Graco Inc. 246639, 246752, 246753, 246365, 246760 Repair - Parts

...
Repair - Parts
309813H
Air Powered, Heated, Plural Component Proportioners
For spraying polyurethane foam and polyurea coatings. Not for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
For model information, see page 3.
TI3699b

Manual Conventions

Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air Powered Reactors . . . . . . . . . . . . . . . . . . . . . 3
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Beginning Repair . . . . . . . . . . . . . . . . . . . . 8
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 9
Temperature Control Diagnostic Codes . . . . . . . 10
E01: High fluid temperature . . . . . . . . . . . . . . . 10
E02: High hose current . . . . . . . . . . . . . . . . . . . 10
E03: No hose current . . . . . . . . . . . . . . . . . . . . 11
E04: FTS or thermocouple not connected . . . . 11
E05: Board overtemperature . . . . . . . . . . . . . . . 11
Manual Conventions
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Proportioning Pump . . . . . . . . . . . . . . . . . . . . . . 15
Circuit Breaker Module . . . . . . . . . . . . . . . . . . . 16
Temperature Control Board . . . . . . . . . . . . . . . . 18
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heated Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 23
Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 29
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 50
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 50
Warning
WARNING
A warning alerts you to possible serious injury or death if you do not follow instructions.
Symbols, such as fluid injection (shown), alert you to a specific hazard and direct you to read the indicated hazard warnings on pages 6-7.
Caution
CAUTION
A caution alerts you to possible equipment damage or destruction if you do not follow instructions.
Note
A note indicates additional helpful information.
2 309813H

Models

Air Powered Reactors
A-XP SERIES
Models
Full
Load Part No., Series Model
246639, B A-XP2 230V (1) 62 14,540 10,200 1 (3.8) .0193 (.073) 3000 (20.7, 207) 246752, B A-XP2 230V (3) 40 14,540 10,200 1 (3.8) .0193 (.073) 3000 (20.7, 207) 246753, B A-XP2 380V (3) 22 14,540 10,200 1 (3.8) .0193 (.073) 3000 (20.7, 207)
Voltag e (phase)
Peak
Amps*
System Watts**
Heater Watts (no hose)
Flow gpm (lpm) at 78 cpm
Output per Cycle (A + B) gal. (liter)
Maximum Fluid Working Pressure psi (MPa, bar)
Heat Packages (do not include proportioner)
Full
Load Part No., Series Model
246365, B HT-6.0 230V (1) 44 10,340 6,000 3500 (24.1, 241) 246760, B HT-6.0 230V (3) 27 10,340 6,000 3500 (24.1, 241) 246761, B HT-6.0 380V (3) 18 10,340 6,000 3500 (24.1, 241) 246607, B HT-10.2 230V (1) 62 14,540 10,200 3500 (24.1, 241) 246762, B HT-10.2 230V (3) 40 14,540 10,200 3500 (24.1, 241) 246763, B HT-10.2 380V (3) 22 14,540 10,200 3500 (24.1, 241) 246364, B HT-15.3 230V (1) 84 19,640 15,300 3500 (24.1, 241) 246764, B HT-15.3 230V (3) 57 19,640 15,300 3500 (24.1, 241) 246765, B HT-15.3 380V (3) 33 19,640 15,300 3500 (24.1, 241)
Voltag e (phase)
Peak
Amps*
System Watts**
Heater Watts (no hose)
Maximum Fluid Working Pressures psi (MPa, bar)
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber
sizes may be less.
**Total system watts for all units, using 310 ft (94.6 m) hose.
309813H 3

Supplied Manuals

Supplied Manuals
The following manuals are shipped with the Reactor™. Refer to them for detailed equipment information.
Air and Hydraulic Reactors Part No. Description
309812 Air and Hydraulic Reactors, Operation Manual (English)
Proportioning Pumps Part No. Description
308224
Motors Part No. Description
306982
Displacement Pumps Part No. Description
307430 Displacement Pumps Repair-Parts Manual (English)
Reactor Electrical Diagrams (one of following included) Part No. Description
309854 Electrical Diagrams, 230V 1 phase 309855 Electrical Diagrams, 230V 3 phase 309576 Electrical Diagrams, 380V 3 phase
Air Regulators (air powered units only)
President
President
®
Pump Repair-Parts Manual (English)
®
Air Motor Repair-Parts Manual (English)
Order Part No. 15B535 for a compact disk of Reactor manuals translated in several languages.
Part No. Description
308168 Instruction-Parts Manual (English)
4 309813H

Related Manuals

Related Manuals
The following manuals are for accessories used with the Reactor
.
Hydraulic Power Supply Part No. Description
307550 Instruction-Parts Manual (English)
Feed Pump Kits 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 Kits Part No. Description
309852 Instruction-Parts Manual (English)
Heated Hose
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.
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 Kit Part No. Description
309818 Instruction-Parts Manual (English)
Data Reporting Kit Part No. Description
309814 Instruction-Parts Manual (English)
309813H 5

Warning

WARNING
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 the gun at anyone or at any part of the body.
Do not put your hand or fingers over the gun fluid nozzle.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Do not “blow back” fluid; this is not an air spray system.
Follow Pressure Relief Procedure, page 9, when you stop spraying and before cleaning, checking,
or servicing equipment.
Use lowest possible pressure when flushing, priming, or troubleshooting.
Engage spray gun piston safety lock when not spraying.
Tighten all fluid connections before operating the equipment.
Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pres­sure hose cannot be recoupled; replace the entire hose.
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Solvent and fumes in work area can ignite or explode. High voltage components can cause electric shock. To help prevent fire, explosion, and electric shock:
Shut off main power switch and wait 5 minutes before opening Reactor cabinet door.
All electrical wiring must be done by trained and qualified personnel and comply with all local codes.
Ground equipment and conductive objects. See Grounding in the Operation manual.
Use equipment only in well ventilated area.
Eliminate all ignition sources, such as pilot lights, cigarettes and plastic drop cloths (potential static arc).
Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
Keep the work area free of debris, including solvent, rags, and gasoline.
Hold gun firmly to side of grounded pail when triggering into pail.
Use only grounded hoses.
If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.
To avoid chemical reaction and explosion, do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment.
6 309813H
Warning
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause serious injury or death.
For professional use only.
Use equipment only for its intended purpose. Call your Graco distributor for information.
Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not alter or modify equipment. Use only Graco parts and accessories.
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.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not use hoses to pull equipment.
Comply with all applicable safety regulations.
BURN HAZARD
This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns:
Do not touch hot fluid or equipment.
Allow equipment to cool completely before touching it.
Wear gloves if fluid temperature exceeds 110°F (43°C).
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 Material Safety Data Sheet (MSDS) 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.
PERSONAL PROTECTIVE EQUIPMENT
You must wear proper 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; and hearing loss. This equipment includes but is not limited to:
Protective eyewear.
Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer.
Hearing protection.
309813H 7

Before Beginning Repair

Before Beginning Repair
WARNING
Repairing this equipment requires access to parts which 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, see the Operation manual. Be sure to shut off all power to the equipment before repairing.
1. Flush if necessary, see right.
2. Trigger gun to park pumps at bottom of stroke.

Flushing

WARNING
Read warnings, page 6. 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 solvent before introducing new fluid.
Use the lowest possible pressure when flushing.
All fluid components are compatible with common solvents. Use only moisture-free solvents.
To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF.
3. Fill wet-cups. See operation manual.
4. Turn main power OFF .
5. Close red-handled valve to shut off power to
motor.
6. Relieve pressure, page 9.
SA
SB
TI3593a
To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).
Always leave some type of fluid in system. Do not use water.
8 309813H

Pressure Relief Procedure

Pressure Relief Procedure
1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual.
2. Verify gun fluid manifold valves A and B are closed.
TI2421A
6. Engage gun piston safety lock.
TI2409A
7. Disconnect gun air line and remove gun fluid mani­fold.
TI2543A
3. Shut off feed pumps and agitator, if used.
4. Check that red-handled valve is closed, to shut off power to motor.
5. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF. Route fluid to waste con­tainers or supply tanks. Ensure gauges drop to 0.
SA
SB
TI3593a
Pump throat seals work best under pressure. Close fluid inlet valves (VA, VB) when Reactor is depressurized, to prevent drum head pressure from leaking past pump piston seals.
8. Close fluid inlet valves (VA, VB).
VA
VB
TI3698b
309813H 9

Temperature Control Diagnostic Codes

Temperature Control Diagnostic Codes
Temperature control diagnostic codes E01 through E05 appear on temperature display.
Code
No.
01 High fluid temperature Individual 10 02 High hose current Hose only 10 03 No hose current with hose heater on Hose only 11 04 FTS or thermocouple not connected Individual 11 05 Board overtemperature All 11
For hose zone only, if FTS is disconnected at startup, display will show hose current 0A.
Code Name Alarm Zone Corrective
These alarms turn off heat. Turn main power OFF
then ON to clear.
Action page
E01: High fluid temperature E02: High hose current
a. Check connections between temperature control
board and heater overtemperature switches, page 22.
a. Check tap connection at transformer, see opera-
tion manual.
b. Check temperature sensors, page 21.
c. Check temperature sensor is contacting heater
element, page 21.
b. Check hose connections for electrical short,
page 22.
c. Move to lower hose length on transformer.
d. Replace temperature control board, page 18.
10 309813H
Temperature Control Diagnostic Codes
E03: No hose current
Do steps in order. Do not skip any step.
a. Check hose connectors for broken electrical
connection, page 22.
b. Test hose continuity, page 25.
c. Test transformer wire harness continuity, page
25.
d. Check 50A (806) and 20A (817A) circuit break-
ers, page 16.
e. Test current sensor continuity, page 25.
f. Do In-Rush Current Limiter Check (380V
only), page 27
e. Use manual current control mode; see operation
manual.
E05: Board overtemperature
a. Check fan operation.
b. Check electrical cabinet door is properly
installed.
c. Check for obstructions blocking cooling holes in
bottom of Reactor.
d. Ambient temperature too high. Reduce gun mix
chamber size, or move Reactor to a cooler loca­tion.
g. Do Transformer Primary Check, page 27.
h. Do Transformer Secondary Check, page 27.
E04: FTS or thermocouple not connected
a. Check FTS operation by connecting directly to
Reactor.
b. Check cable connections between all hose
lengths.
c. Check temperature sensor connection at J1 on
temperature control board, page 18.
d. Check thermocouple with ohmmeter, page 23.
309813H 11

Troubleshooting

Troubleshooting
PROBLEM CAUSE SOLUTION
Reactor does not operate. No power. Plug in power cord.
Tur n m ain pow er O N .
Turn circuit breakers ON, page 16. No air or hydraulic power. Open red-handled valve. Red stop button circuit open. Check button connections. See page
29 and electrical diagrams.
Fan not working. Blown fuse. Replace, page 17.
Loose wire. Check. Defective fan. Replace, page 17.
Pump output low. Obstructed fluid hose or gun; fluid
hose ID too small. Worn piston valve or intake valve in
displacement pump.
Fluid leak in pump packing nut area. Worn throat seals. Replace. See pump manual. No display. Main power OFF. Turn main power ON .
Open, clear; use hose with larger ID.
See pump manual.
Loose display cable. Check cable connections, page 29. Display board failed. Check board, replace; page 29.
No temperature display. Loose display cable. Check cable connections, page 29.
Failed temperature control board. Open cabinet. Check if board LED is
blinking. If not, check power wiring
connections to ensure board has
power. If board has power and LED is
not blinking, replace board, page 18. Inadequate power to temperature
board. Loose power cable (internal to dis-
play). Defective display board. Replace, page 29.
No cycle counter display. Loose display cable. Check cable connections, page 29.
Defective counter. Replace, page 29.
Does not count. Magnet (26) missing from pump
yoke. Defective reed switch (27). Replace.
Check that power supply meets
requirements.
Check cable connections, page 29.
Replace.
12 309813H
PROBLEM CAUSE SOLUTION
Hose display reads 0A on startup.
FTS not installed and zone off.
Troubleshooting
Install FTS (see operation manual), or adjust current to desired setting.
Erratic display; display turns on and off.
Display buttons do not work properly; cannot get out of an operation.
Red stop button does not work. Broken button (fused contact). Replace, page 29.
No heat in any zone. Red stop button circuit open. Check button connections. See page
No heat in A or B zones. Circuit breaker(s) tripped. Reset breaker CB3 or CB4, page 16.
Low heat in A or B zones. A and B temperature setpoints too
Cable not grounded. Ground cable, page 29.
Extension cable too long. Must not exceed 100 ft (30.5 m). Broken membrane switch. Replace, page 29.
Ribbon cable disconnected or bro­ken.
Loose wire. Check connections, page 29.
Heat turned off.
Temperature control alarm. Check temperature displays for diag-
Defective heater. Replace, page 20. Check resistance. Loose connectors or wire nuts. Check connections. Failed temperature control board. Open cabinet. Check if board LED is
low. Flow too high. Use smaller mix chamber. Decrease
Defective heater. Replace, page 20. Check resistance. Loose connectors or wire nuts. Check connections. Low voltage. Check that power supply meets
Overheated temperature control board.
Fluid too cold. Preheat fluid.
Connect cable, or replace.
29 and electrical diagrams.
Press or zone
keys.
nostic code, page 10.
blinking. If not, check power wiring connections to ensure board has power. If board has power and LED is not blinking, replace board, page 18.
Check setpoint. Increase if neces­sary.
pressure.
requirements. Check fan operation.
Check if door is open; close. Check that cooling holes are not
clogged or obstructed.
A
B
309813H 13
Troubleshooting
PROBLEM CAUSE SOLUTION
No hose heat. 380V units only - In-rush current lim-
iter contactor not closing when hose heat is turned on.
Loose hose electrical connections. Check connections. Repair as neces-
Circuit breakers tripped. Reset breakers (CB1 or CB2), page
Hose zone not turned on.
Check to be sure contactor in 288359
is closing when hose heat is turned
on. If not, check fuse (198). If fuse is
not blown, perform transformer
checks.
sary.
16.
Press zone key.
A and B temperature setpoints too low.
Failed temperature control board. Open cabinet. Check if board LED is
Low hose heat. A and B temperature setpoints too
low.
Hose temperature setpoint too low. Check. Increase if necessary to
Flow too high. Use smaller mix chamber. Decrease
Low current; FTS not installed. Install FTS, see operation manual. Hose heat zone not turned on long
enough. Loose hose electrical connections. Check connections. Repair as neces-
Check. Increase if necessary.
blinking. If not, check power wiring
connections to ensure board has
power. If board has power and LED is
not blinking, replace board, page 18.
Increase A and B setpoints. Hose
designed to maintain temperature,
not increase temperature.
maintain heat.
pressure.
Allow hose to heat up, or preheat
fluid.
sary.
14 309813H

Repair

Proportioning Pump
Removal
Repair
1. Shut off , , and heat zones.
2. Flush pump, page 8.
3. Relieve pressure, page 9.
4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF.
SA
A
B
SB
TI3593a
D
E
C
FIG. 1. Pump Removal
D
E
C
TI3582b
5. Turn main power OFF . Disconnect power
supply.
6. Disconnect hoses and fittings from fluid inlets (C) and outlets (D). See F
7. Remove pump. See applicable manuals, supplied.
See page 4 for applicable pump and motor repair-parts manuals. Displacement pumps (E) may be removed without removing entire propor­tioning pump.
8. Reinstall in reverse order.
309813H 15
IG. 1.
+ 35 hidden pages