Graco Reactor 2 E-30i Operation Download Page 2

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Contents

Generator.................................................... 18

Proportioner Control Panel ........................... 19

Air Compressor............................................ 20

Advanced Display Module ............................ 21

Electrical Enclosure...................................... 26

Electrical Cabinet......................................... 27

Motor Control Module (MCM)........................ 28

Engine Control Module................................. 29

Load Center ................................................ 30

Temperature Control Module (TCM) Cable

Connections ................................... 31

Circuit Breakers ........................................... 32

Overview............................................................ 34
Setup................................................................. 37

Locate Reactor ............................................ 37

Trailer Setup Guidelines ............................... 38

Install Wall (optional).................................... 39

Connect Battery........................................... 41

Add Fuel ..................................................... 41

General Equipment Guidelines ..................... 42

Electrical Connections.................................. 42

Connect Feed Pumps................................... 42

Breathing Air................................................ 42

Connect Pressure Relief Lines...................... 43

Install Fluid Temperature Sensor .................. 43

Connect Heated Hose .................................. 43

Close gun ﬂuid manifold valves A and

B ................................................... 44

Connect Whip Hose to Gun Or Gun Fluid

Manifold......................................... 44

Pressure Check Hose .................................. 44

Connect Remote Display Module .................. 44

Grounding ................................................... 45

Supply Wet Cups With Throat Seal Liquid

(TSL) ............................................. 46

Operation........................................................... 47

Initial System Setup ..................................... 47

Advanced Setup Screens ............................. 50

System 1..................................................... 51

System 2..................................................... 51

Recipes....................................................... 51

Run Mode ................................................... 53

Startup............................................................... 57
Fluid Circulation.................................................. 61

Circulation Through Reactor ......................... 61

Circulation Through Gun Manifold ................. 62

Jog Mode .................................................... 62

Spraying ............................................................ 63

Spray Adjustments....................................... 64

Manual Hose Heat Mode .............................. 65

Shutdown........................................................... 67
Pressure Relief Procedure .................................. 69
Flushing............................................................. 70
System Errors .................................................... 71

Troubleshoot Errors ..................................... 72

Clear Alarm ................................................. 72

Maintenance ...................................................... 73

Preventative Maintenance Schedule ............. 73

Wetcup........................................................ 73

Fluid Inlet Strainer Screen ............................ 73

Coolant Filter ............................................... 73

Grease Circulation Valves ............................ 73

ISO Lubrication Level ................................... 73

Wiring Connections...................................... 73

Dust Protection ............................................ 73

Coolant Levels............................................. 73

Compressor Maintenance............................. 73

Clean Heat Sink Fins.................................... 74

Engine Maintenance .................................... 74

Air Compressor Oil Level.............................. 74

Fuel Tank .................................................... 75

Flush Inlet Strainer Screen ........................... 75

Pump Lubrication System............................. 76

USB Data........................................................... 77

USB Logs.................................................... 77

System Conﬁguration Settings ...................... 78

Download Log Files...................................... 79

Custom Language File ................................. 79

Upload Procedure ........................................ 80

Appendix A: Engine Control Module..................... 81
Dimensions ........................................................ 84
Performance Charts............................................ 87
Technical Speciﬁcations...................................... 90
Graco Extended Warranty for Integrated

Reactor® 2 Components ....................... 93

332636C

Summary of Contents for Reactor 2 E-30i

Page 1: ...m With Integrated Generator For spraying polyurethane foam and polyurea coatings For professional use only Not approved for use in explosive atmospheres or hazardous locations Not for outdoor use Important Safety Instructions Read all warnings and instructions in this manual Save these instructions PROVEN QUALITY LEADING TECHNOLOGY ...

Page 2: ... Grounding 45 Supply Wet Cups With Throat Seal Liquid TSL 46 Operation 47 Initial System Setup 47 Register and Activate the Graco Insite 48 Advanced Setup Screens 50 System 1 51 System 2 51 Recipes 51 Run Mode 53 Startup 57 Fluid Circulation 61 Circulation Through Reactor 61 Circulation Through Gun Manifold 62 Jog Mode 62 Spraying 63 Spray Adjustments 64 Manual Hose Heat Mode 65 Shutdown 67 Pressu...

