333023j, reactor 2 e-30 and e-xp2 proportioning systems ... › wp-content › uploads › 2014 ›...

Operation

ReactorReactorReactor 222 E-30E-30E-30 andandand E-XP2E-XP2E-XP2

ProportioningProportioningProportioning SystemsSystemsSystems 333023JEN

Electric,Electric,Electric, Heated,Heated,Heated, PluralPluralPlural ComponentComponentComponent ProportionerProportionerProportioner forforfor sprayingsprayingspraying polyurethanepolyurethanepolyurethane foamfoamfoam andandand polyureapolyureapolyurea coatings.coatings.coatings.NotNotNot forforfor outdooroutdooroutdoor use.use.use. ForForFor professionalprofessionalprofessional useuseuse only.only.only. NotNotNot approvedapprovedapproved forforfor useuseuse ininin explosiveexplosiveexplosive atmospheresatmospheresatmospheres orororhazardoushazardoushazardous locations.locations.locations.

ImportantImportantImportant SafetySafetySafety InstructionsInstructionsInstructionsRead all warnings and instructions in this manual.SaveSaveSave thesethesethese instructions.instructions.instructions.

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PROVEN QUALITY. LEADING TECHNOLOGY.

ContentsContentsContentsWarnings ........................................................... 3Important Isocyanate Information......................... 7Models............................................................... 9Approvals........................................................... 11Accessories........................................................ 11Supplied Manuals ............................................... 12Related Manuals ................................................ 12Typical Installation, without circulation.................. 13Typical Installation, with system fluid manifold

to drum circulation ................................. 14Typical Installation, with gun fluid manifold to

drum circulation..................................... 15Component Identification..................................... 16Advanced Display Module (ADM) ........................ 18

ADM Display Details .................................... 21Navigating the Screens ................................ 21

Electrical Enclosure ............................................ 23Motor Control Module (MCM) .............................. 24Temperature Control Module (TCM) Cable

Connections.......................................... 25Installation.......................................................... 26Setup................................................................. 27

Grounding ................................................... 27General Equipment Guidelines ..................... 27Connect Power ............................................ 28Supply Wet Cups With Throat Seal Liquid

(TSL) ............................................. 29Install Fluid Temperature Sensor .................. 29Connect Heated Hose to Proportioner ........... 30Register and Activate the Graco InSite ........... 30

Advanced Display Module (ADM)Operation.............................................. 31

Advanced Setup Screens.................................... 34Advanced Screen 1 — General..................... 34Advanced Screen 2 — Units ......................... 34Advanced Screen 3 — USB.......................... 34Advanced Screen 4— Software .................... 34

System 1............................................................ 35System 2............................................................ 35Recipes ............................................................. 35

Add Recipe.................................................. 35Enable or Disable Recipes............................ 35

Run Mode .......................................................... 36

Home — System Off .................................... 37Home — System Active................................ 37Home — System With Error.......................... 37Targets........................................................ 37Maintenance................................................ 38Cycles......................................................... 38Events......................................................... 38Errors.......................................................... 38Troubleshooting ........................................... 39Diagnostic ................................................... 40Job Data ..................................................... 40Recipes....................................................... 40

Startup............................................................... 42

Fluid Circulation.................................................. 45Circulation Through Reactor ......................... 45Circulation Through Gun Manifold ................. 46

Jog Mode........................................................... 46

Spraying ............................................................ 47Spray Adjustments....................................... 48

Manual Hose Heat Mode..................................... 49Enable Manual Hose Mode........................... 49Disable Manual Hose Mode.......................... 50

Shutdown........................................................... 51

Pressure Relief Procedure .................................. 53

Flushing ............................................................. 54

Maintenance ...................................................... 55Preventative Maintenance Schedule ............. 55Proportioner Maintenance ............................ 55Flush Inlet Strainer Screen ........................... 56Pump Lubrication System............................. 57

Errors ................................................................ 58View Errors.................................................. 58Troubleshoot Errors ..................................... 58

Troubleshooting.................................................. 59Error Codes and Troubleshooting.................. 59

USB Data........................................................... 60Download Procedure.................................... 60USB Logs.................................................... 60System Configuration Settings ...................... 61Custom Language File ................................. 62Upload Procedure ........................................ 62

Performance Charts............................................ 63

Technical Specifications...................................... 67

Graco Extended Warranty for Reactor® 2Components ......................................... 69

2 333023J

Warnings

WarningsWarningsWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Theexclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specificrisks. When these symbols appear in the body of this manual or on warning labels, refer back to theseWarnings. Product-specific hazard symbols and warnings not covered in this section may appear throughoutthe body of this manual where applicable.

WARNINGWARNINGWARNINGELECTRICELECTRICELECTRIC SHOCKSHOCKSHOCK HAZARDHAZARDHAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system cancause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and beforeservicing or installing equipment.

• Connect only to grounded power source.• All electrical wiring must be done by a qualified electrician and comply with all local codesand regulations.

• Do not expose to rain. Store indoors.

TOXICTOXICTOXIC FLUIDFLUIDFLUID OROROR FUMESFUMESFUMESToxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,inhaled or swallowed.

• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards ofthe fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keep work areawell ventilated and always wear appropriate personal protective equipment. See PersonalPersonalPersonalProtectiveProtectiveProtective EquipmentEquipmentEquipment warnings in this manual.

• Store hazardous fluid in approved containers, and dispose of it according to applicableguidelines.

PERSONALPERSONALPERSONAL PROTECTIVEPROTECTIVEPROTECTIVE EQUIPMENTEQUIPMENTEQUIPMENT

Always wear appropriate personal protective equipment and cover all skin when spraying,servicing equipment, or when in the work area. Protective equipment helps prevent seriousinjury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction;burns; eye injury and hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemicallyimpermeable gloves, protective clothing and foot coverings as recommended by the fluidmanufacturer and local regulatory authority.

• Protective eyewear and hearing protection.

333023J 3

Warnings

WARNINGWARNINGWARNINGSKINSKINSKIN INJECTIONINJECTIONINJECTION HAZARDHAZARDHAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This maylook like just a cut, but it is a serious injury that can result in amputation. GetGetGet immediateimmediateimmediate surgicalsurgicalsurgicaltreatmenttreatmenttreatment.

• Do not spray without tip guard and trigger guard installed.• 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 spray tip.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow the PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure 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.

FIREFIREFIRE ANDANDAND EXPLOSIONEXPLOSIONEXPLOSION HAZARDHAZARDHAZARD

Flammable fumes, such as solvent and paint fumes, in workworkwork areaareaarea can ignite or explode. To helpprevent fire and explosion:

• Use equipment only in well ventilated area.• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, andplastic 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 flammablefumes are present.

• Ground all equipment in the work area. See GroundingGroundingGrounding instructions.• Use only grounded hoses.• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unlessthey are antistatic or conductive.

• StopStopStop operationoperationoperation immediatelyimmediatelyimmediately if static sparking occurs or you feel a shock... Do not useequipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

4 333023J

Warnings

WARNINGWARNINGWARNINGTHERMALTHERMALTHERMAL EXPANSIONEXPANSIONEXPANSION HAZARDHAZARDHAZARD

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressuredue to the thermal expansion. Over-pressurization can result in equipment rupture and seriousinjury.

• Open a valve to relieve the fluid expansion during heating.• Replace hoses proactively at regular intervals based on your operating conditions.

PRESSURIZEDPRESSURIZEDPRESSURIZED ALUMINUMALUMINUMALUMINUM PARTSPARTSPARTS HAZARDHAZARDHAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause seriouschemical reaction and equipment rupture. Failure to follow this warning can result in death,serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbonsolvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your materialsupplier for compatibility.

PLASTICPLASTICPLASTIC PARTSPARTSPARTS CLEANINGCLEANINGCLEANING SOLVENTSOLVENTSOLVENT HAZARDHAZARDHAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause seriousinjury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containingparts.

• See TechnicalTechnicalTechnical DataDataData in this and all other equipment instruction manuals. Read fluid andsolvent manufacturer’s MSDSs and recommendations.

333023J 5

Warnings

WARNINGWARNINGWARNINGEQUIPMENTEQUIPMENTEQUIPMENT MISUSEMISUSEMISUSE HAZARDHAZARDHAZARD

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 ratedsystem component. See TechnicalTechnicalTechnical DataDataData in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Datain all equipment manuals. Read fluid and solvent manufacturer’s warnings. For completeinformation 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 PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure when equipment is not in use.• Check equipment daily. Repair or replace worn or damaged parts immediately with genuinemanufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvalsand create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.• 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.

MOVINGMOVINGMOVING PARTSPARTSPARTS HAZARDHAZARDHAZARD

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 servicingequipment, follow the PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure and disconnect all power sources.

BURNBURNBURN HAZARDHAZARDHAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoidsevere burns:

• Do not touch hot fluid or equipment.

6 333023J

Important Isocyanate Information

ImportantImportantImportant IsocyanateIsocyanateIsocyanate InformationInformationInformationIsocyanates (ISO) are catalysts used in two component materials.

IsocyanateIsocyanateIsocyanate ConditionsConditionsConditions

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, andatomized particulates.

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specifichazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unlessyou are trained, qualified, and have read and understood the information in this manual and in the fluidmanufacturer’s application instructions and SDS.

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, whichcould cause off gassing and offensive odors. Equipment must be carefully maintained and adjustedaccording to instructions in the manual.

• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the workarea must wear appropriate respiratory protection. Always wear a properly fitting respirator, whichmay include a supplied-air respirator. Ventilate the work area according to instructions in the fluidmanufacturer’s SDS.

• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeablegloves, protective clothing and foot coverings as recommended by the fluid manufacturer and localregulatory authority. Follow all fluid manufacturer recommendations, including those regarding handlingof contaminated clothing. After spraying, wash hands and face before eating or drinking.

• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personalprotective equipment must stay out of the work area during application and after application for the timeperiod specified by the fluid manufacturer. Generally this time period is at least 24 hours.

• Warn others who may enter work area of hazard from exposure to isocyanates. Follow therecommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as thefollowing outside the work area is recommended:

333023J 7

Important Isocyanate Information

MaterialMaterialMaterial SelfSelfSelf---IgnitionIgnitionIgnition

Some materials may become self-igniting if appliedtoo thick. Read material manufacturer’s warningsand SDS.

KeepKeepKeep ComponentsComponentsComponents AAA andandand BBB SeparateSeparateSeparate

Cross-contamination can result in curedmaterial in fluid lines which could cause seriousinjury or damage to equipment. To preventcross-contamination:

• NeverNeverNever interchange component A and componentB wetted parts.

• Never use solvent on one side if it has beencontaminated from the other side.

ChangingChangingChanging MaterialsMaterialsMaterials

NOTICENOTICENOTICEChanging the material types used in yourequipment requires special attention to avoidequipment damage and downtime.

• When changing materials, flush the equipmentmultiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers afterflushing.

• Check with your material manufacturer forchemical compatibility.

• When changing between epoxies and urethanesor polyureas, disassemble and clean all fluidcomponents and change hoses. Epoxies oftenhave amines on the B (hardener) side. Polyureasoften have amines on the B (resin) side.

MoistureMoistureMoisture SensitivitySensitivitySensitivity ofofof IsocyanatesIsocyanatesIsocyanates

Exposure to moisture (such as humidity) will causeISO to partially cure, forming small, hard, abrasivecrystals that become suspended in the fluid.Eventually a film will form on the surface and the ISOwill begin to gel, increasing in viscosity.

NOTICENOTICENOTICEPartially cured ISO will reduce performance andthe life of all wetted parts.

• Always use a sealed container with a desiccantdryer in the vent, or a nitrogen atmosphere.NeverNeverNever store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (ifinstalled) filled with appropriate lubricant. Thelubricant creates a barrier between the ISO andthe atmosphere.

• Use only moisture-proof hoses compatible withISO.

• Never use reclaimed solvents, which maycontain moisture. Always keep solventcontainers closed when not in use.

• Always lubricate threaded parts with anappropriate lubricant when reassembling.

NOTE:NOTE:NOTE: The amount of film formation and rate ofcrystallization varies depending on the blend of ISO,the humidity, and the temperature.

FoamFoamFoam ResinsResinsResins withwithwith 245245245 fafafa BlowingBlowingBlowingAgentsAgentsAgents

Some foam blowing agents will froth at temperaturesabove 90°F (33°C) when not under pressure,especially if agitated. To reduce frothing, minimizepreheating in a circulation system.

8 333023J

Models

ModelsModelsModels

ReactorReactorReactor 222 EEE---303030 andandand EEE---303030 EliteEliteElite

All elite systems include fluid inlet sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) heated hose. Forpart numbers, see Accessories, page 11

EEE---303030 ModelModelModel EEE---303030 EliteEliteElite ModelModelModelModelModelModel 101010 kWkWkW 151515 kWkWkW 101010 kWkWkW 15kW15kW15kWProportionerProportionerProportioner ★ 272010 272011 272110 272111MaximumMaximumMaximum FluidFluidFluid WorkingWorkingWorkingPressurePressurePressure psipsipsi (MPa,(MPa,(MPa, bar)bar)bar)

2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 2000 (14, 140)

ApproximateApproximateApproximate OutputOutputOutput perperperCycleCycleCycle (A+B)(A+B)(A+B) gal.gal.gal. (liter)(liter)(liter)

0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034)

MaxMaxMax FlowFlowFlow RateRateRate lb/minlb/minlb/min(kg/min)(kg/min)(kg/min)

30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5)

TotalTotalTotal SystemSystemSystem LoadLoadLoad †††� (Watts)(Watts)(Watts)

17,900 23,000 17,900 23,000

ConfigurableConfigurableConfigurable VoltageVoltageVoltagePhasePhasePhase�

200–240VAC1Ø

200–240VAC3Ø∆

350–415VAC3ØY

200–240VAC1Ø

200–240VAC3Ø∆

350–415VAC3ØY

200–240VAC1Ø

200–240VAC3Ø∆

350–415VAC3ØY

200–240VAC1Ø

200–240VAC3Ø∆

350–415VAC3ØY

FullFullFull LoadLoadLoad PeakPeakPeak Current*Current*Current* 78 50 34 100 62 35 78 50 34 100 62 35

FusionFusionFusion APAPAP PackagePackagePackage �(Gun Part No.)

AP2010(246102)

AH2010(246102)

AP2011(246102)

AH2011(246102)

AP2110(246102)

AH2110(246102)

AP2111(246102)

AH2111(246102)

FusionFusionFusion CSCSCS PackagePackagePackage �(Gun Part No.)

CS2010(CS02RD)

CH2010(CS02RD)

CS2011(CS02RD)

CH2011(CS02RD)

CS2110(CS02RD)

CH2110(CS02RD)

CS2111(CS02RD)

CH2111(CS02RD)

ProblerProblerProbler P2P2P2 PackagePackagePackage �(Gun Part No.)

P22010(GCP2R2)

PH2010(GCP2R2)

P22011(GCP2R2)

PH2011(GCP2R2)

P22110(GCP2R2)

PH2110(GCP2R2)

P22111(GCP2R2)

PH2111(GCP2R2)

24K240 24K240 24K240 24K240 24Y240 24Y240 24Y240 24Y240HeatedHeatedHeated HoseHoseHose505050 ftftft (15(15(15 m)m)m)24K240 (scuff guard)24Y240 (Xtreme-Wrap)

Qty:Qty:Qty: 1 Qty:Qty:Qty: 5 Qty:Qty:Qty: 1 Qty:Qty:Qty: 5 Qty:Qty:Qty: 1 Qty:Qty:Qty: 5 Qty:Qty:Qty: 1 Qty:Qty:Qty: 5

HeatedHeatedHeated WhipWhipWhip HoseHoseHose101010 ftftft (3(3(3 m)m)m)

246050 246050 246050 246050

GracoGracoGraco InsiteInsiteInsite™™™ ✓ ✓FluidFluidFluid InletInletInlet SensorsSensorsSensors (2)(2)(2) ✓ ✓

*** Full load amps with all devices operating atmaximum capabilities. Fuse requirements atvarious flow rates and mix chamber sizes may beless.

� Total system watts used by system, based onmaximum heated hose length for each unit.

• E–30 and E–XP2 series: 310 ft (94.5 m)maximum heated hose length, including whiphose.

★ See Approvals, page 11.

� Packages include gun, heated hose, and whiphose. Elite packages also include Graco InSiteand fluid inlet sensors.

� Low line input voltage will reduce power availableand heaters will not perform at full capacity.

VoltageVoltageVoltage ConfigurationsConfigurationsConfigurations KeyKeyKeyØ Phase∆ DELTAY WYE

333023J 9

Models

ReactorReactorReactor 222 EEE---XP2XP2XP2 andandand EEE---XP2XP2XP2 EliteEliteElite

All elite systems include fluid inlet sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) heated hose. Forpart numbers, see Accessories, page 11

E–XP2E–XP2E–XP2 ModelModelModel E–XP2E–XP2E–XP2 EliteEliteElite ModelModelModelModelModelModel151515 kWkWkW 151515 kWkWkW

ProportionerProportionerProportioner ★ 272012 272112MaximumMaximumMaximum FluidFluidFluid WorkingWorkingWorkingPressurePressurePressure psipsipsi (MPa,(MPa,(MPa, bar)bar)bar)

3500 (24.1, 241) 3500 (24.1, 241)

ApproximateApproximateApproximate OutputOutputOutput perperperCycleCycleCycle (A+B)(A+B)(A+B) gal.gal.gal. (liter)(liter)(liter)

0.0203 (0.0771) 0.0203 (0.0771)

MaxMaxMax FlowFlowFlow Rategpm/minRategpm/minRategpm/min(l/min)(l/min)(l/min)

2 (7.6) 2 (7.6)

TotalTotalTotal SystemSystemSystem LoadLoadLoad ††† � (Watts)(Watts)(Watts)

23,000 23,000

ConfigurableConfigurableConfigurable VoltageVoltageVoltagePhasePhasePhase �

200–240VAC 1Ø

200–240VAC 3Ø∆

350–415VAC 3ØY

200–240VAC 1Ø

200–240VAC 3Ø∆

350–415VAC 3ØY

FullFullFull LoadLoadLoad PeakPeakPeak CurrentCurrentCurrent(amps)(amps)(amps)

100 62 35 100 62 35

FusionFusionFusion APAPAP PackagePackagePackage �(Gun Part No.)

AP2012(246100)

AP2112(246100)

ProblerProblerProbler P2P2P2 PackagePackagePackage �(Gun Part No.)

P22012(GCP2R0)

P22112(GCP2R0)

HeatedHeatedHeated HoseHoseHose505050 ftftft (15(15(15 m)m)m)

24K241(scuff guard)

24Y241(Xtreme-Wrap)

HeatedHeatedHeated WhipWhipWhip HoseHoseHose101010 ftftft (3(3(3 m)m)m)

246055 246055

GracoGracoGraco InsiteInsiteInsite™™™ ✓FluidFluidFluid InletInletInlet SensorsSensorsSensors (2)(2)(2) ✓

*** Full load amps with all devices operating atmaximum capabilities. Fuse requirementsat various flow rates and mix chamber sizesmay be less.

