How do I start up my pneumatic graco reactor?

Proper system start-up is critical for the safe and effective operation of your hydraulic Graco Reactor. This step-by-step guide contains the information you need to start up your machine.

This step-by-step guide walks you through starting up your Pheumatic Graco Reactor. This document is not replacing the manual, for a full overview of safety instructions please see the manual.

Proper system start-up is critical for the safe and effective operation of your pneumatic Graco Reactor equipment. The following procedures ensure steady voltage, avoiding voltage fluctuations that can damage electrical equipment and void the warranty. To prevent serious injury, only operate the Reactor with all the covers and shrouds in place. Proper system start-up and shutdown procedures are critical to electrical equipment reliability. Do not operate Reactor without all covers and shrouds in place.

 

Initial Start Up Pneumatic Graco Reactor

1. Pressure Relief Procedure
   • This equipment stays pressurized until pressure is manually relieved. Follow this pressure relief procedure when you stop spraying and before cleaning, checking, or servicing the equipment.
   1. Turn off the feed pumps and the agitator, if used.
   2. Park component A pump. Follow this procedure to Park:
      1. Trigger the gun until the pump stops at the bottom and relieves pressure.
      2. Close the air motor shutoff valve.
         1. Close the park valve.
         2. Close the air inlet valve.
         3. Trigger the spray gun until the gauges read zero.
      3. Engage the gun piston safety lock.
      4. Close the gun fluid inlet valves A and B.
      5. Close the pump inlet supply valves.
2. Flush Out The Old Fluid
   

*Note - Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents.

• Flush out old fluid with new fluid, or flush out old fluid with a compatible moisture-free solvent.
• Use lowest possible pressure when flushing.
• To flush the feed hoses, pumps, and the heater separately from the heated hoses, set the pressure relief/spray valves to pressure relief/circulation.
• To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).
• Always leave hydraulic oil or a non-water based, non-water absorbent fluid in system. Do not use water.

1. Flush out the bleed lines.
2. To flush the entire system, circulate through the gun fluid manifold (with the manifold removed from the gun).
3. Always leave hydraulic oil or a non-water based, nonwater absorbent fluid in the system. Do not use water.
4. Load The Fluid With The Feed Pumps
   
