Graco 3A1705J - Manual

Important Two-Component Material Information Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system. Changing Materials Changing the ...

Proportioner Models Proportioner Models E-30i Series Includes: Part Available Auxiliary Current at 240 V, 60 Hz*  Booster Heat (4000 Watts) Air Compressor (5000 Watts) Voltage (phase) Total System Load † (Watts) Max Flow Rate lb/min (kg/min) Approxi- mate Out- put per Cy- cle (A+B) gal. (liter) Max...

Systems Approvals Model Approvals: 259079 Conforms to ANSI/UL Std. 73 Certified to CAN/CSA Std. C22.2 No. 68 259080259081 Conforms to ANSI/UL Std. 499 Certified to CAN/CSA Std. C22.2 No. 88 Systems Heated Hose Gun Part Maximum Fluid Working Pressure psi (MPa, bar) Proportioner Remote Display Module Ki...

Accessories Systems with Air Compressor Heated Hose Gun Part Maximum Fluid Working Pressure psi (MPa, bar) Proportioner Air Compressor Remote Display Module Kit 50 ft (15 m) 10 ft (3 m) Model Part AP9089 2000 (13.8, 138) 259089 ✓ 24K240 246050 Fusion™ AP 246101 AP9090 2000 (13.8, 138) 259090 ✓ 24K24...

Supplied Manuals Supplied Manuals The following manuals are shipped with the Reactor. Refer to these manuals for detailed equipment information.Manuals are also available at www.graco.com. Manual Description 3A1705 Reactor E-30i and E-XP2i, Operation 16K761 Reactor E-30i and E-XP2i, Startup Instruct...

Typical Installation, with circulation Typical Installation, with circulation S M B D G K M R J G H K L J R A F C* P E Figure 1* Shown exposed for clarity. Wrap with tape during operation. A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F G...

Typical Installation, without circulation Typical Installation, without circulation G K M J G H K L J A F B C* P E D N S N Figure 2* Shown exposed for clarity. Wrap with tape during operation. A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun...

Component Identi fi cation Component Identification GG PC DG EM PA PB PT MP DB GB SB GA SA BA BB FA FB HC SC HA HB (FM) Front View Figure 3 BA Component A Pressure Relief Outlet BB Component B Pressure Relief Outlet DG Drive Gear Housing DB Electrical Enclosure EM Electric Motor FA Component A Fluid ...

Component Identi fi cation Generator BE HB HF RC FP OD FH EX EA FS FT GD EE DF AF OF ED EB HE ER OL ST RF TR GL FJ FD OS WS Figure 5 AF Air Filter BE Battery (not supplied) DF Diesel Fuel Filter EA 12V Charge Alternator EB Engine Coolant Expansion Bottle EE Engine ED Engine Oil Dipstick ER Radiator ...

Component Identi fi cation Proportioner Control Panel PE PF* PG* PH* PJ* PD PK PL PM PR PP PN ti17151a Figure 6 PD Advanced Display Module (ADM), page 19 PE Engine Control Module, page 24 PF* Component A Feed Pump Air Outlet PG* Component B Feed Pump Air Outlet PH* Agitator Air Outlet PJ* Gun Air Ou...

Component Identi fi cation Advanced Display Module (ADM) NOTICE To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails. A H G C B D E F D Component Identification — Front Figure 8 Call out Button Function A Power On/Off Powers syst...

Component Identi fi cation CS CR CP CN CM CL CK CJ Component Identification — Back Figure 9 CJ Flat Panel Mount (VESA 100) CK Model and Serial Number CL USB Port and Status LEDs CM CAN Cable Connection CN Module Status LEDs CP Accessory Cable Connection CR Token Access Cover CS Battery Access Cover S...

Component Identi fi cation ADM Display Details Power Up Screen The following screen appears when the ADM is powered up. It remains on while the ADM runs through initialization and establishes communication with other modules in the system. Menu Bar The menu bar appears at the top of each screen. (Th...

Component Identi fi cation Icons Icons Icon FunctionComponent A Component B Estimated Supply Material Hose Temperature Jog Mode Speed Engine Coolant Temperature Pressure Cycle Counter (press and hold)Advisory. See Errors, page 51 for more information.Deviation. See Errors, page 51 for more informati...

Component Identi fi cation Engine Control Module NOTICE To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails. For more information about the engine control module, see Appendix A: Engine Control Module, page 93 . Figure 11Engine...

Component Identi fi cation Load Center F3 Radiator Fan Fuse F4 Load Center Power Fuse K1 Fuel Relay K2 Starter Relay K3 Glow Plug Relay K4 Radiator Fan Relay MV Manual Valve Switch LED Related Component Color ON-State Description D1 Fuel Shutoff Solenoid (FS) Green Fuel shutoff solenoid on the engin...

Component Identi fi cation Temperature Control Modules Located inside the Electrical Enclosure (DB). High Power Temperature Control Module (HPTCM) Cable Connections 3 1 2 Figure 12 5 7 6 8 4 Figure 13 1 Not used 2 Fluid Temperature Sensor (FTS) Connection 3 Output Power Connection 4 Contactor Contro...

Component Identi fi cation Adjust Rotary Switch The rotary switch setting indicates which zone the temperature control module will control in the system. The HPTCM uses an 8-position rotary switch. The LPTCM uses a 16-position rotary switch.Set the rotary switch (S) to the specific selection accordin...

Component Identi fi cation Circuit Breakers CB01 CB02 CB03 CB04 CB05 CB06 CB07 CB08 CT01 Circuit Breakers Inside Electrical Enclosure (DB) Figure 18 Note Not all wires are shown. Ref. Size Component CB01 30 A High Power Temperature Control Module (HPTCM) CB02 20 A Motor Control Module (MCM) CB03 5 A...

Component Identi fi cation CB10 Circuit Breakers Inside Alternator Assembly Figure 20 Ref. Size Component CB10 90 A 120/240V Alternator Circuit Breaker Configuration Options Improper configuration can result in electric shock. All changes from the recommended circuit breaker configuration must meet all...

Overview Overview The system uses two coolant loops to use heat released from the engine to heat the A and B component material to the target temperatures defined on the ADM (PD).The engine coolant loop (gray) circulates heated coolant from the engine (EE), through the heat exchanger (HE), radiator (...

Setup Setup 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. NOT...

Setup Trailer Setup Guidelines Route exhaust system away from combustible materials to prevent materials from igniting or gas recirculation into a wall, ceiling, or a concealed space. Provide exhaust system guards to prevent burns. NOTICE Provide recommended size louvers. Failure to do so can damage...

Setup Connect Battery Improper battery installation or maintenance may result in electric shock, chemical burns, or explosion. Battery maintenance must only be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batterie...

Setup Electrical Connections Connect air compressor, breathing air, and auxiliary power electrical connections to the specified circuit breakers. See Circuit Breakers, page 28 . 1. Remove one or more knock-outs on side of electrical enclosure, as required, and route wires through for air compressor, ...

Setup Connect Pressure Relief Lines Do not operate Reactor without all covers and shrouds in place. 1. Recommended: 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. See Typical Installation, with circulation, ...

Setup Supply Wet Cups With Throat Seal Liquid (TSL) 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. To prevent the pump from moving, turn the main power switch OFF. • Co...

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 thecurrent password then press . Press to navigate through the Setup Mode...

Advanced Display Module (ADM) Operation Advanced Setup Screens Advanced setup screens enable users to set units, adjust values, set formats, and view software informationfor each component. Press to scroll through the Advanced setup screens, Once in the desired Advanced setup screen, press to access...

Advanced Display Module (ADM) Operation System Use this screen to set the activation pressure for the Pressure Imbalance Alarm and Advisory, enable or disable diagnostic screens, enable drum alarms, set the maximum drum volume, enable drum alarms, and set low material alarm level. Recipes Use this s...

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 screens. See Run Screens Navigation Diagram, page 44 . From the Run screens, press to access the Setup screens. 48 3A1705J

Advanced Display Module (ADM) Operation Maintenance Use this screen to view daily and lifetime cycles or gallons that have been pumped and gallons or liters remaining in the drums.The lifetime value is the number of pump cycles or gallons since the first time the ADM was turned on.The daily value aut...

Advanced Display Module (ADM) Operation Diagnostic Use this screen to view information for all system components. The following information is displayed: Temperature • Hx A Chem: Heat Exchanger A Chemical • Hx B Chem: Heat Exchanger B Chemical • Hose Chemical • Booster A Chemical • Booster B Chemica...

Advanced Display Module (ADM) Operation Troubleshooting This screen displays the last ten errors that occurred on the system. Use the up and downarrows to select an errors and press to view troubleshooting information for the selected error.Press to access troubleshooting screen for an error code th...

Startup Startup To prevent serious injury, only operate Reactor with all covers and shrouds in place. NOTICE Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will...

Temporary Manual Hose Temperature Control Temporary Manual Hose Temperature Control If T6DH error code appears from a break in the hose RTD cable or FTS sensor, follow the steps for temporary manual hose temperature control. Repair or replace the hose RTD cable or FTS as soon as job is finished.1. Co...

Fluid Circulation Fluid Circulation Circulation Through Reactor NOTICE Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. To circulate through gun manifold and preheat hose, see Circulation Through Gun Manifold, page 60 ...

Jog Mode Circulation Through Gun Manifold NOTICE Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. Circulating fluid through the gun manifold allows rapid preheating of the hose.1. Install gun fluid manifold (P) on access...

Spraying Spraying The Fusion AP gun is shown. 1. Engage gun piston safety lock. 2. Close gun fluid inlet valves A and B. 3. Attach gun fluid manifold. Connect gun air line. Open air line valve. 4. Adjust the gun air regulator on the proportioner control panel to desired gun air pressure. Do not exceed...

Spraying 12. Open gun fluid inlet valves A and B. Note On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced. 13. Disengage gun piston safety lock. 14. Test spray onto cardboard. Adjust pressure and temperature to get desired results. 15. Equipment is ready t...

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

Pressure Relief Procedure Pressure Relief Procedure 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 bef...

Flushing Flushing To prevent fire and explosion, 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 solvent before introducing new fluid. • U...

Maintenance Maintenance Prior to performing any maintenance procedures, follow Pressure Relief Procedure, page 64 . Preventative Maintenance Schedule The operating conditions of your particular system determine how often maintenance is required. Establish a preventive maintenance schedule by recordi...

Maintenance Engine Maintenance The engine instructions that accompany your unit detail specific procedures for maintenance of the engine. Following the engine manufacturer’s recommendations will extend engine work life.Daily• Cooling System Coolant Level — Check• Engine Air Cleaner Service Indicator ...

Maintenance Pump Lubrication System Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the e...

Maintenance Drain Coolant To avoid burns, do not perform maintenance on the coolant system until the coolant system has reached ambient temperature. Drain coolant from the engine and proportioner coolant loops once a year or if the coolant lines need to be disconnected, in order to install a wall be...

Maintenance 6. To drain engine coolant loop: a. Remove the engine coolant loop (RC) cap.b. Remove engine guards as shown. Let the guards rest on the engine to access the drain valve. Engine Coolant Loop Drain Valve Figure 43 c. Place a waste container under the drain valve. Open the drain valve and ...

Maintenance Refill Engine Coolant Loop Refill the engine coolant loop when the coolant is below the cold level line at ambient temperature. To avoid burns, do not perform maintenance on the coolant system until the coolant system has reached ambient temperature. Only use coolant solutions that are com...

Errors Errors View Errors When an error occurs the error information screen displays the active error code and description. To diagnose the active error, see Troubleshoot Errors, page 73 . The error code, alarm bell, and active errors will scroll in the status bar. For a list of the ten most recent ...

Troubleshooting Troubleshooting See Errors, page 73 for information about errors that can occur on the system.See Troubleshooting, page 53 for the ten most recent errors that have occurred on the system. See Troubleshoot Errors, page 73 to diagnose errors on the ADM that have occurred on the system....

USB Data USB Data USB Logs Note The ADM can read/write to FAT (File Allocation Table) storage devices. NTFS, used by 32 GB or greater storage devices, is not supported. During operation, the ADM stores system and performance related information to memory in the form of log files. The ADM maintains fo...

USB Data Daily Log The daily log file name is 3–DAILY.CSV and is stored in the DATAxxxx folder.The daily log maintains a record of the total cycle and volume sprayed on any day that the system is powered up. The volume units will be the same units that were used in the Job Log.The following data is s...

USB Data Download Procedure Note System configuration setting files and custom language files can be modified if the files are in the UPLOAD folder of the USB flash drive. See System Configuration Settings File, Custom Language File, and Upload Procedure sections. Note If needed, set the number of days to ...

USB Data Create Custom Language Strings The custom language file is a tab-delimited text file that contains two columns. The first column consists of a list of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom langu...

Appendix A: Engine Control Module Appendix A: Engine Control Module Run Screens There are seven run screens on the engine control module:• Line-to-neutral voltage• Line-to-line voltage• Frequency• Engine Speed• Engine lifetime counter• Battery voltage Press to scroll through the run screens. Press t...

Appendix A: Engine Control Module Mode Icons An icon is displayed in the mode icon area of the display to indicate what mode the unit is currently in. Icon Description Details Stopped Engine is at rest and the unit is in stop mode. Auto Engine is at rest and the unit is in auto mode. Manual Engine i...

Appendix A: Engine Control Module Alarms There are two types of alarms that can occur on the system. Alarms are indicated by an icon the Run and Information screens. Warning When present on system, a warning alarm will not stop the generator. Icon Description Details Battery High Voltage The DC Supp...

Dimensions Dimensions Top View Figure 45 Side View Figure 46 96 3A1705J

Performance Charts Performance Charts Use these charts 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. Proportioners For Foam AR6060 (03) AR7070 (04) AR5252 (02) AR4242 (01) 2000 (138) 1500 (103) 1000 (69...

Technical Speci fi cations Technical Specifications E-30i Models U.S. Metric Maximum Fluid Working PressurePressure 2000 psi 14 MPa, 140 bar Maximum Fluid TemperatureE-30i 140°F 60°C E-30i with booster heater 180°F 82°C Maximum OutputOutput 30 lb/min 13.5 kg/min Maximum Heated Hose LengthLength 310 f...

Graco Standard 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. With the exception of any special, extended, or limited warr...