Graco 24D829 Instructions-Parts List Manual
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Graco 24D829 Instructions-Parts List Manual

Graco 24D829 Instructions-Parts List Manual

Ac hydraulic power pack module
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Instructions-Parts
AC Hydraulic
Power Pack Module
AC Hydraulic Power Pack, with optional boom and hose kits, for hydraulic actuated
applicators used with Graco HFR and VRM Metering Systems.
For professional use only.
2500 psi (17 MPa, 172 bar) Maximum Hydraulic Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 3 for model information.
24D829 AC Hydraulic Power Pack Module Shown
3A0238G
ENG
r_24d829_3A0238_1f

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Summary of Contents for Graco 24D829

  • Page 1 Power Pack Module 3A0238G AC Hydraulic Power Pack, with optional boom and hose kits, for hydraulic actuated applicators used with Graco HFR and VRM Metering Systems. For professional use only. 2500 psi (17 MPa, 172 bar) Maximum Hydraulic Working Pressure...

  • Page 2: Table Of Contents

    Circuit Breakers ......13 Graco Standard Warranty ....66 Fluid Control Module (FCM) .

  • Page 3: Related Manuals

    Applicator Kits and Individual Applicators on page 4. Includes: Hydraulic S-Head L-Head Power Kit No. Voltage Boom Hose Kits Hose Kits Pack ✔ ✔ ✔ 230V 24D829 ✔ ✔ ✔ 230V 24D830 ✔ ✔ ✔ 400V 24D834 ✔ ✔ ✔ 400V 24D835 ✔...

  • Page 4: Applicator Kits

    Models Applicator Kits The table below lists S-Head and L-Head applicators kits. All applicator kits come with an injection nozzle and needle valve calibration kit. Maximum Working Pressure Applicator Kit No. Model psi (MPa, bar) 24A084 20.20.6/10 3000 (21, 206) L-Head 24A085 20.20.10/14...

  • Page 5: Warnings

    Warnings 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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
  • Page 6 Warnings WARNING WARNING WARNING WARNING 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 treat- ment.
  • Page 7 Warnings WARNING WARNING WARNING WARNING 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 prop- erty damage.

  • Page 8: Isocyanate Conditions

    • Keep the ISO lube pump reservoir (if installed) filled also required for everyone in the work area. ™ ™ with Graco Throat Seal Liquid (TSL ), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.

  • Page 9: Changing Materials

    Warnings 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 use ISO on the A side, but some use ISO on the B side.
  • Page 10 Warnings 3A0238G...

  • Page 11: Component Identification

    Component Identification Component Identification AC Power Pack Module 24D829 AC Power Pack Module shown with circulation lines r_24d829_3A0238_1f . 1: Typical Installation Key: AC Hydraulic Power Pack Hose Kit (includes A, B, and hydraulic hoses) Boom (not included with all power pack kits)

  • Page 12: Hydraulic Power Pack Stand

    Component Identification Hydraulic Power Pack Stand AE, AS r_24C065_3a0238_1d r_24C065_3a0238_11e Key: AA 10 Gallon Hydraulic Oil Reservoir (see Technical Data on AR Electronics Panel (inside stand) page 65 for specifications) AS Heat Exchanger Cover AB Electric Motor AT Cycle Stop Button AC Dipstick AU Stand AD Hydraulic Housing...

  • Page 13: Main Power Disconnect

    Component Identification Main Power Disconnect Circuit Breakers Below are the on and off positions for the main power disconnect (AP) located on the AC Power Pack module. NOTE: The power must be turned “On” at the GMS Circuit breakers are located inside the power pack frame unit first.

  • Page 14: Fluid Control Module (Fcm)

    Component Identification Fluid Control Module (FCM) TI12337A TI12336A Key: BA Fluid Control Module FCM Cable Connections BB Base BC Module Connection Screws BD Access Cover Connections Cable BE Module Status LEDs BF CAN Connectors 123673 123673 121686 121686 24E052 122497 CAN connector 1 123762 CAN connector 2...
  • Page 15 Component Identification Diagnostic Information Module Status LED Signal Diagnosis Solution 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.

