Graco Reactor H-25 Series Operation
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Graco Reactor H-25 Series Operation

Hydraulic, heated, plural component proportioner
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Operation
Hydraulic, 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.
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2007, Graco Inc. is registered to I.S. EN ISO 9001
Model H-40 Shown
312062 rev. A
T9830a

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Summary of Contents for Graco Reactor H-25 Series

  • Page 1 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 T9830a Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2007, Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    Graco Standard Warranty ....38 Graco Information ......38...

  • Page 3: Models

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

  • Page 4: Supplied Manuals

    Reactor Hydraulic Proportioner, Order Part 15M334 for a compact disk of Reactor manu- Repair-Parts Manual (English) als translated in several languages. Reactor Electrical Diagrams Manuals are also available at www.graco.com. Part Description 312064 Reactor Hydraulic Proportioner, Elec- trical Diagrams (English)

  • 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

    • Most materials use ISO on the A side, but some use • Keep the ISO lube pump reservoir filled with Graco ISO on the B side. Throat Seal Liquid (TSL), Part 206995. The lubri- cant creates a barrier between the ISO and the •...

  • Page 8: 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 Fusion Spray Gun Desiccant Dryer Gun Air Supply Hose Gun Fluid Manifold (part of gun) Circulation Lines A Side Supply Detail...

  • Page 9: Typical Installation, Without Circulation

    Typical Installation, without circulation Typical Installation, without circulation Key for F Reactor Proportioner Waste Containers Heated Hose Fluid Supply Lines Fluid Temperature Sensor (FTS) Feed Pumps Heated Whip Hose Agitator Fusion Spray Gun Desiccant Dryer Gun Air Supply Hose Bleed Lines Feed Pump Air Supply Lines Gun Fluid Manifold (part of gun) A Side Supply Detail...

  • Page 10: Component Identification

    Component Identification Component Identification Key for F BA Component A Pressure Relief Outlet LR ISO Lube Pump Reservoir BB Component B Pressure Relief Outlet MC Motor Control Display EC Heated Hose Electrical Connector MP Main Power Switch EM Electric Motor, Fan, and Belt Drive (behind shroud) OP Overpressure Rupture Disk Assembly (on rear of A and B FA Component A Fluid Manifold Inlet (on left side of manifold pumps)
  • Page 11 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) 312062A...

  • Page 12: 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 Key Zone B Arrow Keys Heater B On/Off Key Hose Zone Arrow Keys Hose Heater On/Off Key ° Actual Temperature Key Temperature Scale Keys °...

  • Page 13: Temperature Scale Keys/Leds

    Temperature Controls and Indicators Temperature Scale Keys/LEDs Circuit Breakers ° ° Press to change temperature scale. Heater Zone On/Off Keys/LEDs Located inside Reactor cabinet. Ref. Size Component Press to turn heater zones on and off. Also clears 50 A Hose/Transformer Secondary heater zone diagnostic codes, see page 31.

  • Page 14: 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 Pressure Key/LED Press to turn motor ON and OFF.

  • Page 15: Hydraulic Pressure Control Knob

    Spray Adjustments Spray Adjustments Hydraulic Pressure Control Knob Flow rate, atomization, and amount of overspray are Use to adjust hydraulic pressure available to the hydrau- affected by four variables. lic drive system. Turn knob (HC) clockwise to increase pressure and counterclockwise to decrease pressure. •...

  • Page 16: Setup

    Setup Setup 1. Locate Reactor Table 1: Electrical Requirements (kW/Full Load Amps) a. Locate Reactor on a level surface. See Dimen- Full sions, page 36, for clearance and mounting Load hole dimensions. Voltage Peak System Part Model (phase) Amps* Watts** b.
  • Page 17 Setup 3. Connect electrical cord b. 230V, 3 phase: Using 5/32 or 4 mm hex allen wrench, connect three power leads to L1, L2, and L3. Connect green to ground (GND). Power cord is not supplied. See Table 2. Table 2: Power Cord Requirements Cord Specification Part Model...
  • Page 18 Setup 4. Connect feed pumps 5. Connect pressure relief lines a. Install feed pumps (K) in component A and B supply drums. See F . 1 and F . 2, pages 8 and 9. Do not install shutoffs downstream of the PRES- SURE RELIEF/SPRAY valve outlets (BA, BB).
  • Page 19 Setup 7. Connect heated hose d. Connect cables (Y). Connect electrical connec- tors (V). Be sure cables have slack when hose bends. Wrap cable and electrical connections See Heated Hose manual 309572 for detailed instructions on connecting heated hoses. with electrical tape. CAUTION The fluid temperature sensor (C) and whip hose (D) must be used with heated hose, see page 18.
  • Page 20 11. Ground system 13. Lubrication system setup Component A (ISO) Pump: Fill ISO lube reservoir (LR) with Graco Throat Seal Liquid (TSL), Part 206995 (supplied). a. Lift the lubricant reservoir (LR) out of the a. Reactor: is grounded through power cord. See bracket (RB) and remove the container from the page 17.

  • Page 21: Startup

    Startup Startup Do not operate Reactor without all covers and shrouds in place. 1. Load fluid with feed pumps g. Open fluid inlet valves (FV). Check for leaks. The Reactor is tested with oil at the factory. Flush out the oil with a compatible solvent before spray- ing.
  • Page 22 Startup 2. Set temperatures d. To set heat zone target temperature, press until display shows desired temperature. Repeat for zones. zone only, if FTS is disconnected at star- ° tup, display will show hose current (0A). See step j, page 23. °...
  • Page 23 Startup 3. Set pressure h. Hold to view electrical currents for each zone. Hold to view heater control circuit board temperature. ON / OFF Manual current control mode only: PARK When in manual current control mode, monitor hose temperature with thermometer. Install per instructions below.
  • Page 24 Startup Check the pressure of each proportioning pump using the component A and B gauges. The pres- a. Turn main power switch OFF sures should be approximately equal and must remain fixed. b. Press and hold , then turn main d.

  • Page 25: Spraying

    Spraying Spraying 1. Engage gun piston safety lock. 3. Attach gun fluid manifold. Connect gun air line. Open air line valve. ti2409a 2. Close gun fluid manifold valves A and B. ti2543a 4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY ti2728a ti9877a...
  • Page 26 Spraying 8. Check fluid pressure gauges (GA, GB) to ensure 9. Open gun fluid manifold valves A and B. 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.

  • Page 27: Standby

    Standby Standby Shutdown If you stop spraying for a period of time, the unit will enter standby by shutting down the electric motor and 1. Shut off , and heat zones. hydraulic pump, to reduce equipment wear and mini- mize heat buildup. The ON/OFF LED and the pres- 2.

  • Page 28: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure 1. Relieve pressure in gun and perform gun shutdown gauges drop to 0. procedure. See gun manual. 2.

  • Page 29: Fluid Circulation

    Fluid Circulation Fluid Circulation Circulation Through Reactor 4. Turn main power ON 5. Set temperature targets, see page 22. 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 30: Circulation Through Gun Manifold

    Fluid Circulation Circulation Through Gun 3. Follow Load fluid with feed pumps, page 22. Manifold 4. Turn main power ON 5. Set temperature targets, see page 22. Turn on Do not circulate fluid containing a blowing agent with- , and heat zones by pressing out consulting with your material supplier regarding fluid temperature limits.

  • Page 31: Diagnostic Codes

    Diagnostic Codes Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on tem- perature display. Code Code Name Alarm Zone High fluid temperature Individual These alarms turn off heat. E99 clears automatically High current Individual when communication is regained. Codes E03 through No current Individual FTS not connected...

  • Page 32: Maintenance

    Maintenance Maintenance • Inspect hydraulic and fluid lines for leaks daily. • Clean up all hydraulic leaks; identify and repair cause of leak. • Inspect fluid inlet strainer screens daily, see below. • Grease circulation valves weekly with Fusion grease ti10003a (17773).

  • Page 33: Fluid Inlet Strainer Screen

    Maintenance 3. Remove the screen (59g) from the strainer manifold. Fluid Inlet Strainer Screen Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket (59h) and replace as required.

  • Page 34: Pump Lubrication System

    Maintenance Pump Lubrication System 7. Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom. Important: The return tube (RT) must reach the bottom of the reservoir, to ensure that isocyanate crystals will settle to the bottom and not be Check the condition of the ISO pump lubricant daily.

  • Page 35: 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 36: 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)

  • Page 37: 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) 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 Models H-XP2 and H-XP3: 2.79:1 Fluid Inlets Component A (ISO): 1/2 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum Component B (RES): 3/4 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum...

  • Page 38: 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.

This manual is also suitable for:

Reactor h-40 seriesReactor h-xp2 seriesReactor h-xp3 series

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