Graco 312063S User Manual

Page 1

Repair - Parts

312063S

Hydraulic, Heated, Plural Component Proportioner. For spraying polyurethane foam and polyurea coatings. For professional use only.

Not for use in explosive atmospheres.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 3 for model information, including maximum working pressure and approvals.

For patent information, see www.graco.com/patents.

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Page 2

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Temperature Control Diagnostic Codes . . . . . . . . 8

E01: High fluid temperature . . . . . . . . . . . . . . . . 8

E02: High zone current . . . . . . . . . . . . . . . . . . . . 9

E03: No zone current . . . . . . . . . . . . . . . . . . . . . 9

E04: Fluid Temperature Sensor (FTS) or

thermocouple disconnected . . . . . . . . . . . . 10

E05: Circuit board overheated . . . . . . . . . . . . . 10

E06: Communication cable unplugged . . . . . . . 10

Motor Control Diagnostic Codes . . . . . . . . . . . . . 11

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

E21: No component A transducer . . . . . . . . . . . 12

E22: No component B transducer . . . . . . . . . . . 12

E23: High fluid pressure . . . . . . . . . . . . . . . . . . 12

E24: Pressure imbalance . . . . . . . . . . . . . . . . . 12

E27: High motor temperature . . . . . . . . . . . . . . 14

E30: Momentary loss of communication . . . . . . 14

E31: Pumpline reversing switch

failure/high cycle rate . . . . . . . . . . . . . . . . . 14

E99: Loss of communication . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Reactor Electronics . . . . . . . . . . . . . . . . . . . . . . 16

Primary Heaters (A and B) . . . . . . . . . . . . . . . . 18

Hose Heat System . . . . . . . . . . . . . . . . . . . . . . 19

Hydraulic Drive System . . . . . . . . . . . . . . . . . . . 21

Proportioning System . . . . . . . . . . . . . . . . . . . . 23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Proportioning Pumps . . . . . . . . . . . . . . . . . . . . . 28

Circuit Breaker Module . . . . . . . . . . . . . . . . . . . 30

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Motor Control Board . . . . . . . . . . . . . . . . . . . . . 32

Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Electric Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Temperature Control Module . . . . . . . . . . . . . . . 35

Primary Heaters . . . . . . . . . . . . . . . . . . . . . . . . . 37

Heated Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 40

Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 42

Inlet Fluid Strainer Screen . . . . . . . . . . . . . . . . . 44

Pump Lubrication System . . . . . . . . . . . . . . . . . 44

Change Hydraulic Fluid and Filter . . . . . . . . . . . 45

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Parts Used on All Models . . . . . . . . . . . . . . . . . 54

Parts that Vary by Model . . . . . . . . . . . . . . . . . . 56

Sub Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 59

Proportioner Assembly . . . . . . . . . . . . . . . . . . . 59

10.2 kW and 6.0 kW Heaters . . . . . . . . . . . . . . . 61

8.0 kW Dual Zone Heater . . . . . . . . . . . . . . . . . 62

7.65 kW Single Zone Heater . . . . . . . . . . . . . . . 63

Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . 64

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Temperature Control . . . . . . . . . . . . . . . . . . . . . 66

Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Circuit Breaker Modules . . . . . . . . . . . . . . . . . . 68

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 74

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 74

2 312063S

Page 3

Models

H-25 SERIES

Models

Max Flow Full Load Peak Amps*

Part, Series

255400, F 69 230V (1) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255401, F 46 230V (3) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255402, F 35 400V (3) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255406, F 100 230V (1) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255407, F 59 230V (3) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 255408, F 35 400V (3) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)

Per Phase

Voltage (phase)

System Watts†

Primary Heater Watts

Rate◆

lb/min

(kg/min)

Approximate Output per Cycle (A+B) gal. (liter)

Hydraulic Pressure Ratio

Maximum Fluid Working Pressure psi (MPa, bar)

H-40 SERIES

Max Flow

Full Load

Part, Series

★253400, E 100 230V (1) 23,100 12,000 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)

253401, E 71 230V (3) 26,600 15,300 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 253402, E 41 400V (3) 26,600 15,300 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 253407, E 95 230V (3) 31,700 20,400 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138) 253408, E 52 400V (3) 31,700 20,400 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)

Peak Amps* Per Phase

Voltage (phase)

System Watts†

Primary Heater Watts

Rate◆ lb/min (kg/min)

Approximate Output per Cycle (A+B) gal. (liter)

Hydraulic Pressure Ratio

Maximum Fluid Working Pressure psi (MPa, bar)

H-50 SERIES

Max Flow

Full Load

Part, Series

★253725, E 100 230V (1) 23,100 12,000 52 (24) 0.073 (0.28) 1.64:1 1700 (11.7, 117)

253726, E 71 230V (3) 26,600 15,300 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138) 253727, E 41 400V (3) 26,600 15,300 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138) 256505, E 95 230V (3) 31,700 20,400 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138) 256506, E 52 400V (3) 31,700 20,400 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138)

Peak Amps* Per Phase

Voltage (phase)

System Watts†

Primary Heater Watts

Rate◆ lb/min (kg/min)

Approximate Output per Cycle (A+B) gal. (liter)

Hydraulic Pressure Ratio

Maximum Fluid Working Pressure psi (MPa, bar)

312063S 3

Page 4

Models

H-XP2 SERIES

Approximate Full Load Peak Amps*

Part, Series

255403, F 100 230V (1) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241) 255404, F 59 230V (3) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241) 255405, F 35 400V (3) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241)

Per Phase

Voltage (phase)

System Watts†

Primary Heater Watts

Max Flow Rate◆ gpm (lpm)

Output per

Cycle (A+B)

gal. (liter)

Hydraulic Pressure Ratio

Maximum Fluid Working Pressure psi (MPa, bar)

H-XP3 SERIES

Approximate

Full Load

Part, Series

253403, E 100 230V (1) 23,100 12,000 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241) 253404, E 95 230V (3) 31,700 20,400 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241) 253405, E 52 400V (3) 31,700 20,400 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241)

Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix

Peak Amps* Per Phase

Voltage (phase)

System Watts†

Primary Heater Watts

Max Flow Rate◆ gpm (lpm)

Output per Cycle (A+B) gal. (liter)

Hydraulic Pressure Ratio

Maximum Fluid Working Pressure psi (MPa, bar)

chamber sizes may be less.

† Total system watts, based on maximum hose length for each unit:

• Parts 255400 through 255408, 310 ft (94.6 m) maximum heated hose length, including whip hose.

• Parts 253400 through 253408, 253725 through 25372, 256505, and 256506, 410 ft (125 m) maximum heated hose length, including whip hose.

◆ Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum

flow.

★ CE approval does not apply.

4 312063S

Page 5

Supplied Manuals

The following manuals are shipped with the Reactor™ Proportioner. Refer to these manuals for detailed equipment information.

Order Part 15M334 for a compact disk of Reactor manuals translated in several languages.

Manuals are also available at www.graco.com.

Reactor Hydraulic Proportioner

Part Description

312062 Reactor Hydraulic Proportioner, Oper-

ation Manual (English)

Reactor Electrical Diagrams

Part Description

312064 Reactor Hydraulic Proportioner, Elec-

trical Diagrams (English)

Proportioning Pump

Part Description

312068 Proportioning Pump Repair-Parts

Manual (English)

Translations

The Reactor Repair-Parts manual is available in the following languages. See the following chart for specific

languages and corresponding part numbers.

Related Manuals

The following manuals are for accessories used with the

™

Reactor

Order Part 15M334 for a compact disk of Reactor manuals translated in several languages. Order Part 15B381 for a compact disk of Fusion manual translated in several languages.

Feed Pump Kits

Part Description

309815 Instruction-Parts Manual (English)

Air Supply Kit

Part Description

309827 Instruction-Parts Manual (English) for

Circulation and Return Tube Kits

Part Description

309852 Instruction-Parts Manual (English)

Heated Hose

Part Description

309572 Instruction-Parts Manual (English)

Circulation Kit

Part Description

309818 Instruction-Parts Manual (English)

Circulation Valve Kit

Feed Pump Air Supply Kit

Part Language

312063 English 312428 Chinese 312429 Dutch 312430 French 312431 German 312432 Italian 312433 Japanese 312434 Korean 312435 Russian 312436 Spanish

312063S 5

Part Description

312070 Instruction-Parts Manual (English)

Data Reporting Kit

Part Description

309867 Instruction-Parts Manual (English)

Rupture Disk Assembly Kit

Part Description

309969 Instruction-Parts Manual (English)

Proportioning Pump Repair Kits

Part Description

312071 Seal Kits Instruction-Parts Manual

(English)

Page 6

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Follow Pressure Relief Procedure in this manual, 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 and clean 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 lights on or off when flammable fumes are present.

• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions.

• Use only Graco grounded hoses.

• Check gun resistance daily.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from system.

• Keep a working fire extinguisher in the work area.

6 312063S

Page 7

Warnings

WARNING

THERMAL EXPANSION HAZARD

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating conditions.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• This equipment is for professional use only.

• Do not leave the work are while the equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when the equipment is not in use.

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

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

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

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure in this manual. Disconnect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

312063S 7

Page 8

Temperature Control Diagnostic Codes

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

Temperature control diagnostic codes appear on temperature display.

These alarms turn off heat. E99 clears automatically when communication is regained. Codes E03 through

E06 can be cleared by pressing . For other codes,

turn main power OFF then ON to

clear.

E01: High fluid temperature

Causes of E01 Errors

• Thermocouple A or B (310) senses a fluid temperature above 230°F (110°C).

• Fluid temperature sensor (FTS) senses a fluid temperature above 230°F (110°C).

• Overtemperature switch A or B (308) senses a fluid temperature above 230°F (110°C) and opens. At 190°F (87°C) the switch closes again.

• Thermocouple A or B (310) fails, is damaged, is not touching the heater element (307), or has a poor connection to the temperature control board.

• Overtemperature switch A or B (308) fails in the open position.

• The temperature control board fails to turn off any heat zone.

• Zone power wires or thermocouples are switched from one zone to another.

• Failed heater element where thermocouple is installed.

• Loose wire

• On 8 kW heater models only: Jumper wire on J1 connector, between module (3) and display (4), is loose or incorrectly wired.

Code Code Name Alarm

Zone

01 High fluid temperature Individual

02 High zone current Individual

03 No zone current with

hose heater on

04 FTS not connected Individual

05 Board overtemperature Individual

06 Communication cable

unplugged from module

99 Loss of communication A

For hose zone only, if FTS is disconnected at startup, display will show hose current 0A.

Individual

Corrective

Action page

Checks

Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform all electrical troubleshooting. Be sure to shut off all power to the equipment before repairing.

Check which zone is displaying the E01 error.

1. Check that connector B is firmly plugged into temperature control module (see F

2. Clean and re-plug connections.

3. Check connections between the temperature control module and overtemperature switches A and B (308), and between temperature control module and thermocouples A and B (310) or FTS (21) [depending on which zone is displaying E01]. See T page 35. Ensure that all wires are securely connected to connector B.

. 8, page 35).

ABLE

8 312063S

Page 9

Temperature Control Diagnostic Codes

4. Remove connector B from temperature control module, and check continuity of overtemperature switches A and B, thermocouples A and B, or FTS by measuring resistance across the pins on the plug

end; see T

Before doing the following checks, note which zone (A, B, FTS, or all) has high fluid temperature.

Table 1: Sensor Connector Continuity Checks

Pins Description Reading

1 & 2 OT switch A nearly 0 ohms 3 & 4 OT switch B nearly 0 ohms 5 & 6 Thermocouple A 4-6 ohms 8 & 9 Thermocouple B 4-6 ohms

11 & 12 FTS approximately 35

10 & 12 FTS open

5. Verify fluid temperature, using an external temperature sensing device.

ABLE

ohms per 50 ft (15.2

m) of hose, plus

approximately 10

ohms for FTS

E02: High zone current

1. Turn main power OFF .

2. Relieve pressure, page 27.

Disconnect whip hose.

3. Disconnect hose connector (D) at Reactor.

4. Using an ohmmeter, check between the two terminals of the connector (D). There should be no continuity.

5. Exchange zone module with another one. Turn zone on and check for error. If error disappears, replace faulty module.

For hose zone:

former Primary Check and Transformer Secondary Check starting on page 41.

