Graco Inc. 249570, 249571, 249572, 249576, 249577 Instructions - Parts List

Instructions - Parts List

For spraying or dispensing 1:1 mix ratio materials, including epoxies, 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.

311075L

ENG

See page 4 for a list of models and maximum working pressures.

Heated Package, with

Fusion™ Gun

TI6987b

Taiwan Patent No. 1 303996 Australian Patent No. 2003291660

Other patents pending.

Nonheated Package, with 2K Ultra-Lite™ Gun and Cold

Spray disposable mixer

TI6989b

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . .3

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Isocyanate Hazard . . . . . . . . . . . . . . . . . . .9

Foam Self-ignition . . . . . . . . . . . . . . . . . . . 9

Moisture Sensitivity of Isocyanates . . . . . 9

Keep Components A and B Separate . . 10

Changing Materials . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . .11

Controls and Indicators . . . . . . . . . . . . . 13

Motor/Pump Control Function Knob . . . 13

STATUS Indicator . . . . . . . . . . . . . . . . . 13

Motor Power Switch/Circuit Breaker . . . 14 Heater Power Switch/Circuit Breaker . . 14

Heater Temperature Controls . . . . . . . . 14

Fluid Temperature Sensors and Displays .

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Startup of Heated Units . . . . . . . . . . . . . . 22

Heatup Guidelines . . . . . . . . . . . . . . . . 23

Heat Management Tips . . . . . . . . . . . . 23

Heating Foam Resins with 245 fa Blowing

Agents . . . . . . . . . . . . . . . . . . . . . . . 24

Spraying/Dispensing . . . . . . . . . . . . . . . . 25

Pause (Heated Units) . . . . . . . . . . . . . . . . 26

Refilling Tanks . . . . . . . . . . . . . . . . . . . . . 26

Pressure Relief Procedure . . . . . . . . . . . 27

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . .27

Maintenance . . . . . . . . . . . . . . . . . . . . . . . 28

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Troubleshooting . . . . . . . . . . . . . . . . . . . . 31

Status Codes . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting Chart . . . . . . . . . . . . . 34

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Before Beginning Repair . . . . . . . . . . . .39

Removing Supply Tanks . . . . . . . . . . . .39

Recirc/Spray Valves . . . . . . . . . . . . . . .40

Displacement Pump . . . . . . . . . . . . . . .41

Control Module . . . . . . . . . . . . . . . . . . .43

Fluid Heaters (if supplied) . . . . . . . . . . .48

Pressure Transducers . . . . . . . . . . . . . .48

Drive Housing . . . . . . . . . . . . . . . . . . . .49

Cycle Counter Switch Replacement . . .50

Electric Motor . . . . . . . . . . . . . . . . . . . .51

Motor Brushes . . . . . . . . . . . . . . . . . . .52

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Suggested Spare Replacement Parts . .68

Accessories . . . . . . . . . . . . . . . . . . . . . . .68

Dimensions . . . . . . . . . . . . . . . . . . . . . . . .69

Technical Data . . . . . . . . . . . . . . . . . . . . .70

Graco Standard Warranty . . . . . . . . . . . .72

Graco Information . . . . . . . . . . . . . . . . . .72

2 311075L

Related Manuals

The following manuals are for Reactor E-10 components and accessories. Some are supplied with your package, depending on its configuration. Part No. 15G777 Compact Disk includes all Reactor E-10 manuals. Manuals are also available at www.graco.com.

Displacement Pump Part No. Description

311076 Instruction-Parts Manual (English)

Fluid Heater Part No. Description

311210 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)

Fusion CS Spray Gun Part No. Description

312666 Instruction-Parts Manual (English)

2K Ultra-Lite Dispense Valve Part No. Description

309000 Instruction-Parts Manual (English) 311230 2K Ultra-Lite Cold Spray and Joint Fill

Kits (English)

Systems

Maximum

Working

Pressure,

psi

Part

AP9570 2000

AP9571 2000

AP9572 2000

CS9570 2000

CS9571 2000

CS9572 2000

249806 2000

249808 2000

(MPa, bar)

(14, 140)

Proportioner (see page 4)

249570

249571

249572

249570

249571

249572

249576

249577

Gun

Unheated

Hose

35 ft (10.6 m)

249499 Fusion Air Purge 249810

249499 Fusion CS CS22WD

249633

Model Part

2K Ultra-Lite

™

249834

311075L 3

Models

The model no., series letter, and serial no. are located on the back of the Reactor E-10. For faster assistance, please have that information ready before calling Customer Service.

Maximum

Working Bare Proportioner Part, Series Volts

* Electrical

Connection Application

Pressure,

psi

(MPa, bar)

249570, A 120

15 A cord

(motor)

• Polyurethane Foam

• Hot Polyureas

15 A cord

(heaters)

249571, A 240

10 A cord

(motor)

• Polyurethane Foam

• Hot Polyureas

10 A cord

(heaters)

249572, A 240

20 A cord

(motor and

• Polyurethane Foam

• Hot Polyureas

heaters)

249576, A 120

249577, A 240

15 A cord

(motor only)

10 A cord

(motor only)

• Self-leveling Joint Fillers

• Cold Polyureas

• Self-leveling Joint Fillers

• Cold Polyureas

* See page 16 for detailed electrical requirements.

Approvals:

2000

(14, 140)

2000

(14, 140)

2000

(14, 140)

2000

(14, 140)

2000

(14, 140)

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4 311075L

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 MSDSs 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 chemically impermeable gloves when spraying, dispensing, 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

311075L 5

Warnings

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.

• 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.

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 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 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.

6 311075L

Warnings

WARNING

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 exceed the maximum working pressure or temperature rating of the low-

est 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 from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco 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.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• 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. Dis- connect 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.

311075L 7

Overview

The Reactor E-10 is a portable, electric-powered, 1:1 mix ratio proportioner, for use with a wide variety of coatings, foams, sealants, and adhesives. Materials must be self-leveling and pourable, and may be applied with impingement mix spray guns, disposable mixer guns, or flush-type mix manifolds.

Reactor E-10 is gravity-fed from 7 gal. (26.5 liter) supply tanks mounted on the unit. The tanks are translucent to allow monitoring of fluid level.

Severe duty, positive displacement reciprocating piston pumps meter fluid flow to the gun for mixing and applying. When set to recirculation mode, Reactor E-10 will circulate fluids back to the supply tanks.

Heated models include separate thermostatically controlled heaters for each fluid, and an insulated hose bundle with circulation return hoses. This allows the hoses and gun to be preheated to the desired temperature before spraying. Digital displays show the temperatures of the two fluids.

Reactor E-10 has two recirculation speeds, slow and fast, and an adjustable pressure output.

Slow Recirculation

• Slow circulation results in a higher temperature transfer in the heater, so hoses and gun heat up quicker.

• Good for touchup or low flow spraying, up to moderate temperature.

• Not used to circulate full tanks up to temperature.

• Use with 245 fa blowing agent foams, to minimize heat returned to tank and reduce frothing.

Fast Recirculation

• Use to support higher flow rates or higher temperatures by preheating the tanks.

• Agitates fluid within tanks, to avoid heating only the fluid at the top of the tank.

• Use for flushing.

An electronic processor controls the motor, monitors fluid pressures, and alerts the operator if errors occur. See STATUS Indicator, page 13, for further information.

8 311075L

Pressure Adjust

Automatically maintains selected pressure output for dispensing or spraying.

Isocyanate Hazard

Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

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.

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

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 saturated 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 page 63).

Foam Self-ignition

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

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

• 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.

• Always park pumps when you shutdown, see page 27.

• Always lubricate threaded parts with Part No. 217374 ISO pump oil or grease when reassembling.

311075L 9

Keep Components A and B Separate

NOTICE

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

Changing Materials

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

• Always clean the fluid inlet strainers after flushing, see page 28.

• 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.

10 311075L

Component Identification

Key for FIG. 1

Component Identification

A Supply Tank A B Supply Tank B C Pump A D Pump B E Heater A F Heater B G Fluid Pressure Gauges H Recirc/Spray and Overpressure Relief Valves J Control Panel; see F

IG. 3, page 13

K Electric Motor and Drive Housings L Insulated Hose Bundle (includes circulation

return hoses)

M Fusion Air Purge Spray Gun N Desiccant Dryer (mounts on supply tank A) P Recirculation Tubes Q Air Line Inlet (quick-disconnect fitting) R Outlet Hose Connections S Return Hose Connections T Fluid Temperature Sensors U Hose Rack and Control Shield V Fluid Inlet Ball Valves (1 on each side) W Fluid Inlet Strainers (1 on each side) XPower Cord Y Lift Ring Z Air Filter/Moisture Separator

J P

H S

C Q

FIG. 1: Component Identification, Heated Packages (Part No. 249804 Shown)

V W

TI6987b

311075L 11

Component Identification

Key for FIG. 2

A Supply Tank A B Supply Tank B C Pump A D Pump B G Fluid Pressure Gauges H Recirc/Spray and Overpressure Relief Valves J Control Panel; see F

IG. 3, page 13

K Electric Motor and Drive Housings L Hose Bundle M 2K Ultra-Lite Spray Gun, with disposable static

mixer

N Desiccant Dryer (mounts on supply tank A) P Recirculation Tubes Q Air Line Inlet (quick-disconnect fitting) R Outlet Hose Connections U Hose Rack and Control Shield V Fluid Inlet Ball Valves (1 on each side) W Fluid Inlet Strainers (1 on each side) XPower Cord Y Lift Ring Z Air Filter/Moisture Separator

C Q

V W

FIG. 2: Component Identification, Nonheated Packages (Part No. 249808 Shown)

TI6989b

12 311075L

Controls and Indicators

TD TD

FIG. 3. Controls and Indicators (heated unit shown)

Motor/Pump Control

• Indicator (ST) blinking: If error occurs, STA-

Function Knob

Use knob (CF) to select desired function.

Icon Setting Function

Stop/Park Stops motor and auto-

matically parks pumps.

Slow Recirc

Fast Recirc Fast recirculation

Pressure Adjust

STATUS Indicator

• Indicator (ST) steady on: Motor Power switch is turned on and control board is working.

Slow recirculation speed.

speed. Adjusts fluid pressure

to gun in spray mode.

Code No. Code Name

1 Pressure imbalance between A and B

2 Unable to maintain pressure setpoint 3 Pressure transducer A failure 4 Pressure transducer B failure 5 Excessive current draw 6 High motor temperature 7 No cycle counter switch input

TI7016a

TUS indicator will blink 1 to 7 times to indicate status code, pause, then repeat. See T

ABLE 1 for a brief description of status

codes. For more detailed information and corrective action, see page 31.

Table 1: Status Codes

(see also the label on back of the control

enclosure)

sides

The default is to shut down if a status code indication occurs. Codes 1 and 2 may be set to disable automatic shutdown if desired; see page 32. The other codes are not settable.

311075L 13

Controls and Indicators

Motor Power Switch/Circuit Breaker

Switch (MP) turns power on to control board and function knob. The switch includes a 20 A circuit breaker.

Heater Power Switch/Circuit Breaker

See FIG. 3. Switch (HP) turns power on to heater thermostats. The switch includes a 20 A circuit breaker. Present on heated units only.

Heater Temperature Controls

See FIG. 4. Control knobs (HC) set temperature of component A and B heaters. Indicator lights (HL) turn on when thermostats are heating, and off when heater reaches setpoint. Present on heated units only.

Fluid Temperature Sensors and Displays

See FIG. 3. Fluid temperature sensors (T) monitor actual temperature of component A and B fluid going to spray gun. Temperatures are then displayed (TD). Present on heated units only.

Unit is shipped set to °F. To change to °C, see page 43.

IG. 4. Heater Temperature Controls

TI6984a

14 311075L

Setup

1. Locate Reactor E-10

a. Locate Reactor E-10 on a level

surface.

b. Do not expose Reactor E-10 to

rain.

2. Electrical requirements

Improper wiring may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform any electrical work. Be sure your installation complies with all National, State and Local safety and fire codes.

Setup

a. Reactor E-10: grounded through

power cord.

b. Generator (if used): follow your

local code. Start and stop generator with power cord(s) disconnected.

c. Spray gun: grounded through the

supplied fluid hoses, connected to a properly grounded Reactor E-10. Do not operate without at least one grounded fluid hose.

d. Object being sprayed: follow your

local code.

Connect Reactor E-10 to the correct power source for your model. See TABLE 2. Models with two power cords must be connected to two separate, dedicated circuits. See FIG. 5.

Some models include cord adapters (55, 56) for use outside North America. Connect the appropriate adapter to the unit’s power cord before connecting to your power source.

3. Ground system

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

e. Solvent pails used when flushing:

follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper, plastic, or cardboard, which interrupts grounding continuity.

f. 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.

311075L 15

Setup

Table 2: Electrical Requirements

Model Required Power Source Power Cord Connector

120 V, 1 phase, 50/60 Hz, two 15 ft (4.5 m) power cords, Heated

240 V, 1 phase, 50/60 Hz, two 15 ft (4.5 m) power cords, Heated

240 V, 1 phase, 50/60 Hz, one 15 ft (4.5 m) power cord, Heated

120 V, 1 phase, 50/60 Hz, one 15 ft (4.5 m) power cord, Nonheated

240 V, 1 phase, 50/60 Hz, one 15 ft (4.5 m) power cord, Nonheated

Table 3: Extension Cord Requirements

Two separate, dedicated circuits rated at minimum of 15 A each

Two separate, dedicated circuits rated at minimum of 10 A each

Single dedicated circuit rated at minimum of 16 A

Single dedicated circuit rated at minimum of 15 A

Single dedicated circuit rated at minimum of 8 A

Two NEMA 5-15T

Two IEC 320, with two local adapters:

Euro CEE74 Adapter

Australia/China Adapter

One NEMA 6-20P

One NEMA 5-15T

One NEMA 6-20P

Required Wire Size

Model

Nonheated and two cord heated

Up to 50 ft (15 m) Up to 100 ft (30 m)

AWG 14 AWG 12

models Single cord heated model AWG 12 AWG 10

Cords must be 3-conductor grounded, rated for your environment.

16 311075L

To avoid electric shock, always unplug both cords before servicing Reactor E-10.

Ensure no other high amp loads are connected while running Reactor E-10.

To verify separate circuits, plug in Reactor E-10 or a worklight and cycle breakers on and off.

Heater Power

Setup

Motor Power

FIG. 5. Use Two Separate Circuits for Two Cord Models

4. Connect fluid hoses

Connect fluid supply hoses to outlet hose connections (R, FIG. 6). Red hoses for component A (ISO), blue for component B (RES). Fittings are sized to prevent connection errors. Connect other end of hoses to A and B inputs of gun.

Heated units only: connect recirculation hoses from gun recirculation ports to connections (S).

5. Connect gun air hose

Connect gun air hose to the gun air input and to the air filter outlet (Z). If you are using more than one hose bundle, join the air hoses with the nipple (305) provided with the hose bundle.

6. Connect main air supply

Air Filter/Moisture Separator (Z) is equipped with an automatic moisture drain.

7. Flush before first use

TI7061a

Connect the main air supply to the quick disconnect fitting (Q) on the unit. Air supply hose must be at least 5/16 in. (8 mm) ID up to 50 ft (15 m) or 3/8 in. (10 mm) ID up to 100 ft (30 m).

The Reactor E-10 is tested with a plasticizer oil at the factory. Flush out the oil with a compatible solvent before spraying. See page 29.

On heated units with Fusion guns, connect the supplied ball valve and quick-disconnect coupler to the gun air hose, then connect the coupler to the gun air fitting.

311075L 17

Setup

Heated Units

B (RES)

TI6988b

FIG. 6. Hose Connections

A (ISO)

AIR

B (RES)

AIR

Nonheated

A (ISO)

TI6990b

18 311075L

Setup

8. Fill wet-cups

Keep the felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No. 217374. The lubricant creates a barrier between the ISO and the atmosphere.

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. Shut off Motor Power before filling wet-cup.

9. Fill fluid tanks

NOTICE

To prevent cross-contamination of fluids and equipment parts, never interchange component A (isocyanate) and component B (resin) parts or containers.

Have at least two 5 gal. (19 liter) pails to transfer fluid from drums to supply tanks. Label one pail “A” and the other “B”, using the red and blue labels provided. Always doublecheck which material you have before pouring it in the supply tanks. Pouring is easier if pails are not filled to the top.

Fill wet-cups through slots

in plate, or loosen screws

and swing plate aside.

TI6985a

Open only one supply tank at a time, to avoid splashing material from one tank into the other when filling.

Using a drill and mixing blade, mix filled or separated materials in the pail before adding to the tanks. Material left in the tanks overnight may need to be remixed in the tanks.

311075L 19

Setup

a. Lift hose rack. Remove tank A

cover and pour ISO into tank A (red side, with desiccant filter in

cover). Replace cover .

Desiccant filter is blue when fresh, and turns pink when saturated. Be sure shipping plugs are removed from openings on desiccant filter.

TI7017a

b. Remove tank B cover and pour

resin into tank B (blue side). Replace cover .

10. Purge air and flush fluid from

lines

a. Remove both recirculation tubes

(P) from the tanks and secure each one in a dedicated waste container.

TI7022a

b. Set function knob to Stop/Park

TI7018a

. Add thin coating of grease lubricant to tank o-ring if lid is difficult

to assemble to tank.

c. Plug in power cord(s). See TABLE

2, page 16.

d. Open both pump fluid inlet valves

(V, shown in open position).

TI7019a

20 311075L

Setup

e. Turn on Motor Power.

f. Set Recirc/Spray valves to

Recirc.

g. Set function knob to Slow Recirc

or Fast Recirc .

h. When clean fluids exit both recir-

culation tubes (P), set function

knob to Stop/Park .

i. Replace recirculation tubes in

supply tanks.

j. On nonheated units, purge the

hoses through the gun without a static mixer installed.

For heated units, continue with Startup of Heated Units, page 22.

Nonheated units are ready to spray/dispense. Go to Spraying/Dispensing, page

25.

311075L 21

Startup of Heated Units

Some models heat the fluid, which can cause equipment surfaces to become very hot. To avoid severe burns:

• Do not operate Reactor E-10 without all covers and shrouds in place.

• 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).

3. Turn on Heater Power.

4. Temporarily set heater control knobs to

maximum setting.

1. Perform Setup, pages 15-21.

5. Circulate through heaters until tempera-

ture readouts display desired temperature. See TABLE 4 below.

2. Set function knob to Slow Recirc or

6. Adjust heater control knobs as neces-

Fast Recirc . See Heatup Guidelines, page 23, then continue with steps

3-6.

Table 4: Heatup Time Guidelines for starting a cold machine with 5 gal. (19 l) per side (see

Notes below)

Fluid Spray Target

Temperature

125°F (52°C) 20 minutes 25 minutes 150°F (65°C) 40 minutes 50 minutes

35 ft (10.7 m) Hose

(1 bundle)

sary for a stable spray temperature.

70 ft (21 m) Hose

(2 bundles)

Use fast circulation until temperature is within 20°F (11°C) of target, then use slow circulation to reach final temperature.

Different fluids will absorb heat at different rates. When refilling a warm machine, heatup times will be less.

22 311075L

Startup of Heated Units

Heatup Guidelines

The fluids must be circulated from the pumps through the heaters, hoses, and back to the tanks to ensure warm fluids are supplied to the gun.

Slow Recirculation

• Slow Recirc results in a higher temperature transfer in the heater, so hoses and gun heat up quicker.

• Good for touchup or low flow spraying, up to moderate temperature.

• Not used to circulate full tanks up to temperature.

• Use with 245 fa blowing agent foams, to minimize heat returned to tank and reduce frothing.

Fast Recirculation

Heat Management Tips

• Heaters perform better with lower flow rates or smaller mix modules.

• Triggering the gun for short periods helps maintain efficient heat transfer, keeping material at the desired temperature. Triggering the gun for a long period does not allow enough heating time, and cold material will enter the hose.

• If temperature displays fall below acceptable limits, set function knob to Slow Recirc

and circulate again to bring tempera-

tures back up.

• Each 35 ft (10.7 m) hose bundle adds about 5 minutes to heatup time, with most materials. Water-based materials take longer to heat up. Maximum recommended hose length is 105 ft (32 m).

• Fast Recirc keeps heaters on fulltime to bring fluid tanks up to temperature. The higher your usage rate, the more heat needed in the tanks before spraying.

• For normal usage rates: Use Fast

Recirc to get tanks to approximately 50°F (28°C) below desired spray temperature, then use Slow Recirc to raise hose and gun to desired temperature.

• For higher flow rates or continuous

spraying: Use Fast Recirc to bring temperature of tanks to approximately 20°F (11°C) below desired spray temperature, then use Slow Recirc to raise hose and gun to desired temperature.

• Volume in tanks: Use only what you

need. For example, 2.5 gal. (10 l) in each tank will heat up almost twice as fast as 5 gal. (20 l).

• Mixes fluid within tanks, to avoid heating only the fluid at the top of the tank.

• Use for flushing.

• Use Fast Recirc until tanks are warm to

the touch, then use Slow Recirc until displays read desired temperature.

• For a quicker start, do initial heatup circulation with the tanks 1/4 to 1/3 filled, then add more material.

311075L 23

Startup of Heated Units

Heating Foam Resins with 245 fa Blowing Agents

New foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated.

Never fill the 7 gal. (26 l) supply tanks beyond the 5 gal. (19 l) line on the tanks, to leave room for some frothing.

At High Ambient Temperature (above 75°F/24°C)

• Pour resins slowly to avoid frothing.

• Only use Slow Recirc , to avoid heating and agitating the tank. If temperature

doesn’t keep up, set function knob to

c. Fill tanks, page 19.

d. Set Recirc/Spray valves to Recirc.

e. Set function knob to Slow Recirc .

f. Turn on Heater Power.

At Cool Ambient Temperature (below 75°F/24°C)

• Use Fast Recirc to heat tanks to 75-90°F. (24-32°C), then use Slow Recirc

Stop/Park , then set to Slow Recirc

again.

• When you stop to refill the tanks, avoid boiling off fluid in the heaters by following these steps:

a. Shut off Heater Power.

b. Leave hoses under pressure.

to raise hose and gun to desired spray

temperature.

• If the top of the resin in tank starts frothing,

do not use Fast Recirc any more.

24 311075L

Spraying/Dispensing

Air is supplied to spray gun with gun piston safety lock or trigger safety lock engaged and gun fluid manifold valves A and B closed (if present).

Fusion 2K Ultra-Lite

TI7069a

Spraying/Dispensing

4. Check fluid pressure gauges to ensure

proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures. The pressure imbalance alarm (Status Code

1) is inactive for 10 sec after entering spray pressure mode, to allow time to balance pressures.

n this example, B side pressure is higher, so use the B side valve to balance pressures.

1. Set function knob to Stop/Park .

2. Set Recirc/Spray valves to Spray.

3. Turn function knob to Pressure Adjust

. Keep turning to the right until fluid

pressure gauges show desired pressure.

Watch gauges for 10 sec to be sure pressure holds on both sides and pumps are not moving.

5. Open gun fluid manifold valves A and B

(impingement mix guns only).

On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.

311075L 25

Pause (Heated Units)

6. Disengage piston safety lock or trigger

safety lock.

Fusion 2K Ultra-Lite

TI7070a

7. Test spray onto cardboard or plastic

sheet. Verify that material fully cures in the required length of time, and is the correct color. Adjust pressure and temperature to get desired results. Equipment is ready to spray.

3. Set Recirc/Spray valves to Recirc until

temperature readouts come back up.

4. If you stop spraying for more than 2 min-

utes when using an impingement mix gun, close gun fluid valves A and B.

Doing this will keep the internal parts of the gun cleaner and prevent crossover.

Refilling Tanks

Pause (Heated Units)

To bring the hose and gun back to spray temperature after a brief break, use the following procedure.

1. Engage piston safety lock or trigger

safety lock.

Fusion 2K Ultra-Lite

2. Set function knob to Slow Recirc .

TI7069a

Material can be added to the tanks at any time. See page 19.

If you are operating at high temperatures or flow rates, follow instructions under Pause (Heated Units) to bring tanks up to temperature.

NOTICE

To prevent cross-contamination of fluids and equipment parts, never interchange component A (isocyanate) and component B (resin) parts or containers.

Open only one supply tank at a time, to avoid splashing material from one tank into the other when filling.

26 311075L

Pressure Relief Procedure

1. Engage piston safety lock or trigger

safety lock.

Fusion

2K Ultra-Lite

2. Set function knob to Stop/Park .

TI7069a

Shutdown

For longer breaks (more than 10 minutes), use the following procedure. If you will be shut down for more than 3 days, first see

Flushing, page 29.

1. Follow all steps of Pressure Relief Pro-

cedure, at left.

2. If using an impingement mix gun, close

gun fluid valves A and B. Doing this will keep the internal parts of the gun cleaner and prevent crossover.

3. Turn Recirc/Spray valves to Recirc.

Fluid will be dumped to supply tanks. Pumps will move to the bottom of their stroke. Ensure gauges drop to 0.

3. Shut off Heater Power (heated units

only).

4. Shut off Motor Power.

5. Refer to your separate gun manual and

perform the Shutdown procedure.

311075L 27

Maintenance

• Check pump wet-cups fluid level daily, page

19.

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

• Keep component A from exposure to moisture in atmosphere, to prevent crystallization.

• Wipe supply tank lid o-ring and inner rim daily to prevent ISO crystallization. Keep film of grease on o-ring and inside of lid.

• Check desiccant filter weekly. Filter is blue when fresh, and turns pink when saturated.

• Remove plug (X) and clean fluid inlet strainer (51a) as needed. Always clean the fluid inlet strainers after flushing.

• Generally, flush if you will shutdown for more than three days. Flush more often if material is moisture sensitive and humidity is high in the storage area, or if material may separate or settle out over time.

• If using an impingement mix gun, close gun fluid valves A and B when not spraying. Doing this will keep the internal parts of the gun cleaner and prevent crossover. Clean gun mix chamber ports and check valve screens regularly. See gun manual.

• If using an Fusion Air Purge impingement mix gun, always grease the gun after use until purge air carries grease mist out the front of the gun. Use Part No. 117773 Grease. See gun manual 309550.

51a

TI7021a

28 311075L

Flushing

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

• Generally, flush if you will be shut down for more than 3 days. Flush more often if material is moisture sensitive and humidity is high in the storage area, or if material may separate or settle out over time.

• 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.

Flushing

2. Set function knob to Stop/Park .

3. Shut off Heater Power (heated units

only). Allow system to cool.

4. Remove recirculation tubes (31) from

supply tanks and place in original containers or waste containers.

• Always leave some type of fluid in system. Do not use water.

• For long term storage, flush out the solvent with a storage fluid such as Bayer Mesamoll plasticizer or, at minimum, clean motor oil.

1. Engage piston safety lock or trigger

safety lock. Close fluid valves A and B. Leave air on.

Fusion 2K Ultra-Lite

TI7069a

TI7022a

5. Turn Recirc/Spray valves to Recirc.

6. Set function knob to Fast Recirc .

Pump material from supply tanks until no more comes out.

311075L 29

Flushing

7. Set function knob to Stop/Park .

8. Wipe out any remaining material from

the supply tanks. Fill each supply tank with 1-2 gal. (3.8-7.6 l) of solvent recommended by your material manufacturer.

9. Set function knob to Fast Recirc .

Pump solvent through system to waste containers.

To flush gun, refer to gun instruction manual.

Purge Gun Hoses (Nonheated Units Only)

Disconnect hoses from gun and secure back into the tanks for thorough cleaning with solvent.

• Turn Recirc/Spray valve A to Spray.

• Open gun into waste container A.

• Set function knob to Slow Recirc until hose is flushed.

• Set function knob to Stop/Park .

• Repeat for B side.

10. When nearly clear solvent comes from

recirculation tubes, set function knob to

Stop/Park . Return recirculation tubes to supply tanks.

11. Set function knob to Fast Recirc .

Circulate solvent through system for 10-20 minutes to ensure thorough cleaning.

12. Set function knob to Stop/Park .

13. Solvent flushing is a two step process.

Go back to step 4, drain solvent, and flush again with fresh solvent.

14. Leave unit filled with solvent, plasticizer,

clean motor oil, or refill supply tanks with new material and reprime.

Never leave the unit dry unless it has been disassembled and cleaned. If fluid residue dries in the pumps, the ball checks may stick the next time you use the unit.

30 311075L

Troubleshooting

Status Codes

Determine the status code by counting the number of times the status indicator (ST) blinks.

TI7016a

Status Code 1: Pressure Imbalance

The unit does not check for pressure imbalance at setpoints less than 250 psi (1.75 MPa, 17.5 bar).

n this example, B side pressure is higher, so use the B side valve to balance pressures.

Turn Recirc/Spray valve only enough to balance pressure. If turned completely, all pressure will bleed off.

