Graco Outboard Motor A 25 User Manual

Operation

3A1569B

A-25

P L U R A L C O M P O N E N T P R O P O R T I O N E R

Air operated, electrically heated, plural component proportioner

For spraying or dispensing 1:1 ratio polyurethane foam formulations and other 1:1 fast

setting materials.

Not for use in explosive atmospheres or hazardous locations.

This model is field-configurable to the following supply voltages:

230 V, 1 Phase

230 V, 3 Phase

380 V, 3 Phase

2000 psi (14 MPa, 138 bar) Maximum Fluid Working Pressure

80 psi (550 kPa, 5.5 bar) Maximum Air Working Pressure

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

See page 9 for model information, including maximum

working pressure and approvals.

ti16811a

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Proportioner Models

All proportioners can be configured to operate on 380V (4 wire), 230V (3 wire), or 230V 1Ø.

Includes:

Maximum Fluid Working Maximum Air Working

Pressure

psi (MPa, bar)

Set Pressure

psi (kPa, bar)

DataTrak

(cycle count only) Wheels

Part No.

Approvals

3172585

262572

2000 psi (14, 138)

80 psi (550, 5.5)

---

262614

24A592



Conforms to ANSI/UL

Std. 499 Certified to

CAN/CSA Std.

C22.2 No. 88

Systems

All systems include a proportioner, spray gun, and 60 ft (18.3 m) of heated hose.

Proportioner

(see Typical

Installation,

without

Heated Hose

Gun

Maximum Working

Pressure

Part

psi (MPa, bar)

Circulation) 50 ft (15 m) 10 ft (3 m) Model

Part

2000 (14, 138)

246678

246050

P22614

AP2614

262614

262572

Probler P2

GCP2R1

246101

™

Fusion AP

™

CS2614

CS01RD

Fusion CS

P22572

AP2572

Probler P2

GCP2R1

246101

™

Fusion AP

™

CS2572

CS01RD

Fusion CS

Related Manuals

Manuals are available at www.graco.com.

Manual

Description

Component manuals in English:

309550

™

Fusion AP Spray Gun, Instructions-Parts

312666

™

Manual

3A1570

309577

309815

309827

Description

Fusion CS Spray Gun, Instructions-Parts

313213

313541

312796

Reactor A-25 Proportioner, Repair-Parts

Proportioning Pump, Repair-Parts

Feed Pump Kit, Instructions-Parts

Feed Pump Air Supply KIt, Instruc-

tions-Parts

Probler P2 Spray Gun, Instructions-Parts

DataTrak Kits, Installation-Parts

NXT Air Motor, Instructions-Parts

309852

309572

Circulation and Return Tube Kit, Instruc-

tions-Parts

Heated Hose, Instructions-Parts

3A1569B

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Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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, 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.

TOXIC FLUID OR FUMES HAZARD

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 spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area

of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of

toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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Warnings

WARNING

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.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are

present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until

you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just

a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

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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 system

component. See Technical Data 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. Turn off all equipment and

follow the Pressure Relief Procedure 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.

• 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.

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-trichloroethylene, 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.

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.

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 equipment,

follow the Pressure Relief Procedure and disconnect all power sources.

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Important Two-Component Material Information

Isocyanate Conditions

Moisture Sensitivity of

Isocyanates

Isocyanates (ISO) are catalysts used in two component

foam and polyurea coatings. ISO will react with moisture

(such as humidity) to form small, hard, abrasive crystals,

which become suspended in the fluid. Eventually a film

will form on the surface and the ISO will begin to gel,

increasing in viscosity. If used, this partially cured ISO

will reduce performance and the life of all wetted parts.

Spraying or dispensing materials containing

isocyanates creates potentially harmful mists, vapors,

and atomized particulates.

Read material manufacturer’s warnings and material

MSDS to know specific hazards and precautions

related to isocyanates.

NOTE: The amount of film formation and rate of crystal-

lization varies depending on the blend of ISO, the

humidity, and the temperature.

Prevent inhalation of isocyanate mists, vapors, and

atomized particulates by providing sufficient

ventilation in the work area. If sufficient ventilation is

not available, a supplied-air respirator is required for

everyone in the work area.

To prevent exposing ISO to moisture:

•

Always use a sealed container with a desiccant

dryer in the vent, or a nitrogen atmosphere. Never

store ISO in an open container.

To prevent contact with isocyanates, appropriate

personal protective equipment, including chemically

impermeable gloves, boots, aprons, and goggles, is

also required for everyone in the work area.

•

Keep the ISO lube pump reservoir (if installed) filled

with Graco Throat Seal Liquid (TSL), Part 206995.

The lubricant creates a barrier between the ISO and

the atmosphere.

Material Self-ignition

•

Use moisture-proof hoses specifically designed for

ISO, such as those supplied with your system.

Never use reclaimed solvents, which may contain

moisture. Always keep solvent containers closed

when not in use.

Some materials may become self-igniting if applied

too thickly. Read material manufacturer’s warnings

and material MSDS.

•

Always lubricate threaded parts with ISO pump oil

or grease when reassembling.

Foam Resins with 245 fa

Blowing Agents

Keep Components A and B

Separate

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.

Cross-contamination can result in cured material in

fluid lines which could cause serious injury or

damage equipment. To prevent cross-contamination

of the equipment’s wetted parts, never interchange

component A (isocyanate) and component B (resin)

parts.

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Important Two-Component Material Information

Changing Materials

Changing the material types used in your equipment

requires special attention to avoid equipment damage

and downtime.

•

When changing materials, flush the equipment mul-

tiple 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 compo-

nents and change hoses. Epoxies often have

amines on the B (hardener) side. Polyureas often

have amines on the B (resin) side.

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Typical Installation, without Circulation

ti16812a

* Shown exposed for clarity. Wrap with tape during operation.

FIG. 1: Typical Installation, without Circulation

Key for F IG . 1

Reactor Proportioner

Heated Hose

Fluid Temperature Sensor (FTS)

Heated Whip Hose

Desiccant Dryer

Bleed Lines/Over Pressure Relief

Gun Fluid Manifold

Spray Gun

Proportioner and Gun Air Supply Hose

Feed Pump Air Supply Lines

Waste Containers

Fluid Supply Lines

Feed Pumps

Agitator (if required)

3A1569B

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Typical Installation, with Circulation

Key for FIG. 2

Reactor Proportioner

Heated Hose

Fluid Temperature Sensor (FTS)

Heated Whip Hose

Spray Gun

Proportioner and Gun Air Supply Hose

Feed Pump Air Supply Lines

Fluid Supply Lines

Feed Pumps

Agitator (if required)

Desiccant Dryer

Recirculation/Over Pressure Relief Return Hoses

Gun Fluid Manifold

ti16813a

* Shown exposed for clarity. Wrap with tape during operation.

FIG. 2: Typical Installation, with Circulation

3A1569B

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Component Identification

ti16814a

FIG. 3: Typical Installation

3A1569B

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Component Identification

Key:

Main Disconnect Switch - Controls power to

heating circuits. I

AH *Primary Heater Over-Temperature Switches -

Sends signal to temperature controller if heater

exceeds maximum temperature condition.

Main Air Filter - Filters system air supply.

AI Resin (B) Pump Wet Cup - Access for daily wet

cup refill.

Resin (B) Pressure Gauge - Displays pressure in

resin proportioning system (B side).

DD Main Air Inlet Ball Valve - (1/2 NPT female fitting)

FF ISO (A) Inlet - Fitting (3/4 swivel fitting)

Resin (B) - Inlet Supply Valve

GG Resin (B) Inlet - Fitting (3/4 swivel fitting)

Resin (B) Fluid Y-Strainer - (20 mesh)

W ISO (A) Pressure Gauge - Displays pressure in

isocyanate proportioning system (A side).

ISO (A) - Inlet Supply Valve

ISO (A) Fluid Y-Strainer - (20 mesh)

ISO (A) Pump Lube System - Behind Proportioner

shroud. (A side only)

AA ISO (A) - Packing Nut and Lube Cup - (A side

only)

AB *Primary Heater Thermocouples - Senses

temperature of primary heater and inputs that

information.

AC FTS Jumper Harness - Carries electrical signal

from FTS sensor in isocyanate hose to hose

temperature controller.

AD Primary Heaters - Heats material to required

dispensing temperature.

AE ISO (A) - (Isocyanate) Proportioning Pump -

Draws in and dispenses a fixed volume of

isocyanate to gun.

AF Resin (B) Proportioning Pump - Draws in and

dispenses a fixed volume of resin to gun.

™

AG Power-Lock Hose Heat Connection - Connects

power to heated hoses.

3A1569B

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Component Identification

Control Panel

DataTrak (optional)

See page 32.

See Tempera-

ture Controls

and Indicators

Air Motor

Pressure Gauge

Air Motor

Shutoff Valve

^°F

^°C

Air Pressure

Regulator

ti16815a

Temperature Controls and Indicators

NOTICE

To prevent damage to the softkey buttons, do not press

the buttons with sharp objects such as pens, plastic

cards, or fingernails.

Heater Power Indicators

Temperature Displays

Zone A Arrow Keys

Heater A On/Off Key

Zone B Arrow Keys

Heater B On/Off Key

Hose Zone Arrow Keys

Hose Heater On/Off Key

^°F

Actual Temperature Key

Target Temperature Key

Temperature Scale Keys

^°C

3A1569B

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Component Identification

Main Power Switch

Temperature Displays

Located on right side of unit, page 11. Turns heater

Show actual temperature or target temperature of

heater zones, depending on selected mode. Defaults to

actual at startup. Range is 32-190°F (0-88°C) for A and

B, 32-180°F (0-82°C) for hose.

power ON

and OFF

. Does not turn

heater zones or pumps on.

Circuit Breakers

Actual Temperature Key/LED

Press

to display actual temperature.

Located inside Reactor cabinet.

Press and hold

to display electrical current.

Ref.

CB1

CB2

CB3

CB4

Size

50 A

30 A

25 A

Component

Hose Secondary (single)

Hose Primary (double)

Heater A (double)

Target Temperature Key/LED

Press

to display target temperature.

Heater B (double)

Press and hold

to display heater control circuit

board temperature.

Temperature Scale Keys/LEDs

^°F

^°C

Press

to change temperature scale.

CB1

CB2

CB3

CB4

Heater Zone On/Off Keys/LEDs

ti17569a

Press

to turn heater zones on and off. Also clears

heater zone diagnostic codes, see page 35.

NOTE: LEDs flash when heater zones are on. The dura-

tion of each flash shows the extent that the heater is

turned on.

Temperature Arrow Keys

Press

, then press

to adjust tem-

perature settings in 1 degree increments.

3A1569B

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Setup

Locate Reactor A-25

Electrical Requirements

1. Locate Reactor A-25 on a level surface and bolt in

place to the floor with 3/8 in. (10 mm) bolts, unless

the Reactor needs to remain portable.

Improper wiring may cause electric shock or other

serious injury if work is not performed properly.

•

Two bolts through the 2 in. (50 mm) deep caster

bushings in the rear.

• Have a qualified electrician connect power and

ground to main power switch terminals and

ground lug.

•

Two bolts through the 3-5/8 in. (168 mm) deep

caster bushings in the front.

• Ensure your installation complies with all National,

State, and Local safety and fire codes.

2. Do not expose Reactor A-25 to rain.

• Ensure that incoming power is disconnected and

locked out at the source.

3. If you need to move the machine, add

optional wheel kit.

NOTE: Power cord is not supplied.

4. Lift with hoist only from bar spanning across top of

cart.

Determine Power Source

Reactor A-25 can be wired to 3 types of power source:

•

230 Volt / 1 Phase

230 Volt / 3 Phase Delta (3 wire + ground PE)

380 Volt / 3 Phase WYE (4 wire + ground PE)

(220 Volts to Neutral)

3A1569B

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Setup

Configure to Supply Power

230V, 1 Phase: Use a screwdriver to connect two power

leads to the top two middle terminal positions as shown.

Connect green to ground (GND). See page 17 for proper

jumper positions.

NOTE: Both cord connection AND jumper positioning

steps on page 17 must be completed.

NOTE: Disregard terminal numbers on disconnect

switch blocks. Wire to positions shown.

Step One - Connect Electrical Cord

NOTE: Disregard terminal numbers on disconnect

switch blocks. Wire to positions shown. Terminals will

accept up to #8 AWG (10 mm ) conductors.

1. Using a flat screw driver, turn cover fasteners 90°

counterclockwise. Lift and pull the front cover away.

2. Connect main power cord to electrical console as

follows:

230V, 3 Phase Delta: Use a screwdriver to connect

three power leads to top three left terminals as shown.

Connect green to ground (GND). See page 17 for

proper jumper positions.

a. Feed power cord through strain relief (SR) on

right side of unit. Push black die release lever

(RL) down to release contacts block (PD) for

easy wiring.

NOTE: Strain relief accepts cords 0.59 to 1.0 in. (15-25

mm) diameter.

b. Connect power leads to Power Disconnect

Switch (PD). Snap contacts block (PD) back

onto switch.

c. Tighten strain relief nut.

380V, 3 Phase WYE: Use a screwdriver to connect four

power leads to the top terminals as shown. Connect

neutral only to N. Connect green to ground (GND). See

page 17 for proper jumper positions.

d. Connect ground wire to ground lug (GL).

ti17570a

3. Replace lower front shroud. Reinstall the two

screws retained in Step 1.

3A1569B

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Setup

1. Turn screws counter-clockwise on the upper part of

the shroud until they stop. Pull door up and out.

Step Two - Install Power Jumpers

Find location for power jumpers which are in a plastic

bag tie wrapped to the ground lug.

2. Install red jumpers from the storage bag to the

positions shown for your power.

•

Push the jumper firmly into the new position.

If necessary, a flat-blade screwdriver can be

used under the ridge on the side of the jumper

to remove them.

NEW

Install Power Jumpers

Heater Jumper Location

3. Replace front shroud.

Power Jumper Location

Heater Jumpers

ti17569a

Step Two

TB2

Terminal Blocks

Install red jumpers

380V 3ø WYE

230V 3ø Delta

230V 1ø

1. Turn screws counter-clockwise on the upper part of

the shroud and remove by pulling them out.

Step Three - Reposition Heater Jumpers

(if necessary)

Find location of Heater Jumpers.

2. Move red jumpers from the storage positions to the

positions shown for your power.

•

A flat-blade screwdriver can be used under the

ridge on the side of the jumper to remove them.

Machines are shipped with heaters wired for 6000 watts.

To reposition heater jumpers for 3000 watts, change

jumper positions as shown below.

•

Push the jumper firmly into the new position.

3. Replace lower front shroud.

Step Three

TB2

Terminal Blocks

Position red jumpers

6000 WATTS

3000 WATTS

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Setup

Ground System

Fluid Supply Connections

Feed pumps are typically used. Siphon feeding is not

recommended. Connect material supply to inlets of

proportioning unit as follows:

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.

1. Connect fluid inlet ball valves (U.X) and y-strainers

(V, Y) to pump inlets.

2. Ensure the A- and B- inlet ball valves (U,X) on pro-

portioning unit are closed.

3. Connect and tighten B- supply hose (J) to 3/4 NPT

swivel fitting (GG) on B- inlet ball valve (U), and to

resin transfer pump.

•

Reactor: is grounded through power cord; see page

16.

Spray gun: connect whip hose ground wire to FTS;

see page 19. Do not disconnect wire or spray with-

out whip hose.

•

Fluid supply containers: follow your local code.

Object being sprayed: follow your local code.

ti17571a

Solvent pails used when flushing: follow your local

code. Use only metal pails that are conductive.

Place them on a grounded surface. Do no place pail

on a nonconductive surface, such as paper or

cardboard, which interrupts grounding continuity.

4. Connect and tighten A- supply hose (BB) to 1/2 NPT

swivel fitting (FF) on A- inlet ball valve (X), and to

isocyanate transfer pump. See FIG. 3, page 11.

Air Supply Connection

Connect main air supply (F) to air inlet 1/2 in. npt (f)

valve (DD) at air filter (S). Hose fitting requires a 1/2

NPT male fitting.

•

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.

NOTE: Use a minimum of 3/8 in. ID air line (not sup-

plied) to deliver air supply to proportioning unit. Use 1/2

in. ID hose if over 15 ft long.The main air supply must be

clean and free of oil and contaminants.

Iso Pump Lubrication System

Setup

Prepare isocyanate pump lubrication system as follows:

1. Lift lubricant reservoir out of bracket and remove

reservoir from cap.

2. Fill reservoir 3/4 full with TSL.

3. Thread reservoir onto cap assembly and place it

into bracket.

The lubrication system is now ready for operation; no

priming is required.

ti17572a

3A1569B

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Setup

Recirculation / Pressure Relief

Lines

Connect Heated Hose

NOTE: See heated hose manual for detailed instruc-

tions for Graco heated hoses.

NOTICE

Do not install shutoffs downstream of the

PRESSURE RELIEF/SPRAY valve outlets (BA, BB).

The valves function as over pressure relief valves

when set to SPRAY. Lines must be open so valves

can automatically relieve pressure when machine is

operating.

The fluid temperature sensor (FTS) and whip hose

must be used with heated hose; see page 19. Hose

length, including whip hose, must be 60 ft (18.3 m) min-

imum.

1. Turn main power OFF.

2. Assemble heated hose sections, FTS, and whip

hose. See Heated Hose manual for instructions.

If circulating fluid back to the supply drums, use high

pressure hose rated to withstand the maximum

working pressure of this equipment.

3. Connect A and B hoses to A and B outlets on

Reactor fluid manifold (FM). Hoses are color coded:

red for component A (ISO), blue for component B

(RES). Fittings are sized to prevent connection

errors.

If Recirculating to Supply Drum: Connect high

pressure hose (R) to relief fittings (BA, BB) of both

PRESSURE RELIEF/SPRAY valves. Route hose back

to component A and B drums. Refer to manual 309852.

Alternate recirculation hoses (requires adapter

fittings):

249508 - ISO (A) (moisture guard) red hose, 1/4 in. (6

mm) ID; #5 JIC fittings (m x f); 35 ft (10.7 m) long.

249509 - Resin (B) blue hose; 1/4 in. (6 mm) ID, #6 JIC

fittings (m x f), 35 ft (10.7 m) long.

ti17788a

NOTE: Manifold hose fittings (VV, WW) allow use of 1/4

in. and 3/8 in. ID Reactor heated fluid hoses.

ti8441a

4. Connect heated hose air line (AH) to proportioner

air hose.

Install Fluid Temperature Sensor

(FTS)

Install FTS between main hose and whip hose. See

Heated Hose manual for instructions.

3A1569B

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Setup

5. Connect cables (SS). Connect electrical connectors

(NN). Be sure cables have slack when hose bends.

Wrap cable and electrical connections with electrical

tape.

Connect Whip Hose to Gun or

Gun Fluid Manifold

For Probler P2 guns: Connect hoses to inlet valves.

For Fusion guns: Connect hoses to inlet manifold. Do

not connect manifold to gun.

1. Overlap A and B component hoses and assemble to

gun or gun manifold fittings as shown.

2. Tighten fittings to A and B component hoses.

Ensure hose remains flat after fittings are tightened.

Loosen and retighten fittings as necessary to elimi-

nate any torque on hoses.

ti17787a

Fusion AP Gun shown.

Close Gun Fluid Inlet Valves A

and B

ti12158a

Fusion AP Gun shown.

ti2411a

3A1569B

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Initial Startup

6. Purge air from hoses.

a. For Probler P2 guns: Loosen hose fittings and

bleed out air until air-free fluid comes from

hoses.

Do not operate Reactor without all covers and

shrouds in place.

b. For Fusion guns: 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.

Load Fluid with Feed Pumps

NOTE: The Reactor is tested with oil at the factory.

Flush out the oil with a compatible solvent before spray-

ing; see page 27.

The Fusion AP Gun is shown.

1. Check that Setup process is complete; see page 15.

2. Turn on component B agitator, if used.

3. Turn both PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY.

TI2484a

Pressure Check Hose

See hose manual. Pressure check for leaks. If no leaks,

wrap hose and electrical connections to protect from

damage.

ti8442a

4. Open both fluid valves (FV).

ti17571a

5. Start feed pumps. Do not start proportioner air

motor or pumps.

Always provide two grounded waste containers to

keep component A and component B fluids separate.

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Initial Startup

Set Temperatures

6. Turn on

and

heat zones by pressing

for each zone.

See Setup, page 15.

7. Hold

zone.

to view electrical currents for each

1. Turn main power ON

8. Hold

perature.

to view heater control circuit board tem-

^°F

^°C

2. Press

scale.

to change temperature

9. Manual current control mode only:

3. Press

4. To set

to display target temperatures.

When in manual current control mode, monitor hose

temperature with thermometer. Install per instructions

below. Thermometer reading must not exceed 160°F

(71°C). Never leave machine unattended when in

manual current control mode.

heat zone target temperature, press

until display shows desired temper-

ature. Repeat for

and

zones.

If FTS is disconnected or display shows diag-

nostic code E04, turn main power switch OFF

NOTE: For

zone only, if FTS is disconnected at

then ON

to clear diagnostic

startup, display will show hose current (0A). See step 9,

page 22.

code and enter manual current control mode.

display will show current to hose. Current

is not limited by target temperature.

Do not turn on hose heat without fluid in hoses.

Press

to adjust current setting.

5. Turn on

heat zone by pressing

. Pre-

To prevent overheating, install hose thermome-

ter close to gun end, within operator view. Insert

thermometer through foam cover of A compo-

nent hose so stem is next to inner tube. Ther-

mometer reading will be about 20°F less than

actual fluid temperature.

heat hose (15-60 min). Indicator will flash very

slowly when fluid reaches target temperature. Dis-

play shows actual fluid temperature in hose near

FTS.

If thermometer reading exceeds 160°F (71°C),

reduce current with

key.

Thermal expansion can cause over pressurization,

resulting in equipment rupture and serious injury,

including fluid injection. Do not pressurize system

when preheating hoses.

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Initial Startup

Supply Wet-Cups with Throat

Seal Liquid

Pump rod and connecting rod move during operation.

Moving parts can cause serious injury such as

pinching or amputation. Keep hands and fingers

away from wet-cup during operation. Close main air

valve before filling wet-cup.

1. Component A (ISO) Pump: Keep reservoir (Z) 3/4

filled with TSL. Wet-cup piston circulates TSL

through wet-cup to carry away isocyanate film on

displacement rod. Change the fluid in the reservoir

when it becomes milky-looking.

2. Component B (Resin) Pump: Check felt washers

in packing nut/wet-cup (AK) daily. Keep saturated

with TSL to prevent material from hardening on dis-

placement rod. Replace felt washers when worn or

contaminated with hardened material.

ti16974a

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Spraying

The Fusion AP gun is shown.

5. Open air inlet ball valve (DD).

1. After reaching spray temperatures, engage gun

piston safety lock.

ti17573a

ti2409a

6. Turn the air regulator counterclockwise to 0

pressure.

2. Close gun fluid inlet valves A and B.

air motor

shutoff

valve

air

regulator

ti2728a

ti17574a

3. Attach gun fluid manifold. Connect gun air line.

Open air line valve.

7. Open the air motor shutoff valve.

8. Close the park valve.

ti2543a

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

SPRAY.

Closed

ti8442a

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Spraying

9. Slowly increase the air regulator setting until the

approximate stall (static) pressure is achieved on

fluid gauges (GA) and (GB).

Spray Adjustments

Flow rate, atomization, and amount of overspray are

affected by four variables.

•

Fluid pressure setting. Too little pressure results in

an uneven pattern, coarse droplet size, low flow,

and poor mixing. Too much pressure results in

excessive overspray, high flow rates, difficult control,

and excessive wear.

ti8441a

•

Fluid temperature. Effects are similar to when fluid

pressure setting is too high or too low.

10. Check fluid pressure gauges (GA, GB) to ensure

proper pressure balance. If imbalanced, reduce

pressure of higher component by slightly turning

PRESSURE RELIEF/SPRAY valve for that

component toward PRESSURE

Mix chamber size. Choice of mix chamber is based

on desired flow rate within machine capability and

fluid viscosity.

RELIEF/CIRCULATION, until gauges show

balanced pressures.

•

Cleanoff air adjustment. Too little cleanoff air

results in droplets building up on the front of the

nozzle, and no pattern containment to control over-

spray. Too much cleanoff air results in air-assisted

atomization and excessive overspray.

NOTE: Ensure relief tubes are in waste containers.

11. Open gun fluid inlet valves A and B.

ti2414a

12. Disengage gun piston safety lock.

ti2410a

13. Test spray onto cardboard. Adjust the air regulator

to get the minimum fluid pressure that results in a

good spray pattern.

NOTE: Pumps have fluid to air ratio of 25 to 1. Feed

pumps add 2X feed pressure boost to outlet pressure

(on the up stroke only). For best results, use regulators

on feed pumps to limit inlet feed pressure to approxi-

mately 100 psi (0.7 MPA, 7 bar).

14. Check A and B fluid pressure gauges (GA, GB) to

ensure proper pressure balance between A and B.

15. Equipment is ready to spray.

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Park

5. Engage gun piston safety lock.

Park

Park the pumps at the end of the day to cycle propor-

tioner pumps to home position, submerging displace-

ment rod.

ti2409a

1. Open the park valve.

6. Close gun fluid inlet valves A and B.

ti2421a

Open

7. Close pump inlet supply valves.

2. Trigger the gun until pumps stops at the bottom and

relieves pressure.

3. Close the air motor shutoff valve.

4. Close the park valve.

ti17716a

Pressure Relief

Procedure

Shutdown

1. Turn main heater power OFF

The Fusion AP gun is shown.

2. Follow Park; see page 26.

1. Turn off feed pumps and agitator if used.

3. Check and fill wet-cups (AK, Z).

2. Park component A pump. Follow Park; see page 26.

4. Follow gun shutdown procedure. See gun manual.

3. Close the air inlet valve.

4. Trigger spray gun until gauges read zero.

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Flushing

Flush equipment only in a well-ventilated area. Do

not spray flammable fluids. Do not turn on heaters

while flushing with flammable solvents.

•

Flush out old fluid with new fluid, or flush out old

fluid with a compatible moisture-free solvent.

•

Use lowest possible pressure when flushing.

To flush feed hoses, pumps, and the heater sepa-

rately from the heated hoses, set PRESSURE

RELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION. Flush through bleed lines

(N).

ti8441a

•

To flush entire system, circulate through gun fluid

manifold (with manifold removed from gun).

Always leave hydraulic oil or a non-water based,

non-water absorbent fluid in system. Do not use

water.

Only use flush solvents that are compatible with

Fluoroelastomer seals. Non-compatible solvents will

damage seals and cause hazardous conditions, such

as high pressure leaks.

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Operation

8. Check that hose setpoint temperature is correct.

9. Turn on all three heat zones.

Daily Start-up Procedure

10. The hose power controller automatically adjusts the

hose current to the hose to compensate for hose

length and ambient temperature. Wait for actual

hose temperature readout to match hose setpoint

temperature.

NOTE: The daily start-up procedures describe normal

operation. Assume that all temperature and pressure

settings have been previously set, but that the heating

system is not up to operating temperature.

1. Check condition isocyanate lubrication system and

service as required. Change pump lubricant when it

shows signs of change to a milky color.

To prevent excessive pressure build-up in heated

hoses, always bring hoses and primary heater up to

operating temperature before opening air motor

shutoff valve.

2. Ensure supply fluid is at correct temperature as

recommended by chemical system supplier. Ensure

individual chemicals are correctly agitated within

their drums/day tanks, and moisture protection

system is properly set for operation. Recirculate

heated fluid back to supply drums if necessary; see

page 30.

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

SPRAY.

3. Turn on main air supply to transfer pumps.

4. Pressurize transfer pumps and open A- and B-inlet

supply valves.

5. Open air inlet ball valve (DD).

ti8442a

12. Check that heat zones are on and temperatures are

on target, page 22.

13. Open air motor shutoff valve.

14. Pumps will pressurize the fluid according to air

regulator pressure.

ti17573a

6. Turn main power ON

NOTICE

Uncoil heated hoses before turning on hose heater

switch to prevent overheating and hot spots within

hose.

7. Uncoil heated hose.

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Operation

15. Check A and B fluid pressure gauges (GA, GB) to

ensure proper pressure balance between A and B. If

imbalanced, bleed off the high side with valves SA

and SB until balanced.

ti8442a

16. Open gun fluid manifold valves A and B.

The Fusion AP gun is shown.

ti2414A

17. Disengage gun piston safety lock.

ti2410A

18. Test spray onto cardboard.

19. Equipment is ready to spray.

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Fluid Circulation

5. Set temperature targets, see page 22. Turn on

and heat zones by pressing

Circulation Through Reactor

Do not turn on

heat zone unless hoses are

Do not circulate fluid containing a blowing agent

without consulting with your material supplier

regarding fluid temperature limits.

already loaded with fluid.

6. Press

to display actual temperatures.

To circulate through gun manifold and preheat hose, see

page 31.

1. Follow Initial Startup, page 21.

7. Turn the air regulator to a low pressure until

and

temperatures reach targets. Increase

the pressure once the temperatures are on target.

Do not install shutoffs downstream of the

PRESSURE RELIEF/SPRAY valve outlets (BA, BB).

The valves function as overpressure relief valves

8. Turn on

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

SPRAY

heat zone by pressing

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

10. Route circulation lines back to respective com-

ponent A or B supply drum. Use hoses rated at the

maximum working pressure of this equipment. See

Technical Data, page 37.

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

ti8442a

PRESSURE RELIEF/CIRCULATION

ti8441a

4. Turn main power ON

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Fluid Circulation

5. Set temperature targets, see page 22. Turn on

Circulation Through Gun

Manifold

, and

heat zones by pressing

Do not circulate fluid containing a blowing agent

without consulting with your material supplier

regarding fluid temperature limits.

6. Press

to display actual temperatures.

Circulating fluid through the gun manifold allows rapid

preheating of hose.

7. Turn the air regulator to a low pressure until

1. Install gun fluid manifold (P) on accessory circula-

tion kit (CK). Connect high pressure circulation lines

(R) to circulation manifold.

and

temperatures reach targets. Increase

the pressure once the temperatures are on target.

ti2767a

The Fusion AP gun manifold is shown.

Table 1: Circulation Kit (CK)

Part

Gun

Manual

246362

256566

GC1703 Probler P2

Fusion AP

Fusion CS

309818

313058

313213

2. Route circulation lines back to respective compo-

nent A or B supply drum. Use hoses rated at the

maximum working pressure of this equipment. See

manual for installation instructions.

3. Follow Initial Startup, page 21.

4. Turn main power ON

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DataTrak Controls and Indicators

The DataTrak on the Reactor A-25 sprayers do not have runaway protection. For setup and operation instructions see

DataTrak Operation, page 33.

Key for FIG. 4

AB Combined Lower Displacement (user settable)

/min,

RK Reset Key (Resets faults. Press and hold for 3 seconds to

clear the batch totalizer.) Push to toggle between flow rate

and cycle rate.

AC Flow Rate Units (user settable to

gpm [US], gpm

CF Cycle/Flow Rate

BT Batch Totalizer

GT Grand Totalizer

RT Runaway Toggle (leave disabled)

[Imperial], oz/min [US], oz/min [Imperial], l/min, or cc/min)

AD LED (fault indicator when lit)

AE Display

PF Prime/Flush Key (Enables Prime/Flush mode. While in

Prime/Flush mode, the batch totalizer [BT] will not count.)

LED will flash while in Prime/Flush mode.

Run Mode

AE, see details at right

ti8622b

TI11883a

Setup Mode

ti17741a

FIG. 4. DataTrak Controls and Indicators

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DataTrak Operation

NOTE: The display (AE) will turn off after 1 minute to

save battery life. Press any key to wake up the display.

Counter/Totalizer

See FIG. 4, page 32. The last digit of the batch totalizer

(BT) represents tenths of gallons or liters. To reset the

totalizer, press any key to wake up the display, then

NOTICE

To prevent damage to the soft key buttons, do not

press the buttons with sharp objects such as pens,

plastic cards, or fingernails.

press and hold

for 3 seconds.

•

If AC is set to gallons or ounces, BT and GT dis-

play gallons.

If AC is set to liters or cc, BT and GT display

liters.

Setup Mode

1. See FIG. 4, page 32. Press and hold

onds until Setup menu appears.

for 5 sec-

If AC is set to cycles, BT and GT display cycles.

Press

to toggle between flow rate units and cycles.

2. To enter settings for lower size, flow rate units, and

disable runaway protection press to change the

value, then to save the value and move the cur-

sor to the next data field.

A letter under the BT display indicates that both BT and

GT are displaying gallons (g) or liters (l). No letter

means both BT and GT are displaying cycles.

Display

•

Set lower size to 98cc.

Disable runaway.

See FIG. 4, page 32. The display (AE) will turn off after 1

minute of inactivity in Run mode or 3 minutes in Setup

mode. Press any key to wake up the display.

3. Move the cursor to the E5 error enable option field,

then press

once more to exit Setup mode.

NOTE: DataTrak will continue to count cycles when dis-

play is off.

Run Mode

NOTE: The display (AE) may turn off if a high-level static

discharge is applied to the DataTrak. Press any key to

wake up the display.

Prime/Flush

1. See FIG. 4, page 32. To enter Prime/Flush mode,

press any key to wake up the display, then press

Diagnostics

See DataTrak Diagnostic Codes page 35.

. The Prime/Flush symbol will appear in the dis-

play and the LED will flash

2. While in Prime/Flush mode, the batch totalizer (BT)

will not count. The grand totalizer (GT) continues to

count.

3. To exit Prime/Flush mode, press any key to wake up

the display, then press

. The Prime/Flush sym-

bol will disappear from the display and the LED will

stop flashing.

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Maintenance

•

Check and add TSL to B side pump wet-cup daily.

•

Check ISO lube bottle for significant discoloration or

crystallization daily. Replace with fresh TSL when

needed.

•

Ensure ISO (A) pump is down and in PARK position

during every shutdown.

Keep any ISO (A) fluid from being exposed to atmo-

sphere to prevent crystallization.

Remove inlet filter screen plug (V, Y) and clean

screens if increased unbalanced pressures between

A and B is noticed or as needed for fluids used. Also

clean after flushing.

•

Close gun fluid shutoff valves when not in use.

If using a Fusion AP or Probler P2 gun, add grease

with grease gun per manual.

•

Clean gun filter screens and mix chamber ports reg-

ularly, or when increased unbalanced pressures

between A and B is noticed. See gun manual.

Use lithium grease or Iso Pump Oil on all threaded

fluid fittings on the “A” side.

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Diagnostic Codes

Temperature Control Diagnostic Codes

Temperature control diagnostic codes appear on tem-

perature display.

Code

Code Name

Alarm Zone

High fluid temperature

Individual

All

These alarms turn off heat. E99 clears automatically

when communication is regained. Codes E03 through

High zone current

No zone current

FTS or thermocouple disconnected

Control board over temperature

Communication cable unplugged

Momentary loss of communication

Loss of communication

E06 can be cleared by pressing

. For other codes,

turn main power OFF

then ON to clear.

All

See repair manual for corrective action.

NOTE: For hose zone only, if FTS is disconnected at

startup, display will show hose current 0A.

DataTrak Diagnostic Codes

DataTrak can diagnose several problems with the pump.

When the monitor detects a problem, the LED (AD, FIG.

4) will flash and a diagnostic code will appear on the dis-

play.

To acknowledge the diagnosis and return to the normal

operating screen, press

once to wake up the display,

and once more to clear the diagnostic code screen.

Symbol

Code Code Name

Diagnosis

Cause

E-2

Diving Down

Leak during downstroke.

Worn intake valve.

E-3

Low Battery

Battery voltage too low to stop

runaway.

Low battery. Replace battery;

see Reactor A-25 Repair

manual.

E-6

Blown Fuse

Fuse is blown. Replace fuse;

see Reactor A-25 Repair

manual.

• Faulty solenoid or solenoid

wiring.

• Extreme temperatures

(above 140°F [60°C]).

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Dimensions

ti17605a

With Wheels

in. (mm)

Without Wheels

in. (mm)

Dimension

43.5 (1105)

29 (736.6)

30 (762)

43.5 (1105)

21.5 (546)

24.5 (622)

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Technical Data