Graco 3A2797G User Manual

3A2797GENSetup - Operation HFR™ for NVH Foam - CartHydraulic, Plural-Component, Fixed-Ratio Proportioner.For dispensing NVH foam.For professional use

Warnings 10 3A2797GEQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.• Do not operate the unit when fatigued or under the influence of

Important Two-Component Material Information3A2797G 11Important Two-Component Material InformationIsocyanate Conditions Material Self-ignition Keep Co

A (Red) and B (Blue) Components 12 3A2797GChanging Materials• When changing materials, flush the equipment mul-tiple times to ensure it is thoroughly

Typical Installation3A2797G 13Typical InstallationKey:A Tank Stand - A (Red)B Tank Stand - B (Blue)C AC Power PackD HFR Power PackE Dispense GunF Flui

Component Identification 14 3A2797GComponent IdentificationKey for FIG. 2 and FIG. 3.AA Advanced Display Module (see page 20)BA Component A (Red) Pres

Component Identification3A2797G 15FIG. 3: Component Identification, Continuedti9880a1GAGBSBFBBBHBHABAFASAFluid Manifold (FM) DetailLSTBTAMPRear ViewPr

Component Identification 16 3A2797GMain Power SwitchLocated on top of the power distribution box, see page14. The main power switch turns power ON an

Component Identification3A2797G 17HFR Hydraulic Power PackKey:DA 9 Gallon Hydraulic Oil Reservoir (see Technical Data on page 95 for specifications)DB

Component Identification 18 3A2797GMotor Control Module (MCM)For MCM location, see reference MA in FIG. 2 on page 14. When installed, the end of the M

Component Identification3A2797G 19Diagnostic Information7Ref DescriptionA Access CoverB LEDsC Warning Label1A, 1B CAN Connections2 Three-way Splitter

2 3A2797GContentsRelated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Models . . . . . . . . . . . . . . . . . . . . . . . . .

Component Identification 20 3A2797GAdvanced Display Module (ADM)User InterfaceButtons System Status Indicator (CB) ConditionsGreen Solid - Run Mode, S

Component Identification3A2797G 21Key:CJ Flat Panel MountCK Model NumberCL USB Module InterfaceCM CAN Cable ConnectionsCN Module Status LEDsCP Accesso

Component Identification 22 3A2797GMain Display ComponentsThe following figure calls out the navigational, status, and general informational component

Component Identification3A2797G 23Fluid Control Module (FCM)Key:A Fluid Control ModuleB BaseC Module Connection ScrewsD Access CoverE Module Status LE

Component Identification 24 3A2797GTemperature Control ModuleKey:1 Overtemperature Switch Connection (primary heaters only)2 RTD Temperature Sensor Co

Component Identification3A2797G 25Temperature Control Module Diagnostic InformationModule Status LEDsHeat Control Zone Selection The HFR unit supports

Component Identification 26 3A2797GAdjust Rotary SwitchThe rotary switch setting indicates which zone the tem-perature control module will control in

Component Identification3A2797G 27

Setup 28 3A2797GSetupPerform this setup procedure to secure all necessary machine connections for machine operation.1.Locate system.a. Locate system o

Setup3A2797G 29† Residual Current Device (RCD) must be rated at 300 mA if installed.Electrical Cord Wires by Model230V, 3 phase: L1, L2, L3, GND400V,

Related Manuals3A2797G 3Related ManualsManuals are available at www.graco.com. Component manuals below are in English:System Manuals313998 HFR Repair-

Setup 30 3A2797G5.Connect HFR Proximity Cables to the GX-16.NOTE: Refer to the HFR and GX-16 manuals for more details for the following procedures.NOT

Setup3A2797G 317.Install GX-16 Fitting Adapter Kit(Models 24N575 and 24N576 Only).a. Remove the chemical fittings from the back of the GX-16.b. Instal

Setup 32 3A2797GFIG. 15: Material Hose Connectionsti19507aStep 9g,Step 9hStep 9c,Step 9d,Step 9e,Step 9fStep 9i,Step 9j

Setup3A2797G 3310.Connect Material HosesNOTE: Refer to FIG. 15 on page 32 for visual clarity of the following steps.a. Ensure main power is OFF .b. E

Setup 34 3A2797Gh. Connect cables (Y). Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape. See Heat

Setup3A2797G 35together. This creates a hydraulic fluid circula-tion loop.e. Turn on the power pack by navigating to the Home Screen, Standby Mode and

Setup 36 3A2797G12.Setup the Advanced Display Module (ADM)When main power is turned on by turning the main power switch (MP) to the ON position, the s

Setup3A2797G 3713.Calibrate HFRNOTE: Machine is calibrated from the factory. Only per-form the following steps when changing or rebuilding pumps.The H

Setup 38 3A2797Ga. Navigate to System Screen 3.b. Press to enter the screen.c. Navigate to the pressure imbalance field. d. Type the desired pressur

Setup3A2797G 39NOTE: A minimum feed pressure of 50 psi (0.35 MPa, 3.5 bar) is required at both feed inlet pressure gauges (FP). Maximum feed pressure

Models 4 3A2797GModelsSystemFull Load Peak Amps Per Phase*Voltage (phase)Primary Heater Watts A (Red)Primary Heater Watts B (Blue)Max Flow Rate◆lb/min

Setup 40 3A2797G15.Install GX-16 Orificesa. Close both A side (Red) and B side (Blue) feed inlet valves on the system. See FIG. 2 on page 14.b. Close

Setup3A2797G 4118.IsoGuard Select Fluid System SetupComponent A (Red) Pump: Fill IsoGuard Select reser-voir (LR) with IsoGuard Select fluid (provided

Setup 42 3A2797G20.Install Low Volume Fill Kit (Optional).a. Perform Pressure Relief Procedure, page 44.b. Close the ball valves located on the day ta

Startup3A2797G 43Startup1. Check that all machine connections are setup. See Setup procedure, page 28.2. Check level and condition of ISO lube daily,

Shutdown 44 3A2797GShutdown1. Park pumps.a. From the Home screen, press and select Standby mode. b. Press . Material will not dispense. Pump will p

Flushing3A2797G 45Flushing• Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid.• Use th

Maintenance 46 3A2797GMaintenanceChange Break-in OilAfter initial break-in, see Table 5 for recommended fre-quency of oil changes.Table 3: Frequency o

Maintenance3A2797G 47Install Upgrade TokensNOTE: The Motor Control Module, Fluid Control Mod-ule, and Temperature Control Module connection to the sys

Maintenance 48 3A2797GIsoGuard Select™ SystemCheck the condition of the A (Red) pump IsoGuard Select fluid daily. Change the fluid if it becomes a gel

Troubleshooting3A2797G 49TroubleshootingBefore performing any troubleshooting procedure:1. Perform Pressure Relief Procedure on page 44.2. Turn main p

Models3A2797G 5* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may

Troubleshooting 50 3A2797GMaterial does not maintain temperature while sprayingAmbient temperature is too cold Increase A (Red) and B (Blue) setpoints

Troubleshooting3A2797G 51

Appendix A - ADM Icons Overview 52 3A2797GAppendix A - ADM Icons OverviewSetup Screen IconsIcon DescriptionEnter ScreenExit ScreenOn Learn Mode Calibr

Appendix A - ADM Icons Overview3A2797G 53Run Screen IconsIcon DescriptionSelect mode.Set system in park (icon will be selected when system is parked)O

Appendix B - ADM Setup Screens Overview 54 3A2797GAppendix B - ADM Setup Screens OverviewThe ADM will start in the Run screens at the “Home” screen. F

Appendix B - ADM Setup Screens Overview3A2797G 55Shots ScreenThis screen allows the user to edit shot definitions. The contents of this screen change

Appendix B - ADM Setup Screens Overview 56 3A2797G4. Use the following formula to calculate the ? column value.5. Enter the calculated value in the ?

Appendix B - ADM Setup Screens Overview3A2797G 575. Enter the calculated value in the ? column.Shot Calibration TableThis screen allows the user to se

Appendix B - ADM Setup Screens Overview 58 3A2797GWeight Based Example Using Shot Calibration Table:NOTE: The offset needs to be determined for each r

Appendix B - ADM Setup Screens Overview3A2797G 59Calibration Screen, MainThis screen shows calibration information for the system and provides access

Accessories 6 3A2797GAccessoriesApplicator GX-16 OrificesB (Blue) and A (Red) Feed Tanks AC Power PackRefill KitsGX-16 Shutoff Valve KitGX-16 Proximit

Appendix B - ADM Setup Screens Overview 60 3A2797GSystem Screen 1This screen allows the user to set important system set-tings. Control Mode can be se

Appendix B - ADM Setup Screens Overview3A2797G 61Mix Head Operating Details ScreenThis screen allows the user to define the mix head oper-ating parame

Appendix B - ADM Setup Screens Overview 62 3A2797GKeyboard ScreenThis screen is used to edit the A (Red) and B (Blue) labels on the ADM. Use arrow key

Appendix B - ADM Setup Screens Overview3A2797G 63Supply ScreenThis screen allows the user to specify the operating parameters for off-board, integrate

Appendix B - ADM Setup Screens Overview 64 3A2797GRefill TimeoutThe refill time-out setting may be set by the user as a means to abort the refill in t

Appendix B - ADM Setup Screens Overview3A2797G 652. Press to display the setpoint and alarm values associated with that component. 3. Edit the setpo

Appendix B - ADM Setup Screens Overview 66 3A2797GTime Based Night Mode Conditioning ScreenThis screen allows the user to set a specific time each day

Appendix B - ADM Setup Screens Overview3A2797G 67Advanced Screen 1This screen allows the user to set the language, date format, current date, time, se

Appendix B - ADM Setup Screens Overview 68 3A2797GAdvanced Screen 4• Enable Diagnostic Screen: Check this box to enable the optional ADM screens, enab

Appendix C - ADM Run Screens Overview3A2797G 69Appendix C - ADM Run Screens OverviewRun screens are divided into five major sections: status, errors,

Accessories3A2797G 7Additional Accessories* Flow meter electronics kit, 24J318, is required for flow meter kit installation.Communications Gateway Mod

Appendix C - ADM Run Screens Overview 70 3A2797GHome Screen, Standby ModeIn Standby Mode, the user can enable heating, park the pumps, refill the tank

Appendix C - ADM Run Screens Overview3A2797G 71Home Screen, Sequence ModeThis mode allows the user to select one of five sequences (A-E). The progress

Appendix C - ADM Run Screens Overview 72 3A2797GHome Screen, Night ModeIn Night Mode, the system will cycle on and off periodically or turn on at a pr

Appendix C - ADM Run Screens Overview3A2797G 73Errors ScreensThis screen shows users a list of errors that have occurred in the system. Each error ent

Appendix C - ADM Run Screens Overview 74 3A2797GOptional ScreensThe optional Diagnostic screen can be enabled in the Advanced Screen 4 screen, see pag

Appendix D - ADM Error Codes3A2797G 75Appendix D - ADM Error CodesError Code Error Name Error DescriptionError Type Cause SolutionA4H3Mix Head Motor O

Appendix D - ADM Error Codes 76 3A2797GA4N1Motor Over CurrentA hardware current fault has occurred causing a system shutdownAlarmShort circuit of moto

Appendix D - ADM Error Codes3A2797G 77CAA2Comm. Error Red HoseCommunication error AlarmModule missing power Check power supply connectionCAA3Comm. Err

Appendix D - ADM Error Codes 78 3A2797GD5A1Invalid Learn Mode DataThis calibration lets the MCM know where the ends of the pump are. If the data gathe

Appendix D - ADM Error Codes3A2797G 79L8A1Red Tank Sensor FailureA level sensor had ceased workingDeviation Bad level sensor Replace level sensorDR6BB

Warnings 8 3A2797GWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point

Appendix D - ADM Error Codes 80 3A2797GN4A1Pump Failed to MoveThe MCM attempted to move the pump but no movement was detectedDeviationMotor failureVis

Appendix D - ADM Error Codes3A2797G 81R1D0Low Ratio AlarmRatio monitor has detected an out of ratio conditionAlarmMaterial A to Material B is out of r

Appendix D - ADM Error Codes 82 3A2797GT2AARed Hose Low Fluid Temp.Fluid temperature for a monitor zone is below the defined low alarm limitDeviationT

Appendix D - ADM Error Codes3A2797G 83T4A2Red Hose High Fluid Temp.Fluid temperature is above the defined high alarm limitAlarmDefective Temperature C

Appendix D - ADM Error Codes 84 3A2797GT6C6Red Blanket RTD FaultRTD 2 is giving no or invalid dataAlarmLoose or bad connection Check RTD wiringT6C5Blu

Appendix D - ADM Error Codes3A2797G 85V1H1Motor Control UndervoltageThe voltage to the MCM has dropped to a level where performance is greatly affecte

Appendix D - ADM Error Codes 86 3A2797GWM06Red Tank Con. FaultHigh current to relay 1 Alarm Broken contactor Replace contactorWM05Blue Tank Con. Fault

Appendix E - System Events3A2797G 87Appendix E - System EventsEvent Code and String TriggersEAA0-R: Prepoly Refresh StartedWhile in night mode, the pr

Appendix E - System Events 88 3A2797G

Appendix F - USB Operation3A2797G 89Appendix F - USB OperationOverviewThere are 3 main uses for the USB on a GMS system • Ability to download a log of

Warnings3A2797G 9FIRE AND EXPLOSION HAZARDFlammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire a

Appendix F - USB Operation 90 3A2797GLog Files, Folder StructureEach time a stick-drive is inserted into the ADM USB port, a new folder named DATAxxxx

Appendix F - USB Operation3A2797G 91Example 2-JOB FileThe 2-JOB file is the Shot Data Log file. Example 3-SYSTEM FileThe 3-SYSTEM file is the Software

Appendix F - USB Operation 92 3A2797GTransfer System SettingsUse the following process to transfer system settings from one machine to another.1. Inse

Appendix F - USB Operation3A2797G 93Update Custom LanguageUse the following process to customize the text on the ADM. The language file DISPTEXT.TXT c

Appendix F - USB Operation 94 3A2797GExample SETTINGS.TXT File Example DISPTEXT.TXT FileNOTICEThe user should never attempt to modify the SET-TINGS.TX

Technical Data3A2797G 95Technical DataHFR for NVH FoamUS MetricMaximum fluid working pressure 2000 psi 14 MPa, 138 barMaximum Fluid Temperature 190°F

Technical Data 96 3A2797GMotor Control Module Technical DataMotor Control ModuleUS MetricInput Specifications:Input Line Voltage 0-264 Vac, line-to-li

Technical Data3A2797G 97Dimensionsti19519aACBDimensionsA (Height) 76 in. (193 cm)B (Width) 72 in. (183 cm)C (Length) 58 in. (147 cm)

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves th