Graco 3A0238P User Manual
Instructions-Parts
AC Hydraulic
3A0238P
Power Pack Module
AC Hydraulic Power Pack, with optional boom and hose kits, for hydraulic actuated
applicators used with Graco HFR
For professional use only.
2500 psi (17 MPa, 172 bar) Maximum Hydraulic Working Pressure
Important Safety Instructions
Read all warnings and instr uctions in this
manual. Save these instructions.
™
and VRM™Metering Systems.
EN
See page 3 for model information.
24D829 AC Hydraulic Power Pack Module Shown
r_24d829_3A0238_1f
Related Manuals
Contents
Related Manuals ...........................2
Models ...................................2
AC Hydraulic Power Pack Modules ........... 2
Applicator Kits ...........................3
Individual Applicators ..................... 3
Warnings .................................5
Isocyanate Conditions ..................... 8
Material Self-ignition ...................... 8
Keep Components A and B Separate .........8
Moisture Sensitivity of Isocyanates ...........8
Foam Resins with 245 fa Blowing Agents ......8
Changing Materials ....................... 9
Component Identification ................... 10
AC Power Pack Module ...................10
Hydraulic Power Pack Stand ............... 11
Main Power Disconnect ...................12
Circuit Breakers ......................... 12
Fluid Control Module (FCM) ...............13
Setup ....................................15
Connect Hydraulic Hoses .................15
Connect Material Hoses to System ..........18
Connect Communication Cables ............ 19
Connect Proximity Cables ................. 19
Connect Electrical Cord ..................20
Startup ..................................21
Operation ................................ 21
Pressure Relief Procedure ................ 21
Shutdown ................................ 21
Maintenance ..............................22
Schedule ..............................22
Troubleshooting ........................... 24
Repair ...................................27
Remove Hydraulic Power Pack Shroud .......27
Install Hydraulic Power Pack Shroud .........27
Remove Hydraulic Power Pack .............27
Install Hydraulic Power Pack ...............29
Replace Tank Gasket .....................29
Remove Motor ..........................30
Install Motor ............................31
Remove Hydraulic Gear Pump .............32
Install Hydraulic Gear Pump ...............33
Install FCM Upgrade Token ................34
Parts ....................................36
AC Hydraulic Power Pack Module ...........36
Mix Module Stand .......................38
Heat Exchanger Assembly ................40
230V and 400V MixHead Panel .............42
MixHead Hydraulic Power Pack .............44
Pneumatic Boom Arm ....................50
Hose Kits ..............................52
Hose and Cable Kits .......................54
Optional Equipment ........................55
Electrical Schematics ....................58
Dimensions ...............................66
AC Power Pack Module ...................66
AC Power Pack Stand ....................68
Pneumatic Boom ........................69
Technical Data ............................70
Graco Standard Warranty ...................72
Related Manuals
Manual Description
312753 L-Head, Operation-Maintenance
312752 S-Head, Operation-Maintenance
313536 GX-16, Operation
309582 Circulation and Return Tube Kits,
Instructions-Parts
313997 HFR, Operation
313998 HFR, Repair-Parts
2 3A0238P
Manual Description
313873 VRM, Operation
313874 VRM, Repair-Parts
3A0395 Stainless Steel Tank Stands, Instruc-
tions-Parts
3A0862 Hose Extension Kits, Instructions-Parts
Models
Models
AC Hydraulic Power Pack Modules
The table below lists kit numbers for 230V and 400 VAC hydraulic power pack modules. The modules can come with
a hydraulic power pack, boom, and hose kits for S-Head and L-Head applicators. For applicator kits, see Applicator
Kits and Individual Applicators on page 4 (sold separately).
Includes: Not included
Hydraulic
S-Head
Kit No. Voltage
24D829
24D830
24D834✖
24D835✖
24D831
24D832
24D836✖
24D837✖
24F297★
24F298★✖
24J912★
24J913★✖
★ Purchase required hoses separately. See Hose and Cable Kits on page 54 for hose kits.
