313539G - Reactor H-VR, Operation, (English)

313539G - Reactor H-VR, Operation, (English)
Operation
H-VR
313539G
EN
Hydraulic Variable Ratio, Heated, Plural Component Proportioner. For spraying
polyurethane foam and polyurea coatings. For professional use only.
Not for use in explosive atmospheres.
U.S. Patent Pending
Russian Patent No. 2359181
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for model information, including maximum working pressure.
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Models
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Two-Component Material Information . 6
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 6
For all applications except spray foam . . . . . . . . 7
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 7
Foam Resins with 245 fa Blowing Agents . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation, with circulation . . . . . . . . . . . 9
Typical Installation, without circulation . . . . . . . 10
Component Identification . . . . . . . . . . . . . . . . . . . 11
Reactor H-VR . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . 13
Temperature Controls and Indicators . . . . . . . . . 14
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . 14
Red Stop Button . . . . . . . . . . . . . . . . . . . . . . . . 14
Actual Temperature Key/LED . . . . . . . . . . . . . . 14
Target Temperature Key/LED . . . . . . . . . . . . . . 14
Temperature Scale Keys/LEDs . . . . . . . . . . . . . 15
Heater Zone On/Off Keys/LEDs . . . . . . . . . . . . 15
Temperature Arrow Keys . . . . . . . . . . . . . . . . . 15
Temperature Displays . . . . . . . . . . . . . . . . . . . . 15
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . 15
Motor Controls and Indicators . . . . . . . . . . . . . . . 16
Motor ON/OFF Key/LED . . . . . . . . . . . . . . . . . . 16
PARK Key/LED . . . . . . . . . . . . . . . . . . . . . . . . . 16
PSI/BAR Keys/LEDs . . . . . . . . . . . . . . . . . . . . . 16
Pressure Key/LED . . . . . . . . . . . . . . . . . . . . . . . 16
Cycle Count Key/LED . . . . . . . . . . . . . . . . . . . . 17
Hydraulic Pressure Control Knob . . . . . . . . . . . 17
Motor Control Arrow Keys . . . . . . . . . . . . . . . . . 17
Spray Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 17
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 32
Fluid Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Circulation Through Reactor . . . . . . . . . . . . . . . 33
Circulation Through Gun Manifold . . . . . . . . . . . 34
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Temperature Control Diagnostic Codes . . . . . . 35
Motor Control Diagnostic Codes . . . . . . . . . . . . 36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . . 38
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 42
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 44
Models
Part,
Series
256886
256887
*
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
71
41
230V (3)
400V (3)
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
lb/min
(kg/min)
Approximate
Output per
Hydraulic
Cycle (A+B) Pressure
gal. (liter)
Ratio
Maximum Fluid
Working Pressure
psi (MPa, bar)
26,600
26,600
15,300
15,300
30 (13.6)
30 (13.6)
Variable
Variable
3500 (24.1, 241)
3500 (24.1, 241)
Variable
Variable
◆
Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber
sizes may be less.
Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum flow.
2
313539G
Supplied Manuals
Supplied Manuals
The following manuals are shipped with the Reactor™
H-VR Proportioner. Refer to these manuals for detailed
equipment information.
Order Part 15M334 for a compact disk of Reactor manuals translated in several languages.
Circulation Kit
Part
Description
309818
Instruction-Parts Manual
(English)
Circulation Valve Kit
Part
Description
312070
Instruction-Parts Manual
(English)
Reactor Hydraulic Proportioner
Data Reporting Kit
Part
Description
Part
Description
Reactor H-VR Proportioner,
Repair-Parts Manual (English)
309867
Instruction-Parts Manual
(English)
313540
Reactor Electrical Diagrams
Rupture Disk Assembly Kit
Part
Description
Part
Description
Reactor Hydraulic Proportioner, Electrical Diagrams (English)
309969
Instruction-Parts Manual
(English)
312064
Fluid Pump
Part
313485
Proportioning Pump Repair Kits
Description
H-VR Pump Instructions-Parts Manual
(English)
Part
312071
Description
Seal Kits Instruction-Parts Manual
(English)
Related Manuals
The following manuals are for accessories used with the
Reactor™.
Feed Pump Kits
Part
Description
309815
Instruction-Parts Manual
(English)
Air Supply Kit
Part
Description
309827
Instruction-Parts Manual
(English) for Feed Pump Air Supply Kit
Circulation and Return Tube Kits
Part
Description
309852
Instruction-Parts Manual
(English)
Heated Hose
Part
Description
309572
Instruction-Parts Manual
(English)
313539G
3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or
swallowed.
• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area well
ventilated and always wear appropriate personal protective equipment. See Personal Protective
Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and
hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority.
• Protective eyewear and hearing protection.
SKIN INJECTION HAZARD
High-pressure fluid from gun, 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 treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
4
313539G
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
OR
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
• Wait until equipment/fluid has cooled completely.
313539G
5
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized
particulates.
•
•
•
•
•
•
•
Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.
Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you
are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDS.
Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material.which
could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to instructions in the manual.
To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area
must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include
a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.
Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.
Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal protective equipment must stay out of the work area during application and after application for the time period
specified by the fluid manufacturer. Generally this time period is at least 24 hours.
Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the following outside
the work area is recommended:
TOXIC FUMES
HAZARD
DO NOT ENTER DURING
SPRAY FOAM APPLICATION
OR FOR ___ HOURS AFTER
APPLICATION IS COMPLETE
DO NOT ENTER UNTIL:
DATE: ____________
TIME: ____________
6
313539G
Important Two-Component Material Information
For all applications except spray
foam
Spraying or dispensing fluids that contain isocyanates
creates potentially harmful mists, vapors, and atomized
particulates.
•
Read and understand the fluid manufacturer’s warnings
and Safety Data Sheet (SDS) to know specific hazards
and precautions related to isocyanates.
•
Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are
trained, qualified, and have read and understood the
information in this manual and in the fluid manufacturer’s
application instructions and SDS.
•
Use of incorrectly maintained or mis-adjusted equipment
may result in improperly cured material. Equipment must
be carefully maintained and adjusted according to
instructions in the manual.
•
To prevent inhalation of isocyanate mists, vapors, and
atomized particulates, everyone in the work area must
wear appropriate respiratory protection. Always wear a
properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to
instructions in the fluid manufacturer’s SDS.
•
Avoid all skin contact with isocyanates. Everyone in the
work area must wear chemically impermeable gloves,
protective clothing and foot coverings as recommended
by the fluid manufacturer and local regulatory authority.
Follow all fluid manufacturer recommendations, including
those regarding handling of contaminated clothing. After
spraying, wash hands and face before eating or drinking.
Material Self-ignition
Some materials may become self-igniting if applied too
thick. Read material manufacturer’s warnings and Safety
Data Sheet (SDS).
313539G
Keep Components A and B
Separate
Cross-contamination can result in cured material in fluid
lines which could cause serious injury or damage equipment. To prevent cross-contamination:
•
Never interchange component A and component B
wetted parts.
•
Never use solvent on one side if it has been contaminated from the other side.
Moisture Sensitivity of
Isocyanates
Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystal that become
suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and the life of all
wetted parts.
•
•
•
•
•
Always use a sealed container with a desiccant dryer in
the vent, or a nitrogen atmosphere. Never store ISO in
an open container.
Keep the ISO pump wet cup or reservoir (if installed)
filled with appropriate lubricant. The lubricant creates a
barrier between the ISO and the atmosphere.
Use only moisture-proof hoses compatible with ISO.
Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in
use.
Always lubricate threaded parts with an appropriate
lubricant when reassembling.
NOTE: The amount of film formation and rate of crystallization
varies depending on the blend of ISO, the humidity, and the
temperature.
7
Important Two-Component Material Information
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures above
90°F (33°C) when not under pressure, especially if agitated.
To reduce frothing, minimize preheating in a circulation system.
Changing Materials
NOTICE
Changing the material types used in your equipment
requires special attention to avoid equipment damage
and downtime.
•
When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
•
Always clean the fluid inlet strainers after flushing.
•
Check with your material manufacturer for chemical compatibility.
•
When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have
amines on the B (hardener) side. Polyureas often
have amines on the B (resin) side.
8
313539G
Typical Installation, with circulation
Typical Installation, with circulation
Key for FIG. 1
A
B
C
D
E
F
G
J
K
L
M
P
R
S
T
Reactor H-VR Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
Fusion Spray Gun
Gun Air Supply Hose
A Side Supply Detail
Feed Pump Air Supply Lines
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Gun Fluid Manifold (part of gun)
Circulation Lines
Fluid Inlet
Hose Manifold
B Side Supply Detail
M
K
M
K
K
G
G
L
K
ti7820a 3
ti7820a 2
R
R
A
J
S
T
J
D
T
F
S
E
P
C*
r_256886_313359_1A
B
*Shown exposed for clarity.
Wrap with tape during operation.
ti10000a
FIG. 1: Typical Installation, with circulation
313539G
9
Typical Installation, without circulation
Typical Installation, without circulation
Key for FIG. 2
A
B
C
D
E
F
G
H
J
K
L
M
N
P
S
T
Reactor H-VR Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
Fusion Spray Gun
Gun Air Supply Hose
Feed Pump Air Supply Lines
Waste Containers
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Bleed Lines
Gun Fluid Manifold (part of gun)
Fluid Inlet
Hose Manifold
B Side Supply Detail
A Side Supply Detail
K
K
M
K
G
G
L
K
ti7821a 2
ti7821a 3
J
A
S
T
F
S
J
N
H
D
T
E
P
C*
r_256886_313359_1A
B
*Shown exposed for clarity.
Wrap with tape during operation.
ti10001a
FIG. 2: Typical Installation, without circulation
10
313539G
Component Identification
Component Identification
NOTICE
To prevent damage to soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Reactor H-VR
Key for FIG. 3
BA
BB
EC
EM
FA
FB
FH
FM
FV
GA
GB
HA
HB
HC
HP
LR
MC
MP
OP
RS
SA
SB
SC
SN
SR
TA
TB
TC
TD
VR
Component A Pressure Relief Outlet
Component B Pressure Relief Outlet
Heated Hose Electrical Connector
Electric Motor, Fan, and Belt Drive (behind shroud)
Component A Fluid Manifold Inlet (on left side of manifold
block)
Component B Fluid Manifold Inlet
Fluid Heater (behind shroud)
Reactor Fluid Manifold
Fluid Inlet Valve (B side shown)
Component A Outlet Pressure Gauge
Component B Outlet Pressure Gauge
Component A Hose Connection
Component B Hose Connection
Hydraulic Pressure Control
Hydraulic Pressure Gauge
ISO Lube Pump Reservoir
Motor Control Display
Main Power Switch
Overpressure Rupture Disk Assembly (on rear of A and B
pumps)
Red Stop Button
Component A PRESSURE RELIEF/SPRAY Valve
Component B PRESSURE RELIEF/SPRAY Valve
Fluid Temperature Sensor Cable
Serial Number Plate (one inside cabinet, one on right side
of cabinet)
Electrical Cord Strain Relief
Component A Pressure Transducer (behind gauge GA)
Component B Pressure Transducer (behind gauge GB)
Temperature Control Display
Oil Cooler
Pump Assembly (see page 13)
313539G
11
Component Identification
MC
VR
TC
RS
HC
HP
EM
FM
OP
FV
SC
EC
FH
SN
MP
r_256886_313359_1A
SR
Detail of Reactor Fluid Manifold
(shroud removed for clarity)
SA
TA GA
GB
FA
TB
Detail of Serial No. Plate
(inside cabinet)
SB
BA
FB
ti7823a
BB
HA
HB
ti9880a
SN
FIG. 3: Component Identification (15.3 kW Model Shown)
12
313539G
Component Identification
Pump Assembly
Key for FIG. 4.
