Graco Reactor A-20 Use and care manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2006, Graco Inc. is registered to I.S. EN ISO 9001
311512A
Repair - Parts
Reactor A-20
For spraying or dispensing 1:1 mix ratio materials, including epoxies, and
polyurethane foam. Not for use in explosive atmospheres.
253831 Air operated, electrically heated, plural component
proportioner.
This model is field-configurable to the following supply voltages:
230 V, 1 Phase
230 V, 3 Phase
380 V, 3 Phase
2,000 psi (14 MPa, 140 bar) Maximum Fluid Working Pressure
120 psi (0.84 MPa, 8.4 bar) Maximum Air Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti8447a

2311512A
Contents
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 6
Keep Components A and B Separate . . . . . . . . . . 6
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Beginning Repair . . . . . . . . . . . . . . . . . . . . 7
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . 12
Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . 14
Recirculation / Over Pressure Relief Block . . . . 15
Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reversing Switch . . . . . . . . . . . . . . . . . . . . . . . 16
Solenoid Valve Replacement . . . . . . . . . . . . . . 16
Air Inlet Filter / Water Separator (Auto Drain) . . 16
Primary Heater . . . . . . . . . . . . . . . . . . . . . . . . . 17
Heating Elements . . . . . . . . . . . . . . . . . . . . . . . 18
Fluid Inlet Filter Screen . . . . . . . . . . . . . . . . . . . 19
Isocyanate Pump Lubricant . . . . . . . . . . . . . . . 19
Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 20
Replacing Control Components . . . . . . . . . . . . . . 22
Hose Power Controller / Circuit Breaker / Relays 22
Air Motor Up / Down / Pressure Regulators /
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control Panel Wiring . . . . . . . . . . . . . . . . . . . . . 23
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Recommended Spare Parts . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reactor A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical Control Panel . . . . . . . . . . . . . . . . . . . 28
Relief Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A-20 Air Motor Pump Assembly . . . . . . . . . . . . 32
Primary 6000W Heater . . . . . . . . . . . . . . . . . . . 34
Air Tubing Connections . . . . . . . . . . . . . . . . . . . . . 36
Reactor A-20 Wiring Schematic . . . . . . . . . . . . . . 38
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Heater Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Hose Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

Supplied Manuals
311512A 3
Supplied Manuals
The following manuals are shipped with the Reactor™
A-20 Proportioner. Refer to these manuals for detailed
equipment information.
Order Part No. 15B535 for a compact disk of Reactor
manuals translated in several languages.
Manuals are also available at www.graco.com.
Related Manuals
The following manuals are for accessories used with the
Reactor™.
Order Part No. 15B535 for a compact disk of Reactor
manuals translated in several languages.
Order Part No. 15B381 for a compact disk of Fusion
manual translated in several languages.
Reactor A-20 Proportioner
Part No. Description
311511 Reactor A-20 Proportioner, Operation Man-
ual (English)
Proportioning Pump
Part No. Description
309577 Proportioning Pump Repair-Parts Manual
(English)
Feed Pump Kit
Part No. Description
309815 Instruction-Parts Manual (English)
Air Supply Kit
Part No. Description
309827 Instruction-Parts Manual (English) for Feed
Pump Air Supply Kit
Circulation and Return Tube Kit
Part No. Description
309852 Instruction-Parts Manual (English)
Heated Hose
Part No. Description
309572 Instruction-Parts Manual (English)
Fusion Air Purge Spray Gun
Part No. Description
309550 Instruction-Parts Manual (English)
Fusion Mechanical Purge Spray Gun
Part No. Description
309856 Instruction-Parts Manual (English)
Circulation Hose Manifold Kit
Part No. Description
309818 Instruction-Parts Manual (English)

Warnings
4311512A
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Addi-
tional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appear-
ing 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.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• 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.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warnings
311512A 5
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.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.
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. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
WARNING

Isocyanate Hazard
6311512A
Isocyanate Hazard
Moisture Sensitivity of
Isocyanates
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.
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the felt washers in the pump wet-cups satu-
rated with Graco ISO pump oil, Part No. 217374.
The lubricant creates a barrier between the ISO and
the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system; see
Accessories, page 24.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been contam-
inated from the other side.
• Always park pumps when you shutdown.
• Always lubricate threaded parts with Part No.
217374 ISO pump oil or grease when reassembling.
Keep Components A and
B Separate
Changing Materials
• When changing materials, flush the equipment mul-
tiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing;
see Fluid Inlet Filter Screen, page 19.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
Read material manufacturer’s warnings and material
MSDS to know the specific hazards of isocyanates.
Use equipment in a well-ventilated area. Wear respi-
rator, gloves, and protective clothing when using iso-
cyanates.
The amount of film formation and rate of crystalli-
zation varies depending on the blend of ISO, the
humidity, and the temperature.
CAUTION
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A (isocy-
anate) and component B (resin) parts.

