Graco 334945E, Reactor 2 Hydraulic Proportioning Systems Owner's Manual

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Graco 334945E, Reactor 2 Hydraulic Proportioning Systems Owner's Manual | Manualzz

Operation

Read all warnings and instructions in this manual.

For model information, see page 9.

334945E

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

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

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

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

Approvals........................................................... 15

Accessories........................................................ 15

Supplied Manuals ............................................... 16

Related Manuals ................................................ 16

Typical Installation, without circulation.................. 17

Typical Installation, with system fluid manifold to drum circulation ................................. 18

Typical Installation, with gun fluid manifold to drum circulation..................................... 19

Component Identification..................................... 20

Advanced Display Module (ADM) ........................ 22

ADM Display Details .................................... 24

Navigating the Screens ................................ 25

Electrical Enclosure ............................................ 27

Hydraulic Control Module (HCM) ......................... 28

Temperature Control Module (TCM) Cable

Connections.......................................... 29

Installation.......................................................... 30

Setup................................................................. 30

Grounding ................................................... 30

General Equipment Guidelines ..................... 31

Connect Power ............................................ 32

Lubrication System Setup ............................. 33

Install Fluid Temperature Sensor .................. 33

Install Heated Hose to Proportioner............... 33

Advanced Display Module (ADM)

Operation.............................................. 34

Advanced Setup Screens ............................. 37

System 1 ..................................................... 38

System 2 ..................................................... 38

System 3 ..................................................... 38

Recipes....................................................... 39

Run Mode ................................................... 40

Startup............................................................... 46

Fluid Circulation.................................................. 49

Circulation Through Reactor ......................... 49

Circulation Through Gun Manifold ................. 50

Spraying ............................................................ 51

Spray Adjustments ....................................... 52

Manual Hose Mode............................................. 53

Enable Manual Hose Mode........................... 53

Disable Manual Hose Mode .......................... 54

Standby ............................................................. 55

Shutdown........................................................... 56

Purge Air Procedure ........................................... 57

Pressure Relief Procedure .................................. 59

Flushing ............................................................. 60

Maintenance ...................................................... 61

Preventative Maintenance Schedule ............. 61

Proportioner Maintenance ............................ 61

Flush Inlet Strainer Screen ........................... 62

Pump Lubrication System ............................. 63

Errors ................................................................ 64

View Errors.................................................. 64

Troubleshoot Errors ..................................... 64

Error Codes and Troubleshooting ........................ 65

USB Data .................................................... 65

USB Logs .................................................... 65

System Configuration Settings ...................... 66

Custom Language File ................................. 67

Upload Procedure ........................................ 67

Performance Charts............................................ 68

Technical Specifications...................................... 70

Dimensions ........................................................ 72

Notes ............................................................... 73

Graco Extended Warranty ................................... 74

2 334945E

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these

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

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

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

• Do not expose to rain. Store indoors.

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

• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keep work area

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

Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

• Protective eyewear and hearing protection.

334945E 3

Warnings

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce

• Engage trigger lock when not spraying.

• 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.

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

4

or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

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

• Never spray or flush solvent at high pressure.

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

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

• Use only grounded hoses.

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

equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

334945E

334945E

Warnings

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.

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.

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.

solvent manufacturer’s MSDSs and recommendations.

5

6

Warnings

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

• 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.

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

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

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

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

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

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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

• Do not touch hot fluid or equipment.

334945E

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

Important Isocyanate Information

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDS.

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to instructions in the manual.

• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.

• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal protective equipment must stay out of the work area during application and after application for the time period specified by the fluid manufacturer. Generally this time period is at least 24 hours.

• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the following outside the work area is recommended:

334945E 7

8

Important Isocyanate Information

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

Exposure to moisture (such as humidity) will cause

ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid.

Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.

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

B wetted parts.

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

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

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere.

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

• Use only moisture-proof hoses compatible with

ISO.

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

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

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.

crystallization varies depending on the blend of ISO, the humidity, and the temperature.

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.

334945E

Models

Fusion ® AP

(Gun Part No.)

Fusion ® CS

(Gun Part No.)

(Gun Part No.)

200–

240

79

17H031

2000 (14, 140)

0.074 (0.28)

28 (12.7)

17,960

200–

240

3Ø∆

46

350–

415

3ØY

35

200–

240

100

17H032

2000 (14, 140)

0.074 (0.28)

28 (12.7)

23,260

200–

240

3Ø∆

59

350–

415

3ØY

35

17H131

2000 (14, 140)

0.074 (0.28)

28 (12.7)

17,960

200–

240

79

200–

240

3Ø∆

46

350–

415

3ØY

35

200–

240

100

17H132

2000 (14, 140)

0.074 (0.28)

28 (12.7)

23,260

200–

240

3Ø∆

59

350–

415

3ØY

35

APH031

(246102)

CSH031

(CS02RD)

P2H031

(GCP2R2)

24K240

Qty: 1

AHH031

(246102)

CHH031

(CS02RD)

PHH031

(GCP2R2)

24K240

Qty: 5

APH032

(246102)

CSH032

(CS02RD)

P2H032

(GCP2R2)

24K240

Qty: 1

AHH032

(246102)

CHH032

(CS02RD)

PHH032

(GCP2R2)

24K240

Qty: 5

APH131

(246102)

CSH131

(CS02RD)

P2H131

(GCP2R2)

24Y240

Qty: 1

AHH131

(246102)

CHH131

(CS02RD)

PHH131

(GCP2R2)

24Y240

Qty: 5

APH132

(246102)

CSH132

(CS02RD)

P2H132

(GCP2R2)

24Y240

Qty: 1

AHH132

(246102)

CHH132

(CS02RD)

PHH132

(GCP2R2)

24Y240

Qty: 5

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

***

246050

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

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

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

246050 246050

246050

★ See

Approvals, page 15 .

✖ Packages include gun, heated hose, and whip hose. Elite packages also include ratio monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 15 .

Ø

Y

PHASE

DELTA

WYE

334945E 9

Models

Fusion ® AP

(Gun Part No.)

Fusion ® CS

(Gun Part No.)

(Gun Part No.)

17H043

2000 (14, 140)

0.063 (0.24)

45 (20)

26,600

200–240 3Ø∆

71

17H044

2000 (14, 140)

0.063 (0.24)

45 (20)

31,700

200–240 3Ø∆

95

17H143

2000 (14, 140)

0.063 (0.24)

45 (20)

26,600

200–240 3Ø∆

71

17H144

2000 (14, 140)

0.063 (0.24)

45 (20)

31,700

200–240 3Ø∆

95

APH043

(246102)

CSH043

(CS02RD)

P2H043

(GCP2R2)

24K240

Qty: 1

AHH043

(246102)

CHH043

(CS02RD)

PHH043

(GCP2R2)

24K240

Qty: 6

APH044

(246102)

CSH044

(CS02RD)

P2H044

(GCP2R2)

24K240

Qty: 1

AHH044

(246102)

CHH044

(CS02RD)

PHH044

(GCP2R2)

24K240

Qty: 6

APH143

(246102)

CSH143

(CS02RD)

P2H143

(GCP2R2)

24Y240

Qty: 1

AHH143

(246102)

CHH143

(CS02RD)

PHH143

(GCP2R2)

24Y240

Qty: 6

APH144

(246102)

CSH144

(CS02RD)

P2H144

(GCP2R2)

24Y240

Qty: 1

AHH144

(246102)

CHH144

(CS02RD)

PHH144

(GCP2R2)

24Y240

Qty: 6

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

***

246050

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

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

• H–40 series: 410 ft (125 m) maximum heated hose length, including whip hose.

