Graco 3A1705A - Reactor Integrated Proportioning System Owner's Manual
Operation Reactor® Integrated Proportioning System 3A1705A EN Electric, Heated, Integrated Plural Component Proportioner With Integrated Generator. For spraying polyurethane foam and polyurea coatings. 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. Patents pending PROVEN QUALITY. LEADING TECHNOLOGY. Contents Warnings ........................................................... 3 Important Two-Component Material Information ........................................... 7 Proportioner Models ........................................... 9 Systems............................................................. 10 Accessories........................................................ 11 Supplied Manuals ............................................... 12 Related Manuals ................................................ 12 Typical Installation, with circulation ...................... 13 Typical Installation, without circulation.................. 14 Component Identification..................................... 15 Generator .................................................... 17 Proportioner Control Panel ........................... 18 Air Compressor............................................ 18 Advanced Display Module (ADM).................. 19 Motor Control Module (MCM)........................ 23 Engine Control Module ................................. 24 Temperature Control Modules....................... 25 Circuit Breakers ........................................... 27 Overview............................................................ 29 Setup................................................................. 32 Locate Reactor ............................................ 32 Trailer Setup Guidelines ............................... 34 Install Wall (optional) .................................... 35 Connect Battery ........................................... 37 Add Fuel ..................................................... 37 General Equipment Guidelines ..................... 37 Electrical Connections .................................. 37 Connect Feed Pumps................................... 38 Connect Pressure Relief Lines ...................... 38 Install Fluid Temperature Sensor .................. 38 Connect Heated Hose .................................. 39 Connect gun fluid manifold valves A and B ................................................... 39 Connect Whip Hose to Gun Fluid Manifold ......................................... 40 Pressure Check Hose .................................. 40 Connect Remote Display Module .................. 40 Grounding ................................................... 40 Supply Wet Cups With Throat Seal Liquid (TSL) ............................................. 41 Advanced Display Module (ADM) Operation.............................................. 42 2 Advanced Setup Screens ............................. 45 System........................................................ 46 Recipes....................................................... 46 Run Mode ................................................... 47 Startup............................................................... 54 Fluid Circulation.................................................. 57 Circulation Through Reactor ......................... 57 Circulation Through Gun Manifold ................. 58 Jog Mode ........................................................... 58 Spraying ............................................................ 59 Spray Adjustments ....................................... 60 Shutdown........................................................... 61 Pressure Relief Procedure .................................. 62 Flushing ............................................................. 63 Maintenance ...................................................... 64 Preventative Maintenance Schedule ............. 64 Proportioner Maintenance ............................ 64 Engine Maintenance .................................... 64 Flush Inlet Strainer Screen ........................... 65 Pump Lubrication System ............................. 66 Drain Coolant .............................................. 67 Refill Proportioner Coolant Loop ................... 68 Refill Engine Coolant Loop ........................... 69 Coolant Specifications .................................. 69 Errors ................................................................ 70 View Errors.................................................. 70 Troubleshoot Errors ..................................... 71 Troubleshooting.................................................. 72 Error Codes and Troubleshooting.................. 72 USB Data........................................................... 83 USB Logs .................................................... 83 System Configuration Settings ...................... 84 Custom Language File ................................. 85 Download Procedure.................................... 85 Upload Procedure ........................................ 86 Appendix A: Engine Control Module..................... 87 Dimensions ........................................................ 90 Performance Charts............................................ 93 Technical Specifications...................................... 94 Graco Standard Warranty.................................... 98 3A1705A 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 risks. When these symbols appear in the body of this manual 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. 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 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. CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide can cause death. • Do not operate in an enclosed area. 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, hearing loss, inhalation of toxic fumes, and burns. This 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. 3A1705A 3 Warnings SKIN INJECTION HAZARD WARNING High-pressure fluid from dispensing device, 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 dispensing. Do not point dispensing device at anyone or at any part of the body. Do not put your hand over the fluid outlet. Do not stop or deflect leaks with your hand, body, glove, or rag. Follow the Pressure Relief Procedure when you stop dispensing 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. • Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can ignite or explode if spilled on hot surface. • 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 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. 4 3A1705A Warnings WARNING PRESSURIZED ALUMINUM 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. • 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. 3A1705A 5 Warnings BATTERY HAZARD WARNING The battery may leak, explode, cause burns, or cause an explosion if mishandled. • Only use the battery type specified for use with the equipment. See Technical Data. • Battery maintenance must only be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from battery. • When replacing the battery, use the same lead-acid automotive battery, with 800 CCA minimum, specified for use with the equipment. See Technical Data. • Do not dispose of battery in fire. The battery is capable of exploding. • Follow local ordinances and/or regulations for disposal. • Do not open or mutilate the battery. Released electrolyte has been known to be harmful to the skin and eyes and to be toxic. • Remove watches, rings, or other metal objects. • Only use tools with insulated handles. Do not lay tools or metal parts on top of battery. 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. ENTAGLEMENT HAZARD Rotating parts can cause serious injury. • • • • Keep clear of moving parts. Do not operate equipment with protective guards or covers removed. Do not wear loose clothing, jewelry or long hair while operating equipment. Equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. 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. 6 3A1705A Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions 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. Keep Components A and B Separate Moisture Sensitivity of Isocyanates 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. 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 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 ISO pump oil or grease when reassembling. 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. 3A1705A 7 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 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. 8 3A1705A Proportioner Models Proportioner Models E-30i Series Part Available Auxiliary Current at 240V, 60 Hz* 259079 50 Amps 259080 32 Amps 259089 30 Amps 259090 12 Amps Voltage (phase) 230V (1) 230V (1) 230V (1) 230V (1) System Watts† Booster Max Heat Flow Watts Rate lb/min (kg/min) 7,700 0 30 (13.5) 11,700 4,000 30 (13.5) 7,700 0 30 (13.5) 11,700 4,000 30 (13.5) Approximate Output per Cycle (A+B) gal. (liter) Maximum Fluid Working Pressure psi (MPa, bar) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 2000 140) 2000 140) 2000 140) 2000 140) (14, (14, (14, (14, E-XP2i Series Part Available Auxiliary Current at 240V, 60 Hz* Voltage (phase) System Watts† Booster Heat Watts Max Flow Rate gpm (lpm) 259081 32 Amps 230V (1) 11,700 4,000 2.0 (7.6) 259091 12 Amps 230V (1) 11,700 4,000 2.0 (7.6) Approximate Output per Cycle (A+B) gal. (liter) 0.0203 (0.0771) 0.0203 (0.0771) Maximum Fluid Working Pressure psi (MPa, bar) 3500 (24.1, 241) 3500 (24.1, 241) * Full load amps available for auxiliary equipment when all bare-system components are operating at maximum capabilities. Refer to Circuit Breaker Configuration Options, page 28. Total system watts used by bare system, based on maximum hose length for each unit: E-30i and E-XP2i series, 310 ft (94.5 m) maximum heated hose length, including whip hose. Includes Air Compressor Kit 24K335. 