advertisement
Operation
312062U
EN
Hydraulic, 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.
See page 3 for model information, including
maximum working pressure and approvals.
Model H-40 Shown
T9830a
2
Contents
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Supplied Manuals . . . . . . . . . . . . . . . . . . . 7
Related Manuals . . . . . . . . . . . . . . . . . . . . 8
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Important Two-Component Material
Information . . . . . . . . . . . . . . . . . . . . . 12
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 12
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 12
Keep Components A and B Separate . . . . . . . . 12
Moisture Sensitivity of Isocyanates . . . . . . . . . . 12
Foam Resins with 245 fa Blowing Agents . . . . . 13
Changing Materials . . . . . . . . . . . . . . . . . . . . . . 13
Typical Installation, with circulation . . . 14
Typical Installation, without circulation 15
Component Identification . . . . . . . . . . . . 16
Temperature Controls and Indicators . . 18
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . 18
Red Stop Button . . . . . . . . . . . . . . . . . . . . . . . . 18
Actual Temperature Key/LED . . . . . . . . . . . . . . 19
Target Temperature Key/LED . . . . . . . . . . . . . . 19
Temperature Scale Keys/LEDs . . . . . . . . . . . . . 19
Heater Zone On/Off Keys/LEDs . . . . . . . . . . . . 19
Temperature Arrow Keys . . . . . . . . . . . . . . . . . 19
Temperature Displays . . . . . . . . . . . . . . . . . . . . 19
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . 20
Motor Controls and Indicators . . . . . . . . 21
Motor ON/OFF Key/LED . . . . . . . . . . . . . . . . . . 21
PARK Key/LED . . . . . . . . . . . . . . . . . . . . . . . . . 21
PSI/BAR Keys/LEDs . . . . . . . . . . . . . . . . . . . . . 21
Pressure Key/LED . . . . . . . . . . . . . . . . . . . . . . 21
Cycle Count Key/LED . . . . . . . . . . . . . . . . . . . . 22
Hydraulic Pressure Control Knob . . . . . . . . . . . 22
Motor Control Arrow Keys . . . . . . . . . . . . . . . . . 22
Spray Adjustments . . . . . . . . . . . . . . . . . 22
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pressure Relief Procedure . . . . . . . . . . . 39
Fluid Circulation . . . . . . . . . . . . . . . . . . . .40
Circulation Through Reactor . . . . . . . . . . . . . . . 40
Circulation Through Gun Manifold . . . . . . . . . . . 41
Diagnostic Codes . . . . . . . . . . . . . . . . . . .42
Temperature Control Diagnostic Codes . . . . . . 42
Motor Control Diagnostic Codes . . . . . . . . . . . . 43
Maintenance . . . . . . . . . . . . . . . . . . . . . . .44
Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 45
Pump Lubrication System . . . . . . . . . . . . . . . . . 46
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . .47
Dimensions . . . . . . . . . . . . . . . . . . . . . . . .48
Technical Data . . . . . . . . . . . . . . . . . . . . .49
Performance Charts . . . . . . . . . . . . . . . . .50
Graco Standard Warranty . . . . . . . . . . . .52
Graco Information . . . . . . . . . . . . . . . . . .52
312062U
Systems
Systems
AP3727
AP5400
AP5401
AP5402
AP5403
AP5404
AP5405
AP5406
AP5407
AP5408
AP6505
AP6506
CS5400
CS5401
CS5402
CS5406
CS5407
CS5408
Part
★ AP3400
AP3401
AP3402
★ AP3403
AP3404
AP3405
AP3407
AP3408
★ AP3725
AP3726
★
CE approval does not apply.
