Graco 312878J User Manual
Installation - Operation
Shot Controller
For use with non-flammable polyurethane foams. For professional use only.
Not approved for use in European explosive atmosphere locations.
2000 psi (13.8 MPa, 138 bar) Maximum Working Pressure
312878J
ENG
Important Safety Instructions
Read all warnings and instructions in this
manual and the Hydraulic Reactor
Operation manual. Save all instructions.
See page 3 for model information.
Proportioner shown includes Shot Controller,
™
proportioner also available without Shot Controller
ti11756a
Related Manuals
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 6
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . 6
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 6
Keep Components A and B Separate . . . . . . . . . . 6
Foam Resins with 245 fa Blowing Agents . . . . . . . 6
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . 7
IPH System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Human Machine Interface (HMI) . . . . . . . . . . . . 8
Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Run Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conversion Kit Installation . . . . . . . . . . . . . . . . . . 13
Disable Motor Standby Operation . . . . . . . . . . . 17
Simplified Schematic, Shot Controller Wiring . . 18
Simplified Schematic, Shot Controller Electrical 19
Simplified Schematic, Alternate Gun Connection 20
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hydraulic Proportioner Setup . . . . . . . . . . . . . . 21
Controller Setup . . . . . . . . . . . . . . . . . . . . . . . . 21
Password Protection . . . . . . . . . . . . . . . . . . . . . 23
Learn Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Piston Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Optional External Machine Control . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Change Operating Mode . . . . . . . . . . . . . . . . . . 29
Change Shot Number . . . . . . . . . . . . . . . . . . . . 29
Change Shot Volume/Weight . . . . . . . . . . . . . . 29
Sequence Mode Options . . . . . . . . . . . . . . . . . 30
Dispense Material . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance Mode . . . . . . . . . . . . . . . . . . . . . 31
Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hibernate Mode . . . . . . . . . . . . . . . . . . . . . . . . 31
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 32
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hydraulic Proportioner . . . . . . . . . . . . . . . . . . . . 34
Conversion Kit 24A024 . . . . . . . . . . . . . . . . . . . 34
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 37
Graco Ohio Standard Warranty . . . . . . . . . . . . . . 38
Graco Ohio Information . . . . . . . . . . . . . . . . . . . . . 38
Related Manuals
These manuals can be found at www.graco.com.
Reactor Hydraulic Proportioner
Part Description
312062
312063
Reactor Electric Diagrams
Part Description
312064
AR Pour Gun
Part Description
312888 AR Pour Gun, Operation-Parts Manual
Proportioning Pump
312068 Proportioning Pump Repair-Parts Manual
Reactor Hydraulic Proportioner, Operation
Manual
Reactor Hydraulic Proportioner,
Repair-Parts Manual
Reactor Hydraulic Proportioner, Electrical
Diagrams
2 312878J
Models
Models
IPH-25 SERIES
Max Flow
Full Load
Part,
Series
255814, B 69 230V (1) 15960 8000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255815, B 46 230V (3) 15960 8000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255816, B 35 400V (3) 15960 8000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255819, A 100 230V (1) 23260 15300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255820, A 89 230V (1) 23260 15300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255824, B 69 230V (1) 15960 8000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255825, B 46 230V (3) 15960 8000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255826, B 35 400V (3) 15960 8000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
Peak Amps*
Per Phase
Volt ag e
(phase)
System
Watts
Primary
Heater
Watts
Rate◆
lb/min
(kg/min)
IPH-40 SERIES
Max Flow
Full Load
Part,
Series
255811, B 100 230V (1) 23100 12000 50 (23) 0.076 (0.29) 1.64:1 2000 (13.8, 138)
255812, B 71 230V (3) 26600 15300 50 (23) 0.076 (0.29) 1.64:1 2000 (13.8, 138)
255813, B 41 400V (3) 26600 15300 50 (23) 0.076 (0.29) 1.64:1 2000 (13.8, 138)
255821, B 100 230V (1) 23100 12000 50 (23) 0.076 (0.29) 1.64:1 2000 (13.8, 138)
255822, B 71 230V (3) 26600 15300 50 (23) 0.076 (0.29) 1.64:1 2000 (13.8, 138)
255823, B 41 400V (3) 26600 15300 50 (23) 0.076 (0.29) 1.64:1 2000 (13.8, 138)
Peak Amps*
Per Phase
Voltage
(phase)
System
Watts
Primary
Heater
Watts
Rate◆
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
Maximum Fluid
Working
Pressure
psi (MPa, bar)
CONVERSION KIT
Part, Series Description
24A024, A Conversion kit for existing H-25 and H-40 hydraulic proportioners
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix
chamber sizes may be less.
◆ Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum
flow.
312878J 3
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 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.
WARNING
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.
• Always wear impervious gloves when spraying or cleaning equipment.
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 dispense valve, 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 dispense valve at anyone or at any part of the body.
• Do not put your hand over the end of the dispense nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes 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 and clean 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 lights on or off when flammable fumes are present.
• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See
Grounding instructions.
• Use only Graco grounded hoses.
• Check gun resistance daily.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from
system.
• Keep a working fire extinguisher in the work area.
4 312878J
Warnings
WARNING
ELECTRIC SHOCK HAZARD
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
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
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 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 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 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 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.
312878J 5
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.
Material Self-ignition
• Keep the ISO lube pump reservoir (if installed) filled
with Graco Throat Seal Liquid (TSL), Part 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 lubricate threaded parts with ISO pump oil
or grease when reassembling.
Keep Components A and B Separate
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.
6 312878J
Component Identification
IPH System
B
Component Identification
A
D
C
Model 255811 shown
FIG. 1: IPH System with Front Cover Removed
Key:
A Hydraulic Proportioner
B Shot Controller, HMI, and Bracket
C Electrical Enclosure
D Linear Sensor Assembly
ti11820a
312878J 7
Component Identification
Human Machine Interface (HMI)
AG
AA
AB
AC
F
IG. 2
Key:
AA Up arrow key
AB Down arrow key
AC Mode select button
AD Top soft key
AD
AE
AF
AE Bottom soft key
AF Initiate shot button
AG LCD screen
NOTICE
To prevent damage to soft key buttons, do not press
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
Initiate Shot button
Pressing this button will start a shot for either the
selected shot number, the next shot number in the
selected sequence, or when in manual mode will dis-
Mode Select button
Pressing this button will allow selection of an operating
mode. The available choices will always include Shot,
“Sh,” and Manual, “Mn”.
pense until the user releases the button.
If one or more sequences have been programmed, the
This button is initially set as disabled and can be
enabled or disabled from setup screen #7. See Setup
Sequence modes available will show up as the name of
each sequence (“Sq-A,” “Sq-B,” etc.).
Screen #7: Enable/Disable Run Screen Shot Editing
or “Initiate Shot” button on page 23.
8 312878J
Icons
Icon Function Shown on Screen(s)
General Icons
Confirm changes • All
Exit without saving changes • All
• Setup screen #1
Next
Previous
Learn Mode Active Indicator (shown in lower-left
corner)
Setup Icons - see Controller Setup section on page 21
Reset Piston Counter to Zero • Setup screen #1
• Setup screen #3
• Run screen when Learn Mode is enabled
• Setup screen #1
• Run screen when Learn Mode is enabled
• Run screen when Learn Mode is enabled
Component Identification
Define Shot Amount • Setup screen #2
Define Sequence Modes • Setup screen #3
Open Gun Dispense Valve • Setup screen #4
Close Gun Dispense Valve • Setup screen #4
Change Password • Setup screen #5
Enable “Tap” mode • Setup screen #6
Enable “Hold” mode • Setup screen #6
Enable “Initiate Shot” button on HMI • Setup screen #7
Disable “Initiate Shot” button on HMI • Setup screen #7
Enable Run Screen Shot Editing • Setup screen #7
312878J 9
Component Identification
Icon Function Shown on Screen(s)
Disable Run Screen Shot Editing • Setup screen #7
Enter Learn Mode • Setup screen #8
Exit Learn Mode • Setup screen #8
10 312878J
Run Screen
Component Identification
BA
BB
3
BC
BD
BE
BF
BM
BL
BK
1
1
When no errors are active, “E” will be displayed.
2
Shown only during shot dispensing in Shot or Sequence mode
3
Displayed only in Sequence mode
BJ
2
BH
BG
Key:
BA Current operating mode
BB nth shot in sequence
BC Number of shots executed for selected shot number
BD Quantity of selected shot (Shot or Sequence modes) or previous shot
(Manual mode)
BE Quantity unit of measure (cubic centimeters or grams)
BF Top soft key icon
BG Bottom soft key icon
BH Duration of selected shot (Shot or Sequence modes) or previous shot
(Manual mode)
BJ Progress bar for current shot
BK Error status
BL Piston position
BM Shot number currently selected
F
IG. 3: Run Screen
Run Screen Variables
Available operating modes vary by setup but will include
“Sh” for predefined shot mode and “Mn” for manual shot
mode. If sequences have been defined, operating mode
options will include “Sq-A”, “Sq-B”, etc. to select any of
the defined sequences. See Change Operating Mode
on page 29.
Shot quantity can be displayed either in cubic centimeters or grams depending on whether specific gravity is
entered. See Setup Screen #6: Quantity Units and
Gun Configuration on page 22.
312878J 11
The top and bottom soft key icons indicate the function
of the respective soft key. See Icons section on page 9
for icon descriptions.
Component Identification
Maintenance Mode
Press and hold bottom
soft key for 2 sec
Idle Run Screen
After 15 sec
for 3 se
key
ft
Press and hold top
so
Initiate shot
Pr
e
ar
ss a
r
ow ke
n
d h
ys
o
for 3 s
c
ld b
e
Press up arrow key to
access Setup Screen 8
Enter and confirm
correct password
Password Entry
This screen is skipped
when password is disabled
Dispensing
Run Screen
o
th
c
Setup Screen 1
Press down
arrow key
Setup Screen 2
Press down
arrow key
Setup Screen 3
Press down
arrow key
Press up
arrow key
Press up
arrow key
Press up
arrow key
Splash Screen
Tur n on HM I
START
Run Screen
Shot Editing
Exit setup screens and return to Idle Run Screen by
pressing and holding both soft keys for 3 sec
Setup Screen 4
Press down
arrow key
Setup Screen 5
Press down
arrow key
Setup Screen 6
Press down
arrow key
Setup Screen 7
Press down
arrow key
Press up
arrow key
Press up
arrow key
Press up
arrow key
Press up
arrow key
Setup Screen 8
Press down arrow key to
access Setup Screen 1
FIG. 4: Screen Navigation Diagram
12 312878J
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