� Total system watts used by system, based onmaximum heated hose length for each unit.

• E–30 and E–XP2 series: 310 ft (94.5 m)maximum heated hose length, includingwhip hose.

★ See Approvals, page 11.

� Packages include gun, heated hose, andwhip hose. Elite packages also includeGraco InSite and fluid inlet sensors.

� Low line input voltage will reduce poweravailable and heaters will not perform at fullcapacity.

VoltageVoltageVoltage ConfigurationsConfigurationsConfigurations KeyKeyKeyØ Phase∆ DELTAY WYE

10 333023J

Approvals

ApprovalsApprovalsApprovalsIntertek approvals apply to proportioners withouthoses.

ProportionerProportionerProportioner Approvals:Approvals:Approvals:

990247199024719902471

Conforms to ANSI/UL Std. 499Certified to CAN/CSA Std. C22.2 No. 88

AccessoriesAccessoriesAccessoriesKitKitKit NumberNumberNumber DescriptionDescriptionDescription

24U315 Air Manifold Kit (4 outlets)

24U314 Wheel and Handle Kit

24T280 Graco InSite Kit

16X521 Graco InSite Extension cable 24.6 ft(7.5 m)

24N449 50 ft (15 m) CAN cable (for remotedisplay module)

24K207 Fluid Temperature Sensor (FTS)with RTD

24U174 Remote Display Module Kit

15V551 ADM Protective Covers (10 pack)

15M483 Remote Display Module ProtectiveCovers (10 pack)

24M174 Drum Level Sticks

121006 150 ft (45 m) CAN cable (for remotedisplay module)

24N365 RTD Test Cables (to aide resistancemeasurements)

333023J 11

Supplied Manuals

SuppliedSuppliedSupplied ManualsManualsManualsThe following manuals are shipped with the Reactor2. Refer to these manuals for detailed equipmentinformation.

Manuals are also available at www.graco.com.ManualManualManual DescriptionDescriptionDescription333023 Reactor 2 E-30 and E-XP2

Operation333091 Reactor 2 E-30 and E-XP2 Startup

Quick Guide333092 Reactor 2 E-30 and E-XP2

Shutdown Quick Guide

RelatedRelatedRelated ManualsManualsManualsThe following manuals are for accessories used withthe Reactor.

ComponentComponentComponent ManualsManualsManuals ininin English:English:English:

Manuals are available at www.graco.com.SystemSystemSystem ManualsManualsManuals333024 Reactor 2 E-30 and E-XP2,

Repair-PartsDisplacementDisplacementDisplacement PumpPumpPump ManualManualManual309577 Electric Reactor Displacement Pump,

Repair-PartsFeedFeedFeed SystemSystemSystem ManualsManualsManuals309572 Heated Hose, Instructions-Parts309852 Circulation and Return Tube Kit,

Instructions-Parts309815 Feed Pump Kits, Instructions-Parts309827 Feed Pump Air Supply Kit,

Instructions-PartsSpraySpraySpray GunGunGun ManualsManualsManuals309550 Fusion ™ AP Gun312666 Fusion ™ CS Gun313213 Probler® P2 GunAccessoryAccessoryAccessory ManualsManualsManuals3A1905 Feed Pump Shutdown Kit,

Instructions-Parts3A1906 Light Tower Kit, Instructions-Parts3A1907 Remote Display Module Kit,

Instructions-Parts332735 Air Manifold Kit, Instructions-Parts332736 Handle and Wheel Kit,

Instructions-Parts333276 Graco InSite ™ Kit, Instructions-Parts

12 333023J

Typical Installation, without circulation

TypicalTypicalTypical Installation,Installation,Installation, withoutwithoutwithout circulationcirculationcirculation

��

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B

G

KM

JG

H

K

L

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D

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P

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(RES)

(ISO)

Figure 1

* Shown exposed for clarity. Wrap with tape during operation.A Reactor ProportionerB Heated HoseC Fluid Temperature Sensor (FTS)D Heated Whip HoseE Fusion Spray GunF Gun Air Supply HoseG Feed Pump Air Supply LinesH Agitator Air Supply Line

J Fluid Supply LinesK Feed PumpsL AgitatorM Desiccant DryerN Bleed LinesP Gun Fluid Manifold (part of gun)S Remote Display Module Kit (optional)

333023J 13

Typical Installation, with system fluid manifold to drum circulation

TypicalTypicalTypical Installation,Installation,Installation, withwithwith systemsystemsystem fluidfluidfluid manifoldmanifoldmanifold tototo drumdrumdrumcirculationcirculationcirculation

(RES)

M

K

M

R

J

GH K

L

��

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Figure 2

* Shown exposed for clarity. Wrap with tape during operation.A Reactor ProportionerB Heated HoseC Fluid Temperature Sensor (FTS)D Heated Whip HoseE Fusion Spray GunF Gun Air Supply HoseG Feed Pump Air Supply LinesH Agitator Air Supply Line

J Fluid Supply LinesK Feed PumpsL AgitatorM Desiccant DryerP Gun Fluid Manifold (part of gun)R Recirculation LinesS Remote Display Module (optional)

14 333023J

Typical Installation, with gun fluid manifold to drum circulation

TypicalTypicalTypical Installation,Installation,Installation, withwithwith gungungun fluidfluidfluid manifoldmanifoldmanifold tototo drumdrumdrumcirculationcirculationcirculation

(RES)

M

KM

R

J

GH K

L

B

J

D

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C* P

RA

(ISO)F

N

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Figure 3

* Shown exposed for clarity. Wrap with tape during operation.A Reactor ProportionerB Heated HoseC Fluid Temperature Sensor (FTS)CK Circulation Block (accessory)D Heated Whip HoseF Gun Air Supply HoseG Feed Pump Air Supply LinesH Agitator Air Supply Line

J Fluid Supply LinesK Feed PumpsL AgitatorM Desiccant DryerP Gun Fluid Manifold (part of gun)R Recirculation LinesS Remote Display Module (optional)

333023J 15

Component Identification

ComponentComponentComponent IdentificationIdentificationIdentification

BD

S

C*

P

E

Figure 4

16 333023J

Component Identification

KeyKeyKeyBA ISO Side Pressure Relief OutletBB RES Side Pressure Relief Outlet

CD Advanced Display Module (ADM)DG Drive Gear HousingEC Electrical Cord Strain ReliefEM Electric MotorFA ISO Side Fluid Manifold InletFB RES Side Fluid Manifold InletFH Fluid Heaters (behind shroud)FM Reactor Fluid ManifoldFV Fluid Inlet Valve (RES side shown)GA ISO Side Pressure GaugeGB RES Side Pressure GaugeHA ISO Side Hose ConnectionHB RES Side Hose ConnectionMP Main Power SwitchPA ISO Side PumpPB RES Side PumpRR Graco InSite Cellular Module (Elite models

only)

RS Red Stop ButtonSA ISO Side PRESSURE RELIEF/SPRAY

ValveSB RES Side PRESSURE RELIEF/SPRAY

ValveT Heated Hose Power Termination BoxTA ISO Side Pressure Transducer (behind

gauge GA)TB RES Side Pressure Transducer (behind

gauge GB)XA Fluid Inlet Sensor (ISO side, Elite models

only)XB Fluid Inlet Sensor (RES side, Elite models

only)

333023J 17

Advanced Display Module (ADM)

AdvancedAdvancedAdvanced DisplayDisplayDisplay ModuleModuleModule (ADM)(ADM)(ADM)The ADM display shows graphical and textinformation related to setup and spray operations.

NOTICENOTICENOTICETo prevent damage to the softkey buttons, do notpress buttons with sharp objects such as pens,plastic cards, or fingernails.

Figure 5 Front View

18 333023J


TableTableTable 111 ::: ADMADMADM KeysKeysKeys andandand IndicatorsIndicatorsIndicators

KeyKeyKey FunctionFunctionFunction

Startup/ShutdownStartup/ShutdownStartup/ShutdownKeyKeyKey andandand IndicatorIndicatorIndicator

Press to startup or shutdown the system.

StopStopStop

Press to stop all proportioner processes. This Is not a safety or emergency stop.

SoftSoftSoft KeysKeysKeys

Press to select the specific screen or operation shown on the display directly next toeach key.

NavigationNavigationNavigation KeysKeysKeys

• Left/Right Arrows: Use to move from screen to screen.

• Up/Down Arrows: Use to move among fields on a screen, items on a dropdownmenu, or multiple screens within a function.

NumericNumericNumeric KeypadKeypadKeypad Use to input values.

CancelCancelCancel

Use to cancel a data entry field.

SetupSetupSetup

Press to enter or exit Setup mode.

EnterEnterEnter

Press to choose a field to update, to make a selection, to save a selection or value, toenter a screen, or to acknowledge an event.

