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Operation
Air and Hydraulic, Heated, Plural
Component Proportioners
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 Models, page 3.
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001
309812 rev. D
TI3699b
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Table of Contents
Related Manuals for Graco Reactor A Series
Summary of Contents for Graco Reactor A Series
- Page 1 Not for use in explosive atmospheres. Important Safety instructions. Read all warnings and instructions in this manual. Save these instructions. See Models, page 3. TI3699b Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001...
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Page 2: Table Of Contents
Setup ........16 Graco Information ......42... -
Page 3: Models
Models Models Air Powered Reactors A SERIES Flow Heater lb/min Output per Maximum Fluid Voltage Watts (kg/min) Cycle (A + B) Pressure Working Pressure Part No. Series Model (phase) (no hose) at 75 cpm gal. (liter) Ratio psi (MPa, bar) 246037 A-25 230V (1) - Page 4 Models Hydraulic Powered Reactors H-50 SERIES Flow Heater lb/min Output per Maximum Fluid Voltage Watts (kg/min) at Cycle (A + B) Pressure Working Pressure Part No. Series Model (phase) (no hose) 45 cpm gal. (liter) Ratio psi (MPa, bar) 246039 H-50 230V (1) 15,300...
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Page 5: Manual Conventions
Manual Conventions Manual Conventions Warning Caution CAUTION WARNING A caution alerts you to possible equipment damage or destruction if you do not follow instructions. A warning alerts you to possible serious injury or Note death if you do not follow instructions. A note indicates additional helpful information. -
Page 6: Supplied Manuals
Supplied Manuals Supplied Manuals ™ Order Part No. 15B535 for a compact disk of Reactor The following manuals are shipped with the Reactor manuals translated in several languages. Refer to them for detailed equipment information. Air and Hydraulic Reactors Part No. Description 309813 Air and Hydraulic Reactors, Repair-Parts Manual (English) -
Page 7: Related Manuals
Related Manuals Related Manuals The following manuals are for accessories used with the Order Part No. 15B535 for a compact disk of Reactor ™ manuals translated in several languages. Reactor Order Part No. 15B381 for a compact disk of Fusion manual translated in several languages. -
Page 8: Warning
Warning WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Do not point the gun at anyone or at any part of the body. - Page 9 Misuse can cause serious injury or death. • For professional use only. • Use equipment only for its intended purpose. Call your Graco distributor for information. • Read manuals, warnings, tags, and labels before operating equipment. Follow instructions. • Check equipment daily. Repair or replace worn or damaged parts immediately.
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Page 10: Typical Installation, With Circulation
Typical Installation, with circulation Typical Installation, with circulation Key for F Air Powered Reactor Agitator Heated Hose (see page 38) Desiccant Dryer (part of Return Tube Kit, page 38) Fluid Temperature Sensor (FTS) Gun Fluid Manifold (part of Fusion gun) Heated Whip Hose (see page 38) Air Quick-Disconnect (part of Circulation Kit, page 38) Fusion Spray Gun (see page 38) -
Page 11: Typical Installation, Without Circulation
Typical Installation, without circulation Typical Installation, without circulation Key for F Reactor Proportioner Agitator Heated Hose (see page 38) Desiccant Dryer (part of Return Tube Kit, page 38) Fluid Temperature Sensor (FTS) Bleed Lines Heated Whip Hose (see page 38) Gun Fluid Manifold (part of Fusion gun) Fusion Spray Gun (see page 38) Air Quick-Disconnect (part of Circulation Kit, page 38) -
Page 12: Component Identification
Component Identification Component Identification Key for F AR Air Regulator HR Hydraulic Return Fitting, 1” npt(f) BA Component A Pressure Relief Outlet HS Hydraulic Shutoff Valve, 3/4 npt(f) BB Component B Pressure Relief Outlet MP Main Power Switch BV Bleed-Type Master Air Valve PA Component A Pump CC Cycle Counter PB Component B Pump... -
Page 13: Controls And Indicators
Controls and Indicators Controls and Indicators Heater Power Indicators Heater Displays Zone A Heater A Arrow On/Off Keys Heater B Zone B On/Off Arrow Keys Hose Heater Hose Zone On/Off Key Arrow Keys 1 2 3 4 5 6 7 °... - Page 14 Controls and Indicators Heater Zone On/Off Circuit Breakers Keys/LEDs WARNING Press to turn heater zones on and off. Also clears heater zone diagnostic codes, see page 35. Read warnings, page 8. Located inside Reactor cabinet. LEDs are on steady when heater zones are powering up.
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Page 15: Isocyanate Hazard
Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component • Keep the wet-cup of the pump filled with Graco ISO foam and polyurea coatings. ISO will react with moisture pump oil, Part No. 217374. The lubricant creates a (such as humidity) to form small, hard, abrasive crystals, barrier between the ISO and the atmosphere. -
Page 16: Setup
Setup Setup Locate Reactor To mount on truck, bolt mounting feet of Reactor to truck bed. See page 39. Locate Reactor on a level surface. Do not expose Reactor to rain. TI3582b 309812D... - Page 17 Setup Table 1: Electrical Requirements Electrical requirements (kW/Full Load Amps) A SERIES See T 1. Does not include air compressor ABLE Full or hydraulic power supply. Load Part Voltage Peak System Model (phase) Amps* Watts** WARNING 248636 A-XP2 230V (3) 14,540 248637 A-XP2...
- Page 18 Setup Connect electrical cord 230V, 1 phase: Connect power leads to L1 and L2, and green to ground (GND). Power cord is not supplied. See T 2. Use 5/32 ABLE or 4 mm hex allen wrench to make connections. Table 2: Power Cord Requirements Cord Specification Part No.
- Page 19 Setup Connect power source Connect feed pumps to motor Install feed pumps (K) in component A and B supply drums. See F . 1 and Air powered models: . 2, pages 10 and 11. See F . 1. Connect air supply line (U) to air regulator kit inlet.
- Page 20 Setup Connect pressure relief Recommended: Connect air purge hose (R) to relief fittings (BA, BB) of lines both PRESSURE RELIEF/SPRAY valves. Route hose back to component A and B drums. Also see F . 1, page WARNING Do not install shutoffs downstream of the PRESSURE RELIEF/SPRAY valve outlets (BA, BB).
- Page 21 Setup Install Fluid Temperature Connect whip hose ground wire (U) to ground screw on underside of FTS. Sensor (FTS) Connect main hose (B) to FTS (C). The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. CAUTION Connect electrical connectors (V).
- Page 22 Connect heated hose Connect cables (Y). Connect electrical connectors (V). Secure with plastic ties. Be sure cables have slack when hose See 309572 for detailed instructions for Graco bends. Wrap cable and electrical con- heated hoses. nections with electrical tape.
- Page 23 Setup Connect whip hose to 100 ft 150 ft 200 ft gun fluid manifold 50 ft 250 ft Do not connect manifold to gun yet. 300 ft TI2417A Pressure check hose See hose manual. Pressure check for leaks. If no leaks, fully wrap hose and electrical connec- tions with tape to protect from damage.
- Page 24 (R) during operation. Shut off pumps before cord. See page 18. filling wet cups. Check pump wet-cups (R) daily. Keep filled with Graco ISO pump oil, Part No. 217374, to keep air or moisture Spray gun: connect whip hose ground from reacting with fluids.
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Page 25: Startup
Startup Startup WARNING Open fluid inlet valves (VA, VB). Do not operate Reactor without all covers and shrouds in place. Load fluid with feed pumps The Reactor is tested with oil at the factory. If nec- essary, flush out the oil with a compatible solvent TI3590b before spraying. - Page 26 Startup Set temperatures zone only, if FTS is disconnected at startup, display will show hose current (0A). See step h, page 27. WARNING Press to display actual tempera- This equipment is used with heated fluid, which can tures. cause equipment surfaces to become very hot. To avoid severe burns: WARNING •...
- Page 27 Startup Set pressure Manual current control mode only: WARNING Turn on air or hydraulic pressure to motor. Read warnings, page 8. When in manual current con- Adjust motor input pressure until fluid trol mode, monitor hose temperature with thermome- ter. Install per instructions below. Thermometer pressure gauges (GA, GB) show reading must not exceed 160°F (71°C).
