Operation
Reactor A-20
311511G
ENG
Air Operated, Electrically Heated Plural Component Proportioner
For spraying or dispensing 1:1 mix ratio materials, including epoxies and polyurethane
foam. For professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
US Patent No. 7822326
Russian Patent No. 2359181
TI8447A
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Systems
Systems
Maximum Fluid
Working Pressure
psi
Heated Hose
Gun
System Part
(MPa, bar)
Proportioner 50 ft (15 m)
10 ft (3 m)
Model
Part
AP3831
2000
(13.8, 138)
253831
253831
253831
246678
246678
246678
246050
246050
246050
Fusion Air
Purge
246101
CS01RD
GCP2R1
CS3831
P23831
2000
(13.8, 138)
Fusion CS
2000
Probler P2
(13.8, 138)
253831 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
Approvals:
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311511G
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Warnings
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment.
Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols
appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the
manual, refer back to these pages for a description of the specific hazard.
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.
•
•
•
•
•
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 Pressure Relief Procedure 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.
4
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Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•
•
Use equipment only in well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•
•
Keep work area free of debris, including solvent, rags and gasoline.
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.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
•
•
Open a valve to relieve the fluid expansion during heating.
Replace hoses proactively at regular intervals based on your operating conditions.
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.
•
•
This equipment is for professional use only.
Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
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.
311511G
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Warnings
WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
•
•
•
Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.
Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
6
311511G
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Typical Installation, without Circulation
Typical Installation, without Circulation
Key for FIG. 1
A
B
C
D
E
F
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
Fusion Spray Gun
H
J
K
L
M
N
P
Waste Containers
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Proportioner and Gun Air Supply Hose
Feed Pump Air Supply Lines
Bleed Lines/Over Pressure Relief
Gun Fluid Manifold
G
G
K
M
K
A
N
F
J
D
E
L
P
H
C*
B
ti8489a
* Shown exposed for clarity. Wrap with tape during operation.
FIG. 1: Typical Installation, without Circulation
311511G
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Typical Installation, with Circulation
Typical Installation, with Circulation
Key for FIG. 2
A
B
C
D
E
F
Reactor Proportioner
Heated Hose
Fluid Temperature Sensor (FTS)
Heated Whip Hose
Fusion Spray Gun
G
J
K
L
M
N
P
Feed Pump Air Supply Lines
Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Proportioner and Gun Air Supply Hose
Recirculation/Over Pressure Relief Return Hoses
Gun Fluid Manifold
G
K
M
M
K
A
F
N
J
D
E
L
N
P
C*
B
ti8488a
* Shown exposed for clarity. Wrap with tape during operation.
FIG. 2: Typical Installation, with Circulation
8
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Moisture Sensitivity of Isocyanates
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.
Spraying materials containing isocyanates creates
potentially harmful mists, vapors, and atomized par-
ticulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
The amount of film formation and rate of
crystallization varies depending on the blend of
ISO, the humidity, and the temperature.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventila-
tion in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
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.
To prevent contact with isocyanates, appropriate per-
sonal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
•
Keep the Iso (A) Pump Lube system jar 3/4 filled
with clean Throat Seal Lubricant (TSL) 206995.
Change whenever fluid appears cloudy.
Keep Components A and B
Separate
•
•
Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
NOTICE
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A
(isocyanate) and component B (resin) parts.
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
contaminated from the other side.
Changing Materials
•
•
Always park pumps when you shutdown.
•
When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
Always lubricate threaded parts with Part 217374
ISO pump oil or grease when reassembling.
•
•
Always clean the fluid inlet strainers after flushing.
Check with your material manufacturer for chemical
compatibility.
Foam Self-Ignition
•
•
Most materials use ISO on the A side, but some use
ISO on the B side.
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
material MSDS.
Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
311511G
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Component Identification
Key:
R
Main Disconnect Switch - Controls power to all
AH Resin (B) Proportioning Pump - Draws in and
circuits. It must be ON for proportioning unit to
operate. Temperature displays are lit when main
switch is ON.
dispenses a fixed volume of resin to gun.
™
AI Power-Lock Hose Heat Connection - Connects
power to heated hoses.
S
T
Main Air Filter - Filters system air supply.
*AJ Primary Heater Over-Temperature Switch -
Sends signal to temperature controller if heater
exceeds maximum temperature condition.
Resin (B) Pressure Gauge - Displays pressure in
resin proportioning system (B side).