Maximum Fluid
Working
Pressure psi (MPa, bar)
Proportioner
2000 (13.8, 138) ★ 253400
2000 (13.8, 138) 253401
2000 (13.8, 138) 253402
3500 (24.1, 241) ★ 253403
3500 (24.1, 241) 253404
3500 (24.1, 241) 253405
2000 (13.8, 138) 253407
2000 (13.8, 138) 253408
1700 (11.7, 117) ★ 253725
2000 (13.8, 138) 253726
2000 (13.8, 138) 253727
2000 (13.8, 138) 255400
2000 (13.8, 138) 255401
2000 (13.8, 138) 255402
3500 (24.1, 241) 255403
3500 (24.1, 241) 255404
3500 (24.1, 241) 255405
2000 (13.8, 138) 255406
2000 (13.8, 138) 255407
2000 (13.8, 138) 255408
2000 (13.8, 138) 256505
2000 (13.8, 138) 256506
2000 (13.8, 138) 255400
2000 (13.8, 138) 255401
2000 (13.8, 138) 255402
2000 (13.8, 138) 255406
2000 (13.8, 138) 255407
2000 (13.8, 138) 255408
Heated Hose Gun
50 ft (15 m) 10 ft (3 m) Model
246679
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246679
246679
246679
246678
246678
246678
246678
246678
246678
246678
246678
246679
246679
246055
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246055
246055
246055
246050
246050
246050
246050
246050
246050
246050
246050
246055
246055
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion Air Purge
Fusion CS
Fusion CS
Fusion CS
Fusion CS
Fusion CS
Fusion CS
Part
246100
246101
246101
246101
246101
246101
CS02RD
CS02RD
CS02RD
CS02RD
CS02RD
CS02RD
246101
246101
246101
246100
246100
246100
246101
246101
246101
246101
246101
246101
246101
246101
246100
246100
Mix
Chamber Kit
AR5252
AR5252
AR5252
AR2020
AR2020
AR2020
AR5252
AR5252
AR5252
AR5252
AR5252
AR5252
AR5252
AR5252
AR2020
AR2020
AR2020
AR5252
AR5252
AR5252
AR5252
AR5252
312062U 3
4
Systems Continued
P23727
P25400
P25401
P25402
P25403
P25404
P25405
P25406
P25407
P25408
P26505
P26506
Part
★ P23400
P23401
P23402
★ P23403
P23404
P23405
P23407
P23408
★ P23725
P23726
★ CE approval does not apply.
Maximum Fluid
Working
Pressure psi (MPa, bar)
Proportioner
2000 (13.8, 138) ★ 253400
2000 (13.8, 138) 253401
2000 (13.8, 138) 253402
3500 (24.1, 241) ★ 253403
3500 (24.1, 241) 253404
3500 (24.1, 241) 253405
2000 (13.8, 138) 253407
2000 (13.8, 138) 253408
1700 (11.7, 117) ★ 253725
2000 (13.8, 138) 253726
2000 (13.8, 138) 253727
2000 (13.8, 138) 255400
2000 (13.8, 138) 255401
2000 (13.8, 138) 255402
3500 (24.1, 241) 255403
3500 (24.1, 241) 255404
3500 (24.1, 241) 255405
2000 (13.8, 138) 255406
2000 (13.8, 138) 255407
2000 (13.8, 138) 255408
2000 (13.8, 138) 256505
2000 (13.8, 138) 256506
Heated Hose Gun
50 ft (15 m) 10 ft (3 m) Model
246678
246678
246678
246679
246679
246679
246678
246678
246678
246678
246678
246678
246678
246678
246679
246679
246679
246678
246678
246678
246678
246678
246050
246050
246050
246055
246055
246055
246050
246050
246050
246050
246050
246050
246050
246050
246055
246055
246055
246050
246050
246050
246050
246050
Part
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R0
Probler P2 GCP2R0
Probler P2 GCP2R0
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R0
Probler P2 GCP2R0
Probler P2 GCP2R0
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Systems
312062U
Models
Models
H-25 SERIES
Part, Series
255400, F
255401, F
255402, F
255406, F
255407, F
255408, F
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
69
46
35
100
59
35
230V (1)
230V (3)
400V (3)
230V (1)
230V (3)
400V (3)
System
Watts†
15,960
15,960
15,960
23,260
23,260
23,260
Primary
Heater
Watts
8,000
8,000
8,000
15,300
15,300
15,300
Max Flow
Rate ◆ lb/min
(kg/min)
Approximate
Output per
Cycle (A+B) gal. (liter)
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)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure psi (MPa, bar)
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)
H-40 SERIES
Part, Series
★ 253400, E
253401, E
253402, E
Full Load
Peak Amps*
Per Phase
100
71
41
253407, E
253408, E
95
52
Voltage
(phase)
System
Watts†
230V (1) 23,100
230V (3) 26,600
400V (3) 26,600
230V (3) 31,700
400V (3) 31,700
Primary
Heater
Watts
12,000
15,300
15,300
20,400
20,400
Max Flow
Rate ◆ lb/min
(kg/min)
45 (20)
45 (20)
45 (20)
45 (20)
45 (20)
Approximate
Output per
Cycle (A+B) gal. (liter)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure psi (MPa, bar)
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)
H-50 SERIES
Part, Series
★ 253725, E
253726, E
253727, E
Full Load
Peak Amps*
Per Phase
100
71
41
256505, E
256506, E
95
52
Voltage
(phase)
System
Watts†
230V (1) 23,100
230V (3) 26,600
400V (3) 26,600
230V (3) 31,700
400V (3) 31,700
Primary
Heater
Watts
12,000
15,300
15,300
20,400
20,400
Max Flow
Rate ◆ lb/min
(kg/min)
52 (24)
52 (24)
52 (24)
52 (24)
52 (24)
Approximate
Output per
Cycle (A+B) gal. (liter)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure psi (MPa, bar)
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)
312062U 5
Models
H-XP2 SERIES
Part, Series
255403, F
255404, F
255405, F
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
100
59
35
230V (1)
230V (3)
400V (3)
System
Watts†
23,260
23,260
23,260
Primary
Heater
Watts
15,300
15,300
15,300
Max Flow
Rate ◆ gpm (lpm)
Approximate
Output per
Cycle (A+B) gal. (liter)
1.5 (5.7)
1.5 (5.7)
1.5 (5.7)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure psi (MPa, bar)
2.79:1
2.79:1
2.79:1
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
H-XP3 SERIES
Part, Series
★ 253403, E
253404, E
253405, E
Full Load
Peak Amps*
Per Phase
100
95
52
Voltage
(phase)
230V (1)
230V (3)
400V (3)
System
Watts†
23,100
31,700
31,700
Primary
Heater
Watts
12,000
20,400
20,400
Max Flow
Rate ◆ gpm (lpm)
Approximate
Output per
Cycle (A+B) gal. (liter)
2.8 (10.6) 0.042 (0.16)
2.8 (10.6) 0.042 (0.16)
2.8 (10.6) 0.042 (0.16)
Hydraulic
Pressure
Ratio
2.79:1
2.79:1
2.79:1
Maximum Fluid
Working
Pressure psi (MPa, bar)
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.
†
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.
Approvals:
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6 312062U
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 Description
312063 Reactor Hydraulic Proportioner,
Repair-Parts Manual (English)
Reactor Electrical Diagrams
Part Description
312064 Reactor Hydraulic Proportioner,
Electrical Diagrams (English)
Proportioning Pump
Part Description
312068 Proportioning Pump Repair-Parts
Manual (English)
312062U 7
8
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
Part Description
309815 Instruction-Parts Manual
(English)
Air Supply Kit
Part Description
309827 Instruction-Parts Manual
(English) for Feed Pump Air
Supply Kit
Circulation and Return Tube Kits
Part Description
309852 Instruction-Parts Manual
(English)
Heated Hose
Part Description
309572 Instruction-Parts Manual
(English)
Circulation Kit
Part Description
309818 Instruction-Parts Manual
(English)
Circulation Valve Kit
Part Description
312070 Instruction-Parts Manual
(English)
Data Reporting Kit
Part Description
309867 Instruction-Parts Manual
(English)
Rupture Disk Assembly Kit
Part Description
309969 Instruction-Parts Manual
(English)
Proportioning Pump Repair Kits
Part Description
312071 Seal Kits Instruction-Parts
Manual (English)
312062U
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 MSDSs 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 chemically impermeable gloves when spraying, dispensing, 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
312062U 9
10
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.
312062U
Warnings
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.
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.
312062U 11
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions Keep Components A and B
Separate
Spraying or dispensing 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.
Material Self-ignition
Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.
Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A
(isocyanate) and component B (resin) parts.
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 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.
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 (if installed) filled with Graco Throat Seal Liquid (TSL), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.
12 312062U
Important Two-Component Material Information
• 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 lubricate threaded parts with ISO pump oil or grease when reassembling.
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.
Changing Materials
• 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.
• 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.
312062U 13
Typical Installation, with circulation
Typical Installation, with circulation
Key for F IG . 1
A Reactor Proportioner
B Heated Hose
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose
E Fusion Spray Gun
F Gun Air Supply Hose
G Feed Pump Air Supply Lines
J Fluid Supply Lines
K Feed Pumps
L Agitator
M Desiccant Dryer
P Gun Fluid Manifold (part of gun)
R Circulation Lines
A Side Supply Detail
M
B Side Supply Detail
M
K
K
G ti7820a 2
G
L ti7820a 3
R
A
J
F
B
F IG . 1: Typical Installation, with circulation
14
D
J
E
P
C*
R
* Shown exposed for clarity.
Wrap with tape during operation.
ti10000a
312062U
Typical Installation, without circulation
Typical Installation, without circulation
Key for F IG . 2
A Reactor Proportioner
B Heated Hose
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose
E Fusion Spray Gun
F Gun Air Supply Hose
G Feed Pump Air Supply Lines
H Waste Containers
J Fluid Supply Lines
K Feed Pumps
L Agitator
M Desiccant Dryer
N Bleed Lines
P Gun Fluid Manifold (part of gun)
B Side Supply Detail
A Side Supply Detail
K
M K
G
G
L ti7821a 3 ti7821a 2
J
A
F
N
H
D
J
E
P
C*
* Shown exposed for clarity.
Wrap with tape during operation.
ti10001a B
F IG . 2: Typical Installation, without circulation
312062U 15
Component Identification
BA Component A Pressure Relief Outlet
BB Component B Pressure Relief Outlet
EC Heated Hose Electrical Connector
EM Electric Motor, Fan, and Belt Drive (behind shroud)
FA Component A Fluid Manifold Inlet (on left side of manifold block)
FB Component B Fluid Manifold Inlet
FH Fluid Heater (behind shroud)
FM Reactor Fluid Manifold
FP Feed Inlet Pressure Gauge
FS Feed Inlet Strainer
FT Feed Inlet Temperature Gauge
FV Fluid Inlet Valve (B side shown)
GA Component A Outlet Pressure Gauge
GB Component B Outlet Pressure Gauge
HA Component A Hose Connection
HB Component B Hose Connection
HC Hydraulic Pressure Control
HP Hydraulic Pressure Gauge
LR ISO Lube Pump Reservoir
MC Motor Control Display
MP Main Power Switch
OP Overpressure Rupture Disk Assembly (on rear of A and B pumps)
PA Component A Pump
PB Component B Pump
RS Red Stop Button
SA Component A PRESSURE RELIEF/SPRAY Valve
SB Component B PRESSURE RELIEF/SPRAY Valve
SC Fluid Temperature Sensor Cable
SN Serial Number Plate (one inside cabinet, one on right side of cabinet)
SR Electrical Cord Strain Relief
TA Component A Pressure Transducer (behind gauge GA)
TB Component B Pressure Transducer (behind gauge GB)
TC Temperature Control Display
TD Oil Cooler
Component Identification
16 312062U
Component Identification
TC
PA
FT
FP
HP
FM
EC
SC
MC
RS
HC
EM
FH
OP
PB
FV
LR
SN
MP
FA
Detail of Reactor Fluid Manifold
(shroud removed for clarity)
SA TA GA
GB
TB
SB
SR
FS
Detail of Serial No.
Plate (inside cabinet)
BA
FB
HA BB
HB
SN ti9880a
F IG . 3: Component Identification (H40 15.3 kW Model Shown)
312062U
TI9830a ti7823a
17
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 Heater Displays
Zone A Arrow Keys
Zone B Arrow Keys
Hose Zone Arrow Keys
A
B
Heater A On/Off
Key
Heater B On/Off
Key
Hose Heater On/Off
Key
Actual Temperature
Key
° F
° C
Temperature Scale
Keys
Target Temperature Key
F IG . 4. Temperature Controls and Indicators
Main Power Switch
Located on right side of unit, page 17. Turns
Reactor power ON and OFF
Does not turn heater zones or pumps on.
.
Red Stop Button
Located between temperature control panel
and motor control panel, page 17. Press
to shut off motor and heater zones only. Use main power switch to shut off all power to unit.
18 312062U
Temperature Controls and Indicators
Actual Temperature Key/LED Heater Zone On/Off
Keys/LEDs
Press to display actual temperature.
Press and hold rent.
to display electrical cur-
Press to turn heater zones on and off.
Also clears heater zone diagnostic codes, see
Target Temperature Key/LED
Press to display target temperature.
LEDs flash when heater zones are on.
The duration of each flash shows the extent that the heater is turned on.
Temperature Arrow Keys
Press and hold to display heater control circuit board temperature.
Press , then press or to adjust temperature settings in 1 degree increments.
Temperature Scale
Keys/LEDs
Press scale.
° F or ° C to change temperature
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.
312062U 19
Temperature Controls and Indicators
* Depending on model.
Circuit Breakers
Located inside Reactor cabinet.
Ref.
CB1
CB2
CB3
Size
50 A
40 A
CB4
25, 40, or
50 A*
25, 40, or
50 A*
CB5 20 or 30 A*
Component
Hose/Transformer Secondary
Transformer Primary
Heater A
Heater B
Motor/Pumps
CB1
CB2
CB3
CB4 ti9884a
CB5
For wiring and cabling, see repair manual 312063.
20 312062U
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
PARK Key
Pressure Key
Cycle Count Key
ON / OFF
PARK
PSI
BAR
PSI/BAR Keys
F IG . 5. Motor Controls and Indicators
Motor ON/OFF Key/LED
Press to turn motor ON and OFF. Also clears some motor control diagnostic codes,
PSI/BAR Keys/LEDs
Press PSI or BAR to change pressure scale.
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.
Pressure Key/LED
Press to display fluid pressure.
If pressures are imbalanced, display shows higher of two pressures.
312062U 21
Spray Adjustments
Cycle Count Key/LED
Spray Adjustments
Press to display cycle count.
To clear counter, press and hold for 3 sec.
Hydraulic Pressure Control
Knob
Use to adjust hydraulic pressure available to the hydraulic drive system. Turn knob (HC) clockwise to increase pressure and counterclockwise to decrease pressure. Use hydraulic
pressure gauge (HP, page 17) to view hydrau-
lic 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; Systems , 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 F IG . 3, page 17.
Flow rate, atomization, and amount of overspray are affected by four variables.
• 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.
Motor Control Arrow Keys
• Adjust pressure imbalance settings, page
•
Adjust standby settings, page 37.
22 312062U
Setup
Setup
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.
1. Locate Reactor
NOTICE a. Locate Reactor on a level surface. See
Dimensions , page 48, 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.
2. General equipment guidelines
• Determine the correct size generator.
Using the correct size generator and proper air compressor will enable the proportioner to run at a nearly constant RPM. Failure to do so will cause voltage fluctuations that can damage electrical equipment. 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) c. Use the casters to move Reactor to a fixed location, or bolt to shipping pallet and move with forklift.
d. Select a generator size that is equal to or greater than the determined kVA.
d. To mount on a truck bed or trailer, remove casters and bolt directly to truck
• Use proportioner power cords that meet or exceed the requirements listed in Table 2.
Failure to do so will cause voltage fluctuations that can damage electrical equipment.
• Use an air compressor with constant speed head unloading devices. Direct online air compressors that start and stop during a job will cause voltage fluctuations that can damage electrical equipment.
312062U 23
Setup
• 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.
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 ter-
minals, see page 25. Be sure your installa-
tion complies with all National, State and
Local safety and fire codes.
Table 1 : Electrical Requirements
(kW/Full Load Amps)
Part Model
Voltage
(phase)
253400
253401
H-40
H-40
230V (1)
230V (3)
253402 H-40 400V (3)
253403 H-XP3 230V (1)
253404 H-XP3 230V (3)
253405 H-XP3 400V (3)
Full
Load
Peak
Amps*
100
71
41
100
95
52
System
Watts**
23,100
26,600
26,600
23,100
31,700
31,700
Table 1 : Electrical Requirements
(kW/Full Load Amps)
Part Model
Voltage
(phase)
253407
253408
255400
255401
H-40 230V (3)
H-40 400V (3)
H-25 230V (1)
H-25 230V (3)
255402 H-25 400V (3)
255403 HXP2 230V (1)
255404 HXP2 230V (3)
255405 HXP2 400V (3)
255406
255407
255408
253725
253726
253727
256505
256506
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)
Full
Load
Peak
Amps*
71
41
95
52
100
59
35
100
35
100
59
35
95
52
69
46
System
Watts**
23,260
23,260
23,260
23,100
26,600
26,600
31,700
31,700
31,700
31,700
15,960
15,960
15,960
23,260
23,260
23,260
* 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.
24 312062U
Setup
4. Connect electrical cord
Power cord is not supplied. See Table 2.
Part
253400
253401
253402
253403
253404
253405
253407
253408
255400
255401
255402
255403
255404
255405
255406
255407
255408
253725
253726
253727
256505
256506
Model
H-25
H-25
H-25
H-XP2
H-XP2
H-XP2
H-25
H-25
H-40
H-40
H-40
H-XP3
H-XP3
H-XP3
H-40
H-40
H-25
H-50
H-50
H-50
H-50
H-50
Table 2: Power Cord Requirements
Cord Specification
AWG (mm
2
)
4 (21.2), 2 wire + ground
4 (21.2), 3 wire + ground
8 (8.4), 4 wire + ground
4 (21.2), 2 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
312062U 25
c. Install agitator (L) in component B drum, if necessary.
d. Ensure A and B inlet valves (FV) are closed.
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).
GND
L1
L2
L3
N 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.
FV ti9883a
Supply hoses from feed pumps should be 3/4 in. (19 mm) ID.
5. Connect feed pumps a. Install feed pumps (K) in component A and B supply drums. See F IG . 1 and
F IG . 2, pages 14 and 15.
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.
26 312062U
Setup
6. 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 automati-
. cally 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. b.
R
BA
Alternately:
BB
Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See F IG . 2, page 15.
R ti9880a 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 F IG . 1, 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.
312062U 27
8. Connect heated hose
See Heated Hose manual 309572 for detailed instructions on connecting heated hoses.
Setup d. Connect cables (Y). Connect electrical connectors (V). Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape.
The fluid temperature sensor (C) and whip hose (D) must be used with
heated hose, see page 27. Hose
length, including whip hose, must be 60 ft (18.3 m) minimum.
Y
V a. Turn main power OFF .
ti9881a b. Assemble heated hose sections, FTS, and whip hose.