   • For first start-up of your new pneumatic Graco Reactor, you must load the fluid with the feed pumps. Follow these instructions:
   1. Check that all set-up steps are complete. For more information, please check the installing guide.
   2. Turn on the component B agitator, if used.
   3. Turn both the pressure relief/spray valves to spray.
   4. Open both the fluid valves.
   5. Start the feed pumps. Do not start the proportioner air motor or pumps.
   6. Purge the air from the hoses.
      1. For Probler P2 guns: Loosen the hose fittings and bleed out the air until air-free fluid comes out of the hoses.
      2. For Fusion guns: Hold the gun fluid manifold over two grounded waste containers. Keep the fluids of components A and B separate. Open the fluid valves A and B until clean, air-free fluid comes out of the valves. Close the valves.
5. Pressure Check The Hose
   • For more information, please check the hose manual.
   1. Pressure check the hose for leaks.
   2. If there are no leaks, wrap the hose and the electrical connections to protect them from damage.
6. Set The Temperatures
   1. Turn the main power on .
   2. Press the temperature scale key to change the temperature scale.
   3. Press target temperature key to display the target temperatures.
   4. To set the Zone A heat zone target temperature, press the arrow keys to set the desired temperature.
   5. To set the Zone B heat zone target temperature, press the arrow keys to set the desired temperature.
   6. To set the Hose heat zone target temperature, press the arrow keys to set the desired temperature. If the fluid temperature sensor is disconnected at start-up, the display will show the hose current. See “Only for manual current control mode” .
   7. Turn on the hose heat zone by pressing the hose heat On/Off key .
   8. Preheat the hose for 15 to 60 minutes. The indicator will flash very slowly when the fluid reaches the target temperature. The display shows the actual fluid temperature in the hose near the FTS.
   9. Turn on the A and B heat zones by pressing for each zone.
   10. Hold actual temperature to see the electrical currents for each zone.
   11. Hold target temperature to see the heater control circuit board temperature.
   • Only for Manual Current Control Mode
   1.  When the system is in manual current control mode, monitor the hose temperature with a thermometer. The temperature may not exceed 160°F (71°C).
   2. Never leave the machine unattended when in manual current control mode.
      1. If the FTS is disconnected or the display shows diagnostic code E04, turn the main power switch OFF and back ON to remove the diagnostic code and enter manual current mode. The hose display will show the current to the hose. This current is not limited by the target temperature.
      2. Press or to adjust the current setting.
      3. To prevent overheating, install the hose thermometer close to the gun end, within operator view.
      4. Insert the thermometer through the foam cover of the A component hose so the stem is next to the inner tube. The thermometer reading will be about 20°F (-6,7°C) less than the actual fluid temperature.
      5. If the thermometer reading exceeds 160°F (71°C), reduce the current with the key.
7. Supply Wet Cups With Throat Seal Liquid
   • The pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from the wet-cups during operation.
   1. Close the main air valve before filling the wet-cups.
   2. Component A (ISO) pump: Keep the reservoir ¾ filled with Graco Throat Seal Liquid (TSL - part 206995). The wet-cup piston circulates TSL through the wet-cup to avoid the formation of a isocyanate film on the displacement rod. Change the fluid in the reservoir when it is starting to look “milky”.
   3. Component B (Resin) pump: Check the felt washers in the packing nut/wet-cup daily. Keep them saturated with TSL to prevent the material from hardening on the displacement rod. Replace the felt washers when they are worn or contaminated with hardened material.
8. Daily Start Up Pneumatic Graco Reactor
   • The daily start-up procedures describe normal operation. Assume that all temperature and pressure settings have been previously set, but that the heating system is not up to operating temperature.
   1. Check condition isocyanate lubrication system and service as required. Change pump lubricant when it shows signs of change to a milky color.
   2. Ensure supply fluid is at correct temperature as recommended by chemical system supplier. Ensure individual chemicals are correctly agitated within their drums/day tanks, and moisture protection system is properly set for operation. Recirculate heated fluid back to supply drums if necessary; see Circulation Through Reactor
   3. Turn on main air supply to transfer pumps.
   4. Pressurize transfer pumps and open A- and B-inlet supply valves.
   5. Open air inlet ball valve.
   6. Turn main power ON .
   7. Uncoil heated hose.
   8. Check that hose setpoint temperature is correct.
   9. Turn on all three heat zones.
   10. The hose power controller automatically adjusts the hose current to the hose to compensate for hose length and ambient temperature. Wait for actual hose temperature before opening air motor shutoff valve.
   11. NOTE: To prevent excessive pressure build-up in heated hoses, always bring hoses and primary heater up to operating temperature before opening air motor shutoff valve.
   12. Set PRESSURE RELIEF/SPRAY valves to SPRAY.
   13. Check that heat zones are on and temperatures are on target.
   14. Open air motor shutoff valve.
   15. Pumps will pressurize the fluid according to air regulator pressure.
   16. Check A and B fluid pressure gauges to ensure proper pressure balance between A and B. If imbalanced, bleed off the high side with valves SA and SB until balanced.
   17. Open gun fluid manifold valves A and B.
   18. Disengage gun piston safety lock.
   19. Test spray onto cardboard.
   20. Equipment is ready to spray.

Circulation Through Reactor

• NOTE: To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits.

1. Follow Initial Startup and Typical Installation, with Circulation
2. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working pressure of this equipment.
3. Set PRESSURE RELIEF/SPRAY valves to PRESSURE RELIEF/CIRCULATION .
4. Turn main power ON
5. Set temperature targets
6. Turn on A and B heat zones by pressing On/Off Key. Do not turn on hose heat zone unless hoses are already loaded with fluid.
7. Press actual temperature button to display actual temperatures.
8. Turn the air regulator to a low pressure until A and B temperatures reach targets. Increase the pressure once the temperatures are on target.
9. Turn on hose heat zone by pressing On/Off key.
10. Set PRESSURE RELIEF/SPRAY valves to SPRAY .

Circulate Through Gun Manifold

• NOTE: To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding

1. Install gun fluid manifold on accessory circulation kit. Connect high pressure circulation lines to circulation manifold.
2. Follow Initial Startup
3. Turn main power ON
4. Set temperature targets
5. Turn on A and B heat zones by pressing .
6. Press to display actual temperatures.
7. Turn the air regulator to a low pressure until A and B temperatures reach targets. Increase the pressure once the temperatures are on target.

Refer to the manual for further directions: