Graco 312062G, Reactor, Hydraulic Proportioners Owner's Manual

Operation
312062G
Hydraulic, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
U.S. Patent Pending
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 3 for model information, including
maximum working pressure and approvals.
#ONFORMSTO!.3)5,
3TD#ERTIFIEDTO
#!.#3!3TD
#.O
Model H-40 Shown
T9830a
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supplied Manuals . . . . . . . . . . . . . . . . . . . 5
Related Manuals . . . . . . . . . . . . . . . . . . . . 6
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Isocyanate Hazard . . . . . . . . . . . . . . . . . . 10
Material Self-ignition . . . . . . . . . . . . . . . . 10
Moisture Sensitivity of Isocyanates . . . . 10
Keep Components A and B Separate . . 11
Foam Resins with
245 fa Blowing Agents . . . . . . . . . . . . 11
Changing Materials . . . . . . . . . . . . . . . . . 11
Typical Installation, with circulation . . . 12
Typical Installation, without circulation . 13
Component Identification . . . . . . . . . . . . 14
Temperature Controls and Indicators . . 16
Main Power Switch . . . . . . . . . . . . . . . . 16
Red Stop Button . . . . . . . . . . . . . . . . . . 16
Actual Temperature Key/LED . . . . . . . . 16
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 . . . . . . . . . . . . . . . . . . 18
Motor Controls and Indicators . . . . . . . . 19
Motor ON/OFF Key/LED . . . . . . . . . . . . 19
PARK Key/LED . . . . . . . . . . . . . . . . . . . 19
PSI/BAR Keys/LEDs . . . . . . . . . . . . . . . 19
Pressure Key/LED . . . . . . . . . . . . . . . . 19
Cycle Count Key/LED . . . . . . . . . . . . . . 20
Hydraulic Pressure Control Knob . . . . . 20
Motor Control Arrow Keys . . . . . . . . . . 20
Spray Adjustments . . . . . . . . . . . . . . . . . 20
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Relief Procedure . . . . . . . . . . . 35
2
Fluid Circulation . . . . . . . . . . . . . . . . . . . .36
Circulation Through Reactor . . . . . . . . .36
Circulation Through Gun Manifold . . . .37
Diagnostic Codes . . . . . . . . . . . . . . . . . . .38
Temperature Control Diagnostic Codes 38
Motor Control Diagnostic Codes . . . . . .39
Maintenance . . . . . . . . . . . . . . . . . . . . . . .40
Fluid Inlet Strainer Screen . . . . . . . . . .41
Pump Lubrication System . . . . . . . . . . .42
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . .43
Dimensions . . . . . . . . . . . . . . . . . . . . . . . .44
Technical Data . . . . . . . . . . . . . . . . . . . . .45
Performance Charts . . . . . . . . . . . . . . . . .46
Graco Standard Warranty . . . . . . . . . . . .48
Graco Information . . . . . . . . . . . . . . . . . .48
312062G
Models
Models
H-25 SERIES
Part, Series
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
15,960
15,960
15,960
23,260
23,260
23,260
8,000
8,000
8,000
15,300
15,300
15,300
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
Voltage
(phase)
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
230V (1)
230V (3)
400V (3)
230V (3)
400V (3)
23,100
26,600
26,600
31,700
31,700
12,000
15,300
15,300
20,400
20,400
45 (20)
45 (20)
45 (20)
45 (20)
45 (20)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
Voltage
(phase)
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
230V (1)
230V (3)
400V (3)
230V (3)
400V (3)
23,100
26,600
26,600
31,700
31,700
12,000
15,300
15,300
20,400
20,400
52 (24)
52 (24)
52 (24)
52 (24)
52 (24)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28)
1.64:1
1.64:1
1.64:1
1.64:1
1.64:1
1700 (11.7, 117)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
Full Load
Peak Amps* Voltage
Per Phase
(phase)
255400, D
255401, D
255402, D
255406, D
255407, D
255408, D
69
46
35
100
59
35
230V (1)
230V (3)
400V (3)
230V (1)
230V (3)
400V (3)
H-40 SERIES
Part,
Series
Full Load
Peak Amps*
Per Phase
★253400, D
253401, D
253402, D
253407, D
253408, D
100
71
41
95
52
H-50 SERIES
Part,
Series
★‡253725, D
‡253726, D
‡253727, D
‡256505, D
‡256506, D
312062G
Full Load
Peak Amps*
Per Phase
100
71
41
95
52
3
Models
H-XP2 SERIES
Part, Series
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
100
59
35
230V (1)
230V (3)
400V (3)
255403, D
255404, D
255405, D
System
Watts†
Primary
Heater
Watts
Approximate
Max Flow Output per
Rate◆
Cycle (A+B)
gpm (lpm) gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
23,260
23,260
23,260
15,300
15,300
15,300
1.5 (5.7)
1.5 (5.7)
1.5 (5.7)
2.79:1
2.79:1
2.79:1
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
System
Watts†
Primary
Heater
Watts
Approximate
Max Flow Output per
Rate◆
Cycle (A+B)
gpm (lpm) gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
23,100
31,700
31,700
12,000
20,400
20,400
2.8 (10.6)
2.8 (10.6)
2.8 (10.6)
2.79:1
2.79:1
2.79:1
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
H-XP3 SERIES
Full Load
Peak Amps* Voltage
Per Phase
(phase)
Part,
Series
★253403, D
253404, D
253405, D
100
95
52
230V (1)
230V (3)
400V (3)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
* 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, based on maximum hose length for each unit:
• Parts 255400 through 255408, 310 ft (94.6 m) maximum heated hose length, including whip
hose.
• Parts 253400 through 253408, 253725 through 253727, 256505, and 256506, 410 ft (125 m)
maximum heated hose length, including whip hose.
◆
Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of
60 Hz maximum flow.
★CE approval does not apply.
