
HFRS18 ★HFR for Silicone, 400/3, 4:1, Stainless
Steel, 55/55 Feed
HFRS19 ★HFR for Silicone, 400/3, 4:1, Stainless
Steel, 55/5 Feed
HFRS20 ★HFR for Silicone, 400/3, 4:1, Stainless
Steel, 5/5 Feed
HFRS21 HFR for Silicone, 230/1, 5.33:1, Car-
bon Steel, 55/55 Feed
HFRS22 HFR for Silicone, 230/1, 5.33:1, Car-
bon Steel, 55/5 Feed
HFRS23 HFR for Silicone, 230/1, 5.33:1, Car-
bon Steel, 5/5 Feed
HFRS24 ★HFR for Silicone, 400/3, 5.33:1, Car-
bon Steel, 55/55 Feed
HFRS25 ★HFR for Silicone, 400/3, 5.33:1, Car-
bon Steel, 55/5 Feed
HFRS26 ★HFR for Silicone, 400/3, 5.33:1, Car-
bon Steel, 5/5 Feed
HFRS27 HFR for Silicone, 230/1, 5.33:1, Stain-
less Steel, 55/55 Feed
HFRS28 HFR for Silicone, 230/1, 5.33:1, Stain-
less Steel, 55/5 Feed
HFRS29 HFR for Silicone, 230/1, 5.33:1, Stain-
less Steel, 5/5 Feed
HFRS30 ★HFR for Silicone, 400/3, 5.33:1, Stain-
less Steel, 55/55 Feed
HFRS31 ★HFR for Silicone, 400/3, 5.33:1, Stain-
less Steel, 55/5 Feed
HFRS32 ★HFR for Silicone, 400/3, 5.33:1, Stain-
less Steel, 5/5 Feed
HFRS33 HFR for Silicone, 230/1, 6:1, Carbon
Steel, 55/55 Feed
HFRS34 HFR for Silicone, 230/1, 6:1, Carbon
Steel, 55/5 Feed
HFRS35 HFR for Silicone, 230/1, 6:1, Carbon
Steel, 5/5 Feed
HFRS36 ★HFR for Silicone, 400/3, 6:1, Carbon
Steel, 55/55 Feed
HFRS37 ★HFR for Silicone, 400/3, 6:1, Carbon
Steel, 55/5 Feed
HFRS38 ★HFR for Silicone, 400/3, 6:1, Carbon
Steel, 5/5 Feed
HFRS39 HFR for Silicone, 230/1, 6:1, Stainless
Steel, 55/55 Feed
HFRS40 HFR for Silicone, 230/1, 6:1, Stainless
Steel, 55/5 Feed
HFRS41 HFR for Silicone, 230/1, 6:1, Stainless
Steel, 5/5 Feed
HFRS42 ★HFR for Silicone, 400/3, 6:1, SS 55/55
Feed
HFRS43 ★HFR for Silicone, 400/3, 6:1, Stainless
Steel, 55/5 Feed
HFRS44 ★HFR for Silicone, 400/3, 6:1, Stainless
Steel, 5/5 Feed
Part Num-
ber Description

