Graco Reactor H-40 Operation
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Graco Reactor H-40 Operation

Hydraulic, heated, plural component proportioner for spraying polyurethane foam and polyurea coatings, not for use in explosive atmospheres
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Operation
Hydraulic, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
U.S. Patent Pending
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
312062E rev.k
T9830a

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Summary of Contents for Graco Reactor H-40

  • Page 1 Operation 312062E rev.k Hydraulic, Heated, Plural Component Proportioner For spraying polyurethane foam and polyurea coatings. Not for use in explosive atmospheres. U.S. Patent Pending 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.

  • Page 2: Table Of Contents

    Temperature Controls and Indicators . . 16 Graco Information ....48 Main Power Switch ....16 Red Stop Button .

  • Page 3: Models

    Models Models H-25 SERIES Max Flow Approximate Maximum Fluid Full Load Primary Rate◆ Output per Hydraulic Working Peak Amps* Voltage System Heater lb/min Cycle (A+B) Pressure Pressure Part, Series Per Phase (phase) Watts† Watts (kg/min) gal. (liter) Ratio psi (MPa, bar) 255400, E 230V (1) 15,960...
  • Page 4 Models H-XP2 SERIES Approximate Maximum Fluid Full Load Primary Max Flow Output per Hydraulic Working Peak Amps* Voltage System Heater Rate◆ Cycle (A+B) Pressure Pressure Part, Series Per Phase (phase) Watts† Watts gpm (lpm) gal. (liter) Ratio psi (MPa, bar) 255403, E 230V (1) 23,260...

  • Page 5: Supplied Manuals

    Order Part 15M334 for a compact disk of Part Language Reactor manuals translated in several lan- 312062 English guages. 312419 Chinese 312420 Dutch Manuals are also available at www.graco.com. 312421 French 312422 German Reactor Hydraulic Proportioner 312423 Italian Part Description 312424...

  • Page 6: Related Manuals

    Related Manuals Related Manuals The following manuals are for accessories ™ used with the Reactor Order Part 15M334 for a compact disk of Reactor manuals translated in several lan- guages. Data Reporting Kit Feed Pump Kits Part Description Part Description 309867 Instruction-Parts Manual 309815...

  • Page 7: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equip- ment. 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.
  • Page 8 • Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions. • Use only Graco grounded hoses. • Check gun resistance daily. • If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.
  • Page 9 Warnings WARNING 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.

  • Page 10: Isocyanate Hazard

    • Keep the ISO lube pump reservoir filled plied-air respirator is required for everyone in with Graco Throat Seal Liquid (TSL), Part the work area. 206995. The lubricant creates a barrier between the ISO and the atmosphere.

  • Page 11: Keep Components A And B Separate

    Keep Components A and B Separate Keep Components A Changing Materials and B Separate • When changing materials, flush the equip- ment multiple times to ensure it is thor- oughly clean. CAUTION To prevent cross-contamination of the equipment’s • Always clean the fluid inlet strainers after wetted parts, never interchange component A (isocy- flushing, see page 41.

  • Page 12: Typical Installation, With Circulation

    Typical Installation, with circulation Typical Installation, with circulation Key for F A Reactor Proportioner G Feed Pump Air Supply Lines B Heated Hose Fluid Supply Lines C Fluid Temperature Sensor (FTS) K Feed Pumps D Heated Whip Hose Agitator E Fusion Spray Gun M Desiccant Dryer F Gun Air Supply Hose P Gun Fluid Manifold (part of gun)

  • Page 13: Typical Installation, Without Circulation

    Typical Installation, without circulation Typical Installation, without circulation Key for F A Reactor Proportioner H Waste Containers B Heated Hose Fluid Supply Lines C Fluid Temperature Sensor (FTS) K Feed Pumps D Heated Whip Hose Agitator E Fusion Spray Gun M Desiccant Dryer F Gun Air Supply Hose N Bleed Lines...

  • Page 14: Component Identification

    Component Identification Component Identification Key for F 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)
  • Page 15 Component Identification Detail of Reactor Fluid Manifold (shroud removed for clarity) TI9830a Detail of Serial No. Plate (inside cabinet) ti7823a ti9880a . 3: Component Identification (H40 15.3 kW Model Shown)

  • Page 16: Temperature Controls And Indicators

    Temperature Controls and Indicators Temperature Controls and Indicators Heater Power Indicators Heater Displays Zone A Arrow Keys Heater A On/Off Zone B Arrow Keys Heater B On/Off Hose Zone Arrow Keys Hose Heater On/Off ° Actual Temperature Temperature Scale ° Keys Target Temperature Key .

  • Page 17: Target Temperature Key/Led

    Temperature Controls and Indicators Heater Zone On/Off Press and hold to display electrical cur- Keys/LEDs rent. Press to turn heater zones on and off. Target Temperature Key/LED Also clears heater zone diagnostic codes, see page 38. Press to display target temperature. LEDs flash when heater zones are on.

  • Page 18: Circuit Breakers

    Temperature Controls and Indicators * Depending on model. Circuit Breakers Located inside Reactor cabinet. Ref. Size Component 50 A Hose/Transformer Secondary ti9884a 40 A Transformer Primary For wiring and cabling, see repair manual 312063. 25, 40, or Heater A 50 A* 25, 40, or Heater B 50 A*...

  • Page 19: Motor Controls And Indicators

    Motor Controls and Indicators Motor Controls and Indicators Pressure/Cycle Display Arrow Keys Motor ON/OFF Key ON / OFF PARK Key PARK Pressure Key PSI/BAR Keys Cycle Count Key . 5. Motor Controls and Indicators Motor ON/OFF Key/LED PSI/BAR Keys/LEDs Press to turn motor ON and OFF.

  • Page 20: Cycle Count Key/Led

    Spray Adjustments Cycle Count Key/LED Spray Adjustments Flow rate, atomization, and amount of over- Press to display cycle count. spray are affected by four variables. • Fluid pressure setting. Too little pressure To clear counter, press and hold results in an uneven pattern, coarse droplet size, low flow, and poor mixing.

  • Page 21: Setup

    Setup Setup 1. Locate Reactor : Electrical Requirements Table 1 (kW/Full Load Amps) a. Locate Reactor on a level surface. See Full Dimensions, page 44, for clearance Load and mounting hole dimensions. Voltage Peak System Part Model (phase) Amps* Watts** b.
  • Page 22 Setup 3. Connect electrical cord Power cord is not supplied. See Table 2. Table 2: Power Cord Requirements a. 230V, 1 phase: Using 5/32 or 4 mm hex Cord Specification allen wrench, connect two power leads Part Model AWG (mm to L1 and L2.
  • Page 23 Setup c. 400V, 3 phase: Using 5/32 or 4 mm hex c. Install agitator (L) in component B drum, allen wrench, connect three power if necessary. leads to L1, L2, and L3. Connect neutral d. Ensure A and B inlet valves (FV) are to N.
  • Page 24 Setup 5. 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 ti9880a Lines must be open so valves can automati- cally relieve pressure when machine is oper- ating.
  • Page 25 Setup 7. Connect heated hose d. Connect cables (Y). Connect electrical connectors (V). Be sure cables have See Heated Hose manual 309572 for slack when hose bends. Wrap cable detailed instructions on connecting and electrical connections with electri- heated hoses. cal tape.
  • Page 26 11. Ground system 13. Lubrication system setup Component A (ISO) Pump: Fill ISO lube reservoir (LR) with Graco Throat Seal Liq- uid (TSL), Part 206995 (supplied). a. Lift the lubricant reservoir (LR) out of a. Reactor: is grounded through power the bracket (RB) and remove the con- cord.

  • Page 27: Startup

    Startup Startup g. Open fluid inlet valves (FV). Check for leaks. Do not operate Reactor without all covers and shrouds in place. 1. Load fluid with feed pumps ti10002a The Reactor is tested with oil at the fac- tory. Flush out the oil with a compatible solvent before spraying.
  • Page 28 Startup 2. Set temperatures d. To set heat zone target tempera- ture, press until display shows desired temperature. Repeat for zones. zone only, if FTS is discon- nected at startup, display will show hose ° current (0A). See step j, page 29. °...
  • Page 29 Startup If thermometer reading exceeds 160°F g. Turn on heat zones by (71°C), reduce current with key. pressing for each zone. 3. Set pressure h. Hold to view electrical currents for each zone. ON / OFF i. Hold to view heater control circuit board temperature.
  • Page 30 Startup c. Adjust hydraulic pressure control until Code 24 (pressure imbalance) is set to display shows desired fluid pressure. an alarm as the default. To change to a warning, see Reactor Repair-Parts manual 312063. The pressure imbalance default is factory-set ti7731a ti7732a at 500 psi (3.5 MPa, 35 bar).

  • Page 31: Spraying

    Spraying Spraying 4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY 1. Engage gun piston safety lock. ti9877a ti2409a 5. Check that heat zones are on and tempera- tures are on target, page 28. 2. Close gun fluid manifold valves A and B. 6.
  • Page 32 Spraying 9. Open gun fluid manifold valves A and B. 10. Disengage gun piston safety lock. ti2410a 11. Test spray onto cardboard. Adjust pressure and temperature to get desired results. ti2414a 12. Equipment is ready to spray. On impingement guns, never open fluid If you stop spraying for a period of time, manifold valves or trigger gun if pres- the unit will enter standby (if enabled).

  • Page 33: Standby

    Standby Standby To activate or disable standby, adjust DIP switch #3 on the motor control board. See Reactor Repair-Parts manual 312063. If you stop spraying for a period of time, the unit will enter standby by shutting down the The idle time before entering standby is electric motor and hydraulic pump, to reduce user-settable as follows: equipment wear and minimize heat buildup.

  • Page 34: Shutdown

    Shutdown Shutdown 4. Close both fluid supply valves (FV). 1. Shut off , and heat zones. 2. Park pumps. ti9883a a. Press 5. Relieve pressure, page 35. 6. Shut down feed pumps as required. b. Trigger gun until pump A stops in the retracted position and the pressure of both pumps bleeds down.

  • Page 35: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCU- LATION . Route fluid to waste contain- ers or supply tanks. Ensure gauges drop to 1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual. 2.

  • Page 36: Fluid Circulation

    Fluid Circulation Fluid Circulation Circulation Through Reactor 3. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCU- LATION 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 37.

  • Page 37: Circulation Through Gun Manifold

    Fluid Circulation rated at the maximum working pressure of 9. Turn on heat zone by pressing this equipment. See Typical Installation, without circulation, page 13. 10. Set PRESSURE RELIEF/SPRAY valves 3. Follow Load fluid with feed pumps, page (SA, SB) to SPRAY 4.

  • Page 38: Diagnostic Codes

    Diagnostic Codes Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear Code Code Name Alarm Zone on temperature display. High fluid temperature Individual These alarms turn off heat. E99 clears auto- High current Individual matically when communication is regained. No current Individual Codes E03 through E06 can be cleared by...

  • Page 39: Motor Control Diagnostic Codes

    Diagnostic Codes Motor Control Diagnostic Codes Motor control diagnostic codes E21 through Warnings E27 appear on pressure display. Reactor will continue to run. Press There are two types of motor control codes: clear. A warning will not recur for a predeter- alarms and warnings.

  • Page 40: Maintenance

    Maintenance Maintenance • 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 rec- • Inspect hydraulic and fluid lines for leaks ommended frequency of oil changes daily.

  • Page 41: Fluid Inlet Strainer Screen

    Maintenance 5. Open the fluid inlet valve, ensure that there Fluid Inlet Strainer Screen are no leaks, and wipe the equipment clean. Proceed with operation. 59g* 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.

  • Page 42: Pump Lubrication System

    Maintenance Pump Lubrication System 6. Push the larger diameter supply tube (ST) approximately 1/3 of the way into the reser- voir. 7. Push the smaller diameter return tube (RT) into the reservoir until it reaches the bot- tom. Check the condition of the ISO pump lubricant daily.

  • Page 43: Flushing

    Flushing Flushing • To flush feed hoses, pumps, and heaters separately from heated hoses, set PRES- SURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION Flush through bleed lines (N). Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents.

  • Page 44: Dimensions

    Dimensions Dimensions Dimension in. (mm) Dimension in. (mm) F (side mounting holes) 16.25 (413) A (height) 55.0 (1397) G (mounting post inner diameter)0.44 (11) B (width) 39.6 (1006) H (front mounting post height) 2.0 (51) C (depth) 18.5 (470) J (rear mounting post height) 3.6 (92) D (front mounting holes) 29.34 (745)

  • Page 45: Technical Data

    Technical Data 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...

  • Page 46: Performance Charts

    Performance Charts Performance Charts Foam Performance Chart 2000 (13.8, 138) A = H-25 at 50 Hz B = H-25 at 60 Hz C = H-40 at 50 Hz 1500 D = H-40 at 60 Hz (10.3, 103) E = H-50 at 50 Hz ❄F = H-50 at 60 Hz 1000 (6.9,...
  • Page 47 Performance Charts Heater Performance Chart (78) (72) J = 8 kW K = 12 kW (67) L = 15.3 kW M = 20.4 kW (61) (56) (50) (44) (39) (33) (28) (22) (17) (11) (3.8) (5.7) (7.6) (9.5) (11.4) (13.2) (15.1) (17.0) (1.9)

  • Page 48: 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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