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Operation
312065R
EN
Electric, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings. For professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 4 for model information, including maximum
working pressure and approvals.
Model E-XP1 Shown
TI10953a
2
Contents
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Important Two-Component Material Information 10
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 10
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 10
Keep Components A and B Separate . . . . . . . . 10
Moisture Sensitivity of Isocyanates . . . . . . . . . . 10
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 . . . . . . . . . 15
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . 15
Red Stop Button . . . . . . . . . . . . . . . . . . . . . . . . 15
Actual Temperature Key/LED . . . . . . . . . . . . . . 16
Target Temperature Key/LED . . . . . . . . . . . . . . 16
Temperature Scale Keys/LEDs . . . . . . . . . . . . . 16
Heater Zone On/Off Keys/LEDs . . . . . . . . . . . . 16
Temperature Arrow Keys . . . . . . . . . . . . . . . . . 16
Temperature Displays . . . . . . . . . . . . . . . . . . . . 16
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . 16
Motor Controls and Indicators . . . . . . . . . . . . . . . 17
Motor ON/OFF Key/LED . . . . . . . . . . . . . . . . . . 17
PARK Key/LED . . . . . . . . . . . . . . . . . . . . . . . . . 17
PSI/BAR Keys/LEDs . . . . . . . . . . . . . . . . . . . . . 17
Pressure Key/LED . . . . . . . . . . . . . . . . . . . . . . . 17
Cycle Count Key/LED . . . . . . . . . . . . . . . . . . . . 17
Pressure Arrow Keys . . . . . . . . . . . . . . . . . . . . . 18
Pressure/Cycle Display . . . . . . . . . . . . . . . . . . . 18
Spray Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 18
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 32
Fluid Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Circulation Through Reactor . . . . . . . . . . . . . . . 33
Circulation Through Gun Manifold . . . . . . . . . . . 34
Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Temperature Control Diagnostic Codes . . . . . . 36
Motor Control Diagnostic Codes . . . . . . . . . . . . 36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 37
Pump Lubrication System . . . . . . . . . . . . . . . . . 38
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42
312065R
Systems
CH9034
CS9035
CS9057
CS9058
CS9059
P29024
P29025
PH9025
P29026
P29028
P29029
P29030
PH9030
P29031
P29032
P29033
P29034
PH9034
P29035
P29036
P29057
P29058
P29059
AP9058
AP9059
CS9025
CH9025
CS9026
CS9030
CH9030
CS9031
CS9034
Part
AP9024
AP9025
AH9025
AP9026
AP9028
AP9029
AP9030
AH9030
AP9031
AP9032
AP9033
AP9034
AH9034
AP9035
AP9036
AP9057
Systems
Maximum Fluid
Working
Pressure psi (MPa, bar)
Proportioner
2500 (17.2, 172) 259024
2000 (13.8, 138) 259025
2000 (13.8,138) 259025
2000 (13.8, 138) 259026
3500 (24.1, 241) 259028
2500 (17.2, 172) 259029
2000 (13.8, 138) 259030
2000 (13.8, 138) 259030
2000 (13.8, 138) 259031
3500 (24.1, 241) 259032
2500 (17.2, 172) 259033
2000 (13.8, 138) 259034
2000 (13.8, 138) 259034
2000 (13.8, 138) 259035
3500 (24.1, 241) 259036
2000 (13.8, 138) 259057
2000 (13.8, 138) 259058
2000 (13.8, 138) 259059
2000 (13.8, 138) 259025
2000 (13.8, 138) 259025
2000 (13.8, 138) 259026
2000 (13.8, 138) 259030
2000 (13.8, 138) 259030
2000 (13.8, 138) 259031
2000 (13.8, 138) 259034
2000 (13.8, 138) 259034
2000 (13.8, 138) 259035
2000 (13.8, 138) 259057
2000 (13.8, 138) 259058
2000 (13.8, 138) 259059
2500 (17.2, 172) 259024
2000 (13.8, 138) 259025
2000 (13.8, 138) 259025
2000 (13.8, 138) 259026
3500 (24.1, 241) 259028
2500 (17.2, 172) 259029
