Hydraulic Variable Ratio, Heated, Plural-Component Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 3 for model information, including maximum
working pressure and approvals.
*Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and
mix chamber sizes may be less.
◆ Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum
flow.
313540G3
Supplied Manuals
Supplied Manuals
The following manuals are used with the Reactor™
HV-R Proportioner. Refer to these manuals for detailed
equipment information.
Order Part 15M334 for a compact disk of Reactor manuals.
Reactor Hydraulic Proportioner
PartDescription
313539Reactor H-VR Proportioner, Operation
Manual (English)
Reactor Electrical Diagrams
PartDescription
312064Reactor Hydraulic Proportioner,
Electrical Diagrams (English)
Fluid Pump
Part Description
313485Pump Instructions-Parts Manual
(English)
Related Manuals
The following manuals are for accessories used with the
™
Reactor
Feed Pump Kits
Part Description
309815Instruction-Parts Manual (English)
Air Supply Kit
Part Description
309827Instruction-Parts Manual (English) for
Circulation and Return Tube Kits
Part Description
309852Instruction-Parts Manual (English)
Heated Hose
Part Description
309572Instruction-Parts Manual (English)
Circulation Kit
Part Description
309818Instruction-Parts Manual (English)
Circulation Valve Kit
.
Feed Pump Air Supply Kit
Part Description
312070Instruction-Parts Manual (English)
Data Reporting Kit
Part Description
309867Instruction-Parts Manual (English)
Rupture Disk Assembly Kit
Part Description
309969Instruction-Parts Manual (English)
4313540G
Warnings
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
This equipment must be grounded. 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 power 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.
•If this equipment is used with isocyanate material, see additional information on isocyanates in Isocyanate Conditions Section of this manual.
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.
•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.
•Engage trigger lock when not spraying.
•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
313540G5
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•Use equipment only in well ventilated area.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•Ground all equipment in the work area.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail.
•If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
•Keep a working fire extinguisher in the work area.
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.
OR
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•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.
•Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
•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.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Material Self-ignition
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
To prevent exposing ISO to moisture:
•Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
•Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
•Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
•Never use solvent on one side if it has been contaminated from the other side.
•Always park pumps when you shutdown.
•Always lubricate threaded parts, except for GC1128,
GC0697, and GC2150, with Part 217374 ISO pump
oil or grease when reassembling.
313540G7
Keep Components A and B Separate
Keep Components A and
B Separate
NOTICE
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A (isocyanate) and component B (resin) parts.
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Changing Materials
•When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
•Always clean the fluid inlet strainers after flushing.
•Check with your material manufacturer for chemical
compatibility.
•Most materials use ISO on the A side, but some use
ISO on the B side.
•Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
8313540G
Temperature Control Diagnostic Codes
Temperature Control Diagnostic Codes
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.
CodeCode NameAlarm
01High fluid temperatureIndividual
02High zone currentIndividual
03No zone current with
hose heater on
04FTS not connectedIndividual
05Board overtemperatureIndividual
06Communication cable
unplugged from module
99Loss of communicationA
NOTE: For hose zone only, if FTS is disconnected at
startup, display will show hose current 0A.
Zone
Individual
Individual
Corrective
Action page
9
10
10
11
11
11
15
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 (408) senses a fluid
temperature above 230°F (110°C) and opens. At
190°F (87°C) the switch closes again.
•Thermocouple A or B (410) fails, is damaged, is not
touching the heater element (407), or has a poor
connection to the temperature control board.
•Overtemperature switch A or B (408) 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.
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 and
relieve all pressure (see Pressure Relief Procedure,
page 27) 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 (410) or FTS (21) [depending on which zone is displaying E01]. See T
page 35. Ensure that all wires are securely connected to connector B.
IG. 9, page 35).
ABLE 6,
•Loose wire
313540G9
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
NOTE: Before doing the following checks, note
which zone (A, B, FTS, or all) has high fluid temperature.
5. Verify fluid temperature, using an external temperature sensing device.
ABLE 1.
ohms per 50 ft (15.2
m) of hose, plus
approximately 10
ohms for FTS
E02: High zone current
1. Check hose connections for electrical short, page
39.
2. Exchange zone module with another one. Turn zone
on and check for error (see page 36). If error disappears, replace faulty module.
a. For hose zone: If error still occurs, perform
Transformer Primary Check and Transformer
Secondary Check, starting on page 41.
NOTE: When there is a high current error, the LED
on that zone’s module will turn red while the error is
displayed.
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.
•If temperature is too high (sensor reading is
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.
4. If E03 occurs for all zones, the contactor may not be
closing. Verify wiring from heater control to contactor coil.
a. Hose zone: test hose continuity, page 39.
b. Perform Transformer Primary Check and
Transformer Secondary Check, starting on
page 41.
NOTE: When a no current error occurs, the LED on
the specific zone’s module turns red when the error
is displayed.
10313540G
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 34. Unplug and re-plug sensor wires.
2. Test fluid temperature sensor continuity with ohmmeter, page 9.
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.
F
ti9878a
E05: Circuit board overheated
NOTE: 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
H-VR Operation manual 313539.
2. Replace communication cable if problem persists.
313540G11
Motor Control Diagnostic Codes
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.
NOTE: 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
Code Code NameAlarm (A) or
Warning (W)
99Loss of communicationA
Corrective
Action
page
15
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 12. 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 12. If error does not move, replace motor control board, page 32.
is turned OFF then ON .
E23: High fluid pressure
1. Relieve pressure. Verify low pressure with analog
27High motor temperatureA
30Momentary loss of com-
munication
31Pumpline reversing switch
failure/high cycle rate
12313540G
A
A
select, see
page 32)
A
A
Corrective
Action
page
12
12
12
13
14
15
15
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.
3. Ensure at least one pump is in the number 1 position. See Setup section of Reactor H-VR Operation
manual 313539.
4. If error still persists, reduce hydraulic pressure.
Motor Control Diagnostic Codes
E24: Pressure imbalance
NOTE: Upon initial start-up this diagnostic code will
not cause an alarm for 2 minutes.
NOTE: 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.
NOTE: If spraying at a ratio other than 1:1, an E24
may occur. Size hoses and mix chamber appropriately to avoid pressure imbalance.
NOTE: 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.
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
NOTE: 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 12) and try running the unit
again.
2. If E24 recurs and the gauge readings are still very
close, a pressure transducer has failed.
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.
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 com-
ponent 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
1
reduce pressure of
higher component.
1
ti9877a
4. To test if the failure is with the transducer or the
socket on the motor control board:
313540G13
Motor Control Diagnostic Codes
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.
Turn valve slightly to
1
reduce pressure of
higher component.
1
ti9877a
b. Check and clean the gun mix chamber impinge-
ment ports and center port. See gun manual.
NOTE: 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.
NOTE: If spraying at a ratio other than 1:1, an E24
may occur. Size hoses and mix chamber appropriately to avoid pressure imbalance.
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 hose is not heating properly.
•kinked supply hose.
•bottom of drum is damaged, causing blockage of
feed pump inlet.
•drum is not vented.
NOTE: 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.
4. If a fast E24 error occurs again, and the gauges
readings are not very close:
a. Check and clean the gun inlet screens.
E27: High motor temperature
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:
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,
14313540G
Motor Control Diagnostic Codes
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
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
64). 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:
3. Swap display connection on temperature control
module (C) with display connection on motor control
board (J13).
failure/high cycle rate
Failure of a pumpline switch or switch mechanism may
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.
4. If error no longer occurs, the board or module was
at fault. Switch connections back to ensure connector was not poorly connected.
313540G15
Troubleshooting
Troubleshooting
Reactor Electronics
2. Turn main power OFF .
3. Allow equipment to cool.
Before performing any troubleshooting procedures:
1. Relieve pressure, page 27.
PROBLEMCAUSESOLUTION
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 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-
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)
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.
16313540G
Troubleshooting
PROBLEMCAUSESOLUTION
Hose display reads OA at startup.FTS disconnected or not installed.Verify proper installation of FTS (see
H-VR Operation manual 313539), or
adjust FTS to desired current setting.
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.
313540G17
Troubleshooting
Primary Heaters (A and B)
2. Turn main power OFF .
3. Allow equipment to cool.
Before performing any troubleshooting procedures:
1. Relieve pressure, page 27.
PROBLEMCAUSESOLUTION
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-
Control of primary heat is abnormal;
high temperature overshoots or E01
error occurs intermittently.
Dirty thermocouple connections.Examine connection of thermocou-
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.
Press or zone
keys.
nostic code, page 9.
sor (FTS) or thermocouple disconnected, page 11.
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.
A
B
Thermocouple not contacting heater
element.
Failed heater element.See Primary Heaters, page 18.
Signal failure from thermocouple.See E04: Fluid Temperature Sen-
Thermocouple wired incorrectly.See E04: Fluid Temperature Sen-
Loosen ferrule nut (N), push in thermocouple (410) so tip (T) contacts
heater element (407). Holding thermocouple 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 11.
sor (FTS) or thermocouple disconnected, page 11. Power up zones
one at a time and verify that temperature for each zone rises.
18313540G
Hose Heat System
Troubleshooting
2. Turn main power OFF .
3. Allow equipment to cool.
Before performing any troubleshooting procedures:
1. Relieve pressure, page 27.
PROBLEMCAUSESOLUTION
Ambient temperature is too cold.Use auxiliary hose heat system.
Hose heats but heats slower than
usual or it does not reach temperature.
Hose does not maintain temperature
while spraying.
FTS failed or not installed correctly.Check FTS, page 11.
Low supply voltage.Verify line voltage. Low line voltage
A and B setpoints too low.Increase A and B setpoints. Hose is
Ambient temperature is too cold.Increase A and B setpoints to
Flow too high.Use smaller mix chamber. Decrease
Hose was not fully preheated.Wait for hose to heat to correct tem-
Low supply voltage.Verify line voltage. Low line voltage
Problems
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.
significantly reduces power available
to hose heat system, affecting longer
hose lengths.
designed to maintain temperature,
not to increase it.
increase fluid temperature and keep
it steady.
pressure.
perature before spraying.
significantly 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
Hose temperature exceeds setpoint.
313540G19
Check primary heaters for either a
thermocouple problem or a failed element attached to thermocouple, page
11.
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.
Troubleshooting
PROBLEMCAUSESOLUTION
Erratic hose temperature.
Faulty thermocouple connections.Verify that all FTS connections are
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.
FTS not installed correctly.FTS should be installed close to end
of hose in same environment as gun.
Verify FTS installation, page 39.
Hose does not heat.
Hoses near Reactor are warm, but
hoses downstream are cold.
FTS failed or is not contacting
Check FTS, page 39.
correctly.
FTS not installed correctly.FTS should be installed close to end
of hose in same environment as gun.
Verify FTS installation, page 39.
Temperature control alarm.Check temperature display or diag-
nostic code, page 39.
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.
20313540G
Hydraulic Drive System
Troubleshooting
2. Turn main power OFF .
3. Allow equipment to cool.
Before performing any troubleshooting procedures:
1. Relieve pressure, page 27.
PROBLEMCAUSESOLUTION
Electric motor will not start or stops
during operation.
Loose connections.Check connections at motor control
Circuit breaker tripped.Reset breaker (813); see Circuit
Damaged motor control board.Replace board. See Motor Control
Problems
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.
board.
Breaker Module, page 30. Check
230 Vac at output of breaker.
Board, page 32.
313540G21
Troubleshooting
PROBLEMCAUSESOLUTION
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 Reactor
H-VR Operation manual 313539.
Check dipstick to ensure that hydraulic reservoir is properly filled (see
H-VR Operation manual 313539).
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.
22313540G
Proportioning System
Troubleshooting
2. Turn main power OFF .
3. Allow equipment to cool.
Before performing any troubleshooting procedures:
1. Relieve pressure, page 27.
PROBLEMCAUSESOLUTION
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 Pumps Do Not
Inadequate flow from pump; cavitation.
Problems
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.
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 313485.
Reverse Direction, page 26.
Increase fluid supply to proportioning
pump:
Pressure relief/circulation valve leaking back to supply.
Spraying at a ratio other than 1:1 can
cause pressure imbalance.
•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.
Worn pump inlet valve ball/seat or
gasket. Replace; see pump manual
313485.
Remove return line and determine if
flow is present while in SPRAY
mode.
Size hoses and mix chamber appropriately.
313540G23
Troubleshooting
PROBLEMCAUSESOLUTION
Pumps do not reverse direction or
pumps do not move.
Damaged reversing switch assembly. 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.
Fluid is too thick. Consult your material supplier for recommended fluid
temperature to maintain a viscosity of
250 to 1500 centipoise.
Faulty reversing switch connection.See Pumps Do Not Reverse Direc-
tion, page 26.
Faulty directional valve.Replace directional valve; see
Pumps Do Not Reverse Direction,
page 26.
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 313485.
displacement pump.
Inadequate feed pump pressure.Check feed pump pressure and
adjust to 100 psi (0.7 MPa, 7 bar)
minimum.
One pump is not in position “1”.Move pump to position “1”.
Fluid leak at pump rod seal.Worn throat seals.Replace. See pump manual 313485.
No pressure on one side.Fluid leaking from pump outlet rup-
ture disk (274).
Check if heater (2) and PRESSURE
RELIEF/SPRAY valve (SA or SB) are
plugged. Clear. Replace rupture disk
(274) 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.
24313540G
Ratio Lock Handle
Troubleshooting
B Pump Arm
B (Resin)
Proportioning
Pump
Change Over Box
Hydraulic Cylinder
A Pump Arm
Ratio Adjustment
Wheel
A (ISO)
Proportioning
Pump
Reversing
Switches
3
1
2
1
2
3
Switch Disk
r_256886_313540_4
F
IG. 1. Pump Line when viewed from rear of machine
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.
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.
313540G25
Troubleshooting
Pumps Do Not Reverse Direction
1. For the proportioning pumps to reverse direction,
the switch disk must contact the reversing switches.
Ensure that the change over box is assembled correctly and that none of the components are damaged. See F
2. Check the function of the directional valve. Direction
indication lights should switch on and off based on
the position of the reversing switches (199). LEDs
D19 and D20 (near J5 reversing switch connector
on motor board, see F
nate when each switch is activated.
r_256886_313540_1
Directional Valve
F
IG. 2: Hydraulic Directional Valve Assembly
IG. 1 (page 25) and Parts (page 58).
IG. 6) should alternately illumi-
•verify reversing switches. Unplug the J5
reversing switch connector. Verify that when
the switches are not triggered there is continuity between 1150-NC and 1160-T-COM,
and between 1150-NC and 1170-B-COM.
Toggle reversing switches. Ensure that continuity between 1150-NC and 1160-T-COM,
and between 1150-NC and 1170-B-COM is
lost. Refer to the Electrical Diagrams manual 312064 (Detailed Schematic, Motor
Controls (3-Phase Motor)). If these four
conditions are not verified, replace reversing switches.
•if the reversing switch and wiring are not the
cause, and D19 and D20 will not alternately
illuminate, replace the motor board.
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.
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:
•verify that the reversing switch cable is connected at the bulkhead bracket and that it is
plugged into the J5 connector on the motor
board.
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.
NOTE: 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.
26313540G
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.
Repair
Pressure Relief Procedure
1. Relieve pressure in gun and perform gun shutdown
procedure. See gun manual.
2. Close gun fluid manifold valves A and B.
ti2421a
3. Shut off feed pumps and agitator, if used.
4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)
to PRESSURE RELIEF/CIRCULATION . Route
fluid to waste containers or supply tanks. Ensure
gauges drop to 0.
SB
SA
ti9879a
5. Engage gun piston safety lock.
ti2409a
6. Disconnect gun air line and remove gun fluid manifold.
ti2554a
313540G27
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).
SA
SB
Proportioning Pumps
To avoid injury and damage to pump arms and ratio
adjustment screws, relieve all pressure and shut off all
power before repairing proportioning pumps.
NOTE: See manual 313485 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.
A
B
N
N
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.
5. Shut off both feed pumps. Close both fluid inlet ball
valves (B).
B
ti10971a
28313540G
Repair
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.
SB
SA
ti9879a
NOTE: Use a drop cloth or rags to protect Reactor
H-VR and surrounding area from spills.
7. Remove guard. Loosen all four clamping knobs
(190), and remove guard (180).
8. Disconnect all fluid hoses connected to pumps.
9. Remove pump base pin (183) and top pin (255) on
both pumps. See page 57.
183
F
IG. 4: Remove Pump Pins
184
r_256886_313539_7
10. Remove pump assemblies and take to a workbench.
To avoid injury, never remove guard unless all pressure is relieved and all power is shut off.
r_256886_313539_6
180
190
11. See manual 313485 for pump repair instructions.
12. Reconnect pump in reverse order
NOTE: Insert pump top pin (255) before base pin
(183) when reconnecting pump.
13. Replace guard (180) and tighten all four clamping
knobs (190). Ensure warning label on guard faces
outward on machine.
190
F
IG. 3: Remove Guard
313540G29
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:
a. Refer to electrical diagrams and to T
connect wires and remove bad breaker.
b. Install new breaker and reconnect wires.
ABLE 3. Dis-
Table 3: Circuit Breakers, see FIG. 5
Ref. SizeComponent
80950AHose/Transformer
Secondary Side
81140ATransformer
Primary
812A50AHeater A
812B50AHeater B
81320AMotor/Pumps
809
811
NOTE: To reference cables and connectors, see the electrical diagrams and
812A
812B
813
ti9884a
the parts drawings on page 64.
FIG. 5. Circuit Breaker Module
30313540G
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.
NOTE: 3-Phase Motors: motor must rotate counterclockwise when viewed from shaft end. If rotation is
incorrect, reverse power leads L1 and L2. See Reactor H-VR Operation manual 313539, 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 counter-
clockwise when looking at the output shaft.
NOTICE
Motor is heavy. Two people may be required to lift.
5. Remove screws holding motor to bracket. Lift motor
off unit.
313540G31
Repair
Motor Control Board
NOTE: Motor control board has one red LED (D11).
Power must be on to check. See F
Function 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).
NOTICE
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.
IG. 6 for location.
Table 4: DIP Switch (SW2) Settings
DIP
SwitchON (up)OFF (down)
Switch 1Motor soft start ON
(factory default)
Switch 2ON for pressure
imbalance alarm
(factory default)
(Not applicable to
3-phase motors)
OFF for pressure
imbalance warn-
ing
Switch 3Standby ONStandby OFF
(factory default)
Switch 4N/AOFF
9. Install new board in reverse order. Apply thermal
heatsink compound to mating surfaces of board and
heatsink.
NOTE: Order Part 110009 Thermal Compound.
Table 5: Motor Control Board Connectors
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
IG. 6 for location on board.
ABLE 4
ConnectorPinDescription
J1n/aMain power
J3n/aTransducer A
J4n/aNot used
J7n/aNot used
J8n/aTransducer B
J9n/aMotor thermostat (NC)
J10n/aNot used
J12n/aData reporting
J13n/aTo display board
J14n/aMotor power
J181Directional valve, A+
Hose current should ramp up to 45A. If there is
no hose current, see E03: No zone current,
page 10. If hose current exceeds 45A, see E02: High zone current, page 10. If hose current
stays several amps below 45A, hose is too long
or voltage is too low.
2. Test the SCR circuit in the off position:
a. Make sure everything is connected, including
the hose.
Replacing Temperature Control Assembly
Modules
NOTICE
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.
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.
5. Put on static conductive wrist strap.
6. Disconnect all cables and connectors from assembly; see Temperature Control, page 62.
7. Remove nuts and take entire temperature control
assembly to workbench.
b. Turn main power ON .
c.Adjust the hose heat setpoint below the ambi-
ent hose temperature.
d. Turn on heat zone by pressing .
e. Using a voltmeter, carefully measure the voltage
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.
36313540G
8. Replace defective module.
9. Install assembly in reverse order.
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 page 60 for parts. Disconnect heater element
wires from heater wire connector. Test with ohmmeter.
Total Heater
WattageElementOhms
6. To remove heater element, first remove thermocouple (410) to avoid damage, see step 7, page 38.
7. Remove heater element (407) from housing (401).
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 (407), holding mixer
(409) 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.
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.
7,650255018-21
313540G37
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 temperature control module. See T
9, page 35.
6. Feed thermocouple wires out of cabinet. Note path
as wires must be replaced in the same way.
7. See F
IG. 10. Loosen ferrule nut (N). Remove ther-
mocouple (410) from heater housing (401), then
remove thermocouple housing (H). Do not remove
the thermocouple adapter (405) unless necessary. If
adapter must be removed, ensure that mixer (409)
is out of the way when replacing the adapter.
ABLE 6, page 35 and FIG.
8. Replace thermocouple, F
IG. 10.
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 (405).
c.Push in thermocouple (410) so tip (T) contacts
heater element (407).
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 (407).
S
409
FIG. 10. Thermocouple
1
Apply PTFE tape and thread sealant.
410
2
Apply 110009 thermal heatsink compound.
N
H
1
405
401
407
2
408
T
ti7924a
38313540G
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 (408), 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 (401), and secure with screws (411).
Reconnect wires.
IG. 10. Test across switch with ohm-
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
F
FIG. 11. Heated Hose
IG. 11.
D
ti9878a
NOTE: If wires need replacement, disconnect from
temperature control board. See T
F
IG. 9, page 35.
ABLE 6, page 35 and
Heated Hose
NOTE: 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.
NOTE: Whip hose must be connected.
3. Disconnect hose connector (D) at Reactor, F
IG. 11.
4. Test with ohmmeter between pins of cable connector.
PinsResult
1 to 2approximately 35 ohms per 50 ft (15.2 m) of
hose, plus approximately 10 ohms for FTS
1 to 3infinity
5. If cable fails test, retest at FTS, page 39.
4. Using an ohmmeter, check between the two terminals of the connector (D). There should be continuity.
313540G39
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
IG. 11. Disconnect hose cable (F). Test with
ohmmeter between pins of cable connector.
PinsResult
1 to 2approximately 10 ohms
1 to 3infinity
3 to FTS groundscrew0 ohms
1 to FTS component A
fitting (ISO)
infinity
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.
D
K
ISO
B
A
H
C
B
W
A
L
ti9581c
FIG. 12: Fluid Temperature Sensor and Heated Hoses
40313540G
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-
4. Disconnect the transformer wires; see Reactor Electrical Diagrams manual 312064.
5. Remove transformer from cabinet.
6. Install new transformer in reverse order.
313540G41
Repair
Display Module
Temperature and Pressure Displays
NOTICE
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. Disconnect main display cable (20) at lower left corner of display module; see F
6. Remove screws (509, 510) and cover (504); see
F
IG. 14.
IG. 14.
Red Stop Button
NOTICE
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
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).
IG. 14.
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 display (502); see F
IG. 14.
8. Disconnect ribbon cable(s) (R) from back of display;
see F
IG. 14.
9. Remove nuts (508) and plate (505).
10. Disassemble display, see detail in F
IG. 14.
11. Replace board (501a or 502a) or membrane switch
(501b or 502b) as necessary.
12. Reassemble in reverse order, see F
IG. 14. Apply
medium strength thread sealant where shown. Be
sure display cable ground wire (G) is secured
between cable bushing and cover (504) with screws
(512).
42313540G
1
Apply medium strength thread sealant.
Repair
G
511
511
502
503
504
507
510
506
512
20
501
508
1
505
506
Detail of Membrane Switches and Display Boards
Temperature DisplayPressure Display
1
502c
1
ti2574a
502b
R
FIG. 14. Display Module
502a
501c
1
501a
R
501b
ti3172a
313540G43
Repair
Inlet Fluid Strainer Screen
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.
NOTE: 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 (C) is removed.
2. Place a container under the strainer base to catch
drain off when removing the strainer plug.
3. Remove the screen (A) 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 (B) and replace as
required.
4. Ensure the pipe plug (D) is securely screwed into
the strainer plug (C). Install the strainer plug with the
screen (A) and gasket (B) 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.
Change Hydraulic Fluid and
Filter
See Table 8 for recommended frequency of oil changes.
NOTE: 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
1. Relieve pressure, page 27.
2. Allow hydraulic fluid to cool.
44313540G
Repair
3. Place a pan under reservoir drain plug (110k) to
catch oil.
135
ti9888a
110k
F
IG. 16: Change Hydraulic Fluid and Filter
4. Remove drain plug (110k).
5. Place a rag around base of oil filter (135) to prevent
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
remove.
6. Reinstall drain plug (110k).
7. Replace filter (135):
a. Coat filter seal with fresh oil.
b. Screw filter on snug, then an additional 1/4 turn.
8. Refill reservoir with approved hydraulic fluid. See
Table 9.
9. Proceed with normal operation.
NOTE: 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.
313540G45
Repair
Table 9: Approved Anti-Wear (AW) Hydraulic Oils
SupplierName
CitgoA/W ISO Grade 46
AmsoilAWI ISO Grade 46 (synthetic*)
BP Oil International
Energol
®
HLP-HM, ISO Grade 46
Carl Bechem GmbHStaroil HVI 46
CastrolHyspin AWS 46
Chevron
Rykon
®
AW, ISO 46
ExxonHumble Hydraulic H, ISO Grade 46
MobilMobil DTE 25, ISO Grade 46
ShellShell Tellus, ISO Grade 46
TexacoTexaco 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 require-
506246287 HARNESS, wire, red stop button
507117499 HANDLE
1
508117523 NUT, cap; 10-24
1
510SCREW, machine, pan-hd; M5 x
4
1
0.8; 16 mm
51115B386 CABLE, display
512195853 SCREW, machine; M2.5 x 6
1
1
4
1
1
ti3172a
1
1
2
8
4
1
2
Parts
Temperature Control
602
605
606
601
603
604
603
604
604
To B
Heater
Module
To A
Heater
Module
To Hose
Heater
Module
604
603
TI9843a
Ref.PartDescriptionQty.
601247772 PANEL, module mounting
602247827 HOUSING, control module
603247828 HOUSING, heater module
604115942 NUT, hex
605247801 CABLE, communication
606247825 KIT, cover, connector with screws
62313540G
1
1
3
4
1
1
Fluid Manifold
1
Torque to 355-395 in-lb (40.1-44.6 N•m).
2
Apply sealant (113500) to threads.
3
Valve must be closed with handle position as shown on drawing.
** Apply PTFE tape or thread sealant to tapered threads.
708
2
1
702
3
714
702b
718
2
702a
706
Parts
3
705
703
715
704
701
712
713
Ref.PartDescriptionQty.
701247837 MANIFOLD, fluid
702† 247824 VALVE, drain cartridge
702a† 158674 . O-RING
702b† 247779 . SEAL, seat, valve
703102814 GAUGE, pressure, fluid
704162453 FITTING, 1/4 npsm x 1/4 npt
70524K999 TRANSDUCER, pressure, control
706247788 HANDLE, red
707247789 HANDLE, blue
708† 112309 NUT, hex, jam
712117556 NIPPLE, #8 JIC x 1/2 npt
713117557 NIPPLE, #10 JIC x 1/2 npt
716
707
3
714
717
Ref.PartDescriptionQty.
714121312 ELBOW, 90 degrees
1
715100840 ELBOW, street; 1/4 npsm x 1/4 npt
2
716111457 O-RING, PTFE
1
717▲ 189285 LABEL, caution
1
718† 150829 SPRING, compression
2
2
▲ Replacement Warning labels, signs, tags, and cards
2
1
1
2
1
1
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
2
2
2
1
2
313540G63
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 65 for parts.
803, 804
802
816
818
820
805
806
238CR
810
807
811
178CB
187CB
809
814
168BR
197CB
172CB
812
822
817
170CR
813
821
815
810
808
801
819
B - 400V, 3 Phase Circuit Breaker Modules
For wiring and cable connections, refer to electrical diagrams manual 312064, supplied. See page 65 for parts.
803, 804
802
816
818
820
805
806
238CR
810
807
178CB
811
809
187CB
197CB
172CB
812
822
817
170CR
813
821
808
810
801
819
64313540G
Circuit Breaker Modules Parts List
Ref. Description
801RAIL, mounting
802CLAMP, block, end
Breaker Modules
A
230V, 3 phase B400V, 3 phase
2550282550281
2550452550451
Parts
Qty
803HOLDER, fuse terminal, block
804FUSE
805TERMINAL, block
807BRIDGE, plug in, jumper
808BLOCK, terminal ground
809BREAKER, 1 pole, 50A
810CONTACTOR, relay, 65A
811BREAKER, 2 phase, 40A
812BREAKER, 2 phase, 50A
813BREAKER, 3 pole, 20A
814CONNECTOR, power lug
815BAR, power buss, 3 phase, 3x3
816CABLE, harness lower
817CABLE, harness upper
818CONNECTOR, 2 pin large
819CONNECTOR, 3 pin
2550432550432
2550232550232
2550422550424
2550442550442
2550462550461
2550262550261
2550222550222
2477682477681
1205791205792
2550252550251
1176793
255024
2478032478031
2478082478071
2550272550273
1208951208951
1
820CONNECTOR, 4 pin
821CONNECTOR, 2 pin small
822CABLE, harness, hose wire
313540G65
2550312550311
2550302550301
2477912477911
Dimensions
Dimensions
Dimensionin. (mm)
A (height)57.3 (1455.4)
B (width)37.9 (961.6)
C (depth)33.0 (838.2)
Dimensionin. (mm)
D (front and rear mounting holes)32.5 (825.5)
F (side mounting holes)30.4 (771.6)
G (mounting post inner diameter)0.44 (11.2)
A
C
Top View
Front of Machine
D
D
B
Rear of Machine
r_256886_313539_1
G
F
r_256886_313539_4
66313540G
Technical Data
Technical Data
CategoryData
Maximum Fluid Working Pressure 3500 psi (24.1 MPa, 241 bar)
Fluid Inlets3/4 npsm union in 1 in. npt(f) ball valve
Fluid OutletsComponent 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 Ports1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum
Maximum Fluid Temperature190°F (88°C)
Maximum Output (10 weight oil at
ambient temperature)
Line Voltage Requirement230V 3 phase units: 195-264 Vac, 50/60 Hz
Amperage RequirementSee Models, page 3.
Heater Power
(A and B heaters total, no hose)
Hydraulic reservoir capacity3.5 gal. (13.6 liters)
Recommended hydraulic fluidCitgo A/W Hydraulic Oil, ISO Grade 46
Sound power, per ISO 9614-290.9 dB(A)
Sound pressure,
1 m from equipment
Weight955 lb (433 kg)
Wetted PartsAluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome,
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
313540G67
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2009, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 313540
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revised 01/2012
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