Graco H25, H50, H40 User Manual

Operation

312062W

Hydraulic, Heated, Plural Component Proportioner For spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in European explosive atmosphere locations.

Important Safety Instructions

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

See page 3 for model information, including maximum working pressure and approvals.

Model H-40 Shown

T9830a

Contents

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Supplied Manuals . . . . . . . . . . . . . . . . . . . 7

Related Manuals . . . . . . . . . . . . . . . . . . . . 8

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Important Two-Component Material

Information . . . . . . . . . . . . . . . . . . . . . 12

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 12

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 12

Keep Components A and B Separate . . . . . . . . 12

Moisture Sensitivity of Isocyanates . . . . . . . . . . 12

Foam Resins with 245 fa Blowing Agents . . . . . 13

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 13

Typical Installation, with circulation . . . 14 Typical Installation, without circulation 15

Component Identification . . . . . . . . . . . . 16

Temperature Controls and Indicators . . 18

Main Power Switch . . . . . . . . . . . . . . . . . . . . . . 18

Red Stop Button . . . . . . . . . . . . . . . . . . . . . . . . 18

Actual Temperature Key/LED . . . . . . . . . . . . . . 19

Target Temperature Key/LED . . . . . . . . . . . . . . 19

Temperature Scale Keys/LEDs . . . . . . . . . . . . . 19

Heater Zone On/Off Keys/LEDs . . . . . . . . . . . . 19

Temperature Arrow Keys . . . . . . . . . . . . . . . . . 19

Temperature Displays . . . . . . . . . . . . . . . . . . . . 19

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . 20

Motor Controls and Indicators . . . . . . . . 21

Motor ON/OFF Key/LED . . . . . . . . . . . . . . . . . . 21

PARK Key/LED . . . . . . . . . . . . . . . . . . . . . . . . . 21

PSI/BAR Keys/LEDs . . . . . . . . . . . . . . . . . . . . . 21

Pressure Key/LED . . . . . . . . . . . . . . . . . . . . . . 21

Cycle Count Key/LED . . . . . . . . . . . . . . . . . . . . 22

Hydraulic Pressure Control Knob . . . . . . . . . . . 22

Motor Control Arrow Keys . . . . . . . . . . . . . . . . . 22

Spray Adjustments . . . . . . . . . . . . . . . . . 22

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 38

Pressure Relief Procedure . . . . . . . . . . . 39

Fluid Circulation . . . . . . . . . . . . . . . . . . . .40

Circulation Through Reactor . . . . . . . . . . . . . . . 40

Circulation Through Gun Manifold . . . . . . . . . . . 41

Diagnostic Codes . . . . . . . . . . . . . . . . . . .42

Temperature Control Diagnostic Codes . . . . . . 42

Motor Control Diagnostic Codes . . . . . . . . . . . . 43

Maintenance . . . . . . . . . . . . . . . . . . . . . . .44

Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 45

Pump Lubrication System . . . . . . . . . . . . . . . . . 46

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . .47

Dimensions . . . . . . . . . . . . . . . . . . . . . . . .48

Technical Data . . . . . . . . . . . . . . . . . . . . .49

Performance Charts . . . . . . . . . . . . . . . . .50

Graco Standard Warranty . . . . . . . . . . . .52

Graco Information . . . . . . . . . . . . . . . . . .52

2 312062W

Systems

Maximum Fluid Working Pressure

Part

★AP3400 2000 (13.8, 138) ★253400 246678 246050 Fusion Air Purge 246101 AR5252 AP3401 2000 (13.8, 138) 253401 246678 246050 Fusion Air Purge 246101 AR5252 AP3402 2000 (13.8, 138) 253402 246678 246050 Fusion Air Purge 246101 AR5252 ★AP3403 3500 (24.1, 241) ★253403 246679 246055 Fusion Air Purge 246101 AR4242 AP3404 3500 (24.1, 241) 253404 246679 246055 Fusion Air Purge 246101 AR4242 AP3405 3500 (24.1, 241) 253405 246679 246055 Fusion Air Purge 246101 AR4242 AP3407 2000 (13.8, 138) 253407 246678 246050 Fusion Air Purge 246101 AR5252 AP3408 2000 (13.8, 138) 253408 246678 246050 Fusion Air Purge 246101 AR5252 ★AP3725 1700 (11.7, 117) ★253725 246678 246050 Fusion Air Purge 246101 AR5252 AP3726 2000 (13.8, 138) 253726 246678 246050 Fusion Air Purge 246101 AR5252 AP3727 2000 (13.8, 138) 253727 246678 246050 Fusion Air Purge 246101 AR5252 AP5400 2000 (13.8, 138) 255400 246678 246050 Fusion Air Purge 246101 AR5252 AP5401 2000 (13.8, 138) 255401 246678 246050 Fusion Air Purge 246101 AR5252 AP5402 2000 (13.8, 138) 255402 246678 246050 Fusion Air Purge 246101 AR5252 AP5403 3500 (24.1, 241) 255403 246679 246055 Fusion Air Purge 246100 AR2929 AP5404 3500 (24.1, 241) 255404 246679 246055 Fusion Air Purge 246100 AR2929 AP5405 3500 (24.1, 241) 255405 246679 246055 Fusion Air Purge 246100 AR2929 AP5406 2000 (13.8, 138) 255406 246678 246050 Fusion Air Purge 246101 AR5252 AP5407 2000 (13.8, 138) 255407 246678 246050 Fusion Air Purge 246101 AR5252 AP5408 2000 (13.8, 138) 255408 246678 246050 Fusion Air Purge 246101 AR5252 AP6505 2000 (13.8, 138) 256505 246678 246050 Fusion Air Purge 246101 AR5252 AP6506 2000 (13.8, 138) 256506 246678 246050 Fusion Air Purge 246101 AR5252 CS5400 2000 (13.8, 138) 255400 246678 246050 Fusion CS CS02RD CS5401 2000 (13.8, 138) 255401 246678 246050 Fusion CS CS02RD CS5402 2000 (13.8, 138) 255402 246678 246050 Fusion CS CS02RD CS5406 2000 (13.8, 138) 255406 246678 246050 Fusion CS CS02RD CS5407 2000 (13.8, 138) 255407 246678 246050 Fusion CS CS02RD CS5408 2000 (13.8, 138) 255408 246678 246050 Fusion CS CS02RD

psi (MPa, bar)

Proportioner (see page 3)

Heated Hose Gun

Mix Chamber Kit50 ft (15 m) 10 ft (3 m) Model Part

★CE approval does not apply.

312062W 3

Systems Continued

Systems

Maximum Fluid Working Pressure

Part

★P23400 2000 (13.8, 138) ★253400 246678 246050 Probler P2 GCP2R2 P23401 2000 (13.8, 138) 253401 246678 246050 Probler P2 GCP2R2 P23402 2000 (13.8, 138) 253402 246678 246050 Probler P2 GCP2R2 ★P23403 3500 (24.1, 241) ★253403 246679 246055 Probler P2 GCP2R1 P23404 3500 (24.1, 241) 253404 246679 246055 Probler P2 GCP2R1 P23405 3500 (24.1, 241) 253405 246679 246055 Probler P2 GCP2R1 P23407 2000 (13.8, 138) 253407 246678 246050 Probler P2 GCP2R2 P23408 2000 (13.8, 138) 253408 246678 246050 Probler P2 GCP2R2 ★P23725 1700 (11.7, 117) ★253725 246678 246050 Probler P2 GCP2R2 P23726 2000 (13.8, 138) 253726 246678 246050 Probler P2 GCP2R2 P23727 2000 (13.8, 138) 253727 246678 246050 Probler P2 GCP2R2 P25400 2000 (13.8, 138) 255400 246678 246050 Probler P2 GCP2R2 P25401 2000 (13.8, 138) 255401 246678 246050 Probler P2 GCP2R2 P25402 2000 (13.8, 138) 255402 246678 246050 Probler P2 GCP2R2 P25403 3500 (24.1, 241) 255403 246679 246055 Probler P2 GCP2R0 P25404 3500 (24.1, 241) 255404 246679 246055 Probler P2 GCP2R0 P25405 3500 (24.1, 241) 255405 246679 246055 Probler P2 GCP2R0 P25406 2000 (13.8, 138) 255406 246678 246050 Probler P2 GCP2R2 P25407 2000 (13.8, 138) 255407 246678 246050 Probler P2 GCP2R2 P25408 2000 (13.8, 138) 255408 246678 246050 Probler P2 GCP2R2 P26505 2000 (13.8, 138) 256505 246678 246050 Probler P2 GCP2R2 P26506 2000 (13.8, 138) 256506 246678 246050 Probler P2 GCP2R2

psi (MPa, bar)

Proportioner (see page 3)

Heated Hose Gun

50 ft (15 m) 10 ft (3 m) Model Part

★CE approval does not apply.

4 312062W

Models

H-25 SERIES

Max Flow Full Load Peak Amps*

Part, Series

255400, F 69 230V (1) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255401, F 46 230V (3) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255402, F 35 400V (3) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255406, F 100 230V (1) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255407, F 59 230V (3) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255408, F 35 400V (3) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)

Per Phase

Voltage (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)

H-40 SERIES

Max Flow Full Load Peak Amps*

Part, Series

★253400, E 100 230V (1) 23,100 12,000 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)

253401, E 71 230V (3) 26,600 15,300 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 253402, E 41 400V (3) 26,600 15,300 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 253407, E 95 230V (3) 31,700 20,400 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 253408, E 52 400V (3) 31,700 20,400 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)

Per Phase

Voltage (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)

H-50 SERIES

Max Flow Full Load Peak Amps*

Part, Series

★253725, E 100 230V (1) 23,100 12,000 52 (24) 0.073 (0.28) 1.64:1 1700 (11.7, 117)

253726, E 71 230V (3) 26,600 15,300 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138) 253727, E 41 400V (3) 26,600 15,300 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138) 256505, E 95 230V (3) 31,700 20,400 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138) 256506, E 52 400V (3) 31,700 20,400 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138)

Per Phase

Voltage (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)

312062W 5

H-XP2 SERIES

Models

Approximate Full Load Peak Amps*

Part, Series

255403, F 100 230V (1) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241) 255404, F 59 230V (3) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241) 255405, F 35 400V (3) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241)

Per Phase

Voltage (phase)

System Watts†

Primary Heater Watts

Max Flow Rate◆ gpm (lpm)

Output per

Cycle (A+B)

gal. (liter)

Hydraulic Pressure Ratio

Maximum Fluid Working Pressure psi (MPa, bar)

H-XP3 SERIES

Approximate Full Load Peak Amps*

Part, Series

★253403, E 100 230V (1) 23,100 12,000 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241)

253404, E 95 230V (3) 31,700 20,400 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241) 253405, E 52 400V (3) 31,700 20,400 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241)

Per Phase

Voltage (phase)

System Watts†

Primary Heater Watts

Max Flow Rate◆ gpm (lpm)

Output per

Cycle (A+B)

gal. (liter)

Hydraulic Pressure Ratio

Maximum Fluid Working Pressure psi (MPa, bar)

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at vari-

ous flow rates and mix chamber sizes may be less.

†

Total system watts, based on maximum hose length for each unit:

• Parts 255400 through 255408, 310 ft (94.6 m) maximum heated hose length, including whip hose.

• Parts 253400 through 253408, 253725 through 253727, 256505, and 256506, 410 ft (125 m) maximum heated hose length, including whip hose.

◆

Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of

60 Hz maximum flow.

★CE approval does not apply.

Approvals:



#ONFORMSTO!.3)5,

3TD#ERTIFIEDTO

#!.#3!3TD

#.O

6 312062W

Supplied Manuals

The following manuals are shipped with the Reactor™ Proportioner. Refer to these manu-

als for detailed equipment information.

Order Part 15M334 for a compact disk of Reactor manuals translated in several languages.

Manuals are also available at www.graco.com.

Reactor Hydraulic Proportioner

Part Description

312063 Reactor Hydraulic Proportioner,

Repair-Parts Manual (English)

Reactor Electrical Diagrams

Part Description

312064 Reactor Hydraulic Proportioner,

Electrical Diagrams (English)

Proportioning Pump

Part Description

312068 Proportioning Pump Repair-Parts

Manual (English)

312062W 7

Related Manuals

Related M anuals

The following manuals are for accessories used with the Reactor™.

Order Part 15M334 for a compact disk of Reactor manuals translated in several languages.

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

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

309852 Instruction-Parts Manual

(English)

Heated Hose

Part Description

309572 Instruction-Parts Manual

(English)

Part Description

312071 Seal Kits Instruction-Parts

Manual (English)

8 312062W

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 at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

312062W 9

Warnings

WARNING

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.

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.

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.

10 312062W

Warnings

WARNING

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.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• This equipment is for professional use only.

• Do not leave the work are while the equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when the equipment is not in use.

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

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

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

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

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

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

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

312062W 11

Important Two-Component Material Information

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.

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.

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

Material Self-ignition

To prevent exposing ISO to moisture: Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

12 312062W

• Always use a sealed container with a des-

• Keep the ISO lube pump reservoir (if

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

iccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

installed) filled with Graco Throat Seal Liquid (TSL), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.

Important Two-Component Material Information

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

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

• Never use solvent on one side if it has been contaminated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

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.

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.

312062W 13

Typical Installation, with circulation

Key for FIG. 1

Typical Installation, with circulation

A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F Gun Air Supply Hose

A Side Supply Detail

ti7820a 2

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

B Side Supply Detail

ti7820a 3

FIG. 1: Typical Installation, with circulation

* Shown exposed for clarity.

Wrap with tape during operation.

ti10000a

14 312062W

Typical Installation, without circulation

Key for FIG. 2

A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines

A Side Supply Detail

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)

B Side Supply Detail

ti7821a 3

FIG. 2: Typical Installation, without circulation

* Shown exposed for clarity.

Wrap with tape during operation.

ti10001a

312062W 15

Component Identification

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 FP Feed Inlet Pressure Gauge FS Feed Inlet Strainer FT Feed Inlet Temperature Gauge FV Fluid Inlet Valve (B side shown) GA Component A Outlet Pressure Gauge GB Component B Outlet Pressure Gauge HA Component A Hose Connection HB Component B Hose Connection HC Hydraulic Pressure Control HP Hydraulic Pressure Gauge LR ISO Lube Pump Reservoir MC Motor Control Display MP Main Power Switch OP Overpressure Rupture Disk Assembly (on rear of A and B

pumps) PA Component A Pump PB Component B Pump RS Red Stop Button SA Component A PRESSURE RELIEF/SPRAY Valve SB Component B PRESSURE RELIEF/SPRAY Valve SC Fluid Temperature Sensor Cable SN Serial Number Plate (one inside cabinet, one on right side

of cabinet) SR Electrical Cord Strain Relief TA Component A Pressure Transducer (behind gauge GA) TB Component B Pressure Transducer (behind gauge GB) TC Temperature Control Display TD Oil Cooler

Component Identification

16 312062W

Component Identification

Detail of Reactor Fluid Manifold

(shroud removed for clarity)

ti9880a

TI9830a

Detail of Serial No.

Plate (inside cabinet)

ti7823a

FIG. 3: Component Identification (H40 15.3 kW Model Shown)

312062W 17

Temperature Controls and Indicators

NOTICE

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

Zone A Arrow Keys

Zone B Arrow Keys

Hose Zone Arrow Keys

Actual Temperature

Key

Heater Power Indicators

Heater Displays

Heater A On/Off Key

Heater B On/Off Key

Hose Heater On/Off Key

Temperature Scale Keys

Target Temperature Key

FIG. 4. Temperature Controls and Indicators

Main Power Switch

Located on right side of unit, page 17. Turns

Reactor power ON and OFF .

Does not turn heater zones or pumps on.

18 312062W

Red Stop Button

Located between temperature control panel and motor control panel, page 17. Press

to shut off motor and heater zones

only. Use main power switch to shut off all power to unit.

Temperature Controls and Indicators

Actual Temperature Key/LED

Press to display actual temperature.

Press and hold to display electrical cur-

rent.

Target Temperature Key/LED

Press to display target temperature.

Press and hold to display heater control

circuit board temperature.

Temperature Scale

Heater Zone On/Off Keys/LEDs

Press to turn heater zones on and off.

Also clears heater zone diagnostic codes, see page 42.

LEDs flash when heater zones are on. The duration of each flash shows the extent that the heater is turned on.

Temperature Arrow Keys

Press , then press or to

adjust temperature settings in 1 degree increments.

Keys/LEDs

Press or to change temperature

scale.

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.

312062W 19

Temperature Controls and Indicators

Circuit Breakers

Located inside Reactor cabinet.

Ref. Size Component

CB1 50 A Hose/Transformer Secondary

CB2 40 A Transformer Primary

CB3 25, 40, or

50 A*

CB4 25, 40, or

50 A*

CB5 20 or 30 A* Motor/Pumps

Heater A

Heater B

* Depending on model.

CB1

CB2

CB3

For wiring and cabling, see repair manual 312063.

CB4

CB5

ti9884a

20 312062W

Motor Controls and Indicators

NOTICE

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

Arrow Keys

Motor ON/OFF Key

PARK Key

Pressure Key

Cycle Count Key

FIG. 5. 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

PSI/BAR Keys/LEDs

Press or to change pressure scale.

PSI

BAR

clears some motor control diagnostic codes, see page 43.

Pressure Key/LED

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.

312062W 21

Press to display fluid pressure.

If pressures are imbalanced, display shows higher of two pressures.

Spray Adjustments

Cycle Count Key/LED

Press to display cycle count.

To clear counter, press and hold

for 3 sec.

Hydraulic Pressure Control Knob

Use to adjust hydraulic pressure available to the hydraulic drive system. Turn knob (HC) clockwise to increase pressure and counterclockwise to decrease pressure. Use hydraulic pressure gauge (HP, page 17) to view hydraulic pressure.

Spray Adjustments

Flow rate, atomization, and amount of overspray are affected by four variables.

• Fluid pressure setting. Too little pressure results in an uneven pattern, coarse droplet size, low flow, and poor mixing. Too much pressure results in excessive overspray, high flow rates, difficult control, and excessive wear.

• Fluid temperature. Similar effects to fluid pressure setting. The A and B temperatures can be offset to help balance the fluid pressure.

• Mix chamber size. Choice of mix chamber is based on desired flow rate and fluid viscosity.

ti7731a ti7732a

Component A and B outlet pressures will be higher than the hydraulic set pressure, depending on the model (see Pressure Ratio data; Systems, page 3). Component A and B pressure may be viewed on the pressure gauges (GA, GB), or the higher of the two pressures may be displayed on the motor control

panel (MC). See F

. 3, page 17.

Motor Control Arrow Keys

Use or to:

• Adjust pressure imbalance settings, page

33.

• 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.

• Adjust standby settings, page 37.

22 312062W

Setup

NOTICE

Proper system setup, start up, 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

Dimensions, page 48, for clearance and mounting hole dimensions.

b. Do not expose Reactor to rain.

NOTICE

To prevent damage from tipping over and falling, proper care needs to be taken when lifting the Reactor. Bolt Reactor to original shipping pallet, to keep stable, before lifting.

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

components.

c. Perform the following equation:

Total watts x 1.25 = kVA (kilovolt-amperes)

c. Use the casters to move Reactor to a

fixed location, or bolt to shipping pallet and move with forklift.

d. To mount on a truck bed or trailer,

remove casters and bolt directly to truck or trailer bed. See page 48.

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.

312062W 23

Setup

• 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.

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 page 25. 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

Voltage

Part Model

253407 H-40 230V (3) 95 31,700 253408 H-40 400V (3) 52 31,700 255400 H-25 230V (1) 69 15,960 255401 H-25 230V (3) 46 15,960 255402 H-25 400V (3) 35 15,960 255403 HXP2 230V (1) 100 23,260 255404 HXP2 230V (3) 59 23,260 255405 HXP2 400V (3) 35 23,260 255406 H-25 230V (1) 100 23,260 255407 H-25 230V (3) 59 23,260 255408 H-25 400V (3) 35 23,260 253725 H-50 230V (1) 100 23,100 253726 H-50 230V (3) 71 26,600 253727 H-50 400V (3) 41 26,600 256505 H-50 230V (3) 95 31,700 256506 H-50 400V (3) 52 31,700

(phase)

Peak Amps*

System Watts**

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

Table 1

: Electrical Requirements

(kW/Full Load Amps)

Full Load

Voltage

Part Model

253400 H-40 230V (1) 100 23,100 253401 H-40 230V (3) 71 26,600 253402 H-40 400V (3) 41 26,600 253403 H-XP3 230V (1) 100 23,100 253404 H-XP3 230V (3) 95 31,700 253405 H-XP3 400V (3) 52 31,700

(phase)

Peak Amps*

System Watts**

** Total system watts, based on maximum hose length for each unit:

• Parts 255400 through 255408, 310 ft (94.6 m) maximum heated hose length, including whip hose.

• Parts 253400 through 253408, 410 ft (125 m) maximum heated hose length, including whip hose.

24 312062W

Setup

4. Connect electrical cord

Power cord is not supplied. See Table 2.

Table 2: Power Cord Requirements

Cord Specification

Part Model

253400 H-40 4 (21.2), 2 wire + ground 253401 H-40 4 (21.2), 3 wire + ground 253402 H-40 8 (8.4), 4 wire + ground 253403 H-XP3 4 (21.2), 2 wire + ground 253404 H-XP3 4 (21.2), 3 wire + ground 253405 H-XP3 6 (13.3), 4 wire + ground 253407 H-40 4 (21.2), 3 wire + ground 253408 H-40 6 (13.3), 4 wire + ground 255400 H-25 4 (21.2), 2 wire + ground 255401 H-25 8 (8.4), 3 wire + ground 255402 H-25 8 (8.4), 4 wire + ground 255403 H-XP2 4 (21.2), 2 wire + ground 255404 H-XP2 6 (13.3), 3 wire + ground 255405 H-XP2 8 (8.4), 4 wire + ground 255406 H-25 4 (21.2), 2 wire + ground 255407 H-25 6 (13.3), 3 wire + ground 255408 H-25 8 (8.4), 4 wire + ground 253725 H-50 4 (21.2), 2 wire + ground 253726 H-50 4 (21.2), 3 wire + ground 253727 H-50 8 (8.4), 4 wire + ground 256505 H-50 4 (21.2), 3 wire + ground 256506 H-50 6 (13.3), 4 wire + ground

AWG (mm2)

a. 230V, 1 phase: Using 5/32 or 4 mm hex

allen wrench, connect two power leads to L1 and L2. Connect green to ground (GND).

GND

ti2515b

b. 230V, 3 phase: Using 5/32 or 4 mm hex

allen wrench, connect three power leads to L1, L2, and L3. Connect green to ground (GND).

GND

ti3248b

312062W 25

Setup

c. 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).

GND

ti2725a

Some 3-phase models utilize a 3-phase motor. The motor must rotate counterclockwise when viewed from shaft end. To reverse rotation, disconnect power and reverse power leads L1 and L2.

c. Install agitator (L) in component B drum,

if necessary.

d. Ensure A and B inlet valves (FV) are

closed.

ti9883a

Supply hoses from feed pumps should be 3/4 in. (19 mm) ID.

5. Connect feed pumps

a. Install feed pumps (K) in component A

and B supply drums. See FIG. 1 and FIG. 2, pages 14 and 15.

A minimum feed pressure of 50 psi (0.35 MPa, 3.5 bar) is required at both feed inlet pressure gauges (FP). Maximum feed pressure is 250 psi (1.75 MPa, 17.5 bar). Maintain A and B feed pressures within 10% of each other.

ti10006a

b. Seal component A drum and use desic-

cant dryer (M) in vent.

26 312062W

Setup

6. Connect pressure relief lines

Do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpres-

sure relief valves when set to SPRAY . Lines must be open so valves can automatically relieve pressure when machine is operating.

ti9880a

If circulating fluid back to the supply drums, use high pressure hose rated to withstand the maximum working pressure of this equipment.

a. Recommended: Connect high pressure

hose (R) to relief fittings (BA, BB) of both PRESSURE RELIEF/SPRAY valves, Route hose back to component A and B drums. See FIG. 1, page 14.

b. Alternately: Secure supplied bleed

tubes (N) in grounded, sealed waste containers (H). See FIG. 2, page 15.

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.

312062W 27

Setup

8. Connect heated hose

See Heated Hose manual 309572 for detailed instructions on connecting heated hoses.

The fluid temperature sensor (C) and whip hose (D) must be used with heated hose, see page 27. Hose length, including whip hose, must be 60 ft (18.3 m) minimum.

a. Turn main power OFF .

b. Assemble heated hose sections, FTS,

and whip hose.

d. Connect cables (Y). Connect electrical

connectors (V). Be sure cables have slack when hose bends. Wrap cable and electrical connections with electrical tape.

ti9881a

9. Close gun fluid manifold valves A and B

c. Connect A and B hoses to A and B out-

lets 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.

ti9878a

Manifold hose adapters (N, P) allow use of 1/4 in. and 3/8 in. ID fluid hoses. To use 1/2 in. (13 mm) ID fluid hoses, remove adapters from fluid manifold and install as needed to connect whip hose.

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.

28 312062W

Setup

12.Ground system

Reactor:

is grounded through power

cord. See page 25.

Spray gun:

connect whip hose ground wire to FTS, page 27. Do not disconnect wire or spray without whip hose.

Fluid supply containers:

local code.

Object being sprayed:

code.

Solvent pails used when flushing:

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

follow your

follow your local

14.Lubrication system setup

Component A (ISO) Pump: Fill ISO lube

reservoir (LR) with Graco Throat Seal Liquid (TSL), Part 206995 (supplied).

a. Lift the lubricant reservoir (LR) out of

the bracket (RB) and remove the container from the cap.

b. Fill with fresh lubricant. Thread the res-

ervoir onto the cap assembly and place it in the bracket (RB).

c. Push the larger diameter supply tube

(ST) approximately 1/3 of the way into the reservoir.

ti9911a

To maintain grounding continuity when flushing or relieving pressure,

hold a

metal part of spray gun firmly to the side

metal

of a grounded

pail, then trigger

gun.

d. Push the smaller diameter return tube

(RT) into the reservoir until it reaches the bottom.

Important: The return tube (RT) must reach the bottom of the reservoir, to

13.Check hydraulic fluid level

ensure that isocyanate crystals will settle to the bottom and not be siphoned

Hydraulic reservoir is filled at the factory. Check fluid level before operating the first

into the supply tube (ST) and returned to the pump.

time, and weekly thereafter. See Mainte- nance, page 44.

e. The lubrication system is ready for

operation. No priming is required.

312062W 29

Startup

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.

Startup

a. Check that all Setup steps are com-

plete.

b. Check that inlet screens are clean

before daily startup, page 45.

c. Check level and condition of ISO lube

daily, page 44.

d. Turn on component B agitator, if used.

e. Turn both PRESSURE RELIEF/SPRAY

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

1. Check generator fuel level.

Running out of fuel will cause voltage fluctuations that can damage electrical equipment.

2. Ensure the main breaker on the generator is in the off position.

3. Start the generator. Allow it to reach full operating temperature.

4. Close the bleed valve on the air compressor.

5. Switch on the air compressor starter and air dryer, if included.

6. Turn on power to the Reactor.

7. Load fluid with feed pumps

valves (SA, SB) to SPRAY .

f. Start feed pumps.

g. Open fluid inlet valves (FV). Check for

leaks.

ti10002a

ti9877a

The Reactor is tested with oil at the factory. Flush out the oil with a compatible solvent before spraying. See page 47.

30 312062W

Startup

Do not mix components A and B during startup. Always provide two grounded waste containers to keep component A and component B fluids separate.

h. Use feed pumps to load system. Hold

gun fluid manifold over two grounded waste containers. Open fluid valves A and B until clean, air-free fluid comes from valves. Close valves.

ti2484a

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 .

b. Press or to change tem-

perature scale.

c. Press to display target tempera-

8. Set temperatures

Temperature Controls and Indicators, see page 18

tures.

d. To set heat zone target tempera-

ture, press or until display

shows desired temperature. Repeat for

and zones.

For zone only, if FTS is discon-

nected at startup, display will show hose current (0A). See step j, page 32.

312062W 31

e. Press to display actual tempera-

tures.

Do not turn on hose heat without fluid in hoses.

f. Turn on heat zone by pressing

. Preheat hose (15-60 min). Indi-

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

cator 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.

g. Turn on and heat zones by

pressing for each zone.

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.

Press or to adjust current

setting.

To prevent overheating, install hose thermometer close to gun end, within operator view. Insert thermometer through foam cover of A component hose so stem is next to inner tube. Thermometer reading will be about 20°F less than actual fluid temperature.

If thermometer reading exceeds 160°F

(71°C), reduce current with key.

h. Hold to view electrical currents for

each zone.

i. Hold to view heater control circuit

board temperature.

32 312062W

Startup

9. Set pressure

ON / OFF

PARK

PSI

BAR

Motor Controls and Indicators, see

page 21

a. Press to display the pressure

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 .

To clear counter, press and hold

for 3 sec.

e. Press or to change pres-

PSI

BAR

sure scale.

10.Change pressure imbalance setting (optional)

reading.

b. Press motor . Motor and pumps

start. Display shows system pressure.

Motor must rotate counterclockwise when viewed from shaft end. See Con- nect electrical cord, page 25.

c. Adjust hydraulic pressure control until

display shows desired fluid pressure.

ti7731a ti7732a

If display pressure is greater than desired pressure, reduce the hydraulic pressure and trigger gun to reduce pressure.

The pressure imbalance function (status code 24, page 43) detects conditions that can cause off-ratio spray, such as loss of feed pressure/supply, pump seal failure, clogged fluid inlet filter, or a fluid leak.

Code 24 (pressure imbalance) is set to an alarm as the default. To change to a warning, see Reactor Repair-Parts manual 312063.

The pressure imbalance default is factory-set at 500 psi (3.5 MPa, 35 bar). For tighter ratio error detection, select a lower value. For looser detection or to avoid nuisance alarms, select a higher value.

a. Turn main power switch OFF .

312062W 33

Startup

b. Press and hold or , then turn

PSI

BAR

main power switch ON . Display

will read dP500 for psi or dP_35 for bar.

c. Press or to select desired

pressure differential (100-999 in increments of 100 psi, or 7-70 in increments

ABLE

of 7 bar). See T

Table 3: Available Pressure Imbalance Settings

PSI BAR PSI BAR

100 7 600 42 200 14 700 49 300 21 800 56 400 28 900 63

*500 *35 999 69

* Factory default setting.

d. Turn main power switch OFF to

save changes.

34 312062W

Spraying

1. Engage gun piston safety lock.

4. Set PRESSURE RELIEF/SPRAY valves

(SA, SB) to SPRAY .

ti9877a

ti2409a

2. Close gun fluid manifold valves A and B.

ti2728a

3. Attach gun fluid manifold. Connect gun air line. Open air line valve.

5. Check that heat zones are on and temperatures are on target, page 31.

6. Press motor to start motor and

pumps.

7. Check fluid pressure display and adjust as necessary.

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/CIRCULA-

TION , until gauges show balanced pressures.

In this example, B side pressure is higher, so use the B

ti2543a

312062W 35

balance pressures.

ti9877a

side valve to

9. Open gun fluid manifold valves A and B. 10. Disengage gun piston safety lock.

11.Test spray onto cardboard. Adjust pressure

ti2414a

and temperature to get desired results.

12.Equipment is ready to spray.

Spraying

ti2410a

On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.

If you stop spraying for a period of time, the unit will enter standby (if enabled). See page 37.

36 312062W

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.

The , , and heat zones

will not be 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.

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 312063.

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

setting (5-20, in 5 minute increments). This sets the length of inactive time before the unit will enter standby.

4. Turn main power switch OFF to

save changes.

312062W 37

Shutdown

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. Shut off , , and heat

zones.

2. Park pumps.

a. Press .

b. Trigger gun until pump A stops in the

retracted position and the pressure of both pumps bleeds down.

9. Close both fluid supply valves (FV).

ti9883a

10. Shut down feed pumps as required.

3. Turn main power OFF .

4. Relieve pressure, page 39.

5. Turn off the air compressor and air dryer, if included.

6. Open air compressor bleed valve to relieve pressure and remove water from tank.

7. Turn off the main breaker on the generator.

8. Allow generator dwell time, per manufacturer recommendations, prior to shutdown.

38 312062W

Pressure Relief Procedure

5. Turn PRESSURE RELIEF/SPRAY valves

1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual.

2. Engage gun piston safety lock.

ti2409a

(SA, SB) to PRESSURE RELIEF/CIRCU-

LATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to

ti9879a

3. Close gun fluid manifold valves A and B.

ti2421a

4. Shut off feed pumps and agitator, if used.

6. Disconnect gun air line and remove gun fluid manifold.

ti2554a

312062W 39

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 41.

1. Follow Startup procedures, page 30.

Do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpres-

sure relief valves when set to SPRAY . Lines must be open so valves can automatically relieve pressure when machine is operating.

2. See Typical Installation, with circulation, page 14. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working pressure of this equipment. See Technical Data, page 49.

3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCU-

LATION .

ti9879a

4. Turn main power ON .

5. Set temperature targets, see page 31. Turn

on and heat zones by pressing

. 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 circu-

late fluid until and tempera-

tures reach targets.

ti7732a

8. Press motor to start motor and

pumps. Circulate fluid at lowest possible pressure until temperatures reach targets.

9. Turn on heat zone by pressing .

40 312062W

Fluid Circulation

10.Set PRESSURE RELIEF/SPRAY valves

(SA, SB) to SPRAY .

ti9877a

Circulation Through Gun Manifold

Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.

3. Follow Startup procedures, page 30.

4. Turn main power ON .

5. Set temperature targets, see page 31. Turn

on , , and heat zones by

pressing .

6. Press to display actual temperatures.

7. Before starting motor, reduce hydraulic pressure to the minimum required to circu-

late fluid until and tempera-

tures reach targets.

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.

ti2767a

2. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working pressure of this equipment. See Typical Installation,

without circulation, page 15.

ti7732a

8. Press motor to start motor and

pumps. Circulate fluid at lowest possible pressure until temperatures reach targets.

312062W 41

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.

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 over-temperature Individual

06 Loss of zone communication Individual

30 Momentary loss of communica-

99 Loss of display communication All

Diagnostic Codes

All

tion

See repair manual for corrective action.

For hose zone only, if FTS is disconnected at startup, display will show hose current 0A.

42 312062W

Diagnostic Codes

Motor Control Diagnostic Codes

Motor control diagnostic codes E21 through E27 appear on pressure display.

There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings.

See repair manual for corrective action.

Alarms

Alarms turn off the motor and heat zones. Turn

main power OFF then ON to

clear.

Alarms can also be cleared, except for

code 23, by pressing .

Code 24 (pressure imbalance) is set to an alarm default of 500 psi (3.5 MPa, 35 bar). To change to a warning, see Reactor Repair-Parts manual 312063. To change the default pressure imbalance setting, see page 33.

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

312062W 43

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

• Inspect ISO lubricant level and condition daily, see page 46. Refill or replace as needed.

• 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 4: Frequency of Oil Changes

Ambient Temperature

0 to 90°F (-17 to 32°C)

Recommended Frequency

1000 hours or 12 months, whichever comes first

90°F and above (32°C and above)

500 hours or 6 months, whichever comes first

• 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.

• 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 Technical Data on page 49 and the Approved Anti-Wear (AW) Hydraulic Oils table in the Reactor Repair-Parts manual 312063. If fluid is dark in color, change fluid and filter.

ti10003a

ti7861a

• 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.

44 312062W

Maintenance

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.

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.

5. Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.

59d

59g*

59h

59j

59k

ti9886a

FIG. 6. Fluid Inlet Strainer

* See Reactor Repair-Parts manual 312063 for

fluid filter screen replacements.

1. Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.

2. Place a container under the strainer manifold (59d) to catch fluid. Remove the strainer plug (59j).

3. Remove the screen (59g) from the strainer manifold. Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket (59h) and replace as required.

4. Ensure the pipe plug (59k) is screwed into the strainer plug (59j). Install the strainer plug with the screen (59g) and gasket (59h) in place and tighten. Do not overtighten. Let the gasket make the seal.

312062W 45

Maintenance

Pump Lubrication System

Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible.

Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks.

Important: The return tube (RT) must reach the bottom of the reservoir, to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube (ST) and returned to the pump.

8. The lubrication system is ready for operation. No priming is required.

ti9911a

To change pump lubricant:

1. Relieve pressure, page 39.

2. Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap. Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reattach the

check valve to the inlet hose. See F

. 7.

3. Drain the reservoir and flush it with clean lubricant.

4. When the reservoir is flushed clean, fill with fresh lubricant.

5. Thread the reservoir onto the cap assembly and place it in the bracket.

6. Push the larger diameter supply tube (ST) approximately 1/3 of the way into the reservoir.

. 7. Pump Lubrication System

ti9887a

7. Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom.

46 312062W

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).

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 12.

312062W 47

Dimensions

Dimension in. (mm)

A (height) 55.0 (1397) B (width) 39.6 (1006) C (depth) 18.5 (470) D (front mounting holes) 29.34 (745) E (rear mounting holes) 33.6 (853)

Dimension in. (mm)

F (side mounting holes) 16.25 (413) G (mounting post inner diameter)0.44 (11) H (front mounting post height) 2.0 (51) J (rear mounting post height) 3.6 (92)

Top View

Rear of

Front of

TI9830a

Side View

ti7742a ti7743a

Detail of mounting post height, to

correctly size

mounting bolts

48 312062W

Technical Data

Category Data

Maximum Fluid Working Pressure Models H-25 and H-40: 2000 psi (13.8 MPa, 138 bar)

Model H-50 1 phase: 1700 psi (11.7 MPa, 11.7 bar) Model H-50 3 phase: 2000 psi (13.8 MPa, 138 bar) Models H-XP2 and H-XP3: 3500 psi (24.1 MPa, 241 bar)

Fluid:Oil Pressure Ratio Models H-25 and H-40: 1.91:1

Model H-50: 1.64:1 Models H-XP2 and H-XP3: 2.79:1

Fluid Inlets Component A (ISO): 1/2 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum

Component B (RES): 3/4 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum

Fluid Outlets Component A (ISO): #8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter

Component B (RES): #10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter Fluid Circulation Ports 1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum Maximum Fluid Temperature 190°F (88°C) Maximum Output (10 weight oil at

ambient temperature)

Output per Cycle (A and B) Models H-25 and H-40: 0.063 gal. (0.23 liter)

Line Voltage Requirement 230V 1 phase and 230V 3 phase units: 195-264 Vac, 50/60 Hz

Amperage Requirement See Systems, page 3. 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 90.2 dB(A) Sound pressure,

1 m from equipment Weight Units with 8.0 kW Heaters: 535 lb (243 kg)

Model H-25: 22 lb/min (10 kg/min) (60 Hz)

Model H-XP2: 1.5 gpm (5.7 liter/min) (60 Hz)

Model H-50: 52 lb/min (24 kg/min) (60 Hz)

Model H-40: 45 lb/min (20 kg/min) (60 Hz)

Model H-XP3: 2.8 gpm (10.6 liter/min) (60 Hz)

Model H-50: 0.073 gal. (0.28 liter)

Models H-XP2 and H-XP3: 0.042 gal. (0.16 liter)

400V 3 phase units: 338-457 Vac, 50/60 Hz

See Systems, page 3.

82.6 dB(A)

Units with 12.0 kW Heaters: 597 lb (271 kg)

Units with 15.3 kW Heaters (H-25/H-XP2 models):562 lb (255 kg)

Units with 15.3 kW Heaters (H-40/H-XP3/H-50 models): 597 lb (271 kg)

Units with 20.4 kW Heaters: 597 lb (271 kg) Wetted Parts Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome,

fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, chemically

resistant o-rings

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

312062W 49

Performance Charts

Foam Performance Chart

Performance Charts

2000

(13.8, 138)

A = H-25 at 50 Hz B = H-25 at 60 Hz

1500

(10.3, 103)

1000

69)

(6.9,

C = H-40 at 50 Hz D = H-40 at 60 Hz E = H-50 at 50 Hz ❄F = H-50 at 60 Hz

Pressure in psi (MPa, bar)

500

(3.4, 34)

(2.3)

(6.8)

(11.4)

(15.9)

(20.5)

(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

0.5

(1.9) (3.8) (5.7)

Flow Rate in gal/min (liter/min)

1.0 1.5

2.0 2.5 3.0

(7.6) (9.5) (11.4)

KEY

G = H-XP2 at 50 Hz H= H-XP2 at 60 Hz J = H-XP3 at 50 Hz K = H-XP3 at 60 Hz

50 312062W

Performance Charts

Delta T in degrees F (degrees C)

140

(78)

130

(72)

120

(67)

110

(61)

100

(56)

(50)

(44)

(39)

(33)

(28)

(22)

(17)

(11)

(6)

Heater Performance Chart

KEY

J = 8 kW K = 12 kW L = 15.3 kW M = 20.4 kW

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)

Flow Rate in gpm (lpm)

Heater performance data is based on testing with 10 wt.

★

hydraulic oil and 230V across heater power wires.

4.0

(15.1)

4.5

(17.0)

312062W 51

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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original Instructions.

This manual contains English. MM 312062

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision W, September 2014

Graco H25, H50, H40 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Systems

Models

Supplied Manuals

Related Manuals

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Material Self-ignition

Foam Resins with 245 fa Blowing Agents

Changing Materials

Typical Installation, with circulation

Typical Installation, without circulation

Component Identification

Temperature Controls and Indicators

Main Power Switch

Red Stop Button

Actual Temperature Key/LED

Target Temperature Key/LED

Heater Zone On/Off Keys/LEDs

Temperature Arrow Keys

Temperature Displays

Circuit Breakers

Motor Controls and Indicators

Motor ON/OFF Key/LED

PSI/BAR Keys/LEDs

Pressure Key/LED

PARK Key/LED

Spray Adjustments

Cycle Count Key/LED

Hydraulic Pressure Control Knob

Motor Control Arrow Keys

Setup

Startup

Spraying

Standby

Shutdown

Pressure Relief Procedure

Fluid Circulation

Circulation Through Reactor

Circulation Through Gun Manifold

Diagnostic Codes

Temperature Control Diagnostic Codes

Motor Control Diagnostic Codes

Maintenance

Fluid Inlet Strainer Screen

Pump Lubrication System

Flushing

Dimensions

Technical Data

Performance Charts

Graco Standard Warranty

Graco Information