3A1569E - Reactor A-25/A-XP1, Operation (English)

3A1569E - Reactor A-25/A-XP1, Operation (English)
Operation
®
A-25/A-XP1
3A1569E
PLURAL COMPONENT PROPORTIONER
EN
Air operated, electrically heated, plural component proportioner
A-25: For spraying or dispensing 1:1 ratio polyurethane foam formulations and other
1:1 fast setting materials.
A-XP1: For spraying or dispensing 1:1 ratio polyurea formulations and other 1:1 fast
setting materials.
Not for use in explosive atmosphere or hazardous locations.
This model is field-configurable to the following supply voltages:
200-240 VAC, 1 Phase
200-240 VAC, 3 Phase
350-415 VAC, 3 Phase
A-25:
2000 psi (14 MPa, 138 bar) Maximum Fluid Working Pressure
80 psi (550 kPa, 5.5 bar) Maximum Air Working Pressure
A-XP1:
3500 psi (24 MPa, 241 bar) Maximum Fluid Working Pressure
100psi (689 kPa, 6.9 bar) Maximum Air Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 10 for model information,
including maximum working pressure and approvals.
ti16811b
Contents
Proportioner Models . . . . . . . . . . . . . . . . . . . . . . . . 3
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Important Two-Component Material Information . 8
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 8
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 9
Keep Components A and B Separate . . . . . . . . . 9
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 9
Foam Resins with 245 fa Blowing Agents . . . . . . 9
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Installation, without Circulation . . . . . . . 10
Typical Installation, with Circulation . . . . . . . . . . 11
Component Identification . . . . . . . . . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Locate Reactor A-25/A-XP1 . . . . . . . . . . . . . . . 16
Determine Power Source . . . . . . . . . . . . . . . . . 16
Electrical Requirements . . . . . . . . . . . . . . . . . . 16
Ground System . . . . . . . . . . . . . . . . . . . . . . . . . 19
Iso Pump Lubrication System Setup . . . . . . . . . 19
Fluid Supply Connections . . . . . . . . . . . . . . . . . 19
Air Supply Connection . . . . . . . . . . . . . . . . . . . 19
Recirculation / Pressure Relief Lines . . . . . . . . 20
Install Fluid Temperature Sensor (FTS) . . . . . . 20
Connect Heated Hose . . . . . . . . . . . . . . . . . . . . 20
Close Gun Fluid Inlet Valves A and B . . . . . . . . 21
Connect Whip Hose to Gun or
Gun Fluid Manifold . . . . . . . . . . . . . . . . . . . 21
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Check Hose . . . . . . . . . . . . . . . . . . . . 22
Set Temperatures . . . . . . . . . . . . . . . . . . . . . . . 23
Supply Wet-Cups with Throat Seal Liquid . . . . 24
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spray Adjustments . . . . . . . . . . . . . . . . . . . . . . 26
2
Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 27
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Daily Start-up Procedure . . . . . . . . . . . . . . . . . . 29
Fluid Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Circulation Through Reactor . . . . . . . . . . . . . . . 31
Circulation Through Gun Manifold . . . . . . . . . . . 32
DataTrak Controls and Indicators . . . . . . . . . . . . 33
DataTrak Operation . . . . . . . . . . . . . . . . . . . . . . . . 34
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40
3A1569E
Proportioner Models
Proportioner Models
All proportioners can be configured to operate on 350-415V (4 wire), 200-240V (3 wire), or 200-240V 1Ø.
Part
Maximum Fluid Working Maximum Air Working Includes:
DataTrak
Pressure
Set Pressure
(cycle count only)
psi (MPa, bar)
psi (kPa, bar)
Wheels
262572
2000 (14, 138)
80 (550, 5.5)
---
---
262614
2000 (14, 138)
80 (550, 5.5)
24A592
✔
24Y164
3500 (24, 241)
100 (689, 6.9)
---
---
24Y165
3500 (24, 241)
100 (689, 6.9)
24A592
✔
Approvals
3172585
Conforms to ANSI/UL
Std. 499 Certified to
CAN/CSA Std.
C22.2 No. 88
Systems
All systems include a proportioner, spray gun, and 60 ft (18.3 m) of heated hose.
Part
P22614
AP2614
CS2614
P22572
AP2572
CS2572
P2Y165
APY165
P2Y164
APY164
3A1569E
Maximum Working
Proportioner
Heated Hose
Pressure
(see Typical Installation,
psi (MPa, bar)
without Circulation) 50 ft (15 m) 10 ft (3 m)
2000 (14, 138)
262614
246678
246050
2000 (14, 138)
262614
246678
246050
2000 (14, 138)
262614
246678
246050
2000 (14, 138)
262572
246678
246050
2000 (14, 138)
262572
246678
246050
2000 (14, 138)
262572
246678
246050
3500 (24, 241)
24Y165
246679
246055
3500 (24, 241)
24Y165
246679
246055
3500 (24, 241)
24Y164
246679
246055
3500 (24, 241)
24Y164
246679
246055
Gun
Model
Probler P2
Fusion™ AP
Fusion™ CS
Probler P2
Fusion™ AP
Fusion™ CS
Probler P2
Fusion™ AP
Probler P2
Fusion™ AP
Part
GCP2R1
246101
CS01RD
GCP2R1
246101
CS01RD
GCP2R1
246101
GCP2R1
246101
3
Related Manuals
Related Manuals
Manuals are available at www.graco.com.
Component manuals in English:
Manual
3A1570
309577
309815
309827
309852
309572
309550
312666
313213
313541
312796
4
Description
Reactor A-25 Proportioner, Repair-Parts
Proportioning Pump, Repair-Parts
Feed Pump Kit, Instructions-Parts
Feed Pump Air Supply KIt, Instructions-Parts
Circulation and Return Tube Kit, Instructions-Parts
Heated Hose, Instructions-Parts
Fusion™ AP Spray Gun, Instructions-Parts
Fusion™ CS Spray Gun, Instructions-Parts
Probler P2 Spray Gun, Instructions-Parts
DataTrak Kits, Installation-Parts
NXT® Air Motor, Instructions-Parts
3A1569E
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, 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 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.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or
swallowed.
• Read 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 well ventilated and always wear appropriate personal protective equipment. See Personal Protective
Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
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.
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.
3A1569E
5
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
6
3A1569E
Warnings
WARNING
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.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious
injury, or property damage.
• Do not use 1,1,1-trichloroethylene, 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.
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.
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.
3A1569E
7
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
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:
TOXIC FUMES
HAZARD
DO NOT ENTER DURING
SPRAY FOAM APPLICATION
OR FOR ___ HOURS AFTER
APPLICATION IS COMPLETE
DO NOT ENTER UNTIL:
DATE: ____________
TIME: ____________
8
3A1569E
Important Two-Component Material Information
Material Self-ignition
Some materials may become self-igniting if applied too
thick. Read material manufacturer’s warnings and Safety
Data Sheet (SDS).
Keep Components A and B
Separate
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures above
90°F (33°C) when not under pressure, especially if agitated.
To reduce frothing, minimize preheating in a circulation system.
Changing Materials
NOTICE
Changing the material types used in your equipment
requires special attention to avoid equipment damage
and downtime.
Cross-contamination can result in cured material in fluid lines
which could cause serious injury or damage equipment. To
prevent cross-contamination:
• Never interchange component A and component B wetted parts.
• Never use solvent on one side if it has been contaminated from the other side.
Moisture Sensitivity of
Isocyanates
•
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.
Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystal that become
suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and the life of all
wetted parts.
•
Always use a sealed container with a desiccant dryer in
the vent, or a nitrogen atmosphere. Never store ISO in
an open container.
•
Keep the ISO pump wet cup or reservoir (if installed)
filled with appropriate lubricant. The lubricant creates a
barrier between the ISO and the atmosphere.
•
•
Use only moisture-proof hoses compatible with ISO.
•
Always lubricate threaded parts with an appropriate
lubricant when reassembling.
Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in
use.
NOTE: The amount of film formation and rate of crystallization
varies depending on the blend of ISO, the humidity, and the
temperature.
3A1569E
9
Typical Installation, without Circulation
Typical Installation, without Circulation
G
K
M
J
K
F
A
L
N
H
WLE
J
N
H
D
B
E
C*
P
ti16812a
* Shown exposed for clarity. Wrap with tape during operation.
FIG. 1: Typical Installation, without Circulation
Key for FIG. 1
A
B
C
D
E
F
G
H
J
K
L
10
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
Spray Gun
Proportioner and Gun Air Supply Hose
Feed Pump Air Supply Lines
Waste Containers
Fluid Supply Lines
Feed Pumps
Agitator (if required)
M
N
P
Desiccant Dryer
Bleed Lines/Over Pressure Relief
Gun Fluid Manifold
3A1569E
Typical Installation, with Circulation
Typical Installation, with Circulation
Key for FIG. 2
A
B
C
D
E
F
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
Spray Gun
Proportioner and Gun Air Supply Hose
G
J
K
L
M
N
P
Feed Pump Air Supply Lines
Fluid Supply Lines
Feed Pumps
Agitator (if required)
Desiccant Dryer
Recirculation/Over Pressure Relief Return Hoses
Gun Fluid Manifold
G
K
M
M
J
F
K
A
L
N
N
J
F
WLE
D
B
E
C*
P
ti16813b
* Shown exposed for clarity. Wrap with tape during operation.
FIG. 2: Typical Installation, with Circulation
3A1569E
11
Component Identification
Component Identification
W
T
AG
R
AC
AD
AI
S
AH
AA
DD
AB
AF
FF
Z
X
GG
V
Y
WLE
AE
U
FIG. 3: Typical Installation
12
3A1569E
Component Identification
Key:
R
Main Disconnect Switch - Controls power to
heating circuits. I
S
Main Air Filter - Filters system air supply.
T
Resin (B) Pressure Gauge - Displays pressure in
resin proportioning system (B side).
AC FTS Jumper Harness - Carries electrical signal
from FTS sensor in isocyanate hose to hose
temperature controller.
AD Primary Heaters - Heats material to required
dispensing temperature.
AE ISO (A) - (Isocyanate) Proportioning Pump Draws in and dispenses a fixed volume of
isocyanate to gun.
U
Resin (B) - Inlet Supply Valve
V
Resin (B) Fluid Y-Strainer - (20 mesh)
W ISO (A) Pressure Gauge - Displays pressure in
isocyanate proportioning system (A side).
X
ISO (A) - Inlet Supply Valve
Y
ISO (A) Fluid Y-Strainer - (20 mesh)
Z
ISO (A) Pump Lube System - Behind Proportioner
shroud. (A side only)
AF Resin (B) Proportioning Pump - Draws in and
dispenses a fixed volume of resin to gun.
AG Hose Heat Connection Termination Box Connects power to heated hoses.
AH *Primary Heater Over-Temperature Switches Sends signal to temperature controller if heater
exceeds maximum temperature condition.
AA ISO (A) - Packing Nut and Lube Cup - (A side
only)
AB *Primary Heater Thermocouples - Senses
temperature of primary heater and inputs that
information.
AI Resin (B) Pump Wet Cup - Access for daily wet
cup refill.
DD Main Air Inlet Ball Valve - (1/2 NPT female fitting)
FF ISO (A) Inlet - Fitting (3/4 swivel fitting)
GG Resin (B) Inlet - Fitting (3/4 swivel fitting)
Control Panel
DataTrak (optional)
See page 33.
See Temperature Controls
and Indicators
E L EC T R O N IC M O N I T O R IN G S Y S T E M
Air Motor
Pressure Gauge
A
B
Air Motor
Shutoff Valve
°F
°C
ti16815a
3A1569E
Air Pressure
Regulator
13
Component Identification
Temperature Controls and Indicators
NOTICE
To prevent damage to the softkey buttons, do not press
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
Heater Power Indicators
Zone A Arrow Keys
A
Zone B Arrow Keys
B
Temperature Displays
Heater A On/Off Key
Heater B On/Off Key
Hose Zone Arrow Keys
Actual Temperature
Hose Heater On/Off Key
°F
°C
Temperature Scale Keys
Target Temperature Key
14
3A1569E
Component Identification
Main Power Switch
Circuit Breakers
Located on right side of unit, page 12. Turns heater
power ON
and OFF
. Does not turn
Located inside Reactor cabinet.
heater zones or pumps on.
Actual Temperature Key/LED
Press
Ref.
to display actual temperature.
Press and hold
to display electrical current.
Target Temperature Key/LED
Press
Size
Component
A-25
A-XP1
CB1
50 A
50 A
Hose Secondary (single)
CB2
30 A
30 A
Hose Primary (double)
CB3
25 A
30 A
Heater A (double)
CB4
25 A
30 A
Heater B (double)
to display target temperature.
Press and hold
to display heater control circuit
board temperature.
Temperature Scale Keys/LEDs
Press
°F
or
°C
CB1
to change temperature scale.
CB2
CB3
CB4
ti17569a
Heater Zone On/Off Keys/LEDs
Press
to turn heater zones on and off. Also
clears heater zone diagnostic codes, see page 36.
LEDs flash when heater zones are on. The duration of
each flash shows the extent that the heater is turned on.
Temperature Arrow Keys
Press
, then press
or
to adjust tem-
perature settings in 1 degree increments.
Temperature Displays
Show actual temperature or target temperature of
heater zones, depending on selected mode. Defaults to
actual at startup. Range is 32-190°F (0-88°C) for A and
B, 32-180°F (0-82°C) for hose.
3A1569E
15
Setup
Setup
Locate Reactor A-25/A-XP1
Electrical Requirements
1. Locate Reactor A-25 on a level surface and bolt in
place to the floor with 3/8 in. (10 mm) bolts, unless
the Reactor needs to remain portable.
•
Two bolts through the 2 in. (50 mm) deep caster
bushings in the rear.
•
Two bolts through the 3-5/8 in. (168 mm) deep
caster bushings in the front.
2. Do not expose Reactor to rain.
3. If you need to move the machine, add
optional wheel kit.
Improper wiring may cause electric shock or other
serious injury if work is not performed properly.
• Have a qualified electrician connect power and
ground to main power switch terminals and
ground lug.
• Ensure your installation complies with all
National, State, and Local safety and fire codes.
• Ensure that incoming power is disconnected and
locked out at the source.
Power cord is not supplied.
4. Lift with hoist only from bar spanning across top of
cart.
Determine Power Source
Reactor A-25 can be wired to 3 types of power source:
•
200-240V / 1 Phase
•
200-240V / 3 Phase Delta (3 wire + ground PE)
•
350-415V / 3 Phase WYE (4 wire + ground PE)
(220 Volts to Neutral)
16
3A1569E
Setup
Configure to Supply Power
3. Replace lower front shroud. Reinstall the two
screws retained in Step 1.
Both cord connection AND jumper positioning steps on
page 18 must be completed.
200-240V, 1 Phase: Use a screwdriver to connect two
power leads to the top two middle terminal positions as
shown. Connect green to ground (GND). See page 18 for
proper jumper positions.
Step One - Connect Electrical Cord
Disregard terminal numbers on disconnect switch
blocks. Wire to positions shown.
Disregard terminal numbers on disconnect switch
blocks. Wire to positions shown. Terminals will accept
up to #8 AWG (10 mm2) conductors.
1. Using a flat screw driver, turn cover fasteners 90°
counterclockwise. Lift and pull the front cover away.
2. Connect main power cord to electrical console as
follows:
a. Feed power cord through strain relief (SR) on
right side of unit. Push black die release lever
(RL) down to release contacts block (PD) for
easy wiring.
200-240V, 3 Phase Delta: Use a screwdriver to connect
three power leads to top three left terminals as shown.
Connect green to ground (GND). See page 18 for
proper jumper positions.
Strain relief accepts cords 0.59 to 1.0 in. (15-25 mm)
diameter.
NOTE: A-XP1 disconnect cannot be detached from the
frame.
b. Connect power leads to Power Disconnect
Switch (PD). Snap contacts block (PD) back
onto switch.
c.
Tighten strain relief nut.
d. Connect ground wire to ground lug (GL).
350-415V, 3 Phase WYE: Use a screwdriver to connect
four power leads to the top terminals as shown. Connect
neutral only to N. Connect green to ground (GND). See
page 18 for proper jumper positions.
RL
PD
GL
SR
3A1569E
ti17570a
17
Setup
Step Two - Install Power Jumpers
Find location for power jumpers which are in a plastic
bag tie wrapped to the ground lug.
Heater Jumper Location
Heater Jumpers
NEW
1. Turn screws counter-clockwise on the upper part of
the shroud until they stop. Pull door up and out.
2. Install red jumpers from the storage bag to the
positions shown for your power.
•
Push the jumper firmly into the new position.
•
If necessary, a flat-blade screwdriver can be
used under the ridge on the side of the jumper
to remove them.
3. Replace front shroud.
Power Jumper Location
Install Power Jumpers
ti17569a
Step Two
TB2
Terminal Blocks
Install red jumpers
350-415V 3ø WYE
200-240V 3ø Delta
200-240V 1ø
Step Three - Reposition Heater Jumpers
(if necessary)
1. Turn screws counter-clockwise on the upper part of
the shroud and remove by pulling them out.
Find location of Heater Jumpers.
2. Move red jumpers from the storage positions to the
positions shown for your power.
Machines are shipped with heaters wired for 6000 watts.
To reposition heater jumpers for 3000 watts, change
jumper positions as shown below.
•
A flat-blade screwdriver can be used under the
ridge on the side of the jumper to remove them.
•
Push the jumper firmly into the new position.
3. Replace lower front shroud.
Step Three
TB2
Terminal Blocks
Position red jumpers
18
A-25: 6000 WATTS
A-XP1: 10,200 WATTS
A-25: 3000 WATTS
A-XP1: 5100 WATTS
3A1569E
Setup
Ground System
Fluid Supply Connections
Feed pumps are typically used. Siphon feeding is not
recommended. Connect material supply to inlets of
proportioning unit as follows:
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: is grounded through power cord; see page
17.
•
Spray gun: connect whip hose ground wire to FTS;
see page 20. Do not disconnect 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 that are conductive.
Place them on a grounded surface. Do no place pail
on a non-conductive 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.
Iso Pump Lubrication System
Setup
1. Connect fluid inlet ball valves (U.X) and y-strainers
(V, Y) to pump inlets.
2. Ensure the A- and B- inlet ball valves (U,X) on proportioning unit are closed.
3. Connect and tighten B- supply hose (J) to 3/4 NPT
swivel fitting (GG) on B- inlet ball valve (U), and to
resin transfer pump.
GG
J
V
U
ti17571a
4. Connect and tighten A- supply hose (BB) to 1/2 NPT
swivel fitting (FF) on A- inlet ball valve (X), and to
isocyanate transfer pump. See FIG. 3, page 12.
Air Supply Connection
Connect main air supply (F) to air inlet 1/2 in. npt (f)
valve (DD) at air filter (S). Hose fitting requires a 1/2
NPT male fitting.
Use a minimum of 3/8 in. ID air line (not supplied) to
deliver air supply to proportioning unit. Use 1/2 in. ID
hose if over 15 ft long.The main air supply must be clean
and free of oil and contaminants.
Prepare isocyanate pump lubrication system as follows:
DD
1. Lift lubricant reservoir out of bracket and remove
reservoir from cap.
2. Fill reservoir 3/4 full with TSL.
3. Thread reservoir onto cap assembly and place it
into bracket.
The lubrication system is now ready for operation; no
priming is required.
F
3A1569E
S
ti17572a
19
Setup
Recirculation / Pressure Relief
Lines
Connect Heated Hose
See heated hose manual for detailed instructions for
Graco heated hoses.
NOTICE
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as over pressure relief valves when set to
SPRAY. Lines must be open so valves can automatically relieve pressure when machine is operating.
If circulating fluid back to the supply drums, use high
pressure hose rated to withstand the maximum
working pressure of this equipment.
If Recirculating to Supply Drum: 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. Refer to manual 309852.
The fluid temperature sensor (FTS) and whip hose must
be used with heated hose; see page 20. Hose length,
including whip hose, must be 60 ft (18.3 m) minimum.
1. Turn main power OFF.
2. Assemble heated hose sections, FTS, and whip
hose. See Heated Hose manual for instructions.
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.
FM
Alternate recirculation hoses (requires adapter
fittings):
249508 - ISO (A) (moisture guard) red hose, 1/4 in. (6
mm) ID; #5 JIC fittings (m x f); 35 ft (10.7 m) long.
VV
WW
249509 - Resin (B) blue hose; 1/4 in. (6 mm) ID, #6 JIC
fittings (m x f), 35 ft (10.7 m) long.
PH
AH
BB
R
ti27240a
BA
Manifold hose fittings (VV, WW) allow use of 1/4 in. and
3/8 in. ID Reactor heated fluid hoses.
ti8441a
R
4. Connect heated hose air line (AH) to proportioner
air hose.
Install Fluid Temperature Sensor
(FTS)
Install FTS between main hose and whip hose. See
Heated Hose manual for instructions.
20
3A1569E
Setup
NOTE: For proportioners with termination box (TB), follow step 5. For proportioners with electrical splice connectors (NN) follow step 6. Connect FTS cables (SS).
5. Connect hose power wires to terminal block (C) on
termination box (TB). Remove box cover (D) and
loosen lower strain relief (E). Route wires through
strain relief and fully insert into terminal block (A and
B hose wire positions are not important). Torque
terminal connector screws (C) to 26 - 30 in-lb (2.9 3.3 N•m). Fully tighten strain relief screws and
replace cover.
Close Gun Fluid Inlet Valves A
and B
Fusion AP Gun shown.
ti2411a
Connect Whip Hose to Gun or
Gun Fluid Manifold
66
'
For Probler P2 guns: Connect hoses to inlet valves.
For Fusion guns: Connect hoses to inlet manifold. Do
not connect manifold to gun.
WLD
6. Connect cables (SS). Connect electrical connectors
(NN). Be sure cables have slack when hose bends.
Wrap cable and electrical connections with electrical
tape.
1. Overlap A and B component hoses and assemble to
gun or gun manifold fittings as shown.
2. Tighten fittings to A and B component hoses.
Ensure hose remains flat after fittings are tightened.
Loosen and retighten fittings as necessary to eliminate any torque on hoses.
Fusion AP Gun shown.
SS
NN
ti17787a
ti12158a
3A1569E
21
Initial Startup
Initial Startup
6. Purge air from hoses.
a. For Probler P2 guns: Loosen hose fittings and
bleed out air until air-free fluid comes from
hoses.
Do not operate Reactor without all covers and
shrouds in place.
Load Fluid with Feed Pumps
The Reactor is tested with oil at the factory. Flush out
the oil with a compatible solvent before spraying; see
page 28.
1. Check that Setup process is complete; see page 16.
b. For Fusion guns: 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 is shown.
2. Turn on component B agitator, if used.
3. Turn both PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY.
SB
TI2484a
SA
Pressure Check Hose
See hose manual. Pressure check for leaks. If no leaks,
wrap hose and electrical connections to protect from
damage.
ti8442a
4. Open both fluid valves (FV).
FV
ti17571a
5. Start feed pumps. Do not start proportioner air
motor or pumps.
Always provide two grounded waste containers to
keep component A and component B fluids separate.
22
3A1569E
Initial Startup
Set Temperatures
6. Turn on
A
and
B
heat zones by pressing
for each zone.
See Setup, page 16.
7. Hold
1. Turn main power ON
zone.
.
8. Hold
°F
2. Press
or
°C
to change temperature
scale.
to view heater control circuit board tem-
perature.
9. Manual current control mode only:
3. Press
to display target temperatures.
A
4. To set
or
heat zone target temperature, press
until display shows desired tem-
perature. Repeat for
For
to view electrical currents for each
B
and
zones.
When in manual current control mode, monitor hose
temperature with thermometer. Install per instructions below. Thermometer reading must not exceed
160°F (71°C). Never leave machine unattended
when in manual current control mode.
If FTS is disconnected or display shows diagnostic code E04, turn main power switch OFF
zone only, if FTS is disconnected at startup,
display will show hose current (0A). See step 9, page
23.
then ON
to clear diagnostic
code and enter manual current control mode.
display will show current to hose. Current is not limited by target temperature.
Do not turn on hose heat without fluid in hoses.
5.
Turn on
heat zone by pressing
. Preheat
hose (15-60 min). Indicator will flash very slowly when
fluid reaches target temperature. Display shows actual
fluid temperature in hose near FTS.
Press
or
to adjust current setting.
To prevent overheating, install hose thermometer close to gun end, within operator view. Insert
thermometer through foam cover of A component hose so stem is next to inner tube. Thermometer reading will be about 20°F less than
actual fluid temperature.
If thermometer reading exceeds 160°F (71°C),
Thermal expansion can cause over pressurization,
resulting in equipment rupture and serious injury,
including fluid injection. Do not pressurize system
when preheating hoses.
3A1569E
reduce current with
key.
23
Initial Startup
Supply Wet-Cups with Throat
Seal Liquid
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. Close main air
valve before filling wet-cup.
1. Component A (ISO) Pump: Keep reservoir (Z) 3/4
filled with TSL. Wet-cup piston circulates TSL
through wet-cup to carry away isocyanate film on
displacement rod. Change the fluid in the reservoir
when it becomes milky-looking.
2. Component B (Resin) Pump: Check felt washers
in packing nut/wet-cup (AK) daily. Keep saturated
with TSL to prevent material from hardening on displacement rod. Replace felt washers when worn or
contaminated with hardened material.
AK
Z
ti16974a
24
3A1569E
Spraying
Spraying
The Fusion AP gun is shown.
5. Open air inlet ball valve (DD).
1. After reaching spray temperatures, engage gun
piston safety lock.
DD
ti2409a
ti17573a
6. Turn the air regulator counterclockwise to 0
pressure.
2. Close gun fluid inlet valves A and B.
E L EC T R O N IC M O N I T O R IN G S Y S T E M
air
regulator
DD
air motor
shutoff
valve
ti2728a
ti17574a
3. Attach gun fluid manifold. Connect gun air line.
Open air line valve.
7. Open the air motor shutoff valve.
8. Close the park valve.
ti2543a
4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY.
Closed
SB
SA
ti8442a
3A1569E
25
Spraying
9. Slowly increase the air regulator setting until the
approximate stall (static) pressure is achieved on
fluid gauges (GA) and (GB).
Spray Adjustments
Flow rate, atomization, and amount of overspray are
affected by four variables.
SB
SA
•
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. Effects are similar to when fluid
pressure setting is too high or too low.
•
Mix chamber size. Choice of mix chamber is based
on desired flow rate within machine capability and
fluid viscosity.
•
Cleanoff air adjustment. Too little cleanoff air
results in droplets building up on the front of the
nozzle, and no pattern containment to control overspray. Too much cleanoff air results in air-assisted
atomization and excessive overspray.
GA
GB
ti8441a
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, until gauges show
balanced pressures.
Ensure relief tubes are in waste containers.
11. Open gun fluid inlet valves A and B.
ti2414a
12. Disengage gun piston safety lock.
ti2410a
13. Test spray onto cardboard. Adjust the air regulator
to get the minimum fluid pressure that results in a
good spray pattern.
Pumps have fluid to air ratio of 25 to 1. Feed pumps add
2X feed pressure boost to outlet pressure (on the up
stroke only). For best results, use regulators on feed
pumps to limit inlet feed pressure to approximately 100
psi (0.7 MPA, 7 bar).
14. Check A and B fluid pressure gauges (GA, GB) to
ensure proper pressure balance between A and B.
15. Equipment is ready to spray.
26
3A1569E
Park
Park
5. Engage gun piston safety lock.
Park the pumps at the end of the day to cycle proportioner pumps to home position, submerging displacement rod.
ti2409a
1. Open the park valve.
6. Close gun fluid inlet valves A and B.
ti2421a
Open
Close
7. Close pump inlet supply valves.
2. Trigger the gun until pumps stops at the bottom and
relieves pressure.
3. Close the air motor shutoff valve.
4. Close the park valve.
ti17716a
Pressure Relief
Procedure
Shutdown
1. Turn main heater power OFF
The Fusion AP gun is shown.
1. Turn off feed pumps and agitator if used.
2. Park component A pump. Follow Park; see page
27.
.
2. Follow Park; see page 27.
3. Check and fill wet-cups (AK, Z).
4. Follow gun shutdown procedure. See gun manual.
3. Close the air inlet valve.
4. Trigger spray gun until gauges read zero.
3A1569E
27
Flushing
Flushing
Flush equipment only in a well-ventilated area. Do
not spray flammable fluids. Do not turn on heaters
while flushing with flammable solvents.
•
Flush out old fluid with new fluid, or flush out old
fluid with a compatible moisture-free solvent.
•
Use lowest possible pressure when flushing.
•
To flush feed hoses, pumps, and the heater separately from the heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION. Flush through bleed lines
(N).
N
SB
SA
N
ti8441a
•
To flush entire system, circulate through gun fluid
manifold (with manifold removed from gun).
•
Always leave hydraulic oil or a non-water based,
non-water absorbent fluid in system. Do not use
water.
Only use flush solvents that are compatible with Fluoroelastomer seals. Non-compatible solvents will
damage seals and cause hazardous conditions, such
as high pressure leaks.
28
3A1569E
Operation
Operation
Daily Start-up Procedure
7. Uncoil heated hose.
8. Check that hose setpoint temperature is correct.
9. Turn on all three heat zones.
The daily start-up procedures describe normal operation. Assume that all temperature and pressure settings
have been previously set, but that the heating system is
not up to operating temperature.
10. The hose power controller automatically adjusts the
hose current to the hose to compensate for hose
length and ambient temperature. Wait for actual
hose temperature readout to match hose setpoint
temperature.
1. Check condition isocyanate lubrication system and
service as required. Change pump lubricant when it
shows signs of change to a milky color.
2. Ensure supply fluid is at correct temperature as
recommended by chemical system supplier. Ensure
individual chemicals are correctly agitated within
their drums/day tanks, and moisture protection
system is properly set for operation. Recirculate
heated fluid back to supply drums if necessary; see
page 31.
To prevent excessive pressure build-up in heated
hoses, always bring hoses and primary heater up to
operating temperature before opening air motor shutoff valve.
11. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY.
3. Turn on main air supply to transfer pumps.
SA
4. Pressurize transfer pumps and open A- and B-inlet
supply valves.
SB
5. Open air inlet ball valve (DD).
ti8442a
12. Check that heat zones are on and temperatures are
on target, page 23.
13. Open air motor shutoff valve.
ti17573a
DD
6. Turn main power ON
14. Pumps will pressurize the fluid according to air
regulator pressure.
.
NOTICE
Uncoil heated hoses before turning on hose heater
switch to prevent overheating and hot spots within hose.
3A1569E
29
Operation
15. Check A and B fluid pressure gauges (GA, GB) to
ensure proper pressure balance between A and B. If
imbalanced, bleed off the high side with valves SA
and SB until balanced.
GA
GB
ti8442a
16. Open gun fluid manifold valves A and B.
The Fusion AP gun is shown.
ti2414A
17. Disengage gun piston safety lock.
ti2410A
18. Test spray onto cardboard.
19. Equipment is ready to spray.
30
3A1569E
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
5. Set temperature targets, see page 23. Turn on
A
and
B
Do not turn on
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding
fluid temperature limits.
heat zones by pressing
.
heat zone unless hoses are
already loaded with fluid.
To circulate through gun manifold and preheat hose,
see page 32.
6. Press
1. Follow Initial Startup, page 22.
7. Turn the air regulator to a low pressure until
and
to display actual temperatures.
B
A
temperatures reach targets. Increase
the pressure once the temperatures are on target.
Do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB). The
valves function as overpressure relief valves when
set to SPRAY
. Lines must be open so valves
can automatically relieve pressure when machine is
operating.
8. Turn on
heat zone by pressing
.
9. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY
.
SA
2. See Typical Installation, with Circulation, page
11. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the
maximum working pressure of this equipment. See
Technical Data, page 38.
SB
3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
PRESSURE RELIEF/CIRCULATION
ti8442a
.
SB
SA
ti8441a
4. Turn main power ON
3A1569E
.
31
Fluid Circulation
Circulation Through Gun
Manifold
5. Set temperature targets, see page 23. Turn on
A
,
B
, and
heat zones by pressing
.
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding
fluid temperature limits.
6. Press
Circulating fluid through the gun manifold allows rapid
preheating of hose.
7. Turn the air regulator to a low pressure until
1. Install gun fluid manifold (P) on accessory circulation kit (CK). Connect high pressure circulation lines
(R) to circulation manifold.
and
to display actual temperatures.
B
A
temperatures reach targets. Increase
the pressure once the temperatures are on target.
P
CK
R
ti2767a
The Fusion AP gun manifold is shown.
Table 1: Circulation Kit (CK)
Part
246362
256566
GC1703
Gun
Fusion AP
Fusion CS
Probler P2
Manual
309818
313058
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
manual for installation instructions.
3. Follow Initial Startup, page 22.
4. Turn main power ON
32
.
3A1569E
DataTrak Controls and Indicators
DataTrak Controls and Indicators
The DataTrak on the Reactor A-25 sprayers do not have runaway protection. For setup and operation instructions
see DataTrak Operation, page 34.
Key for FIG. 4
AB Combined Lower Displacement (user settable)
AC Flow Rate Units (user settable to
/min, gpm [US],
gpm [Imperial], oz/min [US], oz/min [Imperial], l/min, or
cc/min)
AD LED (fault indicator when lit)
AE Display
PF Prime/Flush Key (Enables Prime/Flush mode. While in
Prime/Flush mode, the batch totalizer [BT] will not count.)
LED will flash while in Prime/Flush mode.
RK Reset Key (Resets faults. Press and hold for 3 seconds to
clear the batch totalizer.) Push to toggle between flow rate
and cycle rate.
CF Cycle/Flow Rate
BT Batch Totalizer
GT Grand Totalizer
RT Runaway Toggle (leave disabled)
GT
Run Mode
AE, see details at right
RK
PF
ti8622b
CF
AD
TI11883a
BT
Setup Mode
RT
AC
AB
RK
PF
ti17741a
FIG. 4. DataTrak Controls and Indicators
3A1569E
33
DataTrak Operation
DataTrak Operation
The display (AE) will turn off after 1 minute to save battery life. Press any key to wake up the display.
NOTICE
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Counter/Totalizer
See FIG. 4, page 33. The last digit of the batch totalizer
(BT) represents tenths of gallons or liters. To reset the
totalizer, press any key to wake up the display, then
press and hold
•
Setup Mode
1. See FIG. 4, page 33. Press and hold
onds until Setup menu appears.
•
for 5 sec-
2. To enter settings for lower size, flow rate units, and
disable runaway protection press
to change the
value, then
to save the value and move the cursor to the next data field.
•
for 3 seconds.
If AC is set to gallons or ounces, BT and GT display gallons.
If AC is set to liters or cc, BT and GT display
liters.
If AC is set to cycles, BT and GT display cycles.
Press
to toggle between flow rate units and cycles.
A letter under the BT display indicates that both BT and
GT are displaying gallons (g) or liters (l). No letter
means both BT and GT are displaying cycles.
Display
•
•
Set lower size to 98cc.
Disable runaway.
3. Move the cursor to the E5 error enable option field,
then press
once more to exit Setup mode.
Run Mode
DataTrak will continue to count cycles when display is
off.
The display (AE) may turn off if a high-level static discharge is applied to the DataTrak. Press any key to
wake up the display.
Prime/Flush
1. See FIG. 4, page 33. To enter Prime/Flush mode,
press any key to wake up the display, then press
. The Prime/Flush symbol will appear in the display and the LED will flash
See FIG. 4, page 33. The display (AE) will turn off after 1
minute of inactivity in Run mode or 3 minutes in Setup
mode. Press any key to wake up the display.
Diagnostics
See DataTrak Diagnostic Codes page 36.
.
2. While in Prime/Flush mode, the batch totalizer (BT)
will not count. The grand totalizer (GT) continues to
count.
3. To exit Prime/Flush mode, press any key to wake
up the display, then press
. The Prime/Flush
symbol will disappear from the display and the LED
will stop flashing.
34
3A1569E
Maintenance
Maintenance
•
Check and add TSL to B side pump wet-cup daily.
•
Check ISO lube bottle for significant discoloration or
crystallization daily. Replace with fresh TSL when
needed.
•
Ensure ISO (A) pump is down and in PARK position
during every shutdown.
•
Keep any ISO (A) fluid from being exposed to atmosphere to prevent crystallization.
•
Remove inlet filter screen plug (V, Y) and clean
screens if increased unbalanced pressures between
A and B is noticed or as needed for fluids used. Also
clean after flushing.
•
Close gun fluid shutoff valves when not in use.
•
If using a Fusion AP or Probler P2 gun, add grease
with grease gun per manual.
•
Clean gun filter screens and mix chamber ports regularly, or when increased unbalanced pressures
between A and B is noticed. See gun manual.
•
Use lithium grease or Iso Pump Oil on all threaded
fluid fittings on the “A” side.
3A1569E
35
Diagnostic Codes
Diagnostic Codes
Temperature Control Diagnostic Codes
Temperature control diagnostic codes appear on temperature display.
Code
These alarms turn off heat. E99 clears automatically
when communication is regained. Codes E03 through
E06 can be cleared by pressing
turn main power OFF
. For other codes,
then ON
to
clear.
See repair manual for corrective action.
Code Name
Alarm Zone
01
High fluid temperature
Individual
02
High zone current
Individual
03
No zone current
Individual
04
FTS or thermocouple disconnected
Individual
05
Control board over temperature
Individual
06
Communication cable unplugged Individual
30
Momentary loss of communication
All
99
Loss of communication
All
For hose zone only, if FTS is disconnected at startup,
display will show hose current 0A.
DataTrak Diagnostic Codes
DataTrak can diagnose several problems with the
pump. When the monitor detects a problem, the LED
(AD, FIG. 4) will flash and a diagnostic code will appear
on the display.
Symbol
Code
Code Name
To acknowledge the diagnosis and return to the normal
operating screen, press
once to wake up the display, and once more to clear the diagnostic code
screen.
Diagnosis
Cause
E-2
Diving Down
Leak during downstroke.
Worn intake valve.
E-3
Low Battery
Battery voltage too low to
stop runaway.
Low battery. Replace battery; see Reactor A-25
Repair manual.
E-6
Blown Fuse
Fuse is blown. Replace fuse; • Faulty solenoid or solenoid
wiring.
see Reactor A-25 Repair
• Extreme temperatures
manual.
(above 140°F [60°C]).
36
3A1569E
Dimensions
Dimensions
A
WLE
C
ti17605a
B
Dimension
A
B
C
3A1569E
With Wheels
Without Wheels
in. (mm)
43.5 (1105)
29 (736.6)
30 (762)
in. (mm)
43.5 (1105)
21.5 (546)
24.5 (622)
37
Technical Data
Technical Data
Category
Maximum Fluid Working Pressure
Maximum Air Supply Pressure
Maximum Air Working Pressure
Pressure Ratio
Air consumption
Machine Maximum Power with hose
Voltage Requirement (50/60 Hz):
200-240VAC Nominal, 1 Phase
200-240VAC Nominal, 3 Phase (Delta)
350-415VAC Nominal, 3 Phase
(WYE 200-240VAC Line to Neutral)
Amperage Requirement (Full Load Peak)*
Maximum Heater Fluid Temperature
Maximum Hose Fluid Temperature
Maximum Ambient Temperature
Maximum Output
Output Per Cycle (A and B)
Heater Power
Hose Power
Sound Pressure (see NXT air motor manual)
Sound Power (see NXT air motor manual)
Viscosity Range
Maximum Fluid Inlet Pressure
Fluid Inlet/Strainer Filter
Air inlet Filter Mesh
Component B (Resin) Inlet
Component A (Isocyanate) Inlet
Recirculation/Block Hose Connections
Maximum Heated Hose Length***
Weight
Wetted Parts
Data
A-25
2000 psi (14 MPa, 138 bar)
125 psi (0.9 MPa, 9 bar)
80 psi (550 kPa, 5.5 bar)
25:1
A-XP1
3500 psi (24 MPa, 241 bar)
125 psi (0.9 MPa, 9 bar)
100 psi (689 MPa, 6.9 bar)
35:1
28 scfm (0.8m3/min) 02 tip at
1500 psi stall pressure
9000 Watts
50 scfm (1.41 m3/min) 00 tip at
2000 psi stall pressure
13,000 Watts
195-253VAC
195-253VAC
338-457VAC
40 amps @ 230 V, 1 Phase
56 amps @ 230 V, 1 Phase
32 amps @ 230 V, 3 Phase
45amps @ 230 V, 3 Phase
18.5 amps @ 380 V, 3 Phase
26 amps @ 380 V, 3 Phase
190 °F (88 °C)
180 °F (82 °C)
120 °F (49 °C)
25 lb/min. (11.4 kg/min.)
1.5 gal/min. at 2000 psi
0.025 gal/cycle (0.095 ltr/cycle)
0.017 gal/cycle (0.094 ltr/cycle)
6000 Watts
10,200 Watts
2790 Watts
70.2 dB(A)
80.1 dB(A)
250-1500 centipoise (typical)
300 psi (2.1 MPa, 21 bar) or 15% of output pressure
20 mesh standard
40 Micron
3/4 npt(f) swivel
3/4 npt(f) swivel
Iso (A) side: #5 JIC (m); Resin (B) side: #6 JIC (m)
210 ft of 3/8 ID
310 lb (140.6 kg)
Carbon steel, stainless steel, chrome, aluminum,
Fluoroelastomer, PTFE, nylon
*Full load amps with all devices operating at maximum
capabilities with 210 ft (64.1 m) of hose.
***210 ft (64 m) of heated hose will produce the maximum allowable heat capacity. 310 ft (94 m) of heated hose may
be used, but will have 25% less heat capacity.
38
3A1569E
Notes
Notes
3A1569E
39
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 3A1569
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision E, December 2015
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