Graco 313540G User Manual

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
EN
U.S. Patent Pending Russian Patent No. 2359181
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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
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
Supplied Manuals
Supplied Manuals
The following manuals are used with the Reactor™ HV-R Proportioner. Refer to these manuals for detailed equipment information.
Order Part 15M334 for a compact disk of Reactor manu­als.
Reactor Hydraulic Proportioner 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
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama­tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
Turn off and disconnect power cord before servicing equipment.
Use only grounded electrical outlets.
Use only 3-wire extension cords.
Ensure ground prongs are intact on power and extension cords.
Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swal­lowed.
Read MSDS’s to know the specific hazards of the fluids you are using.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
Always wear impervious gloves when spraying or cleaning equipment.
If this equipment is used with isocyanate material, see additional information on isocyanates in Isocy­anate Conditions Section of this manual.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:
Protective eyewear
Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
Hearing protection
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
Do not point gun at anyone or at any part of the body.
Do not put your hand over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Do not spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.
313540G 5
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:
Use equipment only in well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
Keep work area free of debris, including solvent, rags and gasoline.
Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.
Ground all equipment in the work area.
Use only grounded hoses.
Hold gun firmly to side of grounded pail when triggering into pail.
If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.
Keep a working fire extinguisher in the work area.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.
OR
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system com­ponent. See Technical Data in all equipment manuals.
Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu­facturer’s replacement parts only.
Do not alter or modify equipment.
Use equipment only for its intended purpose. Call your distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or over bend hoses or use hoses to pull equipment.
Keep children and animals away from work area.
Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.
Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
Do not touch hot fluid or equipment.
Wait until equipment/fluid has cooled completely.
6 313540G
Isocyanate Conditions
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
Keep Components A and B Separate
Keep Components A and B Separate
NOTICE
To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocy­anate) and component B (resin) parts.
Foam Resins with 245 fa Blowing Agents
Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.
Changing Materials
When changing materials, flush the equipment mul­tiple times to ensure it is thoroughly clean.
Always clean the fluid inlet strainers after flushing.
Check with your material manufacturer for chemical compatibility.
Most materials use ISO on the A side, but some use ISO on the B side.
Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.
8 313540G
Temperature Control Diagnostic Codes
Temperature Control Diagnostic Codes
Temperature control diagnostic codes appear on tem­perature display.
These alarms turn off heat. E99 clears automatically when communication is regained. Codes E03 through
E06 can be cleared by pressing . For other codes,
turn main power OFF then ON to clear.
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
Individual
Corrective
Action page
9 10 10
11 11 11
15
E01: High fluid temperature
Causes of E01 Errors
Thermocouple A or B (310) senses a fluid tempera­ture above 230°F (110°C).
Fluid temperature sensor (FTS) senses a fluid tem­perature above 230°F (110°C).
Overtemperature switch A or B (408) senses a fluid temperature above 230°F (110°C) and opens. At 190°F (87°C) the switch closes again.
Thermocouple A or B (410) fails, is damaged, is not touching the heater element (407), or has a poor connection to the temperature control board.
Overtemperature switch A or B (408) fails in the open position.
The temperature control board fails to turn off any heat zone.
Zone power wires or thermocouples are switched from one zone to another.
Failed heater element where thermocouple is installed.
Checks
Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a quali­fied electrician perform all electrical troubleshooting. Be sure to shut off all power to the equipment and relieve all pressure (see Pressure Relief Procedure, page 27) before repairing.
Check which zone is displaying the E01 error.
1. Check that connector B is firmly plugged into tem­perature control module (see F
2. Clean and re-plug connections.
3. Check connections between the temperature control module and overtemperature switches A and B (308), and between temperature control module and thermocouples A and B (410) or FTS (21) [depend­ing on which zone is displaying E01]. See T page 35. Ensure that all wires are securely con­nected to connector B.
IG. 9, page 35).
ABLE 6,
Loose wire
313540G 9
Temperature Control Diagnostic Codes
4. Remove connector B from temperature control mod­ule, and check continuity of overtemperature switches A and B, thermocouples A and B, or FTS by measuring resistance across the pins on the plug end; see T
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
Temperature Control Diagnostic Codes
E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected
1. Check temperature sensor connections to long green connector (B) on temperature control module, page 34. Unplug and re-plug sensor wires.
