Graco 312062W User's Manual
Contents
1. 13 8 138 253402 246678 246050 Fusion Air Purge 246101 500 24 1 241 x253403 246679 246055 _ Fusion Air Purge 246101 500 24 1 241 500 24 1 241 000 13 8 138 253407 246678 246050 Fusion Air Purge 246101 000 13 8 138 253408 246678 246050 Fusion Air Purge 246101 700 11 7 117 x253725 _ 246678 246050 Fusion Air Purge 246101 000 13 8 138 000 13 8 138 000 13 8 138 255400 246678 246050 Fusion Air Purge 246101 000 13 8 138 255401 246678 246050 Fusion Air Purge 246101 000 13 8 138 255402 246678 246050 Fusion Air Purge 246101 500 24 1 241 500 24 1 241 500 24 1 241 000 13 8 138 000 13 8 138 255407 246678 246050 Fusion Air Purge 246101 000 13 8 138 255408 246678 246050 Fusion Air Purge _ 246101 000 13 8 138 256505 246678 000 13 8 138 000 13 8 138 255400 246678 246050 _ Fusion C8_ CS0RD 000 13 8 138 255401 246678 246050 Fusin CS CSO2RD x x 000 13 8 138 255402 246678 246050 Fusioncs CSO2RD __ CS5406 000 13 8 138 255406 246678 246050 CS02RD 255407 246678 246050 CS02RD 255408 246678 246050 CS02RD os weer lea ee wesw we we wm ZA rms mm lag wm mm pag ZA we we lag a CS5407 000 CS5408 000 CE approval does not apply NO 13 8 138 13 8 138 NO 312062W 3 Systems Systems Continued Mm Maximum Fluid Working Pressure Proportioner psi MPa bar see page 3 10 ft 3 m2. Instruction Parts Manual English Proportioning Pump Repair Kits Manual English 312071 Seal Kits Instruction Parts 312062W Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equip ment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable 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 eguipment 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 MSDSs to know the specific hazards of the fluids you are using Store hazardous fluid in approved containers and dispose of it according to applicable guidelines Always wear chemically impermeable gloves when spraying dispensing or cleaning eguipment PERSONAL PROTECTIVE EOUIPMENT You must wear appropriate protective eguipment when operating servicing or when in the operating area of the eq
3. PWN Probler P2 46678 246050__ Probler P2 253402 46678 46050 _ Probler P2 46679 246055 __ Probler P2 253404 46679 246055 _ Probler P2 46679 246055 __ Probler P2 46678 246050 __ Probler P2 253408 46678 46050 Probler P2 46678 246050 Probler P2 46678 46050 Probler P2 46678 246050 Probler P2 46678 246050 Probler P2 255401 46678 46050 Probler P2 46678 246050 Probler P2 46679 46055 Probler P2 46679 246055 Probler P2 46679 246055 Probler P2 255406 46678 46050 Probler P2 46678 246050 Probler P2 46678 46050 Probler P2 46678 46050 Probler P2 46678 46050 Probler P2 L O o D o L o V D NO NO NO P23401 000 P23402 000 P23403 500 13 8 138 13 8 138 24 1 241 24 1 241 24 1 241 13 8 138 13 8 138 11 7 117 13 8 138 13 8 138 13 8 138 13 8 138 13 8 138 24 1 241 24 1 241 24 1 241 13 8 138 13 8 138 13 8 138 13 8 138 13 8 138 NO NO NO NO N N NO 500 500 000 peP23725 NO IN N 2 NO NO 000 700 000 000 000 000 000 500 00 500 000 000 000 000 000 NO NO P23725 NO NO a NO NO NO NO NO NO NO NO NO NO NO NO NO NO a O1 NO NO NO NO NO NO NO NO NO l Paa weer la lag lag wm rem ZA lag lag lag pag o l la la lag Dm ac NO NO NO Paa P26506 CE approval does not apply NO NO NO 4 312062W Models Models H 25 SERI
4. Rear of Front of D B ti7742a 48 Detail of mounting post height to correctly size mounting bolts T ti7743a 312062W Technical Data Technical Data Category Data S O Maximum Fluid Working Pressure Models H 25 and H 40 2000 psi 13 8 MPa 138 bar Model H 50 1 phase 1700 psi 11 7 MPa 11 7 bar Model H 50 3 phase 2000 psi 13 8 MPa 138 bar Models H XP2 and H XP3 3500 psi 24 1 MPa 241 bar Fluid Oil Pressure Ratio Models H 25 and H 40 1 91 1 Model H 50 1 64 1 Models H XP2 and H XP3 2 79 1 Fluid Inlets Component A ISO 1 2 npt f 250 psi 1 75 MPa 17 5 bar maximum Component B RES 3 4 npt f 250 psi 1 75 MPa 17 5 bar maximum Fluid Outlets Component A ISO 8 1 2 in JIC with 5 5 16 in JIC adapter Component B RES 10 5 8 in JIC with 6 3 8 in JIC adapter Fluid Circulation Ports 1 4 npsm m with plastic tubing 250 psi 1 75 MPa 17 5 bar maximum Maximum Fluid Temperature 190 F 88 C Maximum Output 10 weight oil at Model H 25 22 Ib min 10 kg min 60 Hz ambient temperature Model H XP2 1 5 gpm 5 7 liter min 60 Hz Model H 50 52 Ib min 24 kg min 60 Hz Model H 40 45 Ib min 20 kg min 60 Hz Model H XP3 2 8 gpm 10 6 liter min 60 Hz Output per Cycle A and B Models H 25 and H 40 0 063 gal 0 23 liter Model H 50
5. See Technical Data page 49 40 Fluid Circulation 3 Set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCU TA LATION Os ed SB ti9879a 4 Turn main power ON 1 5 Settemperature targets see page 31 Turn on and B heat zones by pressing o Do not turn on heat zone unless hoses are already loaded with fluid 6 Press D to display actual temperatures 7 Before starting motor reduce hydraulic pressure to the minimum required to circu late fluid until and B tempera tures reach targets ti7732a 8 Press motor o to start motor and pumps Circulate fluid at lowest possible pressure until temperatures reach targets 9 Turn on heat zone by pressing o 312062W Fluid Circulation 10 Set PRESSURE RELIEF SPRAY valves SA SB to SPRAY m Circulation Through Gun Manifold ti9877a AN 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 1 Install gun fluid manifold P on Part 246362 accessory circulation kit CK Con nect high pressure circulation lines R to circulation manifold ti2767a 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 Typical Installation w
