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Operation 312065T EN Electric, Heated, Plural Component Proportioner For spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in European explosive atmosphere locations. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. Model E-XP1 Shown See page 4 for model information, including maximum working pressure and approvals. WLE Contents Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Approvals: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Important Two-Component Material Information 10 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 10 For all applications except spray foam . . . . . . . 11 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 11 Keep Components A and B Separate . . . . . . . . 11 Moisture Sensitivity of Isocyanates . . . . . . . . . . 12 Foam Resins with 245 fa Blowing Agents . . . . . 12 Changing Materials . . . . . . . . . . . . . . . . . . . . . . 12 Typical Installation, with circulation . . . . . . . . . . 13 Typical Installation, without circulation . . . . . . . 14 Component Identification . . . . . . . . . . . . . . . . . . . 15 Temperature Controls and Indicators . . . . . . . . . 16 Main Power Switch . . . . . . . . . . . . . . . . . . . . . . 16 Red Stop Button . . . . . . . . . . . . . . . . . . . . . . . . 16 Actual Temperature Key/LED . . . . . . . . . . . . . . 17 Target Temperature Key/LED . . . . . . . . . . . . . . 17 Temperature Scale Keys/LEDs . . . . . . . . . . . . . 17 Heater Zone On/Off Keys/LEDs . . . . . . . . . . . . 17 Temperature Arrow Keys . . . . . . . . . . . . . . . . . . 17 Temperature Displays . . . . . . . . . . . . . . . . . . . . 17 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 17 2 Motor Controls and Indicators . . . . . . . . . . . . . . . 18 Motor ON/OFF Key/LED . . . . . . . . . . . . . . . . . . 18 PARK Key/LED . . . . . . . . . . . . . . . . . . . . . . . . . 18 PSI/BAR Keys/LEDs . . . . . . . . . . . . . . . . . . . . . 18 Pressure Key/LED . . . . . . . . . . . . . . . . . . . . . . . 18 Cycle Count Key/LED . . . . . . . . . . . . . . . . . . . . 18 Pressure Arrow Keys . . . . . . . . . . . . . . . . . . . . . 19 Pressure/Cycle Display . . . . . . . . . . . . . . . . . . . 19 Spray Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 19 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 33 Fluid Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Circulation Through Reactor . . . . . . . . . . . . . . . 34 Circulation Through Gun Manifold . . . . . . . . . . . 35 Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Temperature Control Diagnostic Codes . . . . . . . 37 Motor Control Diagnostic Codes . . . . . . . . . . . . 37 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 38 Pump Lubrication System . . . . . . . . . . . . . . . . . 39 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 44 312065T Systems Systems Part AP9024 AP9025 AH9025 AP9026 AP9028 AP9029 AP9030 AH9030 AP9031 AP9032 AP9033 AP9034 AH9034 AP9035 AP9036 AP9057 AP9058 AP9059 CS9025 CH9025 CS9026 CS9030 CH9030 CS9031 CS9034 CH9034 CS9035 CS9057 CS9058 CS9059 P29024 P29025 PH9025 P29026 P29028 P29029 P29030 PH9030 P29031 P29032 P29033 P29034 PH9034 P29035 P29036 P29057 P29058 P29059 312065T Maximum Fluid Working Pressure psi (MPa, bar) 2500 (17.2, 172) 2000 (13.8, 138) 2000 (13.8,138) 2000 (13.8, 138) 3500 (24.1, 241) 2500 (17.2, 172) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 3500 (24.1, 241) 2500 (17.2, 172) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 3500 (24.1, 241) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2500 (17.2, 172) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 3500 (24.1, 241) 2500 (17.2, 172) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 3500 (24.1, 241) 2500 (17.2, 172) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 3500 (24.1, 241) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) Heated Hose Proportioner (see page 4) 259024 259025 259025 259026 259028 259029 259030 259030 259031 259032 259033 259034 259034 259035 259036 259057 259058 259059 259025 259025 259026 259030 259030 259031 259034 259034 259035 259057 259058 259059 259024 259025 259025 259026 259028 259029 259030 259030 259031 259032 259033 259034 259034 259035 259036 259057 259058 259059 50 ft (15 m) 246679 246678 246678 246678 246679 246679 246678 246678 246678 246679 246679 246678 246678 246678 246679 246678 246678 246678 246678 246678 246678 246678 246678 246678 246678 246678 246678 246678 246678 246678 246679 246678 246678 246678 246679 246679 246678 246678 246678 246679 246679 246678 246678 246678 246679 246678 246678 246678 Qty 1 1 4 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 1 4 1 1 4 1 1 4 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 Gun 10 ft (3 m) (Qty 1) 246055 246050 246050 246050 246055 246055 246050 246050 246050 246055 246055 246050 246050 246050 246055 246050 246050 246050 246050 246050 246050 246050 246050 246050 246050 246050 246050 246050 246050 246050 246055 246050 246050 246050 246055 246055 246050 246050 246050 246055 246055 246050 246050 246050 246055 246050 246050 246050 Model Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ AP Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Fusion™ CS Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Probler P2 Part (Qty 1) 246100 246101 246100 246101 246100 246100 246101 246100 246101 246100 246100 246101 246100 246101 246100 246101 246101 246101 CS01RD CS01RD CS02RD CS01RD CS01RD CS02RD CS01RD CS01RD CS02RD CS02RD CS02RD CS02RD GCP2RA GCP2R1 GCP2R1 GCP2R2 GCP2R0 GCP2RA GCP2R1 GCP2R1 GCP2R2 GCP2R0 GCP2RA GCP2R1 GCP2R1 GCP2R2 GCP2R0 GCP2R2 GCP2R2 GCP2R2 Mix Chamber Kit AR2020 AR5252 AR5252 AR5252 AR2020 AR2020 AR5252 AR5252 AR5252 AR2020 AR2020 AR5252 AR5252 AR5252 AR2020 AR5252 AR5252 AR5252 3 Models Models E-20 SERIES Max Flow Rate◆ lb/min (kg/min) Approximate Output per Cycle Maximum Fluid (A+B) Working Pressure gal. (liter) psi (MPa, bar) Full Load Part, Series Peak Amps* Nominal Voltage Range (phase) System Watts† Primary Heater Watts 259025, F 259030, F 259034, F 200-240 V (1) 350-415 V (3) 200-240 V (3) 10,200 10,200 10,200 6,000 6,000 6,000 20 (9) 20 (9) 20 (9) 0.0104 (0.0395) 0.0104 (0.0395) 0.0104 (0.0395) Nominal Voltage System Range (phase) Watts† Primary Heater Watts Max Flow Rate◆ lb/min (kg/min) Approximate Output per Cycle Maximum Fluid (A+B) Working Pressure gal. (liter) psi (MPa, bar) 200-240 V (1) 350-415 V (3) 200-240 V (3) 200-240 V (1) 200-240 V (3) 350-415 V (3) 10,200 10,200 10,200 15,300 15,300 15,300 30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) Nominal Voltage System Range (phase) Watts† Primary Heater Watts Max Flow Rate◆ gpm (lpm) Approximate Output per Cycle Maximum Fluid (A+B) Working Pressure gal. (liter) psi (MPa, bar) 200-240 V (1) 350-415 V (3) 200-240 V (3) 10,200 10,200 10,200 1.0 (3.8) 1.0 (3.8) 1.0 (3.8) 0.0104 (0.0395) 0.0104 (0.0395) 0.0104 (0.0395) Nominal Voltage System Range (phase) Watts† Primary Heater Watts Max Flow Rate◆ gpm (lpm) Approximate Output per Cycle Maximum Fluid (A+B) Working Pressure gal. (liter) psi (MPa, bar) 200-240 V (1) 350-415 V (3) 200-240 V (3) 15,300 15,300 15,300 2.0 (7.6) 2.0 (7.6) 2.0 (7.6) 0.0203 (0.0771) 0.0203 (0.0771) 0.0203 (0.0771) 48 24 32 2000 (14, 140) 2000 (14, 140) 2000 (14, 140) E-30 SERIES Part, Series Full Load Peak Amps* 259026, F 259031, F 259035, F 259057, F 259058, F 259059, F 78 34 50 100 62 35 17,900 17,900 17,900 23,000 23,000 23,000 2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 2000 (14, 140) E-XP1 SERIES Part, Series Full Load Peak Amps* 259024, F 259029, F 259033, F 69 24 43 15,800 15,800 15,800 2500 (17.2, 172) 2500 (17.2, 172) 2500 (17.2, 172) E-XP2 SERIES Part, Series Full Load Peak Amps* 259028, F 259032, F 259036, F 100 35 62 23,000 23,000 23,000 3500 (24.1, 241) 3500 (24.1, 241) 3500 (24.1, 241) * 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. † Total system watts, based on maximum hose length Approvals: for each unit: • • 4 E-20 and E-XP1 series, 210 ft (64 m) maximum heated hose length, including whip hose. E-30 and E-XP2 series, 310 ft (94.5 m) maximum heated hose length, including whip hose. #ONFORMSTO!.3)5, 3TD#ERTIFIEDTO #!.#3!3TD #.O 312065T Supplied Manuals Supplied Manuals Related Manuals The following manuals are shipped with the Reactor™ Proportioner. Refer to these manuals for detailed equipment information. The following manuals are for accessories used with the Reactor™. Order Part 15M334 for a compact disk of Reactor manuals translated in several languages. Manuals are also available at www.graco.com. Order Part 15M334 for a compact disk of Reactor manuals translated in several languages. Reactor Data Reporting Kit Part Description Reactor Electric Proportioner 309867 Instruction-Parts Manual (English) Part Description Fusion Spray Gun 312066 Reactor Electric Proportioner, Repair-Parts Manual (English) Part Description 309550 Instruction-Parts Manual (English) Reactor Electrical Diagrams Fusion CS Spray Gun Part Description Part Description 312067 Reactor Electric Proportioner, Electrical Diagrams (English) 312666 Instruction-Parts Manual (English) Proportioning Pump Part Description 309577 Electric Reactor Displacement Pump Repair-Parts Manual (English) Probler P2 Spray Gun Part Description 313213 Instruction-Parts Manual (English) Heated Hose Part Description 309572 Instruction-Parts Manual (English) Circulation and Return Tube Kit Part Description 309852 Instruction-Parts Manual (English) Rupture Disk Assembly Kit Part Description 312416 Instruction-Parts Manual (English) Electric Reactor Installation 312065T Part Description 310815 Instruction Manual (English) 5 Related Manuals 6 312065T 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 at main switch before disconnecting any cables and before servicing 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. 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. 312065T 7 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. • 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. 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. 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. • • 8 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. 312065T Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • This equipment is for professional use only. • 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. • 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 forms from distributor or retailer. • 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. 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. 312065T 9 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: ____________ 10 312065T 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. 312065T Material Self-ignition Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and Safety Data Sheet (SDS). 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. 11 Important Two-Component Material Information Moisture Sensitivity of Isocyanates Foam Resins with 245 fa Blowing Agents 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. 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. 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. 12 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. 312065T 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 Reactor Proportioner Heated Hose Fluid Temperature Sensor (FTS) Heated Whip Hose Fusion Spray Gun Gun Air Supply Hose Feed Pump Air Supply Lines Fluid Supply Lines Feed Pumps Agitator Desiccant Dryer Gun Fluid Manifold (part of gun) Circulation Lines M K K R L J G A F J D B E R P C* TI10976a * Shown exposed for clarity. Wrap with tape during operation, FIG. 1: Typical Installation, with circulation 312065T 13 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 Q Reactor Proportioner Heated Hose Fluid Temperature Sensor (FTS) Heated Whip Hose Fusion Spray Gun Gun Air Supply Hose Feed Pump Air Supply Lines K Waste Containers Fluid Supply Lines Feed Pumps Agitator Desiccant Dryer Bleed Lines Gun Fluid Manifold (part of gun) Air Filter/Separator M K J L G A J N G D F E P B C* H TI10975a * Shown exposed for clarity. Wrap with tape during operation, FIG. 2: Typical Installation, without circulation 14 312065T Component Identification Component Identification Key for FIG. 3 BA BB FA FB GA GB HA HB PA PB SA SB TA TB Component A Pressure Relief Outlet Component B Pressure Relief Outlet Component A Fluid Manifold Inlet (behind manifold block) Component B Fluid Manifold Inlet Component A Pressure Gauge Component B Pressure Gauge Component A Hose Connection Component B Hose Connection Component A Pump Component B Pump Component A PRESSURE RELIEF/SPRAY Valve Component B PRESSURE RELIEF/SPRAY Valve Component A Pressure Transducer (behind gauge GA) Component B Pressure Transducer (behind gauge GB) DG EC EM FH FM FV HC MC MP RS SC SN TC Drive Gear Housing Electrical Cord Strain Relief Electric Motor Fluid Heaters (behind shroud) Reactor Fluid Manifold Fluid Inlet Valve (B side shown) Heated Hose Termination Box (series F) Motor Control Display Main Power Switch Red Stop Button Fluid Temperature Sensor Cable Serial No. Plate Temperature Control Display TC MC RS EM DG FH PA GA DG TA GB TB SA PB FM FA SB BA FV SC HC MP FB EC BB HA HB TI9880a WLE SN TI7823a FIG. 3: Component Identification (Model EXP-1 Shown) 312065T 15 Temperature Controls and Indicators Temperature Controls and Indicators NOTICE To prevent damage to the softkey buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. 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 °C Temperature Scale Keys Target Temperature Key FIG. 4. Temperature Controls and Indicators Main Power Switch Red Stop Button Located on right side of unit, page 15. Turns Reactor Located between temperature control panel and motor power ON control panel, page 15. Press and OFF heater zones or pumps on. 16 . Does not turn to shut off motor and heater zones only. Use main power switch to shut off all power to unit. 312065T Temperature Controls and Indicators Actual Temperature Key/LED Press to display actual temperature. Press and hold 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. to display electrical current. Circuit Breakers Target Temperature Key/LED Press to display target temperature. Located inside Reactor cabinet. Press and hold to display heater control circuit board temperature. Temperature Scale Keys/LEDs Press °F or °C to change temperature scale. Heater Zone On/Off Keys/LEDs Press Ref. Size Component CB1 50 A Hose/Transformer Secondary CB2 40 A Transformer Primary CB3 25, 40* Heater A CB4 25, 40* Heater B CB5 20 Motor/Pumps * Depending on model. to turn heater zones on and off. Also clears heater zone diagnostic codes, see page 37. LEDs flash when heater zones are on. The duration of each flash shows the extent that the heater is turned on. CB2 Temperature Arrow Keys Press , then press or CB1 to adjust tem- CB3 CB4 ti9884a CB5 For wiring and cabling, see repair manual 312066. perature settings in 1 degree increments. 312065T 17 Motor Controls and Indicators Motor Controls and Indicators NOTICE To prevent damage to the softkey buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. 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. 5. 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 37. PARK Key/LED Press 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 18 PSI or BAR If pressures are imbalanced, display shows higher of two pressures. Cycle Count Key/LED Press to display cycle count. To clear counter, press and hold for 3 sec. to change pressure scale. 312065T Spray Adjustments Pressure Arrow Keys Spray Adjustments Press Flow rate, atomization, and amount of overspray are affected by four variables. or to adjust fluid pressure when motor is ON. Setpoint displays for 10 sec. When motor is OFF, pressing will enter jog mode. To exit jog mode, press until display shows dashes or current pressure. • 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. • 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. Pressure/Cycle Display Shows fluid pressure or cycle count, depending on mode selected. Displays J 1 through J 10 when in jog mode, page 36. 312065T 19 Setup Setup Bolt bracket and mounting feet (MF) directly to NOTICE Proper system setup, start up, 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. truck or trailer bed. See page 41. 1. Locate Reactor a. Locate Reactor on a level surface. See Dimensions page 41, for clearance and mounting hole dimensions. b. Do not expose Reactor to rain. NOTICE To prevent damage from tipping over and falling, proper care needs to be taken when lifting the Reactor. Bolt Reactor to original shipping pallet, to keep stable, before lifting. c. MF Use the casters to move Reactor to a fixed location, or bolt to shipping pallet and move with forklift. MB 259024_312065 FIG. 6 2. General equipment guidelines • d. To mount on a truck bed or trailer, remove casters and secure rear axle with 15B805 mobile mounting bracket (MB), available separately. 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. Use the following procedure to determine the correct size generator. a. List system components that use peak load requirements in watts. b. Add the wattage required by the system components. c. 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. • 20 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. 312065T Setup • • • 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. Table 1: Electrical Requirements (kW/Full Load Amps) E SERIES 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. 3. Electrical requirements See TABLE 1. Part No. Model 259025 249030 259034 259026 259031 259035 259057 259058 259059 E-20 E-20 E-20 E-30 E-30 E-30 E-30† E-30† E-30† Nominal Voltage Range (phase) 200-240 V (1) 350-415 V (3) 200-240 V (3) 200-240 V (1) 350-415 V (3) 200-240 V (3) 200-240 V (1) 200-240 V (3) 350-415 V (3) Full Load Peak Amps* System Watts** 48 24 32 78 34 50 100 62 35 10,200 10,200 10,200 17,900 17,900 17,900 23,000 23,000 23,000 69 24 43 100 35 62 15,800 15,800 15,800 23,000 23,000 23,000 E-XP SERIES 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 page 22. Be sure your installation complies with all National, State and Local safety and fire codes. 259024 259029 259033 259028 259032 259036 * E-XP1 E-XP1 E-XP1 E-XP2 E-XP2 E-XP2 200-240 V (1) 350-415 V (3) 200-240 V (3) 200-240 V (1) 350-415 V (3) 200-240 V (3) Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less. ** E-20 and E-XP1 with 210 ft (64.1 m) hose; E-30 and E-XP2 with 310 ft (94.6 m) hose. † E-30 with 15.3 kW of heat. 312065T 21 Setup 4. Connect electrical cord b. Power cord is not supplied. See Table 2. 200-240 V ac, 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). Table 2: Power Cord Requirements Part Model Cord Specification AWG (mm2) 259024 259025 259026 259028 259029 259030 259031 259032 259033 259034 259035 259036 259057 259058 259059 E-XP1 E-20 E-30 E-XP2 E-XP1 E-20 E-30 E-XP2 E-XP1 E-20 E-30 E-XP2 E-30 E-30 E-30 4 (21.2), 2 wire + ground/PE 6 (13.3), 2 wire + ground/PE 4 (21.2), 2 wire + ground/PE 4 (21.2), 2 wire + ground/PE 10 (5.3), 4 wire + ground/PE 10 (5.3), 4 wire + ground/PE 8 (8.4), 4 wire + ground/PE 8 (8.4), 4 wire + ground/PE 8 (8.4), 3 wire + ground/PE 8 (8.4), 3 wire + ground/PE 6 (13.3), 3 wire + ground/PE 6 (13.3), 3 wire + ground/PE 4 (21.2), 2 wire + ground/PE 6 (13.3), 3 wire + ground/PE 8 (8.4), 4 wire + ground/PE GND L1 L2 L3 ti3248b c. 350-415 V ac, 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 L3 L2 N ti2725a a. 200-240 V ac, 1-phase: Using 5/32 or 4 mm hex allen wrench, connect two power leads to L1 and L2. Connect green to ground (GND). GND L1 L2 ti2515b 22 312065T Setup 5. Connect feed pumps a. Install feed pumps (K) in component A and B supply drums. See FIG. 1 and FIG. 2, pages 13 and 14. 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, page 13. b. Seal component A drum and use desiccant dryer (M) in vent. SA c. Install agitator (L) in component B drum, if necessary. BA SB R R d. Ensure A and B inlet valves (FV) are closed. BB b. FV TI10971a Supply hoses from feed pumps should be 3/4 in. (19 mm) ID. 6. Connect pressure relief lines TI10954a Alternately: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See FIG. 2, page 14. 7. Install Fluid Temperature Sensor (FTS) The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions. 8. Connect heated hose See Heated Hose manual 309572 for detailed instructions on connecting heated hoses. 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 The fluid temperature sensor (C) and whip hose (D) must be used with heated hose, see page 23. Hose length, including whip hose, must be 60 ft (18.3 m) minimum. 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. 312065T a. Turn main power OFF b. . Assemble heated hose sections, FTS, and whip hose. 23 Setup c. Grease with Fusion® grease and connect fluid hoses to proportioner fluid manifold (M): red for hardener (ISO, blue for resin (RES). The manifold hose adapters (N, P) allow use of 1/4 in. (6.4 mm) and 3/8 in. (9.5 mm) ID fluid hoses. To check adapter tightness, torque 1/4 in. and 3/8 in. ID hoses to: • A side (HA) to 14 ft-lb (19 N•m). • B side (HB) to 20 ft-lb (27 N•m). To use 1/2 in. (13 mm) ID fluid hoses, remove the adapters (N, P) from the proportioner fluid manifold and install them in the FTS or 3/8 in. ID hose inlets. Torque 1/2 in. ID hoses to: • A side (HA) to 43 ft-lb (58 N•m). • B side (HB) to 55 ft-lb (74 N•m). e. Connect hose power wires to electrical splice connectors (V) from proportioner. Wrap connections with electrical tape. 9 < WLD f. Connect FTS cable connectors (Y). Fully tighten connectors and slide connector covers over the joint. g. Check that all equipment is properly grounded. See proportioner manual. +$ 9. Close gun fluid manifold valves A and B +% WLD For proportioners with a termination box (TB), follow step 8d. For proportioners with electrical splice connectors (v), follow step 8e. ti2411a d. Connect hose power wires to the terminal block (C) on the termination box (TB). Remove box cover (D) and loosen lower strain relief (E). Route wires through strain relief and fully insert into terminal block (A and B hose wire positions are not important). Torque terminal block screws (C) to 35-50 in-lb (4.0-5.6 N•m). Fully tighten strain relief screws and replace cover. 10. Connect whip hose to gun fluid manifold Do not connect manifold to gun. ti2417a 7% 11. Pressure check hose See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage. ' & 24 ( WLD 312065T Setup 12. Ground system a. 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. a. Reactor: is grounded through power cord. See page 22. b. Spray gun: connect whip hose ground wire to FTS, page 23. Do not disconnect wire or spray without whip hose. c. R 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. TI3765a-2 FIG. 7 b. 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. 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. 13. Supply wet cups with Throat Seal Liquid (TSL) S 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. Turn main power OFF before filling wet cup. 312065T TI3765a-1 FIG. 8 25 Startup Startup 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. a. Check that all Setup steps are complete. b. Check that inlet screens are clean before daily startup, page 38. c. Check level and condition of ISO lube daily, page 38. d. Turn on component B agitator, if used. e. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY Do not operate Reactor without all covers and shrouds in place. . SA SB 1. Check generator fuel level. Running out of fuel will cause voltage fluctuations that can damage electrical equipment. 2. Ensure the main breaker on the generator is in the off position. 3. Start the generator. Allow it to reach full operating temperature. 4. Close the bleed valve on the air compressor. WLD f. Start feed pumps. g. Open fluid inlet valves (FV). Check for leaks. FV 5. Switch on the air compressor starter and air dryer, if included. 6. Turn on power to the Reactor. TI10972a 7. Load fluid with feed pumps The Reactor is tested with oil at the factory. Flush out the oil with a compatible solvent before spraying. See page 40. 26 312065T Startup 8. Set temperatures Do not mix components A and B during startup. Always provide two grounded waste containers to keep component A and component B fluids separate. A B h. Use feed pumps to load system. 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. °F °C Temperature Controls and Indicators, see page 16 ti2484a 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 b. Press °F or °C . to change temperature scale. c. Press d. To set press 312065T to display target temperatures. A heat zone target temperature, or until display shows 27 Startup desired temperature. Repeat for B h. Hold and to view electrical currents for each zone. zones. i. For to view heater control circuit board temperature. zone only, if FTS is disconnected at startup, display will show hose current (0A). See step j, page 28. e. Press Hold j. Manual current control mode only: to display actual temperatures. 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. Do not turn on hose heat without fluid in hoses. If FTS is disconnected or display shows diagnostic code E04, turn main power switch OFF f. Turn on 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 then ON to clear diagnostic code and enter manual current control mode. display will show current to hose. Cur- hose near FTS. rent is not limited by target temperature. Press Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose. g. Turn on ing 28 A and B for each zone. or to adjust current setting. 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. heat zones by pressIf thermometer reading exceeds 160°F (71°C), reduce current with key. 312065T Startup 9. Set pressure 10. Change pressure imbalance setting (optional) The pressure imbalance function (status code 24) 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. ON / OFF PARK Code 24 (pressure imbalance) is set to an alarm as the default. To change to a warning, see Reactor Repair-Parts manual 312066. PSI BAR Motor Controls and Indicators, see page 18 a. Press b. . Press motor . Motor and pumps start. Display shows system pressure. Motor runs until setpoint is reached. c. Press or 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. until display shows power switch ON desired fluid pressure. Display will show setpoint for 10 seconds, then change to actual pressure. If display shows J xx, unit is in jog mode. To exit jog mode, see page 36. Press or To clear counter, press . and hold for 3 sec- onds. e. Press scale. 312065T PSI or BAR to change pressure or BAR , then turn main . Display will read to select desired pres- sure differential (100-999 in increments of 100 psi, or 7-70 in increments of 7 bar). See Table 3. Table 3: Available Pressure Imbalance Settings PSI d. To display cycle count, press PSI dP500 for psi or dP_35 for bar. c. If display pressure is greater than setpoint pressure, trigger gun to reduce pressure. Press and hold . 100 200 300 400 *500 BAR PSI 7 600 14 700 21 800 28 900 *35 999 * Factor default setting. d. Turn main power switch OFF BAR 42 49 56 63 69 to save changes. 29 Spraying Spraying 3. Attach gun fluid manifold. Connect gun air line. Open air line valve. 1. Engage gun piston safety lock. ti2543a ti2409a 4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to 2. Close gun fluid manifold valves A and B. SPRAY . SA SB WLD ti2728a 5. Check that heat zones are on and temperatures are on target, page 27. 6. Press motor to start motor and pumps. 7. Check fluid pressure display and adjust as necessary, page 30. 30 312065T Spraying 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 9. Open gun fluid manifold valves A and B. , until gauges show balanced pressures. GA GB In this example, B side pressure is higher, so use the B side valve to balance pressures. WLD ti2414a 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. 312065T 31 Shutdown Shutdown 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. 4. Relieve pressure, page 33. 5. Turn off the air compressor and air dryer, if included. 6. Open air compressor bleed valve to relieve pressure and remove water from tank. 7. Turn off the main breaker on the generator. 1. Shut off A B , , and heat zones. 9. Close both fluid supply valves (FV). 2. Park pumps. a. Press 8. Allow generator dwell time, per manufacturer recommendations, prior to shutdown. . b. Trigger gun until pump A stops in the retracted position and the pressure of both pumps bleeds down. FV ti10971a 10. Shut down feed pumps as required. 3. Turn main power OFF 32 . 312065T 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. ti2409a 2. Close gun fluid manifold valves A and B. 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 312065T 33 Fluid Circulation Fluid Circulation Circulation Through Reactor 4. Turn main power ON . 5. Set temperature targets, see page 27. Turn on A Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. and B Do not turn on To circulate through gun manifold and preheat hose, see page 35. . heat zone unless hoses are already loaded with fluid. 6. Press 1. Follow Startup procedures, page 26. heat zones by pressing to display actual temperatures. 7. Circulate fluid in jog mode until A B and 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 13. 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 . 3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION 8. Turn on heat zone by pressing . 9. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY . SA SB WLD . SA SB 34 312065T Fluid Circulation Circulation Through Gun Manifold 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 14. 3. Follow Startup procedures, page 26. 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. 4. Turn main power ON . 5. Set temperature targets, see page 27. Turn on A 1. Install gun fluid manifold (P) on Part 246362 accessory circulation kit (CK). Connect high pressure circulation lines (R) to circulation manifold. , B , and heat zones by pressing . 6. Press to display actual temperatures. 7. Circulate fluid in jog mode until P CK A and B temperatures reach targets. R ti2767a 312065T 35 Jog Mode Jog Mode Jog mode has two purposes: 4. Press motor • It can speed fluid heating during circulation. • It can ease pump repair/replacement. See repair manual. 5. Press to start motor. or to change jog speed (J1 through J10). 1. Turn main power on 2. Ensure motor . is OFF (LED is off; display may show dashes or pressure). 3. Press 36 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. to select J1 (jog speed 1). 6. To exit jog mode, press until display shows dashes or current pressure. 312065T 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. 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 communication All 99 Loss of display communication All For hose zone only, if FTS is disconnected at startup, display will show hose current 0A. See repair manual for corrective action. Motor Control Diagnostic Codes Motor control diagnostic codes E21 through E29 appear on pressure display. Code No. Code Name Alarm or Warning There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings. 21 No transducer (component A) Alarm 22 No transducer (component B) Alarm See repair manual for corrective action. 23 High pressure Alarm 24 Pressure imbalance Selectable; see repair manual 25 High line voltage Alarm 26 Low line voltage Alarm 27 High motor temperature Alarm 28 High current Alarm 29 Brush wear Warning Alarms can also be cleared, except for code 23, 30 Momentary loss of communication - by pressing 31 Motor control failure Alarm 32 Motor control board overtemperature Alarm 99 Loss of communication - Alarms Alarms turn off motor and heat zones. Turn main power OFF then ON to clear. . 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 is turned OFF 312065T then ON . 37 Maintenance Maintenance • Check wet cup TSL level daily. • Do not overtighten packing nut/wet cup. Throat u-cup is not adjustable. • Inspect fluid inlet strainer screens daily, see below. • Grease circulation valves weekly with Fusion grease (117773). Fluid 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. Use clean chemicals and follow proper storage, transfer, and operating procedures, to minimize contamination of the A-side screen. 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. • Inspect ISO lubricant level and condition daily, see page 39. Refill or replace as needed. 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. • Keep component A from exposure to moisture in atmosphere, to prevent crystallization. 2. Place a container under the strainer manifold (59d) to catch fluid. Remove the strainer plug (59j). • Clean gun mix chamber ports regularly. See gun manual. • Clean gun check valve screens regularly. See gun manual. 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. • 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. 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. 5. Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation. 59d 59g* 59h 59j 59k Ti10974a FIG. 9. Fluid Inlet Strainer 38 312065T Maintenance Pump Lubrication System 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. ST RT 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. RB LR 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. TI10970a To change pump lubricant: 1. Relieve pressure, page 33. 2. Lift the lubricant reservoir (LR) out of the bracket (RB) 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. See FIG. 10. 3. Drain the reservoir and flush it with clean lubricant. RT ST LR 4. When the reservoir is flushed clean, fill with fresh lubricant. 5. Thread the reservoir onto the cap assembly and place it in the bracket. 6. The lubrication system is ready for operation. No priming is required. TI10969a FIG. 10. Pump Lubrication System 312065T 39 Flushing Flushing 246483 Air Supply Kit Hoses and fittings to supply air to feed pumps, agitator, and gun air hose. Included in feed pump kits. See 309827. Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. 246978 Circulation Kit Return hoses and fittings to make circulation system. Includes two 246477 Return Tube Kits. See 309852. 246477 Return Tube Kit • 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 Desiccant dryer, return tube, and fittings for one drum. Two included in 246978 Circulation Kit. See 309852. 248669 Conversion Kit RELIEF/CIRCULATION lines (N). 50 ft (15.2 m) and 25 ft (7.6 m) lengths, 1/4 in. (6 mm), 3/8 in. (10 mm), or 1/2 in. (13 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See 309572. Heated Whip Hoses SB N ti10955b • 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 12. Accessories Feed Pump Kits Pumps, hoses, and mounting hardware to supply fluids to Reactor. Includes 246483 Air Supply Kit. See 309815. 40 Heated Hoses . Flush through bleed SA N Convert any E-XP2 to a E-30 with 15.3kW of heat. Include new pumps, bearing, and fitting to accomplish conversion. See manual 309574. 10 ft (3 m) whip hose, 1/4 in. (6 mm) or 3/8 in. (10 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See 309572. Fusion Spray Gun Air purge gun, available in round or flat pattern. See 309550. 246085 Data Reporting Kit Records actual temperature, temperature setpoint, actual pressure, cycles, and diagnostic code data from Reactor. Downloads data to PC with Microsoft® Windows 98 or later. See 309867. 248848 Data Reporting Kit Records actual temperature, temperature setpoint, actual pressure, cycles, and diagnostic code data from Reactor. Downloads data to PC with Microsoft® Windows 98 or later. Does not include interface module. See 309867. 312065T Dimensions Dimensions Dimension A B C in. (mm) 46.0 (1168) 31.0 (787) 33.0 (838) A WLE C B 312065T 41 Technical Data Technical Data Category Maximum Fluid Working Pressure Data Models E-20 and E-30: 2000 psi (14 MPa, 140 bar) Model E-XP1: 2500 psi (17.2 MPa, 172 bar) Maximum Fluid Temperature Maximum Output Model E-XP2: 3500 psi (24.1 MPa, 241 bar) 190°F (88°C) Model E-20: 20 lb/min (9 kg/min) Model E-30: 30 lb/min (13.5 kg/min) Model E-XP1: 1 gpm (3.8 liter/min) Output per Cycle (A and B) Model E-XP2: 2 gpm (7.6 liter/min) Model E-20 and E-XP1: 0.0104 gal. (0.0395 liter) Model E-30: 0.0272 gal. (0.1034 liter) Model E-XP2: 0.0203 gal. (.0771 liter) Voltage Tolerance Range (50/60 Hz): 200-240 V ac Nominal, 1-Phase 200-240 V ac Nominal, 3-Phase Delta 350-415 V ac Nominal, 3-Phase Wye (200-240 V ac Line-to-Neutral) Amperage Requirement Heater Power 195-264 V ac, 50/60 Hz 195-264 V ac, 50/60 Hz 338-457 V ac, 50/60 Hz See Table 1, page 20. Model E-20: 6000 watts Model E-30 and E-XP1: 10200 watts Sound Power, per ISO 9614-2 Models E-XP2 and E-30 with 15.3kW of heat: 15300 watts Model E-20: 80 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm) Model E-30: 93.5 dB(A) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm) Model E-XP1: 80 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm) Model E-XP2: 83.5 dB(A) at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm) Sound Pressure, 1 m from equipment Model E-20: 70.2 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm) Model E-30: 83.6 dB(A) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm) Model E-XP1: 70.2 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm) Fluid Inlets Fluid Outlets Model E-XP2: 73.6 dB(A) at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm) 3/4 npt(f), with 3/4 npsm(f) union Component A (ISO): #8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter Fluid Circulation Ports Weight Component B (RES): #10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter 1/4 npsm(m), with plastic tubing; 250 psi (1.75 MPa, 17.5 bar) maximum Model E-20 and E-XP1: 342 lb (155 kg) Model E-30: 400 lb (181kg) Wetted Parts Models E-XP2 and E-30 with 15.3kW of heat: 438 lb (198 kg) Aluminum, stainless steel, zinc plated, carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene All other brand names or marks are used for identification purposes and are trademarks of their respective owners. 42 312065T Technical Data 312065T 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. For patent information, see www.graco.com/patents. 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. 2ULJLQDO,QVWUXFWLRQV This manual contains English. MM 312065 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2007, Graco Inc. All Graco manufacturing locations are registered to ISO 9001 www.graco.com Revision T, March 2016 ">
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