333023J 19


Figure 6 Back ViewCJ Flat Panel Mount (VESA 100)CK Model and Serial NumberCL USB Port and Status LEDsCM CAN Cable Connection

CN Module Status LEDsCP Accessory Cable ConnectionCR Token Access CoverCS Battery Access Cover

TableTableTable 222 ADMADMADM LEDLEDLED StatusStatusStatus DescriptionsDescriptionsDescriptions

LEDLEDLED ConditionsConditionsConditions DescriptionDescriptionDescription

Green Solid Run Mode, System On

Green Flashing Setup Mode, System On

Yellow Solid Run Mode, System Off

SystemSystemSystem StatusStatusStatus

Yellow Flashing Setup Mode, System Off

Green Flashing Data recording in progress

Yellow Solid Downloading information to USB

USBUSBUSB StatusStatusStatus (CL)(CL)(CL)

Green and Yellow Flashing ADM is busy, USB cannot transferinformation when in this mode

Green Solid Power applied to module

Yellow Solid Active Communication

Red Steady Flashing Software upload from token inprogress

ADMADMADM StatusStatusStatus (CN)(CN)(CN)

Red Random Flashing or Solid Module error exists

20 333023J


ADMADMADM DisplayDisplayDisplay DetailsDetailsDetails

PowerPowerPower UpUpUp ScreenScreenScreenThe following screen appears when the ADM ispowered up. It remains on while the ADM runs throughinitialization and establishes communication with othermodules in the system.

MenuMenuMenu BarBarBarThe menu bar appears at the top of each screen. (Thefollowing image is only an example.)

DateDateDate andandand TimeTimeTime

The date and time are always displayed in one of thefollowing formats. The time is always displayed as a24-hour clock.

• DD/MM/YY HH:MM

• YY/MM/DD HH:MM

• MM/DD/YY HH:MM

ArrowsArrowsArrows

The left and right arrows indicate screen navigation.

ScreenScreenScreen MenuMenuMenu

The screen menu indicates the currently active screen,which is highlighted. It also indicates the associatedscreens that are available by scrolling left and right.

SystemSystemSystem ModeModeMode

The current system mode is displayed at the lower leftof the menu bar.

Alarm/DeviationAlarm/DeviationAlarm/Deviation

The current system error is displayed in the middle ofthe menu bar. There are four possibilities:

IconIconIcon FunctionFunctionFunctionNo Icon No information or no error has occurred

Advisory

Deviation

Alarm

StatusStatusStatus

The current system status is displayed at the lower rightof the menu bar.

SoftSoftSoft KeysKeysKeysIcons next to the soft keys indicate which mode oraction is associated with each soft key. Soft keys thatdo not have an icon next to them are not active in thecurrent screen.

NOTICENOTICENOTICETo prevent damage to the soft key buttons, do notpress buttons with sharp objects such as pens, plasticcards, or fingernails.

NavigatingNavigatingNavigating thethethe ScreensScreensScreens

There are two sets of screens:

• The Run screens control spraying operations anddisplay system status and data.

• The Setup screens control system parameters andadvanced features.

Press on any Run screen to enter the Setupscreens. If the system has a password lock, thePassword screen displays. If the system is not locked(password is set to 0000), System Screen 1 displays.

Press on any Setup screen to return to theHome screen.

Press the Enter soft key to activate the editingfunction on any screen.

Press the Exit soft key to exit any screen.

Use the other softkeys to select the function adjacentto them.

333023J 21


IconsIconsIconsIconsIconsIcons

IconIconIcon FunctionFunctionFunction

Component A

Component B

Estimated Supply Material

Hose Temperature

Jog Mode Speed

Pressure

Cycle Counter (press andhold)

Advisory.See Errors, page 38 for moreinformation.

Deviation.See Errors, page 38 for moreinformation

Alarm.See Errors, page 38 for moreinformation

SoftkeysSoftkeysSoftkeys

IconIconIcon FunctionFunctionFunction

Start Proportioner

Start and Stop Proportioner in Jog Mode

Stop Proportioner

Turn on or off the specified heat zone.

Park pump

Enter Jog Mode. See Jog Mode, page 46

Reset Cycle Counter(press and hold)

Select Recipe

Search

Move Cursor Left One Character

Move Cursor Right One Character

Toggle between upper-case, lower-case, andnumbers and special characters.

Backspace

Cancel

Clear

Troubleshoot Selected Error

Increase value

Decrease value

Next screen

Previous screen

Return to first screen

22 333023J

Electrical Enclosure

ElectricalElectricalElectrical EnclosureEnclosureEnclosureAAA Temperature Control Module (TCM)

AAB Motor Control Module (MCM)

AAC Enclosure Fan

AAD Wiring Terminal Blocks

AAE Power Supply

AAF Surge Protector

AAG Hose Breaker

AAH Motor Breaker

AAJ A Side Heat Breaker

AAK B Side Heat Breaker

AAL Transformer Breaker

MP Main Power Switch

333023J 23

Motor Control Module (MCM)

MotorMotorMotor ControlControlControl ModuleModuleModule (MCM)(MCM)(MCM)

BaseBaseBase ModelModelModel EliteEliteElite ModelModelModel

Figure 7DescriptionDescriptionDescription

MS Module Status LEDs see LED Status Table1 CAN Communication Connections2 Motor Temperature3 Not used4 Not used5 Not used6 A Pump Output Pressure7 B Pump Output Pressure8 A Fluid Inlet Sensor (Elite only)9 B Fluid Inlet Sensor (Elite only)

10 Accessory output11 Not used12 Pump Cycle Counter14 Graco Insite™

15 Motor Power Output16 Main Power Input***RS Rotary Switch

*** MCMMCMMCM RotaryRotaryRotary SwitchSwitchSwitch PositionsPositionsPositions

2=E-30

3=E-XP2

TableTableTable 333 MCMMCMMCM ModuleModuleModule LEDLEDLED (MS)(MS)(MS) StatusStatusStatus DescriptionsDescriptionsDescriptions



Yellow Flashing Active Communication


MCMMCMMCM StatusStatusStatus


24 333023J

Temperature Control Module (TCM) Cable Connections

TemperatureTemperatureTemperature ControlControlControl ModuleModuleModule (TCM)(TCM)(TCM) CableCableCable ConnectionsConnectionsConnections

Figure 81 Power Input2 Heater Overtemperature3 CAN Communications Connections4 Power Out (ISO)5 Power Out (Res)6 Power Out (Hose)7 Module Status LEDs8 Heater A Temperature (ISO)9 Heater B Temperature (RES)10 Hose Temperature

TableTableTable 444 TCMTCMTCM ModuleModuleModule LEDLEDLED (7)(7)(7) StatusStatusStatus DescriptionsDescriptionsDescriptions



Yellow Flashing Active Communication


TCMTCMTCM StatusStatusStatus


333023J 25

Installation

InstallationInstallationInstallationSetupSetupSetup FromFromFrom ShippingShippingShipping ConfigurationConfigurationConfiguration

1. Remove bolts (A) and nuts.

2. Swing up the electrical enclosure and reinstallbolt (A) with nut. Tighten bolt (B) and nut.

3. Position cable bundles against the frame andattach to the frame with loose wire tie (C) oneach side.

To prevent serious injury due to system tippingover, ensure Reactor is properly secured to wall.

Note

Mounting brackets and bolts are included in the boxof loose parts, shipped with your system.

1. Use the supplied bolts to install the suppliedL-brackets onto the system frame in the top-mostsquare holes. Install brackets on both the leftand right side of system frame.

2. Secure the L-brackets to the wall. If L-bracketsdo not line up with the wall stud spacing, bolt apiece of wood to the studs then secure L-bracketsto wood.

3. Use the four holes in the base of the systemframe to secure base to the floor. Bolts notsupplied.

26 333023J

Setup

SetupSetupSetup

GroundingGroundingGrounding

The equipment must be grounded to reduce therisk of static sparking. Static sparking can causefumes to ignite or explode. Grounding provides anescape wire for the electric current.

• Reactor: System is grounded through the powercord.

• Spray gun: connect whip hose ground wire to FTS.See Install Fluid Temperature Sensor, page 29.Do not disconnect ground wire or spray withoutwhip hose.

• Fluid supply containers: follow your local code.

• Object being sprayed: follow your local code.

• Solvent pails used when flushing: follow your localcode. Use only metal pails, which are conductive,placed on a grounded surface. Do not place pailon a nonconductive surface, such as paper orcardboard, which interrupts grounding continuity.

• To maintain grounding continuity when flushing orrelieving pressure, hold a metal part of spray gunfirmly to the side of a grounded metal pail, thentrigger gun.

GeneralGeneralGeneral EquipmentEquipmentEquipment GuidelinesGuidelinesGuidelines

• Determine the correct size generator. Using thecorrect size generator and proper air compressorwill enable the proportioner to run at a nearlyconstant RPM. Failure to do so will cause voltagefluctuations that can damage electrical equipment.

Use the following procedure to determine the correctsize generator.

1. List system components that use peak loadrequirements in watts.

2. Add the wattage required by the systemcomponents.

3. Perform the following equation:Total watts x 1.25 = kVA (kilovolt-amperes)

4. Select a generator size that is equal to or greaterthan the determined kVA.

• Use proportioner power cords that meet or exceedthe requirements listed in Table 5. Failure to do sowill cause voltage fluctuations that can damageelectrical equipment.

• Use an air compressor with continuous run headunloading devices. Direct online air compressorsthat start and stop during a job will cause voltagefluctuations that can damage electrical equipment.

• Maintain and inspect the generator, aircompressor, and other equipment per themanufacturer recommendations to avoid anunexpected shutdown. Unexpected equipmentshutdown will cause voltage fluctuations that candamage electrical equipment.

• Use a wall power supply with enough currentto meet system requirements. Failure to do sowill cause voltage fluctuations that can damageelectrical equipment.

333023J 27

Setup

ConnectConnectConnect PowerPowerPower

All electrical wiring must be done by a qualifiedelectrician and comply with all local codes andregulations.

1. Turn main power switch (MP) OFF.

2. Open electrical enclosure door.

NOTE:NOTE:NOTE: Terminal jumpers are located inside theelectrical enclosure door.

3. Install supplied terminal jumpers in the positionsshown in image for the power source used.

4. Route power cable through strain relief (EC) inelectrical enclosure.

5. Connect incoming power wires as shown inimage. Gently pull on all connections to verifythey are properly secured.

6. Verify all items are connected properly as shownin image then close electrical enclosure door.

TableTableTable 555 PowerPowerPower CordCordCord RequirementsRequirementsRequirements

ModelModelModel InputInputInput PowerPowerPower CordCordCordSpecifications*Specifications*Specifications*AWGAWGAWG (mm(mm(mm222)))

200–240 VAC, 1Phase

4 (21.2), 2 wire +ground/PE

200–240 VAC, 3Phase, DELTA


E-30,10 kW

350–415 VAC, 3Phase, WYE






E-30,15 kW



ModelModelModel InputInputInput PowerPowerPower CordCordCordSpecifications*Specifications*Specifications*AWGAWGAWG (mm(mm(mm222)))





E-XP2,15 kW



* Values are for reference only. Refer to amperagelisted in Models table (see Models, page 9 ) for givensystem and compare against latest version of localelectrical code to select proper power cord size.

NOTE:NOTE:NOTE: 350–415 VAC systems are not designed tooperate from 480 VAC power source.

28 333023J

Setup

SupplySupplySupply WetWetWet CupsCupsCups WithWithWith ThroatThroatThroat SealSealSealLiquidLiquidLiquid (TSL)(TSL)(TSL)

Pump rod and connecting rod move duringoperation. Moving parts can cause serious injurysuch as pinching or amputation. Keep hands andfingers away from wet-cup during operation.

To prevent the pump from moving, turn the mainpower switch OFF.

• ComponentComponentComponent AAA (ISO)(ISO)(ISO) Pump:Pump:Pump: Keep reservoir (R) filledwith Graco Throat Seal Liquid (TSL), Part 206995.Wet-cup piston circulates TSL through wet-cup, tocarry away isocyanate film on displacement rod.

Figure 9 Component A Pump

• ComponentComponentComponent BBB (Resin)(Resin)(Resin) Pump:Pump:Pump: Check felt washersin packing nut/wet-cup (S) daily. Keep saturatedwith Graco Throat Seal Liquid (TSL), Part No.206995, to prevent material from hardening ondisplacement rod. Replace felt washers when wornor contaminated with hardened material.

Figure 10 Component B Pump

InstallInstallInstall FluidFluidFluid TemperatureTemperatureTemperature SensorSensorSensor

The Fluid Temperature Sensor (FTS) is supplied.Install FTS between main hose and whip hose. SeeHeated Hose manual for instructions.

333023J 29

Setup

ConnectConnectConnect HeatedHeatedHeated HoseHoseHose tototo ProportionerProportionerProportioner

See the heated hose manual for detailed instructions.

1. For proportioners with termination box (TB):

a. Connect hose power wires to terminal block(T) on termination box (TB). Remove boxcover and loosen lower strain relief (E).Route hose wires (V) through the box strainrelief and fully insert into terminal block (T). Aand B hose wire positions are not important.Torque to 35–50 in-lb (4.0–5.6 N·m).

b. Fully tighten strain relief screws and replacecover.

Figure 11 Termination Box

2. For proportioners with electrical splice connectors(S):

a. Connect hose power wires to electrical spliceconnectors (S) from proportioner. Wrapconnections with electrical tape.

Figure 12 Electrical Splice Connectors

3. Connect FTS cable connectors (R). Fully tightenRTD connectors, if provided.

RegisterRegisterRegister andandand ActivateActivateActivate thethethe GracoGracoGraco InSiteInSiteInSite

Note

Elite systems only.

1. Go to www.GracoInSite.com, then follow theinstructions on the screen.

2. Find and record the 15 digit serial number fromthe cellular module below.

30 333023J

Advanced Display Module (ADM) Operation

AdvancedAdvancedAdvanced DisplayDisplayDisplay ModuleModuleModule (ADM)(ADM)(ADM) OperationOperationOperation

When main power is turned on by turning the mainpower switch (MP) to the ON position, the power upscreen will be displayed until communication andinitialization is complete.

Then the power key icon screen will display until the

ADM power on/off button (A) is pressed for thefirst time after system power-up.

To begin using the ADM, the machine must be active.To verify the machine is active, verify that the SystemStatus Indicator Light (B) is illuminated green, seeAdvanced Display Module (ADM), page 18. If theSystem Status Indicator Light is not green, press

the ADM Power On/Off (A) button . The SystemStatus Indicator Light will illuminate yellow if themachine is disabled.

Perform the following tasks to fully setup your system.

1. Set pressure values for the Pressure ImbalanceAlarm to activate. See System Screen 1, page 35.

2. Enter, enable, or disable recipes. SeeRecipes Screen, page 35.

3. Set general system settings. SeeAdvanced Screen 1 — General, page 34.

4. Set units of measure. SeeAdvanced Screen 2 — Units, page 34.

5. Set USB settings. SeeAdvanced Screen 3— USB, page 34.

6. Set target temperatures and pressure. SeeTargets, page 37.

7. Set component A and component B supplylevels. See Maintenance, page 38.

333023J 31


SetupSetupSetup ModeModeMode

The ADM will start in the Run screens at the Home screen. From the Run screens, press toaccess the Setup screens. The system defaults with no password, entered as 0000. Enter the

current password then press . Press to navigate through the Setup Mode screens. SeeSetup Screens Navigation Diagram, page 45.

SetSetSet PasswordPasswordPassword

Set a password to allow Setup screen access, see Advanced Screen 1 – General, page 34. Enter any numberfrom 0001 to 9999. To remove the password, enter the current password in the Advanced Screen – Generalscreen and change the password to 0000.

From the Setup screens, press to return to the Run screens.

32 333023J


Setup Screens Navigation DiagramFigure 13

333023J 33

Advanced Setup Screens

AdvancedAdvancedAdvanced SetupSetupSetup ScreensScreensScreensAdvanced setup screens enable users to set units, adjust values, set formats, and view software information

for each component. Press to scroll through the Advanced setup screens, Once in the desired

Advanced setup screen, press to access the fields and make changes. When changes are complete press

to exit edit mode.

Note

Users must be out of edit mode to scrollthrough the Advanced setup screens.

AdvancedAdvancedAdvanced ScreenScreenScreen 111 ——— GeneralGeneralGeneral

Use this screen to set the language, date format,current date, time, setup screens password (0000 –for none) or (0001 to 9999), and screen saver delay.

AdvancedAdvancedAdvanced ScreenScreenScreen 222 ——— UnitsUnitsUnits

Use this screen to set the temperature units, pressureunits, volume units, and cycle units (pump cycles orvolume).

AdvancedAdvancedAdvanced ScreenScreenScreen 333 ——— USBUSBUSB

Use this screen to enable USB downloads/uploads,enable a logs 90% full advisory, enter the maximumnumber of days to download data, enable specifyingdate range of data to download, and how frequentlyUSB logs are recorded. See USB Data, page 60.

AdvancedAdvancedAdvanced ScreenScreenScreen 4—4—4— SoftwareSoftwareSoftware

This screen displays the software part number andsoftware version for the Advanced Display Module,USB Configuration, Motor Control Module, andTemperature Control Modules.

34 333023J

System 1

SystemSystemSystem 111Use this screen to set the activation pressure for thePressure Imbalance Alarm and Deviation, enable ordisable diagnostic screens, set the maximum andminimum drum volume, and enable drum alarms.

SystemSystemSystem 222Use this screen to enable Manual Hose Mode andinlet sensors, as well as setting the inlet sensorlow pressure alarm and low temperature deviation.Manual Hose Mode disables the hose temperatureRTD sensor so the system can operate if the sensorswere to malfunction. Default settings are 10 psi (0.07MPa, 0.7 bar) for low inlet pressure alarm and 50˚F(10˚C) for low inlet temperature deviation.

RecipesRecipesRecipesUse this screen to add recipes, view saved recipes,and enable or disable saved recipes. Enabledrecipes can be selected at the Home Run Screen. 24recipes can displayed on the three recipe screens.

AddAddAdd RecipeRecipeRecipe

1. Press and then use to select arecipe field. Press to enter a recipe name

(maximum 16 characters). Press to clear theold recipe name.

2. Use to highlight the next field and use the

number pad to enter a value. Press to save.

EnableEnableEnable ororor DisableDisableDisable RecipesRecipesRecipes

1. Press and then use to select therecipe that needs to be enabled or disabled.

2. Use to highlight the enabled check box.

Press to enable or disable the recipe.

333023J 35

Run Mode

RunRunRun ModeModeMode

The ADM will start in the Run screens at the “Home” screen. Press to navigate through the Run Modescreens. See Run Screens Navigation Diagram, page 44.

From the Run screens, press

to access the Setup screens.

Run Screens Navigation DiagramFigure 14

36 333023J

Run Mode

HomeHomeHome ——— SystemSystemSystem OffOffOff

This is the home screen when the system is off.This screen displays actual temperatures, actualpressures at the fluid manifold, jog speed, coolanttemperature, and number of cycles.

HomeHomeHome ——— SystemSystemSystem ActiveActiveActive

When the system is active, the home screen displaysactual temperature for heat zones, actual pressuresat the fluid manifold, coolant temperature, jog speed,the number of cycles, along with all associatedcontrol soft keys.

Use this screen to turn on heat zones, viewcoolant temperature, start the proportioner, stop theproportioner, park the component A pump, enter jogmode, and clear cycles.

NOTE:NOTE:NOTE: Screen shown displays inlet sensortemperatures and pressures. These will not beshown on models without inlet sensors.

HomeHomeHome ——— SystemSystemSystem WithWithWith ErrorErrorError

Active errors are shown in the status bar. The errorcode, alarm bell, and description of the error willscroll in the status bar.

1. Press to acknowledge the error.

2. See Troubleshooting, page 59 for correctiveaction.

TargetsTargetsTargets

Use this screen to define the setpoints for theA Component Temperature, B ComponentTemperature, heated hose temperature, andpressure.

MaximumMaximumMaximum AAA andandand BBB temperature:temperature:temperature: 190°F (88°C)

MaximumMaximumMaximum heatedheatedheated hosehosehose temperature:temperature:temperature: 10°F (5°C)above the highest A or B temperature setpoint or180°F (82°C).

Note

If the remote display module kit is used,these setpoints can be modified at the gun.

333023J 37

Run Mode

MaintenanceMaintenanceMaintenance

Use this screen to view daily and lifetime cycles orgallons that have been pumped and gallons or litersremaining in the drums.

The lifetime value is the number of pump cycles orgallons since the first time the ADM was turned on.

The daily value automatically resets at midnight.

The manual value is the counter that can be manually

reset. Press and hold to reset manual counter.

CyclesCyclesCycles

This screen shows daily cycles and gallons that havebeen sprayed for the day.

All information listed on this screen can bedownloaded on a USB flash drive.

EventsEventsEvents

This screen shows the date, time, event code, anddescription of all events that have occurred onthe system. There are 10 pages, each holding 10events. The 100 most recent events are shown. SeeSystem Eventsfor event code descriptions.See Error Codes and Troubleshooting, page 59 forerror code descriptions.

All events and errors listed on this screen can bedownloaded on a USB flash drive. To download logs,see Download Procedure, page 60.

ErrorsErrorsErrors

This screen shows the date, time, error code, anddescription of all errors that have occurred on thesystem.

All errors listed on this screen can be downloaded ona USB flash drive.

38 333023J

Run Mode

TroubleshootingTroubleshootingTroubleshooting

This screen displays the last ten errors thatoccurred on the system. Use the up and down

arrows to select an error and press to view

the QR code for the selected error. Pressto access the QR code screen for an errorcode that is not listed on this screen. SeeError Codes and Troubleshooting, page 59, for moreinformation on error codes.

QRQRQR CodesCodesCodes

To quickly view online help for a given error code,scan the displayed QR code with your smartphone.Alternately, visit http://help.graco.com and search forthe error code to view online help for that code.

333023J 39

Run Mode

DiagnosticDiagnosticDiagnostic

Use this screen to view information for all systemcomponents.

The following information is displayed:

TemperatureTemperatureTemperature• A Chemical• B Chemical• Hose Chemical• TCM PCB — temperature control moduletemperature

AmpsAmpsAmps• A Current (0–25 A for 10kW heater, 0–38 A for15 kW heater)

• B Current (0–25 A for 10kW heater, 0–38 A for15 kW heater)

• Hose Current (0–45 A typical)

VoltsVoltsVolts• MCM Bus — displays the voltage supplied to themotor controller, which is the DC voltage that hasbeen converted from the AC voltage supplied tothe system (275–400 VAC typical full range)

• Hose Voltage (90V)

PressurePressurePressure• Pressure A — chemical• Pressure B — chemical

CyclesCyclesCycles• CPM — cycles per minute• Total Cycles — lifetime cycles

Note

Maximum values based on maximum inputvoltage. Values will lower with lower inputvoltage.

JobJobJob DataDataData

Use this screen to enter a job name or number.

RecipesRecipesRecipes

Use this screen to select an enabled recipe. Use theup and down arrows to highlight a recipe and press

to load. The currently loaded recipe is outlinedby a green box.

Note

This screen will not display if there are notany enabled recipes. To enable or disablerecipes, see Recipes Setup Screen, page 35.

40 333023J

Run Mode

SystemSystemSystem EventsEventsEventsUse the table below to find a description for all system non-error events. All events are logged in the USBlog files.EventEventEvent CodeCodeCode DescriptionDescriptionDescription

EACX Recipe SelectedEADA Heat On AEADB Heat On BEADH Heat On HoseEAPX Pump OnEARX Jog OnEAUX USB Drive InsertedEB0X ADM Red Stop Button PressedEBDA Heat Off AEBDB Heat Off BEBDH Heat Off HoseEBPX Pump OffEBRX Jog OffEBUX USB Drive RemovedEC0X Setup Value ChangedECDA A Temperature Setpoint ChangedECDB B Temperature Setpoint ChangedECDH Hose Temperature Setpoint ChangedECDP Pressure Setpoint ChangedECDX Recipe ChangedEL0X System Power OnEM0X System Power OffEP0X Pump ParkedEQU1 System Settings DownloadedEQU2 System Settings UploadedEQU3 Custom Language DownloadedEQU4 Custom Language UploadedEQU5 Logs DownloadedER0X User Counter ResetEVUX USB Disabled

333023J 41

Startup

StartupStartupStartup

To prevent serious injury, only operate Reactorwith all covers and shrouds in place.

NOTICENOTICENOTICEProper system setup, startup, and shutdownprocedures are critical to electrical equipmentreliability. The following procedures ensure steadyvoltage. Failure to follow these procedures willcause voltage fluctuations that can damageelectrical equipment and void the warranty.

1. CheckCheckCheck fluidfluidfluid inletinletinlet filterfilterfilter screens.screens.screens.

Before daily startup, ensure that thefluid inlet screens are clean. SeeFlush Inlet Strainer Screen, page 56

2. CheckCheckCheck ISOISOISO lubricationlubricationlubrication reservoir.reservoir.reservoir.

Check level and condition of ISO lube daily. SeePump Lubrication System, page 57.

3. Use A and B Drum Level Sticks (24M174) tomeasure the material level in each drum.. If

desired, the level can be entered and tracked inthe ADM. See Advanced Setup Screens, page 34.

4. CheckCheckCheck generatorgeneratorgenerator fuelfuelfuel level.level.level.

NOTICENOTICENOTICERunning out of fuel will cause voltagefluctuations that can damage electricalequipment and void the warranty. Do not runout of fuel.

5. ConfirmConfirmConfirmmainmainmain powerpowerpower switchswitchswitch isisis OFFOFFOFF beforebeforebefore startingstartingstartinggenerator.generator.generator.

6. Ensure the main breaker on the generator is inthe off position.

7. Start the generator. Allow it to reach full operatingtemperature.

8. TurnTurnTurn mainmainmain powerpowerpower switchswitchswitch ON.ON.ON.

The ADM will display the following screen untilcommunication and initialization is complete.

42 333023J

Startup

9. Switch on the air compressor, air dryer, andbreathing air, if included.

10. ForForFor firstfirstfirst startupstartupstartup ofofof newnewnew system,system,system, loadloadload fluidfluidfluid withwithwithfeedfeedfeed pumps.pumps.pumps.

a. Check that all SetupSetupSetup steps are complete.See Setup, page 27.

b. If an agitator is used, open the agitator’s airinlet valve.

c. If you need to circulate fluid through thesystem to preheat the drum supply, seeCirculation Through Reactor, page 45.If you need to circulate material throughthe heat hose to the gun manifold, seeCirculation Through Gun Manifold, page 46.

d. Turn both PRESSURE RELIEF/SPRAYvalves (SA, SB) to SPRAY .

SBSAGA GB

e. Open fluid inlet valves (FV). Check for leaks.

Cross-contamination can result in curedmaterial in fluid lines which could causeserious injury or damage equipment. Toprevent cross-contamination:

• NeverNeverNever interchange component A andcomponent B wetted parts.

• Never use solvent on one side if it hasbeen contaminated from the other side.

• Always provide two grounded wastecontainers to keep component A andcomponent B fluids separate.

f. Hold gun fluid manifold over two groundedwaste containers. Open fluid valves A and Buntil clean, air-free fluid comes from valves.Close valves.

The Fusion AP gun manifold is shown.

333023J 43

Startup

11. Press to activate ADM.

12. If necessary, setup the ADM in Setup Mode. SeeAdvanced Display Module (ADM) Operation,page 31.

13. Preheat the system:

a. Press to turn on hose heat zone.

This equipment is used with heated fluidwhich can cause equipment surfaces tobecome very hot. To avoid severe burns:

• Do not touch hot fluid or equipment.

• Do not turn on hose heat without fluidin hoses.

• Allow equipment to cool completelybefore touching it.

• Wear gloves if fluid temperature exceeds110°F (43°C).

Thermal expansion can causeoverpressurization, resulting in equipmentrupture and serious injury, including fluidinjection. Do not pressurize system whenpreheating hose.

b. If you need to circulate fluid through thesystem to preheat the drum supply, seeCirculation Through Reactor, page 45.If you need to circulate material throughthe heat hose to the gun manifold, seeCirculation Through Gun Manifold, page 46.

c. Wait for the hose to reach set pointtemperature.

Note

Hose heat-up time may increase atvoltages less than 230 VAC whenmaximum hose length is used.

d. Press to turn on A and B heat zones.

44 333023J

Fluid Circulation

FluidFluidFluid CirculationCirculationCirculation

CirculationCirculationCirculation ThroughThroughThrough ReactorReactorReactor

NOTICENOTICENOTICETo prevent equipment damage, do not circulatefluid containing a blowing agent without consultingwith your material supplier regarding fluidtemperature limits.

NOTE:NOTE:NOTE: Optimum heat transfer is achieved at lowerfluid flow rates with temperature set points at desireddrum temperature. Low temperature rise deviationerrors may result.To circulate through gun manifold and preheat hose,see Circulation Through Gun Manifold, page 46.

1. Follow Startup, page 42.

To avoid injection injury and splashing, do notinstall shutoffs downstream of the PRESSURERELIEF/SPRAY valve outlets (BA, BB). Thevalves function as overpressure relief valveswhen set to SPRAY . Lines must beopen so valves can automatically relievepressure when machine is operating.

2. See Typical Installation, with system fluidmanifold to drum circulation, page 14. Routecirculation lines back to respective componentA or B supply drum. Use hoses rated at themaximum working pressure of this equipment.See Technical Specifications, page 67.

3. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION .

SA SBGA GB

4. Set temperature targets. See Targets, page 37.

5. Press to circulate fluid in jog mode untilA and B temperatures reach targets. SeeJog Mode, page 46 for more information aboutjog mode.

6. Press to turn on the hose heat zone.

7. Turn on the A and B heat zones. Wait until thefluid inlet valve temperature gauges (FV) reachthe minimum chemical temperature from thesupply drums.

8. Exit jog mode.

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

SBSAGA GB

333023J 45

Jog Mode

CirculationCirculationCirculation ThroughThroughThrough GunGunGun ManifoldManifoldManifold

NOTICENOTICENOTICETo prevent equipment damage, do not circulatefluid containing a blowing agent without consultingwith your material supplier regarding fluidtemperature limits.

NOTE:NOTE:NOTE: Optimum heat transfer is achieved at lowerfluid flow rates with temperature set points at desireddrum temperature. Low temperature rise deviationerrors may result.Circulating fluid through the gun manifold allowsrapid preheating of the hose.

1. Install gun fluid manifold (P) on accessorycirculation kit (CK). Connect high pressurecirculation lines (R) to circulation manifold.

P

CK

R

The Fusion AP gun manifold is shown.

CKCKCK GunGunGun ManualManualManual

246362 Fusion AP 309818

256566 Fusion CS 313058

2. Route circulation lines back to respectivecomponent A or B supply drum. Use

hoses rated at the maximum workingpressure of this equipment. SeeTechnical Specifications, page 67.

3. Follow procedures from Startup, page 42.

4. Turn main power switch on .

5. Set temperature targets. See Targets, page 37.

6. Press to circulate fluid in jog mode untilA and B temperatures reach targets. SeeJog Mode, page 46 for more information aboutjog mode.

JogJogJog ModeModeModeJog mode has two purposes:

• It can speed fluid heating during circulation.

• It can ease system flushing and priming.

1. Turn main power switch on .

2. Press circulate to enter jog mode.

3. Press up or down to change jog speed(J1 through J20).

Note

Jog speeds correlate to 3-30% of motorpower, but will not operate over 700 psi(4.9 MPa, 49 bar) for either A or B.

4. Press to start motor.

5. To stop the motor and exit jog mode press

or .

46 333023J

Spraying

SprayingSprayingSpraying

The Fusion AP gun is shown.

1. Engage gun piston safety lock and close gunfluid inlet valves A and B.

FusionFusionFusion ProblerProblerProbler

2. Attach gun fluid manifold. Connect gun air line.Open air line valve.

3. Adjust the gun air regulator to desired gun airpressure. Do not exceed the maximum ratedair pressure.


SB) to SPRAY .

SBSAGA GB

5. Verify heat zones are on and temperaturesand pressures are on target, seeHome screen, page 37.

6. Open fluid inlet valve located at each pump inlet.

7. Press to start motor and pumps.

8. Check fluid pressure gauges (GA, GB) toensure proper pressure balance. If imbalanced,reduce pressure of higher component byslightlyslightlyslightly turning PRESSURE RELIEF/SPRAYvalve for that component toward PRESSURE

RELIEF/CIRCULATION until gauges showbalanced pressures.

SA SBGA GB

333023J 47

Spraying

9. Open gun fluid inlet valves A and B.


NOTICENOTICENOTICETo prevent material crossover on impingementguns, nevernevernever open fluid manifold valves ortrigger gun if pressures are imbalanced.

10. Disengage gun piston safety lock.


11. Pull gun trigger to test spray onto cardboard. Ifnecessary, adjust pressure and temperature toget desired results.

SpraySpraySpray AdjustmentsAdjustmentsAdjustments

Flow rate, atomization, and amount of overspray areaffected by four variables.

• FluidFluidFluid pressurepressurepressure setting.setting.setting. Too little pressure resultsin an uneven pattern, coarse droplet size, lowflow, and poor mixing. Too much pressure resultsin excessive overspray, high flow rates, difficultcontrol, and excessive wear.

• FluidFluidFluid temperature.temperature.temperature. Similar effects to fluid pressuresetting. The A and B temperatures can be offset tohelp balance the fluid pressure.

• MixMixMix chamberchamberchamber size.size.size. Choice of mix chamber is basedon desired flow rate and fluid viscosity.

• Clean-offClean-offClean-off airairair adjustment.adjustment.adjustment. Too little clean-off airresults in droplets building up on the front of thenozzle, and no pattern containment to controloverspray. Too much clean-off air results inair-assisted atomization and excessive overspray.

48 333023J

Manual Hose Heat Mode

ManualManualManual HoseHoseHose HeatHeatHeat ModeModeModeIf the system produces the T6DH sensor error hosealarm or the T6DT sensor error TCM alarm, usemanual hose heat mode until the hose RTD cable orFTS temperature sensor can be repaired.

Do not use Manual Hose Mode for extended periodsof time. The system performs best when the hosehas a valid RTD and can operate in temperaturecontrol mode. If a hose RTD breaks, the first priorityis to fix the RTD. Manual Hose Mode can help finisha job while waiting for repair parts.

EnableEnableEnable ManualManualManual HoseHoseHose ModeModeMode

1. Disconnect the hose RTD sensor from the TCM.

2. Enter Setup Mode and navigate to SystemScreen 2.

3. Select Enable Manual Hose Mode.

Note

When manual hose mode is enabled, themanual hose mode advisory EVCH-Vwill appear.

4. Enter Run Mode and navigate to the Targetscreen. Use the up and down arrows to set thedesired hose current.

HoseHoseHose CurrentCurrentCurrent SettingsSettingsSettings HoseHoseHose CurrentCurrentCurrent

Default 20A

Maximum 37A

333023J 49

Manual Hose Heat Mode

5. Navigate back to the Run Mode Home screen.The hose now displays a current instead of atemperature.

Note

Until the RTD sensor is repaired, theT6DH sensor error alarm will displayeach time the system is powered up.

DisableDisableDisable ManualManualManual HoseHoseHose ModeModeMode

1. Enter Setup Mode and navigate to System 2Screen and deselect Enable Manual Hose Mode,or repair the hose RTD cable or FTS.

2. Manual hose mode is automatically disabledwhen the system detects a valid RTD sensor inthe hose.

50 333023J

Shutdown

ShutdownShutdownShutdown

NOTICENOTICENOTICEProper system setup, startup, and shutdownprocedures are critical to electrical equipmentreliability. The following procedures ensure steadyvoltage. Failure to follow these procedures willcause voltage fluctuations that can damageelectrical equipment and void the warranty.

1. Press to stop the pumps.

2. Turn off all heat zones.

3. Relieve pressure. SeePressure Relief Procedure, page 53.

4. Press to park the Component A Pump. Thepark operation is complete when green dot goesout. Verify the park operation is complete beforemoving to next step.

5. Press to deactivate the system.

6. Turn off the air compressor, air dryer, andbreathing air.

7. Turn main power switch OFF.

To prevent electric shock do not remove anyshrouds or open the electrical enclosure door.

8. Close all fluid supply valves.

333023J 51

Shutdown


SB) to SPRAY to seal out moisture fromdrain line.

SBSAGA GB

10. Engage gun piston safety lock then close fluidinlet valves A and B.


52 333023J

Pressure Relief Procedure

PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedureFollow the Pressure Relief Procedurewhenever you see this symbol.

This equipment stays pressurized until pressureis manually relieved. To help prevent seriousinjury from pressurized fluid, such as skin injection,splashing fluid and moving parts, follow thePressure Relief Procedure when you stop sprayingand before cleaning, checking, or servicingequipment.

The Fusion AP gun is shown.

1. Relieve pressure in gun and perform gunshutdown procedure. See gun manual.

2. Engage gun piston safety lock.

3. Close gun fluid inlet valves A and B.

4. Shut off feed pumps and agitator, if used.

5. Route fluid to waste containers or supply tanks.Turn PRESSURE RELIEF/SPRAY valves (SA,SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

SA SBGA GB

333023J 53

Flushing

FlushingFlushingFlushing

To help prevent fire and explosion:

• Flush equipment only in a well-ventilated area.

• Do not spray flammable fluids.

• Do not turn on heaters while flushing withflammable solvents.

• Flush out old fluid with new fluid, or flush out oldfluid with a compatible solvent before introducingnew fluid.

• Use the lowest possible pressure when flushing.

• All wetted parts are compatible with commonsolvents. Use only moisture-free solvents.

To flush feed hoses, pumps, and heatersseparately from heated hoses, set PRESSURERELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION . Flush through bleedlines (N).

SA SBGA GB

To flush entire system, circulate through gun fluidmanifold (with manifold removed from gun).

To prevent moisture from reacting with isocyanate,always leave the system filled with a moisture-freeplasticizer or oil. Do not use water. Never leave thesystem dry. See Important Isocyanate Information.

54 333023J

Maintenance

MaintenanceMaintenanceMaintenance

Prior to performing any maintenance procedures,follow Pressure Relief Procedure, page 53.

PreventativePreventativePreventative MaintenanceMaintenanceMaintenance ScheduleScheduleSchedule

The operating conditions of your particular systemdetermine how often maintenance is required.Establish a preventive maintenance schedule byrecording when and what kind of maintenance isneeded, and then determine a regular schedule forchecking your system.

ProportionerProportionerProportioner MaintenanceMaintenanceMaintenance

WetWetWet CupCupCup

Check the wet cup daily. Keep it 2/3 full with GracoThroat Seal Liquid (TSL®) or compatible solvent. Donot overtighten packing nut/wet cup.

PackingPackingPacking NutsNutsNuts

Do not overtighten packing nut/wet cup. Throat u-cupis not adjustable.

FluidFluidFluid InletInletInlet StrainerStrainerStrainer ScreensScreensScreens

Inspect fluid inlet strainer screens daily, seeFlush Inlet Strainer Screen, page 56.

GreaseGreaseGrease CirculationCirculationCirculation ValvesValvesValves

Grease circulation valves (SA and SB) with Fusiongrease (117773) weekly.

ISOISOISO LubricantLubricantLubricant LevelLevelLevel

Inspect ISO lubricant level and conditiondaily. Refill or replace as needed. SeePump Lubrication System, page 57.

MoistureMoistureMoisture

To prevent crystallization, do not expose componentA to moisture in air.

GunGunGun MixMixMix ChamberChamberChamber PortsPortsPorts

Clean gun mix chamber ports regularly. See gunmanual.

GunGunGun CheckCheckCheck ValveValveValve ScreensScreensScreens

Clean gun check valve screens regularly. See gunmanual.

DustDustDust ProtectionProtectionProtection

Use clean, dry, oil-free compressed air to preventdust buildup on control modules, fans, and motor(under shield).

VentVentVent HolesHolesHoles

Keep vent holes on bottom of electrical cabinet open.

333023J 55

Maintenance

FlushFlushFlush InletInletInlet StrainerStrainerStrainer ScreenScreenScreen

The inlet strainers filter out particles that can plug thepump inlet check valves. Inspect the screens daily aspart of the startup routine, and clean as required.

Isocyanate can crystallize from moisturecontamination or from freezing. If the chemicals usedare clean and proper storage, transfer, and operatingprocedures are followed, there should be minimalcontamination of the A-side screen.

Note

Clean the A-side screen only duringdaily startup. This minimizes moisturecontamination by immediately flushingout any isocyanate residue at the start ofdispensing operations.

1. Close the fluid inlet valve at the pump inlet andshut off the appropriate feed pump. This preventsmaterial from being pumped while cleaning thescreen.

2. Place a container under the strainer base to catchdrain off when removing the strainer plug (C).

3. Remove the screen (A) from the strainermanifold. Thoroughly flush the screen with

compatible solvent and shake it dry. Inspect thescreen. No more than 25% of the mesh shouldbe restricted. If more than 25% of the mesh isblocked, replace the screen. Inspect the gasket(B) and replace as required.

4. Ensure the pipe plug (D) is screwed into thestrainer plug (C). Install the strainer plug with thescreen (A) and o-ring (B) in place and tighten. Donot overtighten. Let the gasket make the seal.

5. Open the fluid inlet valve, ensure that there areno leaks, and wipe the equipment clean. Proceedwith operation.

Figure 15

56 333023J

Maintenance

PumpPumpPump LubricationLubricationLubrication SystemSystemSystem

Check the condition of the ISO pump lubricant daily.Change the lubricant if it becomes a gel, its colordarkens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by thepump lubricant. The interval between changesdepends on the environment in which the equipmentis operating. The pump lubrication system minimizesexposure to moisture, but some contamination is stillpossible.

Lubricant discoloration is due to continual seepage ofsmall amounts of isocyanate past the pump packingsduring operation. If the packings are operatingproperly, lubricant replacement due to discolorationshould not be necessary more often than every 3 or4 weeks.

To change pump lubricant:

1. Follow Pressure Relief Procedure, page 53.

2. Lift the lubricant reservoir (R) out of the bracketand remove the container from the cap. Holdingthe cap over a suitable container, remove thecheck valve and allow the lubricant to drain.Reattach the check valve to the inlet hose.

3. Drain the reservoir and flush it with cleanlubricant.

4. When the reservoir is flushed clean, fill with freshlubricant.

5. Thread the reservoir onto the cap assembly andplace it in the bracket.

6. The lubrication system is ready for operation. Nopriming is required.

Pump Lubrication SystemFigure 16

333023J 57

Errors

ErrorsErrorsErrors

ViewViewView ErrorsErrorsErrors

When an error occurs the error information screendisplays the active error code and description.

The error code, alarm bell, and active errors will scrollin the status bar. For a list of the ten most recenterrors see Troubleshooting, page 59. Error codesare stored in the error log and displayed on the Errorand Troubleshooting screens on the ADM.

There are three types of errors that can occur. Errorsare indicated on the display as well as by the lighttower (optional).

Alarms are indicated by . This condition indicatesa parameter critical to the process has reached alevel requiring the system to stop. The alarm needsto be addressed immediately.

Deviations are indicated by . This conditionindicates a parameter critical to the process hasreached a level requiring attention, but not sufficientenough to stop the system at this time.

Advisories are indicated by . This conditionindicates a parameter that is not immediately criticalto the process. The advisory needs attention toprevent more serious issues in the future.

To diagnose the active error, seeTroubleshoot Errors, page 58.

TroubleshootTroubleshootTroubleshoot ErrorsErrorsErrors

To troubleshoot the error:

1. Press the soft key next to “Help With This Error”for help with the active error.

Note

Press or to return to thepreviously displayed screen.

2. The QR code screen will be displayed. Scanthe QR code with your smart phone to be sentdirectly to online troubleshooting for the activeerror code. Otherwise, manually navigate tohttp://help.graco.com and search for the activeerror.

3. If no internet connection is available, seeError Codes and Troubleshooting, page 59 forcauses and solutions for each error code.

58 333023J

Troubleshooting

TroubleshootingTroubleshootingTroubleshootingSee Errors, page 58 for information about errors thatcan occur on the system.

See Troubleshooting, page 39 for the ten mostrecent errors that have occurred on the system. SeeTroubleshoot Errors, page 58 to diagnose errors onthe ADM that have occurred on the system.

ErrorErrorError CodesCodesCodes andandand TroubleshootingTroubleshootingTroubleshooting

See system repair manual or visithttp://help.graco.com for causes and solutions toeach error code.

333023J 59

USB Data

USBUSBUSB DataDataData

DownloadDownloadDownload ProcedureProcedureProcedure

Note

System configuration setting files and customlanguage files can be modified if the filesare in the UPLOAD folder of the USB flashdrive. See System Configuration SettingsFile, Custom Language File, and UploadProcedure sections.

1. Insert USB flash drive into USB port.

2. The menu bar and USB indicator lights indicatethat the USB is downloading files. Wait for USBactivity to complete.

3. Remove USB flash drive from USB port.

4. Insert USB flash drive into USB port of computer.

5. The USB flash drive window automatically opens.If it does not, open USB flash drive from withinWindows® Explorer.

6. Open GRACO folder.

7. Instructions continue on next page.

8. Open the system folder. If downloading datafrom more than one system, there will be morethan one folder. Each folder is labeled with thecorresponding serial number of the ADM (Theserial number is on the back of the ADM.)

9. Open DOWNLOAD folder.

10. Open DATAxxxx folder.

11. Open DATAxxxx folder labeled with the highestnumber. The highest number indicates the mostrecent data download.

12. Open log file. Log files open in Microsoft® Excelby default as long as the program is installed.However, they can also be opened in any texteditor or Microsoft® Word.

Note

All USB logs are saved in Unicode(UTF-16) format. If opening the logfile in Microsoft Word, select Unicodeencoding.

USBUSBUSB LogsLogsLogs

Note

The ADM can read/write to FAT (FileAllocation Table) storage devices. NTFS,used by 32 GB or greater storage devices,is not supported.

During operation, the ADM stores system andperformance related information to memory in theform of log files. The ADM maintains six log files:

• Event Log

• Job Log

• Daily Log

• System Software Log

• Blackbox Log

• Diagnostics Log

Follow Download Procedure, page 60, to retrievelog files.

Each time a USB flash drive is inserted into the ADMUSB port, a new folder named DATAxxxx is created.The number at the end of the folder name increaseseach time a USB flash drive is inserted and data isdownloaded or uploaded.

EventEventEvent LogLogLog

The event log file name is 1–EVENT.CSV and isstored in the DATAxxxx folder.

The event log maintains a record of the last 49,000events and errors. Each event record contains:

• Date of event code

• Time of event code

• Event code

• Event type

• Action taken

• Event Description

Event codes include both error codes (alarms,deviations, and advisories) and record only events.

Actions Taken includes setting and clearing eventconditions by the system, and acknowledging errorconditions by the user.

60 333023J

USB Data

JobJobJob LogLogLog

The job log file name is 2–JOB.CSV and is storedin the DATAxxxx folder.

The job log maintains a record of data pointsbased on the USB Log Frequency definedin the Setup screens. The ADM stores thelast 237,000 data points for download. SeeSetup - Advanced Screen 3 — USB, page 34, forinformation on setting the Download Depth and USBLog Frequency.

• Da

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