Graco 312065P - Reactor, Electric Proportioners Owner's Manual

Operation

312065P

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

312065P

Systems

AP9033

AP9034

AP9035

AP9036

AP9057

AP9058

AP9059

CS9025

CS9026

Part

AP9024

AP9025

AP9026

AP9028

AP9029

AP9030

AP9031

AP9032

CS9030

CS9031

CS9034

CS9035

CS9057

CS9058

CS9059

P29024

P29025

P29026

P29028

P29029

P29030

P29031

P29032

P29033

P29034

P29035

P29036

P29057

P29058

P29059

Systems

Maximum Fluid

Working

Pressure psi (MPa, bar)

Proportioner

(see page 4)

2500 (17.2, 172) 259024

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) 259031

3500 (24.1, 241) 259032

2500 (17.2, 172) 259033

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) 259026

2000 (13.8, 138) 259030

2000 (13.8, 138) 259031

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) 259026

3500 (24.1, 241) 259028

2500 (17.2, 172) 259029

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) 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) 10 ft (3 m) Model

246679 246055

246678

246678

246679

246679

246678

246678

246679

246679

246678

246678

246679

246678

246678

246678

246678

246678

246678

246678

246678

246678

246678

246678

246678

246679

246678

246678

246679

246679

246678

246678

246679

246679

246678

246678

246679

246678

246678

246678

246050

246050

246055

246055

246050

246050

246055

246055

246050

246050

246055

246050

246050

246050

246050

246050

246050

246050

246050

246050

246050

246050

246050

246055

246050

246050

246055

246055

246050

246050

246055

246055

246050

246050

246055

246050

246050

246050

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Probler P2

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

Air Purge

Fusion

™

CS

Fusion

™

CS

Fusion

™

CS

Fusion

™

CS

Fusion

™

CS

Fusion

™

CS

Fusion

™

CS

Fusion

™

CS

Fusion

™

CS

Probler P2

246100

246101

246101

246100

246101

246101

246101

CS01RD

CS02RD

Part

246100

246101

246101

246100

246100

246101

246101

246100

CS01RD

CS02RD

CS01RD

CS02RD

CS02RD

CS02RD

CS02RD

GCP2RA

GCP2R1

GCP2R2

GCP2R0

GCP2RA

GCP2R1

GCP2R2

GCP2R0

GCP2RA

GCP2R1

GCP2R2

GCP2R0

GCP2R2

GCP2R2

GCP2R2

Mix

Chamber Kit

AR2020

AR5252

AR5252

AR2020

AR2020

AR5252

AR5252

AR2020

AR2020

AR5252

AR5252

AR2020

AR5252

AR5252

AR5252

312065P 3

Models

4

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



Maximum Fluid


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



Maximum Fluid


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 Maximum Fluid



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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312065P

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.

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 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)

Reactor Data Reporting Kit

Part

309867

Description

Instruction-Parts Manual (English)

Fusion Spray Gun

Part

309550

Description


Fusion CS Spray Gun

Part

312666

Description


Probler P2 Spray Gun

Part

313213

Heated Hose

Description


Part

309572

Description


Circulation and Return Tube Kit

Part

309852

Description


Rupture Disk Assembly Kit

Part

312416

Description


Electric Reactor Installation

Part

310815

Description

Instruction Manual (English)

312065P 5

Related Manuals

6 312065P

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.

312065P 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 312065P

312065P

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 312065P

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.

312065P 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 312065P

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)

Q Air Filter/Separator

K

M

J

K

L

G

A

N

G

F

B

D

J

E

P

C*

H

F IG . 2: Typical Installation, without circulation

TI10975a

* Shown exposed for clarity. Wrap with tape during operation,

312065P 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

312065P

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.

Heater Power Indicators Heater Displays

Temperature Controls and Indicators

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 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

control panel, page 14. Press

to shut off motor and heater zones only. Use main power switch to shut off all power to unit.

312065P 15

Temperature Controls and Indicators

Actual Temperature Key/LED

Press to display actual temperature.

Press and hold to display electrical current.

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

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

Size

50 A

40 A

CB3

CB4

25, 40*

25, 40*

CB5 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 ti9884a

CB5

For wiring and cabling, see repair manual 312066.

16 312065P

Motor Controls and Indicators

Motor Controls and Indicators

NOTICE

To prevent damage to the softkey buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

Pressure/Cycle Display

Arrow Keys

Motor ON/OFF Key

PARK Key

Pressure Key

Cycle Count Key

ON / OFF

PARK

PSI

BAR

PSI/BAR Keys

F IG . 5. Motor Controls and Indicators

Motor ON/OFF Key/LED 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.

