Graco Reactor H-40 Elite, Operation

Page 1: ...a coatings Not for use in explosive atmospheres U S Patent Pending See page 3 for model information including maximum working pressure and approvals Important Safety Instructions Read all warnings and instructions in this manual Save these instructions T9830a Model H 40 Shown ONFORMS TO 3 5 3TD ERTIFIED TO 3 3TD O ...

Page 2: ... Keys LEDs 17 Temperature Arrow Keys 17 Temperature Displays 17 Circuit Breakers 18 Motor Controls and Indicators 19 Motor ON OFF Key LED 19 PARK Key LED 19 PSI BAR Keys LEDs 19 Pressure Key LED 19 Cycle Count Key LED 20 Hydraulic Pressure Control Knob 20 Motor Control Arrow Keys 20 Spray Adjustments 20 Setup 21 Startup 27 Spraying 31 Standby 33 Shutdown 34 Pressure Relief Procedure 35 Fluid Circu...

Page 3: ...utput per Cycle A B gal liter Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi MPa bar 253400 E 100 230V 1 23 100 12 000 45 20 0 063 0 24 1 91 1 2000 13 8 138 253401 E 71 230V 3 26 600 15 300 45 20 0 063 0 24 1 91 1 2000 13 8 138 253402 E 41 400V 3 26 600 15 300 45 20 0 063 0 24 1 91 1 2000 13 8 138 253407 E 95 230V 3 31 700 20 400 45 20 0 063 0 24 1 91 1 2000 13 8 138 253408 E 52 400V ...

Page 4: ...ge phase System Watts Primary Heater Watts Max Flow Rate gpm lpm Approximate Output per Cycle A B gal liter Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi MPa bar 255403 E 100 230V 1 23 260 15 300 1 5 5 7 0 042 0 16 2 79 1 3500 24 1 241 255404 E 59 230V 3 23 260 15 300 1 5 5 7 0 042 0 16 2 79 1 3500 24 1 241 255405 E 35 400V 3 23 260 15 300 1 5 5 7 0 042 0 16 2 79 1 3500 24 1 241 Part...

Page 5: ...g languages See the following chart for specific languages and corresponding part numbers Reactor Hydraulic Proportioner Part Description 312063 Reactor Hydraulic Proportioner Repair Parts Manual English Reactor Electrical Diagrams Part Description 312064 Reactor Hydraulic Proportioner Electrical Diagrams English Proportioning Pump Part Description 312068 Proportioning Pump Repair Parts Manual Eng...

Page 6: ...culation and Return Tube Kits Part Description 309852 Instruction Parts Manual English Heated Hose Part Description 309572 Instruction Parts Manual English Circulation Kit Part Description 309818 Instruction Parts Manual English Circulation Valve Kit Part Description 312070 Instruction Parts Manual English Data Reporting Kit Part Description 309867 Instruction Parts Manual English Rupture Disk Ass...

Page 7: ...dous fluid in approved containers and dispose of it according to applicable guidelines Always wear impervious gloves when spraying or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and h...

Page 8: ...d 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 Do not flush with gun electrostatics on Do not turn on electrostatics until all solvent is removed from system Keep a working fire extingui...

Page 9: ...ir or replace worn or damaged parts immediately with genu ine manufacturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot sur faces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away fr...

Page 10: ...solvent con tainers closed when not in use Never use solvent on one side if it has been contaminated from the other side Always park pumps when you shutdown see page 34 Always lubricate threaded parts with Part 217374 ISO pump oil or grease when reas sembling Spraying materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s wa...

Page 11: ...g materials flush the equip ment multiple times to ensure it is thor oughly clean Always clean the fluid inlet strainers after flushing see page 41 Check with your material manufacturer for chemical compatibility Most materials use ISO on the A side but some use ISO on the B side Epoxies often have amines on the B hard ener side Polyureas often have amines on the B resin side CAUTION To prevent cr...

Page 12: ... Spray Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines J Fluid Supply Lines K Feed Pumps L Agitator M Desiccant Dryer P Gun Fluid Manifold part of gun R Circulation Lines FIG 1 Typical Installation with circulation B C D E F K J ti7820a 3 Shown exposed for clarity Wrap with tape during operation J A G K K M P R R A Side Supply Detail L G K M B Side Supply Detail ti7820a 2 ti10000a ...

Page 13: ...ay Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines H Waste Containers J Fluid Supply Lines K Feed Pumps L Agitator M Desiccant Dryer N Bleed Lines P Gun Fluid Manifold part of gun FIG 2 Typical Installation without circulation B C D E F K J ti7821a 3 Shown exposed for clarity Wrap with tape during operation J A K P N H L G K B Side Supply Detail G K M A Side Supply Detail ti7821a 2 ti10001a...

Page 14: ...sure Gauge GB Component B Outlet Pressure Gauge HA Component A Hose Connection HB Component B Hose Connection HC Hydraulic Pressure Control HP Hydraulic Pressure Gauge LR ISO Lube Pump Reservoir MC Motor Control Display MP Main Power Switch OP Overpressure Rupture Disk Assembly on rear of A and B pumps PA Component A Pump PB Component B Pump RS Red Stop Button SA Component A PRESSURE RELIEF SPRAY ...

Page 15: ...tion H40 15 3 kW Model Shown Detail of Reactor Fluid Manifold shroud removed for clarity ti9880a TC PA FM FS FP FV PB FH EM RS MC GA GB SB FB BB HB HA BA FA SA HC TA TB SC EC LR FT SR HP MP SN TI9830a ti7823a Detail of Serial No Plate inside cabinet SN OP ...

Page 16: ...otor control panel page 15 Press to shut off motor and heater zones only Use main power switch to shut off all power to unit Actual Temperature Key LED Press to display actual temperature FIG 4 Temperature Controls and Indicators F C A B Zone A Arrow Keys Zone B Arrow Keys Hose Zone Arrow Keys Temperature Scale Keys Heater A On Off Key Heater Power Indicators Target Temperature Key Actual Temperat...

Page 17: ...EDs Press to turn heater zones on and off Also clears heater zone diagnostic codes see page 38 Temperature Arrow Keys Press then press or to adjust temperature settings in 1 degree incre ments Temperature Displays Show actual temperature or target temperature of heater zones depending on selected mode Defaults to actual at startup Range is 32 190 F 0 88 C for A and B 32 180 F 0 82 C for hose F C L...

Page 18: ...eactor cabinet Depending on model Ref Size Component CB1 50 A Hose Transformer Secondary CB2 40 A Transformer Primary CB3 25 40 or 50 A Heater A CB4 25 40 or 50 A Heater B CB5 20 or 30 A Motor Pumps ti9884a CB3 CB4 CB5 CB1 CB2 For wiring and cabling see repair manual 312063 ...

Page 19: ...osition submerging dis placement rod Trigger gun until pump stops Once parked motor will automatically shut off PSI BAR Keys LEDs Press or to change pressure scale Pressure Key LED Press to display fluid pressure FIG 5 Motor Controls and Indicators PSI BAR ON OFF PARK PSI BAR Keys Cycle Count Key Pressure Cycle Display Pressure Key Motor ON OFF Key PARK Key Arrow Keys If pressures are imbalanced d...

Page 20: ...spray high flow rates difficult control and exces sive wear Fluid temperature Similar effects to fluid pressure setting The A and B tempera tures can be offset to help balance the fluid pressure Mix chamber size Choice of mix chamber is based on desired flow rate and fluid vis cosity Clean off air adjustment Too little clean off air results in droplets building up on the front of the nozzle and no...

Page 21: ...his equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly Have a qualified electrician connect power and ground to main power switch ter minals see page 22 Be sure your installation complies with all National State and Local safety and fire codes Table 1 Electrical Requirements kW Full Load Amps Part Model Voltage phase Full Loa...

Page 22: ... 40 8 8 4 4 wire ground 253404 H XP3 4 21 2 3 wire ground 253405 H XP3 6 13 3 4 wire ground 253407 H 40 4 21 2 3 wire ground 253408 H 40 6 13 3 4 wire ground 255400 H 25 4 21 2 2 wire ground 255401 H 25 8 8 4 3 wire ground 255402 H 25 8 8 4 4 wire ground 255403 H XP2 4 21 2 2 wire ground 255404 H XP2 6 13 3 3 wire ground 255405 H XP2 8 8 4 4 wire ground 255406 H 25 4 21 2 2 wire ground 255407 H 25...

Page 23: ...p ply hose to the 3 4 npt f swivel on the component B inlet valve f Connect and tighten component A sup ply hose to the 1 2 npt f swivel on the component A inlet valve Some 3 phase models utilize a 3 phase motor The motor must rotate counter clockwise when viewed from shaft end To reverse rotation disconnect power and reverse power leads L1 and L2 A minimum feed pressure of 50 psi 0 35 MPa 3 5 bar...

Page 24: ...FTS The Fluid Temperature Sensor FTS is sup plied Install FTS between main hose and whip hose See Heated Hose manual 309572 for instructions 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 Lines must be open so valves can automati cally relieve pressure when machine is oper ating If circulating...

Page 25: ...nd B 9 Connect whip hose to gun fluid mani fold 10 Pressure check hose See hose manual Pressure check for leaks If no leaks wrap hose and electrical connections to protect from damage 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 24 Hose length including whip hose must...

Page 26: ...servoir is filled at the factory Check fluid level before operating the first time and weekly thereafter See Mainte nance page 40 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 the bracket RB and remove the con tainer from the cap b Fill with fresh lubricant Thread the res ...

Page 27: ...FV Check for leaks h Use feed pumps to load system Hold gun fluid manifold over two grounded waste containers Open fluid valves A and B until clean air free fluid comes from valves Close valves Do not operate Reactor without all covers and shrouds in place The Reactor is tested with oil at the fac tory Flush out the oil with a compatible solvent before spraying See page 43 ti9877a SA SB Do not mix...

Page 28: ...equipment is used with heated fluid which can cause equipment surfaces to become very hot To avoid severe burns Do not touch hot fluid or equipment Allow equipment to cool completely before touching it Wear gloves if fluid temperature exceeds 110 F 43 C F C A B Temperature Controls and Indicators see page 16 F C For zone only if FTS is discon nected at startup display will show hose current 0A See...

Page 29: ...t thermometer through foam cover of A component hose so stem is next to inner tube Ther mometer reading will be about 20 F less than actual fluid temperature If thermometer reading exceeds 160 F 71 C reduce current with key 3 Set pressure a Press to display the pressure reading b Press motor Motor and pumps start Display shows system pressure When in manual current control mode moni tor hose tempe...

Page 30: ...rn main power switch ON Display will read dP500 for psi or dP_35 for bar c Press or to select desired pressure differential 100 999 in incre ments of 100 psi or 7 70 in increments of 7 bar See TABLE 3 Factory default setting d Turn main power switch OFF to save changes If display pressure is greater than desired pressure reduce the hydraulic pressure and trigger gun to reduce pressure Check the pr...

Page 31: ...ess motor to start motor and pumps 7 Check fluid pressure display and adjust as necessary 8 Check fluid pressure gauges GA GB to ensure proper pressure balance If imbal anced reduce pressure of higher compo nent by slightly turning PRESSURE RELIEF SPRAY valve for that component toward PRESSURE RELIEF CIRCULA TION until gauges show balanced pressures ti2409a ti2728a ti2543a ti9877a SA SB In this ex...

Page 32: ...nto cardboard Adjust pressure and temperature to get desired results 12 Equipment is ready to spray On impingement guns never open fluid manifold valves or trigger gun if pres sures are imbalanced ti2414a If you stop spraying for a period of time the unit will enter standby if enabled See page 33 ti2410a ...

Page 33: ... will ramp up to full speed in a few seconds To activate or disable standby adjust DIP switch 3 on the motor control board See Reactor Repair Parts manual 312063 The idle time before entering standby is user settable as follows 1 Turn main power switch OFF 2 Press and hold then turn main power switch ON 3 Press or to select desired timer setting 5 20 in 5 minute increments This sets the length of ...

Page 34: ...rk 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 Close both fluid supply valves FV 5 Relieve pressure page 35 6 Shut down feed pumps as required A B ti9883a FV ...

Page 35: ...fluid manifold valves A and B 3 Shut off feed pumps and agitator if used 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 0 5 Engage gun piston safety lock 6 Disconnect gun air line and remove gun fluid manifold ti2421a ti9879a SA SB ti2409a ti2554a ...

Page 36: ...ot turn on heat zone unless hoses are already loaded with fluid 6 Press to display actual temperatures 7 Before starting motor reduce hydraulic pressure to the minimum required to circu late fluid until and temperatures reach targets 8 Press motor to start motor and pumps Circulate fluid at lowest possible pressure until temperatures reach targets Do not circulate fluid containing a blowing agent ...

Page 37: ...re of this equipment See Typical Installation without circulation page 13 3 Follow Load fluid with feed pumps page 27 4 Turn main power ON 5 Set temperature targets see page 28 Turn on and heat zones by pressing 6 Press to display actual temperatures 7 Before starting motor reduce hydraulic pressure to the minimum required to circu late fluid until and temperatures reach targets 8 Press motor to s...

Page 38: ... other codes turn main power OFF then ON to clear See repair manual for corrective action Code Code Name Alarm Zone 01 High fluid temperature Individual 02 High current Individual 03 No current Individual 04 FTS not connected Individual 05 Board overtemperature Individual 06 Loss of zone communication Individual 30 Momentary loss of communica tion All 99 Loss of display communication All For hose ...

Page 39: ... different warnings or until main power is turned OFF then ON Alarms can also be cleared except for code 23 by pressing Code 24 pressure imbalance is set to an alarm default of 500 psi 3 5 MPa 35 bar To change to a warning see Reac tor Repair Parts manual 312063 To change the default pressure imbalance setting see page 30 Code No Code Name Alarm or Warning 21 No transducer component A Alarm 22 No ...

Page 40: ...manual 312063 If fluid is dark in color change fluid and filter 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 ommended frequency of oil changes Table 4 Frequency of Oil Changes Keep component A from exposure to mois ture in atmosphere to prevent crystalliza tion Clean gun mix chamber ports regularly See gun manual ...

Page 41: ...ainer manifold 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 4 Ensure the pipe plug 59k is screwed into the strainer plug 59j Install the strainer plug with the screen 59g and gasket 59h in place and tighten Do not overtighten Let the gasket make the se...

Page 42: ...35 2 Lift the lubricant reservoir LR out of the bracket RB and remove the container from the cap Holding the cap over a suit able container remove the check valve and allow the lubricant to drain Reattach the check valve to the inlet hose See FIG 7 3 Drain the reservoir and flush it with clean lubricant 4 When the reservoir is flushed clean fill with fresh lubricant 5 Thread the reservoir onto the...

Page 43: ...rom heated hoses set PRES SURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION Flush through bleed lines N To flush entire system circulate through gun fluid manifold with manifold removed from gun To prevent moisture from reacting with iso cyanate always leave the system dry or filled with a moisture free plasticizer or oil Do not use water See page 10 Flush equipment only in a well vent...

Page 44: ...E rear mounting holes 33 6 853 F side mounting holes 16 25 413 G mounting post inner diameter 0 44 11 H front mounting post height 2 0 51 J rear mounting post height 3 6 92 Dimension in mm A C B D E F G H J Top View Front of Rear of Side View Detail of mounting post height to correctly size mounting bolts TI9830a ti7742a ti7743a ...

Page 45: ...n 10 kg min 60 Hz Model H XP2 1 5 gpm 5 7 liter min 60 Hz Model H 50 52 lb min 24 kg min 60 Hz Model H 40 45 lb min 20 kg min 60 Hz Model H XP3 2 8 gpm 10 6 liter min 60 Hz Output per Cycle A and B Models H 25 and H 40 0 063 gal 0 23 liter Model H 50 0 073 gal 0 28 liter Models H XP2 and H XP3 0 042 gal 0 16 liter Line Voltage Requirement 230V 1 phase and 230V 3 phase units 195 264 Vac 50 60 Hz 40...

Page 46: ... 1500 10 3 103 2000 13 8 138 2500 17 2 172 3000 20 7 207 500 3 4 34 G H J K 5 2 3 25 11 4 15 6 8 35 15 9 45 20 5 2000 13 8 138 1500 10 3 103 1000 6 9 69 500 3 4 34 A B C D KEY A H 25 at 50 Hz B H 25 at 60 Hz C H 40 at 50 Hz D H 40 at 60 Hz E H 50 at 50 Hz F H 50 at 60 Hz KEY G H XP2 at 50 Hz H H XP2 at 60 Hz J H XP3 at 50 Hz K H XP3 at 60 Hz F E 55 25 0 Pressure flow curve for model 253725 H 50 23...

Page 47: ...9 2 0 7 6 1 0 3 8 2 5 9 5 1 5 5 7 4 0 15 1 3 0 11 4 3 5 13 2 4 5 17 0 KEY J 8 kW K 12 kW L 15 3 kW M 20 4 kW 10 6 90 50 80 44 70 39 60 33 50 28 40 22 30 17 20 11 140 78 130 72 120 67 110 61 100 56 J K L M Heater performance data is based on testing with 10 wt hydraulic oil and 230V across heater power wires ...

Page 48: ...anship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as se...