246050 246050

246050

★ See

Approvals, page 15 .

✖ Packages include gun, heated hose, and whip hose. Elite packages also include ratio monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 15 .

Ø

Y

PHASE

DELTA

WYE

10 334945E

Models

Fusion ® AP

(Gun Part No.)

Fusion ® CS

(Gun Part No.)

(Gun Part No.)

17H045

2000 (14, 140)

0.063 (0.24)

45 (20)

26,600

350–415 3ØY

41

17H046

2000 (14, 140)

0.063 (0.24)

45 (20)

31,700

350–415 3ØY

52

17H145

2000 (14, 140)

0.063 (0.24)

45 (20)

26,600

350–415 3ØY

41

17H146

2000 (14, 140)

0.063 (0.24)

45 (20)

31,700

350–415 3ØY

52

APH045

(246102)

CSH045

(CS02RD)

P2H045

(GCP2R2)

24K240

Qty: 1

AHH045

(246102)

CHH045

(CS02RD)

PHH045

(GCP2R2)

24K240

Qty: 6

APH046

(246102)

CSH046

(CS02RD)

P2H046

(GCP2R2)

24K240

Qty: 1

AHH046

(246102)

CHH046

(CS02RD)

PHH046

(GCP2R2)

24K240

Qty: 6

APH145

(246102)

CSH145

(CS02RD)

P2H145

(GCP2R2)

24Y240

Qty: 1

AHH145

(246102)

CHH145

(CS02RD)

PHH145

(GCP2R2)

24Y240

Qty: 6

APH146

(246102)

CSH146

(CS02RD)

P2H146

(GCP2R2)

24Y240

Qty: 1

AHH146

(246102)

CHH146

(CS02RD)

PHH146

(GCP2R2)

24Y240

Qty: 6

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

***

246050

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

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

• H–40 series: 410 ft (125 m) maximum heated hose length, including whip hose.

246050 246050

246050

★ See

Approvals, page 15 .

✖ Packages include gun, heated hose, and whip hose. Elite packages also include ratio monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 15 .

Ø

Y

PHASE

DELTA

WYE

334945E 11

Models

Fusion ® AP

(Gun Part No.)

Fusion ® CS

(Gun Part No.)

(Gun Part No.)

17H053

2000 (14, 140)

0.074 (0.28)

52 (24)

31,700

200–240 3Ø∆

95

17H056

2000 (14, 140)

0.074 (0.28)

52 (24)

31,700

350–415 3ØY

52

17H153

2000 (14, 140)

0.074 (0.28)

52 (24)

31,700

200–240 3Ø∆

95

17H156

2000 (14, 140)

0.074 (0.28)

52 (24)

31,700

350–415 3ØY

52

APH053

(246102)

CSH053

(CS02RD)

P2H053

(GCP2R2)

24K240

Qty: 1

AHH053

(246102)

CHH053

(CS02RD)

PHH053

(GCP2R2)

24K240

Qty: 6

APH056

(246102)

CSH056

(CS02RD)

P2H056

(GCP2R2)

24K240

Qty: 1

AHH056

(246102)

CHH056

(CS02RD)

PHH056

(GCP2R2)

24K240

Qty: 6

APH153

(246102)

CSH153

(CS02RD)

P2H153

(GCP2R2)

24Y240

Qty: 1

AHH153

(246102)

CHH153

(CS02RD)

PHH153

(GCP2R2)

24Y240

Qty: 6

APH156

(246102)

CSH156

(CS02RD)

P2H156

(GCP2R2)

24Y240

Qty: 1

AHH156

(246102)

CHH156

(CS02RD)

PHH156

(GCP2R2)

24Y240

Qty: 6

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

***

246050

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

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

• H–50 series: 410 ft (125 m) maximum heated hose length, including whip hose.

246050 246050

246050

★ See

Approvals, page 15 .

✖ Packages include gun, heated hose, and whip hose. Elite packages also include ratio monitoring and fluid inlet sensors. All Elite hose and gun system packages include

Xtreme-Wrap™ 50 ft (15 m) heated hose.

For part numbers, see

Accessories, page 15 .

Ø

Y

PHASE

DELTA

WYE

12 334945E

Models

Fusion ® AP

(Gun Part No.)

(Gun Part No.)

***

200–240

100

APH062

(246101)

P2H062

(GCP2R1)

24K241

Qty. 1

17H062

3500 (24.1, 241)

0.042 (0.16)

1.5 (5.7)

23,260

200–240

3Ø∆

59

246055

350–415

3ØY

35

AHH062

(246101)

PHH062

(GCP2R1)

24K241

Qty. 5

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

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

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

200–240

100

APH162

(246101)

P2H162

(GCP2R1)

24Y241

Qty. 1

17H162

3500 (24.1, 241)

0.042 (0.16)

1.5 (5.7)

23,260

200–240

3Ø∆

59

350–415

3ØY

35

AHH162

(246101)

PHH162

(GCP2R1)

24K241

Qty. 5

246055

★ See

Approvals, page 15 .

✖ Packages include gun, heated hose, and whip hose. Elite packages also include fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap™ 50 ft (15 m) heated hose. For part numbers, see

Accessories, page 15 .

Ø

Y

PHASE

DELTA

WYE

334945E 13

Models

Fusion ® AP

(Gun Part No.)

(Gun Part No.)

17H074

3500 (24.1, 241)

0.042 (0.16)

2.8 (10.6)

31,700

200–240 3Ø∆

95

17H076

3500 (24.1, 241)

0.042 (0.16)

2.8 (10.6)

31,700

350–415 3ØY

52

17H174

3500 (24.1, 241)

0.042 (0.16)

2.8 (10.6)

31,700

200–240 3Ø∆

95

17H176

3500 (24.1, 241)

0.042 (0.16)

2.8 (10.6)

31,700

350–415 3ØY

52

APH074

(246102)

P2H074

(GCP2R2)

24K241

Qty: 1

AHH074

(246102)

PHH074

(GCP2R2)

24K241

Qty: 6

APH076

(246102)

P2H076

(GCP2R2)

24K241

Qty: 1

AHH076

(246102)

PHH076

(GCP2R2)

24K241

Qty: 6

APH174

(246102)

P2H174

(GCP2R2)

24Y241

Qty: 1

AHH174

(246102)

PHH174

(GCP2R2)

24Y241

Qty: 6

APH176

(246102)

P2H176

(GCP2R2)

24Y241

Qty: 1

AHH176

(246102)

PHH176

(GCP2R2)

24Y241

Qty: 6

24K240 (scuff guard)

24Y240 (Xtreme-wrap)

***

246055

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

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

• H–XP3 series: 410 ft (125 m) maximum heated hose length, including whip hose.

246055 246055

246055

★ See

Approvals, page 15 .

✖ Packages include gun, heated hose, and whip hose. Elite packages also include fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap™ 50 ft (15 m) heated hose. For part numbers, see

Accessories, page 15 .

