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Graco Reactor A-XP Series Operation

Graco Reactor A-XP Series Operation

Air powered, heated, plural component proportioner
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Operation
Air Powered, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
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.
Russian Patent No. 2359181
Taiwan Patent No. 1 303996
Australian Patent No. 2003291660
Other patents pending.
Model 259060 Shown
312407C
ENG
TI11252a

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Summary of Contents for Graco Reactor A-XP Series

  • Page 1 Operation 312407C Air Powered, Heated, Plural Component Proportioner For spraying polyurethane foam and polyurea coatings. Not for use in explosive atmospheres. 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

    Circuit Breakers ......13 Graco Information ......36 Setup .

  • Page 3: Models

    Models Models Air Powered Reactors A-XP Series All A-XP2 models are CE compliant. Full Heater Flow Output Maximum Fluid Load Watts per Cycle Working Voltage Peak System Pressure (lpm) at (A+B) Pressure Part, Series Model (phase) Amps Watts hose) Ratio 78 cpm gal.

  • Page 4: Supplied Manuals

    Order Part 15B381 als translated in several languages for a compact disk of Fusion manuals translated in sev- eral languages. Manuals are also available at www.graco.com. Feed Pump Kits Reactor Air Powered Proportioner Part Description...

  • Page 5: 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 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 6 • 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 7: Isocyanate Hazard

    Never store ISO in an open container. • Keep the ISO lube pump reservoir filled with Graco Throat Seal Liquid (TSL), Part 206995. The lubri- cant creates a barrier between the ISO and the Spraying materials containing isocyanates creates atmosphere.

  • Page 8: Keep Components A And B Separate

    Keep Components A and B Separate Keep Components A and Changing Materials B Separate • When changing materials, flush the equipment mul- tiple times to ensure it is thoroughly clean. • Always clean the fluid inlet strainers after flushing, CAUTION see page 31.

  • Page 9: Typical Installation, With Circulation

    Typical Installation, with circulation Typical Installation, with circulation Key for F Air Powered Reactor Agitator Heated Hose (see page 32) Desiccant Dryer (part of Return Tube Kit, page 32) Fluid Temperature Sensor (FTS) Gun Fluid Manifold (part of Fusion gun) Heated Whip Hose (see page 32) Air Quick-Disconnect (part of Circulation Kit, page 32) Fusion Spray Gun (see page 32)

  • Page 10: Typical Installation, Without Circulation

    Typical Installation, without circulation Typical Installation, without circulation Key for F Reactor Proportioner Waste Containers Heated Hose (see page 32) Fluid Supply Lines Fluid Temperature Sensor (FTS) Feed Pumps (see page 32) Heated Whip Hose (see page 32) Agitator Fusion Spray Gun (see page 32) Desiccant Dryer (part of Return Tube Kit, page 32) Gun Air Supply Hose Bleed Lines...

  • Page 11: Component Identification

    Component Identification Component Identification Key for F AR Air Regulator HC Heated Hose Electrical Connector BA Component A Pressure Relief Outlet MP Main Power Switch BB Component B Pressure Relief Outlet PA Component A Pump BV Bleed-Type Master Air Valve PB Component B Pump CC Cycle Counter PM Pump Motor...

  • Page 12: Controls And Indicators

    Controls and Indicators Controls and Indicators CAUTION To prevent damage to the softkey buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. Heater Power Indicators Heater Displays Zone A Arrow Keys Heater A On/Off Key Zone B Arrow Keys...

  • Page 13: Heater Zone On/Off Keys/Leds

    Controls and Indicators Target Temperature Key/LED Circuit Breakers Press to display target temperature. Press and hold to display heater control circuit Located inside Reactor cabinet. board temperature. Ref. Size Component 50 A Hose/Transformer Secondary Temperature Scale Keys/LEDs 40 A Transformer Primary °...

  • Page 14: Setup

    Setup Setup 1. Locate Reactor 2. General Equipment Guidelines • Determine the correct size generator. Using the cor- CAUTION rect size generator and proper air compressor will enable the proportioner to run at a nearly constant Proper system setup, startup, and shutdown proce- RPM.
  • Page 15 Setup 3. Electrical requirements Table 2: Power Cord Requirements See T ABLE Cord Specification Part Model AWG (mm 259060 A-XP2 6 (13.3), 2 wire + ground 259061 A-XP2 8 (8.4), 3 wire + ground 259062 A-XP2 10 (5.3), 4 wire + ground Installing this equipment requires access to parts 259070 HT-6.0...
  • Page 16 Setup c. 400V, 3 phase: Connect power leads to L1, L2, 6. Connect feed pumps and L3. Connect neutral to N. Connect green to a. Install feed pumps (K) in component A and B ground (GND). supply drums. See F .
  • Page 17 Setup 7. Connect pressure relief lines Do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB). The valves function as overpressure relief valves when set to SPRAY . Lines must be open so valves can automatically relieve pressure when machine is oper- ating.
  • Page 18 Setup 9. Connect heated hose bends. Wrap cable and electrical connections with electrical tape. See Heated Hose manual 309572 for detailed instructions on connecting heated hoses. CAUTION The fluid temperature sensor (C) and whip hose (D) must be used with heated hose, see page 17. Hose length, including whip hose, must be 60 ft (18.3 m) minimum.
  • Page 19 Setup 13. Ground system Check pump wet-cups daily. Keep filled with Graco ISO pump oil (217374) to keep air or moisture from reacting with fluids. a. Reactor: is grounded through power cord. See page 15. b. Spray gun: connect whip hose ground wire to FTS, page 17.

  • Page 20: Startup

    Startup Startup e. Turn both PRESSURE RELIEF/SPRAY valves CAUTION Proper system setup, startup, and shutdown proce- (SA, SB) to SPRAY dures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Fail- ure to follow these procedures will cause voltage flucuations that can damage electrical equipment and void the warranty.
  • Page 21 Startup 8. Set temperatures desired temperature. Repeat for zones. zone only, if FTS is disconnected at star- tup, display will show hose current (0A). See step j, page 22. ° e. Press to display actual temperatures. ° Controls and Indicators, see page 12 Do not turn on hose heat without fluid in hoses.
  • Page 22 Startup 9. Check Cycle Count Hold to view heater control circuit board temperature. a. To display cycle count, press Manual current control mode only: To clear counter, press and hold for 3 sec- onds. When in manual current control mode, monitor hose temperature with thermometer.

  • Page 23: Spraying

    Spraying Spraying 1. Engage gun piston safety lock. 4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY ti2409a 2. Close gun fluid manifold valves A and B. TI10963a 5. Check that heat zones are on and temperatures are on target, page 21. 6.
  • Page 24 Spraying 8. Check fluid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY valve for that compo- nent toward PRESSURE RELIEF/CIRCULATION , until gauges show balanced pressures. In this example, B side pressure is higher, so use the B side valve to balance pressures.

  • Page 25: Shutdown

    Shutdown Shutdown 1. Shut off , and heat zones. 2. Park pumps. a. Press b. Trigger gun until pump A stops in the retracted position and the pressure of both pumps bleeds down. 3. Turn main power OFF 4. Relieve pressure, page 26. 312407C...

  • Page 26: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 1. Relieve pressure in gun and perform gun shutdown 6. Disconnect gun air line and remove gun fluid mani- procedure. See gun manual. fold. 2. Engage gun piston safety lock. ti2409a ti2554a 3. Close gun fluid manifold valves A and B. Pump throat seals work best under pressure.

  • Page 27: Fluid Circulation

    Fluid Circulation Fluid Circulation Circulation Through Reactor 4. Turn main power ON 5. Set temperature targets, see page 21. Turn on heat zones by pressing Do not circulate fluid containing a blowing agent with- out consulting with your material supplier regarding fluid temperature limits.

  • Page 28: Circulation Through Gun Manifold

    Fluid Circulation Circulation Through Gun 7. Circulate fluid at lowest possible pressure until tem- peratures reach target. Manifold Do not circulate fluid containing a blowing agent with- out consulting with your material supplier regarding fluid temperature limits. Circulating fluid through the gun manifold allows rapid preheating of hose.

  • Page 29: Diagnostic Codes

    Diagnostic Codes Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on tem- perature display. These alarms turn off heat. E99 clears automatically when communication is regained. Codes E03 through E06 can be cleared by pressing . For other codes, turn main power OFF then ON to clear.

  • Page 30: Maintenance

    • Check pump wet-cups daily, page 19. Keep filled with Graco ISO pump oil (217374), to keep air or moisture from reacting with fluids. If oil on rods appears milky from crystallization, wipe rods clean and refill wet-cups with fresh ISO pump oil.

  • Page 31: Flushing

    Flushing Flushing • To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE 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 32: Accessories

    Accessories Accessories Feed Pump Kits 246086 Data Reporting Kit Pumps, hoses, and mounting hardware to supply fluids Records actual temperature, temperature setpoint, to Reactor. Includes 246483 Air Supply Kit. See actual pressure, cycles, and diagnostic code data from 309815. Reactor. Downloads data to PC with Microsoft® Win- dows 98 or later.

  • Page 33: Dimensions

    Dimensions Dimensions Dimension Model in. (mm) Dimension Model in. (mm) 11 (279) A-XP2 49 (1245) G (hole diameter) 0.625 (16) 35 (889) Weight A-XP2 400 lb (180 kg) 36.5 (927) HT Series 333 lb (150 kg) 25 (635) 27 (686) Side View Front View TI11256a...

  • Page 34: Technical Data

    Technical Data Technical Data Category Data Maximum Fluid Working Model A-XP2: 3000 psi (20.7 MPa, 207 bar) Pressure Maximum Input Pressure Model A-XP2: 120 psi (0.82 MPa, 8.2 bar) air to Motor Pressure Ratio Fluid:Air Model A-XP2: 25:1 Air Inlet Model A-XP2: 1/2 npsm(f) Recommended Air Supply Model A-XP2: 1/2 in.
  • Page 35 Technical Data 312407C...

  • Page 36: 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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