Graco 334945B manual

Operation Reactor® Reactor® Reactor® 2 2 2 Hydraulic Hydraulic Hydraulic Proportioning Proportioning Proportioning Systems Systems Systems 334945B EN Hydraulic, Hydraulic, Hydraulic, Heated, Heated, Heated, Plural Plural Plural Component Component Component Proportioner Proportioner Proportioner for for for spraying spraying spraying polyurethan[...]

Contents Contents Contents Warnings .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. 3 Important Isocyanate Information .. . .. .. .. .. .. .. . .. .. .. .. . 7 Models .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . . 9 Approvals ... .. . .. .. .. .. .. . .. .[...]

Warnings Warnings Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specic risks. When these symbols appear in the body of this manual or on warning labels, refer back to thes[...]

Warnings WARNING WARNING WARNING SKIN SKIN SKIN INJECTION INJECTION INJECTION HAZARD HAZARD HAZARD High-pressure uid from dispensing device, 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 Get Get immediate immediate immediate surgical surgical surg[...]

Warnings WARNING WARNING WARNING PRESSURIZED PRESSURIZED PRESSURIZED ALUMINUM ALUMINUM ALUMINUM PARTS PARTS PARTS HAZARD HAZARD HAZARD Use of uids 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 [...]

Warnings WARNING WARNING WARNING EQUIPMENT EQUIPMENT EQUIPMENT MISUSE MISUSE MISUSE HAZARD HAZARD HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the inuence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Techn[...]

Important Isocyanate Information Important Important Important Isocyanate Isocyanate Isocyanate Information Information Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Isocyanate Isocyanate Conditions Conditions Conditions Spraying or dispensing uids that contain isocyanates creates potentially harmful mis[...]

Important Isocyanate Information Material Material Material Self Self Self - - - Ignition Ignition Ignition Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and SDS. Keep Keep Keep Components Components Components A A A and and and B B B Separate Separate Separate Cross-contamination can result i[...]

Models Models Models Models Reactor Reactor Reactor 2 2 2 H H H - - - 30 30 30 and and and H H H - - - 30 30 30 Elite Elite Elite H H H - - - 30 30 30 Model Model Model H H H - - - 30 30 30 Elite Elite Elite Model Model Model Model Model Model 10 10 10 kW kW kW 15 15 15 kW kW kW 10 10 10 kW kW kW 15 15 15 kW kW kW Proportioner Proportioner Proporti[...]

Models Reactor Reactor Reactor 2 2 2 H H H - - - 40 40 40 and and and H H H - - - 40 40 40 Elite Elite Elite H H H - - - 40 40 40 Model Model Model H H H - - - 40 40 40 Elite Elite Elite Model Model Model Model Model Model 15 15 15 kW kW kW 20 20 20 kW kW kW 15 15 15 kW kW kW 20 20 20 kW kW kW Proportioner Proportioner Proportioner ★ 17H043 17H04[...]

Models Reactor Reactor Reactor 2 2 2 H H H - - - 40 40 40 and and and H H H - - - 40 40 40 Elite Elite Elite (Continued) (Continued) (Continued) H H H - - - 40 40 40 Model Model Model H H H - - - 40 40 40 Elite Elite Elite Model Model Model Model Model Model 15 15 15 kW kW kW 20 20 20 kW kW kW 15 15 15 kW kW kW 20 20 20 kW kW kW Proportioner Propor[...]

Models Reactor Reactor Reactor 2 2 2 H H H - - - 50 50 50 and and and H H H - - - 50 50 50 Elite Elite Elite H H H - - - 50 50 50 Model Model Model H H H - - - 50 50 50 Elite Elite Elite Model Model Model Model Model Model 20 20 20 kW kW kW 20 20 20 kW kW kW 20 20 20 kW kW kW 20 20 20 kW kW kW Proportioner Proportioner Proportioner ★ 17H053 17H05[...]

Models Reactor Reactor Reactor 2 2 2 H H H - - - XP2 XP2 XP2 and and and H H H - - - XP2 XP2 XP2 Elite Elite Elite H H H - - - XP2 XP2 XP2 Model Model Model H H H - - - XP2 XP2 XP2 Elite Elite Elite Model Model Model Model Model Model 15 15 15 kW kW kW 15kW 15kW 15kW Proportioner Proportioner Proportioner ★ 17H062 17H162 Maximum Maximum Maximum F[...]

Models Reactor Reactor Reactor 2 2 2 H H H - - - XP3 XP3 XP3 and and and H H H - - - XP3 XP3 XP3 Elite Elite Elite H H H - - - XP3 XP3 XP3 Model Model Model H H H - - - XP3 XP3 XP3 Elite Elite Elite Model Model Model Model Model Model 20 20 20 kW kW kW 20 20 20 kW kW kW 20 20 20 kW kW kW 20 20 20 kW kW kW Proportioner Proportioner Proportioner ★ [...]

Approvals Approvals Approvals Approvals Intertek approvals apply to proportioners without hoses. Proportioner Proportioner Proportioner Approvals: Approvals: Approvals: 9902471 9902471 9902471 Conforms to ANSI/UL Std. 499 Certied to CAN/CSA Std. C22.2 No. 88 Accessories Accessories Accessories Kit Kit Kit Number Number Number Description Descrip[...]

Supplied Manuals Supplied Supplied Supplied Manuals Manuals Manuals The following manuals are shipped with the Reactor 2 . Refer to these manuals for detailed equipment information. Manuals are also available at www.graco.com. Manual Manual Manual Description Description Description 334945 Reactor 2 Hydraulic Proportioning Systems Operation Manual [...]

Typical Installation, without circulation Typical Typical Typical Installation, Installation, Installation, without without without circulation circulation circulation B G K M J G H K L J D S C* P E A N (B-RES) (A-ISO) F N Figure 1 * Shown exposed for clarity. Wrap with tape during operation. A Reactor Proportioner B Heated Hose C Fluid Temperature[...]

Typical Installation, with system uid manifold to drum circulation Typical Typical Typical Installation, Installation, Installation, with with with system system system uid uid uid manifold manifold manifold to to to drum drum drum circulation circulation circulation (B-RES) M K M R J G H K L B D S C* P E R A (A-ISO) G J F Figure 2 * Sh[...]

Typical Installation, with gun uid manifold to drum circulation Typical Typical Typical Installation, Installation, Installation, with with with gun gun gun uid uid uid manifold manifold manifold to to to drum drum drum circulation circulation circulation (B-RES) M K M R J G H K L B J D S C* P E R (A-ISO) G A N N F Figure 3 * Shown expo[...]

Component Identication Component Component Component Identication Identication Identication B D S C* P E Figure 4 20 334945B[...]

Component Identication Key Key Key BA ISO Side Pressure Relief Outlet BB RES Side Pressure Relief Outlet CD Advanced Display Module (ADM) EC Electrical Cord Strain Relief EM Electric Motor (behind shroud) FA ISO Side Fluid Manifold Inlet FB RES Side Fluid Manifold Inlet FH Fluid Heater (behind shroud) FM Reactor Fluid Manifold FV Fluid Inlet Val[...]

Component Identication Advanced Advanced Advanced Display Display Display Module Module Module (ADM) (ADM) (ADM) The ADM display shows graphical and text information related to setup and spray operations. Figure 5 ADM Front View NOTICE NOTICE NOTICE To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, p[...]

Component Identication Figure 6 ADM Back View CJ Flat Panel Mount (VESA 100) CK Model and Serial Number CL USB Port and Status LEDs CM CAN Communication Cable Connection CN Module Status LEDs CP Accessory Cable Connection CR Token Access Cover CS Backup Battery Access Cover Table Table Table 2 2 2 ADM ADM ADM LED LED LED Status Status Status Des[...]

Component Identication ADM ADM ADM Display Display Display Details Details Details Power Power Power Up Up Up Screen Screen Screen The following screen appears when the ADM is powered up. It remains on while the ADM runs through initialization and establishes communication with other modules in the system. Menu Menu Menu Bar Bar Bar The menu bar[...]

Component Identication Icons Icons Icons Icons Icons Icons Icon Icon Icon Function Function Function Component A Component B Estimated Supply Material Hose Temperature Pressure Cycle Counter (press and hold) Advisory. See Troubleshoot Errors, page 60 for more information. Deviation. See Troubleshoot Errors, page 60 for more information. Alarm. S[...]

Component Identication Electrical Electrical Electrical Enclosure Enclosure Enclosure H-40, H-40, H-40, H-50, H-50, H-50, H-XP3 H-XP3 H-XP3 AAA Temperature Control Module (TCM) AAB Hydraulic Control Module (HCM) AAC Enclosure Fan(s) AAD Wiring Terminal Blocks (H-30/H-XP2 only) AAE Power Supply AAF Sacricial Surge Protector (SSP) AAG Hose Brea[...]

Component Identication Hydraulic Hydraulic Hydraulic Control Control Control Module Module Module (HCM) (HCM) (HCM) Figure 7 Description Description Description MS Module Status LEDs see LED Status Table 1 CAN Communication Connections 2 Motor Over-Temperature 6 A Pump Output Pressure 7 B Pump Output Pressure 8 A Fluid Inlet Sensor 9 B Fluid Inl[...]

Component Identication Temperature Temperature Temperature Control Control Control Module Module Module (TCM) (TCM) (TCM) Cable Cable Cable Connections Connections Connections Figure 8 1 Power Input 2 Heater Overtemperature 3 CAN Communications Connections 4 Power Out Heater A (ISO) 5 Power Out Heater B (Res) 6 Power Out (Heated Hose) 7 Module S[...]

Setup Setup Setup Setup Grounding Grounding Grounding 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: System is grounded thro[...]

Setup Connect Connect Connect Power Power Power NOTE: NOTE: NOTE: All electrical wiring must be done by a qualied electrician and comply with all local codes and regulations. 1. Turn main power switch (MP) OFF. 2. Open electrical enclosure door. NOTE: NOTE: NOTE: Terminal jumpers are located inside the electrical enclosure door if equipped. 3. I[...]

Setup Lubrication Lubrication Lubrication System System System Setup Setup Setup Component Component Component A A A (ISO) (ISO) (ISO) Pump: Pump: Pump: Fill ISO lube reservoir (LR) with Graco Throat Seal Liquid (TSL), part 206995 (supplied). 1. Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap. 2. Fill[...]

Advanced Display Module (ADM) Operation Advanced Advanced Advanced Display Display Display Module Module Module (ADM) (ADM) (ADM) Operation Operation Operation When main power is turned on by turning the main power switch (MP) to the ON position, the power up screen will be displayed until communication and initialization is complete. Then the powe[...]

Advanced Display Module (ADM) Operation Setup Setup Setup Mode Mode Mode The ADM will start in the Run screens at the Home screen. From the Run screens, press to access the Setup screens. The system defaults with no password, entered as 0000. Enter the current password then press . Press to navigate through the Setup Mode screens. See Setup Screens[...]

Advanced Display Module (ADM) Operation Setup Setup Setup Screens Screens Screens Navigation Navigation Navigation 34 334945B[...]

Advanced Display Module (ADM) Operation Advanced Advanced Advanced Setup Setup Setup Screens Screens Screens Advanced setup screens enable users to set units, adjust values, set formats, and view software information for each component. Press to scroll through the Advanced setup screens. Once in the desired Advanced setup screen, press to access th[...]

Advanced Display Module (ADM) Operation System System System 1 1 1 Use this screen to set the activation pressure for the Pressure Imbalance Alarm and Deviation, enable or disable diagnostic screens, set the maximum and minimum drum volume, and enable drum alarms. System System System 2 2 2 Use this screen to enable Manual Hose Mode and inlet senso[...]

Advanced Display Module (ADM) Operation Recipes Recipes Recipes Use this screen to add recipes, view saved recipes, and enable or disable saved recipes. Enabled recipes can be selected at the Home Run Screen. 24 recipes can be displayed on the three recipe screens. Add Add Add Recipe Recipe Recipe 1. Press and then use to select a recipe eld. Pr[...]

Advanced Display Module (ADM) Operation Run Run Run Mode Mode Mode The ADM will start in the Run screens at the “Home” screen. Press to navigate through the Run Mode screens. See Run Screens Navigation Diagram, page 44 . From the Run screens, press to access the Setup screens. Run Screens Navigation Diagram Figure 9 38 334945B[...]

Advanced Display Module (ADM) Operation Home Home Home — — — System System System Off Off Off This is the home screen when the system is off. This screen displays actual temperatures, actual pressures at the uid manifold, and number of cycles. Home Home Home — — — System System System Active Active Active When the system is active, t[...]

Advanced Display Module (ADM) Operation Maintenance Maintenance Maintenance Use this screen to view daily and lifetime cycles or gallons that have been pumped and gallons or liters remaining in the drums. The lifetime value is the number of pump cycles or gallons since the rst time the ADM was turned on. The daily value automatically resets at m[...]

Advanced Display Module (ADM) Operation Troubleshooting Troubleshooting Troubleshooting This screen displays the last ten errors that occurred on the system. Use the up and down arrows to select an error and press to view the QR code for the selected error. Press to access the QR code screen for an error code that is not listed on this screen. See [...]

Advanced Display Module (ADM) Operation Diagnostic Diagnostic Diagnostic Use this screen to view information for all system components. NOTE: If not visible, this screen may be on the Setup Systems screen (see Setup Mode ). The following information is displayed: Temperature Temperature Temperature • A Chemical • B Chemical • Hose Chemical ?[...]

Advanced Display Module (ADM) Operation System System System Events Events Events Use the table below to nd a description for all system non-error events. All events are logged in the USB log les. Event Event Event Code Code Code Description Description Description EACX Recipe Selected EADA Heat On A EADB Heat On B EADH Heat On Hose EAPX Pump[...]

Startup Startup Startup Startup To prevent serious injury, only operate Reactor with all covers and shrouds in place. NOTICE NOTICE 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 uc[...]

Startup 9. Switch on the air compressor, air dryer, and breathing air, if included. 10. For For For rst rst rst startup startup startup of of of new new new system, system, system, load load load uid uid uid with with with feed feed feed pumps. pumps. pumps. a. Check that all Setup Setup Setup steps are complete. See Setup, page 2[...]

Startup 11. Press to activate ADM. 12. If necessary, setup the ADM in Setup Mode. See Advanced Display Module (ADM) Operation, page 32 . 13. Preheat the system: a. Press to turn on hose heat zone. This equipment is used with heated uid which can cause equipment surfaces to become very hot. To avoid severe burns: • Do not touch hot uid or eq[...]

Fluid Circulation Fluid Fluid Fluid Circulation Circulation Circulation Circulation Circulation Circulation Through Through Through Reactor Reactor Reactor NOTICE NOTICE NOTICE To prevent equipment damage, do not circulate uid containing a blowing agent without consulting with your material supplier regarding uid temperature limits. NOTE: NOT[...]

Fluid Circulation Circulation Circulation Circulation Through Through Through Gun Gun Gun Manifold Manifold Manifold NOTICE NOTICE NOTICE To prevent equipment damage, do not circulate uid containing a blowing agent without consulting with your material supplier regarding uid temperature limits. NOTE: NOTE: NOTE: Optimum heat transfer is achie[...]

Spraying Spraying Spraying Spraying The Fusion AP gun is shown. 1. Engage gun piston safety lock and close gun uid inlet valves A and B. Fusion Fusion Fusion Probler Probler Probler 2. Attach gun uid manifold. Connect gun air line. Open air line valve. 3. Adjust the gun air pressure. Do not exceed 130 psi (0.2 MPa, 2 bar). 4. Set PRESSURE REL[...]

Spraying 9. Check uid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly slightly slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF/CIRCULATION until gauges show balanced pressures. SA SB GA GB 10. Open gun uid inlet valves A and B. Fu[...]

Spraying Manual Manual Manual Hose Hose Hose Heat Heat Heat Mode Mode Mode If the system produces the T6DH Sensor Error Hose alarm or the T6DT Sensor Error TCM alarm, use manual hose heat mode until the hose RTD cable or FTS temperature sensor can be repaired. Do not use Manual Hose Mode for extended periods of time. The system performs best when t[...]

Spraying 5. Navigate back to the Run Mode Home screen. The hose now displays a current instead of a temperature. NOTE: NOTE: NOTE: Until the RTD sensor is repaired, the T6DH sensor error alarm will display each time the system is powered up. Disable Disable Disable Manual Manual Manual Hose Hose Hose Mode Mode Mode 1. Enter Setup Mode and navigate [...]

Standby Standby Standby Standby If you stop spraying for a period of time, the unit will enter standby by shutting down the electric motor and hydraulic pump, to reduce equipment wear and minimize heat buildup. The pump icon on the ADM Home screen will ash when in standby. NOTE: NOTE: NOTE: The A, B, and Hose heat zones will not shut off during [...]

Shutdown Shutdown Shutdown Shutdown NOTICE NOTICE 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 uctuations that can damage electrical equipment and void the warranty. 1. Press to s[...]

Pressure Relief Procedure Pressure Pressure Pressure Relief Relief Relief Procedure Procedure 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 uid, such as skin injection, splashing uid and moving p[...]

Flushing Flushing Flushing Flushing To avoid re and explosion: • Flush equipment only in a well-ventilated area. • Ensure main power is off and heater is cool before ushing. • Do not turn on heater until uid lines are clear of solevent. To ush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY v[...]

Maintenance Maintenance Maintenance Maintenance Prior to performing any maintenance procedures, follow Pressure Relief Procedure, page 55 . Preventative Preventative Preventative Maintenance Maintenance Maintenance Schedule Schedule Schedule The operating conditions of your particular system determine how often maintenance is required. Establish a [...]

Maintenance Gun Gun Gun Check Check Check Valve Valve Valve Screens Screens Screens Clean gun check valve screens regularly. See gun manual. Dust Dust Dust Protection Protection Protection Use clean, dry, oil-free compressed air to prevent dust buildup on control modules, fans, and motor (under shield). Vent Vent Vent Holes Holes Holes Keep vent ho[...]

Maintenance Pump Pump Pump Lubrication Lubrication Lubrication System System 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 en[...]

Errors Errors Errors Errors View View View Errors Errors Errors When an error occurs the error information screen displays the active error code and description. The error code, alarm bell, and active errors will scroll in the status bar. For a list of the ten most recent errors see Troubleshooting . Error codes are stored in the error log and disp[...]

Error Codes and Troubleshooting Error Error Error Codes Codes Codes and and and Troubleshooting Troubleshooting Troubleshooting See system repair manual 334946 or visit http://help.graco.com for causes and solutions to each error code, or call your Graco contact listed on the back page of this manual. USB USB USB Data Data Data Download Download Do[...]

Error Codes and Troubleshooting Job Job Job Log Log Log The job log le name is 2–JOB.CSV and is stored in the DATAxxxx folder. The job log maintains a record of data points based on the USB Log Frequency dened in the Setup screens. The ADM stores the last 237,000 data points for download. See Setup - Advanced Screen 3 — USB, page 35 , for[...]

Error Codes and Troubleshooting Custom Custom Custom Language Language Language File File File The custom language le name is DISPTEXT.TXT and is stored in the DOWNLOAD folder. A custom language le automatically downloads each time a USB ash drive is inserted into the ADM. If desired, use this le to create a user-dened set of custom [...]

Performance Charts Performance Performance Performance Charts Charts Charts Use this chart to help identify the proportioner that will work most efciently with each mix chamber. Flow rates are based on a material viscosity of 60 cps. NOTICE NOTICE NOTICE To prevent system damage, do not pressurize the system above the line for the gun tip size b[...]

Performance Charts Coatings Coatings Coatings Performance Performance Performance Chart Chart Chart Table Table Table 8 8 8 Coatings Coatings Coatings Performance Performance Performance Chart Chart Chart 2000 (13.8, 138) 2500 (17.2, 172) 3000 (20.7, 207) 3500 (24.1, 241) 1500 (10.3, 103) 0 1.0 (3.8) 1.5 (5.7) 2.0 (7.6) 0.5 (1.9) 3.0 (11.4) 2.5 (9.[...]

Technical Specications Technical Technical Technical Specications Specications Specications Reactor Reactor Reactor 2 2 2 Hydraulic Hydraulic Hydraulic Proportioning Proportioning Proportioning System System System U.S. U.S. U.S. Metric Metric Metric Maximum Maximum Maximum Fluid Fluid Fluid Working Working Working Pressure Pressure Pre[...]

Technical Specications Line Line Line Voltage Voltage Voltage Options Options Options 230V 1 phase and 230V 3 phase units: 195–264 Vac, 50/60 Hz 400V 3 phase units: 338–457 Vac, 50/60 Hz Amperage Amperage Amperage Requirement Requirement Requirement (phase) (phase) (phase) See the Models listing in the manual. Heater Heater Heater Power Powe[...]

Notes Notes Notes Notes 68 334945B[...]

Dimensions Dimensions Dimensions Dimensions 334945B 69[...]

Graco Graco Graco Extended Extended Extended Warranty Warranty 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. Graco will, for a period as dened in the table below from t[...]