Graco 333023J, Reactor 2 E-30 and E-XP2 Proportioning Systems Owner's Manual

Operation
Reactor 2 E-30 and E-XP2
Proportioning Systems
333023J
EN
Electric, Heated, Plural Component Proportioner for spraying polyurethane foam and polyurea coatings.
Not for outdoor use. For professional use only. Not approved for use in explosive atmospheres or
hazardous locations.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
WL E
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Warnings ........................................................... 3
Important Isocyanate Information......................... 7
Models............................................................... 9
Approvals........................................................... 11
Accessories........................................................ 11
Supplied Manuals ............................................... 12
Related Manuals ................................................ 12
Typical Installation, without circulation.................. 13
Typical Installation, with system fluid manifold
to drum circulation ................................. 14
Typical Installation, with gun fluid manifold to
drum circulation..................................... 15
Component Identification..................................... 16
Advanced Display Module (ADM) ........................ 18
ADM Display Details .................................... 21
Navigating the Screens ................................ 21
Electrical Enclosure ............................................ 23
Motor Control Module (MCM) .............................. 24
Temperature Control Module (TCM) Cable
Connections.......................................... 25
Home — System Off .................................... 37
Home — System Active................................ 37
Home — System With Error.......................... 37
Targets........................................................ 37
Maintenance................................................ 38
Cycles ......................................................... 38
Events......................................................... 38
Errors.......................................................... 38
Troubleshooting ........................................... 39
Diagnostic ................................................... 40
Job Data ..................................................... 40
Recipes....................................................... 40
Startup............................................................... 42
Fluid Circulation.................................................. 45
Circulation Through Reactor ......................... 45
Circulation Through Gun Manifold ................. 46
Jog Mode ........................................................... 46
Spraying ............................................................ 47
Spray Adjustments ....................................... 48
Manual Hose Heat Mode..................................... 49
Enable Manual Hose Mode........................... 49
Disable Manual Hose Mode .......................... 50
Shutdown........................................................... 51
Installation.......................................................... 26
Pressure Relief Procedure .................................. 53
Setup................................................................. 27
Grounding ................................................... 27
General Equipment Guidelines ..................... 27
Connect Power ............................................ 28
Supply Wet Cups With Throat Seal Liquid
(TSL) ............................................. 29
Install Fluid Temperature Sensor .................. 29
Connect Heated Hose to Proportioner ........... 30
Register and Activate the Graco InSite ........... 30
Flushing ............................................................. 54
Advanced Display Module (ADM)
Operation.............................................. 31
Advanced Setup Screens .................................... 34
Advanced Screen 1 — General..................... 34
Advanced Screen 2 — Units ......................... 34
Advanced Screen 3 — USB.......................... 34
Advanced Screen 4— Software .................... 34
System 1............................................................ 35
System 2............................................................ 35
Recipes ............................................................. 35
Add Recipe.................................................. 35
Enable or Disable Recipes............................ 35
Run Mode .......................................................... 36
2
Maintenance ...................................................... 55
Preventative Maintenance Schedule ............. 55
Proportioner Maintenance ............................ 55
Flush Inlet Strainer Screen ........................... 56
Pump Lubrication System ............................. 57
Errors ................................................................ 58
View Errors.................................................. 58
Troubleshoot Errors ..................................... 58
Troubleshooting.................................................. 59
Error Codes and Troubleshooting.................. 59
USB Data........................................................... 60
Download Procedure.................................... 60
USB Logs.................................................... 60
System Configuration Settings ...................... 61
Custom Language File ................................. 62
Upload Procedure ........................................ 62
Performance Charts............................................ 63
Technical Specifications...................................... 67
Graco Extended Warranty for Reactor® 2
Components ......................................... 69
333023J
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 symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, 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.
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 at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES
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.
333023J
3
Warnings
WARNING
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.
treatment
•
•
•
•
•
•
Do not spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
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.
Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
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. Do not use pail liners unless
they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock.. Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
4
333023J
Warnings
WARNING
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
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 property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon
solvents or fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
• See Technical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
333023J
5
Warnings
WARNING
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.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure 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. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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.
MOVING PARTS HAZARD
Moving parts can pinch, cut 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 and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
6
333023J
Important Isocyanate Information
Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
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:
333023J
7
Important Isocyanate Information
Self--Ignition
Material Self
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and SDS.
Keep Components A and B Separate
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure, forming small, hard, abrasive
crystals 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.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage to 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.
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.
• 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.
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.
• 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
333023J
Models
Models
Reactor 2 E-30 and E-30 Elite
All elite systems include fluid inlet sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) heated hose. For
part numbers, see Accessories, page 11
Model
Proportioner ★
Maximum Fluid Working
Pressure psi (MPa, bar)
Approximate Output per
Cycle (A+B) gal. (liter)
Max Flow Rate lb/min
(kg/min)
Total System Load †
�(Watts)
Configurable Voltage
Phase�
Phase
E-30 Model
15 kW
272011
10 kW
272010
E-30 Elite Model
15kW
272111
10 kW
272110
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
0.0272 (0.1034)
0.0272 (0.1034)
0.0272 (0.1034)
0.0272 (0.1034)
30 (13.5)
30 (13.5)
30 (13.5)
30 (13.5)
17,900
23,000
17,900
23,000
200
–240
VAC
1Ø
Full Load Peak Current* 78
200
–240
VAC
3Ø∆
50
350
–415
VAC
3ØY
34
200
–240
VAC
1Ø
100
200
–240
VAC
3Ø∆
62
350
–415
VAC
3ØY
35
200
–240
VAC
1Ø
78
200
–240
VAC
3Ø∆
50
350
–415
VAC
3ØY
34
200
–240
VAC
1Ø
100
200
–240
VAC
3Ø∆
62
350
–415
VAC
3ØY
35
Fusion AP Package �
AP2010
AH2010
AP2011
AH2011
AP2110
AH2110
AP2111
AH2111
(Gun Part No.)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
Fusion CS Package �
CS2010
CH2010
CS2011
CH2011
CS2110
CH2110
CS2111
CH2111
(Gun Part No.)
(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)
Probler P2 Package �
P22010
(Gun Part No.)
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
Heated Hose
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-Wrap)
Heated Whip Hose
10 ft (3 m)
Graco Insite™
24K240
24K240
24K240
24K240
24Y240
24Y240
24Y240
24Y240
Qty: 1
Qty: 5
Qty: 1
Qty: 5
Qty: 1
Qty: 5
Qty: 1
Qty: 5
246050
PH2010
P22011
PH2011
246050
Fluid Inlet Sensors (2)
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements at
various flow rates and mix chamber sizes may be
less.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)
maximum heated hose length, including whip
hose.
★
See Approvals, page 11.
333023J
P22110
PH2110
P22111
246050
246050
✓
✓
✓
✓
PH2111
�
Packages include gun, heated hose, and whip
hose. Elite packages also include Graco InSite
and fluid inlet sensors.
�
Low line input voltage will reduce power available
and heaters will not perform at full capacity.
Voltage Configurations Key
Phase
Ø
∆
DELTA
Y
WYE
9
Models
Reactor 2 E-XP2 and E-XP2 Elite
All elite systems include fluid inlet sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) heated hose. For
part numbers, see Accessories, page 11
Model
Proportioner ★
Maximum Fluid Working
Pressure psi (MPa, bar)
Approximate Output per
Cycle (A+B) gal. (liter)
Max Flow Rategpm/min
(l/min)
Total System Load † �
(Watts)
Configurable Voltage
Phase �
Full Load Peak Current
(amps)
E–XP2 Model
E–XP2 Elite Model
15 kW
272012
15 kW
272112
3500 (24.1, 241)
3500 (24.1, 241)
0.0203 (0.0771)
0.0203 (0.0771)
2 (7.6)
2 (7.6)
23,000
23,000
200–240
VAC 1Ø
100
200–240
VAC 3Ø∆
62
350–415
VAC 3ØY
35
200–240
VAC 1Ø
100
200–240
VAC 3Ø∆
62
Fusion AP Package �
AP2012
AP2112
(Gun Part No.)
(246100)
(246100)
Probler P2 Package �
P22012
P22112
(Gun Part No.)
(GCP2R0)
(GCP2R0)
Heated Hose
50 ft (15 m)
Heated Whip Hose
10 ft (3 m)
Graco Insite™
Fluid Inlet Sensors (2)
24K241
(scuff guard)
246055
24Y241
(Xtreme-Wrap)
246055
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)
maximum heated hose length, including
whip hose.
★
10
See Approvals, page 11.
350–415
VAC 3ØY
35
✓
✓
�
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors.
�
Low line input voltage will reduce power
available and heaters will not perform at full
capacity.
Voltage Configurations Key
Phase
Ø
∆
DELTA
Y
WYE
333023J
Approvals
Approvals
Accessories
Kit Number
Description
24U315
Air Manifold Kit (4 outlets)
24U314
Wheel and Handle Kit
24T280
Graco InSite Kit
16X521
Graco InSite Extension cable 24.6 ft
(7.5 m)
24N449
50 ft (15 m) CAN cable (for remote
display module)
9902471
24K207
Conforms to ANSI/UL Std. 499
Certified to CAN/CSA Std. C22.2 No. 88
Fluid Temperature Sensor (FTS)
with RTD
24U174
Remote Display Module Kit
15V551
ADM Protective Covers (10 pack)
15M483
Remote Display Module Protective
Covers (10 pack)
24M174
Drum Level Sticks
121006
150 ft (45 m) CAN cable (for remote
display module)
24N365
RTD Test Cables (to aide resistance
measurements)
Intertek approvals apply to proportioners without
hoses.
Proportioner Approvals:
333023J
11
Supplied Manuals
Supplied Manuals
The following manuals are shipped with the Reactor
2. Refer to these manuals for detailed equipment
information.
Manuals are also available at www.graco.com.
Manual
333023
333091
333092
Description
Reactor 2 E-30 and E-XP2
Operation
Reactor 2 E-30 and E-XP2 Startup
Quick Guide
Reactor 2 E-30 and E-XP2
Shutdown Quick Guide
Related Manuals
The following manuals are for accessories used with
the Reactor.
Component Manuals in English:
Manuals are available at www.graco.com.
System Manuals
333024
Reactor 2 E-30 and E-XP2,
Repair-Parts
Displacement Pump Manual
309577
Electric Reactor Displacement Pump,
Repair-Parts
Feed System Manuals
309572
Heated Hose, Instructions-Parts
309852
Circulation and Return Tube Kit,
Instructions-Parts
309815
Feed Pump Kits, Instructions-Parts
309827
Feed Pump Air Supply Kit,
Instructions-Parts
Spray Gun Manuals
309550
Fusion ™ AP Gun
312666
Fusion ™ CS Gun
313213
Probler® P2 Gun
Accessory Manuals
3A1905
Feed Pump Shutdown Kit,
Instructions-Parts
3A1906
Light Tower Kit, Instructions-Parts
3A1907
Remote Display Module Kit,
Instructions-Parts
332735
Air Manifold Kit, Instructions-Parts
332736
Handle and Wheel Kit,
Instructions-Parts
333276
Graco InSite ™ Kit, Instructions-Parts
12
333023J
Typical Installation, without circulation
Typical Installation, without circulation
H
J
K
G
A
J
L
M
K
G
F
N
(RES)
00000
N
(ISO)
00000
D
00000
E
S
00
00000
P
C*
00
B
00000
Figure 1
00000
* Shown exposed for clarity. Wrap with tape during operation.
A
B
Reactor Proportioner
Heated Hose
C
D
E
F
Fluid Temperature Sensor (FTS)
Heated Whip Hose
G
H
333023J
Fusion Spray Gun
Gun Air Supply Hose
Feed Pump Air Supply Lines
Agitator Air Supply Line
J
K
L
M
N
P
S
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Bleed Lines
Gun Fluid Manifold (part of gun)
Remote Display Module Kit (optional)
13
Typical Installation, with system fluid manifold to drum circulation
Typical Installation, with system fluid manifold to drum
circulation
K
H
M
G
J
J
R
A
M
K
L
R
G
(RES)
F
00000
(ISO)
00000
D
00000
E
S
00
00000
P
C*
00
B
00000
Figure 2
00000
* Shown exposed for clarity. Wrap with tape during operation.
A
B
Reactor Proportioner
Heated Hose
C
D
E
F
Fluid Temperature Sensor (FTS)
Heated Whip Hose
G
H
14
Fusion Spray Gun
Gun Air Supply Hose
Feed Pump Air Supply Lines
Agitator Air Supply Line
J
K
L
M
P
R
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
S
Remote Display Module (optional)
Gun Fluid Manifold (part of gun)
Recirculation Lines
333023J
Typical Installation, with gun fluid manifold to drum circulation
Typical Installation, with gun fluid manifold to drum
circulation
H
K
M
G
J
J
R
M
A
K
R
L
G
N
(RES)
N
(ISO)
F
D
S
C*
P
B
Figure 3
* Shown exposed for clarity. Wrap with tape during operation.
A
B
Reactor Proportioner
Heated Hose
C
CK
D
F
Fluid Temperature Sensor (FTS)
Circulation Block (accessory)
Heated Whip Hose
G
H
333023J
Gun Air Supply Hose
Feed Pump Air Supply Lines
Agitator Air Supply Line
J
K
L
M
P
R
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
S
Remote Display Module (optional)
Gun Fluid Manifold (part of gun)
Recirculation Lines
15
Component Identification
Component Identification
B
D
S
E
P
C*
Figure 4
16
333023J
Component Identification
Key
BA
BB
ISO Side Pressure Relief Outlet
RES Side Pressure Relief Outlet
RS
SA
CD
DG
EC
EM
FA
FB
FH
FM
FV
Advanced Display Module (ADM)
Drive Gear Housing
Electrical Cord Strain Relief
Electric Motor
SB
ISO Side Fluid Manifold Inlet
RES Side Fluid Manifold Inlet
Fluid Heaters (behind shroud)
Reactor Fluid Manifold
Fluid Inlet Valve (RES side shown)
ISO Side Pressure Gauge
RES Side Pressure Gauge
ISO Side Hose Connection
RES Side Hose Connection
Main Power Switch
ISO Side Pump
RES Side Pump
Graco InSite Cellular Module (Elite models
only)
TB
GA
GB
HA
HB
MP
PA
PB
RR
333023J
T
TA
XA
XB
Red Stop Button
ISO Side PRESSURE RELIEF/SPRAY
Valve
RES Side PRESSURE RELIEF/SPRAY
Valve
Heated Hose Power Termination Box
ISO Side Pressure Transducer (behind
gauge GA)
RES Side Pressure Transducer (behind
gauge GB)
Fluid Inlet Sensor (ISO side, Elite models
only)
Fluid Inlet Sensor (RES side, Elite models
only)
17
Advanced Display Module (ADM)
Advanced Display Module (ADM)
The ADM display shows graphical and text
information related to setup and spray operations.
NOTICE
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
Figure 5 Front View
18
333023J
Advanced Display Module (ADM)
Table 1 : ADM Keys and Indicators
Key
Function
Press to startup or shutdown the system.
Startup/Shutdown
Key and Indicator
Press to stop all proportioner processes. This Is not a safety or emergency stop.
Stop
Press to select the specific screen or operation shown on the display directly next to
each key.
Soft Keys
• Left/Right Arrows: Use to move from screen to screen.
• Up/Down Arrows: Use to move among fields on a screen, items on a dropdown
menu, or multiple screens within a function.
Navigation Keys
Numeric Keypad
Use to input values.
Use to cancel a data entry field.
Cancel
Press to enter or exit Setup mode.
Setup
Press to choose a field to update, to make a selection, to save a selection or value, to
enter a screen, or to acknowledge an event.
Enter
333023J
19
Advanced Display Module (ADM)
Figure 6 Back View
CJ
CK
CL
CM
Flat Panel Mount (VESA 100)
Model and Serial Number
USB Port and Status LEDs
CAN Cable Connection
CN
CP
CR
CS
Module Status LEDs
Accessory Cable Connection
Token Access Cover
Battery Access Cover
Table 2 ADM LED Status Descriptions
LED
Conditions
Description
System Status
Green Solid
Run Mode, System On
Green Flashing
Setup Mode, System On
Yellow Solid
Run Mode, System Off
Yellow Flashing
Setup Mode, System Off
Green Flashing
Data recording in progress
Yellow Solid
Downloading information to USB
Green and Yellow Flashing
ADM is busy, USB cannot transfer
information when in this mode
Green Solid
Power applied to module
Yellow Solid
Active Communication
Red Steady Flashing
Software upload from token in
progress
Red Random Flashing or Solid
Module error exists
USB Status (CL)
ADM Status (CN)
20
333023J
Advanced Display Module (ADM)
ADM Display Details
Alarm/Deviation
Power Up Screen
The current system error is displayed in the middle of
the menu bar. There are four possibilities:
The following screen appears when the ADM is
powered up. It remains on while the ADM runs through
initialization and establishes communication with other
modules in the system.
Icon
No Icon
Function
No information or no error has occurred
Advisory
Deviation
Alarm
Status
The current system status is displayed at the lower right
of the menu bar.
Soft Keys
Icons next to the soft keys indicate which mode or
action is associated with each soft key. Soft keys that
do not have an icon next to them are not active in the
current screen.
Menu Bar
The menu bar appears at the top of each screen. (The
following image is only an example.)
Date and Time
NOTICE
To prevent damage to the soft key buttons, do not
press buttons with sharp objects such as pens, plastic
cards, or fingernails.
Navigating the Screens
The date and time are always displayed in one of the
following formats. The time is always displayed as a
24-hour clock.
There are two sets of screens:
• DD/MM/YY HH:MM
• The Setup screens control system parameters and
advanced features.
• YY/MM/DD HH:MM
• MM/DD/YY HH:MM
Arrows
The left and right arrows indicate screen navigation.
• The Run screens control spraying operations and
display system status and data.
Press
on any Run screen to enter the Setup
screens. If the system has a password lock, the
Password screen displays. If the system is not locked
(password is set to 0000), System Screen 1 displays.
Screen Menu
The screen menu indicates the currently active screen,
which is highlighted. It also indicates the associated
screens that are available by scrolling left and right.
System Mode
The current system mode is displayed at the lower left
of the menu bar.
on any Setup screen to return to the
Press
Home screen.
Press the Enter soft key
function on any screen.
Press the Exit soft key
to activate the editing
to exit any screen.
Use the other softkeys to select the function adjacent
to them.
333023J
21
Advanced Display Module (ADM)
Icons
Icons
Icon
Softkeys
Function
Component A
Component B
Icon
Function
Start Proportioner
Start and Stop Proportioner in Jog Mode
Stop Proportioner
Estimated Supply Material
Turn on or off the specified heat zone.
Hose Temperature
Park pump
Jog Mode Speed
Enter Jog Mode. See Jog Mode, page 46
Pressure
Reset Cycle Counter
(press and hold)
Cycle Counter (press and
hold)
Select Recipe
Advisory.
See Errors, page 38 for more
information.
Search
Deviation.
See Errors, page 38 for more
information
Alarm.
See Errors, page 38 for more
information
Move Cursor Left One Character
Move Cursor Right One Character
Toggle between upper-case, lower-case, and
numbers and special characters.
Backspace
Cancel
Clear
Troubleshoot Selected Error
Increase value
Decrease value
Next screen
Previous screen
Return to first screen
22
333023J
Electrical Enclosure
Electrical Enclosure
AAA Temperature Control Module (TCM)
AAB Motor Control Module (MCM)
AAC Enclosure Fan
AAD Wiring Terminal Blocks
AAE Power Supply
AAF Surge Protector
AAG Hose Breaker
AAH Motor Breaker
AAJ A Side Heat Breaker
AAK B Side Heat Breaker
AAL Transformer Breaker
MP Main Power Switch
333023J
23
Motor Control Module (MCM)
Motor Control Module (MCM)
Base Model
Elite Model
Figure 7
Description
MS
1
2
3
4
5
Module Status LEDs see LED Status Table
CAN Communication Connections
Motor Temperature
Not used
Not used
Not used
6
7
A Pump Output Pressure
B Pump Output Pressure
8
9
A Fluid Inlet Sensor (Elite only)
B Fluid Inlet Sensor (Elite only)
10
11
12
14
15
16
*RS
Accessory output
Not used
Pump Cycle Counter
Graco Insite™
Motor Power Output
Main Power Input
Rotary Switch
* MCM Rotary Switch Positions
2=E-30
3=E-XP2
Table 3 MCM Module LED (MS) Status Descriptions
LED
Conditions
Description
MCM Status
Green Solid
Power applied to module
Yellow Flashing
Active Communication
Red Steady Flashing
Software upload from token in
progress
Red Random Flashing or Solid
Module error exists
24
333023J
Temperature Control Module (TCM) Cable Connections
Temperature Control Module (TCM) Cable Connections
Figure 8
1
2
3
4
5
6
7
8
9
10
Power Input
Heater Overtemperature
CAN Communications Connections
Power Out (ISO)
Power Out (Res)
Power Out (Hose)
Module Status LEDs
Heater A Temperature (ISO)
Heater B Temperature (RES)
Hose Temperature
Table 4 TCM Module LED (7) Status Descriptions
LED
Conditions
Description
TCM Status
Green Solid
Power applied to module
Yellow Flashing
Active Communication
Red Steady Flashing
Software upload from token in
progress
Red Random Flashing or Solid
Module error exists
333023J
25
Installation
Installation
Setup From Shipping Configuration
1. Remove bolts (A) and nuts.
2. Swing up the electrical enclosure and reinstall
bolt (A) with nut. Tighten bolt (B) and nut.
3. Position cable bundles against the frame and
attach to the frame with loose wire tie (C) on
each side.
1. Use the supplied bolts to install the supplied
L-brackets onto the system frame in the top-most
square holes. Install brackets on both the left
and right side of system frame.
2. Secure the L-brackets to the wall. If L-brackets
do not line up with the wall stud spacing, bolt a
piece of wood to the studs then secure L-brackets
to wood.
3. Use the four holes in the base of the system
frame to secure base to the floor. Bolts not
supplied.
To prevent serious injury due to system tipping
over, ensure Reactor is properly secured to wall.
Note
Mounting brackets and bolts are included in the box
of loose parts, shipped with your system.
26
333023J
Setup
Setup
Grounding
General Equipment Guidelines
• 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.
Use the following procedure to determine the correct
size generator.
The equipment must be grounded to reduce the
risk of static sparking. Static sparking can cause
fumes to ignite or explode. Grounding provides an
escape wire for the electric current.
• Reactor: System is grounded through the power
cord.
• Spray gun: connect whip hose ground wire to FTS.
See Install Fluid Temperature Sensor, page 29.
Do not disconnect ground wire or spray without
whip hose.
• Fluid supply containers: follow your local code.
• Object being sprayed: follow your local code.
• 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.
• 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.
1. List system components that use peak load
requirements in watts.
2. Add the wattage required by the system
components.
3. Perform the following equation:
Total watts x 1.25 = kVA (kilovolt-amperes)
4. 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 5. Failure to do so
will cause voltage fluctuations that can damage
electrical equipment.
• Use an air compressor with continuous run 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.
333023J
27
Setup
Connect Power
NOTE: Terminal jumpers are located inside the
electrical enclosure door.
3. Install supplied terminal jumpers in the positions
shown in image for the power source used.
All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
1. Turn main power switch (MP) OFF.
2. Open electrical enclosure door.
Table 5 Power Cord Requirements
Model
E-30,
10 kW
E-30,
15 kW
28
Input Power
Cord
Specifications*
AWG (mm2)
200–240 VAC, 1
Phase
4 (21.2), 2 wire +
ground/PE
200–240 VAC, 3
Phase, DELTA
6 (13.3), 3 wire +
ground/PE
350–415 VAC, 3
Phase, WYE
8 (8.4), 4 wire +
ground/PE
200–240 VAC, 1
Phase
4 (21.2), 2 wire +
ground/PE
200–240 VAC, 3
Phase, DELTA
6 (13.3), 3 wire +
ground/PE
350–415 VAC, 3
Phase, WYE
8 (8.4), 4 wire +
ground/PE
4. Route power cable through strain relief (EC) in
electrical enclosure.
5. Connect incoming power wires as shown in
image. Gently pull on all connections to verify
they are properly secured.
6. Verify all items are connected properly as shown
in image then close electrical enclosure door.
Model
Input Power
Cord
Specifications*
AWG (mm2)
E-XP2,
15 kW
200–240 VAC, 1
Phase
4 (21.2), 2 wire +
ground/PE
200–240 VAC, 3
Phase, DELTA
6 (13.3), 3 wire +
ground/PE
350–415 VAC, 3
Phase, WYE
8 (8.4), 4 wire +
ground/PE
* Values are for reference only. Refer to amperage
listed in Models table (see Models, page 9 ) for given
system and compare against latest version of local
electrical code to select proper power cord size.
NOTE: 350–415 VAC systems are not designed to
operate from 480 VAC power source.
333023J
Setup
Supply Wet Cups With Throat Seal
Liquid (TSL)
• Component B (Resin) Pump: Check felt washers
in packing nut/wet-cup (S) daily. Keep saturated
with Graco Throat Seal Liquid (TSL), Part No.
206995, to prevent material from hardening on
displacement rod. Replace felt washers when worn
or contaminated with hardened material.
Pump rod and connecting rod move during
operation. Moving parts can cause serious injury
such as pinching or amputation. Keep hands and
fingers away from wet-cup during operation.
To prevent the pump from moving, turn the main
power switch OFF.
• Component A (ISO) Pump: Keep reservoir (R) filled
with Graco Throat Seal Liquid (TSL), Part 206995.
Wet-cup piston circulates TSL through wet-cup, to
carry away isocyanate film on displacement rod.
Figure 10 Component B Pump
Install Fluid Temperature Sensor
The Fluid Temperature Sensor (FTS) is supplied.
Install FTS between main hose and whip hose. See
Heated Hose manual for instructions.
Figure 9 Component A Pump
333023J
29
Setup
Connect Heated Hose to Proportioner
See the heated hose manual for detailed instructions.
a. Connect hose power wires to electrical splice
connectors (S) from proportioner. Wrap
connections with electrical tape.
1. For proportioners with termination box (TB):
a. Connect hose power wires to terminal block
(T) on termination box (TB). Remove box
cover and loosen lower strain relief (E).
Route hose wires (V) through the box strain
relief and fully insert into terminal block (T). A
and B hose wire positions are not important.
Torque to 35–50 in-lb (4.0–5.6 N·m).
b. Fully tighten strain relief screws and replace
cover.
Figure 12 Electrical Splice Connectors
3. Connect FTS cable connectors (R). Fully tighten
RTD connectors, if provided.
Register and Activate the Graco InSite
Note
Elite systems only.
1. Go to www.GracoInSite.com, then follow the
instructions on the screen.
Figure 11 Termination Box
2. Find and record the 15 digit serial number from
the cellular module below.
2. For proportioners with electrical splice connectors
(S):
30
333023J
Advanced Display Module (ADM) Operation
Advanced Display Module (ADM) Operation
When main power is turned on by turning the main
power switch (MP) to the ON position, the power up
screen will be displayed until communication and
initialization is complete.
Perform the following tasks to fully setup your system.
1. Set pressure values for the Pressure Imbalance
Alarm to activate. See System Screen 1, page 35.
2. Enter, enable, or disable recipes. See
Recipes Screen, page 35.
Then the power key icon screen will display until the
ADM power on/off button (A)
is pressed for the
first time after system power-up.
To begin using the ADM, the machine must be active.
To verify the machine is active, verify that the System
Status Indicator Light (B) is illuminated green, see
Advanced Display Module (ADM), page 18. If the
System Status Indicator Light is not green, press
. The System
the ADM Power On/Off (A) button
Status Indicator Light will illuminate yellow if the
machine is disabled.
333023J
3. Set general system settings. See
Advanced Screen 1 — General, page 34.
4. Set units of measure. See
Advanced Screen 2 — Units, page 34.
5. Set USB settings. See
Advanced Screen 3— USB, page 34.
6. Set target temperatures and pressure. See
Targets, page 37.
7. Set component A and component B supply
levels. See Maintenance, page 38.
31
Advanced Display Module (ADM) Operation
Setup Mode
The ADM will start in the Run screens at the Home screen. From the Run screens, press
to
access the Setup screens. The system defaults with no password, entered as 0000. Enter the
. Press
current password then press
Setup Screens Navigation Diagram, page 45.
to navigate through the Setup Mode screens. See
Set Password
Set a password to allow Setup screen access, see Advanced Screen 1 – General, page 34. Enter any number
from 0001 to 9999. To remove the password, enter the current password in the Advanced Screen – General
screen and change the password to 0000.
From the Setup screens, press
32
to return to the Run screens.
333023J
Advanced Display Module (ADM) Operation
Setup Screens Navigation Diagram
Figure 13
333023J
33
Advanced Setup Screens
Advanced Setup Screens
Advanced setup screens enable users to set units, adjust values, set formats, and view software information
for each component. Press
Advanced setup screen, press
to scroll through the Advanced setup screens, Once in the desired
to access the fields and make changes. When changes are complete press
to exit edit mode.
Note
Users must be out of edit mode to scroll
through the Advanced setup screens.
Advanced Screen 1 — General
Use this screen to set the language, date format,
current date, time, setup screens password (0000 –
for none) or (0001 to 9999), and screen saver delay.
Advanced Screen 3 — USB
Use this screen to enable USB downloads/uploads,
enable a logs 90% full advisory, enter the maximum
number of days to download data, enable specifying
date range of data to download, and how frequently
USB logs are recorded. See USB Data, page 60.
Advanced Screen 4— Software
Advanced Screen 2 — Units
Use this screen to set the temperature units, pressure
units, volume units, and cycle units (pump cycles or
volume).
34
This screen displays the software part number and
software version for the Advanced Display Module,
USB Configuration, Motor Control Module, and
Temperature Control Modules.
333023J
System 1
System 1
Recipes
Use this screen to set the activation pressure for the
Pressure Imbalance Alarm and Deviation, enable or
disable diagnostic screens, set the maximum and
minimum drum volume, and enable drum alarms.
Use this screen to add recipes, view saved recipes,
and enable or disable saved recipes. Enabled
recipes can be selected at the Home Run Screen. 24
recipes can displayed on the three recipe screens.
System 2
Add Recipe
Use this screen to enable Manual Hose Mode and
inlet sensors, as well as setting the inlet sensor
low pressure alarm and low temperature deviation.
Manual Hose Mode disables the hose temperature
RTD sensor so the system can operate if the sensors
were to malfunction. Default settings are 10 psi (0.07
MPa, 0.7 bar) for low inlet pressure alarm and 50˚F
(10˚C) for low inlet temperature deviation.
1. Press
and then use
recipe field. Press
to select a
to enter a recipe name
(maximum 16 characters). Press
old recipe name.
2. Use
to clear the
to highlight the next field and use the
number pad to enter a value. Press
to save.
Enable or Disable Recipes
1. Press
and then use
to select the
recipe that needs to be enabled or disabled.
2. Use
Press
333023J
to highlight the enabled check box.
to enable or disable the recipe.
35
Run Mode
Run Mode
The ADM will start in the Run screens at the “Home” screen. Press
screens. See Run Screens Navigation Diagram, page 44.
to navigate through the Run Mode
From the Run screens, press
to access the Setup screens.
Run Screens Navigation Diagram
Figure 14
36
333023J
Run Mode
Home — System Off
Home — System With Error
This is the home screen when the system is off.
This screen displays actual temperatures, actual
pressures at the fluid manifold, jog speed, coolant
temperature, and number of cycles.
Active errors are shown in the status bar. The error
code, alarm bell, and description of the error will
scroll in the status bar.
1. Press
to acknowledge the error.
2. See Troubleshooting, page 59 for corrective
action.
Targets
Use this screen to define the setpoints for the
A Component Temperature, B Component
Temperature, heated hose temperature, and
pressure.
Maximum A and B temperature: 190°F (88°C)
Home — System Active
When the system is active, the home screen displays
actual temperature for heat zones, actual pressures
at the fluid manifold, coolant temperature, jog speed,
the number of cycles, along with all associated
control soft keys.
Maximum heated hose temperature: 10°F (5°C)
above the highest A or B temperature setpoint or
180°F (82°C).
Note
If the remote display module kit is used,
these setpoints can be modified at the gun.
Use this screen to turn on heat zones, view
coolant temperature, start the proportioner, stop the
proportioner, park the component A pump, enter jog
mode, and clear cycles.
NOTE: Screen shown displays inlet sensor
temperatures and pressures. These will not be
shown on models without inlet sensors.
333023J
37
Run Mode
Maintenance
Events
Use this screen to view daily and lifetime cycles or
gallons that have been pumped and gallons or liters
remaining in the drums.
This screen shows the date, time, event code, and
description of all events that have occurred on
the system. There are 10 pages, each holding 10
events. The 100 most recent events are shown. See
System Events
for event code descriptions.
See Error Codes and Troubleshooting, page 59 for
error code descriptions.
The lifetime value is the number of pump cycles or
gallons since the first time the ADM was turned on.
The daily value automatically resets at midnight.
The manual value is the counter that can be manually
reset. Press
and hold to reset manual counter.
All events and errors listed on this screen can be
downloaded on a USB flash drive. To download logs,
see Download Procedure, page 60.
Cycles
This screen shows daily cycles and gallons that have
been sprayed for the day.
All information listed on this screen can be
downloaded on a USB flash drive.
Errors
This screen shows the date, time, error code, and
description of all errors that have occurred on the
system.
All errors listed on this screen can be downloaded on
a USB flash drive.
38
333023J
Run Mode
Troubleshooting
This screen displays the last ten errors that
occurred on the system. Use the up and down
arrows to select an error and press
to view
the QR code for the selected error. Press
to access the QR code screen for an error
code that is not listed on this screen. See
Error Codes and Troubleshooting, page 59, for more
information on error codes.
QR Codes
To quickly view online help for a given error code,
scan the displayed QR code with your smartphone.
Alternately, visit http://help.graco.com and search for
the error code to view online help for that code.
333023J
39
Run Mode
Diagnostic
Note
Use this screen to view information for all system
components.
Maximum values based on maximum input
voltage. Values will lower with lower input
voltage.
Job Data
Use this screen to enter a job name or number.
The following information is displayed:
Temperature
• A Chemical
• B Chemical
• Hose Chemical
• TCM PCB — temperature control module
temperature
Recipes
Amps
• A Current (0–25 A for 10kW heater, 0–38 A for
15 kW heater)
to load. The currently loaded recipe is outlined
by a green box.
• B Current (0–25 A for 10kW heater, 0–38 A for
15 kW heater)
• Hose Current
(0–45 A typical)
Use this screen to select an enabled recipe. Use the
up and down arrows to highlight a recipe and press
Note
This screen will not display if there are not
any enabled recipes. To enable or disable
recipes, see Recipes Setup Screen, page 35.
Volts
• MCM Bus — displays the voltage supplied to the
motor controller, which is the DC voltage that has
been converted from the AC voltage supplied to
the system (275–400 VAC typical full range)
• Hose Voltage (90V)
Pressure
• Pressure A — chemical
• Pressure B — chemical
Cycles
• CPM — cycles per minute
• Total Cycles — lifetime cycles
40
333023J
Run Mode
System Events
Use the table below to find a description for all system non-error events. All events are logged in the USB
log files.
Event Code
EACX
EADA
EADB
EADH
EAPX
EARX
EAUX
EB0X
EBDA
EBDB
EBDH
EBPX
EBRX
EBUX
EC0X
ECDA
ECDB
ECDH
ECDP
ECDX
EL0X
EM0X
EP0X
EQU1
EQU2
EQU3
EQU4
EQU5
ER0X
EVUX
333023J
Description
Recipe Selected
Heat On A
Heat On B
Heat On Hose
Pump On
Jog On
USB Drive Inserted
ADM Red Stop Button Pressed
Heat Off A
Heat Off B
Heat Off Hose
Pump Off
Jog Off
USB Drive Removed
Setup Value Changed
A Temperature Setpoint Changed
B Temperature Setpoint Changed
Hose Temperature Setpoint Changed
Pressure Setpoint Changed
Recipe Changed
System Power On
System Power Off
Pump Parked
System Settings Downloaded
System Settings Uploaded
Custom Language Downloaded
Custom Language Uploaded
Logs Downloaded
User Counter Reset
USB Disabled
41
Startup
Startup
desired, the level can be entered and tracked in
the ADM. See Advanced Setup Screens, page 34.
4. Check generator fuel level.
To prevent serious injury, only operate Reactor
with all covers and shrouds in place.
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.
NOTICE
Running out of fuel will cause voltage
fluctuations that can damage electrical
equipment and void the warranty. Do not run
out of fuel.
5. Confirm main power switch is OFF before starting
generator.
1. Check fluid inlet filter screens.
Before daily startup, ensure that the
fluid inlet screens are clean. See
Flush Inlet Strainer Screen, page 56
6. Ensure the main breaker on the generator is in
the off position.
7. Start the generator. Allow it to reach full operating
temperature.
8. Turn main power switch ON.
2. Check ISO lubrication reservoir.
Check level and condition of ISO lube daily. See
Pump Lubrication System, page 57.
The ADM will display the following screen until
communication and initialization is complete.
3. Use A and B Drum Level Sticks (24M174) to
measure the material level in each drum.. If
42
333023J
Startup
9. Switch on the air compressor, air dryer, and
breathing air, if included.
e. Open fluid inlet valves (FV). Check for leaks.
10. For first startup of new system, load fluid with
feed pumps.
a. Check that all Setup steps are complete.
See Setup, page 27.
Cross-contamination can result in cured
material in fluid lines which could cause
serious injury or damage equipment. To
prevent cross-contamination:
b. If an agitator is used, open the agitator’s air
inlet valve.
c.
• Never interchange component A and
component B wetted parts.
If you need to circulate fluid through the
system to preheat the drum supply, see
Circulation Through Reactor, page 45.
If you need to circulate material through
the heat hose to the gun manifold, see
Circulation Through Gun Manifold, page 46.
• Never use solvent on one side if it has
been contaminated from the other side.
• Always provide two grounded waste
containers to keep component A and
component B fluids separate.
d. Turn both PRESSURE RELIEF/SPRAY
valves (SA, SB) to SPRAY
.
GA
SA
f.
GB
SB
Hold gun fluid manifold over two grounded
waste containers. Open fluid valves A and B
until clean, air-free fluid comes from valves.
Close valves.
The Fusion AP gun manifold is shown.
333023J
43
Startup
11. Press
to activate ADM.
Thermal expansion can cause
overpressurization, resulting in equipment
rupture and serious injury, including fluid
injection. Do not pressurize system when
preheating hose.
12. If necessary, setup the ADM in Setup Mode. See
Advanced Display Module (ADM) Operation,
page 31.
13. Preheat the system:
a. Press
to turn on hose heat zone.
b. If you need to circulate fluid through the
system to preheat the drum supply, see
Circulation Through Reactor, page 45.
If you need to circulate material through
the heat hose to the gun manifold, see
Circulation Through Gun Manifold, page 46.
c.
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.
• Do not turn on hose heat without fluid
in hoses.
Wait for the hose to reach set point
temperature.
Note
Hose heat-up time may increase at
voltages less than 230 VAC when
maximum hose length is used.
d. Press
to turn on A and B heat zones.
• Allow equipment to cool completely
before touching it.
• Wear gloves if fluid temperature exceeds
110°F (43°C).
44
333023J
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
NOTICE
3. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
GA
To prevent equipment damage, do not circulate
fluid containing a blowing agent without consulting
with your material supplier regarding fluid
temperature limits.
NOTE: Optimum heat transfer is achieved at lower
fluid flow rates with temperature set points at desired
drum temperature. Low temperature rise deviation
errors may result.
To circulate through gun manifold and preheat hose,
see Circulation Through Gun Manifold, page 46.
1. Follow Startup, page 42.
when set to SPRAY
. Lines must be
open so valves can automatically relieve
pressure when machine is operating.
2. See Typical Installation, with system fluid
manifold to drum circulation, page 14. 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 Specifications, page 67.
333023J
GB
SA
SB
4. Set temperature targets. See Targets, page 37.
5. Press
to circulate fluid in jog mode until
A and B temperatures reach targets. See
Jog Mode, page 46 for more information about
jog mode.
6. Press
To avoid injection injury and splashing, do not
install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The
valves function as overpressure relief valves
.
to turn on the hose heat zone.
7. Turn on the A and B heat zones. Wait until the
fluid inlet valve temperature gauges (FV) reach
the minimum chemical temperature from the
supply drums.
8. Exit jog mode.
9. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
.
GA
SA
GB
SB
45
Jog Mode
Circulation Through Gun Manifold
hoses rated at the maximum working
pressure of this equipment. See
Technical Specifications, page 67.
NOTICE
3. Follow procedures from Startup, page 42.
To prevent equipment damage, do not circulate
fluid containing a blowing agent without consulting
with your material supplier regarding fluid
temperature limits.
NOTE: Optimum heat transfer is achieved at lower
fluid flow rates with temperature set points at desired
drum temperature. Low temperature rise deviation
errors may result.
Circulating fluid through the gun manifold allows
rapid preheating of the hose.
1. Install gun fluid manifold (P) on accessory
circulation kit (CK). Connect high pressure
circulation lines (R) to circulation manifold.
4. Turn main power switch on
.
5. Set temperature targets. See Targets, page 37.
to circulate fluid in jog mode until
6. Press
A and B temperatures reach targets. See
Jog Mode, page 46 for more information about
jog mode.
Jog Mode
Jog mode has two purposes:
• It can speed fluid heating during circulation.
• It can ease system flushing and priming.
P
1. Turn main power switch on
.
CK
2. Press circulate
to enter jog mode.
3. Press up or down
(J1 through J20).
R
to change jog speed
Note
Jog speeds correlate to 3-30% of motor
power, but will not operate over 700 psi
(4.9 MPa, 49 bar) for either A or B.
The Fusion AP gun manifold is shown.
CK
Gun
Manual
246362
Fusion AP
309818
256566
Fusion CS
313058
2. Route circulation lines back to respective
component A or B supply drum. Use
46
4. Press
5.
to start motor.
To stop the motor and exit jog mode press
or
.
333023J
Spraying
Spraying
6. Open fluid inlet valve located at each pump inlet.
The Fusion AP gun is shown.
1. Engage gun piston safety lock and close gun
fluid inlet valves A and B.
Fusion
Probler
2. Attach gun fluid manifold. Connect gun air line.
Open air line valve.
3. Adjust the gun air regulator to desired gun air
pressure. Do not exceed the maximum rated
air pressure.
4. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
to start motor and pumps.
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
balanced pressures.
.
GA
SA
7. Press
GA
SA
GB
until gauges show
GB
SB
SB
5. Verify heat zones are on and temperatures
and pressures are on target, see
Home screen, page 37.
333023J
47
Spraying
9. Open gun fluid inlet valves A and B.
11. Pull gun trigger to test spray onto cardboard. If
necessary, adjust pressure and temperature to
get desired results.
Spray Adjustments
Flow rate, atomization, and amount of overspray are
affected by four variables.
Fusion
Probler
NOTICE
To prevent material crossover on impingement
guns, never open fluid manifold valves or
trigger gun if pressures are imbalanced.
10. Disengage gun piston safety lock.
• 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 and fluid viscosity.
Fusion
48
Probler
• 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.
333023J
Manual Hose Heat Mode
Manual Hose Heat Mode
3. Select Enable Manual Hose Mode.
Note
If the system produces the T6DH sensor error hose
alarm or the T6DT sensor error TCM alarm, use
manual hose heat mode until the hose RTD cable or
FTS temperature sensor can be repaired.
When manual hose mode is enabled, the
manual hose mode advisory EVCH-V
will appear.
Do not use Manual Hose Mode for extended periods
of time. The system performs best when the hose
has a valid RTD and can operate in temperature
control mode. If a hose RTD breaks, the first priority
is to fix the RTD. Manual Hose Mode can help finish
a job while waiting for repair parts.
4. Enter Run Mode and navigate to the Target
screen. Use the up and down arrows to set the
desired hose current.
Enable Manual Hose Mode
1. Disconnect the hose RTD sensor from the TCM.
2. Enter Setup Mode and navigate to System
Screen 2.
Hose Current Settings Hose Current
333023J
Default
20A
Maximum
37A
49
Manual Hose Heat Mode
5. Navigate back to the Run Mode Home screen.
The hose now displays a current instead of a
temperature.
Disable Manual Hose Mode
1. Enter Setup Mode and navigate to System 2
Screen and deselect Enable Manual Hose Mode,
or repair the hose RTD cable or FTS.
Note
Until the RTD sensor is repaired, the
T6DH sensor error alarm will display
each time the system is powered up.
50
2. Manual hose mode is automatically disabled
when the system detects a valid RTD sensor in
the hose.
333023J
Shutdown
Shutdown
NOTICE
6. Turn off the air compressor, air dryer, and
breathing air.
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.
1. Press
to stop the pumps.
7. Turn main power switch OFF.
2. Turn off all heat zones.
3. Relieve pressure. See
Pressure Relief Procedure, page 53.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
8. Close all fluid supply valves.
4. Press
to park the Component A Pump. The
park operation is complete when green dot goes
out. Verify the park operation is complete before
moving to next step.
5. Press
333023J
to deactivate the system.
51
Shutdown
9. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
drain line.
to seal out moisture from
GA
SA
10. Engage gun piston safety lock then close fluid
inlet valves A and B.
GB
SB
Fusion
52
Probler
333023J
Pressure Relief Procedure
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
3. Close gun fluid inlet valves A and B.
4. Shut off feed pumps and agitator, if used.
This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.
5. Route fluid to waste containers or supply tanks.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.
GA
SA
GB
SB
The Fusion AP gun is shown.
1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
2. Engage gun piston safety lock.
333023J
53
Flushing
Flushing
To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
To help prevent fire and explosion:
• Flush equipment only in a well-ventilated area.
• Do not spray flammable fluids.
RELIEF/CIRCULATION
lines (N).
GA
SA
. Flush through bleed
GB
SB
• 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 wetted parts are compatible with common
solvents. Use only moisture-free solvents.
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 filled with a moisture-free
plasticizer or oil. Do not use water. Never leave the
system dry. See Important Isocyanate Information.
54
333023J
Maintenance
Maintenance
Grease Circulation Valves
Grease circulation valves (SA and SB) with Fusion
grease (117773) weekly.
Prior to performing any maintenance procedures,
follow Pressure Relief Procedure, page 53.
Preventative Maintenance Schedule
The operating conditions of your particular system
determine how often maintenance is required.
Establish a preventive maintenance schedule by
recording when and what kind of maintenance is
needed, and then determine a regular schedule for
checking your system.
Proportioner Maintenance
Wet Cup
Check the wet cup daily. Keep it 2/3 full with Graco
Throat Seal Liquid (TSL®) or compatible solvent. Do
not overtighten packing nut/wet cup.
Packing Nuts
Do not overtighten packing nut/wet cup. Throat u-cup
is not adjustable.
Fluid Inlet Strainer Screens
Inspect fluid inlet strainer screens daily, see
Flush Inlet Strainer Screen, page 56.
ISO Lubricant Level
Inspect ISO lubricant level and condition
daily. Refill or replace as needed. See
Pump Lubrication System, page 57.
Moisture
To prevent crystallization, do not expose component
A to moisture in air.
Gun Mix Chamber Ports
Clean gun mix chamber ports regularly. See gun
manual.
Gun Check Valve Screens
Clean gun check valve screens regularly. See gun
manual.
Dust Protection
Use clean, dry, oil-free compressed air to prevent
dust buildup on control modules, fans, and motor
(under shield).
Vent Holes
Keep vent holes on bottom of electrical cabinet open.
333023J
55
Maintenance
Flush Inlet Strainer Screen
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.
Isocyanate can crystallize from moisture
contamination or from freezing. If the chemicals used
are clean and proper storage, transfer, and operating
procedures are followed, there should be minimal
contamination of the A-side screen.
compatible solvent and shake it dry. Inspect the
screen. No more than 25% of the mesh should
be restricted. If more than 25% of the mesh is
blocked, replace the screen. Inspect the gasket
(B) and replace as required.
4. Ensure the pipe plug (D) is screwed into the
strainer plug (C). Install the strainer plug with the
screen (A) and o-ring (B) in place and tighten. Do
not overtighten. Let the gasket make the seal.
5. Open the fluid inlet valve, ensure that there are
no leaks, and wipe the equipment clean. Proceed
with operation.
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.
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.
2. Place a container under the strainer base to catch
drain off when removing the strainer plug (C).
3. Remove the screen (A) from the strainer
manifold. Thoroughly flush the screen with
56
Figure 15
333023J
Maintenance
Pump Lubrication System
4. When the reservoir is flushed clean, fill with fresh
lubricant.
Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color
darkens, or it becomes diluted with isocyanate.
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
Gel formation is due to moisture absorption by the
pump lubricant. The interval between changes
depends on the environment in which the equipment
is operating. The pump lubrication system minimizes
exposure to moisture, but some contamination is still
possible.
6. The lubrication system is ready for operation. No
priming is required.
Lubricant discoloration is due to continual seepage of
small amounts of isocyanate past the pump packings
during operation. If the packings are operating
properly, lubricant replacement due to discoloration
should not be necessary more often than every 3 or
4 weeks.
To change pump lubricant:
1. Follow Pressure Relief Procedure, page 53.
2. Lift the lubricant reservoir (R) out of the bracket
and remove the container from the cap. Holding
the cap over a suitable container, remove the
check valve and allow the lubricant to drain.
Reattach the check valve to the inlet hose.
3. Drain the reservoir and flush it with clean
lubricant.
333023J
Pump Lubrication System
Figure 16
57
Errors
Errors
Troubleshoot Errors
To troubleshoot the error:
View Errors
When an error occurs the error information screen
displays the active error code and description.
1. Press the soft key next to “Help With This Error”
for help with the active error.
The error code, alarm bell, and active errors will scroll
in the status bar. For a list of the ten most recent
errors see Troubleshooting, page 59. Error codes
are stored in the error log and displayed on the Error
and Troubleshooting screens on the ADM.
There are three types of errors that can occur. Errors
are indicated on the display as well as by the light
tower (optional).
Alarms are indicated by
. This condition indicates
a parameter critical to the process has reached a
level requiring the system to stop. The alarm needs
to be addressed immediately.
Deviations are indicated by
. This condition
indicates a parameter critical to the process has
reached a level requiring attention, but not sufficient
enough to stop the system at this time.
Note
Press
or
to return to the
previously displayed screen.
2. The QR code screen will be displayed. Scan
the QR code with your smart phone to be sent
directly to online troubleshooting for the active
error code. Otherwise, manually navigate to
http://help.graco.com and search for the active
error.
Advisories are indicated by
. This condition
indicates a parameter that is not immediately critical
to the process. The advisory needs attention to
prevent more serious issues in the future.
To diagnose the active error, see
Troubleshoot Errors, page 58.
3. If no internet connection is available, see
Error Codes and Troubleshooting, page 59 for
causes and solutions for each error code.
58
333023J
Troubleshooting
Troubleshooting
See Errors, page 58 for information about errors that
can occur on the system.
See Troubleshooting, page 39 for the ten most
recent errors that have occurred on the system. See
Troubleshoot Errors, page 58 to diagnose errors on
the ADM that have occurred on the system.
Error Codes and Troubleshooting
See system repair manual or visit
http://help.graco.com for causes and solutions to
each error code.
333023J
59
USB Data
USB Data
Download Procedure
USB Logs
Note
Note
System configuration setting files and custom
language files can be modified if the files
are in the UPLOAD folder of the USB flash
drive. See System Configuration Settings
File, Custom Language File, and Upload
Procedure sections.
The ADM can read/write to FAT (File
Allocation Table) storage devices. NTFS,
used by 32 GB or greater storage devices,
is not supported.
1. Insert USB flash drive into USB port.
2. The menu bar and USB indicator lights indicate
that the USB is downloading files. Wait for USB
activity to complete.
3. Remove USB flash drive from USB port.
4. Insert USB flash drive into USB port of computer.
5. The USB flash drive window automatically opens.
If it does not, open USB flash drive from within
Windows® Explorer.
6. Open GRACO folder.
7. Instructions continue on next page.
8. Open the system folder. If downloading data
from more than one system, there will be more
than one folder. Each folder is labeled with the
corresponding serial number of the ADM (The
serial number is on the back of the ADM.)
9. Open DOWNLOAD folder.
During operation, the ADM stores system and
performance related information to memory in the
form of log files. The ADM maintains six log files:
• Event Log
• Job Log
• Daily Log
• System Software Log
• Blackbox Log
• Diagnostics Log
Follow Download Procedure, page 60, to retrieve
log files.
Each time a USB flash drive is inserted into the ADM
USB port, a new folder named DATAxxxx is created.
The number at the end of the folder name increases
each time a USB flash drive is inserted and data is
downloaded or uploaded.
Event Log
10. Open DATAxxxx folder.
The event log file name is 1–EVENT.CSV and is
stored in the DATAxxxx folder.
11. Open DATAxxxx folder labeled with the highest
number. The highest number indicates the most
recent data download.
The event log maintains a record of the last 49,000
events and errors. Each event record contains:
12. Open log file. Log files open in Microsoft® Excel
by default as long as the program is installed.
However, they can also be opened in any text
editor or Microsoft® Word.
Note
All USB logs are saved in Unicode
(UTF-16) format. If opening the log
file in Microsoft Word, select Unicode
encoding.
• Date of event code
• Time of event code
• Event code
• Event type
• Action taken
• Event Description
Event codes include both error codes (alarms,
deviations, and advisories) and record only events.
Actions Taken includes setting and clearing event
conditions by the system, and acknowledging error
conditions by the user.
60
333023J
USB Data
Job Log
System Software Log
The job log file name is 2–JOB.CSV and is stored
in the DATAxxxx folder.
The system software file name is 4–SYSTEM.CSV
and is stored in the DATAxxxx folder.
The job log maintains a record of data points
based on the USB Log Frequency defined
in the Setup screens. The ADM stores the
last 237,000 data points for download. See
Setup - Advanced Screen 3 — USB, page 34, for
information on setting the Download Depth and USB
Log Frequency.
The system software log lists the following:
• Data point date
Blackbox Log File
• Data point time
• A side temperature
• B side temperature
• Hose temperature
• A side temperature setpoint
• B side temperature setpoint
• Hose temperature setpoint
• A side inlet pressure
• Date log was created
• Time log was created
• Component name
• Software version loaded on the above component
The black box file name is 5–BLACKB.CSV and is
stored in the DATAxxxx folder.
The Blackbox log maintains a record of how the
system runs and the features that are used. This log
will help Graco troubleshoot system errors.
Diagnostics Log File
The diagnostics file name is 6–DIAGNO.CSV and is
stored in the DATAxxxx folder.
• Inlet pressure setpoint
The Diagnostics log maintains a record of how the
system runs and the features that are used. This log
will help Graco troubleshoot system errors.
• System lifetime pump cycle counts
System Configuration Settings
• B side inlet pressure
• Pressure, volume, and temperature units
• Job name/number
Daily Log
The daily log file name is 3–DAILY.CSV and is stored
in the DATAxxxx folder.
The daily log maintains a record of the total cycle
and volume sprayed on any day that the system is
powered up. The volume units will be the same units
that were used in the Job Log.
The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.
A system configuration settings file automatically
downloads each time a USB flash drive is inserted
into the ADM. Use this file to back up system
settings for future recovery or to easily replicate
settings across multiple systems. Refer to the
Upload Procedure, page 62 for instructions on how
to use this file.
The following data is stored in this file:
• Date that material was sprayed
• Time — unused column
• Total pump cycle count for day
• Total volume sprayed for day
333023J
61
USB Data
Custom Language File
• The file format must be a tab-delimited text file
using Unicode (UTF-16) character representation.
The custom language file name is DISPTEXT.TXT
and is stored in the DOWNLOAD folder.
• The file must contain only two columns, with
columns separated by a single tab character.
A custom language file automatically downloads
each time a USB flash drive is inserted into the ADM.
If desired, use this file to create a user-defined set of
custom language strings to be displayed within the
ADM.
• Do not add or remove rows to the file.
The system is able to display the following Unicode
characters. For characters outside of this set,
the system will display the Unicode replacement
character, which appears as a white question mark
inside of a black diamond.
• U+0020 - U+007E (Basic Latin)
• U+00A1 - U+00FF (Latin-1 Supplement)
• Do not change the order of the rows.
Upload Procedure
Use this procedure to install a system configuration
file and/or a custom language file.
1. If necessary, follow the Download Procedure to
automatically generate the proper folder structure
on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
• U+0386 - U+03CE (Greek)
3. The USB flash drive window automatically opens.
If it does not, open USB flash drive from within
Windows Explorer.
• U+0400 - U+045F (Cyrillic)
4. Open GRACO folder.
Create Custom Language Strings
5. Open the system folder. If working with more
than one system, there will be more than one
folder within the GRACO folder. Each folder is
labeled with the corresponding serial number of
the ADM. (The serial number is on the back of
the module.)
• U+0100 - U+017F (Latin Extended-A)
The custom language file is a tab-delimited text file
that contains two columns. The first column consists
of a list of strings in the language selected at the
time of download. The second column can be used
to enter the custom language strings. If a custom
language was previously installed, this column
contains the custom strings. Otherwise the second
column is blank.
Modify the second column of the custom language file
as needed and the follow Upload Procedure, page 62 ,
to install the file.
The format of the custom language file is critical.
The following rules must be followed in order for the
installation process to succeed.
• Define a custom string for each row in the second
column.
6. If installing the system configuration settings
file, place SETTINGS.TXT file into the UPLOAD
folder.
7. If installing the custom language file, place
DISPTEXT.TXT file into the UPLOAD folder.
8. Remove USB flash drive from the computer.
9. Install USB flash drive into the ADM USB port.
10. The menu bar and USB indicator lights indicate
that the USB is downloading files. Wait for USB
activity to complete.
11. Remove USB flash drive from USB port.
Note
Note
If the custom language file is used, you
must define a custom string for each
entry in the DISPTEXT.TXT file. Blank
second-column fields will be displayed
blank on the ADM.
If the custom language file was installed,
users can now select the new language
from the Language drop-down menu in
Advanced Screen 1 — General, page 34.
• The file name must be DISPTEXT.TXT.
62
333023J
Performance Charts
Performance Charts
Use these charts to help identify the proportioner that will work most efficiently with each mix chamber. Flow
rates are based on a material viscosity of 60 cps.
NOTICE
To prevent system damage, do not pressurize the
system above the line for the gun tip size being used.
Proportioners For Foam
2000
(138)
AR4242
(01)
AR5252
(02)
1500
(103)
PRESSURE
psi (bar)
AR6060
(03)
1000
(69)
AR7070
(04)
E-30
500
(34) 0
5
10
15
20
25
30
35
40
(2.3)
(4.5)
(6.8)
(9.1)
(11.3)
(13.6)
(15.9)
(18.1)
FLOW lbs/min (kg/min)
333023J
63
Performance Charts
Proportioners For Coatings
Table 6 Fusion Air Purge, Round Pattern
3500
(241)
3000
(207)
2500
PRESSURE
psi (bar)
E-XP2
AR2020
(000)
(172)
AR2929
(00)
2000
(138)
1500
(103)
AR4242
(01)
1000
(69)
500
(34) 0
0.5
1.0
1.5
2.0
(1.9)
(3.8)
(5.7)
(7.6)
FLOW gal./min (l/min)
Table 7 Fusion Air Purge, Flat Pattern
3500
(241, 24.1)
3000
(207, 20.7)
AF2929
(FTXX38 TIP)
2500
(174, 17.4)
PRESSURE
psi (bar)
AF2020
(FTXX24 TIP)
2000
(138, 13.8)
E-XP2
AF4242
(FTXX38 TIP)
1500
(103, 10.3)
AF5252
(FTXX48 TIP)
1000
(69,6.9)
500
(35, 3.5)
0
0.5
1.0
1.5
2.0
(1.9)
(3.8)
(5.7)
(7.6)
FLOW gal./min (l/min)
64
333023J
Performance Charts
Table 8 Fusion Mechanical Purge, Round Pattern
3500
(241, 24.1)
E-XP2
3000
(207, 20.7)
XR2323
(RTM040)
2500
(174, 17.4)
PRESSURE
psi (bar)
XR2929
(RTM040)
2000
(138, 13.8)
MR3535
(RTM040)
1500
MR4747
(RTM055)
(103, 10.3)
XR3535
(RTM055)
1000
XR4747
(RTM055)
(69, 6.9)
500
(35, 3.5)
0
0.5
1
1.5
2.0
(1.9)
(3.8)
(5.7)
(7.6)
FLOW gal./min (l/min)
Table 9 Fusion Mechanical Purge, Flat Pattern
3500
(241, 24.1)
XF2323
(FTM424)
XF1313
(FTM424)
3000
(207, 20.7)
MF2929
(FTM424)
2500
MF4747
(FTM638)
(174, 17.4)
PRESSURE
psi (bar)
MF1818
(FTM424)
2000
(138, 13.8)
XF2929
(FTM424)
XF1818
(FTM424)
1500
(103, 10.3)
XF5757
(FTM638)
XF3535
(FTM638)
1000
E-XP2
MF5757
(FTM638)
MF3535
(FTM638)
(69, 6.9)
500
(35, 3.5)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2.0
(0.7)
(1.5)
(2.3)
(3.0)
(3.8)
(4.5)
(5.3)
(6.0)
(6.8)
(7.6)
FLOW gal./min (l/min)
333023J
65
Performance Charts
Heater Performance Chart
ti28705a
140
(60.0)
130
(54.4)
KEY:
K = 10.2 kW
L = 15.3 kW
120
(48.9)
110
(43.3)
L
100
(37.8)
90
(32.2)
80
(26.6)
K
70
(21.1)
Delta T in
degrees F
(degrees C)
60
(15.5)
50
(10.0)
40
(4.4)
30
(-1.1)
20
(-6.6)
10
(-12.2)
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)
3.5
(13.2)
4.0
(15.1)
4.5
(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.
66
333023J
Technical Specifications
Technical Specifications
Reactor 2 E-30 and E-XP2 Proportioning System
Maximum Fluid Working Pressure
E-30
E-XP2
Maximum Fluid Temperature
E-30
E-XP2
Maximum Flow Rate
E-30
E-XP2
Maximum Heated Hose Length
Length
Cycle, ISO and RES
Output per Cycle
E-30
E-XP2
Operating Ambient Temperature Range
Temperature
Line Voltage Requirement
Nominal 200–240 VAC, 1 Phase,
50/60 Hz
Nominal 200–240 VAC, 3 phase,
DELTA, 50/60 Hz
Nominal 350–415 VAC, 3 phase,
WYE, 50/60 Hz
Power, (at 230 VAC)
Heater Power
E-30 10 kW
E-30, 15 kW
E-XP2 15 kW
333023J
U.S.
Metric
2000 psi
3500 psi
14 MPa, 140 bar
24.1 MPa, 241 bar
190°F
190°F
88°C
88°C
30 lb/min
2 gpm
13.5 kg/min
7.6 lpm
310 ft
94 m
0.0272 gal.
0.0203 gal.
0.1034 liter
0.0771 liter
20° to 120°F
-7° to 49°C
195–265 VAC
195–265 VAC
340–455 VAC
10,200 Watts
15,300 Watts
15,300 Watts
67
Technical Specifications
Pressure, Sound Pressure measured per ISO-9614–2.
Sound Pressure
E-30, Measured from 3.1 ft (1 m),
87.3 dBA
at 1000 psi (7 MPa, 70 bar), 3 gpm
(11.4 lpm)
79.6 dBA
E-XP2, Measured from 3.1 ft (1
m), at 3000 psi (21 MPa, 207 bar),
1 gpm (3.8 lpm)
Sound Power
E-30, Measured from 3.1 ft (1 m),
at 1000 psi (7 MPa, 70 bar), 3 gpm
(11.4 lpm)
E-XP2, Measured from 3.1 ft (1
m), at 3000 psi (21 MPa, 207 bar),
1 gpm (3.8 lpm)
Fluid Inlets
Component A ISO) and
Component B (RES)
Fluid Outlets
Component A (ISO)
Component B (RES)
Fluid Circulation Ports
Size
Maximum Pressure
Dimensions
Width
Height
Depth
Weight
E-30, 10 kW
E-30, 15 kW
E-30, 10 kW Elite
E-30, 15 kW Elite
E-XP2
E-XP Elite
Wetted Parts
Material
68
93.7 dBA
86.6 dBA
3/4 NPT(f) with 3/4 NPSM(f) union
#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
1/4 NPSM(m)
250 psi
1.75 MPa, 17.5 bar
26.3 in.
63 in.
15 in.
668 mm
1600 mm
381 mm
315
350
320
355
345
350
lb
lb
lb
lb
lb
lb
143
159
145
161
156
159
kg
kg
kg
kg
kg
kg
Aluminum, stainless steel, zinc plated carbon steel, brass, carbide,
chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight
polyethylene
333023J
Graco Extended Warranty for Reactor® 2
Components
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.
Graco Part Number
Description
Warranty Period
24U050
Electric Motor
36 Months or 3 Million Cycles
24U051
Electric Motor
36 Months or 3 Million Cycles
24U831
Motor Control Module
36 Months or 3 Million Cycles
24U832
Motor Control Module
36 Months or 3 Million Cycles
24U855
Heater Control Module
36 Months or 3 Million Cycles
24U854
Advanced Display Module
36 Months or 3 Million Cycles
All other Reactor 2 parts
12 Months
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 hereunder must be brought within the latter of two (2) years of the date of
sale, or one (1) year the warranty period expires.
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.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 333023
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision J, July 2016