2. Test fluid temperature sensor continuity with ohm­meter, page 9.
3. If an error occurred for the hose zone, check FTS connections at each section of hose.
4. If an error occurred for the hose zone, test FTS by plugging directly into machine.
F
ti9878a
E05: Circuit board overheated
NOTE: Each module has an on-board temperature sensor. Heat is turned off if module temperature exceeds 185°F (85°C) within the heater module.
1. Check that fan above electrical cabinet is operating.
2. Check that electrical cabinet door is properly installed.
3. Check for obstructions blocking cooling holes in bot­tom of electrical cabinet.
4. Clean heatsink fins behind heater control modules.
5. Ambient temperature may be too high. Allow Reac­tor to cool by moving to a cooler location.
E06: Communication cable unplugged
1. Unplug and re-plug cable that connects heater con­trol module to heater module.
5. To verify heater control module is not causing the problem, use a wire to short-circuit the two pins cor­responding to the FTS (red and yellow for A or B zone, red and purple for hose). The display will show the control heater module temperature.
6. If an error occurred for the hose zone, temporarily use the current control mode. Refer to Reactor H-VR Operation manual 313539.
2. Replace communication cable if problem persists.
313540G 11
Motor Control Diagnostic Codes
Motor Control Diagnostic Codes
Motor control diagnostic codes E21 through E27 appear on pressure display.
There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings.
Alarms
Alarms turn off Reactor. Turn main power OFF
then ON to clear.
NOTE: Alarms can also be cleared, except for code
23, by pressing .
Warnings
Reactor will continue to run. Press to clear. A
warning will not recur for a predetermined amount of time (varies for different warnings), or until main power
Code Code Name Alarm (A) or
Warning (W)
99 Loss of communication A
Corrective
Action
page
15
E21: No component A transducer
1. Check transducer A connection at J3 on motor con­trol board, page 33, and clean contacts.
2. Reverse A and B transducer connections. If error moves to transducer B (E22), replace transducer A, page 12. If error does not move, replace motor con­trol board, page 32.
E22: No component B transducer
1. Check transducer B connection at J8 on motor con­trol board, page 33, and clean contacts.
2. Reverse A and B transducer connections. If error moves to transducer A (E21), replace transducer B, page 12. If error does not move, replace motor con­trol board, page 32.
is turned OFF then ON .
E23: High fluid pressure
1. Relieve pressure. Verify low pressure with analog
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
A
A
select, see page 32)
A
A
Corrective
Action
page
12
12
12 13
14 15
15
gauges. Turn main power OFF then ON
. If error persists, do checks below.
2. If pressure imbalance is set to Warning instead of Alarm (see page 32), an E23 will occur. See E24: Pressure imbalance for causes and checks.
3. Ensure at least one pump is in the number 1 posi­tion. See Setup section of Reactor H-VR Operation manual 313539.
4. If error still persists, reduce hydraulic pressure.
Motor Control Diagnostic Codes
E24: Pressure imbalance
NOTE: Upon initial start-up this diagnostic code will not cause an alarm for 2 minutes.
NOTE: If the pressure difference between compo­nents A and B exceeds 500 psi (3.5 MPa, 35 bar), an E24 will occur. This default value is adjustable; see the operation manual.
NOTE: If spraying at a ratio other than 1:1, an E24 may occur. Size hoses and mix chamber appropri­ately to avoid pressure imbalance.
NOTE: E24 can be an alarm or a warning, as desired. Set DIP switch on motor control board ON for alarm, OFF for warning. See page 32.
Fast E24 Errors
Fast E24 errors occur:
within 10 seconds of turning the pumps on, or
as soon as you trigger the gun.
Causes of Fast E24 Errors
one side of the gun is plugged.
a pressure transducer has failed.
damaged pump seals or check valve.
no feed pressure or empty material drum.
plugged heater.
plugged hose.
plugged manifold.
one PRESSURE RELIEF/SPRAY valve is leaking or
is set to PRESSURE RELIEF/CIRCULATION .
Checks for Fast E24 Errors
NOTE: If a fast E24 error occurs, first check the readings of the analog gauges.
If the gauge readings are very close:
1. Clear the error (page 12) and try running the unit again.
2. If E24 recurs and the gauge readings are still very close, a pressure transducer has failed.
The digital display always shows the higher of the two pressures. As soon as the higher analog pres­sure drops below the lower analog pressure, the dis­play changes to the new higher reading. Knowing this, the following checks will show which transducer has failed, or if the motor control board has failed.