2000 (13.8, 138) 259030
2000 (13.8, 138) 259030
2000 (13.8, 138) 259031
3500 (24.1, 241) 259032
2500 (17.2, 172) 259033
2000 (13.8, 138) 259034
2000 (13.8, 138) 259034
2000 (13.8, 138) 259035
3500 (24.1, 241) 259036
2000 (13.8, 138) 259057
2000 (13.8, 138) 259058
2000 (13.8, 138) 259059
Heated Hose Gun
50 ft (15 m) Qty 10 ft (3 m) (Qty 1) Model
246679
246678
246678
246678
246679
246679
246678
246678
246678
246679
246679
246678
246678
246678
246679
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246678
246679
246678
246678
246678
246679
246679
246678
246678
246678
246679
246679
246678
246678
246678
246679
246678
246678
246678
1
1
4
1
1
1
1
4
1
1
1
1
4
1
1
1
1
1
1
4
1
1
4
1
1
4
1
1
1
1
1
246055
246050
246050
246050
246055
246055
246050
246050
246050
246055
246055
246050
246050
246050
246055
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246050
246055
1 246050
4 246050
1 246050
1 246055
1 246055
1 246050
4 246050
1 246050
1 246055
1 246055
1 246050
4 246050
1 246050
1 246055
1 246050
1 246050
1 246050
Fusion
™
Part (Qty 1)
AP 246100
Fusion
™
AP 246101
Fusion
™
AP 246100
Fusion
™
AP 246101
Fusion
™
AP 246100
Fusion
™
AP 246100
Fusion
™
AP 246101
Fusion
™
AP 246100
Fusion
™
AP 246101
Fusion ™ AP 246100
Fusion
™
AP 246100
Fusion
™
AP 246101
Fusion
™
AP 246100
Fusion
™
AP 246101
Fusion
™
AP 246100
Fusion
™
AP 246101
Fusion
™
AP 246101
Fusion
™
AP 246101
Fusion
™
CS CS01RD
Fusion
™
CS CS01RD
Fusion
™
CS CS02RD
Fusion
™
CS CS01RD
Fusion
™
CS CS01RD
Fusion
™
CS CS02RD
Fusion
™
CS CS01RD
Fusion
™
CS CS01RD
Fusion
™
CS CS02RD
Fusion
™
CS CS02RD
Fusion ™ CS CS02RD
Fusion ™ CS CS02RD
Probler P2 GCP2RA
Probler P2 GCP2R1
Probler P2 GCP2R1
Probler P2 GCP2R2
Probler P2 GCP2R0
Probler P2 GCP2RA
Probler P2 GCP2R1
Probler P2 GCP2R1
Probler P2 GCP2R2
Probler P2 GCP2R0
Probler P2 GCP2RA
Probler P2 GCP2R1
Probler P2 GCP2R1
Probler P2 GCP2R2
Probler P2 GCP2R0
Probler P2 GCP2R2
Probler P2 GCP2R2
Probler P2 GCP2R2
Mix
Chamber Kit
AR2020
AR5252
AR5252
AR5252
AR2020
AR2020
AR5252
AR5252
AR5252
AR2020
AR2020
AR5252
AR5252
AR5252
AR2020
AR5252
AR5252
AR5252
312065R 3
Models
Models
E-20 SERIES
Part, Series
259025, E
259030, E
259034, E
Full Load Peak
Amps*
Voltage
(phase)
48
24
32
230V (1)
400V (3)
230V (3)
E-30 SERIES
System
Watts†
10,200
10,200
10,200
Primary
Heater
Watts
6,000
6,000
6,000
Max Flow
Rate lb/min
(kg/min)
20 (9)
20 (9)
20 (9)
Approximate
Output per Cycle
(A+B) gal. (liter)
Maximum Fluid
Working Pressure psi (MPa, bar)
0.0104 (0.0395) 2000 (14, 140)
0.0104 (0.0395) 2000 (14, 140)
0.0104 (0.0395) 2000 (14, 140)
Part,
Series
259026, F
259031, F
259035, F
259057, F
259058, F
259059, F
Full Load Peak
Amps*
Voltage
(phase)
78
34
50
100
62
35
230V (1)
400V (3)
230V (3)
230V (1)
230V (3)
400V (3)
System
Watts†
17,900
17,900
17,900
23,000
23,000
23,000
Primary
Heater
Watts
10,200
10,200
10,200
15,300
15,300
15,300
Max Flow
Rate lb/min
(kg/min)
30 (13.5)
30 (13.5)
30 (13.5)
30 (13.5)
30 (13.5)
30 (13.5)
Approximate
Output per Cycle
(A+B) gal. (liter)
Maximum Fluid
Working Pressure psi (MPa, bar)
0.0272 (0.1034) 2000 (14, 140)
0.0272 (0.1034) 2000 (14, 140)
0.0272 (0.1034) 2000 (14, 140)
0.0272 (0.1034) 2000 (14, 140)
0.0272 (0.1034) 2000 (14, 140)
0.0272 (0.1034) 2000 (14, 140)
E-XP1 SERIES
Part, Series
259024, E
259029, E
259033, E
Full Load Peak
Amps*
Voltage
(phase)
69
24
43
230V (1)
400V (3)
230V (3)
System
Watts†
15,800
15,800
15,800
Primary
Heater
Watts
10,200
10,200
10,200
Max Flow
Rate gpm (lpm)
1.0 (3.8)
1.0 (3.8)
1.0 (3.8)
E-XP2 SERIES
Part,
Series
259028, F
259032, F
259036, F
Full Load Peak
Amps*
Voltage
(phase)
100
35
62
230V (1)
400V (3)
230V (3)
System
Watts†
23,000
23,000
23,000
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.
Primary
Heater
Watts
15,300
15,300
15,300
Max Flow
Rate gpm (lpm)
2.0 (7.6)
2.0 (7.6)
2.0 (7.6)
Approximate
Output per Cycle
(A+B) gal. (liter)
Maximum Fluid
Working Pressure psi (MPa, bar)
0.0203 (0.0771) 3500 (24.1, 241)
0.0203 (0.0771) 3500 (24.1, 241)
0.0203 (0.0771) 3500 (24.1, 241)
Maximum flow rate given for 60 Hz operation. For 50
Hz operation, maximum flow rate is 5/6 of 60 Hz maximum flow.
Approvals:
Approximate
Output per Cycle
(A+B) gal. (liter)
Maximum Fluid
Working Pressure psi (MPa, bar)
0.0104 (0.0395) 2500 (17.2, 172)
0.0104 (0.0395) 2500 (17.2, 172)
0.0104 (0.0395) 2500 (17.2, 172)
† Total system watts, based on maximum hose length for each unit:
• E-20 and E-XP1 series, 210 ft (64 m) maximum heated hose length, including whip hose.
• E-30 and E-XP2 series, 310 ft (94.5 m) maximum heated hose length, including whip hose.
#ONFORMSTO!.3)5,
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4 312065R
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 Electric Proportioner
Part
312066
Description
Reactor Electric Proportioner,
Repair-Parts Manual (English)
Reactor Electrical Diagrams
Part
312067
Description
Reactor Electric Proportioner,
Electrical Diagrams (English)
Proportioning Pump
Part
309577
Description
Electric Reactor Displacement Pump
Repair-Parts Manual (English)
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.
Reactor Data Reporting Kit
Part
309867
Description
Instruction-Parts Manual (English)
Fusion Spray Gun
Part
309550
Description
Instruction-Parts Manual (English)
Fusion CS Spray Gun
Part
312666
Description
Instruction-Parts Manual (English)
Probler P2 Spray Gun
Part
313213
Heated Hose
Description
Instruction-Parts Manual (English)
Part
309572
Description
Instruction-Parts Manual (English)
Circulation and Return Tube Kit
Part
309852
Description
Instruction-Parts Manual (English)
Rupture Disk Assembly Kit
Part
312416
Description
Instruction-Parts Manual (English)
Electric Reactor Installation
Part
310815
Description
Instruction Manual (English)
312065R 5
Related Manuals
6 312065R
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
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.
312065R 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 equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately.
Do not use equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.
• 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.
8 312065R
312065R
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• This equipment is for professional use only.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
9
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.
• 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.
10 312065R
Important Two-Component Material Information
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.
Changing Materials
• 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.
312065R 11
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
M
R
K
J
G
K
L
A
B
F
J
D
E
P
C*
R
F IG . 1: Typical Installation, with circulation
TI10976a
* Shown exposed for clarity. Wrap with tape during operation,
12 312065R
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)
Q Air Filter/Separator
K
M
K
J
L
G
A
N
G
F
B
D
J
E
P
C*
H
TI10975a
F IG . 2: Typical Installation, without circulation
* Shown exposed for clarity. Wrap with tape during operation,
312065R 13
Component Identification
Component Identification
BA Component A Pressure Relief Outlet
BB Component B Pressure Relief Outlet
FA Component A Fluid Manifold Inlet (behind manifold block)
FB Component B Fluid Manifold Inlet
GA Component A Pressure Gauge
GB Component B Pressure Gauge
HA Component A Hose Connection
HB Component B Hose Connection
PA Component A Pump
PB Component B Pump
SA Component A PRESSURE RELIEF/SPRAY Valve
SB Component B PRESSURE RELIEF/SPRAY Valve
TA Component A Pressure Transducer (behind gauge GA)
TB Component B Pressure Transducer (behind gauge GB)
DG Drive Gear Housing
EC Electrical Cord Strain Relief
EM Electric Motor
FH Fluid Heaters (behind shroud)
FM Reactor Fluid Manifold
FV Fluid Inlet Valve (B side shown)
HC Heated Hose Electrical Connector
MC Motor Control Display
MP Main Power Switch
RS Red Stop Button
SC Fluid Temperature Sensor Cable
SN Serial No. Plate
TC Temperature Control Display
TC
RS
SA
FA
BA
HA
TA
GA
DG
GB
TB
SB
PA
FM
HC
SC
HB TI9880a
BB
FB
SN
TI7823a
F IG . 3: Component Identification (Model EXP-1 Shown)
14
TI10953a
312065R
MC
EM
FH
DG
PB
FV
MP
EC
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.