AK Resin (B) Pump Wet Cup - Access for daily wet
U
Resin (B) - Inlet Supply Valve
cup refill.
V
Resin (B) Fluid Y-Strainer
DD Air Inlet Ball Valve - (3/8 NPT male fitting)
FF ISO (A) Inlet - Fitting (1/2 swivel fitting)
GG Resin (B) - Inlet (3/4 swivel fitting)
W ISO (A) Pressure Gauge - Displays pressure in
isocyanate proportioning system (A side).
X
Y
Z
ISO (A) - Inlet Supply Valve
* Components not shown.
ISO (A) Fluid Y-Strainer
ISO (A) Pump Lube System - (A side only)
AA ISO (A) - Packing Nut and Lube Cup - (A side
only)
*ABPressure Limit Switches - Factory set to turn off
air drive system when proportioning pump exceeds
designed operating pressure limit.
*ACPrimary Heater Thermocouple - Senses
temperature of primary heater and inputs that
information.
AD FTS Jumper Harness - Carries electrical signal
from FTS sensor in isocyanate hose to hose
temperature controller.
*AEAir Motor Reversing Switch - (Front of air motor)
Energizes and de-energizes air solenoid valve coils
to reverse direction.
*AFPrimary Heater - Heats material to required
dispensing temperature.
AG ISO (A) - (Isocyanate) Proportioning Pump -
Draws in and dispenses a fixed volume of
isocyanate to gun.
311511G
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Controls and Indicators
Controls and Indicators
AK
AN
AV
AU
AP
AQ
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AR
AM
AL
AO
AT
AS
AW
Key:
AK Primary Heater Switch - Controls and protects
primary heater. It must be ON and lit green for
primary heater to operate.
AP Park/Run Switch -
•
PARK - Use this position for shutdown. Stops air
motor at bottom of stroke with proportioning
pumps in retracted position when trigger is
pulled.
AL Hose Heater Switch - Controls and protects hose
heat circuit. It must be ON and lit green for hose
heater to operate.
•
RUN - Enables Air Motor Power
AQ Pump Directional Indicator Lights (Green) -
Indicates direction the proportioning pump travels.
Both lights are off when pump switch is OFF or
when either proportioning pump exceeds its
operating pressure limit switch.
AM Hose Temperature Controller - Controls
temperature of hose heat. Adjust set point to
desired temperature. From this point, the
temperature control is automatic. Displays current
temperature after time-out.
AR Counter - Records cycle count of proportioning
pumps. One cycle count equals two strokes (one in
each direction). One cycle equals .028 gal. (.106 l).
AN Primary Heater Temperature Controller - Controls
temperature of primary heater. Adjust set point to
desired temperature. From this point, the
temperature control is automatic.
AS Downstroke Air Pressure Regulator - Controls air
pressure to air motor during downstroke.
AO Pump Mode Function Knob - Controls operation
AT Downstroke Air Pressure Gauge - Displays air
of air drive system.
pressure in air drive system during downstroke.
•
•
•
OFF - Air drive system is off.
AU Upstroke Air Pressure Regulator - Controls air
ON - Must be in this position for unit to operate.
pressure to air motor during upstroke.
START - Momentary position that starts the air
motor movement and illuminates green light in
switch.
AV Upstroke Air Pressure Gauge - Displays air
pressure in air drive system during upstroke.
AW Emergency Stop Switch - Shuts off electrical
power to pump control and both heat control
circuits.
12
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Pressure Relief Procedure
Pressure Relief
Procedure
Flushing
Flush equipment only in a well-ventilated area. Do not
spray flammable fluids. Do not turn on heaters while
flushing with flammable solvents.
1. Turn off feed pumps and agitator if used.
2. Turn PARK/RUN switch to PARK.
•
Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent, such as toluene,
naptha, or mineral spirits before introducing new
fluid.
3. Trigger gun to relieve pressure.
4. Turn off air inlet valve.
•
•
Use lowest possible pressure when flushing.
5. Engage gun piston safety lock.
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.
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.
ti2409a
6. Verify gun fluid manifold valves A and B are closed.
ti2421a
7. Close pump inlet supply valves.
311511G
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Setup
Setup
Locate Reactor A-20
Electrical Requirements
1. Locate Reactor A-20 on a level surface and bolt in
place to the floor with 3/8 in. (10 mm) bolts.
•
Two bolts through the 2 in. (50 mm) deep caster
bushings in the rear.
Improper wiring may cause electric shock or other
serious injury if work is not performed properly. Have a
qualified electrician connect power and ground to main
power switch terminals. Ensure your installation
complies with all National, State, and Local safety and
fire codes.
•
Two bolts through the 3-5/8 in. (168 mm) deep
caster bushings in the front.
2. Do not expose Reactor A-20 to rain.
Also ensure that incoming power is disconnected and
locked out at the source.
3. If you need to move the machine, add
provided casters.
4. Lift with hoist only from bar spanning across top of
cart.
NOTICE
Ensure main power source meets all electrical
requirements specified on nameplate of proportioning
unit. Also ensure main power source has a dedicated
fuse disconnect. Power cord is not supplied.
Determine Power Source
Reactor A-20 can be wired to 3 types of power source:
•
•
•
230 Volt / 1 Phase
230 Volt / 3 Phase Delta
380 Volt / 3 Phase WYE
(220 Volts to Neutral)
14
311511G
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Setup
Configure to Supply Power
positions.
Disregard terminal numbers on disconnect switch
blocks. Wire to positions shown.
Both cord connection AND jumper positioning
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blocks. Wire to positions shown. Terminals will
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accept up to #8 AWG (10 mm ) conductors.
ti8611a
1. Remove and retain two screws from lower front
shroud and remove.
230V, 3 Phase Delta: Use a screwdriver to connect
three power leads to top terminals L1, L2, and L3.
proper jumper positions.
2. Connect main power cord to electrical console as
follows:
a. Feed power cord through strain relief (SR) on
right side of unit. Push black die release lever
(RL) down to release contacts block (PD) for
easy wiring.
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Switch (PD). Snap contacts block (PD) back
onto switch.
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ti8612a
c. Tighten strain relief nut.
380V, 3 Phase WYE (as shipped from factory): Use a
screwdriver to connect three power leads to the top
terminals L1, L2, and L3. Connect neutral to N. Connect
positions.
d. Strain relief accepts cords 0.59 to 1.0 in. (15-25
mm) diameter.
e. Connect ground wire to ground lug (GL).
RL
PD
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ti8613a
ti8608a
3. Replace lower front shroud. Reinstall the two
screws retained in Step 1.
230V, 1 Phase: Use a screwdriver to connect two power
leads to the top terminals N and L2 positions. Connect
311511G
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Setup
For 230V, 1 Phase and 230V, 3 Phase Installations,
change jumper positions as shown below. Machine is
shipped with jumpers in the fail-safe 380 3Ø position.
Step Two - Reposition Power Jumpers
Find location of Power Jumpers.
1. Remove upper rear control cover screws and cover.
2. Move one red jumper from the storage positions to
the positions shown for your power.
Power Jumper
Location
•
A flat-blade screwdriver can be used under the
ridge on the side of the jumper to remove them.
•
Push the jumper firmly into the new position.
3. Replace rear cover and two screws.
ti8609a
Step Two
TB2
Terminal Blocks
Position red jumpers
(under back cover on
opposite side)
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ti8610a
16
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Setup
2. Connect and tighten B- supply hose (J) to 3/4 NPT
Ground System
swivel fitting (GG) on B- inlet ball valve (U), and to
resin transfer pump.
U
•
•
Reactor: is grounded through power cord; see page
15.
J
Spray gun: connect whip hose ground wire to FTS;
see page 18. Do not disconnect wire or spray with-
out whip hose.
GG
ti8451a
•
•
•
Fluid supply containers: follow your local code.
Object being sprayed: follow your local code.
3. Connect and tighten A- supply hose (BB) to 1/2 NPT
swivel fitting (FF) on A- inlet ball valve (X), and to
Solvent pails used when flushing: follow your local
code. Use only metal pails that are conductive.
Place them on a grounded surface. Do no place pail
on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.
Air Supply Connection
Connect main air supply (F) to air inlet fitting (DD) at air
filter (S). Hose fitting requires a 3/8 NPT female fitting.
•
To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of spray gun
firmly to the side of a grounded metal pail, then
trigger gun.
Use a minimum of 3/8 in. ID air line (not supplied)
to deliver air supply to proportioning unit. Use 1/2
in. ID hose if over 15 ft long.The main air supply
must be clean and free of oil and contaminants.
Iso Pump Lubrication System
Setup
Prepare isocyanate pump lubrication system as follows:
1. Lift lubricant reservoir out of bracket and remove
reservoir from cap.
DD
2. Fill reservoir 3/4 full with TSL; see Accessories
section in manual 311512.
3. Thread reservoir onto cap assembly and place it
into bracket.
F
The lubrication system is now ready for operation; no
priming is required.
S
Fluid Supply Connections
ti8456a
Connect material supply to inlets of proportioning unit as
follows:
1. Ensure the A- and B- inlet ball valves (U,X) on
proportioning unit are closed.
311511G
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Setup
Connect FTS and Heated Dual Whip Hose
4. Connect fluid hoses to FTS (J).
NOTICE
To prevent damage to probe, do not kink or
excessively bend hose. Do not coil hose
tighter than the minimum bend radius of 3 ft
(0.9 m). Do not subject hose to excessive
weight, impact, or other abuse.
To use 1/2 in. (13 mm) ID fluid hoses,
remove the adapters from the propor-
tioner fluid manifold and install them in
the FTS swivel inlets.
5. Connect electrical connectors (D).
1. Carefully extend FTS probe (H) into the
hose section from the proportioner. Do not
bend or kink probe. Insert in component A
(ISO) side of main hose for foam or poly-
urea systems.
6. Connect air hose (C) to whip air hose (L).
7. Connect hose assembly cable (F) to FTS
cable (R). Slide insulator sleeves (S) over
connection. Leave slack (G) in cables as
stress relief, to prevent cable failure.
2. Connect FTS (J) to whip hose (W).
8. Check hoses for leaks (see your Heated
Hose manual).
3. Connect whip hose ground wire (K) to
ground screw on underside of FTS.
D
B
To Gun
K
J
To Proportioner
G
S
R
F
S
W
A
H
B
A
L
C
TI9581C
FIG. 4: Connect FTS and Heated Dual Whip Hose
18
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Setup
1. Turn main power OFF.
Recirculation / Pressure Relief
Lines
2. Assemble heated hose sections, FTS, and whip
hose; see manual 309572.
3. Connect A and B hoses to A and B outlets on
Reactor fluid manifold (FM). Hoses are color coded:
red for component A (ISO), blue for component B
(RES). Fittings are sized to prevent connection
errors.
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as over pressure relief valves when set to
SPRAY. Lines must be open so valves can
automatically relieve pressure when machine is
operating.
FM
VV
If circulating fluid back to the supply drums, use high
pressure hose rated to withstand the maximum
working pressure of this equipment.
WW
If Recirculating to Supply Drum: Connect high
pressure hose (R) to relief fittings (BA, BB) of both
PRESSURE RELIEF/SPRAY valves. Route hose back
to component A and B drums. Refer to manual 309852.
ti8444a
Manifold hose fittings (VV, WW) allow use of 1/4 in.
and 3/8 in. ID Reactor heated fluid hoses.
Alternate recirculation hoses (requires adapter
fittings):
249508 - ISO (A) (moisture guard) red hose, 1/4 in. (6
mm) ID; #5 JIC fittings (m x f); 35 ft (10.7 m) long.
4. Connect cables (SS). Connect electrical connectors
(NN). Be sure cables have slack when hose bends.
Wrap cable and electrical connections with electrical
tape.
249509 - Resin (B) blue hose; 1/4 in. (6 mm) ID, #6 JIC
fittings (m x f), 35 ft (10.7 m) long.
SS
BB
R
BA
NN
R
ti8441a
ti8444a
Connect Heated Hose
See manual 309572 for detailed instructions for
Graco heated hoses.
The fluid temperature sensor (FTS) and whip hose
length, including whip hose, must be 60 ft (18.3 m)
minimum.
311511G
19
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Setup
Close Gun Fluid Manifold Valves
A and B
ti2411a
Connect Whip Hose to Gun Fluid
Manifold
Do not connect manifold to gun.
ti2417a
Pressure Check Hose
See hose manual. Pressure check for leaks. If no leaks,
wrap hose and electrical connections to protect from
damage.
20
311511G
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Initial Startup
Initial Startup
3. Turn both PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY.
Do not operate Reactor without all covers and shrouds
in place.
SB
SA
Fluid Temperature Sensor (FTS)
Calibration
Calibrate the FTS ONLY at initial startup (the first
time the unit is operated) and any time the hose
length changes.
ti8442a
4. Open both fluid valves (FV).
1. Before turning on the unit, ensure all hoses and
cables are properly connected. To ensure that the
FTS in the hose is at the same temperature as the
heaters, keep heat off and store the hose FTS near
the machine for several minutes.
FV
2. While holding down the temperature unit button
(Fahrenheit - “F” or Celsius - “C”) turn the Reactor
main power ON.
ti8449a
5. Start feed pumps. Do not start proportioner air
motor or pumps.
3. Hold the temperature unit button until temperature is
shown on the display. The fluid temperature sensor
is now correctly calibrated.
Load Fluid with Feed Pumps
Always provide two grounded waste containers to
keep component A and component B fluids separate.
The Reactor is tested with oil at the factory. Flush
out the oil with a compatible solvent before
6. Hold gun fluid manifold over two grounded waste
containers. Open fluid valves A and B until clean,
air-free fluid comes from valves. Close valves.
2. Turn on component B agitator, if used.
TI2484a
311511G
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Initial Startup
Digital Temperature Controllers
To change or enter the set point, proceed as follows:
NOTICE
1. Ensure red main disconnect switch is ON.
Temperature Controllers will illuminate.
Do not turn power on to the hose heat until after all
hose power connectors are connected.
The proportioner has two temperature controllers that
automatically manage the temperature for the primary
heater and the hose heat.
Heat Output
ꢃꢀ
ꢃꢁ
Alarm Normal
Hose Only
NOTICE
To prevent damage to primary heaters and hoses, do
not turn on heat controller switches next to tempera-
ture controllers until purging procedures are complete
and heater and hoses are filled with chemical.
A1
A2
A3
Controller Screens
2. Press and release Scroll button (A1). Display will
read “SP1”. Press and release Up (A2) or Down
(A3) button to display set point.
Push the left side scroll button to cycle through the
following screens.
Current temperature
reading.
Do not change SP2; see Over Temperature Alarm
section.
Home
“XXXX”
“_SP1”
Temperature controller normally displays actual
temperature. When illuminated, red “01” display at
upper left indicates controller is asking for heat. The
“01” disappears when liquid in heater or hose
reaches set point temperature. The “01” cycles on
and off to indicate temperature maintenance.
Set Point 1. Use arrow
keys to enter set point.
Set Point 2. Only shows
on Hose Controller.
High temperature devia-
tion alarm. Leave set at
30°F (17°C).
“_SP2”
3. Press and hold Up (A2) or Down (A3) button to
increase or decrease value.
4. After set point is entered, press and release Up (A2)
and Down (A3) buttons together to display actual
temperature. Actual temperature will also display
after a time-out period.
This screen indicates
power output in percent.
“Hxx.x”
“UNIT”
Use the arrow keys to
select °F or °C.
5. To start heaters, turn green control power switch
from ON to START. Light within switch will
illuminate.
NOTICE
Controllers are factory programmed and are not field
programmable. If you encounter problems with a con-
troller, order a replacement. Do not change any pro-
grammed parameters. Do not substitute with
controller from alternate supplier; its use may damage
equipment.The heater and hose controllers are not
interchangeable.
22
311511G
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Initial Startup
Change Between Fahrenheit and Celsius
The temperature controller is factory-set to display in
Fahrenheit units.
To change to Celsius units:
1. Press and release Scroll button (A1) until Controller
displays “UNIT”.
2. Press and release Down button (A3) once to display
“F”.
3. Press and release Down button (A3) once again to
display “C”.
4. Press and release Scroll button (A1) twice.
Controller will display Celsius units.
To change back to Fahrenheit units:
1. Press and release Scroll button (A1) until Controller
displays “UNIT”.
2. Press and release Down button (A3) once to display
“C”.
3. Press and release Down button (A3) once again to
display “F”.
4. Press and release Scroll button (A1) twice.
Controller will display Fahrenheit units.
311511G
23
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Initial Startup
Over Temperature Alarms
Hose Heat Manual Mode
Both the fluid heater and the hose heat have over
temperature alarms that will turn off the heat zone if high
temperatures are detected. If this happens, the green
light in the switch for that heat zone will go out.
If the hose temperature controller does not see the Fluid
Temperature Sensor (FTS), it will shut off the hose heat
and give a flashing error alternating between:
SbEr = Sensor break error
H20.0 = Heat output 20%
The fluid heater has a fixed temperature switch on the
aluminum heater that opens at 230 °F (110 °C) and
turns off the heat zone. The temperature switch will
automatically reset, but the heat zone will need to be
manually restarted. The over-temperature condition
should never happen unless the solid state relay
(165SSR) fails closed.
The hose can be manually heated by turning the hose
back on with the hose switch and green light. The
up/down arrows can be used to adjust the default 20%
power output.