3. Check fluid inlet strainers (51a, page 28) and fluid filters at gun.

4. Clean or change restrictor at mixer manifold if using disposable mixer gun kit.

Status Code 2: Pressure Deviation from Setpoint

The unit does not check for pressure deviation at setpoint less than 400 psi (2.8 MPa, 28 bar).

The unit does not check for pressure imbalance for 10 sec after entering pressure mode.

Unit senses pressure imbalance between components A and B, and warns or shuts down, depending on settings of DIP switches 1 and 2. To turn off automatic shutdown and/or tighten pressure tolerances for status code 1, see Sta- tus Code 1 and 2 Settings.

1. Check fluid supply of lower pressure component and refill if necessary.

2. Reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures.

Unit senses pressure deviation from setpoint, and warns or shuts down, depending on settings of DIP switches 3 and 4. If equipment cannot maintain enough pressure for a good mix with an impingement mix gun, try using a smaller mix chamber or nozzle.

To turn off automatic shutdown and/or tighten pressure tolerances for status code 2, see Sta- tus Code 1 and 2 Settings.

311075L 31

Troubleshooting

Status Code 1 and 2 Settings

OFF

1. Locate switch SW2 on the control board, page 47.

2. Set the four DIP switches to the desired

IG. 7. DIP Switch (SW2) Settings

positions. See FIG. 7 and TABLE 5 on page

32.

Table 5: Status Code 1 and 2 Settings

DIP Switch and Function Left DIP Switch 1

If selected, causes shutdown or displays a warning if the pressure imbalance exceeds selection made in DIP Switch 2

DIP Switch 2

If selected, causes shutdown if A and B pressure imbal- ance is greater than

If selected, causes warning if A and B pressure imbalance is greater than

DIP Switch 3

If selected, causes shutdown or displays a warning due to deviation of pressure from setpoint exceeds selection made in DIP Switch 4

DIP Switch 4

Causes warning if deviation of pressure from setpoint is greater than

WARNING SHUTDOWN

500 psi (3.5 MPa, 35 bar) (60% if < 800 psi [5.6 MPa, 56 bar] running)

300 psi (2.1 MPa, 21 bar) (50% if < 800 psi [5.6 MPa, 56 bar] running)

WARNING SHUTDOWN

300 psi (2.1 MPa, 21 bar) (25% if < 800 psi [5.6 MPa, 56 bar])

TI7023a

1 2 3 4

(Default)

TI7024a

Right (default setting)

800 psi (5.6 MPa, 56 bar) (70% if < 800 psi [5.6 MPa, 56 bar] running)

500 psi (3.5 MPa, 35 bar) (60% if < 800 psi [5.6 MPa, 56 bar] running)

500 psi (3.5 MPa, 35 bar) (40% if < 800 psi [5.6 MPa, 56 bar])

Status Code 3: Transducer A Failure

1. Check transducer A electrical connection (J3) at board, page 47.

2. Reverse A and B transducer electrical connections at board, page 47. If error moves to transducer B (Status Code 4), replace transducer A, page 48.

Status Code 4: Transducer B Failure

1. Check transducer B electrical connection (J8) at board, page 47.

2. Reverse A and B transducer electrical connections at board, page 47. If error moves to transducer A (Status Code 3), replace transducer B, page 48.

32 311075L

Troubleshooting

Status Code 5: Excessive Current Draw

Shut off unit and contact distributor before resuming operation.

1. Locked rotor; motor unable to turn. Replace motor, page 51.

2. Short on control board. Replace board, page 46.

3. Worn or hung up motor brush causing arcing of brush at commutator. Replace brushes, page 52.

Status Code 6: High Motor Temperature

Motor is running too hot.

1. Motor temperature too high. Reduce pressure duty cycle, gun tip size, or move Reactor E-10 to a cooler location. Allow 1 hour for cooling.

2. Check fan operation. Clean fan and motor housing.

Status Code 7: No Cycle Counter Switch Input

Have not received input from cycle counter switch for 10 seconds after selecting Recirc mode.

1. Check cycle counter switch connection to board (J10, pins 5, 6), page 47.

2. Check that magnet (224) and cycle counter switch (223) are in place under B side motor end cover (227). Replace if necessary.

311075L 33

Troubleshooting

Troubleshooting Chart

PROBLEM CAUSE SOLUTION

Reactor E-10 does not operate. No power. Plug in power cord.

Cycle Motor Power off ,

then on to reset breaker.

Motor does not operate. Power turned on with function

knob set to a run position.

Loose connection on control board.

Worn brushes. Check both sides. Replace

Broken or misaligned brush springs.

Brushes or springs binding in brush holder.

Shorted armature. Replace motor, page 51. Check motor commutator for burn

spots, black pitting, or other damage.

Failed control board. Replace board. See page 46.

Fan not working. Loose fan cable. Check that cable is connected at

Defective fan. Test and replace if necessary,

Pump output low. Plugged fluid inlet strainer. Clear, see page 28.

Plugged disposable mixer. Clean or replace. Leaking or plugged piston valve

or intake valve in displacement pump.

One side doesn’t come up to pressure in spray mode.

Dirty or damaged Recirc/Spray valve.

Plugged fluid inlet strainer. Clear, see page 28. Pump intake valve plugged or

stuck open.

Set function knob to Stop/Park

, then select desired func-

tion. Check connection at J11 (120 V)

or J4 (240 V). See page 46.

brushes worn to less than 1/2 in. (13 mm), see page 52.

Realign or replace, page 52.

Clean brush holder and align brush leads for free movement.

Remove motor. Have motor shop resurface commutator, or replace motor, page 51.

fan and at J9 on control board. See pages 52 and 46.

page 52.

Check valves. See pump manual.

Clean or repair, page 40.

Clean pump intake valve. See page 41.

34 311075L

PROBLEM CAUSE SOLUTION

Troubleshooting

Pressure is higher on one side when setting pressure with func-

Pump intake valve partially plugged.

tion knob.

Air in hose. Fluid is compressible. Purge air from hose. Unequal size hoses or unequal

hose construction.

Pressures are not balanced when

Unequal viscosities. Change temperature setting to running, but pressure is generated and holds on both strokes.

Restriction on one side. Clean mix module or restrictor at

Fluid leak in pump packing nut

Worn throat seals. Replace. See pump manual. area.

Pressure doesn’t hold when

Leaking Recirc/Spray valve. Repair, page 40. stalled against gun in spray mode.

Leaking piston valve or intake

valve in displacement pump.

Leaking gun shutoff. Repair. See gun manual. Pressure is higher on B side dur-

ing startup of recirculation, especially in High Recirc mode.

This is normal. Component B is

typically higher viscosity than

component A until the material is

heated during recirculation. Resin froths and overflows tank

after refilling hot equipment.

Agitation from pouring. Hot mate-

rial in heaters and hoses froths

when not under pressure. One gauge shows half as many

Loss of pressure on downstoke. Intake valve is leaking or not clospulses as the other when pumps are cycling.

Loss of pressure on upstoke. Piston valve is leaking or not clos-

Status indicator (red LED) not lit. Motor Power switch off.

Clean pump intake valve. See page 41.

Use matching hoses, or balance pressures before spraying.

balance viscosities.

Change restrictor at mix point to balance back pressure.

mix manifold. Clean gun check valve screens.

Repair. See pump manual.

No action required.

Turn heaters off before refilling. Leave hoses pressurized. See page 24.

ing. Clean or replace valve; see page 41.

ing. Clean or replace valve or packings; see page 41.

Cycle Motor Power off ,

then on to reset breaker.

Loose indicator cable. Check that cable is connected at

J10 pins 1 (red) and 2 (black) on control board. See page 46.

Failed control board. Replace board. See page 46.

311075L 35

Troubleshooting

PROBLEM CAUSE SOLUTION

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.

No temperature display (heated units only).

Loose display cables on control board.

Failed control board (displays get power from control board).

Check cable connections to each display, page 46.

Remove access panel. Check if board LED is lighted. If not, replace board, page 46.

Inadequate power to control board.

Check that power supply meets requirements.

Loose power cable. Check cable connections, page

46.

Motor Power switch circuit breaker tripped.

Display is powered from Motor Power circuit breaker. Cycle Motor

Power off , then on

to reset breaker.

Wrong temperature displayed. °F/°C switch in wrong position. Set switch, see page 43. Temperature displays do not

match at ambient temperature.

Displays need calibration. Turn calibration screw on back of

displays to correct reading, see page 43.

36 311075L

PROBLEM CAUSE SOLUTION

Troubleshooting

No heat, and heater indicator light is off.

No heat, but heater indicator light is on.

Heater on one side shuts off early or continuously during recirculation.

Heater Power shut off, or circuit

breaker tripped.

Cycle Heater Power off ,

then on to reset circuit

breaker.

Bad thermostat. With power on, check for continu-

ity at clicks of heater control knob. To replace thermostat, see

311210.

Bad overtemperature sensor (this

is a high temperature limit fuse

and must be replaced if blown).

With power on, check for continuity at overtemperature sensor. To replace sensor, see 311210.

Loose heater cable connections. Check connections at Heater

Power switch. See F

IG. 12, page

47.

Bad heater cartridge. Check for continuity at heater car-

tridge connections: 16-18.6 ohms for 120 V, 64-75 ohms for 240 V.

Y-strainer is plugged on that side. Clean or replace strainer, page

28.

Fluid inlet valve (52) closed. Open valve.

311075L 37

Troubleshooting

38 311075L

Repair

Before Beginning Repair Removing Supply Tanks

Displacement pump repair and parts information is included in manual 311076, which is supplied with your unit.

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 page 15. Be sure to shut off all power to the equipment before repairing.

1. Flush if possible, see page 29. If not possible, clean all parts with solvent immediately after removal, to prevent isocyanate from crystallizing due to moisture in the atmosphere.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Close both fluid inlet ball valves (52).

Repair

2. Set function knob to Stop/Park .

3. Shut off Motor Power. Disconnect power supply.

4. Shut off Heater Power. Allow equipment to cool before repairing.

5. Relieve pressure, page 27.

TI7020a

Use dropcloth or rags to protect Reactor E-10 and surrounding area from spills.

3. Open filter drain plug on Y-strainer (51).

4. Disconnect swivel elbow (50) at pump fluid inlet.

5. Remove screws (4) holding tank to cart frame.

6. Pivot top of tank to side and lift it and fluid inlet fittings off cart.

311075L 39

Repair

Recirc/Spray Valves

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

Heated Models Nonheated Models

505

504

503

506

503a 503b

2. See FIG. 8. Disassemble Recirc/Spray valves. Clean and inspect all parts for damage. Ensure that the seat (503a) and gasket (503b) are positioned inside each valve cartridge (503).

3. Apply PTFE pipe sealant to all tapered pipe threads before reassembling.

4. Reassemble in reverse order, following all notes in FIG. 8.

505

504

503

506

503a 503b

508

509510

FIG. 8. Recirc/Spray Valves

507

501

502

507

TI6977a TI6982a

Torque to 250 in-lb (28 N•m).

Use blue threadlocker on valve cartridge threads into manifold.

Part of item 503.

510

511

509

501

502

508

40 311075L

Repair

Displacement Pump

Displacement pump repair and parts information is included in manual 311076, which is supplied with your unit.

Use dropcloth or rags to protect Reactor E-10 and surrounding area from spills.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Close both fluid inlet ball valves (52). Open filter drain plug on Y-strainer (51).

To Remove Intake Valve Only

If pump is not generating any pressure, the intake ball check may be stuck closed with dried material.

If the pump is not generating pressure on the downstroke, intake ball check may be stuck open.

Either of these conditions can be serviced with the pump in place.

3. Disconnect fluid inlet (C) and swing it aside.

4. Remove intake valve by hitting ears (E) firmly right-to-left with a non-sparking hammer. Unscrew from pump. See manual 311076 for repair and parts.

TI7020a

311075L 41

Repair

To Remove Entire Pump Assembly

5. Disconnect fluid inlet (C) and outlet (D) lines. Also disconnect steel outlet tube (16) from heater inlet.

6. Remove pump rod cover (222). Push clip up in back and push pin (217) out. Loosen locknut (218) by hitting firmly right-to-left with a non-sparking hammer. Unscrew pump. See manual 311076 for pump repair and parts.

7. Install pump in reverse order of disassembly, following all notes in FIG. 9. Clean strainer (51). Reconnect fluid inlet (C) and outlet (D) lines.

217

222

8. Tighten fluid outlet fitting (D), then tighten locknut (218) by hitting firmly with a non-sparking hammer.

9. Open fluid inlet valve (52). Set function

knob to Slow Recirc . Purge air and prime. See page 20.

Flat side faces up. Tighten by hitting firmly with non-sparking hammer.

Lubricate threads with ISO oil or grease.

FIG. 9. Displacement Pump

218

TI7025a

42 311075L

Repair

Control Module

Change Display Temperature Units (°F/°C)

Unit is shipped with temperature displays set to °F.

1. Shut off Motor Power. Disconnect power supply.

2. Remove access cover (39) from back of control module.

Replace Temperature Display and Sensor (Heated Units Only)

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Remove temperature sensor (424):

a. Loosen setscrew (22) on thermowell

housing (21). See FIG. 10.

b. Pull sensor (424) out of thermowell

housing.

c. Work sensor and wire out of cable

channel between tanks. It may be easier to remove one tank. See page 39.

3. See FIG. 11. Locate slide switch (FC) at right edge of each temperature display board. Unit is shipped set to °F (down). To change to °C, move both switches to up position.

Calibrate Temperature Displays

1. Remove access cover (39) from back of control module.

2. See FIG. 11. Locate calibration screw (CS) at upper right corner of each temperature display board. Turn screw slightly to correct temperature display.

Temperature displays do not read lower than 50°F (10°C).

3. Remove access cover (39) from back of control module.

4. Disconnect temperature display power cable from J14 or J15 at bottom left of control board (406).

5. Remove four screws from rear panel studs and remove temperature display (403) from front plate (401).

6. Remove screw and nut (409) holding display to plate (403).

7. Pull sensor cable through split in bushing (411).

311075L 43

Repair

8. Reassemble in reverse order. Mount temperature display so Heater Power switch off (0) position is at left when facing control panel.

424

TI7067a

FIG. 10. Temperature Sensor

horizontal. Position knob (416) so pointer (P) faces up. Install knob on shaft so slot (S) engages alignment pin in knob. Push knob onto shaft against detent spring before tightening setscrews (416a).

7. Reconnect potentiometer wires to J2 as shown in F

IG. 12.

Replace Function Knob/Potentiometer

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Remove access cover (39) from back of control module.

3. Disconnect potentiometer wires from J2 on control board (406). See FIG. 12.

4. See F and pull function knob (416) off potentiometer (404) shaft.

5. Remove nut (N, part of 404) and detent plate (415).

IG. 11. Remove two setscrews (416a)

6. Install new potentiometer (404) in reverse order. Position potentiometer so slot (S) is

44 311075L

Detail of Function Knob/Potentiometer

415

404

Repair

TI7076a

409

*424

*403

416a

416

*402

416a

421

424*

405

401

410

402

404

408 407

412

411

410*

413

* These items are not included on the nonheated display.

416a

416

416a

N 415

417

406

TI6979a

FIG. 11. Control Module (Heated Model Shown)

311075L 45

Repair

Control Board

Power Bootup Check

There is one red LED (D11) on the board. Power must be on to check. See F

IG. 12 for location. Function is:

• Startup: 1 blink for 60 Hz, 2 blinks for 50 Hz.

• Motor running: LED on.

• Motor not running: LED off.

• Status code (motor not running): LED blinks status code.

Control Board Replacement

Table 6: Control Board Connectors

(see FIG. 12)

Board

Jack Pin Description

J1 n/a Main power from breaker J2 n/a Function knob J3 n/a Transducer A J4 n/a Motor power (230 V units) J7 1, 2 Motor thermal overload signal J8 n/a Transducer B J9 n/a Fan

J10 1, 2 Status indicator

3, 4 Not used 5, 6 Cycle switch signal

7-8 Jumpered

9-10 Jumpered J11 n/a Motor power (120 V) J14 n/a B temperature display J15 n/a A temperature display

Check motor before replacing board. See Electric Motor, page 51.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Remove access cover (39) at back of control module to expose control board (406).

3. Disconnect all cables and connectors from board. Remove two jumper wires (413) from J10 pins 7-8 and 9-10.

4. Remove screws (408) and remove board from control module.

5. Install new board in reverse order.

Apply thermal compound between the square steel piece on the back of the board and the main aluminum plate. Order Part No. 110009 Thermal Compound.

46 311075L

Repair

Motor

Cycle

Counter

Black Twin Flat Cable

Status

Indicator

Black Sheath

Red

Black

LINE

Ye l l o w

Red

Black

Jumper

Motor Power

Black

White

Heated Models

On/Off

(20 A

Breaker)

Single Cord Models Only

LINE

Heater Power On/Off (20 A Breaker)

Heater

J11 (120 V

J11

Board)

BOARD

CONTROL

not used

1 2

3 4 5

J10

6 7 8 9 10

J15J14

1 2 3 4

D11

ONOFF

SW2 (see page 32 to adjust

not used

Black

Red

White

J3J8

Function

Knob

Black Sheath

2 pin red connectors2 pin red connectors

Gray SheathGray Sheath

Pressure Transducer A

Calibration

Screw

°C

Temperature

Display B

°F

Temperature Sensor B

Calibration

Screw

Temperature

Display A

Gray Sheath

Temperature Sensor A

°C °F

Black Phone Cable and Plug

Pressure Transducer B

Heated Models

FIG. 12. Control Module Wiring Connections

311075L 47

Repair

Fluid Heaters (if supplied) Pressure Transducers

Fluid heater repair and parts information is included in manual 311210, which is supplied with heated units.

1. See Before Beginning Repair, page 39.

To replace a pressure transducer, see at right.

Relieve pressure, page 27.

2. Remove access cover (39) at back of control module to expose control board (406).

3. Disconnect transducer cables from J3 and J8 at board; see F

IG. 12, page 47. Reverse

A and B connections and check if status code follows the bad transducer, page 32.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Control section of heater can be repaired in place. Remove heater to clean fluid section. See manual 311210 for heater repair and parts.

6058

4. Reconnect good transducer to proper connector. Disconnect failed transducer from board, and unscrew from base of fluid heater (heated units) or transducer manifold (nonheated units).

5. Install o-ring (60) on new transducer (58), F

IG. 13.

6. Install transducer in heater or manifold. Mark board end of cable with tape (red=transducer A, blue=transducer B).

7. Route cable through channel to control module.

8. Connect transducer cable at board; see FIG. 12, page 47.

6058

TI7026a

Heated Units

Nonheated Units

TI7027a

FIG. 13. Transducers

48 311075L

Repair

Drive Housing

Removal

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. Remove screws (207) and end covers (221,

227), FIG. 14.

Examine connecting rod (216). If rod needs replacing, first remove the pump (219), page 41.

NOTICE

Do not drop gear reducer (214) and crankshaft (210) when removing drive housing (215). These parts may stay engaged in motor end bell (MB) or may pull away with drive housing.

3. Disconnect pump inlet and outlet lines. Remove screws (220) and pull drive housing (215) off motor (201) Connecting rod (216) will disengage from crankshaft (210).

B side crankshaft (210) includes the cycle counter magnet (224). When reassembling, be sure to install crankshaft with magnet on B side.

If replacing crankshaft, remove magnet (224). Reinstall magnet in center of offset shaft on new crankshaft. Position shaft in Park position.

2. Install bronze bearings (211, 213) in drive housing (215), as shown.

3. Install bronze bearings (209, 211) and steel washer (208) on crankshaft (210). Install bronze bearing (213) and steel washer (212) on gear reducer (214).

4. Install gear reducer (214) and crankshaft (210) into motor end bell (MB).

Crankshaft (210) must be in line with crankshaft at other end of motor. Pumps will move up and down together.

If connecting rod (216) or pump (219) were removed, reassemble rod in housing and install pump, page 41.

5. Push drive housing (215) onto motor (201). Install screws (220).

4. Examine crankshaft (210), gear reducer (214), thrust washers (208, 212), and bearings (209, 211, 213).

6. Install drive housing covers (221 on A side, 227 on B side) and screws (207). Pumps must be in phase (both at same position in stroke).

Installation

1. Apply grease liberally to washers (208,

212), bearings (209, 211, 213), gear reducer (214), crankshaft (210), and inside drive housing (215). Grease is supplied with replacement parts kits.

311075L 49

Repair

Cycle Counter Switch Replacement

B side drive housing cover (227) includes the cycle counter switch (223), mounted in the cover. When reassembling, be sure to install cover with switch on B side.

223

0.6 in. (15.2 mm) from inside edge

1.0 in. (25.4 mm) from inside bottom edge

TI7028a

206

207

221

201

212

(steel)

Crankshaft must be in line with crankshaft at other end of motor, so pumps move up and down in unison.

213

(bronze)

208 (steel)

214

209 (bronze)

210

224

213 (bronze)

211 (bronze)

216

215

220

227

207

219

TI7029a

FIG. 14. Drive Housing

50 311075L

Electric Motor

Repair

Test Motor

If motor is not locked up by pumps, it can be tested using a 9 V battery. Open recirculating valves, disconnect J4 or J11 from control board, see FIG. 12, page 47. Touch jumpers from battery to motor connections. Motor should turn slowly and smoothly.

Removal

If replacing a component with electrical cabling, remove one supply tank, page

39.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

e. Thread motor power switch harness out

bottom of control module and cable channel, to free motor.

NOTICE

Motor is heavy. Two people may be required to lift.

5. Remove screws holding motor to bracket. Lift motor off unit.

Installation

1. If replacing motor, install fan assembly and fan mount threaded bushing on new motor.

2. Place motor and fan on unit. Thread motor switch harness into control module.

3. Fasten motor with screws underneath. Do not tighten yet.

2. Remove four screws (207) and shroud (206). See FIG. 14.

3. Remove drive housing/pump assemblies, page 49.

4. Disconnect motor cables as follows:

a. Find control board at back of control

module, see F

b. Unplug motor power connector from J4

(240 V units) or J11 (120 V units).

c. Unplug motor temp switch harness from

connector J7.

d. Unplug cable (37) from fan (202). See

IG. 15.

IG. 12, page 47.

4. Plug 3-pin connector J7 to board.

5. Plug Motor Power switch harness to connector J4 (240 V units) or J11 (120 V units).

6. Install drive housing/pump assemblies, page 49. Reconnect inlet assemblies to pumps.

7. Tighten motor mounting screws.

8. Return to service.

311075L 51

Repair

Motor Brushes

Replace brushes worn to less than 1/2 in. (13 mm). Brushes wear differently on each side of motor; check both sides. Brush Repair Kit 287735 is available; kit includes instruction sheet

406582.

Motor commutator should be smooth. If not, resurface commutator or replace motor.

1. See Before Beginning Repair, page 39.

Relieve pressure, page 27.

2. See instruction sheet 406582, included with Brush Repair Kit 287735. Remove old brushes and install new ones supplied in kit.

202

TI7030a

FIG. 15. Fan

Fan

1. Disconnect fan cable (37) from fan (202). With Motor Power on, test cable connector for line voltage (120 V or 240 V).

2. If voltage is correct, fan is defective. Remove screws holding fan to shield (206). Install new fan in reverse order.

3. If voltage is not correct, check fan cable connection at J9 on control board; see F 12, page 47.

IG.

52 311075L

Repair

311075L 53

Parts

Part No. 249800, 120 V, 15 A, Heated Package Part No. 249802, 240 V, 10 A, Heated Package Part No. 249804, 240 V, 20 A, Heated Package

101

103

Ref. Part Description Qty

101 249570 PROPORTIONER, heated,

120 V, 15 A; see page 56; 249800 only

249571 PROPORTIONER, heated,

240 V, 10 A; see page 56; 249802 only

249572 PROPORTIONER, heated,

240 V, 20 A; see page 56; 249804 only

Ref. Part Description Qty

102 249499 HOSE BUNDLE, insulated; see

page 63

103 249810 GUN, Fusion, air purge; see

309550

102

TI6988b

54 311075L

Part No. 249806, 120 V, 15 A, Nonheated Package Part No. 249808, 240 V, 10 A, Nonheated Package

103

Parts

101

Ref. Part Description Qty

101 249576 PROPORTIONER, nonheated,

120 V, 15 A; see page 60; 249806 only

249577 PROPORTIONER, heated, 240

V, 10 A; see page 60; 249808 only

Ref. Part Description Qty

102 249633 HOSE BUNDLE, non-insulated;

see page 63

103 249834 GUN, 2K Ultra-Lite; see 309000

and 311230

102

TI6990b

311075L 55

Parts

Part No. 249570, 120 V, 15 A, Heated Proportioner Part No. 249571, 240 V, 10 A, Heated Proportioner

Part No. 249572, 240 V, 20 A, Heated Proportioner

41 39

2 2a

40▲

1 (Ref)

64 65

424 (Ref)

50*13

1 (Ref)

50*

54*

52*

53*

51*

TI7068a

TI6975b

56 311075L

Heated Proportioners

Ref. Part Description Qty

1 249582 CART; see page 67 1 2 249438 TANK, with lid and outlet fitting;

LDPE; includes item 2a 2a 15F895 . O-RING, lid, tank 1 4 111800 SCREW, cap, hex hd; 5/16-18 x

5/8 in. (16 mm) 5 119974 DRYER, desiccant 1 6 113037 MUFFLER, vent 1 7 101044 WASHER, plain; 1/2 in. (13 mm) 1 8 119973 LANYARD; 14 in. (356 mm); sst 2 11 119993 PLUG 2 12 287655 PROPORTIONER, bare, 120 V;

Model 249570; see page 62

287656 PROPORTIONER, bare, 240 V;

Models 249571 and 249572;

see page 62 13 117493 SCREW, machine, hex washer

hd; 1/4-20 x 1-1/2 in. (38 mm) 14 116393 ADAPTER; 1/4 npt (m x f) 2 15 556765 ELBOW; 1/4 npt(m) x 3/8 JIC 2 16 15V422 TUBE, fluid 2 17 287672 HEATER, fluid, 120 V; Model

249570; includes items 58 and

60; see 311210

287673 HEATER, fluid, 240 V; Models

249571 and 249572; includes

items 58 and 60; see 311210 18 167002 INSULATOR, heat 4 19 156849 NIPPLE; 3/8 npt 2 20 119874 CROSS; 3/8 npt(f); 4500 psi

(31.5 MPa, 315 bar) 21 15F692 HOUSING, thermowell 2 22 101118 SCREW, set; 10-24 x 1/4 in. (6

mm) 23 164259 ELBOW; 3/8 npt(m) x 1/4 npt(f) 4 24 113641 GAUGE, pressure, fluid; sst 2 25 119998 ADAPTER, A side;

5/16 JIC x 1/4 npt(m) 26 116704 ADAPTER, B side;

3/8 JIC x 1/4 npt(m) 27 104641 BULKHEAD FITTING 1 28 169970 FITTING, air line; 1/4 npt(m) 1 29 162453 NIPPLE; 1/4 npt x 1/4 npsm 1 30 287712 MANIFOLD, recirculation, with

valves; see page 66 31 15G097 TUBE, recirculation; 3/8 (10

mm) OD; sst 32 249629 HOSE, component A (ISO); 1/4

in. (6 mm) ID; thermoplastic

hose with moisture guard; 1/4

npsm(f) x 48 in. (1219 mm)

Ref. Part Description Qty

33 249630 HOSE, component B (RES); 1/4

in. (6 mm) ID; thermoplastic hose; 1/4 npsm(f) x 48 in. (1219 mm)

34 249556 DISPLAY, heated, 120 V; Model

249570; see page 64

249557 DISPLAY, heated, 240 V; Mod-

els 249571 and 249572; see

page 64 35 117623 NUT, cap; 3/8-16 4 36 15G218 CORD, 120 V; Model 249570 2

15G220 CORD, 240 V; Model 249571 2 15G219 CORD, 240 V; Model 249572 1

37 15G458 CABLE, fan; see page 62 1 38 CONDUIT, flexible; non-metallic 1 39 15G385 COVER, access, display 1 40▲ 15G280 LABEL, warning 1

41 108296 SCREW, machine, hex washer

hd; 1/4-20 x 5/8 in. (16 mm) 43 217374 LUBRICANT, ISO pump; not

shown

44 BOLT; 10-24 x 1 in. (25 mm) 2 45 15G119 GUARD, splash 1 46 15G461 RACK, hose 1 47 PLUG 4

48 109510 STRAP, bungee; 25 in. (635

mm) 49 WASHER, flat; 1/4 in.; nylon 4 50* 160327 ELBOW, swivel; 3/4 npt(m) x 3/4

npsm(f) 51* 101078 Y-STRAINER; includes item 51a 2 51a 180199 . ELEMENT, 20 mesh; not

shown 52* 109077 VALVE, ball; 3/4 npt (fbe) 2 53* C20487 NIPPLE; 3/4 npt 2 54* 157785 UNION, swivel; 3/4 npt(m) x 3/4

npsm(f)

55 242001 ADAPTER, cord; Europe; Model

249571 only

56 242005 ADAPTER, cord; Australia;

Model 249571 only

57 195551 RETAINER, plug, adapter;

Model 249571 only

58 246123 TRANSDUCER, pressure;

included with item 17

60 111457 O-RING; ptfe; included with item 172

61 15G476 LABEL, components A and B;

see page 54

Parts

311075L 57

Parts

Ref. Part Description Qty

62 119992 NIPPLE, pump inlet; 3/4 npt 2 63 157350 NIPPLE; 1/4 npt x 3/8 npt 1 64 117629 AIR FILTER/SEPARATOR, with

3/8 npt auto drain; includes item 2a

64a 114228 . ELEMENT, 5 micron; polypro-

pylene; not shown

65 100176 BUSHING; 3/8 npt(m) x

1/4 npt(f)

* Included in 287718 Pump Inlet Kit (one side).

▲ Replacement Danger and Warning labels, tags,

and cards are available at no cost.

58 311075L

Parts

311075L 59

Parts

Part No. 249576, 120 V, Nonheated Proportioner Part No. 249577, 240 V, Nonheated Proportioner

1 (Ref)

39 41 40▲

1 (Ref)

30 (Ref)

15 59

54*

50*

49 44

1 (Ref)

52*

53*

64 65

60 311075L

51*

50*

TI7068a

TI6981b

Nonheated Proportioners

Ref. Part Description Qty

1 249582 CART; see page 67 1 2 249438 TANK, with lid and outlet fitting;

LDPE; includes item 2a 2a 15F895 . O-RING, lid, tank 1 4 111800 SCREW, cap, hex hd; 5/16-18 x

Model 249576; see page 62

287656 PROPORTIONER, bare, 240 V;

Model 249577; see page 62 13 117493 SCREW, machine, hex washer

hd; 1/4-20 x 1-1/2 in. (38 mm) 15 116702 UNION; 1/4 npt(m) x 3/8 JIC 2 16 15V420 TUBE, fluid 2 23 155541 ELBOW, swivel; 1/4 npt(m) x 1/4

npsm(f) 25 119998 ADAPTER, A side;

1/2 JIC x 1/4 npt(m) 26 116704 ADAPTER, B side;

3/8 JIC x 1/4 npt(m) 27 104641 BULKHEAD FITTING 1 28 169970 FITTING, air line; 1/4 npt(m) 1 29 162453 NIPPLE; 1/4 npt x 1/4 npsm 3 30 287755 MANIFOLD, recirculation, with

valves; see page 66 31 15V421 TUBE, recirculation; 3/8 (10

mm) OD; sst 32 249629 HOSE, component A (ISO); 1/4

in. (6 mm) ID; thermoplastic

hose with moisture guard; 1/4

npsm(f) x 48 in. (1219 mm) 33 249630 HOSE, component B (RES); 1/4

in. (6 mm) ID; thermoplastic

hose; 1/4 npsm(f) x 48 in. (1219

mm) 34 249537 DISPLAY, nonheated, 120 V;

Model 249576; see page 65

249538 DISPLAY, nonheated, 240 V;

Model 249577; see page 65 35 117623 NUT, cap; 3/8-16 4

Ref. Part Description Qty

15G218 CORD, 120 V; Model 249576 1

15G220 CORD, 240 V; Model 249577 1 37 15G458 CABLE, fan; see page 62 1 38 CONDUIT, flexible; non-metallic 1 39 15G385 COVER, access, display 1 40▲ 15G280 LABEL, warning 1 41 108296 SCREW, machine, hex washer

hd; 1/4-20 x 5/8 in. (16 mm)

43 217374 LUBRICANT, ISO pump; not

shown 44 BOLT; 10-24 x 1 in. (25 mm) 2 45 15G119 GUARD, splash 1

46 15G461 RACK, hose 1 47 PLUG 4

48 109510 STRAP, bungee; 25 in. (635

mm) 49 WASHER, flat; 1/4 in.; nylon 4 50* 160327 ELBOW, swivel; 3/4 npt(m) x 3/4

npsm(f) 51* 101078 Y-STRAINER; includes item 51a 2

51a 180199 . ELEMENT, 20 mesh; not

shown 52* 109077 VALVE, ball; 3/4 npt (fbe) 2 53* C20487 NIPPLE; 3/4 npt 2

54* 157785 UNION, swivel; 3/4 npt(m) x 3/4

npsm(f)

55 242001 ADAPTER, cord; Europe; Model

249577 only

56 242005 ADAPTER, cord; Australia;

Model 249577 only

57 195551 RETAINER, plug, adapter;

Model 249577 only

58 246123 TRANSDUCER, pressure 2

59 15G292 MANIFOLD, pressure trans-

ducer 60 111457 O-RING; ptfe 2 61 15G476 LABEL, components A and B;

see page 55 62 119992 NIPPLE; 3/4 npt 2 63 157350 NIPPLE; 1/4 npt x 3/8 npt 1 64 117629 AIR FILTER/SEPARATOR, with

64a 114228 . ELEMENT, 5 micron; polypro-

3/8 npt auto drain; includes item

pylene; not shown

65 100176 BUSHING; 3/8 npt(m) x 1/4

npt(f)

Parts

* Included in 287718 Pump Inlet Kit (one side).

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

311075L 61

Parts

Part No. 287655, 120 V Bare Proportioner Part No. 287656, 240 V Bare Proportioner

207

206

207

201 (Ref)

203

205

‡221

210*209*208*

†212

201

†213

†214

◆216

†213

218

219

Ref. Part Description Qty

201 287650 MOTOR, electric; 120 V 1

287651 MOTOR, electric; 240 V

202 119994 FAN, cooling; 120 V 1

119995 FAN, cooling; 240 V 1 203 115836 GUARD, finger 1 204 RIVET, blind; 5/32 x 3/8 grip 1 205 SCREW, machine, slotted hd;

8-32 x 2 in. (51 mm) 206 249518 SHIELD, proportioner 1 207‡ 115492 SCREW, machine, hex washer

hd; 8-32 x 3/8 in. (10 mm) 208* 116074 WASHER, thrust; steel 2 209* 107434 BEARING, thrust; bronze 2 210* 248231 CRANKSHAFT KIT 2 211* 180131 BEARING, thrust; bronze 2 212† 116073 WASHER, thrust; steel 2 213† 116079 BEARING, thrust; bronze 4 214† 287057 GEAR REDUCER KIT 2 215‡ 287055 DRIVE HOUSING KIT 2 216◆ 287053 CONNECTING ROD KIT 2 217◆ 196762 PIN, straight 2 218 195150 NUT, jam, pump 2

204 202

224

211*

215‡

220‡

217◆

223

227

220‡

207‡

222‡

Ref. Part Description Qty

219 287657 PUMP, displacement; see

311076

220‡ 117493 SCREW, machine, hex washer

hd; 1/4-20 x 1-1/2 in. (38 mm) 221‡ 15B254 COVER, drive housing, A side 1 222‡ 15B589 COVER, pump rod 2

223 117770 SWITCH, reed, w/cable 1 224 119875 MAGNET 1 227 249854 COVER, drive housing, B side;

includes item 223 and 228 228 115711 TAPE, mounting, reed switch;

not shown

* Included in 248231 Crankshaft Kit. † Included in 287057 Gear Reducer Kit. ‡ Included in 287055 Drive Housing Kit.

◆ Included in 287053 Connecting Rod Kit.

TI6978a

62 311075L

Part No. 249499, Insulated Hose Bundle with recirculation lines

Parts

301

302

303 (Ref)

305 303

Ref. Part Description Qty

301 249508 HOSE, fluid (component A),

moisture guard; 1/4 in. (6 mm) ID; no. 5 JIC fittings (mxf); 35 ft (10.7 m)

302 249509 HOSE, fluid (component B); 1/4

in. (6 mm) ID; no. 6 JIC fittings (mxf); 35 ft (10.7 m)

302 (Ref)

304

Ref. Part Description Qty

303 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4

304 buy

locally

npsm (fbe); 35 ft (10.7 m) TUBE, foam, insulated; 1-3/8 in. (35 mm) ID; 31 ft (9.5 m)

305 156971 NIPPLE; 1/4 npt; for joining air

line to another hose bundle

TI6991a

Part No. 249633, Non-insulated Hose Bundle without recirculation lines

301

302 (Ref)

302 305

303

Ref. Part Description Qty

301 249508 HOSE, fluid (component A),

moisture guard; 1/4 in. (6 mm) ID; no. 5 JIC fittings (mxf); 35 ft (10.7 m)

302 249509 HOSE, fluid (component B); 1/4

in. (6 mm) ID; no. 6 JIC fittings (mxf); 35 ft (10.7 m)

303 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4

npsm (fbe); 35 ft (10.7 m)

305 156971 NIPPLE; 1/4 npt; for joining air

line to another hose bundle

TI6992a

311075L 63

Parts

Part No. 249556, 120 V Heated Display Part No. 249557, 240 V Heated Display

409

403

402

421

401

404 402

414

408 407

405 416a

416

416a

404 (Ref)

415

417

406

410

424

Ref. Part Description Qty

401 15F984 PLATE 1 402 119927 SWITCH, motor or heater

power, with circuit breaker

403 15G386 MODULE, display, temperature;

includes (1) item 402 and (2)

item 424 404 249494 POTENTIOMETER 1 405 119930 INDICATOR, status, LED 1 406 249434 BOARD, control; 120 V units

only

249432 BOARD, control; 240 V units

only 407 15G230 CABLE, harness 1 408 107156 SCREW, machine, pan hd 7 409 113505 NUT, keps, hex hd 10 410 119898 BULKHEAD FITTING, cable 2

411

412

413

Ref. Part Description Qty

411 101765 GROMMET 1 412 116773 CONNECTOR, plug 1

413 15C866 WIRE, jumper 2 414 15G279 LABEL, display 1

415 15G053 PLATE, detent 1 416 249453 KNOB, function; includes item

416a

416a 101118 . SCREW, set; no. 10 x 1/4 in. (6

mm) 417 15G454 LABEL, startup, heated 1 421 15G384 ENCLOSURE 1

424 119869 DISPLAY, temperature, with

sensor

425 DUAL TERMINAL; not shown 2

TI6979a

64 311075L

Part No. 249537, 120 V Nonheated Display Part No. 249538, 240 V Nonheated Display

403 405

Parts

421

409

410

401

404

423

414

411

402

408

407

412

416a

416 416a

404 (Ref) 415

417

406

Ref. Part Description Qty

401 15F984 PLATE 1 402 119927 SWITCH, motor power, with cir-

cuit breaker 403 15G408 COVER, display 1 404 249494 POTENTIOMETER 1 405 119930 INDICATOR, status, LED 1 406 249434 BOARD, control; 120 V units

only

249432 BOARD, control; 240 V units

413

Ref. Part Description Qty

414 15G279 LABEL, display 1 415 15G053 PLATE, detent 1

416 249453 KNOB, function; includes item

416a

416a 101118 . SCREW, set; no. 10 x 1/4 in. (6

mm)

417 15G281 LABEL, startup, unheated 1

421 15G384 ENCLOSURE 1 423 PLUG 1

TI6983a

only 407 15G230 CABLE, harness 1 408 107156 SCREW, machine, pan hd 7 409 113505 NUT, keps, hex hd 10 410 119897 BULKHEAD FITTING, cable 1 411 101765 GROMMET 1 412 116773 CONNECTOR, plug 1 413 WIRE, jumper 2

311075L 65

Parts

Part No. 287712 Recirculation Manifold, Heated Models

505

Ref. Part Description Qty

501 15F870 MANIFOLD, recirculation 1

504

502 111763 ELBOW; 1/4 npt (mbe) 2 503 239914 VALVE, recirc/spray; includes

503

503a 15E022 . SEAT 1 503b 111699 . GASKET 1 504 224807 BASE, valve 2 505 187625 HANDLE, valve, drain 2

▲512

506

503a 503b

506 111600 PIN, grooved 2

501

508

502

507 100721 PLUG, pipe; 1/4 npt(m) 2 508 100840 ELBOW, street; 1/4 npt(m) x 1/4

509 116704 ADAPTER; 3/8 JIC x 1/4 npt(m) 1 510 119998 ADAPTER; 5/16 JIC x 1/4

512▲ 189285 LABEL, warning 1

507

▲ Replacement Danger and Warning labels, tags,

and cards are available at no cost.

509510

TI6977a

Part No. 287755 Recirculation Manifold, Nonheated Models

items 503a, 503b

npsm(f)

npt(m)

507

510

511

506

508

509

505

504

503

503a 503b

501

502

TI6982a

Ref. Part Description Qty

501 15F870 MANIFOLD, recirculation 1 502 111763 ELBOW; 1/4 npt (mbe) 4 503 239914 VALVE, recirc/spray; includes

items 503a, 503b 503a 15E022 . SEAT 1 503b 111699 . GASKET 1 504 224807 BASE, valve 2 505 187625 HANDLE, valve, drain 2 506 111600 PIN, grooved 2 507 113641 GAUGE, pressure, fluid 2 508 116504 TEE; 1/4 npt(m) x 1/4 npt(f) run;

1/4 npt(f) branch 509 116704 ADAPTER; 3/8 JIC x 1/4 npt(m) 1 510 119998 ADAPTER; 5/16 JIC x 1/4

npt(m) 511 556765 ELBOW, tube; 1/4 npt(m) x 3/8

in. (10 mm) OD tube

66 311075L

Part No. 249582, Cart

Parts

607

602

603

602

604 605

Ref. Part Description Qty

602 154636 WASHER, flat 4 603 116411 SPRING 2 604 116477 WASHER, flat; nylon 4 605 116478 WHEEL, pneumatic 2 606 101242 RING, retaining 2 607 GRIP, handle 2

604

606

TI6976a

311075L 67

Suggested Spare Replacement Parts

Keep the following spare parts on hand to reduce downtime.

All Units Heated Units Only

Part Description

119974 DRYER, desiccant 15F895 O-RING, lid, tank 119927 SWITCH, motor or heater power, with cir-

cuit breaker 113641 GAUGE, pressure, fluid; sst 101078 Y-STRAINER; includes 180199 element 180199 ELEMENT, Y-strainer, 20 mesh 114228 ELEMENT, air filter, 5 micron; polypropyl-

ene 239914 VALVE, recirc/spray; includes seat and

gasket 249494 POTENTIOMETER, control knob 249434 BOARD, control; 120 V units only 249432 BOARD, control; 240 V units only 246123 TRANSDUCER, pressure 287657 PUMP, displacement; fits either side 287718 INLET KIT, tank to pump 249855 REPAIR KIT, displacement pump;

includes seals, balls, bearings, intake

valve seat)

Part Description

119869 DISPLAY, temperature, with sensor 119857 FUSE, heater over-temperature 119797 THERMOSTAT, heater 15F770 HEATER ELEMENT; 120 V units only 15F771 HEATER ELEMENT; 240 V units only

Accessories

Part Description

249815 GUN, Fusion MP with 4-hose manifold 249634 KIT, 2k Ultra-Lite, restrictor valve, cold

spray 249635 KIT, 2k Ultra-Lite, extension, joint fill

68 311075L

Dimensions

All Models

44 in. (1118 mm)

26.5 in. (673 mm)

30 in. (762 mm)

TI6974a

311075L 69

Technical Data

Maximum fluid working pressure

Electrical requirements Model 249800: 120 Vac, 1 phase, 50/60 Hz, 3500 W; requires two

Generator Size (for Reactor E-10 only)

Maximum Fluid Temperature

2000 psi (14 MPa, 140 bar)

separate, dedicated 15 A circuits Model 249802: 240 Vac, 1 phase, 50/60 Hz, 3800 W; requires two

separate, dedicated 10 A circuits Model 249804: 240 Vac, 1 phase, 50/60 Hz, 3800 W; requires a sin-

gle dedicated 16 A circuit Model 249806: 120 Vac, 1 phase, 50/60 Hz, 1800 W; requires a sin-

gle dedicated 15 A circuit Model 249808: 240 Vac, 1 phase, 50/60 Hz, 1800 W; requires a sin-

gle dedicated 8 A circuit

Heated: 5000 W minimum Nonheated: 2500 W minimum

160°F (71°C)

Maximum Ambient Temperature

Maximum Output 12 lb/min (5.4 kg/min) at 340 cycles/min Output per Cycle (A and B).00352 gal. (.0133 liter)

Overpressure Relief Recirc/Spray valves automatically relieve excessive fluid pressure

Heater Power 120V models: 850 W each; 1700 W total

Sound Pressure 78.7 dB(A) in fast circulation mode

Sound Power, per ISO 9614-2

110°F (43°C)

back to supply tanks

240V models: 1000 W each; 2000 W total

84.5 dB(A) at 2000 psi (14 MPa, 140 bar), 0.72 gpm (2.7 lpm)

88.6 dB(A) in fast circulation mode

94.4 dB(A) at 2000 psi (14 MPa, 140 bar), 0.72 gpm (2.7 lpm)

70 311075L

Tank Capacity 7 gal. (26.5 liters) each (nominal) Fluid Outlets Component A (ISO): #5 JIC (1/2-18) male

Component B (RES): #6 JIC (9/16-18) male

Fluid Circulation Returns Component A (ISO): #5 JIC (1/2-18) male

Component B (RES): #6 JIC (9/16-18) male Air Inlet 1/4 in. quick-disconnect industrial type pin fitting Air Outlet 1/4 npsm(m)

Technical Data

Gun Compressed Air

Fusion Gun (purge air and operating air): 4 scfm (0.112 m3/min) Requirements

2K Ultra-Lite Gun with disposable mixer kit: 14 scfm (0.392 m3/min),

with air spray valve fully open

2K Ultra-Lite Gun with joint fill kit: 2 scfm (.056 m3/min) Hose Markings A Side: Red

B Side: Blue Weight (empty) approximately 160 lb (72 kg), depending on model Wetted Parts Aluminum, stainless steel, carbon steel, brass, carbide, chrome,

chemically resistant o-rings, PTFE, ultra-high molecular weight poly-

ethylene

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

311075L 71

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

For the latest information about Graco products, visit www.graco.com.

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 311075

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

www.graco.com

Revised 09/2010

Graco Inc. 249570, 249571, 249572, 249576, 249577 Instructions - Parts List

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Systems

Models

Warnings

Overview

Isocyanate Hazard

Foam Self-ignition

Moisture Sensitivity of Isocyanates

Keep Components A and B Separate

Changing Materials

Component Identification

Controls and Indicators

STATUS Indicator

Motor Power Switch/Circuit Breaker

Heater Power Switch/Circuit Breaker

Heater Temperature Controls

Fluid Temperature Sensors and Displays

Setup

Startup of Heated Units

Heatup Guidelines

Heat Management Tips

Heating Foam Resins with 245 fa Blowing Agents

Spraying/Dispensing

Pause (Heated Units)

Refilling Tanks

Pressure Relief Procedure

Shutdown

Maintenance

Flushing

Troubleshooting

Status Codes

Troubleshooting Chart

Repair

Before Beginning Repair Removing Supply Tanks

Recirc/Spray Valves

Displacement Pump

Control Module

Fluid Heaters (if supplied) Pressure Transducers

Drive Housing

Cycle Counter Switch Replacement

Electric Motor

Motor Brushes

Parts

Suggested Spare Replacement Parts

Accessories

Dimensions

Technical Data

Graco Standard Warranty

Graco Information