Graco 333023A - Reactor 2 E-30 and E-X2 Proportioning Systems Owner's Manual

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Graco 333023A - Reactor 2 E-30 and E-X2 Proportioning Systems Owner's Manual | Manualzz

Operation

Reactor® 2 E-30 and E-XP2

Proportioning Systems

333023A

EN

Electric, Heated, Plural Component Proportioner for spraying polyurethane foam and polyurea coatings.

Not for outdoor use. For professional use only. Not approved for use in explosive atmospheres or hazardous locations.

Important Safety Instructions

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

PROVEN QUALITY. LEADING TECHNOLOGY.

2

Contents

Warnings ........................................................... 3

Important Isocyanate Information......................... 7

Models............................................................... 9

Approvals........................................................... 11

Accessories........................................................ 11

Typical Installation, without circulation.................. 12

Typical Installation, with system fluid manifold to drum circulation ................................. 13

Typical Installation, with gun fluid manifold to drum circulation..................................... 14

Component Identification..................................... 15

Advanced Display Module (ADM).................. 17

Electrical Enclosure...................................... 22

Motor Control Module (MCM)........................ 23

Temperature Control Module (TCM) Cable

Connections ................................... 24

Installation.......................................................... 25

Setup................................................................. 26

Grounding ................................................... 26

Close gun fluid manifold valves A and

B ................................................... 26

Connect Power ............................................ 27

Supply Wet Cups With Throat Seal Liquid

(TSL) ............................................. 28

Install Fluid Temperature Sensor .................. 28

Register and Activate the Graco InSite ........... 28

Advanced Display Module (ADM)

Operation.............................................. 29

Advanced Setup Screens ............................. 32

System 1 ..................................................... 33

System 2 ..................................................... 33

Recipes....................................................... 33

Run Mode ................................................... 34

Startup............................................................... 40

Fluid Circulation.................................................. 43

Circulation Through Reactor ......................... 43

Circulation Through Gun Manifold ................. 44

Jog Mode........................................................... 44

Spraying ............................................................ 45

Spray Adjustments....................................... 46

Manual Hose Heat Mode .............................. 47

Shutdown........................................................... 49

Pressure Relief Procedure .................................. 50

Flushing............................................................. 51

Maintenance ...................................................... 52

Preventative Maintenance Schedule ............. 52

Proportioner Maintenance ............................ 52

Flush Inlet Strainer Screen ........................... 53

Pump Lubrication System............................. 54

Errors ................................................................ 55

View Errors.................................................. 55

Troubleshoot Errors ..................................... 55

Troubleshooting.................................................. 56

Error Codes and Troubleshooting.................. 56

USB Data........................................................... 57

Download Procedure.................................... 57

USB Logs.................................................... 57

System Configuration Settings ...................... 58

Custom Language File ................................. 59

Upload Procedure ........................................ 59

Performance Charts............................................ 60

Technical Specifications...................................... 63

Graco Extended Warranty for Reactor® 2

Components ......................................... 65

333023A

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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these

Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

ELECTRIC SHOCK HAZARD

WARNING

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 or installing 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.

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES

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

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

333023A 3

4

Warnings

WARNING

SKIN INJECTION HAZARD

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

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

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

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

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIRE AND EXPLOSION HAZARD

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

• Use equipment only in well ventilated area.

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

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

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

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. 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.

333023A

333023A

Warnings

WARNING

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.

• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s MSDSs and recommendations.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• 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 from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

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

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• 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, cut 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 and disconnect all power sources.

5

Warnings

WARNING

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

6 333023A

Important Isocyanate Information

Important Isocyanate Information

Isocyanates (ISO) are catalysts used in two component materials.

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 thick. 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:

• Never interchange component A and component

B wetted parts.

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

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause

ISO to partially cure; forming 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

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

• 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 pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with

ISO.

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

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

333023A 7

8

Important Isocyanate 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

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• 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.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

333023A

Models

Models

Reactor 2 E-30 and E-30 Elite

All elite systems include fluid inlet pressure and temperature sensors, Graco InSite ™ , and Xtreme-Wrap 50 ft

(15 m) head hose. For part numbers, see

Accessories, page 11

Model

Proportioner ★

E-30, 10 kW

272010

Base Model

Maximum Fluid Working

Pressure psi (MPa, bar)

Approximate Output per

Cycle (A+B) gal. (liter)

Max Flow Rate lb/min

(kg/min)

Total System Load †

(Watts)

2000 (14, 140)

0.0272 (0.1034)

30 (13.5)

17,900

Configurable Voltage

Phase

230

Full Load Peak Current

78

230

3Ø∆

50

380

3ØY

34

E-30, 15 kW

272110

2000 (14, 140)

0.0272 (0.1034)

30 (13.5)

23,000

230

230

3Ø∆

100 62

380

3ØY

35

Base Machine

Heated Hose

50 ft (15 m)

Heated Whip Hose

10 ft (3 m)

Fusion AP Package

(Gun Part No.)

Fusion CS Package

(Gun Part No.)

Probler P2 Package

(Gun Part No.)

Graco Insite ™

Fluid Inlet Sensors (2)

272010

24K240 (scuff guard)

246050

AP2010

(246102)

CS2010

(CS02RD)

P22010

(GCP2R2)

272110

24K240 (scuff guard)

246050

AP2110

(246102)

CS2110

(CS02RD)

P22110

(GCP2R2)

Elite, 10 kW

272011

2000 (14, 140)

Elite Model

Elite, 15kW

272111

2000 (14, 140)

0.0272 (0.1034)

30 (13.5)

17,900

230

78

230

3Ø∆

50

380

3ØY

34

272011

24Y240 (Xtreme-

Wrap)

246050

AP2011

(246102)

CS2011

(CS02RD)

P22011

(GCP2R2)

0.0272 (0.1034)

30 (13.5)

23,000

230

230

3Ø∆

100 62

380

3ØY

35

272111

24Y240 (Xtreme-

Wrap)

246050

AP2111

(246102)

CS2111

(CS02RD)

P22111

(GCP2R2)

*

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 used by system, based on maximum heated hose length for each unit.

• E–30 and E–XP2 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.

See

Approvals, page 11 .

333023A 9

Models

Reactor 2 E-XP2 and E-XP2 Elite

All elite systems include fluid inlet pressure and temperature sensors, Graco InSite ™ , and Xtreme-Wrap 50 ft

(15 m) head hose. For part numbers, see

Accessories, page 11

Model

Proportioner ★

Maximum Fluid Working

Pressure psi (MPa, bar)

Approximate Output per

Cycle (A+B) gal. (liter)

Max Flow Rategpm/min

(l/min)

Total System Load †

(Watts)

Configurable Voltage

Phase

Full Load Peak Current

(amps)

Fusion AP Package

(Gun Part No.)

Probler P2 Package

(Gun Part No.)

