Operation
H-VR
Hydraulic Variable Ratio, Heated, Plural Component Proportioner. For spraying
polyurethane foam and polyurea coatings. For professional use only.
Not for use in explosive atmospheres.
U.S. Patent Pending
Russian Patent No. 2359181
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
313539F
ENG
See page 2 for model information, including maximum working pressure.
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Models
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . 6
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . 6
Keep Components A and B Separate . . . . . . . . . . 6
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 6
Foam Resins with 245 fa Blowing Agents . . . . . . . 6
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Installation, with circulation . . . . . . . . . . . 8
Typical Installation, without circulation . . . . . . . . 9
Component Identification . . . . . . . . . . . . . . . . . . . 10
Reactor H-VR . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . 12
Temperature Controls and Indicators . . . . . . . . . 13
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . 13
Red Stop Button . . . . . . . . . . . . . . . . . . . . . . . . 13
Actual Temperature Key/LED . . . . . . . . . . . . . . 13
Target Temperature Key/LED . . . . . . . . . . . . . . 13
Temperature Scale Keys/LEDs . . . . . . . . . . . . . 14
Heater Zone On/Off Keys/LEDs . . . . . . . . . . . . 14
Temperature Arrow Keys . . . . . . . . . . . . . . . . . . 14
Temperature Displays . . . . . . . . . . . . . . . . . . . . 14
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 14
Motor Controls and Indicators . . . . . . . . . . . . . . . 15
Motor ON/OFF Key/LED . . . . . . . . . . . . . . . . . . 15
PARK Key/LED . . . . . . . . . . . . . . . . . . . . . . . . . 15
PSI/BAR Keys/LEDs . . . . . . . . . . . . . . . . . . . . . 15
Pressure Key/LED . . . . . . . . . . . . . . . . . . . . . . . 15
Cycle Count Key/LED . . . . . . . . . . . . . . . . . . . . 16
Hydraulic Pressure Control Knob . . . . . . . . . . . 16
Motor Control Arrow Keys . . . . . . . . . . . . . . . . . 16
Spray Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 16
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 31
Fluid Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Circulation Through Reactor . . . . . . . . . . . . . . . 32
Circulation Through Gun Manifold . . . . . . . . . . . 33
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Temperature Control Diagnostic Codes . . . . . . . 34
Motor Control Diagnostic Codes . . . . . . . . . . . . 35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . . 37
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 44
Models
Max Flow
Full Load
Part,
Series
256886 71 230V (3) 26,600 15,300 30 (13.6) Variable Variable 3500 (24.1, 241)
256887 41 400V (3) 26,600 15,300 30 (13.6) Variable Variable 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.
◆ Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum flow.
2 313539F
Peak Amps*
Per Phase
Voltag e
(phase)
System
Watts†
Primary
Heater
Watts
Rate◆
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working Pressure
psi (MPa, bar)
Supplied Manuals
Supplied Manuals
The following manuals are shipped with the Reactor™
H-VR Proportioner. Refer to these manuals for detailed
equipment information.
Order Part 15M334 for a compact disk of Reactor manuals translated in several languages.
Reactor Hydraulic Proportioner
Part Description
313540 Reactor H-VR Proportioner,
Repair-Parts Manual (English)
Reactor Electrical Diagrams
Part Description
312064 Reactor Hydraulic Proportioner, Electri-
cal Diagrams (English)
Fluid Pump
Part Description
313485 H-VR Pump Instructions-Parts Manual
(English)
Circulation Kit
Part Description
309818 Instruction-Parts Manual
(English)
Circulation Valve Kit
Part Description
312070 Instruction-Parts Manual
(English)
Data Reporting Kit
Part Description
309867 Instruction-Parts Manual
(English)
Rupture Disk Assembly Kit
Part Description
309969 Instruction-Parts Manual
(English)
Proportioning Pump Repair Kits
Part Description
312071 Seal Kits Instruction-Parts Manual
(English)
Related Manuals
The following manuals are for accessories used with the
Reactor™.
Feed Pump Kits
Part Description
309815 Instruction-Parts Manual
(English)
Air Supply Kit
Part Description
309827 Instruction-Parts Manual
(English) for Feed Pump Air Supply Kit
Circulation and Return Tube Kits
Part Description
309852 Instruction-Parts Manual
(English)
Heated Hose
Part Description
309572 Instruction-Parts Manual
(English)
313539F 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
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 cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power 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.