When there is a a high current error, the LED on that zone’s module will turn red while the error is displayed.

If error still occurs, perform Trans-

• If temperature 229°F [109°C] or above):

6. Check if thermocouples A and B are damaged, or not contacting the heater element, page 38.

7. To test that temperature control module turns off when equipment reaches temperature setpoint:

a. Set temperature setpoints far below displayed

temperature.

b. Turn zone on. If temperature rises steadily,

power board is failing.

c. Verify by swapping with another power module.

See Replacing Temperature Control Assem- bly Modules, page 36.

d. If the swapped module does not fix the problem,

the power module is not the cause.

8. Verify continuity of heater elements with an ohmmeter, see page 37.

too high (sensor reading is

E03: No zone current

1. Check for tripped circuit breaker inside electrical cabinet or at power source for that zone. Replace circuit breaker if it trips habitually.

2. Check for loose or broken connection at that zone.

3. Exchange zone module with another one. Turn zone on and check for error (see page 36). If error disappears, replace faulty module.

4. If E03 occurs for all zones, the contactor may not be closing. Verify wiring from heater control to contactor coil.

Hose zone

b. Perform Transformer Primary Check and

Transformer Secondary Check, starting on

page 41.

When a no current error occurs, the LED on the specific zone’s module turns red when the error is displayed.

: test hose continuity, page 39.

312063S 9

Page 10

Temperature Control Diagnostic Codes

E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected

1. Check temperature sensor connections to long green connector (B) on temperature control module, page 35. Unplug and re-plug sensor wires.

2. Test fluid temperature sensor continuity with ohmmeter, page 8.

3. If an error occurred for the hose zone, check FTS connections at each section of hose.

4. If an error occurred for the hose zone, test FTS by plugging directly into machine.

ti9878a

E05: Circuit board overheated

Each module has an on-board temperature sensor. Heat is turned off if module temperature exceeds 185°F (85°C) within the heater module.

1. Check that fan above electrical cabinet is operating.

2. Check that electrical cabinet door is properly installed.

3. Check for obstructions blocking cooling holes in bottom of electrical cabinet.

4. Clean heatsink fins behind heater control modules.

5. Ambient temperature may be too high. Allow Reactor to cool by moving to a cooler location.

E06: Communication cable unplugged

1. Unplug and re-plug cable that connects heater control module to heater module.

5. To verify heater control module is not causing the problem, use a wire to short-circuit the two pins corresponding to the FTS (red and yellow for A or B zone, red and purple for hose). The display will show the control heater module temperature.

6. If an error occurred for the hose zone, temporarily use the current control mode. Refer to Reactor Operation manual 312062.

2. Replace communication cable if problem persists.

10 312063S

Page 11

Motor Control Diagnostic Codes

Motor control diagnostic codes E21 through E27 appear on pressure display.

There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings.

Alarms

Alarms turn off Reactor. Turn main power OFF

then ON to clear.

Alarms can also be cleared, except for code 23, by

pressing .

Warnings

Reactor will continue to run. Press to clear. A

warning will not recur for a predetermined amount of time (varies for different warnings), or until main power

is turned OFF then ON .

Code Code Name Alarm (A) or

Warning (W)

21 No transducer (compo-

nent A)

22 No transducer (compo-

nent B)

23 High fluid pressure A

24 Pressure imbalance A/W (to

27 High motor temperature A

30 Momentary loss of com-

munication

31 Pumpline reversing switch

failure/high cycle rate

99 Loss of communication A

select, see page 32)

Corrective

Action

page

312063S 11

Page 12

Motor Control Diagnostic Codes

E21: No component A transducer

1. Check transducer A connection at J3 on motor control board, page 33, and clean contacts.

2. Reverse A and B transducer connections. If error moves to transducer B (E22), replace transducer A, page 34. If error does not move, replace motor control board, page 32.

E22: No component B transducer

1. Check transducer B connection at J8 on motor control board, page 33, and clean contacts.

2. Reverse A and B transducer connections. If error moves to transducer A (E21), replace transducer B, page 34. If error does not move, replace motor control board, page 32.

E24: Pressure imbalance

Upon initial start-up this diagnostic code will not cause an alarm for 2 minutes.

If the pressure difference between components A and B exceeds 500 psi (3.5 MPa, 35 bar), an E24 will occur. This default value is adjustable; see the operation manual.

E24 can be an alarm or a warning, as desired. Set DIP switch on motor control board ON for alarm, OFF for warning. See page 32.

Fast E24 Errors

Fast E24 errors occur:

• within 10 seconds of turning the pumps on, or

• as soon as you trigger the gun.

E23: High fluid pressure

1. Relieve pressure. Verify low pressure with analog

gauges. Turn main power OFF then ON

. If error persists, do checks below.

2. If pressure imbalance is set to Warning instead of Alarm (see page 32), an E23 will occur. See E24:

Pressure imbalance for causes and checks.

Causes of Fast E24 Errors

• one side of the gun is plugged.

• a pressure transducer has failed.

• damaged pump seals or check valve.

• no feed pressure or empty material drum

• plugged heater.

• plugged hose.

• plugged manifold.

• one PRESSURE RELIEF/SPRAY valve is leaking or

is set to PRESSURE RELIEF/CIRCULATION .

Checks for Fast E24 Errors

If a fast E24 error occurs, first check the readings of the analog gauges.

• If the gauge readings are very close:

1. Clear the error (page 11) and try running the unit again.

2. If E24 recurs and the gauge readings are still very close, a pressure transducer has failed.

12 312063S

Page 13

Motor Control Diagnostic Codes

The digital display always shows the higher of the two pressures. As soon as the higher analog pressure drops below the lower analog pressure, the display changes to the new higher reading. Knowing this, the following checks will show which transducer has failed, or if the motor control board has failed.

3. For testing purposes only, set DIP switch 2 on the motor control board to OFF. See page 32. This will allow the Reactor to continue to run with a pressure imbalance.

c. Run the unit until pressure is 1000-1500 psi

(7-10.5 MPa, 70-105 bar). Shut down the unit, clear the alarm, and power back up, but do not depressurize the unit.

d. Check the analog gauges to see which pressure

is higher, and check if the display matches.

If the higher gauge and display match,

that transducer is communicating with the motor control board. Continue with step e.

4. To test if the failure is with the transducer or the socket on the motor control board:

a. Reverse connections at J3 and J8 on the motor

control board.

b. Run the unit until pressure is 1000-1500 psi

(7-10.5 MPa, 70-105 bar).

c. If the problem stays on the same side as before,

replace the motor control board. If the problem appears to move to the other side, replace the transducer.

• If the gauge readings are not very close:

1. Secure bleed lines in grounded waste containers, or route back to respective component A or B supply drum. Reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE

RELIEF/CIRCULATION , until gauges show balanced pressures.

If the higher gauge and display do not match,

that transducer is not communicating with the motor control board. Check wire connections and replace transducer, page 34.

e. Turn pumps off. Reduce pressure of higher

component by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF/CIRCULATION

, while watching the display and the analog gauges. As soon as the higher analog pressure drops below the lower analog pressure, the display should change to the new higher reading. Continue reducing the original higher pressure an additional 200 psi (1.4 MPa, 14 bar); digital display should stop dropping.

f. Repeat for the other side, to check the other

transducer.

Turn valve slightly

to reduce pressure of higher

Turn valve slightly

to reduce pressure of higher

ti9877a

Turn PRESSURE RELIEF/SPRAY valve only enough to balance pressure. If you turn it completely, all pressure will bleed off.

2. If you cannot get the pressures to balance:

a. Check for damaged pump seals or check

valves.

b. Check if you’ve run out of material.

c. Check for a plugged fluid path by using the feed

pump to push fluid through the gun manifold.

3. If you are able to balance pressures, try running the unit.

ti9877a

312063S 13

Page 14

Motor Control Diagnostic Codes

4. If a fast E24 error occurs again, and the gauges readings are not very close:

a. Check and clean the gun inlet screens.

b. Check and clean the gun mix chamber impinge-

ment ports and center port. See gun manual.

Some mix chambers have counter bored impingement ports, requiring two drill sizes to clean completely.

Slow E24 Errors

Slow E24 errors occur gradually. The pressures are balanced when you begin spraying, but slowly become imbalanced until an E24 occurs.

Causes of Slow E24 Errors

• one side of the gun is partially plugged.

• the A or B proportioner pump has failed.

• the A or B feed pump has failed.

• the A or B feed pump pressure is set too high.

• the A or B proportioner pump inlet screen is plugged.

• the hose is not heating properly.

• kinked supply hose.

• bottom of drum is damaged, causing blockage of feed pump inlet.

• drum is not vented.

1. Turn main power OFF .

2. Allow motor to cool completely. Check continuity between pins 1 and 2 on connector J9 on the motor control board, page 32. If the resistance is infinity, the motor thermal switch or the wire harness is bad. Check wiring, measure thermal switch continuity at motor, and replace failed part.

3. Unplug motor from J9 on motor control board. Install jumper across pins 1 and 2 on board. If error still occurs, replace motor control board.

4. If the E27 error is still occurring, the problem is with the motor control board.

E30: Momentary loss of communication

If communication is lost between the display and the motor control board, the display will normally show E99. The motor control board will register E30 (the red LED will blink 30 times). When communications are reconnected, the display may show E30 briefly (no more than 2 seconds). If the display shows E30 continuously, there is a loose connection causing the display and board to repeatedly lose and regain communication.

E31: Pumpline reversing switch failure/high cycle rate

E27: High motor temperature

Failure of a pumpline switch or switch mechanism may

Causes of E27 Errors

• Motor temperature is too high. Reduce pressure, gun tip size, or move Reactor to a cooler location. Allow 1 hour for cooling.

• Make sure there is no obstruction to fan airflow. Ensure that the motor/fan shroud is installed.

• Check that the motor overtemperature wire assembly is plugged into J9 on the motor control board, page 33.

• If the preceding checks do not correct the problem, perform the following tests:

14 312063S

result in a high cycle rate, causing an E31 to occur. Replace the switch or switch mechanism. See Pumps Do Not Reverse Direction, page 26.

E31 may also occur if the system is modified to produce a higher flow rate.

Page 15

E99: Loss of communication

If communication is lost between the motor control display and the motor control board, or the temperature control display and the temperature control module, the affected display will show E99.

1. Check all wiring between the display and the motor control board and the temperature control module. Pay close attention to the wire crimping at J13 on the motor control board (page 33) and (C) on the temperature control module (page 35). Unplug and re-plug connectors.

2. Incoming voltage should be 230 Vac. Check the temperature control module voltage at terminal block (805) on the circuit breaker module (see page

68). Check the motor control board voltage at motor/pumps circuit breaker (813), see page 30.

• Check if temperature control module or motor control board is causing error:

Motor Control Diagnostic Codes

3. Swap display connection on temperature control module (C) with display connection on motor control board (J13).

4. If error no longer occurs, the board or module was at fault. Switch connections back to ensure connector was not poorly connected.

312063S 15

Page 16

Troubleshooting

Reactor Electronics

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

No power.

Both sides of display do not illuminate.

Temperature display does not illuminate.

Pressure display does not illuminate.

Erratic display; display turns on and off.

Low voltage. Ensure input voltage is within specifi-

Loose wire. Check connections, page 42.

Display disconnected. Check cable connections, page 42.

Display cable damaged or corroded. Clean connections; replace cable if is

Defective circuit board. Swap display connection to motor

Display disconnected. Check cable connections, page 42.

Display cable damaged or corroded. Clean connections; replace cable if is

Defective circuit board. Swap display connection to motor

Low voltage. Ensure input voltage is within specifi-

Poor display connection. Check cable connections, page 42.

Display cable damaged or corroded. Clean connections; replace cable if is

Display cable not grounded. Ground cable, page 42.

Display extension cable too long. Must not exceed 100 ft (30.5 m)

2. Turn main power OFF .

3. Allow equipment to cool.

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.

Plug in power cord.

Turn disconnect ON .

cations, page 42.

damaged.

control board with connection to heater control board. If temperature display illuminates, heater control board is causing problem. Otherwise, display cable or display is failing.

damaged.

control board with connection to heater control board. If pressure display illuminates, motor control board is causing problem. Otherwise, display cable or display is failing.

cations, page 42.