Temperature Controls and Indicators
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
° 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 14. Turns Reactor
power ON and OFF heater zones or pumps on.
. Does not turn
Red Stop Button
Located between temperature control panel and motor
to shut off motor and heater zones only. Use main power switch to shut off all power to unit.
312065R 15
Temperature Controls and Indicators
Actual Temperature Key/LED
Press to display actual 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.
Circuit Breakers
Press and hold to display electrical current.
Target Temperature Key/LED
Press to display target temperature.
Press and hold board temperature.
to display heater control circuit
Temperature Scale Keys/LEDs
Press ° F or ° C to change temperature scale.
Heater Zone On/Off Keys/LEDs
Press to turn heater zones on and off. Also
clears heater zone diagnostic codes, see page 36.
Located inside Reactor cabinet.
Ref.
CB1
CB2
CB3
Size
50 A
40 A
25, 40*
CB4
CB5
25, 40*
20
* Depending on model.
Component
Hose/Transformer Secondary
Transformer Primary
Heater A
Heater B
Motor/Pumps
LEDs flash when heater zones are on. The duration of each flash shows the extent that the heater is turned on.
Temperature Arrow Keys
Press , then press or perature settings in 1 degree increments.
to adjust tem-
CB1
CB2
CB3
CB4
CB5 ti9884a
For wiring and cabling, see repair manual 312066.
16 312065R
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.
Arrow Keys
Motor ON/OFF Key
PARK Key
Pressure Key
Cycle Count Key
ON / OFF
PARK
PSI
BAR
Pressure/Cycle Display
PSI/BAR Keys
F IG . 5. Motor Controls and Indicators
Motor ON/OFF Key/LED Pressure Key/LED
Press to turn motor ON and OFF. Also clears
some motor control diagnostic codes, see page 36.
Press to display fluid pressure.
PARK Key/LED
If pressures are imbalanced, display shows higher of two pressures.
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.
Cycle Count Key/LED
Press to display cycle count.
PSI/BAR Keys/LEDs
To clear counter, press and hold for 3 sec.
Press PSI or BAR to change pressure scale.
312065R 17
Spray Adjustments
Pressure Arrow Keys
Press or to adjust fluid pressure when motor is ON. Setpoint displays for 10 sec.
When motor is OFF, pressing will enter jog mode. To exit jog mode, press shows dashes or current pressure.
until display
Pressure/Cycle Display
Shows fluid pressure or cycle count, depending on mode selected.
Displays J 1 through J 10 when in jog mode, page 35.
Spray Adjustments
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.
18 312065R
Setup
Setup
NOTICE
Proper system setup, start up, and shutdown procedures are critical to electrical equipment reliability.
The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.
Bolt bracket and mounting feet (MF) directly to
truck or trailer bed. See page 40.
1. Locate Reactor
a. Locate Reactor on a level surface. See
Dimensions page 40, 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.
F IG . 6 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 secure rear axle with 15B805 mobile mounting bracket (MB), available separately.
312065R
MB
MF
259024_312065
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) d. Select a generator size that is equal to or greater than the determined kVA.
• Use proportioner power cords that meet or exceed the requirements listed in Table 2. Failure to do so will cause voltage fluctuations that can damage electrical equipment.
19
Setup
• Use an air compressor with constant speed head unloading devices. Direct online air compressors that start and stop during a job will cause voltage fluctuations that can damage electrical equipment.
• 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 T ABLE 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 21. Be sure your installa-
tion complies with all National, State and Local safety and fire codes.
Table 1: Electrical Requirements
(kW/Full Load Amps)
E SERIES
Part
No.
