Graco 332144C User Manual

Instructions-Parts

Reactor

For spraying or dispensing polyurea coatings and polyurethane foam. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

3000 psi (21 MPa, 207 bar) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

E-10hp

332144C

ti21488a

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Important Isocyanate (ISO) Information . . . . . . . . 6

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 6

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 6

Keep Components ISO and RES Separate . . . . 6

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 6

Foam Resins with 245 fa Blowing Agents . . . . . . 6

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 7

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . . . . . . . . . 11

Controls and Indicators . . . . . . . . . . . . . . . . . . . . 12

Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . 12

System Controls . . . . . . . . . . . . . . . . . . . . . . . . 12

Controls and Indicators . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Locate Reactor . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrical Requirements . . . . . . . . . . . . . . . . . . 15

Ground System . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connect Fluid Hoses . . . . . . . . . . . . . . . . . . . . . 16

Connect Gun Air Hose . . . . . . . . . . . . . . . . . . . 16

Connect Main Air Supply . . . . . . . . . . . . . . . . . 16

Flush Before First Use . . . . . . . . . . . . . . . . . . . 16

Fill Wet-Cups . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fill Fluid Tanks . . . . . . . . . . . . . . . . . . . . . . . . . 17

Purge Air and Flush Fluid From Lines . . . . . . . 18

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Heatup Guidelines . . . . . . . . . . . . . . . . . . . . . . 20

Heat Management Tips . . . . . . . . . . . . . . . . . . . 20

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Refill Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 23

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Purge Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Pump Control Status Codes . . . . . . . . . . . . . . . 27

DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . 29

Heat Control Diagnostic Codes . . . . . . . . . . . . . 31

Reactor Electronics . . . . . . . . . . . . . . . . . . . . . . 33

Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Proportioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Before Beginning Repair . . . . . . . . . . . . . . . . . . 39

Remove Supply Tank . . . . . . . . . . . . . . . . . . . . 39

Replace Recirc/Spray Valves . . . . . . . . . . . . . . 40

Displacement Pump . . . . . . . . . . . . . . . . . . . . . 41

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Pressure Transducers . . . . . . . . . . . . . . . . . . . . 50

Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Replace Cycle Counter Switch . . . . . . . . . . . . . 52

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Tank Fluid Level Sensors . . . . . . . . . . . . . . . . . 55

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

System Packages . . . . . . . . . . . . . . . . . . . . . . . 57

E-10hp Proportioners . . . . . . . . . . . . . . . . . . . . 58

Suggested Replacement Parts . . . . . . . . . . . . . . . 74

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 78

2 332144C

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Connect only to 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 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.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

•Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

332144C 3

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. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. 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 pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating conditions.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

4 332144C

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• 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, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

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.

332144C 5

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions

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 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

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

Keep Components ISO and RES

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure; forming 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.

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Separate

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange ISO and RES wetted parts.

• Never use solvent on one side if it has been con-

taminated from the other side.

6 332144C

above 90°F (33°C) when not under pressure, especially

if agitated. To reduce frothing, minimize preheating in a

circulation system.

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the RES (hardener) side. Polyureas often have amines on the RES (resin) side

Important Isocyanate (ISO) Information

332144C 7

Systems

Part

APT100

P2T100

APT900

APT901

APT902

P2T900

P2T901

P2T902

24T900

24T901

24T902

Maximum

Working

Pressure,

psi

(MPa, bar)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

Gun

Unheated

Proportioner

Volts

Model

120 V 24T100 25R000 ---

230 V 24R900 25R000

230 V 24R900 25R000 Europe

230 V 24R900 25R000

230 V 24R900 25R000 Europe

230 V 24R900 25R000

230 V 24R900 ---

Hose

35 ft (10.6 m)

Cord

Adapter

North

America

Australia/

Asia

North

America

Australia/

Asia

North

America

Model Part

Fusion

PROBLER

Fusion

PROBLER

Air Purge

--- ---

249810

GCP2RA

249810

GCP2RA

230 V 24R900 --- Europe --- ---

230 V 24R900 ---

Australia/

Asia

--- ---

Models

The model no., series letter, and serial no. are located on the back of the cart. For faster assistance, please have that information ready before calling Customer Service.