✖ See 400 V Power Requirements.
230V
230V
400V
400V
230V
230V
400V
400V
230V
400V
230V
400V
Boom
✔✔✔✔
✔✔ ✔ ✔
✔✔✔✔
✔✔ ✔ ✔
Hose Kits
✔✔ ✔
✔✔ ✔
L-Head
Hose Kits
✔✔ ✔
✔✔ ✔
Power
Pack
✔✔
✔✔
✔✔
✔✔
L-Head
Applicators
Only
400 V Power Requirements
S-Head
Applicators
Only
• 400 V systems are intended for International voltage
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 interchangeable.
3A0238P 3
Models
Applicator Kits
The table below lists S-Head and L-Head applicators kits. All applicator kits come with an injection nozzle and needle
valve calibration kit.
Maximum Working
Pressure
Applicator Kit No. Model
24A084 20.20.6/10 3000 (21, 206)
L-Head
S-Head
24A085 20.20.10/14 3000 (21, 206)
24A086 20.20.13/20 3000 (21, 206)
24A090 30100-500-4 3000 (21, 206)
24A092 30100-625-2 3000 (21, 206)
24A093 30110-625-4 3000 (21, 206)
psi (MPa, bar)
Individual Applicators
L-Head
The table below lists individual model numbers and chamber inside diameters. See L-Head manual for more information.
Maximum
Impingement
Chamber ID
Model
20.20.5/8 5 8 3000 (21, 206)
20.20.6/10 6 10 3000 (21, 206)
20.20.10/14 10 14 3000 (21, 206)
20.20.13/20 13 20 3000 (21, 206)
20.20.16/25 16 25 3000 (21, 206)
(mm)
S-Head
The table below lists individual model numbers and
stroke lengths. See S-Head manual for more information.
Maximum Working
Stroke
Model
30110-500-2 2.25 3000 (21, 206)
30100-500-4 4 3000 (21, 206)
30100-625-2 2.25 3000 (21, 206)
30110-625-4 4 3000 (21, 206)
(in.)
psi (MPa, bar)
Exiting Chamber
ID (mm)
GX-16
The table below lists individual model numbers. See
GX-16 manual for more information.
Pressure
Working
Pressure
psi (MPa, bar) CE Approved
✔
Applicator Model
GX-16
24E876
24E877
24E878
24J187
24K233
24K234
4 3A0238P
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
DANGER
HIGH VOLTAGE ELECTRIC SHOCK HAZARD
This equipment uses high voltage power. Contact with high voltage equipment and improper grounding,
setup, or usage of the system can cause death or serious injury.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• This equipment must be grounded. Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
WARNING
WARNINGWARNINGWARNING
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injur y or death if splashed in the eyes or on skin, inhaled, or swal-
lowed.
• 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, ser vicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation 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.
3A0238P 5
Warnings
WARNING
WARNINGWARNINGWARNING
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 treat-
ment.
• Engage trigger lock when not dispensing.
• 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.
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.
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.
6 3A0238P
Warnings
WARNING
WARNINGWARNINGWARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.
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 manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distr ibutor 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 war ning. Before checking, moving, or servicing equipment, follow the Pressure Relief Proce-
dure 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.
3A0238P 7
Warnings
Isocyanate Conditions
Spraying or dispensing materials containing isocyanates 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 ventilation 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.
Material Self-ignition
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Keep Components A and B
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 crystallization 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 Graco Throat Seal Liquid™(TSL™), Part
206995. The lubricant creates a barrier 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 contaminated from the other side.
• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Separate
Foam Resins with 245 fa Blowing Agents
Some foam blowing agents will froth at temperatures
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of
the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.
