-
Operation
ReactorReactorReactor 222 E-30E-30E-30 andandand
E-XP2E-XP2E-XP2
ProportioningProportioningProportioning SystemsSystemsSystems
333023JEN
Electric,Electric,Electric, Heated,Heated,Heated,
PluralPluralPlural ComponentComponentComponent
ProportionerProportionerProportioner forforfor
sprayingsprayingspraying polyurethanepolyurethanepolyurethane
foamfoamfoam andandand polyureapolyureapolyurea
coatings.coatings.coatings.NotNotNot forforfor
outdooroutdooroutdoor use.use.use. ForForFor
professionalprofessionalprofessional useuseuse only.only.only.
NotNotNot approvedapprovedapproved forforfor useuseuse ininin
explosiveexplosiveexplosive atmospheresatmospheresatmospheres
orororhazardoushazardoushazardous
locations.locations.locations.
ImportantImportantImportant SafetySafetySafety
InstructionsInstructionsInstructionsRead all warnings and
instructions in this manual.SaveSaveSave thesethesethese
instructions.instructions.instructions.
WWLL�� �� �� �� �� EE
PROVEN QUALITY. LEADING TECHNOLOGY.
-
ContentsContentsContentsWarnings
...........................................................
3Important Isocyanate Information.........................
7Models...............................................................
9Approvals...........................................................
11Accessories........................................................
11Supplied Manuals ...............................................
12Related Manuals ................................................
12Typical Installation, without circulation..................
13Typical Installation, with system fluid manifold
to drum circulation ................................. 14Typical
Installation, with gun fluid manifold to
drum circulation.....................................
15Component Identification.....................................
16Advanced Display Module (ADM) ........................ 18
ADM Display Details ....................................
21Navigating the Screens ................................ 21
Electrical Enclosure
............................................ 23Motor Control Module
(MCM) .............................. 24Temperature Control Module
(TCM) Cable
Connections..........................................
25Installation..........................................................
26Setup.................................................................
27
Grounding ...................................................
27General Equipment Guidelines ..................... 27Connect
Power ............................................ 28Supply Wet
Cups With Throat Seal Liquid
(TSL) ............................................. 29Install
Fluid Temperature Sensor .................. 29Connect Heated Hose
to Proportioner ........... 30Register and Activate the Graco
InSite ........... 30
Advanced Display Module
(ADM)Operation.............................................. 31
Advanced Setup Screens....................................
34Advanced Screen 1 — General..................... 34Advanced
Screen 2 — Units ......................... 34Advanced Screen 3 —
USB.......................... 34Advanced Screen 4— Software
.................... 34
System
1............................................................
35System
2............................................................
35Recipes
.............................................................
35
Add Recipe..................................................
35Enable or Disable Recipes............................ 35
Run Mode
.......................................................... 36
Home — System Off .................................... 37Home —
System Active................................ 37Home — System With
Error..........................
37Targets........................................................
37Maintenance................................................
38Cycles.........................................................
38Events.........................................................
38Errors..........................................................
38Troubleshooting ...........................................
39Diagnostic ...................................................
40Job Data .....................................................
40Recipes.......................................................
40
Startup...............................................................
42
Fluid
Circulation..................................................
45Circulation Through Reactor .........................
45Circulation Through Gun Manifold ................. 46
Jog
Mode...........................................................
46
Spraying
............................................................
47Spray Adjustments....................................... 48
Manual Hose Heat Mode.....................................
49Enable Manual Hose Mode........................... 49Disable
Manual Hose Mode.......................... 50
Shutdown...........................................................
51
Pressure Relief Procedure ..................................
53
Flushing
.............................................................
54
Maintenance
......................................................
55Preventative Maintenance Schedule ............. 55Proportioner
Maintenance ............................ 55Flush Inlet Strainer
Screen ........................... 56Pump Lubrication
System............................. 57
Errors
................................................................
58View Errors..................................................
58Troubleshoot Errors ..................................... 58
Troubleshooting..................................................
59Error Codes and Troubleshooting.................. 59
USB
Data...........................................................
60Download Procedure.................................... 60USB
Logs.................................................... 60System
Configuration Settings ...................... 61Custom Language
File ................................. 62Upload Procedure
........................................ 62
Performance Charts............................................
63
Technical Specifications......................................
67
Graco Extended Warranty for Reactor® 2Components
......................................... 69
2 333023J
-
Warnings
WarningsWarningsWarningsThe following warnings are for the
setup, use, grounding, maintenance, and repair of this equipment.
Theexclamation point symbol alerts you to a general warning and the
hazard symbols refer to procedure-specificrisks. When these symbols
appear in the body of this manual or on warning labels, refer back
to theseWarnings. Product-specific hazard symbols and warnings not
covered in this section may appear throughoutthe body of this
manual where applicable.
WARNINGWARNINGWARNINGELECTRICELECTRICELECTRIC SHOCKSHOCKSHOCK
HAZARDHAZARDHAZARD
This equipment must be grounded. Improper grounding, setup, or
usage of the system cancause electric shock.
• Turn off and disconnect power at main switch before
disconnecting any cables and beforeservicing or installing
equipment.
• Connect only to grounded power source.• All electrical wiring
must be done by a qualified electrician and comply with all local
codesand regulations.
• Do not expose to rain. Store indoors.
TOXICTOXICTOXIC FLUIDFLUIDFLUID OROROR FUMESFUMESFUMESToxic
fluids or fumes can cause serious injury or death if splashed in
the eyes or on skin,inhaled or swallowed.
• Read Safety Data Sheet (SDS) for handling instructions and to
know the specific hazards ofthe fluids you are using, including the
effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area,
always keep work areawell ventilated and always wear appropriate
personal protective equipment. See
PersonalPersonalPersonalProtectiveProtectiveProtective
EquipmentEquipmentEquipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of
it according to applicableguidelines.
PERSONALPERSONALPERSONAL PROTECTIVEPROTECTIVEPROTECTIVE
EQUIPMENTEQUIPMENTEQUIPMENT
Always wear appropriate personal protective equipment and cover
all skin when spraying,servicing equipment, or when in the work
area. Protective equipment helps prevent seriousinjury, including
long-term exposure; inhalation of toxic fumes, mists or vapors;
allergic reaction;burns; eye injury and hearing loss. This
protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a
supplied-air respirator, chemicallyimpermeable gloves, protective
clothing and foot coverings as recommended by the fluidmanufacturer
and local regulatory authority.
• Protective eyewear and hearing protection.
333023J 3
-
Warnings
WARNINGWARNINGWARNINGSKINSKINSKIN INJECTIONINJECTIONINJECTION
HAZARDHAZARDHAZARD
High-pressure fluid from gun, hose leaks, or ruptured components
will pierce skin. This maylook like just a cut, but it is a serious
injury that can result in amputation. GetGetGet
immediateimmediateimmediate
surgicalsurgicalsurgicaltreatmenttreatmenttreatment.
• Do not spray without tip guard and trigger guard installed.•
Engage trigger lock when not spraying.• Do not point gun at anyone
or at any part of the body.• Do not put your hand over the spray
tip.• Do not stop or deflect leaks with your hand, body, glove, or
rag.• Follow the PressurePressurePressure ReliefReliefRelief
ProcedureProcedureProcedure when you stop spraying and before
cleaning, checking,or servicing equipment.
• Tighten all fluid connections before operating the equipment.•
Check hoses and couplings daily. Replace worn or damaged parts
immediately.
FIREFIREFIRE ANDANDAND EXPLOSIONEXPLOSIONEXPLOSION
HAZARDHAZARDHAZARD
Flammable fumes, such as solvent and paint fumes, in
workworkwork areaareaarea can ignite or explode. To helpprevent
fire and explosion:
• Use equipment only in well ventilated area.• Eliminate all
ignition sources; such as pilot lights, cigarettes, portable
electric lamps, andplastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and
gasoline.• Do not plug or unplug power cords, or turn power or
light switches on or off when flammablefumes are present.
• Ground all equipment in the work area. See
GroundingGroundingGrounding instructions.• Use only grounded
hoses.• Hold gun firmly to side of grounded pail when triggering
into pail. Do not use pail liners unlessthey are antistatic or
conductive.
• StopStopStop operationoperationoperation
immediatelyimmediatelyimmediately if static sparking occurs or you
feel a shock... Do not useequipment until you identify and correct
the problem.
• Keep a working fire extinguisher in the work area.
4 333023J
-
Warnings
WARNINGWARNINGWARNINGTHERMALTHERMALTHERMAL
EXPANSIONEXPANSIONEXPANSION HAZARDHAZARDHAZARD
Fluids subjected to heat in confined spaces, including hoses,
can create a rapid rise in pressuredue to the thermal expansion.
Over-pressurization can result in equipment rupture and
seriousinjury.
• Open a valve to relieve the fluid expansion during heating.•
Replace hoses proactively at regular intervals based on your
operating conditions.
PRESSURIZEDPRESSURIZEDPRESSURIZED ALUMINUMALUMINUMALUMINUM
PARTSPARTSPARTS HAZARDHAZARDHAZARD
Use of fluids that are incompatible with aluminum in pressurized
equipment can cause seriouschemical reaction and equipment rupture.
Failure to follow this warning can result in death,serious injury,
or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other
halogenated hydrocarbonsolvents or fluids containing such
solvents.
• Many other fluids may contain chemicals that can react with
aluminum. Contact your materialsupplier for compatibility.
PLASTICPLASTICPLASTIC PARTSPARTSPARTS CLEANINGCLEANINGCLEANING
SOLVENTSOLVENTSOLVENT HAZARDHAZARDHAZARD
Many solvents can degrade plastic parts and cause them to fail,
which could cause seriousinjury or property damage.
• Use only compatible water-based solvents to clean plastic
structural or pressure-containingparts.
• See TechnicalTechnicalTechnical DataDataData in this and all
other equipment instruction manuals. Read fluid andsolvent
manufacturer’s MSDSs and recommendations.
333023J 5
-
Warnings
WARNINGWARNINGWARNINGEQUIPMENTEQUIPMENTEQUIPMENT
MISUSEMISUSEMISUSE HAZARDHAZARDHAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence
of drugs or alcohol.• Do not exceed the maximum working pressure or
temperature rating of the lowest ratedsystem component. See
TechnicalTechnicalTechnical DataDataData in all equipment
manuals.
