Graco REACTOR A-25 Operation
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Graco REACTOR A-25 Operation

Air operated, electrically heated, plural component proportioner
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Operation
P L U R A L C O M P O N E N T P R O P O R T I O N E R
Air operated, electrically heated, plural component proportioner
For spraying or dispensing 1:1 ratio polyurethane foam formulations and other 1:1 fast
setting materials.
Not for use in explosive atmospheres or hazardous locations.
This model is field-configurable to the following supply voltages:
230 V, 1 Phase
230 V, 3 Phase
380 V, 3 Phase
2000 psi (14 MPa, 138 bar) Maximum Fluid Working Pressure
80 psi (550 kPa, 5.5 bar) Maximum Air Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 10 for model information, including maxi-
mum working pressure and approvals.
®
A-25
3A1569C
EN
ti16811b

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Summary of Contents for Graco REACTOR A-25

  • Page 1 Operation ® A-25 3A1569C P L U R A L C O M P O N E N T P R O P O R T I O N E R Air operated, electrically heated, plural component proportioner For spraying or dispensing 1:1 ratio polyurethane foam formulations and other 1:1 fast setting materials.

  • Page 2: Table Of Contents

    Setup ........16 Locate Reactor A-25 ..... 16 Determine Power Source .

  • Page 3: Proportioner Models

    246050 ™ 262572 Fusion CS2572 2000 (14, 138) 246678 246050 ™ CS01RD 262572 Fusion Related Manuals Manuals are available at www.graco.com. Manual Description Component manuals in English: 309550 ™ Fusion AP Spray Gun, Instructions-Parts 312666 ™ Manual Description Fusion CS Spray Gun, Instructions-Parts...

  • Page 4: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
  • Page 5 Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
  • Page 6 Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.

  • Page 7: Important Two-Component Material Information

    Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates. • Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific haz- ards and precautions related to isocyanates.

  • Page 8: For All Applications Except Spray Foam

    Important Two-Component Material Information For all applications except spray Keep Components A and B foam Separate Cross-contamination can result in cured material in fluid Spraying or dispensing fluids that contain isocyanates lines which could cause serious injury or damage equip- creates potentially harmful mists, vapors, and atomized ment.

  • Page 9: Foam Resins With 245 Fa Blowing Agents

    Important Two-Component Material Information 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 sys- tem. Changing Materials NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage...

  • Page 10: Typical Installation, Without Circulation

    Typical Installation, without Circulation Typical Installation, without Circulation ti16812a * Shown exposed for clarity. Wrap with tape during operation. . 1: Typical Installation, without Circulation Key for F Reactor Proportioner Desiccant Dryer Heated Hose Bleed Lines/Over Pressure Relief Fluid Temperature Sensor (FTS) Gun Fluid Manifold Heated Whip Hose Spray Gun...

  • Page 11: Typical Installation, With Circulation

    Typical Installation, with Circulation Typical Installation, with Circulation Key for F Reactor Proportioner Feed Pump Air Supply Lines Heated Hose Fluid Supply Lines Fluid Temperature Sensor (FTS) Feed Pumps Heated Whip Hose Agitator (if required) Spray Gun Desiccant Dryer Proportioner and Gun Air Supply Hose Recirculation/Over Pressure Relief Return Hoses Gun Fluid Manifold ti16813b...

  • Page 12: Component Identification

    Component Identification Component Identification . 3: Typical Installation 3A1569C...
  • Page 13 Component Identification Key: Main Disconnect Switch - Controls power to AH *Primary Heater Over-Temperature Switches - heating circuits. I Sends signal to temperature controller if heater exceeds maximum temperature condition. Main Air Filter - Filters system air supply. AI Resin (B) Pump Wet Cup - Access for daily wet cup refill.
  • Page 14 Component Identification Control Panel DataTrak (optional) See page 34. See Tempera- ture Controls and Indicators E L EC T R O N IC M O N I T O R IN G S Y S T E M Air Motor Pressure Gauge Air Motor Shutoff Valve...
  • Page 15 Component Identification Main Power Switch Temperature Displays Located on right side of unit, page 12. Turns heater 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 power ON and OFF .

  • Page 16: Setup

    Setup Locate Reactor A-25 Electrical Requirements 1. Locate Reactor A-25 on a level surface and bolt in place to the floor with 3/8 in. (10 mm) bolts, unless the Reactor needs to remain portable. Improper wiring may cause electric shock or other •...
  • Page 17 Setup Configure to Supply Power 230V, 1 Phase: Use a screwdriver to connect two power leads to the top two middle terminal positions as shown. Connect green to ground (GND). See page 18 for proper jumper positions. NOTE: Both cord connection AND jumper positioning NOTE: Disregard terminal numbers on disconnect steps on page 18 must be completed.
  • Page 18 Setup Step Two - Install Power Jumpers 1. Turn screws counter-clockwise on the upper part of the shroud until they stop. Pull door up and out. Find location for power jumpers which are in a plastic bag tie wrapped to the ground lug. 2.

  • Page 19: Ground System

    Setup Ground System Fluid Supply Connections Feed pumps are typically used. Siphon feeding is not recommended. Connect material supply to inlets of proportioning unit as follows: The equipment must be grounded to reduce the risk 1. Connect fluid inlet ball valves (U.X) and y-strainers of static sparking and electric shock.

  • Page 20: Recirculation / Pressure Relief Lines

    Recirculation / Pressure Relief Connect Heated Hose Lines NOTE: See heated hose manual for detailed instruc- tions for Graco heated hoses. NOTICE Do not install shutoffs downstream of the The fluid temperature sensor (FTS) and whip hose PRESSURE RELIEF/SPRAY valve outlets (BA, BB).
  • Page 21 Setup NOTE: For proportioners with termination box (TB), fol- low step 5. For proportioners with electrical splice con- nectors (NN) follow step 6. Connect FTS cables (SS). 5. Connect hose power wires to terminal block (C) on termination box (TB). Remove box cover (D) and loosen lower strain relief (E).

