Graco 3A2797G User Manual

Setup - Operation

ti19507a

™

HFR

for NVH

3A2797G

Foam - Cart

Hydraulic, Plural-Component, Fixed-Ratio Proportioner. For dispensing NVH foam.

For professional use only. Not approved for use in explosive atmospheres or hazardous locations.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 4 for model information and maximum working pressure.

Patents Pending

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GX-16 Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . 6

B (Blue) and A (Red) Feed Tanks . . . . . . . . . . . 6

AC Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Refill Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GX-16 Shutoff Valve Kit . . . . . . . . . . . . . . . . . . . 6

Additional Accessories . . . . . . . . . . . . . . . . . . . . 7

Communications Gateway Module (CGM) . . . . . 7

Bag Filter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GX-16 Fitting Kits . . . . . . . . . . . . . . . . . . . . . . . . 7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Important Two-Component Material Information 11

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 11

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 11

Keep Components A (Red) and B (Blue) Separate

Moisture Sensitivity of Isocyanates . . . . . . . . . . 11

Foam Resins with 245 fa Blowing Agents . . . . . 11

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 12

A (Red) and B (Blue) Components . . . . . . . . . . . . 12

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 13

Component Identification . . . . . . . . . . . . . . . . . . . 14

HFR Hydraulic Power Pack . . . . . . . . . . . . . . . . 17

Motor Control Module (MCM) . . . . . . . . . . . . . . 18

Advanced Display Module (ADM) . . . . . . . . . . . 20

Fluid Control Module (FCM) . . . . . . . . . . . . . . . 23

Temperature Control Module . . . . . . . . . . . . . . . 24

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 44

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Install Upgrade Tokens . . . . . . . . . . . . . . . . . . . 47

IsoGuard Select™ System . . . . . . . . . . . . . . . . 48

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Light Tower (Optional) . . . . . . . . . . . . . . . . . . . . 49

Appendix A - ADM Icons Overview . . . . . . . . . . . 52

Setup Screen Icons . . . . . . . . . . . . . . . . . . . . . . 52

Run Screen Icons . . . . . . . . . . . . . . . . . . . . . . . 53

Appendix B - ADM Setup Screens Overview . . . 54

Appendix C - ADM Run Screens Overview . . . . . 69

Appendix D - ADM Error Codes . . . . . . . . . . . . . . 75

Appendix E - System Events . . . . . . . . . . . . . . . . 87

Appendix F - USB Operation . . . . . . . . . . . . . . . . . 89

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

USB Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Download Log Files . . . . . . . . . . . . . . . . . . . . . . 89

Log Files, Folder Structure . . . . . . . . . . . . . . . . 90

Transfer System Settings . . . . . . . . . . . . . . . . . . 92

Update Custom Language . . . . . . . . . . . . . . . . . 93

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Motor Control Module Technical Data . . . . . . . . 96

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 98

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 98

2 3A2797G

Related Manuals

Manuals are available at www.graco.com. Component manuals below are in English:

System Manuals

313998 HFR Repair-Parts

Power Distribution Box Manual

3A0239 Power Distribution Boxes Instruc-

tions-Parts

Pumpline Manuals

3A0019 Z-Series Chemical Pumps Instruc-

tions-Parts

3A0020 HFR Hydraulic Actuator Instruc-

tions-Parts

Feed System Manuals

3A0238 AC Hydraulic Power Pack Instruc-

tions-Parts

3A0235 Feed Supply Kits

Instructions-Parts

3A0395 Stainless Steel Tank Feed Sys-

tems Instructions-Parts

3A1299 Carbon Steel Tank Feed Systems

Instructions-Parts

3A0237 Heated Hoses and Applicator Kits,

Instructions-Parts

308495

Viscon® Heater Kit Manual

Related Manuals

Dispense Valve Manuals

313536 GX-16, Operation

Accessory Manuals

3A1149 HFR Discrete Gateway Module

Kits Manual

312864 HFR Communications Gateway

Module Instructions-Parts

3A1936 Agitator Kit

Instructions-Parts

3A1962 Agitator Kit with Heat Blanket

Instructions-Parts

3A1657 HFR Flow Meter Kits

Instructions-Parts

332544 HFR for NVH Prepoly Refresh Kit

Instructions-Parts

3A2797G 3

Models

Full Load

System

Peak Amps

Per Phase*

Voltage (phase)

24N569 90 230V (3)

24N570 ★✖ 68 400V (3)

24N571 90 230V (3)

24N572 ★✖ 68 400V (3)

24N573 90 230V (3)

24N574 ★✖ 68 400V (3)

24N575 90 230V (3)

24N576 ★✖ 68 400V (3)

System

Material

Ratio (A:B)

A (Red)

Pump

Size

B (Blue)

24N569

24:1 120 5 .061 .011

24N570 ★

24N571

16:1 160 10 .057 .014

24N572 ★

Pump

Size

Primary

Heater

Watts

A (Red)

6,000

A (Red)

Orifice

Primary

Heater

Watts

B (Blue)

Max Flow

Rate◆ lb/min

(kg/min)

Approximate

Output per

Cycle (A+B)

gal. (liter)

Hydraulic

Pressure

Ratio

18 (8.2) 0.033 (0.125) 1.9:1

4,000

24 (11) 0.045 (0.170) 1.4:1

6,000 17 (7.7) 0.032 (0.121) 3.7:1

4,000 18 (8.2) 0.033 (0.125) 1.9:1

B (Blue)

Orifice

25’ (7.6 m)

Chemical

Hose Bundle

10’ (3 m)

Chemical

Hose Bundle

24J290 24J316

Maximum

Fluid Working

Pressure ‡

psi (MPa, bar)

2000

(14, 138)

24N573

24N574 ★

24N575

24N576 ★

System

24N569

24N570 ★

24N571

24N572 ★

24N573

24N574 ★

24N575

24N576 ★

1:1 60 60 .039 .039 24N287 24N289

24:1 120 5 .085 .013 24K681

27.5’ (8.4 m) Hydraulic

Hose Bundle

10’ (3 m)

Hydraulic

Hose Bundle

24V197 24J177

4 3A2797G

Models

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and

mix chamber sizes may be less.

◆ Flow rate is independent of frequency 50/60 Hz.

★ approved.

‡ The maximum fluid working pressure for the base machine without hoses is 3000 psi (20.7 MPa, 207 bar). If

hoses rated at less than 3000 psi are installed, the system maximum fluid working pressure becomes the rating of the hoses. If 2000 psi hoses were purchased and installed by Graco, the working pressure for the machine is already setup for the lower 2000 psi (13.8 MPa, 138 bar) working pressure by Graco. If the machine was purchased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed, see instruction manual 313998 for the procedure to setup the machine for higher rated hoses. The change in working pressure is made by changing a rotary switch setting in the Motor Control Module. The minimum pressure rating for hoses is 2000 psi. Do not install hoses with a pressure rating lower than 2000 psi.

✖ See 400 V Power Requirements.

400 V Power Requirements

• 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.

3A2797G 5

Accessories

Applicator

Part Description

24J187 GX-16, 24:1, Straight, Machine Mount

24K233 GX-16, 24:1, Left, Machine Mount

24K234 GX-16, No Orifice, Left, Machine Mount

24E876 GX-16, No Orifice, Straight, Machine Mount

24E877 GX-16, 24:1, Right, Machine Mount

24E878 GX-16, No Orifice, Right, Machine Mount

GX-16 Orifices

Part Description

257701 0.011 in. Orifice

257702 0.013 in. Orifice

24N158 0.014 in. Orifice

257703 0.016 in. Orifice

257704 0.018 in. Orifice

257705 0.020 in. Orifice

257706 0.022 in. Orifice

257707 0.023 in. Orifice

257708 0.024 in. Orifice

257709 0.025 in. Orifice

257710 0.026 in. Orifice

257711 0.028 in. Orifice

257712 0.029 in. Orifice

257713 0.032 in. Orifice

257714 0.035 in. Orifice

257715 0.036 in. Orifice

257716 0.038 in. Orifice

257717 0.039 in. Orifice

257718 0.040 in. Orifice

257719 0.042 in. Orifice

257720 0.043 in. Orifice

257721 0.044 in. Orifice

257722 0.049 in. Orifice

257723 0.052 in. Orifice

24N159 0.057 in. Orifice

257724 0.061 in. Orifice

24K682 0.085 in. Orifice

B (Blue) and A (Red) Feed Tanks

Part Description

24N594 20 gal. (75 l) Stainless Steel Tank, No Agitation,

Insulation, 3 Level Sensors, A-Side

24N595 20 gal. (75 l) Stainless Steel Tank, No Agitation,

Insulation, 3 Level Sensors, B-Side

24N578 20 gal. (75 l) Carbon Steel Tank, No Agitation, 3

Level Sensors, A-Side

24N597 20 gal. (75 l) Carbon Steel Tank, No Agitation, 3

Level Sensors, B-Side

24N579 2 gal. (8 l) Stainless Steel Tank, No Agitation, 1

Level Sensor, B-Side

AC Power Pack

Part Description

24J912 230V, AC Power Pack

24J913 400V, AC Power Pack

24E347 Hydraulic Power Pack Level Sensor Kit

24C872 Hydraulic Power Pack Pressure Gauge Kit

24E348 Hydraulic Power Pack Temperature Sensor

124217 Power Pack Accumulator Charging Kit

Refill Kits

Part Description

24M418 Low Volume, 2 gal. (7.6 l) tank

24M419 High Volume, 20 gal. (76 l) tank

GX-16 Shutoff Valve Kit

Part Description

24M596 GX-16 Shutoff Valve Kit

For use with: 24N569, 24N570, 24N571, 24N572, 24N573, 24N574

24M368 GX-16 Shutoff Valve Kit

For use with: 24N575, 24N576

GX-16 Proximity Kit

Part Description

24K659 GX-16 Proximity Kit

6 3A2797G

Accessories

Additional Accessories

Part Description

24C871 Hydraulic Power Pack Hydraulic Tank Fluid Level

Sensor

24C873 Hydraulic Power Pack Manifold Oil Temperature

Sensor

24F516 IsoGuard Select fluid, 6 quar ts

121728 Extension Cable for Advanced Display Module,

4 meter,

255468 Light Tower

255244 Foot Switch with Guard and 4 meter Cable

24G389 Pneumatic Agitator for 20 gal. (75 l) Carbon Steel

Tank, No Heat

24K344 Pneumatic Agitator for 20 gal. (75 l) Carbon Steel

Tank, Heat

24K348 Pneumatic Agitator for 20 gal. (75 l) Stainless

Steel Tank, No Heat

24K346 Pneumatic Agitator for 20 gal. (75 l) Stainless

Steel Tank, Heat

24K223 Isolated Pistol Grip Adapter

123694 Straight Gun Cover

123226 90° Gun Cover

123695 12 ft (3.7 m) Hose Cover

125236 Z-Series Pump Cover

125113 Gun Cover Handle Hole Cover

248280 3 oz. Quik Shot Grease Tube (10 Pack)

117792 3 oz. Grease Gun

0553-6 14 oz. Synthetic Grease Tube

255468 Light Tower Kit

24T182* Flow Meter Kit, NVH Cart, 24:1 and 16:1

24T183* Flow Meter Kit, NVH Cart, 1:1

24T180 PrePoly Refresh Kit, NVH Car t, with Autofill

24T181 PrePoly Refresh Kit, NVH Car t, without Autofill

* Flow meter electronics kit, 24J318, is required for flow meter kit

installation.

Communications Gateway Module (CGM)

Part Description

24J415 CGM Mounting Kit

(Required for all applications)

CGMDN0 GCA Gateway Module, DeviceNet Fieldbus

CGMEP0 GCA Gateway Module, EtherNet/IP Fieldbus

CGMPB0 GCA Gateway Module, PROFIBUS Fieldbus

CGMPN0 GCA Gateway Module, PROFINET Fieldbus

Bag Filter Kits

Part Description

24J312 High Volume Filter Kit (40 Mesh)

24P095 Low Volume Filter Kit (100 Mesh)

125147 40 Mesh Filter Replacement

125148 100 Mesh Filter Replacement

0135-4.30x.313 TEV O-Ring for Lid Seal

0131-4.30x.313 EP O-Ring for Lid Seal

GX-16 Fitting Kits

The following kit is for Models 24N575 and 24N576 only.