Before Beginning Repair
311512A 7
Before Beginning Repair
Pressure Relief
Procedure
1. Turn off feed pumps and agitator if used.
2. Turn PARK/RUN switch to PARK.
3. Trigger gun to relieve pressure.
4. Turn off air inlet valve.
5. Engage gun piston safety lock.
6. Verify gun fluid manifold valves A and B are closed.
7. Close pump inlet supply valves.
Flushing
• Flush with a compatible solvent.
• Use lowest possible pressure when flushing.
• To flush entire system, circulate through gun fluid
manifold (with gun removed from manifold).
• Always leave hydraulic oil or a non-water based,
non-water absorbent fluid in system. Do not use
water.
Repairing this equipment requires access to parts
that may cause electric shock or other serious injury if
work is not performed properly. Electrical trouble-
shooting must be done by a qualified electrician. Be
sure to shut off all power to equipment and lock out
power at the source before repairing.
TI2409a
TI2421a
Flush equipment only in a well-ventilated area. Do not
spray flammable fluids. Do not turn on heaters while
flushing with flammable solvents.
Only use flush solvents that are compatible with Fluo-
roelastomer seals. Non-compatible solvents will dam-
age seals and cause hazardous conditions, such as
high pressure leaks and pressure switch failure.

Troubleshooting
8311512A
Troubleshooting
Power
Pumps and Pressures
PROBLEM CAUSE SOLUTION
Reactor does not operate No power Plug in power cord
Turn Main Disconnect Switch ON
Power cord not connected properly Check connections
No power when disconnect switch is
turned on; using 230V, 1 phase or
230V, 3 phase power
Power terminal jumper still at 380V, 3
phase position, as shipped from fac-
tory
Place jumpers in correct position; see
operation manual 311511 and label
inside front lower cabinet.
External main supply power circuit
breaker trips and Reactor disconnect
switch fails when switch is turned on.
Power terminal jumper was left in
230V, 1 phase position. When using
230V, 3 phase or 380V, 3 phase
power
Place jumpers in correct position; see
manual 311511. Replace main power
disconnect switch; see page 26.
No temperature display lights at star-
tup
No power Plug in power cord
Turn Main Disconnect Switch ON
Control power fuses blown Check and replace fuses on long ter-
minal strip
Reactor stops working; all lights are
off except temperature displays
Red stop switch was pushed Reset all control switches to START
PROBLEM CAUSE SOLUTION
Pump does not run up and down but
green switch light is on
PARK/RUN switch in PARK position Turn PARK/RUN switch to RUN
No air supply Air supply line not connected
Open inlet air ball valve
Air pressure regulators set at 0 psi Turn up air pressure regulators
Pump runs but no fluid pressure Fluid inlet ball valves closed Open fluid ball valves
Fluid pressure low or dropping Air supply pressure low when spray-
ing
Increase inlet air pressure
Increase air compressor size to meet
flow requirements
Remove airline quick disconnects
Use 3/8 in. (0.95 cm) ID or larger air
supply hose
Icing in air motor quick exhausts or
mufflers
Check and repair fan
Check inlet filter water separator; see
page ##. Stop spraying for 5 minutes
while fan melts ice.
Pump output low Obstructed gun impingement ports or
filters
Flush and clean gun; see gun manual
One pressure gauge drops when
pumps are stalled on both the
upstroke and the downstroke
Leaking pump throat Repair pump; see 309577
Leak between pump and gun Check fluid tubes, heater, and hoses
Spray gun is leaking on one side Clean and repair spray gun
One pressure gauge drops when
pumps are stalled on the downstroke,
but not the upstroke
Inlet ball check not sealing Clean or replace; see 309577
Inlet check seat o-ring not sealing Repair pump; see 309577

Troubleshooting
311512A 9
One pressure gauge drops when
pumps are stalled on the upstroke,
but not the downstroke
Piston check ball not sealing Repair pump; see 309577
Piston packing not sealing Repair pump; see 309577
Loose piston stud in pump Repair pump; see 309577
Bad inside sleeve seal Repair o-ring; see 309577
A side rich; lack of B side A side gauge is low B side restriction downstream of
gauge. Check gun check valve
screen, mix module, or mix manifold
restrictor.
B side gauge is low B side material supply problem.
Check B side inlet strainer and pump
intake valve.
B side rich; lack of A side A side gauge is low A side material supply problem.
Check A side inlet strainer and pump
intake valve.
B side gauge is low A side restriction downstream of
gauge. Check gun check valve
screen, mix module, or mix manifold
restrictor.
Fluid pressures not balanced
between A and B side
Fluid viscosities not equal Sometimes normal if pressure offset
is below 200 psi (14 bar)
Preheat material in drums by recircu-
lating; see Operation manual 311511
Inlet Y-strainer screen plugged on low
pressure side
Clean inlet filter screen
Gun port or filter plugged on high
pressure side
Clean or replace; see gun manual
Pump inlet ball not seating or sticking Clean seating; see pump manual
Drum fluid outlet supply hose too
small
Use 3/4 in. (1.9 cm) ID hose with
short length
Low side feed pump not working Turn on or repair feed pump
Pump does not reverse direction Obstruction of air motor or pumps Check and clear obstruction
Reversing switch failed Check and service switch assembly;
see page 16.
Air solenoid valve failed. Check solenoid valve, see page 16.
Unequal fluid pressure between
UP/DOWN stroke
Air regulator pressures not set cor-
rectly. Feed pumps boost pressure on
up stroke.
Adjust UP/DOWN air regulators to
create equal fluid outlet pressures;
see Operation manual 311511.
Pumps stop moving, Pump Mode
Function green knob light off
Over-pressure shutdown from imbal-
anced pressures. Plugging one side
will double the pressure. Starving
one side will double the pressure on
the other side.
Check for gun restriction, see Gun
manual
Air pressure set too high; lower air
pressure
Pump cavitating on low pressure
side; check inlet and clean strainer.
Check feed pump.
Heater plugged on low pressure side;
see Repair, page 18.
PROBLEM CAUSE SOLUTION

Troubleshooting
10 311512A
Hose Heat
Air motor doesn’t move with air pres-
sure applied
Reversing switch failed Inspect and repair parts; see page
32.
Solenoid valve failed Replace valve.
Pump movement speed is erratic Worn air motor seals Replace seals; see page see page
32.
Worn pump seals Replace seals; see Pump manual.
Worn solenoid valve seals Replace solenoid valve; see pages
16 and 32.
PROBLEM CAUSE SOLUTION
PROBLEM CAUSE SOLUTION
Hose temperature controller display
flashing “SbEr” and “H20.0”
FTS not connected. Control does not
see thermocouple.
Check and connect FTS connector at
each joint; see page 20.
Hose temperature controller display
dropping with hose switch green light
on
Hose power-lock connector loose Connect hose power-lock at Reactor
Check and reconnect all connector
points along hose. Use wire tie to
hold together.
Hose heat switch green light goes out Hose over-temperature shutdown Measure hose for proper amperage.
Repair or replace hose power con-
trollers. See page 22. Reset
over-temperature hose control knob
to START.
Set Point 2 (SP2) deviation alarm set
too low. Raise SP2 to 30 °F (17 °C)
default setting.
Hose temperature display overshoots
setpoint and/or green switch light
goes out
Hose coiled up on itself too much,
sends overheated fluid to FTS
Straighten out coiled hose
Insulation peeled off of hose at FTS
sensor inside hose causes the rest of
hose to overheat.
Insulate hose up to FTS. FTS must
represent bulk of heated hose.
Hose heat too low Temperature setpoint too low Check setpoint (SP1); adjust if nec-
essary
Fluid flow too high Use smaller mix chamber. Decrease
pressure.
Hose heat not turned on long
enough. More than 310 ft. connected.
Allow more time for hose heat to heat
up or preheat supply drums
Loose electrical connectors. Green
light on Power Controller is off.
Check power and FTS connections;
see page 20.
Either heat temperature controller
display dark
Controller connector loose Check and reconnect
No lights on hose power controller in
lower cabinet while temperature con-
troller 01 output light is on steady.
Green switch light is on. Not heat in
hose.
No 4.5 to 12 Vdc signal from temper-
ature controller
Make sure 01 light on top tempera-
ture controller is on.
Polarity is reversed on 4.5 to 12 Vdc Reverse blue wires.
No power to hose power controller
terminals 2 and 3; 220-240 Vac
Make sure green light on hose switch
is on. Make sure hose primary circuit
breaker is on.