6. e Never use solvent on one side if it has been contaminated from the other side e Always lubricate threaded parts with ISO pump oil or grease when reassembling Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at tem peratures above 90 F 33 C when not under pressure especially if agitated To reduce frothing minimize preheating in a circulation system 312062W Changing Materials When changing materials flush the equip ment multiple times to ensure it is thor oughly 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 hard ener side Polyureas often have amines on the B resin side 13 Typical Installation with circulation Typical Installation with circulation Key for FIG 1 Fusion Spray Gun Gun Air Supply Hose Desiccant Dryer Gun Fluid Manifold part of gun Circulation Lines A Reactor Proportioner Feed Pump Air Supply Lines B Heated Hose Fluid Supply Lines C Fluid Temperature Sensor FTS Feed Pumps D Heated Whip Hose Agitator E F UUECT ATO A Side Supply Detail B Side Supply Detail My ti 820a 2 Mn ND Shown exposed for clarity B R Tane i Wrap with tape during operation ti10000a FIG 1 Typical Installation with circulation 14 312062W T
7. or Heater A CB5 50 A For wiring and cabling see repair manual 312063 CB4 25 40 or Heater B 50 A 20 or 30 A Motor Pumps 20 312062W Motor Controls and Indicators Motor 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 Arrow Keys Pressure Cycle Display Motor ON OFF Key o PARK Key Pressure Key a a PSI BAR Keys x ojo ojofi G GRACO FIG 5 Motor Controls and Indicators Motor ON OFF Key LED PSI BAR Keys LEDs Press o to turn motor ON and OFF Also Press or to change pressure scale clears some motor control diagnostic codes see page 43 Pressure Key LED PARK Key LED Press O to display fluid pressure Press at end of day to cycle component A pump to home position submerging dis If pressures are imbalanced display placement rod Trigger gun until pump stops shows higher of two pressures Once parked motor will automatically shut off 312062W 21 Cycle Count Key LED Press to display cycle count To clear counter press and hold for 3 sec Hydraulic Pressure Control Knob Use to adjust hydraulic pressure available to the hydraulic drive system Turn Knob HC clockwise to increase pressure and counter clockwise to decrease pressure Use hydraulic pressure gauge HP page 17 to view hydrau lic pressure ti7731a
8. all Setup steps are com plete Check that inlet screens are clean before daily startup page 45 Check level and condition of ISO lube daily page 44 Turn on component B agitator if used Turn both PRESSURE RELIEF SPRAY valves SA SB to SPRAY m Start feed pumps Open fluid inlet valves FV Check for leaks ti10002a 312062W Startup N Do not mix components A and B during nent B fluids separate startup Always provide two grounded waste containers to keep component A and compo 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 ti2484a Temperature Controls and Indicators see page 18 312062W UA This equipment is used with heated fluid which can cause equipment surfaces to become very hot To avoid severe burns e Do not touch hot fluid or equipment e Allow equipment to cool completely before touching it e Wear gloves if fluid temperature exceeds 110 F 43 C a Turn main power ON 73 Press o or O to change tem perature scale Press to display target tempera tures Toset heat zone target tempera ture press O Or O until display shows desired temperature Repeat for B and Zones For zone only if FTS is discon nected at startup displa
9. and various flow rates and mix chamber sizes may Local safety and fire codes be less Total system watts based on maximum Table 1 Electrical Reguirements hose length for each unit kW Full Load Amps e Parts 255400 through 255408 310 ft 94 6 m maximum heated hose length including Voltage whip hose phase e Parts 253400 through 253408 410 ft 125 m maximum heated hose length including whip hose 24 312062W Setup 4 Connectelectrical cord Power cord is not supplied See Table 2 i p Table 2 Power Cord Requirements ma a 230V 1 phase Using 5 32 or 4 mm hex Cord Specification m moder 2 allen wrench connect two power leads AWG mm 4 21 2 2 wire 4 ground to L1 and L2 Connect green to ground A 8 8 4 4 wire ground ti2515b b 230V 3 phase Using 5 32 or 4 mm hex IU S gano allen wrench connect three power 255406 HSR 4 212 2 wire ground leads to L1 L2 and L3 Connect green 8 8 4 4 wire ground to ground GND ti3248b 312062W 25 c 400V 3phase 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 ti2725a Some 3 phase models utilize a 3 phase DS motor The motor must rotate counter clockwise when viewed from shaft end To reverse rotation disconnect power and reverse power leads L1 an
10. 0 073 gal 0 28 liter Models H XP2 and H XP3 0 042 gal 0 16 liter Line Voltage Requirement 230V 1 phase and 230V 3 phase units 195 264 Vac 50 60 Hz 400V 3 phase units 338 457 Vac 50 60 Hz Amperage Requirement See Systems page 3 Heater Power See Systems page 3 A and B heaters total no hose Hydraulic reservoir capacity 3 5 gal 13 6 liters Recommended hydraulic fluid itgo A W Hydraulic Oil ISO Grade 46 Sound power per ISO 9614 2 90 2 dB A A Sound pressure 82 6 dB 1 m from equipment Weight Units with 8 0 kW Heaters 535 Ib 243 kg Units with 12 0 kW Heaters 597 Ib 271 kg Units with 15 3 KW Heaters H 25 H XP2 models 562 lb 255 kg Units with 15 3 kW Heaters H 40 H XP3 H 50 models 597 Ib 271 kg Units with 20 4 KW Heaters 597 Ib 271 kg Wetted Parts 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 Performance Charts Performance Charts 50 Foam Performance Chart 2000 KEY 13 8 138 A H 25 at 50 HZ A B H 25 at 60 Hz Z no C H 40 at 50 Hz E ce D H 40 at 60 Hz F H 50 at 60 Hz o i 1000 o 6 9 69 V O o o 500 3 4 34 0 5 15 25 35 45 55 2 3 68 11 4 15 9 20 5 25 0 Flow Rate in Ib min kg min Pre
11. 100 230V 1 23 260 15 300 0 042 0 16 3500 24 1 241 5 15 15 5 7 0 042 0 16 2 79 255404 F 59 230V 3 23 260 15 300 1 5 5 7 0 042 0 16 2 79 1 3500 24 1 241 255405 F 35 400V 3 23 260 15 300 1 5 5 7 0 042 0 16 2 79 1 3500 24 1 241 H XP3 SERIES Approximate Maximum Fluid Full Load Primary Max Flow Output per Hydraulic Working Peak Amps System Heater Cycle A B Pressure Pressure Part Series Per Phase Watts Watts gpm Ipm gal liter Ratio psi MPa bar x253403 E 100 230V 1 23 100 12 000 2 8 10 6 0 042 0 16 2 79 1 3500 24 1 241 253404 E 95 230v 3 31 700 20400 2 8 10 6 0 042 0 16 2 79 1 3500 24 1 241 253405 E 52 400V 3 31 700 20 400 2 8 10 6 0 042 0 16 2 79 1 3500 24 1 241 Full load amps with all devices operating at maximum capabilities Fuse requirements at vari ous flow rates and mix chamber sizes may be less t Total system watts based on maximum hose length for each unit e Parts 255400 through 255408 310 ft 94 6 m maximum heated hose length including whip hose e Parts 253400 through 253408 253725 through 253727 256505 and 256506 410 ft 125 m maximum heated hose length including whip hose e Maximum flow rate given for 60 Hz operation For 50 Hz operation maximum flow rate is 5 6 of 60 Hz maximum flow CE approval does not apply Approvals C LISTEO 9902471 Conforms to ANSI UL Std 499 Certified to CAN CSA St
12. ES Approximate Maximum Fluid Full Load Primary Output per Hydraulic Working Peak Amps Heater i Cycle A B Pressure Pressure Part Series Per Phase i gal liter Ratio psi MPa bar 255400 F 69 1 91 1 000 13 8 138 255401 F 1 91 1 000 13 8 138 255402 F 1 91 1 000 13 8 138 255406 F 100 1 91 1 000 13 8 138 255407 F 59 1 91 1 000 13 8 138 255408 F 35 1 91 1 000 13 8 138 H 40 SERIES Approximate Maximum Fluid Full Load Primary Output per Hydraulic Working Peak Amps System __ Heater i Cycle A B Pressure Pressure Part Series Per Phase Wattst i gal liter Ratio psi MPa bar 230V 3 26 0 063 0 24 400V 3 15 0 063 0 24 230V 3 400V 3 0 063 0 24 H 50 SERIES Approximate Maximum Fluid Full Load i Output per Hydraulic Working Peak Amps i Cycle A B Pressure Pressure Part Series Per Phase i gal liter Ratio psi MPa bar x2537255E 100 230V 1 23 100 _ 2 000 52 24 0 073 0 28 1 64 1 71 30V 3 26 600 0 28 1 64 1 1 26 600 0 28 1 64 1 95 30V 3 073 0 28 2000 13 8 138 N N AS AE we la SS 253726E 71 230V 3 259727 E 41 40OV 3 95 230V 3 312062W 5 Models H XP2 SERIES Approximate Maximum Fluid Full Load Primary Max Flow Output per Hydraulic Working Peak Amps System _ Heater Cycle A B Pressure Pressure Part Series Per Phase Watts _ Watts gpm Ipm gal liter Ratio psi MPa bar 255403 F
13. Operation Rugger Hydraulic Heated Plural Component Proportioner For spraying polyurethane foam and polyurea coatings For professional use only Not approved for use in European explosive atmosphere locations Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 3 for model information including maximum working pressure and approvals T9830a Cf PROVEN QUALITY LEADING TECHNOLOGY Contents SYSTEMS adu AR WR WG RR 3 MOdel ee eu ore reeset st seen eee 5 Supplied Manuals 7 Related Manuals 8 WarningS ee ER ene AA Ape 9 Important Two Component Material Information 12 Isocyanate Conditions 12 Material Self ignition 12 Keep Components A and B Separate 12 Moisture Sensitivity of Isocyanates 12 Foam Resins with 245 fa Blowing Agents 13 Changing Materials 13 Typical Installation with circulation 14 Typical Installation without circulation 15 Component Identification 16 Temperature Controls and Indicators 18 Main Power Switch 18 Red Stop Button 18 Actual Temperature Key LED 19 Target Temperature Key LED 19 Temperature Scale Keys LEDs 19 Heater Zone On Off Keys LEDs 19 Tempe
14. a tion No priming is reguired ti9911a jl ti9887a FIG 7 Pump Lubrication System 312062W Flushing Flushing AN Do not spray flammable fluids Do not turn on heaters while flushing with flammable solvents Flush eguipment only in a well ventilated area e Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing new fluid e Use the lowest possible pressure when flushing e All fluid components are compatible with common solvents Use only moisture free solvents 312062W To flush feed hoses pumps and heaters separately from heated hoses set PRES SURE RELIEF SPRAY valves SA SB to TA PRESSURE RELIEF CIRCULATION WIN Flush through bleed lines N ti9880a To flush entire system circulate through gun fluid manifold with manifold removed from gun To prevent moisture from reacting with iso cyanate always leave the system dry or filled with a moisture free plasticizer or oil Do not use water See page 12 47 Dimensions Dimensions Dimension in mm Dimension in mm E sid ina ol 16 25 413 A height 55 0 1397 side moun ing oles 25 413 B width 39 6 1006 G mounting post inner diameter 0 44 11 C depth 185 470 H front mounting post height 2 0 51 D front mounting holes 29 34 745 AU SCH POSEE O E rear mounting holes 33 6 853 TI9830a Top View Side View E
15. alance is set to an alarm as the default To change to a warning see Reactor Repair Parts manual 312063 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 a Turn main power switch OFF ao 33 34 Startup b Press and hold or GS then turn main power switch ON will read dP500 for psi or dP_35 for bar c Press O Or O to select desired pressure differential 100 999 in incre ments of 100 psi or 7 70 in increments of 7 bar See TABLE 3 Display Table 3 Available Pressure Imbalance Settings PSI BAR Psi BAR 7 600 42 14 700 49 300 21 800 56 400 28 900 63 500 35 999 69 Factory default setting d Turn main power switch OFF ao to save changes 312062W Spraying Spraying 9 1 Engage gun piston safety lock gr aal ti2409a 2 Close gun fluid manifold valves A and B N Wi ti2728a 3 Attach gun fluid manifold Connect gun air line Open air line valve ti2543a 312062 W 4 Set PRESSURE RELIEF SPRAY valves SA SB to SPRAY mt Pa ti9877a 5 Check that heat zones are on and tempera tures are on target page 31 6 Press motor o to start motor and pumps 7 Check fluid pressure display and adjust as necessary 8 Chec
16. amination of the A side screen 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 mani fold 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 312062W 5 Open the fluid inlet valve ensure that there are no leaks and wipe the equipment clean Proceed with operation ti9886a Fic 6 Fluid Inlet Strainer See Reactor Repair Parts manual 312063 for fluid filter screen replacements 45 Pump Lubrication System Check the condition of the IGO 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
17. d C22 2 No 88 6 312062W Supplied Manuals Supplied Manuals The following manuals are shipped with the Reactor Proportioner Refer to these manu als for detailed eguipment information Order Part 15M334 for a compact disk of Reactor manuals translated in several lan guages Manuals are also available at www graco com Reactor Hydraulic Proportioner 312063 Reactor Hydraulic Proportioner Repair Parts Manual English Reactor Electrical Diagrams 312064 Reactor Hydraulic Proportioner Electrical Diagrams English Proportioning Pump Part Description III 312068 Proportioning Pump Repair Parts Manual English 312062W Related Manuals The following manuals are for accessories used with the Reactor Order Part 15M334 for a compact disk of Reactor manuals translated in several lan guages Feed Pump Kits Description 309815 Instruction Parts Manual English Air Supply Kit 309827 Instruction Parts Manual English for Feed Pump Air Supply Kit Circulation and Return Tube Kits Description 309852 Instruction Parts Manual English Heated Hose Description 309572 Instruction Parts Manual English Related Manuals Circulation Kit 309818 Instruction Parts Manual English Circulation Valve Kit 312070 Instruction Parts Manual English Data Reporting Kit 309867 Instruction Parts Manual English Rupture Disk Assembly Kit 309969
18. d L2 5 Connect feed pumps a Install feed pumps K in component A and B supply drums See FIG 1 and FIG 2 pages 14 and 15 A minimum feed pressure of 50 psi 0 35 MPa 3 5 bar is reguired at both feed inlet pressure gauges FP Maxi mum feed pressure is 250 psi 1 75 MPa 17 5 bar Maintain A and B feed pressures within 109e of each other ti10006a b Seal component A drum and use desic cant dryer M in vent 26 Setup c Install agitator L in component B drum If necessary d Ensure A and B inlet valves FV are closed ti9883a Supply hoses from feed pumps should be 3 4 in 19 mm ID 312062W Setup 6 Connect pressure relief lines 2 Do not install shutoffs downstream of the PRESSURE RELIEF SPRAY valve outlets BA BB The valves function as overpres sure relief valves when set to SPRAY mt Lines must be open so valves can automati cally relieve pressure when machine is oper ating 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 FIG 1 page 14 312062W ti9880a b Alternately Secure supplied bleed tubes N in grounded sealed waste containers H See FIG 2 page 15 7 Instal
19. dent marks IM on dipstick Refill as required with approved hydraulic fluid see Technical Data on page 49 and the Approved Anti Wear AW Hydraulic Oils table in the Reactor Repair Parts manual 312063 If fluid is dark in color change fluid and filter ti10003a ti 861a A4 Maintenance Change break in oil in a new unit after first 250 hours of operation or within 3 months whichever comes first See Table 4 for rec ommended freguency of oil changes Table 4 Freguency of Oil Changes Ambient Recommended Temperature Freguency O to 90 F 1000 hours or 12 17 to 32 C months whichever comes first 90 F and above 500 hours or 6 months 32 C and above whichever comes first Keep component A from exposure to mois ture in atmosphere to prevent crystalliza tion 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 motor under shield and hydraulic oil coolers Keep vent holes on bottom of electrical cabinet open 312062W Maintenance Fluid Inlet Strainer Screen AC 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 stor age transfer and operating procedures to minimize cont
20. ed material in fluid lines which could cause seri Ous injury or damage equipment To prevent cross contamination of the equipment s wet ted parts never interchange component A isocyanate and component B resin parts 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 perfor mance 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 tem perature To prevent exposing ISO to moisture e Always use a sealed container with a des iccant dryer in the vent or a nitrogen atmo sphere Never store ISO in an open container e Keep the ISO lube pump reservoir if installed filled with Graco Throat Seal Lig uid TSL Part 206995 The lubricant cre ates a barrier between the ISO and the atmosphere 312062W Important Two Component Material Information e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent con tainers closed when not in use
21. ed between temperature control panel and motor control panel page 17 Press O to shut off motor and heater zones only Use main power switch to shut off all power to unit and OFF Does not turn heater zones or pumps on Reactor power ON 18 312062W Temperature Controls and Indicators Actual Temperature Key LED Press D to display actual temperature Press and hold D to display electrical cur rent Target Temperature Key LED Press to display target temperature Press and hold to display heater control circuit board temperature Temperature Scale Keys LEDs Press o or O to change temperature scale 312062W Heater Zone On Off Keys LEDs Press to turn heater zones on and off Also clears heater zone diagnostic codes see page 42 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 O Or O to adjust temperature settings in 1 degree incre ments Temperature Displays Show actual temperature or target tempera ture 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 829C for hose 19 Temperature Controls and Indicators Circuit Breakers Depending on model AYAN Located inside Reactor cabinet Ret sie Component Hose Transformer Secondary CB2 Transformer Primary aa CBA seni CB3 25 40
22. edure NO MParbar PSI 1 Relieve pressure in gun and perform gun shutdown procedure See gun manual 2 Engage gun piston safety lock ti2409a i i 3 Close gun fluid manifold valves A and B ti2421a 4 Shut off feed pumps and agitator if used 312062W 5 Turn PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCU NN LATION Os Route fluid to waste contain ers or supply tanks Ensure gauges drop to C Hd a i R Sy 1 Da E Fu o gt a ye A A fa MV SB BABA UD ey a ti9879a 6 Disconnect gun air line and remove gun fluid manifold ti2554a 39 Fluid Circulation Circulation Through Reactor AN 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 page 41 1 Follow Startup procedures page 30 A Do not install shutoffs downstream of the PRESSURE RELIEF SPRAY valve outlets BA BB The valves function as overpres sure relief valves when set to SPRAY ma Lines must be open so valves can automati cally relieve pressure when machine is oper ating 2 See Typical Installation with circulation page 14 Route circulation lines back to respective component A or B supply drum Use hoses rated at the maximum working pressure of this equipment
23. interval between changes depends on the environment in which the equipment is operating The pump lubrica tion 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 Relieve pressure page 39 2 Lift the lubricant reservoir LR out of the bracket RB and remove the container from the cap Holding the cap over a suit able container remove the check valve and allow the lubricant to drain Reattach the check valve to the inlet hose See FIG 7 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 reser voir 7 Push the smaller diameter return tube RT into the reservoir until it reaches the bot tom 46 Maintenance Important The return tube RT must reach the bottom of the reservoir to ensure that isocyanate crystals will set tle to the bottom and not be siphoned into the supply tube ST and returned to the pump 8 The lubrication system is ready for oper
24. ir convenu que la r daction du presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires executes donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es 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 For patent information see www graco com patents Original Instructions This manual contains English MM 312062 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 e MINNEAPOLIS MN 55440 1441 e USA Copyright 2007 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revision W September 2014
25. ithout circulation page 15 312062W Follow Startup procedures page 30 Turn main power ON 1 Set temperature targets see page 31 Turn on B and heat zones by pressing o Press O to display actual temperatures Before starting motor reduce hydraulic pressure to the minimum reguired to circu late fluid until and B tempera tures reach targets ti7732a Press motor o to start motor and pumps Circulate fluid at lowest possible pressure until temperatures reach targets 41 Diagnostic Codes Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on temperature display These alarms turn off heat E99 clears auto matically when communication is regained Codes E03 through E06 can be cleared by pressing o For other codes turn main power OFF then ON ii to clear See repair manual for corrective action 42 01 High fluid temperature Board over temperature Individual 06 Loss of zone communication individual Momentary loss of communica tion 99 Loss of display communication For hose zone only if FTS is discon DS nected at startup display will show hose current OA 312062W Diagnostic Codes 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
26. k fluid pressure gauges GA GB to ensure proper pressure balance If imbal anced reduce pressure of higher compo nent by slightly turning PRESSURE RELIEF SPRAY valve for that component toward PRESSURE RELIEF CIRCULA Ta TION Oy until gauges show balanced pressures In this example B side pressure is higher so use the B side valve to balance pressures 9877a 35 9 Open gun fluid manifold valves A and B ti2414a On impingement guns never open fluid manifold valves or trigger gun if pres sures are imbalanced 36 10 Disengage gun piston safety lock t Spraying ti2410a 11 Test spray onto cardboard Adjust pressure and temperature to get desired results 12 Equipment is ready to spray If you stop spraying for a period of time the unit will enter standby if enabled See page 37 312062W 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 eguipment wear and minimize heat buildup The ON OFF LED and the pressure cycle dis play on the motor control panel will flash when in standby The AR B and heat zones will not be shut off in standby To restart spray off target for 2 sec The sys tem will sense the pressure drop and the motor will ramp up to full speed in a few seconds This feature is disabled from the factory 312062W To activate or disable standb
27. l Fluid Temperature Sensor FTS The Fluid Temperature Sensor FTS is sup plied Install FTS between main hose and whip hose See Heated Hose manual 309572 for instructions 27 8 Connect heated hose See Heated Hose manual 309572 for detailed instructions on connecting heated hoses The fluid temperature sensor C and DS whip hose D must be used with heated hose see page 27 Hose length including whip hose must be 60 ft 18 3 m minimum a Turn main power OFF ao b Assemble heated hose sections FTS and whip hose c Connect A and B hoses to A and B out lets on Reactor fluid manifold FM Hoses are color coded red for compo nent A ISO blue for component B RES Fittings are sized to prevent con nection errors ti9878a 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 28 Setup d Connect cables Y Connect electrical connectors V Be sure cables have slack when hose bends Wrap cable and electrical connections with electri cal tape SO re ITO IP EI ti9881a 9 Close gun fluid manifold valves A and B Ka ti2411a 10 Connect whip hose to gun fluid mani fold Do not connect manifold to gun ti2417a 11 Pressure check hose See hose manual Pressure check for leaks If no leaks wrap hose and elec
28. l 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 O key 312062W Startup 9 Setpressure O ON OFF Motor Controls and Indicators see page 21 a Press O to display the pressure reading b Press motor o Motor and pumps start Display shows system pressure when viewed from shaft end See Con nect electrical cord page 25 Motor must rotate counterclockwise c Adjust hydraulic pressure control until display shows desired fluid pressure ti7731a ti7732a If display pressure is greater than desired pressure reduce the hydraulic pressure and trigger gun to reduce pressure 312062W Check the pressure of each proportion ing pump using the component A and B gauges The pressures should be approximately equal and must remain fixed d To display cycle count press To clear counter press and hold for 3 sec e Press or to change pres sure scale 10 Change pressure imbalance setting optional The pressure imbalance function status code 24 page 43 detects conditions that can cause off ratio spray such as loss of feed pres sure supply pump seal failure clogged fluid inlet filter or a fluid leak Code 24 pressure imb
29. ng 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 eguipment fluid has cooled com pletely 11 Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions ACES Spraying or dispensing materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by pro viding sufficient ventilation in the work area If sufficient ventilation is not available a supplied air respirator is required for every one in the work area To prevent contact with isocyanates appro priate personal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition AN Some materials may become self igniting if applied too thickly Read material manufac turer s warnings and material MSDS Keep Components A and B Separate NO Cross contamination can resultin cur
30. 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 avo
31. ower or light switches on or off when flamma ble fumes are present Ground all eguipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area THERMAL EXPANSION HAZARD Fluids subjected to heat in confined spaces including hoses can create a rapid rise in pres sure due to the thermal expansion Over pressurization can result in eguipment rupture and serious injury 0 TE Up i DI E e Open a valve to relieve the fluid expansion during heating e Replace hoses proactively at regular intervals based on your operating conditions 10 312062W Warnings AIA 312062W PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause seri ous chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon sol vents or fluids containing such solvents Many other fluids may contain chemicals that can react with aluminum Contact your material supplier for compatibility EQUIPMENT MISUSE HAZARD Misuse can cause death or serious inj
32. pture Disk Assembly on rear of A and B pumps Component A Pump Component B Pump Red Stop Button Component A PRESSURE RELIEF SPRAY Valve Component B PRESSURE RELIEF SPRAY Valve Fluid Temperature Sensor Cable Serial Number Plate one inside cabinet one on right side of cabinet Electrical Cord Strain Relief Component A Pressure Transducer behind gauge GA Component B Pressure Transducer behind gauge GB Temperature Control Display Oil Cooler Component Identification 312062W Component ldentification FH PA FT OP FP PB FV Detail of Reactor Fluid Manifold shroud removed for clarity TI9830a SA TAGA GB Detail of Serial No Plate inside cabinet wn ti 823a SN HB o880a FIG 3 Component ldentification H40 15 3 KW Model Shown 312062W 17 Temperature Controls and Indicators 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 Heater Displays o e Zone A Arrow Keys st o Heater A On Off Key Zone B Arrow Keys dB D Heater B On Off Key Hose Heater On Off Hose Zone Arrow Keys O D K O lt Actual Temperature 3 Wie Temperature Scale Koy G ec GRACO o Target Temperature Key FIG 4 Temperature Controls and Indicators Main Power Switch Red Stop Button Located on right side of unit page 17 Turns Locat
33. rature Arrow Keys 19 Temperature Displays 19 Circuit Breakers 20 Motor Controls and Indicators 21 Motor ON OFF Key LED 21 PARK Key LED 0 2 0200 21 PSI BAR Keys LEDs 21 Pressure Key LED nnna 21 Cycle Count Key LED 22 Hydraulic Pressure Control Knob 22 Motor Control Arrow Keys 22 Spray Adjustments 22 SelUlD vy cee AA aa Aa 23 SlANUD TH Y 30 Spraying ss GR TR GO OR 35 Standby Y Lu 37 Shutdown ceu RG WD GU 38 Pressure Relief Procedure 39 Fluid Circulation 40 Circulation Through Reactor 40 Circulation Through Gun Manifold 41 Diagnostic Codes 42 Temperature Control Diagnostic Codes 42 Motor Control Diagnostic Codes 43 Maintenance 44 Fluid Inlet Strainer Screen 45 Pump Lubrication System 46 Flushind 22 0200 pet GG eee aes 47 DIMENSIONS 48 Technical Data 49 Performance Charts 50 Graco Standard Warranty 52 Graco Information 52 312062W Systems Systems Working Pressure Proportioner Mix psi MPa bar see page 3 90 ft 15 m 10 ft 3 m w ka Chamber Kit 246050 000
34. repair manual for corrective action Alarms Alarms turn off the motor and heat zones Turn main power OFF then ON 1 to clear Alarms can also be cleared except for code 23 by pressing o Code 24 pressure imbalance is set to an alarm default of 500 psi 3 5 MPa 35 bar To change to a warning see Reac tor Repair Parts manual 312063 To change the default pressure imbalance setting see page 33 312062W Warnings Reactor will continue to run Press O to clear A warning will not recur for a predeter mined amount of time varies for different warnings or until main power is turned OFF Code Code Name Alarm or No Warning No transducer component A No transducer component B 23 High pressure Pressure imbalance Selectable see repair manual 27 High motor temperature 0 Momentary loss of communi Alarm cation 1 Pumpline switch failure high Alarm cycle rate Alarm Loss of communication 43 Maintenance e Inspect hydraulic and fluid lines for leaks daily e Clean up all hydraulic leaks identify and repair cause of leak e Inspect fluid inlet strainer screens daily see below e Grease circulation valves weekly with Fusion grease 117773 ti9879a e Inspect ISO lubricant level and condition daily see page 46 Refill or replace as needed e Check hydraulic fluid level weekly Check hydraulic fluid level on dipstick DS Fluid level must be between in
