Graco 313540G User Manual

Page 1

Repair - Parts

H-VR

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.

313540G

U.S. Patent Pending Russian Patent No. 2359181

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Page 2

Contents

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

Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . 7

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . 7

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7

Keep Components A and B Separate . . . . . . . . . . 8

Foam Resins with 245 fa Blowing Agents . . . . . . . 8

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 8

Temperature Control Diagnostic Codes . . . . . . . . 9

E01: High fluid temperature . . . . . . . . . . . . . . . . 9

E02: High zone current . . . . . . . . . . . . . . . . . . . 10

E03: No zone current . . . . . . . . . . . . . . . . . . . . 10

E04: Fluid Temperature Sensor (FTS) or

thermocouple disconnected . . . . . . . . . . . . 11

E05: Circuit board overheated . . . . . . . . . . . . . 11

E06: Communication cable unplugged . . . . . . . 11

Motor Control Diagnostic Codes . . . . . . . . . . . . . 12

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

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

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

E24: Pressure imbalance . . . . . . . . . . . . . . . . . 13

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

E30: Momentary loss of communication . . . . . . 15

E31: Pumpline reversing switch failure/high cycle

rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

Change Hydraulic Fluid and Filter . . . . . . . . . . . 44

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Sub Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 57

Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 57

Hydraulic Directional Valve Assembly . . . . . . . . 59

7.65 kW Single Zone Heater . . . . . . . . . . . . . . . 60

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Temperature Control . . . . . . . . . . . . . . . . . . . . . 62

Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Circuit Breaker Modules . . . . . . . . . . . . . . . . . . 64

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 68

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 68

2 313540G

Page 3

Models

H-VR SERIES

Models

Part, Series

Full Load Peak Amps* Per Phase

Voltag e (phase)

System Watts†

Primary Heater Watts

Max Flow Rate◆ lb/min (kg/min)

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

Hydraulic Pressure Ratio

Maximum Fluid Working Pressure psi (MPa, bar)

256886 71 230V (3) 26,600 15,300 30 (13.6) Variable Variable 3500 (24.1, 241) 256887 41 400V (3) 26,600 15,300 30 (13.6) Variable Variable 3500 (24.1, 241)

* 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.

313540G 3

Page 4

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 Part Description

313539 Reactor H-VR Proportioner, Operation

Manual (English)

Reactor Electrical Diagrams Part Description

312064 Reactor Hydraulic Proportioner,

Electrical Diagrams (English)

Fluid Pump Part Description

313485 Pump Instructions-Parts Manual

(English)

Related Manuals

The following manuals are for accessories used with the

™

Reactor

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 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)

4 313540G

Page 5

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.

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Page 6

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.

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.

6 313540G

Page 7

Isocyanate Conditions

Moisture Sensitivity of

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

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

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

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

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.

313540G 7

Page 8

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.

8 313540G

Page 9

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.

Code Code Name Alarm

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

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

Zone

Individual

Corrective

Action page

9 10 10

11 11 11

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

313540G 9

Page 10

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.

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 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.

10 313540G

Page 11

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.

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.

313540G 11

Page 12

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 Name Alarm (A) or

Warning (W)

99 Loss of communication A

Corrective

Action

page

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

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

12 313540G

select, see page 32)

Corrective

Action

page

12 13

14 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.

Page 13

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

reduce pressure of higher component.

ti9877a

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

313540G 13

Page 14

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

reduce pressure of higher component.

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,

14 313540G

Page 15

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.

313540G 15

Page 16

Troubleshooting

Reactor Electronics

2. Turn main power OFF .

3. Allow equipment to cool.

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 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)

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 313540G

Page 17

Troubleshooting

PROBLEM CAUSE SOLUTION

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.

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.

313540G 17

Page 18

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.

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-

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

Dirty thermocouple connections. Examine connection of thermocou-

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.

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.

18 313540G

Page 19

Hose Heat System

Troubleshooting

2. Turn main power OFF .

3. Allow equipment to cool.

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

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

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.

313540G 19

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.