Models
8 3A2175Z
HFRS45 HFR for Silicone, 230/1, 10:1, Carbon
Steel, 55/55 Feed
HFRS46 HFR for Silicone, 230/1, 10:1, Carbon
Steel, 55/5 Feed
HFRS47 HFR for Silicone, 230/1, 10:1, Carbon
Steel, 5/5 Feed
HFRS48 ★✖ HFR for Silicone, 400/3, 10:1, Carbon
Steel, 55/55 Feed
HFRS49 ★✖ HFR for Silicone, 400/3, 10:1, Carbon
Steel, 55/5 Feed
HFRS50 ★✖ HFR for Silicone, 400/3, 10:1, Carbon
Steel, 5/5 Feed
HFRS51 HFR for Silicone, 230/1, 10:1, Stainless
Steel, 55/55 Feed
HFRS52 HFR for Silicone, 230/1, 10:1, Stainless
Steel, 55/5 Feed
HFRS53 HFR for Silicone, 230/1, 10:1, Stainless
Steel, 5/5 Feed
HFRS54 ★✖ HFR for Silicone, 400/3, 10:1, Stainless
Steel, 55/55 Feed
HFRS55 ★✖ HFR for Silicone, 400/3, 10:1, Stainless
Steel, 55/5 Feed
HFRS56 ★✖ HFR for Silicone, 400/3, 10:1, Stainless
Steel, 5/5 Feed
HFRS57 HFR for Silicone, 230/1, 2:1, Carbon
Steel, 55/55 Feed
HFRS58 ★HFR for Silicone, 230/1, 2:1, Carbon
Steel, 55/5 Feed
HFRS59 HFR for Silicone, 230/1, 2:1, Carbon
Steel, 5/5 Feed
HFRS60 ★✖ HFR for Silicone, 400/3, 2:1, Carbon
Steel, 55/55 Feed
HFRS61 HFR for Silicone, 400/3, 2:1, Carbon
Steel, 55/5 Feed
HFRS62 ★✖ HFR for Silicone, 400/3, 2:1, Carbon
Steel, 5/5 Feed
HFRS63 HFR for Silicone, 230/1, 2:1, Stainless
Steel, 55/55 Feed
HFRS64 ★✖ HFR for Silicone, 230/1, 2:1, Stainless
Steel, 55/5 Feed
HFRS65 HFR for Silicone, 230/1, 2:1, Stainless
Steel, 5/5 Feed
HFRS66 ★✖ HFR for Silicone, 400/3, 2:1, Stainless
Steel, 55/55 Feed
Part Num-
ber Description
HFRS67 HFR for Silicone, 400/3, 2:1, Stainless
Steel, 55/5 Feed
HFRS68 ★✖ HFR for Silicone, 400/3, 2:1, Stainless
Steel, 5/5 Feed
HFRS69 HFR for Silicone, 230/1, 1:1, Carbon
Steel, No Feed, (10/10 pumps)
HFRS70 ★✖ HFR for Silicone, 400/3, 1:1, Carbon
Steel, No Feed, (10/10 pumps)
HFRS71 HFR for Silicone, 230/1, 1:1, Stainless
Steel, No Feed, (10/10 pumps)
HFRS72 ★✖ HFR for Silicone, 400/3, 1:1, Stainless
Steel, No Feed, (10/10 pumps)
HFRS73 HFR for Silicone, 230/1, 2:1, Carbon
Steel, No Feed
HFRS74 ★✖ HFR for Silicone, 400/3, 2:1, Carbon
Steel, No Feed
HFRS75 HFR for Silicone, 230/1, 2:1, Stainless
Steel, No Feed
HFRS76 ★✖ HFR for Silicone, 400/3, 2:1, Stainless
Steel, No Feed
HFRS77 HFR for Silicone, 230/1, 4:1, Carbon
Steel, No Feed
HFRS78 ★✖ HFR for Silicone, 400/3, 4:1, Carbon
Steel, No Feed
HFRS79 HFR for Silicone, 230/1, 4:1, Stainless
Steel, No Feed
HFRS80 ★✖ HFR for Silicone, 400/3, 4:1, Stainless
Steel, No Feed
HFRS81 HFR for Silicone, 230/1, 5.33:1, Car-
bon Steel, No Feed
HFRS82 ★✖ HFR for Silicone, 400/3, 5.33:1, Car-
bon Steel, No Feed
HFRS83 HFR for Silicone, 230/1, 5.33:1, Stain-
less Steel, No Feed
HFRS84 ★✖ HFR for Silicone, 400/3, 5.33:1, Stain-
less Steel, No Feed
HFRS85 HFR for Silicone, 230/1, 6:1, Carbon
Steel, No Feed
HFRS86 ★✖ HFR for Silicone, 400/3, 6:1, Carbon
Steel, No Feed
HFRS87 HFR for Silicone, 230/1, 6:1, Stainless
Steel, No Feed
HFRS88 ★✖ HFR for Silicone, 400/3, 6:1, Stainless
Steel, No Feed
Part Num-
ber Description

