Setup. Graco 313997ZAC - HFR

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Setup. Graco 313997ZAC - HFR | Manualzz

Setup

Setup

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

1.

Locate HFR.

a.

Locate HFR on a level surface. See

Dimensions on page 119 for space requirements.

b.

Anchor the HFR to the floor (suggested anchors: McMaster Carr anchor, 92403A400).

See

Dimensions , page 119, for bolt locations.

If machine mobility is required, purchase Mobile

Pallet Base with Casters Kit, 24P090.

NOTICE

To avoid tipping the machine and personal injury, do not attach wheels directly to the standard HFR mounting brackets.

c.

Do not expose HFR to rain.

NOTICE

Bolt HFR to original shipping pallet before lifting.

2.

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 3 in this setup procedure.

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

NOTICE

Never connect to 480V, 3 phase power. Severe equipment damage will occur.

3.

Connect electrical cord.

NOTE:

See Power Line Voltage Surges information on page 39.

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

Table 1: Power Cord Requirements

Model

Non-Heated HFR,

230V, 1 phase

Non-Heated HFR,

230V, 3 phase

Non-Heated HFR,

400V, 3 phase

Heated HFR,

230V, 1 phase

Heated HFR,

230V, 3 phase

Heated HFR,

400V, 3 phase

Cord Requirements

AWG (mm

2

)

6 (13.3), 2 wire + ground

8 (8.4), 3 wire + ground

6 (13.3), 4 wire + ground †

1 (42.4), 2 wire + ground

4 (21.2), 3 wire + ground

4 (21.2), 4 wire + ground †

† Residual Current Device (RCD) must be rated at

300 mA if installed.

Electrical Cord Wires by Model

230V, 1 phase: L1, L2, GND

230V, 3 phase: L1, L2, L3, GND

400V, 3 phase: L1, L2, L3, N, GND

Typical Voltage Readings

230V, 1 phase:

L1-L2: 230V

L1 or L2-G: 115V

230V, 3 phase (delta high leg):

L1-L2, L2-L3, L3-L1: 230V

L1-G, L3-G: 115V

L2-G: 208V

400V, 3 phase (Y / wye):

L1-L2, L2-L3, L3-L1: 400V

L1-N, L2-N, L3-N: 230V

L1-G, L2-G, L3-G: 230V

38 313997ZAC

Setup

Use 5/32 or 4 mm hex allen wrench to connect the two or three power leads to L1, L2, and L3, as applicable.

Connect green to ground (GND).

F IG

N L3 L2 L1

. 12: 400V, 3 phase shown

GND r_24C686_313998_1a

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.

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).

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

Maximum Permissible Transient Voltage Surges

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

1400

1200

1000

800

1200Vac, 1697Vdc

<--1 MW Max Surge Power

600

400

200

480Vac, 679Vdc

<--150 KW Max Surge Power

336Vac, 475Vdc

<--50 KW Max Surge Power

288Vac, 407Vdc

0

0.000001 0.00001 0.0001 0.001 0.01

Time (seconds)

0.1

<--No Power Limit

264Vac, 373Vdc

1 10

313997ZAC 39

Setup

4.

Connect feed lines a.

Install feed pumps (K) in component A (Red)

and B (Blue) supply drums. See F IG

. 1 and F IG .

2, pages 23 and 25.

NOTE: 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 is 250 psi (1.75 MPa,

17.5 bar). Maintain A (Red) and B (Blue) feed pressures within 10% of each other.

FP

5.

Connect pressure relief lines

Do not install shutoffs downstream of the PRESSURE

RELIEF/DISPENSE valve outlets (BA, BB). The valves function as overpressure relief valves when set to DISPENSE . Lines must be open so valves can automatically relieve pressure when machine is operating.

If circulating fluid back to the supply drums, use high pressure hose rated to withstand the maximum working pressure of this equipment.

ti10006a1 a.

Recommended : Connect high pressure hose

(R) to relief fittings (BA, BB) of both PRES-

SURE RELIEF/DISPENSE valves. Route hose back to component A (Red) and B (Blue) drums.

See F IG . 1, page 23.

b.

Seal component A (Red) drum and use desiccant dryer (M) in vent.

c.

Install agitator (L) in component B (Blue) drum, if necessary.

d.

Ensure A (Red) and B (Blue) inlet valves (FV) are closed.

SA

SB

BA

R ti9880a1

R

BB

FV ti9883a1

NOTE:

Supply hoses from feed pumps should be 3/4 in.

(19 mm) ID minimum.

e.

Connect and tighten component B (Blue) supply hose to the 3/4 npt(f) swivel on the component

B (Blue) inlet valve.

f.

Connect and tighten component A (Red) supply hose to the 1/2 npt(f) swivel on the component

A (Red) inlet valve.

b.

Alternately: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See

F

IG

. 1, page 23.

6.

For Heated HFR models only, install Fluid Temperature Sensor (FTS) a.

Install FTS between main hose and whip hose.

See Heated Hose manual for instructions.

40 313997ZAC

Setup

7.

Connect heated hose monitor zones

NOTE: For Heated HFR models only, see Heated Hose manual for detailed instructions on connecting heated hoses.

NOTICE

For Heated HFR models only, the FTS (C) and whip hose (D) must be used with heated hose. See step 6 on page 40 for FTS installation. Hose length, including whip hose, must be 10 ft (3 m) minimum.

d.

For Heated HFR Models only, connect cables (Y). Connect electrical connectors (V).

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.

Y a.

Turn main power OFF .

V b.

For Heated HFR Models only, assemble heated hose sections, FTS, and whip hose. See

Heated Hose manual 3A0237 for heated hose connection details and illustrations for the various types of heated hoses.

For Non-Heated HFR Models only, assemble fluid supply hose sections and whip hose. c.

Connect A (Red) and B (Blue) hoses to A (Red) and B (Blue) outlets on HFR fluid manifold (FM).

Hoses are color coded: red for component A, blue for component B. Fittings are sized to prevent connection errors.

NOTE: Gun fluid manifold hose adapters allow use of

1/4 in. and 3/8 in. ID fluid hoses. To use 1/2 in. (13 mm)

ID fluid hoses, remove adapters from gun fluid manifold and install as needed to connect hose.

ti2411a1 ti9881a1

8.

For systems with a gun fluid manifold, close gun fluid manifold valves A (Red) and B (blue).

313997ZAC 41

Setup

9.

For models with an MD2 valve, connect whip hose to MD2 valve component A (Red) and component B (Blue) fluid inlets.

For models with a dispense gun, connect whip hose to gun fluid manifold. Do not connect man-

ifold to gun. See F IG . 13.

F IG . 13 ti2417a1 pense gun firmly to the side of a grounded metal pail, then trigger gun.

12.

Check hydraulic fluid level

Hydraulic reservoir is filled at the factory. Check fluid level before operating the first time, and weekly thereafter. See

Technical Data on page 117 for specifications.

13.

IsoGuard Select Fluid system setup

Component A (Red) Pump: Fill IsoGuard Select reservoir (LR) with IsoGuard Select fluid (24F516).

a.

Lift the reservoir (LR) out of the bracket (RB) and remove the container from the cap.

10.

Pressure check hose

See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage.

11.

Ground system

LR

RB

This equipment must be grounded.

a.

HFR:

grounded through power cord. See step 3 on page 38.

b.

EP Gun or Dispense Valve : If supplied, connect whip hose ground wire to FTS, see step 6 on page 40. Do not disconnect wire or dispense without whip hose. c.

Fluid supply containers : follow your local code.

d.

Object being dispensed : follow your local code.

e.

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.

f.

To maintain grounding continuity when flushing or relieving pressure, hold a metal part of dis-

24C352_312998_8g b.

Fill with fresh fluid. Thread the reservoir onto the cap assembly and place it in the bracket (RB).

c.

Push the supply tube approximately 1/3 of the way into the reservoir. The supply tube is the tube with the check valve with an arrow pointing in the direction of flow towards the IsoGuard

Select fluid cylinder.

d.

Push the return tube into the reservoir until it reaches the bottom. The return tube is the tube with the check valve with an arrow pointing in the direction of flow away from the IsoGuard

Select fluid cylinder.

NOTE: The return tube must reach the bottom of the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube and returned to the pump.

42 313997ZAC

14. Prime IsoGuard Select fluid cylinder

The IsoGuard Select fluid cylinder must be primed when replacing IsoGuard Select fluid. See

IsoGuard Select

®

System on page 57 for instructions.

15. Install dispense valve a.

Navigate to System Screen 2 and select the appropriate dispense valve from the “Dispense

Valve” dropdown menu. See System Screen 2 on page 73.

b.

Set pressure relief valves (SA, SB) to RELIEF.

c.

If dispense valve has a trigger safety lock, engage the trigger safety lock.

LOCKED ti10442a1 d.

Connect gun to machine. Verify gun is ready for operation. See appropriate gun manual listed in

Related Manuals on page 3 for detailed

instructions. e.

If gun has pneumatics, verify air line is connected then open bleed-type master air line valve.

f.

