Graco HVR User manual

313873B
ENG
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.
See page 4 for model information, including max-
imum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
24F391_313873_4d

2313873B
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Important Two-Component Material Information . 8
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 8
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8
Keep Components A (Red) and B (Blue) Separate 8
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9
A (Red) and B (Blue) Components . . . . . . . . . . . . . 9
Component Identification . . . . . . . . . . . . . . . . . . . 10
Hydraulic Power Pack . . . . . . . . . . . . . . . . . . . . 13
Motor Control Module (MCM) . . . . . . . . . . . . . . 14
Advanced Display Module (ADM) . . . . . . . . . . . 16
Fluid Control Module (FCM) . . . . . . . . . . . . . . . 19
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Initial Machine Setup . . . . . . . . . . . . . . . . . . . . . 20
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ADM Operation Overview . . . . . . . . . . . . . . . . . 26
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Flow Meter Calibration . . . . . . . . . . . . . . . . . . . 29
Ratio Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Short-term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
End of Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Motor Control Module (MCM) . . . . . . . . . . . . . . 36
Advanced Display Module (ADM) . . . . . . . . . . . 37
Fluid Control Module (FCM) . . . . . . . . . . . . . . . 38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . 39
Common Problems . . . . . . . . . . . . . . . . . . . . . . 39
ADM Troubleshooting . . . . . . . . . . . . . . . . . . . . 41
Motor Control Module . . . . . . . . . . . . . . . . . . . . 42
Fluid Control Module . . . . . . . . . . . . . . . . . . . . . 44
Appendix A - ADM Icons Overview . . . . . . . . . . . 45
Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . . 45
Home Screen Icons . . . . . . . . . . . . . . . . . . . . . 46
Appendix B - ADM Setup Screens Overview . . . 47
Appendix C - ADM Run Screens Overview . . . . . 54
Optional Screens . . . . . . . . . . . . . . . . . . . . . . . . 57
Appendix D - ADM Event and
Error Codes Overview . . . . . . . . . . . . . . . . . . . 58
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Appendix E - USB Operation . . . . . . . . . . . . . . . . 69
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
USB Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Download Log Files . . . . . . . . . . . . . . . . . . . . . . 69
Log Files, Folder Structure . . . . . . . . . . . . . . . . 70
Transfer System Settings . . . . . . . . . . . . . . . . . . 72
Update Custom Language . . . . . . . . . . . . . . . . . 73
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 76

Related Manuals
313873B 3
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
Feed System Manuals
3A1159 HVR Feed Systems
Valve Manuals
310550 1/2 in. NPT Fluid Port Ball Seat
Applicator
310551 3/4 in. NPT Fluid Port Ball Seat
Applicator

Models
4313873B
Models
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and
mix chamber sizes may be less.
** Values are dependent on installed pump size. Values shown are for largest available pump size.
◆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.
System
Full Load
Peak Amps
Per Phase*
Vol tage
(phase)
System
Watts†
Max Flow
Rate◆**
lb/min (kg/min)
Approximate
Output per
Cycle (A+B)**
gal. (liter)
Hydraulic
Pressure
Ratio**
Maximum Fluid
Working Pressure ‡
psi (MPa, bar)
HVR 60 A 230 (3) 24,000 66 (30) 1.0 (3.8) 1.63 2000 (14, 138)
55 A 400 (3)

Warnings
313873B 5
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 elec-
tric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and reg-
ulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if 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 manufacturer.
+
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings
6313873B
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).
• 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.
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 manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
WARNING

Warnings
313873B 7
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.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
WARNING

