Reactor?? 2 Hydraulic

Proportioning Systems

334945B

EN

Important Isocyanate Information

Material Self-Ignition

Some materials may become self-igniting if applied too thick. Read material manufacturer???s warnings and SDS.

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage to equipment. To prevent cross-contamination:

???Never interchange component A and component B wetted parts.

???Never use solvent on one side if it has been contaminated from the other side.

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

???When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

???Always clean the fluid inlet strainers after flushing.

???Check with your material manufacturer for chemical compatibility.

???When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid.

Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

???Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

???Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

???Use only moisture-proof hoses compatible with ISO.

???Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

???Always lubricate threaded parts with an appropriate lubricant when reassembling.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures above 90??F (33??C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

*Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

???Total system watts used by system, based on maximum heated hose length for each unit.

???H???30 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.

???See Approvals, page 15.

???Packages include gun, heated hose, and whip hose. Elite packages also include Graco InSite and fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap??? 50 ft (15 m) heated hose. For part numbers, see Accessories, page 15.

Voltage Configurations Key

??PHASE

??? DELTA

Y WYE

*Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

???Total system watts used by system, based on maximum heated hose length for each unit.

???H???40 series: 410 ft (125 m) maximum heated hose length, including whip hose.

???See Approvals, page 15.

???Packages include gun, heated hose, and whip hose. Elite packages also include Graco InSite and fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap??? 50 ft (15 m) heated hose. For part numbers, see Accessories, page 15.

Voltage Configurations Key

??PHASE

??? DELTA

Y WYE

*Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

???Total system watts used by system, based on maximum heated hose length for each unit.

???H???40 series: 410 ft (125 m) maximum heated hose length, including whip hose.

???See Approvals, page 15.

???Packages include gun, heated hose, and whip hose. Elite packages also include Graco InSite and fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap??? 50 ft (15 m) heated hose. For part numbers, see Accessories, page 15.

Voltage Configurations Key

??PHASE

??? DELTA

Y WYE

*Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

???Total system watts used by system, based on maximum heated hose length for each unit.

???H???50 series: 410 ft (125 m) maximum heated hose length, including whip hose.

???See Approvals, page 15.

???Packages include gun, heated hose, and whip hose. Elite packages also include Graco InSite and fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap??? 50 ft (15 m) heated hose. For part numbers, see Accessories, page 15.

Voltage Configurations Key

??PHASE

??? DELTA

Y WYE

*Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

???Total system watts used by system, based on maximum heated hose length for each unit.

???H???XP2 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.

???See Approvals, page 15.

???Packages include gun, heated hose, and whip hose. Elite packages also include Graco InSite and fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap??? 50 ft (15 m) heated hose. For part numbers, see Accessories, page 15.

Voltage Configurations Key

??PHASE

??? DELTA

Y WYE

*Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

???Total system watts used by system, based on maximum heated hose length for each unit.

???H???XP3 series: 410 ft (125 m) maximum heated hose length, including whip hose.

???See Approvals, page 15.

???Packages include gun, heated hose, and whip hose. Elite packages also include Graco InSite and fluid inlet sensors. All Elite hose and gun system packages include Xtreme-Wrap??? 50 ft (15 m) heated hose. For part numbers, see Accessories, page 15.

Voltage Configurations Key

??PHASE

??? DELTA

Y WYE

Approvals

Intertek approvals apply to proportioners without hoses.

Proportioner Approvals:

9902471

Conforms to ANSI/UL Std. 499 Certified to CAN/CSA Std. C22.2 No. 88

Approvals

Accessories

The following manuals are shipped with the Reactor 2 . Refer to these manuals for detailed equipment information.

Manuals are also available at www.graco.com.

Manual Description

334945 Reactor 2 Hydraulic Proportioning

Systems Operation Manual

334005 Reactor 2 Hydraulic Proportioning

Systems Shutdown Quick Guide

334006 Reactor 2 Hydraulic Proportioning

Systems Startup Quick Guide

The following manuals are for accessories used with the Reactor 2.

Component Manuals in English:

Manuals are available at www.graco.com.

System Manuals

333946 Reactor 2 Repair-Parts

Displacement Pump Manual

3A3085 Pump Repair-Parts

Feed System Manuals

309572 Heated Hose, Instructions-Parts

309852 Circulation and Return Tube Kit,

Instructions-Parts

309815 Feed Pump Kits, Instructions-Parts

309827 Feed Pump Air Supply Kit,

Instructions-Parts

Spray Gun Manuals

309550 Fusion ??? AP Gun

312666 Fusion ??? CS Gun

313213 Probler?? P2 Gun

Accessory Manuals

3A1905 Feed Pump Shutdown Kit,

Instructions-Parts

3A3009 Inlet Sensor Kit, Instructions-Parts

3A1907 Remote Display Module Kit,

Instructions-Parts

332735 Air Manifold Kit, Instructions-Parts

3A3010 Caster Kit, Instructions-Parts

333276 Graco InSite ??? Kit, Instructions-Parts

3A3084 Elite Kit, Instructions-Part

3A3085 Pumpline Repair, Instructions-Parts

Typical Installation, without circulation

Typical Installation, without circulation

H

G

M

K

G

F

J

(A-ISO)

D

E

S

(B-RES)

N

R

M

K

G

A

R

L

J

(A-ISO)

D

(B-RES)

F

J

Component Identification

Component Identification

Advanced Display Module (ADM)

The ADM display shows graphical and text information related to setup and spray operations.

Figure 5 ADM Front View

NOTICE

To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails.

Table 1 : ADM Keys and Indicators

Setup

Press to choose a field to update, to make a selection, to save a selection or value, to enter a screen,

Enter or to acknowledge an event.

Component Identification

ADM Display Details

Power Up Screen

The following screen appears when the ADM is powered up. It remains on while the ADM runs through initialization and establishes communication with other modules in the system.

Menu Bar

The menu bar appears at the top of each screen. (The following image is only an example.)

Date and Time

The date and time are always displayed in one of the following formats. The time is always displayed as a 24-hour clock.

???DD/MM/YY HH:MM

???YY/MM/DD HH:MM

???MM/DD/YY HH:MM

Arrows

The left and right arrows indicate screen navigation.

Screen Menu

The screen menu indicates the currently active screen, which is highlighted. It also indicates the associated screens that are available by scrolling left and right.

System Mode

The current system mode is displayed at the lower left of the menu bar.

System Errors

The current system error is displayed in the middle of the menu bar. There are four possibilities:

Icon Function

No Icon No information or no error has occurred

Advisory

Deviation

Alarm

See Troubleshoot Errors, page 60 for more information.

Status

The current system status is displayed at the lower right of the menu bar.

Soft Keys

Icons next to the soft keys indicate which mode or action is associated with each soft key. Soft keys that do not have an icon next to them are not active in the current screen.

NOTICE

To prevent damage to the soft key buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails.

Navigating the Screens

There are two sets of screens:

???Run Screens ??? control spraying operations and display system status and data.

???Setup Screens ??? control system parameters and advanced features.

Press on any Run screen to enter the Setup screens. If the system has a password lock, the Password screen displays. If the system is not locked (password is set to 0000), System Screen 1 displays.

Press on any Setup screen to return to the Home screen.

Press the Enter soft key to activate the editing function on any screen.

Press the Exit soft key to exit any screen.

Use the other softkeys to select the function adjacent to them.

Icons

Icons

Component Identification

Softkeys

Icon Function

Start Proportioner

Stop Proportioner

Turn on or off the specified heat zone.

Park pump

Reset Cycle Counter (press and hold)

Select Recipe

Search

Move Cursor Left One Character

Move Cursor Right One Character

Toggle between upper-case, lower-case, and numbers and special characters.

Backspace

Cancel

Clear

Troubleshoot Selected Error

Increase value

Decrease value

Next screen

Previous screen

Return to first screen

Hydraulic Control Module (HCM)

Figure 7

Component Identification

HCM Rotary Switch (RS) Positions

0 = Reactor 2, H-30

1 = Reactor 2, H-40

2 = Reactor 2, H-50

3 = Reactor 2, H-XP2

4 = Reactor 2, H-XP3

Table 3 HCM Module LED (MS) Status Descriptions

Setup

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

???Reactor: System is grounded through the power cord.

???Spray gun:connect whip hose ground wire to FTS. See Install Fluid Temperature Sensor. Do not disconnect ground wire or spray without whip hose.

??? Fluid supply containers: follow your local code.

???Object being sprayed: follow your local code.

???Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

???To maintain grounding continuity when flushing or relieving pressure,hold a metal part of spray gun

firmly to the side of a grounded metalpail, then trigger gun.

Setup

General Equipment Guidelines

NOTICE

Failure to properly size the equipment may result in damage. To avoid damage to the equipment, follow the guidelines listed below.

???Determine the correct size generator. Using the correct size generator and proper air compressor will enable the proportioner to run at a nearly constant RPM. Failure to do so will cause voltage fluctuations that can damage electrical equipment. Ensure that the generator matches the voltage and phase of the proportioner.

Use the following procedure to determine the correct size generator.

1.List peak wattage requirements of all system components.

2.Add the wattage required by the system components.

3.Perform the following equation:

Total watts x 1.25 = kVA (kilovolt-amperes)

4.Select a generator size that is equal to or greater than the determined kVA.

???Use proportioner power cords that meet or exceed the requirements listed in Table 4. Failure to do so will cause voltage fluctuations that can damage electrical equipment, and may cause the power cable to overheat.

???Use an air compressor with continuous run head unloading devices. Direct online air compressors that start and stop during a job will cause voltage fluctuations that can damage electrical equipment.

???Maintain and inspect the generator, air compressor, and other equipment per the manufacturer recommendations to avoid an unexpected shutdown. Unexpected equipment shutdown will cause voltage fluctuations that can damage electrical equipment.

???Use a wall power supply with enough current to meet system requirements. Failure to do so will cause voltage fluctuations that can damage electrical equipment.

Setup

Connect Power

NOTE: All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

1.Turn main power switch (MP) OFF.

2.Open electrical enclosure door.

NOTE: Terminal jumpers are located inside the electrical enclosure door if equipped.

3.Install supplied terminal jumpers in the positions shown in image for the power source used (H-30 and H-XP2 models only).

4.Route power cable through strain relief (EC) in electrical enclosure.

5.Connect incoming power wires as shown in image. Gently pull on all connections to verify they are properly secured.

6.Verify all items are connected properly as shown in image then close electrical enclosure door.

ti26342a_17D775

Table 5 Power Cord Requirements

*Values are for reference only. Refer to amperage listed in Models table (see Models, page 9 ) for given system and compare against latest version of local electrical code to select proper power cord size.

NOTE: 400 VAC systems are not designed to operate from 480 VAC power source.

Lubrication System Setup

Component A (ISO) Pump: Fill ISO lube reservoir (LR) with Graco Throat Seal Liquid (TSL), part 206995 (supplied).

1.Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap.

2.Fill with fresh lubricant. Thread the reservoir onto the cap assembly and place it in the bracket (RB).

3.Push the larger diameter supply tube (ST) approximately 1/3 of the way into the reservoir.

4.Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom.

NOTE: The return (RT) must reach the bottom of the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube (ST) and returned to the pump.

Setup

5.The lubrication is ready for operation. No priming is required.

Install Fluid Temperature Sensor

The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose (see Related Manuals, page 16).

Install Heated Hose to Proportioner

1. Remove cover (CV).

2.Route heated hose wires (HW) through strain relief (SR) and install wires into the open screw terminals on the terminal block (TB). Torque to 35 in-lb (3.95 N???m).

3.Reinstall cover (CV).

When main power is turned on by turning the main power switch (MP) to the ON position, the power up screen will be displayed until communication and initialization is complete.

Then the power key icon screen will display until the

ADM power on/off button (A) is pressed for the first time after system power-up.

To begin using the ADM, the machine must be active. To verify the machine is active, verify that the System Status Indicator Light (B) is illuminated green, see Advanced Display Module (ADM), page 22. 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 tasks to fully setup your system.

1.Set pressure values for the Pressure Imbalance Alarm to activate. See System Screen 1, page 36.

2.Enter, enable, or disable recipes. See Recipes Screen, page 37.

3.Set general system settings. See Advanced Screen 1 ??? General, page 35.

4.Set units of measure. See Advanced Screen 2 ??? Units, page 35.

5.Set USB settings. See

Advanced Screen 3??? USB, page 35.

6.Set target temperatures and pressure. See Targets, page 39.

7.Set component A and component B supply levels. See Maintenance, page 40.

Advanced Screen 2 ??? Units

Use this screen to set the temperature units, pressure units, volume units, and cycle units (pump cycles or volume).

Advanced Screen 4 ??? Software

This screen displays the software part number and software version for the Advanced Display Module, USB Configuration, Hydraulic Control Module, and Temperature Control Module, and Remote Display Module (optional).

Advanced Display Module (ADM) Operation

System 1

Use this screen to set the activation pressure for the Pressure Imbalance Alarm and Deviation, enable or disable diagnostic screens, set the maximum and minimum drum volume, and enable drum alarms.

System 2

Use this screen to enable Manual Hose Mode and inlet sensors, as well as setting the inlet sensor low pressure alarm and low temperature deviation. Manual Hose Mode disables the hose temperature RTD sensor so the system can operate if the sensors were to malfunction (see Manual Hose Heat Mode, page 51 for more information). Default settings are 10 psi (0.07 MPa, 0.7 bar) for low inlet pressure alarm and 50??F (10??C) for low inlet temperature deviation.

System 3

Use this screen to enable alternate pump cylinder sizes, to turn motor standby mode on and off, and to enable recirculation cycle count. Cycles below 700 psi outlet pressure will not be counted unless enabled.

Recipes

Use this screen to add recipes, view saved recipes, and enable or disable saved recipes. Enabled recipes can be selected at the Home Run Screen. 24 recipes can be displayed on the three recipe screens.

Advanced Display Module (ADM) Operation

Add Recipe

1.Press and then use to select a recipe field. Press to enter a recipe name (maximum 16 characters). Press to clear the old recipe name.

2.Use to highlight the next field and use the number pad to enter a value. Press to save.

Enable or Disable Recipes

1.Press and then use to select the recipe that needs to be enabled or disabled.

2.Use to highlight the enabled check box. Press to enable or disable the recipe.

Home ??? System Off

This is the home screen when the system is off. This screen displays actual temperatures, actual pressures at the fluid manifold, and number of cycles.

Home ??? System Active

When the system is active, the home screen displays actual temperature for heat zones, actual pressures at the fluid manifold, the number of cycles, along with all associated control soft keys.

Use this screen to turn on heat zones, start the proportioner, stop the proportioner, park the component A pump, and clear cycles.

NOTE: Screen shown displays inlet sensor temperatures and pressures. These will not be shown on models without inlet sensors.

Advanced Display Module (ADM) Operation

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 status bar.

1.Press to acknowledge the error.

2.See for corrective action.

Targets

Use this screen to define the setpoints for the A Component Temperature, B Component Temperature, heated hose temperature, and pressure.

Maximum A and B temperature: 190??F (88??C)

Maximum heated hose temperature: the lesser of 10??F (5??C) above the highest A or B temperature setpoint or 180??F (82??C).

Note

If the remote display module kit is used, these setpoints can be modified at the gun.

Advanced Display Module (ADM) Operation

Maintenance

Use this screen to view daily and lifetime cycles or gallons that have been pumped and gallons or liters remaining in the drums.

The lifetime value is the number of pump cycles or gallons since the first time the ADM was turned on.

The daily value automatically resets at midnight.

The manual value is the counter that can be manually reset. Press and hold to reset manual counter.

Cycles

This screen shows daily cycles and gallons that have been sprayed for the day.

All information listed on this screen can be downloaded on a USB flash drive. To download logs, see Download Procedure, page 61.

Events

This screen shows the date, time, event code, and description of all events that have occurred on the system. There are 10 pages, each holding 10

events. The 100 most recent events are shown. See System Events, page 43 for event code descriptions. See Error Codes and Troubleshooting, page 61 for error code descriptions.

All events and errors listed on this screen can be downloaded on a USB flash drive. To download logs, see Download Procedure, page 61.

Errors

This screen shows the date, time, error code, and description of all errors that have occurred on the system.

All errors listed on this screen can be downloaded on a USB flash drive. To download logs, see Download Procedure, page 61.

Troubleshooting

This screen displays the last ten errors that occurred on the system. Use the up and down

arrows to select an error and press to view

the QR code for the selected error. Press to access the QR code screen for an error code that is not listed on this screen. See

Error Codes and Troubleshooting, page 61, for more information on error codes.

Advanced Display Module (ADM) Operation

QR Codes

To quickly view online help for a given error code, scan the displayed QR code with your smartphone. Alternately, visit http://help.graco.com and search for the error code to view online help for that code.

Advanced Display Module (ADM) Operation

Diagnostic

Use this screen to view information for all system components. NOTE: If not visible, this screen may be on the Setup Systems screen (see Setup Mode).

The following information is displayed:

Temperature

???A Chemical

???B Chemical

???Hose Chemical

???TCM PCB ??? temperature control module temperature

Amps

???A Current

???B Current

???Hose Current

Volts

???A Voltage

???B Voltage

???Hose Voltage

Pressure

???Pressure A ??? chemical

???Pressure B ??? chemical

Cycles

???CPM ??? cycles per minute

???Total Cycles ??? lifetime cycles

Job Data

Use this screen to enter a job name or number.

Recipes

Use this screen to select an enabled recipe. Use the up and down arrows to highlight a recipe and press

to load. The currently loaded recipe is outlined by a green box.

Note

This screen will not display if there are not any enabled recipes. To enable or disable recipes, see Recipes Setup Screen, page 37.

Startup

Startup

To prevent serious injury, only operate Reactor with all covers and shrouds in place.

NOTICE

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.

1.Check fluid inlet filter screens.

Before daily startup, ensure that the fluid inlet screens are clean. See Flush Inlet Strainer Screen, page 58

2.Check ISO lubrication reservoir.

Check level and condition of ISO lube daily. See Pump Lubrication System, page 59.

3.Use A and B Drum Level Sticks (24M174) to measure the material level in each drum. If needed, the level can be entered and tracked in the ADM. See Advanced Setup Screens, page 35.

4.Check generator fuel level.

NOTICE

Running out of fuel will cause voltage fluctuations that can damage electrical equipment and void the warranty. Do not run out of fuel.

5.Confirm main power switch is OFF before starting generator.

6.Ensure the main breaker on the generator is in the off position.

7.Start the generator. Allow it to reach full operating temperature.

8. Turn main power switch ON.

The ADM will display the following screen until communication and initialization is complete.

9.Switch on the air compressor, air dryer, and breathing air, if included.

10.For first startup of new system, load fluid with feed pumps.

a.Check that all Setup steps are complete. See Setup, page 29.

b.If an agitator is used, open the agitator???s air inlet valve.

c.If you need to circulate fluid through the system to preheat the drum supply, see Circulation Through Reactor, page 47.

If you need to circulate material through the heat hose to the gun manifold, see Circulation Through Gun Manifold, page 48.

d.Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY .

GA GB

Startup

e. Open fluid inlet valves (FV). Check for leaks.

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

???Never interchange component A and component B wetted parts.

