Operation Reactor A-20 311511G ENG Air Operated, Electrically Heated Plural Component Proportioner For spraying or dispensing 1:1 mix ratio materials, including epoxies and polyurethane foam. For professional use only. Not approved for use in European explosive atmosphere locations. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for a list of models and maximum working pressures. US Patent No. 7822326 Russian Patent No.
Contents Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Typical Installation, without Circulation . . . . . . . . 7 Typical Installation, with Circulation . . . . . . . . . . . 8 Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 9 Foam Self-Ignition . . . . . . . . . . . . . . . . . . . . . . . .
Systems Systems System Part Maximum Fluid Working Pressure psi (MPa, bar) Heated Hose Gun Proportioner 50 ft (15 m) 10 ft (3 m) Model Part AP3831 2000 (13.8, 138) 253831 246678 246050 Fusion Air Purge 246101 CS3831 2000 (13.8, 138) 253831 246678 246050 Fusion CS CS01RD P23831 2000 (13.
Warnings Warnings The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.
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 MOVING PARTS HAZARD Moving parts can pinch 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 in this manual. Disconnect power or air supply. BURN HAZARD Equipment surfaces and fluid that’s heated can become very hot during operation.
Typical Installation, without Circulation Typical Installation, without Circulation Key for FIG. 1 A B C D E F G Reactor Proportioner Heated Hose Fluid Temperature Sensor (FTS) Heated Whip Hose Fusion Spray Gun Proportioner and Gun Air Supply Hose Feed Pump Air Supply Lines H J K L M N P Waste Containers Fluid Supply Lines Feed Pumps Agitator Desiccant Dryer Bleed Lines/Over Pressure Relief Gun Fluid Manifold G K M K A N F J D E L H P C* B ti8489a * Shown exposed for clarity.
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 Fusion 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 Desiccant Dryer Recirculation/Over Pressure Relief Return Hoses Gun Fluid Manifold G K M M K A N F J D E L N P C* B ti8488a * Shown exposed for clarity.
Moisture Sensitivity of Isocyanates Moisture Sensitivity of Isocyanates Isocyanate Hazard 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.
Component Identification Component Identification W T AD AI R ti8447a AK AA AH S FF DD GG X Z ti8448a U V Y AG ti8481a FIG.
Component Identification Key: R Main Disconnect Switch - Controls power to all circuits. It must be ON for proportioning unit to operate. Temperature displays are lit when main switch is ON. AH Resin (B) Proportioning Pump - Draws in and dispenses a fixed volume of resin to gun. AI Power-Lock™ Hose Heat Connection - Connects power to heated hoses. S Main Air Filter - Filters system air supply. T Resin (B) Pressure Gauge - Displays pressure in resin proportioning system (B side).
Controls and Indicators Controls and Indicators AK AN AV AQ AP 34!24 AU /. B AR -0A 0 3) /&& 0!2+ 34!24 34!24 /. /. /&& 25. /&& B AR -0A 0 3) AM AR AL Key: AK Primary Heater Switch - Controls and protects primary heater. It must be ON and lit green for primary heater to operate.
Pressure Relief Procedure Pressure Relief Procedure Flushing Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. 1. Turn off feed pumps and agitator if used. 2. Turn PARK/RUN switch to PARK. • Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent, such as toluene, naptha, or mineral spirits before introducing new fluid. • Use lowest possible pressure when flushing.
Setup Setup Locate Reactor A-20 Electrical Requirements 1. Locate Reactor A-20 on a level surface and bolt in place to the floor with 3/8 in. (10 mm) bolts. • 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. Improper wiring 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.
Setup Configure to Supply Power green to ground (GND). See page 16 for proper jumper positions. Disregard terminal numbers on disconnect switch blocks. Wire to positions shown. Both cord connection AND jumper positioning steps on page 16 must be completed. Step One - Connect Electrical Cord , . Disregard terminal numbers on disconnect switch blocks. Wire to positions shown. Terminals will accept up to #8 AWG (10 mm2) conductors. 1. Remove and retain two screws from lower front shroud and remove. 2.
Setup Step Two - Reposition Power Jumpers For 230V, 1 Phase and 230V, 3 Phase Installations, change jumper positions as shown below. Machine is shipped with jumpers in the fail-safe 380 3Ø position. Find location of Power Jumpers. 1. Remove upper rear control cover screws and cover. 2. Move one red jumper from the storage positions to the positions shown for your power. Power Jumper Location • A flat-blade screwdriver can be used under the ridge on the side of the jumper to remove them.
Setup Ground System 2. 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. U • Reactor: is grounded through power cord; see page 15. • Spray gun: connect whip hose ground wire to FTS; see page 18. Do not disconnect wire or spray without whip hose. • Fluid supply containers: follow your local code. • Object being sprayed: follow your local code. • Solvent pails used when flushing: follow your local code.
Setup Connect FTS and Heated Dual Whip Hose 4. Connect fluid hoses to FTS (J). NOTICE To prevent damage to probe, do not kink or excessively bend hose. Do not coil hose tighter than the minimum bend radius of 3 ft (0.9 m). Do not subject hose to excessive weight, impact, or other abuse. To use 1/2 in. (13 mm) ID fluid hoses, remove the adapters from the proportioner fluid manifold and install them in the FTS swivel inlets. 5. Connect electrical connectors (D). 1.
Setup Recirculation / Pressure Relief Lines 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. 1. Turn main power OFF. 2. Assemble heated hose sections, FTS, and whip hose; see manual 309572. 3. Connect A and B hoses to A and B outlets on Reactor fluid manifold (FM).
Setup Close Gun Fluid Manifold Valves A and B ti2411a Connect Whip Hose to Gun Fluid Manifold Do not connect manifold to gun. ti2417a Pressure Check Hose See hose manual. Pressure check for leaks. If no leaks, wrap hose and electrical connections to protect from damage.
Initial Startup Initial Startup 3. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY. Do not operate Reactor without all covers and shrouds in place. SB SA Fluid Temperature Sensor (FTS) Calibration Calibrate the FTS ONLY at initial startup (the first time the unit is operated) and any time the hose length changes. ti8442a 4. Open both fluid valves (FV). 1. Before turning on the unit, ensure all hoses and cables are properly connected.
Initial Startup Digital Temperature Controllers To change or enter the set point, proceed as follows: NOTICE Do not turn power on to the hose heat until after all hose power connectors are connected. The proportioner has two temperature controllers that automatically manage the temperature for the primary heater and the hose heat.
Initial Startup Change Between Fahrenheit and Celsius The temperature controller is factory-set to display in Fahrenheit units. To change to Celsius units: 1. Press and release Scroll button (A1) until Controller displays “UNIT”. 2. Press and release Down button (A3) once to display “F”. 3. Press and release Down button (A3) once again to display “C”. 4. Press and release Scroll button (A1) twice. Controller will display Celsius units. To change back to Fahrenheit units: 1.
Initial Startup Over Temperature Alarms Hose Heat Manual Mode Both the fluid heater and the hose heat have over temperature alarms that will turn off the heat zone if high temperatures are detected. If this happens, the green light in the switch for that heat zone will go out.
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. Turn main power OFF before filling wet-cup. 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 displacement rod.
Spraying Setup Spraying Setup 1. After reaching spray temperatures, engage gun piston safety lock. 5. Open air inlet ball valve (DD). S DD ti8449a ti2409a 6. Turn both air regulators (AU, AS, page 12) counterclockwise to 0 pressure. 2. Close gun fluid manifold valves A and B. 7. Turn RUN/PARK switch to RUN. 8. Turn Pump Mode Function knob to START. 9. Slowly increase each UP/DN air regulator setting by alternating pattern 5-10 psi (0.035-0.07 MPa, 0.35-0.
Spraying Setup 11. Disengage gun piston safety lock. 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. • Fluid temperature. Effects are similar to when fluid pressure setting is too high or too low. • Mix chamber size.
Shutdown Shutdown 1. Shut off Primary and Hose heat switches. 7. Check and fill wet-cups (AK, Z). 8. Follow gun shutdown procedure. 34!24 /. /&& 2. Park component A pump. Turn PARK/RUN switch to PARK. 3. Follow Pressure Relief procedure; see page 13. 4. Turn Pump Mode Function knob to OFF. 34!24 /. /&& 5. Turn Main Power Disconnect switch (R) OFF. 6. Close air inlet ball valve (DD) and fluid inlet valves (X, U).
Operation Operation Daily Start-up Procedure 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. 11. Turn on primary heater switch past ON to START. Ensure heater setpoint is correct.
Operation 16. Open gun fluid manifold valves A and B. ti2414A 17. Disengage gun piston safety lock. ti2410A 18. Test spray onto cardboard. 19. Observe isocyanate-A and resin-B gauges on up and down strokes. Readjust upstroke pressure regulator as required to ensure proportioning pump pressure is equal on both the up and down strokes. 20. Equipment is ready to spray.
Fluid Circulation Fluid Circulation Circulation Through Reactor Do not turn on hose heat unless hoses are already loaded with fluid. Read Warnings; see page 4. 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 32. 7. Set both Air Regulator pressures to start at 15 psi (1.0 bar). 8. Turn PARK/RUN switch to RUN. 9. Turn Pump Mode Function switch to START. 10.
Fluid Circulation Circulation Through Gun Manifold Read Warnings; see page 4. 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 (FM) on Part 246362 accessory circulation kit (CK). 2. Connect high pressure circulation lines (N) to circulation manifold (CK).
Fluid Circulation 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.
Technical Data Technical Data Category Maximum Fluid Working Pressure Maximum Air Working 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) Overpressure Relief Shutdown Over Temperature Shutdown (Primary Heater) Heater Power Hose Power Sound Pressure Sound
Technical Data 311511G 35
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.