Important Two-Component Material Information
8313873B
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 moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystal-
lization varies depending on the blend of ISO, the
humidity, and the temperature.
To prevent exposing ISO to moisture:
• 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 pump wet cups filled with IsoGuard
Select™, part 24F516. The lubricant creates a bar-
rier between the ISO and the atmosphere.
• 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 contam-
inated 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 per-
sonal 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
313873B 9
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.
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
valve stand so that A (Red) is on the right side of the dis-
pense valve stand and B (Blue) is on the left side of the
dispense valve stand.
For all machines:
• The A (Red) side is intended for ISO, hardeners,
and catalysts.
• The B (Blue) side is intended for polyols, resins, and
bases.
NOTE: For machines with material volume ratios other
than 1:1, the higher volume side is typically the B (Blue)
side.
B (Blue)
A (Red)
B (Blue)
A (Red)
24F391_4d

Component Identification
10 313873B
Component Identification
AA Advanced Display Module (see page 16)
AB Hydraulic Power Pack
AC Vertical Hydraulic Driver
AD Pump Lower
AE Flow Meter
AF Power Distribution Box
AG Dispense Stand
AH Mixer
AJ Pump Wet Cup
AK Main Power Switch
AL Air Supply Inlet
AM Electrical Enclosure
AN Ratio Check Dispense Valves/Ports
AP Material Line
AR A (Red) Dispense Valve
AS B (Blue) Dispense Valve
FIG. 1: Component Identification
AA
24F391_313873_4d
AC AB
AG
AH
AE
AM
AF
AN
AP
AS
AR

Component Identification
313873B 11
FIG. 2: Component Identification
AK
24F391_313873_3d
AL
AN
AN
AJ
AD
24F391_313873_5d

Component Identification
12 313873B
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.
Ref.
Size
Component
230V/
3 phase
400V/
3 phase
CB1 30A 63A Motor Control Module
CB5 5A 5A Miscellaneous
CB6 5A 5A Miscellaneous
CB10 30A 63A Motor Control Module
CB1 CB5 CB10CB6
24C687_313873-5_1c

Component Identification
313873B 13
Hydraulic Power Pack
Key:
A 8 Gallon Hydraulic Oil Reservoir (see Technical Data on
page 75 for specifications)
B Electric Motor
C Dipstick
D Hydraulic Housing
E Motor Control Module (see page 14)
FFan
G Hydraulic Oil Filter
H Hydraulic Fluid Drain Port
FIG. 3
A
F
C
D
G
BE
257442_313873-5_1t
Shown with shroud removed
H257442_313873-5_2t

Component Identification
14 313873B
Motor Control Module (MCM)
The MCM is located in the Hydraulic Power Pack.
When installed, the end of the MCM with the power
input connection (12) faces down and the end with the
access cover (A) faces up.
The Motor Control Module uses an 8-position selector
switch to set the system maximum working pressure.
NOTICE
If the Motor Control Module is replaced, the selec-
tor switch must be set prior to initial startup of the
Motor Control Module or damage may occur. See
system repair manual for MCM replacement proce-
dure.
FIG. 4: MCM Component Identification
A
r_257396_3b9905_01b
r_257396_3b9905_03b
C
12
B
13
1A
11
1B
5
7
6
8
9
10
2
3

Component Identification
313873B 15
Ref Description
A Access Cover
B Module Status LEDs
C Warning Label
1A, 1B
A (Red) MCM only:
ADM,
Power Distribution Box
B (Blue) MCM only:
FCM,
Power Distribution Box
NOTE: 1A and 1B are interchangeable.
2 Three-way Splitter to:
Oil Low Level Sensor,
Dispense Valve Solenoid,
Footswitch
3 Oil Temperature Sensor
5 Electric Motor Temperature Sensor
6LVDT
7A (Red) MCM only:
Three-way Splitter to:
Hydraulic Directional Valve,
Oil Overtemperature Switch,
Ratio Check Solenoid Valve
B (Blue) MCM only:
Three-way Splitter to:
Hydraulic Directional Valve,
Oil Overtemperature Switch
(Third connection is not used)
8 Pressure Transducer (for material side
controlled by the MCM)
9 Not used
10 MCM to MCM Analog Connection
11 Motor Position Sensor
12 MCM Power Input Connection
13 Motor Power Connection

Component Identification
16 313873B
Advanced Display Module (ADM)
User Interface
Buttons
FIG. 5: ADM Component Identification - Front
TI12362a1
A
B
C
E
H
G
F
D
Call
out Button Function
AADM
Enable/
Disable
Enable/disable ADM
B System
Status
Indicator
LED
Displays system status
C Stop Stop all system processes
D Softkeys Defined by icon next to softkey
E Abort Abort current operation
F Enter Accept change, acknowledge error,
select item, toggle selected item
GRun/
Setup
Screens
Toggle
Toggle between Run and Setup
screens
HArrow
Keys
Navigate within a screen or to a new
screen
Call
out Button Function

Component Identification
313873B 17
Key:
J Flat Panel Mount
K Model Number Identification Label
L USB Interface (see Appendix E - USB Operation
beginning on page 69)
M CAN Cable Connection to MCM
N Module Status LEDs
P Accessory Cable Connection
R Software Token Access Cover
S Battery Access Cover
See ADM Troubleshooting on page 41 for LED status information.
See Maintenance section beginning on page 35 for battery replacement and software update procedures.
FIG. 6: ADM Component Identification - Rear
R
K
J
L
P
N
M
S
ti12902a

Component Identification
18 313873B
ADM Screen Components
See the ADM appendix sections beginning with Appendix A - ADM Icons Overview on page 45 for more informa-
tion.
FIG. 7: Main Display Components - Typical Setup Screen
FIG. 8: Main Display Components - Home Screen (Shot mode shown)
Current date and time Current screen
Enter/Exit screen
Previous screen Next screen
Settings Detail
Current
screen no.
Next
screen no.
Previous
screen no.
Operating Mode Faults, Status
Current date and time Current screen
Change Operating
Mode
Previous screen Next screen
Dispense Details
Operating Mode Faults, Status
Initiate Dispense
Initiate Ratio
Check Dispense

Component Identification
313873B 19
Fluid Control Module (FCM)
The fluid control module is located inside the electrical
enclosure.
Key:
A Module Connection Screws
B Access Cover
C Module Status LEDs
D CAN Connectors (one is connected to MCM, other is
unused)
FIG. 9:
ti12337a1 ti12336a1
C
A
B
D

Setup
20 313873B
Setup
Initial Machine Setup
Perform this setup procedure to prepare the machine for
initial operation.
1. Locate the machine.
a. Bolt machine to original shipping pallet before
lifting.
b. Locate the machine on a level surface. See
Dimensions on page 75 for space require-
ments.
2. Connect electrical cord.
Electrical Cord Requirements
NOTE: Power cord is not supplied. See the following
table.
† Residual Current Device (RCD) must be rated at
300 mA if installed.
Electrical Cord Wires by Model
230V, 3 phase: L1, L2, L3, GND
400V, 3 phase: L1, L2, L3, N, GND
Electrical Requirements
See Models on page 4 for detailed electrical require-
ments information.
a. Use 5/32 in. or 4 mm hex allen wrench to con-
nect the power leads to L1, L2, L3, and N as
applicable.
b. Connect green wire to ground (GND).
The machine is not properly grounded until this setup
procedure is performed. To prevent risk of electric
shock, do not start the machine until this setup proce-
dure is completed.
NOTICE
Be careful not to hit hydraulic power pack drain port
while moving machine. Applying significant force to
drain port may damage the hydraulic tank.
NOTICE
To prevent machine damage, do not expose system
to rain.
Installing this equipment requires access to parts
which may cause electric shock or other serious injury
if work is not performed properly. Have a qualified
electrician connect power and ground to main power
switch terminals. All electrical wiring must be done by
a qualified electrician and comply with all local codes
and regulations.
Table 1: Power Cord Requirements
Model
Cord Requirements
AWG (mm2)
230V, 3 phase 8 (8.4), 3 wire + ground
400V, 3 phase 6 (13.3), 4 wire + ground †
FIG. 10: 400V, 3 phase shown
r_24C686_313998_1a
L1L2L3N
GND