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 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.

20 313540G

Page 21

Hydraulic Drive System

Troubleshooting

2. Turn main power OFF .

3. Allow equipment to cool.

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

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

board.

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

Board, page 32.

313540G 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 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.

22 313540G

Page 23

Proportioning System

Troubleshooting

2. Turn main power OFF .

3. Allow equipment to cool.

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

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

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.

313540G 23

Page 24

Troubleshooting

PROBLEM CAUSE SOLUTION

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.

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.

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.

24 313540G

Page 25

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

Switch Disk

r_256886_313540_4

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.

313540G 25

Page 26

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

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.

26 313540G

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.

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.

ti9879a

5. Engage gun piston safety lock.

ti2409a

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

ti2554a

313540G 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

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.

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).

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28 313540G

Page 29

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.

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

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

IG. 3: Remove Guard

313540G 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:

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. Size Component

809 50A Hose/Transformer

Secondary Side

811 40A Transformer

Primary

812A 50A Heater A

812B 50A Heater B

813 20A Motor/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

30 313540G

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.

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.

313540G 31

Page 32

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

Switch ON (up) OFF (down)

Switch 1 Motor soft start ON

(factory default)

Switch 2 ON for pressure

imbalance alarm

(factory default)

(Not applicable to

3-phase motors)

OFF for pressure

imbalance warn-

ing

Switch 3 Standby ON Standby OFF

(factory default)

Switch 4 N/A OFF

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

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 Pumpline reversing switch

(1150-NC)

2 Pumpline reversing switch

(1160-T-COM)

3 Pumpline reversing switch

(1170-B-COM)

32 313540G

Page 33

Motor Control

1234

ti3178c-4

Repair

D11

D19 D20

J3 (A)

J8 (B)

J12

OFF

Apply 110009 thermal heatsink compound to mating surfaces.

FIG. 6. Motor Control Board

J14

SW2

J13

J18

ti7724a

313540G 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)

IG. 6,

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

IG. 7.

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

IG. 6, page

33.

706 (B Side)

701

FIG. 7. 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).

IG. 8.

720

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5. Remove fan.

6. Install fan in reverse order.

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FIG. 8. Fan Fuses

34 313540G

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;

Thermocouple (yellow)

SENSOR (B)

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. 9: Temperature Control Module Connections

313540G 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 above the ambi-

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 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.

36 313540G

8. Replace defective module.

9. Install assembly in reverse order.

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 page 60 for parts. Disconnect heater element wires from heater wire connector. Test with ohmmeter.

Total Heater

Wattage Element Ohms

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.

7,650 2550 18-21

313540G 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 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).

409

FIG. 10. Thermocouple

Apply PTFE tape and thread sealant.

410

Apply 110009 thermal heatsink compound.

405

401

407

408

ti7924a

38 313540G

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 (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

FIG. 11. Heated Hose

IG. 11.

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.

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 39.

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

313540G 39

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

IG. 11. Disconnect hose cable (F). Test with

ohmmeter between pins of cable connector.

Pins Result

1 to 2 approximately 10 ohms

1 to 3 infinity

3 to FTS groundscrew 0 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.

ISO

ti9581c

FIG. 12: Fluid Temperature Sensor and Heated Hoses

40 313540G

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

NOTE: Use this procedure to replace transformer.

1. Turn main power OFF . Disconnect power

supply.

2. Open Reactor cabinet.

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

809

IG. 13: Circuit Breaker Module

811

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

5. Remove transformer from cabinet.

6. Install new transformer in reverse order.

313540G 41

Page 42

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.

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).

42 313540G

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

502b

FIG. 14. Display Module

502a

501c

501a

501b

ti3172a

313540G 43

Page 44

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.

161c

FIG. 15. Y Strainer Components

* Fluid filter screen (within 161c) replacements:

Part Description

180199 20 mesh (standard); 1 pack 255082 80 mesh (optional); 2 pack 255083 80 mesh (optional); 10 pack 187758 Replacement gasket

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.