3A1705A 9 Systems Systems Remote Display Module Kit Heated Hose Gun 50 ft (15 m) 10 ft (3 m) Model Part 24K240 246050 Fusion™ AP 246101 24K240 246050 Fusion™ AP 246101 24K241 246055 Fusion™ AP 246100 ✓ 24K394 246050 Fusion™ AP 246101 259080 ✓ 24K394 246050 Fusion™ AP 246101 259081 ✓ 24K395 246055 Fusion™ AP 246100 259079 24K240 246050 Fusion™ CS CS0101 CS9080 259080 24K240 246050 Fusion™ CS CS0101 CS9081 259081 24K241 246055 Fusion™ CS CS0000 CS9179 259079 ✓ 24K394 246050 Fusion™ CS CS0101 CS9180 259080 ✓ 24K394 246050 Fusion™ CS CS0101 CS9181 259081 ✓ 24K395 246055 Fusion™ CS CS0000 P29079 259079 24K240 246050 Probler® P2 GCP2R1 P29080 259080 24K240 246050 Probler® P2 GCP2R1 P29081 259081 24K241 246055 Probler® P2 GCP2R0 P29179 259079 ✓ 24K394 246050 Probler® P2 GCP2R1 P29180 259080 ✓ 24K394 246050 Probler® P2 GCP2R1 P29181 259081 ✓ 24K395 246055 Probler® P2 GCP2R0 Part Proportioner AP9079 259079 AP9080 259080 AP9081 259081 AP9179 259079 AP9180 AP9181 CS9079 10 3A1705A Accessories Integrated Reactor Systems with Air Compressor Remote Air Display Compressor Module Kit ✓ Heated Hose Gun 50 ft (15 m) 10 ft (3 m) Model Part 24K240 246050 Fusion™ AP 246101 ✓ 24K240 246050 Fusion™ AP 246101 259091 ✓ 24K241 246055 Fusion™ AP 246100 AP9189 259089 ✓ ✓ 24K394 246050 Fusion™ AP 246101 AP9190 259090 ✓ ✓ 24K394 246050 Fusion™ AP 246101 AP9191 259091 ✓ ✓ 24K395 246055 Fusion™ AP 246100 CS9089 259089 ✓ 24K240 246050 Fusion™ CS CS0101 CS9090 259091 ✓ 24K240 246050 Fusion™ CS CS0101 CS9091 259091 ✓ 24K241 246055 Fusion™ CS CS0000 CS9189 259089 ✓ ✓ 24K394 246050 Fusion™ CS CS0101 CS9190 259090 ✓ ✓ 24K394 246050 Fusion™ CS CS0101 CS9191 259091 ✓ ✓ 24K395 246055 Fusion™ CS CS0000 P29089 259089 ✓ 24K240 246050 Probler® P2 GCP2R1 P29090 259091 ✓ 24K240 246050 Probler® P2 GCP2R1 P29091 259091 ✓ 24K241 246055 Probler® P2 GCP2R0 P29189 259089 ✓ ✓ 24K394 246050 Probler® P2 GCP2R1 P29190 259090 ✓ ✓ 24K394 246050 Probler® P2 GCP2R1 P29191 259091 ✓ 24K395 246055 Probler® P2 GCP2R0 Part Proportioner AP9089 259089 AP9090 259091 AP9091 ✓ Accessories Kit Number Description Kit Number Description 125379 50 ft (15 m) CAN cable (for remote display module) 24K336 Hose Rack 24K207 Fluid Temperature Sensor (FTS) with RTD 15V551 ADM Protective Covers (10 pack) 15M483 24K338 Remote Display Module Kit Remote Display Module Protective Covers (10 pack) 24K335 Complete Air Compressor Kit 24K334 Feed Pump Shutdown Kit 125970 Air Compressor (without air supply tank) 24K333 Fuel Line and Battery Extension Cable Kit not pulled yet Air Compressor (mounted 30 gallon tank) 24K337 Light Tower Kit 24M174 Drum Level Sticks 24M125 Air Tank (12 gallons, 113.5 liters) 24L911 24M178 Air Dryer (desiccant) System Roller Plate Kit (rollers not included) 24M258 Compressor Rack (frame only) 121006 150 ft (45 m) cable (for remote display module) 3A1705A 11 Supplied Manuals Supplied Manuals The following manuals are shipped with the Reactor Proportioner. Refer to these manuals for detailed equipment information. Manuals are also available at www.graco.com. Manual Description 3A1705 Integrated Reactor, Operation 16K761 Integrated Reactor Startup Instructions Integrated Reactor Shutdown Instructions Perkins® Engine, Repair-Parts 16K913 SEBU7992 – Meccalte Self-Regulating Alternator Series NPE, Repair-Parts Related Manuals The following manuals are for accessories used with the Reactor Proportioner. Manuals are available at www.graco.com Component manuals in English: Manual Description 3A1706 Integrated Reactor, Repair-Parts Fusion AP Spray Gun, Instructions-Parts Fusion CS Spray Gun, Instructions-Parts Probler P2 Spray Gun, Instructions-Parts Compressor Rack, Instructions-Parts Hose Rack, Instructions-Parts Fuel Line and Battery Cable Extension Kit, Instructions-Parts Feed Pump Shut Down Kit, Instructions-Parts Light Tower Kit, Instructions-Parts Remote Display Module Kit, Instructions-Parts Heated Hose, Instructions-Parts Circulation and Return Tube Kit, Instructions-Parts Valve Repair Kit, Repair-Parts 309550 312666 313213 3A1902 3A1903 3A1904 3A1905 3A1906 3A1907 309572 309852 3A1932 12 3A1705A Typical Installation, with circulation Typical Installation, with circulation K M H G R J L R J M K A G D S E P F C* B Figure 1 * Shown exposed for clarity. Wrap with tape during operation. A Reactor Proportioner J Fluid Supply Lines B Heated Hose K Feed Pumps C Fluid Temperature Sensor (FTS) L Agitator D Heated Whip Hose M Desiccant Dryer E Fusion Spray Gun P Gun Fluid Manifold (part of gun) F Gun Air Supply Hose R Recirculation Lines G Feed Pump Air Supply Lines S Remote Display Module (optional) H Agitator Air Supply Line 3A1705A 13 Typical Installation, without circulation Typical Installation, without circulation K H G L J J M K A G F N D E N S P C* B Figure 2 * Shown exposed for clarity. Wrap with tape during operation. A Reactor Proportioner J Fluid Supply Lines B Heated Hose K Feed Pumps C Fluid Temperature Sensor (FTS) L Agitator D Heated Whip Hose M Desiccant Dryer E Fusion Spray Gun N Bleed Lines F Gun Air Supply Hose P Gun Fluid Manifold (part of gun) G Feed Pump Air Supply Lines S Remote Display Module Kit (optional) H Agitator Air Supply Line 14 3A1705A Component Identification Component Identification GA GB PC SB FB BB SA GG HB FA HC HA SC BA DG (FM) EM PA PB PT MP DB Front View Figure 3 HC Heated Hose Electrical Connectors MP Main Power Switch PA Component A Pump PB BA Component A Pressure Relief Outlet BB Component B Pressure Relief Outlet DG Drive Gear Housing DB Electrical Enclosure PC Component B Pump (behind Electrical Enclosure) Proportioner Control Panel, page 18 EM Electric Motor PT Pallet FA Component A Fluid Manifold Inlet SA FB Component B Fluid Manifold Inlet FM Reactor Fluid Manifold GA Component A Pressure Gauge SC Component A PRESSURE RELIEF/SPRAY Valve Component B PRESSURE RELIEF/SPRAY Valve Fluid Temperature Sensor (FTS) Cable GB Component B Pressure Gauge TA GG Generator, page 17 HA Component A Hose Connection HB Component B Hose Connection 3A1705A SB TB Component A Pressure Transducer (behind gauge GA) Component B Pressure Transducer (behind gauge GB) 15 Component Identification MM FF LM FF FH HM SG EC FV LR VC CP VB HE Back View Figure 4 CP Circulation Pump EC Electrical Cord Strain Relief FF Y-strainer (includes pressure gauge and temperature gauge) Booster Fluid Heater (not included with all models) Fluid Inlet Valve (A side shown) FH FV HE HM 16 Heat Exchangers (heat exchanger coolant loop) High Power Temperature Control Module (HPTCM) Cable Connections, page 25 VA LM HE LR Low Power Module (LPTCM) Cable Connections, page 25 (not included with all models) ISO Pump Lubricant Reservoir MM Motor Control Module (MCM), page 23 SG Sight Glass VA Component A Control Valve VB Component B Control Valve VC Bypass Control Valve 3A1705A Component Identification Generator HB RF EX ER RC HF HE EB TR ST GD OL FS FT WS EE EA AF FJ GL OD FD FP ED BE DF OF OS Figure 5 AF Air Filter BE Battery (not supplied) DF Diesel Fuel Filter EA 12V Charge Alternator EB Engine Coolant Expansion Bottle EE Engine ED Engine Oil Dipstick ER Radiator EX Exhaust FD Fuel Shutoff Solenoid FJ Fuel Injector FP Fuel Pump FS Diesel Fuel Fill Cap FT Diesel Fuel Tank 3A1705A GD Generator Power Distribution Box GL Glow Plugs HB Heat Exchanger Coolant Expansion Bottle HE Heat Exchanger HF Heat Exchanger Coolant Fill Bottle OD Oil Drain OF Oil Filter OL Oil Fill OS Oil Pressure Switch RC Engine Coolant Radiator Cap RF Radiator Fan ST Starter TR Coolant Temperature Sensor WS Over-Temperature Switch 17 Component Identification Proportioner Control Panel PN PE PP PR PD PD Advanced Display Module (ADM), page 19 PE Engine Control Module, page 24 PF Component A Feed Pump Air Outlet PG Component B Feed Pump Air Outlet PH Agitator Air Outlet PJ Gun Air Outlet PK Component A Feed Pump Air Regulator PH PL PJ PM Component B Feed Pump and Agitator Air Regulator Gun Air Regulator PN Component A Feed Pump Pressure Gauge PP PR Component B Feed Pump and Agitator Pressure Gauge Gun Pressure Gauge CA Air Compressor CB Power Box CC 12 Gallon Tank CD Air Outlet CE Desiccant Dryer Assembly CF Desiccant Dryer Air Outlet CG Power Cable CH Drain Valve CJ Air Tank Pressure Gauge PF PG PK PL PM Figure 6 Air Compressor Select models are supplied with an air compressor. To order as an accessory, see Accessories, page 11. Figure 7 18 3A1705A Component Identification Advanced Display Module (ADM) NOTICE To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails. B C A D D E F H G Component Identification — Front Figure 8 Call out A B C D Button Function Power On/Off System Status Indicator Light Stop Powers system on and off. Soft Keys 3A1705A Displays system status. Stops all system processes. Is not a safety or emergency stop. Selects the specific screen or operation shown on the display directly next to each key. Call out E Button Function Cancel F Enter G Lock/Setup H Navigation Cancels a selection or number entry in progress. Acknowledges a value change or makes a selection. Toggles between run and setup screens. If setup screens are password protected, button toggles between run and password entry screens. Navigates within a screen or to a new screen. 19 Component Identification CJ CS CK CL CM CR CP Component Identification — Back Figure 9 CN USB Module Status LEDs (CL) Conditions CJ Flat Panel Mount (VESA 100) CK Model and Serial Number Green Flashing - Data recording in progress CL USB Port and Status LEDs CM CAN Cable Connection Yellow Solid - Downloading information to USB CN Module Status LEDs CP Accessory Cable Connection CR Token Access Cover CS Battery Access Cover Green and Yellow Flashing - ADM is busy, USB cannot transfer information when in this mode Module Status LEDs (CN) Conditions Green Solid - Power applied to module System Status Indicator (B) Conditions Green Solid — Run Mode, System On Green Flashing - Setup Mode, System On Yellow Solid - Active Communication Red Steady Flashing - Software upload from token in progress Red Random Flashing or Solid - Module error exists Yellow Solid - Run Mode, System Off Yellow Flashing - Setup Mode, System Off 20 3A1705A Component Identification ADM Display Details Alarm/Deviation Power Up Screen The current system error is displayed in the middle of the menu bar. There are four possibilities: 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. Icon No Icon Function 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 Menu Bar The menu bar appears at the top of each screen. (The following image is only an example.) 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. 3A1705A 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. Jump In/Jump Out In screens that have editable fields, press to access the fields and make changes. When changes are complete press again to exit edit mode. Navigation within Screens Press to open drop-down menus on Setup screens. Press to enter changes or make a selection. Press to navigate to new screens and to navigate left and right within a screen. Press select digits to change within a field. Press to to navigate to new screens and to navigate up and down within a screen. Also press to move between fields within a drop-down menu, and to increment or decrement numbers within a field. 