3. For testing purposes only, set DIP switch 2 on the motor control board to OFF. See page 32. This will allow the Reactor to continue to run with a pressure imbalance.
c. Run the unit until pressure is 1000-1500 psi
(7-10.5 MPa, 70-105 bar). Shut down the unit, clear the alarm, and power back up, but do not depressurize the unit.
d. Check the analog gauges to see which pressure
is higher, and check if the display matches.
If the higher gauge and display match, that transducer is communicating with the motor control board. Continue with step e.
If the higher gauge and display do not match, that transducer is not communicating
with the motor control board. Check wire con­nections and replace transducer, page 34.
e. Turn pumps off. Reduce pressure of higher com-
ponent by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward
PRESSURE RELIEF/CIRCULATION , while watching the display and the analog gauges. As soon as the higher analog pressure drops below the lower analog pressure, the dis­play should change to the new higher reading. Continue reducing the original higher pressure an additional 200 psi (1.4 MPa, 14 bar); digital display should stop dropping.
f. Repeat for the other side, to check the other
transducer.
Turn valve slightly to
1
reduce pressure of higher component.
1
ti9877a
4. To test if the failure is with the transducer or the socket on the motor control board:
313540G 13
Motor Control Diagnostic Codes
a. Reverse connections at J3 and J8 on the motor
control board.
b. Run the unit until pressure is 1000-1500 psi
(7-10.5 MPa, 70-105 bar).
c. If the problem stays on the same side as before,
replace the motor control board. If the problem appears to move to the other side, replace the transducer.
If the gauge readings are not very close:
1. Secure bleed lines in grounded waste containers, or route back to respective component A or B supply drum. Reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE
RELIEF/CIRCULATION , until gauges show balanced pressures.
Turn valve slightly to
1
reduce pressure of higher component.
1
ti9877a
b. Check and clean the gun mix chamber impinge-
ment ports and center port. See gun manual.
NOTE: Some mix chambers have counter bored impingement ports, requiring two drill sizes to clean completely.
Slow E24 Errors
Slow E24 errors occur gradually. The pressures are bal­anced when you begin spraying, but slowly become imbalanced until an E24 occurs.
NOTE: If spraying at a ratio other than 1:1, an E24 may occur. Size hoses and mix chamber appropri­ately to avoid pressure imbalance.
Causes of Slow E24 Errors
one side of the gun is partially plugged.
the A or B proportioner pump has failed.
the A or B feed pump has failed.
the A or B feed pump pressure is set too high.
the hose is not heating properly.
kinked supply hose.
bottom of drum is damaged, causing blockage of feed pump inlet.
drum is not vented.
NOTE: Turn PRESSURE RELIEF/SPRAY valve only enough to balance pressure. If you turn it com­pletely, all pressure will bleed off.
2. If you cannot get the pressures to balance:
a. Check for damaged pump seals or check
valves.
b. Check if you’ve run out of material.
c. Check for a plugged fluid path by using the feed
pump to push fluid through the gun manifold.
3. If you are able to balance pressures, try running the unit.
4. If a fast E24 error occurs again, and the gauges readings are not very close:
a. Check and clean the gun inlet screens.
E27: High motor temperature
Causes of E27 Errors
Motor temperature is too high. Reduce pressure, gun tip size, or move Reactor to a cooler location. Allow 1 hour for cooling.
Make sure there is no obstruction to fan airflow. Ensure that the motor/fan shroud is installed.
Check that the motor overtemperature wire assem­bly is plugged into J9 on the motor control board, page 33.
If the preceding checks do not correct the problem, perform the following tests:
1. Turn main power OFF .
2. Allow motor to cool completely. Check continuity between pins 1 and 2 on connector J9 on the motor control board, page 32. If the resistance is infinity,
14 313540G
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
Troubleshooting
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
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
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-
Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and con­trols are properly set and wiring is correct before assum­ing there is a problem.
Press or zone
keys.
nostic code, page 9.
sor (FTS) or thermocouple discon­nected, page 11.
ples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector.
A
B
Thermocouple not contacting heater element.