Part Description

24N435 Gun Fitting Kit

The following kits are for all other Models.

Part Description

24K672 Right Orientation, 90° Fitting Adapter Kit

24K674 Left Orientation, 90° Fitting Adapter Kit

3A2797G 7

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 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 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 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, 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.

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.

8 3A2797G

Warnings

WARNING

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.

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.

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.

3A2797G 9

Warnings

WARNING

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 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 equipment, 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.

10 3A2797G

Important Two-Component Material Information

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 (Red) and

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 IsoGuard Select™, part 24F516. 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.

B (Blue) 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 (Red) and component B (Blue) parts.

3A2797G 11

above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

A (Red) and B (Blue) Components

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 (Red) side, but some use ISO on the B (Blue) side. See the following 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-sensitive, that material should always be in the A (Red) side.

• The B (Blue) side is intended for polyols, resins, and bases.

12 3A2797G

Typical Installation

* Shown exposed for clarity.

Wrap with tape during operation.

ti19507a

Typical Installation

FIG. 1: Typical Installation

Key:

A Tank Stand - A (Red) B Tank Stand - B (Blue) C AC Power Pack D HFR Power Pack E Dispense Gun F Fluid Temperature Sensor (FTS) G Manifold H Main Hose Bundle J Whip Hose Bundle

3A2797G 13

Component Identification

ti19508a

Component Identification

Key for FIG. 2 and FIG. 3.

AA Advanced Display Module (see page 20) BA Component A (Red) Pressure Relief Outlet BB Component B (Blue) Pressure Relief Outlet FA Component A (Red) Fluid Manifold Inlet (on left side of

manifold block) FB Component B (Blue) Fluid Manifold Inlet FM HFR Fluid Manifold FP Feed Inlet Pressure Gauge FT Feed Inlet Temperature Gauge GA Component A (Red) Outlet Pressure Gauge GB Component B (Blue) Outlet Pressure Gauge HA Component A (Red) Hose Connection (from feed to gun

or mix head) HB Component B (Blue) Hose Connection (from feed to gun

or mix head) HP Hydraulic Power Pack Assembly HT Hydraulic Tank LS Pumpline Linear Sensor

MA Motor Control Module, see page 18 MP Main Power Switch PA Component A (Red) Pump PB Component B (Blue) Pump PD Power Distribution Box PHB Primary Heater - B Side PHA Primary Heater - A Side PI Primary Heater Fluid Inlet PO Primary Heater Fluid Outlet PR Primary Heater RTD PS Primary Heater Overtemperature Switch SA Component A (Red) PRESSURE RELIEF/DISPENSE

Valve

SB Component B (Blue) PRESSURE RELIEF/DISPENSE

Valve TA Component A (Red) Pressure Transducer TB Component B (Blue) Pressure Transducer TC High Power Temperature Control Module (not shown, see

page 24)

FIG. 2: Component Identification, Heated Model shown with shrouds removed

14 3A2797G

Component Identification

ti9880a1

Fluid Manifold (FM) Detail

Rear View

Primary Heater (PHA)

Detail, A (Red) side shown

ti19509a

ti19510a

Primary Heater (PHB)

Detail, B (Blue) side shown

ti19511a

(In Enclosure)

FIG. 3: Component Identification, Continued

3A2797G 15

Component Identification

CB1

CB5

CB2

CB9

CB6

CB11

400V/ 3 phase

230V/ 3 phase

ti19512a

ti19513a

Main Power Switch

Located on top of the power distribution box, see page14. The main power switch turns power

ON and OFF . The main power switch

does not turn pumps or heat zones on.

Circuit Breakers

Most circuit breakers are located inside the power distribution box. The main block of circuit breakers in the power distribution box is shown below, with detailed information in the following table. For more information about items in the power distribution box, see power distribution box manual.

Size

400V/

Ref.

3 phase

CB1 63A 30A Motor Control Module

CB2 40A 40A Primary Heater A

CB5 5A 5A Miscellaneous

CB6 5A 5A Miscellaneous

230V/

3 phase

Component

CB9 40A 40A Primary Heater B

CB11 30A 30A AC Power Pack

16 3A2797G

HFR Hydraulic Power Pack

ti19514a

Component Identification

FIG. 4: HFR Hydraulic Power Pack

Key:

DA 9 Gallon Hydraulic Oil Reservoir (see Technical Data on

page 95 for specifications) DB Electric Motor DD Hydraulic Housing DE Directional Valve DF Motor Control Module (see page 18)

DG Fan DH Oil Filter DJ Shroud (not shown, removed for clarity) DK 3 Way Splitter DL Oil Level Sensor (Optional)

3A2797G 17

Component Identification

r_257396_3b9905_01b

r_257396_3b9905_03b

Motor Control Module (MCM)

NOTICE

If the Motor Control Module is replaced, the selector switch must be set prior to initial startup of the Motor Control Module or damage may occur. See HFR Repair manual for details, see Related Manu- als on page 3.

For MCM location, see reference MA in FIG. 2 on page 14. 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.

FIG. 5: MCM Component Identification

18 3A2797G

Ref Description

A Access Cover

B LEDs

C Warning Label

1A, 1B CAN Connections

2 Three-way Splitter to: Oil Low Level

Sensor, Dispense Valve Solenoid, and Footswitch

3 Oil Temperature Sensor

5 Electric Motor Temperature Sensor

6 LVDT (Position Sensor)

7 Three-way Splitter to:

Hydraulic Directional Valve, Oil Overtemperature Switch

8 Pressure Transducer B (Blue) side

9 Pressure Transducer A (Red) side

10 Not used

11 Motor Position Sensor

12 MCM Power Input Connection

13 Motor Power Connection

Component Identification

Diagnostic Information

Table 1: LED (Ref B) Status Signal

Module Status LED Signal Description

Green on System is powered up.

Yellow on Internal communication in progress.

Red solid MCM hardware failure. Replace MCM.

Red flashing fast Uploading software.

Red flashing slow Token error. Remove token and upload

software token again.

3A2797G 19

Component Identification

TI12362a1

Advanced Display Module (ADM)

User Interface

FIG. 6: ADM Component Identification - Front

Buttons

Ref. Button Function

CA System

enable/ disable

CB System

Status Indicator Light

CC Stop Stop all system processes.

CD Soft Keys Defined by application using ADM.

CE Cancel Cancel a selection or number entry

CF Enter Acknowledge changing a value or

CG Setup Toggle between run and setup

CH Naviga-

tion

Enables/disables system. When system is disabled, temperature control and dispense operation are disabled.

Displays system status. See System Status Indicator (CB) Conditions on page 20 for details.

while in the process of entering a number or making a selection.

making a selection.

screens or password screen if setup screens are password protected.

Navigate within a screen or to a new screen.

System Status Indicator (CB) Conditions

Green Solid - Run Mode, System On Green Flashing - Setup Mode, System On

Yellow Solid - Run Mode, System Off

20 3A2797G

Component Identification

r_24E451_3B9900_1a

FIG. 7: ADM Component Identification - Rear

Key:

CJ Flat Panel Mount CK Model Number CL USB Module Interface CM CAN Cable Connections

CN Module Status LEDs CP Accessory Cable Connections CR Token Access Cover CS Battery Access Cover

ADM Module Status LEDs (CN) Conditions

Module Status LED Signal Description

Green on System is powered up.

Yellow on Communication in progress.

Red solid ADM hardware failure.

Red flashing fast Uploading software.

Red flashing slow Token error. Remove token and upload

software token again.

USB Module Status LEDs (CL) Conditions

Module Status LED Signal Description

Green flashing System is powered up.

Yellow on Downloading information to USB

Green/Yellow Flashing ADM is busy, USB cannot transfer

information when in this mode

3A2797G 21

Component Identification

Current date and time Current chapter

Enter/Exit screen

Previous chapter

(Left Arrow)

Next chapter (Right Arrow)

Function display

Current page

Next page (Down Arrow)

Previous page (Up Arrow)

Mode

Faults, Status

Main Display Components

The following figure calls out the navigational, status, and general informational components of each screen. For details regarding the user interface display see Shutdown, page 44.

FIG. 8: Main Display Components

22 3A2797G

Fluid Control Module (FCM)

ti12337a1

ti12336a1

Component Identification

FIG. 9: Fluid Control Module (FCM)

Key:

A Fluid Control Module B Base C Module Connection Screws

D Access Cover E Module Status LEDs F CAN Connectors

Diagnostic Information

Module Status LED (Ref E) Signal Diagnosis

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.

3A2797G 23

Component Identification

LED Signals

ti12352a1

ti12353a1

ti12356a1

ti12357a1

LED Signals

Temperature Control Module

FIG. 10: High Power Temperature Control Module Sensor Connections

Key:

1 Overtemperature Switch Connection (primary heaters

only) 2 RTD Temperature Sensor Connection 3 Output Power Connection

4 DC Output Connection 5 Input Power Connection 6 CAN Connections 7 Rotary Selector Switch, Token Access

FIG. 11: Low Power Temperature Control Module Cable Connections

1 Overtemperature Switch Connection 2 RTD Temperature Sensor Connection 3 Output Power Connection

4 DC Output Connection 5 Input Power Connection 6 CAN Connections 7 Base

24 3A2797G

Component Identification

Primary Heater B (Blue)

Primary Heater A (Red)

Right Side from

Rear View

Left Side from

Rear View

ti17748a

ti17749a

Material Temperature

FTS - (Red)

Temperature Control Module Diagnostic Information

Module Status LEDs

Signal Description

Green on Temperature control module is

powered up.

Yellow on Internal communication in prog-

ress.

Red solid Temperature control module failure.

See Troubleshooting table.

Red flashing fast

Red flashing slow

Blue light off (High Power Module only)

Blue flashing (High Power Module only)

Uploading software.

Token error. Remove token and upload software token again.

Temperature control module is off. See Troubleshooting table.

Length of flashes indicates amount of power running through temperature control module.

Heat Control Zone Selection

The HFR unit supports four independent temperature control zones and two independent temperature monitoring zones. The high power temperature control modules are located inside the frame below the hydraulic power pack.

3A2797G 25

Component Identification

High Power Module Rotary Switch Location

Low Power Module Rotary Switch Location

ti12360a

ti12361a

Adjust Rotary Switch

The rotary switch setting indicates which zone the temperature control module will control in the system. The high power module uses an 8-position rotary switch. The low power module uses a 16-position rotary switch.

Set the rotary switch (S) to the specific selection according to the settings listed in the following tables.

High Power Module Rotary Switch Settings

Setting Zone

0 Not Used

1 B (Blue) Primary Heat

2 B (Blue) Hose Heat

3 A (Red) Primary Heat

4 A (Red) Hose Heat

5 through 7 Not Used

Low Power Module Rotary Switch Settings

Setting Zone

0 through 4 Not Used

5 B (Blue) Tank Heater

6 A (Red) Tank Heater

7 B (Blue) Chiller

8 A (Red) Chiller

9 through F Not Used

FIG. 12: Rotary Switch

26 3A2797G

Component Identification

3A2797G 27

Setup

Perform this setup procedure to secure all necessary machine connections for machine operation.

Locate system.

a. Locate system on a level surface. See Dimen-

sions on page 97 for space requirements.

b. Do not expose system to rain.

Electrical requirements. See Models on page 4

for detailed electrical requirements information.

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 step 4 in this setup procedure. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Ground system

This equipment must be grounded.

a. System: grounded through power cord. See

step 4 on page 28.

b. Fluid supply containers: follow your local code.

c. Object being dispensed into: follow your local

code.

d. Solvent pails used when flushing: follow your

local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

e. To maintain grounding continuity when flushing

or relieving pressure, hold a metal part of dispense gun firmly to the side of a grounded metal pail, then trigger gun.

Connect electrical cord to system.

NOTE: See Power Line Voltage Surges information on

page 29.

NOTE: Power cord is not supplied. See the following table.

28 3A2797G

Setup

r_24C686_313998_1a

L1L2L3N

GND

Maximum Permissible Transient Voltage Surges

* Constructed from ITIC 1996 curve, referenced by IEC 61000-2-4

1200Vac, 1697Vdc

264Vac, 373Vdc

336Vac, 475Vdc

288Vac, 407Vdc

480Vac, 679Vdc

<--1 MW Max Surge Power

<--150 KW Max Surge Power

<--50 KW Max Surge Power

<--No Power Limit

200

400

600

800

1000

1200

1400

Time (seconds)

Voltage (Volts RMS)

Table 2: Power Cord Requirements

Cord Requirements

Model

Heated system,

4 (21.2), 3 wire + ground

AWG (mm2)

230V, 3 phase

Heated system,

4 (21.2), 4 wire + ground †

400V, 3 phase

† 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

Use 5/32 or 4 mm hex allen wrench to connect the three power leads to L1, L2, L3, and Neutral (as required). Connect green to ground (GND).

The MAX-HOLD feature on a multimeter can be used to determine peak DC voltage on the line. DC is the proper setting, as opposed to AC, because peak voltage is the critical parameter that affects the DC voltage level stored on the capacitive bus in power conversion equipment. Reading should not regularly exceed approximately 400VDC to avoid tripping the 420VDC alarm level in the Motor Control Module. If power quality is suspect, power conditioning or isolation of the device(s) causing poor power quality is recommended. Consult a qualified electrician if there are any concerns about the available power supply.

Power Line Test Steps with Multimeter

a. Set multimeter to “DC voltage”.

b. Connect multimeter probes to supplied power

line.

c. Press “Min Max” successively to show the peak

positive and negative DC voltages.

d. Confirm readings do not exceed 400VDC

(Motor Control Module alarm issued at 420VDC).

FIG. 13: 400V, 3 phase shown

Power Line Voltage Surges

Power conversion equipment can be sensitive to voltage fluctuations on incoming power. The Motor Control Module falls under the category of power conversion equipment because energy is stored on a capacitive bus and then modulated to control a brushless motor. Engineered design takes this into account and withstands a wide range of conditions, but it is possible for supplied power to occasionally fall outside the tolerable range in industrial plants with high-amperage reactive pulsed loads such as welding equipment. If the tolerable range is exceeded, an overvoltage condition is flagged and the system will shut down in an alarm state to protect itself and alert the user of unstable power. Excessive or repeated overvoltage may permanently damage hardware.

3A2797G 29

The chart below shows the permissible magnitude and duration of temporary over-voltage events:

Setup

ti19515a

Connect HFR Proximity Cables to the GX-16.

Connect Hydraulic Lines to the system.

NOTE: Refer to the HFR and GX-16 manuals for more

details for the following procedures.

NOTE: The cable is indicated by a green stripe.

a. Connect the GX-16 proximity sensor to the

proximity cable.

b. Connect the 10 ft (3 m) hydraulic whip hose

cable to the 25 ft (7.6 m) chemical hose cable.

c. Connect the other end of the cable to the electri-

cal connector found near the fluid manifold on the HFR.

NOTE: The electrical connector will be indicated by a green stripe and labeled “PG-MPO”.

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 to the applicator and hydraulic power pack.

a. Connect the hydraulic hose to the hydraulic

hose fittings (A2 and B2) on the AC power pack.

Hydraulic

Hose Fitting

Hydraulic

Hoses

Hydraulic Hose Color Markings

A2 Material close Green B2 Material open Green/White

FIG. 14: Hydraulic Fittings on Hydraulic Housing

b. Hand tighten each fitting.

c. Tighten each fitting 1/4 turn past hand tight.

30 3A2797G

+ 68 hidden pages