21 Component Identification Integrated Reactor Icons Icons Icon Softkeys Function Component A Component B Icon Function Start Proportioner Start and Stop Proportioner in Jog Mode Stop Proportioner Estimated Supply Material Turn on specified heat zone. Hose Temperature Park component A pump Jog Mode Speed Enter Jog Mode. See Jog Mode, page 58 Engine Coolant Temperature Reset Cycle Counter (press and hold) Pressure Select Recipe Cycle Counter (press and hold) Search Advisory. See Errors, page 50 for more information. Move Cursor Left One Character Move Cursor Right One Character Deviation. See Errors, page 50 for more information Toggle between upper-case, lower-case, and numbers and special characters. Alarm. See Errors, page 50 for more information Cancel Backspace Clear Troubleshoot Selected Error Increase value Decrease value Next screen Previous screen Return to first screen 22 3A1705A Component Identification Motor Control Module (MCM) MB MA 6 7 3 9 2 1B 10 11 1A MC 12 8 13 5 Motor Control Module Figure 10 MA Token and Rotary Switch Access Cover MB Module Status LEDs see Module Status LEDs (CN) Conditions, page 20 Warning Label MC 1A, 1B 2 CAN Communication Connections 7 8 Optional Accessory Connection: Feed Pump Shut Down Kit Pressure Transducer B (Blue) side 9 Pressure Transducer A (Red) side 10 11 Motor Brush Wear and Over-Temperature Sensor Connection Not used 12 MCM Power Input Connection 13 Motor Power Connection MCM Rotary Switch Positions 5 Heat Exchanger Control Vave Output (to load center) Two-way Splitter to A and B Heat Exchanger Temperature Sensors Engine Coolant Temperature Sensor 6 Pump Cycle Switch 1=EXP2i 3 3A1705A 0=E30i 23 Component Identification Engine Control Module NOTICE To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails. Icon Description Function On Start Engine Auto Auto mode (not used) Off Stop all system processes. Is not a safety or emergency stop. Scroll Scroll through the instruments or recorded events on the currently displayed page Page Select Toggle between the instrumentation page and the error log page Error Lamp Indicates error is present on generator For more information about the engine control module, see Appendix A: Engine Control Module, page 87. Figure 11 Engine Control Module 24 3A1705A Component Identification Temperature Control Modules Located inside the Electrical Enclosure (DB). High Power Temperature Control Module (HPTCM) Cable Connections Low Power Module (LPTCM) Cable Connections Only used with E-XP2i and E-30i models with booster heat. 1 2 2 1 3 3 Figure 12 7 Figure 14 8 7 5 5 8 4 9 6 Figure 13 1 Not used 2 3 Fluid Temperature Sensor (FTS) Connection Output Power Connection 4 Contactor Control Connection 5 4 6 Figure 15 1 Over-Temperature Switch Connection 2 3 Booster Heat Temperature Sensor Connection Output Power Connection Input Power Connection 4 Not used 6 CAN Communications Connections 5 Input Power Connection 7 Rotary Selector Switch, Token Access 6 CAN Communications Connections 8 Module Status LEDs (see Advanced Display Module (ADM), page 19, (CN) for conditions 7 Rotary Selector Switch, Token Access 8 Module Status LEDs (see Advanced Display Module (ADM), page 19, (CN) for conditions Base 9 3A1705A 25 Component Identification Adjust Rotary Switch The rotary switch setting indicates which zone the temperature control module will control in the system. The HPTCM uses an 8-position rotary switch. The LPTCM uses a 16-position rotary switch. Set the rotary switch (S) to the specific selection according to the settings listed in the following tables. HPTCM A and B Rotary Switch Settings Setting Zone 0 Heated Hose 1 Not Used 2 Not Used 3 Not Used 4 Not Used 5 Not Used 6 Not Used 7 Not Used S LPTCM A and B Rotary Switch Settings HPTCM Rotary Switch Location Figure 16 S LPTCM Rotary Switch Location Figure 17 26 Setting Zone 0 Not Used 1 Not Used 2 Not Used 3 Not Used 4 Not Used 5 Not Used 6 Not Used 7 Not Used 8 Not Used 9 Not Used A Booster Heat A B Booster Heat B C Not Used D Not Used E Not Used F Not Used 3A1705A Component Identification Circuit Breakers Ref. Size Component CB01 30 A High Power Temperature Control Module (HPTCM) CB02 20 A Motor Control Module (MCM) CB03 5A Two Motor Fans, Cabinet Fan, Power Supply, and Coolant Circulation Pump CB04* 30 A Auxiliary Power (Air Compressor) CB05* 10 A Auxiliary Power CB06* 20 A Auxiliary Power 15 A EXP2i and E30i With Heat: Low Power Temperature Control Module (LPTCM) A CB08 CB07 CB06 CB05 CB04 CB03 CT01 CB02 CB07 CB01 E30i: Auxiliary Circuit Breakers Inside Electrical Enclosure (DB) Figure 18 Note CB08 15 A EXP2i and E30i With Heat: Low Power Temperature Control Module (LPTCM) B E30i: Auxiliary * See Circuit Breaker Configuration Options, page 28. Not all wires are shown. CB20 Circuit Breakers Inside Proportioner Cabinet Figure 19 3A1705A Ref. Size Component CB20 50 A Heated Hose 27 Component Identification It is suggested that circuit breakers CB04 be substituted to accommodate larger loads or a sub-panel. The total auxiliary equipment loads added to the configuration must be limited to the system’s available auxiliary current. See Proportioner Models, page 9 , for available auxiliary current at 240V, 60Hz. See the Reactor repair manual for optional circuit breakers and their current ratings. Circuit breakers used must meet UL489 specifications. CB10 Circuit Breakers Inside Alternator Assembly Figure 20 Ref. Size Component CB10 90 A 120/240V Alternator Circuit Breaker Configuration Options The Electrical Enclosure (DB) circuit breaker configuration described in the tables on the previous page is the recommended configuration. Some customer changes are acceptable to accommodate larger loads from auxiliary equipment or a sub-panel. The generator supplies power in a 3-wire, single-phase, mid-point neutral wiring configuration. For 240VAC loads, wire the load across the output terminals of the circuit breaker. For 120VAC loads, wire the load between the neutral terminal blocks next to the three pole main power switch (CT01) to one pole of the circuit breaker. To replace a circuit breaker, use the following steps: 1. Follow Shutdown instructions. See Shutdown, page 61. 2. Refer to circuit breaker identification table and electrical diagrams in Reactor repair manual. 3. Loosen four screws connecting wires and bus bar to circuit breaker that will be replaced. Disconnect wires. 4. Pull locking tab out 1/4 in. (6mm) and pull circuit breaker away from the din rail. Install new circuit breaker. Insert wires and tighten down all screws. Improper configuration can result in serious injury or death. All changes from the recommended circuit breaker configuration must meet all National, State, and Local safety and electrical codes. Consult a qualified electrician before attempting any changes. See page 27 and 28 for correct circuit breaker configuration. 28 3A1705A Overview Overview The Integrated Reactor proportioner uses two coolant loops to use heat released from the engine to heat the A and B component material to the target temperatures defined on the ADM (PD). exchanger (HE), radiator (ER), and back to the engine. Coolant in the proportioner coolant loop (black) captures heat from the engine coolant loop inside the heat exchanger (HE) near the radiator. The engine coolant loop (gray) circulates heated coolant from the engine (EE), through the heat Engine Coolant Loop and Proportioner Coolant Loop Figure 21 3A1705A 29 Overview The proportioner coolant loop circulates coolant through secondary heat exchangers (HE) located on the back of the proportioner to heat the A and B component material before the material is pressurized in the proportioner pumps (PA, PB). After the A and B material has been heated in the heat exchangers, the material enters the fluid manifold (FM) and heated hose. For models with a booster heater, the A and B material enters the booster heater after the material is pressurized in the proportioning pumps to heat the material higher than 140°F (60°C). PA FM PB HE A and B Component Material Flow Figure 22 30 3A1705A Overview Coolant only flows through the secondary heat exchangers when the heat exchanger control valves (VA, VB) are open and the A and B component temperatures are below the target temperatures set on the ADM. See Fig. 24. When the control valves (VA, VB) close, the A and B material has reached target temperature. Coolant flows through the bypass control valve (VC), circulation pump (CP), sight glass (SG), proportioner coolant fill bottle (HF), and back to the heat exchanger in the engine coolant loop. See Fig. 23 CP CP SG VC SG HE VB HE VA Proportioner Coolant Loop — A and B Valves Open (heating material) Figure 24 VC HE VB HE VA Proportioner Coolant Loop — A and B Valves Closed (not heating material) Figure 23 3A1705A 31 Setup Setup c. 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. Locate Reactor If system was not ordered with the air compressor, go to step 2. 1. For systems with an air compressor, install the air tank bracket assembly and connect air lines. For systems without an air compressor, order air compressor kit 24K335. See manual 3A1902 for complete installation instructions. NOTICE Only use air compressors with a continuous run head unloader. Repeated compressor motor startups will cause errors and shutdown the Integrated Reactor system. See Technical Specifications, page 94 for recommended air compressors and requirements. Other models may be used, but must not stop and start during operation. a. Use at least two people to install the air tank assembly (AT). Secure to frame with supplied screws (AS) and nuts (AN). See illustration on next page. b. 32 Connect air line (A1) between compressor and air tank inlet. Connect air line (A2) between proportioner air inlet to air dryer outlet. d. Connect pilot air lines (A3, A4) between the air compressor and air tank. e. Secure water drain line (A5) to the frame and drain outlet. 2. Install hose rack, if ordered. See manual 3A1903 for detailed instructions. 3. Locate Reactor on a level surface that is nonporous and diesel resistant, such as diamond plate. See Dimensions, page 90, for clearance and mounting hole dimensions. 4. Do not expose Reactor to rain. 5. If a wall will be installed between the proportioner and generator, remove the fuel tank and battery bracket. See Trailer Setup Guidelines, page 34 for instructions. 6. To mount in a trailer, use forklift to move Reactor by inserting the forks through the Reactor pallet frame. It is recommended to lift from the engine side. Bolt pallet directly to trailer frame. Note Use Roller Plate Kit 24L911 (rollers not included) to relocate pallet to mounting location when forks are unavailable. See kit manual for instructions. NOTICE Keep the vent holes in the bottom of the proportioner cabinet open. Make sure there is unobstructed incoming air for the cooling fan at the top of the proportioner cabinet that blows air up into the electric motor. Failure to provide unobstructed incoming air can cause the motor to overheat. 3A1705A Setup A4 A2 A3 A3 A1 AT AN AS A2 A4 A5 ti18312a 3A1705A 33 Setup Trailer Setup Guidelines Exhaust pipes that pass through flammable ceilings must be guarded by vented metal thimbles that extend at least 9 in. (228.6 mm) below and above the roof and are at least 6 in. (152.4 mm) in diameter larger than the exhaust pipe. Exhaust pipes that pass through flammable walls must be guarded by either: 5. Remove red exhaust cap. 6. Provide a minimum 2 in. (50.8 mm) diameter engine exhaust outlet with flexible pipe element. Provide rain cap, or equivalent routing, to prevent moisture from entering the metal exhaust pipe. Route exhaust system away from combustible materials to prevent materials from igniting or gas recirculation into enclosure. Note Ensure exhaust is not vented into a wall, ceiling, or a concealed space. • Metal ventilated thimble at least 12 in. (305 mm) larger than the diameter of the exhaust pipe. • Metal or other approved fireproofing materials that provides at least 8 in. (203 mm) of insulation between the exhaust pipe and flammable material. Provide exhaust system guards to prevent burns. Exhaust pipes not covered above must have at least 9 in. (228.6 mm) of clearance from the outside of the exhaust pipe to adjacent flammable materials. NOTICE Provide recommended size louvers. Failure to do so can damage the engine and void the engine warranty. 1. Provide sufficient lighting to safely operate and maintain system equipment. 2. Provide radiator exhaust for Reactor. Use a 400 in.2 (258,064 mm2) minimum louver. 3. Provide air duct to connect radiator exhaust to louver. 4. Provide a 400 in.2 ( 258,064 mm2) minimum fresh air intake louver near the generator. 34 Radiator Exhaust and Air Intake Louvers Figure 25 3A1705A Setup Install Wall (optional) Install a wall between the proportioner and generator to: • Temperature condition the trailer space where chemical is stored. Check with chemical manufacturer for chemical storage temperatures. • Reduce noise for the operator while the Reactor is running. The supplied fuel lines and battery cable may need to be replaced if a wall is installed between the proportioner and generator. Purchase the Fuel Line and Battery Cable Extension Kit 24K333. 1. If necessary drain coolant from system. See Drain Coolant, page 67. Coolant lines do not need to be disconnected to install a wall. Note Battery must be connected to starter to drain coolant from system. 2. Remove bolts and battery bracket from the pallet. 3. Remove fuel tank from the pallet. a. Remove the mounting bolts, washers, and standoffs. b. Disconnect inlet and outlet fuel lines from the fuel tank. c. Use two people to lift fuel tank off of the pallet and place where the fuel fill spout is easily accessible. Note Do not mount fuel tank in front of the generator air intake or where it will limit opening and access to the electrical enclosure (DB). 4. Install wall (IW) where the fuel tank was located. Ensure there is at least 1.25 in. (31.75 mm) between the wall, exhaust muffler, and MCM. See Fig. 27, page 36. Note To prevent an air pocket from forming inside the coolant lines between the proportioner and generator, ensure there is a constant rise in elevation if the coolant lines are adjusted. Failure to have a constant rise in elevation will reduce heating efficiency. 5. Reconnect inlet and outlet fuel lines. 6. Install standoffs, washers, and bolts through the fuel tank bracket and tighten to the floor. 7. Place battery bracket over fuel tank or near the Reactor. Remove existing battery cables from engine and replace with the cables provided from the fuel line and extension kit. 8. Install mounting bolts through battery bracket and tighten to the floor. Torque to 25 ft-lbs (34 N•m). Note Remove Battery Bracket and Fuel Tank Figure 26 3A1705A Pads under the battery bracket help stabilize the fuel tank during operation. 35 Setup 15 in. (381 mm) IW 1 ft min (0.3m) 1.25 in. (31.75 mm) 1.25 in. (31.75 mm) 6 in. min (406.4 mm) Wall (IW) Installation Guidelines Figure 27 36 3A1705A Setup Connect Battery Replace cap. See Perkins engine manual for approved diesel fuels. 2. Squeeze prime bulb (P) to prime engine. Press the prime bulb repeatedly until fuel begins to return to the fuel tank. Battery maintenance must only be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. See Technical Specifications, page 94 for battery requirements and recommended battery size. FS 1. Secure battery (not supplied) to bracket with strap. PC P Figure 28 2. Connect battery cable from the engine starter (ST) and chassis to the battery. Connect the black cable to battery negative (-) and the red cable to battery positive (+). Figure 30 General Equipment Guidelines 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. Electrical Connections Figure 29 3. Cover battery terminals with plastic caps (PC) attached to supplied battery cables. Add Fuel 1. Remove fuel cap (FS) and fill fuel tank with no more than 20 gallons (75 liters) of diesel fuel. 3A1705A Connect air compressor, breathing air, and auxiliary power electrical connections to the specified circuit breakers. See Circuit Breakers, page 27. 1. Remove one or more knock-outs on side of electrical enclosure, as required, and route wires through for air compressor, breathing air, and auxiliary equipment. See Circuit Breaker Configuration Options, page 28, for more information. 37 Setup Connect Feed Pumps 1. Install feed pumps (K) in component A and B supply drums. See Typical Installation, with circulation, page 13 and Typical Installation, without circulation, page 14. 2. Seal component A drum and use desiccant dryer (M) in vent. 3. Install agitator (L) in component B drum, if necessary. 4. Connect supply hoses from feed pumps to the component A and component B material inlets on the system. Ensure A and B inlet valves are closed. Connect Pressure Relief Lines Do not operate Reactor without all covers and shrouds in place. 1. Recommended: Connect high pressure hose (R) to relief fittings (BA, BB) of both PRESSURE RELIEF/SPRAY valves. Route hose back to component A and B drums. See Typical Installation, with circulation, page 13. 2. Alternately: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See Typical Installation, without circulation, page 14. Install Fluid Temperature Sensor Note The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual for instructions. Supply hoses from feed pumps should be 3/4 in. (199 mm) ID. 5. Connect air lines to proportioner. Ensure components are properly connected to correct location. See Proportioner Control Panel, page 18. Note Agitator air supply includes a small restriction orifice to limit the air flow to minimize air compressor load. Do not use the agitator air outlet (PH) for any other component. 38 3A1705A Setup Connect Heated Hose FM Note HA See Heated Hose manual for detailed instructions on connecting heated hoses. A HB Note The FTS (C) and whip hose (D) must be used with heated hose. Hose length, including whip hose, must be 60 ft (18.3 m) minimum. B C V NOTICE Apply grease on all system and hose fluid fittings. This lubricates the threads and prevents material from hardening on the threads. Figure 31 1. Turn main power OFF . 2. Assemble heated hose sections, FTS, and whip hose. 3. 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. Note 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. 3A1705A 4. Connect cables (C). Connect electrical connectors (V). Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape. 5. Connect quick-disconnect pin fitting to 4 ft air hose, shipped loose. Connect other hose end to the gun air hose in the heated hose bundle. Push pin fitting into the lowest air panel outlet (PJ). Connect gun fluid manifold valves A and B 39 Setup Connect Whip Hose to Gun Fluid Manifold Pressure Check Hose See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage. Connect Remote Display Module See Remote Display Module kit manual for installation instructions. Grounding Do not operate Reactor without all covers, doors, and shrouds in place. The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current. • Reactor System: System must be grounded with an appropriately sized conductor to the trailer or vehicle chassis or, if stationary, to true earth ground. Remove bolt and braided cable from pallet. Install grounding cable terminated with a ring terminal (cable and terminal not supplied) under braided cable. Reinstall bolt and torque to minimum 25 ft-lbs (34 N∙m). Follow all National, State, and Local safety and fire codes. 40 • Spray gun: connect whip hose ground wire to FTS. See Install Fluid Temperature Sensor, page 38. 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 metal pail, then trigger gun. 3A1705A 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 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. S Component B Pump Figure 33 R Component A Pump Figure 32 3A1705A 41 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 splash screen will be displayed until communication and initialization is complete. Perform the following tasks to fully setup your system. 1. Select pressure for the Pressure Imbalance Alarm to activate. See System Screen, page 46. 2. Enter, enable, or disable recipes. See Recipes Screen, page 46. Then the power key icon screen will display until the is pressed for the ADM power on/off button (A) first time after system power-up. 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 19. 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. 3. Set general system settings. See Advanced Screen 1 — General, page 45. 4. Set units of measure. See Advanced Screen 2 — Units, page 45. 5. Set USB settings. See Advanced Screen 4 — USB, page 45. 6. Set target temperatures and pressure. See Targets, page 49. 7. Set component A and component B supply levels. See Maintenance, page 50. 8. Ensure engine is at operating temperature on the home screen. 42 3A1705A Advanced Display Module (ADM) Operation Setup Mode The ADM will start in the Run screens at the Home screen. From the Run screens, press to access the Setup screens. If the Setup screens password is turned on, use the ADM keypad to enter . Press to navigate through the Setup Mode screens. See the password then press Setup Screens Navigation Diagram, page 41. From the Setup screens, press 3A1705A to return to the Run screens. 43 Advanced Display Module (ADM) Operation Setup Screens Navigation Diagram Figure 34 44 3A1705A 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 Advanced setup screen, press to scroll through the Advanced setup screens, Once in the desired to access the fields and make changes. When changes are complete press to exit edit mode. Note Users must be out of edit mode to scroll through the Advanced setup screens. Advanced Screen 1 — General Advanced Screen 3 — USB Use this screen to disable USB downloads/uploads, disable USB log errors, enter the maximum number of days to download data, and how frequently USB logs are recorded. See USB Data, page 83. Use this screen to set the language, date format, current date, time, setup screens password (0000 to 9999), screen saver delay, and enable or disable silent mode. Advanced Screen 4— Software Advanced Screen 2 — Units Use this screen to set the temperature units, pressure units, volume units, and cycle units (pump cycles or volume). 3A1705A This screen displays the software part number and software version for the Advanced Display Module, Motor Control Module, High Power Temperature Control Module, Low Power Temperature Control Modules, and USB Configuration. 45 Advanced Display Module (ADM) Operation System Add Recipe Use this screen to set the activation pressure for the Pressure Imbalance Alarm and Advisory, enable or disable diagnostic screens, enable drum alarms, set the maximum drum volume, enable drum alarms, and set low material alarm level. 1. Press 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. recipe field. Press to select a to enter a recipe name (maximum 16 characters). Press old recipe name. 2. Use to clear the to highlight the next field and use the number pad to enter a value. Press to save. Enable or Disable Recipes and then use to select the 1. Press recipe that needs to be enabled or disabled. 2. Use Press 46 and then use to highlight the enabled check box. to enable or disable the recipe. 3A1705A 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. to navigate through the Run Mode From the Run screens, press to access the Setup screens. 3A1705A 47 Advanced Display Module (ADM) Operation Run Screens Navigation Diagram Figure 35 48 3A1705A Advanced Display Module (ADM) Operation Home — System Off Home — System With Error 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. 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 Troubleshooting, page 72 for corrective action. Targets Use this screen to define the setpoints for the A Component Temperature, B Component Temperature, heated hose temperature, and pressure. 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. 3A1705A Maximum A and B temperature for systems without booster heat: 140°F (60°C) Maximum A and B temperature for systems with booster heat: 180°F (82°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 modi• ed at the gun. 49 Advanced Display Module (ADM) Operation Maintenance Events Use this screen to view daily and lifetime cycles or gallons that have been pumped and gallons or liters remaining in the drums. 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 72 for error code descriptions. 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. All events and errors listed on this screen can be downloaded on a USB flash drive. To download logs, see Download Procedure, page 85. 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. 50 3A1705A Advanced Display Module (ADM) Operation Diagnostic Use this screen to view information for all system components. • Booster B Chemical • Booster A PCB — temperature control module temperature • Booster B PCB — temperature control module temperature • Hose PCB — temperature control module temperature • Coolant Outlet Amps • Booster A Current • Booster B Current • Hose Current Volts • MCM Bus • Incoming Hose Voltage (240V) The following information is displayed: Temperature • Hx A Chem: Heat Exchanger A Chemical • Hx B Chem: Heat Exchanger B Chemical • Hose Chemical • Booster A Chemical 3A1705A Pressure • Pressure A — chemical • Pressure B — chemical Cycles • CPM — cycles per minute • Total Cycles 51 Advanced Display Module (ADM) Operation Troubleshooting Recipes This screen displays the last ten errors that occurred on the system. Use the up and down Use this screen to select an enabled recipe. Use the up and down arrows to highlight a recipe and press arrows to select an errors and press to view troubleshooting information for the selected error. to load. The currently loaded recipe is outlined by a green box. Press to access troubleshooting screen for an error code that is not listed on this screen. See Error Codes and Troubleshooting, page 72, for more information on error codes. 52 Note This screen will not display if there are not any enabled recipes. To enable or disable recipes, see Recipes Setup Screen, page 46. 3A1705A Advanced Display Module (ADM) Operation System Events Use the table below to find a description for all system events. All events are logged in the USB log files. Description Event Code E A C X Recipe Selected E A D A Heat On A E A D B Heat On B E A D H E A P X Heat On Hose Pump On E A R X Jog On E A U X E B 0 X USB Drive Inserted ADM Red Stop Button Pressed E B D A Heat Off A E B D B Heat Off B E B D H E B P X Heat Off Hose Pump Off E B R X Jog Off E B U X E C 0 X USB Drive Removed Setup Value Changed E C D A A Temperature Setpoint Changed E C D B B Temperature Setpoint Changed E C D H Hose Temperature Setpoint Changed E C D P Pressure Setpoint Changed E C D X Recipe Changed E L 0 X System Power On E M 0 X System Power Off E P 0 X Pump Parked E Q U 1 System Settings Downloaded E Q U 2 System Settings Uploaded E Q U 3 Custom Language Downloaded E Q U 4 Custom Language Uploaded E Q U 5 Logs Downloaded E R 0 X User Counter Reset E V U X USB Disabled 3A1705A 53 Startup Startup 5. Confirm main power is off before starting generator. Do not operate Reactor without 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 generator fuel level. Running out of fuel will cause voltage fluctuations that can damage electrical equipment. 2. Check coolant levels. Inspect the level of coolant inside the engine coolant expansion bottle (EB) and heat exchanger coolant expansion bottle (HB). HO T CO LD T HO LD CO 6. Start the generator. twice on the engine Press start button control module. The controller will automatically sequence glow plug warming and crank operations. Allow engine to reach full operating speed. Note Engine will not start if main power switch is in the on position. 7. Turn main power on. When the system is powered up by turning the main power switch (MP) to the ON position, the splash screen will display until communication and initialization is complete. 3. Check fluid inlet screens. Before daily startup, ensure that the fluid inlet screens are clean. See Flush Inlet Strainer Screen, page 65 4. Check ISO lubrication reservoir. Check level and condition of ISO lube daily. See Pump Lubrication System, page 66. 54 3A1705A Startup 8. Check coolant color. Use a flashlight to inspect the color of the coolant through sight glass (SG). The mesh filter should be visible inside the sight glass and the coolant should be green. If there are a lot of air bubbles, then the coolant level may be low. If the coolant is a milky color, then that indicates A or B material has likely leaked inside a heat exchanger and that the coolant needs to be drained. • To add more coolant, see Refill Proportioner Coolant Loop, page 68 and Refill Engine Coolant Loop, page 69. • To drain the coolant system, see Drain Coolant, page 67. 9. Switch on the air compressor, air dryer, breathing air, and other accessories. Complete the following steps for systems with a supplied air compressor. a. Close the main air shutoff valve, desiccant air dryer inlet valve, and water drain valve (CH) whenever the pressure in the air supply tank has been relieved. 11. Open the main air shutoff valve. 12. Slowly increase the air pressure regulator settings. 13. Load fluid with feed pumps. a. Check that all Setup steps are complete. See Setup, page 32. 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 57. If you need to circulate material through the heat hose to the gun manifold, see Circulation Through Gun Manifold, page 58. d. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY . GA SA b. Press start on the air compressor power box (CB). Wait until the pressure gauge (CJ) on the air supply tank reaches 30 psi. c. Open the desiccant dryer inlet valve, water drain valve, and the main air shutoff valve. 10. During initial startup, ensure all three air regulators are turned fully counterclockwise. 3A1705A GB SB e. Adjust A and B feed pump air regulators to desired air pressure, on front of proportioner, to start the feed pumps. Do not exceed 130 psi (0.2 MPa, 2 bar) to the A and B feed pumps. 55 Startup f. Open fluid inlet valves (FV). Check for leaks. Do not turn on hose heat without fluid in hoses. 15. 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. • Allow equipment to cool completely before touching it. • Wear gloves if fluid temperature exceeds 110°F (43°C). Do not mix components A and B during startup. Always provide two grounded waste containers to keep component A and component B fluids separate. g. 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. Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose. 16. Wait for the engine to reach operating temperature and the hose to reach setpoint temperature. The engine has reached operating temperature when the black arrow is under the green area of the temperature bar. The radiator fan will turn on when operating temperature is reached. The Fusion AP gun manifold is shown. 14. Setup ADM. Advanced Display Module (ADM) Operation, page 42. 56 17. Press to turn on A and B heat zones. 3A1705A Fluid Circulation Fluid Circulation Circulation Through Reactor NOTICE 3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION GA Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. . GB SA SB To circulate through gun manifold and preheat hose, see Circulation Through Gun Manifold, page 58. 1. Follow Startup, page 54. 4. Set temperature targets. See Targets, page 49. Do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpressure relief valves when set to SPRAY . Lines must be open so valves can automatically relieve pressure when machine is operating. 2. See Typical Installation, with circulation, page 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 94. 5. Press to circulate fluid in jog mode until A and B temperatures reach targets. See Jog Mode, page 58 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 . GA SA 3A1705A GB SB 57 Jog Mode Circulation Through Gun Manifold 3. Follow procedures from Startup, page 54. NOTICE 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 the hose. 1. Install gun fluid manifold (P) on accessory circulation kit (CK). Connect high pressure circulation lines (R) to circulation manifold. 4. Turn main power on . 5. Set temperature targets. See Targets, page 49. to circulate fluid in jog mode until 6. Press A and B temperatures reach targets. See Jog Mode, page 58 for more information about jog mode. Jog Mode Jog mode has two purposes: • It can speed fluid heating during circulation. P • It can ease system flushing and priming. CK 1. Turn main power on 2. Press circulate R to enter jog mode. 3. Press up or down (J1 through J20). The Fusion AP gun manifold is shown. CK Gun Manual 246362 Fusion AP 309818 256566 Fusion CS 313058 GC1703 Probler P2 313213 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 Technical Specifications, page 94. 58 . 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 5. to start motor. To stop the motor and exit jog mode press or . 3A1705A Spraying Spraying 4. 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). The Fusion AP gun is shown. 1. Engage gun piston safety lock. 5. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY . GB GA SB SA 2. Close gun fluid inlet valves A and B. 6. Check that heat zones are on and temperatures are on target, see Home screen, page 49 7. Verify that the engine temperature is at least up to the minimum operation temperature range. The fan will start running when the engine has reached maximum temperature. 8. Press 3. Attach gun fluid manifold. Connect gun air line. Open air line valve. to start motor and pumps. 9. Check fluid pressure and adjust as necessary. 10. 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 SA until gauges show GB SB 11. Instructions continue on next page. 3A1705A 59 Spraying 12. Open gun fluid inlet valves A and B. 15. Equipment is ready to spray. Spray Adjustments Flow rate, atomization, and amount of overspray are affected by four variables. Note On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced. 13. Disengage gun piston safety lock. • 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. 14. Test spray onto cardboard. Adjust pressure and temperature to get desired results. 60 • 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. 3A1705A 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 heat zones. 3. Relieve pressure. See Pressure Relief Procedure, page 62. 4. Press to park the Component A Pump. 5. Press to deactivate the system. 6. Turn off the air compressor, air dryer, and breathing air. 7. Close the main air shutoff valve. 3A1705A 8. Turn main power off. NOTICE 240V is still present in system until engine is stopped. Allow engine dwell time, per manufacturer recommendations, prior to shutdown. Dwell time will help engine cool down after running at operating temperature for any period of time. 9. Allow engine dwell time. 10. Press on the engine control module. 11. Open air compressor bleed valve to relieve pressure and remove water from tank. 12. Close all fluid supply valves. 61 Pressure Relief Procedure Pressure Relief Procedure 5. Engage gun piston safety lock. 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. 6. Disconnect gun air line and remove gun fluid manifold. 3. Shut off feed pumps and agitator, if used. 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 SA 62 GB SB 3A1705A Flushing Flushing • To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE To 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 through bleed RELIEF/CIRCULATION lines (N). GA SA GB SB • 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 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 Important TwoComponent Material Information, page 7 . 3A1705A 63 Maintenance Maintenance Dust Protection Prior to performing any maintenance procedures, follow Pressure Relief Procedure, page 62. 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. Fluid Inlet Strainer Screens Inspect fluid inlet strainer screens daily, see Flush Inlet Strainer Screen, page 65. Grease Circulation Valves Grease circulation valves (SA, SB) with Fusion grease (117773) weekly. ISO Lubricant Level Use compressed air to prevent dust buildup on control boards, fan, motor (under shield), and hydraulic coolers. Coolant Levels Check coolant level inside both overflow tanks daily. Flush and refill the coolant on both the engine and heat exchanger coolant loop once a year. See Refill Proportioner Coolant Loop, page 68. See Refill Engine Coolant Loop, page 69. Engine Maintenance The engine instructions that accompany your unit detail specific procedures for maintenance of the engine. Following the engine manufacturer’s recommendations will extend engine work life. Daily • Cooling System Coolant Level — Check • Engine Air Cleaner Service Indicator — Inspect • Engine Oil Level — Check Every 500 Service Hours or 1 Year • Engine Air Cleaner Element (Dual Element) — Clean/Replace • Engine Oil and Filter — Change • Fuel System Filter — Replace • Battery Voltage — Check. See Appendix A: Engine Control Module, page 87. Inspect ISO lubricant level and condition daily. Refill or replace as needed. See Pump Lubrication System, page 66. 64 3A1705A 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. 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. 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). 3A1705A A B C D Figure 36 65 Maintenance Pump Lubrication System 4. When the reservoir is flushed clean, fill with fresh lubricant. 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. 5. Thread the reservoir onto the cap assembly and place it in the bracket. 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. 6. The lubrication system is ready for operation. No priming is required. 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 62. 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. 66 R Pump Lubrication System Figure 37 3A1705A Maintenance Drain Coolant 4. To drain proportioner coolant loop: a. Remove the proportioner coolant loop fill bottle (HF) cap. b. To avoid burns, do not perform maintenance on the coolant system until the coolant system has reached ambient temperature. Place the other end of the drain tube in a waste container. Open the drain valve. Drain coolant until coolant is no longer visible in the sight glass. Drain coolant from the engine and proportioner coolant loops once a year or if the coolant lines need to be disconnected, in order to install a wall between the generator and proportioner. 1. Perform Shutdown, page 61. 2. Remove the cabinet door from the front of the proportioner. 3. Turn on manual valve switch (MV), located on the load center (LC), to manually open the A and B heat exchanger control valves and bypass control valve. Note The load center (LC) LEDs will stay on when the manual valve switch (MV) is in the on position. LC Proportioner Coolant Loop Drain Valve Figure 39 c. 5. To drain engine coolant loop: a. Remove the engine coolant loop (RC) cap. b. MV Figure 38 LED Component LED Color Manual valve switch (MV) Red A Side Control Valve Red B Side Control Valve Blue Bypass Valve Green 3A1705A To refill coolant loop, see Refill Proportioner Coolant Loop, page 68. Place a waste container under the drain valve. Open the drain valve and drain coolant. Engine Coolant Loop Drain Valve Figure 40 c. To refill coolant loop, see Refill Engine Coolant Loop, page 69. 67 Maintenance Refill Proportioner Coolant Loop Note Air needs to be purged from the proportioner coolant loop when it is filled with new coolant or when air enters the coolant system. It takes about one full warm-up and cool-down cycle to purge air from coolant. 3. Replace cap. 4. Press start button control module. twice on the engine 5. Turn main power on. 6. Inspect coolant flow in sight glass (SG) for bubbles and to verify that the coolant is flowing. To avoid burns, do not perform maintenance on the coolant system until the coolant system has reached ambient temperature. Only use coolant solutions that are compatible with the system. See Coolant Specifications, page 69. 1. Before refilling coolant loop, perform steps 1–3 from Drain Coolant, page 67. Drain coolant loop if necessary. 2. Remove the cap from the metal proportioner coolant loop fill bottle (HF). Fill bottle with 50/50 water and antifreeze mixture until the coolant reaches the cold level line inside the expansion bottle (HB). See Coolant Specifications, page 69. RC HB HF 7. Inspect coolant loops for leaking fittings or valves. 8. The coolant has reached operating temperature when the radiator fan turns on. When the fan turns on, turn the main power off. 9. Press to stop the generator. 10. Add more coolant to expansion bottle (HB) after the coolant system temperature lowers to ambient temperature. 11. Turn off manual valve switch (MV) to close the A and B heat exchanger control valves (VA, VB) and bypass control valve (VC). Note EB When the manual valve switch (MV) is in the off position, the load center (LC) LEDs only turn on when the Integrated Reactor system opens the valves. 12. Add coolant in the proportioner coolant loop if the coolant level is below the cold level inside the proportioner coolant expansion bottle (HB). See Fig. 41. Coolant System Bottles Figure 41 68 3A1705A Maintenance Refill Engine Coolant Loop Refill the engine coolant loop when the coolant is below the cold level line at ambient temperature. To avoid burns, do not perform maintenance on the coolant system until the coolant system has reached ambient temperature. 6. Inspect coolant loops for leaking fittings or valves. 7. The coolant has reached operating temperature when the radiator fan turns on. When the fan turns on, turn the main power off. Only use coolant solutions that are compatible with the system. See Coolant Specifications, page 69. 8. Press 1. Before refilling coolant loop, perform steps 1–3 from Drain Coolant, page 67. Drain coolant loop if necessary. 9. Add more coolant to expansion bottle (EB) after the coolant system temperature lowers to ambient temperature. 2. Remove the engine radiator coolant cap (RC) and fill until the coolant reaches the bottom of the neck. Replace cap. See Coolant Specifications, page 69. Coolant Specifications 3. Remove the cap from the engine coolant loop bottle (EB) and fill until the coolant is at the hot level. Replace cap. 4. Press start button control module. 5. Turn main power on. 3A1705A twice on the engine to stop the generator. Only refill the coolant loops with a solution of 50% distilled or soft water and 50% green ethylene glycol antifreeze with a corrosion inhibitor. Do not use common tap water; it contains chlorides and minerals which form scale on the coolant system walls. Use only antifreeze that meets specification ASTM D3306–89, BS658, or AS 2108. A pre-diluted mix is recommended, such as PEAK Ready Use 50/50 Pre-Diluted. 69 Errors Errors View Errors When an error occurs the error information screen displays the active error code and description. To diagnose the active error, see Troubleshoot Errors, page 71. 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 52. There are three types of errors that can occur. Errors are indicated on the display as well as by the light tower (optional). . This condition indicates Alarms are indicated by 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. 70 3A1705A Errors Troubleshoot Errors See Error Codes and Troubleshooting, page 72 for causes and solutions to each error code. to diagnose the error. Press previous screen. to return to the To troubleshoot the error: 1. Press the soft key for help with the active error. 3. Select conditions that are present in the system until a cause has been identified. Press to go the troubleshooting screen that displays the ten most recent errors. Note or to return to the Press previously displayed screen. 2. Press to select one of following conditions that are present in the system until you are able 3A1705A 71 Troubleshooting Troubleshooting See Troubleshooting, page 52 for the ten most recent errors that have occurred on the system. See Troubleshoot Errors, page 71 to diagnose errors that have occurred on the system. See Errors, page 70 for information about errors that can occur on the system. See Error Codes and Troubleshooting for error codes, possible causes, and solutions. Error Codes and Troubleshooting See Reactor repair manual for non-error based troubleshooting. Note Error codes are stored in the error log and displayed on the Error and Troubleshooting screens on the ADM. Error Error Type Name Cause Solution Code A1N1 Position MCM ALARM No Motor Current Loose or bad connection. Motor brushes completely worn down. Bad MCM. A4CH Hose ALARM High Relay Current Hose Wiring problem. Check wiring between MCM and motor. Check motor brushes and replace if needed. Replace MCM. See Integrated Reactor System Repair manual. Check wiring between HPTCM and contactor. Look for shorted wire between HPTCM and contactor terminals A1 and A2. Measure resistance between A1 and A2 terminals. The resistance should be about 289Ω. If contactor is measuring less than 100Ω, then the contactor is shorted and should be replaced. Shorted contactor. 72 3A1705A Troubleshooting Error Error Type Name Cause Solution Code A4CM Position MCM ALARM High MCM Current MCM is drawing too much current from the system. A4DA Boost A ALARM High Heater Current A4DB Boost B Short circuit in booster heater wiring. Short circuit in hose wiring. A4DH Hose A4NM MCM If problem continues replace MCM. See Integrated Reactor System Repair manual. Check wiring for touching wires. Check continuity of transformer windings, normal reading are about .2Ω on both primary and secondary. If reading is 0Ω replace transformer. Check for shorts between the primary winding and the support frame of the transformer. Measure resistance of heater(s), replace if needed. Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground. Replace motor. See Integrated Reactor System Repair manual. Repair or replace chemical pump. See Integrated Reactor System Repair manual. Replace Module. See Integrated Reactor System Repair manual. Replace Module. See Integrated Reactor System Repair manual. Bad heater. ALARM High Motor Current Short circuit of motor wiring. Motor will not rotate. Chemical pump is stuck A7CH Hose ALARM Unexpected Relay Current Shorted Temperature Control Module. A7DA Boost A ALARM A7DB Boost B Unexpected Heater Current Shorted Temperature Control Module. ALARM No Heater Current Tripped circuit breaker. A7DH Hose A8DA Boost A A8DB Boost B A8DH Hose 3A1705A Loose/broken connection. Visually check circuit breaker for a tripped condition. Check heater wiring for loose wires. 73 Troubleshooting Error Error Type Name Cause Solution Code CACA Position Boost A ALARM Communication Error Module does not have software or dial is set to wrong position. CACB Boost B Insert a system token into the missing GCA module and cycle the power. Wait until the red light on the module to stop flashing before removing the token. Verify the dial on the TCM's are in the correct position: 0 for hose, A for boost A, B for boost B Green light on each module should be lit. If green light is not lit, see if circuit breaker CB03 is tripped. If not tripped, check to make sure each CAN cable connection is tight. Verify the power supply is outputting 24 Vdc. If not, replace power supply. See Integrated Reactor System Repair manual. Check the CAN cables running between GCA modules and tighten if needed. If the problem still persists move each cable around the connector and watch the flashing yellow light on the GCA modules. If the lights stops replace the CAN cable. Replace MCM. See Integrated Reactor System Repair manual for instructions. Replace Remote Display Module. No 24v DC supply to module. CACH Hose Loose or broken CAN cable. CACM MCM Bad module CACP 74 Remote Display Module Bad module 3A1705A Troubleshooting Error Error Type Name Cause Solution Code DADX Position MCM ALARM Pump Runaway Flow rate is too large DE0X MCM ALARM Pump Cycle Switch Fault Faulty or missing cycle switch. F9DX MCM ALARM Pressure Flow Cutback Mix chamber is too large for the set pressure. H1MH Hose ALARM Low Line Frequency Line frequency is below 55 Hz. H4MH Hose ALARM High Line Frequency Line frequency is above 65 Hz. K8NM ALARM Locked Rotor Locked rotor. Mix chamber too large for system selected, use mix chamber rated for system. Make sure the system has chemical and the feed pumps are operating correctly. No material in pumps. Verify pumps are supplying chemical. If necessary, replace or refill drums. Inlet ball valves are closed. Open ball valves. Check wiring between cycle switch and MCM port 6. Reference the pressure flow curves and select a tip size that is the correct size for the set pressure. Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions. Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions. Replace motor. See Integrated Reactor System Repair manual. Repair or replace pump. See Integrated Reactor System Repair manual. MCM Chemical pump is stuck. 3A1705A 75 Troubleshooting Error Error Type Code L1AX Position ADM ALARM L1BX MBN0 MCM Name Low Chemical Level A Low Chemical Level B ADVISORY Motor Brush Wear MMUX USB ADVISORY USB Log Full P4AX ALARM MCM P4BX P6AX P6BX 76 Over Pressure A Over Pressure B MCM ALARM Pressure Transducer Fault A Pressure Transducer Fault B Cause Solution Tanks low on material. Fill tanks with material. Brush has come in contact with the motor. Brushes have worn down and need replacing. USB logs have reached a level were data loss will occur if logs are not downloaded. System pressurized before allowing heat to reach setpoint. Replace Brushes. See Integrated Reactor System Repair manual. Bad pressure transducer. E-XP2i system configured as E-30i. Loose/bad connection. Bad sensor. Use a USB drive and download all logs. Turn on the heat and allow the hose to reach the setpoint before turning on the pumps. Verify the ADM pressure reading the analog gauges at the manifold. Replace transducers if they do not match. Contact technical services. Check to ensure the pressure transducer is properly installed and all wires are properly connected. Swap the A and B side transducers and see if the error follows the transducer. If the error follows the transducer, replace the pressure transducer. If the error does not follow, replace MCM. 3A1705A Troubleshooting Error Error Type Name Cause Solution Code P7AX Position MCM ALARM Pressure Imbalance A High Pressure difference between A and B material is greater than the defined amount. Pressure imbalance is defined too low. Ensure the material flow is equally restricted on both material lines. Out of material. Feed system defective. P7BX P0AX POBX T1DE T2AE 3A1705A Pressure Imbalance B High MCM ADVISORY Pressure Imbalance A High MCM ADVISORY Pressure Imbalance B High ALARM Low Heat Temperature Exchanger Coolant Outlet Heat DEVIATION Low Exchanger Temperature Hx A Ensure that the pressure imbalance value, on the System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses. Fill tanks with material. Check feed pump and hoses for blockage. Check that the feed pumps have the correct air pressure. See P7AX. See P7BX. Radiator fan will not stop. Engine thermostat is stuck open. Coolant circulation pump not working. Replace fan relay. Replace thermostat. Check for 230v AC on pump. If no voltage is measured, check to see if breaker CB03 is tripped. If there is the correct voltage, replace circulation pump. 77 Troubleshooting Error Error Type Name Code T2BE Position Heat DEVIATION Low Exchanger Temperature Hx B Cause Solution No voltage to coil of valve. Turn on the manual valve switch, on the load center, to manually turn on the solenoids and see if the temp rises. If not, confirm the voltage on the connector of the valve is 12 VDC. If no voltage present, check wires in JC of load center for loose or broken wires. If wires are fine, replace load center board. If voltage is present, measure the resistance of the coil, it should be 12.5 Ω, if coil is open replace coil. T2DA Boost A T2DB Boost B T2DH Hose T2DE Heat ADVISORY Low Temperature Exchanger Coolant Outlet T3CA Boost A T3CB Boost B T3CH Hose 78 ALARM Low Chemical Temperature Flow is too high at current setpoint. Bad heater(s) ALARM MCM Over Temperature MCM Over Temperature MCM Over Temperature Radiator fan will not stop. Engine thermostat is stuck open. Cooling fan not operating on power. Overheated MCM. If voltage is present, test the coil with screwdriver. The screwdriver should stick inside the coil. If screwdriver sticks, replace the plunger on valve or replace the complete valve assembly. Use a smaller mix chamber that is rated for the unit in use. Confirm resistance of heater is 23–26.5 ohms. Replace if OL/open loop. Replace fan relay. Replace thermostat. Visually check breaker CB03. If breaker is not tripped replace fan. Turn controller off. Wait a few minutes. If the condition does not clear or regenerates consistently, replace module. 3A1705A Troubleshooting Error Error Type Code T3NM Position MCM T4AE Heat ALARM Exchanger Name ADVISORY High Motor Temperature T4BE High Chemical Temperature Hx A High Chemical Temperature Hx B Cause Solution Motor is operating outside of pressure flow curve. The system is running at a lower setpoint to preserve motor life. Manual override switch on load center board is in the on position. Solenoid is stuck in the open position. Run the system at a lower duty cycle or with a smaller mix chamber. Short on load board. T4CM MCM ALARM High MCM Temperature High ambient temperature. Overheated Control Module. T4DA Boost A T4DB Boost B 3A1705A ALARM High Chemical Temperature Bad RTD. High Chemical Temperature Bad Low Power Temperature Control Module. Open cabinet cover and turn switch to the off position. Disconnect connector from solenoid. If temperature does not decrease, rebuild solenoid. Disconnect connector from the solenoid. If temperature does not decrease, rebuild solenoid. Ensure ambient temperature is below 120°F(48°C) before using the system. Stop the pumps. Wait a few minutes. If the condition does not clear or regenerates consistently, replace MCM. See Integrated Reactor System Repair manual. Swap A and B heater volex cables and RTDs and see if issue follows. If so, replace RTD. Swap the A and B LPTCMs and see if the issue follows the module. If so replace LPTCM. See Integrated Reactor System Repair manual. 79 Troubleshooting Error Error Type Name Cause Solution Code T4DH Position Hose ALARM High Chemical Temperature T4DE Heat ALARM Exchanger High Temperature Coolant Outlet Bad High Power Temperature Control Module. Broken Fan. Replace HPTCM. See Integrated Reactor System Repair manual. Check fan relay (K4) and fuse (30 Amp ATO “F3”) on load center board. Replace if needed. Replace if needed. Plugged radiator. T4NM MCM ALARM High MCM Temperature Cooling fans are not operating properly. Check to see that the fans are moving. Measure voltage to fans. There should be 230 VAC. If no voltage is measured, check to see if breaker CB03 is tripped. If the fans have voltage but are not moving, replace fan. Bad electric motor. T6DA ALARM Heat Exchanger Heat Exchanger Boost A RTD Fault A T6DB Boost B RTD Fault B T6DE Heat Exchanger Hose Coolant Outlet RTD Fault RTD Fault T6AE T6BE T6DH 80 RTD Fault A RTD Fault B The module is reading infinite resistance. Bad RTD. Use an air hose to blow out around the fan housings and remove any built-up debris. Replace electric motor. See Integrated Reactor System Repair manual. Check port on module and wiring to RTD. Switch the RTD with another and see if the error message follows the RTD. Replace RTD if the error follows the RTD. 3A1705A Troubleshooting Error Error Type Code T8AE Position Heat ALARM Exchanger T8BE Name Cause Solution Temperature Not Rising Hx A No coolant flow Temperature Not Rising Hx B Bad solenoid. Ensure that the circulation pump has 230 VAC. If not, check breaker CB03. If 230 VAC is present, replace the circulation pump. See Integrated Reactor System Repair manual. Turn on the manual valve switch, on the load center, and see if the solenoid shifts. if not replace solenoid. Matching LED (red, blue, and green) should light up on load center board. If not, replace load center. Measure resistance, 23 – 26 Ω, of heater rod, replace if reading open. Measure hose resistance, replace if reading open. Wait until temperatures have been reached on engine and hose before spraying. Visually check circuit breaker for a tripped condition. Check wiring for loose wires. Measure voltage across disconnect switch. Voltage should measure between 190 and 264 Vac. Ensure compressor or air drier are setup to be continuous run and sized according to manual. Bad load center. Temperature Not Rising T8DA Boost A T8DB Boost B Bad hose heater. T8DH Hose V1CM MCM ALARM Bus Under Voltage Started spraying before engine and hose reached operating temperature. Tripped circuit breaker. V1MH Hose ALARM Low Line Voltage ALARM Bad heater rod (boost). Loose or bad connection. Low generator line voltage High auxiliary inrush current. 3A1705A 81 Troubleshooting Error Error Type Name Cause Solution Code V4CM Position MCM ALARM Bus Overvoltage V4MH Hose ALARM High Line Voltage Incoming line voltage is too high. Incoming line voltage is too high. WBNM MCM ALARM Motor Sensor Fault Measure voltage across disconnect switch. Voltage should measure between 190 and 264 Vac. If voltage is too high, see supplied alternator manual for generator specifications and repair. Check connection and cables. WMCE MCM ALARM ALARM WM0E Heat Exchanger WSUX USB Load Center Fault Missing Relay Radiator Fan ADVISORY USB Invalid Configuration Bad Connection between MCM (Port 10) and brush wear/over temperature board. Bad brush wear/over temperature board. Bad Connection between MCM (Port 2) and load center board. Bad load center. Loose or bad connection between load center and MCM. Bad relay. A valid configuration file can't be found for the USB. Bad ADM. WX00 82 MCM ALARM External Input The alarm external input has been driven low. Replace Motor. See Integrated Reactor System Repair manual. Check connection and cables. Replace load center. See Integrated Reactor System Repair manual. Check relay wiring. Replace relay. Insert a system token into the ADM and cycle the power. Wait until the lights on USB port stop flashing before Removing the token. Replace ADM. See Integrated Reactor System Repair manual. An active alarm is being generated by the external trigger. If the external alarm is not configured check for a short in the wiring going to MCM port 2, pins 1 and 3. 3A1705A USB Data USB Data USB Logs Event codes include both error codes (alarms, deviations, and advisories) and record only events. Note Actions Taken includes setting and clearing event conditions by the system, and acknowledging error conditions by the user. 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 four log files: • Event Log • Job Log • Daily Log • System Software Log • Blackbox Log Follow Download Procedure, page 85, 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 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 415,413 data points for download. See Setup - Advanced Screen 3 — USB, page 45, for information on setting the Download Depth and USB Log Frequency. • Data point date • Data point time • A side heat exchanger temperature • A side boost heater temperature • B side heat exchanger temperature • B side boost heater temperature • Hose temperature The event log file name is 1–EVENT.CSV and is stored in the DATAxxxx folder. • Engine coolant temperature The event log maintains a record of the last 49,182 events and errors. Each event record contains: • B side temperature setpoint • A side temperature setpoint • Date of event code • Hose temperature setpoint • Time of event code • A side pressure • Event code • B side pressure • Event type • Pressure setpoint • Action taken • System lifetime pump cycle counts • Event Description • Pressure, volume, and temperature units 3A1705A 83 USB Data Daily Log Blackbox Log File The daily log file name is 3–DAILY.CSV and is stored in the DATAxxxx folder. The black box file name is 5–BLACKB.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 Blackbox log maintains a record of how the system runs and the features that are used. This log will help Graco troubleshoot system errors. The following data is stored in this file: System Configuration Settings • 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: 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 86 for instructions on how to use this file. • Date log was created • Time log was created • Component name • Software version loaded on the above component 84 3A1705A 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. • 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. • U+0020 - U+007E (Basic Latin) • Do not add or remove rows to the file. • U+00A1 - U+00FF (Latin-1 Supplement) • Do not change the order of the rows. • U+0100 - U+017F (Latin Extended-A) • U+0386 - U+03CE (Greek) Download Procedure • U+0400 - U+045F (Cyrillic) Note 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 86 , 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. 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. 3A1705A 85 USB Data 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. 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. 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 45. 2. Insert USB flash drive into USB port of computer. 86 3A1705A Appendix A: Engine Control Module Appendix A: Engine Control Module Run Screens There are seven run screens on the engine control module: • Line-to-neutral voltage • Line-to-line voltage • Frequency • Engine Speed • Engine lifetime counter • Battery voltage to scroll through the run screens. Press Press to enter the Information screens. Run Screen Layout Inst Icon Instrumentation Units Alarm Icon Mode Icon Information Screens From the Run Screen, press generator events. Press to enter the information screens. Press to scroll through the last five to return to the Run Screens. Information Screen Layout Event # Time of Event (Engine Run Hours) 3A1705A Units Alarm Icon Mode Icon 87 Appendix A: Engine Control Module Mode Icons An icon is displayed in the mode icon area of the display to indicate what mode the unit is currently in. Icon Description Details Stopped Engine is at rest and the unit is in stop mode. Auto Engine is at rest and the unit is in auto mode. Manual Engine is at rest and the unit is in manual run mode. Timer animation Engine is starting up. Running animation Engine is running. Instrumentation Icons A small icon is displayed in the instrumentation icon area to indicate what value is currently being displayed. Icon 88 Description Details Generator Generator voltage and frequency screen Engine Speed Engine speed screen Engine Lifetime Counter Hours run Event Log Event is being displayed. Unit Time Unused feature 3A1705A Appendix A: Engine Control Module Alarms There are two types of alarms that can occur on the system. Alarms are indicated by an icon the Run and Information screens. Warning When present on system, a warning alarm will not stop the generator. Icon Description Details Battery High Voltage The DC Supply has risen above the high volts setting level for the duration of the high battery volts timer. Battery Low Voltage The DC Supply has fallen below the low volts setting level for the duration of the low battery volts timer. Fail To Stop The module detected a condition that indicates that the engine is running when it has been instructed to stop. Flexible Sensor The flexible sensor warning alarm has been triggered. Shutdown When present on system, a shutdown alarm will stop the generator. Clear the alarm and remove the fault. Then press the stop button to reset the module. See the information screen to see the latest alarm. Icon Description Details Fail To Start The engine has not fired after the preset number of start attempts. Generator High Voltage Shutdown The generator output voltage has risen above the preset level. Generator Low Voltage Shutdown The generator output voltage has fallen below the preset level. High Coolant Temperature Shutdown The module detects that the engine coolant temperature has exceeded the high engine temperature shutdown setting after the Safety On timer has expired. Low Oil Pressure Shutdown The engine oil pressure has fallen below the low oil pressure trip setting level after the Safety On timer has expired. Over Frequency Shutdown The generator output frequency has risen above the preset level. Under Frequency Shutdown The generator output frequency has fallen below the preset level. 3A1705A 89 Dimensions Dimensions Top View Figure 42 Side View Figure 43 90 3A1705A Dimensions Top View: System with Compressor and Hose Rack Accessories Figure 44 Side View: System with Compressor and Hose Rack Accessories Figure 46 Front View Figure 45 3A1705A 91 Dimensions Pallet Mounting Dimensions Figure 47 92 3A1705A 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. Proportioners For Foam 2000 (138) AR4242 (01) AR5252 (02) 1500 (103) PRESSURE psi (bar) AR6060 (03) 1000 (69) AR7070 (04) E-30i 500 (34) 0 5 (2.3) 10 (4.5) 15 20 (6.8) (9.1) 25 30 (11.3) (13.6) 35 (15.9) 40 (18.1) 45 (20.4) 50 (22.7) 55 (25.9) FLOW lbs/min (kg/min) Proportioners For Coatings 3500 (241) 3000 (207) 2500 PRESSURE psi (bar) E-XP2i AR2020 (000) (172) AR2929 (00) 2000 (138) 1500 (103) AR4242 (01) 1000 (69) 500 (34) 0 0.5 (1.9) 1.0 (3.8) 1.5 (5.7) 2.0 (7.6) 2.5 (9.5) 3.0 (11.3) FLOW lbs/min (kg/min) 3A1705A 93 Technical Specifications Technical Specifications E-30i Models U.S. Metric 2000 psi 14 MPa, 140 bar E-30i 140°F 60°C E-30i with booster heater 180°F 82°C 30 lb/min 13.5 kg/min 310 ft 94 m 0.0272 gal. 0.1034 liter Maximum Fluid Working Pressure Pressure Maximum Fluid Temperature Maximum Output Output Maximum Heated Hose Length Length Output per Cycle A and B Auxiliary Power Available Voltage 120 Vac or 240 Vac, 60 Hz Engine Model Perkins 404–22G, 2.2 L, 29 HP Alternator Model Mecc Alte 22 kW, 230 V, 1 PH, 60 Hz, pancake style Battery Requirements Voltage 12 Vdc Minimum Cold Cranking Amps 800 CCA Connection Type Post Style Recommended Battery Size 34 BC Group Number Length 10.25 in. 260 mm Width 6.81 in. 173 mm Height 7.88 in. 200 mm Booster Heater Power E-30i E-30i with booster heat 94 None 4000 Watts 3A1705A Technical Specifications Recommended Air Compressors Champion® BR-5, Base Mount 5 HP, 230 V, 1 Phase, 60 Hz Specifications Required Features Belt guard aftercooler Pilot valve unloader Quincy PLT5–5B, Base Mount 5 HP, 230 V, 1 Phase, 60 Hz Specifications Required Features Belt guard aftercooler Pilot valve unloader Champion® HR5-3, 30 Gallon Tank Mount 5 HP, 230V, 1 Phase, 60 Hz Specifications Required Features Pilot valve unloader Noise (Reactor Without Air Compressor) Sound Power, per ISO 9614–2, measured at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm) 93.5 dB(A) Sound Pressure measured from 3.1 ft (1 m), at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm) 83.6 dB(A) Fluid Inlets Component A (ISO) and Component B (RES) 3/4 NPT(f) with 3/4 NPSM(f) union Fluid Outlets 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 Fluid Circulation Ports Size Maximum Pressure 1/4 NPSM(m), with plastic tubing 250 psi 1.75 MPa, 17.5 bar E-30i 1750 lb 794 kg E-30i with booster heat 1800 lb 816 kg E–30i with compressor 2250 lb 1020 kg E–30i with booster heat and compressor 2300 lb 1043 kg Weight Wetted Parts Material 3A1705A Aluminum, stainless steel, zinc plated carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene 95 Technical Specifications E-XP2i Models U.S. Metric 3500 psi 24.1 MPa, 241 bar 180°F 82°C 2 gpm 7.6 lpm 310 ft 94 m 0.0203 gal. 0.0771 liter Maximum Fluid Working Pressure Pressure Maximum Fluid Temperature E-XP2i Maximum Output Output Maximum Heated Hose Length Length Output per Cycle A and B Auxiliary Power Available Voltage 120 Vac or 240 Vac, 60 Hz Engine Model Perkins 404–22G, 2.2 L, 29 HP Alternator Model Mecc Alte 22 kW, 230 V, 1 PH, 60 Hz, pancake style Battery Requirements Voltage 12 Vdc Minimum Cold Cranking Amps 800 CCA Connection Type Post Style Recommended Battery Size 34 BC Group Number Length 10.25 in. 260 mm Width 6.81 in. 173 mm Height 7.88 in. 200 mm Booster Heater Power Wattage 96 4000 Watts 3A1705A Technical Specifications Recommended Air Compressors Champion® BR-5, Base Mount 5 HP, 230 V, 1 Phase, 60 Hz Specifications Required Features Belt guard aftercooler Pilot valve unloader Quincy PLT5–5B, Base Mount 5 HP, 230 V, 1 Phase, 60 Hz Specifications Required Features Belt guard aftercooler Pilot valve unloader Champion® HR5-3, 30 Gallon Tank Mount 5 HP, 230V, 1 Phase, 60 Hz Specifications Required Features Pilot valve unloader Noise (Reactor Without Air Compressor) Sound Power, per ISO 9614–2, measured at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm) 93.5 dB(A) Sound Pressure measured from 3.1 ft (1 m), at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm) 83.6 dB(A) Fluid Inlets Component A (ISO) and Component B (RES) 3/4 NPT(f) with 3/4 NPSM(f) union Fluid Outlets 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 Fluid Circulation Ports Size Maximum Pressure 1/4 NPSM(m), with plastic tubing 250 psi 1.75 MPa, 17.5 bar E-XP2i 1800 lb 816 kg E-XP2i with compressor 2500 lb 1043 kg Weight Wetted Parts Material 3A1705A Aluminum, stainless steel, zinc plated carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene 97 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. Original Instructions. This manual contains English. MM 3A1705 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2011, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com
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