Heated Hose

50 ft (15 m)

Heated Whip Hose

10 ft (3 m)

Graco Insite ™

Fluid Inlet Sensors (2)

E–XP2, 15 kW

272012

Base Model

3500 (24.1, 241)

0.0203 (0.0771)

2 (7.6)

23,000

240 1Ø

100

AP2012

(246101)

P22012

(GCP2R1)

24K241

(scuff guard)

246050

240 3Ø

62

380 3Ø

35

E–XP2, 15 kW

272112

AP2112

(246101)

P22112

(GCP2R1)

24Y241

(Xtreme-Wrap)

246050

Elite Model

3500 (24.1, 241)

0.0203 (0.0771)

2 (7.6)

23,000

240 1Ø

100

240 3Ø

62

380 3Ø

35

*

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 used by system, based on maximum heated hose length for each unit.

• E–30 and E–XP2 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.

★ See

Approvals, page 11 .

10 333023A

Approvals

Intertek approvals apply to proportioners without hoses.

Proportioner Approvals:

9902471

Conforms to ANSI/UL Std. 499

Certified to CAN/CSA Std. C22.2 No. 88

Note

Heated hoses provided with a system or sold individually are not approved by Intertek.

Approvals

Accessories

Kit Number Description

24N449 50 ft (15 m) CAN cable (for remote display module)

24K207

24U174

15V551

15M483

Fluid Temperature Sensor (FTS) with RTD

Remote Display Module Kit

ADM Protective Covers (10 pack)

Remote Display Module Protective

Covers (10 pack)

24M174

24L911

121006

24N365

24U315

24U314

24T280

16X521

Drum Level Sticks

Pallet Support Kit

150 ft (45 m) CAN cable (for remote display module)

RTD Test Cables (to aide resistance measurements)

Air Manifold Kit (4 outlets)

Wheel and Handle Kit

Graco InSite Kit

Graco InSite Extension cable 24.6 ft

(7.5 m)

333023A 11

Typical Installation, without circulation

Typical Installation, without circulation

H

K

J

G

L

K

M

G

J

A

F

N

(RES)

N

(ISO)

D

S

E

P

C*

B

Figure 1

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

F

G

D

E

H

A

B

C

Reactor Proportioner

Heated Hose

Fluid Temperature Sensor (FTS)

Heated Whip Hose

Fusion Spray Gun

Gun Air Supply Hose

Feed Pump Air Supply Lines

Agitator Air Supply Line

P

S

M

N

J

K

L

Fluid Supply Lines

Feed Pumps

Agitator

Desiccant Dryer

Bleed Lines

Gun Fluid Manifold (part of gun)

Remote Display Module Kit (optional)

12 333023A

Typical Installation, with system fl uid manifold to drum circulation

Typical Installation, with system fluid manifold to drum circulation

G

H

K M

J

J

R

A

K

M

L

R

G

(RES)

F

(ISO)

D

S

E

P

C*

B

Figure 2

A

B

C

D

E

F

G

H

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

Reactor Proportioner

Heated Hose

Fluid Temperature Sensor (FTS)

Heated Whip Hose

Fusion Spray Gun

Gun Air Supply Hose

Feed Pump Air Supply Lines

Agitator Air Supply Line

R

S

M

P

J

K

L

Fluid Supply Lines

Feed Pumps

Agitator

Desiccant Dryer

Gun Fluid Manifold (part of gun)

Recirculation Lines

Remote Display Module (optional)

333023A 13

Typical Installation, with gun fl uid manifold to drum circulation

Typical Installation, with gun fluid manifold to drum circulation

G

H

K M

J

J

R

K

M

L

A R

G

N

(RES)

N

(ISO)

F

D

S

C*

P

B

Figure 3

A

B

C

G

H

CK

D

F

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

Reactor Proportioner

Heated Hose

Fluid Temperature Sensor (FTS)

Circulation Block (accessory)

Heated Whip Hose

Gun Air Supply Hose

Feed Pump Air Supply Lines

Agitator Air Supply Line

P

R

S

L

M

J

K

Fluid Supply Lines

Feed Pumps

Agitator

Desiccant Dryer

Gun Fluid Manifold (part of gun)

Recirculation Lines

Remote Display Module (optional)

14 333023A

Component Identification

Component Identi fi cation

S

D

E

P

C*

B

333023A

Figure 4

15

Component Identi fi cation

Key

BA

BB

HA

HB

HC

MP

FM

FV

GA

GB

PA

PB

CD

DG

EC

EM

FA

FB

FH

ISO Side Pressure Relief Outlet

RES Side Pressure Relief Outlet

Advanced Display Module (ADM)

Drive Gear Housing

Electrical Cord Strain Relief

Electric Motor

ISO Side Fluid Manifold Inlet

RES Side Fluid Manifold Inlet

Fluid Heaters (behind shroud)

Reactor Fluid Manifold

Fluid Inlet Valve (RES side shown)

ISO Side Pressure Gauge

RES Side Pressure Gauge

ISO Side Hose Connection

RES Side Hose Connection

Heated Hose Electrical Connectors

Main Power Switch

ISO Side Pump

RES Side Pump

TB

XA

XB

RR

RS

SA

SB

TA

Graco InSite Cellular Module (Elite models only)

Red Stop Button

ISO Side PRESSURE RELIEF/SPRAY

Valve

RES Side PRESSURE RELIEF/SPRAY

Valve

ISO Side Pressure Transducer (behind gauge GA)

RES Side Pressure Transducer (behind gauge GB)

Fluid Inlet Sensor (ISO side, Elite models only)

Fluid Inlet Sensor (RES side, Elite models only)

16 333023A

Component Identi fi cation

Advanced Display Module (ADM)

The ADM display shows graphical and text information related to setup and spray operations.

NOTICE

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

Figure 5 Front View

333023A 17

Component Identi fi cation

Table 1 : ADM Keys and Indicators

Key Function

Press to startup or shutdown the system.

Startup/Shutdown

Key and Indicator

Press to stop all proportioner processes. This Is not a safety or emergency stop.

Stop

Press to select the specific screen or operation shown on the display directly next to each key.

Soft Keys

Left/Right Arrows:

Use to move from screen to screen.

Up/Down Arrows:

Use to move among fields on a screen, items on a dropdown menu, or multiple screens within a function.

Navigation Keys

Numeric Keypad Use to input values.

Use to cancel a data entry field.

Cancel

Press to enter or exit Setup mode.

Setup

Press to choose a field to update, to make a selection, to save a selection or value, to enter a screen, or to acknowledge an event.

Enter

18 333023A

Component Identi fi cation

Figure 6 Back View

CJ

CK

CL

CM

Flat Panel Mount (VESA 100)

Model and Serial Number

USB Port and Status LEDs

CAN Cable Connection

CN

CP

CR

CS

Table 2 ADM LED Status Descriptions

LED

System Status

USB Status (CL)

Conditions

Green Solid

Green Flashing

Yellow Solid

Yellow Flashing

Green Flashing

Yellow Solid

Green and Yellow Flashing

ADM Status (CN) Green Solid

Yellow Solid

Red Steady Flashing

Red Random Flashing or Solid

Module Status LEDs

Accessory Cable Connection

Token Access Cover

Battery Access Cover

Description

Run Mode, System On

Setup Mode, System On

Run Mode, System Off

Setup Mode, System Off

Data recording in progress

Downloading information to USB

ADM is busy, USB cannot transfer information when in this mode

Power applied to module

Active Communication

Software upload from token in progress

Module error exists

333023A 19

Component Identi fi cation

ADM Display Details

Power Up Screen

The following screen appears when the ADM is powered up. It remains on while the ADM runs through initialization and establishes communication with other modules in the system.

Menu Bar

The menu bar appears at the top of each screen. (The following image is only an example.)

Alarm/Deviation

The current system error is displayed in the middle of the menu bar. There are four possibilities:

Icon Function

No Icon No information or no error has occurred

Advisory

Deviation

Alarm

Status

The current system status is displayed at the lower right of the menu bar.

Soft Keys

Icons next to the soft keys indicate which mode or action is associated with each soft key. Soft keys that do not have an icon next to them are not active in the current screen.

NOTICE

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

Date and Time

The date and time are always displayed in one of the following formats. The time is always displayed as a

24-hour clock.

• DD/MM/YY HH:MM

• YY/MM/DD HH:MM

• MM/DD/YY HH:MM

Arrows

The left and right arrows indicate screen navigation.

Screen Menu

The screen menu indicates the currently active screen, which is highlighted. It also indicates the associated screens that are available by scrolling left and right.

System Mode

The current system mode is displayed at the lower left of the menu bar.

Navigating the Screens

There are two sets of screens:

• The Run screens control spraying operations and display system status and data.

• The Setup screens control system parameters and advanced features.

Press on any Run screen to enter the Setup screens. If the system has a password lock, the

Password screen displays. If the system is not locked

(password is set to 0000), System Screen 1 displays.

Press on any Setup screen to return to the

Home screen.

Press the Enter soft key function on any screen.

to activate the editing

20

Press the Exit soft key to exit any screen.

Use the other softkeys to select the function adjacent to them.

333023A

Icons

Icons

Icon

Component Identi fi cation

Function

Component A

Component B

Estimated Supply Material

Hose Temperature

Jog Mode Speed

Pressure

Cycle Counter (press and hold)

Advisory.

See

Errors, page 36

for more information.

Deviation.

See

Errors, page 36

for more information

Alarm.

See

Errors, page 36

for more information

Softkeys

Icon Function

Start Proportioner

Start and Stop Proportioner in Jog Mode

Stop Proportioner

Turn on or off the specified heat zone.

Park pump

Enter Jog Mode. See

Jog Mode, page 44

Reset Cycle Counter

(press and hold)

Select Recipe

Search

Move Cursor Left One Character

Move Cursor Right One Character

Toggle between upper-case, lower-case, and numbers and special characters.

Backspace

Cancel

Clear

Troubleshoot Selected Error

Increase value

Decrease value

Next screen

Previous screen

Return to first screen

333023A 21

Component Identi fi cation

Electrical Enclosure

AAA Temperature Control Module (TCM)

AAB Motor Control Module (MCM)

AAC Enclosure Fan

AAD Wiring Terminal Blocks

AAE Power Supply

AAF Surge Protector

AAG Hose Breaker

AAH Motor Breaker

AAJ A Side Heat Breaker

AAK B Side Heat Breaker

AAL Transformer Breaker

MP Main Power Switch

22 333023A

Motor Control Module (MCM)

Base Model

Component Identi fi cation

Elite Model

7

8

9

5

6

3

4

MS

1

2

Figure 7

Description

Module Status LEDs see LED Status Table

CAN Communication Connections

Motor Temperature

Not used

Not used

Not used

A Pump Output Pressure

B Pump Output Pressure

A Fluid Inlet Sensor (Elite only)

B Fluid Inlet Sensor (Elite only)

10

11

12

14

15

16

RS

Table 3 MCM Module LED (MB) Status Descriptions

LED

MCM Status

Conditions

Green Solid

Yellow Solid

Red Steady Flashing

Red Random Flashing or Solid

Accessory output

Not used

Pump Cycle Counter

Graco Insite ™

Motor Power Output

Main Power Input

Rotary Switch

MCM Rotary Switch Positions

2=E-30

3=E-XP2

Description

Power applied to module

Active Communication

Software upload from token in progress

Module error exists

333023A 23

Component Identi fi cation

Temperature Control Module (TCM)

Cable Connections

Figure 8

6

7

4

5

1

2

3

8

9

10

Power Input

Heater Overtemperature

CAN Communications Connections

Power Out (ISO)

Power Out (Res)

Power Out (Hose)

Module Status LEDs

Heater A Temperature (ISO)

Heater B Temperature (RES)

Hose Temperature

24 333023A

Installation

Installation

Setup From Shipping Configuration

1. Remove bolts (A) and nuts.

2. Swing up the electrical enclosure and reinstall bolt (A) with nut. Tighten bolt (B) and nut.

3. Position cable bundles against the frame and attach to the frame with loose wire tie (C) on each side.

1. Use the supplied bolts to install the supplied

L-brackets onto the system frame in the top-most square holes. Install brackets on both the left and right side of system frame.

2. Secure the L-brackets to the wall. If L-brackets do not line up with the wall stud spacing, bolt a piece of wood to the studs then secure L-brackets to wood.

3. Use the four holes in the base of the system frame to secure base to the floor. Bolts not supplied.

To prevent serious injury due to system tipping over, ensure Reactor is properly secured to wall.

333023A 25

Setup

Setup

Grounding

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

Reactor:

System is grounded through the power cord.

Spray gun:

connect whip hose ground wire to FTS.

See

Install Fluid Temperature Sensor, page 28 .

Do not disconnect ground wire or spray without whip hose.

Fluid supply containers:

follow your local code.

Object being sprayed:

follow your local code.

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.

To maintain grounding continuity when flushing or relieving pressure,

hold a metal part of spray gun firmly to the side of a grounded trigger gun.

metal

pail, then

Close gun fluid manifold valves A and

B

26 333023A

Connect Power

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

1. Turn main power switch (MP) OFF.

2. Open electrical enclosure door.

NOTE: Terminal jumpers are located inside the electrical enclosure door.

Setup

3. Install supplied terminal jumpers in the positions shown in image for the power source used.

4. Route power cable through strain relief (EC) in electrical enclosure.

5. Connect incoming power wires as shown in image. Gently pull on all connections to verify they are properly secured.

6. Verify all items are connected properly as shown in image then close electrical enclosure door.

333023A 27

Setup

Supply Wet Cups With Throat Seal

Liquid (TSL)

• 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.

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.

To prevent the pump from moving, turn the main power switch OFF.

• 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.

Figure 10 Component B Pump

Install Fluid Temperature Sensor

The Fluid Temperature Sensor (FTS) is supplied.

Install FTS between main hose and whip hose. See

Heated Hose manual for instructions.

Register and Activate the Graco InSite

Note

Elite systems only.

1. Go to www.GracoInSite.com, then follow the instructions on the screen.

2. Find and record the 15 digit serial number from the cellular module below.

Figure 9 Component A Pump

28 333023A

Advanced Display Module (ADM) Operation

Advanced Display Module (ADM) Operation

When main power is turned on by turning the main power switch (MP) to the ON position, the power up screen will be displayed until communication and initialization is complete.

Then the power key icon screen will display until the

ADM power on/off button (A) first time after system power-up.

is pressed for the

To begin using the ADM, the machine must be active.

To verify the machine is active, verify that the System

Status Indicator Light (B) is illuminated green, see

Advanced Display Module (ADM), page 17 . If the

System Status Indicator Light is not green, press the ADM Power On/Off (A) button . The System

Status Indicator Light will illuminate yellow if the machine is disabled.

Perform the following tasks to fully setup your system.

1. Set pressure values for the Pressure Imbalance

Alarm to activate. See

System Screen 1, page 33 .

2. Enter, enable, or disable recipes. See

Recipes Screen, page 33

.

3. Set general system settings. See

Advanced Screen 1 — General, page 32

.

4. Set units of measure. See

Advanced Screen 2 — Units, page 32 .

5. Set USB settings. See

Advanced Screen 3— USB, page 32 .

6. Set target temperatures and pressure. See

Targets, page 35

.

7. Set component A and component B supply levels. See

Maintenance, page 36

.

333023A 29

Advanced Display Module (ADM) Operation

Setup Mode

The ADM will start in the Run screens at the Home screen. From the Run screens, press access the Setup screens. The system defaults with no password, entered as 0000. Enter the to current password then press . Press

Setup Screens Navigation Diagram, page 45 .

to navigate through the Setup Mode screens. See

Set Password

Set a password to allow Setup screen access, see

Advanced Screen 1 – General, page 32

. Enter any number from 0001 to 9999. To remove the password, enter the current password in the Advanced Screen – General screen and change the password to 0000.

From the Setup screens, press to return to the Run screens.

30 333023A

Advanced Display Module (ADM) Operation

Setup Screens Navigation Diagram

Figure 11

333023A 31

Advanced Display Module (ADM) Operation

Advanced Setup Screens

Advanced setup screens enable users to set units, adjust values, set formats, and view software information for each component. Press to scroll through the Advanced setup screens, Once in the desired

Advanced setup screen, press to access the fields and make changes. When changes are complete press to exit edit mode.

Note

Advanced Screen 3 — USB

Users must be out of edit mode to scroll through the Advanced setup screens.

Advanced Screen 1 — General

Use this screen to enable USB downloads/uploads, enable a logs 90% full advisory, enter the maximum number of days to download data, enable specifying date range of data to download, and how frequently

USB logs are recorded. See .

Use this screen to set the language, date format, current date, time, setup screens password (0000 – for none) or (0001 to 9999), and screen saver delay.

Advanced Screen 2 — Units

Use this screen to set the temperature units, pressure units, volume units, and cycle units (pump cycles or volume).

Advanced Screen 4— Software

This screen displays the software part number and software version for the Advanced Display Module,

USB Configuration, Motor Control Module, and

Temperature Control Modules.

32 333023A

System 1

Use this screen to set the activation pressure for the

Pressure Imbalance Alarm and Deviation, enable or disable diagnostic screens, set the maximum and minimum drum volume, and enable drum alarms.

Advanced Display Module (ADM) Operation

Recipes

Use this screen to add recipes, view saved recipes, and enable or disable saved recipes. Enabled recipes can be selected at the Home Run Screen. 24 recipes can displayed on the three recipe screens.

System 2

Use this screen to enable Manual Hose Mode and inlet sensors, as well as setting the inlet sensor low pressure alarm and low temperature deviation.

Manual Hose Mode disables the hose temperature

RTD sensor so the system can operate if the sensors were to malfunction. Default settings are 10 psi (0.07

MPa, 0.7 bar) for low inlet pressure alarm and 50˚F

(10˚C) for low inlet temperature deviation.

Add Recipe

1. Press and then use recipe field. Press to select a to enter a recipe name

(maximum 16 characters). Press old recipe name.

to clear the

333023A

2. Use to highlight the next field and use the number pad to enter a value. Press to save.

Enable or Disable Recipes

1. Press and then use to select the recipe that needs to be enabled or disabled.

2. Use

Press to highlight the enabled check box.

to enable or disable the recipe.

33

Advanced Display Module (ADM) Operation

Run Mode

The ADM will start in the Run screens at the “Home” screen. Press screens. See

Run Screens Navigation Diagram, page 44

.

From the Run screens, press to access the Setup screens.

to navigate through the Run Mode

34

Run Screens Navigation Diagram

Figure 12

333023A

Home — System Off

This is the home screen when the system is off.

This screen displays actual temperatures, actual pressures at the fluid manifold, jog speed, coolant temperature, and number of cycles.

Advanced Display Module (ADM) Operation

Home — System With Error

Active errors are shown in the status bar. The error code, alarm bell, and description of the error will scroll in the status bar.

1. Press to acknowledge the error.

2. See for corrective action.

Home — System Active

When the system is active, the home screen displays actual temperature for heat zones, actual pressures at the fluid manifold, coolant temperature, jog speed, the number of cycles, along with all associated control soft keys.

Use this screen to turn on heat zones, view coolant temperature, start the proportioner, stop the proportioner, park the component A pump, enter jog mode, and clear cycles.

NOTE: Screen shown displays inlet sensor temperatures and pressures. These will not be shown on models without inlet sensors.

Targets

Use this screen to define the setpoints for the

A Component Temperature, B Component

Temperature, heated hose temperature, and pressure.

Maximum A and B temperature: 190°F (88°C)

Maximum heated hose temperature: 10°F (5°C) above the highest A or B temperature setpoint or

180°F (82°C).

Note

If the remote display module kit is used, these setpoints can be modified at the gun.

333023A 35

Advanced Display Module (ADM) Operation

Maintenance

Use this screen to view daily and lifetime cycles or gallons that have been pumped and gallons or liters remaining in the drums.

The lifetime value is the number of pump cycles or gallons since the first time the ADM was turned on.

The daily value automatically resets at midnight.

The manual value is the counter that can be manually reset. Press and hold to reset manual counter.

Events

This screen shows the date, time, event code, and description of all events that have occurred on the system. There are 10 pages, each holding 10 events. The 100 most recent events are shown. See

System Events

for event code descriptions.

See

Error Codes and Troubleshooting, page 56

for error code descriptions.

All events and errors listed on this screen can be downloaded on a USB flash drive. To download logs, see

Download Procedure, page 57 .

Cycles

This screen shows daily cycles and gallons that have been sprayed for the day.

All information listed on this screen can be downloaded on a USB flash drive.

Errors

This screen shows the date, time, error code, and description of all errors that have occurred on the system.