Replace damaged cable.

damaged.

16 312063S

Page 17

Troubleshooting

PROBLEM CAUSE SOLUTION

Hose display reads OA at startup. FTS disconnected or not installed. Verify proper installation of FTS (see

Operation manual 312062), or adjust FTS to desired current setting.

Poor display connection. Check cable connections, page 42.

Replace damaged cable.

Display does not respond properly to button pushes.

Display cable damaged or corroded. Clean connections; replace cable if is

damaged.

Ribbon cable on display circuit board

Connect cable (page 42) or replace.

disconnected or broken.

Broken display button. Replace, page 42.

Red stop button does not work. Broken button (fused contact). Replace, page 42.

Loose wire. Check connections, page 42.

Blown fuse. Verify with ohmmeter; replace if nec-

essary (page 42).

Fan not working.

Loose wire. Check fan wire.

Defective fan. Replace, page 42.

312063S 17

Page 18

Troubleshooting

Primary Heaters (A and B)

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

Heat turned off.

Primary heater(s) does not heat.

Temperature control alarm. Check temperature display for diag-

Signal failure from thermocouple. See E04: Fluid Temperature Sen-

2. Turn main power OFF .

3. Allow equipment to cool.

Press or zone

keys.

nostic code, page 8.

sor (FTS) or thermocouple disconnected, page 10.

Control of primary heat is abnormal; high temperature overshoots or E01 error occurs intermittently.

Dirty thermocouple connections. Examine connection of thermocou-

ples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector.

Thermocouple not contacting heater element.

Failed heater element. See Primary Heaters, page 37.

Signal failure from thermocouple. See E04: Fluid Temperature Sen-

Thermocouple wired incorrectly. See E04: Fluid Temperature Sen-

Loosen ferrule nut (N), push in thermocouple (310) so tip (T) contacts heater element (307). Holding themocouple tip (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. See page 38 for illustration.

sor (FTS) or thermocouple disconnected, page 10.

sor (FTS) or thermocouple disconnected, page 10. Power up zones

one at a time and verify that temperature for each zone rises.

18 312063S

Page 19

Hose Heat System

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

Ambient temperature is too cold. Use auxiliary hose heat system.

Troubleshooting

2. Turn main power OFF .

3. Allow equipment to cool.

Problems

Hose heats but heats slower than usual or it does not reach temperature.

Hose does not maintain temperature while spraying.

Hose temperature exceeds setpoint.

FTS failed or not installed correctly. Check FTS, page 10.

Low supply voltage. Verify line voltage. Low line voltage sig-

nificantly reduces power available to hose heat system, affecting longer hose lengths.

A and B setpoints too low. Increase A and B setpoints. Hose is

designed to maintain temperature, not to increase it.

Ambient temperature is too cold. Increase A and B setpoints to increase

fluid temperature and keep it steady.

Flow too high. Use smaller mix chamber. Decrease

pressure.

Hose was not fully preheated. Wait for hose to heat to correct tem-

perature before spraying.

Low supply voltage. Verify line voltage. Low line voltage sig-

nificantly reduces power available to hose heat system, affecting longer hose lengths.

A and/or B heaters are overheating material.

Faulty thermocouple connections. Verify that all FTS connections are

Check primary heaters for either a thermocouple problem or a failed element attached to thermocouple, page 10.

snug and that pins of connectors are clean. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector on heater control board.

Missing or damaged insulation around FTS, causing the hose heat to be ON constantly.

312063S 19

Make sure the hose bundle has adequate insulation evenly covering the entire length and connection joints.

Page 20

Troubleshooting

PROBLEM CAUSE SOLUTION

Erratic hose temperature.

Faulty thermocouple connections. Verify that all FTS connections are

FTS not installed correctly. FTS should be installed close to end of

hose in same environment as gun. Verify FTS installation, page 40.

Hose does not heat.

Hoses near Reactor are warm, but hoses downstream are cold.

Missing or damaged insulation around FTS, causing the hose heat to be ON constantly.

FTS failed or is not contacting

Make sure the hose bundle has adequate insulation evenly covering the entire length and connection joints.

Check FTS, page 40.

correctly.

FTS not installed correctly. FTS should be installed close to end of

hose in same environment as gun. Verify FTS installation, page 40.

Temperature control alarm. Check temperature display or diagnos-

tic code, page 40.

Shorted connection or failed hose heating element.

With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between connectors at each section of hose.

Voltage should drop incrementally for each section of hose further from Reactor. Use safety precautions when hose heat is turned on.

20 312063S

Page 21

Hydraulic Drive System

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

Troubleshooting

2. Turn main power OFF .

3. Allow equipment to cool.

Problems

Electric motor will not start or stops during operation.

Loose connections. Check connections at motor control

board.

Circuit breaker tripped. Reset breaker (813); see Circuit

Breaker Module, page 30. Check 230 Vac at output of breaker.

Damaged motor control board. Replace board. See Motor Control

Board, page 32.

312063S 21

Page 22

Troubleshooting

PROBLEM CAUSE SOLUTION

Hydraulic pump does not develop pressure. Low or zero pressure with screeching noise.

Pump is not primed or lost its prime. Check electric motor rotation. Both

motor and hydraulic pump must rotate counterclockwise when viewed from shaft end. If rotation is incorrect, reverse leads L1 and L2. See Con- nect Electrical Cord in Operation manual 312062.

Check dipstick to ensure that hydraulic reservoir is properly filled (see Operation manual).

Check that inlet fitting is fully tight, to ensure no air is leaking into the pump inlet.

To prime pump, run unit at lowest pressure setting and slowly increase pressure. In some cases it may be necessary to remove motor cover and drive belt to allow for manual (counterclockwise) rotation of hydraulic pump. Turn fan pulley by hand. Verify oil flow by removing oil filter to see flow into filter manifold. Reinstall oil filter. Do NOT operate unit without a properly installed oil filter.

Screeching noise is characteristic of

If noise continues longer than 30 seccavitation and is normal at initial startup for a maximum of 30 seconds.

onds, press motor key to shut

off the motor. Check that the inlet fit-

tings are tight and that the pump has

not lost its prime.

Hydraulic fluid is too hot. Ensure that the reservoir is properly

serviced. Improve ventilation to allow

more efficient heat dissipation.

Electric motor operating in wrong direction for 3 Phase system.

Motor must operate counter-clock-

wise from pully end.

Drive belt loose or broken. Check drive belt condition. Replace if

broken.

22 312063S

Page 23

Proportioning System

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

Troubleshooting

2. Turn main power OFF .

3. Allow equipment to cool.

Problems

Proportioning pump does not hold pressure when stalled.

Material imbalance. See Pres- sure/Material Imbalance, page 25.

Pump piston or intake valve leaking.

Restriction at the gun. Clean the gun; see your separate

Inadequate flow from pump; cavitation.

1. Observe gauges to determine which pump is losing pressure.

2. Determine in which direction the pump has stalled by observing which directional valve indicator light is on. See Table 2, page 25 to isolate the problem.

3. Repair the valve; see pump manual 312068.

gun manual.

Increase fluid supply to proportioning pump:

• Use 2:1 supply pump

• Use minimum 3/4 in. (19 mm) ID supply hose, as short as practical

Fluid is too thick. Consult your material supplier for the recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise.

Clean inlet strainer screen, page 44.

Worn pump inlet valve ball/seat or gasket. Replace, see pump manual

312068.

Pressure relief/circulation valve leaking back to supply.

312063S 23

Remove return line and determine if flow is present while in SPRAY

mode.

Page 24

Troubleshooting

PROBLEM CAUSE SOLUTION

Pumps do not reverse direction or pumps do not move.

Bent or loose activator plate, rocker arm, or reversing switch.

See Pumps Do Not Reverse Direc- tion, page 26.

Loose piston packing bolt. See Pumps Do Not Reverse Direc-

tion, page 26.

Faulty directional valve. See Pumps Do Not Reverse Direc-

tion, page 26.

Erratic pump movement. Pump cavitation. Feed pump pressure is too low.

Adjust pressure to maintain 100 psi (0.7 MPa, 7 bar) minimum.

Fluid is too thick. Consult your material supplier for recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise.

Loose activator plate, rocker arm, or reversing switch.

See Pumps Do Not Reverse Direc- tion, page 26.

Faulty directional valve. Replace directional valve.

Pump output low. Obstructed fluid hose or gun; fluid

Open, clear; use hose with larger ID.

hose ID too small.

Worn piston valve or intake valve in

See pump manual 312068.

displacement pump.

Inadequate feed pump pressure. Check feed pump pressure and

adjust to 100 psi (0.7 MPa, 7 bar) minimum.

Fluid leak at pump rod seal. Worn throat seals. Replace. See pump manual 312068.

No pressure on one side. Fluid leaking from pump outlet rup-

ture disk (216).

Check if heater (2) and PRESSURE RELIEF/SPRAY valve (SA or SB) are plugged. Clear. Replace rupture disk (216) with a new one; do not replace with a pipe plug.

Inadequate feed pump pressure. Check feed pump pressure and

adjust to 100 psi (0.7 MPa, 7 bar) minimum.

24 312063S

Page 25

A (ISO) Proportioning Pump

Directional

Valve

A (ISO) Inlet Supply Valve

A (ISO) Over-pressure Rupture Disk

Activator Plate

Reversing Switch Rocker Arm

Troubleshooting

B (Resin) Over-pressure Rupture Disk

B (Resin) Proportioning Pump

B (Resin) Inlet Supply Valve

. 1. Proportioning System

Table 2. Directional Valve Indicator Status

Left Pump Directional

Indicator Lighted

B-side pump piston valve

dirty or damaged

A-side pump inlet valve

dirty or damaged

Right Pump Directional

Indicator Lighted

B-side pump inlet valve

dirty or damaged

A-side pump piston valve

dirty or damaged

Pressure/Material Imbalance

To determine which component is out of balance, check the color of some sprayed material. Two-component materials are usually a mix of light and dark fluids, so the under-proportioned component can often be readily determined.

When you have determined which component is under-proportioned, spray off-target, focusing on the pressure gauge for that component.

ti9874a

For example:

if component B is under-proportioned, focus on the B-side pressure gauge. If the B gauge reads considerably higher than the A gauge, the problem is at the gun. If the B gauge reads considerably lower than the A gauge, the problem is at the pump.

312063S 25

Page 26

Troubleshooting

Pumps Do Not Reverse Direction

1. For the proportioning pumps to reverse direction, the activator plate (219) must contact the rocker arm to activate the reversing switch (210). Check for a bent or loose activator plate, rocker arm, or reversing switch. See F drawing on page 59.

2. Check the function of the directional valve. Direction indication lights should switch on and off based on the reversing switch (210) position. LEDs D19 and D20 (near J5 reversing switch connector on motor board) should alternately illuminate based on the reversing switch position.

There are two possible problems with the directional valve:

a. If D19 and D20 do not alternately illuminate, the

possible causes include:

• faulty reversing switch wiring,

• faulty reversing switch, or

• faulty motor board.

To resolve this problem:

. 1 on page 25, and the parts

b. If D19 and D20 do illuminate but the direction

indication lights do not, the possible causes include:

• faulty motor board,

• faulty directional valve wiring, or

• faulty directional valve.

To resolve this problem:

• verify the motor board output voltages at the J18 directional valve connector. When the reversing switch is toggled one direction, there should be 230V output between pins 1 and 2 (A+ and A-). When it is toggled the other direction, there should be 230V output between pins 3 and 4 (B+ and B-). If output voltages are not present, replace the motor board.

• verify continuity of each directional valve wire and verify wiring connections (see Electrical Diagrams manual 312064).

• if motor board and wiring are not the cause, replace the directional valve.

• verify the continuity of each reversing switch wire. Replace faulty wires.

• verify reversing switch. Unplug the J5 reversing switch connector. Verify that continuity alternates between NC2 to com and N03 to com by toggling the reversing switch (see Electrical Diagrams manual 312064). If continuity does not alternate, replace the reversing switch and reconnect the J5 reversing switch connector.

• if the reversing switch and wiring are not the cause, and D19 and D20 will not alternately illuminate, replace the motor board.

For diagnostic purposes, it is possible to manually override the directional valve by using a small screwdriver to depress the button in the center of either directional valve end cap. Depressing the button in the right end cap should cause the pump to travel to the right. Depressing the left button should cause the pump to travel to the left.

3. If you have determined that the cause is none of the above, check for a loose piston packing retaining bolt. This causes the piston to contact the inner face of the pump inlet flange before the activator plate contacts the rocker arm. Shut down the unit and disassemble the appropriate pump for repair.

26 312063S

Page 27

Repair

Repairing this equipment requires access to parts that 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 operation manual. Be sure to shut off all power to the equipment before repairing.

Pressure Relief Procedure

Repair

5. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)

to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks.

Ensure gauges drop to 0.

ti9879a

1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual.

2. Engage gun piston safety lock.

ti2409a

3. Close gun fluid manifold valves A and B.

ti2421a

4. Shut off feed pumps and agitator, if used.

6. Disconnect gun air line and remove gun fluid manifold.

ti2554a

312063S 27

Page 28

Repair

Flushing

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/CIRCULATION . Flush through bleed lines (N).

Proportioning Pumps

See manual 312068 for pump repair instructions.

1. Shut off , , and heat zones.

2. Flush, page 28.

3. If pumps are not parked, press . Trigger gun

until pumps stop.

4. Turn main power OFF . Disconnect power

supply.

5. Shut off both feed pumps. Close both fluid inlet ball valves (B).

ti9880a

• To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).

• To prevent moisture from reacting with isocyanate, always leave the system dry or filled with a moisture-free plasticizer or oil. Do not use water.

ti9883a

6. Turn both PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0.

ti9879a

28 312063S

Page 29

Repair

Use drop cloth or rags to protect Reactor and surrounding area from spills.

7. See FIG. 2. Disconnect the B (Resin) side pump inlet and outlet lines. Remove the pin (219) from the clevis (218) to disconnect the pump from the hydraulic cylinder (201). Remove the four screws (203) holding the pump to the spacers (413) of the cylinder. Take the pump assembly to a workbench.

Torque to 200 in-lb (22.6 N•m).

218

Torque to 200 in-lb (22.6 N•m).

413

219

244

203

. 3: Proportioning Pump - A Side

9. See manual 312068 for pump repair instructions.

10. Reconnect the pump in the reverse order. Torque the screws (203) to 200 in-lb (22.6 N•m).

219

413

203

. 2. Proportioning Pump - B Side

8. See F

. 3. Disconnect the A (ISO) side pump inlet and outlet lines. Use the pin extractor tool (244) to remove the pin (219), which disconnects the pump from the hydraulic cylinder (201). Remove the four screws (203) holding the pump to the spacers (413) of the cylinder. Take the pump assembly to a workbench.

ti9882a

312063S 29

Page 30

Repair

Circuit Breaker Module

1. Turn main power OFF . Disconnect power

supply. Turn circuit breakers on to test.

2. Relieve pressure, page 27.

3. Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows:

ABLE

a. Refer to electrical diagrams and to T

connect wires and remove bad breaker.

b. Install new breaker and reconnect wires.

3. Dis-

Table 3: Circuit Breakers, see FIG. 4

Ref. Size Component

809 50A Hose/Transformer

Secondary Side

811 40A Transformer

812A 25A, 40A, or

50A*

812B 25A, 40A, or

50A*

813 20A or 30A* Motor/Pumps

* Depending on model.

Primary

Heater A

Heater B

809

811

NOTE: To reference cables and connectors, see the electrical diagrams and

812A

812B

813

ti9884a

the parts drawings on pages 68-69.

FIG. 4. Circuit Breaker Module

30 312063S

Page 31

Repair

Electric Motor

Removal

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Remove motor shroud.

4. Disconnect motor cables as follows:

a. Refer to electrical diagrams in the Reactor Elec-

trical Diagram manual 312064. Motor control board is on right side inside cabinet, see page

32.

Installation

1. Place motor on unit.

2. Fasten motor with screws.

3. Connect the wires, using wire nuts. Refer to the Reactor Electrical Diagram manual 312064 and the diagram inside the motor junction box cover. The motor must operate counterclockwise when looking

at the output shaft.

3-Phase Motors: motor must rotate counterclockwise when viewed from shaft end. If rotation is incorrect, reverse power leads L1 and L2. See Reactor Operation manual 312062, Connect Electrical Cord.

4. Return to service.

b. Remove motor electric junction box cover.

c. Make a note of or label the wire connections.

Refer to the Reactor Electrical Diagram manual 312064 and the diagram inside the motor junction box cover. The motor must operate counterclockwise when looking at the output shaft.

CAUTION

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

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

312063S 31

Page 32

Repair

Motor Control Board

Motor control board has one red LED (D11). Power must be on to check. See F tion is:

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

• Motor running: LED on.

• Motor not running: LED off.

• Diagnostic code (motor not running): LED blinks diagnostic code, pauses, then repeats (for example, E21=21 blinks, pause, 21 blinks).

CAUTION

Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap.

1. Turn main power OFF . Disconnect power

supply.

. 5 for location. Func-

Table 4: DIP Switch (SW2) Settings

DIP

Switch ON (up) OFF (down)

Switch 1 Motor soft start ON

(factory default)

Motor soft start

OFF

(Not applicable to

3-phase motors)

Switch 2 ON for pressure

imbalance alarm

OFF for pressure

imbalance warning

(factory default)

Switch 3 Standby ON Standby OFF

(factory default)

Switch 4 ON for Models H-25

and H-40

(system dependent)

OFF for Models

H-XP2 and H-XP3

(system depen-

dent)

9. Install new board in reverse order. Apply thermal heatsink compound to mating surfaces of board and heatsink.

Order Part 110009 Thermal Compound.

2. Relieve pressure, page 27.

3. Refer to electrical diagrams. Motor control board is on right side inside cabinet.

4. Put on static conductive wrist strap.

5. Disconnect all cables and connectors from board.

6. Remove nuts (40) and take entire motor control assembly to workbench.

7. Remove screws and take board off heatsink.

8. Set DIP switch (SW2) on new board. See T for factory settings. See F

. 5 for location on board.

ABLE

To prevent overpressurization, DIP switch 2 must be set to ON for Model H-25.

Table 5: Motor Control Board Connectors

Connector Pin Description

J1 n/a Main power J3 n/a Transducer A J4 n/a Not used J7 n/a Not used J8 n/a Transducer B

J9 n/a Motor thermostat (NC) J10 n/a Not used J12 n/a Data reporting J13 n/a To display board J14 n/a Motor power J18 1 Directional valve, A+

2 Directional valve, A3 Directional valve, B+ 4 Directional valve, B5GND

J5 1 Unused (VDD)

2 Pumpline reversing switch

(COM)

3 Pumpline reversing switch

(NC)

4 Pumpline reversing switch

(NO)

32 312063S

Page 33

Motor Control

DIP Switch (SW2) Settings

Models H-25, H-40, H-50

1234

ti3178c-3

Models H-XP2 & H-XP3

Repair

D11

J3 (A)

J8 (B)

J12

OFF

1234

ti3178c-4

Apply 110009 thermal heatsink compound to mating surfaces.

FIG. 5. Motor Control Board

J14

SW2

J13

J18

ti7724a

312063S 33

Page 34

Repair

Transducers

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Refer to electrical diagrams. Motor control board is on right side inside cabinet.

4. Disconnect transducer cables at board; see F page 33. Reverse A and B connections and check if

706 (A Side)

. 5,

diagnostic code follows; see E21: No component A transducer, page 12.

5. If transducer fails test, thread cable through top of cabinet. Note path as cable must be replaced in same way.

6. Install o-ring (720) on new transducer (706), F

. 6.

7. Install transducer in manifold. Mark end of cable with tape (red=transducer A, blue=transducer B).

8. Route cable into cabinet and thread into bundle as before.

9. Connect transducer cable at board; see F

. 5, page

33.

706 (B Side)

701

FIG. 6. Transducers

Electric Fan

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Check fuses (F) at left of breaker module, F Replace if blown. If good, continue with step 4.

4. Refer to electrical diagrams. Disconnect fan wires from fuses (F).

. 7.

720

ti9885a

5. Remove fan.

6. Install fan in reverse order.

ti9884a-1

FIG. 7. Fan Fuses

34 312063S

Page 35

Temperature Control Module

Repair

Table 6: Temperature Control Module Connections

Connector Description

DATA (A) Data reporting

HOSE T/C P; FTS (purple)

12 11 HOSE T/C R; FTS (red) 10 HOSE T/C S; FTS (silver

(unshielded bare wire))

9 HEATER T/C B, Y;

SENSOR (B)

Thermocouple (yellow)

8 HEATER T/C B, R;

Thermocouple (red) 7 Not used 6 HEATER T/C A, Y;

Thermocouple (yellow) 5 HEATER T/C A, R;

Thermocouple (red)

4, 3 OVERTEMPERATURE B;

Overtemperature switch B

2, 1 OVERTEMPERATURE A;

Overtemperature switch A

DISPLAY (C) Display

COMMUNICATION (D) Communication to power

boards

PROGRAM (E) Software programming

BOOT (F) Software bootloader

POWER/RELAY (G) Circuit board power input and

contactor control output

Table 7: Temperature Power Module Connections

Connector Description

COMMUNICATION

(H)

Communication to control board

POWER (J) Power to heater

ti9875a

ti9843a1

Right Side of

Control Heater Module

ti9843a4

Bottom of Power Modules

FIG. 8: Temperature Control Module Connections

312063S 35

Page 36

Repair

Test SCR Circuit

1. Test the SCR circuit in the on position:

a. Make sure everything is connected, including

the hose.

b. Turn main power ON .

c. Adjust the hose heat setpoint

ent hose temperature.

d. Turn on heat zone by pressing .

e. Hold down to view electrical current.

Hose current should ramp up to 45A. If there is no hose current, see E03: No zone current, page 9. If hose current exceeds 45A, see E02: High zone current, page 9. If hose current stays several amps below 45A, hose is too long or voltage is too low.

above

Replacing Temperature Control Assembly Modules

CAUTION

Before handling assembly, put on a static conductive wrist strap to protect against static discharge which can damage assembly. Follow instructions provided with wrist strap.

the ambi-

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Refer to electrical diagrams; see Electrical Diagrams manual 312064. Temperature control assembly is on left side inside cabinet.

4. Remove bolts that secure transformer assembly and slide assembly to side in cabinet.

2. Test the SCR circuit in the off position:

a. Make sure everything is connected, including

the hose.

b. Turn main power ON .

c. Adjust the hose heat setpoint

ent hose temperature.

d. Turn on heat zone by pressing .

e. Using a voltmeter, carefully measure the volt-

age at the hose connector. You should not get a voltage reading. If you do, the SCR on the temperature control board is bad. Replace the temperature control assembly.

below

the ambi-

5. Put on static conductive wrist strap.

6. Disconnect all cables and connectors from assembly; see Parts - Temperature Control, page 66.

7. Remove nuts and take entire temperature control assembly to workbench.

8. Replace defective module.

9. Install assembly in reverse order.

36 312063S

Page 37

Repair

Primary Heaters

Heater Element

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. See pages 61-63 for illustrations of each heater. Disconnect heater element wires from heater wire connector. Test with ohmmeter.

Total Heater

Wattage Element Ohms

Line Voltage

The primary heaters output their rated wattage at 230 Vac. Low line voltage will reduce power available and the heaters will not perform at full capability.

6,000 1500 30-35

7,650 2550 18-21

8,000 2000 23-26

10,200 2550 18-21

6. To remove heater element, first remove thermocouple (310) to avoid damage, see step 7, page 38.

7. Remove heater element (307) from housing (301). Be careful not to spill any fluid left in housing.

8. Inspect element. It should be relatively smooth and shiny. If there is a crusted, burnt, ash-like material adhered to element or sheath shows pitting marks, replace element.

9. Install new heater element (307), holding mixer (309) so it does not block thermocouple port (P).

10. Reinstall thermocouple, page 38.

11. Reconnect heater element leadwires to heater wire connector.

12. Replace heater shroud.

312063S 37

Page 38

Repair

Thermocouple

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect thermocouple wires from B on tempera-

ABLE

ture control module. See T 8, page 35.

6. Feed thermocouple wires out of cabinet. Note path as wires must be replaced in the same way.

7. See F

. 9. Loosen ferrule nut (N). Remove thermocouple (310) from heater housing (301), then remove thermocouple housing (H). Do not remove the thermocouple adapter (305) unless necessary. If adapter must be removed, ensure that mixer (309) is out of the way when replacing the adapter.

6, page 35 and FIG.

8. Replace thermocouple, F

. 9.

a. Remove protective tape from thermocouple tip

(T).

b. Apply PTFE tape and thread sealant to male

threads and tighten thermocouple housing (H) into adapter (305).

c. Push in thermocouple (310) so tip (T) contacts

heater element (307).

d. Holding thermocouple (T) against heater ele-

ment, tighten ferrule nut (N) 1/4 turn past tight.

9. Route wires (S) into cabinet and thread into bundle as before. Reconnect wires to board.

10. Replace heater shroud.

11. Turn on heaters A and B simultaneously to test. Temperatures should rise at same rate. If one heater is low, loosen ferrule nut (N) and tighten thermocouple housing (H) to ensure thermocouple tip (T) contacts element (307).

309

FIG. 9. Thermocouple

Apply PTFE tape and thread sealant.

310

Apply 110009 thermal heatsink compound.

305

301

307

308

ti7924a

38 312063S

Page 39

Repair

Overtemperature Switch

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect one leadwire from overtemperature switch (308), F meter. Resistance must be approximately 0 ohms.

6. If switch fails test, remove wires and screws. Discard failed switch. Apply thermal compound 110009, install new switch in same location on housing (301), and secure with screws (311). Reconnect wires.

. 9. Test across switch with ohm-

4. Using an ohmmeter, check between the two terminals of the connector (D). There should be continuity.

5. If hose fails test, retest at each length of hose, including whip hose, until failure is isolated.

Check FTS Cables

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Disconnect FTS cable (F) at Reactor, F

. 10.

If wires need replacement, disconnect from temperature control board. See T F

. 8, page 35.

ABLE

6, page 35 and

Heated Hose

Refer to the heated hose manual 309572 for hose replacement parts.

Check Hose Connectors

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

Whip hose must be connected.

ti9878a

FIG. 10. Heated Hose

4. Test with ohmmeter between pins of cable connector.

Pins Result

1 to 2 approximately 35 ohms per 50 ft (15.2 m) of

hose, plus approximately 10 ohms for FTS

1 to 3 infinity

5. If cable fails test, retest at FTS, page 40.

3. Disconnect hose connector (D) at Reactor, F

312063S 39

. 10.

Page 40

Repair

Fluid Temperature Sensor (FTS)

Test/Removal

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Remove tape and protective covering from FTS

(21), F ohmmeter between pins of cable connector.

3 to FTS groundscrew 0 ohms

1 to FTS component A

. 10. Disconnect hose cable (F). Test with

Pins Result

1 to 2 approximately 10 ohms

1 to 3 infinity

infinity

fitting (ISO)

4. If FTS fails any test, replace FTS.

5. Disconnect air hoses (C, L), and electrical connectors (D).

6. Disconnect FTS from whip hose (W) and fluid hoses (A, B).

7. Remove ground wire (K) from ground screw on underside of FTS.

8. Remove FTS probe (H) from component A (ISO) side of hose.

Installation

The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions.

ISO

ti9581c

FIG. 11: Fluid Temperature Sensor and Heated Hoses

40 312063S

Page 41

Repair

Transformer Primary Check

1. Turn main power OFF .

2. Locate the two smaller (10 AWG) wires coming out of transformer. Trace these wires back to contactor and circuit breaker (811). Use an ohmmeter to test for continuity between two wires; there should be continuity.

Transformer Secondary Check

1. Turn main power OFF .

2. Locate the two larger (6 AWG) wires coming out of transformer. Trace these wires back to large green connector under hose control module and circuit breaker (809). Use an ohmmeter to test for continuity between two wires; there should be continuity.

If you are not sure which wire in green plug under hose module connects to transformer, test both wires. One wire should have continuity with the other transformer wire in breaker (809) and the other wire should not.

3. To verify transformer voltage, turn on hose zone. Measure voltage from 18CB-2 to POD-HOSE-P15-2; see Reactor Electrical Dia-

grams manual 312064.

Model Secondary Voltage

310 ft. 90 Vac*

410 ft. 120 Vac*

* For 230 Vac line voltage.

Replace Transformer

Use this procedure to replace transformer.

1. Turn main power OFF . Disconnect power

supply.

2. Open Reactor cabinet.

809

. 12: Circuit Breaker Module

811

3. Remove bolts holding transformer to cabinet floor. Slide transformer forward.

4. Disconnect the transformer wires; see Reactor Electrical Diagrams manual 312064.

5. Remove transformer from cabinet.

6. Install new transformer in reverse order.

312063S 41

Page 42

Repair

Display Module

Temperature and Pressure Displays

CAUTION

Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap.

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Refer to electrical diagrams.

between cable bushing and cover (504) with screws (512).

Red Stop Button

CAUTION

Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap.

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 27.

3. Refer to electrical diagrams.

4. Put on static conductive wrist strap.

5. Remove screws (509, 510) and cover (504), F

13.

4. Put on static conductive wrist strap.

5. Disconnect main display cable (20) at lower left corner of display module; see F

. 13.

6. Remove screws (509, 510) and cover (504); see F

. 13.

If replacing both displays, label temperature display cables TEMP and pressure display cables PUMP before disconnecting.

7. Disconnect cable connectors (506 and 511) from back of temperature display (501) or pressure dis-

play (502); see F

. 13.

8. Disconnect ribbon cable(s) (R) from back of display; see F

. 13.

9. Remove nuts (508) and plate (505).

10. Disassemble display, see detail in F

. 13.

11. Replace board (501a or 502a) or membrane switch (501b or 502b) as necessary.

6. Disconnect button cable connectors (506) from back of temperature display (501) and pressure display (502).

7. Remove red stop button (506).

8. Reassemble in reverse order. Be sure display cable ground wire (G) is secured between cable bushing and cover (504) with screws (512).

12. Reassemble in reverse order, see F

. 13. Apply medium strength thread sealant where shown. Be sure display cable ground wire (G) is secured

42 312063S

Page 43

Apply medium strength thread sealant.

Repair

511

502

503

504

507

510

506

512

501

508

505

506

Detail of Membrane Switches and Display Boards

Temperature Display Pressure Display

502c

ti2574a

502a

502b

501c

501a

501b

ti3172a

FIG. 13. Display Module

312063S 43

Page 44

Repair

Inlet Fluid Strainer Screen

59g*

The inlet strainer at each proportioning pump filters out solid matter that can plug the inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.

Isocyanate can crystallize from moisture contamination or from freezing. If the chemicals used are clean and proper storage, transfer, and operating procedures are followed, there should be minimal contamination of the A-side screen.

Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.

1. Close the material supply valve at the pump inlet to prevent material from being pumped while the strainer plug (59j) is removed.

2. Place a container under the strainer base to catch drain off when removing the strainer plug.

3. Remove the screen (59g) from the strainer manifold. Thoroughly flush the screen with gun cleaner and shake it dry. Inspect the screen for blockage. No more than 25% of the mesh should be restricted. If more than 25% is blocked, replace the screen. Inspect the strainer gasket (59h) and replace as required.

59h

59j

59k

ti9886a

FIG. 14. Y Strainer Components

* Fluid filter screen (59g) replacements:

Part Description

180199 20 mesh (standard); 1 pack 255082 80 mesh (optional); 2 pack 255083 80 mesh (optional); 10 pack

Pump Lubrication System

Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible.

4. Ensure the pipe plug (59k) is securely screwed into the strainer plug (59j). Install the strainer plug with the screen (59g) and gasket (59h) in place and tighten. Do not overtighten. Let the gasket make the seal.

5. Open the material supply valve, ensure that there are no leaks, and wipe the equipment clean.

6. Proceed with operation.

44 312063S

Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks.

To change pump lubricant:

1. Relieve pressure, page 27.

2. Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap. Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reattach the check valve to the inlet hose. See F

. 15.

Page 45

Repair

3. Drain the reservoir and rinse with clean lubricant.

4. When the reservoir is clean, fill with fresh lubricant.

5. Thread the reservoir onto the cap assembly and place it into the bracket.

6. Push the larger diameter supply tube (ST) approximately 1/3 of the way into the reservoir.

7. Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom.

Important: The return tube (RT) must reach the bottom of the reservoir, to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube (ST) and returned to the pump.

8. The lubrication system is ready for operation. No priming is required.

Change Hydraulic Fluid and Filter

See Table 8 for recommended frequency of oil changes.

Change break-in oil in a new unit after first 250 hours of operation or within 3 months, whichever comes first.

Table 8: Frequency of Oil Changes

Ambient Temperature

0 to 90°F (-17 to 32°C)

90°F and above (32°C and above)

Recommended Frequency

1000 hours or 12 months, whichever comes first

500 hours or 6 months, whichever comes first

ti9911a

1. Relieve pressure, page 27.

2. Allow hydraulic fluid to cool.

3. Place a pan under reservoir drain plug (110k) to catch oil.

135

ti9888a

110k

. 16: Change Hydraulic Fluid and Filter

ti9887a

. 15. Pump Lubrication System

312063S 45

4. Remove drain plug (110k).

Page 46

Repair

5. Place a rag around base of oil filter (135) to prevent

b. Screw filter on snug, then an additional 1/4 turn. oil from spilling. Unscrew filter 1/4-3/4 turn to break air lock in filter. Wait five minutes to allow oil in filter to drain back into reservoir. Unscrew filter and

8. Refill reservoir with approved hydraulic fluid. See Table 9.

remove.

9. Proceed with normal operation.

6. Reinstall drain plug (110k).

7. Replace filter (135):

a. Coat filter seal with fresh oil.

Upon starting motor, hydraulic pump may make a screeching noise until primed. If this noise continues for more than 30 seconds, switch off motor control. See Hydraulic Drive System, page 21.

Table 9: Approved Anti-Wear (AW) Hydraulic Oils

Supplier Name

Citgo A/W ISO Grade 46

Amsoil AWI ISO Grade 46 (synthetic*)

BP Oil International

Energol

HLP-HM, ISO Grade 46

Carl Bechem GmbH Staroil HVI 46

Castrol Hyspin AWS 46

Chevron

Rykon

AW, ISO 46

Exxon Humble Hydraulic H, ISO Grade 46

Mobil Mobil DTE 25, ISO Grade 46

Shell Shell Tellus, ISO Grade 46

Texaco Texaco AW Hydraulic, ISO Grade 46

* Note: Do not mix mineral-based and synthetic hydraulic oils. Completely drain oil from reservoir and pump prior to converting between oils.

If the approved oils are not available in your area, use an alternative hydraulic oil meeting the following requirements:

Oil Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Wear (AW) Hydraulic

ISO Grade:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Viscosity, cSt at 40°C: . . . . . . . . . . . . . . . . . . . . . 43.0-47.0

Viscosity, cSt at 100°C: . . . . . . . . . . . . . . . . . . . . 6.5-9.0

Viscosity Index: . . . . . . . . . . . . . . . . . . . . . . . . . .95 or higher

Pour Point, ASTM D 97: . . . . . . . . . . . . . . . . . . . -15°F (-26°C) or lower

Other essential properties:. . . . . . . . . . . . . . . . . . Formulated for anti-wear, anti-foaming, oxidation stability,

corrosion protection, and water separation

46 312063S

Page 47

Repair

312063S 47

Page 48

Parts

See page 51

100

107

See page 52

42▲

See page 52

48 312063S

See page 49

See pages 61 - 63

ti9831a

Page 49

Detail of Cabinet Area

8.0 kW Heater Bracket (Ref. 36) Shown

102

Parts

102

See page 50

25, 147

54▲

TI9834a

312063S 49

Page 50

Parts

Left Side of Cabinet

8 (Ref)

103 (Ref)

Right Side of Cabinet

55, 56

TI9835a

TI9836a

50 312063S

Page 51

Detail, Fluid Manifold Area

Parts

717 (Ref)

111 (Ref)

Detail, Proportioner Area

151

7, see page 67

TI9838a

59, see page 53

See page 60

243

180

111 (Ref)

59, see page 53

TI9833a

312063S 51

Page 52

Parts

111 (Ref)

118 (Ref)

103

153

Detail, Electric Motor Area

ti7709a

Detail, Hydraulic Reservoir Area

135

114

129

See page 53

134

133

See page 49

125

111 (Ref)

126

139

133

116

119, 120

132

117

127

132

146

122

137

113

112

111 (Ref)

115

142, 143

118

150

114

111

52 312063S

1 (Ref)

TI9832b

Page 53

Parts

Ref. 59, Fluid Inlet Kit

59m

59a

59p

59c

59b

59a

A Side

59n

59d

59p

59e

59f

59j

59g

59h

59n

59b

59c

59d◆

B Side

59g

59k

59e

59f

59h◆ 59j◆

TI9841a

59k◆

NOTE: Fluid Inlet Kit (59) has two versions: Series A and Series B. Fluid Inlet Kit Series A uses a flat gasket (59h) and can be identified by a white seal. The gasket material has been upgraded for improved sealing and is now a light gray color. Fluid Inlet Kit Series B, shown above, uses an o-ring seal (59h) with a different manifold (59d) and strainer plug (59j). The seal is not visible when fully assembled.

59a

Ref. 110, Hydraulic Reservoir

110f

110m

110b

110c

110d

ti9840a

110j

110k

312063S 53

Page 54

Parts

Parts Used on All Models

Qty

Ref Part Description

2 HEATER; see page 56 for part

numbers

3 MOTOR; see page 56 for part num-

bers 4 245974 DISPLAY; page 65 1 5 CONTROL, temperature; see page

66 for part numbers 6 BOARD, circuit, motor control; see

page 56 for part numbers 7 247823 MANIFOLD, fluid; page 67 1 8 TRANSFORMER; see page 56 for

part numbers 9 247832 COVER, motor 1 10 246976 COVER, main cabinet 1 11 PUMP, proportioning; see page 56

for part numbers 13 115834 FAN, cooling 1 14 TUBE, inlet, component A; see

page 56 for part numbers 15 TUBE, outlet, component A; see

page 56 for part numbers 16 TUBE, inlet, component B; see

page 56 for part numbers 17 TUBE, outlet, component B; see

page 56 for part numbers 18★ 247787 CABLE, harness, heater overtemp.,

includes 12-pin connector 19 15B380 CABLE, hose, control; see manual

312064 20 15B383 CABLE, display 1 21★ 261669 KIT, fluid temp sensor, coupler 1 23 103181 WASHER, lock ext 1 24 15B360 GASKET, fan 1 25 255047 STRAIN RELIEF, M40 thread 1 26 MODULE; see page 56 for part

numbers 27 116149 SPACER 4 29 117666 TERMINAL, ground 1 30 C19843 SCREW, CAP, socket hd 1 31✖ 123969 SWITCH, disconnect 1 32✖ 123967 KNOB, operator disconnect 1 33 117723 SCREW, mach, slotted hd 4 34 C20487 NIPPLE, hex 2 35 COVER, heater wire; see page 56

for part numbers 36 BRACKET, heater; see page 56 for

part numbers 37 167002 INSULATOR, heat 4 38 117623 NUT, cap (3/8-16) 4 39 113796 SCREW, flanged, hex hd 14 40 115942 NUT, hex, flange head 9 42 15K817 LABEL, fault codes 1

Ref Part Description

44 RIVET, pop; 3/16 in. (5 mm) x 0.4

45▲ 189930 LABEL, caution 2

46 247844 BRACKET, reservoir, lube 1 47 247845 PULLEY, drive 1 48 803889 BELT 1

49★ 15B593 SHIELD, membrane switch 1 50★ 308212 PAD, pamphlet safety 1

51 15B775 COVER, wire access 1 52 COVER, heater; see page 56 for

53 SCREW, machine, pan hd; 8-32 x

54▲ 15G280 LABEL, warning 1 55 113505 NUT, KEPS, hex hd 4

56 112776 WASHER, plain 2 57 113802 SCREW, hex hd, flanged 8 58

★ STRAP, tie, wire 20

59◆ 255159 FLUID INLET KIT; see page 53 1 59a 118459 . UNION, swivel; 3/4 npt(m) x 3/4

59b 109077 . VALVE, ball; 3/4 npt (fbe) 2

59c C20487 . NIPPLE; 3/4 npt 2 59d◆‡ . MANIFOLD, strainer, inlet (Fluid

◆†16W714 . MANIFOLD, strainer, inlet (Fluid

59e 102124 . THERMOMETER, dial 2 59f 120300 . GAUGE, pressure, fluid 2 59g 180199 . ELEMENT, filter; 20 mesh (stan-

59h◆ 15H200 . GASKET, strainer; PTFE (Fluid

◆†C20203 . GASKET, strainer; PTFE (Fluid

59j◆ 15H199 . PLUG, strainer (Fluid Inlet Kit

◆† 16V879 . PLUG, strainer (Fluid Inlet Kit

59k◆ 104813 . PLUG, pipe; 3/8 npt (Fluid Inlet Kit

◆†555808 . PLUG, pipe; 1/4 npt (Fluid Inlet Kit

59m 296178 . UNION, swivel; 3/4 npt(m) x 1/2

59n 15D757 . HOUSING, thermometer 2 59p 253481 . GUARD, gauge 2 60 111800 SCREW, cap, hex hd 39

61 247849 RESERVOIR, lube hose assy 1 62 247782 SPACER 4 63 247850 COVER, front 1 65 15H185 WIRE, mechanical switch cable;

in. (10 mm)

part numbers

3/8

npsm(f)

Inlet Kit Series A)

Inlet Kit Series B)

dard)

Inlet Kit Series A)

Inlet Kit Series B)

Series A)

Series B)

Series A)

Series B)

npt(f); A side only

see page 59

Qty

54 312063S

Page 55

Parts

Qty

Ref Part Description

66★ CONNECTOR, 2 PIN, motor

power; see page 56 for part num-

bers 67 117284 GRILL, fan guard 1 68 SWITCH, added pole; see page 56

for part numbers 74★ 206995 THROAT SEAL LIQUID; 1 quart 1 76 115836 GUARD, finger 1 77 186494 CLIP, spring 5 78 205447 COUPLING, hose 2 79 054826 TUBE, PTFE; 1/4 in. (6 mm) ID; 8 ft

(2.4 m) 82 15H207 BRACKET, tensioner 1 84▲ 189285 LABEL, caution 2 85 114269 GROMMET, rubber 2 88 247851 FITTING, reducer #5 x #8 JIC 1 89 247852 FITTING, reducer #6 x #10 JIC 1 90 111802 SCREW, cap, hex hd; 1/2-13 x 3/4

in. (19 mm) 92 112958 NUT, hex, flanged; 3/8-16 4 93 15T895 HOSE, supply 1 94 247784 TUBE, return 1 96 247853 ADJUSTER, belt, tensioner 1 97 15G816 COVER, plate, wire way 1 98 120302 CASTER 4 99 112125 PLUG, tube 2 100 LABEL; see page 56 for part num-

bers 102 15H189 BOOT, wire feed through 1 103 CONDUIT, assembly, motor power;

see page 56 for part numbers 107 119253 SUPPRESSOR, ferrite; 151 ohm 1 110 247826 RESERVOIR, hydraulic; includes

110b-110m; see page 53 110b 247778 . HOUSING, inlet 1 110c 247771 . GASKET, inlet 1 110d 247777 . TUBE, inlet 1 110f 247770 . TUBE, return 1 110j 116919 . FILTER, inlet 1 110k 255032 . PLUG 1 110m 255021 . FITTING, straight 1 111 247822 BRACKET, motor mount 1 112 BRACKET, mounting, pump 1

247819 H-40, H-50, H-XP3 models only 247830 H-25, H-XP2 models only

113 PUMP, hydraulic 1

255019 H-40, H-50, H-XP3 models only

247855 H-25, H-XP2 models only 114 247821 BRACKET, reservoir, hydraulic 2 115 247820 BRACKET, support, pumpmount 1 116 247829 COOLER, hydraulic 1 117 ELBOW; 1-1/16 npt(m) x 1/2 in. (13

mm) tube 255020 H-40, H-50, H-XP3 models only 255035 H-25, H-XP2 models only

118 PULLEY, fan 1

247856 H-40, H-50, H-XP3 models only

Ref Part Description

119 15H512 LABEL, control 1 120 15H204 KNOB, pressure 1 122 117560 SCREW, set, socket hd 1 125 247793 HOSE, inlet, coupled 1 126 255029 GAUGE, pressure, fluid, panel

127 ELBOW 1

129 255036 ELBOW, male 1

130★ 117792 GUN, grease 1 131★ 117773 GREASE, lubricant 1 132 15G782 HOSE, coupled 1 133 15G784 HOSE, coupled 1 134 116915 DIPSTICK with breather cap 1 135 247792 FILTER, oil,18-23 psi bypass 1 137 FITTING 1

139 107156 SCREW, cap socket head 3 140★ 115764 FITTING, npt (part of hydraulic

141★ 112161 SCREW (part of hydraulic pump

142 112586 SCREW, cap, hex hd 2 143 110996 NUT, hex, flange hd; 5/16-18 2 144 C19862 NUT, lock, hex 1

146 247836 COVER, access 1 147 255048 NUT, strain relief, M40 thread 1 148★ 255039 CONNECTOR, heater 1

150 SCREW, set; 1/4 x 1/2 (13 mm) 2 151 261821 CONNECTOR, wire, 6 AWG (pair) 1 153 104373 WASHER, thrust 2

▲

247857 H-25, H-XP2 models only

mount

121320 H-40, H-50, H-XP3 models only 121321 H-25, H-XP2 models only

116793 H-40, H-50, H-XP3 models only 110792 H-25, H-XP2 models only

pump assembly); H-25, H-XP2 models only

assembly); H-25, H-XP2 models only

Replacement Danger and Warning labels, tags, and cards are available at no cost.

★

Not shown.

✖

Required for all A-D series models. Included in Knob Repair Kit 258920 (purchase separately).

◆

Fluid Inlet Kit (59) has two versions: Series A and Series B. Fluid Inlet Kit Series A uses a flat gasket (59h) and can be identified by a white seal. The gasket material has been upgraded for improved sealing and is now a light gray color. Fluid Inlet Kit Series B, shown on page 53, uses an o-ring seal (59h) with

a different manifold (59d) and strainer plug (59j). The seal is not visible when fully assembled.

† Included in Strainer Manifold Kit 247503.

‡ Series A manifold is not available. Order replace-

ment kit 247503.

Qty

312063S 55

Page 56

Parts

Parts that Vary by Model

Use the following tables to find parts that vary by model. See Parts, starting on page 48 for parts used on all models.

H-25 and H-XP2 Models

255400

H-25

8.0 kW (230V,

Ref Description

2 HEATER; pages

61-63

3 MOTOR; page 52 247816 247816 247816 247816 247816 247816 247816 247816 247816 1

6 BOARD, motor

control; page 50

8 TRANSFORMER;

page 50

11 PUMP,

proportioning; page 59

14 TUBE, inlet,

component A; page 51

15 TUBE, outlet,

component A; page 51

16 TUBE, inlet,

component B; page 51

17 TUBE, outlet,

component B; page 51

26 MODULE, breaker;

page 68

35 COVER, heater

wire

36 BRACKET, heater;

page 48

52 COVER, heater 247847 247847 247847 247846 247846 247846 247846 247846 247846 2

66 CONNECTOR,

2-pin, motor power

68 SWITCH, added

pole; 400V only

100 LABEL 15H194 15H194 15H194 15H195 15H195 15H195 15H194 15H194 15H194 1

103 CONDUIT, assy,

motor power

1 phase)

247815 (Qty. 1)

247839 247839 247839 247839 247839 247839 247839 247839 247839 1

247812 247812 247812 247812 247812 247812 247812 247812 247812 1

Model

120

15R648 15R648 15R648 15R646 15R646 15R646 15R646 15R646 15R646 1

15R649 15R649 15R649 15R645 15R645 15R645 15R645 15R645 15R645 1

15R653 15R653 15R653 15R650 15R650 15R650 15R650 15R650 15R650 1

15R651 15R651 15R651 15R644 15R644 15R644 15R644 15R644 15R644 1

C A B C A B C A B 1

247831 247831 247831 247843 247843 247843 247843 247843 247843 2

120871 120871 120871 120871 120871 120871 120871 120871 120871 1

247814 247814 247814 247814 247814 247814 247814 247814 247814 1

255401

H-25

8.0 kW (230V,

3 phase)

247815 (Qty. 1)

Model

120

255402

H-25

8.0 kW (400V,

3 phase)

247815 (Qty. 1)

Model

120

123968 123968 123968 1

255403

H-XP2

15.3 kW (230V,

1 phase)

247813 (Qty. 2)

Model 80Model 80Model 80Model

247502 247502 247502 247502 247502 247502 2

255404

H-XP2

15.3 kW (230V,

3 phase)

247813 (Qty. 2)

255405

H-XP2

15.3 kW (400V,

3 phase)

247813 (Qty. 2)

255406

H-25

15.3 kW (230V,

1 phase)

247813 (Qty. 2)

120

255407

H-25

15.3 kW (230V,

3 phase)

247813 (Qty. 2)

Model

120

255408

H-25

15.3 kW (400V,

3 phase)

247813 (Qty. 2)

Model

120

Qty

56 312063S

Page 57

H-40 and H-XP3 Models

Parts

253400

H-40

12.0 kW (230V,

Ref Description

2 HEATER;

pages 61-63

3 MOTOR; page 52247810 247785 247785 247810 247785 247785 247785 247785 1

6 BOARD,

motor control; page 50

8 TRANS-

FORMER; page 50

11 PUMP,

proportioning; page 59

14 TUBE, inlet,

component A; page 51

15 TUBE, outlet,

component A; page 51

16 TUBE, inlet,

component B; page 51

17 TUBE, outlet,

component B; page 51

26 MODULE,

breaker; page 68

35 COVER,

heater wire

36 BRACKET,

heater; page 48

52 COVER,

heater

66 CONNEC-

TOR, 2-pin, motor power

68 SWITCH,

added pole; 400V only

100 LABEL 247780 247780 247780 247781 247781 247781 247780 247780 1

103 CONDUIT,

assy, motor power

1 phase)

247834 247813 247813 247834 247833 247833 247833 247833 2

247835 247835 247835 247835 247835 247835 247835 247835 1

247786 247786 247786 247786 247786 247786 247786 247786 1

Model 120 Model 120 Model 120 Model 80 Model 80 Model 80 Model 120 Model 120 1

15R646 15R646 15R646 15R646 15R646 15R646 15R646 15R646 1

15R645 15R645 15R645 15R645 15R645 15R645 15R645 15R645 1

15R650 15R650 15R650 15R650 15R650 15R650 15R650 15R650 1

15R644 15R644 15R644 15R644 15R644 15R644 15R644 15R644 1

C D E C D E D E 1

247502 247502 247502 247502 247502 247502 247502 247502 2

247843 247843 247843 247843 247843 247843 247843 247843 2

247846 247846 247846 247846 247846 247846 247846 247846 2

120871 120871 1

247814 247790 247790 247814 247790 247790 247790 247790 1

253401

H-40

15.3 kW (230V,

3 phase)

253402

H-40

15.3 kW (400V,

3 phase)

123968 123968 123968 1

253403

H-XP3

12.0 kW (230V, 1

phase)

253404

H-XP3

20.0 kW (230V,

3 phase)

253405

H-XP3

20.0 kW (400V,

3 phase)

253407

H-40

20.4 kW (230V,

3 phase)

253408

H-40

20.4 kW (400V,

3 phase)

Qty

312063S 57

Page 58

Parts

H-50 Models

253725

H-50

12.0 kW

Ref Description

2 HEATER; pages

61-63

3 MOTOR; page 52 247810 247785 247785 247785 247785 1

6BOARD, motor

control; page 50

8 TRANSFORMER;

page 50

11 PUMP,

proportioning; page 59

14 TUBE, inlet,

component A; page 51

15 TUBE, outlet,

component A; page 51

16 TUBE, inlet,

component B; page 51

17 TUBE, outlet,

component B; page 51

26 MODULE,

breaker; page 68

35 COVER, heater

wire

36 BRACKET, heater;

page 48

52 COVER, heater 247846 247846 247846 247846 247846 2

66 CONNECTOR,

2-pin, motor power

68 SWITCH, added

pole; 400V only

100 LABEL 256509 256509 256509 256509 256509 1

103 CONDUIT, assy,

motor power

(230V, 1 phase)

247834 247813 247813 247833 247833 2

247835 247835 247835 247835 247835 1

247786 247786 247786 247786 247786 1

Model 140 Model 140 Model 140 Model 140 Model 140 1

15R646 15R646 15R646 15R646 15R646 1

15R645 15R645 15R645 15R645 15R645 1

15R650 15R650 15R650 15R650 15R650 1

15R644 15R644 15R644 15R644 15R644 1

C D E D E 1

247502 247502 247502 247502 247502 2

247843 247843 247843 247843 247843 2

120871 1

247814 247790 247790 247790 247790 1

253726

H-50

15.3 kW

(230V, 3 phase)

253727

H-50

15.3 kW

(400V, 3 phase)

123968 123968 1

256505

H-50

20.4 kW

(230V, 3 phase)

256506

H-50

20.4 kW

(400V, 3 phase)

Qty

58 312063S

Page 59

Sub Assemblies

Proportioner Assembly

207

206

208

Parts

224

223

222

227

203

239

202, see manual 312068

226

204

215

233

227

240

226

216

241

232

217

234

219

228

227

201, see page 64

220

221

205

219

239

209

218

213

214

210

212

211

226

217

216

215

203

TI9837b

204

235

Torque to 10-15 ft-lb (13.6 - 20.3 N•m).

312063S 59

218

229

230

231

203

Page 60

Parts

Proportioner Assembly

Qty

Ref Part Description

201 295027 CYLINDER, hydraulic, w/spacers;

see page 64 for parts 202 PUMP; see manual 312068 2 203 295824 SCREW, socket hd; 5/16-24 x 3 in.

(76 mm) 204 106258 O-RING 2 205 298040 MANIFOLD, hydraulic 1 206 113467 SCREW, socket hd 4 207 120299 VALVE, directional, hydraulic 1 208 C19986 SCREW, socket hd 4 209 247817 BRACKET, mounting 1 210 247818 SWITCH, reversing 1 211 157021 WASHER, lock 2 212 SCREW, pan hd; 8-32 x 3/8 2 213 100214 WASHER, lock 4 214 108751 SCREW, socket hd 4 215 159842 ADAPTER 2 216 248187 HOUSING, rupture, disc; kit, see

manual 309969 217 M70430 SCREW, socket hd; 1/4-28 x 0.19 2 218 261864 CLEVIS, hex 2 219 296653 PIN, clevis 2 220 261862 KIT, activator and bushing 1 221 158683 ELBOW, 90 degree 1

Ref Part Description

222 100206 BUSHING 1

223 15H524 ACCUMULATOR, pressure;1/4 npt 1

224 155541 FITTING, union, swivel, 90 degrees 1 226 121312 ELBOW; 3/4 SAE-ORB x 1/2 in. JIC 3 227 295225 PLUG, pipe, flush 4

228 112793 O-RING 2 229 295852 NUT 1 230❄ ADAPTER, lube, cylinder 1 231 177156 O-RING 1 232❄ CYLINDER, lube 1 233 295829 PLUG; 3/8 mpt x 0.343 in. 1 234 295826 ELBOW, 90 degree; 1/4 npt(m) x

3/8 in. (9.5 mm) OD tube

235 295397 ELBOW; 3/4 npt(m) x 1/2 in. (13

mm) OD tube 239 295229 FITTING, grease; 1/4-28 2 240 255037 ELBOW; 3/4 npt(f) 1 241 255038 CONNECTOR 1 242★ 15H184 WIRE, bidirectional cable assy 1

243 15H253 HOSE, gauge, hydraulic, 3000 psi;

shown on page 51 244★ 296607 TOOL, clevis pin, extractor 1

★

Not shown.

❄

Parts available in Kit 261863.

Qty

60 312063S

Page 61

10.2 kW and 6.0 kW Heaters

(Two Per Machine)

Parts 247833 and 247834

Parts

304

301

303

314

302

305

310

306

311

308

313

304

309

r_247833_312063

Apply 110009 thermal heatsink compound.

307

315

Qty

Ref Part Description

Qty

Ref Part Description

301 HOUSING, heater

303 121309 ADAPTER, 3/4 SAE-ORB x

1/2 in. JIC

304 15H304 PLUG

305 15H306 ADAPTER, thermocouple

306 120336 O-RING; fluoroelastomer

307 HEATER, immersion

310 117484 SENSOR

311 100518 SCREW, machine, pan hd

313 15H305 PLUG, hollow

314 295607 PLUG; not shown

315 124132 O-RING

16A110 2550W; 10.4 kW heater only

16A112 1500 W; 6.0 kW heater only

308 15B137 SWITCH, overtemperature

309 15B135 MIXER, immersion heater

312063S 61

Page 62

Parts

8.0 kW Dual Zone Heater

(One Per Machine)

Part 247815

302

310

304

313

307

308

309

310

304

305

303

311

306

302

303

301

Apply 110009 thermal heatsink compound.

Ref. Part Description

301 HOUSING, heater 302 15H302 FITTING, reducer 303 121319 ADAPTER, 1/2 npt(m) x 1/2 in. JIC 304 15H304 PLUG 305 15H306 ADAPTER, thermocouple 306 120336 O-RING; fluoroelastomer 307 16A111 HEATER, immersion; 2000 W 308 15B137 SWITCH, over temperature

62 312063S

309

Qty

307

Ref. Part Description

309 15B135 MIXER, immersion heater

310 117484 SENSOR

311 100518 SCREW, machine, pan hd

312 15M177 INSULATION; not shown

313 124132 O-RING

2 2 4 1

313

r_247815_312063

Qty

4 2 2 1 4

Page 63

7.65 kW Single Zone Heater

(Two Per Machine)

Part 247813

Parts

304

313

303

314

306

305

310

301

313

311

308

304

309

307

r_247813_312063

315

Apply 110009 thermal heatsink compound.

Ref. Part Description Qty

301 HOUSING, heater 303 121309 ADAPTER, 3/4 SAE-ORB x

1/2 in. JIC 304 15H304 PLUG 305 15H306 ADAPTER, thermocouple 306 120336 O-RING; fluoroelastomer 307 15B138 HEATER, immersion; 2550 W 308 15B137 SWITCH, overtemperature 309 15B135 MIXER, immersion heater

312063S 63

Ref. Part Description Qty

310 117484 SENSOR

311 100518 SCREW, machine, pan hd

313 15H305 PLUG, hollow 314 295607 PLUG; not shown

315 124132 O-RING

1 1 3 1 3

1 2 5 1 3

Page 64

Parts

Hydraulic Cylinder

Rod Bushing Detail

409

410

411

405

402

405

416

412

413

415

401

403

See Rod

Bushing

Detail

413

414

401

416

404

406

407

415

408

407

406

Qty

Ref. Part Description

401 295029 PLATE, retainer 402 295030 CYLINDER 403 295031 BUSHING, rod 404 296642 PISTON 405 295640 O-RING 406 295641 U-CUP 407 295642 RING, backup 408 296643 RING, wear

64 312063S

Ref. Part Description

409 158776 O-RING

410 295644 RING, backup

411 295645 WIPER, rod

412 296644 SEAL, shaft

413 295032 SPACER, proportioning pump

414 261861 SPACER, reverse switch

415 295034 ROD, tie

416 295035 BLOCK, port

ti7727a

Qty

2 2 2 2 7 1 4 2

Page 65

Display

502

503

Parts

511

504

507

506

502b

508

505

506

501

510

512

20 (Ref)

ti2574a

502c502a

501c

501a

501b

Qty

Ref. Part Description

501 24G884 DISPLAY, pressure; includes

501a-501c 501a 24G882 .BOARD, circuit 501b 246479 .SWITCH, membrane 501c 112324 .SCREW 502 24G883 DISPLAY, temperature; includes

502a-502c 502a 24G882 .BOARD, circuit 502b 246479 .SWITCH, membrane 502c 112324 .SCREW 503 15B293 GASKET

312063S 65

Ref. Part Description

504 15B292 COVER

505 15B291 PLATE 506 246287 HARNESS, wire, red stop button

507 117499 HANDLE

508 117523 NUT, cap; 10-24

510 111393 SCREW, machine, pan-hd; M5 x

0.8; 16 mm

511 15B386 CABLE, display

512 195853 SCREW, machine; M2.5 x 6

1 4 1

ti3172a

Qty

1 1 1 2 8 4

1 2

Page 66

Parts

Temperature Control

602

605

606

601

603

604

603

604

To B Heater Module

To A Heater Module

To Hose Heater Module

604

603

TI9843a

Qty

Ref. Part Description

601 247772 PANEL, module mounting 602 247827 HOUSING, control module 603 247828 HOUSING, heater module 604 115942 NUT, hex 605 247801 CABLE, communication 606 247825 KIT, cover, connector with screws

66 312063S

1 1 3 4 1 1

Page 67

Fluid Manifold

Torque to 355-395 in-lb (40.1-44.6 N•m).

Apply sealant (113500) to threads.

Valve must be closed with handle position as shown on drawing.

** Apply PTFE tape or thread sealant to tapered threads.

708

702

714

702b

718

702a

706

Parts

705

703

715

704

701

712

713

Ref. Part Description

701 247837 MANIFOLD, fluid 702† 247824 VALVE, drain cartridge 702a† 158674 . O-RING 702b† 247779 . SEAL, seat, valve 703 102814 GAUGE, pressure, fluid 704 162453 FITTING, 1/4 npsm x 1/4 npt 705 246123 TRANSDUCER, pressure, control 706 247788 HANDLE, red 707 247789 HANDLE, blue 708† 112309 NUT, hex, jam 712 117556 NIPPLE, #8 JIC x 1/2 npt 713 117557 NIPPLE, #10 JIC x 1/2 npt

Qty

716

707

714

717

Ref. Part Description

714 121312 ELBOW, 90 degrees

715 100840 ELBOW, street; 1/4 npsm x 1/4 npt

716 111457 O-RING, PTFE

717▲ 189285 LABEL, caution

718† 150829 SPRING, compression

2 2

▲

2 1 1 2 1 1

Replacement Warning labels, signs, tags, and cards

are available at no cost.

† Included in the following complete valve kits*:

ISO Valve Kit (left/red handle) 255149. Resin Valve Kit (right/blue handle) 255150. Valve Set Kit (both handles and grease gun) 255148.

* Complete valve kits also include thread sealant.

(Purchase kits separately).

TI9839b

Qty

2 2 2 1 2

312063S 67

Page 68

Parts

Circuit Breaker Modules

A - 230V, 3 Phase Circuit Breaker Modules

For wiring and cable connections, refer to electrical diagrams manual 312064, supplied. See page 71 for parts.

803, 804

816

818

B - 400V, 3 Phase Circuit Breaker Modules

802

820

805

806

238CR

810

807

811

178CB

187CB

809

814

168BR

197CB

172CB

812

817

822

813

815

808

801

819

For wiring and cable connections, refer to electrical diagrams manual 312064, supplied. See page 71 for parts.

803, 804

802

816

818

820

805

806

238CR

810

807

811

178CB

187CB

809

197CB

817

172CB

812

822

813

808

801

819

68 312063S

Page 69

C - 230V, 1 Phase Circuit Breaker Modules

For wiring and cable connections, refer to electrical diagrams manual 312064, supplied. See page 71 for parts.

820

805

806

810

811

814

Parts

817

803, 804

816

818

D - 230V, 3 Phase Circuit Breaker Modules

For wiring and cable connections, refer to electrical diagrams manual 312064, supplied. See page 71 for parts.

802

820

805

806

238CR

810

178CB

807

811

187CB

809

814

168BR

197CB

172CB

812

822

817

813

815

808

801

819

821

803, 804

815

810

808

801

819

818

816

802

238CR

178CB

187CB

168BR

197CB

172CB

812

170CR

813

809

807

312063S 69

822

Page 70

Parts

E - 400V, 3 Phase Circuit Breaker Modules

For wiring and cable connections, refer to electrical diagrams manual 312064, supplied. See page 71 for parts.

820

803, 804

802

816

805

806

238CR

810

178CB

811

187CB

197CB

172CB

817

821

808

810

170CR

801

818

807

809

812

822

813

819

70 312063S

Page 71

Circuit Breaker Modules Parts List

Ref. Description

801 RAIL, mounting

802 CLAMP, block, end

803 HOLDER, fuse terminal, block

804 FUSE

805 TERMINAL, block

807 BRIDGE, plug in, jumper

808 BLOCK, terminal ground

809 BREAKER, 1 pole, 50A

810 CONTACTOR, relay, 65A

CONTACTOR, relay, 65A

811 BREAKER, 2 phase, 40A

812 BREAKER, 2 phase, 25A

BREAKER, 2 phase, 40A

BREAKER, 2 phase, 50A

813 BREAKER, 2 phase, 20A

BREAKER, 3 pole, 20A

BREAKER, 2 phase, 30A

814 CONNECTOR, power lug

CONNECTOR, power lug

815 BAR, power buss, 3 phase

BAR, power buss, 1 phase

BAR, power buss, 3 phase, 3x3

816 CABLE, harness lower

817 CABLE, harness upper

818 CONNECTOR, 2 pin large

819 CONNECTOR, 3 pin

820 CONNECTOR, 4 pin

821 CONNECTOR, 2 pin small

822 CABLE, harness, hose wire

230V, 3 phase B400V, 3 phase C230V, 1 phase D230V, 3 phase E400V, 3 phase

255028 255028 255028 255028 255028 1

255045 255045 255045 255045 255045 1

255043 255043 255043 255043 255043 2

255023 255023 255023 255023 255023 2

255042 255042 255042 255042 255042 4

255044 255044 255044 255044 255044 2

255046 255046 255046 255046 255046 1

255026 255026 255026 255026 255026 1

255022 255022 255022 1

247768 247768 247768 247768 247768 1

*255050 *255050 *255050 2

†247768 †247768 †✠ 247768 2

255049 255049 *†255049 1

117679 117679 3

117805 1

247802 247802 247802 247803 247803 1

247805 247806 247804 247808 247807 1

255027 255027 255027 255027 255027 3

120895 120895 120895 120895 120895 1

255031 255031 255031 255031 255031 1

247791 247791 247791 247791 247791 1

Parts

Breaker Modules

Qty

255022 255022 2

120579 120579 2

255025 255025 1

✠ 255041 1

117679 2

117678 1

255024 1

255030 255030 1

* 8 kW H-25 models only.

† 15.3 kW H-25, H-XP2, H-40, H-50 models only.

✠

12kW H-40, H-50 models only.

312063S 71

Page 72

Dimensions

Dimension in. (mm)

A (height) 55.0 (1397) B (width) 39.6 (1006) C (depth) 18.5 (470) D (front mounting holes) 29.34 (745) E (rear mounting holes) 33.6 (853)

Dimension in. (mm)

F (side mounting holes) 16.25 (413) G (mounting post inner diameter) 0.44 (11) H (front mounting post height) 2.0 (51) J (rear mounting post height) 3.6 (92)

Top View

Rear of Machine

Front of Machine

ti9830a

Side View

ti7742a ti7743a

Detail of mounting post height,

to correctly size mounting bolts

72 312063S

Page 73

Technical Data

Category Data

Maximum Fluid Working Pressure Models H-25 and H-40: 2000 psi (13.8 MPa, 138 bar)

Model H-50 1 phase: 1700 psi (11.7 MPa, 11.7 bar) Model H-50 3 phase: 2000 psi (13.8 MPa, 138 bar) Models H-XP2 and H-XP3: 3500 psi (24.1 MPa, 241 bar)

Fluid:Oil Pressure Ratio Models H-25 and H-40: 1.91:1

Model H-50: 1.64:1 Models H-XP2 and H-XP3: 2.79:1

Fluid Inlets Component A (ISO): 1/2 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum

Component B (RES): 3/4 npt(f), 250 psi (1.75 MPa, 17.5 bar) maximum

Fluid Outlets Component A (ISO): -8 (1/2 in.) JIC, with -5 (5/16 in.) JIC adapter

Component B (RES): -10 (5/8 in.) JIC, with -6 (3/8 in.) JIC adapter Fluid Circulation Ports 1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum Maximum Fluid Temperature 190°F (88°C) Maximum Output (10 weight oil at

ambient temperature)

Output per Cycle (A and B) Models H-25 and H-40: 0.063 gal. (0.23 liter)

Line Voltage Requirement 230V 1 phase and 230V 3 phase units: 195-264 Vac, 50/60 Hz

Amperage Requirement See Models, page 3. Heater Power

(A and B heaters total, no hose) Hydraulic reservoir capacity 3.5 gal. (13.6 liters) Recommended hydraulic fluid Citgo A/W Hydraulic Oil, ISO Grade 46 Sound power, per ISO 9614-2 90.2 dB(A) Sound pressure, 1 m from equip-

ment Weight Units with 8.0 kW Heaters: 535 lb (243 kg)

Model H-25: 22 lb/min (10 kg/min) (60 Hz)

Model H-XP2: 1.5 gpm (5.7 liter/min) (60 Hz)

Model H-50: 52 lb/min (24 kg/min) (60 Hz)

Model H-40: 45 lb/min (20 kg/min) (60 Hz)

Model H-XP3: 2.8 gpm (10.6 liter/min) (60 Hz)

Model H-50: 0.073 gal. (0.28 liter)

Models H-XP2 and H-XP3: 0.042 gal. (0.16 liter)

400V 3 phase units: 338-457 Vac, 50/60 Hz

See Models, page 3.

82.6 dB(A)

Units with 12.0 kW Heaters: 597 lb (271 kg)

Units with 15.3 kW Heaters (H-25/H-XP2 models):562 lb (255 kg)

Units with 15.3 kW Heaters (H-40/H-XP3/H-50 models): 597 lb (271 kg)

Units with 20.4 kW Heaters: 597 lb (271 kg) Wetted Parts Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome,

fluoroelastomer, PTFE, ultra-high molecular weight polyethylene, chemically

resistant o-rings

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

312063S 73

Page 74

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,

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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

contact your Graco distributor or call to identify the nearest distributor.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions

International Offices: Belgium, China, Japan, Korea

. This manual contains English. MM 312063

Graco Headquarters: Minneapolis

www.graco.com

Revised February 2015

Graco 312063S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

Supplied Manuals

Related Manuals

Warnings

Temperature Control Diagnostic Codes

E01: High fluid temperature

E02: High zone current

E03: No zone current

E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected

E05: Circuit board overheated

E06: Communication cable unplugged

Motor Control Diagnostic Codes

Alarms

Warnings

E21: No component A transducer

E22: No component B transducer

E24: Pressure imbalance

E23: High fluid pressure

E30: Momentary loss of communication

E31: Pumpline reversing switch failure/high cycle rate

E27: High motor temperature

E99: Loss of communication

Troubleshooting

Reactor Electronics

Primary Heaters (A and B)

Hose Heat System

Hydraulic Drive System

Proportioning System

Repair

Pressure Relief Procedure

Flushing

Proportioning Pumps

Circuit Breaker Module

Electric Motor

Motor Control Board

Transducers

Electric Fan

Temperature Control Module

Primary Heaters

Heated Hose

Fluid Temperature Sensor (FTS)

Display Module

Inlet Fluid Strainer Screen

Pump Lubrication System

Change Hydraulic Fluid and Filter

Parts

Parts Used on All Models

Parts that Vary by Model

Sub Assemblies

Proportioner Assembly

10.2 kW and 6.0 kW Heaters

8.0 kW Dual Zone Heater

7.65 kW Single Zone Heater

Hydraulic Cylinder

Display

Temperature Control

Fluid Manifold

Circuit Breaker Modules

Dimensions

Technical Data

Graco Standard Warranty

Graco Information