Model
Voltage
(phase)
259025 E-20
249030 E-20
259034 E-20
259026 E-30
230V (1)
400V (3)
230V (3)
230V (1)
259031 E-30
259035 E-30
400V (3)
230V (3)
259057 E-30† 230V (1)
259058 E-30† 230V (3)
259059 E-30† 400V (3)
E-XP SERIES
Full
Load
Peak
Amps*
34
50
100
62
35
48
24
32
78
259024 E-XP1 230V (1)
259029 E-XP1 400V (3)
259033 E-XP1 230V (3)
259028 E-XP2 230V (1)
259032 E-XP2 400V (3)
259036 E-XP2 230V (3)
69
24
43
100
35
62
System
Watts**
10,200
10,200
10,200
17,900
17,900
17,900
23,000
23,000
23,000
15,800
15,800
15,800
23,000
23,000
23,000
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.
** E-20 and E-XP1 with 210 ft (64.1 m) hose; E-30 and
E-XP2 with 310 ft (94.6 m) hose.
† E-30 with 15.3 kW of heat.
20 312065R
4. Connect electrical cord
Power cord is not supplied. See Table 2.
Part
259024
259025
259026
259028
259029
259030
259031
259032
259033
259034
259035
259036
259057
259058
259059
Model
E-XP1
E-20
E-30
E-XP2
E-XP1
E-20
E-30
E-XP2
E-XP1
E-20
E-30
E-XP2
E-30
E-30
E-30
Table 2: Power Cord Requirements
Cord Specification
AWG (mm
2
)
4 (21.2), 2 wire + ground
6 (13.3), 2 wire + ground
4 (21.2), 2 wire + ground
4 (21.2), 2 wire + ground
10 (5.3), 4 wire + ground
10 (5.3), 4 wire + ground
8 (8.4), 4 wire + ground
8 (8.4), 4 wire + ground
8 (8.4), 3 wire + ground
8 (8.4), 3 wire + ground
6 (13.3), 3 wire + ground
6 (13.3), 3 wire + ground
4 (21.2), 2 wire + ground
6 (13.3), 3 wire + ground
8 (8.4), 4 wire + ground
Setup 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 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
312065R 21
Setup
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 12 and 13.
b. Seal component A drum and use desiccant dryer (M) in vent.
c. Install agitator (L) in component B drum, if necessary.
d. Ensure A and B inlet valves (FV) are closed.
FV
TI10971a
Supply hoses from feed pumps should be 3/4 in.
(19 mm) ID.
6. Connect pressure relief lines
a. Recommended: Connect high pressure hose
(R) to relief fittings (BA, BB) of both PRES-
SURE RELIEF/SPRAY valves, Route hose back to component A and B drums. See F IG . 1, page 12.
SA
SB
R
BA
R
BB
TI10954a b.
Alternately: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See
F IG . 2, page 13.
7. Install Fluid Temperature Sensor (FTS)
The Fluid Temperature Sensor (FTS) is supplied. Install
FTS between main hose and whip hose. See Heated
Hose manual 309572 for instructions.
8. Connect heated hose
See Heated Hose manual 309572 for detailed instructions on connecting heated hoses.
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpressure relief valves when set to
SPRAY . Lines must be open so 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.
The fluid temperature sensor (C) and whip hose (D)
must be used with heated hose, see page 22. Hose
length, including whip hose, must be 60 ft (18.3 m) minimum.
a. Turn main power OFF .
b. Assemble heated hose sections, FTS, and whip hose.
22 312065R
Y
Setup 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
HA
A
HB
9. Close gun fluid manifold valves A and B
ti2411a
B
10.Connect whip hose to gun fluid manifold
Do not connect manifold to gun.
TI10964a
Manifold hose adapters (HA, HB) 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.
ti2417a d. Connect cables (Y). Connect electrical connectors (V). Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape.
11.Pressure check hose
See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage.
V
TI10956a
312065R 23
Setup
12.Ground system
a.
Component A (ISO) Pump: Keep reservoir (R) filled with Graco Throat Seal Liquid (TSL), Part
206995. Wet-cup piston circulates TSL through wet-cup, to carry away isocyanate film on displacement rod.
a.
Reactor: is grounded through power cord. See
b.
Spray gun: connect whip hose ground wire to
FTS, page 22. Do not disconnect wire or spray
without whip hose.
c.
Fluid supply containers: follow your local code.
d.
Object being sprayed: follow your local code.
e.
Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity f.
To maintain grounding continuity when flushing or relieving pressure, hold a metal part of spray gun firmly to the side of a grounded metal pail, then trigger gun.
13.Supply wet cups with Throat Seal Liquid
(TSL)
F IG . 7
R
TI3765a-2 b.
Component B (Resin) Pump: Check felt washers in packing nut/wet-cup (S) daily. Keep saturated with Graco Throat Seal Liquid (TSL), Part
No. 206995, to prevent material from hardening on displacement rod. Replace felt washers when worn or contaminated with hardened material.
S
Pump rod and connecting rod move during operation.
Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from wet-cup during operation. Turn main power OFF
before filling wet cup.
F IG . 8
TI3765a-1
24 312065R
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 39.
a. Check that all
steps are complete.
b. Check that inlet screens are clean before daily
c. Check level and condition of ISO lube daily,
d. Turn on component B agitator, if used.
e. Turn both PRESSURE RELIEF/SPRAY valves
(SA, SB) to SPRAY .
SA
SB
TI10963a f.
Start feed pumps.
g. Open fluid inlet valves (FV). Check for leaks.
FV
TI10972a
312065R 25
Startup
8. Set temperatures
Do not mix components A and B during startup.
Always provide two grounded waste containers to keep component A and component B fluids separate. 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.
A
B
° F
° C
Temperature Controls and Indicators , see page 15
ti2484a
This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
• Wear gloves if fluid temperature exceeds 110°F
(43°C).
a. Turn main power ON .
b. Press scale.
° F or ° C to change temperature c. Press to display target temperatures.
26 312065R
Startup d. To set
A press or until display shows desired temperature. Repeat for
B
and
zones.
heat zone target temperature, h. Hold zone.
to view electrical currents for each i.
Hold to view heater control circuit board temperature.
j.
Manual current control mode only:
For zone only, if FTS is disconnected at startup, display will show hose current (0A). See
e. Press to display actual temperatures.
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.
Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose.
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.
Press or to adjust current setting.
To prevent overheating, install hose thermometer close to gun end, within operator view. Insert thermometer through foam cover of A component hose so stem is next to inner tube. Thermometer reading will be about 20°F less than actual fluid temperature.
If thermometer reading exceeds 160°F (71°C), reduce current with key.
g. Turn on
A
and
B
heat zones by pressing for each zone.
312065R 27
Startup
9. Set pressure
ON / OFF
PARK
PSI
BAR
Motor Controls and Indicators , see page 17
10.Change pressure imbalance setting
(optional)
The pressure imbalance function (status code 24) detects conditions that can cause off-ratio spray, such as loss of feed pressure/supply, pump seal failure, clogged fluid inlet filter, or a fluid leak.
Code 24 (pressure imbalance) is set to an alarm as the default. To change to a warning, see Reactor
Repair-Parts manual 312066.
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. Press .
b. Press motor . Motor and pumps start.
Display shows system pressure. Motor runs until setpoint is reached.
c. Press desired fluid pressure. Display will show setpoint for 10 seconds, then change to actual pressure.
If display pressure is greater than setpoint pressure, trigger gun to reduce pressure.
If display shows J xx, unit is in jog mode. To exit jog
d. To display cycle count, press .
To clear counter, press onds.
or until display shows
and hold for 3 sece. Press PSI scale.
or BAR to change pressure a. Turn main power switch OFF b. Press and hold d. Turn main power switch OFF changes.
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 of 7 bar). See Table
3.
Table 3: Available Pressure Imbalance Settings
PSI BAR PSI
100
200
300
400
*500
7
14
21
28
*35
600
700
800
900
999
* Factor default setting.
BAR
42
49
56
63
69
to save
28 312065R
Spraying
Spraying
3. Attach gun fluid manifold. Connect gun air line.
Open air line valve.
1. Engage gun piston safety lock.
2. Close gun fluid manifold valves A and B.
ti2409a ti2543a
4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY .
SA
SB ti2728a
TI10963a
5. Check that heat zones are on and temperatures are on target, page 26.
6. Press motor to start motor and pumps.
7. Check fluid pressure display and adjust as neces-
312065R 29
Spraying
8. Check fluid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning
PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF/CIRCULATION
, until gauges show balanced pressures.
GA GB
In this example, B side pressure is higher, so use the B side valve to balance pressures.
9. Open gun fluid manifold valves A and B.
ti2414a
On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.
TI10963a
10. Disengage gun piston safety lock.
ti2410a
11. Test spray onto cardboard. Adjust pressure and temperature to get desired results.
12. Equipment is ready to spray.
30 312065R
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.
1. Shut off
A
,
B
, and
2. Park pumps.
heat zones.
a. Press .
b. Trigger gun until pump A stops in the retracted position and the pressure of both pumps bleeds down.
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.