• Always wear impervious gloves when spraying or cleaning equipment.
• If this equipment is used with isocyanate material, see additional information on isocyanites in Isocyanate Conditions Section of this manual.
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.
4 313539F
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.
OR
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.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
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.
313539F 5
Isocyanate Conditions
Isocyanate Conditions
Moisture Sensitivity of
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
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.
NOTE:
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.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Keep Components A and B Separate
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage
equipment. To prevent cross-contamination of the
equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.
• 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
30.
• Always lubricate threaded parts, except for GC1128,
GC0518, GC0697, and GC2150, with Part 217374
ISO pump oil or grease when reassembling.
Foam Resins with 245 fa Blowing Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
6 313539F
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.
Changing Materials
313539F 7
Typical Installation, with circulation
Typical Installation, with circulation
Key for FIG. 1
A Reactor H-VR Proportioner
BHeated Hose
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose
E Fusion Spray Gun
F Gun Air Supply Hose
A Side Supply Detail
M
K
G
ti7820a 3
G Feed Pump Air Supply Lines
J Fluid Supply Lines
K Feed Pumps
L Agitator
M Desiccant Dryer
P Gun Fluid Manifold (part of gun)
R Circulation Lines
S Fluid Inlet
T Hose Manifold
B Side Supply Detail
K
K
G
K
M
L
ti7820a 2
R
J
T
F
S
B
FIG. 1: Typical Installation, with circulation
R
A
S
J
D
T
E
P
C*
r_256886_313359_1A
*Shown exposed for clarity.
Wrap with tape during operation.
ti10000a
8 313539F
Typical Installation, without circulation
Typical Installation, without circulation
Key for FIG. 2
A Reactor H-VR Proportioner
BHeated 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
A Side Supply Detail
K
M
G
ti7821a 2
H Waste Containers
J Fluid Supply Lines
K Feed Pumps
L Agitator
M Desiccant Dryer
N Bleed Lines
P Gun Fluid Manifold (part of gun)
S Fluid Inlet
T Hose Manifold
B Side Supply Detail
K
K
G
L
K
ti7821a 3
J
T
F
S
N
B
FIG. 2: Typical Installation, without circulation
A
S
J
H
D
T
E
P
C*
r_256886_313359_1A
*Shown exposed for clarity.
Wrap with tape during operation.
ti10001a
313539F 9
Component Identification
Component Identification
NOTICE
To prevent damage to soft key buttons, do not press
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
Reactor H-VR
Key for FIG. 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
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)
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
TD Oil Cooler
VR Pump Assembly (see page 12)
10 313539F
TC
Component Identification
MC
VR
EC
SN
RS
HP
FM
HC
EM
OP
FV
SC
FH
MP
SR
r_256886_313359_1A
Detail of Reactor Fluid Manifold
(shroud removed for clarity)
TA
SA
FA
GA
GB
TB
Detail of Serial No. Plate
(inside cabinet)
SB
BA
FB
ti7823a
HA
HB
BB
ti9880a
SN
FIG. 3: Component Identification (15.3 kW Model Shown)
313539F 11
Component Identification
Pump Assembly
Key for FIG. 4.
AA Component A Pump
AB Component B Pump
AC Hydraulic Proportioner Pump
AD Yoke and Rod Guide Assembly
AE Pump Drive Link
AF Pump Adapter
AG Pivot Bracket
AA
AH Guard
AJ Clamping Knob
AK Lube Fitting
AL Ratio Lock Handle
AM Ratio Adjustment Wheel
AN Frame
AP Ratio Adjustment Screw
AH
AJ
AB
Detail of Pump Assembly
(guard removed for clarity)
AL
AE
AG
AM
AC
AN
FIG. 4: Front View of Pump Assembly
AD
AK
AK
(behind
pivot bracket)
AP
AF
AB
12 313539F
Temperature Controls and Indicators
Temperature Controls and Indicators
Zone A Arrow Keys
Zone B Arrow Keys
Hose Zone Arrow Keys
Actual Temperature Key
Heater Power Indicators
A
B
Heater Displays
°
F
°
C
Heater A On/Off Key
Heater B On/Off Key
Hose Heater On/Off Key
Temperature Scale Keys
Target Temperature Key
IG. 5. Temperature Controls and Indicators
F
Main Power Switch
Located on right side of unit, page 11. Turns Reactor
power ON and OFF . Does not turn
heater zones or pumps on.
Red Stop Button
Located between temperature control panel and motor
control panel, page 11. Press to shut off motor
and heater zones only. Use main power switch to shut
off all power to unit.
Actual Temperature Key/LED
Press to display actual temperature.
Press and hold to display electrical current.
Target Temperature Key/LED
Press to display target temperature.
Press and hold to display heater control circuit
board temperature.
313539F 13
Temperature Controls and Indicators
Temperature Scale Keys/LEDs
Press or to change temperature scale.
°
F
°
C
Heater Zone On/Off Keys/LEDs
Press to turn heater zones on and off. Also clears
heater zone diagnostic codes, see page 34.
NOTE:
LEDs flash when heater zones are on. The duration of
each flash shows the extent that the heater is turned on.
Temperature Arrow Keys
Press , then press or to adjust tem-
perature settings in 1 degree increments.
Circuit Breakers
Located inside Reactor cabinet.
Ref. Size Component
CB1 50 A Hose/Transformer Secondary
CB2 40 A Transformer Primary
CB3 50 A Heater A
CB4 50 A Heater B
CB5 20 A 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
For wiring and cabling, see repair manual 313540.
CB4
CB5
ti9884a
14 313539F
Motor Controls and Indicators
Motor Controls and Indicators
Arrow Keys
Motor ON/OFF Key
PAR K Ke y
Pressure Key
Cycle Count Key
F
IG. 6. Motor Controls and Indicators
Pressure/Cycle Display
ON / OFF
PARK
PSI/BAR Keys
PSI
BAR
Motor ON/OFF Key/LED
Press to turn motor ON and OFF. Also clears
some motor control diagnostic codes, see page 35.
PARK 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.
PSI/BAR Keys/LEDs
Press or to change pressure scale.
PSI
BAR
Pressure Key/LED
Press to display fluid pressure.
NOTE:
If pressures are imbalanced, display shows higher of
two pressures.
313539F 15
Spray Adjustments
Cycle Count Key/LED
Press to display cycle count.
NOTE:
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 counterclockwise to decrease pressure.
Use hydraulic pressure gauge (HP, page 11) to view
hydraulic pressure.
+-
ti7731a ti7732a
• 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, fluid viscosity, and selected
ratio.
• 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.
NOTE:
Component A and B outlet pressures will be higher than
the hydraulic set pressure, depending on the model.
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 F
IG. 3, page 11.
Motor Control Arrow Keys
Use or to:
• Adjust pressure imbalance settings, page 26.
• Adjust standby settings, page 30.
Spray Adjustments
Flow rate, atomization, and amount of overspray are
affected by four variables.
16 313539F
Setup
Setup
NOTICE
Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage fluctuations that can damage electrical equipment and void the warranty.
1. Locate Reactor
a. Locate Reactor on a level surface. See Dimen-
sions, page 39, for clearance and mounting
hole dimensions.
b. Do not expose Reactor to rain.
NOTICE
Bolt Reactor to original shipping pallet before lifting.
c. Use the casters to move Reactor to a fixed loca-
tion, or bolt to shipping pallet and move with
forklift.
d. To mount on a truck bed or tailer, remove cast-
ers and bolt directly to truck or trailer bed. See
page 39.
2. General equipment guidelines
• Determine the correct size generator. Using the correct size generator and proper air compressor will
enable the proportioner to run at a nearly constant
RPM. Failure to do so will cause voltage fluctuations
that can damage electrical equipment. Ensure the
generator matches the voltage and phase of the
proportioner.
Use the following procedure to determine the correct size generator.
a. List system components that use peak load
requirements in watts.
b. Add the wattage required by the system compo-
nents.
c. Perform the following equation:
Total watts x 1.25 = kVA (kilovolt-amperes)
d. Select a generator size that is equal to or
greater than the determined kVA.
• Use proportioner power cords that meet or exceed
the requirements listed in Table 2. Failure to do so
will cause voltage fluctuations that can damage
electrical equipment.
• 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.
• Maintain and inspect the generator, air compressor,
and other equipment per the manufacturer recommendations to avoid an unexpected shutdown.
Unexpected equipment shutdown will cause voltage
fluctuations that can damage electrical equipment.
• Use a wall power supply with enough current to
meet system requirements. Failure to do so will
cause voltage fluctuations that can damage electrical equipment.
313539F 17
Setup
3. Electrical requirements
See table 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 step 3. Be sure your installation
complies with all National, State and Local safety and
fire codes.
Table 1: Electrical Requirements (kW/Full Load
Amps)
Full
Load
Peak
Amps*
Part Model
256886
256887
H-VR 230V (3) 71 26,600
H-VR 400V (3) 41 26,600
Volt age
(phase)
* Full load amps with all devices operating at maxi-
mum capabilities. Fuse requirements at various flow
rates, ratios, and mix chamber sizes may be less.
** Total system watts, based on maximum hose length
for each unit, 410 ft (125 m) including whip hose.
System
Watts**
4. Connect electrical cord
NOTE:
Power cord is not suppled. See table 2.
Table 2: Power Cord Requirements
Cord Specification
Part Model
256886
256887
H-VR 4 (21.2), 3 wire + ground
H-VR 8 (8.4), 4 wire + ground
AWG (mm
a. 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
b. 400V, 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).
2
)
ti2515b
GND
L1
L2
L3
ti3248b
NOTE:
The motor must rotate counter-clockwise when viewed
from shaft end. To reverse rotation, disconnect power
and reverse power leads L1 and L2.
18 313539F
Setup
5. Connect feed pumps
a. Install feed pumps (K) in component A and B
supply drums. See F
and 9.
b. Seal component A drum and use desiccant
dryer (M) in vent.
c. Install agitator (L) in component B drum, if nec-
essary.
d. Ensure A and B inlet valves (FV) are closed.
NOTE:
Supply hoses from feed pumps should be 3/4 in. (19
mm) ID.
IG. 1 and FIG. 2, pages 8
FV
ti10971a
to component A and B drums. See F
IG. 1, page
8.
SB
SA
R
BA
R
BB
ti9880a
b. Alternatively: Secure supplied bleed tubes (N)
in grounded, sealed waste containers (H). See
F
IG. 2, page 9.
7. 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.
e. Connect and tighten component A and B supply
hose to the 3/4 npt(f) swivel on the component A
and B inlet valve.
6. Connect pressure relief lines
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as overpressure relief valves when set to
SPRAY . Lines must be open so valves can
automatically relieve pressure when machine is operating.
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
313539F 19
Setup
8. Connect heated hose
NOTE:
See Heated Hose manual 309572 for detailed instructions on connecting heated hoses.
NOTE:
If spraying at a ratio other than 1:1, an E24 may occur.
Size hoses and mix chamber appropriately to avoid
pressure imbalance.
NOTICE
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.
a. Turn main power OFF .
b. Assemble heated hose sections, FTS, and whip
hose.
bends. Wrap cable and electrical connections
with electrical tape.
Y
V
ti9881a
9. Close gun fluid manifold valves A and B
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
P
B
ti9878a
NOTE:
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.
ti2411a
10. Connect whip hose to gun fluid manifold
Do not connect manifold to gun.
ti2417a
11. Pressure check hose
See hose manual. Pressure check for leaks. If no leaks,
wrap hose and electrical connections to protect from
damage.
d. Connect cables (Y). Connect electrical connec-
tors (V). Be sure cables have slack when hose
20 313539F
12. Ground system
a. Reactor: is grounded through power cord. See
page 18.
b. Spray gun: connect whip hose ground wire to
FTS, page 19. Do not disconnect 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 on a grounded surface. Do not
place pail on a nonconductive surface, such as
paper or cardboard, which interrupts grounding
continuity
Setup
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
a. Hydraulic reservoir is filled at the factory. Check
fluid level before operating the first time, and
weekly thereafter. See Maintenance, page 36.
313539F 21
Startup
Startup
See table 3 for ratios with the one pump set at 1.0 and
available settings for the second pump.
Do not operate Reactor without all covers and shrouds
in place. Do not attempt to change ratio while machine
is pressurized or running. Do not loosen ratio lock
handle if A and B component pumps are pressurized
or while the pumps are operating.
1. Select ratio
The stroke lengths of the fluid pumps (AA and AB) can
be adjusted to select the ratio. The frame (AN) has three
pin positions for the bottom of the pump and a slider
mechanism at the top of the pump, which allows for
positioning of the pump at any required position. This
allows for a a range of ratio settings between the first
and last settings on the pump drive link.
a. Shutdown system, see page 30.
b. Relieve pressure, see page 31.
c. Loosen four clamping knobs (AJ) and remove
guard (AH).
Table 3: Ratio Range
Pump with higher
flow
1.0
1.0
POSN #1
1.0
1.0
1.0
1.0
POSN #1
POSN #1
1.0
1.0
1.0
1.0
1.0
1.0
Pump with lower
flow Ratio
1.0
0.95
POSN #1
POSN #2
POSN #3
0.90
0.85
0.80
0.75
0.70
0.66
0.60
0.55
0.50
0.45
1:1
1.05
1.11:1
1.2:1
1.25:1
1.33:1
1.42:1
1.51:1
1.66:1
1.88:1
2:1
2.22:1
AH
AL
AJ
AA
F
IG. 7: Front View
d. Use label on the pump drive link (AE) to identify
the correct position of the pump that needs to
be adjusted. See F
IG. 8.
AB
r_256886_313359_6
1.0
0.40
2.5:1
Pump A when viewed from rear of machine
Pump B when viewed from rear of machine
F
IG. 8: Pump Ratio Indicator Labels
22 313539F
Startup
e. Remove base pin (BP) from frame (AN) if the
base of the pump needs to be moved. See F
8.
TP
BP
3
IG. 9
F
f. Loosen ratio lock handle (AL) over the pump
that needs adjustment. Use a soft mallet to
loosen ratio lock handle if necessary. Turn ratio
adjustment wheel (AM) until the mark on the
pump adapter block (AF) lines up with the correct position on the ratio indicator label on the
pump drive link (AE).
g. Reinstall base pin (BP) if it was removed.
Ensure bottom of pump is in correct position.
See F
12
IG. 8.
r_256886_313359_7
IG.
AL
1
23
FIG. 10
h. Ensure top of pump is in correct ratio position.
Tighten ratio lock handle (AL).
i. Install guard (AH) and tighten clamping knobs
(AJ). See F
IG. 7.
AF
AE
AP
r_256886_313359_5
AM
NOTICE
Move bottom position of pump once top of pump
enters a new position #. Failure to adjust bottom
position of pump will damage the machine.
NOTE:
For highest volume of material: Ensure pump has longest stroke length. Set the pump with more flow closest
to hydraulic pump (AC) or at 1.0 to achieve maximum
flowrates. See F
313539F 23
IG. 8.
Startup
2. Load fluid with feed pumps
NOTE:
The Reactor is tested with oil at the factory. Flush out
the oil with a compatible solvent before spraying. See
page 38.
a. Check that all Setup steps are complete.
b. Turn on component B agitator, if used.
c. Turn both PRESSURE RELIEF/SPRAY valves
(SA, SB) to SPRAY .
SA
SB
ti9877a
Open fluid valves A and B until clean, air-free
fluid comes from valves. Close valves.
ti2484a
d. Start feed pumps.
e. Open fluid inlet valves (FV). Check for leaks.
FV
ti10972a
Do not mix components A and B during startup.
Always provide two grounded waste containers to
keep component A and component B fluids separate.
f. Use feed pumps to load system. Hold gun fluid
manifold over two grounded waste containers.
24 313539F
3. Set temperatures
A
NOTE:
Startup
desired temperature. Repeat for and
zones.
B
B
°
F
°
C
Temperature Controls and Indicators, see page 13
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).
a. Turn main power ON .
For zone only, if FTS is disconnected at startup,
display will show hose current (0A). See step j, page 26.
e. Press to display actual temperatures.
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.
Thermal expansion can cause overpressurization,
resulting in equipment rupture and serious injury,
including fluid injection. Do not pressurize system
when preheating hose.
b. Press or to change temperature
scale.
c. Press .
d. To set heat zone target temperature,
press or until display shows
313539F 25
°
A
F
°
C
g. Turn on and heat zones by press-
ing for each zone.
h. Hold to view electrical currents for each
zone.
i. Hold to view heater control circuit board
temperature.
A
B
Startup
j. Manual current control mode only:
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.
4. Set pressure
ON / OFF
PARK
PSI
BAR
Motor Controls and Indicators, see page 15
a. Press to display the pressure reading.
b. Press motor . Motor and pumps start.
If thermometer reading exceeds 160°F (71°C),
reduce current with key.
Display shows system pressure.
NOTE:
Motor must rotate counterclockwise when viewed from
shaft end. See Connect electrical cord, page 18.
c. Adjust hydraulic pressure control until display
shows desired fluid pressure.
+-
ti7731a ti7732a
NOTICE
Never adjust hydraulic pressure while spraying. This
will result in over pressure alarm E23.
NOTE:
If display pressure is greater than desired pressure,
reduce the hydraulic pressure and trigger gun to reduce
pressure.
26 313539F
Startup
NOTE:
Check the pressure of each proportioning pump using
the component A and B gauges. The pressures should
be approximately equal and must remain fixed.
d. To display cycle count, press .
NOTE:
To clear counter, press and hold for 3 sec.
e. Press or to change pressure
PSI
BAR
scale.
5. Change pressure imbalance setting (optional)
The pressure imbalance function (status code 24, page
35) 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.
Table 4: Available Pressure Imbalance Settings
PSI BAR PSI BAR
100 7 600 42
2001470049
3002180056
4002890063
*500 *35 999 69
* Factory default setting.
d. Turn main power switch OFF to save
changes.
NOTE:
Code 24 (pressure imbalance) is set to an alarm as the
default. To change to a warning, see H-VR Repair-Parts
manual 313540.
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 .
b. Press and hold or , then turn main
PSI
BAR
power switch ON . Display will read
dP500 for psi or dP_35 for bar.
c. Press or to select desired pres-
sure differential (100-999 in increments of 100
psi, or 7-70 in increments of 7 bar). See T
ABLE
4.
313539F 27
Spraying
Spraying
4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY .
1. Engage gun piston safety lock.
ti2409a
2. Close gun fluid manifold valves A and B.
ti2728a
3. Attach gun fluid manifold. Connect gun air line.
Open air line valve.
SA
SB
ti9877a
5. Check that heat zones are on and temperatures are
on target, page 25.
6. Press motor to start motor and pumps.
7. Check fluid pressure display while the gun is detriggered and adjust as necessary, page 26.
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/CIRCULATION
, until gauges show balanced pressures.
GA
GB
In this example, B side
pressure is higher, so
use the B side valve to
balance pressures.
ti9877a
ti2543a
28 313539F
9. Open gun fluid manifold valves A and B.
ti2414a
NOTE:
On impingement guns, never open fluid manifold valves
or trigger gun if pressures are imbalanced.
10. Disengage gun piston safety lock.
Spraying
ti2410a
11. Test spray onto cardboard. Adjust pressure and
temperature to get desired results.
12. Equipment is ready to spray.
NOTE:
If you stop spraying for a period of time, the unit will
enter standby (if enabled). See page 30.
313539F 29
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.
NOTE:
The , , and heat zones will not be
A
shut off in standby.
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.
NOTE:
This feature is disabled from the factory.
To activate or disable standby, adjust DIP switch #3 on
the motor control board. See Reactor Repair-Parts manual 313540.
B
Shutdown
1. Shut off , , and heat zones.
2. Park pumps.
a. Press .
b. Trigger gun until pump A stops in the retracted
3. Turn main power OFF .
4. Close both fluid supply valves (FV).
A
position and the pressure of both pumps bleeds
down.
B
The idle time before entering standby is user-settable as
follows:
1. Turn main power switch OFF .
2. Press and hold , then turn main power switch
ON .
3. Press or to select desired timer set-
ting (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.
FV
ti10971a
5. Relieve pressure, page 31.
30 313539F
Pressure Relief Procedure
1. Relieve pressure in gun and perform gun shutdown
procedure. See gun manual.
Pressure Relief Procedure
5. Engage gun piston safety lock.
2. Close gun fluid manifold valves A and B.
ti2421a
3. Shut off feed pumps and agitator, if used.
4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)
to PRESSURE RELIEF/CIRCULATION . Route
fluid to waste containers or supply tanks. Ensure
gauges drop to 0.
ti2409a
6. Disconnect gun air line and remove gun fluid manifold.
ti2554a
SA
SB
ti9879a
313539F 31
Fluid Circulation
Fluid Circulation
Circulation Through Reactor
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 33.
1. Load fluid with feed pumps, page 24.
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as overpressure relief valves when set to
SPRAY . Lines must be open so valves can
automatically relieve pressure when machine is operating.
5. Set temperature targets, see page 25. Turn on
and heat zones by pressing .
A
Do not turn on heat zone unless hoses are
already loaded with fluid.
6. Press to display actual temperatures.
7. Before starting motor, reduce hydraulic pressure to
the minimum required to circulate fluid until
and temperatures reach targets.
B
B
A
-
ti7732a
2. See Typical Installation, with circulation, page 8.
Route circulation lines back to respective component A or B supply drum. Use hoses rated at the
maximum working pressure of this equipment. See
Technical Data, page 40.
3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
PRESSURE RELIEF/CIRCULATION .
SA
SB
ti9879a
4. Turn main power ON .
8. Press motor to start motor and pumps. Cir-
culate fluid at lowest possible pressure until temperatures reach targets.
9. Turn on heat zone by pressing .
10. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY .
SA
SB
ti9877a
32 313539F
Fluid Circulation
Circulation Through Gun Manifold
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). Connect high pressure circulation lines (R) to circulation manifold.
P
7. Before starting motor, reduce hydraulic pressure to
the minimum required to circulate fluid until
and temperatures reach targets.
B
A
-
ti7732a
8. Press motor to start motor and pumps. Cir-
culate fluid at lowest possible pressure until temperatures reach targets.
CK
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, without circulation, page 9.
3. Follow Select ratio, page 22.
4. Turn main power ON .
5. Set temperature targets, see page 25. Turn on
, , and heat zones by pressing
A
B
.
R
ti2767a
6. Press to display actual temperatures.
313539F 33
Diagnostic Codes
Diagnostic Codes
Temperature Control Diagnostic Codes
Temperature control diagnostic codes appear on temperature display.
These alarms turn off heat. E99 clears automatically
when communication is regained. Codes E03 through
E06 can be cleared by pressing . For other codes,
turn main power OFF then ON to clear.
See repair manual for corrective action.
Code Code Name Alarm Zone
01 High fluid temperature Individual
02 High current Individual
03 No current Individual
04 FTS not connected Individual
05 Board overtemperature Individual
06 Loss of zone communication Individual
30 Momentary loss of communica-
tion
99 Loss of display communication All
NOTE:
For hose zone only, if FTS is disconnected at startup,
display will show hose current 0A.
All
34 313539F
Motor Control Diagnostic Codes
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
Alarms turn off Reactor. Turn main power OFF
then ON to clear.
NOTE:
Alarms can also be cleared, except for code 23, by
pressing .
NOTE:
Code 24 (pressure imbalance) is set to an alarm default
of 500 psi (3.5 MPa, 35 bar). To change to a warning,
see Reactor Repair-Parts manual 313540. To change
the default pressure imbalance setting, see page 27.
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 .
Code
No.
21 No transducer (component A) Alarm
22 No transducer (component B) Alarm
23 High pressure Alarm
24 Pressure imbalance Selectable;
27 High motor temperature Alarm
30 Momentary loss of communi-
cation
31 Pumpline switch failure/high
cycle rate
99 Loss of communication Alarm
Code Name
Alarm or
Warning
see repair
manual
Alarm
Alarm
313539F 35
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.
• Grease circulation valves weekly with Fusion grease
(117773).
ti9879a
• Check hydraulic fluid level weekly. Check hydraulic
fluid level on dipstick (DS). Fluid level must be
between indent marks (IM) on dipstick. Refill as
required with approved hydraulic fluid; see Techni-
cal Data on page 40 and the Approved Anti-Wear
(AW) Hydraulic Oils table in the Reactor
Repair-Parts manual 313540. If fluid is dark in color,
change fluid and filter.
• 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, motor (under shield), and hydraulic
oil coolers.
• Keep vent holes on bottom of electrical cabinet
open.
DS
S
IM
ti10003a
ti7861a
• 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 recommended frequency of oil changes
Table 5: Frequency of Oil Changes
Ambient
Temperature
0 to 90°F
(-17 to 32°C)
90°F and above
(32°C and above)
36 313539F
Recommended
Frequency
1000 hours or 12 months,
whichever comes first
500 hours or 6 months,
whichever comes first
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.
NOTE:
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).
Fluid Inlet Strainer Screen
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
FIG. 11: Fluid Inlet Strainer
* See Reactor Repair-Parts manual 313540 for fluid filter
screen replacements.
59g*
59h
59j
59k
ti9886a
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.
313539F 37
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/CIRCULATION . Flush through bleed
lines (N).
SA
SB
N
N
ti9880a
• 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
page 6.
38 313539F
Dimensions
Dimensions
Dimension in. (mm)
A (height) 57.31 (1455.42)
B (width) 37.86 (961.6)
C (depth) 33 (838.2)
A
Dimension in. (mm)
D (front and rear mounting holes) 32.5 (825.5)
F (side mounting holes) 30.375 (7715)
G (mounting post inner diameter) 0.44 (11)
Top View
D
Front of Machine
C
G
F
r_256886_313359_1A
Rear of Machine
D
B
313539F 39
Technical Data
Technical Data
Category Data
Maximum Fluid Working Pressure 3500 psi (24.1 MPa, 241 bar)
Fluid Inlets 3/4 npsm union in 1 in. npt(f) ball valve
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
ambient temperature) 1:1
Output per Cycle Variable: 2 oz.- 5 oz. (60 cc - 150 cc) per pump*
Stroke Length Variable: 2 in. - 5 in. (5.08 cm - 12.7 cm)
Line Voltage Requirement 230V 3 phase units: 195-264 Vac, 50/60 Hz
Amperage Requirement See Models, page 2.
Heater Power
(A and B heaters total, no hose)
Hydraulic reservoir capacity 3.5 gal. (13.6 liters)
Recommended hydraulic fluid Citgo A/W Hydraulic Oil, ISO Grade 46
Sound power, per ISO 9614-2 90.9 dB(A)
Sound pressure,
1 m from equipment
Weight 955 lb (433 kg)
Wetted Parts Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome,
Model H-VR: 3.0 gpm (11.4 liter/min) (60 Hz)
400V 3 phase units: 338-457 Vac, 50/60 Hz
See Models, page 2.
84.0 dB(A)
fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, chemically
resistant o-rings
*Output example: 2.5:1 ratio = 150 cc (B side):60 cc (A side)
2.5:1 output = 150 cc (B side) + 60 cc (A side) = 210 cc per cycle
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
40 313539F
Performance Charts
Foam Performance Chart
Performance Charts
2000
(13.8, 138)
KEY
A = H-25 at 50 Hz
B = H-25 at 60 Hz
1500
(10.3, 103)
1000
(6.9, 69)
A
B
G
C
C = H-40 at 50 Hz
D = H-40 at 60 Hz
E = H-50 at 50 Hz
❄F = H-50 at 60 Hz
G = H-VR at 60 Hz
E
Pressure in psi (MPa, bar)
500
(3.4, 34)
D
F
0
5
15
(2.3)
(6.8)
25
(11.4)
35
(15.9)
45
(20.5)
55
(25.0)
Flow Rate in lb/min (kg/min)
❄ Pressure flow curve for model 253725 (H-50 230V 1 phase) not shown.
Maximum pressure limited to 1700 psi (11.7 MPa, 11.7 bar)
Pressure in psi (MPa, bar)
3500
(24.1, 241)
3000
(20.7, 207)
2500
(17.2, 172)
2000
(13.8, 138)
1500
(10.3, 103)
1000
(6.9, 69)
500
(3.4, 34)
Coatings Performance Chart
H
J
0
0.5
(1.9) (3.8) (5.7)
1.0 1.5
Flow Rate in gal/min (liter/min)
2.0 2.5 3.0
(7.6) (9.5) (11.4)
KEY
H = H-XP2 at 50 Hz
J = H-XP2 at 60 Hz
K = H-XP3 at 50 Hz
L = H-XP3 at 60 Hz
M = H-VR at 60 Hz
K
M
L
313539F 41
Performance Charts
140
(78)
130
(72)
120
(67)
110
(61)
100
(56)
90
(50)
80
(44)
70
(39)
60
(33)
50
(28)
Delta T in degrees F (degrees C)
40
(22)
30
(17)
20
(11)
10
(6)
Heater Performance Chart
KEY
H-VR = 15.3 kW
H-VR
0
0.5
(1.9)
1.0
(3.8)
1.5
(5.7)
2.0
(7.6)
2.5
(9.5)
3.0
(11.4)
3.5
(13.2)
4.0
(15.1)
4.5
(17.0)
Flow Rate in gpm (lpm)
★ Heater performance data is based on testing with 10 wt.
hydraulic oil and 230V across heater power wires.
42 313539F
Performance Charts
313539F 43
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 313539
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2009, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 08/2010
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