• Use fluids and solvents that are compatible with equipment
wetted parts. See Technical Datain all equipment manuals. Read
fluid and solvent manufacturer’s warnings. For completeinformation
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or
under pressure.• Turn off all equipment and follow the
PressurePressurePressure ReliefReliefRelief
ProcedureProcedureProcedure when equipment is not in use.• Check
equipment daily. Repair or replace worn or damaged parts
immediately with genuinemanufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications
may void agency approvalsand create safety hazards.
• Make sure all equipment is rated and approved for the
environment in which you are using it.• 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 surfaces.• Do not kink or over bend hoses or use
hoses to pull equipment.• Keep children and animals away from work
area.• Comply with all applicable safety regulations.
MOVINGMOVINGMOVING PARTSPARTSPARTS HAZARDHAZARDHAZARD
Moving parts can pinch, cut or amputate fingers and other body
parts.
• Keep clear of moving parts.• Do not operate equipment with
protective guards or covers removed.• Pressurized equipment can
start without warning. Before checking, moving, or
servicingequipment, follow the PressurePressurePressure
ReliefReliefRelief ProcedureProcedureProcedure and disconnect all
power sources.
BURNBURNBURN HAZARDHAZARDHAZARD
Equipment surfaces and fluid that is heated can become very hot
during operation. To avoidsevere burns:
• Do not touch hot fluid or equipment.
6 333023J
-
Important Isocyanate Information
ImportantImportantImportant IsocyanateIsocyanateIsocyanate
InformationInformationInformationIsocyanates (ISO) are catalysts
used in two component materials.
IsocyanateIsocyanateIsocyanate
ConditionsConditionsConditions
Spraying or dispensing fluids that contain isocyanates creates
potentially harmful mists, vapors, andatomized particulates.
• Read and understand the fluid manufacturer’s warnings and
Safety Data Sheet (SDS) to know specifichazards and precautions
related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures.
Do not spray with this equipment unlessyou are trained, qualified,
and have read and understood the information in this manual and in
the fluidmanufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may
result in improperly cured material, whichcould cause off gassing
and offensive odors. Equipment must be carefully maintained and
adjustedaccording to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors and atomized
particulates, everyone in the workarea must wear appropriate
respiratory protection. Always wear a properly fitting respirator,
whichmay include a supplied-air respirator. Ventilate the work area
according to instructions in the fluidmanufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in the work
area must wear chemically impermeablegloves, protective clothing
and foot coverings as recommended by the fluid manufacturer and
localregulatory authority. Follow all fluid manufacturer
recommendations, including those regarding handlingof contaminated
clothing. After spraying, wash hands and face before eating or
drinking.
• Hazard from exposure to isocyanates continues after spraying.
Anyone without appropriate personalprotective equipment must stay
out of the work area during application and after application for
the timeperiod specified by the fluid manufacturer. Generally this
time period is at least 24 hours.
• Warn others who may enter work area of hazard from exposure to
isocyanates. Follow therecommendations of the fluid manufacturer
and local regulatory authority. Posting a placard such as
thefollowing outside the work area is recommended:
333023J 7
-
Important Isocyanate Information
MaterialMaterialMaterial
SelfSelfSelf---IgnitionIgnitionIgnition
Some materials may become self-igniting if appliedtoo thick.
Read material manufacturer’s warningsand SDS.
KeepKeepKeep ComponentsComponentsComponents AAA andandand BBB
SeparateSeparateSeparate
Cross-contamination can result in curedmaterial in fluid lines
which could cause seriousinjury or damage to equipment. To
preventcross-contamination:
• NeverNeverNever interchange component A and componentB wetted
parts.
• Never use solvent on one side if it has beencontaminated from
the other side.
ChangingChangingChanging MaterialsMaterialsMaterials
NOTICENOTICENOTICEChanging the material types used in
yourequipment requires special attention to avoidequipment damage
and downtime.
• When changing materials, flush the equipmentmultiple times to
ensure it is thoroughly clean.
• Always clean the fluid inlet strainers afterflushing.
• Check with your material manufacturer forchemical
compatibility.
• When changing between epoxies and urethanesor polyureas,
disassemble and clean all fluidcomponents and change hoses. Epoxies
oftenhave amines on the B (hardener) side. Polyureasoften have
amines on the B (resin) side.
MoistureMoistureMoisture SensitivitySensitivitySensitivity
ofofof IsocyanatesIsocyanatesIsocyanates
Exposure to moisture (such as humidity) will causeISO to
partially cure, forming small, hard, abrasivecrystals that become
suspended in the fluid.Eventually a film will form on the surface
and the ISOwill begin to gel, increasing in viscosity.
NOTICENOTICENOTICEPartially cured ISO will reduce performance
andthe life of all wetted parts.
• Always use a sealed container with a desiccantdryer in the
vent, or a nitrogen atmosphere.NeverNeverNever store ISO in an open
container.
• Keep the ISO pump wet cup or reservoir (ifinstalled) filled
with appropriate lubricant. Thelubricant creates a barrier between
the ISO andthe atmosphere.
• Use only moisture-proof hoses compatible withISO.
• Never use reclaimed solvents, which maycontain moisture.
Always keep solventcontainers closed when not in use.
• Always lubricate threaded parts with anappropriate lubricant
when reassembling.
NOTE:NOTE:NOTE: The amount of film formation and rate
ofcrystallization varies depending on the blend of ISO,the
humidity, and the temperature.
FoamFoamFoam ResinsResinsResins withwithwith 245245245 fafafa
BlowingBlowingBlowingAgentsAgentsAgents
Some foam blowing agents will froth at temperaturesabove 90°F
(33°C) when not under pressure,especially if agitated. To reduce
frothing, minimizepreheating in a circulation system.
8 333023J
-
Models
ModelsModelsModels
ReactorReactorReactor 222 EEE---303030 andandand EEE---303030
EliteEliteElite
All elite systems include fluid inlet sensors, Graco InSite™,
and Xtreme-Wrap 50 ft (15 m) heated hose. Forpart numbers, see
Accessories, page 11
EEE---303030 ModelModelModel EEE---303030 EliteEliteElite
ModelModelModelModelModelModel 101010 kWkWkW 151515 kWkWkW 101010
kWkWkW 15kW15kW15kWProportionerProportionerProportioner ★ 272010
272011 272110 272111MaximumMaximumMaximum FluidFluidFluid
WorkingWorkingWorkingPressurePressurePressure psipsipsi
(MPa,(MPa,(MPa, bar)bar)bar)
2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 2000 (14, 140)
ApproximateApproximateApproximate OutputOutputOutput
perperperCycleCycleCycle (A+B)(A+B)(A+B) gal.gal.gal.
(liter)(liter)(liter)
0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272
(0.1034)
MaxMaxMax FlowFlowFlow RateRateRate
lb/minlb/minlb/min(kg/min)(kg/min)(kg/min)
30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5)
TotalTotalTotal SystemSystemSystem LoadLoadLoad †††�
(Watts)(Watts)(Watts)
17,900 23,000 17,900 23,000
ConfigurableConfigurableConfigurable
VoltageVoltageVoltagePhasePhasePhase�
200–240VAC1Ø
200–240VAC3Ø∆
350–415VAC3ØY
200–240VAC1Ø
200–240VAC3Ø∆
350–415VAC3ØY
200–240VAC1Ø
200–240VAC3Ø∆
350–415VAC3ØY
200–240VAC1Ø
200–240VAC3Ø∆
350–415VAC3ØY
FullFullFull LoadLoadLoad PeakPeakPeak Current*Current*Current*
78 50 34 100 62 35 78 50 34 100 62 35
FusionFusionFusion APAPAP PackagePackagePackage �(Gun Part
No.)
AP2010(246102)
AH2010(246102)
AP2011(246102)
AH2011(246102)
AP2110(246102)
AH2110(246102)
AP2111(246102)
AH2111(246102)
FusionFusionFusion CSCSCS PackagePackagePackage �(Gun Part
No.)
CS2010(CS02RD)
CH2010(CS02RD)
CS2011(CS02RD)
CH2011(CS02RD)
CS2110(CS02RD)
CH2110(CS02RD)
CS2111(CS02RD)
CH2111(CS02RD)
ProblerProblerProbler P2P2P2 PackagePackagePackage �(Gun Part
No.)
P22010(GCP2R2)
PH2010(GCP2R2)
P22011(GCP2R2)
PH2011(GCP2R2)
P22110(GCP2R2)
PH2110(GCP2R2)
P22111(GCP2R2)
PH2111(GCP2R2)
24K240 24K240 24K240 24K240 24Y240 24Y240 24Y240
24Y240HeatedHeatedHeated HoseHoseHose505050 ftftft (15(15(15
m)m)m)24K240 (scuff guard)24Y240 (Xtreme-Wrap)
Qty:Qty:Qty: 1 Qty:Qty:Qty: 5 Qty:Qty:Qty: 1 Qty:Qty:Qty: 5
Qty:Qty:Qty: 1 Qty:Qty:Qty: 5 Qty:Qty:Qty: 1 Qty:Qty:Qty: 5
HeatedHeatedHeated WhipWhipWhip HoseHoseHose101010 ftftft (3(3(3
m)m)m)
246050 246050 246050 246050
GracoGracoGraco InsiteInsiteInsite™™™ ✓ ✓FluidFluidFluid
InletInletInlet SensorsSensorsSensors (2)(2)(2) ✓ ✓
*** Full load amps with all devices operating atmaximum
capabilities. Fuse requirements atvarious flow rates and mix
chamber sizes may beless.
� Total system watts used by system, based onmaximum heated hose
length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)maximum heated hose
length, including whiphose.
★ See Approvals, page 11.
� Packages include gun, heated hose, and whiphose. Elite
packages also include Graco InSiteand fluid inlet sensors.
� Low line input voltage will reduce power availableand heaters
will not perform at full capacity.
