Graco 3A2797G- User Manual

Models 3A2797G 5 * 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 30...

Accessories 6 3A2797G Accessories Applicator GX-16 Orifices B (Blue) and A (Red) Feed Tanks AC Power Pack Refill Kits GX-16 Shutoff Valve Kit GX-16 Proximity Kit Part Description 24J187 GX-16, 24:1, Straight, Machine Mount 24K233 GX-16, 24:1, Left, Machine Mount 24K234 GX-16, No Orifice, Left, Machi...

Accessories 3A2797G 7 Additional Accessories * Flow meter electronics kit, 24J318, is required for flow meter kit installation. Communications Gateway Module (CGM) Bag Filter Kits GX-16 Fitting Kits The following kit is for Models 24N575 and 24N576 only. The following kits are for all other Models. ...

Warnings 8 3A2797G 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-sp...

Important Two-Component Material Information 3A2797G 11 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 ...

A (Red) and B (Blue) Components 12 3A2797G 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...

Typical Installation 3A2797G 13 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 F IG . 1: Typical Installation * Shown exposed for clarity. Wrap ...

Component Identification 14 3A2797G Component Identification Key for F IG . 2 and F IG . 3. AA Advanced Display Module (see page 20)BA Component A (Red) Pressure Relief OutletBB Component B (Blue) Pressure Relief OutletFA Component A (Red) Fluid Manifold Inlet (on left side of manifold block) FB Com...

Component Identification 3A2797G 15 F IG . 3: Component Identification, Continued ti9880a1 GA GB SB FB BB HB HA BA FA SA Fluid Manifold (FM) Detail LS TB TA MP Rear View Primary Heater (PHA) Detail, A (Red) side shown ti19509a ti19510a PO PR PS PI Primary Heater (PHB) Detail, B (Blue) side shown ti1...

Component Identification 16 3A2797G Main Power Switch Located on top of the power distribution box, see page 14 . 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 distri-buti...

Component Identification 3A2797G 17 HFR Hydraulic Power Pack Key: DA 9 Gallon Hydraulic Oil Reservoir (see Technical Data on page 95 for specifications) DB Electric MotorDD Hydraulic HousingDE Directional ValveDF Motor Control Module (see page 18) DG FanDH Oil FilterDJ Shroud (not shown, removed for...

Component Identification 18 3A2797G Motor Control Module (MCM) For MCM location, see reference MA in F IG . 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 sel...

Component Identification 3A2797G 19 Diagnostic Information 7 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 (Positi...

Component Identification 20 3A2797G Advanced Display Module (ADM) User Interface Buttons System Status Indicator (CB) Conditions Green Solid - Run Mode, System On Green Flashing - Setup Mode, System On Yellow Solid - Run Mode, System Off F IG . 6: ADM Component Identification - Front TI12362a1 CA CB...

Component Identification 3A2797G 21 Key: CJ Flat Panel MountCK Model NumberCL USB Module InterfaceCM CAN Cable Connections CN Module Status LEDsCP Accessory Cable ConnectionsCR Token Access CoverCS Battery Access Cover ADM Module Status LEDs (CN) Conditions USB Module Status LEDs (CL) Conditions F I...

Component Identification 22 3A2797G 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. F IG . 8: Main Display Components Current date and time C...

Component Identification 3A2797G 23 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 F IG . 9: Fluid Control Module (FCM) ti12337a1 ti12336a1 A E B C D F Module Status LED (Ref E) Sign...

Component Identification 24 3A2797G Temperature Control Module 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 1 Over...

Component Identification 3A2797G 25 Temperature Control Module Diagnostic Information Module Status LEDs Heat Control Zone Selection The HFR unit supports four independent temperature control zones and two independent temperature moni-toring zones. The high power temperature control mod-ules are loc...

Component Identification 26 3A2797G Adjust Rotary Switch The rotary switch setting indicates which zone the tem-perature 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)...

Setup 28 3A2797G Setup Perform this setup procedure to secure all necessary machine connections for machine operation. 1. 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. 2. Electrical requirements. See Models on...

Setup 3A2797G 29 † Residual Current Device (RCD) must be rated at 300 mA if installed. Electrical Cord Wires by Model230V, 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 g...

Setup 3A2797G 33 10. Connect Material Hoses NOTE: Refer to F IG . 15 on page 32 for visual clarity of the following steps. a. Ensure main power is OFF . b. Ensure A (Red) and B (Blue) inlet valves on the HFR and the material supply ball valves on the tanks are closed. c. Remove reducer fitting from ...

Setup 34 3A2797G h. Connect cables (Y). Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape. See Heated Hose manual for heated hose connection details and illustrations for the various types of heated hoses. i. Connect the other end of the supply hos...

Setup 38 3A2797G a. Navigate to System Screen 3. b. Press to enter the screen. c. Navigate to the pressure imbalance field. d. Type the desired pressure imbalance setting then press . e. Press and input the specific gravity (SG) of each material into the ADM. 14. Flush the System NOTE: System compon...

Setup 40 3A2797G 15. Install GX-16 Orifices a. Close both A side (Red) and B side (Blue) feed inlet valves on the system. See F IG . 2 on page 14. b. Close A side (Red) material return ball valves on the material tank stand. c. Follow Pressure Relief Procedure on page 44. d. Remove plugs from GX-16....

Setup 3A2797G 41 18. IsoGuard Select Fluid System Setup Component A (Red) Pump: Fill IsoGuard Select reser- voir (LR) with IsoGuard Select fluid (provided by Graco). a. Lift the reservoir (LR) out of the bracket (RB) and remove the container from the cap. b. Fill with fresh fluid. Thread the reservo...

Startup 3A2797G 43 Startup 1. Check that all machine connections are setup. See Setup procedure, page 28. 2. Check level and condition of ISO lube daily, see IsoGuard Select ™ System on page 48. 3. Verify both PRESSURE RELIEF/DISPENSE valves (SA, SB) are set to DISPENSE . 4. If dispense valve has a ...

Flushing 3A2797G 45 Flushing • Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid. • Use the lowest possible pressure when flushing. • All fluid components are compatible with common solvents. Use only moisture-free solvents. See Run Scr...

Maintenance 46 3A2797G Maintenance Change Break-in Oil After initial break-in, see Table 5 for recommended fre-quency of oil changes. Table 3: Frequency of Oil Changes Grease Circulation Valves With Fusion Grease (117773) Check Hydraulic Fluid Level Check hydraulic fluid level on dipstick. Fluid lev...

Maintenance 3A2797G 47 Install Upgrade Tokens NOTE: The Motor Control Module, Fluid Control Mod- ule, and Temperature Control Module connection to the system is temporarily disabled during the installation of upgrade tokens. To install software upgrades: 1. Use correct software token stated in the t...

Maintenance 48 3A2797G IsoGuard Select ™ System Check the condition of the A (Red) pump IsoGuard Select fluid daily. Change the fluid if it becomes a gel, its color darkens, or it becomes diluted with isocyanate. Gel formation is due to moisture absorption by the pump IsoGuard Select fluid. The inte...

Troubleshooting 3A2797G 49 Troubleshooting Before performing any troubleshooting procedure: 1. Perform Pressure Relief Procedure on page 44. 2. Turn main power OFF. 3. Allow equipment to cool. Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, dete...

Appendix A - ADM Icons Overview 52 3A2797G Appendix A - ADM Icons Overview Setup Screen Icons Icon Description Enter Screen Exit Screen On Learn Mode Calibration screen: Move pump All other screens: Begin Dispense Stop Dispense Abort Changing the Label Select left direction Select right direction Ba...

Appendix A - ADM Icons Overview 3A2797G 53 Run Screen Icons Icon Description Select mode. Set system in park (icon will be selected when system is parked) Open, Close Valve A (Red) and B (Blue) refill button (Press to start/abort refill) With a mix head installed: Turns on the mix head hydraulics an...

Appendix B - ADM Setup Screens Overview 54 3A2797G Appendix B - ADM Setup Screens Overview The ADM will start in the Run screens at the “Home” screen. From the Run screens, press to access the Setup screens. If the Setup screens password is turned on, use the ADM keypad to enter the password then pr...

Appendix B - ADM Setup Screens Overview 3A2797G 55 Shots Screen This screen allows the user to edit shot definitions. The contents of this screen change based on the flow units selection. Shots are defined by flow rate and weight or time (duration). See Home Screen, Shot Mode on page 70 for informat...

Appendix B - ADM Setup Screens Overview 3A2797G 57 5. Enter the calculated value in the ? column. Shot Calibration Table This screen allows the user to set the offset, ? (g), for a calculated range of shot sizes based on pump sizes and material specific gravity. NOTE: This table is only available wh...

Appendix B - ADM Setup Screens Overview 58 3A2797G Weight Based Example Using Shot Calibration Table: NOTE: The offset needs to be determined for each range and may need to be modified if the flow rate changes. Visit www.graco.com and search for PKE “Shot Calibration Table Worksheet” to assist in th...

Appendix B - ADM Setup Screens Overview 60 3A2797G System Screen 1 This screen allows the user to set important system set-tings. Control Mode can be set to Flow. With Control Mode set to Flow, the machine will dispense at a contin-uous flow rate regardless of pressure fluctuations unless pressure a...

Appendix B - ADM Setup Screens Overview 3A2797G 61 Mix Head Operating Details Screen This screen allows the user to define the mix head oper-ating parameters. • Low Pressure Circulation: The percentage of set- point, 10%-90%, at which the system will run during low pressure circulation. • Pre-Dispen...

Appendix B - ADM Setup Screens Overview 62 3A2797G Keyboard Screen This screen is used to edit the A (Red) and B (Blue) labels on the ADM. Use arrow keys to select the desired letter and press to accept the letter. 1. Use arrow keys to select the desired letter and press to accept the letter. To era...

Appendix B - ADM Setup Screens Overview 3A2797G 63 Supply Screen This screen allows the user to specify the operating parameters for off-board, integrated tanks and indicate which positions have level sensors installed. See the Tank Feed Systems manual for information about install-ing level sensors...

Appendix B - ADM Setup Screens Overview 64 3A2797G Refill Timeout The refill time-out setting may be set by the user as a means to abort the refill in the case of a high level sen-sor failure. When an automatic refill begins, the time-out counter will begin to count down. If the timer expires before...

Appendix B - ADM Setup Screens Overview 3A2797G 65 2. Press to display the setpoint and alarm values associated with that component. 3. Edit the setpoint and alarm values and then press to return to Conditioning Screen 2 . NOTE: The high alarm and low alarm values must be at least +/-9 ° F (5 ° C) t...

Appendix B - ADM Setup Screens Overview 66 3A2797G Time Based Night Mode Conditioning Screen This screen allows the user to set a specific time each day to turn the machine on or off. The times can be set on or off by either each day separately, Monday through Friday where each day has the same on o...

Appendix C - ADM Run Screens Overview 3A2797G 69 Appendix C - ADM Run Screens Overview Run screens are divided into five major sections: status, errors, events, and maintenance. The following diagram demonstrates the flow of the Run screens beginning with the Home screen. Home Screen The Home screen...

Appendix C - ADM Run Screens Overview 3A2797G 73 Errors Screens This screen shows users a list of errors that have occurred in the system. Each error entry includes a description and error code along with a date and time stamp. There are 5 pages, each holding 10 errors. The 50 most recent errors are...

Appendix C - ADM Run Screens Overview 74 3A2797G Optional Screens The optional Diagnostic screen can be enabled in the Advanced Screen 4 screen, see page 68. Diagnostic The Diagnostic screen shows status information for vari-ous components in the Motor Control Module.

Appendix D - ADM Error Codes 3A2797G 75 Appendix D - ADM Error Codes Error Code Error Name Error Description Error Type Cause Solution A4H3 Mix Head Motor Overload Refer to AC Power Pack manual DEH3 Soft Stop Asserted MBH3 Low Mix Head Oil Level P1H3 Low Accumulator Pressure P4H3 High Accumulator Pr...

Appendix F - USB Operation 3A2797G 89 Appendix F - USB Operation Overview There are 3 main uses for the USB on a GMS system • Ability to download a log of up to the past 50,000 errors, events, or jobs that can contain over 150,000 snapshots of critical dispense information. • Ability to download, mo...

Appendix F - USB Operation 90 3A2797G Log Files, Folder Structure Each time a stick-drive is inserted into the ADM USB port, a new folder named DATAxxxx is created. The number at the end of the folder name is incremented each time a stick-drive is inserted and data is downloaded or uploaded. In each...

Appendix F - USB Operation 3A2797G 91 Example 2-JOB File The 2-JOB file is the Shot Data Log file. Example 3-SYSTEM File The 3-SYSTEM file is the Software Version log file.

Appendix F - USB Operation 92 3A2797G Transfer System Settings Use the following process to transfer system settings from one machine to another. 1. Insert a high-quality USB stick-drive into the USB port on the system with the settings to be trans-ferred. Once the download is complete the SET-TINGS...

Appendix F - USB Operation 3A2797G 93 Update Custom Language Use the following process to customize the text on the ADM. The language file DISPTEXT.TXT can be modi-fied in Excel but must be saved as a Unicode Text file with the extension .TXT in order for it to properly import. 1. Insert a high-qual...

Appendix F - USB Operation 94 3A2797G Example SETTINGS.TXT File Example DISPTEXT.TXT File NOTICE The user should never attempt to modify the SET-TINGS.TXT file in any way. Graco is not responsible for damages caused by an improperly modified setup file.

Technical Data 3A2797G 95 Technical Data HFR for NVH Foam US Metric Maximum fluid working pressure 2000 psi 14 MPa, 138 bar Maximum Fluid Temperature 190°F 88°C Fluid Inlet Feed Pressure Range 50 psi to 100 psi 345 kPa, 3.4 bar to 0.7 MPa, 7 bar Fluid Inlet: Component A (Red) 1/2 npt(f) Fluid Inlet:...

Technical Data 96 3A2797G Motor Control Module Technical Data Motor Control Module US Metric Input Specifications: Input Line Voltage 0-264 Vac, line-to-line Input Line Phasing Single or Three Phase Input Line Frequency 50/60 Hz Input Current per Phase 25A (three-phase), 50A (single-phase) Maximum B...

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. For patent information, see www.graco.com/patents. Original instructions. This manual contains Eng...