9. 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.
FM
N
A
P ti2411a
10. Connect whip hose to gun fluid manifold
Do not connect manifold to gun.
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.
11. Pressure check hose
See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage.
28 312062U
Setup
12. Ground system a.
Reactor: is grounded through power
b.
Spray gun: connect whip hose ground
wire to FTS, page 27. Do not discon-
nect wire or spray without whip hose.
c.
Fluid supply containers: follow your local code.
d.
Object being sprayed: follow your local code.
e.
Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity f.
To maintain grounding continuity when flushing or relieving pressure, hold a metal part of spray gun firmly to the side of a grounded metal pail, then trigger gun.
13. Check hydraulic fluid level
Hydraulic reservoir is filled at the factory.
Check fluid level before operating the first
time, and weekly thereafter. See Maintenance , page 44.
14. 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.
ST
RT
LR b. Fill with fresh lubricant. Thread the reservoir onto the cap assembly and place it in the bracket (RB).
c. Push the larger diameter supply tube
(ST) approximately 1/3 of the way into the reservoir.
d. Push the smaller diameter return tube
(RT) into the reservoir until it reaches the bottom.
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.
RB ti9911a
312062U 29
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.
Do not operate Reactor without all covers and shrouds in place.
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.
5. Switch on the air compressor starter and air dryer, if included.
6. Turn on power to the Reactor.
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 47.
steps are complete.
b. Check that inlet screens are clean
before daily startup, page 45.
c. Check level and condition of ISO lube
d. Turn on component B agitator, if used.
SA e. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY .
SB f.
Start feed pumps.
g. Open fluid inlet valves (FV). Check for leaks.
FV ti9877a ti10002a
30 312062U
Startup
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.
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 .
8. Set temperatures
A
B
° F
° C ti2484a b. Press ° F ature scale.
or ° C to change temperc. Press tures.
to display target temperad. To set
A
heat zone target temperature, press or until display shows desired temperature. Repeat for
B
and zones.
For zone only, if FTS is disconnected at startup, display will show hose
current (0A). See step j, page 32.
Temperature Controls and Indicators , see page 18
312062U 31
32
Startup j.
Manual current control mode only: e. Press tures.
to display actual tempera-
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.
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. display will show current to hose. Current is not limited by target temperature.
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 pressing
A
and
B
heat zones by
for each zone.
Press setting.
or to adjust current
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.
If thermometer reading exceeds 160°F
(71°C), reduce current with key.
h. Hold each zone.
to view electrical currents for i.
Hold to view heater control circuit board temperature.
312062U
Startup
9. Set pressure
Check the pressure of each proportioning pump using the component A and B gauges. The pressures should be approximately equal and must remain fixed.
ON / OFF d. To display cycle count, press .
PARK
PSI
BAR
To clear counter, press and hold for 3 sec.
Motor Controls and Indicators , see
a. Press 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 25.
c. Adjust hydraulic pressure control until display shows desired fluid pressure.
+
to display the pressure
-
ti7732a e. Press PSI or BAR to change pressure scale.
10. Change pressure imbalance setting
(optional)
The pressure imbalance function (status code
24, page 43) 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.
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.
ti7731a a. Turn main power switch OFF .
If display pressure is greater than desired pressure, reduce the hydraulic pressure and trigger gun to reduce pressure.
312062U 33
34 b. Press and hold PSI or BAR , then turn main power switch ON . Display will read dP500 for psi or dP_35 for bar.
c. Press or to select desired pressure differential (100-999 in increments of 100 psi, or 7-70 in increments
Table 3: Available Pressure Imbalance Settings
PSI
100
200
300
400
*500
BAR
7
14
21
28
*35
PSI
600
700
800
900
999
* Factory default setting.
BAR
42
49
56
63
69 d. Turn main power switch OFF save changes.
to
Startup
312062U
Spraying
Spraying
4. Set PRESSURE RELIEF/SPRAY valves
(SA, SB) to SPRAY
SA
.
SB
1. Engage gun piston safety lock.
5. Check that heat zones are on and tempera-
ti9877a ti2409a
2. Close gun fluid manifold valves A and B.
ti2728a
3. Attach gun fluid manifold. Connect gun air line. Open air line valve.
ti2543a
6. Press motor pumps.
to start motor and
7. Check fluid pressure display and adjust as necessary.
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/CIRCULA-
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.
ti9877a
312062U 35
9. Open gun fluid manifold valves A and B.
10. Disengage gun piston safety lock.
Spraying ti2410a ti2414a
On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.
11. Test spray onto cardboard. Adjust pressure and temperature to get desired results.
12. Equipment is ready to spray.
If you stop spraying for a period of time, the unit will enter standby (if enabled).