VoltageVoltageVoltage ConfigurationsConfigurationsConfigurations
KeyKeyKeyØ Phase∆ DELTAY WYE
333023J 9
-
Models
ReactorReactorReactor 222 EEE---XP2XP2XP2 andandand
EEE---XP2XP2XP2 EliteEliteElite
All elite systems include fluid inlet sensors, Graco InSite™,
and Xtreme-Wrap 50 ft (15 m) heated hose. Forpart numbers, see
Accessories, page 11
E–XP2E–XP2E–XP2 ModelModelModel E–XP2E–XP2E–XP2 EliteEliteElite
ModelModelModelModelModelModel151515 kWkWkW 151515 kWkWkW
ProportionerProportionerProportioner ★ 272012
272112MaximumMaximumMaximum FluidFluidFluid
WorkingWorkingWorkingPressurePressurePressure psipsipsi
(MPa,(MPa,(MPa, bar)bar)bar)
3500 (24.1, 241) 3500 (24.1, 241)
ApproximateApproximateApproximate OutputOutputOutput
perperperCycleCycleCycle (A+B)(A+B)(A+B) gal.gal.gal.
(liter)(liter)(liter)
0.0203 (0.0771) 0.0203 (0.0771)
MaxMaxMax FlowFlowFlow
Rategpm/minRategpm/minRategpm/min(l/min)(l/min)(l/min)
2 (7.6) 2 (7.6)
TotalTotalTotal SystemSystemSystem LoadLoadLoad ††† �
(Watts)(Watts)(Watts)
23,000 23,000
ConfigurableConfigurableConfigurable
VoltageVoltageVoltagePhasePhasePhase �
200–240VAC 1Ø
200–240VAC 3Ø∆
350–415VAC 3ØY
200–240VAC 1Ø
200–240VAC 3Ø∆
350–415VAC 3ØY
FullFullFull LoadLoadLoad PeakPeakPeak
CurrentCurrentCurrent(amps)(amps)(amps)
100 62 35 100 62 35
FusionFusionFusion APAPAP PackagePackagePackage �(Gun Part
No.)
AP2012(246100)
AP2112(246100)
ProblerProblerProbler P2P2P2 PackagePackagePackage �(Gun Part
No.)
P22012(GCP2R0)
P22112(GCP2R0)
HeatedHeatedHeated HoseHoseHose505050 ftftft (15(15(15
m)m)m)
24K241(scuff guard)
24Y241(Xtreme-Wrap)
HeatedHeatedHeated WhipWhipWhip HoseHoseHose101010 ftftft (3(3(3
m)m)m)
246055 246055
GracoGracoGraco InsiteInsiteInsite™™™ ✓FluidFluidFluid
InletInletInlet SensorsSensorsSensors (2)(2)(2) ✓
*** Full load amps with all devices operating atmaximum
capabilities. Fuse requirementsat various flow rates and mix
chamber sizesmay be less.
� Total system watts used by system, based onmaximum heated hose
length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)maximum heated hose
length, includingwhip hose.
★ See Approvals, page 11.
� Packages include gun, heated hose, andwhip hose. Elite
packages also includeGraco InSite and fluid inlet sensors.
� Low line input voltage will reduce poweravailable and heaters
will not perform at fullcapacity.
VoltageVoltageVoltage ConfigurationsConfigurationsConfigurations
KeyKeyKeyØ Phase∆ DELTAY WYE
10 333023J
-
Approvals
ApprovalsApprovalsApprovalsIntertek approvals apply to
proportioners withouthoses.
ProportionerProportionerProportioner
Approvals:Approvals:Approvals:
990247199024719902471
Conforms to ANSI/UL Std. 499Certified to CAN/CSA Std. C22.2 No.
88
AccessoriesAccessoriesAccessoriesKitKitKit NumberNumberNumber
DescriptionDescriptionDescription
24U315 Air Manifold Kit (4 outlets)
24U314 Wheel and Handle Kit
24T280 Graco InSite Kit
16X521 Graco InSite Extension cable 24.6 ft(7.5 m)
24N449 50 ft (15 m) CAN cable (for remotedisplay module)
24K207 Fluid Temperature Sensor (FTS)with RTD
24U174 Remote Display Module Kit
15V551 ADM Protective Covers (10 pack)
15M483 Remote Display Module ProtectiveCovers (10 pack)
24M174 Drum Level Sticks
121006 150 ft (45 m) CAN cable (for remotedisplay module)
24N365 RTD Test Cables (to aide resistancemeasurements)
333023J 11
-
Supplied Manuals
SuppliedSuppliedSupplied ManualsManualsManualsThe following
manuals are shipped with the Reactor2. Refer to these manuals for
detailed equipmentinformation.
Manuals are also available at www.graco.com.ManualManualManual
DescriptionDescriptionDescription333023 Reactor 2 E-30 and
E-XP2
Operation333091 Reactor 2 E-30 and E-XP2 Startup
Quick Guide333092 Reactor 2 E-30 and E-XP2
Shutdown Quick Guide
RelatedRelatedRelated ManualsManualsManualsThe following manuals
are for accessories used withthe Reactor.
ComponentComponentComponent ManualsManualsManuals ininin
English:English:English:
Manuals are available at www.graco.com.SystemSystemSystem
ManualsManualsManuals333024 Reactor 2 E-30 and E-XP2,
Repair-PartsDisplacementDisplacementDisplacement PumpPumpPump
ManualManualManual309577 Electric Reactor Displacement Pump,
Repair-PartsFeedFeedFeed SystemSystemSystem
ManualsManualsManuals309572 Heated Hose, Instructions-Parts309852
Circulation and Return Tube Kit,
Instructions-Parts309815 Feed Pump Kits,
Instructions-Parts309827 Feed Pump Air Supply Kit,
Instructions-PartsSpraySpraySpray GunGunGun
ManualsManualsManuals309550 Fusion ™ AP Gun312666 Fusion ™ CS
Gun313213 Probler® P2 GunAccessoryAccessoryAccessory
ManualsManualsManuals3A1905 Feed Pump Shutdown Kit,
Instructions-Parts3A1906 Light Tower Kit,
Instructions-Parts3A1907 Remote Display Module Kit,
Instructions-Parts332735 Air Manifold Kit,
Instructions-Parts332736 Handle and Wheel Kit,
Instructions-Parts333276 Graco InSite ™ Kit,
Instructions-Parts
12 333023J
-
Typical Installation, without circulation
TypicalTypicalTypical Installation,Installation,Installation,
withoutwithoutwithout circulationcirculationcirculation
��
��
B
G
KM
JG
H
K
L
J
D
S
C*
P
E
A
F
N
N
�����
�����
�����
�����
�����
�����
(RES)
(ISO)
Figure 1
* Shown exposed for clarity. Wrap with tape during operation.A
Reactor ProportionerB Heated HoseC Fluid Temperature Sensor (FTS)D
Heated Whip HoseE Fusion Spray GunF Gun Air Supply HoseG Feed Pump
Air Supply LinesH Agitator Air Supply Line
J Fluid Supply LinesK Feed PumpsL AgitatorM Desiccant DryerN
Bleed LinesP Gun Fluid Manifold (part of gun)S Remote Display
Module Kit (optional)
333023J 13
-
Typical Installation, with system fluid manifold to drum
circulation
TypicalTypicalTypical Installation,Installation,Installation,
withwithwith systemsystemsystem fluidfluidfluid
manifoldmanifoldmanifold tototo
drumdrumdrumcirculationcirculationcirculation
(RES)
M
K
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(ISO)
G
Figure 2
* Shown exposed for clarity. Wrap with tape during operation.A
Reactor ProportionerB Heated HoseC Fluid Temperature Sensor (FTS)D
Heated Whip HoseE Fusion Spray GunF Gun Air Supply HoseG Feed Pump
Air Supply LinesH Agitator Air Supply Line
J Fluid Supply LinesK Feed PumpsL AgitatorM Desiccant DryerP Gun
Fluid Manifold (part of gun)R Recirculation LinesS Remote Display
Module (optional)
14 333023J
-
Typical Installation, with gun fluid manifold to drum
circulation
TypicalTypicalTypical Installation,Installation,Installation,
withwithwith gungungun fluidfluidfluid manifoldmanifoldmanifold
tototo drumdrumdrumcirculationcirculationcirculation
(RES)
M
KM
R
J
GH K
L
B
J
D
S
C* P
RA
(ISO)F
N
N
G
Figure 3
* Shown exposed for clarity. Wrap with tape during operation.A
Reactor ProportionerB Heated HoseC Fluid Temperature Sensor (FTS)CK
Circulation Block (accessory)D Heated Whip HoseF Gun Air Supply
HoseG Feed Pump Air Supply LinesH Agitator Air Supply Line
J Fluid Supply LinesK Feed PumpsL AgitatorM Desiccant DryerP Gun
Fluid Manifold (part of gun)R Recirculation LinesS Remote Display
Module (optional)
333023J 15
-
Component Identification
ComponentComponentComponent
IdentificationIdentificationIdentification
BD
S
C*
P
E
Figure 4
16 333023J
-
Component Identification
KeyKeyKeyBA ISO Side Pressure Relief OutletBB RES Side Pressure
Relief Outlet
CD Advanced Display Module (ADM)DG Drive Gear HousingEC
Electrical Cord Strain ReliefEM Electric MotorFA ISO Side Fluid
Manifold InletFB RES Side Fluid Manifold InletFH Fluid Heaters
(behind shroud)FM Reactor Fluid ManifoldFV Fluid Inlet Valve (RES
side shown)GA ISO Side Pressure GaugeGB RES Side Pressure GaugeHA
ISO Side Hose ConnectionHB RES Side Hose ConnectionMP Main Power
SwitchPA ISO Side PumpPB RES Side PumpRR Graco InSite Cellular
Module (Elite models
only)
RS Red Stop ButtonSA ISO Side PRESSURE RELIEF/SPRAY
ValveSB RES Side PRESSURE RELIEF/SPRAY
ValveT Heated Hose Power Termination BoxTA ISO Side Pressure
Transducer (behind
gauge GA)TB RES Side Pressure Transducer (behind
gauge GB)XA Fluid Inlet Sensor (ISO side, Elite models
only)XB Fluid Inlet Sensor (RES side, Elite models
only)
333023J 17
-
Advanced Display Module (ADM)
AdvancedAdvancedAdvanced DisplayDisplayDisplay
ModuleModuleModule (ADM)(ADM)(ADM)The ADM display shows graphical
and textinformation related to setup and spray operations.
NOTICENOTICENOTICETo prevent damage to the softkey buttons, do
notpress buttons with sharp objects such as pens,plastic cards, or
fingernails.
Figure 5 Front View
18 333023J
-
Advanced Display Module (ADM)
TableTableTable 111 ::: ADMADMADM KeysKeysKeys andandand
IndicatorsIndicatorsIndicators
KeyKeyKey FunctionFunctionFunction
Startup/ShutdownStartup/ShutdownStartup/ShutdownKeyKeyKey
andandand IndicatorIndicatorIndicator
Press to startup or shutdown the system.
StopStopStop
Press to stop all proportioner processes. This Is not a safety
or emergency stop.
SoftSoftSoft KeysKeysKeys
Press to select the specific screen or operation shown on the
display directly next toeach key.
NavigationNavigationNavigation KeysKeysKeys
• Left/Right Arrows: Use to move from screen to screen.
• Up/Down Arrows: Use to move among fields on a screen, items on
a dropdownmenu, or multiple screens within a function.
NumericNumericNumeric KeypadKeypadKeypad Use to input
values.
CancelCancelCancel
Use to cancel a data entry field.
SetupSetupSetup
Press to enter or exit Setup mode.
EnterEnterEnter
Press to choose a field to update, to make a selection, to save
a selection or value, toenter a screen, or to acknowledge an
event.
333023J 19
-
Advanced Display Module (ADM)
Figure 6 Back ViewCJ Flat Panel Mount (VESA 100)CK Model and
Serial NumberCL USB Port and Status LEDsCM CAN Cable Connection
CN Module Status LEDsCP Accessory Cable ConnectionCR Token
Access CoverCS Battery Access Cover
TableTableTable 222 ADMADMADM LEDLEDLED StatusStatusStatus
DescriptionsDescriptionsDescriptions
LEDLEDLED ConditionsConditionsConditions
DescriptionDescriptionDescription
Green Solid Run Mode, System On
Green Flashing Setup Mode, System On
Yellow Solid Run Mode, System Off
SystemSystemSystem StatusStatusStatus
Yellow Flashing Setup Mode, System Off
Green Flashing Data recording in progress
Yellow Solid Downloading information to USB
USBUSBUSB StatusStatusStatus (CL)(CL)(CL)
Green and Yellow Flashing ADM is busy, USB cannot
transferinformation when in this mode
Green Solid Power applied to module
Yellow Solid Active Communication
Red Steady Flashing Software upload from token inprogress
ADMADMADM StatusStatusStatus (CN)(CN)(CN)
Red Random Flashing or Solid Module error exists
20 333023J
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Advanced Display Module (ADM)
ADMADMADM DisplayDisplayDisplay DetailsDetailsDetails
PowerPowerPower UpUpUp ScreenScreenScreenThe following screen
appears when the ADM ispowered up. It remains on while the ADM runs
throughinitialization and establishes communication with
othermodules in the system.
MenuMenuMenu BarBarBarThe menu bar appears at the top of each
screen. (Thefollowing image is only an example.)
DateDateDate andandand TimeTimeTime
The date and time are always displayed in one of thefollowing
formats. The time is always displayed as a24-hour clock.
• DD/MM/YY HH:MM
• YY/MM/DD HH:MM
• MM/DD/YY HH:MM
ArrowsArrowsArrows
The left and right arrows indicate screen navigation.
ScreenScreenScreen MenuMenuMenu
The screen menu indicates the currently active screen,which is
highlighted. It also indicates the associatedscreens that are
available by scrolling left and right.
SystemSystemSystem ModeModeMode
The current system mode is displayed at the lower leftof the
menu bar.
Alarm/DeviationAlarm/DeviationAlarm/Deviation
The current system error is displayed in the middle ofthe menu
bar. There are four possibilities:
IconIconIcon FunctionFunctionFunctionNo Icon No information or
no error has occurred
Advisory
Deviation
Alarm
StatusStatusStatus
The current system status is displayed at the lower rightof the
menu bar.
SoftSoftSoft KeysKeysKeysIcons next to the soft keys indicate
which mode oraction is associated with each soft key. Soft keys
thatdo not have an icon next to them are not active in thecurrent
screen.
NOTICENOTICENOTICETo prevent damage to the soft key buttons, do
notpress buttons with sharp objects such as pens, plasticcards, or
fingernails.
NavigatingNavigatingNavigating thethethe
ScreensScreensScreens
There are two sets of screens:
• The Run screens control spraying operations anddisplay system
status and data.
• The Setup screens control system parameters andadvanced
features.
Press on any Run screen to enter the Setupscreens. If the system
has a password lock, thePassword 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 theHome screen.
Press the Enter soft key to activate the editingfunction on any
screen.
Press the Exit soft key to exit any screen.
Use the other softkeys to select the function adjacentto
them.
333023J 21
-
Advanced Display Module (ADM)
IconsIconsIconsIconsIconsIcons
IconIconIcon FunctionFunctionFunction
Component A
Component B
Estimated Supply Material
Hose Temperature
Jog Mode Speed
Pressure
Cycle Counter (press andhold)
Advisory.See Errors, page 38 for moreinformation.
Deviation.See Errors, page 38 for moreinformation
Alarm.See Errors, page 38 for moreinformation
SoftkeysSoftkeysSoftkeys
IconIconIcon FunctionFunctionFunction
Start Proportioner
Start and Stop Proportioner in Jog Mode
Stop Proportioner
Turn on or off the specified heat zone.
Park pump
Enter Jog Mode. See Jog Mode, page 46
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, andnumbers and special
characters.
Backspace
Cancel
Clear
Troubleshoot Selected Error
Increase value
Decrease value
Next screen
Previous screen
Return to first screen
22 333023J
-
Electrical Enclosure
ElectricalElectricalElectrical EnclosureEnclosureEnclosureAAA
Temperature Control Module (TCM)
AAB Motor Control Module (MCM)
AAC Enclosure Fan
AAD Wiring Terminal Blocks
AAE Power Supply
AAF Surge Protector
AAG Hose Breaker
AAH Motor Breaker
AAJ A Side Heat Breaker
AAK B Side Heat Breaker
AAL Transformer Breaker
MP Main Power Switch
333023J 23
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Motor Control Module (MCM)
MotorMotorMotor ControlControlControl ModuleModuleModule
(MCM)(MCM)(MCM)
BaseBaseBase ModelModelModel EliteEliteElite ModelModelModel
Figure 7DescriptionDescriptionDescription
MS Module Status LEDs see LED Status Table1 CAN Communication
Connections2 Motor Temperature3 Not used4 Not used5 Not used6 A
Pump Output Pressure7 B Pump Output Pressure8 A Fluid Inlet Sensor
(Elite only)9 B Fluid Inlet Sensor (Elite only)
10 Accessory output11 Not used12 Pump Cycle Counter14 Graco
Insite™
15 Motor Power Output16 Main Power Input***RS Rotary Switch
*** MCMMCMMCM RotaryRotaryRotary SwitchSwitchSwitch
PositionsPositionsPositions
2=E-30
3=E-XP2
TableTableTable 333 MCMMCMMCM ModuleModuleModule LEDLEDLED
(MS)(MS)(MS) StatusStatusStatus
DescriptionsDescriptionsDescriptions
LEDLEDLED ConditionsConditionsConditions
DescriptionDescriptionDescription
Green Solid Power applied to module
Yellow Flashing Active Communication
Red Steady Flashing Software upload from token inprogress
MCMMCMMCM StatusStatusStatus
Red Random Flashing or Solid Module error exists
24 333023J
-
Temperature Control Module (TCM) Cable Connections
TemperatureTemperatureTemperature ControlControlControl
ModuleModuleModule (TCM)(TCM)(TCM) CableCableCable
ConnectionsConnectionsConnections
Figure 81 Power Input2 Heater Overtemperature3 CAN
Communications Connections4 Power Out (ISO)5 Power Out (Res)6 Power
Out (Hose)7 Module Status LEDs8 Heater A Temperature (ISO)9 Heater
B Temperature (RES)10 Hose Temperature
TableTableTable 444 TCMTCMTCM ModuleModuleModule LEDLEDLED
(7)(7)(7) StatusStatusStatus
DescriptionsDescriptionsDescriptions
LEDLEDLED ConditionsConditionsConditions
DescriptionDescriptionDescription
Green Solid Power applied to module
Yellow Flashing Active Communication
Red Steady Flashing Software upload from token inprogress
TCMTCMTCM StatusStatusStatus
Red Random Flashing or Solid Module error exists
333023J 25
-
Installation
InstallationInstallationInstallationSetupSetupSetup FromFromFrom
ShippingShippingShipping
ConfigurationConfigurationConfiguration
1. Remove bolts (A) and nuts.
2. Swing up the electrical enclosure and reinstallbolt (A) with
nut. Tighten bolt (B) and nut.
3. Position cable bundles against the frame andattach to the
frame with loose wire tie (C) oneach side.
To prevent serious injury due to system tippingover, ensure
Reactor is properly secured to wall.
Note
Mounting brackets and bolts are included in the boxof loose
parts, shipped with your system.
1. Use the supplied bolts to install the suppliedL-brackets onto
the system frame in the top-mostsquare holes. Install brackets on
both the leftand right side of system frame.
2. Secure the L-brackets to the wall. If L-bracketsdo not line
up with the wall stud spacing, bolt apiece of wood to the studs
then secure L-bracketsto wood.
3. Use the four holes in the base of the systemframe to secure
base to the floor. Bolts notsupplied.
26 333023J
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Setup
SetupSetupSetup
GroundingGroundingGrounding
The equipment must be grounded to reduce therisk of static
sparking. Static sparking can causefumes to ignite or explode.
Grounding provides anescape wire for the electric current.
• Reactor: System is grounded through the powercord.
• Spray gun: connect whip hose ground wire to FTS.See Install
Fluid Temperature Sensor, page 29.Do not disconnect ground wire or
spray withoutwhip hose.
• Fluid supply containers: follow your local code.
• Object being sprayed: follow your local code.
• Solvent pails used when flushing: follow your localcode. Use
only metal pails, which are conductive,placed on a grounded
surface. Do not place pailon a nonconductive surface, such as paper
orcardboard, which interrupts grounding continuity.
• To maintain grounding continuity when flushing orrelieving
pressure, hold a metal part of spray gunfirmly to the side of a
grounded metal pail, thentrigger gun.
GeneralGeneralGeneral EquipmentEquipmentEquipment
GuidelinesGuidelinesGuidelines
• Determine the correct size generator. Using thecorrect size
generator and proper air compressorwill enable the proportioner to
run at a nearlyconstant RPM. Failure to do so will cause
voltagefluctuations that can damage electrical equipment.
Use the following procedure to determine the correctsize
generator.
1. List system components that use peak loadrequirements in
watts.
2. Add the wattage required by the systemcomponents.
3. Perform the following equation:Total watts x 1.25 = kVA
(kilovolt-amperes)
4. Select a generator size that is equal to or greaterthan the
determined kVA.
• Use proportioner power cords that meet or exceedthe
requirements listed in Table 5. Failure to do sowill cause voltage
fluctuations that can damageelectrical equipment.
• Use an air compressor with continuous run headunloading
devices. Direct online air compressorsthat start and stop during a
job will cause voltagefluctuations that can damage electrical
equipment.
• Maintain and inspect the generator, aircompressor, and other
equipment per themanufacturer recommendations to avoid anunexpected
shutdown. Unexpected equipmentshutdown will cause voltage
fluctuations that candamage electrical equipment.
• Use a wall power supply with enough currentto meet system
requirements. Failure to do sowill cause voltage fluctuations that
can damageelectrical equipment.
333023J 27
-
Setup
ConnectConnectConnect PowerPowerPower
All electrical wiring must be done by a qualifiedelectrician and
comply with all local codes andregulations.
1. Turn main power switch (MP) OFF.
2. Open electrical enclosure door.
NOTE:NOTE:NOTE: Terminal jumpers are located inside
theelectrical enclosure door.
3. Install supplied terminal jumpers in the positionsshown in
image for the power source used.
4. Route power cable through strain relief (EC) inelectrical
enclosure.
5. Connect incoming power wires as shown inimage. Gently pull on
all connections to verifythey are properly secured.
6. Verify all items are connected properly as shownin image then
close electrical enclosure door.
TableTableTable 555 PowerPowerPower CordCordCord
RequirementsRequirementsRequirements
ModelModelModel InputInputInput PowerPowerPower
CordCordCordSpecifications*Specifications*Specifications*AWGAWGAWG
(mm(mm(mm222)))
200–240 VAC, 1Phase
4 (21.2), 2 wire +ground/PE
200–240 VAC, 3Phase, DELTA
6 (13.3), 3 wire +ground/PE
E-30,10 kW
350–415 VAC, 3Phase, WYE
8 (8.4), 4 wire +ground/PE
200–240 VAC, 1Phase
4 (21.2), 2 wire +ground/PE
200–240 VAC, 3Phase, DELTA
6 (13.3), 3 wire +ground/PE
E-30,15 kW
350–415 VAC, 3Phase, WYE
8 (8.4), 4 wire +ground/PE
ModelModelModel InputInputInput PowerPowerPower
CordCordCordSpecifications*Specifications*Specifications*AWGAWGAWG
(mm(mm(mm222)))
200–240 VAC, 1Phase
4 (21.2), 2 wire +ground/PE
200–240 VAC, 3Phase, DELTA
6 (13.3), 3 wire +ground/PE
E-XP2,15 kW
350–415 VAC, 3Phase, WYE
8 (8.4), 4 wire +ground/PE
* Values are for reference only. Refer to amperagelisted in
Models table (see Models, page 9 ) for givensystem and compare
against latest version of localelectrical code to select proper
power cord size.
NOTE:NOTE:NOTE: 350–415 VAC systems are not designed tooperate
from 480 VAC power source.
28 333023J
-
Setup
SupplySupplySupply WetWetWet CupsCupsCups WithWithWith
ThroatThroatThroat SealSealSealLiquidLiquidLiquid
(TSL)(TSL)(TSL)
Pump rod and connecting rod move duringoperation. Moving parts
can cause serious injurysuch as pinching or amputation. Keep hands
andfingers away from wet-cup during operation.
To prevent the pump from moving, turn the mainpower switch
OFF.
• ComponentComponentComponent AAA (ISO)(ISO)(ISO)
Pump:Pump:Pump: Keep reservoir (R) filledwith Graco Throat Seal
Liquid (TSL), Part 206995.Wet-cup piston circulates TSL through
wet-cup, tocarry away isocyanate film on displacement rod.
Figure 9 Component A Pump
• ComponentComponentComponent BBB (Resin)(Resin)(Resin)
Pump:Pump:Pump: Check felt washersin packing nut/wet-cup (S) daily.
Keep saturatedwith Graco Throat Seal Liquid (TSL), Part No.206995,
to prevent material from hardening ondisplacement rod. Replace felt
washers when wornor contaminated with hardened material.
Figure 10 Component B Pump
InstallInstallInstall FluidFluidFluid
TemperatureTemperatureTemperature SensorSensorSensor
The Fluid Temperature Sensor (FTS) is supplied.Install FTS
between main hose and whip hose. SeeHeated Hose manual for
instructions.
333023J 29
-
Setup
ConnectConnectConnect HeatedHeatedHeated HoseHoseHose tototo
ProportionerProportionerProportioner
See the heated hose manual for detailed instructions.
1. For proportioners with termination box (TB):
a. Connect hose power wires to terminal block(T) on termination
box (TB). Remove boxcover and loosen lower strain relief (E).Route
hose wires (V) through the box strainrelief and fully insert into
terminal block (T). Aand B hose wire positions are not
important.Torque to 35–50 in-lb (4.0–5.6 N·m).
b. Fully tighten strain relief screws and replacecover.
Figure 11 Termination Box
2. For proportioners with electrical splice connectors(S):
a. Connect hose power wires to electrical spliceconnectors (S)
from proportioner. Wrapconnections with electrical tape.
Figure 12 Electrical Splice Connectors
3. Connect FTS cable connectors (R). Fully tightenRTD
connectors, if provided.
RegisterRegisterRegister andandand ActivateActivateActivate
thethethe GracoGracoGraco InSiteInSiteInSite
Note
Elite systems only.
1. Go to www.GracoInSite.com, then follow theinstructions on the
screen.
2. Find and record the 15 digit serial number fromthe cellular
module below.
30 333023J
-
Advanced Display Module (ADM) Operation
AdvancedAdvancedAdvanced DisplayDisplayDisplay
ModuleModuleModule (ADM)(ADM)(ADM) OperationOperationOperation
When main power is turned on by turning the mainpower switch
(MP) to the ON position, the power upscreen will be displayed until
communication andinitialization is complete.
Then the power key icon screen will display until the
ADM power on/off button (A) is pressed for thefirst time after
system power-up.
To begin using the ADM, the machine must be active.To verify the
machine is active, verify that the SystemStatus Indicator Light (B)
is illuminated green, seeAdvanced Display Module (ADM), page 18. If
theSystem Status Indicator Light is not green, press
the ADM Power On/Off (A) button . The SystemStatus Indicator
Light will illuminate yellow if themachine is disabled.
Perform the following tasks to fully setup your system.
1. Set pressure values for the Pressure ImbalanceAlarm to
activate. See System Screen 1, page 35.
2. Enter, enable, or disable recipes. SeeRecipes Screen, page
35.
3. Set general system settings. SeeAdvanced Screen 1 — General,
page 34.
4. Set units of measure. SeeAdvanced Screen 2 — Units, page
34.
5. Set USB settings. SeeAdvanced Screen 3— USB, page 34.
6. Set target temperatures and pressure. SeeTargets, page
37.
7. Set component A and component B supplylevels. See
Maintenance, page 38.
333023J 31
-
Advanced Display Module (ADM) Operation
SetupSetupSetup ModeModeMode
The ADM will start in the Run screens at the Home screen. From
the Run screens, press toaccess the Setup screens. The system
defaults with no password, entered as 0000. Enter the
current password then press . Press to navigate through the
Setup Mode screens. SeeSetup Screens Navigation Diagram, page
45.
SetSetSet PasswordPasswordPassword
Set a password to allow Setup screen access, see Advanced Screen
1 – General, page 34. Enter any numberfrom 0001 to 9999. To remove
the password, enter the current password in the Advanced Screen –
Generalscreen and change the password to 0000.
From the Setup screens, press to return to the Run screens.
32 333023J
-
Advanced Display Module (ADM) Operation
Setup Screens Navigation DiagramFigure 13
333023J 33
-
Advanced Setup Screens
AdvancedAdvancedAdvanced SetupSetupSetup
ScreensScreensScreensAdvanced setup screens enable users to set
units, adjust values, set formats, and view software
information
for each component. Press to scroll through the Advanced setup
screens, Once in the desired
Advanced setup screen, press to access the fields and make
changes. When changes are complete press
to exit edit mode.
Note
Users must be out of edit mode to scrollthrough the Advanced
setup screens.
AdvancedAdvancedAdvanced ScreenScreenScreen 111 ———
GeneralGeneralGeneral
Use this screen to set the language, date format,current date,
time, setup screens password (0000 –for none) or (0001 to 9999),
and screen saver delay.
AdvancedAdvancedAdvanced ScreenScreenScreen 222 ———
UnitsUnitsUnits
Use this screen to set the temperature units, pressureunits,
volume units, and cycle units (pump cycles orvolume).
AdvancedAdvancedAdvanced ScreenScreenScreen 333 ———
USBUSBUSB
Use this screen to enable USB downloads/uploads,enable a logs
90% full advisory, enter the maximumnumber of days to download
data, enable specifyingdate range of data to download, and how
frequentlyUSB logs are recorded. See USB Data, page 60.
AdvancedAdvancedAdvanced ScreenScreenScreen 4—4—4—
SoftwareSoftwareSoftware
This screen displays the software part number andsoftware
version for the Advanced Display Module,USB Configuration, Motor
Control Module, andTemperature Control Modules.
34 333023J
-
System 1
SystemSystemSystem 111Use this screen to set the activation
pressure for thePressure Imbalance Alarm and Deviation, enable
ordisable diagnostic screens, set the maximum andminimum drum
volume, and enable drum alarms.
SystemSystemSystem 222Use this screen to enable Manual Hose Mode
andinlet sensors, as well as setting the inlet sensorlow pressure
alarm and low temperature deviation.Manual Hose Mode disables the
hose temperatureRTD sensor so the system can operate if the
sensorswere to malfunction. Default settings are 10 psi (0.07MPa,
0.7 bar) for low inlet pressure alarm and 50˚F(10˚C) for low inlet
temperature deviation.
RecipesRecipesRecipesUse this screen to add recipes, view saved
recipes,and enable or disable saved recipes. Enabledrecipes can be
selected at the Home Run Screen. 24recipes can displayed on the
three recipe screens.
AddAddAdd RecipeRecipeRecipe
1. Press and then use to select arecipe field. Press to enter a
recipe name
(maximum 16 characters). Press to clear theold recipe name.
2. Use to highlight the next field and use the
number pad to enter a value. Press to save.
EnableEnableEnable ororor DisableDisableDisable
RecipesRecipesRecipes
1. Press and then use to select therecipe that needs to be
enabled or disabled.
2. Use to highlight the enabled check box.
Press to enable or disable the recipe.
333023J 35
-
Run Mode
RunRunRun ModeModeMode
The ADM will start in the Run screens at the “Home” screen.
Press to navigate through the Run Modescreens. See Run Screens
Navigation Diagram, page 44.
From the Run screens, press
to access the Setup screens.
Run Screens Navigation DiagramFigure 14
36 333023J
-
Run Mode
HomeHomeHome ——— SystemSystemSystem OffOffOff
This is the home screen when the system is off.This screen
displays actual temperatures, actualpressures at the fluid
manifold, jog speed, coolanttemperature, and number of cycles.
HomeHomeHome ——— SystemSystemSystem ActiveActiveActive
When the system is active, the home screen displaysactual
temperature for heat zones, actual pressuresat the fluid manifold,
coolant temperature, jog speed,the number of cycles, along with all
associatedcontrol soft keys.
Use this screen to turn on heat zones, viewcoolant temperature,
start the proportioner, stop theproportioner, park the component A
pump, enter jogmode, and clear cycles.
NOTE:NOTE:NOTE: Screen shown displays inlet sensortemperatures
and pressures. These will not beshown on models without inlet
sensors.
HomeHomeHome ——— SystemSystemSystem WithWithWith
ErrorErrorError
Active errors are shown in the status bar. The errorcode, alarm
bell, and description of the error willscroll in the status
bar.
1. Press to acknowledge the error.
2. See Troubleshooting, page 59 for correctiveaction.
TargetsTargetsTargets
Use this screen to define the setpoints for theA Component
Temperature, B ComponentTemperature, heated hose temperature,
andpressure.
MaximumMaximumMaximum AAA andandand BBB
temperature:temperature:temperature: 190°F (88°C)
MaximumMaximumMaximum heatedheatedheated hosehosehose
temperature:temperature:temperature: 10°F (5°C)above the highest A
or B temperature setpoint or180°F (82°C).
Note
If the remote display module kit is used,these setpoints can be
modified at the gun.
333023J 37
-
Run Mode
MaintenanceMaintenanceMaintenance
Use this screen to view daily and lifetime cycles orgallons that
have been pumped and gallons or litersremaining in the drums.
The lifetime value is the number of pump cycles orgallons 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.
CyclesCyclesCycles
This screen shows daily cycles and gallons that havebeen sprayed
for the day.
All information listed on this screen can bedownloaded on a USB
flash drive.
EventsEventsEvents
This screen shows the date, time, event code, anddescription of
all events that have occurred onthe system. There are 10 pages,
each holding 10events. The 100 most recent events are shown.
SeeSystem Eventsfor event code descriptions.See Error Codes and
Troubleshooting, page 59 forerror code descriptions.
All events and errors listed on this screen can bedownloaded on
a USB flash drive. To download logs,see Download Procedure, page
60.
ErrorsErrorsErrors
This screen shows the date, time, error code, anddescription of
all errors that have occurred on thesystem.
All errors listed on this screen can be downloaded ona USB flash
drive.
38 333023J
-
Run Mode
TroubleshootingTroubleshootingTroubleshooting
This screen displays the last ten errors thatoccurred on the
system. Use the up and down
arrows to select an error and press to view
the QR code for the selected error. Pressto access the QR code
screen for an errorcode that is not listed on this screen. SeeError
Codes and Troubleshooting, page 59, for moreinformation on error
codes.
QRQRQR CodesCodesCodes
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 forthe error code to view online
help for that code.
333023J 39
-
Run Mode
DiagnosticDiagnosticDiagnostic
Use this screen to view information for all
systemcomponents.
The following information is displayed:
TemperatureTemperatureTemperature• A Chemical• B Chemical• Hose
Chemical• TCM PCB — temperature control moduletemperature
AmpsAmpsAmps• A Current (0–25 A for 10kW heater, 0–38 A for15 kW
heater)
• B Current (0–25 A for 10kW heater, 0–38 A for15 kW heater)
• Hose Current (0–45 A typical)
VoltsVoltsVolts• MCM Bus — displays the voltage supplied to
themotor controller, which is the DC voltage that hasbeen converted
from the AC voltage supplied tothe system (275–400 VAC typical full
range)
• Hose Voltage (90V)
PressurePressurePressure• Pressure A — chemical• Pressure B —
chemical
CyclesCyclesCycles• CPM — cycles per minute• Total Cycles —
lifetime cycles
Note
Maximum values based on maximum inputvoltage. Values will lower
with lower inputvoltage.
JobJobJob DataDataData
Use this screen to enter a job name or number.
RecipesRecipesRecipes
Use this screen to select an enabled recipe. Use theup and down
arrows to highlight a recipe and press
to load. The currently loaded recipe is outlinedby a green
box.
Note
This screen will not display if there are notany enabled
recipes. To enable or disablerecipes, see Recipes Setup Screen,
page 35.
40 333023J
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Run Mode
SystemSystemSystem EventsEventsEventsUse the table below to find
a description for all system non-error events. All events are
logged in the USBlog files.EventEventEvent CodeCodeCode
DescriptionDescriptionDescription
EACX Recipe SelectedEADA Heat On AEADB Heat On BEADH Heat On
HoseEAPX Pump OnEARX Jog OnEAUX USB Drive InsertedEB0X ADM Red Stop
Button PressedEBDA Heat Off AEBDB Heat Off BEBDH Heat Off HoseEBPX
Pump OffEBRX Jog OffEBUX USB Drive RemovedEC0X Setup Value
ChangedECDA A Temperature Setpoint ChangedECDB B Temperature
Setpoint ChangedECDH Hose Temperature Setpoint ChangedECDP Pressure
Setpoint ChangedECDX Recipe ChangedEL0X System Power OnEM0X System
Power OffEP0X Pump ParkedEQU1 System Settings DownloadedEQU2 System
Settings UploadedEQU3 Custom Language DownloadedEQU4 Custom
Language UploadedEQU5 Logs DownloadedER0X User Counter ResetEVUX
USB Disabled
333023J 41
-
Startup
StartupStartupStartup
To prevent serious injury, only operate Reactorwith all covers
and shrouds in place.
NOTICENOTICENOTICEProper system setup, startup, and
shutdownprocedures are critical to electrical equipmentreliability.
The following procedures ensure steadyvoltage. Failure to follow
these procedures willcause voltage fluctuations that can
damageelectrical equipment and void the warranty.
1. CheckCheckCheck fluidfluidfluid inletinletinlet
filterfilterfilter screens.screens.screens.
Before daily startup, ensure that thefluid inlet screens are
clean. SeeFlush Inlet Strainer Screen, page 56
2. CheckCheckCheck ISOISOISO lubricationlubricationlubrication
reservoir.reservoir.reservoir.
Check level and condition of ISO lube daily. SeePump Lubrication
System, page 57.
3. Use A and B Drum Level Sticks (24M174) tomeasure the material
level in each drum.. If
desired, the level can be entered and tracked inthe ADM. See
Advanced Setup Screens, page 34.
4. CheckCheckCheck generatorgeneratorgenerator fuelfuelfuel
level.level.level.
NOTICENOTICENOTICERunning out of fuel will cause
voltagefluctuations that can damage electricalequipment and void
the warranty. Do not runout of fuel.
5. ConfirmConfirmConfirmmainmainmain powerpowerpower
switchswitchswitch isisis OFFOFFOFF beforebeforebefore
startingstartingstartinggenerator.generator.generator.
6. Ensure the main breaker on the generator is inthe off
position.
7. Start the generator. Allow it to reach full
operatingtemperature.
8. TurnTurnTurn mainmainmain powerpowerpower switchswitchswitch
ON.ON.ON.
The ADM will display the following screen untilcommunication and
initialization is complete.
42 333023J
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Startup
9. Switch on the air compressor, air dryer, andbreathing air, if
included.
10. ForForFor firstfirstfirst startupstartupstartup ofofof
newnewnew system,system,system, loadloadload fluidfluidfluid
withwithwithfeedfeedfeed pumps.pumps.pumps.
a. Check that all SetupSetupSetup steps are complete.See Setup,
page 27.
b. If an agitator is used, open the agitator’s airinlet
valve.
c. If you need to circulate fluid through thesystem to preheat
the drum supply, seeCirculation Through Reactor, page 45.If you
need to circulate material throughthe heat hose to the gun
manifold, seeCirculation Through Gun Manifold, page 46.
d. Turn both PRESSURE RELIEF/SPRAYvalves (SA, SB) to SPRAY .
SBSAGA GB
e. Open fluid inlet valves (FV). Check for leaks.
Cross-contamination can result in curedmaterial in fluid lines
which could causeserious injury or damage equipment. Toprevent
cross-contamination:
• NeverNeverNever interchange component A andcomponent B wetted
parts.
• Never use solvent on one side if it hasbeen contaminated from
the other side.
• Always provide two grounded wastecontainers to keep component
A andcomponent B fluids separate.
f. Hold gun fluid manifold over two groundedwaste containers.
Open fluid valves A and Buntil clean, air-free fluid comes from
valves.Close valves.
The Fusion AP gun manifold is shown.
333023J 43
-
Startup
11. Press to activate ADM.
12. If necessary, setup the ADM in Setup Mode. SeeAdvanced
Display Module (ADM) Operation,page 31.
13. Preheat the system:
a. Press to turn on hose heat zone.
This equipment is used with heated fluidwhich can cause
equipment surfaces tobecome very hot. To avoid severe burns:
• Do not touch hot fluid or equipment.
• Do not turn on hose heat without fluidin hoses.
• Allow equipment to cool completelybefore touching it.
• Wear gloves if fluid temperature exceeds110°F (43°C).
Thermal expansion can causeoverpressurization, resulting in
equipmentrupture and serious injury, including fluidinjection. Do
not pressurize system whenpreheating hose.
b. If you need to circulate fluid through thesystem to preheat
the drum supply, seeCirculation Through Reactor, page 45.If you
need to circulate material throughthe heat hose to the gun
manifold, seeCirculation Through Gun Manifold, page 46.
c. Wait for the hose to reach set pointtemperature.
Note
Hose heat-up time may increase atvoltages less than 230 VAC
whenmaximum hose length is used.
d. Press to turn on A and B heat zones.
44 333023J
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Fluid Circulation
FluidFluidFluid CirculationCirculationCirculation
CirculationCirculationCirculation ThroughThroughThrough
ReactorReactorReactor
NOTICENOTICENOTICETo prevent equipment damage, do not
circulatefluid containing a blowing agent without consultingwith
your material supplier regarding fluidtemperature limits.
NOTE:NOTE:NOTE: Optimum heat transfer is achieved at lowerfluid
flow rates with temperature set points at desireddrum temperature.
Low temperature rise deviationerrors may result.To circulate
through gun manifold and preheat hose,see Circulation Through Gun
Manifold, page 46.
1. Follow Startup, page 42.
To avoid injection injury and splashing, do notinstall shutoffs
downstream of the PRESSURERELIEF/SPRAY valve outlets (BA, BB).
Thevalves function as overpressure relief valveswhen set to SPRAY .
Lines must beopen so valves can automatically relievepressure when
machine is operating.
2. See Typical Installation, with system fluidmanifold to drum
circulation, page 14. Routecirculation lines back to respective
componentA or B supply drum. Use hoses rated at themaximum working
pressure of this equipment.See Technical Specifications, page
67.
3. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION .
SA SBGA GB
4. Set temperature targets. See Targets, page 37.
5. Press to circulate fluid in jog mode untilA and B
temperatures reach targets. SeeJog Mode, page 46 for more
information aboutjog mode.
6. Press to turn on the hose heat zone.
7. Turn on the A and B heat zones. Wait until thefluid inlet
valve temperature gauges (FV) reachthe minimum chemical temperature
from thesupply drums.
8. Exit jog mode.
9. Set PRESSURE RELIEF/SPRAY valves (SA,SB) to SPRAY .
SBSAGA GB
333023J 45
-
Jog Mode
CirculationCirculationCirculation ThroughThroughThrough
GunGunGun ManifoldManifoldManifold
NOTICENOTICENOTICETo prevent equipment damage, do not
circulatefluid containing a blowing agent without consultingwith
your material supplier regarding fluidtemperature limits.
NOTE:NOTE:NOTE: Optimum heat transfer is achieved at lowerfluid
flow rates with temperature set points at desireddrum temperature.
Low temperature rise deviationerrors may result.Circulating fluid
through the gun manifold allowsrapid preheating of the hose.
1. Install gun fluid manifold (P) on accessorycirculation kit
(CK). Connect high pressurecirculation lines (R) to circulation
manifold.
P
CK
R
The Fusion AP gun manifold is shown.
CKCKCK GunGunGun ManualManualManual
246362 Fusion AP 309818
256566 Fusion CS 313058
2. Route circulation lines back to respectivecomponent A or B
supply drum. Use
hoses rated at the maximum workingpressure of this equipment.
SeeTechnical Specifications, page 67.
3. Follow procedures from Startup, page 42.
4. Turn main power switch on .
5. Set temperature targets. See Targets, page 37.
6. Press to circulate fluid in jog mode untilA and B
temperatures reach targets. SeeJog Mode, page 46 for more
information aboutjog mode.
JogJogJog ModeModeModeJog mode has two purposes:
• It can speed fluid heating during circulation.
• It can ease system flushing and priming.
1. Turn main power switch on .
2. Press circulate to enter jog mode.
3. Press up or down to change jog speed(J1 through J20).
Note
Jog speeds correlate to 3-30% of motorpower, but will not
operate over 700 psi(4.9 MPa, 49 bar) for either A or B.
4. Press to start motor.
5. To stop the motor and exit jog mode press
or .
46 333023J
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Spraying
SprayingSprayingSpraying
The Fusion AP gun is shown.
1. Engage gun piston safety lock and close gunfluid inlet valves
A and B.
FusionFusionFusion ProblerProblerProbler
2. Attach gun fluid manifold. Connect gun air line.Open air line
valve.
3. Adjust the gun air regulator to desired gun airpressure. Do
not exceed the maximum ratedair pressure.
4. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY .
SBSAGA GB
5. Verify heat zones are on and temperaturesand pressures are on
target, seeHome screen, page 37.
6. Open fluid inlet valve located at each pump inlet.
7. Press to start motor and pumps.
8. Check fluid pressure gauges (GA, GB) toensure proper pressure
balance. If imbalanced,reduce pressure of higher component
byslightlyslightlyslightly turning PRESSURE RELIEF/SPRAYvalve for
that component toward PRESSURE
RELIEF/CIRCULATION until gauges showbalanced pressures.
SA SBGA GB
333023J 47
-
Spraying
9. Open gun fluid inlet valves A and B.
FusionFusionFusion ProblerProblerProbler
NOTICENOTICENOTICETo prevent material crossover on
impingementguns, nevernevernever open fluid manifold valves
ortrigger gun if pressures are imbalanced.
10. Disengage gun piston safety lock.
FusionFusionFusion ProblerProblerProbler
11. Pull gun trigger to test spray onto cardboard. Ifnecessary,
adjust pressure and temperature toget desired results.
SpraySpraySpray AdjustmentsAdjustmentsAdjustments
Flow rate, atomization, and amount of overspray areaffected by
four variables.
• FluidFluidFluid pressurepressurepressure
setting.setting.setting. Too little pressure resultsin an uneven
pattern, coarse droplet size, lowflow, and poor mixing. Too much
pressure resultsin excessive overspray, high flow rates,
difficultcontrol, and excessive wear.
• FluidFluidFluid temperature.temperature.temperature. Similar
effects to fluid pressuresetting. The A and B temperatures can be
offset tohelp balance the fluid pressure.
• MixMixMix chamberchamberchamber size.size.size. Choice of mix
chamber is basedon desired flow rate and fluid viscosity.
• Clean-offClean-offClean-off airairair
adjustment.adjustment.adjustment. Too little clean-off airresults
in droplets building up on the front of thenozzle, and no pattern
containment to controloverspray. Too much clean-off air results
inair-assisted atomization and excessive overspray.
48 333023J
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Manual Hose Heat Mode
ManualManualManual HoseHoseHose HeatHeatHeat ModeModeModeIf the
system produces the T6DH sensor error hosealarm or the T6DT sensor
error TCM alarm, usemanual hose heat mode until the hose RTD cable
orFTS temperature sensor can be repaired.
Do not use Manual Hose Mode for extended periodsof time. The
system performs best when the hosehas a valid RTD and can operate
in temperaturecontrol mode. If a hose RTD breaks, the first
priorityis to fix the RTD. Manual Hose Mode can help finisha job
while waiting for repair parts.
EnableEnableEnable ManualManualManual HoseHoseHose
ModeModeMode
1. Disconnect the hose RTD sensor from the TCM.
2. Enter Setup Mode and navigate to SystemScreen 2.
3. Select Enable Manual Hose Mode.
Note
When manual hose mode is enabled, themanual hose mode advisory
EVCH-Vwill appear.
4. Enter Run Mode and navigate to the Targetscreen. Use the up
and down arrows to set thedesired hose current.
HoseHoseHose CurrentCurrentCurrent SettingsSettingsSettings
HoseHoseHose CurrentCurrentCurrent
Default 20A
Maximum 37A
333023J 49
-
Manual Hose Heat Mode
5. Navigate back to the Run Mode Home screen.The hose now
displays a current instead of atemperature.
Note
Until the RTD sensor is repaired, theT6DH sensor error alarm
will displayeach time the system is powered up.
DisableDisableDisable ManualManualManual HoseHoseHose
ModeModeMode
1. Enter Setup Mode and navigate to System 2Screen and deselect
Enable Manual Hose Mode,or repair the hose RTD cable or FTS.
2. Manual hose mode is automatically disabledwhen the system
detects a valid RTD sensor inthe hose.
50 333023J
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Shutdown
ShutdownShutdownShutdown
NOTICENOTICENOTICEProper system setup, startup, and
shutdownprocedures are critical to electrical equipmentreliability.
The following procedures ensure steadyvoltage. Failure to follow
these procedures willcause voltage fluctuations that can
damageelectrical equipment and void the warranty.
1. Press to stop the pumps.
2. Turn off all heat zones.
3. Relieve pressure. SeePressure Relief Procedure, page 53.
4. Press to park the Component A Pump. Thepark operation is
complete when green dot goesout. Verify the park operation is
complete beforemoving to next step.
5. Press to deactivate the system.
6. Turn off the air compressor, air dryer, andbreathing air.
7. Turn main power switch OFF.
To prevent electric shock do not remove anyshrouds or open the
electrical enclosure door.
8. Close all fluid supply valves.
333023J 51
-
Shutdown
9. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY to seal out moisture fromdrain line.
SBSAGA GB
10. Engage gun piston safety lock then close fluidinlet valves A
and B.
FusionFusionFusion ProblerProblerProbler
52 333023J
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Pressure Relief Procedure
PressurePressurePressure ReliefReliefRelief
ProcedureProcedureProcedureFollow the Pressure Relief
Procedurewhenever you see this symbol.
This equipment stays pressurized until pressureis manually
relieved. To help prevent seriousinjury from pressurized fluid,
such as skin injection,splashing fluid and moving parts, follow
thePressure Relief Procedure when you stop sprayingand before
cleaning, checking, or servicingequipment.
The Fusion AP gun is shown.
1. Relieve pressure in gun and perform gunshutdown procedure.
See gun manual.
2. Engage gun piston safety lock.
3. Close gun fluid inlet valves A and B.
4. Shut off feed pumps and agitator, if used.
5. Route fluid to waste containers or supply tanks.Turn PRESSURE
RELIEF/SPRAY valves (SA,SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.
SA SBGA GB
333023J 53
-
Flushing
FlushingFlushingFlushing
To help prevent fire and explosion:
• Flush equipment only in a well-ventilated area.
• Do not spray flammable fluids.
• Do not turn on heaters while flushing withflammable
solvents.
• Flush out old fluid with new fluid, or flush out oldfluid with
a compatible solvent before introducingnew fluid.
• Use the lowest possible pressure when flushing.
• All wetted parts are compatible with commonsolvents. Use only
moisture-free solvents.
To flush feed hoses, pumps, and heatersseparately from heated
hoses, set PRESSURERELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION . Flush through bleedlines (N).
SA SBGA GB
To flush entire system, circulate through gun fluidmanifold
(with manifold removed from gun).
To prevent moisture from reacting with isocyanate,always leave
the system filled with a moisture-freeplasticizer or oil. Do not
use water. Never leave thesystem dry. See Important Isocyanate
Information.
54 333023J
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Maintenance
MaintenanceMaintenanceMaintenance
Prior to performing any maintenance procedures,follow Pressure
Relief Procedure, page 53.
PreventativePreventativePreventative
MaintenanceMaintenanceMaintenance ScheduleScheduleSchedule
The operating conditions of your particular systemdetermine how
often maintenance is required.Establish a preventive maintenance
schedule byrecording when and what kind of maintenance isneeded,
and then determine a regular schedule forchecking your system.
ProportionerProportionerProportioner
MaintenanceMaintenanceMaintenance
WetWetWet CupCupCup
Check the wet cup daily. Keep it 2/3 full with GracoThroat Seal
Liquid (TSL®) or compatible solvent. Donot overtighten packing
nut/wet cup.
PackingPackingPacking NutsNutsNuts
Do not overtighten packing nut/wet cup. Throat u-cupis not
adjustable.
FluidFluidFluid InletInletInlet StrainerStrainerStrainer
ScreensScreensScreens
Inspect fluid inlet strainer screens daily, seeFlush Inlet
Strainer Screen, page 56.
GreaseGreaseGrease CirculationCirculationCirculation
ValvesValvesValves
Grease circulation valves (SA and SB) with Fusiongrease (117773)
weekly.
ISOISOISO LubricantLubricantLubricant LevelLevelLevel
Inspect ISO lubricant level and conditiondaily. Refill or
replace as needed. SeePump Lubrication System, page 57.
MoistureMoistureMoisture
To prevent crystallization, do not expose componentA to moisture
in air.
GunGunGun MixMixMix ChamberChamberChamber PortsPortsPorts
Clean gun mix chamber ports regularly. See gunmanual.
GunGunGun CheckCheckCheck ValveValveValve
ScreensScreensScreens
Clean gun check valve screens regularly. See gunmanual.
DustDustDust ProtectionProtectionProtection
Use clean, dry, oil-free compressed air to preventdust buildup
on control modules, fans, and motor(under shield).
VentVentVent HolesHolesHoles
Keep vent holes on bottom of electrical cabinet open.
333023J 55
-
Maintenance
FlushFlushFlush InletInletInlet StrainerStrainerStrainer
ScreenScreenScreen
The inlet strainers filter out particles that can plug thepump
inlet check valves. Inspect the screens daily aspart of the startup
routine, and clean as required.
Isocyanate can crystallize from moisturecontamination or from
freezing. If the chemicals usedare clean and proper storage,
transfer, and operatingprocedures are followed, there should be
minimalcontamination of the A-side screen.
Note
Clean the A-side screen only duringdaily startup. This minimizes
moisturecontamination by immediately flushingout any isocyanate
residue at the start ofdispensing operations.
1. Close the fluid inlet valve at the pump inlet andshut off the
appropriate feed pump. This preventsmaterial from being pumped
while cleaning thescreen.
2. Place a container under the strainer base to catchdrain off
when removing the strainer plug (C).
3. Remove the screen (A) from the strainermanifold. Thoroughly
flush the screen with
compatible solvent and shake it dry. Inspect thescreen. No more
than 25% of the mesh shouldbe restricted. If more than 25% of the
mesh isblocked, replace the screen. Inspect the gasket(B) and
replace as required.
4. Ensure the pipe plug (D) is screwed into thestrainer plug
(C). Install the strainer plug with thescreen (A) and o-ring (B) in
place and tighten. Donot overtighten. Let the gasket make the
seal.
5. Open the fluid inlet valve, ensure that there areno leaks,
and wipe the equipment clean. Proceedwith operation.
Figure 15
56 333023J
-
Maintenance
PumpPumpPump LubricationLubricationLubrication
SystemSystemSystem
Check the condition of the ISO pump lubricant daily.Change the
lubricant if it becomes a gel, its colordarkens, or it becomes
diluted with isocyanate.
Gel formation is due to moisture absorption by thepump
lubricant. The interval between changesdepends on the environment
in which the equipmentis operating. The pump lubrication system
minimizesexposure to moisture, but some contamination is
stillpossible.
Lubricant discoloration is due to continual seepage ofsmall
amounts of isocyanate past the pump packingsduring operation. If
the packings are operatingproperly, lubricant replacement due to
discolorationshould not be necessary more often than every 3 or4
weeks.
To change pump lubricant:
1. Follow Pressure Relief Procedure, page 53.
2. Lift the lubricant reservoir (R) out of the bracketand remove
the container from the cap. Holdingthe cap over a suitable
container, remove thecheck valve and allow the lubricant to
drain.Reattach the check valve to the inlet hose.
3. Drain the reservoir and flush it with cleanlubricant.
4. When the reservoir is flushed clean, fill with
freshlubricant.
5. Thread the reservoir onto the cap assembly andplace it in the
bracket.
6. The lubrication system is ready for operation. Nopriming is
required.
Pump Lubrication SystemFigure 16
333023J 57
-
Errors
ErrorsErrorsErrors
ViewViewView ErrorsErrorsErrors
When an error occurs the error information screendisplays the
active error code and description.
The error code, alarm bell, and active errors will scrollin the
status bar. For a list of the ten most recenterrors see
Troubleshooting, page 59. Error codesare stored in the error log
and displayed on the Errorand Troubleshooting screens on the
ADM.
There are three types of errors that can occur. Errorsare
indicated on the display as well as by the lighttower
(optional).
Alarms are indicated by . This condition indicatesa parameter
critical to the process has reached alevel requiring the system to
stop. The alarm needsto be addressed immediately.
Deviations are indicated by . This conditionindicates a
parameter critical to the process hasreached a level requiring
attention, but not sufficientenough to stop the system at this
time.
Advisories are indicated by . This conditionindicates a
parameter that is not immediately criticalto the process. The
advisory needs attention toprevent more serious issues in the
future.
To diagnose the active error, seeTroubleshoot Errors, page
58.
TroubleshootTroubleshootTroubleshoot ErrorsErrorsErrors
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 thepreviously displayed screen.
2. The QR code screen will be displayed. Scanthe QR code with
your smart phone to be sentdirectly to online troubleshooting for
the activeerror code. Otherwise, manually navigate
tohttp://help.graco.com and search for the activeerror.
3. If no internet connection is available, seeError Codes and
Troubleshooting, page 59 forcauses and solutions for each error
code.
58 333023J
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Troubleshooting
TroubleshootingTroubleshootingTroubleshootingSee Errors, page 58
for information about errors thatcan occur on the system.
See Troubleshooting, page 39 for the ten mostrecent errors that
have occurred on the system. SeeTroubleshoot Errors, page 58 to
diagnose errors onthe ADM that have occurred on the system.
ErrorErrorError CodesCodesCodes andandand
TroubleshootingTroubleshootingTroubleshooting
See system repair manual or visithttp://help.graco.com for
causes and solutions toeach error code.
333023J 59
-
USB Data
USBUSBUSB DataDataData
DownloadDownloadDownload ProcedureProcedureProcedure
Note
System configuration setting files and customlanguage files can
be modified if the filesare in the UPLOAD folder of the USB
flashdrive. See System Configuration SettingsFile, Custom Language
File, and UploadProcedure sections.
1. Insert USB flash drive into USB port.
2. The menu bar and USB indicator lights indicatethat the USB is
downloading files. Wait for USBactivity 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 withinWindows® Explorer.
6. Open GRACO folder.
7. Instructions continue on next page.
8. Open the system folder. If downloading datafrom more than one
system, there will be morethan one folder. Each folder is labeled
with thecorresponding serial number of the ADM (Theserial number is
on the back of the ADM.)
9. Open DOWNLOAD folder.
10. Open DATAxxxx folder.
11. Open DATAxxxx folder labeled with the highestnumber. The
highest number indicates the mostrecent data download.
12. Open log file. Log files open in Microsoft® Excelby default
as long as the program is installed.However, they can also be
opened in any texteditor or Microsoft® Word.
Note
All USB logs are saved in Unicode(UTF-16) format. If opening the
logfile in Microsoft Word, select Unicodeencoding.
USBUSBUSB LogsLogsLogs
Note
The ADM can read/write to FAT (FileAllocation Table) storage
devices. NTFS,used by 32 GB or greater storage devices,is not
supported.
During operation, the ADM stores system andperformance related
information to memory in theform 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 60, to retrievelog files.
Each time a USB flash drive is inserted into the ADMUSB port, a
new folder named DATAxxxx is created.The number at the end of the
folder name increaseseach time a USB flash drive is inserted and
data isdownloaded or uploaded.
EventEventEvent LogLogLog
The event log file name is 1–EVENT.CSV and isstored in the
DATAxxxx folder.
The event log maintains a record of the last 49,000events 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 eventconditions by
the system, and acknowledging errorconditions by the user.
60 333023J
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USB Data
JobJobJob LogLogLog
The job log file name is 2–JOB.CSV and is storedin the DATAxxxx
folder.
The job log maintains a record of data pointsbased on the USB
Log Frequency definedin the Setup screens. The ADM stores thelast
237,000 data points for download. SeeSetup - Advanced Screen 3 —
USB, page 34, forinformation on setting the Download Depth and
USBLog Frequency.
• Da