AA
AB
AC
AD
AE
AF
AG
Component A Pump
Component B Pump
Hydraulic Proportioner Pump
Yoke and Rod Guide Assembly
Pump Drive Link
Pump Adapter
Pivot Bracket
AH
AJ
AK
AL
AM
AN
AP
Guard
Clamping Knob
Lube Fitting
Ratio Lock Handle
Ratio Adjustment Wheel
Frame
Ratio Adjustment Screw
AH
AJ
AB
AA
Detail of Pump Assembly
(guard removed for clarity)
AL
AC
AD
AG
AE
AM
AK
AK
(behind
pivot bracket)
AP
AN
AF
AB
FIG. 4: Front View of Pump Assembly
313539G
13
Temperature Controls and Indicators
Temperature Controls and Indicators
Heater Power Indicators
Zone A Arrow Keys
A
Zone B Arrow Keys
B
Heater Displays
Heater A On/Off Key
Heater B On/Off Key
Hose Zone Arrow Keys
Hose Heater On/Off Key
°F
Actual Temperature Key
Temperature Scale Keys
°C
Target Temperature Key
FIG. 5. Temperature Controls and Indicators
Main Power Switch
Actual Temperature Key/LED
Located on right side of unit, page 12. Turns Reactor
Press
power ON
and OFF
. Does not turn
heater zones or pumps on.
Press and hold
Red Stop Button
Located between temperature control panel and motor
control panel, page 12. Press
to display actual temperature.
to shut off motor
and heater zones only. Use main power switch to shut
off all power to unit.
to display electrical current.
Target Temperature Key/LED
Press
to display target temperature.
Press and hold
to display heater control circuit
board temperature.
14
313539G
Temperature Controls and Indicators
Temperature Scale Keys/LEDs
Press
°F
or
°C
Circuit Breakers
to change temperature scale.
Heater Zone On/Off Keys/LEDs
Located inside Reactor cabinet.
to turn heater zones on and off. Also
Ref.
Size
Component
clears heater zone diagnostic codes, see page 35.
CB1
50 A
Hose/Transformer Secondary
CB2
40 A
Transformer Primary
CB3
50 A
Heater A
CB4
50 A
Heater B
CB5
20 A
Motor/Pumps
Press
NOTE:
LEDs flash when heater zones are on. The duration of
each flash shows the extent that the heater is turned on.
Temperature Arrow Keys
Press
, then press
or
to adjust tem-
perature settings in 1 degree increments.
Temperature Displays
Show actual temperature or target temperature of
heater zones, depending on selected mode. Defaults to
actual at startup. Range is 32-190°F (0-88°C) for A and
B, 32-180°F (0-82°C) for hose.
CB1
CB2
CB3
CB4
ti9884a
CB5
For wiring and cabling, see repair manual 313540.
313539G
15
Motor Controls and Indicators
Motor Controls and Indicators
Pressure/Cycle Display
Arrow Keys
Motor ON/OFF Key
ON / OFF
PARK Key
Pressure Key
PARK
PSI/BAR Keys
Cycle Count Key
PSI
BAR
FIG. 6. Motor Controls and Indicators
Motor ON/OFF Key/LED
Pressure Key/LED
Press
Press
to turn motor ON and OFF. Also clears
to display fluid pressure.
some motor control diagnostic codes, see page 36.
NOTE:
PARK Key/LED
Press
If pressures are imbalanced, display shows higher of
two pressures.
at end of day to cycle component A pump
to home position, submerging displacement rod. Trigger
gun until pump stops. Once parked, motor will automatically shut off.
PSI/BAR Keys/LEDs
Press
16
PSI
or
BAR
to change pressure scale.
313539G
Spray Adjustments
Cycle Count Key/LED
Press
•
Fluid pressure setting. Too little pressure results
in an uneven pattern, coarse droplet size, low flow,
and poor mixing. Too much pressure results in
excessive overspray, high flow rates, difficult control, and excessive wear.
•
Fluid temperature. Similar effects to fluid pressure
setting. The A and B temperatures can be offset to
help balance the fluid pressure.
•
Mix chamber size. Choice of mix chamber is based
on desired flow rate, fluid viscosity, and selected
ratio.
•
Clean-off air adjustment. Too little clean-off air
results in droplets building up on the front of the
nozzle, and no pattern containment to control overspray. Too much clean-off air results in air-assisted
atomization and excessive overspray.
to display cycle count.
NOTE:
To clear counter, press and hold
for 3 sec.
Hydraulic Pressure Control
Knob
Use to adjust hydraulic pressure available to the hydraulic drive system. Turn knob (HC) clockwise to increase
pressure and counterclockwise to decrease pressure.
Use hydraulic pressure gauge (HP, page 12) to view
hydraulic pressure.
+
ti7731a
ti7732a
NOTE:
Component A and B outlet pressures will be higher than
the hydraulic set pressure, depending on the model.
Component A and B pressure may be viewed on the
pressure gauges (GA, GB), or the higher of the two
pressures may be displayed on the motor control panel
(MC). See FIG. 3, page 12.
Motor Control Arrow Keys
Use
or
to:
•
Adjust pressure imbalance settings, page 27.
•
Adjust standby settings, page 31.
Spray Adjustments
Flow rate, atomization, and amount of overspray are
affected by four variables.
313539G
17
Setup
Setup
NOTICE
Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage fluctuations that can damage electrical equipment and void the warranty.
2. General equipment guidelines
•
1. Locate Reactor
Use the following procedure to determine the correct size generator.
a. Locate Reactor on a level surface. See Dimensions, page 40, for clearance and mounting
hole dimensions.
a. List system components that use peak load
requirements in watts.
b. Do not expose Reactor to rain.
b. Add the wattage required by the system components.
NOTICE
Bolt Reactor to original shipping pallet before lifting.
c.
c.
Use the casters to move Reactor to a fixed location, or bolt to shipping pallet and move with
forklift.
Perform the following equation:
Total watts x 1.25 = kVA (kilovolt-amperes)
d. Select a generator size that is equal to or
greater than the determined kVA.
•
Use proportioner power cords that meet or exceed
the requirements listed in Table 2. Failure to do so
will cause voltage fluctuations that can damage
electrical equipment.
•
Use an air compressor with constant speed head
unloading devices. Direct online air compressors
that start and stop during a job will cause voltage
fluctuations that can damage electrical equipment.
•
Maintain and inspect the generator, air compressor,
and other equipment per the manufacturer recommendations to avoid an unexpected shutdown.
Unexpected equipment shutdown will cause voltage
fluctuations that can damage electrical equipment.
•
Use a wall power supply with enough current to
meet system requirements. Failure to do so will
cause voltage fluctuations that can damage electrical equipment.
d. To mount on a truck bed or tailer, remove casters and bolt directly to truck or trailer bed. See
page 40.
18
Determine the correct size generator. Using the correct size generator and proper air compressor will
enable the proportioner to run at a nearly constant
RPM. Failure to do so will cause voltage fluctuations
that can damage electrical equipment. Ensure the
generator matches the voltage and phase of the
proportioner.
313539G
Setup
3. Electrical requirements
4. Connect electrical cord
See table 1.
NOTE:
Power cord is not suppled. See table 2.
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. Be sure your installation
complies with all National, State and Local safety and
fire codes.
Table 1: Electrical Requirements (kW/Full Load
Amps)
Part
Model
Voltage
(phase)
Full
Load
Peak
Amps*
256886
H-VR
230V (3)
71
26,600
256887
H-VR
400V (3)
41
26,600
System
Watts**
Table 2: Power Cord Requirements
Part
Model
Cord Specification
AWG (mm2)
256886
H-VR
4 (21.2), 3 wire + ground
256887
H-VR
8 (8.4), 4 wire + ground
a. 230V, 3 phase: Using 5/32 or 4 mm hex allen
wrench, connect three power leads to L1, L2,
and L3. Connect green to ground (GND).
GND
L1
*
Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow
rates, ratios, and mix chamber sizes may be less.
**
Total system watts, based on maximum hose length
for each unit, 410 ft (125 m) including whip hose.
L2
ti2515b
b. 400V, 3 phase: Using 5/32 or 4 mm hex allen
wrench, connect three power leads to L1, L2,
and L3. Connect neutral to N. Connect green to
ground (GND).
GND
L1
L2
L3
ti3248b
NOTE:
The motor must rotate counter-clockwise when viewed
from shaft end. To reverse rotation, disconnect power
and reverse power leads L1 and L2.
313539G
19
Setup
5. Connect feed pumps
page 9.
a. Install feed pumps (K) in component A and B
supply drums. See FIG. 1 and FIG. 2, pages 9
and 10.
SB
SA
b. Seal component A drum and use desiccant
dryer (M) in vent.
R
c.
Install agitator (L) in component B drum, if necessary.
BA
R
BB
ti9880a
d. Ensure A and B inlet valves (FV) are closed.
b. Alternatively: Secure supplied bleed tubes (N)
in grounded, sealed waste containers (H). See
FIG. 2, page 10.
7. Install Fluid Temperature Sensor (FTS)
FV
The Fluid Temperature Sensor (FTS) is supplied. Install
FTS between main hose and whip hose. See Heated
Hose manual 309572 for instructions.
ti10971a
NOTE:
Supply hoses from feed pumps should be 3/4 in. (19
mm) ID.
e. Connect and tighten component A and B supply
hose to the 3/4 npt(f) swivel on the component
A and B inlet valve.
6. Connect pressure relief lines
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as overpressure relief valves when set to
SPRAY
. 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.
a. Recommended: Connect high pressure hose
(R) to relief fittings (BA, BB) of both PRESSURE RELIEF/SPRAY valves, Route hose
back to component A and B drums. See FIG. 1,
20
313539G
Setup
8. Connect heated hose
bends. Wrap cable and electrical connections
with electrical tape.
NOTE:
See Heated Hose manual 309572 for detailed instructions on connecting heated hoses.
NOTE:
If spraying at a ratio other than 1:1, an E24 may occur.
Size hoses and mix chamber appropriately to avoid
pressure imbalance.
Y
V
NOTICE
The fluid temperature sensor (C) and whip hose (D)
must be used with heated hose, see page 20. Hose
length, including whip hose, must be 60 ft (18.3 m)
minimum.
ti9881a
9. Close gun fluid manifold valves A and B
a. Turn main power OFF
.
b. Assemble heated hose sections, FTS, and whip
hose.
c.
Connect A and B hoses to A and B outlets on
Reactor fluid manifold (FM). Hoses are color
coded: red for component A (ISO), blue for
component B (RES). Fittings are sized to prevent connection errors.
ti2411a
10. Connect whip hose to gun fluid manifold
Do not connect manifold to gun.
FM
N
A
P
ti2417a
11. Pressure check hose
B
ti9878a
See hose manual. Pressure check for leaks. If no leaks,
wrap hose and electrical connections to protect from
damage.
NOTE:
Manifold hose adapters (N, P) 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 fluid manifold and install
as needed to connect whip hose.
d. Connect cables (Y). Connect electrical connectors (V). Be sure cables have slack when hose
313539G
21
Setup
12. Ground system
a. Reactor: is grounded through power cord. See
page 19.
b. Spray gun: connect whip hose ground wire to
FTS, page 20. Do not disconnect wire or spray
without whip hose.
c.
Fluid supply containers: follow your local code.
d. Object being sprayed: 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 spray
gun firmly to the side of a grounded metal pail,
then trigger gun.
13. Check hydraulic fluid level
a. Hydraulic reservoir is filled at the factory. Check
fluid level before operating the first time, and
weekly thereafter. See Maintenance, page 37.
22
313539G
Startup
Startup
See table 3 for ratios with the one pump set at 1.0 and
available settings for the second pump.
Do not operate Reactor without all covers and shrouds
in place. Do not attempt to change ratio while machine
is pressurized or running. Do not loosen ratio lock
handle if A and B component pumps are pressurized
or while the pumps are operating.
Table 3: Ratio Range
Pump with higher
flow
Pump with lower
flow
1.0
1:1
0.95
1.05
1.0
0.90
1.11:1
1.0
0.85
1.2:1
1.0
0.80
1.25:1
1.0
0.75
1.33:1
0.70
1.42:1
1.0
1.0
1. Select ratio
POSN #1
The stroke lengths of the fluid pumps (AA and AB) can
be adjusted to select the ratio. The frame (AN) has three
pin positions for the bottom of the pump and a slider
mechanism at the top of the pump, which allows for
positioning of the pump at any required position. This
allows for a a range of ratio settings between the first
and last settings on the pump drive link.
POSN #1
Ratio
POSN #1
1.0
POSN #2
a. Shutdown system, see page 31.
1.0
0.66
1.51:1
b. Relieve pressure, see page 32.
1.0
0.60
1.66:1
1.0
0.55
1.88:1
0.50
2:1
1.0
0.45
2.22:1
1.0
0.40
2.5:1
c.
Loosen four clamping knobs (AJ) and remove
guard (AH).
1.0
POSN #1
POSN #3
AH
Pump A when viewed from rear of machine
AL
AJ
Pump B when viewed from rear of machine
AA
AB
r_256886_313359_6
FIG. 8: Pump Ratio Indicator Labels
FIG. 7: Front View
d. Use label on the pump drive link (AE) to identify
the correct position of the pump that needs to
be adjusted. See FIG. 8.
313539G
23
Startup
e. Remove base pin (BP) from frame (AN) if the
base of the pump needs to be moved. See FIG.
8.
AL
AF
AE
AM
TP
BP
3 21
AP
r_256886_313359_7
FIG. 9
f.
r_256886_313359_5
Loosen ratio lock handle (AL) over the pump
that needs adjustment. Use a soft mallet to
loosen ratio lock handle if necessary. Turn ratio
adjustment wheel (AM) until the mark on the
pump adapter block (AF) lines up with the correct position on the ratio indicator label on the
pump drive link (AE).
1 2 3
FIG. 10
h. Ensure top of pump is in correct ratio position.
Tighten ratio lock handle (AL).
i.
g. Reinstall base pin (BP) if it was removed.
Ensure bottom of pump is in correct position.
See FIG. 8.
Install guard (AH) and tighten clamping knobs
(AJ). See FIG. 7.
NOTICE
Move bottom position of pump once top of pump
enters a new position #. Failure to adjust bottom
position of pump will damage the machine.
NOTE:
For highest volume of material: Ensure pump has longest stroke length. Set the pump with more flow closest
to hydraulic pump (AC) or at 1.0 to achieve maximum
flowrates. See FIG. 8.
24
313539G
Startup
2. Load fluid with feed pumps
Open fluid valves A and B until clean, air-free
fluid comes from valves. Close valves.
NOTE:
The Reactor is tested with oil at the factory. Flush out
the oil with a compatible solvent before spraying. See
page 39.
a. Check that all Setup steps are complete.
b. Turn on component B agitator, if used.
c.
Turn both PRESSURE RELIEF/SPRAY valves
ti2484a
(SA, SB) to SPRAY
.
SB
SA
ti9877a
d. Start feed pumps.
e. Open fluid inlet valves (FV). Check for leaks.
FV
ti10972a
Do not mix components A and B during startup.
Always provide two grounded waste containers to
keep component A and component B fluids separate.
f.
Use feed pumps to load system. Hold gun fluid
manifold over two grounded waste containers.
313539G
25
Startup
3. Set temperatures
desired temperature. Repeat for
B
and
zones.
A
NOTE:
B
For
zone only, if FTS is disconnected at startup,
display will show hose current (0A). See step j, page 27.
e. Press
to display actual temperatures.
°F
°C
Do not turn on hose heat without fluid in hoses.
Temperature Controls and Indicators, see page 14
f.
b. Press
°F
or
°C
.
to change temperature
g. Turn on
ing
Press
press
A
and
B
heat zones by press-
for each zone.
.
h. Hold
d. To set
.
Thermal expansion can cause overpressurization,
resulting in equipment rupture and serious injury,
including fluid injection. Do not pressurize system
when preheating hose.
scale.
c.
heat zone by pressing
Preheat hose (15-60 min). Indicator will flash
very slowly when fluid reaches target temperature. Display shows actual fluid temperature in
hose near FTS.
This equipment is used with heated fluid, which can
cause equipment surfaces to become very hot. To
avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
Wear gloves if fluid temperature exceeds 110°F
(43°C).
a. Turn main power ON
Turn on
A
to view electrical currents for each
zone.
heat zone target temperature,
or
until display shows
i.
Hold
to view heater control circuit board
temperature.
26
313539G
Startup
j.
Manual current control mode only:
4. Set pressure
When in manual current control mode, monitor hose
temperature with thermometer. Install per instructions
below. Thermometer reading must not exceed 160°F
(71°C). Never leave machine unattended when in
manual current control mode.
ON / OFF
If FTS is disconnected or display shows diagnostic code E04, turn main power switch OFF
then ON
PARK
PSI
to clear diagnostic
code and enter manual current control mode.
BAR
display will show current to hose. Current is not limited by target temperature.
To prevent overheating, install hose thermometer close to gun end, within operator view. Insert
thermometer through foam cover of A component hose so stem is next to inner tube. Thermometer reading will be about 20°F less than
actual fluid temperature.
Motor Controls and Indicators, see page 16
a. Press
b. Press motor
If thermometer reading exceeds 160°F (71°C),
reduce current with
key.
to display the pressure reading.
. Motor and pumps start.
Display shows system pressure.
NOTE:
Motor must rotate counterclockwise when viewed from
shaft end. See Connect electrical cord, page 19.
c.
Adjust hydraulic pressure control until display
shows desired fluid pressure.
+
ti7731a
ti7732a
NOTICE
Never adjust hydraulic pressure while spraying. This
will result in over pressure alarm E23.
NOTE:
If display pressure is greater than desired pressure,
reduce the hydraulic pressure and trigger gun to reduce
pressure.
313539G
27
Startup
NOTE:
Table 4: Available Pressure Imbalance Settings
Check the pressure of each proportioning pump using
the component A and B gauges. The pressures should
be approximately equal and must remain fixed.
d. To display cycle count, press
.
NOTE:
PSI
BAR
PSI
BAR
100
200
300
400
*500
7
14
21
28
*35
600
700
800
900
999
42
49
56
63
69
* Factory default setting.
To clear counter, press and hold
for 3 sec.
d. Turn main power switch OFF
e. Press
PSI
or
BAR
to change pressure
to save
changes.
scale.
5. Change pressure imbalance setting (optional)
The pressure imbalance function (status code 24, page
36) detects conditions that can cause off-ratio spray,
such as loss of feed pressure/supply, pump seal failure,
clogged fluid inlet filter, or a fluid leak.
NOTE:
Code 24 (pressure imbalance) is set to an alarm as the
default. To change to a warning, see H-VR Repair-Parts
manual 313540.
The pressure imbalance default is factory-set at 500 psi
(3.5 MPa, 35 bar). For tighter ratio error detection, select
a lower value. For looser detection or to avoid nuisance
alarms, select a higher value.
a. Turn main power switch OFF
b. Press and hold
power switch ON
PSI
or
BAR
.
, then turn main
. Display will read
dP500 for psi or dP_35 for bar.
c.
Press
or
to select desired pres-
sure differential (100-999 in increments of 100
psi, or 7-70 in increments of 7 bar). See TABLE
4.
28
313539G
Spraying
Spraying
4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY
.
SA
1. Engage gun piston safety lock.
SB
ti9877a
ti2409a
5. Check that heat zones are on and temperatures are
on target, page 26.
2. Close gun fluid manifold valves A and B.
6. Press motor
to start motor and pumps.
7. Check fluid pressure display while the gun is detriggered and adjust as necessary, page 27.
ti2728a
3. Attach gun fluid manifold. Connect gun air line.
Open air line valve.
8. Check fluid pressure gauges (GA, GB) to ensure
proper pressure balance. If imbalanced, reduce
pressure of higher component by slightly turning
PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF/CIRCULATION
, until gauges show balanced pressures.
GA
GB
In this example, B side
pressure is higher, so
use the B side valve to
balance pressures.
ti9877a
ti2543a
313539G
29
Spraying
9. Open gun fluid manifold valves A and B.
ti2414a
NOTE:
On impingement guns, never open fluid manifold valves
or trigger gun if pressures are imbalanced.
10. Disengage gun piston safety lock.
ti2410a
11. Test spray onto cardboard. Adjust pressure and
temperature to get desired results.
12. Equipment is ready to spray.
NOTE:
If you stop spraying for a period of time, the unit will
enter standby (if enabled). See page 31.
30
313539G
Standby
Standby
Shutdown
If you stop spraying for a period of time, the unit will
enter standby by shutting down the electric motor and
hydraulic pump, to reduce equipment wear and minimize heat buildup. The ON/OFF LED and the pressure/cycle display on the motor control panel will flash
when in standby.
A
,
B
, and
heat zones will not be
shut off in standby.
To restart, spray off target for 2 sec. The system will
sense the pressure drop and the motor will ramp up to
full speed in a few seconds.
NOTE:
A
B
,
, and
heat zones.
2. Park pumps.
a. Press
NOTE:
The
1. Shut off
.
b. Trigger gun until pump A stops in the retracted
position and the pressure of both pumps bleeds
down.
3. Turn main power OFF
.
4. Close both fluid supply valves (FV).
This feature is disabled from the factory.
To activate or disable standby, adjust DIP switch #3 on
the motor control board. See Reactor Repair-Parts manual 313540.
The idle time before entering standby is user-settable as
follows:
FV
ti10971a
1. Turn main power switch OFF
2. Press and hold
ON
3. Press
.
5. Relieve pressure, page 32.
, then turn main power switch
.
or
to select desired timer set-
ting (5-20, in 5 minute increments). This sets the
length of inactive time before the unit will enter
standby.
4. Turn main power switch OFF
to save
changes.
313539G
31
Pressure Relief Procedure
Pressure Relief Procedure
5. Engage gun piston safety lock.
1. Relieve pressure in gun and perform gun shutdown
procedure. See gun manual.
2. Close gun fluid manifold valves A and B.
ti2409a
6. Disconnect gun air line and remove gun fluid manifold.
ti2421a
3. Shut off feed pumps and agitator, if used.
ti2554a
4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)
to PRESSURE RELIEF/CIRCULATION
.
Route fluid to waste containers or supply tanks.
Ensure gauges drop to 0.
SA
SB
ti9879a
32
313539G
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
5. Set temperature targets, see page 26. Turn on
A
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding
fluid temperature limits.
To circulate through gun manifold and preheat hose,
see page 34.
B
and
Do not turn on
heat zones by pressing
.
heat zone unless hoses are
already loaded with fluid.
6. Press
to display actual temperatures.
7. Before starting motor, reduce hydraulic pressure to
1. Load fluid with feed pumps, page 25.
A
the minimum required to circulate fluid until
and
B
temperatures reach targets.
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as overpressure relief valves when set to
-
SPRAY
. Lines must be open so valves can
automatically relieve pressure when machine is operating.
2. See Typical Installation, with circulation, page 9.
Route circulation lines back to respective component A or B supply drum. Use hoses rated at the
maximum working pressure of this equipment. See
Technical Data, page 41.
ti7732a
8. Press motor
to start motor and pumps. Circu-
late fluid at lowest possible pressure until temperatures reach targets.
9. Turn on
heat zone by pressing
.
3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
10. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
PRESSURE RELIEF/CIRCULATION
.
SPRAY
SA
.
SA
SB
SB
ti9879a
4. Turn main power ON
313539G
ti9877a
.
33
Fluid Circulation
Circulation Through Gun
Manifold
7. Before starting motor, reduce hydraulic pressure to
the minimum required to circulate fluid until
and
B
temperatures reach targets.
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding
fluid temperature limits.
-
Circulating fluid through the gun manifold allows rapid
preheating of hose.
1. Install gun fluid manifold (P) on Part 246362 accessory circulation kit (CK). Connect high pressure circulation lines (R) to circulation manifold.
A
ti7732a
8. Press motor
to start motor and pumps. Circu-
late fluid at lowest possible pressure until temperatures reach targets.
P
CK
R
ti2767a
2. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the
maximum working pressure of this equipment. See
Typical Installation, without circulation, page 10.
3. Follow Select ratio, page 23.
4. Turn main power ON
.
5. Set temperature targets, see page 26. Turn on
A
,
B
, and
heat zones by pressing
.
6. Press
34
to display actual temperatures.
313539G
Diagnostic Codes
Diagnostic Codes
Temperature Control Diagnostic Codes
Temperature control diagnostic codes appear on temperature display.
These alarms turn off heat. E99 clears automatically
when communication is regained. Codes E03 through
E06 can be cleared by pressing
turn main power OFF
. For other codes,
then ON
to
clear.
See repair manual for corrective action.
Code
Code Name
Alarm Zone
01
High fluid temperature
Individual
02
High current
Individual
03
No current
Individual
04
FTS not connected
Individual
05
Board overtemperature
Individual
06
Loss of zone communication
Individual
30
Momentary loss of communica- All
tion
99
Loss of display communication
All
NOTE:
For hose zone only, if FTS is disconnected at startup,
display will show hose current 0A.
313539G
35
Diagnostic Codes
Motor Control Diagnostic Codes
Motor control diagnostic codes E21 through E27 appear
on pressure display.
Warnings
There are two types of motor control codes: alarms and
warnings. Alarms take priority over warnings.
Reactor will continue to run. Press
to clear. A
warning will not recur for a predetermined amount of
time (varies for different warnings), or until main power
See repair manual for corrective action.
is turned OFF
Alarms
Alarms turn off Reactor. Turn main power OFF
then ON
to clear.
NOTE:
Code
No.
then ON
Code Name
.
No transducer (component A)
Alarm
22
No transducer (component B)
Alarm
23
High pressure
Alarm
24
Pressure imbalance
Selectable;
see repair
manual
27
High motor temperature
Alarm
30
Momentary loss of communication
Alarm
31
Pumpline switch failure/high
cycle rate
Alarm
99
Loss of communication
Alarm
NOTE:
Code 24 (pressure imbalance) is set to an alarm default
of 500 psi (3.5 MPa, 35 bar). To change to a warning,
see Reactor Repair-Parts manual 313540. To change
the default pressure imbalance setting, see page 28.
36
Alarm or
Warning
21
Alarms can also be cleared, except for code 23, by
pressing
.
313539G
Maintenance
Maintenance
•
Inspect hydraulic and fluid lines for leaks daily.
•
Keep component A from exposure to moisture in
atmosphere, to prevent crystallization.
•
Clean up all hydraulic leaks; identify and repair
cause of leak.
•
Clean gun mix chamber ports regularly. See gun
manual.
•
Clean gun check valve screens regularly. See gun
manual.
•
Use compressed air to prevent dust buildup on control boards, fan, motor (under shield), and hydraulic
oil coolers.
•
Keep vent holes on bottom of electrical cabinet
open.
•
Inspect fluid inlet strainer screens daily, see below.
•
Grease circulation valves weekly with Fusion
grease (117773).
ti9879a
•
Check hydraulic fluid level weekly. Check hydraulic
fluid level on dipstick (DS). Fluid level must be
between indent marks (IM) on dipstick. Refill as
required with approved hydraulic fluid; see Technical Data on page 41 and the Approved Anti-Wear
(AW) Hydraulic Oils table in the Reactor
Repair-Parts manual 313540. If fluid is dark in color,
change fluid and filter.
DS
S
IM
ti10003a
ti7861a
•
Change break-in oil in a new unit after first 250
hours of operation or within 3 months, whichever
comes first. See Table 4 for recommended frequency of oil changes
Table 5: Frequency of Oil Changes
Ambient
Temperature
Recommended
Frequency
0 to 90°F
(-17 to 32°C)
1000 hours or 12 months,
whichever comes first
90°F and above
(32°C and above)
500 hours or 6 months,
whichever comes first
313539G
37
Fluid Inlet Strainer Screen
Fluid Inlet Strainer Screen
4. Ensure the pipe plug (59k) is screwed into the
strainer plug (59j). Install the strainer plug with the
screen (59g) and gasket (59h) in place and tighten.
Do not overtighten. Let the gasket make the seal.
The inlet strainers filter out particles that can plug the
pump inlet check valves. Inspect the screens daily as
part of the startup routine, and clean as required.
Use clean chemicals and follow proper storage, transfer,
and operating procedures, to minimize contamination of
the A-side screen.
5. Open the fluid inlet valve, ensure that there are no
leaks, and wipe the equipment clean. Proceed with
operation.
59d
59g*
59h
NOTE:
Clean the A-side screen only during daily startup. This
minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing
operations.
59j
59k
ti9886a
FIG. 11: Fluid Inlet Strainer
1. Close the fluid inlet valve at the pump inlet and shut
off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.
* See Reactor Repair-Parts manual 313540 for fluid filter screen replacements.
2. Place a container under the strainer manifold (59d)
to catch fluid. Remove the strainer plug (59j).
3. Remove the screen (59g) from the strainer manifold. Thoroughly flush the screen with compatible
solvent and shake it dry. Inspect the screen. If more
than 25% of the mesh is blocked, replace the
screen. Inspect the gasket (59h) and replace as
required.
38
313539G
Flushing
Flushing
Flush equipment only in a well-ventilated area. Do not
spray flammable fluids. Do not turn on heaters while
flushing with flammable solvents.
•
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.
•
To flush feed hoses, pumps, and heaters separately
from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).
. Flush through bleed
SA
SB
N
N
ti9880a
•
To flush entire system, circulate through gun fluid
manifold (with manifold removed from gun).
•
To prevent moisture from reacting with isocyanate,
always leave the system dry or filled with a moisture-free plasticizer or oil. Do not use water. See
page 7.
313539G
39
Dimensions
Dimensions
Dimension
in. (mm)
Dimension
in. (mm)
A (height)
B (width)
C (depth)
57.31 (1455.42)
37.86 (961.6)
33 (838.2)
D (front and rear mounting holes)
F (side mounting holes)
G (mounting post inner diameter)
32.5 (825.5)
30.375 (7715)
0.44 (11)
Top View
D
G
Front of Machine
A
C
F
Rear of Machine
r_256886_313359_1A
D
B
40
313539G
Technical Data
Technical Data
Category
Maximum Fluid Working Pressure
Fluid Inlets
Fluid Outlets
Data
3500 psi (24.1 MPa, 241 bar)
3/4 npsm union in 1 in. npt(f) ball valve
Component A (ISO): #8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
Component B (RES): #10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
Fluid Circulation Ports
1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum
Maximum Fluid Temperature
190°F (88°C)
Maximum Output (10 weight oil at Model H-VR: 3.0 gpm (11.4 liter/min) (60 Hz)
ambient temperature) 1:1
Output per Cycle
Variable: 2 oz.- 5 oz. (60 cc - 150 cc) per pump*
Stroke Length
Variable: 2 in. - 5 in. (5.08 cm - 12.7 cm)
Line Voltage Requirement
230V 3 phase units: 195-264 Vac, 50/60 Hz
400V 3 phase units: 338-457 Vac, 50/60 Hz
Amperage Requirement
See Models, page 2.
Heater Power
See Models, page 2.
(A and B heaters total, no hose)
Hydraulic reservoir capacity
3.5 gal. (13.6 liters)
Recommended hydraulic fluid
Citgo A/W Hydraulic Oil, ISO Grade 46
Sound power, per ISO 9614-2
90.9 dB(A)
Sound pressure,
84.0 dB(A)
1 m from equipment
Weight
955 lb (433 kg)
Wetted Parts
Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome,
fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, chemically
resistant o-rings
*Output example: 2.5:1 ratio = 150 cc (B side):60 cc (A side)
2.5:1 output = 150 cc (B side) + 60 cc (A side) = 210 cc per cycle
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
313539G
41
Performance Charts
Performance Charts
Foam Performance Chart
Pressure in psi (MPa, bar)
2000
(13.8, 138)
KEY
A = H-25 at 50 Hz
B = H-25 at 60 Hz
C = H-40 at 50 Hz
D = H-40 at 60 Hz
E = H-50 at 50 Hz
❄F = H-50 at 60 Hz
G = H-VR at 60 Hz
A
1500
(10.3, 103)
B
G
1000
(6.9, 69)
C
E
500
(3.4, 34)
D
F
0
5
15
25
35
45
55
(2.3)
(6.8)
(11.4)
(15.9)
(20.5)
(25.0)
Flow Rate in lb/min (kg/min)
❄ Pressure flow curve for model 253725 (H-50 230V 1 phase) not shown.
Maximum pressure limited to 1700 psi (11.7 MPa, 11.7 bar)
Coatings Performance Chart
KEY
H = H-XP2 at 50 Hz
J = H-XP2 at 60 Hz
K = H-XP3 at 50 Hz
L = H-XP3 at 60 Hz
M = H-VR at 60 Hz
Pressure in psi (MPa, bar)
3500
(24.1, 241)
3000
(20.7, 207)
H
2500
(17.2, 172)
J
K
2000
(13.8, 138)
M
1500
(10.3, 103)
L
1000
(6.9, 69)
500
(3.4, 34)
0
0.5
(1.9)
1.0
(3.8)
1.5
(5.7)
2.0
(7.6)
2.5
(9.5)
3.0
(11.4)
Flow Rate in gal/min (liter/min)
42
313539G
Performance Charts
Heater Performance Chart
140
(78)
130
KEY
H-VR = 15.3 kW
(72)
120
Delta T in degrees F (degrees C)
(67)
110
(61)
100
H-VR
(56)
90
(50)
80
(44)
70
(39)
60
(33)
50
(28)
40
(22)
30
(17)
20
(11)
10
(6)
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
(1.9)
(3.8)
(5.7)
(7.6)
(9.5)
(11.4)
(13.2)
(15.1)
(17.0)
Flow Rate in gpm (lpm)
★ Heater performance data is based on testing with 10 wt.
hydraulic oil and 230V across heater power wires.
313539G
43
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. 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. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs
will be 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
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
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.
Original instructions. This manual contains English. MM 313539
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2009, Graco Inc. is registered to ISO 9001
www.graco.com
Revision G - August 2015
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