Failed heater element. See Primary Heaters, page 18. Signal failure from thermocouple. See E04: Fluid Temperature Sen-
Thermocouple wired incorrectly. See E04: Fluid Temperature Sen-
Loosen ferrule nut (N), push in ther­mocouple (410) so tip (T) contacts heater element (407). Holding ther­mocouple tip (T) against heater ele­ment, tighten ferrule nut (N) 1/4 turn past tight. See page 38 for illustra­tion.
sor (FTS) or thermocouple discon­nected, page 11.
sor (FTS) or thermocouple discon­nected, page 11. Power up zones
one at a time and verify that tempera­ture for each zone rises.
18 313540G
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
Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and con­trols are properly set and wiring is correct before assum­ing there is a problem.
significantly reduces power available to hose heat system, affecting longer hose lengths.
designed to maintain temperature, not to increase it.
increase fluid temperature and keep it steady.
pressure.
perature before spraying.
significantly reduces power available to hose heat system, affecting longer hose lengths.
A and/or B heaters are overheating material.
Faulty thermocouple connections. Verify that all FTS connections are
Hose temperature exceeds setpoint.
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.
Troubleshooting
PROBLEM CAUSE SOLUTION
Erratic hose temperature.
Faulty thermocouple connections. Verify that all FTS connections are
snug and that pins of connectors are clean. Examine connection of ther­mocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector.
FTS not installed correctly. FTS should be installed close to end
of hose in same environment as gun. Verify FTS installation, page 39.
Hose does not heat.
Hoses near Reactor are warm, but hoses downstream are cold.
FTS failed or is not contacting
Check FTS, page 39.
correctly.
FTS not installed correctly. FTS should be installed close to end
of hose in same environment as gun. Verify FTS installation, page 39.
Temperature control alarm. Check temperature display or diag-
nostic code, page 39.
Shorted connection or failed hose heating element.
With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between connectors at each section of hose.
Voltage should drop incrementally for each section of hose further from Reactor. Use safety precautions when hose heat is turned on.
20 313540G
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
Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and con­trols are properly set and wiring is correct before assum­ing there is a problem.
board.
Breaker Module, page 30. Check 230 Vac at output of breaker.
Board, page 32.
313540G 21
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
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
Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and con­trols are properly set and wiring is correct before assum­ing there is a problem.
1. Observe gauges to determine which pump is losing pressure.
2. Determine in which direction the pump has stalled by observing which directional valve indicator light is on. See Table 2, page 25 to isolate the problem.
3. Repair the valve; see pump man­ual 313485.
Reverse Direction, page 26.
Increase fluid supply to proportioning pump:
Pressure relief/circulation valve leak­ing back to supply.
Spraying at a ratio other than 1:1 can cause pressure imbalance.
Use 2:1 supply pump
Use minimum 3/4 in. (19 mm) ID supply hose, as short as practical
Fluid is too thick. Consult your mate­rial supplier for the recommended fluid temperature to maintain a vis­cosity of 250 to 1500 centipoise.
Worn pump inlet valve ball/seat or gasket. Replace; see pump manual
313485.
Remove return line and determine if flow is present while in SPRAY
mode.
Size hoses and mix chamber appro­priately.
313540G 23
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
Ratio Lock Handle
Troubleshooting
B Pump Arm
B (Resin) Proportioning Pump
Change Over Box
Hydraulic Cylinder
A Pump Arm
Ratio Adjustment Wheel
A (ISO) Proportioning Pump
Reversing Switches
3
1
2
1
2
3
Switch Disk
r_256886_313540_4
F
IG. 1. Pump Line when viewed from rear of machine
Table 2. Directional Valve Indicator Status
Left Pump Directional
Indicator Lighted
B-side pump piston valve
dirty or damaged
A-side pump inlet valve
dirty or damaged
Right Pump Directional
Indicator Lighted
B-side pump inlet valve
dirty or damaged
A-side pump piston valve
dirty or damaged
Pressure/Material Imbalance
To determine which component is out of balance, check the color of some sprayed material. Two-component materials are usually a mix of light and dark fluids, so the under-proportioned component can often be readily determined.
When you have determined which component is under-proportioned, spray off-target, focusing on the pressure gauge for that component.
For example: if component B is under-proportioned, focus on the B-side pressure gauge. If the B gauge reads considerably higher than the A gauge, the prob­lem is at the gun. If the B gauge reads considerably lower than the A gauge, the problem is at the pump.
