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

Operation

Hydraulic, Heated, Plural Component Proportioner

For spraying polyurethane foam and polyurea coatings.

Not for use in explosive atmospheres.

U.S. Patent Pending

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 3 for model information, including

maximum working pressure and approvals.

312062D

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Model H-40 Shown

T9830a

2

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Supplied Manuals . . . . . . . . . . . . . . . . . . . 5

Related Manuals . . . . . . . . . . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Isocyanate Hazard . . . . . . . . . . . . . . . . . . 10

Material Self-ignition . . . . . . . . . . . . . . . . 10

Moisture Sensitivity of Isocyanates . . . . 10

Keep Components A and B Separate . . 11

Foam Resins with 245 fa Blowing Agents .

11

Changing Materials . . . . . . . . . . . . . . . . . 11

Typical Installation, with circulation . . . 12

Typical Installation, without circulation . 13

Component Identification . . . . . . . . . . . . 14

Temperature Controls and Indicators . . 16

Main Power Switch . . . . . . . . . . . . . . . . 16

Red Stop Button . . . . . . . . . . . . . . . . . . 16

Actual Temperature Key/LED . . . . . . . . 16

Target Temperature Key/LED . . . . . . . . 17

Temperature Scale Keys/LEDs . . . . . . . 17

Heater Zone On/Off Keys/LEDs . . . . . . 17

Temperature Arrow Keys . . . . . . . . . . . 17

Temperature Displays . . . . . . . . . . . . . . 17

Circuit Breakers . . . . . . . . . . . . . . . . . . 18

Motor Controls and Indicators . . . . . . . .19

Motor ON/OFF Key/LED . . . . . . . . . . . .19

PARK Key/LED . . . . . . . . . . . . . . . . . . .19

PSI/BAR Keys/LEDs . . . . . . . . . . . . . . .19

Pressure Key/LED . . . . . . . . . . . . . . . .19

Cycle Count Key/LED . . . . . . . . . . . . . .20

Hydraulic Pressure Control Knob . . . . .20

Motor Control Arrow Keys . . . . . . . . . . .20

Spray Adjustments . . . . . . . . . . . . . . . . .20

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . .31

Standby . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . .34

Pressure Relief Procedure . . . . . . . . . . .35

Fluid Circulation . . . . . . . . . . . . . . . . . . . .36

Circulation Through Reactor . . . . . . . . .36

Circulation Through Gun Manifold . . . .37

Diagnostic Codes . . . . . . . . . . . . . . . . . . .39

Temperature Control Diagnostic Codes 39

Motor Control Diagnostic Codes . . . . . .40

Maintenance . . . . . . . . . . . . . . . . . . . . . . .41

Fluid Inlet Strainer Screen . . . . . . . . . .42

Pump Lubrication System . . . . . . . . . . .43

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . .44

Dimensions . . . . . . . . . . . . . . . . . . . . . . . .47

Technical Data . . . . . . . . . . . . . . . . . . . . .48

Performance Charts . . . . . . . . . . . . . . . . .49

Graco Standard Warranty . . . . . . . . . . . .51

Graco Information . . . . . . . . . . . . . . . . . .51

312062D

Models

Models

H-25 SERIES

Part,

Series

255400, B

255401, B

255402, B

255406, B

255407, B

255408, B

Full Load

Peak

Amps* Per

Phase

69

46

35

100

59

35

Voltage

(phase)

System

Watts†

Primary

Heater

Watts

Max Flow

Rate

◆ lb/min

(kg/min)

230V (1) 15,960 8,000

230V (3) 15,960 8,000

22 (10)

22 (10)

400V (3) 15,960 8,000 22 (10)

230V (1) 23,260 15,300 22 (10)

230V (3) 23,260 15,300 22 (10)

400V (3) 23,260 15,300 22 (10)

Approximate

Output per

Cycle (A+B) gal. (liter)

Hydraulic

Pressure

Ratio

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

Maximum Fluid

Working

Pressure psi (MPa, bar)

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,

B

253401, B

253402, B

253407, B

253408, B

Full Load

Peak Amps*

Per Phase

100

Voltage

(phase)

System

Watts†

Primary

Heater

Watts

Max Flow

Rate ◆ lb/min

(kg/min)

230V (1) 23,100 12,000 45 (20)

71

41

90

52

230V (3) 26,600

400V (3) 26,600

230V (3) 31,700

400V (3) 31,700

15,300

15,300

20,400

20,400

45 (20)

45 (20)

45 (20)

45 (20)

Approximate

Output per


Hydraulic

Pressure

Ratio

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

0.063 (0.24) 1.91:1

Maximum Fluid

Working


2000 (13.8, 138)

2000 (13.8, 138)

2000 (13.8, 138)

2000 (13.8, 138)

2000 (13.8, 138)

312062D 3

Models

H-XP2 SERIES

Part,

Series

255403, B

255404, B

255405, B

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


Hydraulic

Pressure

Ratio

1.5 (5.7) 0.042 (0.16) 2.79:1

1.5 (5.7) 0.042 (0.16) 2.79:1

1.5 (5.7) 0.042 (0.16) 2.79:1

Maximum Fluid

Working


3500 (24.1, 241)

3500 (24.1, 241)

3500 (24.1, 241)

H-XP3 SERIES

Part,

Series

★ 253403,

B

253404, B

253405, B

Full Load

Peak

Amps* Per

Phase

100

90

52

Voltage

(phase)

System

Watts†

230V (1) 23,100

230V (3) 31,700

400V (3) 31,700

Primary

Heater

Watts

12,000

20,400

20,400

Max Flow

Rate ◆ gpm (lpm)

Approximate

Output per


Hydraulic

Pressure

Ratio

2.8 (10.6) 0.042 (0.16) 2.79:1

Maximum Fluid

Working


3500 (24.1, 241)

2.8 (10.6)

2.8 (10.6)

0.042 (0.16)

0.042 (0.16)

2.79:1

2.79:1

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, and 253725 through 253727, 410 ft (125 m) maximum heated hose length, including whip hose.

◆ Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of

60 Hz maximum flow.

★ CE approval does not apply.

4 312062D

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


312064 Reactor Hydraulic Proportioner,

Electrical Diagrams (English)

Proportioning Pump


312068 Proportioning Pump Repair-Parts

Manual (English)

Translations

The Reactor Operation manual is available in the following languages. See the following chart for specific languages and corresponding part numbers.

Part Language

312062 English

312419 Chinese

312420 Dutch

312421 French

312422 German

312423 Italian

312424 Japanese

312425 Korean

312426 Russian

312427 Spanish

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


309815 Instruction-Parts Manual

(English)

Air Supply Kit



(English) for Feed Pump Air

Supply Kit

Circulation and Return Tube Kits



(English)

312062D 5

Related Manuals

6

Heated Hose



(English)

Circulation Kit



(English)

Circulation Valve Kit



(English)

Data Reporting Kit



(English)

Rupture Disk Assembly Kit



(English)

Proportioning Pump Repair Kits


312071 Seal Kits Instruction-Parts

Manual (English)

312062D

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate sur- gical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

312062D 7

8

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use and clean equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions.

• Use only Graco grounded hoses.

• Check gun resistance daily.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from system.

• Keep a working fire extinguisher in the work area.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

312062D

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• This equipment is for professional use only.

• Do not leave the work are while the equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when the equipment is not in use.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical

Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

312062D 9

Isocyanate Hazard

Isocyanate Hazard

Read material manufacturer’s warnings and material MSDS to know the specific hazards of isocyanates. Use equipment in a well-ventilated area. Wear respirator, gloves, and protective clothing when using isocyanates.

Material Self-ignition

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Moisture Sensitivity of

Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which 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 filled with Graco Throat Seal Liquid (TSL), Part

206995. The lubricant creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always park pumps when you shutdown,

see page 33.

• Always lubricate threaded parts with Part

217374 ISO pump oil or grease when reassembling.

10 312062D

Keep Components A and B Separate

Keep Components A and B Separate

CAUTION

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

Foam Resins with 245 fa Blowing Agents

New foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after

flushing, see page 42.

• 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.

312062D 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

A Side Supply Detail

M

B Side Supply Detail

M

K

K

G ti7820a 2

K

K

G

L ti7820a 3

R

J

A

D

J

R

F

E

P

C*

* Shown exposed for clarity.

Wrap with tape during operation.

ti10000a

B

F IG . 1: Typical Installation, with circulation

12 312062D

Typical Installation, without circulation

Typical Installation, without circulation


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

K

G

G

K

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

312062D 13

Component Identification

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

14 312062D

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)

312062D

TI9830a ti7823a

15

Temperature Controls and Indicators

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

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 15. 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 15. Press

to shut off motor and heater zones only.

Use main power switch to shut off all power to unit.

Actual Temperature Key/LED

Press to display actual temperature.

16 312062D


Press and hold rent.

to display electrical cur-

Heater Zone On/Off

Keys/LEDs

Target Temperature Key/LED

Press to turn heater zones on and off.

Also clears heater zone diagnostic codes, see

page 39.

Press and hold to display heater control circuit board 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

Temperature Scale

Keys/LEDs

Press scale.

° F or ° C to change temperature

Press , or adjust temperature settings in 1 degree increments.

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.

312062D 17


* 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.

18 312062D

Motor Controls and Indicators

Motor Controls and Indicators

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 PSI/BAR Keys/LEDs

Press to turn motor ON and OFF. Also clears some motor control diagnostic codes,

see page 40.

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.

312062D 19

Cycle Count Key/LED

Press to display cycle count.

Spray Adjustments

• Adjust pressure imbalance settings, page

29.

•

Adjust standby settings, page 33.

To clear counter, press and hold sec.

for 3

Hydraulic Pressure Control

Knob

Use to adjust hydraulic pressure available to the hydraulic drive system. Turn knob (HC) clockwise to increase pressure and counterclockwise to decrease pressure. Use hydraulic

pressure gauge (HP, page 15) to view 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; Models, page 3). Component

A and B pressure may be viewed on the pressure gauges (GA, GB), or the higher of the two pressures may be displayed on

the motor control panel (MC). See F IG . 3, page 15.

Motor Control Arrow Keys

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.

20 312062D

Setup

Setup

1. Locate Reactor

a. Locate Reactor on a level surface. See , page 45, for clearance and mounting

hole dimensions.

b. Do not expose Reactor to rain.

CAUTION

Bolt Reactor to original shipping pallet before lifting.

c. Use the casters to move Reactor to a fixed location, or bolt to shipping pallet and move with forklift.

d. To mount on a truck bed or trailer, remove casters and bolt directly to truck

or trailer bed. See page 45.

2. 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 ter-

minals, see page 22. Be sure your installation

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 230V (1)

H-40 230V (3)

253402 H-40 400V (3)

253403 H-XP3 230V (1)

253404 H-XP3 230V (3)

253405 H-XP3 400V (3)

253407

253408

H-40

H-40

230V (3)

400V (3)

255400

255401

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

H-25

H-25

H-25

230V (1)

230V (3)

400V (3)

Full

Load

Peak

Amps*

69

46

35

100

59

35

100

59

35

90

52

90

52

100

71

41

100

System

Watts**

15,960

15,960

15,960

23,260

23,260

23,260

23,260

23,260

23,260

23,100

26,600

26,600

23,100

31,700

31,700

31,700

31,700

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

** Total system watts, based on maximum hose length for each unit:

• Parts 255400 through 255408, 310 ft (94.6 m) maximum heated hose length, including whip hose.

• Parts 253400 through 253408, 410 ft (125 m) maximum heated hose length, including whip hose.

312062D 21

Setup

3. Connect electrical cord

Power cord is not supplied. See Table 2.

Table 2: Power Cord Requirements

Part

253400

253401

253402

253404

253405

253407

253408

255400

255401

255402

255403

255404

255405

255406

255407

255408

Model

H-25

H-25

H-XP2

H-XP2

H-XP2

H-25

H-25

H-25

H-40

H-40

H-40

H-XP3

H-XP3

H-40

H-40

H-25

Cord Specification

AWG (mm

2

)

4 (21.2), 2 wire + ground















8 (8.4), 4 wire + ground a. 230V, 1 phase: Using 5/32 or 4 mm hex allen wrench, connect two power leads to L1 and L2. Connect green to ground

(GND).

GND

L1

L2 ti2515b b. 230V, 3 phase: Using 5/32 or 4 mm hex allen wrench, connect three power leads to L1, L2, and L3. Connect green to ground (GND).

GND

L1

L2

L3 ti3248b

22 312062D

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 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.

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.

4. 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.

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.

e. Connect and tighten component B supply hose to the 3/4 npt(f) swivel on the component B inlet valve.

f.

Connect and tighten component A supply hose to the 1/2 npt(f) swivel on the component A inlet valve.

FP ti10006a

312062D 23

Setup

5. Connect pressure relief lines valves, Route hose back to component

A and B drums. See F IG . 1, page 12.

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.

R

BA

BB b. Alternately: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See F IG . 2, page 13.

R ti9880a a. Recommended: Connect high pressure hose (R) to relief fittings (BA, BB) of both PRESSURE RELIEF/SPRAY

6. 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.

24 312062D

Setup

7. Connect heated hose

See Heated Hose manual 309572 for detailed instructions on connecting heated hoses.

CAUTION

The fluid temperature sensor (C) and whip hose (D) must be used with heated hose,

see page 24. Hose length, including whip

hose, must be 60 ft (18.3 m) minimum.

Y d. Connect cables (Y). Connect electrical connectors (V). Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape.

V a. Turn main power OFF .

ti9881a b. Assemble heated hose sections, FTS, and whip hose.

8. Close gun fluid manifold valves A and B c. Connect A and B hoses to A and B outlets on Reactor fluid manifold (FM).

Hoses are color coded: red for component A (ISO), blue for component B

(RES). Fittings are sized to prevent connection errors.

FM

N

A

P ti2411a

9. 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.

10. Pressure check hose

See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage.

312062D 25

Setup

11. Ground system a. Reactor: is grounded through power

cord. See page 22.

b. Spray gun: connect whip hose ground

wire to FTS, page 24. Do not disconnect

wire or spray without whip hose.

13. Lubrication system setup

Component A (ISO) Pump: Fill ISO lube reservoir (LR) with Graco Throat Seal Liquid (TSL), Part 206995 (supplied).

a. Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap.

ST

RT

RB c. Fluid supply containers: follow your local code.

LR 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.

12. Check hydraulic fluid level

Hydraulic reservoir is filled at the factory.

Check fluid level before operating the first

time, and weekly thereafter. See Mainte-

nance, page 41.

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.

ti9911a

26 312062D

Startup

Startup

Do not operate Reactor without all covers and shrouds in place.

1. 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 44.

g. Open fluid inlet valves (FV). Check for leaks.

FV

a. Check that all Setup steps are com-

plete.

b. Check that inlet screens are clean

before daily startup, page 42.

c. Check level and condition of ISO lube

daily, page 41.

d. Turn on component B agitator, if used.

SA e. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY .

SB ti10002a

Do not mix components A and B during startup. Always provide two grounded waste containers to keep component A and component B fluids separate. h. Use feed pumps to load system. Hold gun fluid manifold over two grounded waste containers. Open fluid valves A and B until clean, air-free fluid comes from valves. Close valves.

ti9877a f.

Start feed pumps.

ti2484a

312062D 27

2. Set temperatures

A

B

° F

° C

Temperature Controls and Indicators, see

Startup d. To set

A

heat zone target temperaor 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 29.

e. Press tures.

to display actual tempera-

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).

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.

a. Turn main power ON .

b. Press ° F or ° C to change temperature scale.

c. Press .

Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose.

28 312062D

Startup g. Turn on pressing

A

and

B

heat zones by

for each zone.

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.

3. Set pressure j.

Manual current control mode only:

ON / OFF

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.

PARK

PSI

BAR

If FTS is disconnected or display shows diagnostic code E04, turn main power

Motor Controls and Indicators, see page 19

switch OFF then ON to clear diagnostic code and enter manual a. Press reading.

to display the pressure show current to hose. Current is not limited by target temperature. b. Press motor . Motor and pumps start. Display shows system pressure.

Motor must rotate counterclockwise when

viewed from shaft end. See Connect elec-

trical cord, page 22.

312062D 29

Startup c. Adjust hydraulic pressure control until display shows desired fluid pressure.

+ -

ti7732a ti7731a

If display pressure is greater than desired pressure, reduce the hydraulic pressure and trigger gun to reduce pressure.

The pressure imbalance default is factory-set at 500 psi (3.5 MPa, 35 bar). For tighter ratio error detection, select a lower value. For looser detection or to avoid nuisance alarms, select a higher value.

a. Turn main power switch OFF .

b. Press and hold PSI or BAR , then turn

Check the pressure of each proportioning pump using the component A and B gauges. The pressures should be approximately equal and must remain fixed.

main power switch ON . Display will read dP500 for psi or dP_35 for bar.

d. To display cycle count, press

To clear counter, press and hold sec.

.

for 3 e. Press PSI or BAR to change pressure scale.

4. Change pressure imbalance setting

(optional)

The pressure imbalance function (status code

24, page 40) 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.

c. Press or to select desired pressure differential (100-999 in increments of 100 psi, or 7-70 in increments of 7 bar). See T ABLE 3.

Table 3: Available Pressure Imbalance Settings

PSI

100

200

300

400

*50

0

7

14

21

28

*35

BA

R PSI

600

700

800

900

999

* Factory default setting.

BA

R

42

49

56

63

69 d. Turn main power switch OFF save changes.

to

Code 24 (pressure imbalance) is set to an alarm as the default. To change to a warning, see Reactor Repair-Parts manual

312063.

30 312062D

Spraying

Spraying

1. Engage gun piston safety lock.

4. Set PRESSURE RELIEF/SPRAY valves

(SA, SB) to SPRAY

SA

.

SB ti2409a

2. Close gun fluid manifold valves A and B.

ti9877a

5. Check that heat zones are on and tempera-

tures are on target, page 28.

ti2728a

3. Attach gun fluid manifold. Connect gun air line. Open air line valve.

6. Press motor pumps.

to start motor and

7. Check fluid pressure display and adjust as

necessary, page 31.

ti2543a

312062D 31

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/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.

9. Open gun fluid manifold valves A and B.

On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.

ti2414a ti9877a

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.

If you stop spraying for a period of time, the unit will enter standby (if enabled). See

page 33.

32 312062D

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

A B and zones will not be shut off in standby.

2. Press and hold 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.

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.

This feature is disabled from the factory.

4. Turn main power switch OFF save changes.

to

312062D 33

Shutdown

Shutdown

1. Shut off zones.

A

,

B

, and

2. Park pumps.

heat a. Press .

b. Trigger gun until pump A stops in the retracted position and the pressure of both pumps bleeds down.

4. Close both fluid supply valves (FV).

FV

5. Relieve pressure, page 35.

6. Shut down feed pumps as required.

ti9883a

3. Turn main power OFF .

34 312062D

Pressure Relief Procedure

Pressure Relief Procedure

4. Turn PRESSURE RELIEF/SPRAY valves

(SA, SB) to PRESSURE RELIEF/CIRCU-

1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual.

2. Close gun fluid manifold valves A and B.

LATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to

0.

SA

SB ti9879a ti2421a

3. Shut off feed pumps and agitator, if used.

5. Engage gun piston safety lock.

ti2409a

6. Disconnect gun air line and remove gun fluid manifold.

ti2554a

312062D 35

Fluid Circulation

Fluid Circulation

Circulation Through Reactor


(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

hose, see page 37.

1. Load fluid with feed pumps, page 27.

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 28. 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 12. Route circulation lines back to

respective component A or B supply drum.

Use hoses rated at the maximum working

pressure of this equipment. See Technical

Data, page 48.

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.

36 312062D

Fluid Circulation

9. Turn on heat zone by pressing


(SA, SB) to SPRAY .

.

Circulation Through Gun

Manifold

SA

SB ti9877a

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.

P

CK

R ti2767a

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 Load fluid with feed pumps, page

28.

4. Turn main power ON .

312062D 37

Fluid Circulation

5. Set temperature targets, see page 28. Turn

on

A

,

B

, and heat zones by pressing .

late fluid until reach targets.