All errors listed on this screen can be downloaded on a USB flash drive.

36 333023A

Troubleshooting

This screen displays the last ten errors that occurred on the system. Use the up and down arrows to select an error and press to view the QR code for the selected error. Press to access the QR code screen for an error code that is not listed on this screen. See

Error Codes and Troubleshooting, page 56 , for more

information on error codes.

Advanced Display Module (ADM) Operation

QR Codes

To quickly view online help for a given error code, scan the displayed QR code with your smartphone.

Alternately, visit http://help.graco.com and search for the error code to view online help for that code.

333023A 37

Advanced Display Module (ADM) Operation

Diagnostic

Use this screen to view information for all system components.

Job Data

Use this screen to enter a job name or number.

The following information is displayed:

Temperature

• A Chemical

• B Chemical

• Hose Chemical

• TCM PCB — temperature control module temperature

Amps

• A Current

• B Current

• Hose Current

Volts

• MCM Bus — displays the voltage supplied to the motor controller, which is the DC voltage that has been converted from the AC voltage supplied to the system

• Hose Voltage (90V)

Pressure

• Pressure A — chemical

• Pressure B — chemical

Cycles

• CPM — cycles per minute

• Total Cycles — lifetime cycles

Recipes

Use this screen to select an enabled recipe. Use the up and down arrows to highlight a recipe and press to load. The currently loaded recipe is outlined by a green box.

Note

This screen will not display if there are not any enabled recipes. To enable or disable recipes, see

Recipes Setup Screen, page 33

.

38 333023A

Advanced Display Module (ADM) Operation

System Events

Use the table below to find a description for all system non-error events. All events are logged in the USB log files.

Event Code Description

EQU1

EQU2

EQU3

EQU4

EQU5

ER0X

EVUX

ECDA

ECDB

ECDH

ECDP

ECDX

EL0X

EM0X

EP0X

EB0X

EBDA

EBDB

EBDH

EBPX

EBRX

EBUX

EC0X

EACX

EADA

EADB

EADH

EAPX

EARX

EAUX

Recipe Selected

Heat On A

Heat On B

Heat On Hose

Pump On

Jog On

USB Drive Inserted

ADM Red Stop Button Pressed

Heat Off A

Heat Off B

Heat Off Hose

Pump Off

Jog Off

USB Drive Removed

Setup Value Changed

A Temperature Setpoint Changed

B Temperature Setpoint Changed

Hose Temperature Setpoint Changed

Pressure Setpoint Changed

Recipe Changed

System Power On

System Power Off

Pump Parked

System Settings Downloaded

System Settings Uploaded

Custom Language Downloaded

Custom Language Uploaded

Logs Downloaded

User Counter Reset

USB Disabled

333023A 39

Startup

Startup

4. Confirm main power switch is OFF before starting generator.

To prevent serious injury, only operate Reactor with all covers and shrouds in place.

NOTICE

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.

1. Check fluid inlet filter screens.

Before daily startup, ensure that the fluid inlet screens are clean. See

Flush Inlet Strainer Screen, page 53

2. Check ISO lubrication reservoir.

Check level and condition of ISO lube daily. See

Pump Lubrication System, page 54

.

3. Check generator fuel level.

NOTICE

Running out of fuel will cause voltage fluctuations that can damage electrical equipment and void the warranty. Do not run out of fuel.

5. Ensure the main breaker on the generator is in the off position.

6. Start the generator. Allow it to reach full operating temperature.

7. Turn main power switch ON.

The ADM will display the following screen until communication and initialization is complete.

40 333023A

Startup

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

8. Switch on the air compressor, air dryer, and breathing air, if included.

9. For first startup of new system, load fluid with feed pumps.

a. Check that all Setup steps are complete.

See

Setup, page 26

.

b. If an agitator is used, open the agitator’s air inlet valve.

c. If you need to circulate fluid through the system to preheat the drum supply, see

Circulation Through Reactor, page 43 .

If you need to circulate material through the heat hose to the gun manifold, see

Circulation Through Gun Manifold, page 44 .

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

SA

GA GB

SB

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange component A and component B wetted parts.

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

• Always provide two grounded waste containers to keep component A and component B fluids separate.

f. 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.

The Fusion AP gun manifold is shown.

333023A 41

Startup

10. Press to activate ADM.

11. If necessary, setup the ADM in Setup Mode. See

Advanced Display Module (ADM) Operation, page 29 .

12. Preheat the system: a. Press to turn on hose heat zone.

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.

• Do not turn on hose heat without fluid in hoses.

• Allow equipment to cool completely before touching it.

• Wear gloves if fluid temperature exceeds

110°F (43°C).

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

b. If you need to circulate fluid through the system to preheat the drum supply, see

Circulation Through Reactor, page 43

.

If you need to circulate material through the heat hose to the gun manifold, see

Circulation Through Gun Manifold, page 44

.

c. Wait for the hose to reach set point temperature.

d. Press to turn on A and B heat zones.

42 333023A

Fluid Circulation

Fluid Circulation

Circulation Through Reactor

NOTICE

To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.

NOTE: Optimum heat transfer is achieved at lower fluid flow rates with temperature set points at desired drum temperature. Low temperature rise deviation errors may result.

To circulate through gun manifold and preheat hose, see

Circulation Through Gun Manifold, page 44 .

1. Follow

Startup, page 40 .

To avoid injection injury and splashing, do not install shutoffs downstream of the PRESSURE

RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpressure relief valves when set to SPRAY . Lines must be open so valves can automatically relieve pressure when machine is operating.

2. See

Typical Installation, with system fluid manifold to drum circulation, page 13

. 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 Specifications, page 63

.

3. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

GA GB

SA SB

.

4. Set temperature targets. See

Targets, page 35

.

5. Press to circulate fluid in jog mode until

A and B temperatures reach targets. See

Jog Mode, page 44

for more information about jog mode.

6. Press to turn on the hose heat zone.

7. Turn on the A and B heat zones. Wait until the fluid inlet valve temperature gauges (FV) reach the minimum chemical temperature from the supply drums.

8. Exit jog mode.

9. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY .

SA

GA GB

SB

333023A 43

Jog Mode

Circulation Through Gun Manifold

NOTICE

To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.

NOTE: Optimum heat transfer is achieved at lower fluid flow rates with temperature set points at desired drum temperature. Low temperature rise deviation errors may result.

Circulating fluid through the gun manifold allows rapid preheating of the hose.

1. Install gun fluid manifold (P) on accessory circulation kit (CK). Connect high pressure circulation lines (R) to circulation manifold.

pressure of this equipment. See

Technical Specifications, page 63 .

3. Follow procedures from

Startup, page 40 .

4. Turn main power switch on .

5. Set temperature targets. See

Targets, page 35

.

6. Press to circulate fluid in jog mode until

A and B temperatures reach targets. See

Jog Mode, page 44

for more information about jog mode.

Jog Mode

Jog mode has two purposes:

• It can speed fluid heating during circulation.