Ø

Y

PHASE

DELTA

WYE

14 334945E

Approvals

Intertek approvals apply to proportioners without hoses.

Conforms to ANSI/UL Std. 499

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

24U315

17G340

17F837

16X521

24N449

24K207

24U174

15V551

15M483

24M174

121006

24N365

17F838

24N748

*979200

*979201

*979202

Air Manifold (4 outlets)

Caster Kit

Inlet Sensor Kit

Graco InSite Extension Cable 24.6 ft

(7.5 m)

50 ft (15 m) CAN Cable (for remote display module)

Fluid Temperature Sensor (FTS) with

RTD

Remote Display Module Kit

ADM Protective Covers (10 pack)

Remote Display Module Protective

Covers (10 pack)

Drum Level Sticks

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

RTD Test Cables (to aide resistance measurements)

Elite Kit

Ratio Monitoring Kit

Integrated PowerStation, Tier 4 Final, no air

Integrated PowerStation, Tier 4 Final,

20 cfm

Integrated PowerStation, Tier 4 Final,

35 cfm compatible with Reactor 2 H-30 and H-XP2 proportioning systems.

334945E 15

Supplied Manuals

The following manuals are shipped with the Reactor

2 Hydraulic. Refer to these manuals for detailed equipment information.

334945

334005

334006

Reactor 2 Hydraulic Proportioning

Systems Operation Manual

Reactor 2 Hydraulic Proportioning

Systems Shutdown Quick Guide

Reactor 2 Hydraulic Proportioning

Systems Startup Quick Guide

The following manuals (English) are for accessories used with the Reactor 2 Hydraulic.

334946

3A3085

Reactor 2 Hydraulic Repair-Parts

Pump Repair-Parts

309572

309852

309815

309827

309550

312666

313213

Heated Hose, Instructions-Parts

Circulation and Return Tube Kit,

Instructions-Parts

Feed Pump Kits, Instructions-Parts

Feed Pump Air Supply Kit,

Instructions-Parts

Fusion ™ AP Gun, Instructions-Parts

Fusion ™ CS Gun, Instructions-Parts

Probler ® P2 Gun, Instructions-Parts

3A3009

3A1907

332735

3A3010

3A6738

3A3084

3A6335

Inlet Sensor Kit, Instructions-Parts

Remote Display Module Kit,

Instructions-Parts

Air Manifold Kit, Instructions-Parts

Caster Kit, Instructions-Parts

Ratio Monitoring Retrofit Kit,

Instructions-Parts

Elite Kit, Instructions-Parts

Integrated PowerStation, Instructions

Manuals are available at www.graco.com.

16 334945E

Typical Installation, without circulation

H

J

K

G

A

L

K

M

G

F

S

(A-ISO)

D

E

J

P

C*

(B-RES)

N

B

Figure 1

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

E

F

G

H

A

B

C

D

Reactor Proportioner

Heated Hose

Fluid Temperature Sensor (FTS)

Heated Whip Hose

Fusion Spray Gun

Gun Air Supply Hose

Feed Pump Air Supply Lines

Agitator Air Supply Line

N

P

S

J

K

L

M

Fluid Supply Lines

Feed Pumps

Agitator

Desiccant Dryer

Bleed Lines

Gun Fluid Manifold (part of gun)

Remote Display Module Kit (optional)

N

334945E 17

Typical Installation, with system fluid manifold to drum circulation

G

H

K M

A

K

M

R

L

G

(B-RES)

J

S

(A-ISO)

D

E

P

C*

J

Figure 2

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

A

B

C

D

E

F

G

H

Reactor Proportioner

Heated Hose

Fluid Temperature Sensor (FTS)

Heated Whip Hose

Fusion Spray Gun

Gun Air Supply Hose

Feed Pump Air Supply Lines

Agitator Air Supply Line

M

P

R

S

J

K

L

Fluid Supply Lines

Feed Pumps

Agitator

Desiccant Dryer

Gun Fluid Manifold (part of gun)

Recirculation Lines

Remote Display Module (optional)

B

F

R

18 334945E

Typical Installation, with gun fluid manifold to drum circulation

G

H

K M

L

J

K

M

R

G

S

D

(A-ISO)

J

E

(B-RES)

P

C*

R

N

A

F

B

N

Figure 3

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

F

G

H

A

B

C

CK

D

Reactor Proportioner

Heated Hose

Fluid Temperature Sensor (FTS)

Circulation Block (accessory)

Heated Whip Hose

Gun Air Supply Hose

Feed Pump Air Supply Lines

Agitator Air Supply Line

M

N

P

R

S

J

K

L

Fluid Supply Lines

Feed Pumps

Agitator

Desiccant Dryer

Bleed Lines

Gun Fluid Manifold (part of gun)

Recirculation Lines

Remote Display Module (optional)

334945E 19

Component Identification

Figure 4

20

S

D

E

P

B

C*

334945E

BA

BB

CD

EC

EM

FA

FB

FH

FM

FV

GA

GB

HA

HB

HC

HP

MP

PA

PB

RS

ISO Side Pressure Relief Outlet

RES Side Pressure Relief Outlet

Advanced Display Module (ADM)

Electrical Cord Strain Relief

Electric Motor (behind shroud)

ISO Side Fluid Manifold Inlet

RES Side Fluid Manifold Inlet

Fluid Heater (behind shroud)

Reactor Fluid Manifold

Fluid Inlet Valve (RES side shown)

ISO Side Pressure Gauge

RES Side Pressure Gauge

ISO Side Hose Connection

RES Side Hose Connection

Heated Hose Electrical Junction Box

Hydraulic Driver (behind shroud)

Main Power Switch

ISO Side Pump

RES Side Pump

Red Stop Button

Component Identification

S

SA

SB

TA

TB

XA

XB

Remote Display Module (optional)

ISO Side PRESSURE RELIEF/SPRAY

Valve

RES Side PRESSURE RELIEF/SPRAY

Valve

ISO Side Pressure Transducer (behind gauge GA)

RES Side Pressure Transducer (behind gauge GB)

Fluid Inlet Sensor (ISO side, Elite models only)

Fluid Inlet Sensor (RES side, Elite models only)

Heated Hose Transformer (behind cover) XF

YA

YB

Flow Meter (ISO side, Elite models only)

Flow Meter (Resin side, Elite models only)

FPG Fluid Inlet Valve Pressure Gauge

FTG Fluid Inlet Valve Temperature Gauge

FTS FTS Connection

HPG Hydraulic Pressure Gauge

334945E 21

Advanced Display Module (ADM)

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

Figure 5 ADM Front View

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

Press to startup or shutdown the system.

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

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

Left/Right Arrows:

Use to move from screen to screen.

Up/Down Arrows:

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

Use to input values.

Use to cancel a data entry field.

Also used to return to Home screen.

Press to enter or exit Setup mode.