313540G 25
Troubleshooting
Pumps Do Not Reverse Direction
1. For the proportioning pumps to reverse direction, the switch disk must contact the reversing switches. Ensure that the change over box is assembled cor­rectly and that none of the components are dam­aged. See F
2. Check the function of the directional valve. Direction indication lights should switch on and off based on the position of the reversing switches (199). LEDs D19 and D20 (near J5 reversing switch connector on motor board, see F nate when each switch is activated.
r_256886_313540_1
Directional Valve
F
IG. 2: Hydraulic Directional Valve Assembly
IG. 1 (page 25) and Parts (page 58).
IG. 6) should alternately illumi-
verify reversing switches. Unplug the J5 reversing switch connector. Verify that when the switches are not triggered there is conti­nuity between 1150-NC and 1160-T-COM, and between 1150-NC and 1170-B-COM.
Toggle reversing switches. Ensure that con­tinuity between 1150-NC and 1160-T-COM, and between 1150-NC and 1170-B-COM is lost. Refer to the Electrical Diagrams man­ual 312064 (Detailed Schematic, Motor Controls (3-Phase Motor)). If these four conditions are not verified, replace revers­ing switches.
if the reversing switch and wiring are not the cause, and D19 and D20 will not alternately illuminate, replace the motor board.
b. If D19 and D20 do illuminate but the direction
indication lights do not, the possible causes include:
faulty motor board,
faulty directional valve wiring, or
faulty directional valve.
There are two possible problems with the directional valve:
a. If D19 and D20 do not alternately illuminate, the
possible causes include:
faulty reversing switch wiring,
faulty reversing switch, or
faulty motor board.
To resolve this problem:
verify that the reversing switch cable is con­nected at the bulkhead bracket and that it is plugged into the J5 connector on the motor board.
To resolve this problem:
verify the motor board output voltages at the J18 directional valve connector. When the reversing switch is toggled one direction, there should be 230V output between pins 1 and 2 (A+ and A-). When it is toggled the other direction, there should be 230V output between pins 3 and 4 (B+ and B-). If output voltages are not present, replace the motor board.
verify continuity of each directional valve wire and verify wiring connections (see Electrical Diagrams manual 312064).
if motor board and wiring are not the cause, replace the directional valve.
NOTE: For diagnostic purposes, it is possible to manually override the directional valve by using a small screwdriver to depress the button in the cen­ter of either directional valve end cap.
26 313540G
Repair
Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified elec­trician connect power and ground to main power switch terminals, see operation manual. Be sure to shut off all power to the equipment before repairing.
Repair
Pressure Relief Procedure
1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual.
2. Close gun fluid manifold valves A and B.
ti2421a
3. Shut off feed pumps and agitator, if used.
4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)
to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure
gauges drop to 0.
SB
SA
ti9879a
5. Engage gun piston safety lock.
ti2409a
6. Disconnect gun air line and remove gun fluid mani­fold.
ti2554a
313540G 27
Repair
Flushing
Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents.
Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid.
Use the lowest possible pressure when flushing.
All fluid components are compatible with common solvents. Use only moisture-free solvents.
To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION . Flush through bleed lines (N).
SA
SB
Proportioning Pumps
To avoid injury and damage to pump arms and ratio adjustment screws, relieve all pressure and shut off all power before repairing proportioning pumps.
NOTE: See manual 313485 for pump repair instruc­tions.
1. Shut off , , and heat zones.
2. Flush, page 28.
3. If pumps are not parked, press . Trigger gun
until pumps stop.
4. Turn main power OFF . Disconnect power
supply.
A
B
N
N
ti9880a
To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).
To prevent moisture from reacting with isocyanate, always leave the system dry or filled with a mois­ture-free plasticizer or oil. Do not use water.
5. Shut off both feed pumps. Close both fluid inlet ball valves (B).
B
ti10971a
28 313540G
Repair
6. Turn both PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0.
SB
SA
ti9879a
NOTE: Use a drop cloth or rags to protect Reactor H-VR and surrounding area from spills.
7. Remove guard. Loosen all four clamping knobs (190), and remove guard (180).
8. Disconnect all fluid hoses connected to pumps.
9. Remove pump base pin (183) and top pin (255) on both pumps. See page 57.
183
F
IG. 4: Remove Pump Pins
184
r_256886_313539_7
10. Remove pump assemblies and take to a workbench.
To avoid injury, never remove guard unless all pres­sure is relieved and all power is shut off.
r_256886_313539_6
180
190
11. See manual 313485 for pump repair instructions.
12. Reconnect pump in reverse order
NOTE: Insert pump top pin (255) before base pin (183) when reconnecting pump.
13. Replace guard (180) and tighten all four clamping knobs (190). Ensure warning label on guard faces outward on machine.
190
F
IG. 3: Remove Guard
313540G 29
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
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
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
Motor Control
ON
1234
ti3178c-4
Repair
J5
D11
1
D19 D20
J3 (A)
J8 (B)
J9
ON
J12
OFF
1
Apply 110009 thermal heatsink compound to mating surfaces.
FIG. 6. Motor Control Board
J1
J14
SW2
J13
J7
J18
J4
ti7724a
313540G 33
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
ti9885a
5. Remove fan.
6. Install fan in reverse order.
F
ti9884a-1
FIG. 8. Fan Fuses
34 313540G
Temperature Control Module
Repair
Table 6: Temperature Control Module Connections
Connector Description
DATA (A) Data reporting
PIN
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
A
H
B
C
ti9875a
D
E
F
G
ti9843a1
Right Side of
Control Heater Module
J
ti9843a4
Bottom of Power Modules
FIG. 9: Temperature Control Module Connections
313540G 35
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.
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
Repair
Thermocouple
1. Turn main power OFF . Disconnect power
supply.
2. Relieve pressure, page 27.
3. Wait for heaters to cool.
4. Remove heater shroud.
5. Disconnect thermocouple wires from B on tempera­ture control module. See T 9, page 35.
6. Feed thermocouple wires out of cabinet. Note path as wires must be replaced in the same way.
7. See F
IG. 10. Loosen ferrule nut (N). Remove ther-
mocouple (410) from heater housing (401), then remove thermocouple housing (H). Do not remove the thermocouple adapter (405) unless necessary. If adapter must be removed, ensure that mixer (409) is out of the way when replacing the adapter.
ABLE 6, page 35 and FIG.
8. Replace thermocouple, F
IG. 10.
a. Remove protective tape from thermocouple tip
(T).
b. Apply PTFE tape and thread sealant to male
threads and tighten thermocouple housing (H) into adapter (405).
c. Push in thermocouple (410) so tip (T) contacts
heater element (407).
d. Holding thermocouple (T) against heater ele-
ment, tighten ferrule nut (N) 1/4 turn past tight.
9. Route wires (S) into cabinet and thread into bundle as before. Reconnect wires to board.
10. Replace heater shroud.
11. Turn on heaters A and B simultaneously to test. Temperatures should rise at same rate. If one heater is low, loosen ferrule nut (N) and tighten ther­mocouple housing (H) to ensure thermocouple tip (T) contacts element (407).
S
409
FIG. 10. Thermocouple
1
Apply PTFE tape and thread sealant.
410
2
Apply 110009 thermal heatsink compound.
N
H
1
405
401
407
2
408
T
ti7924a
38 313540G
Repair
Overtemperature Switch
1. Turn main power OFF . Disconnect power
supply.
2. Relieve pressure, page 27.
3. Wait for heaters to cool.
4. Remove heater shroud.
5. Disconnect one leadwire from overtemperature switch (408), F meter. Resistance must be approximately 0 ohms.
6. If switch fails test, remove wires and screws. Dis­card failed switch. Apply thermal compound 110009, install new switch in same location on housing (401), and secure with screws (411). Reconnect wires.
IG. 10. Test across switch with ohm-
5. If hose fails test, retest at each length of hose, including whip hose, until failure is isolated.
Check FTS Cables
1. Turn main power OFF . Disconnect power
supply.
2. Relieve pressure, page 27.
3. Disconnect FTS cable (F) at Reactor, F
F
FIG. 11. Heated Hose
IG. 11.
D
ti9878a
NOTE: If wires need replacement, disconnect from temperature control board. See T F
IG. 9, page 35.
ABLE 6, page 35 and
Heated Hose
NOTE: Refer to the heated hose manual 309572 for hose replacement parts.
Check Hose Connectors
1. Turn main power OFF . Disconnect power
supply.
2. Relieve pressure, page 27.
NOTE: Whip hose must be connected.
3. Disconnect hose connector (D) at Reactor, F
IG. 11.
4. Test with ohmmeter between pins of cable connec­tor.
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
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.
D
K
ISO
B
A
H
C
B
W
A
L
ti9581c
FIG. 12: Fluid Temperature Sensor and Heated Hoses
40 313540G
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
F
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
Repair
Display Module
Temperature and Pressure Displays
NOTICE
Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap.
1. Turn main power OFF . Disconnect power
supply.
2. Relieve pressure, page 27.
3. Refer to electrical diagrams.
4. Put on static conductive wrist strap.
5. Disconnect main display cable (20) at lower left cor­ner of display module; see F
6. Remove screws (509, 510) and cover (504); see F
IG. 14.
IG. 14.
Red Stop Button
NOTICE
Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap.
1. Turn main power OFF . Disconnect power
supply.
2. Relieve pressure, page 27.
3. Refer to electrical diagrams.
4. Put on static conductive wrist strap.
5. Remove screws (509, 510) and cover (504), F
6. Disconnect button cable connectors (506) from back of temperature display (501) and pressure display (502).
7. Remove red stop button (506).
8. Reassemble in reverse order. Be sure display cable ground wire (G) is secured between cable bushing and cover (504) with screws (512).
IG. 14.
If replacing both displays, label temperature display cables TEMP and pressure display cables PUMP before disconnecting.
7. Disconnect cable connectors (506 and 511) from back of temperature display (501) or pressure dis­play (502); see F
IG. 14.
8. Disconnect ribbon cable(s) (R) from back of display; see F
IG. 14.
9. Remove nuts (508) and plate (505).
10. Disassemble display, see detail in F
IG. 14.
11. Replace board (501a or 502a) or membrane switch (501b or 502b) as necessary.
12. Reassemble in reverse order, see F
IG. 14. Apply
medium strength thread sealant where shown. Be sure display cable ground wire (G) is secured between cable bushing and cover (504) with screws (512).
42 313540G
1
Apply medium strength thread sealant.
Repair
G
511
511
502
503
504
507
510
506
512
20
501
508
1
505
506
Detail of Membrane Switches and Display Boards
Temperature Display Pressure Display
1
502c
1
ti2574a
502b
R
FIG. 14. Display Module
502a
501c
1
501a
R
501b
ti3172a
313540G 43
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
C
D
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
A*
B
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
Repair
3. Place a pan under reservoir drain plug (110k) to catch oil.
135
ti9888a
110k
F
IG. 16: Change Hydraulic Fluid and Filter
4. Remove drain plug (110k).
5. Place a rag around base of oil filter (135) to prevent oil from spilling. Unscrew filter 1/4-3/4 turn to break air lock in filter. Wait five minutes to allow oil in filter to drain back into reservoir. Unscrew filter and remove.
6. Reinstall drain plug (110k).
7. Replace filter (135):
a. Coat filter seal with fresh oil.
b. Screw filter on snug, then an additional 1/4 turn.
8. Refill reservoir with approved hydraulic fluid. See Table 9.
9. Proceed with normal operation.
NOTE: Upon starting motor, hydraulic pump may make a screeching noise until primed. If this noise continues for more than 30 seconds, switch off motor control. See Hydraulic Drive System, page 21.
