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Operation
311299E
Hydraulic, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 3 for model information, including maximum working pressure.
Model H-XP2 with 15.3 kW Heater
Model H-25 with 8 kW Heater
ti7705a ti7706a
2
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . . 7
Foam Resins with 245 fa Blowing Agents . . . . . . . 7
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Installation, with circulation . . . . . . . . . . . 8
Typical Installation, without circulation . . . . . . . . 9
Component Identification . . . . . . . . . . . . . . . . . . . 10
Temperature Controls and Indicators . . . . . . . . . 12
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . 12
Red Stop Button . . . . . . . . . . . . . . . . . . . . . . . . 12
Actual Temperature Key/LED . . . . . . . . . . . . . . 12
Target Temperature Key/LED . . . . . . . . . . . . . . 12
Temperature Scale Keys/LEDs . . . . . . . . . . . . . 12
Heater Zone On/Off Keys/LEDs . . . . . . . . . . . . 13
Temperature Arrow Keys . . . . . . . . . . . . . . . . . . 13
Temperature Displays . . . . . . . . . . . . . . . . . . . . 13
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 13
Motor Controls and Indicators . . . . . . . . . . . . . . . 14
Motor ON/OFF Key/LED . . . . . . . . . . . . . . . . . . 14
PARK Key/LED . . . . . . . . . . . . . . . . . . . . . . . . . 14
PSI/BAR Keys/LEDs . . . . . . . . . . . . . . . . . . . . . 14
Pressure Key/LED . . . . . . . . . . . . . . . . . . . . . . . 14
Cycle Count Key/LED . . . . . . . . . . . . . . . . . . . . 14
Hydraulic Pressure Control Knob . . . . . . . . . . . 15
Motor Control Arrow Keys . . . . . . . . . . . . . . . . . 15
Spray Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 15
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 29
Fluid Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Circulation Through Reactor . . . . . . . . . . . . . . . 30
Circulation Through Gun Manifold . . . . . . . . . . 31
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . 32
Temperature Control Diagnostic Codes . . . . . . 32
Motor Control Diagnostic Codes . . . . . . . . . . . . 32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 33
Pump Lubrication System . . . . . . . . . . . . . . . . . 34
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Feed Pump Kits . . . . . . . . . . . . . . . . . . . . . . . . . 36
246483 Air Supply Kit . . . . . . . . . . . . . . . . . . . . 36
246978 Circulation Kit . . . . . . . . . . . . . . . . . . . . 36
246477 Return Tube Kit . . . . . . . . . . . . . . . . . . . 36
15B593 Membrane Switch Shield . . . . . . . . . . . 36
Heated Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Heated Whip Hoses . . . . . . . . . . . . . . . . . . . . . . 36
Fusion Spray Gun . . . . . . . . . . . . . . . . . . . . . . . 36
246085 Data Reporting Kit . . . . . . . . . . . . . . . . 36
248848 Data Reporting Kit . . . . . . . . . . . . . . . . 36
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 40
311299E
Models
Models
H-25 SERIES
Part No.,
Series
253200, B
253201, B
253202, B
253206, B
253207, B
253208, B
253300, C
253301, C
253302, C
253306, C
253307, C
253308, C
Full
Load
Peak
Amps*
95
58
35
69
63
40
29
45
35
100
58
35
Voltage
(phase)
230V (1)
230V (3)
380V (3)
230V (1)
230V (3)
380V (3)
230V (1)
230V (3)
380V (3)
230V (1)
230V (3)
380V (3)
H-XP2 SERIES
System
Watts**
14,700
14,700
14,700
22,000
22,000
22,000
15,960
15,960
15,960
23,260
23,260
23,260
Primary
Heater
Watts
8000
8000
8000
15,300
15,300
15,300
8000
8000
8000
15,300
15,300
15,300
Flow lb/min
(kg/min) at
35 cpm
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
22 (10)
Output per
Cycle (A+B) gal. (liter)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
Pressure
Ratio
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
1.91:1
Maximum Fluid
Working
Pressure psi (MPa, bar)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
2000 (13.8, 138)
Part No.,
Series
253203, B
253204, B
253205, B
253303, C
253304, C
253305, C
Full
Load
Peak
Amps*
95
58
35
100
58
35
Voltage
(phase)
230V (1)
230V (3)
380V (3)
230V (1)
230V (3)
380V (3)
System
Watts**
22,000
22,000
22,000
23,260
23,260
23,260
Primary
Heater
Watts
15,300
15,300
15,300
15,300
15,300
15,300
Flow gpm (lpm) at 35 cpm
1.5 (5.7)
1.5 (5.7)
1.5 (5.7)
1.5 (5.7)
1.5 (5.7)
1.5 (5.7)
Output per
Cycle (A+B) gal. (liter)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
Pressure
Ratio
2.79:1
2.79:1
2.79:1
2.79:1
2.79:1
2.79:1
Maximum Fluid
Working
Pressure psi (MPa, bar)
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.
** Total system watts, based on maximum hose length for each unit:
• Part Nos. 253200 through 253208, 210 ft (64 m) maximum heated hose length, including whip hose.
• Part Nos. 253300 through 253308, 310 ft (94.6 m) maximum heated hose length, including whip hose.
311299E 3
4
Supplied Manuals
Supplied Manuals
The following manuals are shipped with the Reactor
™
Proportioner. Refer to these manuals for detailed equipment information.
Order Part No. 15B535 for a compact disk of Reactor manuals translated in several languages.
Manuals are also available at www.graco.com.
Reactor Hydraulic Proportioner
Part No.
Description
311300 Reactor Hydraulic Proportioner,
Repair/Parts Manual (English)
Reactor Electrical Diagrams
Part No.
Description
311508 Electrical Diagrams (English)
Proportioning Pump
Part No.
Description
312068 Proportioning Pump Repair-Parts
Manual (English)
Related Manuals
The following manuals are for accessories used with the
Reactor
™
.
Order Part No. 15B535 for a compact disk of Reactor manuals translated in several languages.
Order Part No. 15B381 for a compact disk of Fusion manual translated in several languages.
Feed Pump Kits
Part No.
Description
309815 Instruction-Parts Manual (English)
Air Supply Kit
Part No.
Description
309827 Instruction-Parts Manual (English) for
Feed Pump Air Supply Kit
Circulation and Return Tube Kits
Part No.
Description
309852 Instruction-Parts Manual (English)
Heated Hose
Part No.
Description
309572 Instruction-Parts Manual (English)
Fusion Air Purge Spray Gun
Part No.
Description
309550 Instruction-Parts Manual (English)
Fusion Mechanical Purge Spray Gun
Part No.
Description
309856 Instruction-Parts Manual (English)
Circulation Kit
Part No.
Description
309818 Instruction-Parts Manual (English)
Data Reporting Kit
Part No.
Description
309867 Instruction-Parts Manual (English)
Transformer Repair Kit
Part No.
Description
309930 Instruction-Parts Manual (English)
Rupture Disk Assembly Kit
Part No.
Description
309969 Instruction-Parts Manual (English)
Proportioning Pump Repair Kits
Part No.
Description
312071 Instruction-Parts Manual (English)
311299E
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. Refer back to these Warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
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 MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.
311299E 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.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.
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 forms from distributor or retailer.
• 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.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
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. Wait until equipment/fluid has cooled completely.
6 311299E
Isocyanate Hazard
Isocyanate Hazard
Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.
• Keep the ISO lube pump reservoir filled with Graco
Throat Seal Liquid (TSL), Part No. 206995. The lubricant creates a barrier between the ISO and the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.
• Never use solvent on one side if it has been contaminated from the other side.
• Always park pumps when you shutdown, see page
• Always lubricate threaded parts with Part No.
217374 ISO pump oil or grease when reassembling.
Keep Components A and
B Separate
Material Self-ignition
CAUTION
To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.
Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.
The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.
Foam Resins with 245 fa
Blowing Agents
New 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
• 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.
• Most materials use ISO on the A side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.
311299E 7
8
Typical Installation, with circulation
Typical Installation, with circulation
Key for F
IG
. 1
A Reactor Proportioner
B Heated Hose
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose
E Fusion Spray Gun
F Gun Air Supply Hose
G Feed Pump Air Supply Lines
J Fluid Supply Lines
K Feed Pumps
L Agitator
M Desiccant Dryer
P Gun Fluid Manifold (part of Fusion gun)
R Circulation Lines
A Side Supply Detail
B Side Supply Detail
M
K
K
M
G ti7820a 3
K
G ti7820a 2
L
K
R
A J
F
B
F
IG
. 1: Typical Installation, with circulation
D
J
R
E
P
C*
* Shown exposed for clarity.
Wrap with tape during operation.
ti10388a
311299E
Typical Installation, without circulation
Typical Installation, without circulation
Key for F
IG
. 2
A Reactor Proportioner
B Heated Hose
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose
E Fusion Spray Gun
F Gun Air Supply Hose
G Feed Pump Air Supply Lines
H Waste Containers
J Fluid Supply Lines
K Feed Pumps
L Agitator
M Desiccant Dryer
N Bleed Lines
P Gun Fluid Manifold (part of Fusion gun)
A Side Supply Detail
K
M
B Side Supply Detail
K
G ti7821a 2
K
K
G
L ti7821a 3
J
A
F
B
F
IG
. 2: Typical Installation, without circulation
311299E
N
H
D
J
E
P
C*
* Shown exposed for clarity.
Wrap with tape during operation.
ti7821a 1, 2, 3
9
Component Identification
Component Identification
Key for F
IG
. 3
BA Component A Pressure Relief Outlet
BB Component B Pressure Relief Outlet
EC Heated Hose Electrical Connector
EM Electric Motor, Fan, and Belt Drive (behind shroud)
FA Component A Fluid Manifold Inlet (on left side of manifold block)
FB Component B Fluid Manifold Inlet
FH Fluid Heater (behind shroud)
FM Reactor Fluid Manifold
FP Feed Inlet Pressure Gauge
FS Feed Inlet Strainer
FT Feed Inlet Temperature Gauge
FV Fluid Inlet Valve (B side shown)
GA Component A Outlet Pressure Gauge
GB Component B Outlet Pressure Gauge
HA Component A Hose Connection
HB Component B Hose Connection
HC Hydraulic Pressure Control
HP Hydraulic Pressure Gauge
LR ISO Lube Pump Reservoir
MC Motor Control Display
MP Main Power Switch
OP Overpressure Rupture Disk Assembly (on rear of A and B pumps)
PA Component A Pump
PB Component B Pump
RS Red Stop Button
SA Component A PRESSURE RELIEF/SPRAY Valve
SB Component B PRESSURE RELIEF/SPRAY Valve
SC Fluid Temperature Sensor Cable
SN Serial Number Plate (one inside cabinet, one on right side of cabinet)
SR Electrical Cord Strain Relief
TA Component A Pressure Transducer (behind gauge GA)
TB Component B Pressure Transducer (behind gauge GB)
TC Temperature Control Display
10 311299E
Component Identification
MC
TC
RS
PA
FT
FP
HC
FM
HP
EM
FH
OP
EC
SC
PB
FV
LR
SN
MP
FA
Detail of Reactor Fluid Manifold
(shroud removed for clarity)
SA TA GA
GB
TB
SB
BA
SR FS
Detail of Serial No. Plate
(inside cabinet)
ti7705a
HA HB BB ti3170
FB
F
IG
. 3: Component Identification (H-25 8 kW Model Shown)
311299E
SN ti7823a
11
Temperature Controls and Indicators
Temperature Controls and Indicators
Heater Power Indicators Heater Displays
Zone A Arrow Keys
Zone B Arrow Keys
Hose Zone Arrow Keys
A
B
Heater A On/Off Key
Heater B On/Off Key
Hose Heater On/Off Key
Actual Temperature Key
°
F
°
C
Temperature Scale Keys
Target Temperature Key
F
IG
. 4. Temperature Controls and Indicators
Main Power Switch
Located on right side of unit, page 11. Turns Reactor
Actual Temperature Key/LED
Press to display actual temperature.
power ON and OFF heater zones or pumps on.
. Does not turn
Target Temperature Key/LED
Red Stop Button
Located between temperature control panel and motor
Press to display target temperature.
Temperature Scale Keys/LEDs
control panel, page 11. Press to shut off motor and heater zones only. Use main power switch to shut off all power to unit.
Press
°
F
or
°
C
to change temperature scale.
12 311299E
Temperature Controls and Indicators
Heater Zone On/Off Keys/LEDs Circuit Breakers
Press to turn heater zones on and off. Also clears
heater zone diagnostic codes, see page 32.
LEDs are on steady when heater zones are powering up. They begin flashing as heat reaches targets.
LEDs will also flash if cutback point is reached.
Temperature Arrow Keys
Press , then press or perature settings in 1 degree increments.
to adjust tem-
Located inside Reactor cabinet.
Ref.
CB1
CB2
CB3
Size
50 A
20 A
25 or 40 A*
CB4 25 or 40 A*
CB5 20 A
* Depending on model.
Component
Hose/Transformer Secondary
Transformer Primary
Heater A
Heater B
Motor/Pumps
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.
CB1
CB2
CB3
CB4
CB5
For wiring and cabling, see repair manual.
ti2514a
311299E 13
Motor Controls and Indicators
Motor Controls and Indicators
Pressure/Cycle Display
Arrow Keys
Motor ON/OFF Key
PARK Key
Pressure Key
Cycle Count Key
ON / OFF
PARK
PSI
BAR
PSI/BAR Keys
F
IG
. 5. Motor Controls and Indicators
Motor ON/OFF Key/LED Pressure Key/LED
Press to turn motor ON and OFF. Also clears
some motor control diagnostic codes, see page 32.
Press to display fluid pressure.
PARK Key/LED
If pressures are imbalanced, display shows higher of two pressures.
Cycle Count Key/LED
Press at end of day to cycle component A pump to home position, submerging displacement rod. Trigger gun until pump stops. Once parked, motor will automatically shut off.
Press to display cycle count.
PSI/BAR Keys/LEDs
To clear counter, press and hold for 3 sec.
Press
PSI
or
BAR
to change pressure scale.
14 311299E
Spray Adjustments
Hydraulic Pressure Control
Knob
Use to adjust hydraulic pressure available to the hydraulic drive system. Turn knob (HC) clockwise to increase pressure and counterclockwise to decrease pressure.
Use hydraulic pressure gauge (HP, page 11) to view hydraulic pressure.
+
ti7731a
-
ti7732a
Component A and B outlet pressures will be higher than the hydraulic set pressure, depending on the
model (see Pressure Ratio data on page 3). Com-
ponent A and B pressure may be viewed on the pressure gauges (GA, GB), or the higher of the two pressures may be displayed on the motor control panel (MC). See F
IG
. 3, page 11.
Spray Adjustments
Flow rate, atomization, and amount of overspray are affected by four variables.
• Fluid pressure setting. Too little pressure results in an uneven pattern, coarse droplet size, low flow, and poor mixing. Too much pressure results in excessive overspray, high flow rates, difficult control, and excessive wear.
• Fluid temperature. Similar effects to fluid pressure setting. The A and B temperatures can be offset to help balance the fluid pressure.
• Mix chamber size. Choice of mix chamber is based on desired flow rate and fluid viscosity.
• 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.
Motor Control Arrow Keys
•
Adjust pressure imbalance settings, page 25.
•
Adjust standby settings, page 28.
311299E 15
Setup
Setup
1.
CAUTION
Bolt Reactor to original shipping pallet before lifting.
2.
Locate Reactor a.
b.
c.
Locate Reactor on a level surface. See
Dimensions, page 38, for clearance
and mounting hole dimensions.
Do not expose Reactor to rain.
Use the casters to move Reactor to a fixed location, or bolt to shipping pallet and move with forklift.
d.
To mount on a truck bed or trailer, remove casters and bolt directly to truck
Electrical requirements
See T
ABLE
1.
Installing this equipment requires access to parts which 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, see page 17. Be sure your
installation complies with all National, State and Local safety and fire codes.
Table 1: Electrical Requirements
(kW/Full Load Amps)
Part No.
Model
Voltage
(phase)
Full
Load
Peak
Amps*
System
Watts**
253200 H-25
253201 H-25
230V (1)
230V (3)
253202 H-25 380V (3)
253203 H-XP2 230V (1)
253204 H-XP2 230V (3)
253205 H-XP2 380V (3)
253206 H-25
253207 H-25
230V (1)
230V (3)
253208 H-25
253300 H-25
253301 H-25
253302 H-25
380V (3)
230V (1)
230V (3)
380V (3)
253303 H-XP2 230V (1)
253304 H-XP2 230V (3)
253305 H-XP2 380V (3)
253306 H-25 230V (1)
253307 H-25
253308 H-25
230V (3)
380V (3)
63
40
29
95
58
35
95
58
35
69
45
35
100
58
35
100
58
35
14,700
14,700
14,700
22,000
22,000
22,000
22,000
22,000
22,000
15,960
15,960
15,960
23,260
23,260
23,260
23,260
23,260
23,260
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.
** Total system watts, based on maximum hose length for each unit:
• Part Nos. 253200 through 253208, 210 ft (64 m) maximum heated hose length, including whip hose.
• Part Nos. 253300 through 253308, 310 ft (94.6 m) maximum heated hose length, including whip hose.
16 311299E
3.
Connect electrical cord
Power cord is not supplied. See T
Part No.
253200
253201
253202
253203
253204
253205
253206
253207
253208
253300
253301
253302
253303
253304
253305
253306
253307
253308
Model
H-25
H-25
H-25
H-25
H-XP2
H-XP2
H-XP2
H-25
H-25
H-25
H-25
H-25
H-25
H-XP2
H-XP2
H-XP2
H-25
H-25
Table 2: Power Cord Requirements
Cord Specification
AWG (mm
2
)
6 (13.3), 2 wire + ground
10 (5.3), 3 wire + ground
10 (5.3), 4 wire + ground
4 (21.2), 2 wire + ground
8 (8.4), 3 wire + ground
10 (5.3), 4 wire + ground
4 (21.2), 2 wire + ground
8 (8.4), 3 wire + ground
10 (5.3), 4 wire + ground
6 (13.3), 2 wire + ground
8 (8.4), 3 wire + ground
10 (5.3), 4 wire + ground
4 (21.2), 2 wire + ground
8 (8.4), 3 wire + ground
10 (5.3), 4 wire + ground
4 (21.2), 2 wire + ground
8 (8.4), 3 wire + ground
10 (5.3), 4 wire + ground
311299E
a.
230V, 1 phase: Using 5/32 or 4 mm hex allen wrench, connect two power leads to L1 and L2. Connect green to ground
(GND).
GND
L1
L2
ti2515b
Setup
b.
230V, 3 phase: Using 5/32 or 4 mm hex allen wrench, connect three power leads to L1, L2, and L3. Connect green to ground (GND).
GND
L1
L2
L3
ti3248b
c.
380V, 3 phase: Using 5/32 or 4 mm hex allen wrench, connect three power leads to L1, L2, and L3. Connect neutral to N. Connect green to ground (GND).
GND
L1
L2
L3
N
ti2725a
Some 3-phase models utilize a 3-phase motor. The motor must rotate counterclockwise when viewed from shaft end.
To reverse rotation, disconnect power and reverse power leads L1 and L2.
17
Setup
4.
Connect feed pumps f.
Connect and tighten component A supply hose to the 1/2 npt(f) swivel on the component A inlet valve.
a.
Install feed pumps (K) in component A and B supply drums. See F
IG
. 1 and
F
IG
. 2, pages 8 and 9.
5.
Connect pressure relief lines
A minimum feed pressure of 50 psi (0.35 MPa, 3.5 bar) is required at both feed inlet pressure gauges
(FP). Maximum feed pressure is 250 psi (1.75 MPa,
17.5 bar). Maintain A and B feed pressures within
10% of each other.
b.
c.
FP ti7718a
Seal component A drum and use desiccant dryer (M) in vent.
Install agitator (L) in component B drum, if necessary.
Do not install shutoffs downstream of the PRES-
SURE RELIEF/SPRAY valve outlets (BA, BB, page
11). 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.
If circulating fluid back to the supply drums, use high pressure hose rated to withstand the maximum working pressure of this equipment.
a.
Recommended: Connect high pressure hose (R) to relief fittings (BA, BB) of both PRESSURE RELIEF/SPRAY valves, Route hose back to component
A and B drums. See F
IG
. 1, page 8.
d.
Ensure A and B inlet valves (FV) are closed.
R
R
FV ti7737a
Supply hoses from feed pumps should be 3/4 in.
(19 mm) ID.
e.
Connect and tighten component B supply hose to the 3/4 npt(f) swivel on the component B inlet valve.
BA BB ti3171a
b.
Alternately: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See F
IG
. 2, page 9.
18 311299E
Setup
6.
Install Fluid Temperature
Sensor (FTS)
The Fluid Temperature Sensor (FTS) is supplied. Install
FTS between main hose and whip hose. See Heated
Hose manual 309572 for instructions.
7.
Connect heated hose
Manifold hose adapters (N, P) allow use of 1/4 in. and 3/8 in. ID fluid hoses. To use 1/2 in. (13 mm) ID fluid hoses, remove adapters from fluid manifold and install as needed to connect whip hose.
d.
Connect cables (Y). Connect electrical connectors (V). Secure with plastic ties.
Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape.
See 309572 for detailed instructions for Graco heated hoses.
CAUTION
The fluid temperature sensor (C) and whip hose (D)
must be used with heated hose, see page 19. Hose
length, including whip hose, must be 60 ft (18.3 m) minimum.
Y
V
a.
Turn main power OFF .
ti2727a
8.
Close gun fluid manifold valves A and B b.
Assemble heated hose sections, FTS, and whip hose.
c.
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
N
A ti2411a
9.
Connect whip hose to gun fluid manifold
Do not connect manifold to gun.
P
B ti2417a ti9878a
311299E 19
Setup
10. Pressure check hose
See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage.
11. Set transformer wire taps
50 ft
100 ft 150 ft 200 ft
250 ft
300 ft
Turn main power switch OFF . Transformer wire tap connections vary depending on length of heated hose. See F
IG
. 7. Verify that wire taps are cor-
rect.
50 ft
100 ft
150 ft
200 ft ti3469a
.
Hose Length* ft (m) Tap Terminal
Label (ft)
60-85 (18.3-25.9)
110-135 (33.5-41.2)
50
100
160-185 (48.8-56.4)
210-235 (64.1-71.7)
150
200
* Length includes heated fluid hose and whip hose.
F
IG
. 6: Transformer Wire Taps, Units with Part No.
15B351 Transformer
20
ti3469a
.
Hose Length* ft (m) Tap Terminal
Label (ft)
60-85 (18.3-25.9) 50
110-135 (33.5-41.2)
160-185 (48.8-56.4)
210-235 (64.1-71.7)
260-285 (79.3-86.9)
310 (94.6)
100
150
200
250
300
* Length includes heated fluid hose and whip hose.
F
IG
. 7: Transformer Wire Taps, Units with Part No.
15B352 Transformer
311299E
Setup
12. Ground system a.
Reactor: is grounded through power
b.
Spray gun: connect whip hose ground
wire to FTS, page 19. Do not disconnect
wire or spray without whip hose.
14. Lubrication system setup
Component A (ISO) Pump: Fill ISO lube reservoir (LR) with Graco Throat Seal Liquid (TSL),
Part No. 206995 (supplied).
ST
a.
Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap.
RT
RB
LR
c.
Fluid supply containers: follow your local code.
d.
Object being sprayed: follow your local code.
ti7738a
b.
Fill with fresh lubricant. Thread the reservoir onto the cap assembly and place it in the bracket (RB).
e.
Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.
f.
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.
13. Check hydraulic fluid level
Hydraulic reservoir is filled at the factory. Check fluid level before operating the first time, and
weekly thereafter. See Maintenance, page 33.
c.
Push the larger diameter supply tube
(ST) approximately 1/3 of the way into the reservoir.
d.
Push the smaller diameter return tube
(RT) into the reservoir until it reaches the bottom.
Important: The return tube (RT) must reach the bottom of the reservoir, to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube (ST) and returned to the pump.
e.
The lubrication system is ready for operation. No priming is required.
311299E 21
Startup
Startup
WARNING
Do not operate Reactor without all covers and shrouds in place.
1.
Fluid Temperature
Sensor (FTS) Calibration
c.
Check level and condition of ISO lube
d.
Turn on component B agitator, if used.
e.
Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY.
SA
SB
Calibrate the FTS ONLY at initial startup (the first time the unit is operated) and any time the hose length changes.
a.
Before turning on the unit, ensure all hoses and cables are properly connected. To ensure that the FTS in the hose is at the same temperature as the heaters, keep heat off and store the hose FTS near the machine for several minutes.
b.
While holding down the temperature unit button (Fahrenheit - “F” or Celsius -
“C”) turn the Reactor main power ON.
c.
Hold the temperature unit button until temperature is shown on the display.
The fluid temperature sensor is now correctly calibrated.
1.
Load fluid with feed pumps
FV ti7736a
Do not mix components A and B during startup.
Always provide two grounded waste containers to keep component A and component B fluids separate.
h.
Use feed pumps to load system. 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 Reactor is tested with oil at the factory. Flush out the oil with a compatible solvent before spray-
ti7739a
f.
Start feed pumps.
g.
Open fluid inlet valves (FV). Check for leaks.
a.
Check that Setup steps 1-14 are complete, pages 16-21.
b.
Check that inlet screens are clean
before daily startup, page 33.
ti2484a
22 311299E
2.
Set temperatures
Startup
d.
To set
A
heat zone target temperature, press or until display shows desired temperature. Repeat for
B
and zones.
A
B
°
F
°
C
Temperature Controls and Indicators, see page 12
For zone only, if FTS is disconnected at startup, display will show hose current (0A). See step h, page 24.
e.
Press to display actual temperatures.
This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns:
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
• Wear gloves if fluid temperature exceeds 110°F
(43°C).
Do not turn on hose heat without fluid in hoses.
f.
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.
a.
Turn main power ON .
b.
Press
°
F
or
°
C
to change temperature scale.
c.
Press .
311299E 23
Startup
3.
Set pressure
Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose.
g.
Turn on
A
and
B
heat zones by pressing for each zone.
h.
Manual current control mode only:
ON / OFF
PARK
PSI
BAR
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 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.
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), reduce current with key.
Motor Controls and Indicators, see page 14
a.
Press to display the pressure reading.
b.
Press motor . Motor and pumps start. Display shows system pressure.
c.
Adjust hydraulic pressure control until display shows desired fluid pressure.
+ -
ti7732a ti7731a
If display pressure is greater than desired pressure, reduce the hydraulic pressure and trigger gun to reduce pressure.
24 311299E
Startup
Check the pressure of each proportioning pump using the component A and B gauges. The pressures should be approximately equal and must remain fixed.
b.
Press and hold
PSI
or
BAR
, then turn main power switch ON .
Display will read dP500 for psi or dP_35 for bar.
d.
To display cycle count, press .
To clear counter, press and hold for 3 sec.
c.
Press or to select desired pressure differential (100-999 in increments of 100 psi, or 7-70 in increments of 7 bar). See T
ABLE
3.
e.
Press
PSI
or
BAR
to change pressure scale.
4.
Change pressure imbalance setting (optional)
The pressure imbalance function (status code 24, page
32) detects conditions that can cause off-ratio spray,
such as loss of feed pressure/supply, pump seal failure, clogged fluid inlet filter, or a fluid leak.
Code 24 (pressure imbalance) is set to an alarm as the default. To change to a warning, see repair/parts manual 311300.
The pressure imbalance default is factory-set at 500 psi
(3.5 MPa, 35 bar). For tighter ratio error detection, select a lower value. For looser detection or to avoid nuisance alarms, select a higher value.
Table 3: Available Pressure Imbalance Settings
PSI BAR PSI BAR
100
200
300
400
*500
7
14
21
28
*35
600
700
800
900
999
* Factory default setting.
42
49
56
63
69
d.
Turn main power switch OFF save changes.
to
a.
Turn main power switch OFF .
311299E 25
Spraying
Spraying
1.
Engage gun piston safety lock.
4.
Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY.
SA
SB ti2409a
2.
Close gun fluid manifold valves A and B.
ti7739a
5.
Check that heat zones are on and temperatures
6.
Press motor to start motor and pumps.
ti2728a
3.
Attach gun fluid manifold. Connect gun air line.
Open air line valve.
ti2543a
26 311299E
Spraying
7.
Check fluid pressure display and adjust as necessary, page 24.
10.
Disengage gun piston safety lock.
8.
Check fluid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF, until gauges show balanced pressures.
ti2410a
11.
Test spray onto cardboard. Adjust pressure and temperature to get desired results.
GA GB
12.
Equipment is ready to spray.
In this example, B side pressure is higher, so use the B side valve to balance pressures.
ti7741a
If you stop spraying for a period of time, the unit will
enter standby (if enabled). See page 28.
9.
Open gun fluid manifold valves A and B.
ti2414a
On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.
311299E 27
Standby
Standby
If you stop spraying for a period of time, the unit will enter standby by shutting down the electric motor and hydraulic pump, to reduce equipment wear and minimize heat buildup. The ON/OFF LED and the pressure/cycle display on the motor control panel will flash when in standby.
Shutdown
1.
Shut
A
B
2.
Park pumps.
The
A
,
B
, and be shut off in standby.
heat zones will not
To restart, spray off target for 2 sec. The system will sense the pressure drop and the motor will ramp up to full speed in a few seconds.
To activate or disable standby, adjust DIP switch #3 on the motor control board. See repair/parts manual
311300.
The idle time before entering standby is user-settable as follows:
a.
b.
Press .
Trigger gun until pump A stops in the retracted position and the pressure of both pumps bleeds down.
3.
Turn main power OFF .
4.
Close both fluid supply valves (FV).
1.
Turn main power switch OFF .
2.
Press and hold , then turn main power
FV switch ON .
5.
3.
Press or to select desired timer setting (5-20, in 5 minute increments). This sets the length of inactive time before the unit will enter standby.
6.
Shut down feed pumps as required.
ti7737a
4.
Turn main power switch OFF changes.
to save
28 311299E
Pressure Relief Procedure
Pressure Relief Procedure
5.
Engage gun piston safety lock.
1.
Relieve pressure in gun and perform gun shutdown procedure. See gun manual.
2.
Close gun fluid manifold valves A and B.
ti2409a
6.
Disconnect gun air line and remove gun fluid manifold.
ti2421a
3.
Shut off feed pumps and agitator, if used.
4.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF. Route fluid to waste containers or supply tanks. Ensure gauges drop to 0.
SA
SB ti7740a ti2554a
311299E 29
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
5.
Set temperature targets, see page 23. Turn on
A
and
B
heat zones by pressing
. Do not turn on heat zone unless hoses are already loaded with fluid.
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.
To circulate through gun manifold and preheat hose, see
6.
Press to display actual temperatures.
1.
Load fluid with feed pumps, page 22.
7.
Before starting motor, reduce hydraulic pressure to the minimum required to circulate fluid until
A
and
B
temperatures reach targets.
Do not install shutoffs downstream of the PRES-
SURE RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpressure relief valves when set to SPRAY. Lines must be open so valves can automatically relieve pressure when machine is operating.
2.
See Typical Installation, with circulation, page 8. Route circulation lines back to respec-
tive component A or B supply drum. Use hoses rated at the maximum working pressure of this
equipment. See Technical Data, page 39.
8.
Press motor
-
ti7732a
to start motor and pumps.
Circulate fluid at lowest possible pressure until temperatures reach targets.
3.
Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF.
SA
SB
9.
Turn on heat zone by pressing .
ti7740a
10.
Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY.
SA
SB
4.
Turn main power ON .
30
ti7739a
311299E
Fluid Circulation
Circulation Through Gun
Manifold
2.
Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working pressure of this equip-
ment. See Typical Installation, without circu-
Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.
Circulating fluid through the gun manifold allows rapid preheating of hose.
3.
Follow Load fluid with feed pumps, page 22.
4.
Turn main power ON .
1.
Install gun fluid manifold (P) on Part No. 246362 accessory circulation kit (CK). Connect high pressure circulation lines (R) to circulation manifold.
5.
Set temperature targets, see page 23. Turn on
A
,
B
, and heat zones by pressing .
P
CK
R
6.
Press to display actual temperatures.
ti2767a
7.
Before starting motor, reduce hydraulic pressure to the minimum required to circulate fluid until
A
and
B
temperatures reach targets.
-
ti7732a
8.
Press motor to start motor and pumps.
Circulate fluid at lowest possible pressure until temperatures reach targets.
311299E 31
Diagnostic Codes
Diagnostic Codes
Temperature Control Diagnostic Codes
Temperature control diagnostic codes E01 through E05 appear on temperature display.
These alarms turn off heat. Turn main power OFF
then ON to clear.
See repair manual for corrective action.
Code
No.
05
30
99
01
02
03
04
Code Name Alarm Zone
High fluid temperature
High hose current
Individual
Hose only
No hose current with hose heater on Hose only
FTS or thermocouple not connected Individual
Board overtemperature
Momentary loss of communication
Loss of communication
All
All
All
For hose zone only, if FTS is disconnected at startup, display will show hose current 0A.
Motor Control Diagnostic Codes
Motor control diagnostic codes E21 through E27 appear on pressure display.
There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings.
See repair manual for corrective action.
Alarms
Warnings
Reactor will continue to run. Press to clear. A warning will not recur for a predetermined amount of time (varies for different warnings), or until main power is turned OFF then ON .
Alarms turn off Reactor. Turn main power OFF then ON to clear.
Alarms can also be cleared, except for code 23, by pressing .
Code 24 (pressure imbalance) is set to an alarm default of 500 psi (3.5 MPa, 35 bar). To change to a warning, see repair/parts manual 311300. To change the default pressure imbalance setting, see
27
30
31
Code
No.
21
22
23
24
99
Code Name Alarm or
Warning
No transducer (component A)
No transducer (component B)
High pressure
Pressure imbalance
Alarm
Alarm
Alarm
Selectable; see repair manual
Alarm High motor temperature
Momentary loss of communication Alarm
Pumpline switch failure/high cycle rate
Alarm
Loss of communication Alarm
32 311299E
Maintenance
Maintenance
• Inspect hydraulic and fluid lines for leaks daily.
• Clean up all hydraulic leaks; identify and repair cause of leak.
• Inspect fluid inlet strainer screens daily, see below.
• Inspect ISO lubricant level and condition daily, see
page 34. Refill or replace as needed.
• Check hydraulic fluid level weekly. Remove cover plate (CP) and check hydraulic fluid level on dipstick
(DS). Fluid level must be between indent marks (IM) on dipstick. Refill as required with approved hydrau-
lic fluid; see Technical Data on page 39. If fluid is
dark in color, change fluid and filter (see repair/parts manual 311300).
Fluid Inlet Strainer Screen
The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.
Use clean chemicals and follow proper storage, transfer, and operating procedures, to minimize contamination of the A-side screen.
CP ti7824a
DS
IM
S ti7861a
• Keep component A from exposure to moisture in atmosphere, to prevent crystallization.
• Clean gun mix chamber ports regularly. See gun manual.
• Clean gun check valve screens regularly. See gun manual.
• Use compressed air to prevent dust buildup on control boards, fan, and motor (under shield).
Clean the A-side screen only during daily startup.
This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.
1.
Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.
2.
Place a container under the strainer manifold (59d) to catch fluid. Remove the strainer plug (59j).
3.
Remove the screen (59g) from the strainer manifold.
Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. If more than
25% of the mesh is blocked, replace the screen.
Inspect the gasket (59h) and replace as required.
4.
Ensure the pipe plug (59k) is screwed into the strainer plug (59j). Install the strainer plug with the screen (59g) and gasket (59h) in place and tighten.
Do not overtighten. Let the gasket make the seal.
5.
Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.
59d
59g
59h
59j
59k ti7734a
F
IG
. 8. Fluid Inlet Strainer
311299E 33
Maintenance
Pump Lubrication System
ST
RT
RB
Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.
Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible.
Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks.
To change pump lubricant:
1.
2.
Lift the lubricant reservoir (LR) out of the bracket
(RB) and remove the container from the cap. Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reattach the check valve to the inlet hose. See F
IG
. 9.
3.
Drain the reservoir and flush it with clean lubricant.
4.
When the reservoir is flushed clean, fill with fresh lubricant.
5.
Thread the reservoir onto the cap assembly and place it in the bracket.
6.
Push the larger diameter supply tube (ST) approximately 1/3 of the way into the reservoir.
7.
Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom.
LR
ST
F
IG
. 9. Pump Lubrication System
Important: The return tube (RT) must reach the bottom of the reservoir, to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube (ST) and returned to the pump.
8.
The lubrication system is ready for operation. No priming is required.
ti7738a
RT
LR ti7822a
34 311299E
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 solvent before introducing new fluid.
• Use the lowest possible pressure when flushing.
• All fluid components are compatible with common solvents. Use only moisture-free solvents.
• To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF. Flush through bleed lines (N).
SA
N
SB
N ti2481a
• To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).
• To prevent moisture from reacting with isocyanate, always leave the system dry or filled with a moisture-free plasticizer or oil. Do not use water. See
311299E 35
Accessories
Accessories
Feed Pump Kits
Pumps, hoses, and mounting hardware to supply fluids to Reactor. Includes 246483 Air Supply Kit. See
309815.
Heated Hoses
50 ft (15.2 m) and 25 ft (7.6 m) lengths, 1/4 in. (6 mm),
3/8 in. (10 mm), or 1/2 in. (13 mm) diameter, 2000 psi
(14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See
309572.
246483 Air Supply Kit
Hoses and fittings to supply air to feed pumps, agitator, and gun air hose. Included in feed pump kits. See
309827.
Heated Whip Hoses
10 ft (3 m) whip hose, 1/4 in. (6 mm) or 3/8 in. (10 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24
MPa, 241 bar). See 309572.
246978 Circulation Kit
Return hoses and fittings to make circulation system.
Includes two 246477 Return Tube Kits. See 309852.
Fusion Spray Gun
Air purge gun, available in round or flat pattern. See
309550.
246477 Return Tube Kit
Desiccant dryer, return tube, and fittings for one drum.
Two included in 246978 Circulation Kit. See 309852.
15B593 Membrane Switch
Shield
10 pack of clear labels to protect membrane switches on
Reactor temperature and motor control displays.
246085 Data Reporting Kit
Records actual temperature, temperature setpoint, actual pressure, cycles, and diagnostic code data from
Reactor. Downloads data to PC with Microsoft
® Windows 98 or later. See 309867.
248848 Data Reporting Kit
Records actual temperature, temperature setpoint, actual pressure, cycles, and diagnostic code data from
Reactor. Downloads data to PC with Microsoft
® Windows 98 or later. Does not include interface module. See
309867.
36 311299E
Notes
Accessories
311299E 37
Dimensions
Dimensions
Dimension
A (height)
B (width)
C (depth)
D (front mounting holes)
E (rear mounting holes)
in. (mm)
55.0 (1397)
39.6 (1006)
18.5 (470)
29.34 (745)
33.6 (853)
Dimension in. (mm)
F (side mounting holes) 16.25 (413)
G (mounting post inner diameter) 0.44 (11)
H (front mounting post height)
J (rear mounting post height)
2.0 (51)
3.6 (92)
A
38
C
Top View
E
Rear of Machine
G
F
Front of Machine
D
B
ti7742a ti7705a
H
Side View
Detail of mounting post height, to correctly size mounting bolts
J
ti7743a
311299E
Technical Data
Technical Data
Category
Maximum Fluid Working Pressure
Fluid:Oil Pressure Ratio
Fluid Inlets
Data
Model H-25: 2000 psi (13.8 MPa, 138 bar)
Model H-XP2: 3500 psi (24.1 MPa, 241 bar)
Model H-25: 1.91:1
Model H-XP2: 2.79:1
Component A (ISO): 3/4 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum
Component B (RES): 1/2 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum
Component A (ISO): #8 JIC (3/4-16 unf), with #5 JIC adapter Fluid Outlets
Fluid Circulation Ports
Maximum Fluid Temperature
Maximum Output (10 weight oil at ambient temperature)
Component B (RES): #10 JIC (7/8-14 unf), with #6 JIC adapter
1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum
190°F (88°C)
Model H-25: 22 lb/min (10 kg/min) at 35 cycles/min (60 Hz)
Output per Cycle (A and B)
Model H-XP2: 1.5 gpm (5.7 liter/min) at 35 cycles/min (60 Hz)
Model H-25: 0.063 gal. (0.23 liter)
Model H-XP2: 0.042 gal. (0.16 liter)
230V 1 phase and 230V 3 phase units: 195-264 Vac, 50/60 Hz Line Voltage Requirement
Amperage Requirement
Heater Power
(A and B heaters total, no hose)
380V 3 phase units: 338-457 Vac, 50/60 Hz
Hydraulic reservoir capacity
Recommended hydraulic fluid
1.2 gal. (4.5 liters)
Citgo A/W Hydraulic Oil, ISO Grade 46
Sound power, per ISO 9614-2 87.8 dB(A)
Sound pressure, 1 m from equipment 80.2 dB(A)
Weight Units with 8 kW Heaters: 498 lb (226 kg)
Wetted Parts
Units with 15.3 kW Heaters: 525 lb (238 kg)
Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome, fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, chemically resistant o-rings
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
311299E 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
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.
This manual contains English. MM 311299
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2006, Graco Inc. is registered to I.S. EN ISO 9001 www.graco.com
Revised 7/2008
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