‡
4
does not apply
312062G
Supplied Manuals
Supplied Manuals
The following manuals are shipped with the
Reactor™ Proportioner. Refer to these manuals for detailed equipment information.
Order Part 15M334 for a compact disk of
Reactor manuals translated in several languages.
Manuals are also available at www.graco.com.
Reactor Hydraulic Proportioner
Part
312063
Description
Reactor Hydraulic Proportioner,
Repair-Parts Manual (English)
Reactor Electrical Diagrams
Part
312064
Translations
The Reactor Operation manual is available in
the following languages. See the following
chart for specific languages and corresponding
part numbers.
Part
312062
312419
312420
312421
312422
312423
312424
312425
312426
312427
Language
English
Chinese
Dutch
French
German
Italian
Japanese
Korean
Russian
Spanish
Description
Reactor Hydraulic Proportioner,
Electrical Diagrams (English)
Proportioning Pump
Part
312068
312062G
Description
Proportioning Pump Repair-Parts
Manual (English)
5
Related Manuals
Related Manuals
The following manuals are for accessories
used with the Reactor™.
Order Part 15M334 for a compact disk of
Reactor manuals translated in several languages.
Feed Pump Kits
Data Reporting Kit
Part
309815
Part
309867
Air Supply Kit
Description
Instruction-Parts Manual
(English)
Rupture Disk Assembly Kit
Part
309827
Part
309969
Description
Instruction-Parts Manual
(English)
Description
Instruction-Parts Manual
(English) for Feed Pump Air
Supply Kit
Circulation and Return Tube Kits
Part
309852
Description
Instruction-Parts Manual
(English)
Heated Hose
Description
Instruction-Parts Manual
(English)
Proportioning Pump Repair Kits
Part
312071
Description
Seal Kits Instruction-Parts
Manual (English)
Part
309572
Description
Instruction-Parts Manual
(English)
Circulation Kit
Part
309818
Description
Instruction-Parts Manual
(English)
Circulation Valve Kit
Part
312070
6
Description
Instruction-Parts Manual
(English)
312062G
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
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the
operating area of the equipment to help protect you from serious injury, including eye injury,
inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited
to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate
surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before
cleaning, checking, or servicing equipment.
312062G
7
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To
help prevent fire and explosion:
• Use and clean 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 lights on or off when flammable fumes are
present.
• Ground equipment, personnel, object being sprayed, and conductive objects in work
area. See Grounding instructions.
• Use only Graco grounded hoses.
• Check gun resistance daily.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use
equipment until you identify and correct the problem.
• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is
removed from system.
• Keep a working fire extinguisher in the work area.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can
cause serious chemical reaction and equipment rupture, and result in death, serious injury,
and property damage.
8
312062G
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• This equipment is for professional use only.
• Do not leave the work are while the equipment is energized or under pressure. Turn off all
equipment and follow the Pressure Relief Procedure in this manual when the 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.
312062G
9
Isocyanate Hazard
Isocyanate Hazard
become suspended in the fluid. Eventually a
film will form on the surface and the ISO will
begin to gel, increasing in viscosity. If used,
this partially cured ISO will reduce performance and the life of all wetted parts.
Spraying materials containing isocyanates
creates potentially harmful mists, vapors,
and atomized particulates.
Read material manufacturer’s warnings and
material MSDS to know specific hazards
and precautions related to isocyanates.
Prevent inhalation of isocyanate mists,
vapors, and atomized particulates by providing sufficient ventilation in the work area. If
sufficient ventilation is not available, a supplied-air respirator is required for everyone in
the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots,
aprons, and goggles, is also required for
everyone in the work area.
The amount of film formation and rate of
crystallization varies depending on the
blend of ISO, the humidity, and the temperature.
To prevent exposing ISO to moisture:
•
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 lube pump reservoir filled
with Graco Throat Seal Liquid (TSL), Part
206995. The lubricant creates a barrier
between the ISO and the atmosphere.
•
Use moisture-proof hoses specifically
designed for ISO, such as those supplied
with your system.
•
Never use reclaimed solvents, which may
contain moisture. Always keep solvent containers closed when not in use.
•
Never use solvent on one side if it has been
contaminated from the other side.
•
Always park pumps when you shutdown,
see page 33.
•
Always lubricate threaded parts with Part
217374 ISO pump oil or grease when reassembling.
Material Self-ignition
Some materials may become self-igniting if
applied too thickly. Read material manufacturer’s warnings and material MSDS.
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two
component foam and polyurea coatings. ISO
will react with moisture (such as humidity) to
form small, hard, abrasive crystals, which
10
312062G
Keep Components A and B Separate
Keep Components A
and B Separate
CAUTION
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A (isocyanate) and component B (resin) parts.
Foam Resins with 245
fa Blowing Agents
New 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.
312062G
Changing Materials
•
When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
•
Always clean the fluid inlet strainers after
flushing, see page 41.
•
Check with your material manufacturer for
chemical compatibility.
•
Most materials use ISO on the A side, but
some use ISO on the B side.
•
Epoxies often have amines on the B (hardener) side. Polyureas often have amines on
the B (resin) side.
11
Typical Installation, with circulation
Typical Installation, with circulation
Key for FIG. 1
A
B
C
D
E
F
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
Fusion Spray Gun
Gun Air Supply Hose
A Side Supply Detail
G
J
K
L
M
P
R
Feed Pump Air Supply Lines
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Gun Fluid Manifold (part of gun)
Circulation Lines
B Side Supply Detail
M
K
M
K
K
G
G
L
K
ti7820a 3
ti7820a 2
R
J
A
J
D
R
F
E
P
C*
B
* Shown exposed for clarity.
Wrap with tape during operation.
ti10000a
FIG. 1: Typical Installation, with circulation
12
312062G
Typical Installation, without circulation
Typical Installation, without circulation
Key for FIG. 2
A
B
C
D
E
F
G
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
Fusion Spray Gun
Gun Air Supply Hose
Feed Pump Air Supply Lines
H
J
K
L
M
N
P
Waste Containers
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Bleed Lines
Gun Fluid Manifold (part of gun)
B Side Supply Detail
A Side Supply Detail
K
K
M
K
G
G
L
K
ti7821a 2
ti7821a 3
J
A
J
F
N
H
D
E
P
C*
* Shown exposed for clarity.
Wrap with tape during operation.
B
ti10001a
FIG. 2: Typical Installation, without circulation
312062G
13
Component Identification
Component Identification
Key for FIG. 3
BA
BB
EC
EM
FA
FB
FH
FM
FP
FS
FT
FV
GA
GB
HA
HB
HC
HP
LR
MC
MP
OP
PA
PB
RS
SA
SB
SC
SN
SR
TA
TB
TC
TD
14
Component A Pressure Relief Outlet
Component B Pressure Relief Outlet
Heated Hose Electrical Connector
Electric Motor, Fan, and Belt Drive (behind shroud)
Component A Fluid Manifold Inlet (on left side of manifold
block)
Component B Fluid Manifold Inlet
Fluid Heater (behind shroud)
Reactor Fluid Manifold
Feed Inlet Pressure Gauge
Feed Inlet Strainer
Feed Inlet Temperature Gauge
Fluid Inlet Valve (B side shown)
Component A Outlet Pressure Gauge
Component B Outlet Pressure Gauge
Component A Hose Connection
Component B Hose Connection
Hydraulic Pressure Control
Hydraulic Pressure Gauge
ISO Lube Pump Reservoir
Motor Control Display
Main Power Switch
Overpressure Rupture Disk Assembly (on rear of A and B
pumps)
Component A Pump
Component B Pump
Red Stop Button
Component A PRESSURE RELIEF/SPRAY Valve
Component B PRESSURE RELIEF/SPRAY Valve
Fluid Temperature Sensor Cable
Serial Number Plate (one inside cabinet, one on right side
of cabinet)
Electrical Cord Strain Relief
Component A Pressure Transducer (behind gauge GA)
Component B Pressure Transducer (behind gauge GB)
Temperature Control Display
Oil Cooler
312062G
Component Identification
MC
RS
TC
HC
HP
EM
FM
FH
PA
OP
FT
FP
PB
SC
EC
FV
LR
SN
MP
FS
SR
Detail of Reactor Fluid Manifold
(shroud removed for clarity)
SA
TA GA
GB
TI9830a
TB
FA
Detail of Serial No.
Plate (inside cabinet)
SB
BA
FB
ti7823a
BB
HA
HB
ti9880a
SN
FIG. 3: Component Identification (H40 15.3 kW Model Shown)
312062G
15
Temperature Controls and Indicators
Temperature Controls and Indicators
Heater Power Indicators
Zone A Arrow Keys
A
Zone B Arrow Keys
B
Heater Displays
Heater A On/Off
Key
Heater B On/Off
Key
Hose Heater On/Off
Key
Hose Zone Arrow Keys
°F
Actual Temperature
Key
°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
Located between temperature control panel
and motor control panel, page 15. Press
Reactor power ON
and OFF
.
to shut off motor and heater zones only.
Does not turn heater zones or pumps on.
Use main power switch to shut off all power to
unit.
Actual Temperature Key/LED
Press
16
to display actual temperature.
312062G
Temperature Controls and Indicators
Press and hold
to display electrical cur-
rent.
Target Temperature Key/LED
Press
to display target temperature.
Press and hold
Heater Zone On/Off
Keys/LEDs
Press
Also clears heater zone diagnostic codes, see
page 38.
LEDs flash when heater zones are on.
The duration of each flash shows the
extent that the heater is turned on.
to display heater control
circuit board temperature.
Temperature Scale
Keys/LEDs
Press
°F
or
°C
to change temperature
to turn heater zones on and off.
Temperature Arrow Keys
Press
, then press
or
to
adjust temperature settings in 1 degree increments.
scale.
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.
312062G
17
Temperature Controls and Indicators
* Depending on model.
Circuit Breakers
Located inside Reactor cabinet.
18
Ref.
Size
Component
CB1
50 A
Hose/Transformer Secondary
CB2
40 A
Transformer Primary
CB3
25, 40, or
50 A*
Heater A
CB4
25, 40, or
50 A*
Heater B
CB5
20 or 30 A*
Motor/Pumps
CB1
CB2
CB3
CB4
ti9884a
CB5
For wiring and cabling, see repair manual 312063.
312062G
Motor Controls and Indicators
Motor Controls and Indicators
Pressure/Cycle Display
Arrow Keys
Motor ON/OFF Key
ON / OFF
PARK Key
Pressure Key
PARK
PSI/BAR Keys
Cycle Count Key
PSI
BAR
FIG. 5. Motor Controls and Indicators
Motor ON/OFF Key/LED
PSI/BAR Keys/LEDs
Press
Press
to turn motor ON and OFF. Also
clears some motor control diagnostic codes,
see page 39.
PARK Key/LED
Press
or
BAR
to change pressure scale.
Pressure Key/LED
Press
to display fluid pressure.
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.
312062G
PSI
If pressures are imbalanced, display
shows higher of two pressures.
19
Spray Adjustments
Cycle Count Key/LED
Spray Adjustments
Press
Flow rate, atomization, and amount of overspray are affected by four variables.
to display cycle count.
To clear counter, press and hold
•
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.
for 3 sec.
Hydraulic Pressure Control
Knob
Use to adjust hydraulic pressure available to
the hydraulic drive system. Turn knob (HC)
clockwise to increase pressure and counterclockwise to decrease pressure. Use hydraulic
pressure gauge (HP, page 15) to view hydraulic pressure.
+
ti7731a
ti7732a
Component A and B outlet pressures
will be higher than the hydraulic set
pressure, depending on the model (see
Pressure Ratio data; Models, page 3).