313540G 45
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
Parts
Parts
52
60
See page 52
See page 52
84
38
4
107
See page 53
99
20
30
60
42
9
37
77
37
84
60
67
44
76
44
100
60
63
See page 50
See page 60
60
See page 53
52
ti9831a
313540G 47
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
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
Parts
Detail of Cabinet Area
36
35
51
85
102
23
97
102
23
13
24
2
10
53
See page 51
45
25, 147
97
33
85
32
54
TI9834a
50 313540G
40
Parts
Left Side of Cabinet
5
62
8 (Ref)
103 (Ref)
Right Side of Cabinet
26
55, 56
TI9835a
39
31
29
68
27
6
40
8
TI9836a
313540G 51
Parts
Detail, Fluid Manifold Area
15
78
79
717 (Ref)
88
111 (Ref)
39
Detail, Proportioner Area
151
19
7, see page 63
78
17
79
89
39
TI9838a
94
57
93
111 (Ref)
343
See page 59
52 313540G
Parts
3
57
111 (Ref)
96
118 (Ref)
103
153
Detail, Electric Motor Area
82
90
47
48
ti7709a
Detail, Hydraulic Reservoir Area
135
114
94
60
129
See page 54
60
134
133
See page 50
125
111 (Ref)
126
139
133
116
93
119, 120
132
117
127
132
60
146
122
137
113
112
111 (Ref)
115
60
142, 143
118
150
114
111
313540G 53
1 (Ref)
92
60
TI9832b
Parts
Ref. 161, Fluid Inlet Kit
161d
161a
161b
161d
Ref. 110, Hydraulic Reservoir
110f
161c
r_256886_313540_7
39
110m
110b
110c
110d
110j
110k
ti9840a
54 313540G
Parts
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
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
1
in. (19 mm) 93 15T895 HOSE, supply 1
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
8
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
3
8
2
1
1
313540G 55
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 130117792 GUN, grease 1 131117773 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 148255039 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 18115W800 LABEL, warning 1 18215W349 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
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.
2
2
1
4
56 313540G
Sub Assemblies
Pump Assembly
Parts
Pump Detail
(A Side Pump Shown)
211
214
222
217 184
229
215
225
5
228
227
222
220
184
218
224 225
225
223
226
184
279
222
213
184
212
255
216
3
254
see manual 313485
Apply blue Loctite and torque to 250 ft-lbs (337.5 N•m).
3
Apply blue Loctite and torque to 15 ft-lbs (20.3 N•m).
5
238
273
280
275 or 276
274
r_256886_313540_5
313540G 57
Parts
250
249
252
258
253
249
246
250
250
253
278
205
204
Air Motor Detail
251
265
3
247
271
208
272
Apply blue Loctite and torque to 250 ft-lbs (337.5 N•m).
3
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
2
279 PIN, clevis; 1/2 in. 2 280 100081 BUSHING, pipe 2
2
Available with pin and bearing kit 257794.
10
6
58 313540G
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
Parts
7.65 kW Single Zone Heater
(Two Per Machine)
Part 247813
404
413
403
414
406
405
410
401
413
411
408
1
404
409
407
r_247813_312063
415
1
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
1
411 100518 SCREW, machine, pan hd
2
413 15H305 PLUG, hollow 414 295607 PLUG, not shown
3
415 124132 O-RING
1 1 3 1 3
1 2 5 1 3
Display
502
503
Parts
511
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
1
506 246287 HARNESS, wire, red stop button 507 117499 HANDLE
1
508 117523 NUT, cap; 10-24
1
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
Parts
Temperature Control
602
605
606
601
603
604
603
604
604
To B Heater Module
To A Heater Module
To Hose Heater Module
604
603
TI9843a
Ref. 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
Fluid Manifold
1
Torque to 355-395 in-lb (40.1-44.6 N•m).
2
Apply sealant (113500) to threads.
3
Valve must be closed with handle position as shown on drawing.
** Apply PTFE tape or thread sealant to tapered threads.
708
2
1
702
3
714
702b
718
2
702a
706
Parts
3
705
703
715 704
701
712
713
Ref. 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
3
714
717
Ref. Part Description Qty.
714 121312 ELBOW, 90 degrees
1
715 100840 ELBOW, street; 1/4 npsm x 1/4 npt
2
716 111457 O-RING, PTFE
1
717189285 LABEL, caution
1
718† 150829 SPRING, compression
2 2
Replacement Warning labels, signs, tags, and cards
2 1 1 2 1 1
are available at no cost.
† Included in the following complete valve kits*:
ISO Valve Kit (left/red handle) 255149. Resin Valve Kit (right/blue handle) 255150. Valve Set Kit (both handles and grease gun) 255148.
* Complete valve kits also include thread sealant.
(Purchase kits separately).
TI9839b
2 2 2 1 2
313540G 63
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
Circuit Breaker Modules Parts List
Ref. Description
801 RAIL, mounting
802 CLAMP, block, end
Breaker Modules
A
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
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
Dimensions
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)
A
C
Top View
Front of Machine
D
D
B
Rear of Machine
r_256886_313539_1
G
F
r_256886_313539_4
66 313540G
Technical Data
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
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2009, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 313540
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revised 01/2012
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