Set PRESSURE RELIEF/DISPENSE valves

(SA, SB) to DISPENSE .

SA

SB

Setup g.

Press to enable system. LED should be solid green.

h.

Check that heat zones are on and temperatures are on target, see Status Screen on page 86.

i.

Check fluid pressure display and adjust as necessary.

j.

For MD2 and Auto-Fusion dispense valves, perform Connect Solenoid Kit procedure. See

Heated Hoses and Applicator Kits manual for procedure.

k.

Check fluid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning PRESSURE RELIEF/DIS-

PENSE valve for that component toward PRES-

SURE RELIEF/CIRCULATION gauges show balanced pressures.

, until

GA

GB

In this example, B (Blue) side pressure is higher, so use the B (Blue) side valve to balance pressures.

ti9877a1 l.

For MD2 and Auto-Fusion dispense valves, perform Connect Solenoid Kit procedure. See

Heated Hoses and Applicator Kits manual for procedure.

m.

If dispense valve has a trigger safety lock, disengage the trigger safety lock. ti9877a1 UNLOCKED ti10441a1

313997ZAC 43

Setup n.

For EP Gun and GX-16, perform a test pour into a waste container. Adjust pressure and temperature to get desired results. Equipment is ready to dispense.

o.

For all dispense valves other than the EP Gun, perform mix ratio test using two tared cups.

Weigh the cups and divide the weights to verify the mix ratio by weight. See Ratio Checking section in the dispense valve manual for more information.

p.

For Fusion dispense valves, perform DC Power

Pack Hydraulic Pressure Setup. See HFR

Repair manual for procedure.

q.

Equipment is ready to dispense.

Vacuum De-gas

NOTE: This procedure is for assemblies with vacuum tree manifold and no agitator or auto-refill.

1.

Disable machine movement by pressing the

Machine Disable Mode key ( ).

2.

Close the shut-off ball valves at the base of the tanks.

3.

If the tank lid has a fill port, turn off any systems that might refill the tank during the vacuum de-gas procedure.

4.

Close the fill port ball valve.

5.

If the tank lid requires a desiccant dryer or nitrogen pump installed, install one into the top ball valve of the vacuum tree manifold.

6.

Close the top ball valve of the vacuum tree manifold.

7.

Attach vacuum pump to the bottom ball valve of the vacuum tree manifold then open the ball valve.

8.

Turn on the vacuum pump.

9.

Continue to de-gas for sufficient time to de-gas the material.

10. Close bottom ball valve of the vacuum tree manifold.

11. Turn off the vacuum pump.

12. Open the top ball valve of the vacuum tree manifold.

NOTICE

Operating the tank after the vacuum de-gas procedure without the top ball valve open will result in pump cavitation, off-ratio conditions, and possible collapse of the tank.

13. Open the shutoff valves at the base of the tanks.

44 313997ZAC

Setup

Vacuum De-gas and Vacuum

Manual Refill

NOTE: This procedure is for assemblies with a vacuum tree manifold, agitator, and auto-refill.

12. Close bottom ball valve of the vacuum tree manifold).

13. Turn off the vacuum pump.

14. Open the top ball valve of the vacuum tree manifold.

Operating the tank after the vacuum de-gas procedure without the top ball valve open will result in pump cavitation, off-ratio conditions, and possible collapse of the tank.

NOTICE

1.

Press the Select Operating Mode button ( ) repeatedly to select Shot, Sequence, or Operator

(Manual) mode.

2.

Close the shut-off ball valves at the base of the tanks.

3.

If the tank lid requires a desiccant dryer or nitrogen pump installed, install one into the top ball valve of the vacuum tree manifold).

4.

Close the top ball valve of the vacuum tree manifold.

5.

Attach vacuum pump to the bottom ball valve of the vacuum tree manifold then open the ball valve.

6.

Turn on the vacuum pump.

7.

Turn on agitator.

8.

Select Manual Refill mode. See operation manual referenced at the beginning of this manual for more information.

9.

Press the appropriate Auto-Refill Tank Select button or buttons ( and/or ) to select the tanks to refill.

15. Open the shutoff valves at the base of the tanks.

10. If necessary, press the Abort/Cancel button ( to cancel auto-refill.

)

If an auto-refill is aborted or times out, the software will not initiate a new auto-refill until a manually initiated auto-refill has completed. To complete a manually initiated auto-refill after an aborted or timed out auto-refill, restart at step 2.

NOTICE

If an auto-refill is stopped and not restarted as described in the previous note, the pumps may be run dry and chemical crossover at the valve may occur.

11. Continue to de-gas for sufficient time to de-gas the material.

313997ZAC 45

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