Graco 259079, Operation Manuals

Page 1: ...With Integrated Generator For spraying polyurethane foam and polyurea coatings For professional use only Not approved for use in explosive atmospheres or hazardous locations Important Safety Instructi...

Page 2: ...e Check Hose 41 Connect Remote Display Module 41 Grounding 41 Supply Wet Cups With Throat Seal Liquid TSL 42 Advanced Display Module ADM Operation 43 Advanced Setup Screens 46 System 47 Recipes 47 Run...

Page 3: ...electrician and comply with all local codes and regulations TOXIC FLUID OR FUMES Toxic uids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDS...

Page 4: ...is running or hot shut off engine and let it cool Fuel is ammable and can ignite or explode if spilled on hot surface Eliminate all ignition sources such as pilot lights cigarettes portable electric...

Page 5: ...us injury Do not operate the unit when fatigued or under the in uence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Tech...

Page 6: ...er metal objects Only use tools with insulated handles Do not lay tools or metal parts on top of battery MOVING PARTS HAZARD Moving parts can pinch cut or amputate ngers and other body parts Keep clea...

Page 7: ...and component B resin parts Moisture Sensitivity of Isocyanates Cross contamination can result in cured material in uid lines which could cause serious injury or damage equipment To prevent cross cont...

Page 8: ...d in your equipment requires special attention to avoid equipment damage and downtime When changing materials ush the equipment multiple times to ensure it is thoroughly clean Always clean the uid inl...

Page 9: ...rking Pressure psi MPa bar 259081 32 Amps 240 V 1 11 700 2 0 7 6 0 0203 0 0771 3500 24 1 241 259091 12 Amps 240 V 1 16 700 2 0 7 6 0 0203 0 0771 3500 24 1 241 Total system watts used by system based o...

Page 10: ...246101 AP9180 259080 24K394 246050 Fusion AP 246101 AP9181 259081 24K395 246055 Fusion AP 246100 CS9079 259079 24K240 246050 Fusion CS CS0101 CS9080 259080 24K240 246050 Fusion CS CS0101 CS9081 25908...

Page 11: ...2R1 P29091 259091 24K241 246055 Probler P2 GCP2R0 P29189 259089 24K394 246050 Probler P2 GCP2R1 P29190 259090 24K394 246050 Probler P2 GCP2R1 P29191 259091 24K395 246055 Probler P2 GCP2R0 Accessories...

Page 12: ...ls in English System Manuals 3A1706 Reactor E 30i and E XP2i Repair Parts Displacement Pump Manual 309577 Electric Reactor Displacement Pump Repair Parts Feed System Manuals 309572 Heated Hose Instruc...

Page 13: ...e during operation A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor FTS D Heated Whip Hose E Fusion Spray Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines H Agitator Air Supply Li...

Page 14: ...tape during operation A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor FTS D Heated Whip Hose E Fusion Spray Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines H Agitator Air Suppl...

Page 15: ...Manifold GA Component A Pressure Gauge GB Component B Pressure Gauge GG Generator page 17 HA Component A Hose Connection HB Component B Hose Connection HC Heated Hose Electrical Connectors MP Main Po...

Page 16: ...ncluded with all models FV Fluid Inlet Valve A side shown HE Heat Exchangers heat exchanger coolant loop HM High Power Temperature Control Module HPTCM Cable Connections page 26 LM Low Power Module LP...

Page 17: ...l Dipstick ER Radiator EX Exhaust FD Fuel Shutoff Solenoid FJ Fuel Injector FP Fuel Pump FS Diesel Fuel Fill Cap FT Diesel Fuel Tank GD Generator Power Distribution Box GL Glow Plugs HB Heat Exchanger...

Page 18: ...r PL Component B Feed Pump and Agitator Air Regulator PM Gun Air Regulator PN Component A Feed Pump Pressure Gauge PP Component B Feed Pump and Agitator Pressure Gauge PR Gun Pressure Gauge Not for br...

Page 19: ...lays system status C Stop Stops all system processes Is not a safety or emergency stop D Soft Keys Selects the speci c screen or operation shown on the display directly next to each key Call out Butto...

Page 20: ...System On Green Flashing Setup Mode System On Yellow Solid Run Mode System Off Yellow Flashing Setup Mode System Off USB Module Status LEDs CL Conditions Green Flashing Data recording in progress Yel...

Page 21: ...u bar There are four possibilities Icon Function No Icon No information or no error has occurred Advisory Deviation Alarm Status The current system status is displayed at the lower right of the menu b...

Page 22: ...information Softkeys Icon Function Start Proportioner Start and Stop Proportioner in Jog Mode Stop Proportioner Turn on speci ed heat zone Park component A pump Enter Jog Mode See Jog Mode page 60 Re...

Page 23: ...s 2 Heat Exchanger Control Vave Output to load center 3 Two way Splitter to A and B Heat Exchanger Temperature Sensors 5 Engine Coolant Temperature Sensor 6 Pump Cycle Switch 7 Optional Accessory Conn...

Page 24: ...see Appendix A Engine Control Module page 90 Figure 11 Engine Control Module Icon Description Function On Start Engine Auto Auto mode not used Off Stop all system processes Is not a safety or emergenc...

Page 25: ...enoid FS Green Fuel shutoff solenoid on the engine is open D2 Starter ST Red Starter is cranking D3 Glow Plugs GL Green Glow plugs are heating D4 Radiator Fan RF Green Radiator fan is on D10 A Coolant...

Page 26: ...ections 7 Rotary Switch Token Access 8 Module Status LEDs see Advanced Display Module ADM page 19 CN for conditions Low Power Module LPTCM Cable Connections Only used with E XP2i and E 30i models with...

Page 27: ...ings listed in the following tables S HPTCM Rotary Switch Location Figure 16 S LPTCM Rotary Switch Location Figure 17 HPTCM A and B Rotary Switch Settings Setting Zone 0 Heated Hose 1 Not Used 2 Not U...

Page 28: ...Cabinet Fan Power Supply and Coolant Circulation Pump CB04 30 A Auxiliary Power Air Compressor CB05 10 A Auxiliary Power CB06 20 A Auxiliary Power E XP2i and E 30i With Heat Low Power Temperature Con...

Page 29: ...optional circuit breakers and their current ratings Circuit breakers used must meet UL489 speci cations Auxiliary Wiring Diagram Options The generator supplies power in a 3 wire single phase mid point...

Page 30: ...on the ADM PD The engine coolant loop gray circulates heated coolant from the engine EE through the heat exchanger HE radiator ER and back to the engine Coolant in the proportioner coolant loop black...

Page 31: ...ed in the proportioner pumps PA PB After the A and B material has been heated in the heat exchangers the material enters the uid manifold FM and heated hose For models with a booster heater the A and...

Page 32: ...lose the A and B material has reached target temperature Coolant ows through the bypass control valve VC circulation pump CP sight glass SG proportioner coolant ll bottle HF and back to the heat excha...

Page 33: ...d Connect air line A2 between proportioner air inlet to air dryer outlet e Connect pilot air lines A3 and A4 between the air compressor and air tank f Secure water drain lines A5 and A6 to the frame...

Page 34: ...Setup A5 A1 A2 AS AN A3 AT A3 A4 A2 A6 A4 34 3A1705E...

Page 35: ...the diameter of the exhaust pipe Metal or other approved reproo ng materials that provides at least 8 in 203 mm of insulation between the exhaust pipe and ammable material Exhaust pipes not covered a...

Page 36: ...of the pallet and place where the fuel ll spout is easily accessible Note Do not mount fuel tank in front of the generator air intake or where it will limit opening and access to the electrical enclos...

Page 37: ...Setup 1 25 in 31 75 mm IW 1 25 in 31 75 mm 15 in 381 mm 6 in min 406 4 mm 1 ft min 0 3m Wall IW Installation Guidelines Figure 27 3A1705E 37...

Page 38: ...t bypass the fusible link when damaged The fusible link prevents damage to other system components See the system repair manual for repair instructions Figure 29 3 Cover battery terminals with plastic...