Maximum Bare Proportioner Part, Series Volts

* Electrical

Connection

24T100, A 120 V 20 A cord

(motor)

20 A cord

(heaters)

24R900, A 230 V 15 A cord

(motor)

15 A cord

(heaters)

* See page 15 for detailed electrical requirements.

8 332144C

Working

Pressure,

psi (MPa, bar) Approvals

3000

(21, 207)

3000

(21, 207)

9902471

Conforms to ANSI/UL

Std. 499 Certified to

CAN/CSA Std.

C22.2 No. 88

Related Manuals

The following manuals are for Reactor E-10hp components and accessories. Some are supplied with your package, depending on its configuration. Manuals are also available at www.graco.com.

Displacement Pump

Part No. Description

311076 Instruction-Parts Manual (English)

Fusion Air Purge Spray Gun

Part No. Description

309550 Instruction-Parts Manual (English)

Probler P2 Spray Gun

Part No. Description

313213 Instruction-Parts Manual (English)

Probler P2 Recirculation Kit

Part No. Description

406842 Instruction-Parts Manual (English)

Lift Ring Kit

Part No. Description

332977 Instruction-Parts Manual (English)

332144C 9

Overview

The Reactor E-10hp is a portable, electric-powered, 1:1 mix ratio proportioner for use with:

•Polyurea

• Polyurea hybrid coatings

• Polyurethane foam

Material may be applied with impingement mix spray guns.

The Reactor E-10hp is gravity-fed from 6 gal. (22.7 liter) supply tanks mounted on the unit.

Severe duty, positive displacement reciprocating piston pumps meter fluid flow to the gun for mixing and applying. When set to recirculation mode, Reactor E-10hp will circulate fluids back to the supply tanks.

The Reactor E-10hp uses primary heating rods and boost heating rods, for each fluid, and an insulated hose bundle with circulation return hoses. This allows the hoses and gun to be preheated to the desired temperature before spraying. The boost heating rods are used during circulation mode to reduce heatup time. Digital displays show the temperatures of the two fluids.

Electronic controls monitor fluid pressures, drive the motor, and alerts the operator if errors occur. See Motor/Pump Status Codes, page 14, for further information.

The Reactor E-10hp has two recirculation speeds, slow and fast, and an adjustable pressure output.

Slow Recirculation

• Slow circulation results in a higher temperature transfer in the heater, so hoses and gun heat up quicker.

• Good for touchup or low flow spraying, up to moderate temperature.

• Not used to circulate full tanks up to temperature.

• Use with 245 fa blowing agent foams, to minimize heat returned to tank and reduce frothing.

Fast Recirculation

• Use to support higher flow rates or higher temperatures by preheating the tanks.

• Agitates fluid within tanks, to avoid heating only the fluid at the top of the tank.

• Use for flushing.

Pressure Adjust

Automatically maintains selected pressure output for dispensing or spraying.

10 332144C

Component Identification

Key for FIG. 1

A Supply Tank (ISO) B Supply Tank (RES) CPump (ISO) DPump (RES) E Heater (under shroud) F Fluid Pressure Gauges G Recirc/Spray and Overpressure Relief Valves H Tank Level Sensors (bottom of tanks) J Control Panel; see F K Electric Motor and Drive Housings L Insulated Hose Bundle (includes circulation return

hoses)

M Fusion Air Purge Spray Gun

. 2, page 12

Component Identification

N Desiccant Dryer P Recirculation Tubes Q Air Line Inlet (quick-disconnect fitting) R Outlet Hose Connections S Return Hose Connections T Fluid Temperature Sensors (located on heater

assembly, under shroud) U Hose Rack and Control Shield V Fluid Inlet Ball Valves (each side) W Fluid Inlet Strainers (each side) X Power Cords (not shown) Y Fluid Temperature Gauges (each side) Z Air Filter/Moisture Separator

. 1: Component Identification

332144C 11

ti21488a

Controls and Indicators

See Controls and Indicators identification table, page

13.

Heater Controls

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

FIG. 2. Heater Controls and Indicators

System Controls

I I

STATUS

AXAW

. 3. System Controls and Indicators

12 332144C

Controls and Indicators

Key Name Description

Heater Controls

AA ISO Setpoint Increase Increases the temperature setpoint by one degree in the units selected

within the setpoint limits. Press target key prior to adjusting.

