Graco H25 manual

312062W Operation Hydraulic, Heated, Plur al Component Pr oportioner For spraying polyurethane foam and po lyurea coatings. For professional use only. Not approved for use in European explosive atmosphere locations. See p age 3 for mode l in format ion, incl udin g maximum wo rking p ressure an d appro vals. Important Safety Instructions Read a ll [...]

2 312062W Contents Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Supplied Ma nuals . . . . . . . . . . . . . . . . . . . 7 Related Manuals . . . . . . . . . . . . . . . . . . . . 8 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Important Two-Component[...]

Systems 312062W 3 Systems ★ CE appr oval doe s not appl y. Part Maximu m Fluid Working Pr essure psi (MPa, ba r) Proportioner (see page 3 ) Heated Hose Gun Mix Chamber Kit 50 ft (15 m ) 10 ft (3 m ) Model Part ★ AP3400 2000 (13.8, 138) ★ 253400 246678 246050 Fusion Air Purge 246101 AR5252 AP3401 2000 (13.8, 138) 253401 246678 246050 Fusion Ai[...]

Syst ems 4 312062W Systems Continued ★ CE appr oval doe s not appl y. Part Maximu m Fluid Working Pr essure psi (MPa, ba r) Proportioner (see page 3 ) Heated Hose Gun 50 ft (15 m ) 10 ft (3 m ) Model Part ★ P23400 2000 (13.8, 138) ★ 253400 246678 246050 Probler P2 GCP2R2 P23401 2000 (13.8, 138) 253401 246678 246050 Probler P2 GCP2R2 P23402 20[...]

Models 312062W 5 Models H-25 SE RIES H-40 SE RIES H-50 SE RIES Part, Series Full Load Peak Amps* Per Phase Voltage (phase) System Watts† Prim ary Heater Watts Max Flow Rate ◆ lb/min (kg/min) Appr oxi mat e Output per Cycle (A+B) gal. (liter) Hydrauli c Pressu re Ratio Maximum Fluid Work ing Pressu re psi (MPa, bar) 255400 , F 69 230V (1) 15,960[...]

Models 6 312062W H-XP2 SE RIES H-XP3 SE RIES * Full lo ad amps with a ll devices oper ating a t maxim um capabi lities . Fuse re quiremen ts at va ri- ous flow rate s and mix chambe r sizes may be less. † Total system watt s, based on maximum hose length for each unit : • Parts 25 5400 through 2554 08, 31 0 ft ( 94.6 m ) maxi mum he ated h ose [...]

Supplied Manuals 312062W 7 Supplied Manuals The fol l owing manuals are shipped with the Reactor ™ Propo rtioner. Ref er to these ma nu- als fo r detail ed equip ment inf ormatio n. Order Part 15M334 for a comp act disk of Reacto r manuals tran slated in seve ral lan- guage s. Manual s are also available at www.graco.com . Reactor Hydraulic Pr o [...]

Rela ted M anu als 8 312062W Related Manuals The fol lowing manual s are for accesso ries used with th e Reactor ™ . Order Part 15M334 for a comp act disk of Reacto r manu als translate d in seve ral l an- guage s. Feed Pump Kits Part De scription 309815 Instructio n-Part s Manual (English ) Air Supply Kit Part De scription 309827 Instructio n-Pa[...]

Warnings 312062W 9 Warnings The fol l owi ng warnings are for the setup, use, grou nding, mai ntenance, and repair of this eq uip- ment. The exclamation point symbol alerts you to a genera l warning an d the hazard symbol refe rs to pro cedure- specific risk. R e fer back to these wa rnings. Additional, p roduct-specifi c warnings may be found thro[...]

Warn ings 10 312062W SKIN INJECTION HAZARD High-press ure fluid from gun, hose leaks, or ru ptured components wil l pierce skin. This may look like just a cut, but it is a serious injury that can re sult in amputati on. Get imm edia te surgical tr eatment. • Engage trigger lock when not spraying. • Do not point gun at anyone or at any part of t[...]

Warnings 312062W 11 PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatibl e with aluminum in pressurized equipment can caus e seri- ous chemical reaction an d equipment r upture. Failure to follow thi s warning can result in death, se rious injury, or property damage. • Do not use 1,1,1-tr ichloroethane, methyl ene chlori de, other[...]

Importa n t Two-Com ponent M a teria l Informat ion 12 312062W Important Two-Component Materia l Information Isocyan ate C onditions Material Self-igni tion Keep Co mponent s A and B Separate Moisture Sensitivit y of Isocya nates Isocyanates ( ISO) are catalysts u sed in two comp onent foam an d polyu rea co atings. ISO will react with moisture (su[...]

Importan t Two-Component Material Info rmation 312062W 13 • Use m oisture-proof hoses spec ifically designed for ISO, such as t hose supplie d with your system. • Never use r e claimed solvents, whic h may contain moistu r e. Always keep solvent con- tainer s clos ed when not in u se. • Never use solv ent on one side if it has been c ontam in[...]

Typical Installa tion, with circulat ion 14 312062W Typical Installation, with circulation Key for F IG . 1 A Reactor Pr oportioner B Heated Hose C Flui d Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F Gun Air Sup ply Hose G Feed Pump Air Supply Lines J F luid Supply Lines K Feed Pumps L Agi tator M Desiccant Dr yer P Gun Fluid Ma[...]

Typica l Install ation, without circul ation 312062W 15 Typical Installation, without circula t ion Key for F IG . 2 A Reactor Pr oportioner B Heated Hose C Flui d Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F Gun Air Sup ply Hose G Feed Pump A ir Suppl y Lines H Waste Container s J Fluid Supply Lines K Feed Pumps L Agi tator M D[...]

Component Ide ntification 16 312062W Component Identification Key for F IG . 3 BA Com ponen t A Pres sure R elie f Out let BB Com ponen t B Pres sure R elie f Out let EC Heated Hose Elec trical Connector EM Electric Motor, Fan , and Belt Drive (be hind shroud) FA Compone nt A Fluid Ma nifold Inlet ( on left side of m anifold block) FB Compone nt B [...]

Component Id entification 312062W 17 F IG . 3: Component Identification (H40 1 5 .3 kW Model Shown) Detail of Reactor Fluid Manifold (shroud removed for clarity) ti988 0a TC PA FM FS FP FV PB FH EM RS MC GA GB SB FB BB HB HA BA FA SA HC TA TB SC EC LR FT SR HP MP SN TI 9830a ti7823a Detail of Serial No. Plate (i nside cabinet) SN OP[...]

Temperatu re Controls an d Indicators 18 312062W Temperature Controls and In dicators Main Power Switch Located on right side of unit, page 17. Turns Reacto r power ON and OFF . Does no t turn heate r zones o r pump s on. Red Stop Button Loca ted bet ween te mperat ure co ntrol pa nel and mot or control pane l, page 17. P ress to shut of f motor an[...]

Tempera ture Controls an d Indicators 312062W 19 Actual Temperatur e Key/LED Press to display actual temp erature. Press and hold to display ele ctrical cur- rent. Target Te mperatur e Key/LED Press to display tar get temperatur e. Press an d hold to disp lay heater con trol circuit b oard tempera ture. Tempera ture Scale Keys/LEDs Press or to chan[...]

Temperatu re Controls an d Indicators 20 312062W Circuit Brea kers Located inside Reactor cabinet. * D epen ding on mod el. Ref. Size Component CB1 50 A Hose/Tr ansformer Seco ndary CB2 40 A Transform er Pri mary CB3 25, 40, or 50 A* Heater A CB4 25, 40, or 50 A* Heater B CB5 20 or 30 A* Motor/Pum ps ti9884a CB3 CB4 CB5 CB1 CB2 For wiring and ca bl[...]

Motor Con trols and Indica tors 312062W 21 Motor Controls and Indicators Motor ON /OFF Key/ LED Press to turn motor ON and OFF. Also clears some motor co ntrol diagno stic codes, see pa ge 43. PARK Key/LED Press at end of day t o cycle compone nt A pump to home posi tion, submergi ng dis- placem ent ro d. Trigger gun until pump stop s. Once parked,[...]

Spray Adjustmen ts 22 312062W Cycl e Count Key/L ED Press to display cycle count. Hydraulic Pressu re Control Knob Use to adjust hydr aulic pressu re avai lable to the hydr aulic drive sy stem. Turn knob (HC) clockwise to increa se pressure an d counter- clockwis e to decre ase pressure. U se hydraulic press ure gau ge (HP, page 17 ) to vie w hydra[...]

Setup 312062W 23 Setup 1. Locate R eactor a. Loca te Reactor on a l evel surface. See Dimensions , p age 48, f or clearance and mo unting hol e dimensions . b. Do not exp ose Reactor to rain. c. Use the cast ers to move Reactor to a fixed l ocation , or bolt to shipping pa llet and move with forklift. d. To mo unt on a truc k bed or trail er, remov[...]

Setup 24 312062W • Maintain and inspect the generato r, air compr essor, and ot her equ ipment per the manuf actur er r ecommend ati ons to avo id an unex pec ted sh utdown . Unex pected equi pment s hutd own will ca use volt age fluctua tions that can d amage electri cal equi pmen t. • Use a wal l power supply with enough cur- rent to meet sys[...]

Setup 312062W 25 4. Connect electrical cord Table 2: Powe r Cord Requirements a. 230V, 1 phase: Using 5/32 or 4 mm hex allen wr ench, c onnect two powe r leads to L1 and L2. Connect g r een to ground (GND ). b. 230V, 3 phase: Using 5/32 or 4 mm hex allen wr ench, c onnect three power lea ds to L1, L2, an d L3. Co nnect green to groun d (GND) . Powe[...]

Setup 26 312062W c. 400V, 3 phase : Using 5/3 2 or 4 mm hex allen w rench, connect three power leads to L1 , L2, and L3. Co nnect neut ral to N. Co nnect green to gr ound (GND). 5. Connect feed pumps a. Inst all fee d pumps (K) in comp onent A and B su pply drums. S ee F IG . 1 an d F IG . 2, pages 14 and 15. b. Seal co mponent A dr um and use desi[...]

Setup 312062W 27 6. Connect pressure reli ef lines a. Reco mmen ded: Co nnect high pr essu re hose (R) to relief fittings (BA, BB) of both PRESSURE REL IEF/SPRAY valves, R oute hose back to component A and B drums. See F IG . 1, page 14. b. Alte rnately: Secure supp lied blee d tube s (N) in gr ounded , sea led wast e containe rs (H). See F IG . 2,[...]

Setup 28 312062W 8. Connect heated hose a. Turn main power OFF . b. Assemble heated hose sections, FTS, and whip hose. c. Connec t A and B hoses t o A and B out- lets on Rea ctor fluid manifold (FM). Hoses a re color code d: red for compo- nent A (ISO), blue fo r compo nent B (RES). Fitti ngs are sized to prevent co n- nection erro rs. d. C onnect [...]

Setup 312062W 29 12. Ground system a. Reactor: is grou nded through power cord. S ee page 25. b. Spray gun: connect w hip hose gr ound wire to FTS, pa ge 27. Do not discon - nect wi re or spray without whip hose. c. Fluid sup ply containers: follow your local code. d. Object being sprayed: follow your loca l code. e. Solven t pails used when flu sh[...]

Sta rtup 30 312062W Startup 1. Check ge nerator fuel le vel. Running ou t of fuel will cause voltage fluc- tuat ions t hat can damage electrical equip - ment. 2. Ensure t he main brea ker on the genera- tor is in the off position. 3. St art th e gene rator. Allo w it to reach full operating temperature. 4. Close t he blee d valve on th e air com- p[...]

Startup 312062W 31 h. Use feed p umps to load system. Hold gun fl uid manifo ld over two grounded waste co ntainers. Ope n flui d valves A and B un til cle an, ai r-free fluid comes from valves. Clos e valves. 8. Set te mperature s a. Turn ma in power ON . b. Press or to change tem - peratur e scale. c. Press to display target tempera- tures. d. To[...]

Sta rtup 32 312062W e. Press to display actual temp era- tures. f. Turn o n heat z one by press ing . Preh eat hose (15- 60 min). Ind i- cator will flash very slow ly when fluid reach es targe t tempera ture. Display shows ac tual fl uid te mperat ure in ho se near FTS. g. Tur n on an d hea t zones by press ing for eac h zone . h. Hold to vie w ele[...]

Startup 312062W 33 9. Set pres sure a. Press to display the pressu r e readin g. b. Press mo tor . Motor and pu mps start. Display sho ws system pressure. c. Adjust hydraulic pre ssure control until display shows desired fluid pressure. d. To display cycle cou nt, press . e. Press or to change pres- sure scale. 10. Change pressure i m balance se t [...]

Sta rtup 34 312062W b. Pr ess and hold or , t hen turn main power switch ON . Display will read dP500 fo r psi or dP_ 35 for bar. c. Press or to select desired pressur e diffe rential (100-999 in i ncre- ments o f 100 psi , or 7-70 in in crements of 7 bar ). Se e T ABL E 3. * Factory default se tting. d. Turn main power switch OFF to save chan ges.[...]

Spraying 312062W 35 Spraying 1. Enga ge gun piston safety lock. 2. Clos e gun fl uid man ifold va lves A and B. 3. Attach gun fluid ma nifold. Conne ct gun air line. Open air lin e valve. 4. Set PRES SURE RELIEF/SPRAY valve s (SA, SB) to SPRAY . 5. Check that heat zo nes are on a nd tempera- ture s are on targ et, page 31 . 6. Press motor to start [...]

Spraying 36 312062W 9. Open gun fluid ma nifold valves A a nd B. 10. D iseng age gun pisto n safety lock. 11. Test spray onto cardbo ard. Adjust pressure and tem perature to get desired resu lts. 12. E quipment is rea d y to spray. On impi ngement gun s, never open fl uid manifol d valves or tr igger gun if pres- sures ar e imbalanced. ti241 4a If [...]

Stan dby 312062W 37 Standby If you sto p spraying for a period of time, the unit will enter stan dby by shutting do wn the electr ic motor an d hydraulic p ump, to redu ce equi pment we ar an d minim ize hea t buildu p. The ON/OFF LE D and th e pressure/cycle dis- play on the motor control panel will flash whe n in standby. To restart, spra y off t[...]

Shutdown 38 312062W Shutdown 1. Shut off , , and heat zones. 2. Park pumps. a. Pr ess . b. Trig ger gun until pu mp A stop s in the retra cted position an d the pressu re of both p umps bl eeds down . 3. Turn main power OFF . 4. Reli eve pre ssure, page 39. 5. Turn off the air compressor and a ir dryer, i f includ ed. 6. Open air compr essor blee d[...]

Pressure Relief Proce dure 312062W 39 Pressure Relief Procedure 1. Reli eve pressure in gun and pe rform gun shutdow n procedu re. See gun manual . 2. Enga ge gun piston safety lock. 3. Clos e gun fl uid man ifold va lves A and B. 4. Shut off feed pum ps an d agita tor, if used. 5. Turn PR ESSURE RELIEF/SPR AY valves (SA, SB) to PRESSURE RELIEF/CIR[...]

Fluid C irculation 40 312062W Fluid Circulation Circulatio n Through Reactor To circ ulate throu gh gun manifold a nd pre heat hose, see pa ge 41. 1. Fol low Startu p procedures, page 30. 2. See Typical Ins tallation, with circulation , page 14 . Rout e circula tion lin es back to respective component A o r B supp ly drum. Use hose s rated a t the [...]

Fluid C irculati on 312062W 41 10. Set PRESS U RE RELI EF/SPRAY valves (SA, S B) to SP RAY . Circul ation Thro ugh Gun Manifold Circ ulating f l uid t hrough the gun manifol d allo ws rapi d preh eating of hos e. 1. Inst all gu n fluid ma nifold (P) on Pa rt 246362 accessory circulat ion kit (CK). Co n- nect hi gh pressure circ ulation lines (R) to[...]

Diagnostic Codes 42 312062W Diagnostic Codes Temperature Co ntrol Diagnos tic Codes Temper ature contro l diagnosti c codes app ear on temp erat ure di splay. These al arms turn of f heat. E99 cle ars auto - matica lly when communicati on is regain ed. Codes E03 through E 06 can be cl eared b y press ing . For othe r codes , turn main power OFF the[...]

Diagn ostic Codes 312062W 43 Motor Control Diagn ostic Codes Motor c ontro l diagno stic codes E 21 th rough E27 appea r on pressure display. There are two t ypes of motor co ntrol cod es: alarm s and wa rnings. Alarm s take p riority o ver warning s. See re pair manua l for corre ctive ac tion. Alarms Alarms turn off the m otor and he at zones. Tu[...]

Main tenance 44 312062W Maintenance • Inspect hydr aulic and flui d lines for l eaks daily. • C lean up all h ydraulic le aks; identify and repair cause of leak. • I nspect fluid inlet stra iner screens daily, see below. • Grease circula tion val ves week ly with Fusi on grease (117 773). • Inspec t ISO lu brican t leve l and co ndition d[...]

Maint enanc e 312062W 45 Fluid I nlet Strainer Screen The inle t strainers fil ter out part icles that can plug the pum p inlet c heck valv es. Ins pect the screens da ily as part of the startup routi ne, and clean as requi red. Use clean chemicals and follow proper stor- age, tr ansfer, and op erating procedur es, to minimi ze contaminatio n of th[...]

Main tenance 46 312062W Pump Lubrication Sys tem Check the condi tion of the ISO pu mp lubrican t daily. Change the lubrica nt if it becomes a gel, its col o r dar kens, or it bec omes diluted with isocyana te. Gel fo rmation is due to moisture ab sorption by the pum p lubrican t. The interva l bet ween changes d epends on the en vironmen t in whic[...]

Flushin g 312062W 47 Flushing • Flush out ol d fluid with new fluid, or fl ush out ol d flui d with a co mpatible solv ent befor e intr oduci ng ne w fluid. • Use the lowest possible pressure when flushi ng. • All flui d components a re compatible with commo n solvents. Use only moistur e-free solvent s. • To flush feed hoses, pumps, a nd h[...]

Dimen sio ns 48 312062W Dimensions Dimension in. (mm) A (hei ght) 55. 0 (1397 ) B (wid th) 39. 6 (1006) C (dep th) 18. 5 (470) D (fro nt mounting hole s) 29. 34 (745) E (rear mount ing holes) 33.6 (853) F (side mounting hol es) 16.25 (413) G (mount ing post inner diamet er) 0.44 (11) H (front mounti ng post height ) 2 .0 (5 1) J (rea r mount ing po[...]

Technic al Data 312062W 49 Technical Data All othe r brand names or marks ar e used for i dentif ication p urposes an d are tr ademarks o f their respecti ve owner s. Category Data Maxim um Fluid W orking Pr essure Model s H-25 and H -40: 2 000 psi (13 .8 MPa , 138 bar) Model H- 50 1 phas e: 1700 ps i (11.7 M Pa, 11.7 ba r) Model H- 50 3 phas e: 20[...]

Performance Cha rts 50 312062W Performance Charts Coatings Performance Chart Foam Performance Chart Flow Rate in lb/min (kg/min) Pressure in psi (MPa, bar) Pressur e in psi ( MPa, bar) Flow Rate in gal/min (li ter/min) 0 0 0.5 1.0 1.5 2.0 2.5 3.0 (1.9) (3.8) (5.7) (7.6) (9.5) (1 1.4) 3500 (24.1, 24 1) 1000 (6.9, 69) 1500 (10.3, 10 3) 2000 (13.8, 13[...]

Performance Charts 312062W 51 Heater P erformance Chart Flow Rate in gpm (lpm) Delta T in degrees F (degrees C) 0 0.5 (1.9) 2.0 (7.6 ) 1.0 (3.8) 2.5 (9.5) 1.5 (5.7) 4.0 (15.1) 3.0 (11.4) 3.5 (13.2) 4.5 (17.0) KEY J = 8 kW K = 12 k W L = 15.3 kW M = 2 0.4 kW 10 (6) 90 (50) 80 (44) 70 (39) 60 (33) 50 (28) 40 (22) 30 (17) 20 (11) 140 (78) 130 (72) 120[...]

All written and visual data contained in this document reflects the lat es t product i nformation available at the time of publica tion. Graco rese rves the right to m ake changes at any time without notice. For patent information, see www.graco.com/patents. This ma nual con tains Eng lish. M M 312062 Graco H eadquarters: Min neapolis International[...]