Graco 24N572 Setup Download

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3A2797ZAA

Setup - Operation

HFR

™

for NVH

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.

See page 4 for model information and maximum

working pressure.

Patents Pending

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

ti19507a

Summary of Contents for 24N572

Page 1: ...dispensing NVH foam For professional use only Not approved for use in explosive atmospheres or hazardous locations See page 4 for model information and maximum working pressure Patents Pending Import...

Page 2: ...ure Relief Procedure 43 Flushing 44 Maintenance 45 Install Upgrade Tokens 46 Programming Tokens Updating System Software 46 Troubleshooting 49 Light Tower Optional 49 Appendix A ADM Icons Overview 51...

Page 3: ...Feed Systems Instructions Parts 3A0237 Heated Hoses and Applicator Kits Instructions Parts 308495 Viscon Heater Kit Manual Dispense Valve Manuals 313536 GX 16 Operation Accessory Manuals 3A1149 HFR D...

Page 4: ...N572 68 400V 3 24N573 90 230V 3 6 000 17 7 7 0 032 0 121 3 7 1 24N574 68 400V 3 24N575 90 230V 3 4 000 18 8 2 0 033 0 125 1 9 1 24N576 68 400V 3 System Material Ratio A B A Red Pump Size B Blue Pump S...

Page 5: ...chine was pur chased without hoses and aftermarket hoses rated at or above 3000 psi are to be installed see instruction man ual 313998 for the procedure to setup the machine for higher rated hoses The...

Page 6: ...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 Part Description 24N594 20 gal...

Page 7: ...k 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 PrePo...

Page 8: ...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 equ...

Page 9: ...fy 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 seri...

Page 10: ...or replace worn or damaged parts immediately with genuine man ufacturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for...

Page 11: ...on taminated from the other side Always lubricate threaded parts with ISO pump oil or grease when reassembling Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperature...

Page 12: ...B Blue side See the follow ing 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 ma...

Page 13: ...tand 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 FIG 1 Typical Installation Shown exposed...

Page 14: ...onnection 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...

Page 15: ...tification 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 D...

Page 16: ...he 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...

Page 17: ...ical Data on page 117 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...

Page 18: ...up The Motor Control Module uses an 8 position selector switch to set the system maximum working pressure NOTICE If the Motor Control Module is replaced the selec tor switch must be set prior to init...

Page 19: ...itter 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...

Page 20: ...rature control and dispense operation are disabled CB System Status Indicator Light Displays system status See System Status Indicator CB Conditions on page 20 for details CC Stop Stop all system proc...

Page 21: ...ponent Identification Rear CR CK CJ CL CP CN CM CS r_24E451_3B9900_1a Module Status LED Signal Description Green on System is powered up Yellow on Communication in progress Red solid ADM hardware fail...

Page 22: ...ormational components of each screen For details regarding the user interface display see Shutdown page 43 FIG 8 Main Display Components Current date and time Current chapter Enter Exit Previous chapt...

Page 23: ...Connectors Diagnostic Information FIG 9 Fluid Control Module FCM ti12337a1 ti12336a1 A E B C D F Module Status LED Ref E Signal Diagnosis Green on System is powered up Yellow Internal communication i...

Page 24: ...N Connections 7 Rotary Selector Switch Token Access 1 Overtemperature Switch Connection 2 RTD Temperature Sensor Connection 3 Output Power Connection 4 DC Output Connection 5 Input Power Connection 6...

Page 25: ...is powered up Yellow on Internal communication in prog ress Red solid Temperature control module fail ure See Troubleshooting table Red flashing fast Uploading software Red flashing slow Token error...

Page 26: ...ion according to the settings listed in the following tables High Power Module Rotary Switch Settings Low Power Module Rotary Switch Settings FIG 12 Rotary Switch High Power Module Rotary Switch Locat...

Page 27: ...or cardboard which interrupts grounding continuity e To maintain grounding continuity when flushing or relieving pressure hold a metal part of dis pense gun firmly to the side of a grounded metal pail...

Page 28: ...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 approxi...

Page 29: ...d PG MPO 7 Connect Hydraulic Lines to the system a Connect the hydraulic hose to the hydraulic hose fittings A2 and B2 on the AC power pack b Hand tighten each fitting c Tighten each fitting 1 4 turn...

Page 30: ...c Install JIC 6 fitting assembly into the B Return port d Install JIC 8 fitting assembly into both A Sup ply and A Return ports 10 Install Flow Meter Kit Optional Refer to HFR Flow Meter Kits Instruc...

Page 31: ...Setup 3A2797ZAA 31...

Page 32: ...Setup 32 3A2797ZAA FIG 15 Material Hose Connections ti19507a Step 10d Step 7a Step 7b Step 7c Step 7d Step 10f...

Page 33: ...the remaining material lines Refer to FIG 15 and FIG 16 e Install ball valves optional between main hose and whip hose Connect the main hose bundle to the whip hose bundle NOTE The ball valve kit is...

Page 34: ...utlet identification NOTE The other end of the return hose will be con nected in step n on page 39 13 Connect GX 16 Hydraulic Lines a Navigate to the System Screen 2 and set the mode to run as straigh...

Page 35: ...C male male adapter connecting the hydraulic hoses i Fill both open and close gun chambers with hydraulic fluid j Attach hydraulic hoses to the gun Tighten each fitting 1 4 turn past hand tight NOTE T...

Page 36: ...the button a Define shots See Shots Screen page 54 for more detail b Define sequences See Sequences Screen page 57 for more detail c Calibrate HFR page 37 See Calibration Screen Main page 58 for more...

Page 37: ...ason repeat the procedure Set temperatures For detailed temperature adjustments including alarm levels or upon initial machine configuration see Condi tioning Screen 2 on page 63 for details For minor...

Page 38: ...ed Both supply and pressure relief must be flushed a Close both A side Red and B side Blue feed inlet valves on the system See FIG 2 on page 14 b Close A side Red and B side Blue material return ball...

Page 39: ...t this time Continue to dispense fluid until no material contamination is noticed NOTE If necessary navigate to Operator Mode to adjust the flow rate l Stop dispensing by pushing from the Standby Scre...

Page 40: ...page 43 d Remove plugs from GX 16 e Install orifices provided 18 Pressure check hose See hose manual Pressure check for leaks If no leaks wrap hose and electrical connections to protect from damage 1...

Page 41: ...e fitting installed in step e above 21 Install Low Volume Fill Kit Optional a Perform Pressure Relief Procedure page 43 b Close the ball valves located on the day tanks c Remove the swivel fitting fro...

Page 42: ...rial supply applica tor return and pressure relief Check for leaks 5 Press to enable system LED should be solid green 6 Navigate to Home Standby screen and press to initiate auto startup 7 Check that...

Page 43: ...y valves 5 Perform Pressure Relief Procedure on page 43 6 Shut down feed pumps as required See feed pump manual Pressure Relief Procedure 1 Press to disable the ADM 2 Shut off feed pumps and agitator...

Page 44: ...un fluid manifold with manifold removed from gun To prevent moisture from reacting with isocyanate always leave the system dry or filled with a mois ture free plasticizer or oil Do not use water See I...

Page 45: ...yanate crys tallization Weekly Verify vent holes on bottom of electrical cabinet are clear and unobstructed Weekly Inspect HFR Powerpack air filter part 24H018 clean or replace as necessary Weekly Use...

Page 46: ...Software On system software version 1 12 001 February 2020 and later a single 16H821 programming token can be inserted into the ADM to re program most of the soft ware modules after power is cycled To...

Page 47: ...he screen below 4 Select and check the Use ADM to Program Token checkbox option select out of the current screen and navigate one screen left Go to the Advanced setup screen pages 5 Navigate to the Ad...

Page 48: ...to the token 10 To start the programming process press the soft key 11 The transfer from the USB stick to the token will take several minutes After completion the screen should show a 100 completion a...

Page 49: ...eplace Advanced Display Module No or incorrect amount of material dispensed from either side Ball Valve closed if Installed Open tank ball valve Tank Empty Add fluid Tank Clogged Clean tank Air In Mat...

Page 50: ...of hose in same environment as gun Verify FTS installation Temperature control alarm See Advanced Display Module ADM on page 20 Proportioning System Proportioning pump does not hold pressure when sta...

Page 51: ...to next step in calibration procedure On Main Calibration screen Calibrate Weight Dispense or Enter Specific Gravity Information On Flow Meter Calibration screen Use Dispensed Material Weight to Calib...

Page 52: ...o enter the Conditioning Con trol screen Turn on or off the highlighted zone Turn on or off all zones Erase a single batch Erase all batch data points Sets machine to low pressure Sets machine to high...

Page 53: ...sword is turned on use the ADM keypad to enter the password then press From the Setup screens press to access the Run screens For Run screens information see Technical Data on page 117 FIG 27 shows th...

Page 54: ...ickly enter the same value for the rate and time volume weight 4 Repeat step 2 as required Due to variation in material properties the column gives the ability to adjust the shot time volume weight fo...

Page 55: ...e for 75 cc 1 Dispense 5 shots into 5 separate containers 2 Measure the dispensed amount and record the data 3 Calculate the average of the 5 shots Example 3 72 5cc 4 Use the following formula to calc...

Page 56: ...ng the shot by weight To enable the shot calibration table 1 Navigate to Advanced Screen 4 2 Press then use the arrow keys to navigate to the Enable Range Calibration option 3 Press to activate the op...

Page 57: ...reens After a sequence is defined the user can dispense the sequence starting from the first posi tion containing a shot number and ending with the last position containing a non zero number The Seque...

Page 58: ...avel See Calibra tion Screen Learn Mode Press to go to the Calibration Screen Learn Mode screen Press to erase the motor control database in the motor control module Calibration Screen Learn Mode This...

Page 59: ...lled on the machine The hydraulic level sensor and hydraulic RTD for both the pump line and mix head must be marked as enabled when installed in the system If the sensors are not marked as enabled the...

Page 60: ...chine The labels set for the A Red and B Blue sides of the machine are displayed throughout the screens Labels are limited to five characters To edit a label 1 Press 2 To edit the A Red label press To...

Page 61: ...e cursor one letter to the right press To toggle the letters from upper lower case press 2 When finished entering the new label press Maintenance Screen This screen shows shot number sequence position...

Page 62: ...rs Same as Manual 2 Sensors section except that a filled condition is considered as material filled up to the second or middle sensor Refill operations will fill to middle sensor and material reaching...

Page 63: ...the timer expires before the high level sensor is triggered the refill will abort A refill must be manually started to enable auto refills again Refill Sensor Type The Low Temp Sensor setting limits t...

Page 64: ...ulate in low pressure The installed conditioning zones will be on and controlling to their respective setpoints When the system is in Night Mode and in an Off cycle the system will be idle The system...

Page 65: ...desired time duration has been selected NOTE If times are entered in the weekly schedule indi vidual days can not be erased NOTE Set the Prepoly Timeout one minute beyond the time it takes for the mat...

Page 66: ...d Disable Operator Mode Adjustments When this box is checked the user will not be able to adjust the dispense settings in Operator Mode Temperature Alarm Disables Dispense When this box is checked the...

Page 67: ...ix F USB Operation on page 91 For more information about the optional screens see Diagnostic screen on page 75 Low Material Disables Dispense When this box is checked the current dispense will termina...

Page 68: ...ptions and is disabled if the system is NOT a full recirculation system Other items on this screen do not pertain to full recircu lation systems and are therefore disabled Advanced Screen 7 The HFR se...

Page 69: ...hrough a manual or semi automatic recircula tion kit Light Tower Options If using the light tower option for the HFR the user must select the correct light tower option used with their system The Stan...

Page 70: ...splayed as either Red 1 or Blue 1 depending on which display has been setup See System Screen 3 on page 60 To select an operating mode press repeatedly until the desired mode is shown then press to se...

Page 71: ...00 pre defined shot numbers See Shots Screen on page 54 for information about editing shot definitions To use a predefined shot 1 Enter shot mode 2 Press and use the numeric keypad to enter the desire...

Page 72: ...tton to begin dispensing 6 Press to skip to the next sequence position 7 Press to abort the sequence 8 See Home Screen Shot Mode on page 71 for other button functions Home Screen Operator Mode This mo...

Page 73: ...trol Status Screen Conditioning Control This screen allows users to turn on and off heat zones individually or all at once When a zone is on it is actively controlling temperature Refer to the table b...

Page 74: ...ages each holding 10 events The 200 most recent events are shown Refer to the Troubleshooting section on page 49 for a detailed description of all of the system events Maintenance Screen This screen d...

Page 75: ...iew 3A2797ZAA 75 Optional Screens The optional Diagnostic screen can be enabled in the Advanced Screen 4 screen see page 67 Diagnostic The Diagnostic screen shows status information for various compon...

Page 76: ...cessive Current to AC Power Pack Motor Short circuit within AC Power Pack Motor Replace motor A4M1 Motor Over Current Too much current is being drawn from the wall Low voltage from the wall during loa...

Page 77: ...er s A9C1 Motor Over Current A software error has occurred commanding too much current Bad Motor Control Module code Check for MCM software update load latest MCM software if problem persists contact...

Page 78: ...Pendant CAD1 Comm Error Mixer Voltex Mixer Module is Off line HFR Only Alarm CAN cable to Voltex FCM3 is disconnected FCM3 failure Reconnect ensure cable Verify proper LED indications on Voltex FCM3 C...

Page 79: ...ssure on feed system Verify that incoming ball valves are open DDB2 Blue Pump Cavitation Verify that feed pumps are supplying material Debris or packout in the incoming fluid filter Inspect filter for...

Page 80: ...fittings L9BX Blue Tank Leak Detected Possible Leak in Blue Tank detected L8A1 Red Tank Sensor Failure A level sensor had ceased working Deviation Bad level sensor Replace level sensor MBH1 Low Oil Le...

Page 81: ...to bleed pressure P4A1 Red Pressure Shutdown The material pump pressure exceeded the maximum operating pressure as defined in the setup screens Alarm Dispense valve failed to open Check to make sure t...

Page 82: ...ad dispense valve a hose manifold etc Fix accordingly R1D0 Low Ratio Alarm Ratio monitor has detected an out of ratio condition Alarm Material A to Material B is out of ratio Check feed system R2D0 Lo...

Page 83: ...erature is approaching a level where damage is possible so the Motor Control Module is limiting the output to a safe level Deviation No power to fan Check cord to make sure fan has power Debris is fan...

Page 84: ...debris from MCM heat sink fins T4H1 Oil Temp Shutdown The hydraulic oil is at a temperature where performance is impacted significantly and has resulted in a system shutdown Alarm No Power to Fan Che...

Page 85: ...ne filter Voltage should measure between 190 and 264 Vac T8B4 No Heat Blue Hose Bad heater s Measure resistance of heater s T8B5 No Heat Blue Tank Tripped circuit breaker Visually check circuit breake...

Page 86: ...1 Blue Inline Overvoltage V4B4 Blue Hose Overvoltage V4B5 Blue Blanket Overvoltage V4B8 Blue Chiller Overvoltage V4H0 MotorControl Overvoltage The voltage to the MCM has reached an unsafe level and ha...

Page 87: ...to the directional valve is connected to the correct port and the cord is not damaged Directional valve failure The directional valve will need to be replaced Hydraulic power pack failure The hydrauli...

Page 88: ...olling value pressure or flow is outside the limits of the system Deviation System incorrectly setup On the ADM go into the setup screens System and ensure that all pages have properly defined values...

Page 89: ...unt has been altered by the controlling CGM PLC interface when the system was in shot mode ECH0 R Learn Mode Executed A learn mode calibration was success fully completed EH00 R Gel Timer Dispense The...

Page 90: ...ble cycle counter for the Blue pump was reset to zero EWA0 R Prepoly Refresh Canceled While in night mode the prepoly refresh was canceled REQU R Settings Uploaded The system settings file was success...

Page 91: ...loaded This will allow the user to download all the USB log entries which may take over 2 hours if the log files are full Currently the ADM does not monitor the USB logs and alert the user when data m...

Page 92: ...e folder name is incremented each time a stick drive is inserted and data is downloaded or uploaded In each DATAxxxx folder there are three log files They are formatted as csv comma separated value fi...

Page 93: ...Appendix F USB Operation 3A2797ZAA 93 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...

Page 94: ...ser of the update and the system will lock Once the update is complete the ADM will tell the user to cycle power to apply the updates Once this box appears it is safe to remove the drive before cyclin...

Page 95: ...OAD folder 7 Remove the USB stick drive from the computer and install it into the ADM USB port The software will automatically begin updating NOTE Before the update begins the ADM automati cally shuts...

Page 96: ...6 3A2797ZAA 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 impro...

Page 97: ...A1704 Furthermore this newer map will support some of the newer features provided by the HFR product such as a Dynamic Mixer option ability to change recirculation flow rates and ability to request a...

Page 98: ...4 8 See Available Internal Data page 101 for details on FieldBus pinout setup 9 Perform the setup to configure the FieldBus Setup Gateway Screens The gateway screens are used to configure the fieldbus...

Page 99: ...have a DeviceNet FieldBus CGM installed This screen enables the user to set the device address and baud rate and to view the hardware revision system serial number and data map identification informa...

Page 100: ...e screens are shown only if you have a PROFINET FieldBus CGM installed Screen 1 This screen enables the user to set the IP address DHCP settings subnet mask gateway and DNS infor mation See FIG 40 Scr...

Page 101: ...4 8 9 I64 I79 Current Dispense Duration which counts up starting from 0 in 0 01 second units 5 10 13 I80 I111 Amount for current Dispense In 0 01 CC or 0 01 Gram units starting from 0 6 14 17 I112 I14...

Page 102: ...it 2 4 4 5 O32 Turn On System Request O33 PLC Robot CGM Control Request O34 Heart Beat from PLC O35 ADM Lock Out Request O36 Red Tank Manual Fill Request O37 Blue Tank Manual Fill Request O38 Turn ON...

Page 103: ...screen provides graphical representations of the data provided to the controlling logic The bit data below is on high when the circle graphic is green and off low when the graphic is Grey See New Fie...

Page 104: ...pability for 26 different sequences A Z each with up to 20 positions The sequences can be defined using the sequences screens in the ADM See FIG 44 Positions in possible 20 positions can be skipped an...

Page 105: ...ing the system startup control bit after the NVH system has been idle for some time System is Ready for Dispense Request I175 This informs the controlling logic it is OK to request a dispense If set t...

Page 106: ...the HFR system to data exchange interface output data element location output byte locations 22 25 O176 O207 2 Write to the data exchange interface data pointer command location on the map output byte...

Page 107: ...1 C0 units Write 12 Read 13 Red Material Chiller Temperature Set point temperature Set or Get Set Point temperature in 0 1 C0 units Write 14 Read 15 Blue Material Chiller Temperature Set Point tempera...

Page 108: ...yte 1 Material is below Low Level sensor 2 Material between Low and High Level 2nd sensors 3 Tank Full at 2nd sensor or above 7 Material at or above top sensor Report xxx High Level in bit 2 feature O...

Page 109: ...rror provided If this register is assigned one of the read configu rable data registers see next items in table if more than 1 error is present the HFR will present all the active error numbers at app...

Page 110: ...ller Write 188 Read 200 Mixed Material in Current or Last Dispense Sum of Blue and Red Materials Dispensed In 0 01 CC or 0 01 Gram units Read 202 Blue Material in Current or Last Dispense In 0 01 CC o...

Page 111: ...write If sending a Turn On Request the system should be idle and Not dispensing Write 244 Read 251 Recirculation Flow Rate Set Point Set Write or get read the recirculation flow rate set point in in 0...

Page 112: ...A Blue Motor Over Current 7 7 A4N1 A Blue Motor Over Current 8 8 A4M1 A Blue Motor Over Current 9 9 A9C1 A Blue Motor Over Current 10 10 T4C1 A Blue MCM High Temp 11 11 V4H0 A Blue MCM Overvoltage 12...

Page 113: ...61 92 A4B8 A Blue Chiller Overcurrent 62 93 A7A6 A Red Blanket Control Fault 63 94 A7B5 A Blue Blanket Control Fault Item Error Number Code Level Description 64 95 A7A3 A Red Inline Control Fault 65 9...

Page 114: ...T1B1 D Blue Inline Low Fluid Temp Item Error Number Code Level Description 108 147 T1A2 D Red Hose Low Fluid Temp 109 148 T1B4 D Blue Hose Low Fluid Temp 110 149 T1A7 D Red Chiller Low Fluid Temp 111...

Page 115: ...Blue Tank Con Fault Unexpected Relay I 156 195 WMC3 A Red Inline Con Fault Unexpected Relay I 157 196 WMC1 A Blue Inline Con Fault Unexpected Relay I Item Error Number Code Level Description 158 197 W...

Page 116: ...mm Error Blue Chiller 208 252 CACN A Comm Error Field Bus Item Error Number Code Level Description 209 253 CUCN A Field Bus Heartbeat Failure 210 254 CACP A Comm Error Discrete I O 211 255 CACR A Comm...

Page 117: ...mum Line Voltage Requirement 230V 3 phase Models 195 264V 50 60 Hz Line Voltage Requirement 400V 3 phase Models 360 440V 50 60 Hz See 400 V Power Requirements on page 5 Amperage Requirement See Model...

Page 118: ...63A single phase Short Circuit Current Rating 5 kA Output Specifications Output Line Voltage 0 264 Vac Output Line Phasing Three Phase Output Current 0 30A Output Overload 200 for 0 2 seconds DC Powe...

Page 119: ...5 3A2797ZAA 119 Dimensions California Proposition 65 CALIFORNIA RESIDENTS WARNING Cancer and reproductive harm www P65warnings ca gov ti19519a A C B Dimensions A Height 76 in 193 cm B Width 72 in 183...

Page 120: ...made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT...

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