9. Close both fluid supply valves (FV).
FV ti10971a
10. Shut down feed pumps as required.
3. Turn main power OFF .
312065R 31
Pressure Relief Procedure
Pressure Relief Procedure
Route fluid to waste containers or supply tanks.
Ensure gauges drop to 0.
1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual.
2. Close gun fluid manifold valves A and B.
SA
SB
TI10955a
5. Engage gun piston safety lock.
ti2421a
3. Shut off feed pumps and agitator, if used.
4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . ti2409a
6. Disconnect gun air line and remove gun fluid manifold.
32 312065R
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.
To circulate through gun manifold and preheat hose,
1. Follow
4. Turn main power ON .
5. Set temperature targets, see page 26. 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.
7. Circulate fluid in jog mode until temperatures reach targets.
A
and
B
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 com-
ponent A or B supply drum. Use hoses rated at the maximum working pressure of this equipment. See
Technical Data , page 41.
3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
PRESSURE RELIEF/CIRCULATION .
SA
8. Turn on heat zone by pressing .
9. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY .
SA
SB
TI10963a
SB
TI10955a
312065R 33
Fluid Circulation
Circulation Through Gun
Manifold
2. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working pressure of this equipment. See
Typical Installation, without circulation , page 13.
3. Follow
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.
4. Turn main power ON .
5. Set temperature targets, see page 26. Turn on
A
,
B
, and heat zones by pressing
.
6. Press to display actual temperatures.
7. Circulate fluid in jog mode until temperatures reach targets.
A
and
B
P
CK R ti2767a
34 312065R
Jog Mode
Jog Mode
Jog mode has two purposes:
• It can speed fluid heating during circulation.
• It can ease pump repair/replacement. See repair manual.
1. Turn main power on .
2. Ensure motor is OFF (LED is off; display may show dashes or pressure).
3. Press to select J1 (jog speed 1).
4. Press motor to start motor.
5. Press through J10).
or to change jog speed (J1
Jog speeds correlate to 3-30% of motor power, but will not operate over 700 psi (4.9 MPa, 49 bar) for either A or B.
6. To exit jog mode, press dashes or current pressure.
until display shows
312065R 35
Diagnostic Codes
Diagnostic Codes
Temperature Control Diagnostic Codes
Temperature control diagnostic codes appear on temperature display.
These alarms turn off heat. E99 clears automatically when communication is regained. Codes E03 through
E06 can be cleared by pressing turn main power OFF clear.
. For other codes,
then ON to
05
06
30
99
01
02
03
04
High fluid temperature
High current
No current
FTS not connected
Board overtemperature
Loss of zone communication
Momentary loss of communication
Loss of display communication
See repair manual for corrective action.
Individual
Individual
Individual
Individual
Individual
Individual
All
All
For hose zone only, if FTS is disconnected at startup, display will show hose current 0A.
Motor Control Diagnostic Codes
Motor control diagnostic codes E21 through E29 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.
Alarms
Alarms turn off motor and heat zones. Turn main power
Alarms can also be cleared, except for code 23, by pressing .
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 .
25
26
27
28
29
30
Code
No.
21
22
23
24
31
32
99
Code Name Alarm or Warning
No transducer (component A) Alarm
No transducer (component B) Alarm
High pressure
Pressure imbalance
High line voltage
Low line voltage
High motor temperature
High current
Brush wear
Momentary loss of communication
Motor control failure
Motor control board overtemperature
Loss of communication -
Alarm
Selectable; see repair manual
Alarm
Alarm
Alarm
Alarm
-
Warning
Alarm
Alarm
36 312065R
Maintenance
• Check wet cup TSL level daily.
• Do not overtighten packing nut/wet cup. Throat u-cup is not adjustable.
• Inspect fluid inlet strainer screens daily, see below.
• Grease circulation valves weekly with Fusion grease (117773).
Fluid Inlet Strainer Screen
Maintenance
TI10955a
• Inspect ISO lubricant level and condition daily, see
page 38. Refill or replace as needed.
• 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.
The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.
Use clean chemicals and follow proper storage, transfer, and operating procedures, to minimize contamination of the A-side screen.
Clean the A-side screen only during daily startup.
This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.
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.
5. Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.
312065R
F IG . 9. Fluid Inlet Strainer
59g*
59h
59j
59k
59d
Ti10974a
37
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 . 10.
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. The lubrication system is ready for operation. No priming is required.
ST
LR
RT
LR
F IG . 10. Pump Lubrication System
TI10970a
ST
TI10969a
RT
RB
38 312065R
Accessories
Flushing
• To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
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.
RELIEF/CIRCULATION lines (N).
