Operation H-VR 313539F ENG Hydraulic Variable Ratio, Heated, Plural Component Proportioner. For spraying polyurethane foam and polyurea coatings. For professional use only. Not for use in explosive atmospheres. U.S. Patent Pending Russian Patent No. 2359181 Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 2 for model information, including maximum working pressure. r_256886_313359_1A #ONFORMS TO !.3) 5, 3TD #ERTIFIED TO #!.
Models Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . 6 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . 6 Keep Components A and B Separate . . . . . . . . . .
Supplied Manuals Supplied Manuals The following manuals are shipped with the Reactor™ H-VR Proportioner. Refer to these manuals for detailed equipment information. Order Part 15M334 for a compact disk of Reactor manuals translated in several languages.
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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found 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.
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.
Isocyanate Conditions Isocyanate Conditions Spraying 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. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area.
Changing Materials Changing Materials • When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. • Always clean the fluid inlet strainers after flushing. • Check with your material manufacturer for chemical compatibility. • Most materials use ISO on the A side, but some use ISO on the B side. • Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.
Typical Installation, with circulation Typical Installation, with circulation Key for FIG.
Typical Installation, without circulation Typical Installation, without circulation Key for FIG.
Component Identification Component Identification NOTICE To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. Reactor H-VR Key for FIG.
Component Identification MC VR TC RS HC HP EM FM OP FV SC EC FH SN MP r_256886_313359_1A SR Detail of Reactor Fluid Manifold (shroud removed for clarity) SA TA GA GB FA TB Detail of Serial No. Plate (inside cabinet) SB BA FB ti7823a BB HA HB ti9880a SN FIG. 3: Component Identification (15.
Component Identification Pump Assembly Key for FIG. 4. AA AB AC AD AE AF AG Component A Pump Component B Pump Hydraulic Proportioner Pump Yoke and Rod Guide Assembly Pump Drive Link Pump Adapter Pivot Bracket AH AJ AK AL AM AN AP Guard Clamping Knob Lube Fitting Ratio Lock Handle Ratio Adjustment Wheel Frame Ratio Adjustment Screw AH AJ AB AA Detail of Pump Assembly (guard removed for clarity) AL AC AD AG AE AM AK AK (behind pivot bracket) AP AN AF AB FIG.
Temperature Controls and Indicators Temperature Controls and Indicators Heater Displays Heater Power Indicators Zone A Arrow Keys A Zone B Arrow Keys B Heater A On/Off Key Heater B On/Off Key Hose Heater On/Off Key Hose Zone Arrow Keys °F Actual Temperature Key Temperature Scale Keys °C Target Temperature Key FIG. 5. Temperature Controls and Indicators Main Power Switch Actual Temperature Key/LED Located on right side of unit, page 11. Turns Reactor Press power ON and OFF .
Temperature Controls and Indicators Temperature Scale Keys/LEDs Press °F or °C to change temperature scale. Heater Zone On/Off Keys/LEDs Press Circuit Breakers to turn heater zones on and off. Also clears heater zone diagnostic codes, see page 34. Located inside Reactor cabinet. Ref. Size Component CB1 50 A Hose/Transformer Secondary CB2 40 A Transformer Primary CB3 50 A Heater A CB4 50 A Heater B CB5 20 A Motor/Pumps NOTE: LEDs flash when heater zones are on.
Motor Controls and Indicators Motor Controls and Indicators Pressure/Cycle Display Arrow Keys Motor ON/OFF Key ON / OFF PARK Key Pressure Key PARK PSI/BAR Keys Cycle Count Key PSI BAR FIG. 6. Motor Controls and Indicators Motor ON/OFF Key/LED Pressure Key/LED Press Press to turn motor ON and OFF. Also clears to display fluid pressure. some motor control diagnostic codes, see page 35. NOTE: PARK Key/LED Press If pressures are imbalanced, display shows higher of two pressures.
Spray Adjustments Cycle Count Key/LED Press • 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. Similar effects to fluid pressure setting. The A and B temperatures can be offset to help balance the fluid pressure. • Mix chamber size.
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. 2. General equipment guidelines • 1. Locate Reactor Use the following procedure to determine the correct size generator. a. Locate Reactor on a level surface.
Setup 3. Electrical requirements 4. Connect electrical cord See table 1. NOTE: Power cord is not suppled. See table 2. Installing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals, see step 3. Be sure your installation complies with all National, State and Local safety and fire codes.
Setup 5. Connect feed pumps to component A and B drums. See FIG. 1, page 8. a. Install feed pumps (K) in component A and B supply drums. See FIG. 1 and FIG. 2, pages 8 and 9. b. Seal component A drum and use desiccant dryer (M) in vent. c. Install agitator (L) in component B drum, if necessary. SB SA R BA d. Ensure A and B inlet valves (FV) are closed. R b. BB ti9880a Alternatively: Secure supplied bleed tubes (N) in grounded, sealed waste containers (H). See FIG. 2, page 9. 7.
Setup 8. Connect heated hose bends. Wrap cable and electrical connections with electrical tape. NOTE: See Heated Hose manual 309572 for detailed instructions on connecting heated hoses. NOTE: If spraying at a ratio other than 1:1, an E24 may occur. Size hoses and mix chamber appropriately to avoid pressure imbalance. Y V NOTICE The fluid temperature sensor (C) and whip hose (D) must be used with heated hose, see page 19. Hose length, including whip hose, must be 60 ft (18.3 m) minimum. ti9881a 9.
Setup 12. Ground system a. Reactor: is grounded through power cord. See page 18. b. Spray gun: connect whip hose ground wire to FTS, page 19. Do not disconnect wire or spray without whip hose. c. Fluid supply containers: follow your local code. d. Object being sprayed: follow your local code. e. Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface.
Startup Startup See table 3 for ratios with the one pump set at 1.0 and available settings for the second pump. Do not operate Reactor without all covers and shrouds in place. Do not attempt to change ratio while machine is pressurized or running. Do not loosen ratio lock handle if A and B component pumps are pressurized or while the pumps are operating. Table 3: Ratio Range Pump with higher flow Pump with lower flow 1.0 1:1 0.95 1.05 1.0 0.90 1.11:1 1.0 0.85 1.2:1 1.0 0.80 1.25:1 1.0 0.
Startup e. Remove base pin (BP) from frame (AN) if the base of the pump needs to be moved. See FIG. 8. AL AF AE AM TP BP 3 21 AP r_256886_313359_7 FIG. 9 f. r_256886_313359_5 Loosen ratio lock handle (AL) over the pump that needs adjustment. Use a soft mallet to loosen ratio lock handle if necessary. Turn ratio adjustment wheel (AM) until the mark on the pump adapter block (AF) lines up with the correct position on the ratio indicator label on the pump drive link (AE). 1 2 3 FIG. 10 h.
Startup 2. Load fluid with feed pumps Open fluid valves A and B until clean, air-free fluid comes from valves. Close valves. NOTE: The Reactor is tested with oil at the factory. Flush out the oil with a compatible solvent before spraying. See page 38. a. Check that all Setup steps are complete. b. Turn on component B agitator, if used. c. Turn both PRESSURE RELIEF/SPRAY valves ti2484a (SA, SB) to SPRAY . SB SA ti9877a d. Start feed pumps. e. Open fluid inlet valves (FV). Check for leaks.
Startup 3. Set temperatures desired temperature. Repeat for B and zones. A NOTE: B For zone only, if FTS is disconnected at startup, display will show hose current (0A). See step j, page 26. e. Press to display actual temperatures. °F °C Do not turn on hose heat without fluid in hoses. Temperature Controls and Indicators, see page 13 f. b. Press °F or °C . to change temperature g. Turn on ing Press press A and B heat zones by press- for each zone. . h. Hold d. To set .
Startup j. Manual current control mode only: 4. Set pressure 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. ON / OFF If FTS is disconnected or display shows diagnostic code E04, turn main power switch OFF then ON PARK PSI to clear diagnostic code and enter manual current control mode.
Startup NOTE: Table 4: Available Pressure Imbalance Settings Check the pressure of each proportioning pump using the component A and B gauges. The pressures should be approximately equal and must remain fixed. d. To display cycle count, press . NOTE: PSI BAR PSI BAR 100 200 300 400 *500 7 14 21 28 *35 600 700 800 900 999 42 49 56 63 69 * Factory default setting. To clear counter, press and hold for 3 sec. d. Turn main power switch OFF e.
Spraying Spraying 4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY . SA 1. Engage gun piston safety lock. SB ti9877a ti2409a 5. Check that heat zones are on and temperatures are on target, page 25. 2. Close gun fluid manifold valves A and B. 6. Press motor to start motor and pumps. 7. Check fluid pressure display while the gun is detriggered and adjust as necessary, page 26. ti2728a 3. Attach gun fluid manifold. Connect gun air line. Open air line valve. 8.
Spraying 9. Open gun fluid manifold valves A and B. ti2414a NOTE: On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced. 10. Disengage gun piston safety lock. ti2410a 11. Test spray onto cardboard. Adjust pressure and temperature to get desired results. 12. Equipment is ready to spray. NOTE: If you stop spraying for a period of time, the unit will enter standby (if enabled). See page 30.
Standby Standby Shutdown 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 ON/OFF LED and the pressure/cycle display on the motor control panel will flash when in standby. A , B , and heat zones will not be shut off in standby. To restart, spray off target for 2 sec. The system will sense the pressure drop and the motor will ramp up to full speed in a few seconds.
Pressure Relief Procedure Pressure Relief Procedure 5. Engage gun piston safety lock. 1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual. 2. Close gun fluid manifold valves A and B. ti2409a 6. Disconnect gun air line and remove gun fluid manifold. ti2421a 3. Shut off feed pumps and agitator, if used. ti2554a 4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0.
Fluid Circulation Fluid Circulation Circulation Through Reactor 5. Set temperature targets, see page 25. Turn on A 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 page 33. B and Do not turn on heat zones by pressing . heat zone unless hoses are already loaded with fluid. 6. Press to display actual temperatures. 7.
Fluid Circulation Circulation Through Gun Manifold 7. Before starting motor, reduce hydraulic pressure to the minimum required to circulate fluid until and B temperatures reach targets. 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 hose. 1. Install gun fluid manifold (P) on Part 246362 accessory circulation kit (CK).
Diagnostic Codes Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on temperature display. These alarms turn off heat. E99 clears automatically when communication is regained. Codes E03 through E06 can be cleared by pressing turn main power OFF . For other codes, then ON to clear. See repair manual for corrective action.
Diagnostic Codes Motor Control Diagnostic Codes Motor control diagnostic codes E21 through E27 appear on pressure display. Warnings There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings. Reactor will continue to run. Press to clear. A warning will not recur for a predetermined amount of time (varies for different warnings), or until main power See repair manual for corrective action. is turned OFF Alarms Alarms turn off Reactor.
Maintenance Maintenance • Inspect hydraulic and fluid lines for leaks daily. • Keep component A from exposure to moisture in atmosphere, to prevent crystallization. • Clean up all hydraulic leaks; identify and repair cause of leak. • Clean gun mix chamber ports regularly. See gun manual. • Clean gun check valve screens regularly. See gun manual. • Use compressed air to prevent dust buildup on control boards, fan, motor (under shield), and hydraulic oil coolers.
Fluid Inlet Strainer Screen Fluid Inlet Strainer Screen 4. Ensure the pipe plug (59k) is screwed into the strainer plug (59j). Install the strainer plug with the screen (59g) and gasket (59h) in place and tighten. Do not overtighten. Let the gasket make the seal. 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.
Flushing 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 solvent before introducing new fluid. • Use the lowest possible pressure when flushing. • All fluid components are compatible with common solvents. Use only moisture-free solvents.
Dimensions Dimensions Dimension in. (mm) Dimension in. (mm) A (height) B (width) C (depth) 57.31 (1455.42) 37.86 (961.6) 33 (838.2) D (front and rear mounting holes) F (side mounting holes) G (mounting post inner diameter) 32.5 (825.5) 30.375 (7715) 0.
Technical Data Technical Data Category Maximum Fluid Working Pressure Fluid Inlets Fluid Outlets Data 3500 psi (24.1 MPa, 241 bar) 3/4 npsm union in 1 in. npt(f) ball valve Component A (ISO): #8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter Component B (RES): #10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter Fluid Circulation Ports 1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum Maximum Fluid Temperature 190°F (88°C) Maximum Output (10 weight oil at Model H-VR: 3.0 gpm (11.
Performance Charts Performance Charts Foam Performance Chart Pressure in psi (MPa, bar) 2000 (13.8, 138) KEY A = H-25 at 50 Hz B = H-25 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 G = H-VR at 60 Hz A 1500 (10.3, 103) B G 1000 (6.9, 69) C E 500 (3.4, 34) D F 0 5 15 25 35 45 55 (2.3) (6.8) (11.4) (15.9) (20.5) (25.0) Flow Rate in lb/min (kg/min) ❄ Pressure flow curve for model 253725 (H-50 230V 1 phase) not shown.
Performance Charts Heater Performance Chart 140 (78) 130 KEY H-VR = 15.3 kW (72) 120 Delta T in degrees F (degrees C) (67) 110 (61) 100 H-VR (56) 90 (50) 80 (44) 70 (39) 60 (33) 50 (28) 40 (22) 30 (17) 20 (11) 10 (6) 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 (1.9) (3.8) (5.7) (7.6) (9.5) (11.4) (13.2) (15.1) (17.0) Flow Rate in gpm (lpm) ★ Heater performance data is based on testing with 10 wt. hydraulic oil and 230V across heater power wires.
Performance Charts 313539F 43
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 warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