  • Page 16: Setup

    Setup Setup Connect Hydraulic Hoses Avoid breathing of vapors and contact with Isocyante as some people have severe allergic reactions. See Hydraulic lines could rupture and cause injury. Use Isocyanate Conditions on page 8. hydraulic hoses with a pressure rating lower than Avoid routing hoses in walkway areas to prevent what the system is set to.
  • Page 17 Setup S-Head and GX-16 Hydraulic Hydraulic Hydraulic Hose See F . 8. Hose Fitting Hoses Color Markings A1✖ Cleanout close Green/Green 1. Connect the B2 hose, with green/white markings, to the hydraulic open (HO) port fitting. A2✖ Material close Green Cleanout open Green/White/Green 2.

  • Page 18: Connect Material Hoses To System

    Setup Connect Material Hoses to System For System With Circulation NOTICE Avoid routing hoses in walkway areas to prevent operators from tripping on hoses running between system components. This also prevents fittings from leaking. 1. Connect the A (red) and B (blue) supply hoses, from fluid inlet hose kit (3), to the GMS material manifold.

  • Page 19: Connect Communication Cables

    Setup Connect Communication Cables Connect Proximity Cables 1. Feed communication cable (83) through base cube L-Head bulk head. 1. Connect the applicator end of the proximity sensor cable (418) to the dispense proximity sensor on the L-Head. 2. Connect the applicator end of the proximity sensor cable (419) to the cleanout proximity sensor on the L-Head.

  • Page 20: Connect Electrical Cord

    Setup Connect Electrical Cord NOTE: Power cord is not supplied. See Table 2. Table 2: Power Cord Requirements Model Cord Requirements AWG (mm Electrical Requirements. See Table 1. 230V 10 (5.3), 3 wire 400V 10 (5.3), 4 wire Installing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

  • Page 21: Startup

    Startup Startup 3. Ensure that the pressure gauge is zero psi. 4. To relieve pressure in material hoses, perform Pres- sure Relief Procedure in HFR manual 313997. Shutdown The hydraulic power pack operates at a high pres- sure and high voltage. Be careful during operation and always wear the appropriate protective gear.

  • Page 22: Maintenance

    Maintenance Maintenance Check the Accumulator Pre-Charge Graco Charging Harness (part no. 124217) can be pur- chased to aid in quick charging of the accumulator. Schedule 1. Turn off main power and lockout. 2. Bleed the accumulator charging valve hydraulic Procedure Frequency pressure to zero.
  • Page 23 Maintenance Check Hydraulic Fluid 6. To add clean hydraulic fluid see Check Hydraulic Fluid Level. NOTE: Standard temperature switch cuts out at a housing temperature of 160°F (71°C) and approxi- mately 180°F (82°C) hydraulic fluid temperature. Check Hydraulic Fluid Level 1.

  • Page 24: Troubleshooting

    Troubleshooting Troubleshooting Problem Cause Solution Pressure gauge drops to zero while Accumulator precharge is too high. Ensure accumulator precharge is in operation. no more than 1200 psi. No hydraulic pressure. Motor is not turning. Ensure main power is ON. Ensure all electrical connections to the motor are secure.
  • Page 25 Troubleshooting Problem Cause Solution Hydraulic fluid over heating. Fan in base cube is not spinning. Check electrical connections to fan. Replace fan. Heat exchanger in base cube is Replace. clogged or leaking. Low hydraulic fluid level in oil reser- Check hydraulic fluid level. Refill as voir.
  • Page 26 Troubleshooting Problem Cause Solution Applicator not cycling. (continued) Accumulator directional valve is not Ensure accumulator charging direc- charging. tional valve is shifting. Verify LED lights turn ON and OFF. Check circuit breaker to see if it has been tripped. Replace directional valve. See page Replace accumulator.