36 312062U
Standby
Standby
To activate or disable standby, adjust DIP switch #3 on the motor control board. See
Reactor Repair-Parts manual 312063.
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.
The idle time before entering standby is user-settable as follows:
1. Turn main power switch OFF
2. Press and hold
A B and zones will not be shut off in standby.
switch ON .
.
, then turn main power
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.
3. Press 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 save changes.
to
312062U 37
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.
9. Close both fluid supply valves (FV).
FV
10. Shut down feed pumps as required.
ti9883a
A B zones.
2. Park pumps.
a. Press .
b. Trigger gun until pump A stops in the retracted position and the pressure of both pumps bleeds down.
3. Turn main power OFF .
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.
8. Allow generator dwell time, per manufacturer recommendations, prior to shutdown.
38 312062U
Pressure Relief Procedure
Pressure Relief Procedure
5. Turn PRESSURE RELIEF/SPRAY valves
(SA, SB) to PRESSURE RELIEF/CIRCU-
1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual.
2. Engage gun piston safety lock.
LATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to
0.
SA
SB ti2409a
3. Close gun fluid manifold valves A and B.
ti9879a
6. Disconnect gun air line and remove gun fluid manifold.
ti2421a
4. Shut off feed pumps and agitator, if used.
ti2554a
312062U 39
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
3. Set PRESSURE RELIEF/SPRAY valves
(SA, SB) to PRESSURE RELIEF/CIRCU-
LATION .
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.
To circulate through gun manifold and preheat
1. Follow Startup procedures, page 30.
SA
SB ti9879a
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 automati-
. cally relieve pressure when machine is operating.
4. Turn main power ON .
5. Set temperature targets, see page 31. Turn
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.
2. See Typical Installation, with circulation , page 14. Route circulation lines back to
respective component A or B supply drum.
Use hoses rated at the maximum working pressure of this equipment. See
7. Before starting motor, reduce hydraulic pressure to the minimum required to circulate fluid until reach targets.
A
and
B
temperatures
-
ti7732a
8. Press motor to start motor and pumps. Circulate fluid at lowest possible pressure until temperatures reach targets.
40 312062U
Fluid Circulation
9. Turn on heat zone by pressing
10. Set PRESSURE RELIEF/SPRAY valves
(SA, SB) to SPRAY .
.
rated at the maximum working pressure of
this equipment. See Typical Installation, without circulation , page 15.
3. Follow
4. Turn main power ON .
SA
SB ti9877a
5. Set temperature targets, see page 31. Turn
on
A
,
B
, and heat zones by pressing .
Circulation Through Gun
Manifold
6. Press to display actual temperatures.
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.
Circulating fluid through the gun manifold allows rapid preheating of hose.
1. Install gun fluid manifold (P) on Part
246362 accessory circulation kit (CK). Connect high pressure circulation lines (R) to circulation manifold.
7. Before starting motor, reduce hydraulic pressure to the minimum required to circulate fluid until reach targets.
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
312062U 41
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 power OFF
. For other codes, turn main
then ON to clear.
Code
04
05
06
30
01
02
03
99
Code Name Alarm Zone
High fluid temperature
High current
No current
Individual
Individual
Individual
FTS not connected
Board overtemperature
Loss of zone communication
Momentary loss of communication
Loss of display communication All
Individual
Individual
Individual
All
See repair manual for corrective action.
For hose zone only, if FTS is disconnected at startup, display will show hose current 0A.
42 312062U
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.
See repair manual for corrective action.
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
then ON .
Alarms
Alarms turn off the motor and heat zones. Turn main power OFF clear.
then ON to
Alarms can also be cleared, except for code 23, by pressing .
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
Code
No.
21
22
23
24
27
30
31
99
Code Name Alarm or
Warning
No transducer (component A) Alarm
No transducer (component B) Alarm
High pressure
Pressure imbalance
Alarm
Selectable; see repair manual
High motor temperature
Momentary loss of communication
Pumpline switch failure/high cycle rate
Loss of communication
Alarm
Alarm
Alarm
Alarm
312062U 43
Maintenance
Maintenance
• Inspect hydraulic and fluid lines for leaks daily.
• Clean up all hydraulic leaks; identify and repair cause of leak.
• Inspect fluid inlet strainer screens daily, see below.
• Grease circulation valves weekly with
Fusion grease (117773).
• Change break-in oil in a new unit after first
250 hours of operation or within 3 months, whichever comes first. See Table 4 for recommended frequency of oil changes
Table 4: Frequency of Oil Changes
Ambient
Temperature
Recommended
Frequency
0 to 90°F
(-17 to 32°C)
1000 hours or 12 months, whichever comes first
90°F and above
(32°C and above)
500 hours or 6 months, whichever comes first ti9879a
• Inspect ISO lubricant level and condition
daily, see page 46. 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 49 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 ti10003a
IM
S ti7861a
44 312062U
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
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.