8 3A0238P
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Changing Materials
• When changing materials, flush the equipment multiple 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 side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
Warnings
3A0238P 9
Component Identification
Component Identification
AC Power Pack Module
24D829 AC Power Pack Module shown with circulation lines
B
D
A
FIG. 1: Typical Installation
Key:
A AC Hydraulic Power Pack
B Hose Kit (includes A, B, and hydraulic hoses)
C Boom (not included with all power pack kits)
D Applicator (not included)
E GMS
™
Fluid Manifold (not included)
C
E
r_24d829_3A0238_1f
10 3A0238P
Hydraulic Power Pack Stand
AB
Component Identification
AG
AH
AM
AW
AJ
AX
AL
AK
AE, AS
AV
AN
AD
AF
AC
AA
AU
AP
AT
r_24C065_3a0238_1d
r_24C065_3a0238_11e
FIG.2
Key:
AA 10 Gallon Hydraulic Oil Reservoir (see Technical Data on
page 70 for specifications)
AB Electric Motor
AC Dipstick
AD Hydraulic Housing
AE Heat Exchanger
AF Filter
AG Shroud
AH Mixhead Accumulator - 1200 psi (24.1 MPa, 241 bar) pre-
charge
AJ Cleanout Directional Valve
AK Accumulator Directional Valve
AL Dispense Directional Valve
AM Applicator Adapter Housing
AN Diverter Block
3A0238P 11
AP Main Power Disconnect
AR Electronics Panel (inside stand)
AS Heat Exchanger Cover
AT Cycle Stop Button
AU Stand
AV Hydraulic Pressure Gauge
AW Return Accumulator - 150 psi (1.0 MPa, 10 bar) precharge
AX Check Valve
Component Identification
Main Power Disconnect
Below are the on and off positions for the main power
disconnect (AP) located on the AC Power Pack module.
NOTE: The power must be turned “On” at the GMS
unit first.
On position
r_121148_3a0238_1a r_121148_3a0238_2a
FIG. 3: Main Power Disconnect
Off Position
Circuit Breakers
Circuit breakers are located inside the power pack frame
stand.
CB125CB113
r_24d427_3a0238_1c
FIG. 4: Circuit Breakers
Model Ref. No. Size Component
230V CB125 30 A Directional Valve and
heat exchanger fan
CB113 5 A Motor
400V CB125 20 A Directional valve and
heat exchanger fan
CB113 5 A Motor
12 3A0238P
Fluid Control Module (FCM)
Component Identification
BA
BC
BE
BB
FIG.5
Key:
BA Fluid Control Module
BB Base
BC Module Connection Screws
BD Access Cover
BE Module Status LEDs
BF CAN Connectors
BF
TI12337A
TI12336A
BD
FCM Cable Connections
FCM
Connections Cable
1 123673
2 123673
3 121686
4 121686
5 24E052
6 122497
CAN connector 1 123762
CAN connector 2 123856
3A0238P 13
Component Identification
Diagnostic Information
7
Module Status LED Signal Diagnosis Solution
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.
Adjust Selector Switch
The fluid control module uses a 16-position selector
switch. Set selector switch (S) to specific selection
according to the settings listed in the following table.
Setting 1 is the only valid position.
Selector Switch Settings
Setting Zone
00
11
22
33
44
55
66
77
88
99
AA
BB
CC
DD
EE
FF
14 3A0238P
Setup
Avoid breathing of vapors and contact with Isocyante
as some people have severe allergic reactions. See
Isocyanate Conditions on page 8.
Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components.
1. Anchor the stand to the floor (mounting hardware
not included). See Dimensions on starting on page
66 for mounting dimensions. Suggested anchors:
McMaster-Carr (part no. 92403A400).
NOTE: The AC power pack (A) needs to be mounted
no more than 6 ft (1.8m) away from the front of the
GMS unit.
2. If the AC power pack has a boom (C), anchor the
boom to the floor (mounting hardware not included).
See Dimensions on starting on page 66 for mounting dimensions. Suggested anchors: McMaster-Carr
(part no. 92403A400).
Setup
Connect Hydraulic Hoses
Hydraulic lines could rupture and cause injury. Use
hydraulic hoses with a pressure rating higher than
what the system is set to.