44 313540G

Page 45

Repair

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

135

ti9888a

110k

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.

313540G 45

Page 46

Repair

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 require-

ments:

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 313540G

Page 47

Parts

See page 52

107

See page 53

42▲

100

See page 50

See page 60

See page 53

ti9831a

313540G 47

Page 48

Parts

170

169

174

175

169

182

177

185, 186, 187

146

174

181

180

160

See page 49

104

105

168

106

171

162

172

173

163

177

165

See page 54

161

164

166

167

r_256886_313540_2

48 313540G

Page 49

Pump Assembly Overview

Parts

See page 57

See page 58

189

See page 57

191

188

182

190

198

199

182

192

193

183, 184

194

195, 196, 197

r_256886_313540_4

313540G 49

Page 50

Parts

Detail of Cabinet Area

102

See page 51

25, 147

54▲

TI9834a

50 313540G

Page 51

Parts

Left Side of Cabinet

8 (Ref)

103 (Ref)

Right Side of Cabinet

55, 56

TI9835a

TI9836a

313540G 51

Page 52

Parts

Detail, Fluid Manifold Area

717 (Ref)

111 (Ref)

Detail, Proportioner Area

151

7, see page 63

TI9838a

111 (Ref)

343

See page 59

52 313540G

Page 53

Parts

111 (Ref)

118 (Ref)

103

153

Detail, Electric Motor Area

ti7709a

Detail, Hydraulic Reservoir Area

135

114

129

See page 54

134

133

See page 50

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

313540G 53

1 (Ref)

TI9832b

Page 54

Parts

Ref. 161, Fluid Inlet Kit

161d

161a

161b

161d

Ref. 110, Hydraulic Reservoir

110f

161c

r_256886_313540_7

110m

110b

110c

110d

110j

110k

ti9840a

54 313540G

Page 55

Parts

Ref. Part Description Qty.

2 247813 HEATER 2 3 247785 MOTOR 1 4 245974 DISPLAY; see page 61 1 5 CONTROL, temperature; see page

62 6 247835 BOARD, circuit, motor control 1 7 247823 MANIFOLD, fluid; see page 63 1 8 247786 TRANSFORMER 1 9 247832 COVER, motor 1 10 246976 COVER, main cabinet 1 11 PUMP, proportioning; see page 59 1 13 115834 FAN, cooling 1 14 15X243 TUBE, inlet, component A 1 15 15R645 TUBE, outlet, component A 1 16 15X241 TUBE, inlet, component B 1 17 15R644 TUBE, outlet, component B 1 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, breaker; see page 64 1 27 116149 SPACER 4 29 117666 TERMINAL, ground 1 30 C19843 SCREW, CAP, socket hd 1 31 247841 SWITCH, disconnect 1 32 247842 KNOB, operator disconnect 1 33 117723 SCREW, mach, slotted hd 4 34 C20487 NIPPLE, hex 2 35 247502 COVER, heater wire 2 36 247843 BRACKET, heater 2 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 44 RIVET, pop; 3/16 in. (5 mm) x 0.4

in. (10 mm) 45▲ 189930 LABEL, caution 2 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 247846 COVER, heater 2 53 SCREW, machine, pan hd;

8-32 x 3/8 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

Ref. Part Description Qty.

60 111800 SCREW, cap, hex hd 35 62 247782 SPACER 4 63 247850 COVER, front 1 67 117284 GRILL, fan guard 1

68† 117553 SWITCH, added pole 1 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) 93 15T895 HOSE, supply 1

94 247784 TUBE, return 1 96 247853 ADJUSTER, belt, tensioner 1 97 15G816 COVER, plate, wire way 1 99 112125 PLUG, tube 2 100 247780 LABEL 1 102 15H189 BOOT, wire feed through 1 103 247790 CONDUIT, assembly, motor power 1 104 100560 SCREW, cap, hex hd; 3/8-16 4 105 100133 WASHER, lock; 3/8 in. 4 106 100731 WASHER; 3/8 in. 4 107 119253 SUPPRESSOR, ferrite; 151 ohm 1 110 247826 RESERVOIR, hydraulic; includes

110b-110m; see page 54 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 247819 BRACKET, mounting, pump 1

113 255019 PUMP, hydraulic 1 114 247821 BRACKET, reservoir, hydraulic 2 115 247820 BRACKET, support, pumpmount 1 116 247829 COOLER, hydraulic 1 117 255020 ELBOW; 1-1/16 npt(m) x 1/2 in. (13

mm) tube

313540G 55

Page 56

Parts

Ref. Part Description Qty.

118 247856 PULLEY, fan 1 119 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

mount 127 121320 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 116793 FITTING 1 139 107156 SCREW, cap socket head 3 142 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 2 160 PUMP, assy.; see page 57 1 161 255653 KIT, fluid inlet; each kit includes

161a-161d

161a VALVE, ball; 3/4 in. 1 161b NIPPLE, hex 1 161c Y-STRAINER 1

161d FITTING, union, swivel; 3/4 in. 2 162 KIT, skid 1 163 257543 KIT, caster; includes 4 casters 1 164 100060 SCREW, cap, hex hd 4 165 101044 WASHER, plain 4 166 100018 WASHER, lock, spring 4 167 100321 NUT 4 168 15W350 BRACKET 1 169 122400 ELBOW, bulkhead; #8 JIC 2 170 117502 REDUCER; #5 x #8 JIC 1 171✿ HOSE, moisture lock, assy., A; 3 ft. 1 172 122398 REDUCER; #6 x #8 JIC 1 173✿ HOSE, moisture lock, assy., B; 3 ft. 1 174 122401 ADAPTER, bulkhead; #8 JIC - #6

nptf 175 111856 ELBOW, street; 3/8-18 npt 1 176 155677 ADAPTER, union,90 deg.;

3/8 nptf x 3/8 npsm 177 15X244 HOSE, coupled; 5600 psi 2 180 15X710 GUARD 1 181▲ 15W800 LABEL, warning 1 182▲ 15W349 LABEL, caution, pinch point 16 183✖ PIN, base, fluid pump 2 184✖ PIN, hitch 14 185 15X743 HANDLE, round 2 186 GC2108 WASHER, lock, spring, #10 4

Ref. Part Description Qty.

187 GC2188 SCREW, socket hd 4 188 GC0530 LABEL, calibration, right 2 189 GC0531 LABEL, calibration, left 2 190 GC0541 KNOB, clamping 4 191 GC1196 FITTING, lube; 1/8 npt 1 192 GC1139 SHAFT, guard 1

193 GC1126 EXTENSION, standoff, hex; 1 in. x

2 in. 194 GC1137 SHAFT, cylinder, hydraulic 1 195 GC2109 WASHER, lock, spring; 1/4 in. 4 196 100270 SCREW, cap, hex hd 4 197 GC2042 WASHER, flat, fender; 1/4 in. 4 198 FRAME 1 199 15W005 WIRE, switch, cable 1

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

† Model 256887 only.

✿ Available with fluid hose kit 257791. ✖ Available with pin and bearing kit 257794. ★ Not shown.

56 313540G

Page 57

Sub Assemblies

Pump Assembly

Parts

Pump Detail

(A Side Pump Shown)

211

214

222

217 184

229

215

225

228

227

222

220

184

218

224 225

225

223

226

184

279

222

213

184

212

255

216

254

see manual 313485

Apply blue Loctite and torque to 250 ft-lbs (337.5 N•m).

Apply blue Loctite and torque to 15 ft-lbs (20.3 N•m).

238

273

280

275 or 276

274

r_256886_313540_5

313540G 57

Page 58

Parts

250

249

252

258

253

249

246

250

253

278

205

204

Air Motor Detail

251

265

247

271

208

272

Apply blue Loctite and torque to 250 ft-lbs (337.5 N•m).

Ref. Part Description Qty.