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

22 334945E

Advanced Display Module (ADM)

Figure 6 ADM Back View

CN

CP

CR

CS

CJ

CK

CL

CM

Flat Panel Mount (VESA 100)

Model and Serial Number

USB Port and Status LEDs

CAN Communication Cable Connection

Module Status LEDs

Accessory Cable Connection

Token Access Cover

Backup Battery Access Cover

Green Solid

Green Flashing

Yellow Solid

Yellow Flashing

Green Flashing

Yellow Solid

Green and Yellow Flashing

Green Solid

Yellow Solid

Red Steady Flashing

Red Random Flashing or Solid

Run Mode, System On

Setup Mode, System On

Run Mode, System Off

Setup Mode, System Off

Data recording in progress

Downloading information to USB

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

Power applied to module

Active Communication

Software upload from token in progress

Module error exists

334945E 23

Advanced Display Module (ADM)

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.

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.

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

The menu bar appears at the top of each screen.

(The following image is only an example.)

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

No Icon

No information or no error has occurred

Advisory

Deviation

Alarm

See

Troubleshoot Errors, page 64

for more information.

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

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

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.

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

The left and right arrows indicate screen navigation.

24 334945E

Advanced Display Module (ADM)

There are two sets of screens: display system status and data.

advanced features.

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

Password screen displays. If the system is not locked

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

Press on any Setup screen to return to the

Home screen.

Press the Enter soft key function on any screen.

to activate the editing

Press the Exit soft key to exit any screen.

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

Component A

Component B

Estimated Supply Material

Hose Temperature

Pressure

Cycle Counter (press and hold)

Advisory.

See

Troubleshoot Errors, page 64

for more information.

Deviation.

See

Troubleshoot Errors, page 64

for more information.

Alarm.

See

Troubleshoot Errors, page 64

for more information.

Pump Moving Left

Pump Moving Right

334945E 25

Advanced Display Module (ADM)

Icon Function

Start Proportioner

Stop Proportioner

Turn on or off the specified heat zone.

Park pump

Reset Cycle Counter

(press and hold)

Select Recipe

Search

Move Cursor Left One Character

Move Cursor Right One Character

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

Icon Function

Backspace

Cancel

Clear

Troubleshoot Selected Error

Increase value

Decrease value

Next screen

Previous screen

Return to first screen

26 334945E

Electrical Enclosure

$$ $$ %% $$ $$ && $$ $$ (( $$ $$ 00

00 33

77 **

$$ $$ ))

77 %%

WWLL EE

$$ $$ $$ $$ $$ ** $$ $$ ++ $$ $$ -$$ $$ 11

$$ $$ //

$$ $$ ..

AAA Temperature Control Module (TCM)

AAB Hydraulic Control Module (HCM)

AAC Enclosure Fan(s)

AAD Wiring Terminal Blocks (H-30/H-XP2 only)

AAE Power Supply

AAF Sacrificial Surge Protector (SSP)

AAG Hose Breaker

AAH Motor Breaker

AAJ A Side Heat Breaker

AAK B Side Heat Breaker

AAL Hose Transformer Breaker

AAM Motor Contactor

AAN TB21 Terminal Block (if equipped)

MP Main Power Switch

TB Terminal Bus

TG Terminal Ground

$$ $$ )) $$ $$ %% $$ $$ && $$ $$ (( $$ $$ 00

$$ $$ ''

00 33

77 **

WWLL EE

$$ $$ $$ $$ $$ ** $$ $$ ++

$$ $$ --

77 %%

$$ $$ //

$$ $$ 11

$$ $$ ..

334945E 27

Hydraulic Control Module (HCM)

Figure 7

6

7

8

9

10

MS

1

2

14

15

RS

Module Status LEDs see LED Status Table

CAN Communication Connections

Motor Over-Temperature

A Pump Output Pressure

B Pump Output Pressure

A Fluid Inlet Sensor

B Fluid Inlet Sensor

Pump Position Switches

Graco Insite ™

Motor Contactor and Solenoids

Rotary Switch

0 = Reactor 2, H-30

1 = Reactor 2, H-40

2 = Reactor 2, H-50

3 = Reactor 2, H-XP2

4 = Reactor 2, H-XP3

Green Solid

Yellow Solid

Red Steady

Flashing

Red Random

Flashing or Solid

Power applied to module

Active

Communication

Software upload from token in progress

Module error exists

28 334945E

Temperature Control Module (TCM) Cable Connections

Figure 8

3

4

5

1

2

8

9

6

7

10

Power Input

Heater Overtemperature

CAN Communications Connections

Power Out Heater A (ISO)

Power Out Heater B (Res)

Power Out (Heated Hose)

Module Status LEDs

Heater A (ISO) Temperature

Heater B (RES) Temperature

Hose Temperature

Green Solid

Yellow Solid

Red Steady

Flashing

Red Random

Flashing or Solid

Power applied to module

Active

Communication

Software upload from token in progress

Module error exists

334945E 29

Installation

To prevent serious injury due to system tipping over, make sure the Reactor is secured to the floor.

the system. Evaluate the installation to determine if additional support is required beyond the floor mounting screws.

1.

See

Dimensions, page 72

for mounting hole specifications.

2.

Use a minimum of 4 of the 6 mounting holes, evenly spaced in the base of the system frame, to secure base to the floor.

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 is grounded through the power cord.

Spray gun:

connect whip hose ground wire to FTS.

See

Install Fluid Temperature Sensor, page 33

.

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.

30 334945E

Setup

Failure to properly size the equipment may result in damage. To avoid damage to the equipment, follow the guidelines listed below.

• Determine the correct size generator. Using the correct size generator and proper air compressor will enable the proportioner to run at a nearly constant RPM. Failure to do so will cause voltage fluctuations that can damage electrical equipment.

Ensure that the generator matches the voltage and phase of the proportioner.

Use the following procedure to determine the correct size generator.

1.

List peak wattage requirements of all system components.

2.

Add the wattage required by the system components.

3.

Perform the following equation:

Total watts x 1.25 = kVA (kilovolt-amperes)

4.

Select a generator size that is equal to or greater than the determined kVA.

• Use proportioner power cords that meet or exceed the requirements listed in Table 5. Failure to do so will cause voltage fluctuations that can damage electrical equipment, and may cause the power cable to overheat.

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

• Maintain and inspect the generator, air compressor, and other equipment per the manufacturer recommendations to avoid an unexpected shutdown. Unexpected equipment shutdown will cause voltage fluctuations that can damage electrical equipment.

• Use a wall power supply with enough current to meet system requirements. Failure to do so will cause voltage fluctuations that can damage electrical equipment.

334945E 31

Setup

qualified electrician and comply with all local codes and regulations.

1.

Turn main power switch (MP) OFF.

2.

Open electrical enclosure door.

electrical enclosure door if equipped.

3.

Install supplied terminal jumpers in the positions shown in image for the power source used (H-30 and H-XP2 models only).

4.

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

5.

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

6.

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

ti26342a_17D775

H-30, 10.2

kW

H-30, 15.3

kW

H-XP2,

15.3 kW

H-40, 15.3

kW

H-40, 20.4

kW

H-50, 20.4

kW

H-XP3,

20.4 kW

200-240 VAC,

1 Phase

200-240 VAC,

3 Phase, DELTA

350-415 VAC,

3 Phase, WYE

200-240 VAC,

1 Phase

200-240 VAC,

3 Phase, DELTA

350-415 VAC,

3 Phase, WYE

200-240 VAC,

1 Phase

200-240 VAC,

3 Phase, DELTA

350-415 VAC,

3 Phase, WYE

200-240 VAC,

3 Phase, DELTA

350-415 VAC,

3 Phase, WYE

200-240 VAC,

3 Phase, DELTA

350-415 VAC,

3 Phase, WYE

200-240 VAC,

3 Phase, DELTA

350-415 VAC,

3 Phase, WYE

200-240 VAC,

3 Phase, DELTA

350-415 VAC,

3 Phase, WYE

4 (21.2),

2 wire + ground

8 (8.4),

3 wire + ground

8 (8.4),

4 wire + ground

4 (21.2),

2 wire + ground

6 (13.3),

3 wire + ground

8 (8.4),

4 wire + ground

4 (21.2),

2 wire + ground

6 (13.3),

3 wire + ground

8 (8.4),

4 wire + ground

6 (13.3),

3 wire + ground

8 (8.4),

4 wire + ground

4 (21.2),

3 wire + ground

6 (13.3),

4 wire + ground

4 (21.2),

3 wire + ground

6 (13.3),

4 wire + ground

4 (21.2),

3 wire + ground

6 (13.3),

4 wire + ground

*Values are for reference only. Refer to amperage listed in Models table (see

Models, page 9 ) for given

system and compare against latest version of local electrical code to select proper power cord size.

operate from 480 VAC power source.

32 334945E

Setup

5.

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

(LR) with Graco Throat Seal Liquid (TSL), part

206995 (supplied).

1.

Lift the lubricant reservoir (LR) out of the bracket

(RB) and remove the container from the cap.

The Fluid Temperature Sensor (FTS) is supplied.

Install FTS between main hose and whip hose (see

Related Manuals, page 16

).

1.

Remove cover (CV).

2.

Fill with fresh lubricant. Thread the reservoir onto the cap assembly and place it in the bracket (RB).

3.

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

4.

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

the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube (ST) and returned to the pump.

2.

Route heated hose wires (HW) through strain relief (SR) and install wires into the open screw terminals on the terminal block (TB). Torque to

35 in-lb (3.95 N•m).

3.

Reinstall cover (CV).

334945E 33

Advanced Display Module (ADM) Operation

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

Then the power key icon screen will display until the

ADM power on/off button time after system power-up.

is pressed for the first

To begin using the ADM, the machine must be active. To verify the machine is active, verify that the

System Status Indicator Light is illuminated green, see

Advanced Display Module (ADM), page 22 . If the

System Status Indicator Light is not green, press the

ADM Power On/Off button . The System Status

Indicator Light will illuminate yellow if the machine is disabled.

Perform the following tasks to fully setup your system.

1.

Set pressure values for the Pressure Imbalance

Alarm to activate. See

System Screen 1, page 38

.

2.

Enter, enable, or disable recipes. See

Recipes Screen, page 39

.

3.

Set general system settings. See

Advanced Screen 1 — General, page 37

.

4.

Set units of measure.

See

Advanced Screen 2 — Units, page 37 .

5.

Set USB settings.

See

Advanced Screen 3— USB, page 37 .

6.

Set target temperatures and pressure. See

Targets, page 41 .

7.

Set component A and component B supply levels. See

Maintenance, page 42

.

34 334945E

Advanced Display Module (ADM) Operation

The ADM will start in the Run screens at the Home screen. From the Run screens, press to access the

Setup screens. The system defaults with no password, entered as 0000. Enter the current password then press

. Press to navigate through the Setup Mode screens (see

Navigating the Screens, page 25

).

Set a password to allow Setup screen access, see

Advanced Screen 1 – General, page 37 . Enter any number

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

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

334945E 35

Advanced Display Module (ADM) Operation

36 334945E

Advanced Display Module (ADM) Operation

Advanced setup screens enable users to set units, adjust values, set formats, and view software information for each component. Press to scroll through the Advanced setup screens. Once in the desired Advanced setup screen, press to access the fields and make changes. When changes are complete press to exit edit mode.

through the Advanced setup screens.

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

(zero equals screen saver off).

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

USB logs are recorded. See

USB Data, page 65

.

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

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

USB Configuration, Hydraulic Control Module, and

Temperature Control Module, and Remote Display

Module (optional).

334945E 37

Advanced Display Module (ADM) Operation

Use this screen to enable pressure imbalance alarms and deviations, set pressure imbalance values, and enable inlet sensors. Select accessories using this screen. If the flow meter accessory is installed, use this screen to:

Reactor 2 Hydraulic systems.

• Enable ratio errors

• Set the ratio alarm percentage

Use this screen to enable Manual Hose Mode,

Integrated Mode, and the diagnostic screen. This screen can also be used to set the primary heater size, set the maximum and minimum drum volume, and enable the drum alarms.

Manual Hose Mode disables the hose temperature

RTD sensor so the system can operate if the sensors were to malfunction (see

Manual Hose Mode, page 53

for more information).

Integrated Mode allows the Reactor 2 to control an Integrated PowerStation, if the Integrated

PowerStation is installed. If the flow meter accessory is installed, use this screen to set the k-factors printed on the flow meter serial number labels.

Use this screen to enable alternate pump cylinder sizes, to turn motor standby mode on and off, and to enable recirculation cycle count. Cycles below

700 psi outlet pressure will not be counted unless enabled.

38 334945E

Advanced Display Module (ADM) Operation

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 be displayed on the three recipe screens.

1.

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

(maximum 16 characters). Press old recipe name.

to clear the

2.

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

1.

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

2.

Use

Press to highlight the enabled check box.

to enable or disable the recipe.

334945E 39

Advanced Display Module (ADM) Operation

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

Run Screens Navigation Diagram, page 44

.

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

to navigate through the Run Mode

Run Screens Navigation Diagram

Figure 9

40 334945E

Advanced Display Module (ADM) Operation

This is the home screen when the system is off.

This screen displays actual temperatures, actual pressures at the fluid manifold, 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 43

for corrective action.

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

Use this screen to turn on heat zones, start the proportioner, stop the proportioner, park the component A pump, and clear cycles.

Use this screen to define the setpoints for the

A Component Temperature, B Component

Temperature, heated hose temperature, and pressure.

flow ratio. The vertical bars indicate the level of flow through the meters. The numerical ratio indicates the ratio of A-side component to B-side component

(ISO : RES). For example, if the ratio is 1.10 : 1, the proportioner is pumping more A-side component

(ISO) than B-side component (RES). If the ratio is

0.90 : 1, the proportioner is pumping more B-side component (RES) than A-side component (ISO).

10°F (5°C) above the highest A or B temperature setpoint or 180°F (82°C).

Note

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

334945E 41

Advanced Display Module (ADM) Operation

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

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

The daily value automatically resets at midnight.

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

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, page 45

for event code descriptions.

See

Error Codes and Troubleshooting, page 65

for error code descriptions.

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

Download Procedure, page 65 .

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. To download logs, see

Download Procedure, page 65 .

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. To download logs, see

Download Procedure, page 65

.

42 334945E

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

Error Codes and Troubleshooting, page 65

, for more information on error codes.

Advanced Display Module (ADM) Operation

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

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

334945E 43

Advanced Display Module (ADM) Operation

Use this screen to view information for all system components. NOTE: If not visible, this screen may be on the Setup Systems screen (see

Setup Mode

).

Use this screen to enter a job name or number.

The following information is displayed:

• A Chemical

• B Chemical

• Hose Chemical

• TCM PCB — temperature control module temperature

• A Current

• B Current

• Hose Current

• A Voltage

• B Voltage

• Hose Voltage

• Pressure A — chemical

• Pressure B — chemical

• CPM — cycles per minute

• Total Cycles — lifetime cycles

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

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

Recipes, page 39 .

44 334945E

Advanced Display Module (ADM) Operation

EBDA

EBDB

EBDH

EBPX

EBUX

EC0X

ECDA

ECDB

ECDH

ECDP

EACX

EADA

EADB

EADH

EAPX

EAUX

EB0X

ECDX

EL0X

EM0X

EP0X

EQU1

EQU2

EQU3

EQU4

EQU5

ER0X

EVSX

EVUX

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

Event Code Description

Recipe Selected

Heat On A

Heat On B

Heat On Hose

Pump On

USB Drive Inserted

ADM Red Stop Button Pressed

Heat Off A

Heat Off B

Heat Off Hose

Pump Off

USB Drive Removed

Setup Value Changed

A Temperature Setpoint Changed

B Temperature Setpoint Changed

Hose Temperature Setpoint Changed

Pressure Setpoint Changed

Recipe Changed

System Power On

System Power Off

Pump Parked

System Settings Downloaded

System Settings Uploaded

Custom Language Downloaded

Custom Language Uploaded

Logs Downloaded

User Counter Reset

Standby

USB Disabled

334945E 45

Startup

5.

Confirm

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

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

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

Fluid Inlet Strainer Screens, page 61 .

6.

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

7.

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

8.

Turn main

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

2.

Check

Check level and condition of ISO lube daily. See

Pump Lubrication System, page 63 .

3.

Use A and B Drum Level Sticks (24M174) to measure the material level in each drum. If needed, the level can be entered and tracked in the ADM. See

Advanced Setup Screens, page 37

.

4.

Check

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

46 334945E

9.

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

Startup

e.

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

a.

Setup steps are complete.

See

Setup Mode .

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 49

.

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

Circulation Through Gun Manifold, page 50

.

d.

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

SA

GA GB

SB

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

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

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

f.

Hold gun fluid manifold over two grounded waste containers. Open fluid valves A and B until clean, air-free fluid comes from valves.

Close valves.

The Fusion AP gun manifold is shown.

334945E 47

Startup

11. Press to activate ADM.

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

Advanced Display Module (ADM) Operation, page 34

.

13. Preheat the system: a.

Press to turn on hose heat zone.

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

b.

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

Circulation Through Reactor, page 49

.

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

Circulation Through Gun Manifold, page 50

.

c.

Wait for the hose to reach set point temperature.

This equipment is used with heated fluid which can cause equipment surfaces to become very hot. To avoid severe burns:

• Do not touch hot fluid or equipment.

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

• Allow equipment to cool completely before touching it.

• Wear gloves if fluid temperature exceeds 110°F (43°C).

d.

voltages less than nominal 230 VAC when maximum hose length is used.

Press to turn on A and B heat zones.

48 334945E

Fluid Circulation

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

fluid flow rates with temperature set points at desired drum temperature. Low temperature rise deviation errors may result.

To circulate through gun manifold and preheat hose, see

Circulation Through Gun Manifold, page 50 .

1.

Follow

Startup, page 46 .

4.

Set temperature targets. See

Targets, page 41 .

5.

Before starting the motor, unlock the hydraulic compensator knob, then rotate counter-clockwise until it ceases to move.

To avoid injection injury and splashing, do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpressure relief valves when set to

SPRAY . Lines must be open so valves can automatically relieve pressure when machine is operating.

2.

See

Typical Installation, with system fluid manifold to drum circulation, page 18 . Route

circulation lines back to respective component

A or B supply drum. Use hoses rated for the maximum working pressure of this equipment.

3.

Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

GA GB

SA SB

.

6.

Press motor to start motor and pumps.

Circulate fluid at lowest possible pressure until temperatures reach targets.

7.

Press to turn on the hose heat zone.

8.

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

9.

Turn off motor.

10. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY .

SA

GA GB

SB

334945E 49

Fluid Circulation

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

2.

Route circulation lines back to respective component A or B supply drum. Use hoses rated for the maximum working pressure of this

3.

Follow procedures from

Startup, page 46 .

4.

Turn main power switch on.

fluid flow rates with temperature set points at desired drum temperature. Low temperature rise deviation errors may result.

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

1.

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

5.

Set temperature targets. See

Targets, page 41 .

6.

Before starting the motor, unlock the hydraulic compensator knob, then rotate counter-clockwise until it ceases to move.

P

CK

R

The Fusion AP gun manifold is shown.

246362

256566

Fusion AP

Fusion CS

309818

313058

7.

Press motor to start motor and pumps.

Circulate fluid at lowest possible pressure until temperatures reach targets.

8.

Press to turn on the hose heat zone.

9.

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

10. Turn off motor.

50 334945E

The Fusion AP gun is shown.

1.

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

Spraying

6.

Open fluid inlet valve (FV) located at each pump inlet.

2.

Attach gun fluid manifold. Connect gun air line.

Open air line valve.

7.

Press to start motor and pumps.

3.

Adjust the gun air pressure. Do not exceed 130 psi (0.2 MPa, 2 bar).

4.

Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY .

SA

GA GB

SB

8.

Adjust pressure compensator knob to desired fluid stall pressure. Turn knob clockwise to increase pressure and counter-clockwise to decrease pressure. Use hydraulic pressure gauge (HPG) to view hydraulic pressure. Once desired fluid stall pressure is set, lock the knob in place by rotating lower portion clockwise until tight.

5.

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

Home — System Off, page 41 .

334945E

Component A and B outlet pressures will be higher than the hydraulic set pressure, depending on the model. Component A and B (GA, GB) pressure may be viewed on the pressure gauges or the ADM.

51

Spraying

9.

Check fluid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by valve for that component toward PRESSURE

RELIEF/CIRCULATION balanced pressures.

GA GB

SA until gauges show

SB

11. Disengage gun piston safety lock.

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

10. Open gun fluid inlet valves A and B.

To prevent material crossover on impingement trigger gun if pressures are imbalanced.

Flow rate, atomization, and amount of overspray are affected by four variables.

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.

setting. The A and B temperatures can be offset to help balance the fluid pressure.

on desired flow rate and fluid viscosity.

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.

52 334945E

Manual Hose Mode

If the system produces the T6DH Sensor Error Hose alarm or the T6DT Sensor Error TCM alarm, use manual hose mode until the hose RTD cable or FTS temperature sensor can be repaired.

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

4.

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

1.

Disconnect the hose RTD sensor from the TCM.

2.

Enter Setup Mode and navigate to System

Screen 2.

Current Settings Hose

Default

Maximum

20A

37A

5.

Navigate back to the Run Mode Home screen.

The hose now displays a current instead of a temperature.

3.

Select Enable Manual Hose Mode.

manual hose mode advisory EVCH-V will appear.

334945E

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

53

Manual Hose Mode

1.

Enter Setup Mode and navigate to System 2

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

2.

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

54 334945E

Standby

If you stop spraying for a period of time, the unit will enter standby by shutting down the electric motor and hydraulic pump, to reduce equipment wear and minimize heat buildup. The pump icon on the ADM

Home screen will flash when in standby.

off during standby.

To restart, spray off target for two seconds. The system will sense the pressure drop and the motor will ramp up to full speed in a few seconds.

To activate or deactivate standby:

1.

Enter setup mode by pressing

2.

Go to screen System 3 and select to the page for editing.

on the ADM.

enter

3.

Select the “Standby Idle Time” drop down using and the arrow keys. Select the desired delay using and the arrow keys. Press enter to select the desired value.

4.

Exit the page and return to run mode by pressing

, then .

334945E 55

Shutdown

6.

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

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

1.

Press to stop the pumps.

2.

Turn off all heat zones.

7.

Turn main power switch OFF.

3.

Relieve pressure.

See

Pressure Relief Procedure, page 59 .

To prevent electric shock do not remove any covers or open the electrical enclosure door while the power is ON.

8.

Close all fluid supply valves.

4.

Press to park the Component A and

Component B pumps. The park operation is complete when green dot goes out. Verify the park operation is complete before moving to next step.

9.

Set PRESSURE RELIEF/SPRAY valves to

SPRAY to seal out moisture from the drain line.

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

5.

Press to deactivate the system.

56 334945E

Purge Air Procedure

5.

Set the PRESSURE RELIEF/SPRAY valves

(SA, SB) to PRESSURE RELIEF/CIRCULATION

.

SA

GA GB

SB introduced into the system.

1.

Relieve pressure.

See

Pressure Relief Procedure, page 59 .

2.

Install a recirculation kit or install bleed lines between the outlet manifold recirculation fitting and a waste container.

6.

Adjust the pressure in the feed pump air supply lines to 100 psi.

7.

To pressurize the feed pumps, connect the air supply lines (G) to the feed pumps (K).

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

3.

Press the proportioner stop button off the motor.

to turn

4.

To relieve air pressure from the feed pumps, disconnect the air supply lines (G) from the feed pumps (K).

8.

Press the Jog mode button mode. Use the arrow keys speed to J20.

to enter Jog to set the jog

9.

Press the jog mode start button to start the motor. Run 1 gallon (3.8 L) of material through the system.

10. Set the PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY .

SA

GA GB

SB

334945E 57

Purge Air Procedure

11. To relieve air pressure from the feed pumps, disconnect the air supply lines (G) from the feed pumps (K).

13. Set the PRESSURE RELIEF/SPRAY valves

(SA, SB) to PRESSURE RELIEF/CIRCULATION

.

SA

GA GB

SB

12. Press the jog mode stop button mode.

to exit Jog

14. Listen for a “spitting” sound from the bleed lines (N) or recirculation lines (R). See

Typical Installation, without circulation, page 17

,

Typical Installation, with system fluid manifold to drum circulation, page 18 , and

Typical Installation, with gun fluid manifold to drum circulation, page 19 . This sound indicates

that the Reactor 2 system still contains unwanted air. If the system still contains air, repeat the purge air procedure.

58 334945E

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

4.

Close gun fluid inlet valves A and B.

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

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

The Fusion AP gun is shown.

1.

Press to stop the pumps.

2.

Turn off all heat zones.

5.

Shut off feed pumps and agitator, if used.

6.

Route fluid to waste containers or supply tanks.

Turn PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

GA GB

SA SB

7.

Engage gun piston safety lock.

3.

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

8.

Disconnect gun air line and remove gun fluid manifold.

334945E 59

Flushing

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area.

• Ensure main power is off and heater is cool before flushing.

• Do not turn on heater until fluid lines are clear of solevent.

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

RELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION lines (N).

GA GB

. Flush through bleed

SA SB

To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).

To prevent moisture from reacting with isocyanate, always leave the system filled with a moisture-free plasticizer or oil. Do not use water. Never leave the system dry. See

Important Two-

Component Material Information, page 7 .

60 334945E

Maintenance

Prior to performing any maintenance procedures, follow

Pressure Relief Procedure, page 59

.

0° to 90° F

(-17° to 32° C)

90° F and above

(32° C and above)

1000 hours or 12 months, whichever comes first

500 hours or 6 months, whichever comes first

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.

• Inspect hydraulic and fluid lines for leaks daily.

• Clean up all hydraulic leaks; identify and repair the cause of the leak.

• Inspect fluid inlet strainer screens daily. See below.

• Keep component A from exposure to moisture to prevent crystallization.

• Check hydraulic fluid level weekly. Check hydraulic fluid level on a dipstick. Fluid level must be between indent marks on dipstick.

Refill as required with approved hydraulic fluid,

Anti-Wear (AW) Hydraulic Oils table in the Reactor

Repair-Parts manual 334946. If fluid is dark in color, change fluid and filter.

Inspect fluid inlet strainer screens daily, see

Fluid Inlet Strainer Screens, page 61

.

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

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

Pump Lubrication System, page 63

.

To prevent crystallization, do not expose component

A to moisture in air.

• Change break-in oil in a new unit after the first 250 hours of operation or within 3 months, whichever comes first. See the table below for recommended frequency of oil changes.

Clean gun mix chamber ports regularly. See gun manual.

334945E 61

Maintenance

Clean gun check valve screens regularly. See gun manual.

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

(under shield).

Keep vent holes on bottom and back of electrical enclosure and sides and back of transformer enclosure open..

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

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

Note

Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.

1.

Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.

2.

Place a container under the strainer base to catch drain off when removing the strainer plug (C).

3.

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

(B) and replace as required.

4.

Ensure the pipe plug (D) is screwed into the strainer plug (C). Install the strainer plug with the screen (A) and o-ring (B) in place and tighten. Do not overtighten. Let the o-ring make the seal.

5.

Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.

Figure 10

62 334945E

Maintenance

Check the condition of the ISO pump lubricant daily.

Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

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

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

4 weeks.

To change pump lubricant:

1.

Follow

Pressure Relief Procedure, page 59 .

2.

Lift the lubricant reservoir (LR) out of the bracket

(RB) and remove the container from the cap.

Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain.

Reattach the check valve to the inlet hose.

3.

Drain the reservoir and flush it with clean lubricant.

4.

When the reservoir is flushed clean, fill with fresh lubricant.

5.

Thread the reservoir onto the cap assembly and place it in the bracket.

6.

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

7.

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

the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube and returned to the pump.

8.

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

Pump Lubrication System

Figure 11

334945E 63

Errors

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

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

Troubleshooting, page 43

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

To troubleshoot the error:

1.

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

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

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

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

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

To diagnose the active error, see

Troubleshoot Errors, page 64

.

Note

Press or to return to the previously displayed screen.

2.

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

3.

If no internet connection is available, see

Error Codes and Troubleshooting, page 65

for causes and solutions for each error code.

64 334945E

Error Codes and Troubleshooting

See system repair manual 334946 or visit http://help.graco.com for causes and solutions to each error code, or call your Graco contact listed on the back page of this manual.

flash drive (for example, missing or empty log files), save desired data off of the USB flash drive and reformat it before repeating the download procedure.

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.

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.)

8.

Open DOWNLOAD folder.

9.

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

10. 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.

(UTF-16) format. If opening the log file in

Microsoft Word, select Unicode encoding.

Allocation Table) storage devices. NTFS, used by 32

GB or greater storage devices, is not supported.

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

• Event Log

• Job Log

• Daily Log

• System Software Log

• Blackbox Log

• Diagnostics Log

Follow

Download Procedure, page 65 , 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.

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

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

• Date of event code

• Time of event code

• Event code

• Event type

• Action taken

• Event Description

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

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

334945E 65

Error Codes and Troubleshooting

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

The job log maintains a record of data points based on the USB Log Frequency defined in the Setup screens.

The ADM stores the last 237,000 data points for download. See

Advanced Setup Screens, page 37 ,

for information on setting the Download Depth and

USB Log Frequency.

• Data point date

• Data point time

• A side temperature

• B side temperature

• Hose temperature

• A side temperature setpoint

• B side temperature setpoint

• Hose temperature setpoint

• Pressure A

• Pressure B

• A side inlet pressure (Elite only)

• B side inlet pressure (Elite only)

• A side inlet temperature (Elite only)

• B side inlet temperature (Elite only)

• Inlet pressure setpoint

• System lifetime pump cycle counts

• Usage Volume (manual)

• Pressure, volume, and temperature units

• Job name/number

The following data is stored in this file:

• Date that material was sprayed

• Time — unused column

• Total pump cycle count for day

• Total volume sprayed for day

The system software file name is 4–SYSTEM.CSV

and is stored in the DATAxxxx folder.

The system software log lists the following:

• Date log was created

• Time log was created

• Component name

• Software version loaded on the above component

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

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

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

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

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

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

The 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 67

for instructions on how to use this file.

66 334945E

Error Codes and Troubleshooting

The custom language file name is DISPTEXT.TXT

and is stored in the DOWNLOAD folder.

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

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

ADM.

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

• U+0020 - U+007E (Basic Latin)

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

• U+0100 - U+017F (Latin Extended-A)

• U+0386 - U+03CE (Greek)

• U+0400 - U+045F (Cyrillic)

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 then follow the

Upload Procedure, page 67

The format of the custom language file is critical.

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

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

to install the file.

must define a custom string for each entry in the

DISPTEXT.TXT file. Blank second-column fields will be displayed blank on the ADM.

• The file name must be DISPTEXT.TXT.

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

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

• Do not add or remove rows from the file.

• Do not change the order of the rows.

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

1.

Download Procedure automatically generate the proper folder structure on the USB flash drive.

2.

Insert USB flash drive into USB port of computer.

3.

The USB flash drive window automatically opens.

If it does not, open USB flash drive from within

Windows Explorer.

4.

Open GRACO folder.

5.

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

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.

users can now select the new language from the Language drop-down menu in

Advanced Screen 1 — General, page 37

.

334945E 67

Performance Charts

Use this chart 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.

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

ti26328a

2000

(13.8, 138)

1500

(10.3, 103)

PRESSURE psi

(MPa, bar)

1000

(6.9, 69)

A

B

C

E

D

F

500

(3.4, 34)

0 5

(2.3)

15

(6.8)

25

(11.4)

35

(15.9)

45

(20.5)

55

(25.0)

FLOW rate in lb/min (kg/min)

A = H-30 at 50 Hz

B = H30 at 60 Hz

C = H-40 at 50 Hz

D = H-40 at 60 Hz

E = H-50 at 50 Hz

F = H-50 at 60 Hz

68 334945E

Performance Charts

PRESSURE psi

(MPa, bar)

3500

(24.1, 241)

3000

(20.7, 207)

2500

(17.2, 172)

2000

(13.8, 138)

1500

(10.3, 103)

1000

(6.9, 69)

500

(3.4, 34)

0

G

H

J ti26345a

K

0.5

(1.9)

1.0

(3.8)

1.5

(5.7)

2.0

(7.6)

2.5

(9.5)

3.0

(11.4)

FLOW rate in gpm (lpm)

G = H-XP2 at 50 Hz

H = H-XP2 at 60 Hz

J = H-XP3 at 50 Hz

K = H-XP3 at 60 Hz

Delta T in degrees F

(degrees C)

L = 10.2 kW

M = 15.3 kW

N = 20.4 kW

FLOW rate in gpm (lpm)

* Heater performance data is based on testing with 10 wt. hydraulic oil and 230V across heater power wires.

334945E 69

Technical Specifications

Models H-30, H-40, and H-50

Models H-XP2 and H-XP3

H-30

H-40, H-50

H-XP2

H-XP3

Model H-40

Models H-30 and H-50

Models H-XP2 and H-XP3

Component A (ISO)

Component B (RES)

Component A (ISO)

Component B (RES)

1/4 npsm(m)

Model H-30

Model H-XP2

Model H-50

Model H-40

Model H-XP3

Model H-40

Models H-30 and H-50

Models H-XP2 and H-XP3

70

2000 psi

3500 psi

700 psi

600 psi

1200 psi

850 psi

13.8 MPa, 138 bar

24.1 MPa, 241 bar

4.8 MPa, 48 bar

4.1 MPa, 41 bar

8.2 MPa, 82 bar

5.8 MPa, 58 bar

1.91 : 1

1.64 : 1

2.79 : 1

3/4 npt(f), 300 psi maximum

3/4 npt(f), 300 psi maximum

3/4 npt(f), 2.07 MPa, 20.7

bar maximum

3/4 npt(f), 2.07 MPa, 20.7

bar maximum

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

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

250 psi

190° F

1.75 MPa, 17.5 bar

88° C

28 lb/min (60 Hz)

1.5 gpm (60 Hz)

52 lb/min (60 Hz)

45 lb/min (60 Hz)

2.8 gpm (60 Hz)

0.063 gal.

0.074 gal.

0.042 gal.

13 kg/min (60 Hz)

5.7 liter/min (60 Hz)

24 kg/min (60 Hz)

20 kg/min (60 Hz)

10.6 liter/min (60 Hz)

0.24 liter

0.28 liter

0.16 liter

334945E

Technical Specifications

200–240V nominal, 1 phase

(H-30, H-XP2 only)

200–240V nominal, 3 phase

350–415V nominal, 3 phase

See the Models listing in the manual.

See the Models listing in the manual.

195–264 VAC, 50/60 Hz

195–264 VAC, 50/60 Hz

338–457 VAC, 50/60 Hz

3.5 gal.

13.6 liters

Citgo, A/W Hydraulic Oil, ISO Grade 46

90.2 dB(A)

82.6 dB(A)

H-40, H-50, H-XP3,

H-30, 10 kW

H-30, H-XP2, 15 kW

600 lb

544 lb

556 lb

272 kg

247 kg

252 kg

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

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

334945E 71

Dimensions

72 334945E

Notes

334945E 73

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.

Graco will, for a period as defined in the table below 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.

24U854

24Y263

24U855

Advanced Display Module 36 Months or 2 Million Cycles (whichever comes first)

Hydraulic Control Module

Temperature Control

Module

All Other Parts

36 Months or 2 Million Cycles (whichever comes first)

36 Months or 2 Million Cycles (whichever comes first)

12 Months

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

INCLUDING

FOR

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

AND

MATERIALS

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.

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.

For the latest information about Graco products, visit www.graco.com.

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

place an

Phone:

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 334945

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

334945

GRACO

Copyright Graco www.graco.com

Revision E, January 2019

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