Graco Reactor A-25 Instructions Manual
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Graco Reactor A-25 Instructions Manual

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Instructions
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
A-25: For spraying or dispensing 1:1 ratio polyurethane foam formulations and other 1:1
fast setting materials.
A-XP1: For spraying or dispensing 1:1 ratio polyurea formulations and other 1:1 fast
setting materials.
Not for use in explosive atmosphere or hazardous locations.
See page 3 for model information, including maximum working pressure and approvals.
This model is field-configurable to the following supply voltages:
200-240 VAC, 1 Phase
200-240 VAC, 3 Phase
350-415 VAC, 3 Phase
2000 psi (14 MPa, 138 bar) Maximum Fluid Working Pressure
80 psi (550 kPa, 5.5 bar) Maximum Air Working Pressure
A-XP1:
3500 psi (24 MPa, 241 bar) Maximum Fluid Working Pressure
100psi (689 kPa, 6.9 bar) Maximum Air Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
®
A-25/A-XP1
3A1570V
EN
ti16811b

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Summary of Contents for Graco Reactor A-25

  • Page 1 Instructions ® A-25/A-XP1 3A1570V 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 A-25: For spraying or dispensing 1:1 ratio polyurethane foam formulations and other 1:1 fast setting materials.

  • Page 2: Table Of Contents

    Graco Standard Warranty ....64 Graco Information ......64...

  • Page 3: Proportioner Models

    Proportioner Models Proportioner Models All proportioners can be configured to operate on 350-415 V (4 wire), 200-240 V (3 wire), or 200-240 V 1Ø. Includes: Maximum Fluid Working Maximum Air Working Pressure Set Pressure DataTrak Part psi (MPa, bar) psi (kPa, bar) (cycle count only) Wheels Approvals...

  • Page 4: Related Manuals

    Related Manuals Related Manuals Manuals are available at www.graco.com. Component manuals in English: Manual in English Description 3A1569 Reactor A-25 Proportioner, Operation 309577 Proportioning Pump, Repair-Parts 309815 Feed Pump Kit, Instructions-Parts 309827 Feed Pump Air Supply KIt, Instructions-Parts 309852 Circulation and Return Tube Kit,...

  • Page 5: 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-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 6 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 7 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 8: Important Isocyanate (Iso) Information

    Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two-component materials. 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 hazards and precautions related to isocyanates.

  • Page 9: Material Self-Ignition

    Important Isocyanate (ISO) Information Material Self-ignition NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature. Foam Resins with 245 fa Some materials may become self-igniting if applied Blowing Agents too thick.

  • Page 10: Datatrak Diagnostic Codes

    DataTrak Diagnostic Codes DataTrak Diagnostic Codes DataTrak can diagnose several problems with the pump. When the monitor detects a problem, the LED will flash and a diagnostic code will appear on the display. To acknowledge the diagnosis and return to the normal operating screen, press once to wake up the display, and once more to clear the diagnostic code screen.

  • Page 11: Temperature Control Diagnostic Codes

    Temperature Control Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on • Overtemperature switch (359) fails in the open temperature display. position. • The temperature control module fails to turn off any These alarms turn off heat. E99 clears automatically heat zone.

  • Page 12: E02: High Zone Current

    Temperature Control Diagnostic Codes E02: High zone current Table 1: Sensor Connector Continuity Checks Pins Description Reading 1. Turn main power OFF 1 & 2 OT switch nearly 0 ohms 3 & 4 Jumpered nearly 0 ohms 2. Follow the Pressure Relief Procedure, page 15. 5 &...

  • Page 13: E04: Fluid Temperature Sensor (Fts) Or Thermocouple Disconnected

    Temperature Control Diagnostic Codes E04: Fluid Temperature Sensor E05: Control board over (FTS) or thermocouple temperature disconnected NOTE: Each module has an on-board temperature sensor. Heat is turned off if module temperature 1. Check temperature sensor connections to long exceeds 185°F (85°C) within the heater module. green connector (B) on temperature control module.

  • Page 14: E99: Loss Of Communication

    Temperature Control Diagnostic Codes E99: Loss of communication Communications between the display and the temperature control module has been lost. When Step 2 measures line voltage and should be done by communication is lost, the display will show E99. a qualified electrician. If work is not performed properly it may cause electric shock or other serious 1.

  • Page 15: Before Beginning Repair

    Before Beginning Repair Before Beginning Repair Pressure Relief Procedure Repairing this equipment requires access to parts NOTE: The Fusion AP gun is shown. that may cause electric shock or other serious injury if work is not performed properly. Electrical 1. Turn off feed pumps and agitator if used. troubleshooting must be done by a qualified electrician.

  • Page 16: Shutdown

    Shutdown Shutdown Park Park the pumps at the end of the day to cycle 1. Turn main heater power OFF component A pump to home position, submerging displacement rod. 2. Follow Park. 1. Open the park valve. 3. Check and fill wet-cups (AK, Z). Open Close 2.

  • Page 17: Flushing

    Flushing Flushing • To flush entire system, circulate through gun fluid manifold (with manifold removed from gun). • Always leave hydraulic oil or a non-water based, Flush equipment only in a well-ventilated area. Do non-water absorbent fluid in system. Do not use not spray flammable fluids.

  • Page 18: Troubleshooting

    Troubleshooting Troubleshooting Problems Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and Before performing any troubleshooting procedures: controls are properly set and wiring is correct before assuming there is a problem.
  • Page 19 Troubleshooting PROBLEM CAUSE SOLUTION Fluid pressure low or dropping Air supply pressure low when spraying Increase inlet air pressure Increase air compressor size to meet flow requirements Remove airline quick disconnects Use 3/8 in. (0.95 cm) ID or larger air supply hose.

  • Page 20: Electronics

    Troubleshooting PROBLEM CAUSE SOLUTION Fluid pressures not balanced between A Fluid viscosities not equal Adjust A and B temperature settings to and B side balance viscosity. Sometimes normal if pressure offset is below 200 psi (14 bar) Preheat material in drums by recirculating;...
  • Page 21 Troubleshooting PROBLEM CAUSE SOLUTION Erratic display; display turns on and off. Low voltage. Ensure input voltage is within specifications. See Temperature Display, page 39. Poor display connection. Check cable connections. See Temperature Display, page 39. Replace damaged cable. Display cable damaged or corroded. Clean connections;...

  • Page 22: Heater

    Troubleshooting Heater PROBLEM CAUSE SOLUTION Primary heater(s) does not heat. Heat turned off. Press zone keys. Temperature control alarm. Check temperature display for diagnostic code. See Temperature Control Diagnostic Codes, page 11. Signal failure from thermocouple. See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 13.

  • Page 23: Hose Heat System

    Troubleshooting Hose Heat System PROBLEM CAUSE SOLUTION Hose heats but heats slower than usual Ambient temperature is too cold. Use auxiliary hose heat system. or it does not reach temperature. FTS failed or not installed correctly. Check FTS. See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 13.
  • Page 24 Troubleshooting PROBLEM CAUSE SOLUTION Hose does not heat. FTS failed or is not contacting Check FTS. See E04: Fluid correctly. Temperature Sensor (FTS) or thermocouple disconnected, page 13. FTS not installed correctly. FTS should be installed close to end of hose in same environment as gun.

  • Page 25: Repair

    Repair Repair 6. Shut off inlet air ball valve (G). 7. Remove screws (13, 15) and pump covers (63). Unless otherwise noted, all repair procedures must be completed with incoming power switched OFF and locked out at the source. Any electrical repair or troubleshooting required beyond the scope of this manual must be performed by a qualified electrician.

  • Page 26: Connect Pump

    Repair 11. Push retaining wire clip (307) up. Push retaining pin 5. For Iso A pump only: (306) out. a. Install two pipe plugs (324). b. Reconnect two tubing lines (N) from ISO Pump Lube reservoir. Flush and refill reservoir with TSL 206995.

  • Page 27: Install Air Motor

    Repair 5. Loosen two screws (314) behind air motor bracket. 4. Tighten nut (313) to 32-38 ft-lbs (43-51 N•m). Carefully lift air motor and tie rods away from the 5. Evenly torque four tie rod nuts (310) in small proportioner frame and plate (301). increments to 27-32 ft-lbs (37-43N•m).

  • Page 28: Air Inlet Filter / Water Separator (Auto Drain)

    Repair Air Inlet Filter / Water Separator 3. Unscrew clear drain cover by hand. (Auto Drain) 4. Unscrew black filter element retainer to remove element. Air Filter Element Removal 5. Inspect filter element. Clean or replace. 1. Close air inlet valve (302) on filter (301). Air Filter Element Installation 2.

  • Page 29: Temperature Control Module

    Repair Temperature Control Module Table 2: Temperature Control Module Connections Connector Description DISPLAY (C) Display OVERTEMPERATURE A; 1, 2 Overtemperature switch A 3, 4 OVERTEMPERATURE B; Overtemperature switch B HEATER T/C A, R; Thermocouple (red) HEATER T/C A, Y; Thermocouple (yellow) SENSOR (B) Not used HEATER T/C B, R;...
  • Page 30 Repair Test SCR Circuit Replacing Temperature Control Assembly Modules 1. Test the SCR circuit in the on position: a. Make sure everything is connected, including the hose. b. Turn main power ON NOTICE Before handling assembly, put on static conductive wrist strap to protect against static discharge which c.

  • Page 31: Primary Heater

    Repair Primary Heater 6. To remove heater element, first remove thermocouple (361) to avoid damage, see Thermocouple, step 7, page 33. 7. Remove heater element (358) from housing (351). Be careful not to spill any fluid left in housing. Read Warnings on page 5. Wait for heater to cool 8.
  • Page 32 Repair Torque to 120 ft-lbs (163 N•m). Torque to 23 ft-lbs (31 N•m). Torque to 40 ft-lbs (54 N•m). ti17998a Apply 110009 thermal heatsink compound. Apply sealant and PTFE tape to all non swiveling and threads without o-rings. Apply lubricant to o-rings. Orient rupture disc housing (369) with exhaust hole pointing towards the bottom of the heater.
  • Page 33 Repair Thermocouple 8. Replace thermocouple, F . 8. a. Remove protective tape from thermocouple tip (T). Read Warnings on page 5. Wait for heater to cool before repairing. b. Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing (H) into adapter (356).

  • Page 34: Heated Hose

    Repair Overtemperature Switch 2. Follow the Pressure Relief Procedure, page 15. NOTE: Whip hose must be connected. 3. Disconnect Reactor power harness (PH) from hose termination box terminal block (TB). Read Warnings on page 5. Wait for heater to cool before repairing.
  • Page 35 Repair Check FTS Cables Fluid Temperature Sensor (FTS) Test/Removal 1. Turn main power OFF . Disconnect power supply. 1. Turn main power OFF . Disconnect power 2. Follow the Pressure Relief Procedure, page 15. supply. 3. Disconnect FTS cable (F) at Reactor, F .
  • Page 36 Repair ti9581c . 12: Fluid Temperature Sensor and Heated Hoses 3A1570V...
  • Page 37 Repair Transformer Primary Check Replace Transformer 1. Turn main power OFF 2. Locate the two smaller (10 AWG) wires coming out of transformer. Trace these wires back to contactor and circuit breaker (911). Use an ohmmeter to test 1. Turn main power OFF .

  • Page 38: Pump Lubrication System

    Repair b. Install new breaker and reconnect wires. 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 Size the check valve and allow the lubricant to drain. Ref.

  • Page 39: Fluid Inlet Strainer Screen

    Repair Fluid Inlet Strainer Screen Temperature Display The inlet strainers filter out particles that can plug the NOTICE pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required. Before handling board, put on static conductive wrist strap to protect against static discharge which can Isocyanate can crystallize from moisture contamination damage assembly.
  • Page 40 Repair ti18026a Detail of Membrane Switches and Temperature Display Board 102a Temperature Display 102b 102c ti18003a . 17. Display Module 3A1570V...

  • Page 41: Replace Datatrak Battery Or Fuse

    Use only the following approved replacement batteries. Use of an unapproved battery will void 1. Remove the screw, metal strap, and plastic holder. Graco’s warranty and FM and Ex approvals. 2. Pull the fuse away from the board. • Ultralife lithium # U9VL •...

  • Page 42: Accessories

    Accessories Accessories Feed Pump Kits Heated Whip Hoses Pumps, hoses, and mounting hardware to supply fluids A-25: 2000 psi (14 MPa, 138 bar) to Reactor. Includes 246483 Air Supply Kit. See A-XP1: 3500 psi (24 MPa, 241 bar) 309815. 10 ft (3 m) whip hose, 1/4 in. (6 mm) or 3/8 in. (10 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 246483 Air Supply Kit MPa, 241 bar).

  • Page 43: Recommended Spare Parts

    Recommended Spare Parts Recommended Spare Parts Keep the following spare parts on hand to reduce Model Part Description downtime. A-XP1 24Y174 Pump, Resin (B) side Model Part Description 24Y175 Pump, ISO (A) side 17K351 ISO (A) Pump Repair Kit for 24Y175 A-25 245971 Pump, Resin (B) side...

  • Page 44: Parts

    Parts Parts 262572, Bare Reactor A-25 / 24Y164, A-XP1 Bare 262614, Reactor A-25 with DataTrak and Wheels / 24Y165, A-XP1 with DataTrak and Wheels 14 (x4) 56 (x4) 100 (x4) 9 (x4) 91, 92 90 (x6) 3A1570V...
  • Page 45 Parts 25 (x2) 13 (x2) 9 (x4) 13 (x2) Torque pump locking nuts to 66-74 ft-lbs (90-100 N•m). Apply anaerobic polyacrylate pipe sealant to all non-swiveling pipe threads. Torque tube ends to 212-265 in-lbs (24-30 N•m). Connect ground wire (94) from motor lug to ground lug in cabinet. For Series A only.
  • Page 46 Parts 13 (x4) 13 (x4) ti18007a 262572, Bare Reactor A-25 / 24Y164, Bare Reactor A-XP1 262614, Reactor A-25 with DataTrak and Wheels / 24Y165, Reactor A-XP1 with DataTrak and Wheels Ref. Part Description Qty. Ref. Part Description Qty. 262576 MODULE (A-25), breaker; see page 54...
  • Page 47 Parts Ref. Part Description Qty. Ref. Part Description Qty. 123970 SWITCH (A-25), disconnect, 40a ----- TUBE, polyurethane, rnd, black; 5.12 ft (1.56 m); see page 53 123969 SWITCH (A-XP1), disconnect, 40a ----- INSERT, control panel 123971 KNOB (A-25), disconnect, operator 67†...

  • Page 48: Control Panel

    Parts Control Panel A-25: 262575 A-XP1: 24Y176 Apply sealant to all non swiveling pipe threads. Attach ground wire from harness (116) between connector on harness (106) and display cover (105). Attach harness (106) to J13 on board (102). Attach harness (119) to J1 on board (102). ti18002a Ref.

  • Page 49: Temperature Control

    Parts Temperature Control Wheel Kit (262695) To B Heater Module To A Heater Module To Hose ti18006a Heater Module Ref. Part Description 191† 16H182 AXLE, wheel 192† 111841 WASHER, plain 5/8 Ref. Part Description Qty. 193† 191824 WASHER, space 151 16G925 PANEL, pod, mounting 194†...

  • Page 50: Fluid Manifold

    Parts Fluid Manifold Fluid Inlet Kit (234366) A-25: 262577 A-XP1: 24Y177 ti18027a Assemble ball valves in orientation shown. Apply anaerobic polyacrylate pipe sealant to all NPT connections. Apply sealant and torque to 250 in-lbs (28 N•m). Ref. Part Description Qty. Use blue thread lock on valve cartridge threads into manifold.

  • Page 51: Dual Zone Heater

    Parts Dual Zone Heater A-XP1: 10 kw (24Y163) A-25: 6 kw (24J788) Torque to 120 ft-lbs (163 N•m). Torque to 23 ft-lbs (31 N•m). Torque to 40 ft-lbs (54 N•m). ti17998a Apply 110009 thermal heatsink compound. Apply sealant and PTFE tape to all non swiveling and threads without o-rings.

  • Page 52: Air Motor Pump Assembly

    Parts Air Motor Pump Assembly A-25 (262573) A-XP1 (24Y086) Ref. Part Description Qty. 16G915 PLATE, mounting, cylinder 193031 NUT, retaining 246831 PUMP (A-25), displacement, with lube; iso 24Y175 PUMP (A-XP1), displacement, with lube; iso 245971 PUMP (A-25), displacement; resin 24Y174 PUMP (A-XP1), displacement; resin 15J132 LINK (A-25), connecting...

  • Page 53: Air Tubing Connections

    Parts Air Tubing Connections Connection Length Ref. ft (m) From Material Color Outside Diameter 0.75 ft (0.23 m) UHMWPE Black 5/32 in. (4 mm) 2.66 ft (0.8 m) Nylon Black 1/2 in. (12.7 mm) 1.66 ft (0.5 m) Nylon Black 1/2 in.

  • Page 54: Breaker Module

    Parts Breaker Module A-25 (262576) A-XP1 (24Y166) 404 (8x) 410 (4x) 404 (7x) A-25: A-XP1: Ref. Part Description Qty. Ref. Part Description Qty. 401 16H309 RAIL, mounting 401 16H309 RAIL, mounting 402 112446 BLOCK, clamp end 402 112446 BLOCK, clamp end 403 120490 COVER, end 403 120490 COVER, end 404 120570 BLOCK, terminal...

  • Page 55: Wiring Schematics

    Wiring Schematics Wiring Schematics 3A1570V...

  • Page 56: 25

    Wiring Schematics A-25 3A1570V...

  • Page 57: A-Xp1

    Wiring Schematics A-XP1 3A1570V...

  • Page 58: 25

    Wiring Schematics A-25 3A1570V...

  • Page 59: A-Xp1

    Wiring Schematics A-XP1 3A1570V...
  • Page 60 Wiring Schematics A-25 3A1570V...

  • Page 61: A-Xp1

    Wiring Schematics A-XP1 3A1570V...

  • Page 62: Technical Specifications

    Technical Specifications Technical Specifications Reactor A-25 Plural Component Proportioner Metric 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...
  • Page 63 Technical Specifications Reactor A-XP1 Plural Component Proportioner Metric Maximum Fluid Working Pressure 3500 psi 24 MPa, 241 bar Maximum Air Supply Pressure 125 psi 0.9 MPa, 9 bar Maximum Air Working Pressure 100 psi 689 MPa, 6.9 bar Pressure Ratio 35:1 Air consumption 32 scfm (0.9 m...

  • Page 64: 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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