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Page 28: Spraying
Spraying Spraying Engage gun piston safety lock. Attach gun fluid manifold. Connect gun air line. Open gun air line valve (W). TI2409A Close gun fluid manifold valves A and B. TI2543A Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY. TI2728A TI3591a Check that heat zones are on and temperatures are on target, page 26. - Page 29 Spraying Open gun fluid manifold valves A and B. Disengage gun piston safety lock. TI2410A Test spray onto cardboard for several seconds. TI2414A Adjust pressure and temperature to get desired results. Equipment is ready to spray. 309812D...
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Page 30: Shutdown
Shutdown Shutdown Shut off , and heat zones. Turn main power OFF Trigger gun to park pumps at bottom of stroke. Close red-handled valve (BV or HS, page 12) to shut off power to motor. Fill wet-cups, page 24. Relieve pressure, page 31. 309812D... -
Page 31: Pressure Relief Procedure
Pressure Relief Procedure Pressure Relief Procedure Relieve pressure in gun and perform gun shut- Engage gun piston safety lock. down procedure. See gun manual. Close gun fluid manifold valves A and B. TI2409A Disconnect gun air line and remove gun fluid manifold. -
Page 32: Fluid Circulation
Fluid Circulation Fluid Circulation Circulation Through Reactor Set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF. Use this procedure to purge air from pumps, heat- ers, and lines. WARNING Read warnings, page 8. Do not circulate fluid contain- ing a blowing agent without consulting with your mate- rial supplier regarding fluid temperature limits. - Page 33 Fluid Circulation Circulation Through Gun Connect high pressure circulation lines (R) to Manifold circulation manifold. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working pres- WARNING sure of this equipment. Read warnings, page 8.
- Page 34 Fluid Circulation 309812D...
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Page 35: Diagnostic Codes
Diagnostic Codes Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes E01 through E05 appear on temperature display. Code Code Name Alarm Zone These alarms turn off heat. Turn main power OFF High fluid temperature Individual High hose current Hose only then ON to clear. -
Page 36: Maintenance
Check pump wet-cups (R) daily, page 24. Keep filled • Remove plugs (S) and clean fluid inlet screens as with Graco ISO pump oil, Part No. 217374, to keep needed. 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 37: Flushing
Flushing Flushing • To flush feed hoses, pumps, and heaters separately WARNING from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF. Flush through bleed lines (N). Read warnings, page 8. Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable sol- vents. -
Page 38: Accessories
Accessories Accessories Feed Pump Kits Heated Hoses Pumps, hoses, and mounting hardware to supply fluids 50 ft (15.2 m) and 25 ft (7.6 m) lengths, 1/4 in. (6 mm), to Reactor. Includes 246483 Air Supply Kit. See 3/8 in. (10 mm), or 1/2 in. (13 mm) diameter, 2000 psi 309815. -
Page 39: Dimensions
Dimensions Dimensions Dimension Model in. (mm) Dimension Model in. (mm) 11 (279) A-25, A-XP2, 49 (1245) G (hole diameter) 0.625 (16) A-XP2 2:1 55 (1397) Weight A-25, A-XP2 400 lb (180 kg) A-50 53 (1346) A-50 480 lb (216 kg) H-50 60.5 (1537) H-50... -
Page 40: Technical Data
Technical Data Technical Data Category Data Maximum Fluid Working Model A-25: 1920 psi (13 MPa, 130 bar) Pressure Models A-50 and H-50: 2000 psi (14 MPa, 140 bar) Models A-XP2 2:1: 2000 psi (14 MPa, 140 bar) Models A-XP2 and H-XP3: 3000 psi (20.7 MPa, 207 bar) Maximum Input Pressure Models A-25, A-XP2, and A-XP2 2:1: 120 psi (0.82 MPa, 8.2 bar) air to Motor... - Page 41 Technical Data Category Data Fluid Inlets Models A-25, A-XP2, A-XP2 2:1, and H-XP3: 3/4 npt(f) Models A-50 and H-50: 1” npt(f) Model HT heat packages: 1/2 npt(f) on heater inlet blocks Fluid Outlets Component A (ISO): #8 JIC (3/4-16 unf), with #5 JIC adapter Component B (RES): #10 JIC (7/8-14 unf), with #6 JIC adapter Fluid Circulation Ports 1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum...
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Page 42: 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.