312065P 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 dashes or current pressure.

until display shows

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 312065P

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. SeeDimen-

sions page 40, for clearance and mounting hole

dimensions.

MF 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

MB 259024_312065 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.

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.

312065P 19

Setup

• Use proportioner power cords that meet or exceed the requirements listed in Table 2. Failure to do so will cause voltage fluctuations that can damage electrical equipment.

• Use an air compressor with constant speed head unloading devices. Direct online air compressors that start and stop during a job will cause voltage fluctuations that can damage electrical equipment.

• 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 312065P

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















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

312065P 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.

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

FV

TI10971a

Supply hoses from feed pumps should be 3/4 in.

(19 mm) ID.

6. Connect pressure relief lines

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 312065P

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

312065P 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

page 21.

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 312065P

Startup

Startup

NOTICE

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability.


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 spray-

ing. See page 39.

a.

Check that all Setup steps are complete.

b.

Check that inlet screens are clean before daily

startup, page 37.

c.

Check level and condition of ISO lube daily,

page 37.

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

312065P 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

° F

or

° C

to change temperature scale.

c.

Press to display target temperatures.

26 312065P

Startup d.

To set

A

heat zone target temperature, press or until display shows desired temperature. Repeat for

B

and

zones.

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

step j, page 27.

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.

312065P 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.

a.

Turn main power switch OFF .

b.

Press and hold PSI or BAR , then turn main c.

Press or until display shows 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

mode, see page 35.

d.

To display cycle count, press

To clear counter, press onds.

.

and hold for 3 secpower 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 e.

Press scale.

PSI or BAR to change pressure d.

Turn main power switch OFF changes.

to save

28 312065P

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-

sary, page 29.

312065P 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 312065P

Shutdown

Shutdown

NOTICE

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability.


4.

Relieve pressure, page 32.

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).

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.

FV

10. Shut down feed pumps as required.

3.

Turn main power OFF .

ti10971a

312065P 31

Pressure Relief Procedure

Pressure Relief Procedure

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) ti2409a

Route

Disconnect gun air line and remove gun fluid manifold.

32 312065P

Fluid Circulation

Fluid Circulation

Circulation Through Reactor

4.


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 34.

1.

Follow Startup procedures, page 25.

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.


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.

8.

Turn on heat zone by pressing .

9.


SPRAY .

SA 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.


PRESSURE RELIEF/CIRCULATION .

SB

TI10963a

SA

SB

TI10955a

312065P 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 Startup procedures, page 25.

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.


5.

Set temperature targets, see page 26. Turn on

A

,

B

, and heat zones by pressing

.

6.


7.

Circulate fluid in jog mode until temperatures reach targets.

A

and

B

P

CK

R ti2767a

34 312065P

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.

4.

Press motor to start motor.

5.

Press through J10).

or to change jog speed (J1

1.

Turn main power on .

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.

2.

Ensure motor is OFF (LED is off; display may show dashes or pressure).

6.

To exit jog mode, press dashes or current pressure.

until display shows

3.

Press to select J1 (jog speed 1).

312065P 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

. For other codes,

then ON to clear.

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

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

Alarm

Selectable; see repair manual

High line voltage

Low line voltage

High motor temperature

High current

Alarm

Alarm

Alarm

Alarm

Brush wear

Momentary loss of communication

Motor control failure

Motor control board overtemperature

Loss of communication -

-

Warning

Alarm

Alarm is turned OFF then ON .

36 312065P

Maintenance

Maintenance

• Check wet cup TSL level daily.

• Do not overtighten packing nut/wet cup. Throat u-cup is not adjustable.

• Inspect fluid inlet strainer screens daily, see below.

• Grease circulation valves weekly with Fusion grease

(117773).

Fluid Inlet Strainer Screen

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

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

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.

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.

312065P

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:

1.

Relieve pressure, page 32.

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 312065P

Flushing

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.

RELIEF/CIRCULATION lines (N).

SA

. Flush through bleed

SB

N

• 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.

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

page 10.

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.

312065P 39

Dimensions

Dimensions

Dimension

A

B

C in. (mm)

46.0 (1168)

31.0 (787)

33.0 (838)

A

40

B

C

TI10953a

312065P

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

See Table 1, page 19.

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)



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.

312065P 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.

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

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

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original Instructions.

This manual contains English. MM 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

Revised November 2013

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