Component A and B pressure may be
viewed on the pressure gauges (GA,
GB), or the higher of the two pressures
may be displayed on the motor control
panel (MC). See FIG. 3, page 15.
Motor Control Arrow Keys
Use
or
to:
•
Adjust pressure imbalance settings, page
29.
•
Adjust standby settings, page 33.
20
312062G
Setup
Setup
1. Locate Reactor
Table 1:
Electrical Requirements
(kW/Full Load Amps)
a. Locate Reactor on a level surface. See
Dimensions, page 44, for clearance
and mounting hole dimensions.
b. Do not expose Reactor to rain.
CAUTION
Bolt Reactor to original shipping pallet before
lifting.
c. Use the casters to move Reactor to a
fixed location, or bolt to shipping pallet
and move with forklift.
d. To mount on a truck bed or trailer,
remove casters and bolt directly to truck
or trailer bed. See page 44.
2. Electrical requirements
See TABLE 1.
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.
312062G
Part
Model
Voltage
(phase)
Full
Load
Peak
Amps*
253400
253401
253402
253403
253404
253405
253407
253408
255400
255401
255402
255403
255404
255405
255406
255407
255408
253725
253726
253727
256505
256506
H-40
H-40
H-40
H-XP3
H-XP3
H-XP3
H-40
H-40
H-25
H-25
H-25
HXP2
HXP2
HXP2
H-25
H-25
H-25
H-50
H-50
H-50
H-50
H-50
230V (1)
230V (3)
400V (3)
230V (1)
230V (3)
400V (3)
230V (3)
400V (3)
230V (1)
230V (3)
400V (3)
230V (1)
230V (3)
400V (3)
230V (1)
230V (3)
400V (3)
230V (1)
230V (3)
400V (3)
230V (3)
400V (3)
100
71
41
100
95
52
95
52
69
46
35
100
59
35
100
59
35
100
71
41
95
52
System
Watts**
23,100
26,600
26,600
23,100
31,700
31,700
31,700
31,700
15,960
15,960
15,960
23,260
23,260
23,260
23,260
23,260
23,260
23,100
26,600
26,600
31,700
31,700
* 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, based on maximum
hose length for each unit:
•
Parts 255400 through 255408, 310 ft (94.6
m) maximum heated hose length, including
whip hose.
•
Parts 253400 through 253408, 410 ft (125
m) maximum heated hose length, including
whip hose.
21
Setup
3. Connect electrical cord
Power cord is not supplied. See Table 2.
Table 2: Power Cord Requirements
Part
253400
253401
253402
253404
253405
253407
253408
255400
255401
255402
255403
255404
255405
255406
255407
255408
253725
253726
253727
256505
256506
Model
H-40
H-40
H-40
H-XP3
H-XP3
H-40
H-40
H-25
H-25
H-25
H-XP2
H-XP2
H-XP2
H-25
H-25
H-25
H-50
H-50
H-50
H-50
H-50
Cord Specification
AWG (mm2)
4 (21.2), 2 wire + ground
4 (21.2), 3 wire + ground
8 (8.4), 4 wire + ground
4 (21.2), 3 wire + ground
6 (13.3), 4 wire + ground
4 (21.2), 3 wire + ground
6 (13.3), 4 wire + ground
4 (21.2), 2 wire + ground
8 (8.4), 3 wire + ground
8 (8.4), 4 wire + ground
4 (21.2), 2 wire + ground
6 (13.3), 3 wire + ground
8 (8.4), 4 wire + ground
4 (21.2), 2 wire + ground
6 (13.3), 3 wire + ground
8 (8.4), 4 wire + ground
4 (21.2), 2 wire + ground
4 (21.2), 3 wire + ground
8 (8.4), 4 wire + ground
4 (21.2), 3 wire + ground
6 (13.3), 4 wire + ground
a. 230V, 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
b. 230V, 3 phase: Using 5/32 or 4 mm hex
allen wrench, connect three power
leads to L1, L2, and L3. Connect green
to ground (GND).
GND
L1
L2
L3
ti3248b
22
312062G
Setup
c. 400V, 3 phase: Using 5/32 or 4 mm hex
allen wrench, connect three power
leads to L1, L2, and L3. Connect neutral
to N. Connect green to ground (GND).
c. Install agitator (L) in component B drum,
if necessary.
d. Ensure A and B inlet valves (FV) are
closed.
GND
L1
L3
L2 N
FV
ti9883a
ti2725a
Some 3-phase models utilize a 3-phase
motor. The motor must rotate counterclockwise when viewed from shaft end.
To reverse rotation, disconnect power
and reverse power leads L1 and L2.
4. Connect feed pumps
a. Install feed pumps (K) in component A
and B supply drums. See FIG. 1 and
FIG. 2, pages 12 and 13.
Supply hoses from feed pumps should
be 3/4 in. (19 mm) ID.
e. Connect and tighten component B supply hose to the 3/4 npt(f) swivel on the
component B inlet valve.
f. Connect and tighten component A supply hose to the 1/2 npt(f) swivel on the
component A inlet valve.
A minimum feed pressure of 50 psi
(0.35 MPa, 3.5 bar) is required at both
feed inlet pressure gauges (FP). Maximum feed pressure is 250 psi (1.75
MPa, 17.5 bar). Maintain A and B feed
pressures within 10% of each other.
FP
ti10006a
b. Seal component A drum and use desiccant dryer (M) in vent.
312062G
23
Setup
5. Connect pressure relief lines
SB
SA
Do not install shutoffs downstream of the
PRESSURE RELIEF/SPRAY valve outlets
(BA, BB). The valves function as overpressure relief valves when set to SPRAY
.
Lines must be open so valves can automatically relieve pressure when machine is operating.
If circulating fluid back to the supply drums,
use high pressure hose rated to withstand
the maximum working pressure of this
equipment.
