Operation
Reactor® 2 Hydraulic
Proportioning Systems
334945B
EN
Hydraulic, Heated, Plural Component Proportioner for spraying polyurethane foam and polyurea
coatings. Not for outdoor use. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
For model information, see page 9.
PROVEN QUALITY. LEADING TECHNOLOGY.
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Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
• Do not expose to rain. Store indoors.
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 Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of
the fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
Personal
well ventilated and always wear appropriate personal protective equipment. See
Protective Equipment
warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying,
servicing equipment, or when in the work area. Protective equipment helps prevent serious
injury, 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, chemically
impermeable gloves, protective clothing and foot coverings as recommended by the fluid
manufacturer and local regulatory authority.
• Protective eyewear and hearing protection.
334945B
3
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Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce
Get
skin. This may look like just a cut, but it is a serious injury that can result in amputation.
immediate surgical treatment.
• Engage trigger lock when not spraying.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
Pressure Relief Procedure
• Follow the
when you stop dispensing 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.
FIRE AND EXPLOSION HAZARD
work area
Flammable fumes, such as solvent and paint fumes, in
can ignite or explode. Paint
or solvent flowing through the equipment can cause static sparking. 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 sparking).
Grounding
• Ground all equipment in the work area. See
instructions.
• Never spray or flush solvent at high pressure.
• 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 flammable
fumes are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are anti-static or conductive.
Stop operation immediately
.
•
if static sparking occurs or you feel a shock Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
4
334945B
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Warnings
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical 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 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 degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
Technical Data
• See
in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
334945B
5
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Warnings
WARNING
EQUIPMENT MISUSE HAZARD
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 rated
Technical Data
system component. See
in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
Pressure Relief Procedure
• Turn off all equipment and follow the
when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and 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.
MOVING PARTS HAZARD
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 servicing
Pressure Relief Procedure
equipment, follow the
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.
6
334945B
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Important Isocyanate Information
Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific
hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless
you are trained, qualified, and have read and understood the information in this manual and in the fluid
manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which
could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted
according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area
must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include
a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of
contaminated clothing. After spraying, wash hands and face before eating or drinking.
• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal
protective equipment must stay out of the work area during application and after application for the time
period 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 the
recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the
following outside the work area is recommended:
334945B
7
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Important Isocyanate Information
Material Self-Ignition
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure, forming small, hard, abrasive
crystals that become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and SDS.
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
Keep Components A and B Separate
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never
store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage to equipment. To prevent
cross-contamination:
• Use only moisture-proof hoses compatible with
ISO.
Never
•
interchange component A and component
B wetted parts.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Never use solvent on one side if it has been
contaminated from the other side.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
Changing Materials
NOTICE
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
NOTE:
The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Foam Resins with 245 fa Blowing
Agents
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure,
especially if agitated. To reduce frothing, minimize
preheating in a circulation system.
• Always clean the fluid inlet strainers after
flushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.
8
334945B
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Models
Models
Reactor 2 H-30 and H-30 Elite
H-30 Model
15 kW
H-30 Elite Model
15 kW
Model
10 kW
10 kW
Proportioner
★
17H031
17H032
17H131
17H132
Maximum Fluid Working
Pressure psi (MPa, bar)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
Approximate Output per Cycle
(A+B) gal. (liter)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28)
Max Flow Rate lb/min (kg/min)
Total System Load † (Watts)
Configurable Voltage Phase
28 (12.7)
17,960
28 (12.7)
23,260
28 (12.7)
17,960
28 (12.7)
23,260
230
1Ø
230
3Ø∆
380
3ØY
230
1Ø
230
3Ø∆
380
3ØY
230
1Ø
230
3Ø∆
380
3ØY
230
1Ø
230
3Ø∆
380
3ØY
Full Load Peak Current*
79
46
35
100
59
35
79
46
35
100
59
35
Fusion AP Package
APH031
(246102)
CSH031
AHH031
(246102)
CHH031
APH032
(246102)
CSH032
AHH032
(246102)
CHH032
APH131
(246102)
CSH131
AHH131
(246102)
CHH131
APH132
(246102)
CSH132
AHH132
(246102)
CHH132
®
�
�
(Gun Part No.)
Fusion CS Package
®
(Gun Part No.)
(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)
Probler P2 Package
(Gun Part No.)
P2H031
PHH031
P2H032
PHH032
P2H131
PHH131
P2H132
PHH132
�
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
Heated Hose
24K240
Qty: 1
24K240
Qty: 5
24K240
Qty: 1
24K240
Qty: 5
24Y240
Qty: 1
24Y240
Qty: 5
24Y240
Qty: 1
24Y240
Qty: 5
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-wrap)
Heated Whip Hose
10 ft (3 m)
246050
246050
246050
246050
Graco Insite
✓
✓
✓
✓
Fluid Inlet Sensors (2)
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
★
�
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors. All Elite
hose and gun system packages include
Xtreme-Wrap™ 50 ft (15 m) heated hose.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• H–30 series: 310 ft (94.5 m) maximum
heated hose length, including whip hose.
Voltage Configurations Key
Ø
∆
Y
PHASE
DELTA
WYE
334945B
9
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Models
Reactor 2 H-40 and H-40 Elite
H-40 Model
20 kW
H-40 Elite Model
20 kW
Model
15 kW
15 kW
Proportioner
★
17H043
17H044
17H143
17H144
Maximum Fluid Working
Pressure psi (MPa, bar)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
Approximate Output per Cycle
(A+B) gal. (liter)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
Max Flow Rate lb/min (kg/min)
Total System Load † (Watts)
Voltage Phase
45 (20)
26,600
230 3Ø∆
71
45 (20)
31,700
230 3Ø∆
95
45 (20)
26,600
230 3Ø∆
71
45 (20)
31,700
230 3Ø∆
95
Full Load Peak Current*
Fusion AP Package
APH043
(246102)
CSH043
AHH043
(246102)
CHH043
APH044
(246102)
CSH044
AHH044
(246102)
CHH044
APH143
(246102)
CSH143
AHH143
(246102)
CHH143
APH144
(246102)
CSH144
AHH144
(246102)
CHH144
®
�
�
(Gun Part No.)
Fusion CS Package
®
(Gun Part No.)
(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)
Probler P2 Package
(Gun Part No.)
P2H043
PHH043
P2H044
PHH044
P2H143
PHH143
P2H144
PHH144
�
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
Heated Hose
24K240
Qty: 1
24K240
Qty: 5
24K240
Qty: 1
24K240
Qty: 5
24Y240
Qty: 1
24Y240
Qty: 5
24Y240
Qty: 1
24Y240
Qty: 5
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-wrap)
Heated Whip Hose
10 ft (3 m)
246050
246050
246050
246050
Graco Insite
✓
✓
✓
✓
Fluid Inlet Sensors (2)
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
★
�
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors. All Elite
hose and gun system packages include
Xtreme-Wrap™ 50 ft (15 m) heated hose.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• H–40 series: 410 ft (125 m) maximum
heated hose length, including whip hose.
Voltage Configurations Key
Ø
∆
Y
PHASE
DELTA
WYE
10
334945B
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Models
Reactor 2 H-40 and H-40 Elite
(Continued)
H-40 Model
H-40 Elite Model
20 kW
Model
15 kW
20 kW
15 kW
Proportioner
★
17H045
17H046
17H145
17H146
Maximum Fluid Working
Pressure psi (MPa, bar)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
Approximate Output per Cycle
(A+B) gal. (liter)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
0.063 (0.24)
Max Flow Rate lb/min (kg/min)
Total System Load † (Watts)
Voltage Phase
45 (20)
26,600
380 3Ø∆
41
45 (20)
31,700
380 3Ø∆
52
45 (20)
26,600
380 3Ø∆
41
45 (20)
31,700
380 3Ø∆
52
Full Load Peak Current*
Fusion AP Package
APH045
(246102)
CSH045
AHH045
(246102)
CHH045
APH046
(246102)
CSH046
AHH046
(246102)
CHH046
APH145
(246102)
CSH145
AHH145
(246102)
CHH145
APH146
(246102)
CSH146
AHH146
(246102)
CHH146
®
�
�
(Gun Part No.)
Fusion CS Package
®
(Gun Part No.)
(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)
Probler P2 Package
(Gun Part No.)
P2H045
PHH045
P2H046
PHH046
P2H145
PHH145
P2H146
PHH146
�
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
Heated Hose
24K240
Qty: 1
24K240
Qty: 5
24K240
Qty: 1
24K240
Qty: 5
24Y240
Qty: 1
24Y240
Qty: 5
24Y240
Qty: 1
24Y240
Qty: 5
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-wrap)
Heated Whip Hose
10 ft (3 m)
246050
246050
246050
246050
Graco Insite
✓
✓
✓
✓
Fluid Inlet Sensors (2)
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
★
�
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors. All Elite
hose and gun system packages include
Xtreme-Wrap™ 50 ft (15 m) heated hose.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• H–40 series: 410 ft (125 m) maximum
heated hose length, including whip hose.