• It can ease system flushing and priming.

P

R

CK

The Fusion AP gun manifold is shown.

CK

246362

256566

Gun

Fusion AP

Fusion CS

Manual

309818

313058

2. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working

1. Turn main power switch on .

2. Press circulate

3. Press up or down

(J1 through J20).

to enter jog mode.

to change jog speed

Note

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.

4. Press to start motor.

5.

To stop the motor and exit jog mode press or .

44 333023A

Spraying

Spraying

The Fusion AP gun is shown.

1. Engage gun piston safety lock and close gun fluid inlet valves A and B.

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 balanced pressures.

GA GB

SA until gauges show

SB

Fusion Probler

2. Attach gun fluid manifold. Connect gun air line.

Open air line valve.

9. Open gun fluid inlet valves A and B.

3. Adjust the gun air regulator on the proportioner control panel to desired gun air pressure. Do not exceed 130 psi (0.2 MPa, 2 bar).

4. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY .

SA

GA GB

SB

Fusion Probler

NOTICE

To prevent material crossover on impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.

10. Disengage gun piston safety lock.

5. Verify heat zones are on and temperatures are on target, see

Home screen, page 35 .

6. Open fluid inlet valve located at each pump inlet.

Fusion Probler

11. Pull gun trigger to test spray onto cardboard. If necessary, adjust pressure and temperature to get desired results.

7. Press to start motor and pumps.

333023A 45

Spraying

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.

46 333023A

Manual Hose Heat Mode

If the system produces the T6DH sensor error hose alarm or the T6DT sensor error TCM alarm, use manual hose heat mode until the hose RTD cable or

FTS temperature sensor can be repaired.

Do not use Manual Hose Mode for extended periods of time. The system performs best when the hose has a valid RTD and can operate in temperature control mode. If a hose RTD breaks, the first priority is to fix the RTD. Manual Hose Mode can help finish a job while waiting for repair parts.

Spraying

3. Select Enable Manual Hose Mode.

Note

When manual hose mode is enabled, the manual hose mode advisory EVCH-V will appear.

Enable Manual Hose Mode

1. Disconnect the hose RTD sensor from the TCM.

2. Enter Setup Mode and navigate to System

Screen 2.

4. Enter Run Mode and navigate to the Target screen. Use the up and down arrows to set the desired hose current.

Hose Current Settings Hose Current

Default

Maximum

20A

37A

333023A 47

Spraying

5. Navigate back to the Run Mode Home screen.

The hose now displays a current instead of a temperature.

Disable Manual Hose Mode

1. Enter Setup Mode and navigate to System 2

Screen and deselect Enable Manual Hose Mode, or repair the hose RTD cable or FTS.

Note

Until the RTD sensor is repaired, the

T6DH sensor error alarm will display each time the system is powered up.

2. Manual hose mode is automatically disabled when the system detects a valid RTD sensor in the hose.

48 333023A

Shutdown

Shutdown

NOTICE

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.

1. Press to stop the pumps.

2. Turn off all heat zones.

3. Relieve pressure. See

Pressure Relief Procedure, page 50

.

7. Turn main power switch OFF.

To prevent electric shock do not remove any shrouds or open the electrical enclosure door.

8. Close all fluid supply valves.

4. Press to park the Component A Pump. The park operation is complete when green dot goes out. Verify the park operation is complete before moving to next step.

5. Press to deactivate the system.

6. Turn off the air compressor, air dryer, and breathing air.

9. Engage gun piston safety lock then close fluid inlet valves A and B.

Fusion Probler

333023A 49

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

4. Route fluid to waste containers or supply tanks.

Turn PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

GA GB

SA SB

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the

Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

The Fusion AP gun is shown.

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

2. Close gun fluid inlet valves A and B.

5. Engage gun piston safety lock.

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

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

50 333023A

Flushing

Flushing

To help prevent fire and explosion:

• 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 wetted parts are compatible with common solvents. Use only moisture-free solvents.

To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE

RELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION lines (N).

GA

SA

GB

. Flush through bleed

SB

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 filled with a moisture-free plasticizer or oil. Do not use water. Never leave the system dry. See

Important Two-

Component Material Information, page 7 .

333023A 51

Maintenance

Maintenance

Grease Circulation Valves

Grease circulation valves (SA and SB) with Fusion grease (117773) weekly.

SA SB

Prior to performing any maintenance procedures, follow

Pressure Relief Procedure, page 50 .

Preventative Maintenance Schedule

The operating conditions of your particular system determine how often maintenance is required.

Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

Proportioner Maintenance

Wet Cup

Check the wet cup daily. Keep it 2/3 full with Graco

Throat Seal Liquid (TSL ® ) or compatible solvent. Do not overtighten packing nut/wet cup.

Packing Nuts

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

Fluid Inlet Strainer Screens

Inspect fluid inlet strainer screens daily, see

Flush Inlet Strainer Screen, page 53

.

ti10955a

ISO Lubricant Level

Inspect ISO lubricant level and condition daily. Refill or replace as needed. See

Pump Lubrication System, page 54

.

Moisture

To prevent crystallization, do not expose component

A to moisture in air.

Gun Mix Chamber Ports

Clean gun mix chamber ports regularly. See gun manual.

Gun Check Valve Screens

Clean gun check valve screens regularly. See gun manual.

Dust Protection

Use clean, dry, oil-free compressed air to prevent dust buildup on control modules, fans, and motor

(under shield).

Vent Holes

Keep vent holes on bottom of electrical cabinet open.

52 333023A

Maintenance

Flush 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.

Isocyanate can crystallize from moisture contamination or from freezing. If the chemicals used are clean and proper storage, transfer, and operating procedures are followed, there should be minimal contamination of the A-side screen.

Note

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 base to catch drain off when removing the strainer plug (C).

3. Remove the screen (A) from the strainer manifold. Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. No more than 25% of the mesh should be restricted. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket

(B) and replace as required.

4. Ensure the pipe plug (D) is screwed into the strainer plug (C). Install the strainer plug with the screen (A) and gasket (B) 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.

Figure 13

333023A 53

Maintenance

Pump Lubrication System

Field Test Units: Contact Graco if a lot of ISO is found in the 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. Follow

Pressure Relief Procedure, page 50

.

2. Lift the lubricant reservoir (R) out of the bracket 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.

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.

Pump Lubrication System

Figure 14

54 333023A

Errors

View Errors

When an error occurs the error information screen displays the active error code and description.

The error code, alarm bell, and active errors will scroll in the status bar. For a list of the ten most recent errors see

Troubleshooting, page 56 . Error codes

are stored in the error log and displayed on the Error and Troubleshooting screens on the ADM.

Errors

Troubleshoot Errors

To troubleshoot the error:

1. Press the soft key next to “Help With This Error” for help with the active error.

There are three types of errors that can occur. Errors are indicated on the display as well as by the light tower (optional).

Alarms are indicated by . This condition indicates a parameter critical to the process has reached a level requiring the system to stop. The alarm needs to be addressed immediately.

Deviations are indicated by . This condition indicates a parameter critical to the process has reached a level requiring attention, but not sufficient enough to stop the system at this time.

Advisories are indicated by . This condition indicates a parameter that is not immediately critical to the process. The advisory needs attention to prevent more serious issues in the future.

To diagnose the active error, see

Troubleshoot Errors, page 55

.

Note

Press or to return to the previously displayed screen.

2. The QR code screen will be displayed. Scan the QR code with your smartphone to be sent directly to online troubleshooting for the active error code. Otherwise, manually navigate to http://help.graco.com and search for the active error.

333023A

3. If no internet connection is available, see

Error Codes and Troubleshooting, page 56

for causes and solutions for each error code.

55

Troubleshooting

Troubleshooting

See

Errors, page 55

for information about errors that can occur on the system.

Error Codes and Troubleshooting

See system repair manual or visit http://help.graco.com for causes and solutions to each error code.

See

Troubleshooting, page 37

for the ten most recent errors that have occurred on the system. See

Troubleshoot Errors, page 55

to diagnose errors on the ADM that have occurred on the system.

56 333023A

USB Data

USB Data

Download Procedure

Note

System configuration setting files and custom language files can be modified if the files are in the UPLOAD folder of the USB flash drive. See System Configuration Settings

File, Custom Language File, and Upload

Procedure sections.

1. Insert USB flash drive into USB port.

2. The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete.

3. Remove USB flash drive from USB port.

4. Insert USB flash drive into USB port of computer.

5. The USB flash drive window automatically opens.

If it does not, open USB flash drive from within

Windows® Explorer.

6. Open GRACO folder.

7. Instructions continue on next page.

8. Open the system folder. If downloading data from more than one system, there will be more than one folder. Each folder is labeled with the corresponding serial number of the ADM (The serial number is on the back of the ADM.)

9. Open DOWNLOAD folder.

10. Open DATAxxxx folder.

11. Open DATAxxxx folder labeled with the highest number. The highest number indicates the most recent data download.

12. Open log file. Log files open in Microsoft® Excel by default as long as the program is installed.

However, they can also be opened in any text editor or Microsoft® Word.

Note

All USB logs are saved in Unicode

(UTF-16) format. If opening the log file in Microsoft Word, select Unicode encoding.

USB Logs

Note

The ADM can read/write to FAT (File

Allocation Table) storage devices. NTFS, used by 32 GB or greater storage devices, is not supported.

During operation, the ADM stores system and performance related information to memory in the form of log files. The ADM maintains six log files:

• Event Log

• Job Log

• Daily Log

• System Software Log

• Blackbox Log

• Diagnostics Log

Follow

Download Procedure, page 57 , to retrieve

log files.

Each time a USB flash drive is inserted into the ADM

USB port, a new folder named DATAxxxx is created.

The number at the end of the folder name increases each time a USB flash drive is inserted and data is downloaded or uploaded.

Event Log

The event log file name is 1–EVENT.CSV and is stored in the DATAxxxx folder.

The event log maintains a record of the last 49,000 events and errors. Each event record contains:

• Date of event code

• Time of event code

• Event code

• Event type

• Action taken

• Event Description

Event codes include both error codes (alarms, deviations, and advisories) and record only events.

Actions Taken includes setting and clearing event conditions by the system, and acknowledging error conditions by the user.

333023A 57

USB Data

Job Log

The job log file name is 2–JOB.CSV and is stored in the DATAxxxx folder.

The job log maintains a record of data points based on the USB Log Frequency defined in the Setup screens. The ADM stores the last 237,000 data points for download. See

Setup - Advanced Screen 3 — USB, page 32

, for information on setting the Download Depth and USB

Log Frequency.

• Data point date

• Data point time

• A side temperature

• B side temperature

• Hose temperature

• A side temperature setpoint

• B side temperature setpoint

• Hose temperature setpoint

• A side inlet pressure

• B side inlet pressure

• Inlet pressure setpoint

• System lifetime pump cycle counts

• Pressure, volume, and temperature units

• Job name/number

Daily Log

The daily log file name is 3–DAILY.CSV and is stored in the DATAxxxx folder.

The daily log maintains a record of the total cycle and volume sprayed on any day that the system is powered up. The volume units will be the same units that were used in the Job Log.

The following data is stored in this file:

• Date that material was sprayed

• Time — unused column

• Total pump cycle count for day

• Total volume sprayed for day

System Software Log

The system software file name is 4–SYSTEM.CSV

and is stored in the DATAxxxx folder.

The system software log lists the following:

• Date log was created

• Time log was created

• Component name

• Software version loaded on the above component

Blackbox Log File

The black box file name is 5–BLACKB.CSV and is stored in the DATAxxxx folder.

The Blackbox log maintains a record of how the system runs and the features that are used. This log will help Graco troubleshoot system errors.

Diagnostics Log File

The diagnostics file name is 6–DIAGNO.CSV and is stored in the DATAxxxx folder.

The Diagnostics log maintains a record of how the system runs and the features that are used. This log will help Graco troubleshoot system errors.

System Configuration Settings

The system configuration settings file name is

SETTINGS.TXT and is stored in the DOWNLOAD folder.

A system configuration settings file automatically downloads each time a USB flash drive is inserted into the ADM. Use this file to back up system settings for future recovery or to easily replicate settings across multiple systems. Refer to the

Upload Procedure, page 59

for instructions on how to use this file.

58 333023A

USB Data

Custom Language File

The custom language file name is DISPTEXT.TXT

and is stored in the DOWNLOAD folder.

A custom language file automatically downloads each time a USB flash drive is inserted into the ADM.

If desired, use this file to create a user-defined set of custom language strings to be displayed within the

ADM.

The system is able to display the following Unicode characters. For characters outside of this set, the system will display the Unicode replacement character, which appears as a white question mark inside of a black diamond.

• U+0020 - U+007E (Basic Latin)

• U+00A1 - U+00FF (Latin-1 Supplement)

• U+0100 - U+017F (Latin Extended-A)

• U+0386 - U+03CE (Greek)

• U+0400 - U+045F (Cyrillic)

Create Custom Language Strings

The custom language file is a tab-delimited text file that contains two columns. The first column consists of a list of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was previously installed, this column contains the custom strings. Otherwise the second column is blank.

Modify the second column of the custom language file as needed and the follow

Upload Procedure, page 59

, to install the file.

The format of the custom language file is critical.

The following rules must be followed in order for the installation process to succeed.

• Define a custom string for each row in the second column.

Note

If the custom language file is used, you must define a custom string for each entry in the DISPTEXT.TXT file. Blank second-column fields will be displayed blank on the ADM.

• The file name must be DISPTEXT.TXT.

• The file format must be a tab-delimited text file using Unicode (UTF-16) character representation.

• The file must contain only two columns, with columns separated by a single tab character.

• Do not add or remove rows to the file.

• Do not change the order of the rows.

Upload Procedure

Use this procedure to install a system configuration file and/or a custom language file.

1. If necessary, follow the Download Procedure to automatically generate the proper folder structure on the USB flash drive.

2. Insert USB flash drive into USB port of computer.

3. The USB flash drive window automatically opens.

If it does not, open USB flash drive from within

Windows Explorer.

4. Open GRACO folder.

5. Open the system folder. If working with more than one system, there will be more than one folder within the GRACO folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial number is on the back of the module.)

6. If installing the system configuration settings file, place SETTINGS.TXT file into the UPLOAD folder.

7. If installing the custom language file, place

DISPTEXT.TXT file into the UPLOAD folder.

8. Remove USB flash drive from the computer.

9. Install USB flash drive into the ADM USB port.

10. The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete.

11. Remove USB flash drive from USB port.

Note

If the custom language file was installed, users can now select the new language from the Language drop-down menu in

Advanced Screen 1 — General, page 32

.

333023A 59

Performance Charts

Performance Charts

Use these charts to help identify the proportioner that will work most efficiently with each mix chamber. Flow rates are based on a material viscosity of 60 cps.

NOTICE

To prevent system damage, do not pressurize the system above the line for the gun tip size being used.

Proportioners For Foam

2000

(138)

AR4242

(01)

PRESSURE psi (bar)

1500

(103)

AR5252

(02)

AR6060

(03)

1000

(69)

AR7070

(04)

E-30

500

(34)

0 5

(2.3)

10

(4.5)

15

(6.8)

20

(9.1)

25

(11.3)

FLOW lbs/min (kg/min)

30

(13.6)

35

(15.9)

40

(18.1)

60 333023A

Performance Charts

Proportioners For Coatings

Table 4 Fusion Air Purge, Round Pattern

PRESSURE psi (bar)

3500

(241)

3000

(207)

2500

(172)

2000

(138)

1500

(103)

1000

(69)

500

(34) 0

AR2020

(000)

AR2929

(00)

AR4242

(01)

Table 5 Fusion Air Purge, Flat Pattern

0.5

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

E-XP2

1.5

(5.7)

PRESSURE psi (bar)

3500

(241, 24.1)

3000

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0

AF2020

(FTXX24 TIP)

AF2929

(FTXX38 TIP)

AF4242

(FTXX38 TIP)

AF5252

(FTXX48 TIP)

0.5

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

1.5

(5.7)

E-XP2

2.0

(7.6)

2.0

(7.6)

333023A 61

Performance Charts

Table 6 Fusion Mechanical Purge, Round Pattern

PRESSURE psi (bar)

3500

(241, 24.1)

3000

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0

XR2323

(RTM040)

E-XP2

XR2929

(RTM040)

MR3535

(RTM040)

XR3535

(RTM055)

XR4747

(RTM055)

MR4747

(RTM055)

0.5

(1.9)

1

(3.8)

FLOW gal./min (l/min)

Table 7 Fusion Mechanical Purge, Flat Pattern

1.5

(5.7)

2.0

(7.6)

PRESSURE psi (bar)

3500

(241, 24.1)

3000

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0

XF1313

(FTM424)

MF1818

(FTM424)

XF1818

(FTM424)

XF2323

(FTM424)

MF2929

(FTM424)

XF2929

(FTM424)

MF3535

(FTM638)

XF3535

(FTM638)

0.2

(0.7)

0.4

(1.5)

0.6

(2.3)

0.8

(3.0)

1

(3.8)

MF4747

(FTM638)

MF5757

(FTM638)

XF5757

(FTM638)

1.2

(4.5)

FLOW gal./min (l/min)

1.4

(5.3)

E-XP2

1.6

(6.0)

1.8

(6.8)

2.0

(7.6)

62 333023A

Technical Speci fi cations

Technical Specifications

Reactor 2 E-30 and E-XP2 Proportioning System

U.S.

Maximum Fluid Working Pressure

E-30

E-XP2

Maximum Fluid Temperature

E-30

E-XP2

Maximum Flow Rate

E-30

E-XP2

Maximum Heated Hose Length

Length

Output per Cycle

ISO and RES

E-30

E-XP2

Operating Ambient Temperature Range

Temperature

Heater Power

E-30 10 kw

E-30, 15 kw

E-XP2 15 kw

Sound Pressure

Sound Pressure measured per ISO-9614–2.

E-30

Measured from 3.1 ft (1 m), at

1000 psi (7 MPa, 70 bar), 3 gpm

(11.4 lpm)

E-XP2

Measured from 3.1 ft (1 m), at

3000 psi (21 MPa, 207 bar), 1 gpm

(3.8 lpm)

2000 psi

3500 psi

150°F

190°F

30 lb/min

2 gpm

310 ft

0.0272 gal.

0.0203 gal.

20° to 120°F

10,200 Watts

15,300 Watts

15,300 Watts

87.3 dBA

79.6 dBA

Metric

14 MPa, 140 bar

24.1 MPa, 241 bar

66°C

88°C

13.5 kg/min

7.6 lpm

94 m

0.1034 liter

0.0771 liter

-7° to 49°C

333023A 63

Technical Speci fi cations

Sound Power

E-30

Measured from 3.1 ft (1 m), at

1000 psi (7 MPa, 70 bar), 3 gpm

(11.4 lpm)

E-XP2

Measured from 3.1 ft (1 m), at

3000 psi (21 MPa, 207 bar), 1 gpm

(3.8 lpm)

Fluid Inlets

Component A ISO) and

Component B (RES)

Fluid Outlets

Component A (ISO)

Component B (RES)

Fluid Circulation Ports

Size

Maximum Pressure

Dimensions

Width

Height

Depth

Weight

E-30, 10 kw

E-30, 15 kw

E-30, 10 kw Elite

E-30, 15 kw Elite

E-XP2

E-XP Elite

Wetted Parts

Material

93.7 dBA

86.6 dBA

3/4 NPT(f) with 3/4 NPSM(f) union

#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter

#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter

250 psi

1/4 NPSM(m)

1.75 MPa, 17.5 bar

26.3 in.

63 in.

15 in.

315 lb

350 lb

320 lb

355 lb

345 lb

350 lb

668 mm

1600 mm

381 mm

143 kg

159 kg

145 kg

161 kg

156 kg

159 kg

Aluminum, stainless steel, zinc plated carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene

64 333023A

Graco Extended Warranty for Reactor

®

2

Components

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.

Graco Part Number

24U049

24N953

24R912

24N750

24E451

All other Reactor 2 parts

Description

Electric Motor

Motor Control Module

Motor Control Module

Heater Control Module

Advanced Display Module

Warranty Period

36 Months

36 Months

36 Months

36 Months

36 Months

12 Months 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 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.

free of charge any defective parts. The equipment will be returned to the original purchaser transportation made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

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 hereunder must be brought within the latter of two (2) years of the date of sale, or one (1) year the warranty period expires.

their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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 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

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 333023

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

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