Page 39: ...A drum and use desiccant dryer M in vent 3 Install agitator L in component B drum if necessary 4 Connect supply hoses from feed pumps to the component A and component B material inlets on the system...

Page 40: ...18 3 m minimum NOTICE Apply grease on all system and hose uid ttings This lubricates the threads and prevents material from hardening on the threads 1 Turn main power switch OFF 2 Assemble heated hose...

Page 41: ...bolt and braided cable from pallet Install grounding cable terminated with a ring terminal cable and terminal not supplied under braided cable Reinstall bolt and torque to minimum 25 ft lbs 34 N m An...

Page 42: ...SO Pump Keep reservoir R lled with Graco Throat Seal Liquid TSL Part 206995 Wet cup piston circulates TSL through wet cup to carry away isocyanate lm on displacement rod R Component A Pump Figure 33 C...

Page 43: ...19 If the System Status Indicator Light is not green press the ADM Power On Off A button The System Status Indicator Light will illuminate yellow if the machine is disabled Perform the following task...

Page 44: ...password then press Press to navigate through the Setup Mode screens See Setup Screens Navigation Diagram page 45 Set Password Set a password to allow Setup screen access see Advanced Screen 1 General...

Page 45: ...Advanced Display Module ADM Operation Setup Screens Navigation Diagram Figure 35 3A1705E 45...

Page 46: ...at current date time setup screens password 0000 for none or 0001 to 9999 screen saver delay and enable or disable silent mode Advanced Screen 2 Units Use this screen to set the temperature units pres...

Page 47: ...able saved recipes Enabled recipes can be selected at the Home Run Screen 24 recipes can displayed on the three recipe screens Add Recipe 1 Press and then use to select a recipe eld Press to enter a r...

Page 48: ...eration Run Mode The ADM will start in the Run screens at the Home screen Press to navigate through the Run Mode screens See Run Screens Navigation Diagram page 44 From the Run screens press to access...

Page 49: ...Advanced Display Module ADM Operation Run Screens Navigation Diagram Figure 36 3A1705E 49...

Page 50: ...park the component A pump enter jog mode and clear cycles Home System With Error Active errors are shown in the status bar The error code alarm bell and description of the error will scroll in the sta...

Page 51: ...All information listed on this screen can be downloaded on a USB ash drive Events This screen shows the date time event code and description of all events that have occurred on the system There are 1...

Page 52: ...hemical Hose Chemical Booster A Chemical Booster B Chemical Booster A PCB temperature control module temperature Booster B PCB temperature control module temperature Hose PCB temperature control modul...

Page 53: ...ooting screen for an error code that is not listed on this screen See Error Codes and Troubleshooting page 74 for more information on error codes Recipes Use this screen to select an enabled recipe Us...

Page 54: ...at Off B E B D H Heat Off Hose E B P X Pump Off E B R X Jog Off E B U X USB Drive Removed E C 0 X Setup Value Changed E C D A A Temperature Setpoint Changed E C D B B Temperature Setpoint Changed E C...

Page 55: ...ns Before daily startup ensure that the uid inlet screens are clean See Flush Inlet Strainer Screen page 67 4 Check ISO lubrication reservoir Check level and condition of ISO lube daily See Pump Lubri...

Page 56: ...has been relieved b Press start on the air compressor power box CB Wait until the pressure gauge CJ on the air supply tank reaches 30 psi c Open the desiccant dryer inlet valve water drain valve and...

Page 57: ...hot uid or equipment Do not turn on hose heat without uid in hoses Allow equipment to cool completely before touching it Wear gloves if uid temperature exceeds 110 F 43 C Thermal expansion can cause...

Page 58: ...S cables SC at the Reactor Fluid Manifold FM SC B 15V837 A 2 Insert the RTD sensor probe between the two hoses where the scuff guard ends 3 Lower the hose temperature setpoint on the system ADM screen...

Page 59: ...chine is operating 2 See Typical Installation with circulation page 13 Route circulation lines back to respective component A or B supply drum Use hoses rated at the maximum working pressure of this e...

Page 60: ...Use hoses rated at the maximum working pressure of this equipment See Technical Speci cations page 98 3 Follow procedures from Startup page 55 4 Turn main power switch on 5 Set temperature targets Se...

Page 61: ...ratures are on target see Home screen page 50 7 Verify that the engine temperature is at least up to the minimum operation temperature range The fan will start running when the engine has reached maxi...

Page 62: ...esults in an uneven pattern coarse droplet size low ow and poor mixing Too much pressure results in excessive overspray high ow rates dif cult control and excessive wear Fluid temperature Similar effe...

Page 63: ...the system 6 Turn off the air compressor air dryer and breathing air 7 Close the main air shutoff valve 8 Turn main power switch OFF To prevent electric shock do not remove any shrouds or open the el...

Page 64: ...and before cleaning checking or servicing equipment The Fusion AP gun is shown 1 Relieve pressure in gun and perform gun shutdown procedure See gun manual 2 Close gun uid inlet valves A and B 3 Shut o...

Page 65: ...ible with common solvents Use only moisture free solvents To ush feed hoses pumps and heaters separately from heated hoses set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION Flush t...

Page 66: ...cation System page 68 Compressor Tank Water Drain Open the manual water drain valve weekly See valve location on page 34 Open only when air pressure is less than 25 psi Dust Protection Use clean dry o...

Page 67: ...e at the pump inlet and shut off the appropriate feed pump This prevents material from being pumped while cleaning the screen 2 Place a container under the strainer base to catch drain off when removi...

Page 68: ...operation If the packings are operating properly lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks To change pump lubricant 1 Follow Pressure Relie...

Page 69: ...d B heat exchanger control valves and bypass control valve Note The battery must be connected to operate valves The load center LC LEDs will stay on when the manual valve switch MV is in the ON positi...

Page 70: ...air enters the coolant system It takes about one full warm up and cool down cycle to purge air from coolant To avoid burns do not perform maintenance on the coolant system until the coolant system has...

Page 71: ...y use coolant solutions that are compatible with the system See Coolant Speci cations page 71 1 Perform Shutdown page 63 2 Remove the engine radiator coolant cap RC and ll until the coolant reaches th...

Page 72: ...play as well as by the light tower optional Alarms are indicated by This condition indicates a parameter critical to the process has reached a level requiring the system to stop The alarm needs to be...

Page 73: ...Note Press or to return to the previously displayed screen 2 Press to select one of following conditions that are present in the system until you are able to diagnose the error Press to return to the...

Page 74: ...og and displayed on the Error and Troubleshooting screens on the ADM Error Code Error Location Type Name Cause Solution Loose or bad connection Check wiring between MCM and motor Motor brushes complet...

Page 75: ...he support frame of the transformer Short circuit of motor wiring Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground Motor will not rotate Replace m...

Page 76: ...module should be lit If green light is not lit check to make sure each CAN cable connection is tight Verify the power supply is outputting 24 Vdc If not replace power supply See System Repair manual C...

Page 77: ...le switch and MCM port 6 F9DX MCM ALARM Pressure Flow Cutback Mix chamber is too large for the set pressure Reference the pressure ow curves and select a tip size that is the correct size for the set...

Page 78: ...on the pumps Bad pressure transducer Verify the ADM pressure reading the analog gauges at the manifold Replace transducers if they do not match P4BX MCM ALARM Over Pressure B E XP2i system con gured a...

Page 79: ...unnecessary alarms and abort dispenses Out of material Fill tanks with material P7AX Pressure Imbalance A High P7BX MCM ALARM Pressure Imbalance B High Feed system defective Check feed pump and hoses...

Page 80: ...ter board See system repair manual If voltage is present measure the resistance of the coil it should be 12 5 if coil is open replace coil If voltage is present test the coil with screwdriver The scre...

Page 81: ...stics in Reactor repair manual T4CA Boost A LPTCM Over Temperature Cooling fan not operating on power If fan is not working check wiring between CB03 and fan If wiring is good replace fan T4CB Boost B...

Page 82: ...lugged radiator Replace if needed Cooling fans are not operating properly Ensure ambient temperature is less than 120 F 48 C Check to see that the fans are moving Measure voltage to fans There should...

Page 83: ...nnection to check and retighten any loose connector Measure hose RTD cable and FTS continuity See system repair manual Order RTD Test Kit 24N365 for measurement See Temporary Manual Hose Temperature C...

Page 84: ...ires Low generator line voltage Measure voltage across main power switch CT01 Voltage should measure between 190 and 264 VAC V1MH Hose ALARM Low Line Voltage High auxiliary inrush current Ensure compr...

Page 85: ...the lights on USB port stop ashing before Removing the token WSUX USB ADVISORY USB Invalid Con guration Bad ADM Replace ADM See System Repair manual WXUD ADM ADVISORY USB Download Error Log Download...

Page 86: ...vent code Event code Event type Action taken Event Description Event codes include both error codes alarms deviations and advisories and record only events Actions Taken includes setting and clearing...

Page 87: ...te log was created Time log was created Component name Software version loaded on the above component Blackbox Log File The black box le name is 5 BLACKB CSV and is stored in the DATAxxxx folder The B...

Page 88: ...load Procedure page 89 to install the le The format of the custom language le is critical The following rules must be followed in order for the installation process to succeed De ne a custom string fo...

Page 89: ...roper folder structure on the USB ash drive 2 Insert USB ash drive into USB port of computer 3 The USB ash drive window automatically opens If it does not open USB ash drive from within Windows Explor...

Page 90: ...tery voltage Press to scroll through the run screens Press to enter the Information screens Run Screen Layout Inst Icon Alarm Icon Instrumentation Units Mode Icon Information Screens From the Run Scre...

Page 91: ...Manual Engine is at rest and the unit is in manual run mode Timer animation Engine is starting up Running animation Engine is running Instrumentation Icons A small icon is displayed in the instrument...

Page 92: ...top the generator Clear the alarm and remove the fault Then press the stop button to reset the module See the information screen to see the latest alarm Icon Description Details Fail To Start The engi...

Page 93: ...Dimensions Dimensions Top View Figure 43 Side View Figure 44 3A1705E 93...

Page 94: ...Dimensions Top View System with Compressor and Hose Rack Accessories Figure 45 Front View Figure 46 Side View System with Compressor and Hose Rack Accessories Figure 47 94 3A1705E...

Page 95: ...Dimensions Pallet Mounting Dimensions Figure 48 3A1705E 95...

Page 96: ...6060 03 AR7070 04 AR5252 02 AR4242 01 2000 138 1500 103 1000 69 500 34 0 5 2 3 15 6 8 20 9 1 25 11 3 30 13 6 35 15 9 45 20 4 40 18 1 55 25 9 50 22 7 10 4 5 E 30i PRESSURE psi bar FLOW lbs min kg min P...

Page 97: ...Notes Notes 3A1705E 97...

Page 98: ...gal 0 1034 liter Operating Ambient Temperature Range Temperature 20 to 120 F 7 to 49 C Auxiliary Power Available Voltage 120 Vac or 240 Vac 60 Hz Engine Model Perkins 404 22G 2 2 L 29 HP Alternator M...

Page 99: ...0 MPa 103 bar 2 gpm 7 6 lpm 91 0 dBA Fluid Inlets Component A ISO and Component B RES 3 4 NPT f with 3 4 NPSM f union Fluid Outlets Component A ISO 8 1 2 in JIC with 5 5 16 in JIC adapter Component B...

Page 100: ...perating Ambient Temperature Range Temperature 20 to 120 F 7 to 49 C Auxiliary Power Available Voltage 120 Vac or 240 Vac 60 Hz Engine Model Perkins 404 22G 2 2 L 29 HP Alternator Model Mecc Alte 22 k...

Page 101: ...essure measured from 3 1 ft 1 m at 2000 psi 14 MPa 138 bar 1 0 gpm 3 8 lpm 91 0 dBA Fluid Inlets Component A ISO and Component B RES 3 4 NPT f with 3 4 NPSM f union Fluid Outlets Component A ISO 8 1 2...

Page 102: ...es for lost pro ts lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the...