Voltage Configurations Key
Ø
∆
Y
PHASE
DELTA
WYE
334945B
11
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Models
Reactor 2 H-50 and H-50 Elite
H-50 Model
20 kW
H-50 Elite Model
20 kW
Model
20 kW
20 kW
Proportioner
★
17H053
17H056
17H153
17H156
Maximum Fluid Working
Pressure psi (MPa, bar)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
Approximate Output per Cycle
(A+B) gal. (liter)
0.073 (0.28)
0.073 (0.28)
0.073 (0.28
0.073 (0.28
Max Flow Rate lb/min (kg/min)
Total System Load † (Watts)
Configurable Voltage Phase
Full Load Peak Current*
52 (24)
31,700
230 3Ø∆
95
52 (24)
31,700
380 3ØY
52
52 (24)
31,700
230 3Ø∆
95
52 (24)
31,700
380 3ØY
52
Fusion AP Package
APH053
(246102)
CSH053
AHH053
(246102)
CHH053
APH056
(246102)
CSH056
AHH056
(246102)
CHH056
APH153
(246102)
CSH153
AHH153
(246102)
CHH153
APH156
(246102)
CSH156
AHH156
(246102)
CHH156
®
�
�
(Gun Part No.)
Fusion CS Package
®
(Gun Part No.)
(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)
Probler P2 Package
(Gun Part No.)
P2H053
PHH053
P2H056
PHH056
P2H153
PHH153
P2H156
PHH156
�
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
Heated Hose
24K240
Qty: 1
24K240
Qty: 5
24K240
Qty: 1
24K240
Qty: 5
24Y240
Qty: 1
24Y240
Qty: 5
24Y240
Qty: 1
24Y240
Qty: 5
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-wrap)
Heated Whip Hose
10 ft (3 m)
246050
246050
246050
246050
Graco Insite
✓
✓
✓
✓
Fluid Inlet Sensors (2)
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
★
�
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors. All Elite
hose and gun system packages include
Xtreme-Wrap™ 50 ft (15 m) heated hose.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• H–50 series: 410 ft (125 m) maximum
heated hose length, including whip hose.
Voltage Configurations Key
Ø
∆
Y
PHASE
DELTA
WYE
12
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Models
Reactor 2 H-XP2 and H-XP2 Elite
H-XP2 Model
H-XP2 Elite Model
Model
15 kW
15kW
Proportioner
★
17H062
17H162
Maximum Fluid Working
Pressure psi (MPa, bar)
3500 (24.1, 241)
3500 (24.1, 241)
Approximate Output per Cycle
(A+B) gal. (liter)
0.042 (0.16)
0.042 (0.16)
Max Flow Rate lb/min (kg/min)
Total System Load † (Watts)
Configurable Voltage Phase
Full Load Peak Current*
1.5 (5.7)
23,260
230 1Ø
100
1.5 (5.7)
23,260
230 1Ø
100
230 3Ø∆
59
230 3ØY
35
230 3Ø∆
59
230 3ØY
35
Fusion AP Package
APH062
(246101)
AHH062
(246101)
APH162
(246101)
AHH162
(246101)
®
�
(Gun Part No.)
Probler P2 Package
(Gun Part No.)
P2H062
(GCP2R1)
PHH062
(246101)
P2H162
(GCP2R1)
PHH162
(246101)
�
Heated Hose
50 ft (15 m)
24K241
(scuff guard)
24Y241
(Xtreme-wrap)
Heated Whip Hose
10 ft (3 m)
246055
246055
Graco Insite
✓
✓
Fluid Inlet Sensors (2)
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
★
�
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors. All Elite
hose and gun system packages include
Xtreme-Wrap™ 50 ft (15 m) heated hose.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• H–XP2 series: 310 ft (94.5 m) maximum
heated hose length, including whip hose.
Voltage Configurations Key
Ø
∆
Y
PHASE
DELTA
WYE
334945B
13
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Models
Reactor 2 H-XP3 and H-XP3 Elite
H-XP3 Model
H-XP3 Elite Model
20 kW
Model
20 kW
20 kW
20 kW
Proportioner
★
17H074
17H076
17H174
17H176
Maximum Fluid Working
Pressure psi (MPa, bar)
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
3500 (24.1, 241)
Approximate Output per Cycle
(A+B) gal. (liter)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
0.042 (0.16)
Max Flow Rate lb/min (kg/min)
Total System Load † (Watts)
Configurable Voltage Phase
Full Load Peak Current*
2.8 (10.6)
31,700
230 3Ø∆
95
2.8 (10.6)
31,700
380 3ØY
52
2.8 (10.6)
31,700
230 3Ø∆
95
2.8 (10.6)
31,700
380 3ØY
52
Fusion AP Package
APH074
(246102)
P2H074
APH074
(246102)
P2H074
APH076
(246102)
P2H076
APH076
(246102)
P2H076
APH174
(246102)
P2H174
APH174
(246102)
P2H174
APH176
(246102)
P2H176
APH176
(246102)
P2H176
®
�
(Gun Part No.)
Probler P2 Package
�
(Gun Part No.)
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
Heated Hose
24K240
24K240
24K240
24K240
24Y240
24Y240
24Y240
24Y240
50 ft (15 m)
Qty: 1
Qty: 5
Qty: 1
Qty: 5
Qty: 1
Qty: 5
Qty: 1
Qty: 5
24K240 (scuff guard)
24Y240 (Xtreme-wrap)
Heated Whip Hose
10 ft (3 m)
246050
246050
246050
246050
Graco Insite
✓
✓
✓
✓
Fluid Inlet Sensors (2)
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
★
�
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors. All Elite
hose and gun system packages include
Xtreme-Wrap™ 50 ft (15 m) heated hose.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• H–XP3 series: 410 ft (125 m) maximum
heated hose length, including whip hose.
Voltage Configurations Key
Ø
∆
Y
PHASE
DELTA
WYE
14
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Approvals
Approvals
Accessories
Intertek approvals apply to proportioners without
hoses.
Kit Number
24U315
17G340
24T280
17F837
16X521
Description
Air Manifold (4 outlets)
Caster Kit
Proportioner Approvals:
Graco InSite Kit
Inlet Sensor Kit
Graco InSite Extension cable 24.6 ft
(7.5 m)
9902471
24N449
24K207
50 ft (15 m) CAN cable (for remote
display module)
Conforms to ANSI/UL Std. 499
Certified to CAN/CSA Std. C22.2 No. 88
Fluid Temperature Sensor (FTS)
with RTD
24U174
15V551
15M483
Remote Display Module Kit
ADM Protective Covers (10 pack)
Remote Display Module Protective
Covers (10 pack)
24M174
121006
Drum Level Sticks
150 ft (45 m) CAN cable (for remote
display module)
24N365
RTD Test Cables (to aide resistance
measurements)
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Supplied Manuals
Related Manuals
Supplied Manuals
The following manuals are for accessories used with
the Reactor 2.
The following manuals are shipped with the Reactor
2 . Refer to these manuals for detailed equipment
information.
Component Manuals in English:
Manual
334945
Description
Reactor 2 Hydraulic Proportioning
Systems Operation Manual
Reactor 2 Hydraulic Proportioning
Systems Shutdown Quick Guide
Reactor 2 Hydraulic Proportioning
Systems Startup Quick Guide
System Manuals
333946
Displacement Pump Manual
3A3085 Pump Repair-Parts
Feed System Manuals
Reactor 2 Repair-Parts
334005
334006
309572
309852
Heated Hose, Instructions-Parts
Circulation and Return Tube Kit,
Instructions-Parts
Feed Pump Kits, Instructions-Parts
Feed Pump Air Supply Kit,
Instructions-Parts
309815
309827
Spray Gun Manuals
309550
312666
313213
Fusion ™ AP Gun
Fusion ™ CS Gun
Probler® P2 Gun
Accessory Manuals
3A1905
Feed Pump Shutdown Kit,
Instructions-Parts
3A3009
3A1907
Inlet Sensor Kit, Instructions-Parts
Remote Display Module Kit,
Instructions-Parts
Air Manifold Kit, Instructions-Parts
Caster Kit, Instructions-Parts
Graco InSite ™ Kit, Instructions-Parts
Elite Kit, Instructions-Part
332735
3A3010
333276
3A3084
3A3085
Pumpline Repair, Instructions-Parts
16
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Typical Installation, without circulation
Typical Installation, without circulation
H
J
K
G
A
L
M
K
G
F
(B-RES)
N
J
(A-ISO)
D
N
E
S
B
P
C*
Figure 1
* Shown exposed for clarity. Wrap with tape during operation.
A
B
C
D
E
F
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
J
K
L
M
N
P
S
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Bleed Lines
Fusion Spray Gun
Gun Air Supply Hose
Feed Pump Air Supply Lines
Agitator Air Supply Line
Gun Fluid Manifold (part of gun)
Remote Display Module Kit (optional)
G
H
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Typical Installation, with system fluid manifold to drum circulation
Typical Installation, with system fluid manifold to drum
circulation
M
K
H
G
A
R
R
L
M
K
G
J
(B-RES)
F
J
(A-ISO)
D
E
S
B
P
C*
Figure 2
* Shown exposed for clarity. Wrap with tape during operation.
A
B
C
D
E
F
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
J
K
L
M
P
R
S
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Fusion Spray Gun
Gun Fluid Manifold (part of gun)
Recirculation Lines
Remote Display Module (optional)
Gun Air Supply Hose
Feed Pump Air Supply Lines
Agitator Air Supply Line
G
H
18
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Typical Installation, with gun fluid manifold to drum circulation
Typical Installation, with gun fluid manifold to drum
circulation
M
K
R
H
G
L
R
J
A
M
K
F
G
(B-RES)
N
J
(A-ISO)
E
D
N
S
B
P
C*
Figure 3
* Shown exposed for clarity. Wrap with tape during operation.
A
B
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Circulation Block (accessory)
Heated Whip Hose
Gun Air Supply Hose
Feed Pump Air Supply Lines
Agitator Air Supply Line
J
K
L
M
N
P
R
S
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Bleed Lines
Gun Fluid Manifold (part of gun)
Recirculation Lines
Remote Display Module (optional)
C
CK
D
F
G
H
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Component Identification
Key
BA
BB
ISO Side Pressure Relief Outlet
RES Side Pressure Relief Outlet
RR
Graco InSite Cellular Module (Elite models
only)
RS
SA
Red Stop Button
CD
EC
EM
FA
FB
FH
FM
FV
GA
GB
HA
HB
HC
HP
MP
PA
PB
Advanced Display Module (ADM)
Electrical Cord Strain Relief
Electric Motor (behind shroud)
ISO Side Fluid Manifold Inlet
RES Side Fluid Manifold Inlet
Fluid Heater (behind shroud)
Reactor Fluid Manifold
Fluid Inlet Valve (RES side shown)
ISO Side Pressure Gauge
RES Side Pressure Gauge
ISO Side Hose Connection
RES Side Hose Connection
Heated Hose Electrical Junction Box
Hydraulic Driver (behind shroud)
Main Power Switch
ISO Side PRESSURE RELIEF/SPRAY
Valve
SB
TA
RES Side PRESSURE RELIEF/SPRAY
Valve
ISO Side Pressure Transducer (behind
gauge GA)
TB
XA
XB
XF
RES Side Pressure Transducer (behind
gauge GB)
Fluid Inlet Sensor (ISO side, Elite models
only)
Fluid Inlet Sensor (RES side, Elite models
only)
Heated Hose Transformer (behind cover)
FPG Fluid Inlet Valve Pressure Gauge
FTG
FTS
Fluid Inlet Valve Temperature Gauge
FTS Connection
HPG Hydraulic Pressure Gauge
ISO Side Pump
RES Side Pump
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Component Identification
Advanced Display Module (ADM)
Table 1 : ADM Keys and Indicators
The ADM display shows graphical and text
information related to setup and spray operations.
Key
Function
Press to startup or shutdown the
system.
Startup /
Shutdown
Key and
Indicator
Press to stop all proportioner
processes. This is not a safety or
emergency stop.
Stop
Press to select the specific screen
or operation shown on the display
directly next to each key.
Soft Keys
• Left/Right Arrows: Use to move
from screen to screen.
Figure 5 ADM Front View
• Up/Down Arrows: Use to move
among fields on a screen, items
on a dropdown menu, or multiple
screens within a function.
NOTICE
Navigation
Keys
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
Numeric
Keypad
Use to input values.
Use to cancel a data entry field.
Also used to return to Home screen.
Cancel
Setup
Enter
Press to enter or exit Setup mode.
Press to choose a field to update,
to make a selection, to save a
selection or value, to enter a screen,
or to acknowledge an event.
22
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Component Identification
Figure 6 ADM Back View
CJ
Flat Panel Mount (VESA 100)
CK
CL
CM
CN
CP
CR
CS
Model and Serial Number
USB Port and Status LEDs
CAN Communication Cable Connection
Module Status LEDs
Accessory Cable Connection
Token Access Cover
Backup Battery Access Cover
Table 2 ADM LED Status Descriptions
LED
Conditions
Description
System Status
Green Solid
Run Mode, System On
Green Flashing
Yellow Solid
Setup Mode, System On
Run Mode, System Off
Yellow Flashing
Green Flashing
Yellow Solid
Setup Mode, System Off
Data recording in progress
Downloading information to USB
USB Status (CL)
ADM Status (CN)
Green and Yellow Flashing
ADM is busy, USB cannot transfer information
when in this mode
Green Solid
Power applied to module
Active Communication
Yellow Solid
Red Steady Flashing
Red Random Flashing or Solid
Software upload from token in progress
Module error exists
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Component Identification
ADM Display Details
System Errors
The current system error is displayed in the middle of
the menu bar. There are four possibilities:
Power Up Screen
The following screen appears when the ADM is
powered up. It remains on while the ADM runs
through initialization and establishes communication
with other modules in the system.
Icon
No Icon
Function
No information or no error has occurred
Advisory
Deviation
Alarm
information.
Status
The current system status is displayed at the lower
right of the menu bar.
Soft Keys
Icons next to the soft keys indicate which mode or
action is associated with each soft key. Soft keys
that do not have an icon next to them are not active
in the current screen.
Menu Bar
The menu bar appears at the top of each screen.
(The following image is only an example.)
NOTICE
To prevent damage to the soft key buttons, do not
press buttons with sharp objects such as pens, plastic
cards, or fingernails.
Date and Time
Navigating the Screens
The date and time are always displayed in one of
the following formats. The time is always displayed
as a 24-hour clock.
There are two sets of screens:
Run Screens
•
– control spraying operations and
• DD/MM/YY HH:MM
• YY/MM/DD HH:MM
• MM/DD/YY HH:MM
Arrows
display system status and data.
Setup Screens
•
– control system parameters and
advanced features.
Press on any Run screen to enter the Setup
screens. If the system has a password lock, the
Password screen displays. If the system is not locked
(password is set to 0000), System Screen 1 displays.
The left and right arrows indicate screen navigation.
Screen Menu
The screen menu indicates the currently active
screen, which is highlighted. It also indicates the
associated screens that are available by scrolling left
and right.
Press
on any Setup screen to return to the
Home screen.
Press the Enter soft key
function on any screen.
to activate the editing
System Mode
The current system mode is displayed at the lower
left of the menu bar.
Press the Exit soft key
to exit any screen.
Use the other softkeys to select the function adjacent
to them.
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Component Identification
Icons
Icons
Icon
Softkeys
Function
Icon Function
Component A
Start Proportioner
Stop Proportioner
Component B
Turn on or off the specified heat zone.
Park pump
Estimated Supply Material
Hose Temperature
Pressure
Reset Cycle Counter
(press and hold)
Select Recipe
Cycle Counter (press and
hold)
Search
Advisory.
page 60 for more information.
Move Cursor Left One Character
Move Cursor Right One Character
Deviation.
page 60 for more information.
Toggle between upper-case, lower-case, and
numbers and special characters.
Backspace
Alarm.
page 60 for more information.
Cancel
Pump Moving Left
Clear
Pump Moving Right
Troubleshoot Selected Error
Increase value
Decrease value
Next screen
Previous screen
Return to first screen
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Component Identification
Electrical Enclosure
H-40, H-50, H-XP3
H-30, H-XP2
AAA Temperature Control Module (TCM)
AAB Hydraulic Control Module (HCM)
AAC Enclosure Fan(s)
AAD Wiring Terminal Blocks (H-30/H-XP2 only)
AAE Power Supply
AAF Sacrificial Surge Protector (SSP)
AAG Hose Breaker
AAH Motor Breaker
AAJ A Side Heat Breaker
AAK B Side Heat Breaker
AAL Hose Transformer Breaker
AAM Motor Contactor
AAN TB21 Terminal Block (if equipped)
MP Main Power Switch
26
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Component Identification
Hydraulic Control Module (HCM)
HCM Rotary Switch (RS) Positions
0 = Reactor 2, H-30
1 = Reactor 2, H-40
2 = Reactor 2, H-50
3 = Reactor 2, H-XP2
4 = Reactor 2, H-XP3
Table 3 HCM Module LED (MS) Status Descriptions
LED
Conditions
Description
HCM Status
Power applied to
module
Green Solid
Yellow Solid
Active
Communication
Red Steady
Flashing
Software upload
from token in
progress
Figure 7
Red Random
Module error
Description
Flashing or Solid exists
MS
1
2
6
7
Module Status LEDs see LED Status Table
CAN Communication Connections
Motor Over-Temperature
A Pump Output Pressure
B Pump Output Pressure
A Fluid Inlet Sensor
8
9
B Fluid Inlet Sensor
Pump Position Switches
Graco Insite™
Motor Contactor and Solenoids
Rotary Switch
10
14
15
RS
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Component Identification
Temperature Control Module (TCM) Cable Connections
Table 4 TCM Module LED (7) Status Descriptions
Figure 8
1
2
3
4
5
6
7
8
9
10
Power Input
LED
Conditions
Description
Heater Overtemperature
CAN Communications Connections
Power Out Heater A (ISO)
Power Out Heater B (Res)
Power Out (Heated Hose)
Module Status LEDs
Heater A (ISO) Temperature
Heater B (RES) Temperature
Hose Temperature
TCM Status
Power applied to
module
Green Solid
Yellow Solid
Active
Communication
Red Steady
Flashing
Software upload
from token in
progress
Red Random
Module error
Flashing or Solid exists
28
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Setup
General Equipment Guidelines
NOTICE
Failure to properly size the equipment may result
in damage. To avoid damage to the equipment,
follow the guidelines listed below.
Setup
Grounding
• Determine the correct size generator. Using the
correct size generator and proper air compressor
will enable the proportioner to run at a nearly
constant RPM. Failure to do so will cause voltage
fluctuations that can damage electrical equipment.
Ensure that the generator matches the voltage and
phase of the proportioner.
The equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
Use the following procedure to determine the correct
size generator.
• Reactor: System is grounded through the power
cord.
1. List peak wattage requirements of all system
components.
• Spray gun: connect whip hose ground wire to FTS.
See Install Fluid Temperature Sensor. Do not
disconnect ground wire or spray without whip hose.
2. Add the wattage required by the system
components.
• Fluid supply containers: follow your local code.
• Object being sprayed: follow your local code.
3. Perform the following equation:
Total watts x 1.25 = kVA (kilovolt-amperes)
4. Select a generator size that is equal to or greater
than the determined kVA.
• Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place pail
on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.
• Use proportioner power cords that meet or exceed
the requirements listed in Table 4. Failure to do so
will cause voltage fluctuations that can damage
electrical equipment, and may cause the power
cable to overheat.
• To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of spray gun
firmly to the side of a grounded metal pail, then
trigger gun.
• Use an air compressor with continuous run head
unloading devices. Direct online air compressors
that start and stop during a job will cause voltage
fluctuations that can damage electrical equipment.
• Maintain and inspect the generator, air
compressor, and other equipment per the
manufacturer recommendations to avoid an
unexpected shutdown. Unexpected equipment
shutdown will cause voltage fluctuations that can
damage electrical equipment.
• Use a wall power supply with enough current
to meet system requirements. Failure to do so
will cause voltage fluctuations that can damage
electrical equipment.
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Setup
Connect Power
Table 5 Power Cord Requirements
Model
Input Power
Cord Specifications*
AWG (mm^2)
NOTE:
All electrical wiring must be done by a
qualified electrician and comply with all local codes
and regulations.
H-30, 10.2 200-240 VAC,
kW
4 (21.2),
2 wire + ground
1 Phase
1. Turn main power switch (MP) OFF.
2. Open electrical enclosure door.
200-240 VAC,
3 Phase, DELTA
8 (8.4),
3 wire + ground
350-415 VAC,
3 Phase, WYE
8 (8.4),
NOTE:
Terminal jumpers are located inside the
4 wire + ground
electrical enclosure door if equipped.
H-30, 15.3 200-240 VAC,
4 (21.2),
2 wire + ground
3. Install supplied terminal jumpers in the positions
shown in image for the power source used (H-30
and H-XP2 models only).
kW
1 Phase
200-240 VAC,
3 Phase, DELTA
6 (13.3),
3 wire + ground
4. Route power cable through strain relief (EC) in
electrical enclosure.
350-415 VAC,
3 Phase, WYE
8 (8.4),
4 wire + ground
5. Connect incoming power wires as shown in
image. Gently pull on all connections to verify
they are properly secured.
H-XP2,
15.3 kW
200-240 VAC,
1 Phase
4 (21.2),
2 wire + ground
200-240 VAC,
3 Phase, DELTA
6 (13.3),
3 wire + ground
6. Verify all items are connected properly as shown
in image then close electrical enclosure door.
350-415 VAC,
3 Phase, WYE
8 (8.4),
4 wire + ground
H-40, 15.3 200-240 VAC,
6 (13.3),
3 wire + ground
kW
3 Phase, DELTA
350-415 VAC,
3 Phase, WYE
8 (8.4),
4 wire + ground
H-40, 20.4 200-240 VAC,
4 (21.2),
3 wire + ground
kW
3 Phase, DELTA
ti26342a_17D775
350-415 VAC,
3 Phase, WYE
6 (13.3),
4 wire + ground
H-50, 20.4 200-240 VAC,
4 (21.2),
3 wire + ground
kW
3 Phase, DELTA
350-415 VAC,
3 Phase, WYE
6 (13.3),
4 wire + ground
H-XP3,
20.4 kW
200-240 VAC,
3 Phase, DELTA
4 (21.2),
3 wire + ground
350-415 VAC,
3 Phase, WYE
6 (13.3),
4 wire + ground
*Values are for reference only. Refer to amperage
system and compare against latest version of local
electrical code to select proper power cord size.
NOTE:
400 VAC systems are not designed to operate
from 480 VAC power source.
30
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Setup
Lubrication System Setup
5. The lubrication is ready for operation. No priming
is required.
Component A (ISO) Pump:
Fill ISO lube reservoir
Install Fluid Temperature Sensor
(LR) with Graco Throat Seal Liquid (TSL), part
206995 (supplied).
The Fluid Temperature Sensor (FTS) is supplied.
Install FTS between main hose and whip hose (see
1. Lift the lubricant reservoir (LR) out of the bracket
(RB) and remove the container from the cap.
Install Heated Hose to Proportioner
1. Remove cover (CV).
2. Fill with fresh lubricant. Thread the reservoir onto
the cap assembly and place it in the bracket (RB).
3. Push the larger diameter supply tube (ST)
approximately 1/3 of the way into the reservoir.
4. Push the smaller diameter return tube (RT) into
the reservoir until it reaches the bottom.
2. Route heated hose wires (HW) through strain
relief (SR) and install wires into the open screw
terminals on the terminal block (TB). Torque to
35 in-lb (3.95 N•m).
NOTE:
The return (RT) must reach the bottom of
the reservoir to ensure that isocyanate crystals
will settle to the bottom and not be siphoned into
the supply tube (ST) and returned to the pump.
3. Reinstall cover (CV).
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Advanced Display Module (ADM) Operation
Advanced Display Module (ADM) Operation
When main power is turned on by turning the main
power switch (MP) to the ON position, the power up
screen will be displayed until communication and
initialization is complete.
1. Set pressure values for the Pressure Imbalance
Then the power key icon screen will display until the
2. Enter, enable, or disable recipes. See
ADM power on/off button (A)
first time after system power-up.
is pressed for the
3. Set general system settings. See
To begin using the ADM, the machine must be active.
To verify the machine is active, verify that the System
Status Indicator Light (B) is illuminated green, see
System Status Indicator Light is not green, press
4. Set units of measure. See
5. Set USB settings. See
the ADM Power On/Off (A) button
. The System
6. Set target temperatures and pressure. See
Status Indicator Light will illuminate yellow if the
machine is disabled.
7. Set component A and component B supply
Perform the following tasks to fully setup your system.
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Advanced Display Module (ADM) Operation
Setup Mode
The ADM will start in the Run screens at the Home screen. From the Run screens, press
to
access 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. See
Setup Screens Navigation Diagram, page 45.
Set Password
Set a password to allow Setup screen access, see Advanced Screen 1 – General, page 35. 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.
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Advanced Display Module (ADM) Operation
Setup Screens Navigation
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Advanced Display Module (ADM) Operation
Advanced Setup Screens
Advanced 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
to access the fields and make changes. When changes are
desired Advanced setup screen, press
complete press
to exit edit mode.
NOTE:
Advanced Screen 3 — USB
Users must be out of edit mode to scroll
through the Advanced setup screens.
Use this screen to enable USB downloads/uploads,
enable a logs 90% full advisory, enter the maximum
number of days to download data, enable specifying
date range of data to download, and how frequently
Advanced Screen 1 — General
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
(zero equals screen saver off).
Advanced Screen 4 — Software
Advanced Screen 2 — Units
This screen displays the software part number and
software version for the Advanced Display Module,
USB Configuration, Hydraulic Control Module, and
Temperature Control Module, and Remote Display
Module (optional).
Use this screen to set the temperature units, pressure
units, volume units, and cycle units (pump cycles or
volume).
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Advanced Display Module (ADM) Operation
System 1
System 3
Use this screen to set the activation pressure for the
Pressure Imbalance Alarm and Deviation, enable or
disable diagnostic screens, set the maximum and
minimum drum volume, and enable drum alarms.
Use this screen to enable alternate pump cylinder
sizes, to turn motor standby mode on and off, and
to enable recirculation cycle count. Cycles below
700 psi outlet pressure will not be counted unless
enabled.
System 2
Use this screen to enable Manual Hose Mode
and inlet sensors, as well as setting the inlet
sensor low pressure alarm and low temperature
deviation. Manual Hose Mode disables the hose
temperature RTD sensor so the system can
operate if the sensors were to malfunction (see
information). Default settings are 10 psi (0.07 MPa,
0.7 bar) for low inlet pressure alarm and 50˚F (10˚C)
for low inlet temperature deviation.
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Advanced Display Module (ADM) Operation
Recipes
Add Recipe
Use this screen to add recipes, view saved recipes,
and enable or disable saved recipes. Enabled
recipes can be selected at the Home Run Screen. 24
recipes can be displayed on the three recipe screens.
1. Press
and then use
to select a
recipe field. Press
to enter a recipe name
(maximum 16 characters). Press
old recipe name.
to clear the
2. Use
to highlight the next field and use the
to save.
number pad to enter a value. Press
Enable or Disable Recipes
1. Press
and then use
to select the
recipe that needs to be enabled or disabled.
2. Use
Press
to highlight the enabled check box.
to enable or disable the recipe.
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Advanced Display Module (ADM) Operation
Run Mode
The ADM will start in the Run screens at the “Home” screen. Press
to navigate through the Run Mode
From the Run screens, press
to access the Setup screens.
Run Screens Navigation Diagram
Figure 9
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Advanced Display Module (ADM) Operation
Home — System Off
Home — System With Error
This is the home screen when the system is off.
This screen displays actual temperatures, actual
pressures at the fluid manifold, and number of cycles.
Active errors are shown in the status bar. The error
code, alarm bell, and description of the error will
scroll in the status bar.
1. Press
to acknowledge the error.
2. See for corrective action.
Home — System Active
When the system is active, the home screen displays
actual temperature for heat zones, actual pressures
at the fluid manifold, the number of cycles, along with
all associated control soft keys.
Targets
Use this screen to define the setpoints for the
A Component Temperature, B Component
Temperature, heated hose temperature, and
pressure.
Use this screen to turn on heat zones, start the
proportioner, stop the proportioner, park the
component A pump, and clear cycles.
Maximum A and B temperature:
190°F (88°C)
NOTE:
Screen shown displays inlet sensor
Maximum heated hose temperature:
10°F (5°C) above the highest A or B temperature
setpoint or 180°F (82°C).
the lesser of
temperatures and pressures. These will not be
shown on models without inlet sensors.
Note
If the remote display module kit is used,
these setpoints can be modified at the gun.
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Advanced Display Module (ADM) Operation
Maintenance
Events
Use this screen to view daily and lifetime cycles or
gallons that have been pumped and gallons or liters
remaining in the drums.
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
error code descriptions.
The lifetime value is the number of pump cycles or
gallons since the first time the ADM was turned on.
The daily value automatically resets at midnight.
All events and errors listed on this screen can be
downloaded on a USB flash drive. To download logs,
The manual value is the counter that can be manually
reset. Press
and hold to reset manual counter.
Cycles
Errors
This screen shows daily cycles and gallons that have
been sprayed for the day.
This screen shows the date, time, error code, and
description of all errors that have occurred on the
system.
All information listed on this screen can be
downloaded on a USB flash drive. To download logs,
All errors listed on this screen can be downloaded
on a USB flash drive. To download logs, see
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Advanced Display Module (ADM) Operation
Troubleshooting
QR Codes
This screen displays the last ten errors that
occurred on the system. Use the up and down
arrows to select an error and press
to view
the QR code for the selected error. Press
to access the QR code screen for an error
code that is not listed on this screen. See
information on error codes.
To quickly view online help for a given error code,
scan the displayed QR code with your smartphone.
the error code to view online help for that code.
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Advanced Display Module (ADM) Operation
Diagnostic
Job Data
Use this screen to view information for all system
components. NOTE: If not visible, this screen may
Use this screen to enter a job name or number.
Recipes
The following information is displayed:
Use this screen to select an enabled recipe. Use the
up and down arrows to highlight a recipe and press
Temperature
to load. The currently loaded recipe is outlined
by a green box.
• A Chemical
• B Chemical
Note
• Hose Chemical
• TCM PCB — temperature control module
temperature
This screen will not display if there are not
any enabled recipes. To enable or disable
Amps
• A Current
• B Current
• Hose Current
Volts
• A Voltage
• B Voltage
• Hose Voltage
Pressure
• Pressure A — chemical
• Pressure B — chemical
Cycles
• CPM — cycles per minute
• Total Cycles — lifetime cycles
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Advanced Display Module (ADM) Operation
System Events
Use the table below to find a description for all system non-error events. All events are logged in the USB
log files.
Event Code
Description
Recipe Selected
Heat On A
Heat On B
Heat On Hose
EACX
EADA
EADB
EADH
EAPX
EAUX
EB0X
EBDA
EBDB
EBDH
EBPX
EBUX
EC0X
ECDA
ECDB
ECDH
ECDP
ECDX
EL0X
EM0X
EP0X
EQU1
EQU2
EQU3
EQU4
EQU5
ER0X
EVSX
EVUX
Pump On
USB Drive Inserted
ADM Red Stop Button Pressed
Heat Off A
Heat Off B
Heat Off Hose
Pump Off
USB Drive Removed
Setup Value Changed
A Temperature Setpoint Changed
B Temperature Setpoint Changed
Hose Temperature Setpoint Changed
Pressure Setpoint Changed
Recipe Changed
System Power On
System Power Off
Pump Parked
System Settings Downloaded
System Settings Uploaded
Custom Language Downloaded
Custom Language Uploaded
Logs Downloaded
User Counter Reset
Standby
USB Disabled
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Startup
Startup
Confirm main power switch is OFF before starting
generator.
5.
To prevent serious injury, only operate Reactor with
all covers and shrouds in place.
NOTICE
Proper system setup, startup, and shutdown
procedures are critical to electrical equipment
reliability. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage fluctuations that can damage
electrical equipment and void the warranty.
6. Ensure the main breaker on the generator is in
the off position.
7. Start the generator. Allow it to reach full operating
temperature.
Check fluid inlet filter screens.
1.
Before daily startup, ensure that the
fluid inlet screens are clean. See
Turn main power switch ON.
8.
The ADM will display the following screen until
communication and initialization is complete.
Check ISO lubrication reservoir.
2.
Check level and condition of ISO lube daily. See
3. Use A and B Drum Level Sticks (24M174) to
measure the material level in each drum. If
needed, the level can be entered and tracked in
Check generator fuel level.
4.
NOTICE
Running out of fuel will cause voltage
fluctuations that can damage electrical
equipment and void the warranty. Do not run
out of fuel.
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Startup
9. Switch on the air compressor, air dryer, and
breathing air, if included.
e. Open fluid inlet valves (FV). Check for leaks.
For first startup of new system, load fluid with
feed pumps.
10.
Cross-contamination can result in cured
material in fluid lines which could cause
serious injury or damage equipment. To
prevent cross-contamination:
Setup
a. Check that all
steps are complete.
Never
•
interchange component A and
b. If an agitator is used, open the agitator’s air
inlet valve.
component B wetted parts.
• Never use solvent on one side if it
has been contaminated from the other
side.
c. If you need to circulate fluid through the
system to preheat the drum supply, see
If you need to circulate material through
the heat hose to the gun manifold, see
• Always provide two grounded waste
containers to keep component A and
component B fluids separate.
d. Turn both PRESSURE RELIEF/SPRAY
f. Hold gun fluid manifold over two grounded
waste containers. Open fluid valves A and B
until clean, air-free fluid comes from valves.
Close valves.
valves (SA, SB) to SPRAY
.
GA
GB
SA
SB
The Fusion AP gun manifold is shown.
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Startup
11. Press
to activate ADM.
Thermal expansion can cause
over-pressurization, resulting in
equipment rupture and serious injury,
including fluid injection. Do not
pressurize system when preheating
hose.
12. If necessary, setup the ADM in Setup Mode. See
Advanced Display Module (ADM) Operation,
page 32.
13. Preheat the system:
a. Press
to turn on hose heat zone.
b. If you need to circulate fluid through the
system to preheat the drum supply, see
If you need to circulate material through
the heat hose to the gun manifold, see
c. Wait for the hose to reach set point
temperature.
This equipment is used with heated fluid
which can cause equipment surfaces
to become very hot. To avoid severe
burns:
NOTE:
Hose heat-up time may increase at
• Do not touch hot fluid or equipment.
voltages less than nominal 230 VAC when
maximum hose length is used.
• Do not turn on hose heat without fluid
in hoses.
d. Press
to turn on A and B heat zones.
• Allow equipment to cool completely
before touching it.
• Wear gloves if fluid temperature
exceeds 110°F (43°C).
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Fluid Circulation
Fluid Circulation
Circulation Through Reactor
NOTICE
5. Before starting the motor, unlock the hydraulic
compensator knob, then rotate counter-clockwise
until it ceases to move.
To prevent equipment damage, do not circulate
fluid containing a blowing agent without consulting
with your material supplier regarding fluid
temperature limits.
NOTE:
Optimum heat transfer is achieved at lower
fluid flow rates with temperature set points at desired
drum temperature. Low temperature rise deviation
errors may result.
To circulate through gun manifold and preheat hose,
6. Press motor
to start motor and pumps.
To avoid injection injury and splashing,
do not install shutoffs downstream of
the PRESSURE RELIEF/SPRAY valve
outlets (BA, BB). The valves function as
overpressure relief valves when set to
Circulate fluid at lowest possible pressure until
temperatures reach targets.
7. Press
to turn on the hose heat zone.
8. Turn on the A and B heat zones. Wait until the
fluid inlet valve temperature gauges (FTG) reach
the minimum chemical temperature from the
supply drums.
SPRAY
. Lines must be open so
valves can automatically relieve pressure
when machine is operating.
circulation lines back to respective component
A or B supply drum. Use hoses rated for the
maximum working pressure of this equipment.
9. Turn off motor.
10. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
.
GA
GB
SA
SB
3. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
.
GB
GA
SA
SB
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Fluid Circulation
Circulation Through Gun Manifold
NOTICE
2. Route circulation lines back to respective
component A or B supply drum. Use hoses
rated for the maximum working pressure of this
equipment. See Technical Specifications.
To prevent equipment damage, do not circulate
fluid containing a blowing agent without consulting
with your material supplier regarding fluid
temperature limits.
4. Turn main power switch on.
NOTE:
Optimum heat transfer is achieved at lower
fluid flow rates with temperature set points at desired
drum temperature. Low temperature rise deviation
errors may result.
Circulating fluid through the gun manifold allows
rapid preheating of the hose.
6. Before starting the motor, unlock the hydraulic
compensator knob, then rotate counter-clockwise
until it ceases to move.
1. Install gun fluid manifold (P) on accessory
circulation kit (CK). Connect high pressure
circulation lines (R) to circulation manifold.
P
CK
7. Press motor
to start motor and pumps.
Circulate fluid at lowest possible pressure until
temperatures reach targets.
R
8. Press
to turn on the hose heat zone.
The Fusion AP gun manifold is shown.
9. Turn on the A and B heat zones. Wait until the
fluid inlet valve temperature gauges (FTG) reach
the minimum chemical temperature from the
supply drums.
CK
Gun
Manual
309818
313058
246362
256566
Fusion AP
Fusion CS
10. Turn off motor.
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Spraying
Spraying
6. Open fluid inlet valve (FV) located at each pump
inlet.
The Fusion AP gun is shown.
1. Engage gun piston safety lock and close gun
fluid inlet valves A and B.
7. Press
to start motor and pumps.
Fusion
Probler
2. Attach gun fluid manifold. Connect gun air line.
Open air line valve.
8. Adjust pressure compensator knob to desired
fluid stall pressure. Turn knob clockwise to
increase pressure and counter-clockwise to
decrease pressure. Use hydraulic pressure
gauge (HPG) to view hydraulic pressure. Once
desired fluid stall pressure is set, lock the knob
in place by rotating lower portion clockwise until
tight.
3. Adjust the gun air pressure. Do not exceed 130
psi (0.2 MPa, 2 bar).
4. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
.
GA
GB
SA
SB
5. Verify heat zones are on and temperatures are
Component A and B outlet pressures will be
higher than the hydraulic set pressure, depending
on the model. Component A and B (GA, GB)
pressure may be viewed on the pressure gauges
or the ADM.
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Spraying
9. Check fluid pressure gauges (GA, GB) to
ensure proper pressure balance. If imbalanced,
reduce pressure of higher component by
11. Disengage gun piston safety lock.
slightly
turning PRESSURE RELIEF/SPRAY
valve for that component toward PRESSURE
RELIEF/CIRCULATION
balanced pressures.
until gauges show
Fusion
Probler
GB
GA
SA
12. Pull gun trigger to test spray onto cardboard. If
necessary, adjust pressure and temperature to
get desired results.
SB
Spray Adjustments
Flow rate, atomization, and amount of overspray are
affected by four variables.
10. Open gun fluid inlet valves A and B.
Fluid pressure setting.
•
Too little pressure results
in an uneven pattern, coarse droplet size, low
flow, and poor mixing. Too much pressure results
in excessive overspray, high flow rates, difficult
control, and excessive wear.
Fluid temperature.
setting. The A and B temperatures can be offset to
help balance the fluid pressure.
•
Similar effects to fluid pressure
Fusion
Probler
NOTICE
Mix chamber size.
•
•
Choice of mix chamber is based
on desired flow rate and fluid viscosity.
To prevent material crossover on impingement
never
guns,
open fluid manifold valves or
Clean-off air adjustment.
Too little clean-off air
trigger gun if pressures are imbalanced.
results in droplets building up on the front of the
nozzle, and no pattern containment to control
overspray. Too much clean-off air results in
air-assisted atomization and excessive overspray.
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Spraying
Manual Hose Heat Mode
3. Select Enable Manual Hose Mode.
NOTE:
When manual hose mode is enabled, the
If the system produces the T6DH Sensor Error Hose
alarm or the T6DT Sensor Error TCM alarm, use
manual hose heat mode until the hose RTD cable or
FTS temperature sensor can be repaired.
manual hose mode advisory EVCH-V will appear.
Do not use Manual Hose Mode for extended periods
of time. The system performs best when the hose has
a valid RTD signal and can operate in temperature
control mode. If a hose RTD breaks, the first priority
is to fix the RTD. Manual Hose Mode can help finish
a job while waiting for repair parts.
4. Enter Run Mode and navigate to the Target
screen. Use the up and down arrows to set the
desired hose current.
Enable Manual Hose Mode
1. Disconnect the hose RTD sensor from the TCM.
2. Enter Setup Mode and navigate to System
Screen 2.
Hose Current Settings Hose Current
Default
20A
37A
Maximum
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Spraying
Disable Manual Hose Mode
5. Navigate back to the Run Mode Home screen.
The hose now displays a current instead of a
temperature.
1. Enter Setup Mode and navigate to System 2
Screen and deselect Enable Manual Hose Mode,
or repair the hose RTD cable or FTS.
NOTE:
Until the RTD sensor is repaired, the
T6DH sensor error alarm will display each time
the system is powered up.
2. Manual hose mode is automatically disabled
when the system detects a valid RTD sensor in
the hose.
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Standby
Standby
If you stop spraying for a period of time, the unit will
enter standby by shutting down the electric motor
and hydraulic pump, to reduce equipment wear and
minimize heat buildup. The pump icon on the ADM
Home screen will flash when in standby.
NOTE:
The A, B, and Hose heat zones will not shut
off during standby.
To restart, spray off target for two seconds. The
system will sense the pressure drop and the motor
will ramp up to full speed in a few seconds.
NOTE:
This feature is disabled from the factory.
To activate or deactivate standby:
1. Enter setup mode by pressing
3. Select the “Standby Idle Time” drop down using
and the arrow keys. Select the desired delay
on the ADM.
enter
2. Go to screen System 3 and select to
the page for editing.
using
and the arrow keys. Press enter to
select the desired value.
4. Exit the page and return to run mode by pressing
, then
.
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Shutdown
Shutdown
6. Turn off the air compressor, air dryer, and
breathing air.
NOTICE
Proper system setup, startup, and shutdown
procedures are critical to electrical equipment
reliability. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage fluctuations that can damage
electrical equipment and void the warranty.
1. Press
to stop the pumps.
7. Turn main power switch OFF.
2. Turn off all heat zones.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door while
the power is ON.
3. Relieve pressure. See
8. Close all fluid supply valves.
4. Press
to park the Component A and
Component B pumps. The park operation is
complete when green dot goes out. Verify the
park operation is complete before moving to next
step.
9. Set PRESSURE RELIEF/SPRAY valves to
SPRAY to seal out moisture from the drain line.
10. Engage gun piston safety lock then close fluid
inlet valves A and B.
5. Press
to deactivate the system.
Fusion
Probler
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Pressure Relief Procedure
Pressure Relief Procedure
4. Close gun fluid inlet valves A and B.
Follow the Pressure Relief Procedure
whenever you see this symbol.
5. Shut off feed pumps and agitator, if used.
6. Route fluid to waste containers or supply tanks.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.
. Ensure gauges drop to 0.
GB
GA
SA
SB
The Fusion AP gun is shown.
1. Press
to stop the pumps.
2. Turn off all heat zones.
7. Engage gun piston safety lock.
8. Disconnect gun air line and remove gun fluid
manifold.
3. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
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Flushing
Flushing
To flush entire system, circulate through gun fluid
manifold (with manifold removed from gun).
To prevent moisture from reacting with
To avoid fire and explosion:
isocyanate, always leave the system filled
with a moisture-free plasticizer or oil. Do not
use water. Never leave the system dry. See
Important Two-Component Material Information.
• Flush equipment only in a well-ventilated area.
• Ensure main power is off and heater is cool
before flushing.
• Do not turn on heater until fluid lines are clear of
solevent.
To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).
. Flush through bleed
GB
GA
SA
SB
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Maintenance
Maintenance
Table 6 Frequency of Oil Changes
Ambient
Temperature
Recommended
Frequency
0° to 90° F
1000 hours or 12 months,
whichever comes first
Prior to performing any maintenance procedures,
(-17° to 32° C)
90° F and above
(32° C and above)
500 hours or 6 months,
whichever comes first
Preventative Maintenance Schedule
The operating conditions of your particular system
determine how often maintenance is required.
Establish a preventive maintenance schedule by
recording when and what kind of maintenance is
needed, and then determine a regular schedule for
checking your system.
Proportioner Maintenance
Fluid Inlet Strainer Screens
Inspect fluid inlet strainer screens daily, see
• Inspect hydraulic and fluid lines for leaks daily.
• Clean up all hydraulic leaks; identify and repair the
cause of the leak.
Grease Circulation Valves
• Inspect fluid inlet strainer screens daily. See below.
Grease circulation valves (SA and SB) with Fusion
grease (117773) weekly.
• Keep component A from exposure to moisture to
prevent crystallization.
• Check hydraulic fluid level weekly. Check
hydraulic fluid level on a dipstick. Fluid level
must be between indent marks on dipstick.
Refill as required with approved hydraulic fluid
Approved Anti-Wear (AW) Hydraulic Oils table in
the Reactor Repair-Parts manual 334946. If fluid is
dark in color, change fluid and filter.
ISO Lubricant Level
Inspect ISO lubricant level and condition
daily. Refill or replace as needed. See
Moisture
To prevent crystallization, do not expose component
A to moisture in air.
Gun Mix Chamber Ports
• Change break-in oil in a new unit after the first 250
hours of operation or within 3 months, whichever
comes first. See the table below for recommended
frequency of oil changes.
Clean gun mix chamber ports regularly. See gun
manual.
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Maintenance
Gun Check Valve Screens
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.
Clean gun check valve screens regularly. See gun
manual.
Dust Protection
2. Place a container under the strainer base to catch
drain off when removing the strainer plug (C).
Use clean, dry, oil-free compressed air to prevent
dust buildup on control modules, fans, and motor
(under shield).
3. Remove the screen (A) from the strainer
manifold. Thoroughly flush the screen with
compatible solvent and shake it dry. Inspect the
screen. No more than 25% of the mesh should
be restricted. If more than 25% of the mesh is
blocked, replace the screen. Inspect the gasket
(B) and replace as required.
Vent Holes
Keep vent holes on bottom and back of electrical
enclosure and sides and back of transformer
enclosure open..
4. Ensure the pipe plug (D) is screwed into the
strainer plug (C). Install the strainer plug with the
screen (A) and o-ring (B) in place and tighten. Do
not overtighten. Let the o-ring make the seal.
Flush Inlet Strainer Screen
5. Open the fluid inlet valve, ensure that there are
no leaks, and wipe the equipment clean. Proceed
with operation.
The inlet strainers filter out particles that can plug the
pump inlet check valves. Inspect the screens daily as
part of the startup routine, and clean as required.
Isocyanate can crystallize from moisture
contamination or from freezing. If the chemicals used
are clean and proper storage, transfer, and operating
procedures are followed, there should be minimal
contamination of the A-side screen.
Note
Clean the A-side screen only during
daily startup. This minimizes moisture
contamination by immediately flushing
out any isocyanate residue at the start of
dispensing operations.
Figure 10
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Maintenance
Pump Lubrication System
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color
darkens, or it becomes diluted with isocyanate.
6. Push the larger diameter supply (ST) tube
approximately 1/3 of the way into the reservoir.
7. Push the smaller diameter return tube (RT) into
the reservoir until it reaches the bottom.
Gel formation is due to moisture absorption by the
pump lubricant. The interval between changes
depends on the environment in which the equipment
is operating. The pump lubrication system minimizes
exposure to moisture, but some contamination is still
possible.
NOTE:
The return tube must reach the bottom of
the reservoir to ensure that isocyanate crystals
will settle to the bottom and not be siphoned into
the supply tube and returned to the pump.
8. The lubrication system is ready for operation. No
priming is required.
Lubricant discoloration is due to continual seepage of
small amounts of isocyanate past the pump packings
during operation. If the packings are operating
properly, lubricant replacement due to discoloration
should not be necessary more often than every 3 or
4 weeks.
To change pump lubricant:
2. Lift the lubricant reservoir (LR) out of the bracket
(RB) and remove the container from the cap.
Holding the cap over a suitable container, remove
the check valve and allow the lubricant to drain.
Reattach the check valve to the inlet hose.
3. Drain the reservoir and flush it with clean
lubricant.
Pump Lubrication System
Figure 11
4. When the reservoir is flushed clean, fill with fresh
lubricant.
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Errors
Troubleshoot Errors
Errors
View Errors
To troubleshoot the error:
1. Press the soft key next to “Help With This Error”
for help with the active error.
When an error occurs the error information screen
displays the active error code and description.
The error code, alarm bell, and active errors will
scroll in the status bar. For a list of the ten most
recent errors see Troubleshooting. Error codes are
stored in the error log and displayed on the Error and
Troubleshooting screens on the ADM.
There are three types of errors that can occur. Errors
are indicated on the display as well as by the light
tower (optional).
Note
Alarms are indicated by . This condition indicates
a parameter critical to the process has reached a
level requiring the system to stop. The alarm needs
to be addressed immediately.
Press
or
to return to the
previously displayed screen.
2. The QR code screen will be displayed. Scan
the QR code with your smartphone to be sent
directly to online troubleshooting for the active
error code. Otherwise, manually navigate to
error.
Deviations are indicated by
. This condition
indicates a parameter critical to the process has
reached a level requiring attention, but not sufficient
enough to stop the system at this time.
Advisories are indicated by
. This condition
indicates a parameter that is not immediately critical
to the process. The advisory needs attention to
prevent more serious issues in the future.
To diagnose the active error, see
3. If no internet connection is available, see
causes and solutions for each error code.
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Error Codes and Troubleshooting
Error Codes and Troubleshooting
call your Graco contact listed on the back page of this manual.
USB Data
USB Logs
NOTE:
The ADM can read/write to FAT (File
Download Procedure
Allocation Table) storage devices. NTFS, used by 32
GB or greater storage devices, is not supported.
NOTE:
System configuration setting files and custom
language files can be modified if the files are in the
UPLOAD folder of the USB flash drive. See System
Configuration Settings File, Custom Language File,
and Upload Procedure sections.
During operation, the ADM stores system and
performance related information to memory in the
form of log files. The ADM maintains six log files:
• Event Log
1. Insert USB flash drive into USB port.
• Job Log
2. The menu bar and USB indicator lights indicate
that the USB is downloading files. Wait for USB
activity to complete.
• Daily Log
• System Software Log
• Blackbox Log
• Diagnostics Log
3. Remove USB flash drive from USB port.
4. Insert USB flash drive into USB port of computer.
5. The USB flash drive window automatically opens.
If it does not, open USB flash drive from within
Windows® Explorer.
log files.
Each time a USB flash drive is inserted into the ADM
USB port, a new folder named DATAxxxx is created.
The number at the end of the folder name increases
each time a USB flash drive is inserted and data is
downloaded or uploaded.
6. Open GRACO folder.
7. Open the system folder. If downloading data
from more than one system, there will be more
than one folder. Each folder is labeled with the
corresponding serial number of the ADM (The
serial number is on the back of the ADM.)
Event Log
8. Open DOWNLOAD folder.
The event log file name is 1–EVENT.CSV and is
stored in the DATAxxxx folder.
9. Open DATAxxxx folder labeled with the highest
number. The highest number indicates the most
recent data download.
The event log maintains a record of the last 49,000
events and errors. Each event record contains:
10. Open log file. Log files open in Microsoft® Excel
by default as long as the program is installed.
However, they can also be opened in any text
editor or Microsoft® Word.
• Date of event code
• Time of event code
• Event code
NOTE:
All USB logs are saved in Unicode
• Event type
(UTF-16) format. If opening the log file in
Microsoft Word, select Unicode encoding.
• 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.
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Error Codes and Troubleshooting
Job Log
The following data is stored in this file:
• Date that material was sprayed
• Time — unused column
The job log file name is 2–JOB.CSV and is stored
in the DATAxxxx folder.
The job log maintains a record of data points
based on the USB Log Frequency defined
in the Setup screens. The ADM stores the
last 237,000 data points for download. See
information on setting the Download Depth and USB
Log Frequency.
• Total pump cycle count for day
• Total volume sprayed for day
System Software Log
The system software file name is 4–SYSTEM.CSV
and is stored in the DATAxxxx folder.
• Data point date
The system software log lists the following:
• Date log was created
• Data point time
• A side temperature
• Time log was created
• B side temperature
• Component name
• Hose temperature
• Software version loaded on the above component
Blackbox Log File
• A side temperature setpoint
• B side temperature setpoint
• Hose temperature setpoint
• Pressure A
The black box file name is 5–BLACKB.CSV and is
stored in the DATAxxxx folder.
The Blackbox log maintains a record of how the
system runs and the features that are used. This log
will help Graco troubleshoot system errors.
• Pressure B
• A side inlet pressure (Elite only)
• B side inlet pressure (Elite only)
• A side inlet temperature (Elite only)
• B side inlet temperature (Elite only)
• Inlet pressure setpoint
• System lifetime pump cycle counts
• Usage Volume (manual)
• Pressure, volume, and temperature units
• Job name/number
Diagnostics Log File
The diagnostics file name is 6–DIAGNO.CSV and is
stored in the DATAxxxx folder.
The Diagnostics log maintains a record of how the
system runs and the features that are used. This log
will help Graco troubleshoot system errors.
System Configuration Settings
The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.
Daily Log
A system configuration settings file automatically
downloads each time a USB flash drive is inserted
into the ADM. Use this file to back up system
settings for future recovery or to easily replicate
settings across multiple systems. Refer to the
to use this file.
The daily log file name is 3–DAILY.CSV and is stored
in the DATAxxxx folder.
The daily log maintains a record of the total cycle
and volume sprayed on any day that the system is
powered up. The volume units will be the same units
that were used in the Job Log.
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Error Codes and Troubleshooting
Custom Language File
• The file format must be a tab-delimited text file
using Unicode (UTF-16) character representation.
The custom language file name is DISPTEXT.TXT
and is stored in the DOWNLOAD folder.
• The file must contain only two columns, with
columns separated by a single tab character.
A custom language file automatically downloads
each time a USB flash drive is inserted into the ADM.
If desired, use this file to create a user-defined set of
custom language strings to be displayed within the
ADM.
• Do not add or remove rows from the file.
• Do not change the order of the rows.
Upload Procedure
The system is able to display the following Unicode
characters. For characters outside of this set,
the system will display the Unicode replacement
character, which appears as a white question mark
inside of a black diamond.
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.
• U+0020 - U+007E (Basic Latin)
• U+00A1 - U+00FF (Latin-1 Supplement)
• U+0100 - U+017F (Latin Extended-A)
• U+0386 - U+03CE (Greek)
2. Insert USB flash drive into USB port of computer.
3. The USB flash drive window automatically opens.
If it does not, open USB flash drive from within
Windows Explorer.
• U+0400 - U+045F (Cyrillic)
4. Open GRACO folder.
Create Custom Language Strings
5. Open the system folder. If working with more
than one system, there will be more than one
folder within the GRACO folder. Each folder is
labeled with the corresponding serial number of
the ADM. (The serial number is on the back of
the ADM.)
The custom language file is a tab-delimited text file
that contains two columns. The first column consists
of a list of strings in the language selected at the
time of download. The second column can be used
to enter the custom language strings. If a custom
language was previously installed, this column
contains the custom strings. Otherwise the second
column is blank.
6. If installing the system configuration settings
file, place SETTINGS.TXT file into the UPLOAD
folder.
7. If installing the custom language file, place
DISPTEXT.TXT file into the UPLOAD folder.
Modify the second column of the custom language file
to install the file.
8. Remove USB flash drive from the computer.
9. Install USB flash drive into the ADM USB port.
The format of the custom language file is critical.
The following rules must be followed in order for the
installation process to succeed.
10. The menu bar and USB indicator lights indicate
that the USB is downloading files. Wait for USB
activity to complete.
• Define a custom string for each row in the second
column.
11. Remove USB flash drive from USB port.
NOTE:
If the custom language file is used, you
must define a custom string for each entry in the
DISPTEXT.TXT file. Blank second-column fields
will be displayed blank on the ADM.
NOTE:
If the custom language file was installed,
users can now select the new language
from the Language drop-down menu in
• The file name must be DISPTEXT.TXT.
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Performance Charts
Performance Charts
Use this chart to help identify the proportioner that will work most efficiently with each mix chamber. Flow rates
are 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.
Foam Performance Chart
Table 7 Foam Performance Chart
ti26328a
KEY
A = H-30 at 50 Hz
B = H30 at 60 Hz
C = H-40 at 50 Hz
D = H-40 at 60 Hz
E = H-50 at 50 Hz
F = H-50 at 60 Hz
PRESSURE psi
(MPa, bar)
FLOW rate in lb/min (kg/min)
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Performance Charts
Coatings Performance Chart
Table 8 Coatings Performance Chart
ti26345a
KEY
G = H-XP2 at 50 Hz
H = H-XP2 at 60 Hz
J = H-XP3 at 50 Hz
K = H-XP3 at 60 Hz
PRESSURE psi
(MPa, bar)
FLOW rate in lb/min (kg/min)
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Technical Specifications
Technical Specifications
Reactor 2 Hydraulic Proportioning System
U.S.
Maximum Fluid Working Pressure for Bare Proportioners
Metric
Models H-30, H-40, and H-50
Models H-XP2 and H-XP3
Fluid: Oil Pressure Ratio
Model H-40
2000 psi
3500 psi
13.8 MPa, 138 bar
24.1 MPa, 241 bar
1.91 : 1
1.64 : 1
2.79 : 1
Models H-30 and H-50
Models H-XP2 and H-XP3
Fluid Inlets
Component A (ISO)
3/4 npt(f), 250 psi maximum
3/4 npt(f), 250 psi maximum
3/4 npt(f), 1.75 MPa, 17.5
bar maximum
Component B (RES)
3/4 npt(f), 1.75 MPa, 17.5
bar maximum
Fluid Outlets
Component A (ISO)
Component B (RES)
Fluid Circulation Ports
1/4 npsm(m)
#8 1/2 in. JIC, with #5 5/16 in. JIC adapter
#10 5/8 in. JIC, with #6 3/8 in. JIC adapter
250 psi
1.75 MPa, 17.5 bar
Maximum Fluid Temperature
190° F
88° C
Maximum Output (10 weight oil at ambient temperature)
Model H-30
28 lb/min (60 Hz)
13 kg/min (60 Hz)
5.7 liter/min (60 Hz)
24 kg/min (60 Hz)
20 kg/min (60 Hz)
10.6 liter/min (60 Hz)
Model H-XP2
1.5 gpm (60 Hz)
52 lb/min (60 Hz)
45 lb/min (60 Hz)
2.8 gpm (60 Hz)
Model H-50
Model H-40
Model H-XP3
Output Per Cycle (A and B)
Model H-40
0.063 gal.
0.073 gal.
0.042 gal.
0.23 liter
0.28 liter
0.16 liter
Models H-30 and H-50
Models H-XP2 and H-XP3
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Technical Specifications
Line Voltage Options
230V 1 phase and 230V 3 phase units: 195–264 Vac, 50/60 Hz
400V 3 phase units: 338–457 Vac, 50/60 Hz
Amperage Requirement (phase)
See the Models listing in the manual.
Heater Power (A and B heaters total)
See the Models listing in the manual.
Hydraulic Reservoir Capacity
3.5 gal.
13.6 liters
Recommended Hydraulic Fluid
Sound Power, per ISO 9614–2
Sound Pressure 1 m From Equipment
Citgo, A/W Hydraulic Oil, ISO Grade 46
90.2 dB(A)
82.6 dB(A)
Weight
H-40, H-50, H-XP3,
H-30, 10 kW
600 lb
544 lb
556 lb
272 kg
247 kg
252 kg
H-30, H-XP2, 15 kW
Wetted Parts
Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide,
chrome, fluoroelastomer, PTFE, ultra-high molecular weight
polyethylene, chemically resistant o-rings
All other brand names or marks are used for identification purposes and are trademarks of their respective
owners.
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Graco Extended Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its
name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.
Graco will, for a period as defined in the table below from the date of sale, repair or replace any part of the
equipment determined by Graco to be defective. This warranty applies only when the equipment is installed,
operated and maintained in accordance with Graco’s written recommendations.
Description
Warranty Period
Part
Advanced Display Module
Hydraulic Control Module
36 Months or 2 Million Cycles (whichever comes first)
36 Months or 2 Million Cycles (whichever comes first)
36 Months or 2 Million Cycles (whichever comes first)
12 Months
24U854
24Y263
24U855
Temperature Control
Module
All Other Parts
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
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 PURPOSE
.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost
profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO
.
These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making
any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices
and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
To place an order,
contact your Graco Distributor or call to identify the nearest distributor.
Phone:
or Toll Free:
Fax:
1-800-328-0211 612-378-3505
612-623-6921
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
334945
Original Instructions. This manual contains English. MM
Graco Headquarters:
Minneapolis
International Offices:
Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Revision B, May 2015
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