A

and

B

temperatures

-

ti7732a

7. Before starting motor, reduce hydraulic pressure to the minimum required to circu8. Press motor to start motor and pumps. Circulate fluid at lowest possible pressure until temperatures reach targets.

38 312062D

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.

312062D 39

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 Reactor. Turn main power OFF

then ON to clear.

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 setting,

see page 30.

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

40 312062D

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).

ti9879a

• Inspect ISO lubricant level and condition

daily, see page 43. 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 48 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.

• ti10003a

IM

DS

S ti7861a

• 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)

90°F and above

(32°C and above)

1000 hours or 12 months, whichever comes first

500 hours or 6 months, whichever comes first

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.

312062D 41

Maintenance

Fluid Inlet Strainer Screen

The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.

Use clean chemicals and follow proper storage, transfer, and operating procedures, to minimize contamination of the A-side screen.

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.

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).

F IG . 6. Fluid Inlet Strainer

59d

59g*

59h

59j

59k ti9886a

* See Reactor Repair-Parts manual 312063 for fluid filter screen replacements.

42 312062D

Maintenance

Pump Lubrication System

6. Push the larger diameter supply tube (ST) approximately 1/3 of the way into the reservoir.

7. Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom.

Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible.

Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks.

To change pump lubricant:

1. Relieve pressure, page 35.

2. Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap. Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reattach the check valve to the inlet hose. See 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.

RT

LR

Important: The return tube (RT) must reach the bottom of the reservoir, to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube (ST) and returned to the pump.

8. The lubrication system is ready for operation. No priming is required.

ST

RT

LR

F IG . 7. Pump Lubrication System

ST

RB ti9911a ti9887a

312062D 43

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 10.

44 312062D

Flushing

312062D 45

Flushing

46 312062D

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

C

312062D

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

47

Technical Data

Technical Data

Category

Maximum Fluid Working Pressure

Fluid:Oil Pressure Ratio

Fluid Inlets

Fluid Outlets

Fluid Circulation Ports

Maximum Fluid Temperature

Maximum Output (10 weight oil at ambient temperature)

Data

Models H-25 and H-40: 2000 psi (13.8 MPa, 138 bar)

Models H-XP2 and H-XP3: 3500 psi (24.1 MPa, 241 bar)

Models H-25 and H-40: 1.91:1

Models H-XP2 and H-XP3: 2.79:1

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 JIC (3/4-16 unf), with #5 JIC adapter

Component B (RES): #10 JIC (7/8-14 unf), with #6 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)

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) Output per Cycle (A and B)

Line Voltage Requirement

Amperage Requirement

Heater Power

(A and B heaters total, no hose)

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

See Models, page 3.

See Models, page 3.

Hydraulic reservoir capacity

Recommended hydraulic fluid

3.5 gal. (13.6 liters)

Citgo A/W Hydraulic Oil, ISO Grade 46

Sound power, per ISO 9614-2 90.2 dB(A)

Sound pressure, 1 m from equipment 82.6 dB(A)

Weight Units with 8.0 kW Heaters: 535 lb (243 kg)

Units with 12.0 kW Heaters: 597 lb (271 kg)

Units with 15.3 kW Heaters (H-25/H-XP2 models):562 lb (255 kg)

Wetted Parts

Units with 15.3 kW Heaters (H-40/H-XP3 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.

48 312062D

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

D

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

0 5

(2.3)

10

(4.5)

15

(6.8)

20

(9.1)

25 30 35 40 45

(11.4) (13.6) (15.9) (18.2) (20.5)

Flow Rate in gal/min (lpm/min)

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

E

F

G

H

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 (lpm/min)

KEY

E = H-XP2 at 50 Hz

F = H-XP2 at 60 Hz

G = H-XP3 at 50 Hz

H = H-XP3 at 60 Hz

312062D 49

50

Performance Charts

Heater Performance Chart

(44)

70

(39)

60

(33)

50

(28)

40

(22)

30

(17)

20

(11)

10

(6)

140

(78)

130

(72)

120

(67)

110

(61)

100

(56)

90

(50)

80

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

312062D

Graco Standard Warranty

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by

Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts.

The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING

BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS

SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211, Fax: 612-378-3505

312062D 51

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.

MM 312062 This manual contains English.

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 www.graco.com

3/2008

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