R
BA
R
BB
ti9880a
b. Alternately: Secure supplied bleed
tubes (N) in grounded, sealed waste
containers (H). See FIG. 2, page 13.
6. Install Fluid Temperature Sensor (FTS)
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 12.
24
The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip
hose. See Heated Hose manual 309572 for
instructions.
312062G
Setup
7. Connect heated hose
See Heated Hose manual 309572 for
detailed instructions on connecting
heated hoses.
CAUTION
The fluid temperature sensor (C) and whip
hose (D) must be used with heated hose,
see page 24. Hose length, including whip
hose, must be 60 ft (18.3 m) minimum.
a. Turn main power OFF
d. Connect cables (Y). Connect electrical
connectors (V). Be sure cables have
slack when hose bends. Wrap cable
and electrical connections with electrical tape.
Y
V
.
ti9881a
b. Assemble heated hose sections, FTS,
and whip hose.
8. Close gun fluid manifold valves A and B
c. Connect A and B hoses to A and B outlets on Reactor fluid manifold (FM).
Hoses are color coded: red for component A (ISO), blue for component B
(RES). Fittings are sized to prevent connection errors.
ti2411a
9. Connect whip hose to gun fluid manifold
FM
N
A
Do not connect manifold to gun.
P
B
ti2417a
ti9878a
Manifold hose adapters (N, P) allow use
of 1/4 in. and 3/8 in. ID fluid hoses. To
use 1/2 in. (13 mm) ID fluid hoses,
remove adapters from fluid manifold and
install as needed to connect whip hose.
312062G
10. Pressure check hose
See hose manual. Pressure check for leaks. If
no leaks, wrap hose and electrical connections
to protect from damage.
25
Setup
11. Ground system
13. Lubrication system setup
Component A (ISO) Pump: Fill ISO lube
reservoir (LR) with Graco Throat Seal Liquid (TSL), Part 206995 (supplied).
a. Lift the lubricant reservoir (LR) out of
the bracket (RB) and remove the container from the cap.
a. Reactor: is grounded through power
cord. See page 22.
b. Spray gun: connect whip hose ground
wire to FTS, page 24. Do not disconnect
wire or spray without whip hose.
ST
RT
RB
c. Fluid supply containers: follow your
local code.
d. Object being sprayed: follow your local
code.
ti9911a
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
b. Fill with fresh lubricant. Thread the reservoir onto the cap assembly and place
it in the bracket (RB).
f. To maintain grounding continuity when
flushing or relieving pressure, hold a
metal part of spray gun firmly to the side
of a grounded metal pail, then trigger
gun.
d. Push the smaller diameter return tube
(RT) into the reservoir until it reaches
the bottom.
12. Check hydraulic fluid level
Hydraulic reservoir is filled at the factory.
Check fluid level before operating the first
time, and weekly thereafter. See Maintenance, page 40.
26
LR
c. Push the larger diameter supply tube
(ST) approximately 1/3 of the way into
the reservoir.
Important: The return tube (RT) must
reach the bottom of the reservoir, to
ensure that isocyanate crystals will settle to the bottom and not be siphoned
into the supply tube (ST) and returned
to the pump.
e. The lubrication system is ready for
operation. No priming is required.
312062G
Startup
Startup
Do not operate Reactor without all covers
and shrouds in place.
1. Load fluid with feed pumps
g. Open fluid inlet valves (FV). Check for
leaks.
The Reactor is tested with oil at the factory. Flush out the oil with a compatible
solvent before spraying. See page 43.
FV
a. Check that all Setup steps are complete.
ti10002a
b. Check that inlet screens are clean
before daily startup, page 41.
c. Check level and condition of ISO lube
daily, page 40.
d. Turn on component B agitator, if used.
e. Turn both PRESSURE RELIEF/SPRAY
valves (SA, SB) to SPRAY
SA
.
SB
Do not mix components A and B during
startup. Always provide two grounded waste
containers to keep component A and component B fluids separate.
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.
ti9877a
f. Start feed pumps.
ti2484a
312062G
27
Startup
2. Set temperatures
d. To set
A heat zone target tempera-
ture, press
A
or
until display
shows desired temperature. Repeat for
B and
B
For
zones.
zone only, if FTS is discon-
nected at startup, display will show hose
current (0A). See step j, page 29.
°F
°C
e. Press
Temperature Controls and Indicators, see
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
ature scale.
c. Press
28
.
°C
.
to display actual tempera-
tures.
Do not turn on hose heat without fluid in
hoses.
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 hose
near FTS.
to change temperThermal expansion can cause overpressurization, resulting in equipment rupture and
serious injury, including fluid injection. Do not
pressurize system when preheating hose.
312062G
Startup
g. Turn on
A and B heat zones by
pressing
If thermometer reading exceeds 160°F
(71°C), reduce current with
key.
for each zone.
3. Set pressure
h. Hold
to view electrical currents for
each zone.
ON / OFF
i.
Hold
to view heater control circuit
board temperature.
j.
PARK
Manual current control mode only:
PSI
BAR
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.
If FTS is disconnected or display shows
diagnostic code E04, turn main power
switch OFF
then ON
to
clear diagnostic code and enter manual
current control mode.
Motor Controls and Indicators, see page 19
a. Press
to display the pressure
reading.
b. Press motor
. Motor and pumps
start. Display shows system pressure.
Motor must rotate counterclockwise
when viewed from shaft end. See Connect electrical cord, page 22.
display will
show current to hose. Current is not limited by target temperature.
To prevent overheating, install hose
thermometer close to gun end, within
operator view. Insert thermometer
through foam cover of A component
hose so stem is next to inner tube. Thermometer reading will be about 20°F
less than actual fluid temperature.
312062G
29
Startup
c. Adjust hydraulic pressure control until
display shows desired fluid pressure.
+
ti7731a
ti7732a
If display pressure is greater than
desired pressure, reduce the hydraulic
pressure and trigger gun to reduce
pressure.
Code 24 (pressure imbalance) is set to
an alarm as the default. To change to a
warning, see Reactor Repair-Parts
manual 312063.
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
Check the pressure of each proportioning pump using the component A and B
gauges. The pressures should be
approximately equal and must remain
fixed.
b. Press and hold
PSI
or
BAR
main power switch ON
.
, then turn
. Display
will read dP500 for psi or dP_35 for bar.
d. To display cycle count, press
.
c. Press
To clear counter, press and hold
for 3 sec.
or
to select desired
pressure 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
e. Press
PSI
or
BAR
to change pres-
sure scale.
4. Change pressure imbalance setting
(optional)
The pressure imbalance function (status code
24, page 39) 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.
PSI
100
200
300
400
*500
BAR
7
14
21
28
*35
PSI
600
700
800
900
999
BAR
42
49
56
63
69
* Factory default setting.
d. Turn main power switch OFF
to
save changes.
30
312062G
Spraying
Spraying
1. Engage gun piston safety lock.
4. Set PRESSURE RELIEF/SPRAY valves
(SA, SB) to SPRAY
.
SA
SB
ti2409a
2. Close gun fluid manifold valves A and B.
ti9877a
5. Check that heat zones are on and temperatures are on target, page 28.
6. Press motor
to start motor and
pumps.
ti2728a
3. Attach gun fluid manifold. Connect gun air
line. Open air line valve.
7. Check fluid pressure display and adjust as
necessary, page 31.
8.
9. 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/CIRCULA-
ti2543a
312062G
31
Spraying
11. Disengage gun piston safety lock.
TION
, until gauges show balanced
pressures.
GA
GB
In this example, B side
pressure is higher, so
use the B side valve to
balance pressures.
ti2410a
12. Test spray onto cardboard. Adjust pressure
and temperature to get desired results.
13. Equipment is ready to spray.
ti9877a
10. Open gun fluid manifold valves A and B.
If you stop spraying for a period of time,
the unit will enter standby (if enabled).
See page 33.
ti2414a
On impingement guns, never open fluid
manifold valves or trigger gun if pressures are imbalanced.
32
312062G
Standby
Standby
If you stop spraying for a period of time, the
unit will enter standby by shutting down the
electric motor and hydraulic pump, to reduce
equipment wear and minimize heat buildup.
The ON/OFF LED and the pressure/cycle display on the motor control panel will flash when
in standby.
To activate or disable standby, adjust DIP
switch #3 on the motor control board. See
Reactor Repair-Parts manual 312063.
The idle time before entering standby is
user-settable as follows:
1. Turn main power switch OFF
2. Press and hold
The
A , B , and
heat zones
will not be shut off in standby.
To restart, spray off target for 2 sec. The system will sense the pressure drop and the motor
will ramp up to full speed in a few seconds.
This feature is disabled from the factory.
switch ON
3. Press
.
, then turn main power
.
or
to select desired timer
setting (5-20, in 5 minute increments). This
sets the length of inactive time before the
unit will enter standby.
4. Turn main power switch OFF
to
save changes.
312062G
33
Shutdown
Shutdown
1. Shut off
4. Close both fluid supply valves (FV).
A , B , and
heat
zones.
2. Park pumps.
FV
ti9883a
a. Press
.
5. Relieve pressure, page 35.
b. Trigger gun until pump A stops in the
retracted position and the pressure of
both pumps bleeds down.
3. Turn main power OFF
34
6. Shut down feed pumps as required.
.
312062G
Pressure Relief Procedure
Pressure Relief Procedure
4. Turn PRESSURE RELIEF/SPRAY valves
(SA, SB) to PRESSURE RELIEF/CIRCU-
1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
LATION
. Route fluid to waste containers or supply tanks. Ensure gauges drop to
0.
2. Close gun fluid manifold valves A and B.
SA
SB
ti9879a
5. Engage gun piston safety lock.
ti2421a
3. Shut off feed pumps and agitator, if used.
ti2409a
6. Disconnect gun air line and remove gun
fluid manifold.
ti2554a
312062G
35
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
3. Set PRESSURE RELIEF/SPRAY valves
(SA, SB) to PRESSURE RELIEF/CIRCULATION
Do not circulate fluid containing a blowing
agent without consulting with your material
supplier regarding fluid temperature limits.
.
SA
SB
To circulate through gun manifold and preheat
hose, see page 37.
ti9879a
1. Load fluid with feed pumps, page 27.
4. Turn main power ON
.
5. Set temperature targets, see page 28. Turn
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 12. 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 45.
on
A and B heat zones by pressing
. Do not turn on
heat zone
unless hoses are already loaded with fluid.
6. Press
to display actual temperatures.
7. Before starting motor, reduce hydraulic
pressure to the minimum required to circulate fluid until
A and B temperatures
reach targets.
ti7732a
8. Press motor
to start motor and
pumps. Circulate fluid at lowest possible
pressure until temperatures reach targets.
36
312062G
Fluid Circulation
9. Turn on
heat zone by pressing
.
rated at the maximum working pressure of
this equipment. See Typical Installation,
without circulation, page 13.
10. Set PRESSURE RELIEF/SPRAY valves
(SA, SB) to SPRAY
3. Follow Load fluid with feed pumps, page
28.
.
SA
4. Turn main power ON
.
SB
5. Set temperature targets, see page 28. Turn
ti9877a
Circulation Through Gun
Manifold
on
A , B , and
pressing
6. Press
heat zones by
.
to display actual temperatures.
7. Before starting motor, reduce hydraulic
pressure to the minimum required to circuDo not circulate fluid containing a blowing
agent without consulting with your material
supplier regarding fluid temperature limits.
late fluid until
reach targets.
Circulating fluid through the gun manifold
allows rapid preheating of hose.
1. Install gun fluid manifold (P) on Part
246362 accessory circulation kit (CK). Connect high pressure circulation lines (R) to
circulation manifold.