F IG . 6. Fluid Inlet Strainer
59g*
59h
59j
59k ti9886a
Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.
1. Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump.
This prevents material from being pumped while cleaning the screen.
2. Place a container under the strainer 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.
* See Reactor Repair-Parts manual 312063 for fluid filter screen replacements.
312062U 45
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.
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.
To change pump lubricant:
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 F IG . 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.
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.
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.
RT
LR
ST
RT
LR
F IG . 7. Pump Lubrication System
ST
RB ti9911a ti9887a
46 312062U
Flushing
Flushing
• To flush feed hoses, pumps, and heaters separately from heated hoses, set PRES-
SURE RELIEF/SPRAY valves (SA, SB) to
Flush equipment only in a well-ventilated area.
Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents.
• Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid.
• Use the lowest possible pressure when flushing.
• All fluid components are compatible with common solvents. Use only moisture-free solvents.
PRESSURE RELIEF/CIRCULATION .
Flush through bleed lines (N).
SA
N
SB
N ti9880a
• To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).
• To prevent moisture from reacting with isocyanate, always leave the system dry or filled with a moisture-free plasticizer or oil.
Do not use water. See page 12.
312062U 47
Dimensions
Dimensions
Dimension
A (height)
B (width)
C (depth)
D (front mounting holes)
E (rear mounting holes) in. (mm)
55.0 (1397)
39.6 (1006)
18.5 (470)
29.34 (745)
33.6 (853)
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)
A
48
C
Top View
E
Rear of
G
F
Front of
D
B
ti7742a
TI9830a
Side View
Detail of mounting post height, to correctly size mounting bolts
H J
ti7743a
312062U
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)
Fluid:Oil Pressure Ratio
Models H-XP2 and H-XP3: 3500 psi (24.1 MPa, 241 bar)
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
Fluid Outlets
Fluid Circulation Ports
Maximum Fluid Temperature
Maximum Output (10 weight oil at ambient temperature)
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
Component A (ISO): #8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
Component B (RES): #10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum
190°F (88°C)
Model H-25: 22 lb/min (10 kg/min) (60 Hz)
Model H-XP2: 1.5 gpm (5.7 liter/min) (60 Hz)
Output per Cycle (A and B)
Line Voltage Requirement
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)
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)
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
Heater Power
(A and B heaters total, no hose)
Hydraulic reservoir capacity
Recommended hydraulic fluid
Sound power, per ISO 9614-2
Sound pressure,
1 m from equipment
Weight
3.5 gal. (13.6 liters)
Citgo A/W Hydraulic Oil, ISO Grade 46
90.2 dB(A)
82.6 dB(A)
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)
Wetted Parts
Units with 15.3 kW Heaters (H-40/H-XP3/H-50 models): 597 lb (271 kg)
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.
312062U 49
Performance Charts
Performance Charts
Foam Performance Chart
2000
(13.8, 138)
1500
(10.3, 103)
A
B
1000
(6.9, 69)
500
(3.4, 34)
C
E
D
F
K EY
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
0 5
(2.3)
15
(6.8)
25
(11.4)
35
(15.9)
45
(20.5)
55
(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
3500
(24.1, 241)
3000
(20.7, 207)
2500
(17.2, 172)
2000
(13.8, 138)
1500
(10.3, 103)
1000
(6.9, 69)
500
(3.4, 34)
0
G
H
J
K
0.5
1.0
1.5
2.0
2.5
3.0
(1.9) (3.8) (5.7) (7.6) (9.5) (11.4)
Flow Rate in gal/min (liter/min)
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
50 312062U
Performance Charts
Heater Performance Chart
140
(78)
130
(72)
120
(67)
110
(61)
100
(56)
90
(50)
80
(44)
70
(39)
60
(33)
50
(28)
40
(22)
30
(17)
20
(11)
10
(6)
0
J
K
L
M
0.5
(1.9)
1.0
(3.8)
1.5
(5.7)
2.0
(7.6)
2.5
(9.5)
3.0
(11.4)
3.5
(13.2)
4.0
(15.1)
4.5
(17.0)
Flow Rate in gpm (lpm)
★ Heater performance data is based on testing with 10 wt. hydraulic oil and 230V across heater power wires.
KEY
J = 8 kW
K = 12 kW
L = 15.3 kW
M = 20.4 kW
312062U 51
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by
Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts.
The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS
SOLD BUT NOT MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 312062
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 U, May 2014
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