  • Page 22: Close Gun Fluid Inlet Valves A And B

    Setup Close Gun Fluid Inlet Valves A Connect Whip Hose to Gun or and B Gun Fluid Manifold For Probler P2 guns: Connect hoses to inlet valves. For Fusion guns: Connect hoses to inlet manifold. Do not connect manifold to gun. Fusion AP Gun shown.

  • Page 23: Initial Startup

    Initial Startup Initial Startup 6. Purge air from hoses. a. For Probler P2 guns: Loosen hose fittings and bleed out air until air-free fluid comes from Do not operate Reactor without all covers and hoses. shrouds in place. Load Fluid with Feed Pumps b.

  • Page 24: Set Temperatures

    Initial Startup Set Temperatures 6. Turn on heat zones by pressing for each zone. See Setup, page 16. 7. Hold to view electrical currents for each zone. 1. Turn main power ON 8. Hold to view heater control circuit board tem- °...

  • Page 25: Supply Wet-Cups With Throat Seal Liquid

    Initial Startup Supply Wet-Cups with Throat Seal Liquid Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from wet-cup during operation. Close main air valve before filling wet-cup. 1.

  • Page 26: Spraying

    Spraying Spraying The Fusion AP gun is shown. 5. Open air inlet ball valve (DD). 1. After reaching spray temperatures, engage gun piston safety lock. ti17573a ti2409a 6. Turn the air regulator counterclockwise to 0 2. Close gun fluid inlet valves A and B. pressure.

  • Page 27: Spray Adjustments

    Spraying 9. Slowly increase the air regulator setting until the Spray Adjustments approximate stall (static) pressure is achieved on fluid gauges (GA) and (GB). 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.

  • Page 28: Park

    Park Park 5. Engage gun piston safety lock. Park the pumps at the end of the day to cycle propor- tioner pumps to home position, submerging displace- ment rod. ti2409a 1. Open the park valve. 6. Close gun fluid inlet valves A and B. ti2421a Open Close...

  • Page 29: Flushing

    Flushing Flushing Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. • Flush out old fluid with new fluid, or flush out old fluid with a compatible moisture-free solvent. •...

  • Page 30: Operation

    Operation Operation Daily Start-up Procedure 8. Check that hose setpoint temperature is correct. 9. Turn on all three heat zones. 10. The hose power controller automatically adjusts the hose current to the hose to compensate for hose NOTE: The daily start-up procedures describe normal length and ambient temperature.
  • Page 31 Operation 15. Check A and B fluid pressure gauges (GA, GB) to ensure proper pressure balance between A and B. If imbalanced, bleed off the high side with valves SA and SB until balanced. ti8442a 16. Open gun fluid manifold valves A and B. The Fusion AP gun is shown.

  • Page 32: Fluid Circulation

    Fluid Circulation Fluid Circulation Circulation Through Reactor 5. Set temperature targets, see page 24. Turn on heat zones by pressing Do not turn on heat zone unless hoses are Do not circulate fluid containing a blowing agent already loaded with fluid. without consulting with your material supplier regarding fluid temperature limits.

  • Page 33: Circulation Through Gun Manifold

    Fluid Circulation Circulation Through Gun 5. Set temperature targets, see page 24. Turn on Manifold , and heat zones by pressing Do not circulate fluid containing a blowing agent without consulting with your material supplier 6. Press to display actual temperatures. regarding fluid temperature limits.

  • Page 34: Datatrak Controls And Indicators

    DataTrak Controls and Indicators DataTrak Controls and Indicators The DataTrak on the Reactor A-25 sprayers do not have runaway protection. For setup and operation instructions see DataTrak Operation, page 35. Key for F AB Combined Lower Displacement (user settable) RK Reset Key (Resets faults. Press and hold for 3 seconds to clear the batch totalizer.) Push to toggle between flow rate...

  • Page 35: Datatrak Operation

    DataTrak Operation DataTrak Operation NOTE: The display (AE) will turn off after 1 minute to Counter/Totalizer save battery life. Press any key to wake up the display. See F . 4, page 34. The last digit of the batch totalizer (BT) represents tenths of gallons or liters.

  • Page 36: Maintenance

    Maintenance Maintenance • Check and add TSL to B side pump wet-cup daily. • Check ISO lube bottle for significant discoloration or crystallization daily. Replace with fresh TSL when needed. • Ensure ISO (A) pump is down and in PARK position during every shutdown.

  • Page 37: Diagnostic Codes

    Leak during downstroke. Worn intake valve. Low Battery Battery voltage too low to stop Low battery. Replace battery; runaway. see Reactor A-25 Repair manual. Blown Fuse Fuse is blown. Replace fuse; • Faulty solenoid or solenoid see Reactor A-25 Repair wiring.

  • Page 38: Dimensions

    Dimensions Dimensions ti17605a With Wheels Without Wheels Dimension in. (mm) in. (mm) 43.5 (1105) 43.5 (1105) 29 (736.6) 21.5 (546) 30 (762) 24.5 (622) 3A1569C...

  • Page 39: Technical Data

    Technical Data Technical Data Category Data Maximum Fluid Working Pressure 2000 psi (14 MPa, 138 bar) Maximum Air Supply Pressure 125 psi (0.9 MPa, 9 bar) Maximum Air Working Pressure 80 psi (550 kPa, 5.5 bar) Pressure Ratio 25:1 Air consumption with 02 tip at 1500 psi stall pres- 28 scfm (0.8m /min) sure...

  • Page 40: Graco Standard Warranty

    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.

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