A and B temperatures
ti7732a
8. Press motor
to start motor and
pumps. Circulate fluid at lowest possible
pressure until temperatures reach targets.
P
CK
R
ti2767a
2. Route circulation lines back to respective
component A or B supply drum. Use hoses
312062G
37
Diagnostic Codes
Diagnostic Codes
Temperature Control Diagnostic Codes
Temperature control diagnostic codes appear
on temperature display.
Code
Code Name
Alarm Zone
01
High fluid temperature
Individual
These alarms turn off heat. E99 clears automatically when communication is regained.
Codes E03 through E06 can be cleared by
02
High current
Individual
03
No current
Individual
04
FTS not connected
Individual
pressing
05
Board overtemperature
Individual
06
Loss of zone communication
Individual
30
Momentary loss of communica- All
tion
99
Loss of display communication
power OFF
. For other codes, turn main
then ON
to clear.
See repair manual for corrective action.
38
All
For hose zone only, if FTS is disconnected at startup, display will show hose
current 0A.
312062G
Diagnostic Codes
Motor Control Diagnostic Codes
Motor control diagnostic codes E21 through
E27 appear on pressure display.
There are two types of motor control codes:
alarms and warnings. Alarms take priority over
warnings.
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
See repair manual for corrective action.
then ON
.
Alarms
Alarms turn off Reactor. Turn main power OFF
then ON
to clear.
Alarms can also be cleared, except for
code 23, by pressing
Code Name
Alarm or
Warning
21
No transducer (component A)
Alarm
22
No transducer (component B)
Alarm
23
High pressure
Alarm
24
Pressure imbalance
Selectable;
see repair
manual
27
High motor temperature
Alarm
30
Momentary loss of communication
Alarm
31
Pumpline switch failure/high
cycle rate
Alarm
99
Loss of communication
Alarm
.
Code 24 (pressure imbalance) is set to
an alarm default of 500 psi (3.5 MPa, 35
bar). To change to a warning, see Reactor Repair-Parts manual 312063. To
change the default pressure imbalance
setting, see page 30.
312062G
Code
No.
39
Maintenance
Maintenance
•
Change break-in oil in a new unit after first
250 hours of operation or within 3 months,
whichever comes first. See Table 4 for recommended frequency of oil changes
•
Inspect hydraulic and fluid lines for leaks
daily.
•
Clean up all hydraulic leaks; identify and
repair cause of leak.
Table 4: Frequency of Oil Changes
Ambient
Recommended
Temperature
Frequency
•
Inspect fluid inlet strainer screens daily, see
below.
0 to 90°F
(-17 to 32°C)
1000 hours or 12
months, whichever
comes first
•
Grease circulation valves weekly with
Fusion grease (117773).
90°F and above
(32°C and above)
500 hours or 6 months,
whichever comes first
ti9879a
•
•
Inspect ISO lubricant level and condition
daily, see page 42. Refill or replace as
needed.
Check hydraulic fluid level weekly. Check
hydraulic fluid level on dipstick (DS). Fluid
level must be between indent marks (IM)
on dipstick. Refill as required with approved
hydraulic fluid; see Technical Data on
page 45 and the Approved Anti-Wear
(AW) Hydraulic Oils table in the Reactor
Repair-Parts manual 312063. If fluid is dark
in color, change fluid and filter.
•
Keep component A from exposure to moisture in atmosphere, to prevent crystallization.
•
Clean gun mix chamber ports regularly.
See gun manual.
•
Clean gun check valve screens regularly.
See gun manual.
•
Use compressed air to prevent dust buildup
on control boards, fan, motor (under
shield), and hydraulic oil coolers.
•
Keep vent holes on bottom of electrical
cabinet open.
DS
S
IM
ti10003a
ti7861a
40
312062G
Maintenance
Fluid Inlet Strainer Screen
5. Open the fluid inlet valve, ensure that there
are no leaks, and wipe the equipment
clean. Proceed with operation.
59d
59g*
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.
59h
59j
59k
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.
ti9886a
FIG. 6. Fluid Inlet Strainer
* See Reactor Repair-Parts manual 312063 for
fluid filter screen replacements.
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 manifold (59d) to catch fluid. Remove the
strainer plug (59j).
3. Remove the screen (59g) from the strainer
manifold. Thoroughly flush the screen with
compatible solvent and shake it dry. Inspect
the screen. If more than 25% of the mesh is
blocked, replace the screen. Inspect the
gasket (59h) and replace as required.
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.
312062G
41
Maintenance
Pump Lubrication System
6. Push the larger diameter supply tube (ST)
approximately 1/3 of the way into the reservoir.
7. Push the smaller diameter return tube (RT)
into the reservoir until it reaches the bottom.
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.
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.
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.
Important: The return tube (RT) must
reach the bottom of the reservoir, to
ensure that isocyanate crystals will settle to the bottom and not be siphoned
into the supply tube (ST) and returned
to the pump.
8. The lubrication system is ready for operation. No priming is required.
ST
RT
RB
LR
To change pump lubricant:
ti9911a
1. Relieve pressure, page 35.
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. 7.
3. Drain the reservoir and flush it with clean
lubricant.
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.
42
ST
RT
LR
ti9887a
FIG. 7. Pump Lubrication System
312062G
Flushing
Flushing
•
To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to
PRESSURE RELIEF/CIRCULATION
Flush through bleed lines (N).
Flush equipment only in a well-ventilated area.
Do not spray flammable fluids. Do not turn on
heaters while flushing with flammable
solvents.
•
.
SA
SB
N
Flush out old fluid with new fluid, or flush
out old fluid with a compatible solvent
before introducing new fluid.
N
ti9880a
•
Use the lowest possible pressure when
flushing.
•
•
All fluid components 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 dry or
filled with a moisture-free plasticizer or oil.
Do not use water. See page 10.
312062G
43
Dimensions
Dimensions
Dimension
A (height)
B (width)
C (depth)
D (front mounting holes)
E (rear mounting holes)
Dimension
in. (mm)
F (side mounting holes)
16.25 (413)
G (mounting post inner diameter)0.44 (11)
H (front mounting post height) 2.0 (51)
J (rear mounting post height)
3.6 (92)
in. (mm)
55.0 (1397)
39.6 (1006)
18.5 (470)
29.34 (745)
33.6 (853)
A
TI9830a
Top View
E
Side View
G
Rear of
C
F
Detail of mounting post height, to
correctly size mounting bolts
H
J
Front of
D
B
44
ti7742a
ti7743a
312062G
Technical Data
Technical Data
Category
Data
Maximum Fluid Working Pressure Models H-25 and H-40: 2000 psi (13.8 MPa, 138 bar)
Model H-50 1 phase: 1700 psi (11.7 MPa, 11.7 bar)
Model H-50 3 phase: 2000 psi (13.8 MPa, 138 bar)
Models H-XP2 and H-XP3: 3500 psi (24.1 MPa, 241 bar)
Fluid:Oil Pressure Ratio
Models H-25 and H-40: 1.91:1
Model H-50: 1.64:1
Models H-XP2 and H-XP3: 2.79:1
Fluid Inlets
Component A (ISO): 1/2 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum
Component B (RES): 3/4 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum
Fluid Outlets
Component A (ISO): #8 (1/2 in.) JIC (3/4-16 unf), with #5 (5/16 in.) JIC adapter
Component B (RES): #10 (5/8 in.) JIC (7/8-14 unf), with #6 (3/8 in.) JIC adapter
Fluid Circulation Ports
1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum
Maximum Fluid Temperature
190°F (88°C)
Maximum Output (10 weight oil at Model H-25: 22 lb/min (10 kg/min) (60 Hz)
ambient temperature)
Model H-XP2: 1.5 gpm (5.7 liter/min) (60 Hz)
Model H-50: 52 lb/min (24 kg/min) (60 Hz)
Model H-40: 45 lb/min (20 kg/min) (60 Hz)
Model H-XP3: 2.8 gpm (10.6 liter/min) (60 Hz)
Output per Cycle (A and B)
Models H-25 and H-40: 0.063 gal. (0.23 liter)
Model H-50: 0.073 gal. (0.28 liter)
Models H-XP2 and H-XP3: 0.042 gal. (0.16 liter)
Line Voltage Requirement
230V 1 phase and 230V 3 phase units: 195-264 Vac, 50/60 Hz
400V 3 phase units: 338-457 Vac, 50/60 Hz
Amperage Requirement
See Models, page 3.
Heater Power
See Models, page 3.
(A and B heaters total, no hose)
Hydraulic reservoir capacity
3.5 gal. (13.6 liters)
Recommended hydraulic fluid
Citgo A/W Hydraulic Oil, ISO Grade 46
Sound power, per ISO 9614-2
90.2 dB(A)
Sound pressure,
82.6 dB(A)
1 m from equipment
Weight
Units with 8.0 kW Heaters: 535 lb (243 kg)
Units with 12.0 kW Heaters: 597 lb (271 kg)
Units with 15.3 kW Heaters (H-25/H-XP2 models):562 lb (255 kg)
Units with 15.3 kW Heaters (H-40/H-XP3/H-50 models): 597 lb (271 kg)
Wetted Parts
Units with 20.4 kW Heaters: 597 lb (271 kg)
Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome,
fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, chemically
resistant o-rings
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
312062G
45
Performance Charts
Performance Charts
Foam Performance Chart
Pressure in psi (MPa, bar)
2000
(13.8, 138)
1500
(10.3, 103)
KEY
A = H-25 at 50 Hz
B = H-25 at 60 Hz
C = H-40 at 50 Hz
D = H-40 at 60 Hz
E = H-50 at 50 Hz
❄F = H-50 at 60 Hz
A
B
1000
(6.9, 69)
C
E
D
500
(3.4, 34)
F
0
5
(2.3)
15
25
35
45
55
(6.8)
(11.4)
(15.9)
(20.5)
(25.0)
Flow Rate in lb/min (kg/min)
❄ Pressure flow curve for model 253725 (H-50 230V 1 phase) not shown.
Maximum pressure limited to 1700 psi (11.7 MPa, 11.7 bar)
Coatings Performance Chart
KEY
G = H-XP2 at 50 Hz
H= H-XP2 at 60 Hz
J = H-XP3 at 50 Hz
K = H-XP3 at 60 Hz
Pressure in psi (MPa, bar)
3500
(24.1, 241)
3000
(20.7, 207)
2500
(17.2, 172)
G
2000
(13.8, 138)
H
1500
(10.3, 103)
J
1000
(6.9, 69)
K
500
(3.4, 34)
0
0.5
(1.9)
1.0
(3.8)
1.5
(5.7)
2.0
(7.6)
2.5
(9.5)
3.0
(11.4)
Flow Rate in gal/min (liter/min)
46
312062G
Performance Charts
Heater Performance Chart
140
(78)
130
KEY
J = 8 kW
K = 12 kW
L = 15.3 kW
M = 20.4 kW
(72)
120
Delta T in degrees F (degrees C)
(67)
110
(61)
100
(56)
90
M
(50)
80
L
(44)
70
K
(39)
60
J
(33)
50
(28)
40
(22)
30
(17)
20
(11)
10
(6)
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
(1.9)
(3.8)
(5.7)
(7.6)
(9.5)
(11.4)
(13.2)
(15.1)
(17.0)
Flow Rate in gpm (lpm)
★ Heater performance data is based on testing with 10 wt.
hydraulic oil and 230V across heater power wires.
312062G
47
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
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.
This manual contains English. MM 312062
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2007, Graco Inc. is registered to I.S. EN ISO 9001
www.graco.com
Revised 07/2008