There is no monitoring or alarm in manual mode. You
must monitor the temperature by inserting a probe
thermometer inside the hose insulation against the
hose. The thermometer will read 10-20 °F less than
actual fluid temperature. Repair the temperature sensor
or cable as soon as possible to avoid damaging the
heated hose.
The hose heat uses the temperature controller alarm,
monitoring the hose thermocouple (FTS) to watch for
high temperature conditions. This alarm is controlled by
SP2 (Set Point 2) and is factory set for 30 °F (17 °C).
This means that the alarm set point is 30° (17 °C) over
the SP1 operating temperature set point. Under normal
conditions, the output 02 light will be lit on the hose
controller. This output holds the hose heat power
contact ON and lights the green light in the switch any
time power is available to heat the hose. If the hose
temperature reading is 30 °F (17 °C) (SP2 setting) over
the temperature set point (SP1), the output 02 light and
switch light will go out. Hose heat will only return after a
manual START of the control switch, after alarm
conditions are gone.
The hose heat deviation alarm is controlled by the SP2
setpoint. This is factory set to 30 °F (17 °C) and should
not be changed. A loss of alarm function and loss of
automatic over temperature shut-down could result.
Fluid Heater Temperature Offset
The fluid heater has been calibrated to provide setpoint
temperature fluid under flow conditions. When the
machine is powered up and no heat has been turned on,
the heater display will read somewhat lower than the
hose display. This is normal. The hose display has no
offset and will always read the actual temperature at the
sensor in the hose.
24
311511G
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Initial Startup
2. Component B (Resin) Pump: Check felt washers
in packing nut/wet-cup (AK) daily. Keep saturated
with TSL to prevent material from hardening on
displacement rod. Replace felt washers when worn
or contaminated with hardened material.
Supply Wet-Cups with Throat
Seal Liquid
Pump rod and connecting rod move during operation.
Moving parts can cause serious injury such as
pinching or amputation. Keep hands and fingers away
from wet-cup during operation. Turn main power OFF
before filling wet-cup.
AK
1. Component A (ISO) Pump: Keep reservoir (Z) 3/4
filled with TSL. Wet-cup piston circulates TSL
through wet-cup to carry away isocyanate film on
displacement rod. Change the fluid in the reservoir
when it becomes milky-looking.
ti8448a
Z
ti8610a
311511G
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Spraying Setup
Spraying Setup
1. After reaching spray temperatures, engage gun
piston safety lock.
5. Open air inlet ball valve (DD).
S
DD
ti8449a
ti2409a
counterclockwise to 0 pressure.
2. Close gun fluid manifold valves A and B.
7. Turn RUN/PARK switch to RUN.
8. Turn Pump Mode Function knob to START.
9. Slowly increase each UP/DN air regulator setting by
alternating pattern 5-10 psi (0.035-0.07 MPa,
0.35-0.7 bar) at a time until the approximate stall
(static) pressure is achieved on fluid gauges (GA)
and (GB). Leave UP stroke regulator setting at
approximately 10 psi (0.07MPa, 0.7 bar) lower than
DN stroke.
ti2728a
3. Attach gun fluid manifold. Connect gun air line.
Open air line valve.
GA
GB
ti8441a
ti2543a
10. Open gun fluid manifold valves A and B.
4. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY.
SB
SA
ti2414a
ti8442a
26
311511G
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Spraying Setup
11. Disengage gun piston safety lock.
Spray Adjustments
Flow rate, atomization, and amount of overspray are
affected by four variables.
•
Fluid pressure setting. Too little pressure results in
an uneven pattern, coarse droplet size, low flow,
and poor mixing. Too much pressure results in
excessive overspray, high flow rates, difficult control,
and excessive wear.
ti2410a
12. Test spray onto cardboard. Adjust for desired fluid
pressure on the DN stroke with regulator (AS).
Briefly spray until the UP stroke indicator light is on
and increase the UP regulator setting until the fluid
pressure (GA, GB) matches the DN stroke pressure.
This compensates for feed pump pressure boost.
•
•
Fluid temperature. Effects are similar to when fluid
pressure setting is too high or too low.
Mix chamber size. Choice of mix chamber is based
on desired flow rate within machine capability and
fluid viscosity.
Pumps have fluid to air ratio of 17.5 to 1. Feed
pumps add 2X feed pressure boost to outlet
pressure (on the up stroke only).
•
Cleanoff air adjustment. Too little cleanoff air
results in droplets building up on the front of the
nozzle, and no pattern containment to control over-
spray. Too much cleanoff air results in air-assisted
atomization and excessive overspray.
13. Check A and B fluid pressure gauges (GA, GB) to
ensure proper pressure balance between A and B. If
imbalanced, see repair manual 311512.
14. Equipment is ready to spray.
311511G
27
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Shutdown
Shutdown
1. Shut off Primary and Hose heat switches.
7. Check and fill wet-cups (AK, Z).
8. Follow gun shutdown procedure.
34!24
/.
/&&
2. Park component A pump. Turn PARK/RUN switch to
PARK.
4. Turn Pump Mode Function knob to OFF.
34!24
/.
/&&
5. Turn Main Power Disconnect switch (R) OFF.
6. Close air inlet ball valve (DD) and fluid inlet valves
(X, U).
28
311511G
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Operation
Operation
11. Turn on primary heater switch past ON to START.
Daily Start-up Procedure
Ensure heater setpoint is correct. Wait for operating
temperature to be reached.
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.
To prevent excessive pressure build-up in heated
hoses, always bring hoses and primary heater up to
operating temperature before turning on pump switch.
12. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY.
1. Check condition isocyanate lubrication system and
service as required. Change pump lubricant when it
shows signs of change to a milky color.
SA
SB
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
ti8442a
3. Turn on main air supply to transfer pumps.
4. Pressurize transfer pumps and open A- and B-inlet
supply valves.
13. Turn PARK/RUN switch to RUN.
14. Turn Pump Mode Function switch to ON and
momentarily to START. Pumps will pressurize the
fluid according to air regulator pressure.
5. Open air inlet ball valve.
6. Switch ON main power disconnect switch.
7. Uncoil heated hose.
15. Check A and B fluid pressure gauges (GA, GB) to
ensure proper pressure balance between A and B. If
imbalanced, bleed off the high side with valves SA
and SB until balanced.
NOTICE
Uncoil heated hoses before turning on hose heater
switch to prevent overheating and hot spots within
hose.
8. Check that hose setpoint temperature is correct.
9. Turn hose heat control switch past ON to START.
Switch will illuminate.
GA
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 readout to match hose setpoint
temperature.
GB
ti8442a
311511G
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Operation
16. Open gun fluid manifold valves A and B.
ti2414A
17. Disengage gun piston safety lock.
ti2410A
18. Test spray onto cardboard.
19. Observe isocyanate-A and resin-B gauges on up
and down strokes. Readjust upstroke pressure
regulator as required to ensure proportioning pump
pressure is equal on both the up and down strokes.
20. Equipment is ready to spray.
30
311511G
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Fluid Circulation
Fluid Circulation
Circulation Through Reactor
Do not turn on hose heat unless hoses are already
loaded with fluid.
7. Set both Air Regulator pressures to start at 15 psi
(1.0 bar).
containing a blowing agent without consulting with
your material supplier regarding fluid temperature
limits.
8. Turn PARK/RUN switch to RUN.
9. Turn Pump Mode Function switch to START.
10. Recirculate until desired temperature reaches set
point.
To circulate through gun manifold and preheat hose; see
11. Turn Pump Mode Function knob to OFF.
12. Turn on hose heat if hose is filled with fluid without
air pockets or solvent.
13. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to
SPRAY.
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as overpressure relief valves when set to
SPRAY. Lines must be open so valves can
automatically relive pressure when machine is
operating.
SA
SB
2. Route circulation lines back to respective
component A or B supply drum. Use hoses rated at
the maximum working pressure of this equipment,
see hose manual.
ti8442a
3. Set RECIRC/SPRAY valves (SA, SB) to RECIRC.
For additional circulation information, refer to
manual 309852.
SA
SB
BA
BB
ti8442a
4. Turn Main Disconnect Switch (R) ON.
5. Open air inlet ball valve.
heater.
311511G
31
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Fluid Circulation
2. Connect high pressure circulation lines (N) to
circulation manifold (CK). Route circulation lines
back to respective component A or B supply drum.
Use hoses rated at the maximum working pressure
of this equipment.
Circulation Through Gun
Manifold
3. Follow Load Fluid with Feed Pumps procedure; see
containing a blowing agent without consulting with
your material supplier regarding fluid temperature
limits.
4. Turn Main Power Disconnect Switch (R) ON.
5. Open air inlet ball valve.
Circulating fluid through the gun manifold allows rapid
preheating of hose.
heater.
1. Install gun fluid manifold (FM) on Part 246362
accessory circulation kit (CK).
Do not turn on hose heat unless hoses are already
loaded with fluid.
7. Set both Air Regulator pressures to start at 15 psi
(1.0 bar).
8. Turn PARK/RUN switch to RUN.
FM
9. Turn Pump Mode Function switch to START.
10. Recirculate until desired temperature reaches set
point.
CK
N
11. Turn Pump Mode Function switch to OFF.
12. Close gun fluid manifold valves.
ti2767a
13. Reconnect gun to fluid manifold and air hose.
For additional recirculation information, refer to
manual 309818.
32
311511G
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Fluid Circulation
Maintenance
•
Check and add TSL to B side pump wet-cup daily.
•
Check ISO lube bottle for significant discoloration or
crystallization daily. Replace with fresh TSL when
needed.
•
•
•
Ensure ISO (A) pump is down and in PARK position
during every shutdown.
Keep any ISO (A) fluid from being exposed to atmo-
sphere to prevent crystallization.
Remove inlet filter screen plug (V, Y) and clean
screens if increased unbalanced pressures between
A and B is noticed or as needed for fluids used. Also
clean after flushing.
•
•
Close gun fluid shutoff valves when not in use.
If using a Fusion Air Purge gun, add grease with
grease gun per manual.
•
•
Clean gun filter screens and mix chamber ports reg-
ularly, or when increased unbalanced pressures
between A and B is noticed. See gun manual.
Use lithium grease or Iso Pump Oil on all threaded
fluid fittings on the “A” side.
311511G
33
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Technical Data
Technical Data
Category
Data
Maximum Fluid Working Pressure
Maximum Air Working Pressure
Machine Maximum Power with hose
2000 psi (1.4 MPa, 140 bar)
120 psi (0.84 MPa, 8.4 bar)
9000 Watts
Voltage Requirement (50/60 Hz)
(230 V Nominal: 195-253 VAC)
(380 V Nominal: 338-457 VAC)
230 V, 1 Phase
230 V, 3 Phase (Delta)
380 V, 3 Phase (WYE 220 V Neutral)
Amperage Requirement (Full Load Peak)*
40 amps @ 230 V, 1 Phase
32 amps @ 230 V, 3 Phase
18.5 amps @ 380 V, 3 Phase
Maximum Heater Fluid Temperature
Maximum Hose Fluid Temperature
Maximum Ambient Temperature
Maximum Output
Output Per Cycle (A and B)
Overpressure Relief Shutdown
Over Temperature Shutdown (Primary Heater)
Heater Power
190 °F (88 °C)
180 °F (82 °C)
120 °F (49 °C)
20 lb/min. (9.0 kg/min.)
.028 gal/cycle (.105 ltr/cycle)
2250 psi (15.5 MPa, 155 bar)
230 °F (110 °C)
6000 Watts
Hose Power
2790 Watts
Sound Pressure
Sound Power, per ISO 9614-2
Viscosity Range
86.3 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)
91.6 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)
250-1500 centipoise
Maximum Fluid Inlet Pressure
Fluid Inlet/Strainer Filter
Air inlet Filter Mesh
400 psi (2.7 MPa, 27 bar)
20 mesh standard
5 Micron
Component B (Resin) Inlet
Component A (Isocyanate) Inlet
Recirculation/Block Hose Connections
Maximum Heated Hose Length***
Height
3/4 npt(f) swivel
1/2 npt(f) swivel
Iso (A) side: #5 JIC (m); Resin (B) side: #6 JIC (m)
210 ft of 3/8 ID
39.5 in. (1003.3 cm)
Width
27.2 in. (690.9 cm)
Depth
25.0 in. (635 cm)
Weight
250 lb (117.6 kg)
Wetted Parts
Carbon steel, stainless steel, chrome, aluminum,
Fluoroelastomer, PTFE, nylon
Certification
CE **
*Full load amps with all devices operating at maximum
capabilities with 210 ft (64.1 m) of hose.
**When a surge transient is applied to the power lines of the unit, heat to the hose may be interrupted and require the
hose heat switch to be manually cycled.
***210 ft (64 m) of heated hose will produce the maximum allowable heat capacity. 310 ft (94 m) of heated hose may
be used, but will have 25% less heat capacity.
34
311511G
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Technical Data
311511G
35
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Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 311511
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2006, Graco Inc. is registered to ISO 9001
Revised 01/2011
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