Twisted hydraulic hoses can cause the hoses to
fatigue sooner and rupture. Ensure that the hydraulic
hoses do not twist between the AC power pack and
the applicator.
NOTICE
Damage can occur to the directional valve if the
hydraulic hose diameter is larger than 3/8 in. (9.5
mm).
To prevent damage to the applicator or directional
valves, do not allow any dirt or foreign matter to
enter the lines, when connecting the hose kit (B) to
the applicator (D) and hydraulic power pack (A).
NOTE:
• If your AC Power Pack Module has a boom (C),
the AC Power Pack (A) needs to be installed
within 12 in. (304.8 mm) of the boom and the
boom needs to be installed within 3 ft (1 m) of
the GMS unit.
• Ensure that the hose connections for applicator
(D) face the mast. See FIG.1onpage10.
3. If the AC power pack has a boom (C), mount the
applicator (D) to the boom (C). Complete Installa-
tion instructions in the applicator manual.
Connect Hydraulic Hoses to Power Pack
1. Connect L-Head hydraulic hoses:
a. Connect the hydraulic hose fittings (A1, A2, B1,
and B2) on the AC power pack to the ends of
hydraulic hose (401) on the mast side of the
boom (C) as listed in the table below. See FIG.
1, page 10 and FIG. 6, page 16.
2. Connect S-Head and GX-16 hydraulic hoses:
a. Connect the hydraulic hose fittings (A2 and B2)
on the AC power pack to the ends of hydraulic
hose (402) on the mast side of the boom (C) as
listed in the table below. See FIG. 1, page 10
and FIG . 6, page 16.
b. Use caps (6) to plug A1 and B1 fittings.
3A0238P 15
Setup
Hydraulic
Hose Fitting
Hydraulic
Hoses
Hydraulic Hose
Color Markings
A1✖ Cleanout close Green/Green
A2 Material close Green
B1✖ Cleanout open Green/White/Green
B2 Material open Green/White
✖ Not used for S-Head and GX-16 applicators.
Connect Hydraulic Hoses to Applicator
If the AC power pack (A) has a boom (C), these connections will be hanging off the end of the boom.
L-Head
See FIG .8.
1. Connect the A1 hose, with green/green markings, to
the cleanout close port (CC) on the applicator.
2. Connect the A2 hose, with the green markings, to
the material close port (MC) on the applicator.
B1
A1
A2
FIG. 6: L-Head Applicator Hydraulic Housing
B2
A2
FIG. 7: S-Head Applicator Hydraulic Housing
B2
ti17743a
3. Connect the B1 hose, with the green/white/green
markings, to the cleanout open port (CO) on the
applicator.
4. Connect the B2 hose, with the green/white markings, to the material open (MO) port on applicator.
5. Hand tighten each fitting.
6. Bleed air from the hydraulic fluid lines. See the
applicator manual for instructions.
7. Tighten each fitting 1-1/2 flats past hand tight.
CC
CO
3. Hand tighten each fitting.
4. Tighten each fitting 1-1/2 flats past hand tight.
MC
MO
FIG. 8: Hydraulic connections on L-Head
16 3A0238P
S-Head and GX-16
See FIG . 9 and FIG. 10.
1. Connect the B2 hose, with green/white markings, to
the hydraulic open (HO) port fitting.
2. Connect the A2 hose, with green markings, to the
hydraulic close (HC) port fitting.
3. Hand tighten each fitting.
4. Bleed air from the hydraulic fluid lines. See the
applicator manual for instructions.
5. Tighten each fitting 1-1/2 flats past hand tight.
Setup
TOP
HC
RIGHT
HO
FIG. 9: Hydraulic connections on S-Head
HC
HO
ti17747a
FIG. 10: Hydraulic connections on GX-16
3A0238P 17
Setup
Connect Material Hoses to System
For System With Circulation
NOTICE
Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components. This also prevents fittings from
leaking.
1. Connect the A (red) and B (blue) supply hoses, from
hose kit (3), to the GMS material manifold. See FIG.
11.
2. Connect the other end of the supply hoses to the
applicator. See the applicator manual for fluid inlet
identification.
A
GMS material
manifold
3
421
422
B
fluid inlet
fitting
FIG. 12: Tank Stand Connections
5. Tighten each fitting.
r_257968_3a0238_1c
For System Without Circulation
NOTICE
Avoid routing hoses in walkway areas to prevent
operators from tripping on hoses running between
system components. This also prevents fittings from
leaking.
1. Connect the A (red) and B (blue) supply hoses, from
hose kit (3), to the GMS material manifold. See FIG.
11.
2. Connect the other end of the supply hoses to the
applicator. See the applicator manual for fluid inlet
identification.
3. Hand tighten each fitting.
4. Tighten each fittings 1-1/2 flats past hand tight.
FIG.11
NOTE: The circulation hoses contain a 10 ft (3 m)
extension hose to reach the tank stands.
3. Connect the other end of the A (red) circulation
hose (421) to the fluid inlet fitting on the A (red) tank
stand. See FIG. 11 and FIG. 12.
4. Connect the other end of the B (blue) circulation
hose (422) to the fluid inlet fitting on the B (blue)
tank stand.
18 3A0238P
Setup
Connect Communication Cables
83
121
84
122
123
FIG.13
1. Feed end of communication cable (83) through bulkhead of the HFR base unit.
2. Connect communication cable (83) to any open
CAN connector of a GCA cube.
5. Connect the termination connector (425) to the connector (121), labeled 5A. Feed the connector (425)
and cables (121, 84) into the base cube and secure.
S-Head (Includes GX-16)
1. Connect control cable (84) to the motor control module splitter labeled “2A” found on the HFR unit.
Refer to the HFR manual for detailed locations
2. Connect the S-head proximity sensor to the electrical connector found within the material hose bundle.
3. Connect the other end of the cord to the electrical
connector found near the fluid manifold on the HFR.
4. Feed the cables (121, 122, 123) into the base cube
and secure.
TI12337A
FIG.14
Connect Proximity Cables
L-Head
1. Connect the applicator end of the proximity sensor
cable (418) to the dispense proximity sensor on the
L-Head.
2. Connect the applicator end of the proximity sensor
cable (419) to the cleanout proximity sensor on the
L-Head.
3. Connect the other end of the proximity sensor cable
(418) to the dispense proximity sensor cable (122),
labeled A1, on the AC power pack. See FIG. 13.
4. Connect the other end of the proximity sensor cable
(419) to the cleanout proximity sensor pigtail (123),
labeled 2C, on the AC power pack. See FIG. 13.
3A0238P 19
Setup
Connect Electrical Cord
Electrical Requirements. See Table 1.
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, see FIG. 15. Be sure your
installation complies with all National, State, and
Local safety and fire codes.
Table 1: Electrical Requirements
(kW/Full Load Amps)
Voltage
Model
230V 230V (3) 17 4000
400V✖ 400V (3) 18 3200
* Full load amps with all devices operating at maximum
capabilities. Fuse requirements at various flow rates and
mix chamber sizes may be less.
(phase)
Full Load
Peak Amps*
System
Watts
NOTE: Power cord is not supplied. See Table 2.
Table 2: Power Cord Requirements
Model Cord Requirements AWG (mm2)
230V 10 (5.3), 3 wire
400V 10 (5.3), 4 wire
✖ See 400 V Power Requirements, page 3.
Electrical Cord Wires by Model
230V, 3 phase: L1, L2, L3
400V, 3 phase ✖ : L1, L2, L3, N
✖ See 400 V Power Requirements, page 3.
Use 5/32 or 4 mm hex allen wrench to connect three
power leads to L1, L2, and L3.
✖ See 400 V Power Requirements, page 3.
L3
L2
L1
FIG. 15: 230V, 3 phase shown
L3
L2
L1
N
FIG. 16: 400V, 3 phase shown
20 3A0238P
Startup
Startup
The hydraulic power pack operates at a high pres-
sure and high voltage. Be careful during operation
and always wear the appropriate protective gear.
1. Ensure all hydraulic connections are tight.
2. Turn on main power to power pack.
3. Turn power switch to the ON position.
4. Set system settings in ADM. See system operation
manual for instructions.
Operation
Pressure Relief Procedure
3. Press in the lower solenoid of the accumulator
charging directional valve.
FIG.17
4. Ensure that the pressure gauge is zero psi.
5. To relieve pressure in material hoses, perform Pres-
sure Relief Procedure in HFR manual 313997.
Shutdown
Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury from splashing or moving parts.
Always relieve hydraulic pressure of AC power pack:
• Before performing system maintenance
• Long term (over night) shutdown
1. Shutdown the power pack. See Shutdown.
2. Open the needle valve to show the pressure on the
gauge.
NOTE: Ensure that the motor is not running.
1. Shutdown HFR.
2. Turn main power switch to the OFF position.
3. Turn off and lock out main power.
3A0238P 21
Maintenance
Maintenance
Check the Accumulator Pre-Charge
Graco Charging Harness (part no. 124217) can be purchased to aid in quick charging of the accumulator.
Schedule
Procedure Frequency
Check Accumulator Pre-Charge Weekly
Check Tightness of all Clamps and
Fittings
Check Hoses for Wear Monthly
Check Hydraulic Fluid and Filter 6 months
NOTICE
Recommended Hydraulic Oil
Use Graco-approved Hydraulic Oil, Part No. 169236
(5 gal) or 207428 (1 gal)) or a premium, ISO grade
46 petroleum-based hydraulic oil containing rust
and oxidation inhibitors and anti-wear agents.
Before using any other type of oil in this motor, contact your Graco distributor. Unauthorized use of
lesser grade oil or substitutes may void the warranty.
Hydraulic Oil Working Temperature
The maximum hydraulic oil operating temperature is
180 °F (82 °C). The motor seals will wear faster and
leakage may occur if the pump is operated at higher
oil temperatures.
If the hydraulic oil temperature approaches 180 °F
(82 °C), check the hydraulic fluid supply cooling system, filters, etc. and clean or repair as needed.
Keep the hydraulic system clean
To reduce the risk of damaging the hydraulic driver,
verify that the hydraulic power supply fluid lines and
reservoir are clean and free from contaminants.
Carefully follow the manufacturer’s recommendations on reservoir and filter cleaning, flushing, and
periodic changes of hydraulic fluid.
Weekly
1. Turn off main power and lockout.
2. Bleed the accumulator charging valve hydraulic
pressure to zero. See Pressure Relief Procedure,
page 21.
3. Connect the charging harness to the accumulator.
4. Check the reading on the nitrogen harness pressure
gauge. If the pressure is below 1200 psi, then
Pre-Charge the Accumulator to 1200 psi.
5. Repeat the procedure for the return accumulator
(AW, FIG. 2) with the precharge set to 150 psi
(1.0 MPa, 10 bar).
Pre-Charge the Accumulator
NOTICE
During this procedure the nitrogen bottle, the accumulator, and the charging harness will all be under
significant pressure. Use dry nitrogen gas only.
1. Check the Accumulator Pre-Charge.
2. Connect the other end of the harness to the nitrogen
bottle. Slowly open the nitrogen bottle valve while
observing the pressure gauge.
3. When the1200 psi is reached, close the nitrogen
valve.
4. Open the bleed valve on the charging harness to
relieve residual pressure in the charging harness.
5. Remove the charging harness and replace the bottle guard.
6. Repeat the procedure for the return accumulator
(AW, FIG. 2) with the precharge set to 150 psi
(1.0 MPa, 10 bar).
Always plug the hydraulic inlets, outlets and lines
when disconnecting them to avoid introducing dirt
and other contaminants into the system.
22 3A0238P
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