35. ritten 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 inadeguate 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
36. size generator procedures are critical to electrical eguip Using the correct size generator and proper ment reliability The following procedures air compressor will enable the proportioner ensure steady voltage Failure to follow these to run at a nearly constant RPM Failure to procedures will cause voltage fluctuations do so will cause voltage fluctuations that that can damage electrical eguipment and can damage electrical eguipment Ensure void the warranty the generator matches the voltage and phase of the proportioner 1 Locate Reactor Use the following procedure to determine a Locate Reactor on a level surface See the correct size generator Dimensions page 48 for clearance and mounting hole dimensions a List system components that use peak load reguirements in watts b Do not expose Reactor to rain b Add the wattage required by the system NOTICE components To prevent damage from tipping over and fall ing proper care needs to be taken when lift c Perform the following equation ing the Reactor Bolt Reactor to original Total watts x 1 25 kVA kilo shipping pallet to Keep stable before lifting volt amperes d Select a generator size that is equal to or greater than the determined kVA c Use the casters to move Reactor to a fixed location or bolt to shipping pallet and move with forklift e Use proportioner power cords that meet or exceed the requirements listed in Table 2 d To mount on a
37. ssure flow curve for model 253725 H 50 230V 1 phase not shown Maximum pressure limited to 1700 psi 11 7 MPa 11 7 bar Coatings Performance Chart 3500 24 1 241 3000 20 7 207 KEY G H XP2 at 50 Hz H H XP2 at 60 Hz J H XP3 at 50 Hz K H XP3 at 60 Hz 2500 17 2 172 2000 13 8 138 1500 10 3 103 1000 6 9 69 Pressure in psi MPa bar 500 3 4 34 5 30 19 38 5 7 76 95 114 Flow Rate in gal min liter min 312062W Performance Charts Heater Performance Chart KEY J 8 kW K 12 kW L 15 3 kW M 20 4 kW Delta T in degrees F degrees C 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 1 9 3 8 57 7 6 9 5 114 13 2 15 1 17 0 Flow Rate in gpm Ipm Heater performance data is based on testing with 10 wt hydraulic oil and 230V across heater power wires 312062W 51 Graco Standard Warranty Graco warrants all eguipment 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 eguipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s w
38. ti7732a Component A and B outlet pressures will be higher than the hydraulic set pressure depending on the model see Pressure Ratio data Systems page 3 Component 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 FIG 3 page 17 Motor Control Arrow Keys Use O Or O to e Adjust pressure imbalance settings page e Adjust standby settings page 37 22 Spray Adjustments Spray Adjustments Flow rate atomization and amount of over spray are affected by four variables e 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 exces sive wear e Fluid temperature Similar effects to fluid pressure setting The A and B tempera tures can be offset to help balance the fluid pressure e Mix chamber size Choice of mix chamber is based on desired flow rate and fluid vis cosity e Clean off air adjustment Too little clean off air results in droplets building up on the front of the nozzle and no pattern containment to control overspray Too much clean off air results in air assisted atomization and excessive overspray 312062W Setup Setup NOTICE 2 General equipment guidelines Proper system setup start up and shutdown Determine the correct
39. trical connections to protect from damage 312062W Setup 12 Ground system NOD a Reactor is grounded through power cord See page 25 b Spray gun connect whip hose ground wire to FTS page 27 Do not discon nect wire or spray without whip hose c Fluid supply containers follow your local code d Object being sprayed follow your local code e Solvent pails used when flushing follow your local code Use only metal pails which are conductive placed ona grounded surface Do not place pail on a nonconductive surface such as paper or cardboard which interrupts ground ing 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 Mainte nance page 44 312062W 14 Lubrication system setup Component A ISO Pump Fill ISO lube reservoir LR with Graco Throat Seal Lig uid TSL Part 206995 supplied a Lift the lubricant reservoir LR out of the bracket RB and remove the con tainer from the cap ti9911a b Fill with fresh lubricant Thread the res ervoir onto the cap assembly and place it in the bracket RB c Push the larger diameter supply tube ST approximately 1 3 of the wa
40. truck bed or trailer Failure to do so will cause voltage fluctua remove casters and bolt directly to truck tions that can damage electrical equip or trailer bed See page 48 ment e Use an air compressor with constant speed head unloading devices Direct online air compressors that start and stop during a job will cause voltage fluctuations that can damage electrical equipment 312062W 23 Setup e Maintain and inspect the generator air Table 1 Electrical Requirements compressor and other equipment per the kW Full Load Amps manufacturer recommendations to avoid an unexpected shutdown Unexpected equipment shutdown will cause voltage l i Voltage fluctuations that can damage electrical phase SAADEN e Use a wall power supply with enough cur 255400 H 25 230V 1 69 15 960 rent to meet system reguirements Failure to do so will cause voltage fluctuations that can damage electrical eguipment 3 Electrical requirements 255405 See Table 1 Y 255408 35 263725 253726 255408 H 253725 253726 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 ter Full load amps with all devices operating at minals see page 25 Be sure your installa maximum capabilities Fuse reguirements at tion complies with all National State
41. uipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This eguipment includes but is not limited to Protective eyewear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection 312062W 9 Warnings 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 spray tip mann 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 eguipment Tighten all fluid connections before operating the eguipment SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may Check hoses and couplings daily Replace worn or damaged parts immediately FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use eguipment 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 p
42. ury This equipment is for professional use only Do not leave the work are while the equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure in this manual when the equipment is not in use 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 manufacturers warnings For com plete information about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genu ine 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 sur faces 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 checki
43. y adjust DIP switch 3 on the motor control board See Reactor Repair Parts manual 312063 The idle time before entering standby is user settable as follows 1 Turn main power switch OFF ao 2 Press and hold then turn main power 3 Press O Or O to select desired timer setting 5 20 in 5 minute increments This sets the length of inactive time before the unit will enter standby 4 Turn main power switch OFF to save changes 37 Shutdown Proper system setup startup and shutdown procedures are critical to electrical equip ment reliability The following procedures ensure steady voltage Failure to follow these procedures will cause voltage fluctua tions that can damage electrical eguipment and void the warranty 1 Shutoff 23 2 and heat ZOnes 2 Park pumps a Press b Trigger gun until pump A stops in the retracted position and the pressure of both pumps bleeds down 3 Turn main power OFF ao 4 Relieve pressure page 39 5 Turn off the air compressor and air dryer if included 6 Open air compressor bleed valve to relieve pressure and remove water from tank 7 Turn off the main breaker on the generator 8 Allow generator dwell time per manufac turer recommendations prior to shutdown 38 9 Close both fluid supply valves FV 10 Shut down feed pumps as reguired Shutdown ti9883a 312062W Pressure Relief Procedure Pressure Relief Proc
44. y 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 set tle 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 29 Startup NOTICE Proper system setup startup and shutdown procedures are critical to electrical equip ment reliability The following procedures ensure steady voltage Failure to follow these procedures will cause voltage fluctua tions that can damage electrical eguipment and void the warranty zt ma IA Do not operate Reactor without all covers and shrouds in place 1 Check generator fuel level Running out of fuel will cause voltage fluc tuations that can damage electrical equip ment 2 Ensure the main breaker on the genera tor is in the off position 3 Start the generator Allow it to reach full operating temperature 4 Close the bleed valve on the air com pressor 5 Switch on the air compressor starter and air dryer if included 6 Turn on power to the Reactor 7 Load fluid with feed pumps The Reactor is tested with oil at the fac tory Flush out the oil with a compatible solvent before spraying See page 47 30 h g Startup Check that
45. y will show hose current 0A See step j page 32 31 e Press D to display actual tempera tures Pd NO M Do not turn on hose heat without fluid in hoses f Turnon ef heat zone by pressing o Preheat hose 15 60 min Indi cator will flash very slowly when fluid reaches target temperature Display shows actual fluid temperature in hose near FTS Startup j Manual current control mode only AA When in manual current control mode moni tor 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 2 Thermal expansion can cause overpressur ization resulting in equipment rupture and serious injury including fluid injection Do not pressurize system when preheating hose g Turn on and B heat zones by pressing o for each zone h Hold O to view electrical currents for each zone i Hold to view heater control circuit board temperature 32 If FTS is disconnected or display shows diagnostic code E04 turn main power switch OFF then ON clear diagnostic code and enter manual to current control mode display will show current to hose Current is not lim ited by target temperature Press O Or O to adjust current setting To prevent overheating instal
46. ypical Installation without circulation Typical Installation without circulation Key for FIG 2 A Reactor Proportioner H Waste Containers B Heated Hose J Fluid Supply Lines C Fluid Temperature Sensor FTS K Feed Pumps D Heated Whip Hose L Agitator E Fusion Spray Gun M Desiccant Dryer F Gun Air Supply Hose N Bleed Lines G P Feed Pump Air Supply Lines Gun Fluid Manifold part of gun B Side Supply Detail A Side Supply Detail ti7821a 2 Shown exposed for clarity Wrap with tape during operation Pam T fp ins ti10001a B a ie ee ee ee oe a d ng 7 a c a RE EE 7 LZ DE a E _ FIG 2 Typical Installation without circulatio 312062W 15 Component ldentification Key for FIG 3 BA BB EC EM FA 16 Component A Pressure Relief Outlet Component B Pressure Relief Outlet Heated Hose Electrical Connector Electric Motor Fan and Belt Drive behind shroud Component A Fluid Manifold Inlet on left side of manifold block Component B Fluid Manifold Inlet Fluid Heater behind shroud Reactor Fluid Manifold Feed Inlet Pressure Gauge Feed Inlet Strainer Feed Inlet Temperature Gauge Fluid Inlet Valve B side shown Component A Outlet Pressure Gauge Component B Outlet Pressure Gauge Component A Hose Connection Component B Hose Connection Hydraulic Pressure Control Hydraulic Pressure Gauge ISO Lube Pump Reservoir Motor Control Display Main Power Switch Overpressure Ru
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