Models
3A2175Z 9
★ approved.
✖See 400 V Power Requirements.
400 V Power Requirements
• 400 V systems are intended for International volt-
age requirements. Not for voltage requirements in
North America.
• If a 400 volt configuration is operated in North
America, a special transformer rated for 400 V (“Y”
configuration (4 wire)) may be required.
• North America mostly employs a 3 wire or Delta
configuration. The two configurations are not inter-
changeable.
HFRS89 HFR for Silicone, 230/1, 10:1, Carbon
Steel, No Feed
HFRS90 ★✖ HFR for Silicone, 400/3, 10:1, Carbon
Steel, No Feed
HFRS91 HFR for Silicone, 230/1, 10:1, Stainless
Steel, No Feed
HFRS92 ★✖ HFR for Silicone, 400/3, 10:1, Stainless
Steel, No Feed
HFRS93 HFR for Silicone, 230/1, 1:1, Carbon
Steel, 55/55 Feed, (40/40 pumps)
HFRS94 HFR for Silicone, 230/1, 1:1, Carbon
Steel, 5/5 Feed, (40/40 pumps)
HFRS95 ★✖ HFR for Silicone, 400/3, 1:1, Carbon
Steel, 55/55 Feed, (40/40 pumps)
HFRS96 ★✖ HFR for Silicone, 400/3, 1:1, Carbon
Steel, 5/5 Feed, (40/40 pumps)
HFRS97 HFR for Silicone, 230/1, 1:1, Stainless
Steel, 55/55 Feed, (40/40 pumps)
HFRS98 HFR for Silicone, 230/1, 1:1, Stainless
Steel, 5/5 Feed, (40/40 pumps)
HFRS99 ★✖ HFR for Silicone, 400/3, 1:1, Stainless
Steel, 55/55 Feed, (40/40 pumps)
HFRSA0
★✖
HFR for Silicone, 400/3, 1:1, Stainless
Steel, 5/5 Feed, (40/40 pumps)
HFRSA1 HFR for Silicone, 230/1, 1:1, Carbon
Steel, No Feed, (40/40 pumps)
HFRSA2
★✖
HFR for Silicone, 400/3, 1:1, Carbon
Steel, No Feed, (40/40 pumps)
HFRSA3 HFR for Silicone, 230/1, 1:1, Stainless
Steel, No Feed, (40/40 pumps)
HFRSA4
★✖
HFR for Silicone, 400/3, 1:1, Stainless
Steel, No Feed, (40/40 pumps)
HFRSA7
★✖
HFR for Silicone, 400/3, 2:1, Carbon
Steel, No Feed, (10/5 pumps)
HFRSA8
★✖
HFR for Silicone, 400/3, 2:1, Carbon
Steel, 55/55 Feed, (10/5 pumps)
Part Num-
ber Description

Warnings
10 3A2175Z
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.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servic-
ing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• 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:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac-
turer.
+
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.

Warnings
3A2175Z 11
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help pre-
vent 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).
• 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.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If 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 EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
WARNING

Warnings
12 3A2175Z
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• 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 man-
ufacturer’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 applicable safety regulations.
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.
WARNING

Warnings
3A2175Z 13

Important Two-Component Material Information
14 3A2175Z
Important Two-Component Material Information
Isocyanate Conditions
Material Self-ignition
Keep Components A (Red) and
B (Blue) Separate
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with mois-
ture (such as humidity) to form small, hard, abrasive
crystals, which become suspended in the fluid. Eventu-
ally 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:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• 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.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been con-
taminated from the other side.
• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
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
personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
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.

A (Red) and B (Blue) Components
3A2175Z 15
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:
• 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.
For HFRS Systems:
The high volume material is typically the ISO and is
located on the A (Red) side. Some material chemistries
may have an ISO which is the low volume material.
For HFRL Systems:
The high volume material will always be the B (Blue)
side.Typical Installation

Typical HFRS System
16 3A2175Z
Typical HFRS System
Key:
A HFR Unit (Silicone)
B Power Module
C B “Blue” Pump
D A ”Red” Pump
E Outlet Module
F B Hose Kit
G A Hose Kit
H Dispense Gun
J Orifice Block
K Orifice, 1/4”
L Supply Unit, B Side
M Supply Unit, A Side
N Supply Hose
P Inlet Regulator
FIG. 1: HFR Silicone System
M
ti18208a
N
D
P
E
A
C
P
L
B
F
G
J,
H
J,
N
KK

Typical HFRL System
3A2175Z 17
Typical HFRL System
Key:
AA HFR Unit (Laminate)
AB Power Module
AC B “Blue” Pump
AD A “Red” Pump
AE Outlet Module
AF B Hose Kit
AG A Hose Kit
AH Dispense Gun
AJ Orifice Block
AK Orifice, 1/4”
AL Inlet Assembly
AM Grease Reservoir Bottle (not shown)
FIG. 2: HFR Laminate System
ti18209a
AA
AC
AD
AL
AE
AG
AF
AJ,
AB
AK
AL
AH

Component Identification
18 3A2175Z
Component Identification
Key for FIG. 4.
BA Advanced Display Module (see page 24)
BB Component A (Red) Pressure Relief Outlet
BC Component B (Blue) Pressure Relief Outlet
BD Component A (Red) Fluid Manifold Inlet (on left side of
manifold block)
BE Component B (Blue) Fluid Manifold Inlet
BF HFR Fluid Manifold
BG Feed Inlet Pressure Gauge
BH Feed Inlet Strainer (standard filter size is 20 mesh)
BJ Feed Inlet Valve (A (Red) side shown)
BK Component A (Red) Outlet Pressure Gauge
BL Component B (Blue) Outlet Pressure Gauge
BM Component A (Red) Hose Connection (from feed to gun or
mix head)
BN Component B (Blue) Hose Connection (from feed to gun or
mix head)
BP Hydraulic Power Pack Assembly
BR Hydraulic Tank
BS Grease Reservoir Bottle (Included on all HFLR)
BT Pumpline Linear Sensor
BU Motor Control Module, see page 22
BV Main Power Switch
BW Component A (Red) Pump
BX Component B (Blue) Pump
BY Power Distribution Box
BZ Component A (Red) PRESSURE RELIEF/DISPENSE Valve
CA Component B (Blue) PRESSURE RELIEF/DISPENSE Valve
CB Component A (Red) Pressure Transducer
CC Component B (Blue) Pressure Transducer
CD Material Pressure Regulator Component A (Red)
CE Power Distribution Box
FIG. 3: Component Identification, shown with shrouds removed
BA
ti18210a
BR
BJ
BS
BH
BG
BX
BP
BH
BG
CE
BY
BF
BV
(Located on
opposite side
of machine)

Component Identification
3A2175Z 19
FIG. 4: Component Identification, shown with shrouds removed
ti9880a1
Fluid Manifold (FM) Detail
BU
CC
CB
Rear View
24C352_313998_4e
HFRL Material Inlet
(250 psi Max)
HFRS Material Inlet
(3000 psi Max)
ti18211a ti18212a
BJ
BH BG
BJ
CD BG
BZBD CABLBK BE
BMBB BCBN
BT

Component Identification
20 3A2175Z
Main Power Switch
Located on rear of machine.
The main power switch turns power ON and
OFF . The main power switch does not turn
pumps on.
Circuit Breakers
The circuit breakers are located on the panel assembly
mounted directly behind the disconnect switch panel
on the right side of the enclosure. For more information
about items on the power distribution panel, see man-
ual 3A2176
ti18213a
Ref.
230V/ 1 phase,
400V/ 3 phase Component
CB1 63A Motor Control Module
CB5 5A Miscellaneous
ti18215a
ti18214a
CB1
CB5