Page 3: ...ician and comply with all local codes and regulations TOXIC FLUID OR FUMES Toxic ﬂuids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDSs to know the speciﬁc hazards of the ﬂuids you are using Store hazardous ﬂuid in approved containers and dispose of it according to applicable guidelines Always wear chemically impermeable gloves when spra...

Page 4: ...rts immediately FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent ﬁre and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline ...

Page 5: ...ent 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 hydrocarbon solvents or ﬂuids containing such solvents Many other ﬂuids may contain chemicals that can react with aluminum Contact your material supplier for compatibility PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degra...

Page 6: ... 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 BATTERY HAZARD The battery may leak explode cause burns or cause an explosion if mishandled Only use the battery type speciﬁed for use with the equipment See Technical Data Battery maintenance must only be performed or sup...

Page 7: ... without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources BURN HAZARD Equipment surfaces and ﬂuid that is heated can become very hot during operation To avoid severe burns Do not touch hot ﬂuid or equipment CALIFORNIA PROPOSITION 65 The engine exhaust from this product contains a chemical known to the State of California to...

Page 8: ... Separate 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 Moisture Sensitivity of Isocyanates Exposure to moisture such as humidity will cause ISO to partially cure...

Page 9: ... 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 ...

Page 10: ...22089 GCP2R2 P22090 GCP2R2 Heated Hose 50 ft 15 m 24Y240 24Y240 24Y240 24Y240 Heated Whip Hose 10 ft 3 m 246055 246055 246055 246055 Total system watts used by system based on maximum heated hose length of 310 ft 94 5 m for each unit Full load amps available for auxiliary equipment when all bare system components are operating at maximum capabilities Available auxiliary current is based on 310 ft ...

Page 11: ...based on maximum heated hose length of 310 ft 94 5 m for each unit Full load amps available for auxiliary equipment when all bare system components are operating at maximum capabilities Available auxiliary current is based on 310 ft 94 5 m of heated hose An additional 3 0 amps 240 VAC of auxiliary current is available for each 50 ft 15 2 m section of heated hose that is not used Auxiliary current ...

Page 12: ... Intertek Accessories Kit Number Description 15M483 Remote Display Module Protective Covers 10 pack 15V551 ADM Protective Covers 10 pack 24K207 Fluid Temperature Sensor FTS with RTD 24K333 Fuel Line and Cable Extension Kit 24K336 Hose Rack 24K337 Light Tower Kit 24L911 Pallet Support Kit 24M174 Drum Level Sticks 24U174 Remote Display Module Kit 24U176 Complete Air Compressor Kit 24U177 Feed Pump S...

Page 13: ...y Service tab and select contact us to request manuals 33227482 Refrigerated Air Dryer Instruction manual Access from Service Department 724 746 1100 or www spx com en hankison Related Manuals The following manuals are for accessories used with the Reactor Component Manuals in English Manuals are available at www graco com System Manuals 332737 Reactor 2 E 30i and E XP2i Repair Parts Displacement ...

Page 14: ...tion A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor FTS D Heated Whip Hose E Fusion Spray Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines H Agitator Air Supply Line J Fluid Supply Lines K Feed Pumps L Agitator M Desiccant Dryer N Bleed Lines P Gun Fluid Manifold part of gun S Remote Display Module Kit optional 14 332636C ...

Page 15: ...A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor FTS D Heated Whip Hose E Fusion Spray Gun F Gun Air Supply Hose G Feed Pump Air Supply Lines H Agitator Air Supply Line J Fluid Supply Lines K Feed Pumps L Agitator M Desiccant Dryer P Gun Fluid Manifold part of gun R Recirculation Lines S Remote Display Module optional 332636C 15 ...

Page 16: ...e Gauge GB Component B Pressure Gauge GG Generator page 18 HA Component A Hose Connection HB Component B Hose Connection HC Heated Hose Electrical Connectors MP Main Power Switch PA Component A Pump PB Component B Pump behind Electrical Enclosure PC Proportioner Control Panel page 19 PT Pallet SA Component A PRESSURE RELIEF SPRAY Valve SB Component B PRESSURE RELIEF SPRAY Valve SC Fluid Temperatur...

