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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