???Never use solvent on one side if it has been contaminated from the other side.

???Always provide two grounded waste containers to keep component A and component B fluids separate.

f.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.

Startup

11.Press to activate ADM.

12.If necessary, setup the ADM in Setup Mode. See Advanced Display Module (ADM) Operation, page 32.

13.Preheat the system:

a. Press to turn on hose heat zone.

This 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.

???Do not turn on hose heat without fluid in hoses.

???Allow equipment to cool completely before touching it.

???Wear gloves if fluid temperature exceeds 110??F (43??C).

Thermal expansion can cause over-pressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose.

b.If you need to circulate fluid through the system to preheat the drum supply, see Circulation Through Reactor, page 47.

If you need to circulate material through the heat hose to the gun manifold, see Circulation Through Gun Manifold, page 48.

c.Wait for the hose to reach set point temperature.

NOTE: Hose heat-up time may increase at voltages less than nominal 230 VAC when maximum hose length is used.

d.Press to turn on A and B heat zones.

Circulation Through Reactor

NOTICE

To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.

NOTE: Optimum heat transfer is achieved at lower fluid flow rates with temperature set points at desired drum temperature. Low temperature rise deviation errors may result.

To circulate through gun manifold and preheat hose, see Circulation Through Gun Manifold, page 48.

1. Follow Startup, page 44.

To avoid injection injury and splashing, 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 operating.

2.See Typical Installation, with system fluid manifold to drum circulation, page 18. Route circulation lines back to respective component A or B supply drum. Use hoses rated for the maximum working pressure of this equipment. See Technical Specifications, page 66.

3.Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION .

4.Set temperature targets. See Targets, page 39.

5.Before starting the motor, unlock the hydraulic compensator knob, then rotate counter-clockwise until it ceases to move.

6.Press motor to start motor and pumps. Circulate fluid at lowest possible pressure until temperatures reach targets.

7.Press to turn on the hose heat zone.

8.Turn on the A and B heat zones. Wait until the fluid inlet valve temperature gauges (FTG) reach the minimum chemical temperature from the supply drums.

9.Turn off motor.

10.Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY .

GA GB

Fluid Circulation

Circulation Through Gun Manifold

NOTICE

To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.

NOTE: Optimum heat transfer is achieved at lower fluid flow rates with temperature set points at desired drum temperature. Low temperature rise deviation errors may result.

Circulating fluid through the gun manifold allows rapid preheating of the hose.

1.Install gun fluid manifold (P) on accessory circulation kit (CK). Connect high pressure circulation lines (R) to circulation manifold.

P

CK

R

The Fusion AP gun manifold is shown.

2.Route circulation lines back to respective component A or B supply drum. Use hoses rated for the maximum working pressure of this equipment. See Technical Specifications.

3.Follow procedures from Startup, page 44.

4.Turn main power switch on.

5.Set temperature targets. See Targets, page 39.

6.Before starting the motor, unlock the hydraulic compensator knob, then rotate counter-clockwise until it ceases to move.

7.Press motor to start motor and pumps. Circulate fluid at lowest possible pressure until temperatures reach targets.

8.Press to turn on the hose heat zone.

9.Turn on the A and B heat zones. Wait until the fluid inlet valve temperature gauges (FTG) reach the minimum chemical temperature from the supply drums.

10.Turn off motor.

2.Attach gun fluid manifold. Connect gun air line. Open air line valve.

3.Adjust the gun air pressure. Do not exceed 130 psi (0.2 MPa, 2 bar).

4.Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY .

GA GB

5.Verify heat zones are on and temperatures are on target, see Home screen, page 39.

7. Press to start motor and pumps.

8.Adjust pressure compensator knob to desired fluid stall pressure. Turn knob clockwise to increase pressure and counter-clockwise to decrease pressure. Use hydraulic pressure gauge (HPG) to view hydraulic pressure. Once desired fluid stall pressure is set, lock the knob

in place by rotating lower portion clockwise until tight.

Component A and B outlet pressures will be higher than the hydraulic set pressure, depending on the model. Component A and B (GA, GB) pressure may be viewed on the pressure gauges or the ADM.

Spraying

9.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 component toward PRESSURE

RELIEF/CIRCULATION until gauges show balanced pressures.

10. Open gun fluid inlet valves A and B.

NOTICE

To prevent material crossover on impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.

11. Disengage gun piston safety lock.

12.Pull gun trigger to test spray onto cardboard. If necessary, adjust pressure and temperature to get desired results.

Spray Adjustments

Flow rate, atomization, and amount of overspray are affected by four variables.

???Fluid pressure setting. Too little pressure results in an uneven pattern, coarse droplet size, low flow, and poor mixing. Too much pressure results in excessive overspray, high flow rates, difficult control, and excessive wear.

???Fluid temperature. Similar effects to fluid pressure setting. The A and B temperatures can be offset to help balance the fluid pressure.

???Mix chamber size. Choice of mix chamber is based on desired flow rate and fluid viscosity.

???Clean-off air adjustment. Too little clean-off air results in droplets building up on the front of the nozzle, and no pattern containment to control overspray. Too much clean-off air results in air-assisted atomization and excessive overspray.

Manual Hose Heat Mode

If the system produces the T6DH Sensor Error Hose alarm or the T6DT Sensor Error TCM alarm, use manual hose heat mode until the hose RTD cable or FTS temperature sensor can be repaired.

Do not use Manual Hose Mode for extended periods of time. The system performs best when the hose has a valid RTD signal and can operate in temperature control mode. If a hose RTD breaks, the first priority is to fix the RTD. Manual Hose Mode can help finish a job while waiting for repair parts.

Spraying

3.Select Enable Manual Hose Mode.

NOTE: When manual hose mode is enabled, the manual hose mode advisory EVCH-V will appear.

4.Enter Run Mode and navigate to the Target screen. Use the up and down arrows to set the desired hose current.

Spraying

5.Navigate back to the Run Mode Home screen. The hose now displays a current instead of a temperature.

NOTE: Until the RTD sensor is repaired, the T6DH sensor error alarm will display each time the system is powered up.

Disable Manual Hose Mode

1.Enter Setup Mode and navigate to System 2 Screen and deselect Enable Manual Hose Mode, or repair the hose RTD cable or FTS.

2.Manual hose mode is automatically disabled when the system detects a valid RTD sensor in the hose.

If you stop spraying for a period of time, the unit will enter standby by shutting down the electric motor and hydraulic pump, to reduce equipment wear and minimize heat buildup. The pump icon on the ADM Home screen will flash when in standby.

NOTE: The A, B, and Hose heat zones will not shut off during standby.

To restart, spray off target for two seconds. The system will sense the pressure drop and the motor will ramp up to full speed in a few seconds.

NOTE: This feature is disabled from the factory.

To activate or deactivate standby:

1.Enter setup mode by pressing on the ADM.

2.Go to screen System 3 and select to enter the page for editing.

3.Select the ???Standby Idle Time??? drop down using and the arrow keys. Select the desired delay using and the arrow keys. Press enter to select the desired value.

4.Exit the page and return to run mode by pressing , then .

Shutdown

Shutdown

NOTICE

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.

1.Press to stop the pumps.

2.Turn off all heat zones.

3.Relieve pressure. See

Pressure Relief Procedure, page 55.

4.Press to park the Component A and Component B pumps. The park operation is complete when green dot goes out. Verify the park operation is complete before moving to next step.

6.Turn off the air compressor, air dryer, and breathing air.

7. Turn main power switch OFF.

To prevent electric shock do not remove any shrouds or open the electrical enclosure door while the power is ON.

8. Close all fluid supply valves.

9.Set PRESSURE RELIEF/SPRAY valves to SPRAY to seal out moisture from the drain line.

10.Engage gun piston safety lock then close fluid inlet valves A and B.

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

The Fusion AP gun is shown.

1.Press to stop the pumps.

2.Turn off all heat zones.

3.Relieve pressure in gun and perform gun shutdown procedure. See gun manual.

4. Close gun fluid inlet valves A and B.

5.Shut off feed pumps and agitator, if used.

6.Route fluid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

7. Engage gun piston safety lock.

8.Disconnect gun air line and remove gun fluid manifold.

Flushing

Flushing

To avoid fire and explosion:

???Flush equipment only in a well-ventilated area.

???Ensure main power is off and heater is cool before flushing.

???Do not turn on heater until fluid lines are clear of solevent.

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).

To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).

To prevent moisture from reacting with isocyanate, always leave the system filled with a moisture-free plasticizer or oil. Do not use water. Never leave the system dry. See Important Two-Component Material Information.

Maintenance

Prior to performing any maintenance procedures, follow Pressure Relief Procedure, page 55.

Preventative Maintenance Schedule

The operating conditions of your particular system determine how often maintenance is required. Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

???Inspect hydraulic and fluid lines for leaks daily.

???Clean up all hydraulic leaks; identify and repair the cause of the leak.

???Inspect fluid inlet strainer screens daily. See below.

???Keep component A from exposure to moisture to prevent crystallization.

???Check hydraulic fluid level weekly. Check hydraulic fluid level on a dipstick. Fluid level must be between indent marks on dipstick. Refill as required with approved hydraulic fluid (see Technical Specifications, page 66 and the Approved Anti-Wear (AW) Hydraulic Oils table in the Reactor Repair-Parts manual 334946. If fluid is dark in color, change fluid and filter.

Maintenance

Table 6 Frequency of Oil Changes

Proportioner Maintenance

Fluid Inlet Strainer Screens

Inspect fluid inlet strainer screens daily, see Flush Inlet Strainer Screen, page 58.

Grease Circulation Valves

Grease circulation valves (SA and SB) with Fusion grease (117773) weekly.

???Change break-in oil in a new unit after the first 250 hours of operation or within 3 months, whichever comes first. See the table below for recommended frequency of oil changes.