Page 17: ...e sensor FH Booster Fluid Heater not included with all models FV Fluid Inlet Valve A side shown HE Heat Exchangers heat exchanger coolant loop HM Temperature Control Module TCM Cable Connections page 31 LR ISO Pump Lubricant Reservoir MM Motor Control Module MCM page 28 SG Sight Glass VA Component A Control Valve VB Component B Control Valve VC Bypass Control Valve 332636C 17 ...

Page 18: ...Solenoid FH Filter Housing FJ Fuel Injector FP Fuel Pump FS Diesel Fuel Fill Cap FT Diesel Fuel Tank GD Generator Power Distribution Box GL Glow Plugs HB Heat Exchanger Coolant Expansion Bottle HE Heat Exchanger HF Heat Exchanger Coolant Fill Bottle OD Oil Drain OF Oil Filter OL Oil Fill OS Oil Pressure Switch RC Engine Coolant Radiator Cap RF Radiator Fan ST Starter TR Coolant Temperature Sensor ...

Page 19: ...ump Air Outlet PG Component B Feed Pump Air Outlet PH Agitator Air Outlet PJ Gun Air Outlet PK Component A Feed Pump Air Regulator PL Component B Feed Pump and Agitator Air Regulator PM Gun Air Regulator PN Component A Feed Pump Pressure Gauge PP Component B Feed Pump and Agitator Pressure Gauge PR Gun Pressure Gauge Not for breathing air use 332636C 19 ...

Page 20: ...pplied with an air compressor and air dryer Figure 7 CA Air Compressor CB Power Box CC Air Compressor and Dryer On Off Switch CD Refrigerated Air Dryer CE Air Dryer Drain Tube bottom of refrigerated air dryer not shown CF Air Compressor Pressure Gauge 20 332636C ...

Page 21: ...l on the display and individual screens see Run Mode page 53 or Setup Mode Use the USB port on the ADM to download or upload data For more information about the USB data see USB Data page 77 NOTICE To prevent damage to the softkey buttons do not press buttons with sharp objects such as pens plastic cards or ﬁngernails Figure 8 Front View 332636C 21 ...

Page 22: ...n shown on the display directly next to each key Navigation Keys Left Right Arrows Use to move from screen to screen Up Down Arrows Use to move among ﬁelds on a screen items on a dropdown menu or multiple screens within a function Numeric Keypad Use to input values Cancel Use to cancel a data entry ﬁeld Setup Press to enter or exit Setup mode Enter Press to choose a ﬁeld to update to make a select...

Page 23: ...n Mode System On Green Flashing Setup Mode System On Yellow Solid Run Mode System Off System Status Yellow Flashing Setup Mode System Off Green Flashing Data recording in progress Yellow Solid Downloading information to USB USB Status CL Green and Yellow Flashing ADM is busy USB cannot transfer information when in this mode Green Solid Power applied to module Yellow Solid Active Communication Red ...

Page 24: ...ystem mode is displayed at the lower left of the menu bar Alarm Deviation 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 Status The current system status is displayed at the lower right of the menu bar Navigating the Screens There are two sets of screens The Run ...

Page 25: ...1 for more information Softkey Icons The following icons appear in the ADM directly to the left or right of the soft key which activates that operation Icon Function Start Proportioner Start and Stop Proportioner in Jog Mode Stop Proportioner Turn on speciﬁed heat zone Park component A pump Enter Jog Mode See Jog Mode page 62 Reset Cycle Counter press and hold Select Recipe Search Move Cursor Left...

Page 26: ...Component Identification Electrical Enclosure AAA Temperature Control Module TCM AAB Motor Control Module MCM AAC Enclosure Fan AAD Circuit Breakers MP Main Power Switch 26 332636C ...

Page 27: ...Component Identification Electrical Cabinet AAM Hose Breaker AAN Transformer AAP Load Center AAS Fan AAU Wiring Terminal Blocks 332636C 27 ...

Page 28: ... Pressure 8 A Fluid Inlet Sensor 9 B Fluid Inlet Sensor 10 Accessory Output 11 Load Center 12 Pump Cycle Counter 13 Not Used 14 Graco Insite 15 Motor Power Output 16 Main Power Input MCM Rotary Switch Positions 0 E 30i 1 E XP2i Table 3 MCM Module LED MB Status Descriptions LED Conditions Description Green Solid Power applied to module Yellow Solid Active Communication Red Steady Flashing Software ...

Page 29: ...trol module see Appendix A Engine Control Module page 81 Figure 11 Icon Description Function On Start Engine Auto Auto mode not used Off Stop all system processes Is not a safety or emergency stop Scroll Scroll through the instruments or recorded events on the currently displayed page Page Select Toggle between the information page and the error log page Error Lamp Indicates error is present on ge...

Page 30: ...lenoid FS Green Fuel shutoff solenoid on the engine is open D2 Starter ST Red Starter is cranking D3 Glow Plugs GL Green Glow plugs are heating D4 Radiator Fan RF Green Radiator fan is on D10 A Coolant Valve Red A side red coolant valve is open D12 B Coolant Valve Blue B side blue coolant valve is open D14 Bypass Coolant Valve Green Bypass coolant valve is open D23 Manual Valve Switch MV Red Manua...

Page 31: ...er Input 2 Heater Overtemperature 3 CAN Communications Connections 4 Power Out ISO 5 Power Out Res 6 Power Out Hose 7 Module Status LEDs see Advanced Display Module ADM page 21 CN for conditions 8 Boost Heater A Temperature ISO 9 Boost Heater B Temperature RES 10 Hose Temperature 332636C 31 ...

Page 32: ... TCM 24N750 MCM 24N953 Disconnect CT01 PS1 CB01 CB02 CB03 CB04 CB05 CB06 CB07 CB NEUTRAL 08 TB11 TB12 5 A 15 A 15 A 30 A 20 A 40 A 20 A 15 A FAN Blulkhead Connector Breaker DIN Rail Ground Terminal Ground Bar 24R754 Figure 13 Circuit Breaker Connections Inside Electrical Enclosure DB Note Not all wires are shown Ref Size Component CB01 5 A Power Supply Fan Coolant Pump CB02 15 A Boost Heat A CB03 ...

Page 33: ...o accommodate larger loads or a sub panel The total auxiliary equipment loads added to the conﬁguration must be limited to the system s available auxiliary current See Models page 10 for available auxiliary current at 240V 60Hz See the Reactor repair manual for optional circuit breakers and their current ratings Circuit breakers used must meet UL489 speciﬁcations Auxiliary Wiring Diagram Options T...

Page 34: ...d on the ADM PD The engine coolant loop gray circulates heated coolant from the engine EE through the heat exchanger HE radiator ER and back to the engine Coolant in the proportioner coolant loop black captures heat from the engine coolant loop inside the heat exchanger HE near the radiator Figure 16 Engine Coolant Loop and Proportioner Coolant Loop 34 332636C ...

Page 35: ...ssurized in the proportioner pumps PA PB After the A and B material has been heated in the heat exchangers the material enters the ﬂuid manifold FM and heated hose For models with a booster heater the A and B material enters the booster heater after the material is pressurized in the proportioning pumps to heat the material higher than 140 F 60 C Figure 17 A and B Component Material Flow 332636C 3...

Page 36: ... Proportioner Coolant Loop A and B Valves Open heating material When the control valves VA VB close the A and B material has reached target temperature Coolant ﬂows through the bypass control valve VC circulation pump CP sight glass SG proportioner coolant ﬁll bottle HF and back to the heat exchanger in the engine coolant loop See Fig 19 Figure 19 Proportioner Coolant Loop A and B Valves Closed no...

Page 37: ...l for engine maintenance access 3 Do not expose Reactor to rain or below 20 F 7 C NOTICE To ensure the heat exchanger control valves open and close properly do not store Reactor below 20 F 7 C 4 If a wall will be installed between the proportioner and generator remove the fuel tank and battery bracket See Trailer Setup Guidelines page 38 5 To mount in a trailer use forklift to move Reactor by inse...

Page 38: ... the diameter of the exhaust pipe Metal or other approved ﬁreprooﬁng materials that provides at least 8 in 203 mm of insulation between the exhaust pipe and ﬂammable material Exhaust pipes not covered above must have at least 9 in 228 6 mm of clearance from the outside of the exhaust pipe to adjacent ﬂammable materials 1 Provide sufﬁcient lighting to safely operate and maintain system equipment 2 ...

Page 39: ...l tank c Use two people to lift fuel tank off of the pallet and place where the fuel ﬁll spout is easily accessible Note Do not mount fuel tank in front of the generator air intake or where it will limit opening and access to the electrical enclosure DB 4 Install wall IW where the fuel tank was located Ensure there is at least 1 25 in 31 75 mm between the wall and exhaust mufﬂer See Fig 22 Note To...

Page 40: ...Setup Figure 22 Top View With Wall Figure 23 Side View With Wall 40 332636C ...

Page 41: ...o properly connect the battery cable to the battery will damage the fusible link when the engine control module is turned ON Do not bypass the fusible link when damaged The fusible link prevents damage to other system components See the system repair manual for repair instructions Engine Starter Connections Figure 25 3 Cover battery terminals with plastic caps PC attached to supplied battery cable...

Page 42: ...feed pumps K in component A and B supply drums 2 Seal component A drum and use desiccant dryer M in vent 3 Install agitator L in component B drum if necessary 4 Connect supply hoses from feed pumps to the component A and component B material inlets on the system Ensure A and B inlet valves are closed Note Supply hoses from feed pumps should be 3 4 in 199 mm ID 5 Connect air lines to proportioner E...

Page 43: ...hip hose D must be used with heated hose Hose length including whip hose must be 60 ft 18 3 m minimum NOTICE Apply grease on all system and hose ﬂuid ﬁttings This lubricates the threads and prevents material from hardening on the threads 1 Turn main power switch OFF 2 Assemble heated hose sections FTS and whip hose 3 Connect A and B hoses to A and B outlets on Reactor ﬂuid manifold FM Hoses are co...

Page 44: ... outlet PJ Figure 28 Close gun ﬂuid manifold valves A and B Connect Whip Hose to Gun Or Gun Fluid Manifold See hose manual for proper connections Pressure Check Hose See hose manual Pressure check for leaks If no leaks wrap hose and electrical connections to protect from damage Connect Remote Display Module See Remote Display Module kit manual for installation instructions 44 332636C ...

Page 45: ...imum 25 ft lbs 34 N m An alternate grounding location is to the ground bar in the electrical enclosure Follow all National State and Local safety and ﬁre codes Spray gun connect whip hose ground wire to FTS See Install Fluid Temperature Sensor page 43 Do not disconnect ground wire or spray without whip hose Fluid supply containers follow your local code Object being sprayed follow your local code ...

Page 46: ...SO Pump Keep reservoir R ﬁlled with clean Graco Throat Seal Liquid TSL Part 206995 Wet cup piston circulates TSL through wet cup to carry away isocyanate ﬁlm on displacement rod Figure 29 Component A Pump Component B Resin Pump Check felt washers in packing nut wet cup S daily Keep saturated with Graco Throat Seal Liquid TSL Part No 206995 to prevent material from hardening on displacement rod Rep...

Page 47: ...abled Initial System Setup Perform the following tasks to fully setup your system 1 Select pressure for the Pressure Imbalance Alarm to activate See System Screen page 51 2 Enter enable or disable recipes See Recipes Screen page 56 3 Set general system settings See Advanced Screen 1 General page 50 4 Set units of measure See Advanced Screen 2 Units page 50 5 Set USB settings See Advanced Screen 3 ...

Page 48: ...ellular box below Serial No Verify Module Status To check the status of the cellular module locate the status LEDs on the module then refer to the following chart LED Status Description Green ﬂashing Finding GPS location Green solid GPS location identiﬁed Orange ﬂashing Cellular connection in process Orange solid Cellular connection established Green and orange off Reactor power is OFF 48 332636C ...

Page 49: ... current password then press Press to navigate through the Setup Mode screens Set Password Set a password to allow Setup screen access see Advanced Screen 1 General page 50 Enter any number from 0001 to 9999 To remove the password enter the current password in the Advanced Screen General screen and change the password to 0000 From the Setup screens press to return to the Run screens 332636C 49 ...

Page 50: ...set the language date format current date time setup screens password 0000 for none or 0001 to 9999 and screen saver delay 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 3 USB Use this screen to disable USB downloads uploads disable USB log errors enter the maximum number of days to download dat...

Page 51: ... 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 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 Recipes Use this screen to add recipes view saved recipes and enable or disable saved recipes Enable...

Page 52: ... 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 52 332636C ...

Page 53: ...ant temperature start the proportioner stop the proportioner park the component A pump enter jog mode and clear cycles Home System With Error Active errors are shown in the status bar The error code alarm bell and description of the error will scroll in the status bar 1 Press to acknowledge the error 2 See Troubleshoot Errors page 72 for corrective action Targets Use this screen to deﬁne the setpo...

Page 54: ... 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 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 55: ... EBDB Heat Off B EBDH Heat Off Hose EBPX Pump Off EBRX Jog Off EBUX USB Drive Removed EC0X Setup Value Changed ECDA A Temperature Setpoint Changed ECDB B Temperature Setpoint Changed ECDH Hose Temperature Setpoint Changed ECDP Pressure Setpoint Changed ECDX Recipe Changed EL0X System Power On EM0X System Power Off EP0X Pump Parked EQU1 System Settings Downloaded EQU2 System Settings Uploaded EQU3 ...

Page 56: ...ors listed on this screen can be downloaded on a USB ﬂash drive Job Data Use this screen to enter a job name or number 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 displayed on the three recipe screens 56 332636C ...

Page 57: ...or fuel level Running out of fuel will cause voltage ﬂuctuations that can damage electrical equipment 2 Check coolant levels Inspect the level of coolant inside the engine coolant expansion bottle EB and heat exchanger coolant expansion bottle HB COLD HOT COLD HOT 3 Check ﬂuid inlet ﬁlter screens Before daily startup ensure that the ﬂuid inlet screens are clean See Flush Inlet Strainer Screen page...

Page 58: ...ng speed Note Engine will not start if main power switch is in the ON position 7 Turn main power switch ON The ADM will display the following screen until communication and initialization is complete 8 For ﬁrst startup of new system set system settings on ADM in Setup Mode See Initial System Setup page 47 9 For ﬁrst startup of new system adjust air settings to zero a Close the main air shutoff val...

Page 59: ...gh Reactor page 61 If you need to circulate material through the heated hose to the gun manifold see Circulation Through Gun Manifold page 62 d Turn both PRESSURE RELIEF SPRAY valves SA SB to SPRAY e Adjust A and B feed pump air regulators to desired air pressure on front of proportioner to start the feed pumps Do not exceed 130 psi 0 2 MPa 2 bar to the A and B feed pumps f Open ﬂuid inlet valves ...

Page 60: ...ut 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 overpressurization resulting in equipment rupture and serious injury including ﬂuid injection Do not pressurize system when preheating hose a Press to turn on hose heat zone b Wait for the engine to reach operating temperature indicated when the blac...

Page 61: ... 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 circulation page 15 Route circulation lines back to respective component A or B supply drum Use hoses rated at the maximum working pressure of this equipment 3 Set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CI...

Page 62: ...ve component A or B supply drum Use hoses rated at the maximum working pressure of this equipment 3 Follow procedures from Startup page 57 4 Turn main power switch on 5 Set temperature targets See Targets page 53 6 Press to circulate ﬂuid in jog mode until A and B temperatures reach targets See Jog Mode page 62 for more information about jog mode Jog Mode Jog mode has two purposes Speed ﬂuid heati...

Page 63: ...eat zones are on and temperatures are on target see Home screen page 53 6 Verify that the engine temperature is at least up to the minimum operation temperature range The fan will start running when the engine has reached maximum temperature 7 Open ﬂuid inlet valves 8 Press to start motor and pumps 9 Check ﬂuid pressure gauges GA GB to ensure proper pressure balance If imbalanced reduce pressure o...

Page 64: ...ting 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 an...

Page 65: ...ob while waiting for repair parts Enable Manual Hose Mode 1 Disconnect the hose RTD sensor from the TCM 2 Enter Setup Mode and navigate to System Screen 2 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 Set the desired hose current Hose Current Settings Hose Current Default 20...

Page 66: ...e Mode 1 Enter Setup Mode and navigate to System 2 Screen and deselect Enable Manual Hose Mode or repair the hose RTD 2 Manual hose mode is automatically disabled when the system detects a valid RTD sensor in the hose 66 332636C ...

Page 67: ...w 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 Set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION 4 Relieve pressure See Pressure Relief Procedure page 69 5 Press to park the Component A Pump The park operation is complete when green dot goes out Verify the park op...

Page 68: ...ine cooling dwell time per manufacturer recommendations prior to shutdown Dwell time will help engine properly cool down after running at operating temperature for any period of time Stopping the engine immediately after running it at full load for an extended period of time can cause the engine to overheat due to the lack of coolant ﬂow See engine manual 10 Press to stop the engine 11 Close all ﬂ...

Page 69: ...e when you stop spraying and before cleaning checking or servicing equipment The Fusion AP gun is shown 1 Relieve pressure in gun and perform gun shutdown procedure See gun manual 2 Close gun ﬂuid inlet valves A and B Fusion Probler 3 Shut off feed pumps and agitator if used 4 Route ﬂuid to waste containers or supply tanks Turn PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION Ensu...

Page 70: ...ted parts are compatible with common solvents Use only moisture free solvents 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 sy...

Page 71: ...s well as by the light tower optional Error Description Alarms A parameter critical to the process has reached a level requiring the system to stop The alarm needs to be addressed immediately Deviations A parameter critical to the process has reached a level requiring attention but not sufﬁcient enough to stop the system at this time Advisories A parameter that is not immediately critical to the p...

Page 72: ...earch for the active error Note Press or to return to the previously displayed screen 3 If no internet connection is available see Error Code Troubleshooting in the system repair manual for causes and solutions for each error code Clear Alarm When a deviation or alarm occurs be sure to determine the error code before resetting it Note If you forget which code occurred go to Errors page 56 to view ...

Page 73: ...Valves Grease circulation valves SA SB with Fusion grease 117773 weekly ISO Lubrication Level Inspect ISO lubricant level and condition daily Reﬁll or replace as needed See Pump Lubrication System page 76 Wiring Connections Tighten all screw type wiring connections in the Electrical Enclosure DB Reactor cabinet and air compressor control box if supplied monthly Dust Protection Use clean dry oil fr...

Page 74: ...er Element Dual Element Clean Replace Engine Oil and Filter Change Fuel System Filter Replace Battery Voltage Check See Appendix A Engine Control Module page 81 Contact an Authorized Perkins Dealer or Distributor for replacement ﬁlter elements Refer to Perkins engine part number GN66141N for compatible parts Air Compressor Oil Level Daily check air compressor oil level through sight glass Change o...

Page 75: ...ation 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 Thoroug...

Page 76: ... 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 69 2 Lift the lubricant reservoir R out of the bracket and remove the container from the cap Holding the cap over a suitable container remove the check valve and allow the lubricant t...

Page 77: ...nt 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 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...

Page 78: ...e 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 a...

Page 79: ...lder 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 10 Open DATAxxxx folder labeled with the highest number The highest number indicates the most recent data download 11 Open log ﬁle Log ﬁles open in Microsoft Excel by default as long as the program is installed However they can also b...

Page 80: ...ot add or remove rows to 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...

Page 81: ...tery voltage Press to scroll through the run screens Press to enter the Information screens Run Screen Layout Inst Icon Alarm Icon Instrumentation Units Mode Icon Information Screens From the Run Screen press to enter the information screens Press to scroll through the last ﬁve generator events Press to return to the Run Screens Information Screen Layout Alarm Icon Event Time of Event Engine Run H...

Page 82: ... run mode Timer animation Engine is starting up Running animation Engine is running Instrumentation Icons A small icon is displayed in the instrumentation icon area to indicate what value is currently being displayed Icon Description Details Generator Generator voltage and frequency screen Engine Speed Engine speed screen Engine Lifetime Counter Hours run Event Log Event is being displayed Unit Ti...

Page 83: ...Flexible Sensor The ﬂexible sensor warning alarm has been triggered Shutdown Clear the alarm and remove the fault Then press the stop button to reset the module Icon Description Details Fail To Start The engine has not ﬁred after the preset number of start attempts Generator High Voltage Shutdown The generator output voltage has risen above the preset level Generator Low Voltage Shutdown The gener...

Page 84: ...Dimensions Dimensions Figure 35 84 332636C ...

Page 85: ...Dimensions Figure 36 Figure 37 332636C 85 ...

Page 86: ...Dimensions Figure 38 Floor Mount Hole Pattern 86 332636C ...

Page 87: ...based on a material viscosity of 60 cps NOTICE To prevent system damage do not pressurize the system above the line for the gun tip size being used Proportioners For Foam AR6060 03 AR7070 04 AR5252 02 AR4242 01 2000 138 1500 103 1000 69 500 34 0 5 2 3 15 6 8 20 9 1 25 11 3 30 13 6 35 15 9 40 18 1 10 4 5 E 30i PRESSURE psi bar FLOW lbs min kg min 332636C 87 ...

Page 88: ...9 00 E XP2i 0 0 5 1 9 1 5 5 7 1 0 3 8 2 0 7 6 PRESSURE psi bar FLOW gal min l min Table 5 Fusion Air Purge Flat Pattern 3500 241 24 1 3000 207 20 7 2500 174 17 4 2000 138 13 8 1500 103 10 3 1000 69 6 9 500 35 3 5 AF2020 FTXX24 TIP E XP2i 0 0 5 1 9 1 5 5 7 1 0 3 8 2 0 7 6 AF2929 FTXX38 TIP AF4242 FTXX38 TIP AF5252 FTXX48 TIP PRESSURE psi bar FLOW gal min l min 88 332636C ...

Page 89: ...747 RTM055 PRESSURE psi bar FLOW gal min l min Table 7 Fusion Mechanical Purge Flat Pattern 3500 241 24 1 3000 207 20 7 2500 174 17 4 2000 138 13 8 1500 103 10 3 1000 69 6 9 500 35 3 5 E XP2i 0 0 4 1 5 0 6 2 3 0 8 3 0 0 2 0 7 1 4 5 3 1 2 4 5 1 6 6 0 1 8 6 8 1 3 8 2 0 7 6 XF1313 FTM424 MF1818 FTM424 XF1818 FTM424 XF2323 FTM424 MF2929 FTM424 XF2929 FTM424 MF3535 FTM638 MF4747 FTM638 XF3535 FTM638 MF...

Page 90: ...b min 13 5 kg min E XP2i 2 gpm 7 6 lpm Maximum Heated Hose Length Length 310 ft 94 m Output per Cycle A and B E 30i 0 0272 gal 0 1034 liter E XP2i 0 0203 gal 0 0771 liter Operating Ambient Temperature Range Temperature 20 to 120 F 7 to 49 C Auxiliary Power Available Voltage 120 Vac or 240 Vac 60 Hz Engine Model Perkins 404 22G 2 2 L 29 HP Alternator Model Mecc Alte 22 kW 240 V 1 PH 60 Hz pancake s...

Page 91: ...PM 240 V 1 Phase OPSB Required Features C face lift rings Refrigerated Air Dryer Hankison Model H1T20 Speciﬁcations 115VAC 1 Phase 60 Hz 22 scfm at 150 psi 1 MPa 10 3 bar Required Features Pilot valve unloader Noise Sound Pressure measured per ISO 9614 2 Sound Pressure measured from 3 1 ft 1 m at 1500 psi 10 MPa 103 bar 2 gpm 7 6 lpm 91 0 dBA Fluid Inlets Component A ISO and Component B RES 3 4 NP...

Page 92: ...b 816 kg E 30i with booster heat compressor and dryer 2250 lb 1021 kg E XP2i 1800 lb 816 kg E XP2i with compressor and dryer 2200 lb 998 kg Wetted Parts Material Aluminum stainless steel zinc plated carbon steel brass carbide chrome chemically resistant o rings PTFE ultra high molecular weight polyethylene ...

Page 93: ...tion prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURP...

Page 94: ...latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original Instructions This manual contains English MM 332636 Graco Headquarters Minneapolis International Ofﬁces Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright ...

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