204 GC2041 WASHER, flat, std; 1/2 in. 8 205 GC2112 WASHER, lock, spring;1/2 in, 8 208 159239 NIPPLE, pipe 2 211 GC0518 YOKE, guide rod 1 212 GC0527 WASHER, flat 4 213✖ PIN, clevis; 1/2 in. 2 214 GC0419 WASHER, flat 4 215 GC0519 LINK, drive, pump 2 216 GC0521 BRACKET, pivot 2 217✖ PIN, clevis; 1/2 in. 2 218 GC0420 WASHER, flat 4 220 GC0520 ADAPTER, pump 2 222 GC1195 FITTING, lube; 1/4-28 6 223 GC0524 SCREW, adjustment;1/2-20 2 224 GC0421 WASHER, flat 4 225 GC0526 SHAFT, locking 10 226 GC0532 WHEEL, hand, aluminum 2 227 GC0536 STUD; 5/8-11 x 3 in. 2 228 GC0912 SPACER; 1 5/16 in. diameter,

9/16 in. 229 GC0535 HANDLE 2 238 157191 FITTING, adapter (1/2 npt x 3/4

npt) 241 GC1147 PUMP, assy., fluid 2 246 15X709 PLATE, change over, bottom 1 247 GC1132 EXTENSION, stndoff, change over 4 249 GC2107 WASHER, lock, spring; #8 10

r_256886_313540_8

Ref. Part Description Qty.

250 GC2194 SCREW, shdc; SST, 0.164-32 x

0.0750 SST

251 GC2118 SCREW, rdhd; CS,0.164-32 x

0.750 zp 252 15X708 GUARD, change over box 2 253 GC2052 WASHER, flat, std; #8 8 254 15W983 DISK, switch 1 255✖ PIN, 2.75 in. base, fluid pump 2 256 GC1137 SHAFT, cylinder, hydraulic 1 258 15W340 BRACKET, limit switch 1 265 15X711 PLATE, change over, top 1 271 111856 ELBOW, street 1 272 155677 ADAPTER, union, 90 deg 1 273 108126 FITTING, tee, street 2 274 248187 HOUSING, rupture, disc 2 275 117832 ADAPTER; 9/16-18 JIC x 3/8 npt 1 276 122406 ADAPTER; 1/2-20 JIC x 3/8 npt 1 278 192348 NUT, head 4

279✖ PIN, clevis; 1/2 in. 2 280 100081 BUSHING, pipe 2

✖ Available with pin and bearing kit 257794.

58 313540G

Page 59

Hydraulic Directional Valve Assembly

308

Parts

345

340

326

341

306

327

307

342

322

304

343

321

305

313

314

309

347

Proportioner Assembly

Ref. Part Description Qty.

304 106258 O-RING 2 305 298040 MANIFOLD, hydraulic 1 306 113467 SCREW, socket head 4 307 120299 VALVE, directional, hydraulic 1 308 C19986 SCREW, socket head 4 309 247817 BRACKET, mounting 1 313 100214 WASHER, lock 4 314 108751 SCREW, socket head 4 321 158683 ELBOW, 90 deg. 1 322 100206 BUSHING, pipe 1 326 121312 ELBOW; 3/4 SAE x 1/2 JIC 1 327 295225 PLUG, pipe, flush 2

344

346

r_256886_313540_6

Ref. Part Description Qty.

340 255037 ELBOW; 3/4 nptf 1 341 255038 CONNECTOR 1 342 15H184 WIRE, bi-directional cable, assy. 1 343 15H253 HOSE, gauge, hydraulic, 3000 psi 1 344 121309 CONNETOR; 3/4 SAE x 1/2 JIC 2 345 15W003 BLOCK, port 2 346 15X237 BRACKET, shroud 1 347 111800 SCREW, cap, hex hd 2

313540G 59

Page 60

Parts

7.65 kW Single Zone Heater

(Two Per Machine)

Part 247813

404

413

403

414

406

405

410

401

413

411

408

404

409

407

r_247813_312063

415

Apply 110009 thermal heatsink compound.

Ref. Part Description Qty

401 HOUSING, heater 403 121309 ADAPTER, 3/4 SAE-ORB x

1/2 in. JIC 404 15H304 PLUG 405 15H306 ADAPTER, thermocouple 406 120336 O-RING; fluoroelastomer 407 15B138 HEATER, immersion; 2550 W 408 15B137 SWITCH, overtemperature 409 15B135 MIXER, immersion heater

60 313540G

Ref. Part Description Qty

410 117484 SENSOR

411 100518 SCREW, machine, pan hd

413 15H305 PLUG, hollow 414 295607 PLUG, not shown

415 124132 O-RING

1 1 3 1 3

1 2 5 1 3

Page 61

Display

502

503

Parts

511

504

507

506

502b

508

505

506

501

510

512

20 (Ref)

ti2574a

502c502a

501c

501a

501b

Ref. Part Description Qty.

501 245978 DISPLAY, pressure; includes

501a-501c 501a 246130 .BOARD, circuit 501b 246478 .SWITCH, membrane 501c 112324 .SCREW 502 245977 DISPLAY, temperature; includes

502a-502c 502a 246130 .BOARD, circuit 502b 246479 .SWITCH, membrane 502c 112324 .SCREW 503 15B293 GASKET 504 15B292 COVER

313540G 61

Ref. Part Description Qty.

505 15B291 PLATE

506 246287 HARNESS, wire, red stop button 507 117499 HANDLE

508 117523 NUT, cap; 10-24

510 SCREW, machine, pan-hd; M5 x

4 1

0.8; 16 mm 511 15B386 CABLE, display 512 195853 SCREW, machine; M2.5 x 6

1 1 4 1 1

ti3172a

1 1 2 8 4

1 2

Page 62

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

Ref. Part Description Qty.

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

62 313540G

1 1 3 4 1 1

Page 63

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 Qty.

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 24K999 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

716

707

714

717

Ref. Part Description Qty.

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

▲ 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

313540G 63

Page 64

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

64 313540G

Page 65

Circuit Breaker Modules Parts List

Ref. Description

801 RAIL, mounting

802 CLAMP, block, end

Breaker Modules

230V, 3 phase B400V, 3 phase

255028 255028 1

255045 255045 1

Parts

Qty

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

811 BREAKER, 2 phase, 40A

812 BREAKER, 2 phase, 50A

813 BREAKER, 3 pole, 20A

814 CONNECTOR, power lug

815 BAR, power buss, 3 phase, 3x3

816 CABLE, harness lower

817 CABLE, harness upper

818 CONNECTOR, 2 pin large

819 CONNECTOR, 3 pin

255043 255043 2

255023 255023 2

255042 255042 4

255044 255044 2

255046 255046 1

255026 255026 1

255022 255022 2

247768 247768 1

120579 120579 2

255025 255025 1

117679 3

255024

247803 247803 1

247808 247807 1

255027 255027 3

120895 120895 1

820 CONNECTOR, 4 pin

821 CONNECTOR, 2 pin small

822 CABLE, harness, hose wire

313540G 65

255031 255031 1

255030 255030 1

247791 247791 1

Page 66

Dimensions

Dimension in. (mm)

A (height) 57.3 (1455.4) B (width) 37.9 (961.6) C (depth) 33.0 (838.2)

Dimension in. (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)

Top View

Front of Machine

Rear of Machine

r_256886_313539_1

r_256886_313539_4

66 313540G

Page 67

Technical Data

Category Data

Maximum Fluid Working Pressure 3500 psi (24.1 MPa, 241 bar) Fluid Inlets 3/4 npsm union in 1 in. npt(f) ball valve 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) Line Voltage Requirement 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 90.9 dB(A) Sound pressure,

1 m from equipment Weight 955 lb (433 kg) Wetted Parts Aluminum, stainless steel, zinc-plated carbon steel, brass, carbide, chrome,

3.0 gpm (11.4 liter/min) (60 Hz)

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

See Models, page 3.

84.0 dB(A)

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.

313540G 67

Page 68

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

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

Graco 313540G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual