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

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

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

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.

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

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

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 appear on temperature display.

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

E06 can be cleared by pressing . For other codes,

turn main power OFF then ON to clear.

Code Code Name Alarm

01 High fluid temperature Individual 02 High zone current Individual 03 No zone current with

hose heater on

04 FTS not connected Individual 05 Board overtemperature Individual 06 Communication cable

unplugged from module

99 Loss of communication A

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

Zone

Individual

Corrective

Action page

9 10 10

11 11 11

E01: High fluid temperature

Causes of E01 Errors

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

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

• Overtemperature switch A or B (408) senses a fluid temperature above 230°F (110°C) and opens. At 190°F (87°C) the switch closes again.

• Thermocouple A or B (410) fails, is damaged, is not touching the heater element (407), or has a poor connection to the temperature control board.

• Overtemperature switch A or B (408) fails in the open position.

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

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

• Failed heater element where thermocouple is installed.

Checks

Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform all electrical troubleshooting. Be sure to shut off all power to the equipment and relieve all pressure (see Pressure Relief Procedure, page 27) before repairing.

Check which zone is displaying the E01 error.

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

2. Clean and re-plug connections.

3. Check connections between the temperature control module and overtemperature switches A and B (308), and between temperature control module and thermocouples A and B (410) or FTS (21) [depending on which zone is displaying E01]. See T page 35. Ensure that all wires are securely connected to connector B.

IG. 9, page 35).

ABLE 6,

• Loose wire

313540G 9

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.

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 E21 through E27 appear on pressure display.

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

Alarms

Alarms turn off Reactor. Turn main power OFF

then ON to clear.

NOTE: Alarms can also be cleared, except for code

23, by pressing .

Warnings

Reactor will continue to run. Press to clear. A

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

Code Code Name Alarm (A) or

Warning (W)

99 Loss of communication A

Corrective

Action

page

E21: No component A transducer

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

2. Reverse A and B transducer connections. If error moves to transducer B (E22), replace transducer A, page 12. If error does not move, replace motor control board, page 32.

E22: No component B transducer

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

2. Reverse A and B transducer connections. If error moves to transducer A (E21), replace transducer B, page 12. If error does not move, replace motor control board, page 32.

is turned OFF then ON .

E23: High fluid pressure

1. Relieve pressure. Verify low pressure with analog

Code Code Name Alarm (A) or

Warning (W)

21 No transducer (compo-

nent A)

22 No transducer (compo-

nent B)

23 High fluid pressure A 24 Pressure imbalance A/W (to

27 High motor temperature A 30 Momentary loss of com-

munication

31 Pumpline reversing switch

failure/high cycle rate

12 313540G

select, see page 32)

Corrective

Action

page

12 13

14 15

gauges. Turn main power OFF then ON

. If error persists, do checks below.

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

3. Ensure at least one pump is in the number 1 position. See Setup section of Reactor H-VR Operation manual 313539.

4. If error still persists, reduce hydraulic pressure.

Motor Control Diagnostic Codes

E24: Pressure imbalance

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

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

NOTE: If spraying at a ratio other than 1:1, an E24 may occur. Size hoses and mix chamber appropriately to avoid pressure imbalance.

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

Fast E24 Errors

Fast E24 errors occur:

• within 10 seconds of turning the pumps on, or

• as soon as you trigger the gun.

Causes of Fast E24 Errors

• one side of the gun is plugged.

• a pressure transducer has failed.

• damaged pump seals or check valve.

• no feed pressure or empty material drum.

• plugged heater.

• plugged hose.

• plugged manifold.

• one PRESSURE RELIEF/SPRAY valve is leaking or

is set to PRESSURE RELIEF/CIRCULATION .

Checks for Fast E24 Errors

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

• If the gauge readings are very close:

1. Clear the error (page 12) and try running the unit again.

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

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

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

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

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

d. Check the analog gauges to see which pressure

is higher, and check if the display matches.

If the higher gauge and display match, that transducer is communicating with the motor control board. Continue with step e.

If the higher gauge and display do not match, that transducer is not communicating

with the motor control board. Check wire connections and replace transducer, page 34.

e. Turn pumps off. Reduce pressure of higher com-

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

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

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

transducer.

Turn valve slightly to

reduce pressure of higher component.

ti9877a

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

313540G 13

Motor Control Diagnostic Codes

a. Reverse connections at J3 and J8 on the motor

control board.

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

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

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

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

• If the gauge readings are not very close:

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

RELIEF/CIRCULATION , until gauges show balanced pressures.

Turn valve slightly to

reduce pressure of higher component.

ti9877a

b. Check and clean the gun mix chamber impinge-

ment ports and center port. See gun manual.

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

Slow E24 Errors

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

NOTE: If spraying at a ratio other than 1:1, an E24 may occur. Size hoses and mix chamber appropriately to avoid pressure imbalance.

Causes of Slow E24 Errors

• one side of the gun is partially plugged.

• the A or B proportioner pump has failed.

• the A or B feed pump has failed.

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

• the hose is not heating properly.

• kinked supply hose.

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

• drum is not vented.

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

2. If you cannot get the pressures to balance:

a. Check for damaged pump seals or check

valves.

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

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

pump to push fluid through the gun manifold.

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

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

a. Check and clean the gun inlet screens.

E27: High motor temperature

Causes of E27 Errors

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

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

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

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

1. Turn main power OFF .

2. Allow motor to cool completely. Check continuity between pins 1 and 2 on connector J9 on the motor control board, page 32. If the resistance is infinity,

14 313540G

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

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-

Press or zone

keys.

nostic code, page 9.

sor (FTS) or thermocouple disconnected, page 11.

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

Thermocouple not contacting heater element.

Failed heater element. See Primary Heaters, page 18. Signal failure from thermocouple. See E04: Fluid Temperature Sen-

Thermocouple wired incorrectly. See E04: Fluid Temperature Sen-

Loosen ferrule nut (N), push in thermocouple (410) so tip (T) contacts heater element (407). Holding thermocouple tip (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. See page 38 for illustration.

sor (FTS) or thermocouple disconnected, page 11.

sor (FTS) or thermocouple disconnected, page 11. Power up zones

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

18 313540G

Hose Heat System

Troubleshooting

2. Turn main power OFF .

3. Allow equipment to cool.

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

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

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

Hose does not maintain temperature while spraying.

FTS failed or not installed correctly. Check FTS, page 11.

Low supply voltage. Verify line voltage. Low line voltage

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

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

Flow too high. Use smaller mix chamber. Decrease

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

Low supply voltage. Verify line voltage. Low line voltage

Problems

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

designed to maintain temperature, not to increase it.

increase fluid temperature and keep it steady.

pressure.

perature before spraying.

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

A and/or B heaters are overheating material.

Faulty thermocouple connections. Verify that all FTS connections are

Hose temperature exceeds setpoint.

313540G 19

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

11.

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

Troubleshooting

PROBLEM CAUSE SOLUTION

Erratic hose temperature.

Faulty thermocouple connections. Verify that all FTS connections are

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

of hose in same environment as gun. Verify FTS installation, page 39.

Hose does not heat.

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

FTS failed or is not contacting

Check FTS, page 39.

correctly.

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

of hose in same environment as gun. Verify FTS installation, page 39.

Temperature control alarm. Check temperature display or diag-

nostic code, page 39.

Shorted connection or failed hose heating element.

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

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

20 313540G

Hydraulic Drive System

Troubleshooting

2. Turn main power OFF .

3. Allow equipment to cool.

Before performing any troubleshooting procedures:

1. Relieve pressure, page 27.

PROBLEM CAUSE SOLUTION

Electric motor will not start or stops during operation.

Loose connections. Check connections at motor control

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

Damaged motor control board. Replace board. See Motor Control

Problems

board.

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

Board, page 32.

313540G 21

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