AB ISO Setpoint Decrease Decreases the temperature setpoint by one degree in the units

selected within the setpoint limits. Press target key prior to adjusting.

AC RES Setpoint Increase Increases the temperature setpoint by one degree in the units selected

within the setpoint limits. Press target key prior to adjusting.

AD RES Setpoint Decrease Decreases the temperature setpoint by one degree in the units

selected within the setpoint limits. Press target key prior to adjusting.

AE ISO Heater On/Off Key Turns heater on or off for ISO zone. Also clears heater zone diagnostic

codes, see page 31.

AF RES Heater On/Off Key Turns heater on or off for RES zone. Also clears heater zone diagnostic

codes, see page 31.

AG Actual Temperature Key Press to display actual temperature. Press and hold to display electrical

current.

AH Target Temperature Key Press to display target temperature. Press and hold to display heater

control circuit board temperature. AJ Temperature Scale Key °F Press to change temperature scale to degrees Fahrenheit. AK Temperature Scale Key °C Press to change temperature scale to degrees Celsius. AL Temperature Display Show actual temperature or target temperature of heater zones,

depending on selected mode. Defaults to actual at startup. Range is

32-170°F (0-77°C) for ISO and RES.

Heater Indicators

AM ISO Heater Activity

AN RES Heater Activity

AO Actual Temperatures Active Actual temperatures are displayed. AP Target Temperatures Active Target temperatures are displayed. AR Fahrenheit Units Active Indicates that temperatures are displayed in °F. AS Celsius Units Active Indicates that temperatures are displayed in °C.

System Controls

AT Heater Power Enables heater control. The switch includes a 20 A circuit breaker. AU Motor Power Enables motor. The switch includes a 20 A circuit breaker. AV Motor Pump Control Function Knob Selects operation mode / pressure setpoint. See Motor/Pump Control

System Indicators

AW Boost Heat Indicator Indicates boost heat is active. AX Tank Level Indicator See Tank Level Sensor LED, page 14. AY System Status Indicator Flashes an error code if alarm or deviation is active. See Motor/Pump

LEDs flash when heater zones are on. The duration

of each flash shows the extent that the heater is

turned on.

LEDs flash when heater zones are on. The duration

of each flash shows the extent that the heater is

turned on.

Function Knob, page 14.

Status Codes, page 14.

332144C 13

Controls and Indicators

Motor/Pump Control Function Knob

Use knob (AV) to select desired function

Icon Setting Function

Stop/Park

Slow Recirc Slow recirculation speed.

Fast Recirc Fast recirculation speed.

Pressure Adjust

Stops motor and automatically parks pumps.

Adjusts fluid pressure to gun in spray mode.

Motor/Pump Status Codes

If error occurs, status indicator (AY) will blink 1 to 19 times to indicate status code, pause, then repeat, or will blink other active error codes. See T description of status codes.

Table 1: Motor/Pump Status Codes

No. Name

1 Pressure imbalance between ISO and RES sides

2 Pressure deviation from setpoint

3 Pressure transducer ISO failure

4 Pressure transducer RES failure

5 Excessive current draw

6 High motor temperature

7 No cycle counter switch input

8 High cycle rate deviation (more than 1.0 GPM)

High cycle rate shutdown (more than 1.1 GPM)

9 Low tank level

10 Not used

11 Locked motor rotor

12 Motor controller bus overvoltage

13 Motor controller bus undervoltage

14 Motor controller high temperature

15-19 Motor controller fault

ABLE

1 for a brief

Heater Control Diagnostic Codes

Heater control diagnostic codes appear on the temperature display. These alarms turn off heat.

Table 2: Heater Control Diagnostic Codes

Code Name Alarm Zone

01 High fluid temperature Individual

02 High zone current Individual

03 No zone current with heater on Individual

04 Thermocouple not connected Individual

05 High controller temperature Individual

06 No communications with zone

pod

09 Display is missing Individual

99 No communication with heater

control module

Individual

Tank Level Sensor LED

The tank level sensor LED (AX) is triggered when chemical is not present in either tank.

Table 3: Tank Level Indicator (AX)

Chemical Status

> 1 gallon Off

< 1 gallon Flashing

NOTE: The default is to shut down if a status code indi-

cation occurs.

14 332144C

Setup

Locate Reactor

1. Locate Reactor on a level surface.

2. Do not expose Reactor to rain.

Electrical Requirements

Improper wiring may cause electric shock or other serious injury if work is not performed properly. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

1. Connect Reactor to the correct power source for your model. See nected to two separate, dedicated circuits. See F

2. Some models include cord adapters for use outside North America. Connect the appropriate adapter to the unit’s power cord before connecting to your power source.

Table 4

. Power cords must be con-

To avoid electric shock, always unplug both cords before servicing Reactor and wait one minute.

Heater Power

Ensure no other high amp loads are connected while running Reactor.

To verify separate circuits, plug in Reactor or a worklight and cycle breakers on and off.

FIG. 4: Use Two Separate Circuits

Motor Power

Setup

TI7061a

Table 4: Electrical Requirements

Model

230 V, 1 phase, 50/60 Hz, two 15 ft (4.5 m) power cords

120V, 50/60 Hz, two 15 ft (4.5 m) power cords

Required Power Source

Two separate, dedicated circuits rated at minimum of 15 A each

Two separate dedicated circuits rated at minimum of 20 A each

Power Cord Connectors Supplied Local Adapters

NEMA 6-15P

Two IEC 3-20 C20

Euro CEE74

Plugs

YP-39 AS3112

Two NEMA

5-20P Plugs

(North America)

(Australia/Asia)

Table 5: Extension Cord Requirements

Required Wire Size

Model

Up to 50 ft (15 m) Up to 100 ft (30 m)

All models AWG 12 AWG 10

NOTE: Cords must be 3-conductor grounded, rated for your environment.

(Europe)

332144C 15

Setup

Ground System

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Reactor:

Generator (if used):

stop generator with power cord(s) disconnected.

Spray gun:

connected to a properly grounded Reactor. Do not operate without at least one grounded fluid hose.

Object being sprayed:

Solvent pails used when flushing:

code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper, plastic, or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure:

firmly to the side of a grounded gun.

grounded through power cord.

follow your local code. Start and

grounded through the supplied fluid hoses,

follow your local code.

follow your local

hold a metal part of spray gun

metal

pail, then trigger

2. Connect recirculation hoses from gun recirculation ports to connections (S).

(ISO)

Air

FIG. 5

(RES)

Connect Gun Air Hose

1. Connect gun air hose to the gun air input and to the air filter outlet (Z). If you are using more than one hose bundle, join the air hoses with the nipple provided with the hose bundle.

2. On units with Fusion guns, connect the supplied ball valve and quick-disconnect coupler to the gun air hose, then connect the coupler to the gun air fitting.

Connect Fluid Hoses

Connect Main Air Supply

1. Connect fluid supply hoses to outlet hose connections (R, F Fittings are sized to prevent connection errors. Connect other end of hoses to ISO and RES inputs of gun.

NOTE: Probler guns use recirc accessory kit 24E727.

. 5). Red hoses for ISO, blue for RES.

Connect the main air supply to the quick disconnect fitting (Q) on the unit. Air supply hose must be at least 5/16 in. (8 mm) ID up to 50 ft (15 m) or 3/8 in. (10 mm) ID up to 100 ft (30 m).

NOTE: Air Filter/Moisture Separator (Z) is equipped with an automatic moisture drain.

Flush Before First Use

The Reactor is tested with a plasticizer oil at the factory. Flush out the oil with a compatible solvent before spraying. See Flushing, page 25.

16 332144C

Setup

Fill Wet-Cups

Keep the felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No. 217374. The lubricant creates a barrier between the ISO and the atmosphere.

Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from wet-cup during operation. Shut off Motor

Power before filling wet-cup.

Fill wet-cups through slots in plate, or loosen screws and swing plate aside.

1. Lift hose rack. Remove tank cover and pour ISO into tank (red side, with desiccant filter in cover).

Replace cover .

RES

ISO

Add thin coating of grease lubricant to tank o-ring

if lid is difficult to assemble to tank.

NOTE: Desiccant filter is blue when fresh, and turns pink when saturated. Be sure shipping plugs are removed from openings on desiccant filter.

2. Remove tank cover and pour resin into RES tank

(blue side). Replace cover .

Fill Fluid Tanks

NOTICE

To prevent cross-contamination of fluids and equipment parts, never interchange (isocyanate) and (resin) parts or containers.

Have at least two 5 gal. (19 liter) pails to transfer fluid from drums to supply tanks. Label one pail “ISO” and the other “RES”, using the red and blue labels provided. Always double-check which material you have before pouring it in the supply tanks. Pouring is easier if pails are not filled to the top.

Open only one supply tank at a time, to avoid splashing material from one tank into the other when filling.

NOTE: Using a drill and mixing blade, mix filled or separated materials in the pail before adding to the tanks. Material left in the tanks overnight may need to be remixed in the tanks.

332144C 17

Setup

STATUS

Purge Air and Flush Fluid From Lines

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area.

• Ensure main power is off and heater is cool before flushing.

• Do not turn on heater until fluid lines are clear of solvent.

1. Remove both recirculation tubes (P) from the tanks and secure each one in a dedicated waste container.

5. Turn on Motor Power. System status indicator (AY) should turn on.

6. Set Recirc/Spray valves to Recirc.

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7. Set function knob to Slow Recirc or Fast Recirc

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2. Set function knob to Stop/Park .

3. Plug in power cords(s). See Table 2, page 15.

4. Open both pump fluid inlet valves (V, shown in open position).

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8. When clean fluids exit both recirculation tubes (P),

set function knob to Stop/Park .

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9. Replace recirculation tubes in supply tanks.

18 332144C

Startup

d. Press to display actual temperatures.

Heated fluid can cause equipment surfaces to become very hot. To avoid severe burns:

• Do not operate Reactor without all covers and shrouds in place.

• Do not touch hot fluid or equipment.

• Allow equipment to cool completely before touching it.

1. Perform Setup, page 15.

2. Set function knob to Slow Recirc or Fast Recirc

. See Heatup Guidelines, page 20, then con-

tinue with steps 3-6.

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3. Turn on Heater Power.

5. Circulate through heater until temperature readouts display desired temperature. See Table 6.

6. Adjust heat controls as necessary for a stable spray temperature.

Table 6: Approximate heatup time for starting a cold

machine with 5 gallons (19 liters) per side

120 V 230 V

Fluid Spray Target

Temperature

35 ft (10.7 m) Hose

(1 bundle)

125°F (52°C) 15 minutes 10 minutes 170°F (77°C) 40 minutes 20 minutes

NOTE: Heatup times are based on 70°F (21°C) starting material temperature and 70°F (21°C) ambient temperature.

NOTE: Different fluids will absorb heat at different rates. When refilling a warm machine, heatup times will be less.

4. Set temperatures:

a. Press or to change temperature

scale.

b. Press to display target temperatures.

c. To set heat zone target temperature,

press or until display shows

desired temperature. Repeat for zone.

332144C 19

Startup

Heatup Guidelines

The fluids must be circulated from the pumps through the heater, hoses, and back to the tanks to ensure warm fluids are supplied to the gun.

Slow Recirculation

• Slow Recirc results in a higher temperature transfer in the heater, so hoses and gun heat up quicker.

• Good for touchup or low flow spraying, up to moderate temperature.

Fast Recirculation

Fast Recirc keeps heaters on full-time to bring fluid tanks up to temperature. The higher your flow rate, the more heat needed in the tanks before spraying.

•

For 230 V systems:

fluid temperature gauges (Y) are within 45°F (25°C) of target outlet temperature.

•

For 120 V systems:

fluid temperature gauges (Y) are within 30°F (17°C) of target temperature.

Use Fast Recirc until pump inlet

Heat Management Tips

• Heaters perform better with lower flow rates or smaller mix modules.

• Triggering the gun for short periods helps maintain efficient heat transfer, keeping material at the desired temperature. Triggering the gun for a long period may not allow enough heating time, depending on material temperature in tanks.

• If temperature displays fall below acceptable limits,

set function knob to Slow Recirculation and circulate again to bring temperatures back up.

• Each 35 ft (10.7 m) hose bundle adds about 5 minutes to heatup time, with most materials. Maximum recommended hose length is 105 ft (32 m).

• For a quicker start, do initial heatup circulation with the tanks 1/4 to 1/3 filled, then add more material.

•

Volume in tanks:

example, 2.5 gal. (10 l) in each tank will heat up almost twice as fast as 5 gal. (20 l).

• Mixes fluid within tanks, to avoid heating only the fluid at the top of the tank.

• Use for flushing.

Use only what you need. For

20 332144C

Spraying

NOTE: Air is supplied to spray gun with gun piston

safety lock or trigger safety lock engaged and gun fluid manifold valves closed (if present).

Fusion

Probler

Spraying

4. Check fluid pressure gauges to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures. The pressure imbalance alarm (Status Code 1) is inactive for 10 seconds after entering spray pressure mode, to allow time to balance pressures.

In this example, RES side pressure is higher, so use the RES side valve to balance pressures.

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1. Set function knob to Stop/Park . Verify system

status indicator LED is on.

2. Set Recirc/Spray valves to Spray

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3. Turn function knob to Pressure Adjust . Keep

turning to the right until fluid pressure gauges show desired pressure.

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NOTE: Watch gauges for 10 seconds to be sure pressure holds on both sides and pumps are not moving.

5. Open gun fluid manifold valves (impingement mix guns only).

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Probler

NOTE: On impingement guns, never open fluid manifold

valves or trigger gun if pressure are imbalanced.

6. Disengage piston safety lock or trigger safety lock.

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Probler

7. Test spray onto cardboard or plastic sheet. Verify that material fully cures in the required length of time, and is the correct color. Adjust pressure and temperature to get desired results. Equipment is ready to spray.

332144C 21

Pause

To bring the hose and gun back to spray temperature after a brief break, use the following procedure.

1. Engage piston safety lock or trigger safety lock.

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Fusion

2. Set function knob to Slow Recirc .

3. Set Recirc/Spray valves to Recirc until temperature readouts come back up.

Refill Tanks

Material can be added to the tanks at any time. See Fill Fluid Tanks, page 17.

NOTE: If you are operating at high temperatures or flow

rates, follow Pause instructions to bring tanks up to temperature.

NOTICE

To prevent cross-contamination of fluids and equipment parts, never interchange ISO and RES parts or containers.

Open only one supply tank at a time, to avoid splashing material from one tank into the other when filling.

If you stop spraying for more than 2 minutes when using an impingement mix gun,

close gun fluid valves. Doing this will keep the internal parts of the gun cleaner and prevent crossover.

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Probler

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22 332144C

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Engage piston safety lock or trigger safety lock.

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Probler

Shutdown

NOTE: For longer breaks (more than 10 minutes) use

the following procedure. If you will be shutdown for more than 3 days, first see Flushing, page 25.

1. Shut off Heater Power.

2. Shut off Motor Power.

3. Follow all steps of Pressure Relief Procedure, page 23.

4. Close gun fluid valves ISO and RES. Doing this will keep the internal parts of the gun cleaner and prevent crossover.

2. Set function knob to Stop/Park .

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3. Turn Recirc/Spray valves to Recirc. Fluid will be dumped to supply tanks. Pumps will move to the bottom of their stroke. Ensure gauges drop to 0.

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Probler

5. Refer to your separate gun manual and perform Shutdown procedure.

332144C 23

Maintenance

• Check pump wet-cups fluid level daily, page 17.

• Throat u-cup is not adjustable. Do not overtighten packing nut/wet-cup.

• Keep component ISO from exposure to moisture in atmosphere, to prevent crystallization.

• Wipe supply tank lid o-ring, inner rim, and inner tank walls daily to prevent ISO crystallization. Keep film of grease on o-ring and inside of lid.

• Check desiccant filter weekly. Filter is blue when fresh, and turns pink when saturated.

• Remove plug (X) and clean fluid inlet strainer (S) as needed. Always clean the fluid inlet strainers after flushing.

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• Generally, flush if you will shutdown for more than three days. Flush more often if material is moisture sensitive and humidity is high in the storage area, or if material may separate or settle out over time.

•

If using an impingement mix gun,

valves when not spraying. Doing this will keep the internal parts of the gun cleaner and prevent crossover. Clean gun mix chamber ports and check valve screens regularly. See gun manual.

Fusion

•

If using an Fusion Air Purge impingement mix gun,

always grease the gun after use until purge air carries grease mist out the front of the gun. Use Part No. 117773 Grease. See gun manual.

close gun fluid

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24 332144C

+ 54 hidden pages