Operation ® A-25 3A1569B EN PLURAL COMPONENT PROPORTIONER 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.
Contents Proportioner Models . . . . . . . . . . . . . . . . . . . . . . . . 3 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Important Two-Component Material Information . 7 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . .
Proportioner Models Proportioner Models All proportioners can be configured to operate on 380V (4 wire), 230V (3 wire), or 230V 1Ø. Maximum Fluid Working Maximum Air Working Pressure Set Pressure psi (MPa, bar) psi (kPa, bar) Part No. Includes: DataTrak (cycle count only) Wheels 262572 2000 psi (14, 138) 80 psi (550, 5.5) --- --- 262614 2000 psi (14, 138) 80 psi (550, 5.5) 24A592 Approvals 3172585 Conforms to ANSI/UL Std. 499 Certified to CAN/CSA Std. C22.2 No.
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, 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.
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.
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.
Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions 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. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area.
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 multiple times to ensure it is thoroughly clean. • Always clean the fluid inlet strainers after flushing. • Check with your material manufacturer for chemical compatibility.
Typical Installation, without Circulation Typical Installation, without Circulation K G M J K F A N H J H N L D B E C* P ti16812a * Shown exposed for clarity. Wrap with tape during operation. FIG. 1: Typical Installation, without Circulation Key for FIG.
Typical Installation, with Circulation Typical Installation, with Circulation Key for FIG. 2 A B C D E F Reactor Proportioner Heated Hose Fluid Temperature Sensor (FTS) Heated Whip Hose Spray Gun Proportioner and Gun Air Supply Hose G J K L M N P Feed Pump Air Supply Lines Fluid Supply Lines Feed Pumps Agitator (if required) Desiccant Dryer Recirculation/Over Pressure Relief Return Hoses Gun Fluid Manifold G K M M J F K A N N N J F L D B E C* P ti16813a * Shown exposed for clarity.
Component Identification Component Identification W T AG R AC AD AI S AH AA DD AB AF FF Z GG V Y X AE ti16814a U FIG.
Component Identification Key: R 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. S Main Air Filter - Filters system air supply. AI Resin (B) Pump Wet Cup - Access for daily wet cup refill. T Resin (B) Pressure Gauge - Displays pressure in resin proportioning system (B side).
Component Identification Control Panel DataTrak (optional) See page 32. See Temperature Controls and Indicators E L EC T R O N IC M O N I T O R IN G S Y S T E M Air Motor Pressure Gauge A B 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.
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.
Setup 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. • Two bolts through the 2 in. (50 mm) deep caster bushings in the rear. • Two bolts through the 3-5/8 in. (168 mm) deep caster bushings in the front. 2. Do not expose Reactor A-25 to rain. 3. If you need to move the machine, add optional wheel kit. 4.
Setup Configure to Supply Power NOTE: Both cord connection AND jumper positioning steps on page 17 must be completed. 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: Disregard terminal numbers on disconnect switch blocks. Wire to positions shown. Step One - Connect Electrical Cord NOTE: Disregard terminal numbers on disconnect switch blocks.
Setup Step Two - Install Power Jumpers Find location for power jumpers which are in a plastic bag tie wrapped to the ground lug. Heater Jumper Location Heater Jumpers NEW 1. Turn screws counter-clockwise on the upper part of the shroud until they stop. Pull door up and out. 2. Install red jumpers from the storage bag to the positions shown for your power. • Push the jumper firmly into the new position.
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. • Reactor: is grounded through power cord; see page 16.
Setup Recirculation / Pressure Relief Lines Connect Heated Hose NOTE: See heated hose manual for detailed instructions 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.
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. SS NN 2. Tighten fittings to A and B component hoses.
Initial Startup 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. Load Fluid with Feed Pumps b. NOTE: The Reactor is tested with oil at the factory. Flush out the oil with a compatible solvent before spraying; see page 27. 1. Check that Setup process is complete; see page 15.
Initial Startup Set Temperatures 6. Turn on A and B heat zones by pressing for each zone. See Setup, page 15. 7. Hold 1. Turn main power ON zone. . 8. Hold °F 2. Press °C or to view electrical currents for each to change temperature scale. to view heater control circuit board tem- perature. 9. Manual current control mode only: 3. Press to display target temperatures. A 4. To set or heat zone target temperature, press until display shows desired temper- ature.
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.
Spraying Spraying 5. Open air inlet ball valve (DD). The Fusion AP gun is shown. 1. After reaching spray temperatures, engage gun piston safety lock. DD ti2409a ti17573a 6. Turn the air regulator counterclockwise to 0 pressure. 2. Close gun fluid inlet valves A and B. E L EC T R O N IC M O N I T O R IN G S Y S T E M air regulator DD air motor shutoff valve ti2728a ti17574a 3. Attach gun fluid manifold. Connect gun air line. Open air line valve. 7. Open the air motor shutoff valve. 8.
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. SB SA • 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.
Park Park 5. Engage gun piston safety lock. Park the pumps at the end of the day to cycle proportioner pumps to home position, submerging displacement rod. ti2409a 1. Open the park valve. 6. Close gun fluid inlet valves A and B. ti2421a Open Close 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 .
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 moisture-free solvent. • Use lowest possible pressure when flushing. • To flush feed hoses, pumps, and the heater separately from the heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION. Flush through bleed lines (N).
Operation Operation Daily Start-up Procedure 8. Check that hose setpoint temperature is correct. 9. Turn on all three heat zones. 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. 2.
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. GA GB 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.
Fluid Circulation Fluid Circulation Circulation Through Reactor 5. Set temperature targets, see page 22. Turn on A and B Do not turn on Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. heat zones by pressing . heat zone unless hoses are already loaded with fluid. To circulate through gun manifold and preheat hose, see page 31. 6. Press 1. Follow Initial Startup, page 21. 7.
Fluid Circulation Circulation Through Gun Manifold 5. Set temperature targets, see page 22. Turn on A , B , and heat zones by pressing . 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 accessory circulation kit (CK). Connect high pressure circulation lines (R) to circulation manifold. 6.
DataTrak Controls and Indicators 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) AC Flow Rate Units (user settable to /min, gpm [US], gpm [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.
DataTrak Operation DataTrak Operation NOTE: The display (AE) will turn off after 1 minute to save battery life. Press any key to wake up the display. NOTICE To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. 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 press and hold • Setup Mode 1.
Maintenance 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 atmosphere 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.
Diagnostic Codes Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on temperature display. Code 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.
Dimensions Dimensions A C ti17605a B Dimension A B C 36 With Wheels Without Wheels in. (mm) 43.5 (1105) 29 (736.6) 30 (762) in. (mm) 43.5 (1105) 21.5 (546) 24.
Technical Data Technical Data Category Maximum Fluid Working Pressure Maximum Air Supply Pressure Maximum Air Working Pressure Pressure Ratio Air consumption with 02 tip at 1500 psi stall pressure Machine Maximum Power with hose Voltage Requirement (50/60 Hz) (230 V Nominal: 195-253 VAC) (380 V Nominal: 338-457 VAC) Amperage Requirement (Full Load Peak)* Maximum Heater Fluid Temperature Maximum Hose Fluid Temperature Maximum Ambient Temperature Maximum Output Output Per Cycle (A and B) Heater Power Hose P
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.