SA
. Flush through bleed
SB
N
N
TI10955a
• 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
Accessories
Feed Pump Kits
Pumps, hoses, and mounting hardware to supply fluids to Reactor. Includes 246483 Air Supply Kit. See
309815.
246483 Air Supply Kit
Hoses and fittings to supply air to feed pumps, agitator, and gun air hose. Included in feed pump kits. See
309827.
246978 Circulation Kit
Return hoses and fittings to make circulation system.
Includes two 246477 Return Tube Kits. See 309852.
246477 Return Tube Kit
Desiccant dryer, return tube, and fittings for one drum.
Two included in 246978 Circulation Kit. See 309852.
248669 Conversion Kit
Convert any E-XP2 to a E-30 with 15.3kW of heat.
Include new pumps, bearing, and fitting to accomplish conversion. See manual 309574.
Heated Hoses
50 ft (15.2 m) and 25 ft (7.6 m) lengths, 1/4 in. (6 mm),
3/8 in. (10 mm), or 1/2 in. (13 mm) diameter, 2000 psi
(14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See
309572.
Heated Whip Hoses
10 ft (3 m) whip hose, 1/4 in. (6 mm) or 3/8 in. (10 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24
MPa, 241 bar). See 309572.
Fusion Spray Gun
Air purge gun, available in round or flat pattern. See
309550.
246085 Data Reporting Kit
Records actual temperature, temperature setpoint, actual pressure, cycles, and diagnostic code data from
Reactor. Downloads data to PC with Microsoft ®
Windows 98 or later. See 309867.
248848 Data Reporting Kit
Records actual temperature, temperature setpoint, actual pressure, cycles, and diagnostic code data from
Reactor. Downloads data to PC with Microsoft ®
Windows 98 or later. Does not include interface module.
See 309867.
312065R 39
Dimensions
Dimensions
B
C
Dimension
A in. (mm)
46.0 (1168)
31.0 (787)
33.0 (838)
A
40
B
C
TI10953a
312065R
Technical Data
Technical Data
Category Data
Maximum Fluid Working Pressure Models E-20 and E-30: 2000 psi (14 MPa, 140 bar)
Model E-XP1: 2500 psi (17.2 MPa, 172 bar)
Maximum Fluid Temperature
Maximum Output
Model E-XP2: 3500 psi (24.1 MPa, 241 bar)
190°F (88°C)
Model E-20: 20 lb/min (9 kg/min)
Model E-30: 30 lb/min (13.5 kg/min)
Model E-XP1: 1 gpm (3.8 liter/min)
Output per Cycle (A and B)
Line Voltage Requirement
Amperage Requirement
Heater Power
Model E-XP2: 2 gpm (7.6 liter/min)
Model E-20 and E-XP1: 0.0104 gal. (0.0395 liter)
Model E-30: 0.0272 gal. (0.1034 liter)
Model E-XP2: 0.0203 gal. (.0771 liter)
Parts 259024, 259025, 259026, 259028, 259057: 195-264 Vac, 50/60 Hz
Parts 259029, 259030, 259031, 259032, 259059: 338-457 Vac, 50/60 Hz
Parts 2590330, 259034, 259035, 259036, 259058: 195-264 Vac, 50/60 Hz
Model E-20: 6000 Watts
Sound Power, per ISO 9614-2
Model E-30 and E-XP1: 10200 Watts
Models E-XP2 and E-30 with 15.3kW of heat: 15300 Watts
Model E-20: 80 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)
Model E-30: 93.5 dB(A) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm)
Model E-XP1: 80 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)
Model E-XP2: 83.5 dB(A) at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm)
Sound Pressure, 1 m from equipment Model E-20: 70.2 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)
Fluid Inlets
Fluid Outlets
Fluid Circulation Ports
Weight
Wetted Parts
Model E-30: 83.6 dB(A) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm)
Model E-XP1: 70.2 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)
Model E-XP2: 73.6 dB(A) at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm)
3/4 npt(f), with 3/4 npsm(f) union
Component A (ISO): #8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
Component B (RES): #10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
1/4 npsm(m), with plastic tubing; 250 psi (1.75 MPa, 17.5 bar) maximum
Model E-20 and E-XP1: 342 lb (155 kg)
Model E-30: 400 lb (181kg)
Models E-XP2 and E-30 with 15.3kW of heat: 438 lb (198 kg)
Aluminum, stainless steel, zinc plated, carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
312065R 41
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211, Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original Instructions.
This manual contains English. MM 312065
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2007, Graco Inc. All Graco manufacturing locations are registered to ISO 9001 www.graco.com
Revision R, June 2015
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