  • Page 27: Repair

    Repair Repair 3. Disconnect all hydraulic lines from A1, A2, B1, and B2 fittings at the applicator housing. Remove Hydraulic Power Pack Shroud 1. Remove four screws from base of shroud. 2. Lift shroud off of hydraulic power pack. Install Hydraulic Power Pack Shroud .

  • Page 28: Install Hydraulic Power Pack

    Repair 6. Remove the two bolts from (258) from the fluid Install Hydraulic Power Pack housing (206) and replace each with a 5/16-18 thread eye bolt. Install a third 5/16-18 eye-bolt as NOTICE indicated. If any debris falls into the hydraulic tank, the debris must be removed or machine damage will result.

  • Page 29: Replace Tank Gasket

    Repair Replace Tank Gasket Remove Motor 1. Remove Hydraulic Power Pack. See page 27. 1. Shutdown the system. See Shutdown on page 21. 2. Remove hex head cap screws (239) and washers 2. Remove Hydraulic Power Pack. See page 27. (238) securing hydraulic housing (206) to tank 3.

  • Page 30: Install Motor

    Repair 6. Remove the four socket head cap screws (204) con- 2. Apply thread sealant to threads of four socket head necting the motor adapter plate (203) to the hydrau- cap screws (205). Use four screws (205) to attach lic housing (206). the motor adapter plate (203) to motor (201).

  • Page 31: Remove Hydraulic Gear Pump

    Repair Remove Hydraulic Gear Pump 7. Remove the two hex head cap screws (214) and carefully remove the gear pump (211) from the hydraulic housing (206). 1. Shutdown the system. See Shutdown on page 21. NOTE: Do not lose the pump coupler (212). 2.

  • Page 32: Install Fcm Upgrade Token

    Graco Control Architecture based system they 2. Remove access cover (BD). must remain in the FCM for features or settings to be enabled. Key tokens are not present on all Graco Con- trol Architecture based systems. 6. Replace access cover (BD).
  • Page 33 Repair 3A0238G...

  • Page 34: Parts

    Blue B side material supply Blue See Hose Kits on page 48 for fluid line connections. 24D829 AC Hydraulic Power Pack Module Shown Torque all screws on hydraulic and material hose clamps to 6 ft-lbs (8 N•m). r_24d829_3A0238_1f 2c, 2d Torque to 113 ft-lbs (153 N•m).
  • Page 35 Parts Power Pack Kit and Quantity 24D829 24D830 24D831 24D832 24F297 24D834 24D835 24D836 24D837 24F298 230 V Modules 400V Modules Ref Part Description MODULE, mixhead stand, 230v; see page MODULE, mixhead stand, 400v; see page ARM, boom, floor mounted; includes...

  • Page 36: Mix Module Stand

    Parts Mix Module Stand 56, 57 Fill power pack (55) tank with hydraulic oil. Check after initial startup to ensure proper fluid level. Apply anaerobic sealant to threads and torque to 17 ft-lbs (23 N•m). Apply anaerobic pipe sealant to adapter fitting (86) threads and thread in to power pack (55).
  • Page 37 Parts 230V Mix Module Stand 400V Mix Module Stand 123764 HARNESS, m8, 4p, straight x pig- Ref. tail Part Description 122970 FITTING, adapter, JIC(08) x ENCLOSURE, frame SAE(08), m 24D021 BRACKET, anchor, cube 123140 FITTING, cap, 1/2 jic, cs 111800 SCREW, cap, hex hd; 5/16-18 x 24D495 CORD, fan, heat exchanger, mix- 0.625 head...

  • Page 38: Heat Exchanger Assembly

    Parts Heat Exchanger Assembly Torque to 65 ft-lb. Apply anaerobic sealant to threads. Apply lubricant to o-rings before Orient fan with airflow arrow pointing assembling. toward cover. Torque to 8 ft-lb. Align fan plug as shown. Torque to 2.5 ft-lb. Part Description 257967...
  • Page 39 Parts 3A0238G...