ISO Lubricant Level

Inspect ISO lubricant level and condition daily. Refill or replace as needed. See Pump Lubrication System, page 59.

Moisture

To prevent crystallization, do not expose component A to moisture in air.

Gun Mix Chamber Ports

Clean gun mix chamber ports regularly. See gun manual.

Maintenance

Gun Check Valve Screens

Clean gun check valve screens regularly. See gun manual.

Dust Protection

Use clean, dry, oil-free compressed air to prevent dust buildup on control modules, fans, and motor (under shield).

Vent Holes

Keep vent holes on bottom and back of electrical enclosure and sides and back of transformer enclosure open..

Flush Inlet Strainer Screen

The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.

Isocyanate can crystallize from moisture contamination or from freezing. If the chemicals used are clean and proper storage, transfer, and operating procedures are followed, there should be minimal contamination of the A-side screen.

Note

Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.

1.Close the fluid inlet valve 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 removing the strainer plug (C).

3.Remove the screen (A) from the strainer manifold. Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. No more than 25% of the mesh should be restricted. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket

(B) and replace as required.

4.Ensure the pipe plug (D) is screwed into the strainer plug (C). Install the strainer plug with the screen (A) and o-ring (B) in place and tighten. Do not overtighten. Let the o-ring make the seal.

5.Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.

Figure 10

Pump Lubrication System

Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible.

Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during 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 Relief Procedure, page 55.

2.Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap. Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reattach the check valve to the inlet hose.

3.Drain the reservoir and flush it with clean lubricant.

4.When the reservoir is flushed clean, fill with fresh lubricant.

Maintenance

5.Thread the reservoir onto the cap assembly and place it in the bracket.

6.Push the larger diameter supply (ST) tube approximately 1/3 of the way into the reservoir.

7.Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom.

NOTE: The return tube must reach the bottom of the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube and returned to the pump.

8.The lubrication system is ready for operation. No priming is required.

Pump Lubrication System

Figure 11

Errors

Errors

View Errors

When an error occurs the error information screen displays the active error code and description.

The error code, alarm bell, and active errors will scroll in the status bar. For a list of the ten most recent errors see Troubleshooting. Error codes are stored in the error log and displayed on the Error and Troubleshooting screens on the ADM.

There are three types of errors that can occur. Errors are indicated on the display 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 addressed immediately.

Deviations are indicated by . This condition indicates a parameter critical to the process has reached a level requiring attention, but not sufficient enough to stop the system at this time.

Advisories are indicated by . This condition indicates a parameter that is not immediately critical to the process. The advisory needs attention to prevent more serious issues in the future.

To diagnose the active error, see

Troubleshoot Errors, page 60.

Troubleshoot Errors

To troubleshoot the error:

1.Press the soft key next to ???Help With This Error??? for help with the active error.

Note

Press or to return to the previously displayed screen.

2.The QR code screen will be displayed. Scan the QR code with your smartphone to be sent directly to online troubleshooting for the active error code. Otherwise, manually navigate to http://help.graco.com and search for the active error.

3.If no internet connection is available, see Error Codes and Troubleshooting, page 61 for causes and solutions for each error code.

Download Procedure

NOTE: System configuration setting files and custom language files can be modified if the files are in the UPLOAD folder of the USB flash drive. See System Configuration Settings File, Custom Language File, and Upload Procedure sections.

1.Insert USB flash drive into USB port.

2.The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete.

3.Remove USB flash drive from USB port.

4.Insert USB flash drive into USB port of computer.

5.The USB flash drive window automatically opens. If it does not, open USB flash drive from within Windows?? Explorer.

6.Open GRACO folder.

7.Open the system folder. If downloading data from more than one system, there will be more than one folder. Each folder is labeled with the corresponding serial number of the ADM (The serial number is on the back of the ADM.)

8.Open DOWNLOAD folder.

9.Open DATAxxxx folder labeled with the highest number. The highest number indicates the most recent data download.

10.Open log file. Log files open in Microsoft?? Excel by default as long as the program is installed. However, they can also be opened in any text editor or Microsoft?? Word.

NOTE: All USB logs are saved in Unicode (UTF-16) format. If opening the log file in Microsoft Word, select Unicode encoding.

NOTE: The ADM can read/write to FAT (File Allocation Table) storage devices. NTFS, used by 32 GB or greater storage devices, is not supported.

During operation, the ADM stores system and performance related information to memory in the form of log files. The ADM maintains six log files:

???Event Log

???Job Log

???Daily Log

???System Software Log

???Blackbox Log

???Diagnostics Log

Follow Download Procedure, page 61, to retrieve log files.

Each time a USB flash drive is inserted into the ADM USB port, a new folder named DATAxxxx is created. The number at the end of the folder name increases each time a USB flash drive is inserted and data is downloaded or uploaded.

Event Log

The event log file name is 1???EVENT.CSV and is stored in the DATAxxxx folder.

The event log maintains a record of the last 49,000 events and errors. Each event record contains:

???Date of event code

???Time of event 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 event conditions by the system, and acknowledging error conditions by the user.

Error Codes and Troubleshooting

Job Log

The job log file name is 2???JOB.CSV and is stored in the DATAxxxx folder.

The job log maintains a record of data points based on the USB Log Frequency defined in the Setup screens. The ADM stores the last 237,000 data points for download. See

Setup - Advanced Screen 3 ??? USB, page 35, for information on setting the Download Depth and USB Log Frequency.

???Data point date

???Data point time

???A side temperature

???B side temperature

???Hose temperature

???A side temperature setpoint

???B side temperature setpoint

???Hose temperature setpoint

???Pressure A

???Pressure B

???A side inlet pressure (Elite only)

???B side inlet pressure (Elite only)

???A side inlet temperature (Elite only)

???B side inlet temperature (Elite only)

???Inlet pressure setpoint

???System lifetime pump cycle counts

???Usage Volume (manual)

???Pressure, volume, and temperature units

???Job name/number

Daily Log

The daily log file name is 3???DAILY.CSV and is stored in the DATAxxxx folder.

The daily log maintains a record of the total cycle and volume sprayed on any day that the system is powered up. The volume units will be the same units that were used in the Job Log.

The following data is stored in this file:

???Date that material was sprayed

???Time ??? unused column

???Total pump cycle count for day

???Total volume sprayed for day

System Software Log

The system software file name is 4???SYSTEM.CSV and is stored in the DATAxxxx folder.

The system software log lists the following:

???Date log was created

???Time log was created

???Component name

???Software version loaded on the above component

Blackbox Log File

The black box file name is 5???BLACKB.CSV and is stored in the DATAxxxx folder.

The Blackbox log maintains a record of how the system runs and the features that are used. This log will help Graco troubleshoot system errors.

Diagnostics Log File

The diagnostics file name is 6???DIAGNO.CSV and is stored in the DATAxxxx folder.

The Diagnostics log maintains a record of how the system runs and the features that are used. This log will help Graco troubleshoot system errors.

System Configuration Settings

The system configuration settings file name is SETTINGS.TXT and is stored in the DOWNLOAD folder.

A system configuration settings file automatically downloads each time a USB flash drive is inserted into the ADM. Use this file to back up system settings for future recovery or to easily replicate settings across multiple systems. Refer to the Upload Procedure, page 63 for instructions on how to use this file.

Custom Language File

The custom language file name is DISPTEXT.TXT and is stored in the DOWNLOAD folder.

A custom language file automatically downloads each time a USB flash drive is inserted into the ADM. If desired, use this file to create a user-defined set of custom language strings to be displayed within the ADM.

The system is able to display the following Unicode characters. For characters outside of this set,

the system will display the Unicode replacement character, which appears as a white question mark inside of a black diamond.

???U+0020 - U+007E (Basic Latin)

???U+00A1 - U+00FF (Latin-1 Supplement)

???U+0100 - U+017F (Latin Extended-A)

???U+0386 - U+03CE (Greek)

???U+0400 - U+045F (Cyrillic)

Create Custom Language Strings

The custom language file is a tab-delimited text file that contains two columns. The first column consists of a list of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was previously installed, this column contains the custom strings. Otherwise the second column is blank.

Modify the second column of the custom language file as needed and the follow Upload Procedure, page 63 , to install the file.

The format of the custom language file is critical. The following rules must be followed in order for the installation process to succeed.

???Define a custom string for each row in the second column.

NOTE: If the custom language file is used, you must define a custom string for each entry in the DISPTEXT.TXT file. Blank second-column fields will be displayed blank on the ADM.

???The file name must be DISPTEXT.TXT.

Error Codes and Troubleshooting

???The file format must be a tab-delimited text file using Unicode (UTF-16) character representation.

???The file must contain only two columns, with columns separated by a single tab character.

???Do not add or remove rows from the file.

???Do not change the order of the rows.

Upload Procedure

Use this procedure to install a system configuration file and/or a custom language file.

1.If necessary, follow the Download Procedure to automatically generate the proper folder structure on the USB flash drive.

2.Insert USB flash drive into USB port of computer.

3.The USB flash drive window automatically opens. If it does not, open USB flash drive from within Windows Explorer.

4.Open GRACO folder.

5.Open the system folder. If working with more than one system, there will be more than one folder within the GRACO folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial number is on the back of the ADM.)

6.If installing the system configuration settings file, place SETTINGS.TXT file into the UPLOAD folder.

7.If installing the custom language file, place DISPTEXT.TXT file into the UPLOAD folder.

8.Remove USB flash drive from the computer.

9.Install USB flash drive into the ADM USB port.

10.The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete.

11.Remove USB flash drive from USB port.

NOTE: If the custom language file was installed, users can now select the new language

from the Language drop-down menu in Advanced Screen 1 ??? General, page 35.