  • Page 40: And 400V Mixhead Panel

    Parts 230V and 400V MixHead Panel 230V MixHead Panel Shown See Electrical Schematics starting on page 53 for wire connections. r_24c357_3a0238_3c 106, 108 r_24c357_3a0238_5b r_24c357_3a0238_6b r_24c357_3a0238_7b 3A0238G...
  • Page 41 Parts 230V and 400V MixHead Panels Ref. Part Description PANEL, electric, heat 289697 MODULE, cube, gca, base 102598 SCREW, cap, socket head; #10-32 x 1/2 289696 MODULE, gca, cube, fcm 24D207 POWER SUPPLY, 24vdc, 4A, 100w, 230vac in, 103833 SCREW, machine MODULE, breaker, mixhead, 230v MODULE, breaker, mixhead, 400v 123452 HOLDER, anchor, wire tie, nylon...

  • Page 42: Mixhead Hydraulic Power Pack

    Parts MixHead Hydraulic Power Pack See Electrical Schematics starting on page 53. See page 43 for assembly notes. See Hose and Cable Kits starting on page 50. See page 43. 2 14 2 14 2 14 2 14 3 13 See page 43.
  • Page 43 Parts Assemble coupler (202, 212) to specified dimension prior to Apply sealant to threads prior to assembly. mounting motor and pump to housing. Apply a light coating of lubricant to seals prior to assembly. Torque to 40 ft-lbs (54 N•m). Tighten tubing nuts hand tight and then with a wrench.
  • Page 44 Parts MixHead Hydraulic Power Module 101971 WASHER, thrust 111302 SCREW, cap, hex hd; 5/16-18 x 2 4 Ref. PLATE, accumulator mounting Part Description 123293 BRACKET, accumulator mounting 2 122953 MOTOR, mixhead 122952 ACCUMULATOR, mixhead 16A954 COUPLER, motor 122968 FITTING, elbow, 90, JIC (08) x PLATE, motor adapter SAE (08) 123338 SCREW, shc, 3/8-16 x 2.75...
  • Page 45 Parts 3A0238G...

  • Page 46: Pneumatic Boom Arm

    Parts Pneumatic Boom Arm 320, 321 Torque to 35 ft-lbs (47.5 N•m). Hand tighten only. Do not torque. r_257553_3a0238_2a Apply PTFE tape on installation end only prior to assembly. 3A0238G...
  • Page 47 Parts Pneumatic Boom Arm Ref. Part Description 24D349 BASE, boom assembly BEARING, thrust, 45 x 65 x 14 15Y044 BEARING, support 113470 BOLT, hex 109570 WASHER, plain 100018 WASHER, lock, spring 100338 NUT, jam POST, boom assembly 122634 COLLAR, 2.875 clamp 1pc 100096 SCREW, cap, hex hd;...

  • Page 48: Hose Kits

    Parts Hose Kits L-Head Hose Kit Shown 413 1 r_24d628_3a0238_1h Wrap bundle of hose with electrical tape every 2 ft. Connect to A side supply fitting on applicator. Torque to 6 ft-lbs (8 N•m). Connect to A side return fitting on applicator. Wrap electrical tape on each end of scuff guard (413, 414, and Connect material open hose to B2 connection marked on 420)
  • Page 49 Parts Hose Kits Quantity Boom Hose Kits No Boom Hose Kits L-Head S-Head L-Head S-Head Part Description 401✿ 24A524 HOSE, assy, hydraulic, 3/8, 20 ft (6 m); JIC 8; 4000 psi 262193 HOSE, A, 25 ft. (7.6 m), 1/2 in., moisture-lock 262194 HOSE, B, 25 ft.

  • Page 50: Hose And Cable Kits

    Hose and Cable Kits Hose and Cable Kits Required for power pack modules 24F297 and 24F298. Compatible Applicators and Part Number Length ft (m) S-Head L-Head Qty. Heated or Unheated A and B Material Hoses Maximum operating pressure: 3500 psi (24 MPa, 241 bar) 10 ft (4.6 m) See manual 3A0237 for See manual 3A0237 for...

  • Page 51: Optional Equipment

    Optional Equipment Optional Equipment Fluid Level Sensor 24E347 Hydraulic Pressure Gauge Kit 24C872 6° r_257840_3a0238_24e347 r_257840_3a0238_24c872 Torque to 16 in.-lbs (1.8 N•m. Apply sealant to threads prior to assembly. Connect cable (502) to (503). Remove plug (222) from (206). Route and cable tie (503) with existing signal-wire bundle and connect free end of (503) to port #3 of FCM.
  • Page 52 Optional Equipment Hydraulic RTD Sensor Kit 24E348 r_257840_3a0238_24E348 Apply sealant to threads prior to assembly. Remove plug (223) from (206). Connect signal end of (523) to (524). Route and cable tie (524) with existing signal-wire bundle and connect free end of (524) to port #4 of FCM. Apply a minimal amount of thermal grease to contact end of (523).

  • Page 53: Electrical Schematics

    Optional Equipment Electrical Schematics 230V Power Pack 3A0238G...
  • Page 54 Optional Equipment 230V Power Pack - 2 3A0238G...
  • Page 55 Optional Equipment 230V Power Pack - 3 3A0238G...
  • Page 56 Optional Equipment 230V Power Pack - 4 LOCATED ON THE MIX HEAD CLOSED CLEAN OUT HYDRAULIC POWER PACK SOL210 SOL221 SOL204 24D636 24D635 PRESSURE TRANSDUCER ACCUMULATOR 257432 OIL TEMP PRESSURE RTD OPTIONAL GAUGE RTD245 SOL211 SOL205 OIL OVERTEMP OTS234 SWITCH 24D634 5 HP PRESSURE...
  • Page 57 Optional Equipment 400V Power Pack 3A0238G...
  • Page 58 Optional Equipment 400V Power Pack -2 3A0238G...
  • Page 59 Optional Equipment 400V Power Pack -3 3A0238G...
  • Page 60 Optional Equipment 400V Power Pack -4 LOCATED ON THE MIX HEAD CLOSED CLEAN OUT HYDRAULIC POWER PACK SOL210 SOL204 SOL221 24D636 24D635 PRESSURE TRANSDUCER 257432 ACCUMULATOR OIL TEMP PRESSURE RTD OPTIONAL GAUGE RTD245 SOL211 SOL205 OIL OVERTEMP OTS234 SWITCH 24D634 5 HP M110 PRESSURE...

  • Page 61: Dimensions

    Dimensions Dimensions AC Power Pack Module Front View Top View 7.7 ft (2.3 m) Side View 26 in. (660.4 mm) 8.4 ft (2.5 m) See page 62 for mounting dimensions. 3A0238G...
  • Page 62 Dimensions Mounting Dimensions 24 in. (609.6 mm) AC Power Pack Stand page 63 13 in. (330 mm) 5 in. (127 mm) Pneumatic Boom 22 in. (558.8 mm) page 64 14 in. (355.6 mm) 3A0238G...

  • Page 63: Ac Power Pack Stand

    Dimensions AC Power Pack Stand Front View Side View 4.7 ft (1.4 m) r_24c065_3a0238_9d r_24c065_3a0238_8d 26 in. 19.48 in. (494.79 mm) (660.4 mm) Top View 13 in. 18 in. (330 mm) (457.2 mm) r_24c065_3a0238_10d 24 in. (609.6 mm) 3A0238G...

  • Page 64: Pneumatic Boom

    Dimensions Pneumatic Boom Front View Side View 8.4 ft (2.5 m) r_24d628_3a0238_2h r_24d628_3a0238_3h 7.7 ft (2.3 m) 16 in. Mounting Dimensions (406.4 mm) 24 in. (609.6 mm) 14 in. (355.6 mm) 22 in. (558.8 mm) 3A0238G...

  • Page 65: Technical Data

    Technical Data Technical Data Maximum hydraulic fluid working pressure ..2500 psi (17 MPa, 172 bar) Minimum hydraulic hose working pressure ..3000 psi (21 MPa, 207 bar) Maximum hydraulic fluid temperature .

  • Page 66: Graco Standard Warranty

    With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

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